SK125SRL PDF

HYDRAULIC EXCAVATOR
MAINTENANCE SPECIFICATIONS
SK125SR
SHOP SK135SR-2
MANUAL model SK135SRLC-2
INDEX
1 SPECIFICATIONS SECTION
SYSTEM
2 MAINTENANCE SECTION
3 SYSTEM SECTION
4 DISASSEMBLY SECTION
DISASSEMBLING
5 TROUBLESHOOTING
6 ENGINE SECTION
7 PROCEDURE E / G TROUBLESHOOTING
OF INSTALLING
OPTIONS SECTION OPT.
Book Code No.S5YY0013E01

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

situation which, if not avoided, could result in
death or serious injury and is represented as
follows:
0-2
SAFETY PRECAUTIONS stands, capable of supporting the machine, before
performing any disassembly.
The proper and safe lubrication and maintenance

for this machine, recommended by Manufacturer, Do not operate this machine unless you have
are outlined in the OPERATOR’S MANUAL for the read and understand the instructions in the OP-
machine. ERATOR’S MANUAL. Improper machine opera-
Improper performance of lubrication or mainte- tion is dangerous and could result in injury or
nance procedures are dangerous and could result death.
in injury or death. Read and understand the MAN-
(6) Relieve all pressure in air, oil or water systems be-
UAL before performing any lubrication or mainte-
fore any lines, fittings or related items are discon-
nance.
nected or removed. Always make sure all raised
The serviceman or mechanic may be unfamiliar with components are blocked correctly and be alert for
many of the systems on this machine. This makes it possible pressure when disconnecting any device
important to use caution when performing service work. from a system that utilizes pressure.
A knowledge of the system and or components is im- (7) Lower the bucket, dozer, or other attachments to
portant before the removal or disassembly of any com- the ground before performing any work on the ma-
ponent. chine. If this cannot be done, make sure the bucket,
Because of the size of some of the machine compo- dozer, ripper or other attachment is blocked correct-
nents, the serviceman or mechanic should check the ly to prevent it from dropping unexpectedly.
weights noted in this manual. Use proper lifting proce- (8) Use steps and grab handles when mounting or dis-
dures when removing any components. Weight of com- mounting a machine. Clean any mud or debris from
ponents table is shown in the section ; steps, walkways or work platforms before using.
SPECIFICATIONS. Always face to the machine when using steps, lad-
The following is a list of basic precautions that must al- ders and walkways. When it is not possible to use
ways be observed. the designed access system, provide ladders, scaf-
folds, or work platforms to perform safe repair oper-
(1) Read and understand all Warning plates and decal
ations.
on the machine before Operating, Maintaining or
Repairing this machine. (9) To avoid back injury, use a hoist when lifting com-
ponents which weigh 20kg (45lbs) or more. Make
(2) Always wear protective glasses and protective
sure all chains, hooks, slings, etc., are in good con-
shoes when working around machines. In particu-
dition and are the correct capacity. Be sure hooks
lar, wear protective glasses when using hammers,
are positioned correctly. Lifting eyes are not to be
punches or drifts on any part of the machine or at-
side loaded during a lifting operation.
tachments. Use welders gloves, hood/goggles,
apron and the protective clothing appropriate to the (10)To avoid burns, be alert for hot parts on machines
welding job being performed. Do not wear loose fit- which have just been stopped and hot fluids in
ting or torn clothing. Remove all rings from fingers, lines, tubes and compartments.
loose jewelry, confine long hair and loose clothing (11)Be careful when removing cover plates. Gradually
before working on this machinery. back off the last two capscrews or nuts located at
(3) Disconnect the battery and hang a "Do Not Oper- opposite ends of the cover or device and carefully
ate" tag in the Operators Compartment. Remove ig- pry cover loose to relieve any spring or other pres-
nition keys. sure, before removing the last two capscrews or
nuts completely.
(4) If possible, make all repairs with the machine
parked on a firm level surface. Block the machine (12)Be careful when removing filler caps, breathers and
so it does not roll while working on or under the ma- plugs on the machine. Hold a rag over the cap or
chine. Hang a "Do Not Operate" tag in the Opera- plug to prevent being sprayed or splashed by liq-
tors Compartment. uids under pressure. The danger is even greater if
the machine has just been stopped because fluids
(5) Do not work on any machine that is supported only
can be hot.
by lift, jacks or a hoist. Always use blocks or jack
0-3
(13)Always use the proper tools that are in good condi- (21)Do not operate a machine if any rotating part is
tion and that are suited for the job at hand. Be sure damaged or contacts any other part during opera-
you understand how to use them before performing tion. Any high speed rotating component that has
any service work. been damaged or altered should be checked for
(14)Reinstall all fasteners with the same part number. balance before reusing.
Do not use a lesser quality fastener if replacements (22)Be careful when servicing or separating the tracks
are necessary. (crawlers). Chips can fly when removing or install-
(15)Repairs which require welding should be per- ing a track (crawlers) pin. Wear safety glasses and
formed only with the benefit of the appropriate ref- long sleeve protective clothing. Tracks (crawlers)
erence information and by personnel adequately can unroll very quickly when separated. Keep away
trained and knowledgeable in welding procedures. from front and rear of machine. The machine can
Determine type of metal being welded and select move unexpectedly when both tracks (crawlers)
correct welding procedure and electrodes, rods or are disengaged from the sprockets. Block the ma-
wire to provide a weld metal strength equivalent at chine to prevent it from moving.
least to that of the parent metal. Make sure to dis-
connect battery before any welding procedures are
attempted.
(16)Do not damage wiring during removal operations.
Reinstall the wiring so it is not damaged nor will be
damaged in operation of the machine by contacting
sharp corners, or by rubbing against some object or
hot surface. Do not connect wiring to a line contain-
ing fluid.
(17)Be sure all protective devices including guards and
shields are properly installed and functioning cor-
rectly before starting a repair. If a guard or shield
must be removed to perform the repair work, use
extra caution and replace the guard or shield after
repair is completed.
(18)The maintenance and repair work while holding the
bucket raised is dangerous due to the possibility of
a falling attachment. Don’t fail to lower the attach-
ment and place the bucket to the ground before
starting the work.
(19)Loose or damaged fuel, lubricant and hydraulic
lines, tubes and hoses can cause fires. Do not bend
or strike high pressure lines or install ones which
have been bent or damaged. Inspect lines, tubes
and hoses carefully. Do not check for leaks with
your hands. Very small (pinhole) leaks can result in
a high velocity oil stream that will be invisible close
to the hose. This oil can penetrate the skin and
cause personal injury. Use card-board or paper to
locate pinhole leaks.
(20)Tighten connections to the correct torque. Make
sure that all heat shields, clamps and guards are in-
stalled correctly to avoid excessive heat, vibration
or rubbing against other parts during operation.
Shields that protect against oil spray onto hot ex-
haust components in event of a line, tube or seal
failure must be installed correctly.
0-4
SK125SR
OCE/S.E.ASIA INDEX SK135SR-2
SK135SRLC-2
Book Code No. Index
Title
Distribution Year–Month No.
MAINTENANCE SPECIFICATIONS
S5YN0118E01
2007-12
OUTLINE 1
S5YY0213E01
2007-12
SPECIFICATIONS 2
S5YY0313E01
ATTACHMENT DIMENSIONS 3
2007-12
S5YY1113E01
TOOLS 11
2007-12
S5YY1213E01 STANDARD MAINTENANCE
2007-12
12
TIME SCHEDULE
S5YY1313E01 MAINTENANCE STANDARD
2007-12
13
AND TEST PROCEDURE
S5YY2113E01 MECHATRO CONTROL
2007-12
21
SYSTEM
S5YY2213E01
2007-12
HYDRAULIC SYSTEM 22
S5YY2313E01
SYSTEM
2007-12
ELECTRIC SYSTEM 23
S5YY2413E01
2007-12
COMPONENTS SYSTEM 24
S5YY2511E01
2007-12
AIR-CONDITIONER SYSTEM 25
_
S5YN3118E01 DISASSEMBLING
DISASSEMBLING
2007-12 & ASSEMBLING

31
S5YY3213E01
ATTACHMENT 32
2007-12
S5YY3313E01
2007-12
UPPER STRUCTURE 33
S5YY3413E01
2007-12
TRAVEL SYSTEM 34
E / G TROUBLESHOOTING
S5YY4613E01
2007-12
BY ERROR CODES 46
S5YY4711E01
2007-12
BY TROUBLE 47
S5YN4818E01
2007-12
TROUBLE DIAGNOSIS MODE 48
_
S5YY5111E01
ENGINE 51
2007-12
_
YV05-04501~
YY05-12001~ APPLICABLE MACHINES
YH05-07001~
0-5
NOTE:
This Manual is prepared as a technical material in This Manual may be properly revised due to the im-
which the information necessary for the maintenance provement of products, modification of specifications,
and repairing services of our hydraulic excavators are etc. And there are cases where the system on actual
collected, and is categorized into 7 Chapters, Specifica- machine and a part of the contents of this manual may
tion, Maintenance, System, Disassembly, Trouble- differ due to the variations of specification by countries.
shooting, Engine, and Installation Procedures for For the section in which the description is hardly under-
Optional Attachment. stood, contact our distributor.
• The Chapter "Specification" describes the specifi- The number is assigned to every part handled in this
cations for entire machine and material, which are Manual on account of the description, but the parts,
instructive for replacement and repairing of attach- which cannot be supplied as service parts are con-
ments. tained. Therefore, the order must be placed with re-
spective formal number with due confirmation on the
• The Chapter "Maintenance" describes the material,
Parts Manual for applicable machine.
which is helpful for maintenance service and adjust-
ments for entire machine.
• The Chapter "System" describes the operating sys-
tem like hydraulic system, electric system, compo-
nents, and so on.
• The Chapter "Disassembly" describes the removal
and installing of assembly mounted on the upper
structure and undercarriage, and the assembling
and disassembling of the associated hydraulic
equipment.
• The Chapter "Troubleshooting" describes how to
find the fault equipment.
• The Chapter "Engine" describes the engines mak-
ing use of the "Maintenance Manual" provided by
the suppliers.
• The Chapter "Installation Procedures for Optional
Attachment" describes the supplements added on
request as required.
0-6
1
1. OUTLINE
TABLE OF CONTENTS
1.1 GENERAL PRECAUTIONS FOR MAKING REPAIRS ......................................................1-4

1.1.1 PREPARATION BEFORE DISASSEMBLING..........................................................1-4
1.1.2 SAFETY WHEN DISASSEMBLING AND ASSEMBLING ........................................1-4
1.1.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT .......................1-4
1.1.4 ELECTRICAL EQUIPMENT .....................................................................................1-5
1.1.5 HYDRAULIC PARTS ................................................................................................1-6
1.1.6 WELD REPAIR .........................................................................................................1-6
1.1.7 ENVIRONMENTAL ISSUES.....................................................................................1-6
1.2 INTERNATIONAL UNIT SYSTEM .....................................................................................1-7
Book Code No. S5YN0118E01
1-1
1. OUTLINE
Issue Date of Issue Applicable Machines Remarks

SK250-8: LQ12-06001~ ↑
First edition October, 2006 K
SK260LC–8 : LL12-05001~ (ASIA, OCE)
↑ December, 2006 SK850LC: LY01-00101~ ↑ K
E235BSR : YF05-02001~ ↑
↑ February, 2007 K
E235BSR(N)LC : YU05-02001~ (NHK)
↑
↑ ↑ SK235SRLC-2 : YU05-02001~ K
(North America)
E215B : YN11-45001~ ↑
↑ March, 2007 K
E215BLC : YQ11-06001~ (NHK Russia)
SK235SR-2 : YF05-02001~ ↑
↑ April, 2007 K
SK235SRLC-2 : YU05-02001~ (OCE)
SK200-8 : YN11-45001~ ↑
↑ ↑ K
SK210LC-8 : YQ11-06001~ ASIA (HS Engine)
SK250-8: LQ12-06001~ ↑
↑ May, 2007 K
SK260LC–8 : LL12-05001~ ASIA (HS Engine)
E225BSR : YB05-03001~ ↑
↑ June, 2007 K
E225BSRLC : LA05-02001~ (NHK)
↑
↑ ↑ SK215SRLC : LA05-02001~ K
(North America)
E135BSR : YY05-12001~ ↑
↑ July, 2007 K
E135BSRLC : YH05-07001~ (NHK)
SK225SR : YB05-03001~ ↑
↑ ↑ K
SK225SRLC : LA05-02001~ (OCE)
SK460-8: LS10-02001~ ↑
↑ ↑ K
SK480LC–8 : YS10-01501~ (ASIA, OCE)
E215B : YN11-45001~ ↑
↑ ↑ K
E215BLC : YQ11-06001~ (NHK Middle East)
E265B : LQ12-06001~ ↑
↑ ↑ K
E265BLC : LL12-05001~ (NHK Russia)
↑
↑ ↑ ↑ K
(NHK Middle East)
E215B : YN11-45001~ ↑
↑ ↑ K
E215BLC : YQ11-06001~ (NHK Russia) HS Engine
↑
↑ ↑ ↑ K
(NHK Middle East) HS Engine
E385B : LC10-07001~ ↑
↑ August, 2007 K
E385BLC : YC10-03501~ (NHK Middle East)
E265B : LQ12-06001~ ↑
↑ September, 2007 K
E265BLC : LL12-05001~ NHK Russia (HS Engine)
↑
↑ ↑ ↑ K
NHK Middle East (HS Engine)
↑
↑ ↑ SK135SRLC-2 : YH05-07001~ K
(North America)
SK125SR : YV05-04501~
↑
↑ December, 2007 SK135SR-2 : YY05-12001~ K
(OCE/S.E.ASIA)
SK135SRLC-2 : YH05-07001~
1-2
1. OUTLINE
1.1 GENERAL PRECAUTIONS FOR 2) Attach "Don’t operate" tag to control lever, and
MAKING REPAIRS begin a meeting before starting the work.
3) Before starting inspection and maintenance
1.1.1 PREPARATION BEFORE stop the engine.
DISASSEMBLING
4) Confirm the position of first-aid kit and fire
extinguisher, and also where to make contact
Read Operator's Manual
for emergency measure and ambulance to
before disassembling
prepare for accidents and fire.

(1) Knowledge of operating procedure
5) Choose a hard, lever and safe place, and put
Read Operator’s Manual carefully to understand
attachment on the ground without fail.
the operating procedure.
6) Use hoist, etc. to remove parts of heavy weight
(2) Cleaning machines
(23kg [50 lb] or more).
Clean machines of soil, mud, and dust before
carrying into the service shop. 7) Use proper tools, and change or repair
Carrying a soiled machine into the service shop, defective tools.
causes making less efficient work and damage of 8) Machine and attachment required to work in the
parts. lifting condition should be supported with
(3) Inspecting machines supports or blocks securely.
Confirm the disassembling section before starting 1.1.3 DISASSEMBLING AND ASSEMBLING
work, determine the disassembly procedure taking HYDRAULIC EQUIPMENT
the conditions in work shop into account, and
request to procure necessary parts in advance.
(4) Recording
Record the following items to keep contact and (1) Removing hydraulic equipment assy
prevent malfunction from recurring. 1) Before removing pipes, release the pressure of
1) Inspecting date, place hydraulic oil tank, or open the cover on the
2) Model name, Serial number and Record on return side to tank, and take out the filter.
hour meter 2) Drain the oil in the removed pipes into pan to
3) Trouble condition, place, cause prevent the oil from spilling on the ground.
4) Visible oil leak, water leak and damage 3) Pipes with plugs or caps to prevent oil leaking,
entry of dust, etc.
5) Clogging of filters, oil level, oil quality, oil
contamination and looseness. 4) Clean the outside surface of equipment, etc.
before disassembling, and drain hydraulic oil
6) Examine the problems on the basis of monthly
and gear oil before putting them on working
operation rate with the last inspection date and
bench.
records on hour meter.
(2) Disassembling hydraulic equipment
(5) Arrangement and cleaning in service shop
1) Since performance and function of hydraulic
1) Tools required for repair work.
equipment after disassembly and assembly
2) Prepare the places to put the disassembled
results in immunity from responsibility on the
parts.
manufacture’s side, disassembly, assembly
3) Prepare oil pans for leaking oil, etc. and modification without permission are strictly
prohibited.
1.1.2 SAFETY WHEN DISASSEMBLING AND
ASSEMBLING 2) If it is unavoidably necessary to disassemble
and modify, it should be carried out by experts
or personnel qualified through service training.
WARNING
3) Make match mark on parts for reassembling.
(1) Safety 4) Before disassembling, read Disassembling
1) Wear appropriate clothing, safety shoes, safety Instruction in advance, and determine if the
helmet, goggles, and clothes with long sleeves. disassembly and assembly are permitted or
not.
1-3
1. OUTLINE
5) For parts which are required to use jig and

tools, don’t fail to use the specified jig and tools.
6) For parts which can not be removed in the
If hydraulic oil and lubricating oil are not
specified procedure, never force removal. First
filled and also air bleed is not performed,
check for the cause.
the hydraulic equipment may be damaged.
7) The removed parts should be put in order and
tagged so as to install on proper places without 3) For air bleed of hydraulic pump and swing
confusion. motor, loosen drain plug on the upper part, start
8) For common parts, pay attention to the quantity engine, and run in low idling, then bleed air until
and places. hydraulic oil is comes out. After completion of
comes, tighten plug securely.
(3) Inspecting parts
4) For air bleed of travel motor and hydraulic
1) Check that the disassembled parts are free
cylinder, starts engine and operate it for 10
from adherence, interference and uneven
minutes or more at no-load and low speed.
working face.
2) Measure the wear of parts and clearance, and
record the measured values.
3) If an abnormality is detected, repair or replace For cylinder, don’t move it to the stroke end
the parts. at beginning.
(4) Reassembling hydraulic equipment
5) Air in pilot circuit can be bleed out by only
1) During the parts cleaning, ventilate the room. operating digging, swing and traveling motions
2) Before assembly, clean parts roughly first, and thoroughly.
then completely. 6) Check hydraulic oil level.
3) Remove adhering oil by compressed air, and Move attachments to hydraulic oil check
apply hydraulic oil or gear oil, and then position, and check hydraulic oil level of tank.
assemble them. Refill oil if the oil level is lower than the specified
4) Replace the removed O-ring, back-up rings and level.
oil seal with new ones, and apply grease oil on How to check oil level of hydraulic oil tank
them before assembling.

5) Removes dirt and water on the surface on
which liquid sealant are applied, decrease LEVEL GAUGE
Oil level of hydraulic oil tank.
them, and apply liquid sealant on them. If the indicator is within
level marks, the oil quantity
6) Before assembling, remove rust preventives on is acceptable.
new parts.
7) Use special tools to fit bearings, bushing and oil 1.1.4 ELECTRICAL EQUIPMENT
seal.
8) Assemble parts matching to the marks.
9) After completion, check that there is no
(1) The disassembly of electrical equipment is not
omission of parts.
allowed.
(5) Installing hydraulic equipment
(2) Handle equipment with care so as not to drop it or
1) Confirm hydraulic oil and lubrication oil.
bump it.
2) Air release is required in the following cases ;
(3) Connector should be removed by unlocking while
1. Change of hydraulic oil holding the connector.
2. Replacement of parts on suction pipe side Never stress in tension to the caulked section by
3. Removing and attaching hydraulic pump pulling wire.
4. Removing and attaching swing motor (4) Check that connector is connected and locked
completely.
5. Removing and attaching travel motor
(5) Engine key off before removing and connecting
6. Removing and attaching hydraulic cylinder
connector.
1-4
1. OUTLINE
(6) Engine key off before touching terminals of starter (2) Flexible hose (F hose)
and alternator. • Even if the connector and length of hose are the
(7) Remove battery grounding terminal before same, the parts differ according to the
beginning work close to battery and battery relay withstanding pressure. Use proper parts.
with tools. • Tighten it to the specified torque, and check that
(8) Wash machine with care so as not to splash water it is free from twist, over tension, interference,
on electrical equipment and connector. and oil leak.
(9) When water has entered in the waterproofed
1.1.6 WELD REPAIR
connector, the removing of water is not easy. So
(1) The weld repair should be carried out by qualified
check the removed waterproofed connector with
personnel in the specified procedure after
care to protect it from entry of water. If moisture
disconnecting the grounding cable of battery. If the
adheres on it, dry it completely before connecting.
grounding cable is not disconnected, the electrical
equipment may be damaged.
(2) Remove parts which may cause fire due to the
Battery fluid is dangerous. entry of spark beforehand.
The battery fluid is dilute sulfuric acid, and causes (3) Repair attachments which are damaged, giving
scald and loss of eyesight by adhering on eyes, particular attention to the plated section of piston
skin and clothes. When the fluid has adhered on rod to protect it from sparks, and don’t fail to cover
them, take an emergency measure immediately and the section with flame-proof clothes.
see a doctor for medical advice.
1.1.7 ENVIRONMENTAL ISSUES
• When it has adhered on skin ;
Wash with soap and water. (1) Engine should be started and operated in the place
where air can be sufficiently ventilated.
• When it has got in eyes ;
Wash in water for 10 minutes or more (2) Waste disposal
immediately. The following parts follows the regulation.
Waste oil, waste container and battery
• When it has spilled out in large quantity ;
Use sodium bicarbonate to neutralize, or wash (3) Precautions for handling hydraulic oil
away with water. Hydraulic oil may cause inflammation of eyes.
Wear goggles to protect eyes on handling it.
• When it was swallowed ;
Drink milk or water. • When it has got in eyes ;
Wash eyes with water until the stimulus is gone.
• When it has adhered on clothes ;
Wash it immediately. • When it was swallowed ;
Don’t force him to vomit it, but immediately
1.1.5 HYDRAULIC PARTS receive medical treatment.
• When it has adhered on skin ;
Wash with soap and water.
(4) Others
(1) O-ring For spare parts, grease and oil, use KOBELCO
• Check that O-ring is free from flaw and has genuine ones.
elasticity before fitting.
• Even if the size of O-ring is equal, the usage
differs, for example in dynamic and static
sections, the rubber hardness also differs
according to the pressure force, and also the
quality differs depending on the materials to be
seated. So, choose proper O-ring.
• Fit O-ring so as to be free from distortion and
bend.
• Floating seal should be put in pairs.
1-5
1. OUTLINE
1.2 INTERNATIONAL UNIT SYSTEM (4) Derived Units bearing Peculiar Designations
Introduction Table1-4
Although this manual uses the SI units system. Outline QUANTITY UNIT SYMBOL FORMULA
of SI units system is described here. Frequency hertz Hz 1Hz=1/s
Given hereinunder are an excerpt of the units that are Force newton N kg • m/s 2
related to this manual : Pressure and
pascal Pa N/m2
1. Etymology of SI Units Stress
English : International System of units Energy, Work
2. Construction of SI Unit System and Quantity of joule J N•m
heat
Base units Power watt W J/s
Table 1-1
Derived units Quantity of
coulomb C A•s
Supplemen of base units electricity
SI units tary units Table 1-3
SI unit Table 1-2 Electric
system Derived units potential
Derived bearing peculiar
designations difference,
units volt V W/A
Table 1-4 Voltage, and
Electromotive
Prefixes of SI
(n-th power of 10, where n is an integer) force
Table 1- 5 Quantity of
static electricity
(1) Basic Units farad F C/V
and Electric
Table1-1 capacitance
Electric
QUANTITIES DESIGNATION SIGN ohm V/A
resistance
Length Meter m
celcius
Mass Kilogram kg Celcius
degree or C
°
(t+273.15)K
Time Second s temperature
degree
Current Ampere A
Thermodynamic Kelvin K Illuminance lux lx l m/m2
temperature
(5) Prefixes of SI
Gram molecule Mol mol
Luminous intensity Candela cd Table1-5
PREFIX
(2) Supplementary Units POWER
DESIGNATION SIGN
Table1-2 Giga G 109
QUANTITIES DESIGNATION SIGN Mega M 106
Plain angle Radian rad Kilo k 103
Solid angle Steradian sr Hecto h 102
Deca da 10
(3) Derived Units of Basic Units
Deci d 10–1
Table1-3 Centi c 10–2
QUANTITIES DESIGNATION SIGN Milli m 10–3
Area Square meter m2 Micro µ 10–6
Volume Cubic meter m3 Nano n 10–9
Velocity Meter per second m/s Pico p 10–12
Acceleration Meter per second / second m/s2
Density Kilogram per cubic meter kg/m3
1-6
1. OUTLINE
(6) Unit Conversion Table
QUANTITIES JIS SI REMARKS

Mass kg kg
Force kgf N 1kgf=9.807N
Torque kgf•m N•m 1kgf•m=9.807N•m
Pressure kgf/cm2 MPa 1kgf/cm2=0.098MPa
Motive power PS kW 1PS=0.7355kW
Revolution r.p.m min –1
1r.p.m=1min–1
1-7
1. OUTLINE
[MEMO]
1-8
2
2. SPECIFICATIONS
TABLE OF CONTENTS
2.1 NAME OF COMPONENTS................................................................................................2-3

2.2 GENERAL DIMENSIONS ..................................................................................................2-4
2.2.1 SK125SR [4.68m (15ft-4in) Boom+2.38m (7ft-10in) Standard Arm+0.45m3 (0.40cu•yd) Bucket]
SK135SR/SK135SRLC-2 [4.68m (15ft-4in) Boom+2.38m (7ft-10in) Standard Arm+0.50m3 (0.65cu•yd) Bucket] ........2-4
2.2.2 SK125SR/SK135SR-2/SK135SRLC-2 [4.68m (15ft-4in)+2.84m (9ft-4in) Long Arm+0.38m3 (0.50cu•yd) Bucket] .......2-4
2.3 WEIGHT OF COMPONENTS............................................................................................2-5
2.4 TRANSPOTATION ............................................................................................................2-6
2.4.1 OVERALL DIMENSIONS OF MACHINE ON A TRAILER ........................................2-6
2.4.2 DIMENSIONS OF ATTACHMENT ...........................................................................2-7
2.5 SPECIFICATIONS AND PERFORMANCE .......................................................................2-9
2.5.1 SPEED AND CLIMBING CAPABILITY.....................................................................2-9
2.5.2 ENGINE ....................................................................................................................2-9
2.5.3 HYDRAULIC COMPONENTS ..................................................................................2-9
2.5.4 WEIGHT ...................................................................................................................2-9
2.6 TYPE OF CRAWLER.........................................................................................................2-10
2.7 TYPE OF BUCKET ............................................................................................................2-12
2.8 COMBINATIONS OF ATTACHMENT................................................................................2-13
2.9 ENGINE SPECIFICATIONS ..............................................................................................2-14
2.9.1 SPECIFICATIONS....................................................................................................2-14
2.9.2 ENGINE CHARACTERISTIC CURVE ......................................................................2-15
Book Code No. S5YY0213E01
2-1
2. SPECIFICATIONS

SK125SR : YV05-04501~
S5YY0213E01
First edition December, 2007 SK135SR-2 : YY05-12001~ K
(OCE/S.E.ASIA)
SK135SRLC-2 : YH05-07001~
2-2
2. SPECIFICATIONS
2.1 NAME OF COMPONENTS

2-3
2. SPECIFICATIONS
2.3 WEIGHT OF COMPONENTS

Unit ; kg (lb)
Model
SK125SR SK135SR-2 SK135SRLC-2
Item
13,000 13,800 13,900
Fully equipped weight
(28,600) (30,420) (30,640)
1. Upper frame assy (Assembly of following :) 6,710 (14,789) 7,298 (16,085) ←
1.1 Upper frame 1,385 (3,053) 1,400 (3,086) ←
1.2 Counter weight 2,840 (6,259) 3,400 (7,494) ←
1.3 Cab 266 (587) ← ←
1.4 Engine * 395 (871) ← ←
1.5 Hydraulic oil tank * 112 (247) ← ←
1.6 Fuel tank * 89 (196) ← ←
1.7 Slewing motor (including reduction unit) * 106 (234) ← ←
1.8 Control valve * 158 (348) ← ←
1.9 Boom cylinder * 96 (212) × 2 ← ←
1.10 Pin (for mounting boom) 61 (134) ← ←
1.11 Pump * 85 (187) ← ←
1.12 Radiator (including intercooler) * 77 (170) ← ←
2. Lower frame assy (Assembly of following :) 4,031 (8,884) ← 4,224 (9,310)
2.1 Lower frame 1,411 (31,10) ← 1,471 (3,242)
2.2 Slewing bearing 150 (330) ← ←
2.3 Travel motor (including reduction unit) * 145 (320) × 2 ← ←
2.4 Upper roller 9 (20) ← 9 (20) × 2
2.5 Lower roller 25 (55) × 12 ← 25 (55) × 14
2.6 Front idler 74 (163) × 2 ← ←
2.7 Idler adjuster 58 (128) × 2 ← ←
2.8 Sprocket 40 (88) × 2 ← ←
2.9 Swivel joint * 24 (53) ← ←
2.10 Track link with 500mm (19.7in) shoes assy (STD) 732 (1,613) × 2 ← 760 (1,675) × 2
Track link with 600mm (23.6in) shoes assy 872 (1,922) × 2 ← 912 (2,010) × 2
3. Attachment (Assembly of following :)
{4.68m (15ft-4in) Boom + 2.38m (7ft-10in) Arm + 0.45m3 (0.59cu•yd) Bucket} 1,962 (4,324) — —
{4.68m (15ft-4in) Boom + 2.38m (7ft-10in) Arm + 0.50m (0.65cu•yd) Bucket}
3
— 2,126 (4,686) ←
3.1 Bucket assy (STD) 353 (778) 384 (846) ←
3.2 STD Arm assy (Assembly of following :) 600 (1,322) 628 (1,384) ←
3.2.1 STD Arm 369 (813) 397 (875) ←
3.2.2 Bucket cylinder 82 (180) ← ←
3.2.3 Idler link 30 (66) ← ←
3.2.4 Bucket link 42 (93) 64 (141) ←
3.2.5 Pin (2pcs. for mounting bucket cylinder / 2pcs. for mounting bucket) 46 (101) ← ←
3.3 Boom assy (Assembly of following :) 1,009 (2,224) 1,344 (2,962) ←
3.3.1 Boom 790 (1,741) ← ←
3.3.2 Arm cylinder 138 (304) ← ←
3.3.3 Pin (Mounting arm • Mounting arm cylinder) 29 (64) ← ←
2-5
2. SPECIFICATIONS
Unit ; kg (lb)
Model
Item
4. Lubricant and water (Assembly of following :) 334 (736) ← ←
4.1 Hydraulic oil 137 (302) ← ←
4.2 Engine oil 16 (35) ← ←
4.3 Fuel 167 (368) ← ←
4.4 Water 14 (31) ← ←
Marks * show dry weight.
2.4 TRANSPOTATION
2.4.1 OVERALL DIMENSIONS OF MACHINE ON A TRAILER
(1) 4.68m (15ft-4in) Boom+2.84m (9ft-4in) Long Arm+0.38m3 (0.50cu•yd) Bucket
Shoe type
600mm (23.6in) 600mm (23.6in) LC
Item
Width mm (ft-in) 2,590 (8'6") 2,590 (8'6")
Weight kg (lbs) 14,300kg (31,530 lbs) 14,400kg (31,750 lbs)
1100 (3'7") 7070 (23'2") 3480 (11'5")

3950 (12'12")
3210 (10'6")
3660 (12'0")
2910 (9'7")
150(5.9")
(29.5")
750
2-6
2. SPECIFICATIONS
2.4.2 DIMENSIONS OF ATTACHMENT

(1) BOOM
Type
4.68m (15ft-4in) Boom
Item
Length×Height×Width 4.84 × 1.42 × 0.60
m (ft-in)
L×H×W (15'11"× 4'8"× 1'12")
Weight kg (lbs) SK125SR : 1,030 (2,271) / SK135SR-2 : 1,350 (2,975)
H
L
(2) Arm and bucket
Type 2.38m (7ft-10in) Arm + 2.84m (9ft-4in) Arm +

0.50m 3 (0.65cu•yd) Bucket 0.38m 3(0.50cu•yd) Bucket
Item
Length×Height×Width 4.28 × 0.82 × 1.00 4.74 × 0.82 ×1.00
m (ft-in)
L×H×W (14'1"×2'8"×3'3") (15'7"×2'8"×3'3")
Weight kg (lbs) 1,000 (2,205) 1,100 (2,426)
(3) Arm
Type
2.38 m (7ft-10in) Arm 2.84 m (9ft-4in) Arm
Item
Length×Height×Width 3.13 × 0.65 × 0.53 3.59 × 0.66 × 0.56
m (ft-in)
L×H×W (10'3"×2'2"×1'9") (11'9"×2'2"×1'10")
Weight kg (lbs) 590 (1,300) 690 (1,521)
H
2-7
2. SPECIFICATIONS
(4) Bucket
Type Hoe bucket

Length×Height×Width 1.19 × 1.07× 0.70 1.19 × 1.07× 0.70 1.19 × 1.07× 0.80
m (ft-in)
L×H×W (3'11"×3'6"×2'4") (3'11"×3'6"×2'4") (3'11"×3'6"×2'7")
Weight kg (lbs) 280 (620) 300 (660) 320 (706)
Bucket capacity m3 (cu•yd) 0.24 (0.31) 0.31 (0.41) 0.38 (0.50)
Type Hoe bucket

Length×Height×Width 1.19 × 1.07× 0.90 1.19 × 1.07× 1.00 1.19 × 1.07× 1.10
m (ft-in)
L×H×W (3'11"×3'6"×2'11") (3'11"×3'6"×3'3") (3'11"×3'6"×3'7")
Weight kg (lbs) 350 (770) 390 (860) 400 (880)
SK125SR STD SK135SR-2 STD
Bucket capacity m3 (cu•yd) 0.57 (0.75)
0.45 (0.59) 0.50 (0.65)
Hoe bucket
2-8
2. SPECIFICATIONS
2.5 SPECIFICATIONS AND PERFORMANCE

2.5.1 SPEED AND CLIMBING CAPABILITY
Model
Item
Swing speed min-1 {rpm} 11.5 {11.5}
Travel speed (1-speed/2-
km/h (mile/h) 3.4 / 5.6 (2.1 / 3.5)
speed)
Gradeability % (degree) 70 (35)
2.5.2 ENGINE
Engine model MITSUBISHI D04FR-74kW

Water-cooled, 4 cycle 4 cylinder direct injection type diesel engine
Type
with inter cooler turbo-charger
4 -ø102 mm × 130 mm
Number of cylinders—Bore×Stroke
(4.02 in × 5.12 in)
Total displacement 4.249 L (259.27 cu•in)
Rated output / Engine speed 74 kW (101 PS) / 2,000 min-1
Maximum torque / Engine speed 375 N•m (277 lbf•ft)/ 1,600 min-1
Starter 24 V / 5.0kW
Alternator 24 V / 50A
2.5.3 HYDRAULIC COMPONENTS
Hydraulic pump Variable displacement axial piston pump × 2 + gear pump × 1

Hydraulic motor (swing) Axial piston motor × 1
Variable displacement axial piston motor × 2
Hydraulic motor (travel)
(with counterbalance valve)
Control valve 8-spool control valve × 1
Cylinder
Double action cylinder
(Boom, Arm, Bucket)
Oil cooler Air-cooled type
2.5.4 WEIGHT
Unit : kg (lbs)
Fully equipped weight 13,000 (28,600) 13,800 (30,420) 13,900 (30,640)
Upper structure 6,710 (14,789) 7,298 (16,085) ←
Lower machinery
4,031 (8,884) ← 4,224 (9,310)
(500mm grouser shoe)
Attachment
4.68m (15 ft-4in) Boom+2.38m (7ft-10in) Arm 1,962 (4,324) — —
+0.45m3 (0.59cu•yd) Bucket
Attachment
4.68m (15 ft-4in) Boom+2.38m (7ft-10in) Arm — 2,126 (4,686) ←
+0.50m3 (0.65cu•yd) Bucket
2-9
2. SPECIFICATIONS
2.6 TYPE OF CRAWLER
SK125SR
Shoe width Overall width of crawler Ground pressure
Shape
mm (in) mm (ft-in) kPa (psi)
Grouser shoe 500 2,490 41
(19.7) (8'2") (5.95)
600 2,590 35
(23.6) (8'6") (5.08)
700 2,690 30
(27.6) (8'10") (4.35)
Flat shoe
500 2,490 42
(19.7) (8'2") (6.10)
Triangle shoe
800 2,790 26
(31.5) (9'2") (3.77)
Use 500mm (19.7") grouser shoes on rough ground (areas covered with rocks and gravel). If you drive or excavate
with other shoes, this may cause shoe bending, shoe bolt looseness, and track assembly (link, roller, etc.)
2-10
2. SPECIFICATIONS
SK135SR-2 / SK135SRLC-2
Shoe width Overall width of crawler Ground pressure
Shape
mm (in) mm (ft-in) kPa (psi)
2,490 43
STD
500 (8'2") (6.24)
(19.7) 2,490 42
Grouser shoe LC
(8'2") (6.10)
2,590 37
STD
600 (8'6") (5.37)
(23.6) 2,590 36
LC
(8'6") (5.22)
2,690 32
STD
700 (8'10") (4.64)
(27.6) 2,690 31
LC
(8'10") (4.50)
Flat shoe
2,490 44
STD
(8'2") (6.39)
500
(19.7)
2,490 42
LC
(8'2") (6.10)
Triangle shoe
2,790 28
STD
(9'2") (4.06)
800
(31.5)
2,790 27
LC
(9'2") (3.92)
Use 500mm (19.7") grouser shoes on rough ground (areas covered with rocks and gravel). If you drive or excavate
with other shoes, this may cause shoe bending, shoe bolt looseness, and track assembly (link, roller, etc.)
2-11
2. SPECIFICATIONS
2.7 TYPE OF BUCKET

Heaped Outer width mm (ft-in) Availability
Struck Number W or W/O Weight
capacity With side Without side of face
m3(cu•yd) of tooth side cutter kg (lbs)
m3(cu•yd) cutter cutter shovel
0.20 280
0.24 (0.31) 590 (1'11") 500 (1'7.7") 3 W YES
(0.26) (620)
Hoe bucket 0.23 300
0.31 (0.41) 700 (2'3.6") 600 (1'11.6") 3 W YES
(0.30) (660)
0.28 320
0.38 (0.50) 800 (2'7.5") 700 (2'3.6") 4 W YES
(0.37) (706)
SK125SR
0.35 350
[STD] 910 (2'12") 810 (2'8") 4 W YES
(0.46) (770)
0.45 (0.59)
SK135SR-2
0.38 390
[STD] 1,000 (3'3") 900 (2'11.4") 5 W YES
(0.50) (860)
0.50 (0.65)
0.43 400
0.57 (0.75) 1,100 (3'7") 1,000 (3'3") 5 W YES
(0.56) (880)
0.50 410
0.70 (0.90) — 1,150 (3'9") 5 W YES
(0.65) (904)
2-12
2. SPECIFICATIONS
2.8 COMBINATIONS OF ATTACHMENT

SK125SR Bucket Available Arm
Heaped capacity Struck 2.38m (7ft-10in) Arm 2.84m (9ft-4in)
Type
m3 (cu•yd) m3 (cu•yd) (STD) Arm (Long)
0.24 (0.31) 0.20 (0.26)

0.31 (0.41) 0.23 (0.30)
0.38 (0.50) 0.28 (0.37)
Hoe bucket [STD] 0.45 (0.59) 0.35 (0.46)
0.50 (0.65) 0.38 (0.50)
0.57 (0.75) 0.43 (0.56)
0.70 (0.90) 0.50 (0.65)
Breaker — —
Nibbler — —
SK135SR(LC)-2 Bucket Available Arm

Heaped capacity Struck 2.38m (7ft-10in) Arm 2.84m (9ft-4in)
Type
m3 (cu•yd) m (cu•yd)
3 (STD) Arm (Long)
0.24 (0.31) 0.20 (0.26)

0.31 (0.41) 0.23 (0.30)
0.38 (0.50) 0.28 (0.37)
Hoe bucket 0.45 (0.59) 0.35 (0.46)
[STD] 0.50 (0.65) 0.38 (0.50)
0.57 (0.75) 0.43 (0.56)
0.70 (0.90) 0.50 (0.65)
Breaker — —
Nibbler — —
Standard combination
General operation : Excavation or loading of sand, gravel, and clay
Light operation : Mainly loading or loose gravel (e.g., cultivation or loading of sand or gravel)
Prohibited combination : There are problems from the view points of strength and stability.
• Use the attachments recommended by manufacturer.
The trouble due to the use in the condition "Use not allowed" described in the above table is not included in our
responsibility
When the only 2.38m (7ft-10in) arm is using, do not turn the bucket back to front to use as a shovel.
2-13
2. SPECIFICATIONS
2.9 ENGINE SPECIFICATIONS

2.9.1 SPECIFICATIONS
Applicable machine SK125SR / SK135SR-2 / SK135SRLC-2

Engine model MITSUBISHI D04FR-74kW
Water-cooled, 4 cycle 4 cylinder direct injection type
Type
diesel engine with inter cooler turbo-charger
Number of cylinder×Bore×Stroke mm (in) 4 × 102 × 130 (4.02 × 5.12)
Total displacement cc (cu•in) 4,249 (259.27)
Compression ratio 17.8
Rated output kW (PS) at min -1
74 (101) at 2,000
N•m (lb•ft) at
Maximum torque 375 (277) at 1,600
min-1
High idling min-1 2,240 ± 20
Low idling min -1
1,015 ± 20
Injection starting pressure MPa (psi) —
Start/Full open
Thermostat action 344 (160) / 358 (185)
K (°F)
Firing order 1-3-4-2
Starter capacity V × kW 24 × 5.0
Generator capacity (Alternator) V×A 24 × 50
ø600 (23.6") × suction type 6 fans, V-belt drive,
Cooling fan drive method
pulley ratio Crank / Fan= 0.9
Full level 17.5 (4.62)
Engine oil quantity L (gal) Low level 14.5 (3.83)
Total 18.5 (4.89)
Dry weight kg (lbs) 395 (871)
Fuel consumption ratio
g/kW•h (g/ps•h) 233 (171)
(At rated output)
Allowable inclination Front / Rear and Right / Left : 35°
Dimension (L×W×H) mm (in) 911 × 719 × 940 (35.9in × 28.3in × 37.0in)
Rotating direction Counterclockwise seeing from flywheel side
2-14
2. SPECIFICATIONS
2.9.2 ENGINE CHARACTERISTIC CURVE
Condition to be measured: The net value is indicated, measuring without cooling fan.
TORQUE Nm
OUTPUT kW
ENGINE SPEED (min-1)
Fuel consumption volume

Fuel consumption rate X kW X Load factor ( )
0.835 X 1000
233g/kW.h
X 74kW X
0.835 X 1000 : Standard load factor
. L/h (0.70~0.80)
20.65
Fuel consumption in regular operation
(load factor 0.70~0.80)
14.5 L/h~16.5 L/h
2-15
2. SPECIFICATIONS
[MEMO]
2-16
3
3. ATTACHMENT DIMENSIONS
TABLE OF CONTENTS
3.1 BOOM ................................................................................................................................3-3

3.1.1 BOOM DIMENSIONAL DRAWING...........................................................................3-3
3.1.2 BOOM MAINTENANCE STANDARD.......................................................................3-4
3.2 ARM ...................................................................................................................................3-6
3.2.1 ARM DIMENSIONAL DRAWING..............................................................................3-6
3.2.2 ARM MAINTENANCE STANDARD ..........................................................................3-7
3.3 BUCKET ............................................................................................................................3-10
3.3.1 BUCKET DIMENSIONAL DRAWING .......................................................................3-10
3.3.2 BUCKET DIMENSIONAL TABLE .............................................................................3-10
3.3.3 LUG SECTION DIMENSIONAL DRAWING .............................................................3-11
3.3.4 BOSS SECTION DIMENSIONAL DRAWING...........................................................3-12
3-1

SK125SR : YV05-04501~
S5YY0313E01
(OCE/S.E.ASIA)
SK135SRLC-2 : YH05-07001~
3-2
3.1 BOOM
3.1.1 BOOM DIMENSIONAL DRAWING
d2
J
X-X
Fig. 3-1 Boom dimensional drawing
Unit : mm (ft-in)
SK125SR SK135SR-2
4.68M (15ft-4in) BOOM
YY02B00287F1 YY02B00273F1
No NAME DIMENSION
A Boom length 4,680 (15'4") ←
B Boom foot width 575 (22.6") ←
C Boom end inner width 274 (10.8") ←
D Boom end outer width 386 (15.2") ←
E Height of boom cylinder rod pin 952 (37.5") ←
F Height of arm cylinder (head side) pin 1,079 (3'6") ←
G Distance between pins of boss R2,110 (6'11") ←
H Distance between pins of bracket R2,293 (7'6") ←
I Arm cylinder (head side) inner width 111 (4.4") ←
J Outer width of bracket on the arm cylinder (rod side) 399 (15.7") ←
mounting
d1 Boom foot pin dia. ø 70 (2.76") ←
d2 Boom cylinder (rod side) pin dia. ø 80 (3.15") ←
d3 Pin dia. of boom end. ø 70 (2.76") ←
d4 Arm cylinder (head side) pin dia. ø 70 (2.76") ←
3-3
3.1.2 BOOM MAINTENANCE STANDARD

(1) Clearance of pin and bushing on boom section
A
C
Fig. 3-2 Clearance of pin and bushing on boom section
Unit : mm (in)
Standard value Clearance
Sym- Bushing Repaira
Item Pin part No. Pin dia. Standard Service Remedy
bol Pin dia. i.d. ble
tolerance value limit
tolerance level
+ 0.223 + 0.243
(+0.0088) (+0.0096)
A Boom foot YY02B01521P1
+ 0.081 + 0.061
ø 70 (+0.0032) (+0.0024)
(2.7559) + 0.237 + 0.257
Boom cylinder (+0.0093) (0.0101)
B YY02B01174P1
(Head side) + 0.020 + 0.101 + 0.081 More
Replace
(+0.0008) (+0.0040) (+0.0032) than 2.0
bushing
- 0.020 + 0.229 + 0.249 1.2 (0.079)
or pin
Boom cylinder ø 80 (-0.0008) (+0.0090) (+0.0098) (0.047)
C YY02B01177P1
(Rod side) (3.1496) + 0.089 + 0.069
(+0.0035) (+0.0027)
+ 0.231 + 0.251
Arm cylinder ø 70 (+0.0091) (+0.0099)
D YY12B01435P1
(Head side) (2.7559) + 0.091 + 0.071
(+0.0036) (+0.0028)
3-4
(2) Clearance in thrust direction on the boom cylinder installation section
D
D C
B A
SECTION C-C
SECTION D-D
SECTION A-A
SECTION B-B
Fig. 3-3 Clearance in thrust direction on the boom cylinder installation section
Unit : mm (in)
Clearance X adjusted with shim
Basic size Pin length
(total of both sides)
Sec. Item Remedy
Standard Repairable Service
No. Size No. Length
value level limit
575
Boom
(22.6) 0.5 (0.02) 1.0 1.5 732
A-A Boom foot L1 PL1
581 or less (0.04) (0.06) (28.8)
Upper frame
(22.9)
90
Boom cylinder
Boom cylinder (3.54) 0.6~1.0 2.0 2.5 185
B-B L2 PL2
(Head side) 96 (0.02~0.04) (0.08) (0.10) (7.28)
Upper frame Shim
(3.78)
adjust
80
Boom cylinder L3 ment
Boom cylinder (3.15) 0.6~2.0 2.5 3.0 597
C-C PL3
(Rod side) 399 (0.02~0.08) (0.10) (0.12) (23.5)
Boom L3'
(15.7)
105
Arm cylinder
Arm cylinder (4.13) 0.6~1.0 2.0 2.5 222
D-D L4 PL4
(Head side) 111 (0.02~0.04) (0.08) (0.10) (8.74)
Boom
(4.37)
3-5
3.2 ARM
3.2.1 ARM DIMENSIONAL DRAWING

Fig. 3-4 ARM DIMENSIONAL DRAWING
2.38m (7ft-10in) ARM YY12B00433F1 Unit : mm (ft-in)

Code NAME DIMENSION Code NAME DIMENSION
C Arm length 2,380 (7'10") N Bracket inner width 110 (4.33")
Distance between pins of boss
D R625 (24.6") O Bracket inner width 91 (3.58")
and bracket
D1 I.D of boss ø95 (3.74") P Idler link dimension 514 (20.2")
D2 I.D of boss ø75 (2.95") Q Bucket link dimension 492 (19.4")
Height between pins of boss and
D4 I.D of boss ø85 (3.35") R 20 (0.79")
center
E R1,862.8 (6'1") d1 Pin dia. ø65 (2.56")
and bracket
F R350 (13.8") d2 Pin dia. ø60 (2.36")
and boss
G 462.3 (18.2") d3 Pin dia. ø70 (2.76")
bracket
H 200 (7.9") d4 Pin dia. ø70 (2.76")
bracket
K Arm top end boss width 249 (9.8") d5 Pin dia. ø60 (2.36")
L Arm link section boss width 254 (10.0")
M Boss width 269 (10.6")
3-6
3.2.2 ARM MAINTENANCE STANDARD

(1) Clearance of pin and bushing
E F
D, D'
B
C
G
Fig. 3-5 Clearance of pin and bushing on arm section
Unit : mm (in)
Standard dimensions Clearance
No. Item Pin part No. Pin dia. Bushing i.d. Standard Repairable Service Remedy
Pin dia.
tolerance tolerance value level limit
+0.267 +0.327
(+0.0105) (+0.0129)
A Arm point
–0.020 +0.090 +0.110
ø65 (-0.0008) (+0.0035) (+0.0043)
YY12B01427P1
(2.5591) –0.060 +0.225 +0.258
Bucket link (-0.0024) (+0.0089) (+0.0102)
B
(Bucket side) +0.089 +0.105
(+0.0035) (+0.0041)
+0.203 +0.243
Idler link
ø60 (+0.0080) (+0.0096)
C (Connected part YY12B01428P1
(2.3622) +0.093 +0.093
of arm) (+0.0037) (+0.0037)
0 +0.198 +0.238
Bucket link (0) (+0.0078) (+0.0094)
D
(Idler link side) –0.040 +0.085 +0.085
Replace
ø65 (-0.0016) (+0.0033) (+0.0033) 1.2 2.0
YY12B01429P1 bushing
(2.5591) +0.198 +0.238 (0.05) (0.008)
or pin
Bucket cylinder (+0.0078) (+0.0094)
D'
(Rod side) +0.085 +0.085
(+0.0033) (+0.0033)
+0.195 +0.215
Bucket cylinder ø60 (+0.0077) (+0.0085)
E YY12B01436P1
(Head side) (2.3622) +0.081 +0.061
(+0.0032) (+0.0024)
+0.020 +0.231 +0.251
Arm cylinder (+0.0008) (+0.0091) (+0.0085)
F YY12B01435P1
(Rod side) –0.020 +0.091 +0.071
ø70 (-0.0008) (+0.0036) (+0.0024)
(2.7559) +0.226 +0.246
Arm foot
(+0.0089) (+0.0097)
G (Connected part YY12B01432P1
+0.085 +0.065
of boom) (+0.0033) (+0.0026)
3-7
(2) Clearance of arm and cylinder installing sections in thrust direction
E
D, D'
B
F
E
B C
D, D' F
A A
C G
G
X1 L1
X L3 PL5
X L6
X L5
PL1 PL3 PL6

SECTION A-A SECTION C-C SECTION E-E SECTION F-F
PL7
X2 L2 X7 L7
X L4
X4' L4'
PL2 PL4
SECTION B-B SECTION D-D
SECTION G-G
Fig. 3-6 Clearance of arm and cylinder installing sections in thrust direction
3-8
Unit : mm (in)
Clearance X adjusted with shim
Basic size Pin length
(total of both sides)
Sec. Item Remedy
Standard Repairable
No. Size Service limit No. Length
value level
294
Arm
(11.6)
A-A Arm point L1 PL1
251
Bucket
(9.88) 0.6~1.0 1.2 391
250 (0.024~0.04) (0.05) (15.4)
Link side
(9.84)
B-B Bucket link L2 PL2
252
Bucket
(9.92)
254 0.5 2.0
Idler link Arm 1.0
C-C L3 (10.0) (0.02) (0.08) PL3
(Arm connection) (0.04)
Link side - or less
Bucket link Rod side -
D-D (Idler link L4 254 336
Link side
connection) (10.0) (13.2)
0.6~1.0 1.2 Shim
85 PL4
Rod side (0.024~0.04) (0.05) adjust
Bucket link (3.35)
D’-D’ L4’ -ment
(Rod side) 90
Link side
(3.54)
85
Head side
Bucket cylinder (3.35) 190
E-E L5 PL5
(Head side) 91 (7.48)
Arm
(3.58) 0.6~2.0 2.0 2.5
105 (0.024~0.08) (0.08) (0.10)
Rod side
Arm cylinder (4.13) 222
F-F L6 PL6
(Rod side) 110 (8.74)
Arm
(4.33)
269
Arm 0.5
(10.59) 1.0 2.0 399
G-G Arm foot L7 (0.02) PL7
274 (0.04) (0.08) (15.7)
Boom or less
(10.79)
3-9
3.3 BUCKET
3.3.1 BUCKET DIMENSIONAL DRAWING
(1) Hoe bucket
Fig. 3-7 Bucket dimensional drawing
No. NAME No. NAME

A Distance between pin and bracket G Inner width of bucket bottom
B Distance between bucket pin and tooth end H Bucket outer width of front side
C Inner width of bucket top end I Pitch between teeth
D Inner width of bracket Io Pitch between teeth
E Inner width of lug d1 Outer dia. of bushing
F Outer width of side cutter d2 Pin dia.
3.3.2 BUCKET DIMENSIONAL TABLE
Unit : mm (ft-in)
Type Normal digging
SK125SR SK135SR-2
0.24 0.31 0.38 [STD] [STD] 0.57 0.70
Capacity
(0.20) m3 (0.23) m3 (0.28) m3 0.45 0.50 (0.43) m3 (0.50) m3
(0.35) m3 (0.38) m3
Part No. YY61B00079F1 YY61B00080F1 YY61B00081F1 YY61B00075F1 YY61B00072F1 YY61B00082F1 YY61B00083F1
A R376 (14.8") ← ← ← ← ← ←
B R1,225 (4'0.23") ← ← ← ← ← ←
C 462 (18.2") 562 (22.1") 662 (26.1") 772 (30.4") 863 (34.0") 962 (37.9") 1,112 (3'7.8")
D 324 (12.8") ← ← ← ← ← ←
E 252 (9.9") ← ← ← ← ← ←
F 593 (23.3") 700 (27.6") 800 (31.5") 910 (35.8") 1,000 (3'3.37") 1,100 (3'3.7") —
G 383 (15.1") 439 (17.3") 539 (21.2") 649 (25.6") 739 (29.1") 839 (33.0") 989 (39.0")
H 500 (19.7") 600 (23.6") 700 (27.6") 772 (30.4") 903 (35.6") 1,000 (3'3.37") 1,150 (3'9.3")
I 187 (7.4") 237 (9.3") 191 (7.5") 228 (9.0") 192.5 (7.6") 218.5 (8.6") 256 (10.1")
IO 187 (7.4") 237 (9.3") 191 (7.5") 228 (9.0") 192.5 (7.6") 218.5 (8.6") 256 (10.1")
d1 ø 80 (3.2") ← ← ← ← ← ←
d2 ø 65 (2.6") ← ← ← ← ← ←
Bucket capacity : SAE heaped (Stuck)
3-10
3.3.3 LUG SECTION DIMENSIONAL DRAWING
X B
J
A
Roughness of counterbore bottom X

surface is to be 100S or less in
range of diameter 39mm. BOSS
And M16 bolt is to be installed. (3 places) M
28 2418P26832
(1.10) Apply rust prevention oil
19
(0.748)
3-G
B
F
N
D E
H
BOSS
SHIM 1 Insert this pin flush with surface YY61B01005P1
Five shims are installed
at shipping SECTION X-X
DETAIL B
Fig. 3-8 Dimension of lug section
Unit : mm (ft-in)
Lug plate thickness
Screw hole P.C.D

Boss outer dia.
Boss outer dia.

Spring pin dia.
Pin hole dia.
Boss width.
Boss width.
Capacity of
Screw dia.
bucket
Hole dia.
Type of Part No. of

bucket (SAE heaped) bucket
m3
A B D E F G H J M N
0.24 (0.20) YY61B00079F1
0.31 (0.23) YY61B00080F1
0.38 (0.28) YY61B00081F1
SK125SR [STD]
Normal 65 22 80 10 146 22 138 36 115
digging 0.45 (0.35) YY61B00075F1 (2.56") (0.866") (3.14") (0.394") (5.75") M14 (0.866") (5.43") (1.42") (4.53")
SK135SR-2 [STD]
0.50 (0.38) YY61B00072F1
0.57 (0.43) YY61B00082F1
0.70 (0.50) YY61B00083F1
Bucket capacity : SAE heaped (Struck)
3-11
3.3.4 BOSS SECTION DIMENSIONAL DRAWING
H 5
(0.197")
oG
oC
oD
oA
oB
15 (0.591")
DETAIL A
E
Fig. 3-9 Dimension of boss section
Unit : mm (ft-in)
Capacity of
Type of Part No. of Part No.
bucket øA øB øC øD E F øG H I
bucket bucket of boss
m3
0.24 (0.20) YY61B00079F1
101.6 69 94.5 99.5 15 30 15 13 2.5
0.31 (0.23) YY61B00080F1 YY61B01005P1
(4.0") (2.72") (3.72") (3.92") (0.591") (1.18") (0.591") (0.512") (0.098")
0.38 (0.28) YY61B00081F1
SK125SR [STD]
Normal
0.45 (0.35) YY61B00075F1
digging
SK135SR-2 [STD] 101.6 69 94.5 99.5 19 34 15 13 2.5
2418P26832
0.50 (0.38) YY61B00072F1 (4.0") (2.72") (3.72") (3.92") (0.748") (1.34") (0.591") (0.512") (0.098")
0.57 (0.43) YY61B00082F1
0.70 (0.50) YY61B00083F1
Bucket capacity : SAE heaped (Struck)
3-12
11. TOOLS
11
TABLE OF CONTENTS
11.1 TIGHTENING TORQUES FOR CAPSCREWS AND NUTS ............................................11-3

11.2 SCREW SIZE...................................................................................................................11-5
11.2.1 CAPSCREW (BOLT) ..............................................................................................11-5
11.2.2 CAPSCREW (SOCKET BOLT) ..............................................................................11-5
11.2.3 SOCKET SET SCREW...........................................................................................11-5
11.3 TIGHTENING TORQUE FOR HOSE AND FITTING .......................................................11-6
11.3.1 JOINT (O-RING TYPE)...........................................................................................11-6
11.3.2 HYDRAULIC HOSE (30° FLARE TYPE) ................................................................11-6
11.3.3 JOINT (ORS TYPE)................................................................................................11-6
11.3.4 SPLIT FLANGE ......................................................................................................11-6
11.4 TIGHTENING TORQUES FOR NUTS AND SLEEVES...................................................11-7
11.5 PLUG ...............................................................................................................................11-8
11.5.1 PLUG FOR HYDRAULIC PIPE JOINT ...................................................................11-8
11.5.2 PLUG FOR HYDRAULIC EQUIPMENT .................................................................11-9
11.6 SPECIAL SPANNER FOR TUBE ....................................................................................11-11
11.7 SPECIAL TOOLS.............................................................................................................11-12
11.8 APPLICATION OF SCREW LOCKING COMPOUND AND SEALING COMPOUND......11-14
11.9 SUCTION STOPPER.......................................................................................................11-15
11.9.1 COMPONENTS ......................................................................................................11-15
11.9.2 DIMENSION ...........................................................................................................11-15
11.9.3 APPLICABLE MODEL ............................................................................................11-15
11.10 COUNTERWEIGHT LIFTING JIG ...................................................................................11-16
11.11 TOOL FOR PULLING OUT OF BOOM MOUNTING PIN ................................................11-17
11.12 UPPER FRAME LIFTING JIG..........................................................................................11-18
11.13 ENGINE MOUNTING PEDESTAL...................................................................................11-20
11.14 TRACK SPRING SET JIG ...............................................................................................11-21
11-1
11. TOOLS

SK125SR : YV05-04501~
S5YY1113E01
(OCE/S.E.ASIA)
SK135SRLC-2 : YH05-07001~
11-2
11. TOOLS
11.1 TIGHTENING TORQUES FOR CAPSCREWS AND NUTS

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

Torque value Unit : N•m (lbf•ft)
Classification 4.8T 7T 10.9T
Nominal size No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication
11.3±1.1 9.5±1.0 24.5±2.0 20.6±2.0 44.1±3.9 37.3±3.9
M8 P=1.0
(8.3±0.8) (7.0±0.7) (18.1±1.5) (15.2±1.5) (32.5±2.9) (27.5±2.9)
22.6±2.0 18.7±1.9 48.1±4.9 41.2±3.9 87.3±8.8 73.5±6.9
M10 P=1.25
(16.7±1.5) (13.8±1.4) (35.5±3.6) (30.3±2.9) (64.4±6.5) (54.2±5.1)
39.2±3.9 33.3±2.9 85.3±8.8 71.6±6.9 154±16 129±13
M12 P=1.25
(28.9±2.9) (24.6±2.1) (62.9±6.5) (52.8±5.1) (114±12) (95.2±9.6)
92.2±8.8 77.5±7.8 196±20 169±17 363±39 304±29
M16 P=1.5
(68.0±6.5) (57.2±5.8) (145±15) (125±13) (268±29) (224±21)
186±19 155±16 402±39 333±29 726±69 608±59
M20 P=1.5
(137±14) (114±12) (297±29) (246±21) (535±51) (448±44)
314±29 265±29 686±69 569±59 1240±118 1030±98
M24 P=2
(232±21) (195±21) (506±51) (420±44) (915±87) (760±72)
637±59 530±49 1390±137 1157±118 2500±255 2080±206
M30 P=2
(470±44) (391±36) (1030±101) (853±87) (1840±188) (1530±152)
853±88 706±70 1860±186 1550±155 3350±334 2790±275
M33 P=2
(629±65) (521±52) (1370±137) (1140±114) (2470±246) (2060±203)
1070±108 892±88 2330±226 1940±196 4200±422 3500±353
M36 P=3
(789±80) (658±65) (1720±167) (1430±145) (3100±311) (2580±260)
11-4
11. TOOLS
11.2 SCREW SIZE

11.2.1 CAPSCREW (BOLT)
Nominal B mm Nominal B mm
screw size screw size
Tool size Tool size
(d) (d)
M6 10 M36 55
M8 13 M42 65 d
M10 17 M45 70
M12 19 M48 75
(M14) 22 M56 85
M16 24 (M60) 90 B
(M18) 27 M64 95
M20 30 (M68) 100
(M22) 32 M72 105
M24 36 M76 110
(M27) 41 M80 115
M30 46
11.2.2 CAPSCREW (SOCKET BOLT)
screw size screw size
Tool size Tool size
(d) (d)
(M3) 2.5 M20 17
(M4) 3 (M22) 17 @
(M5) 5 M24 19
M6 5 (M27) 19
M8 6 M30 22
M10 8 M36 27
*
M12 10 M42 32
M14 12 (M45) 32
M16 14 M48 36
(M18) 14 M52 36
11.2.3 SOCKET SET SCREW
screw size screw size d
Tool size Tool size
(d) (d)
M2.5 1.27 M8 4
M3 1.5 M10 5
M4 2 M12 6
M5 2.5 M16 8 B
M6 3 M20 10
11-5
11. TOOLS
11.3 TIGHTENING TORQUE FOR HOSE AND FITTING

11.3.1 JOINT (O-RING TYPE)
Size Wrench Tightening torque

(PF) (mm) N•m (lbf•ft) O-RING O-RING
1/8 14 17±2 (13±1.5)
1/4 19 36±2 (27±1.5)
3/8 22 74±5 (55±4)
1/2 27 108±9.8 (80.0±7)
3/4 36 162±9.8 (119±7)
1 41 255±9.8 (188±7)
11.3.2 HYDRAULIC HOSE (30° FLARE TYPE)
Size Tightening torque

Wrench(mm) UNION NUT
(PF) N•m (lbf•ft)
1/8 17 15±2.0 (11±1.5)
1/4 19 29±4.9 (21±3.6)
3/8 22 49±4.9 (36±3.6)
1/2 27 78±4.9 (58±3.6)
3/4 36 118±9.8 (87±7.2)
1 41 137±15 (101±11)
11.3.3 JOINT (ORS TYPE)
Tightening Torque CONNECTOR O-RING FITTING

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

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

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

ød Ihara Koatu Nippon A.M.C. ød flats Ihara Koatu Nippon A.M.C.
(HEX) mm
6 ZF93S06000 — 6 14 ZF93N06000 —
8 ZF93S08000 — 8 17 ZF93N08000 —
10 ZF93S10000 ZA93S10000 10 19 ZF93N10000 ZA93N10000
12 ZF93S12000 — 12 22 ZF93N12000 —
15 ZF93S15000 ZA93S15000 15 27 ZF93N15000 ZA93N15000
18 ZF93S18000 ZA93S18000 18 32 ZF93N18000 ZA93N18000
22 ZF93S22000 ZA93S22000 22 36 ZF93N22000 ZA93N22000
28 ZF93S28000 ZA93S28000 28 41 ZF93N28000 ZA93N28000
32 ZF93S32000 — 32 50 ZF93N32000 —
35 ZF93S35000 ZA93S35000 35 55 ZF93N35000 ZA93N35000
38 ZF93S38000 — 38 60 ZF93N38000 —
11-7
11. TOOLS
11.5 PLUG
11.5.1 PLUG FOR HYDRAULIC PIPE JOINT
(1) Cap nut (Joint plug)
Applicable Cap nut parts Opposing flats

A
tube T screw
No.
O. D : A H1 H
6 ZF83H06000 M12 X 1.5 14 14
8 ZF83H08000 M14 X 1.5 17 17
10 ZF83H10000 M16 X 1.5 17 19
12 ZF83H12000 M18 X 1.5 19 22
H1 T screw H 15 ZF83H15000 M22 X 1.5 24 27
18 ZF83H18000 M26 X 1.5 27 32
22 ZF83H22000 M30 X 1.5 32 36
28 ZF83H28000 M36 X 1.5 38 41
(2) Plug (Tube plug)
Applicable
tube Plug parts No.
O. D : A
A
6 ZF83P06000
8 ZF83P08000
10 ZF83P10000
12 ZF83P12000
Sleeve Nut
Type 15 ZF83P15000
joint body 18 ZF83P18000
22 ZF83P22000
28 ZF83P28000
(3) Nut
Applicable
A
d screw tube Nut parts No. d screw Opposing flats

O. D : A
6 ZF93N06000 M12 X 1.5 14
8 ZF93N08000 M14 X 1.5 17
10 ZF93N10000 M16 X 1.5 19
12 ZF93N12000 M18 X 1.5 22
15 ZF93N15000 M22 X 1.5 27
18 ZF93N18000 M26 X 1.5 32
22 ZF93N22000 M30 X 1.5 36
28 ZF93N28000 M36 X 1.5 41
32 ZF93N32000 M42 X 1.5 50
35 ZF93N35000 M45 X 1.5 55
38 ZF93N38000 M48 X 1.5 60
11-8
11. TOOLS
11.5.2 PLUG FOR HYDRAULIC EQUIPMENT

(1) PF screw
B
O-ring
PF screw Plug parts No. B mm O-ring parts No. Nominal O-ring
PF1/4 ZE72X04000 19 ZD12P01100 1B P11
PF3/8 ZE72X06000 22 ZD12P01400 1B P14
PF1/2 ZE72X08000 27 ZD12P01800 1B P18
PF3/4 ZE72X12000 36 ZD12P02400 1B P24
PF screw PF1 ZE72X16000 41 ZD12P02900 1B P29
(2) PT screw
B
PT screw
PT screw Plug parts No. B mm
PT1/8 ZE82T02000 5
PT1/4 ZE82T04000 6
PT3/8 ZE82T06000 8
PT1/2 ZE82T08000 10
PT3/4 ZE82T12000 14
PT1 ZE82T16000 17
PT1 1/4 ZE82T20000 22
PT1 1/2 ZE82T24000 22
(3) Plug for (F) flare hose
PF screw
PF screw Plug parts No. B mm

PF1/4 2444Z2728D1 14
60
PF3/8 2444Z2728D2 17
PF1/2 2444Z2728D3 22
PF3/4 2444Z2728D4 27
Opposing flats B PF1 2444Z2728D5 36
PF screw Plug parts No. E mm F mm

PF PF1/4 2444Z2729D1 14 19
60
screw
PF3/8 2444Z2729D2 17 22
PF1/2 2444Z2729D3 23 27
PF3/4 2444Z2729D4 27 36
Opposing PF1 2444Z2729D5 36 41
Opposing
flats F PF1 1/4 2444Z2729D6 40 50
flats E
11-9
11. TOOLS
(4) Plug for ORS joints

Male

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

% &"'()
!"
!"#
!"
(5) Plug for half clamp
4-oH For standard pressure : 20.6 MPa (2990 psi)

Plug O-ring
Size part No. C mm D mm G mm H mm part No.
25.53~
1/2 ZE12Q08000 38.10 17.48 9 45Z91D2
C 25.40
31.88~
3/4 ZE12Q12000 47.63 22.23 11 ZD12P02600
31.75
ZE12Q16000 52.37 39.75~ ZD12P03400
1 26.19 11
39.62
44.58~
D 1 1/4 ZE12Q20000 58.72 30.18 11 ZD12P03800
44.45
For high pressure : 41.2 MPa (5970 psi)

Plug O-ring
G Size part No. C mm D mm G mm H mm part No.
25.53~
1/2 ZE13Q08000 40.49 18.24 9 2445Z831D1
25.40
31.88~
3/4 ZE13Q12000 50.80 23.80 11 ZD12P02600
31.75
ZE13Q16000 57.15 39.75~ ZD12P03400
1 27.76 13
39.62
44.58~
1 1/4 ZE13Q20000 66.68 31.75 15 ZD12P03800
44.45
11-10
11. TOOLS
11.6 SPECIAL SPANNER FOR TUBE

Applicable tube
diameter Part No. HEX (mm) Drawing of a special spanner mm (in)
mm (in)
70(2.76)
16 22
15 (0.591) 2421T160 27 (0.630) (0.315) (0.866)
40(1.57) 12.7 (0.500 )
70(2.76)
42(1.65)
19 22
18 (0.709) 2421T138 32 (0.748) (0.866)
12.7 (0.500 )
22(0.866)
70(2.76)
48(1.89) 11.5(0.453)
23 22
22 (0.866) 2421T130 36 (0.906) (0.866)
12.7 (0.500 )
109(4.29)
60(2.36)
14.5(0.571)
29 22
28 (1.10) 2421T115 41 (1.142) (0.866)
12.7 (0.500 )

28 (1.10) 2421T231 46

32 (1.26) 2421T232 50

81(3.19) 90(3.54)
20.5(0.807)
35 (1.38) 2421T314 55 41 PART-No. 45

(1.61) (1.77)
HEX55 19.05 (0.750 )
11-11
11. TOOLS
11.7 SPECIAL TOOLS

Table11-4
No. Tools name Tools No. Shape Applicable
Allen wrench
ZT22A10000 Pump
1 Nominal
suction
B : 10, C : 11.3
Commercial tool length (L1) - cut length = Required length

40 (1.57") - 10 (0.39") = 30 (1.18")
Spanner or
Pump
2 socket General tools
install
Nominal B : 17
CUT
Spanner ZT12A36000 Swing motor

3
Nominal S : 36 A,B port
Commercial tool outer width (D) - cut length = Required length

81 (3.19") - 16 (0.63") = 65 (2.56")
M10 Eye bolt
ZS91C01000 For slinging the

Eye bolt
or swing motor
4 M10×18
commercial &
equivalent Flare hose
18
M10
M8 Eye bolt
Plug
ZF83P22000
(Nominal
tube dia. 22)
5 Reference nut Flare hose
Reference
ZS91C00800
Eye bolt
ZF93N22000 M8 X 18
Nut Addtional
threading for
M8 Eye bolt
11-12
11. TOOLS
Table11-4
M8 Eye bolt
M8 X 18
Plug YN01H01001P1
Additional
threading
Nominal
6 1-14UNS HEX 27 Flare hose
Eye bolt ZS91C00800

1-14UNS
M8 Eye bolt
M8 X 18
Additional
Plug YN01H01002P1 threading
Nominal
7 1 3/16-12UN HEX 36 Flare hose
Eye bolt ZS91C00800

1 3/16-12UN
M12 Eye nut
Plug ZE25F08000
PF1/2 For slinging the
8 Weld
Coupling swivel joint
half Coupling half
PF 1/2
TORX driver 5.49

(with tamper
For instrument
9 proof) — Point shape
panel cover (RH)
T30
(For M6)
11-13
11. TOOLS
11.8 APPLICATION OF SCREW LOCKING COMPOUND AND SEALING

COMPOUND
(1) For general use
Manufacturer
Service Features
Loctite Three-Bond
Low
#242 1360K
strength
Screw locking Middle
#262 1374
compound strength
High
#271 1305
strength
Sealing
#515 1215 Sealing
compound
(2) For specific location
No. Use Manufacturer Name Equivalent Applicable

(Manufacturer ; Loctite)
# 1901 Anti-seizure Cylinder
Three-Bond # 1215 gray # 5699 Swing motor
# 1211 white # 5301J Swing motor
# 1303B # 211 Main pump
(Manufacturer ; Three-
Bond)
Sealing Loctite
# 222 # 1344N Main pump
compound
1 # 277 # 1307N Pilot valve
&
adhesive (Manufacturer ; Three-
Bond)
Loctite Parmatex 98D # 1121 Hydraulic oil tank : Hose
Sumitomo
Chemical Co., Cyano Bond PO-1 swing bearing : Seal
Ltd.
Shell
Shell Alvania EP2 New Molyknock Grease 2 Swing bearing grease bath
petroleum
11-14
11. TOOLS
11.9 SUCTION STOPPER

11.9.1 COMPONENTS
No. NAME PARTS No. Q'TY

SUCTION STOPPER ASSY 24100P978F2
1 ROD 2420T4660D1 1
1 Rod
2 NUT ZN16C08007 1
3 COVER 2414T2123D2 1
4 O-RING 45Z91D6 1
2 Nut
3 Cover
4 O-ring
Fig. 11-1 Components of suction stopper
11.9.2 DIMENSION
50
(1.97")
R
(1 8 O113 (4.45")
.3
15" 2
) M8 NUT (0.08")
O8 (1.315")
600 (23.6")
M8 O100 +0.5
0
(0.787")
(3.94 +0.0197
0 )
O108
20
(4.25")
ROD COVER
Fig. 11-2 Dimension of suction stopper
11.9.3 APPLICABLE MODEL

SK135SR-2
Applicable
SK125SR
model
Part No.
24100P978F2
11-15
11. TOOLS
11.10 COUNTERWEIGHT LIFTING JIG

(1) Two lifting jigs (YY60C01111P1, YY60C01112P1)
180 (7.09")
(1.18")
80 4
(3.15") (0 -C1
30
.5 5
9"
)
(2.36") (2.44")
42 ")
(1.10")
62
28
65
(1.
180 (7.09")
180 (7.09")
(2.44") (2.36")
60
60
(1.10")
(1 42
28
62
.6
5"
)
(1.18")
4
30
(0 -C1
.5 5 80
9"
) (3.15")180 (7.09")
225 (8.86") 225 (8.86")
R R
(1 50 (1 50
.9 .9
7" 7"
) )
)
4"
(3 100
.9
)
4"
(3
200 (7.87")
200 (7.87")
R
.9
40 ")
00
40 ")
58
R1
(1. 58
(1.
0 )
(1 R50
R5 97"
)
7"
120 (4.72")
.9
18 1 . 120 (4.72")
( 18
(0.71") (0.71")
(1.10")
(1.10")
28
28
155 (6.10") 155 (6.10")
FOR R.H (YY60C01111P1) FOR L.H (YY60C01112P1)
Q'ty : Each one

Material : Mild steel
Fig. 11-3 Counterweight lifting jig
11-16
11. TOOLS
11.11 TOOL FOR PULLING OUT OF BOOM MOUNTING PIN
Fig. 11-4 Slide hammer for boom foot pin

Tool accesories assy YX01T00002F1
No. TOOLS NAME TOOLS No. SHAPE APPLICATION
ROD YX01T01002P1
(0.16")
A 4
80 6
(3.15") (0.24") For boom
1 M24 mounting pin.
HOLE 35 (1.38")
(3.94")
100
ITEM A
26 (1.02")
34 (1.34")
100 14 16 50 10
Preheating 300~350 4 (3.94") (0.55") (0.63") (1.97") (0.39")
1350 (4'5")
(0.16") 4
1416 (4'8") (0.16")
4
(0. -R5
(2.36")
20 10 )
R 9"
60
")
2- (0.3
(1.41")
(0 2-C
(3.94")
100
36
.3 8
2" For boom
)
2 HAMMER YR02B01286P1 mounting pin.
25 (0.98") 25 (0.98")
30 100 (3.94") 30
(1.18") 160 (6.30") (1.18")
11-17
11. TOOLS
11.12 UPPER FRAME LIFTING JIG
(2.36")
(4.92")
(1.18")
7
1
(4'1.7")
5 (5.04")
(3.47")
4
(0.47")
(4.49")
(0.35")
(9.96")
6X12 piece 7X22 piece t9 (0.35")
)
7"
.9
(1
(1.38")
(1.97")
(0.8
7")
(1.77")
8X12 piece
(1.34")
(1.34")
(1.97")
(6.50") (0.59") Q'ty : 2 sets

(13.0")
Fig. 11-5 Upper frame lifting jig (1/2)
11-18
11. TOOLS
1X1 piece t6 (0.24") 2X1 piece t9 (0.35")

(4.21")
(2.36")
(0.35")
(1.18")
7")
(0.8
(31.3")
(3.34")
(11.3")
(0
.
35
(1.97")
")
(7.05")
(4.21")
(2.01")
(3.82")
(0
.7
1"
) (5.39")
(3.94")
(2.80")
(1.58")
(1
.1
")
8"
39
(6.46") )
(0.
(9.61")
3X1 piece t9 (0.35") 4X1 piece t12 (0.47")

(2.36")
(0.35")
(3.94")
(1.39
")
(3.47")
(5.04")
(3'3.8")
5X2 piece t12 (0.47")

(2.76")
(4.72")
(1.53")
(6.46")
)
9"
.8
)
39"
(1
(0
.18
")
(0.
(3.47")
(9.96") (5.04")
Q'ty : 2 sets
Fig. 11-6 Upper frame lifting jig (2/2)
11-19
11. TOOLS
11.13 ENGINE MOUNTING PEDESTAL
Material : Wood
Unit : mm (inch)
(8.07")
(12.2")
(28.3")
3 3
(10.6")
(8.07")
2
(11.8") (0.83")
(11.8")
(0.79") (0.79")
(3.15") (17.2") (3.15")
(23.5")
1X1 piece 3X2 piece
(20.3") (12.2")
(6.50")
(11.8")
(6.30")
(0.83")
(11.8")
(0.83")
2X1 piece 5X2 piece

(3.15")
(20.3") (0.83")
(11.8")
(28.3")
(0.83")
Fig. 11-7 Engine stand
11-20
11. TOOLS
11.14 TRACK SPRING SET JIG
M30
Retainer nut
Retainer plate
)
.6"
(12
(27.6")
Stand
(15.0")
Hydraulic jack
Base
Fig. 11-8 Track spring set jig
11-21
11. TOOLS
[MEMO]
11-22
12. STANDARD MAINTENANCE
TIME TABLE
12
TABLE OF CONTENTS
12.1 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR ...12-4
12.2 ENGINE MAINTENANCE SERVICE STANDARD TIME LIST ........................................12-15
12-1
12. STANDARD MAINTENANCE TIME TABLE

SK125SR : YV05-04501~
S5YY1213E01
(OCE/S.E.ASIA)
SK135SRLC-2 : YH05-07001~
12-2
PREFACE
(1) Working Conditions
1) Workers :
More than one worker shall be 1st class service technician (having five years or more of field experience and
having received training in the operation).
2) Equipment :
Jigs, tools, apparatuses and testers used in field service work shall be available commercially. The
maintenance plant shall be equipped with a service shop, a crane and inspection apparatuses necessary for
specific self inspection activities.
3) Place :
A flat land where work may be performed and to which a service car or a truck crane is accessible.
(2) Range of standard maintenance time
1) Standard maintenance time=Direct maintenance time×Preparation time
2) Direct maintenance time : Net time actually spent for maintenance
3) Spare time :
Time needed to move machines for service, prepare safety operations, discuss work, and process the needs
of the body.
(3) Extra time (not included in the standard service time)
1) Repair time :
Machining, sheet metal, welding, melt cutting, folding and extracting bolts, servicing parts, and painting.
2) Items excluded from service time because of uncertainty in time :
Receiving a vehicle into shop, transfer, delivery, inspection on completion, investigation of causes of faults,
diagnosis, and inspection.
3) Indirect time :
Time for ; field work, preparation of necessary parts before leaving for work, return for field work, waiting time
because of user’s convenience in the field, paper work after returning to shop, and preparation of bills.
4) Special time : Work at early morning, at midnight and on holidays are to be calculated separately.
5) Separate calculation : The operating time for service cars, trucks with a crane and crane trucks.
(4) Applicable machine for estimation of standard maintenance time
1) Standard machine
2) A well maintained and controlled machine with a standard combination of attachments which is used in a
general environment.
12-3
12.1 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF

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

ASSY : Assembly Cyl : Cylinder SOL : Solenoid
ATT : Attachment E/G : Engine SW : Switch
BRG : Bearing F hose : Flexible hose V : Valve
(2) Classification of working code
No. Group Remarks

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

1) Tools designated by E/G maker are used
2) Genuine parts are changed
3) Correct working procedures are observed.
• The time required for works specified in this Chapter shows the total time for maintenance.
12-4
Work to be Unit :
Group Location Unit Remarks
done Hour
00 Bucket relation See 32.1.2
01 Bucket ASSY Detach/attach 1 pc. Include adjustment. 0.5
02 • Bucket attaching and detaching position Preparation 1 pc. 0.1
03 • Bucket attaching pin Detach/attach 1 Include stopper pin. 0.1
04 • Bucket drive pin Detach/attach 1 0.1
05 • Bucket sling and movement Preparation 1 pc. 0.1
06 Bucket (single) O/H 1 pc. Not include attaching and detaching 2.0
07 • Tooth Replace 1 pc. 0.5
08 • Side cutter Replace 1 pc. 1.0
09 • Bushing Replace 1 pc. 0.5
10 Arm relation See 32.1.3

11 Arm ASSY Detach/attach 1 pc. 1.0
12 • Bucket cylinder attaching and Preparation 1 pc. 0.3
detaching position and piping
13 • Bucket cylinder rod pin Detach/attach 1 pc. Include stopper pin 0.1
14 • Bucket cylinder head pin Detach/attach 1 pc. Include stopper pin 0.1
15 • Bucket cylinder assy Detach/attach 1 pc. 0.1
16 • Arm cylinder rod pin Detach/attach 1 pc. Include stopper pin 0.1
17 • Boom top pin Detach/attach 1 pc. 0.1
01 Attachment
18 • Arm sling and movement Detach/attach 1 pc. 0.1
30 Boom relation See 32.1.4

31 Boom ASSY Detach/attach 1 pc. 1.0
32 • Boom attaching and detaching position Preparation 1 pc. 0.1
33 • Boom cylinder temporary slinging Preparation 2 pcs. 0.2
34 • Boom cylinder rod pin Detach/attach 2 Include two stopper pins. 0.2
35 • Boom cylinder piping Detach/attach 2 pc. 0.2
36 • Arm & bucket piping Detach/attach 1 pc. 0.2
37 • Boom assy temporary slinging Detach/attach 1 pc. 0.1
38 • Boom foot pin Detach/attach 1 Include stopper pin. 0.2
39 • Boom assy slinging Detach/attach 1 pc. 0.1
40 Arm cylinder attaching and detaching Detach/attach 1 pc. 0.3
41 • Arm cylinder piping Detach/attach 1 pc. 0.1
42 • Arm cylinder head pin Detach/attach 1 pc. Include stopper pin. 0.1
43 • Arm cylinder slinging Detach/attach 1 pc. 0.1
50 Boom cylinder attaching and detaching Detach/attach 2 pcs. 0.6
51 • Boom cylinder piping Detach/attach 2 0.2
52 • Boom cylinder head pin Detach/attach 2 pcs. 0.2
53 • Boom cylinder slinging Detach/attach 2 0.2
60 Bucket cylinder O/H 1 3.0
61 • Pin bushing Replace 1 Include seal. 1.0
70 Arm cylinder O/H 1 3.0
12-5
Work to be Unit :
done Hour
71 • Pin bushing Replace 1 set Include seal. 1.0
80 Boom cylinder O/H 2 6.0
01
81 • Pin bushing Replace 1 set Include seal. 1.0
10 Cab relation See 33.1.2

11 Cab ASSY Detach/attach 1 pc. 1.4
12 • Front lower glass, floor mat Detach/attach 1 pc. each 0.1
13 • Seat rear cover attaching bolt Detach/attach 4 places 0.2
14 • Seat rear cover Detach/attach 1 pc. each 0.2
15 • Right side panel (include A/C duct) Detach/attach 3 0.3
16 • Cable and harness (electric) Detach/attach 6 0.2
17 • Cab mounting bolt Detach/attach 8 pcs. 0.2
18 • Cab slinging Detach/attach 3 places 0.2
20 Guard relation See 33.1.4

21 Bonnet (H1) Detach/attach 1 pc. 0.2
22 Bonnet assy (H3) Detach/attach 1 pc. 0.2
23 Bonnet assy (H2) Detach/attach 1 pc. 0.2
24 Bracket (5) Detach/attach 1 pc. 0.2
02 Cab & Guard
25 Bracket assy (3) Detach/attach 1 pc. 0.2

26 Cover assy (1,2,4,9) Detach/attach 1 pc. 0.5
27 Bracket (7,8) Detach/attach 1 pc. 0.4
28 Bracket (20,22) Detach/attach 1 pc. 0.3
29 Cover assy (21) Detach/attach 1 pc. 0.2
30 Cover assy (A1,A3,A4) Detach/attach 1 pc. 0.3
31 Panel assy (B1) Detach/attach 1 pc. 0.2
32 Guard assy (33,34) Detach/attach 1 pc. 0.3
33 Cover assy (C4) Detach/attach 1 pc. 0.2
34 Panel assy (C1) Detach/attach 1 pc. 0.2
36 Stay (D1) Detach/attach 1 pc. 0.2
38 Bracket (32) Detach/attach 1 pc. 0.2
39 Box (29) Detach/attach 1 pc. 0.2
40 Bracket assy (27) Detach/attach 1 pc. 0.2
41 Cover (E1,E2) Detach/attach 1 pc. 0.3
42 Cover assy (36) Detach/attach 1 pc. 0.2
43 Duct (F1) Detach/attach 1 pc. After removing counterweight 1.0
Note: The numbers in the parenthesis like guard (14) match the guard numbers on the upper structure.
12-6
Work to be Unit :
done Hour
50 Under cover relation See 33.1.5
51 Cover (1) Detach/attach 1 pc. 0.1
02 Cab & Guard

60 Counterweight relation See 33.1.11
61 Counterweight ASSY Detach/attach 1 pc. 0.4
62 • Counterweight lifting jig Detach/attach 1 set 0.1
63 • Counterweight temporary slinging Preparation 1 pc. 0.1
64 • Counterweight mounting bolt Detach/attach 1 pc. 0.1
65 • Counterweight slinging Detach/attach 1 pc. 0.1
10 Intake relation See 33.1.9

11 Air cleaner ASSY Detach/attach 1 pc. 0.5
12 • Hose (2) Detach/attach 1 0.1
13 • Hose (4) Detach/attach 1 0.1
14 • Air cleaner mounting bolt Detach/attach 1 set 0.1
15 • Element Replace 1 0.1
20 Exhaust relation See 33.1.10
21 Muffler ASSY Detach/attach 1 pc. 0.4
22 • U bolt Detach/attach 1 pc. 0.2
23 • Clamp ASSY Detach/attach 1 pc. 0.2
03 Swing frame
30 Radiator relation See 33.1.12

31 Radiator ASSY Detach/attach 1 pc. 5.0
32 • Coolant (LLC) Replace 1 pc. 0.2
33 • • Concentration of coolant Measuring 1 pc. 0.2
34 • A/C condenser Detach/attach 1 pc. 0.2
35 • Stay Detach/attach 1 pc. 0.1
36 • Bracket Detach/attach 1 0.2
37 • Sub tank hose Detach/attach 1 pc. 0.1
38 • Fan guard Detach/attach 1 pc. 0.2
39 • Water hose (radiator to E/G) Detach/attach 2 0.4
40 • Radiator mounting bolts removing Detach/attach 1 set 0.2
41 • Under cover Detach/attach 3 pc. 0.3
42 • Hydraulic oil tank suction stopper Detach/attach 1 pc. 0.2
43 • Hydraulic oil piping Detach/attach 1 pc. 0.6
Note: The numbers in the parenthesis like cover (2) match the guard numbers on the upper structure.
12-7
Work to be Unit :
done Hour
44 • Inter cooler hose & tube Detach/attach 2 pcs. 0.4
(E/G to inter cooler)
45 • Radiator lifting or hoisting Detach/attach 1 pc. 0.2
46 • Radiator inter cooler core & oil cooler Cleaning 1 pc. 0.8
Other necessary works Detach/attach 1 pc. 1.0
50 Fuel relation See 33.1.6
51 Fuel tank ASSY Detach/attach 1 pc. 1.0
52 • Fuel Replace 1 pc. 0.2
53 • Hose (tank side) Detach/attach 2 0.1
54 • Fuel filter Detach/attach 1 pc. 0.1
55 • Fuel tank installing bolts Detach/attach 1 set 0.2
56 • Tank slinging Detach/attach 1 pc. 0.2
Other necessary works Detach/attach 1 pc. Guard 0.6
60 Hydraulic oil tank relation See 33.1.7

61 Hydraulic oil tank ASSY Detach/attach 1 pc. 2.5
62 • Cover Detach/attach 1 pc. 0.2
63 • Hydraulic oil Replace 1 pc. 0.4
64 • Main line return hose Detach/attach 2 pc. 0.4
65 • Pilot drain hose Detach/attach 1 pc. 0.2
03 Swing frame
66 • Pump suction hose Detach/attach 1 pc. 0.4

67 • Mounting bolt Detach/attach 1 pc. 0.2
68 • Hydraulic oil tank slinging Detach/attach 1 pc. 0.2
69 • Return filter Replace 1 0.2
70 • Suction filter Cleaning 1 0.2
Other necessary works Detach/attach 1 pc. Guard 1.0
80 Pump relation See 33.1.8
81 Pump ASSY Detach/attach 1 pc. 2.0
82 • Hydraulic oil tank cover Detach/attach 1 pc. 0.2
83 • Strainer & stopper Detach/attach 1 pc. 0.3
84 • Piping Detach/attach 1 set 0.8
85 • Pump slinging Detach/attach 1 pc. 0.4
86 • Cleaning Cleaning 1 pc. 0.1
87 • Vent air Adjust 1 pc. 0.1
88 Pump ASSY O/H 1 pc. 3.0
Other necessary works Detach/attach 1 pc. Guard, Counterweight 1.0
90 Swing motor unit relation See 33.1.18
91 Swing motor ASSY Detach/attach 1 pc. 2.2
93 • Mounting bolt Detach/attach 1 set 0.6
94 • Unit slinging Detach/attach 1 pc. 0.4
95 • Cleaning and sealant Cleaning 1 set 0.2
96 Swing motor O/H 1 pc. 3.0
97 Swing reduction gear O/H 1 pc. 3.5
12-8
Work to be Unit :
done Hour
100 Swivel joint relation See 33.1.19
101 Swivel joint ASSY Detach/attach 1 2.2
102 • Piping (Top part only) Detach/attach 1 set 0.4
103 • Whirl stop bolt Detach/attach 1 0.2
104 • Cover Detach/attach 1 0.3
105 • Joint & elbow Detach/attach 1 set 0.3
106 • Mounting bolts Detach/attach 1 set 0.3
107 • Swivel joint slinging Detach/attach 1 0.3
108 • Cleaning Cleaning 1 set 0.2
109 Swivel joint O/H 1 set 3.0
Other necessary works Detach/attach 1 set Lower piping 0.5
110 Multi control valve See 33.1.15

111 • Multi C/V ASSY Detach/attach 1 After removing guard 1.7
112 Write hose name on multi C/V connecting hose Detach/attach 1 set 0.3
114 • Mounting bolt Detach/attach 1 set 0.3
Other necessary works Detach/attach 1 set Guard 0.4
120 Main control valve See 33.1.15
121 Main control valve ASSY Detach/attach 1 pc. 2.0
03 Swing frame
122 • Attach tag to port name of pipe Preparation 1 pc. 0.5

124 • Bracket mounting bolts Detach/attach 1 set 0.1
125 • Valve slinging Detach/attach 1 pc. 0.1
126 Main control valve ASSY Detach/attach 1 set 5.0
130 Valve relation

131 Solenoid valve ASSY (7-section) Detach/attach 1 1.0
132 • Attach tag to port name of pipe Preparation 1 0.2
135 Hydro valve assy (Swing pilot line) Detach/attach 1 set 0.3
140 Engine (E/G) mounting relation See 33.1.13

141 Engine ASSY Detach/attach 1 pc. After removing pump & radiator 1.5
142 • Harness connector & grounding & Detach/attach 1 set 0.2
cable connection
143 • Fuel hose Detach/attach 1 set 0.1
144 • Others Detach/attach 1 set 0.4
145 • Mounting bolt Detach/attach 1 pc. 0.4
146 • Engine slinging Detach/attach 1 set 0.2
147 • Cleaning Cleaning 1 pc. 0.2
148 Engine O/H 1 set Reference for engine (Chapter 51)
12-9
Work to be Unit :
done Hour
Other necessary works Detach/attach 1 set Removing and installing guard 0.6
Detach/attach 1 set Removing and installing Counterweight 0.4
Detach/attach 1 set Removing and installing pump 2.0
Detach/attach 1 set Removing and installing air cleaner 0.4
Detach/attach 1 set Removing and installing muffler 0.4
Detach/attach 1 set Removing and installing radiator 2.5
03 Swing frame
150 Upper frame See 33.1.20

151 Upper frame ASSY Detach/attach 1 pc. After removing swivel joint 1.0
153 • Upper frame slinging Detach/attach 1 pc. 0.3
155 • Sealant Apply 1 set 0.2
Other necessary works Detach/attach 1 set Cab 1.4
Detach/attach 1 set Guard 0.3
Detach/attach 1 set Counterweight 0.4
Detach/attach 1 set Boom 1.4
00 Travel relation See 34.1.2

01 Track link ASSY Detach/attach One side Include adjustment of tension 1.0
02 • Track link attaching and detaching position Preparation One side 0.1
03 • Master pin Detach/attach One side 0.4
04 • Track link extending and winding Detach/attach One side 0.4
05 Shoe plate Replace 1 pc. 0.4
10 Upper roller relation See 34.1.3

11 Upper roller ASSY Detach/attach 1 After removing track link 0.2
12 Upper roller O/H 1 1.0
04 Travel system
20 Lower roller relation See 34.1.4

21 Lower roller ASSY Detach/attach 1 0.2
22 Lower roller O/H 1 1.0
30 Front idler relation See 34.1.5

31 Front idler ASSY Detach/attach One side After removing track link 0.5
32 Front idler ASSY slinging Detach/attach One side 0.2
33 Front idler ASSY Detaching One side 0.2
34 Idler ASSY O/H One side 1.0
35 Idler adjuster ASSY O/H One side Replace spring 2.0
36 • Grease cylinder O/H One side 0.5
40 Sprocket See 34.1.6

41 Sprocket Replace One side After removing track link 0.5
12-10
Work to be Unit :
done Hour
50 Travel motor relation See 34.1.7
51 Travel motor ASSY Detach/attach One side After removing track link 1.4
52 • Motor cover Detach/attach One side 0.1
53 • Hydraulic piping Detach/attach One side 0.7
54 • Motor mounting bolts Detach/attach One side 0.4
55 • Motor slinging Detach/attach One side 0.1
56 Motor cleaning Cleaning One side 0.1
57 Travel motor O/H One side 3.0
04 Travel system
58 Travel reduction gear O/H One side 3.0
60 Swivel joint relation

61 Pipe on swivel joint travel side Detach/attach 1 pc. See 33.1.19 0.5
62 Swivel joint O/H 1 pc. See 33.2.6 3.0
70 Swing bearing See 34.1.8

71 Swing bearing ASSY Detach/attach 1 pc. After removing upper frame 0.6
72 Swing bearing mounting bolts Detach/attach 1 set 0.4
73 Swing bearing slinging Detach/attach 1 pc. 0.2
Controller
C-1 Controller (KPSS) Replace 1 0.5
C-2 Gauge cluster Replace 1 1.0
C-4 Air conditioner Amplifier Replace 1 2.0
C-8 Engine controller Replace 1 0.5
Diode
06 Electric equipments
D-4 Diode Replace 1 0.3

12-11
Work to be Unit :
done Hour
Electric equipments
E-1 Fuse & relay box Replace 1 0.3
E-2 Alternator Replace 1 1.0
E-3 Hour meter Replace 1 0.3
E-5 Horn (High) Replace 1 0.3
E-6 Horn (Low) Replace 1 0.3
E-7 Tuner AM / FM (OCE) Replace 1 0.3
E-8 Speaker left Replace 1 0.3
E-9 Speaker right Replace 1 0.3
E-10 Receiver dryer Replace 1 Include gas sealing. 1.0
E-11 Air-con compressor Replace 1 0.4
E-12 Battery Replace 2 0.4
E-13 Travel alarm Replace 1 0.3
E-14 Cigarette lighter Replace 1 0.3
E-15 Fusible link Replace 1 0.2
E-16 One way call amp Replace 1 0.3
E-17 One way call speaker Replace 1 0.3

E-22 DC-DC controller Replace 1 0.2
Light
L-1 Boom work light left Replace 1 Bulb 0.2
L-2 Frame work light right Replace 1 0.2
L-3 Swing flasher left Replace 1 0.2
L-4 Swing flasher right Replace 1 0.2
L-5 Room light Replace 1 0.2
Motor
M-1 Starter motor Replace 1 Include Counterweight removing and installing. 1.0
M-3 Wiper motor Replace 1 0.5
M-4 Washer motor Replace 1 0.5
M-8 Grease motor Replace 1 0.5
M-9 Roof wiper motor Replace 1 0.5
Proportional valve
PSV-A Arm variable recirculation proportional valve Replace 1 0.3
PSV-B P2 unload proportional valve Replace 1 0.3
PSV-C Travel straight proportional valve Replace 1 0.3
PSV-D P1 unload proportional valve Replace 1 0.3
12-12
Work to be Unit :
done Hour
Opt. relief adjustment proportional
PSV-E Replace 1 0.3
valve 1
Opt. relief adjustment proportional
PSV-I Replace 1 0.3
valve 2
PSV-P1 P1 pump proportional valve Replace 1 0.3
PSV-P2 P2 pump proportional valve Replace 1 0.3
Relay
R-1 Battery relay Replace 1 0.3
R-2 Starter relay Replace 1 0.3
R-3 Glow relay Replace 1 0.3
R-4 Safety relay Replace 1 0.1
R-5 Horn relay Replace 1 0.1
R-6 Work light relay Replace 1 0.1
R-8 Travel alarm relay Replace 1 0.1
R-12 Revolution right relay Replace 1 0.1
R-13 Revolution left relay Replace 1 0.1
R-15 Nibbler open relay Replace 1 0.1
R-16 Nibbler ciose relay Replace 1 0.1

R-23 Auto idle stop relay 1 Replace 1 0.1
R-24 Auto idle stop relay 2 Replace 1 0.1
R-25 E/G emergency stop relay Replace 1 0.1
R-26 Safety lock lever relay Replace 1 0.1
R-28 Alternator relay Replace 1 0.1
R-29 Wiper motor relay (Normal rotation) Replace 1 0.1
R-30 Wiper motor relay (Reverse rotation) Replace 1 0.1
R-31 Wiper motor arc prevention relay Replace 1 0.1
R-32 Washer motor relay Replace 1 0.1
R-53 Glow relay (ECU) Replace 1 0.1
Sensor
SE-1 Pressure sensor : Bucket digging Replace 1 0.3
SE-2 Pressure sensor : Bucket dump Replace 1 0.3
SE-3 Pressure sensor : Boom up Replace 1 0.3
SE-4 Pressure sensor : Boom down Replace 1 0.3
SE-5 Pressure sensor : Swing Replace 1 0.3
SE-7 Pressure sensor : Arm in Replace 1 0.3
SE-8 Pressure sensor : Arm out Replace 1 0.3
SE-9 Pressure sensor : Travel right Replace 1 Include under cover removing and installing 0.5
SE-10 Pressure sensor : Travel left Replace 1 Include under cover removing and installing 0.5
SE-11 Pressure sensor : P2 side OPT. Replace 1 Include under cover removing and installing 0.3
12-13
Work to be Unit :
done Hour
SE-13 E/G speed sensor Replace 1 0.3
SE-15 Fuel level sensor Replace 1 Include guard removing and installing 0.5
SE-16 Accel potentio Replace 1 0.5
SE-20 Pressure sensor : P1 side (OPT.) Replace 1 Include under cover removing and installing 0.5
SE-22 Pressure sensor : P1 pump Replace 1 0.3
SE-23 Pressure sensor : P2 pump Replace 1 0.3
SE-29 Opt. selector detect sensor Replace 1 0.3
Solenoid
SV-1 Swing parking SOL Replace 1 0.3
SV-3 2-speed travel SOL Replace 1 0.3
SV-4 Safety lock lever SOL Replace 1 0.3
Switch
SW-1 Key switch Replace 1 0.3

SW-4 Swing parking release switch Replace 1 0.3
SW-5 Horn switch (RH) Replace 1 0.3
SW-8 Clogged air filter switch Replace 1 0.3
SW-10 Horn switch (left) Replace 1 0.3
SW-11 Safety lock lever switch Replace 1 0.3
SW-13 Travel alarm switch Replace 1 0.3
SW-15 Conflux/single select switch Replace 1 0.3
SW-17 Skylight wiper switch Replace 1 0.3
SW-19 Wiper interlock switch Replace 1 0.3
SW-22 KPSS release switch Replace 1 0.3
SW-26 Cab work light switch Replace 1 0.3
SW-29 Nibbler open switch Replace 1 0.3
SW-30 Nibbler close switch Replace 1 0.3
SW-33 Revolution right switch Replace 1 0.3
SW-34 Revolution left switch Replace 1 0.3
SW-36 Water separator restrlction switch Replace 1 0.3
SW-37 Travel independent switch Replace 1 0.3
SW-55 Boom work light switch Replace 1 0.3
12-14
12.2 ENGINE MAINTENANCE SERVICE STANDARD TIME LIST
This page is left blank because we had not received related infomation from "Engineerring Division".
12-15
[MEMO]
12-16
13. MAINTENANCE STANDARD AND
TEST PROCEDURE
TABLE OF CONTENTS 13
13.1 HOW TO USE THE MAINTENANCE STANDARD AND CAUTIONS TO BE EXERCISED ..........13-3
13.2 PERFORMANCE INSPECTION STANDARD TABLE.....................................................13-4
13.3 MEASUREMENT OF ENGINE SPEED ...........................................................................13-6
13.3.1 MEASUREMENT OF ENGINE SPEED..................................................................13-6
13.4 MEASUREMENT OF HYDRAULIC PRESSURE ............................................................13-7
13.4.1 PREPARING TO MEASURE HYDRAULIC PRESSURE .......................................13-7
13.4.2 PLACE TO INSTALL PRESSURE GAUGE............................................................13-7
13.4.3 PRESSURE ADJUSTMENT POSITION.................................................................13-8
13.4.4 PROCEDURE FOR ADJUSTING RELIEF VALVE.................................................13-10
13.5 MEASURING TRAVEL PERFORMANCES.....................................................................13-11
13.5.1 TRAVEL SPEED.....................................................................................................13-11
13.5.2 DEVIATION OF TRAVEL .......................................................................................13-11
13.5.3 PERFORMANCES OF PARKING BRAKE .............................................................13-12
13.5.4 DRAIN RATE OF TRAVEL MOTOR.......................................................................13-13
13.6 MEASURING SWING PERFORMANCES.......................................................................13-14
13.6.1 SWING SPEED ......................................................................................................13-14
13.6.2 PERFORMANCE OF SWING BRAKE ...................................................................13-14
13.6.3 PERFORMANCE OF SWING PARKING BRAKE ..................................................13-15
13.6.4 DRAIN RATE OF SWING MOTOR ........................................................................13-16
13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES ....................................13-17
13.7.1 OPERATING TIME OF CYLINDERS .....................................................................13-17
13.7.2 OIL TIGHTNESS OF CYLINDERS.........................................................................13-18
13.8 MEASURING PERFORMANCES OF SWING BEARING ...............................................13-19
13.9 MECHATRO CONTROLLER...........................................................................................13-20
13.9.1 ENGINE CONTROL INPUT / OUTPUT..................................................................13-20
13.9.2 ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT (B-C ADJUSTMENT) .............. 13-20
13-1
13. MAINTENANCE STANDARD AND TEST PROCEDURE

SK125SR : YV05-04501~
S5YY1313E01
(OCE/S.E.ASIA)
SK135SRLC-2 : YH05-07001~
13-2
13.1 HOW TO USE THE MAINTENANCE STANDARD AND CAUTIONS TO BE

EXERCISED
(1) Application
1) When the machine is new ;
Confirm that the performances are in accordance with standard specifications as compared to the
performance standards.
2) At specific self inspection ; (Rule by country)
Use the data for the criterion, for the purpose of correction, adjustment and replacement.
3) When performances are deteriorated ;
Determine whether it is caused by a fault or end of service life after long hours of operation, to be used for
safety and economical considerations.
4) When main components are replaced ;
For example, use data to restore performances of pumps and others.
(2) Terminology
1) Standard values ;
Values to be used to condition or assemble a new machine. Where special notes are not given, these values
represent standard specifications (machine with standard attachments and standard shoes).
2) Reference values for remedy ;
Values at which readjustment is required. In order to ensure performance and safety it is strictly prohibited
to use the machine over the specified values.
3) Service limit ;
This is the limit value at which reconditioning is impossible without replacement of parts. If the value is
expected to exceed the service limit before next inspection and correction are performed, replace the parts
immediately. The operation over the specified values causes increase of damage and requires the down time
of machine, and also causes safety problems.
(3) Cautions to be Exercised at Judgment
1) Evaluation of measured data ;
Disagreement of measuring conditions, variations of data peculiar to a new machine, and measuring errors
are to be evaluated. Determine generally at what levels measured values are located, instead of determining
whether or not values fall within or run out of the reference values.
2) Determining correction, adjustment or replacement ;
Machine performances deteriorate with time as parts wear and some deteriorated performances may be
restored to new levels. Therefore, determine correction, adjustment or replacement, depending upon the
operating hours, kind of work and circumstances in which the machine is placed, and condition the machine
performances to its most desirable levels.
(4) Other Cautions to be Exercised
1) Parts liable to degrade ;
Rubber products, such as, hydraulic hoses,
O rings, and oil seals deteriorate with time ; replace them at regular intervals or at overhauls.
2) Parts requiring regular replacement ;
Out of critical hoses that are necessary to secure safety, we designate Very Important Parts (V.I.P) and
recommend that they should be replaced regularly.
3) Inspection and replacement of oils and greases ;
In performing maintenance, it is necessary for the user to familiarize himself with how to handle the machine
safely, cautions to be exercised and inspection/lubrication procedures. Refer to the operators manuals as
well.
13-3
13.2 PERFORMANCE INSPECTION STANDARD TABLE
Unless otherwise specified, measure it on "H" mode.
Table13-1
Measuring Position Standard Tolerance Adjusting Measuring
Inspection Item Unit
Position Size Port value Hi Lo Point condition
Class
NAS 9
Cleanliness of hydraulic oil Hydraulic oil in tank — — — Sampling
Standard Measuring condition
or less
Hydraulic oil temperature Tank surface 50 (122) + 5 (41) - 5 (23)
°C
— Atmospheric temp
50°C~-10°C
Water temperature Radiator surface 75 (167) + 15 (59) - 15 (5) (°F) — (122°F~14°F)
H mode Lo idle 1000 + 30 - 30 LOW throttle
Measure the engine
Engine speed
H mode Hi idle 2000 + 30 - 30 Full throttle (HI idle)
not required
Adjustment
speed at multi display on
B mode Hi idle 2000 + 30 - 30 Perform all
the gauge cluster, or min-1
A mode Hi idle 2000 + 30 - 30 measurement with
measure with diesel
Decel 1050 + 30 - 30 the air-conditioner
speed meter.
S mode Hi idle 1900 + 30 - 30 "OFF".
Pilot primary pressure circuit G pump a3 5.0 (725) + 0.5 (+73) 0 PR1 HI idle
valve pressure
P1 a1
Main relief
ATT 34.3 (4970) + 0.7 (+100) - 0.5 (-73) MR1 Boom up

P2 a2
P1 a1
Boost — — — — —
P2 a2
R 37.8 (5480) 0 - 4.0 (-580) OR4 Boom down
Boom a1
High pressure circuit
H 37.8 (5480) 0 - 4.0 (-580) OR3 Boom up

Over load relief valve pressure
R 37.8 (5480) 0 - 4.0 (-580) OR8 Arm out

Main pump
Arm a2
H PF1/4 37.8 (5480) 0 - 4.0 (-580) MPa OR7 Arm in
R 37.8 (5480) 0 - 4.0 (-580) (psi) OR2 Bucket dump
Bucket a1
H 37.8 (5480) 0 - 4.0 (-580) OR1 Bucket digging
RH 28.0 (4060) + 3.4 (+493) + 0.5 (+73) OR6 Swing RH
Swing a2
LH 28.0 (4060) + 3.4 (+493) + 0.5 (+73) OR5 Swing LH
FW —
RH a1 34.3 (4970) + 1.7 (+240) - 0.5 (-73) Simultaneous
Travel
RV —
operation of travel
FW —
LH a2 34.3 (4970) + 1.7 (+240) - 0.5 (-73) RH and LH
RV —
13-4
Standard
Inspection item Unit
value
Sprocket revolution 1st speed 30.4 ~ 33.6
min-1
(RH,LH) 2nd speed 50.6 ~ 56.0
Up 3.0 ~ 3.6
Boom
Down 2.7 ~ 3.3
Operating speed
Operating time of In 2.8 ~ 3.4

Arm sec (At no load)
cylinder Out 2.4 ~ 3.0
Digging 2.2 ~ 2.8
Bucket
Dumping 2.1 ~ 2.7
RH
Swing speed 4.7 ~ 5.9 sec / 1 rev
LH
1st speed Iron shoe 20.6 ~ 22.8
Travel speed sec / 20 m
2nd speed Iron shoe 12.8 ~ 14.0
Amount of travel
2nd speed 0 ~ 240 mm / 20 m
deviation
Parking brake drift 15 degree gradient 0 mm / 5 min
Performance of Swing Neutral position after
Performance
55 ~ 75 degree
brake 180° full speed swing
Performance of Swing
15 degree gradient 0 mm
parking brake
Tip of the bucket tooth 90
ATT amount of drift Boom cylinder 3 mm / 5min (At no load)
Arm cylinder 4
Amount of horizontal play at the bucket tooth 30 ~ 50 mm
The port relief valves No.OR1~OR8 on the control section are adjusted to the following operation numbers in
advance.
(1) Bucket digging, (2) Bucket dump, (3) Boom up, (4) Boom down
(5) Swing left, (6) Swing right, (7) Arm in, (8) Arm out

13-5
13.3 MEASUREMENT OF ENGINE SPEED

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

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

pushed.

4) The screen returns like No.45, No.44....each

time the "Washer switch" is pushed.
5) The display does not disappear unless the

starter switch is turned to"OFF".

Fig. 13-1 Switch for E/G speed indication
NO.2 ENG
G-3 SPEED SET 2205
MEAS 1 2201
MEAS 2 2201
G-5 ENG OIL PRS. LIVE
WATER TEMP. 100 OF
F
MODE HM
H-1 ACCEL. VOLT. 4.2V
POS 100%
ECU OUTPUT 0.5V
Fig. 13-2 Service diagnosis for E/G speed

measuring (Example)
13-6
13.4 MEASUREMENT OF HYDRAULIC PRESSURE

13.4.1 PREPARING TO MEASURE HYDRAULIC PRESSURE
(1) Hydraulic equipment
6.9 MPa (1000psi) pressure gauge : 1unit
49 MPa (7100psi) pressure gauge : 2 units
Pressure measuring equipment and instrument for
analysis : 1 set
(2) Measuring cleanliness of hydraulic oil
After releasing air in the hydraulic oil tank, open the

cover and sample oil in the hydraulic tank, and
measure with the instrument for analysis. If the
measured value is higher than the standard value,
replace the return filter or change the hydraulic oil.
13.4.2 PLACE TO INSTALL PRESSURE GAUGE

(1) Main circuit =" 258 258 =#
After releasing the pressure in hydraulic oil tank
and system, replace plugs PF1/4 of main pump
gauge ports (a1) (a2) with plugs for pressure
measurement, and attach pressure gauge 49 MPa
(7100 psi).
,H
,H *!
(2) Pilot circuit
Replace pilot gauge plug (a3) with plug PF1/4 for
pressure measurement, and attach pressure gauge
6.9 MPa (1000 psi). ,H ,H
=!
= =
Fig. 13-3 Gauge port on main pump
13-7
13.4.3 PRESSURE ADJUSTMENT POSITION

(1) Main control valve
PLUG FOR
OR7 : ARM (H) OPTIONAL RELIEF
MACHINE
TOP
MR1 : MAIN RELIEF OR3 : BOOM (H) OR2 : BUCKET (R)

(ATT & TRAVEL)
VIEW FROM RIGHT FRONT OF MACHINE
OR4 : BOOM (R) OR1 : BUCKET (H)
MACHINE
TOP
OR8 : ARM (R) PLUG FOR OPTIONAL RELIEF
VIEW FROM LEFT REAR OF MACHINE
Fig. 13-4 Relief valve position on main control valve
13-8
(2) Pilot relief valve

The pilot relief valve PR1 is located on the gear pump that is attached to the main pump.
A3
a3
Dr3
B3
PR1 ADJUST SCREW
FOR PILOT RELIEF
Fig. 13-5 Pilot relief valve position

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

OVERLOAD RELIEF OVERLOAD RELIEF
OR6 OR5
Fig. 13-6 Swing over load relief position
13-9
13.4.4 PROCEDURE FOR ADJUSTING RELIEF VALVE

(1) Pilot relief valve
Adjust it with adjust screw (311).
: 24 mm,
Tightening torque : 29.4 N•m (22 lbf•ft)
: 6 mm
No. of turns of adjust screw Pressure change MPa (psi)

LOCK NUT HEX24
1 turn Approx. 2.1 (305) 311
Fig. 13-7 Pilot relief valve
(2) Main relief valve
(Common for travel and ATT sections) %
Loosen lock nut (7) and adjust the pressure with
adjust screw (6). $
Tightening torque : 27~31 N•m (20~23 lbf•ft)
: 19 mm, Adjust screw
: 4 mm Fig. 13-8 Main relief valve

(Travel section, ATT common section)
1 turn Approx. 17.7 (2560)
(3) Over load relief valve

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

: 6 mm 0-:
Fig. 13-9 Over load relief valve
No. of turns of adjust screw Pressure change MPa (psi) (Boom, bucket, arm sections)
1 turn Approx. 17.7 (2560)
(4) Over load relief valve (Swing)

0-:!& 0-:!
When the pressure adjustment is required, loosen
lock nut (1) and adjust the pressure with cap (2).
: 30, 38mm,
Tightening torque :118 N•m (87 lbf•ft)
: 12 mm 4 !
Fig. 13-10 Swing over load relief valve
1 turn Approx. 10 (1450)
(5) Travel over load relief valve #

This valve was adjusted by manufacturer and
shipped. Do not replace the parts except O-ring.
Loosen cap (205) and adjust the pressure with shim
(213).
!
: 10 mm Fig. 13-11 Travel over load relief valve
13-10
13.5 MEASURING TRAVEL PERFORMANCES

13.5.1 TRAVEL SPEED
(1) Purposes
Measure the travel sprocket revolution and confirm
the performances between the hydraulic pump and
the travel motor of the travel drive system.
(2) Conditions
Hydraulic oil temperature ;
45~55°C (113~131°F)
Crawler on the right and left sides are tensioned
evenly.
(3) Preparation
Attach the reflection panel with a magnet to the Fig. 13-12 One side lifted position
travel motor cover.
Swing the swing frame through 90°as shown in Fig.
13-12 and make the crawler on one side take off the REFLECTION
ground, using the attachment. PANEL
(4) Measurement
Engine revolution; Hi idle
2-speed travel switch; 1st speed and 2nd speed
Measuring points ; Right and left
Method, example 1 ;
Measure revolution with a stroboscope
Fig. 13-13 Adhering position of reflection panel
Method, example 2 ;
Measure the revolutions per minute visually. Sprocket revolution Unit min-1
Measurement item Standard Reference value Service
value for remedy limit
RH H mode 1st speed 30.4~33.6 23.7~26.2 21.4 or less
&
LH H mode 2nd speed 50.6~56.0 39.5~43.7 35.7 or less
13.5.2 DEVIATION OF TRAVEL

(1) Purpose
Measure the amount of deviation at 20m (66ft) BOOM FOOT PIN
travel and confirm the horizontal balance between
the hydraulic pump and the travel motor of the
travel drive system.
(2) Condition
Hydraulic oil temperature ; ARM TOP PIN
45~55°C (113~131°F)
RH and LH crawler are tensioned evenly.
Firm, level ground Fig. 13-14 Travel position
13-11
(3) Preparation
1) Straight course more than 30m (108ft)
2) Travel position in which the bottom of the bucket
is lifted by about 30cm (1ft). A
(4) Measurement 20m (66ft)
1) Measure the max. deviation distance of the
circular arc in the 20m (66ft) length, excluding
Fig. 13-15 Measuring method
the preliminary run of 3~5m (10~16ft).
2) Operate the travel lever at the same time. Travel deviation Unit : mm (in) / 20m (66ft)
Measuring Reference value
position Standard value for remedy Service limit
A 240 (9.45) or less 480 (18.9) 720 (28.4)
13.5.3 PERFORMANCES OF PARKING BRAKE

(1) Purpose
Confirm that the parking brake holds a stopped
condition of the machine in a no-load travel position
and on a 15 degree slope.
(2) Condition BOOM FOOT PIN
A slope with (Approx. 15 deg) gradient and a
stopped condition in a no-load travel position
ARM TOP PIN
(3) Preparation
Place an angle meter on the shoe plate and confirm
that it makes an angle more than 15 degree. 15 degree slope
Hang a perpendicular in parallel with the guide
frame rib on the track frame and put a mark Fig. 13-16 Parking brake operating position
(matching mark) on the shoe plate.
(4) Measurement
Five minutes after the engine stops, measure the
movement distance of the matching mark.
C
GUIDE FRAME
Fig. 13-17 Method of measurement
Parking brake Unit : mm(in)/5min

C 0 1 (0.04) 2 (0.08)
13-12
13.5.4 DRAIN RATE OF TRAVEL MOTOR

(1) Purpose FORWARD 90 o 10
To measure the drain rate of the travel motor and to (3.54") (0.394")
confirm the performances of the travel motor. o 22 PIPE 40

(0.866") (1.57")
(2) Conditions
Hydraulic oil temperature ; RIB "A" STOPPER
150
(5.91")
45~55°C (113~131°F) "B"
(3) Preparation o 80
(3.15")
ROTARY DIRECTION
1) Place a stopper under the RH and LH travel
sprockets. Fig. 13-18 Location of stopper applied to travel
2) Stop the engine and release pressure from the sprocket
hydraulic circuit.
3) Connect a hose with the drain port of the travel
motor and take drain in a container.
(4) Measurement ; at Travel Lock
Unless you observe the rotary force direction at

travel lock, rib "A" may be broken by stopper "B" in
some cases. (See Fig. 13-18)
1) Start the engine and relieve pressure at the full

stroke of the travel lever. Fig. 13-19 Method of measuring the drain rate of
2) Measure the drain rate for 30 seconds of travel motor
relieving.
Drain rate of motor Unit : L(gal)/30sec
Drain rate 5 (1.3) 13 (3.4) 15~ (4.0~)
13-13
13.6 MEASURING SWING PERFORMANCES

13.6.1 SWING SPEED
(1) Purpose
Measure the swing time and confirm the
performances between the hydraulic pump and the
swing motor of the swing drive system.
(2) Conditions
45~55°C (113~131°F)
Firm, level ground
(3) Preparation
Put the bucket empty and extend the boom, arm
and bucket cylinder fully. Fig. 13-20 Swing speed measuring position (at the
And the machine becomes a position of minimum min. reach)
reach.
Swing speed Unit : sec/rev
(4) Measurement Measuring Reference value
Swing the machine by bringing the swing lever to its
Swing speed at
full stroke. Measure the time required to make two min. reach 4.7~5.9 6.0~7.6 8.0~
turns after one turn of preliminary run and calculate
the time required for one turn.
13.6.2 PERFORMANCE OF SWING BRAKE

(1) Purpose
Confirm the braking torque performances by the ARM TOP BOOM FOOT
swing relief valve. PIN PIN
(2) Conditions
45~55°C (113~131°F)
Firm, level ground
(3) Preparation Fig. 13-21 Swing brake performance measuring
1) Put the bucket empty, retract the arm cylinder position
fully and extend the bucket cylinders fully. And
move the boom so that the arm top pin is
positioned at same height with boom foot pin.
2) Put a matching mark on the outer circumference
of the swing bearing of the upper frame side and
of the track frame side. Place two poles (flags)
on the front and back of the extended line of the
matching mark.
13-14
(4) Measurement MEASURING THE LENGTH OF THE ARC OVER

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

Fig. 13-22 Measuring position of swing brake
performances

Swing brake performance Unit : degree
Swing 180 75 83 90 ~
13.6.3 PERFORMANCE OF SWING PARKING BRAKE

(1) Purpose
To confirm the mechanical performances of the
swing parking brake that is fitted to the inside of the
swing motor.
(2) Conditions
On a slope of 15 degree incline.
Stop the machine at right angles with the slope. Put
the bucket empty, retract the arm cylinder fully and
extend the bucket cylinder fully. And move the
boom so that the arm top pin is positioned at same
height with boom foot pin.
Fig. 13-23 Swing parking brake performance
measuring position
(3) Preparation MEASUREING THE LENGTH OF THE ARC OVER
Put the angle meter on the shoe plate and make THE OUTER CIRCUMFERENCE OF OUTER RACE
MATCHING MARKS ON
sure that the angle is more than 15 degree. OUTER RACE
Put a matching mark on the outer race side and on
the inner race side.
(4) Measurement
When five minutes has passed after the engine
stops, measure the length of the movement of the
MATCHING MARKS
matching marks. ON INNER RACE
Fig. 13-24 Measuring position of swing parking

brake performances
Performance of swing parking brake Unit : mm(in)/5min

C 0 1 (0.04) 2 (0.08)
13-15
13.6.4 DRAIN RATE OF SWING MOTOR

(1) Purpose
Measure the drain rate of the swing motor and
confirm the performances of the swing motor.
(2) Conditions
Hydraulic oil temperature ; 45~55°C (113~131°F)
Firm, level ground
(3) Preparation
1) Stop the engine.
2) Release pressure from inside the hydraulic
circuit.
3) Disconnect the swing motor drain hose from its
end returning to the hydraulic oil tank and take
oil in a container.
4) Put a plug to the tank side.
(4) Measurement ; at Swing Lock Fig. 13-25
1) Start the engine and put the side faces of bucket
Travel deviation Unit : L(gal)/30sec
against the inside of the right or left shoe plates. Measuring Reference value
2) Relieve the swing motor at full stroke of the
swing motion. Drain rate 5.0 (1.3) 8.0 (2.1) 11~ (2.9~)
3) Collect the amount of drained oil in a container

for 30 seconds.
13-16
13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES

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

(3) Preparation

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

soft ground or cushioning such as rubber tires ;
never put the bucket against concrete or other
solid material.
30cm (1ft)
Measurement 2 ; Arm in and out, bucket digging
and dump Fig. 13-28 Measuring position for arm in and out
In a position in which the tooth of the bucket rises to motions
a level of about 30cm (1ft) above ground, measure
Cylinder Operating time Unit : sec
the full stroke operating time required with the arm
and bucket operating levers at full stroke. position Standard value for remedy Service limit
2.2~2.8 2.8~3.6 3.8~
2.1~2.7 2.7~3.5 3.6~
3.0~3.6 3.8~4.6 5.0~
2.7~3.3 3.5~4.2 4.5~
2.8~3.4 3.6~4.4 4.7~
2.4~3.0 3.1~3.8 4.1~
13-17
13.7.2 OIL TIGHTNESS OF CYLINDERS

(1) Purpose B
Confirm that the cylinder oil tight by checking the BOOM FOOT PIN
moving length of the cylinder rods. C
(2) Condition A
Hydraulic oil temperature ; 45~55°C (113~131°F)
Firm, level ground ARM TOP PIN D
After cylinders are replaced, bleed off air from the
cylinders, before checking for oil tightness. Fig. 13-29
Retract the arm cylinder rod 50mm (2in) from stroke
end so that the piston does not match a same range Oil tightness of cylinder Unit : mm(in)/5min
of the cushioning mechanism. Measuring
Standard value
Reference value
Service limit
position for remedy
(3) Preparation A 3 (0.12) 6 (0.24) 9~ (0.35~)
Put the bucket empty. Extend the arm cylinder rod B 4 (0.16) 8 (0.32) 12~ (0.47~)
50mm (2in) from the most retracted position. And C - - -
extend the bucket cylinders fully. Then hold the D 90 (3.54) 115 (4.53) 150~ (5.91~)
boom so that the arm top pin is positioned at same
height with boom foot pin.
(4) Measurement
Measure the items five minutes after the engine is
turned off.
13-18
13.8 MEASURING PERFORMANCES OF SWING BEARING

(1) Purpose
LOCATION OF BEARING
Measure the gap between the lower frame and the MOUNTING BOLTS
bottom face of the swing bearing and estimate the
degree of wear of the swing bearing.
SWING BEARING
(2) Condition A
Firm, level ground
The swing bearing mounting bolts are not
DIAL INDICATOR
loosened.
The swing bearing is lubricated well, not making LOWER FLAME
abnormal sound during turning.
Fig. 13-30 How to measure the axial play of swing
bearing
(3) Preparation
1) Install a dial indicator to the magnetic base and
fix it to the lower frame.
90 ~100
2) Direct the upper swing body and the lower frame
toward the travel direction, bring the probe of the
dial indicator in contact with the bottom surface
of the outer race on the swing body side and set 30cm (1ft)
the reading at zero. Fig. 13-31 Measuring position 1

(4) Measurement 1 (Measuring position 1 and 2)
1) Measure the displacement of the outer race in ARM TOP BOOM FOOT
PIN PIN
the axial direction in position 1 [The arm at
90°~110° and the crawler front is lifted by
attachment about 30cm (1ft)] and in position 2,
using a dial indicator.
Fig. 13-32 Measuring position 2
Axial play of swing bearing Unit : mm (in)

0.5~1.5 1.9~2.9 3.0~
A (0.02~0.06) (0.08~0.11) (0.12~)
(5) Measurement 2 (Measuring position 3)

1) Retract the arm cylinder fully and extend the ARM TOP BOOM FOOT
PIN PIN
bucket cylinder fully. And move the boom so that
the arm top pin is positioned at same height with
boom foot pin. Then swing the bucket right and
left by man power.
But in this case, the gap of the attachment is
included.
Fig. 13-33 Measuring position 3
Right and left movement of the tip of bucket Unit : mm (in)

Bucket 30~50 (1.18~1.97) 80 (3.15) 120 (4.72)
13-19
13.9 MECHATRO CONTROLLER

13.9.1 ENGINE CONTROL INPUT / OUTPUT
INJECTOR
C-8:
ENGINE CONTROLLER
E-1:
C-2: FUSE&RELAY (ECU)
GAUGE CLUSTER BOX
ENGINE
ENGINE SPEED
SENSOR
PUMP
PROPORTIONAL
C-1: VALVE
STARTER ACCEL MECHATRO CONTROLLER
SWITCH POTENTIO METER
Fig. 13-34 INPUT / OUTPUT
13.9.2 ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT (B-C ADJUSTMENT)
13.9.2.1 PURPOSE OF THE ADJUSTMENT

There are 2 kinds of adjustment of mechatro controller as shown below; every adjustment is an essential function
to ensure performance of machine.
(1) Adjustment of pump ("B" adjustment)
This adjustment is performed to correct the output variation by coordinating the output hydraulic pressure with
engine rated output.
(2) Adjustment of unloading valve ("C" adjustment)
This adjustment is performed to correct the open variation of unloading valve to improve the operability further.
13.9.2.2 IN CASES WHERE THE ADJUSTMENT OF MECHATRO CONTROLLER IS REQUIRED;

When the following parts are replaced or repaired, carry out the adjustment without fail.
(1) Mechatro controller
(2) Engine or engine controller
(3) Hydraulic pump or hydraulic pump proportional valve
(4) Unloading proportional valve, spool of unloading valve
13-20
13.9.2.3 PREPARATION
(1) Raise the oil temperature to about 50°C (122°F) to warm up the engine.
(2) Turn the air-conditioner OFF.
(3) Turn the starter key switch OFF to stop the engine.
When the mechatro controller was replaced, the following error code is displayed because the adjustment data
is not entered.
A215, A225, A015, A025, A035
As the error codes other than those shown above may suggest failures of machine, repair the machine into the
ordinary operating condition according to Error Code List.
13-21
13.9.2.4 ADJUSTING PROCEDURE
MULTI DISPLAY
BUZZER STOP SWITCH WORK MODE SELECT SWITCH
WASHER SWITCH
WIPER SWITCH
SELECT SWITCH
Fig. 13-35 Gauge cluster

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

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

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

And the unloading proportional valve and pump proportional valve actuate,

accordingly the loading of pump is increased.

The "ENGINE SPEED", P1, P2 "PUMP PRESSURE" and P1, P2 pump
"PROPO-VALVE" current (command value) are indicated.
5) After detection of the engine rated speed, the adjustment of pump is
FINISH PUMP
automatically completed. And "FINISH PUMP" is displayed. ENGINE SPEED
2000rpm
(Press the buzzer stop switch on gauge cluster while this display is appeared PUMP PRESSURE
C-1 35.0M C-2 35.0M
and the adjustment is completed. The unloading adjustment required later is PROPO-VALVE
E-1 300mA E-2 300mA
not performed, and default value is written.)
13-22
(2) Adjustment of unloading valve ("C" adjustment)

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

unloading proportional valve is automatically terminated. And "FINISH

UNLOAD" is displayed.

The speed is shifted to the speed corresponding to acceleration potentiometer.

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

unloading proportional valves. The adjusting range is usually 520~635mA.
Stop the engine. (The adjusted data is automatically stored.)
(3) Corrective actions taken when the adjustment can not be performed;
1) In cases where the adjustment of pump can not be performed; And "ERROR
ERROR PUMP
PUMP" is displayed. ENGINE SPEED
2000rpm
Judging condition 1: PUMP PRESSURE
C-1 35.0M C-2 35.0M
PROPO-VALVE
P1 and P2 average pump pressure at the time when the adjustment is E-1 300mA E-2 300mA
completed is 25MPa or less.
Judging condition 2:
The adjustment does not complete although the pump proportional valve
current reaches to the specified value.
The P1 and P2 pump pressures usually increase to 33~38MPa.

When the pressure does not increase;
a. Identify the reason why the pressure does not increase,
• Check that the relief valve operates normally.
• Check that the hydraulic circuit is free from leak of pressure.
• Check that the pressure sensor functions normally.
And so on.
b. Identify the reason why the actual flow rate does not increase,
• Check that the pump proportional valve operates normally.
• Check that the pump regulator operates normally.
And so on.
13-23
2) In cases where unloading valve can not be performed; And "ERROR

ERROR UNLOAD
UNLOAD" is displayed. ENGINE SPEED
2000rpm
Judging condition 1: PUMP PRESSURE
C-1 2.0M C-2 2.0M
PROPO-VALVE
The pump pressure does not increase up to the pressure in the range of the D-1 300mA D-2 300mA
specified adjustment. Or the increased pressure is held as it is.
Judging condition 2:
Pressure sensor of either P1 pump or P2 pump is failed.
Normally the pump pressures of P1 and p2 pumps gradually increase to

10~25MPa.
(It may be affected by operating oil temperature.)
When the pump pressure does not increase;

a. Identify the reason why the pressure does not increase,
• Check that the relief valve operates normally.
• Check that the hydraulic circuit is free from leak of pressure.
• Check that the pressure sensor functions normally.
And so on.
(4) Other precautions:
1) In the event of a failure, there is case where the adjustment may not be
performed normally.
First serve the machine, and perform the adjustment work.
2) In the condition where large load is constantly applied to engine, the
adjustment could not be performed normally.
13-24
(5) When the adjustment of unloading valve only is performed; ("C" adjustment)
In the event where only unloading valve and unloading proportional valve are
replaced, perform the adjustment of unloading valve only.
Procedure
1) Turn starter switch ON keeping the work mode selector switch on the gauge
cluster pressed, and hold it for 5~10 seconds, and then release it.
(If the engine is started, the following indication is not displayed. Therefore do
not start the engine.)

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

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

Like the output adjustment, when adjustment data is not entered in mechatro
controller, "READY" is indicated. If the adjustment operation is once
performed, "FIN" is indicated.
4) Press selector switch on gauge cluster to display "START ENG".
START ENG
"ENGINE SPEED", P1, P2 "PUMP PRESSURE" and "STEP" (acceleration ENGINE SPEED
2000rpm
command voltage) are indicated. PUMP PRESSURE
C-1 00.0M C-2 00.0M
STEP
140
5) After starting engine, press selector switch on gauge cluster and "MEMORY
MEMORY UNLOAD
UNLOAD" is indicated, the engine speed is automatically increased and the ENGINE SPEED
2000rpm
adjustment of unloading valve is performed. PUMP PRESSURE
C-1 2.0M C-2 2.0M
"ENGINE SPEED", P1, P2 "PUMP PRESSURE" and "PROPO-VALVE" PROPO-VALVE
D-1 300mA D-2 300mA
(acceleration command current) are indicated.
6) When the unloading proportional valve operates to the specified value, the

adjustment of unloading proportional valve automatically completes. "FINISH

UNLOAD" is indicated.

The speed is shifted to the speed corresponding to acceleration potentiometer.

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

P2 unloading proportional valves. The adjusting range is usually 520~635mA.
Stop the engine. (The adjusted data is automatically stored.)
13-25
[MEMO]
13-26
21. MECHATRO CONTROL SYSTEM
TABLE OF CONTENTS
21.1 SUMMARY OF MECHATRO CONTROL SYSTEM.........................................................21-4

21.1.1 MECHATRO CONTROL SYSTEM IN GENERAL ..................................................21-4
21.1.2 UNLOAD VALVE CONTROL..................................................................................21-6
21
21.1.3 POSITIVE CONTROL & P-Q CONTROL ...............................................................21-7
21.1.4 BOOM UP CONFLUX CONTROL ..........................................................................21-9
21.1.5 ARM IN RECIRCULATION & CONFLUX CONTROL.............................................21-10
21.1.6 ARM-IN ANTI-CAVITATION CONTROL ................................................................21-12
21.1.7 ARM-OUT CONFLUX CONTROL ..........................................................................21-13
21.1.8 BUCKET DIGGING (DUMP) CONTROL ................................................................21-14
21.1.9 SWING PRIORITY CONTROL ...............................................................................21-15
21.1.10 TRAVEL STRAIGHT CONTROL ............................................................................21-16
21.1.11 PRESSURE RELEASE CONTROL........................................................................21-18
21.1.12 N&B SWITCH CONTROL (OPTION) .....................................................................21-20
21.1.13 OPTION CONFLUX CONTROL (OPTION) ............................................................21-21
21.1.14 N&B SOLENOID RELIEF VALVE CONTROL ........................................................21-22
21.2 MECHATRO CONTROLLER...........................................................................................21-23
21.2.1 SUMMARY OF MULTI DISPLAY ...........................................................................21-23
21.2.2 SELF DIAGNOSIS DISPLAY..................................................................................21-28
21.2.3 SERVICE DIAGNOSIS DISPLAY FUNCTION .......................................................21-31
21.2.4 TROUBLE HISTORY DIAGNOSIS.........................................................................21-41
21.2.5 TROUBLE DIAGNOSIS MODE ..............................................................................21-42
21.2.6 SET PROCEDURE OF MAINTENANCE SCHEDULE ...........................................21-43
21.2.7 ADJUSTING PROCEDURE OF DISPLAY .............................................................21-44
21.2.8 MECHATRO CONTROL EQUIPMENT ..................................................................21-48
21-1

SK125SR : YV05-04501~
S5YY2113E01
(OCE/S.E.ASIA)
SK135SRLC-2 : YH05-07001~
21-2
PREFACE
This manual explains only those related to the electro hydraulic conversion as mechatro control. This manual
summarizes the mechatro system and the function of the mechatro controller related apparatuses. Regarding the
conditions before and after each conversion, refer to the hydraulic system and the electric system.
21-3
21.1 SUMMARY OF MECHATRO CONTROL SYSTEM

21.1.1 MECHATRO CONTROL SYSTEM IN GENERAL
ELECTRIC
CONTROLLER INPUT SIGNAL
HYDRAULIC
PILOT SECONDARY PRESSURE VOLTAGE OUTPUT L1
SOLENOID PROPORTIONAL VALVE SECONDARY PRESSURE
SOLENOID PROPORTIONAL VALVE PRIMARY PRESSURE MAIN CIRCUIT
LH RH LH RH
OPTION PILOT VALVE
PILOT VALVE
PILOT VALVE FOR TRAVEL
FOR ATT
SE-9
SE-10
SE-11
MULTI CONTROL VALVE OR SENSOR BLOCK
LOW PRESSURE SENSOR

SE-4
(4)
SE-3
(3) L2
GAUGE CLUSTER
SE-2 L3
(2)
LCD DISPLAY
FOR SELECTION SE-1
(1)
FUEL GAUGE
COOLANT TEMP. GAUGE SE-8
(8)
LOWER SW.
SCREEN CHANGE SE-7
(7)
BUZZER STOP L4
MODE (6)
WASHER
WIPER SE-5
(5)
OUTPUT VOLTAGE
TRAVEL
DECEL
SERIAL COMMUNICATION
SERIAL COMMUNICATION
ACCEL DIAL
SE-16
SE-23
PROPORTIONAL VOLTAGE
HIGH PRESSURE SENSOR
C-1 SE-22 L5
MECHATRO CONTROLLER A1 A2
ENGINE A3
INJECTOR SPEED SENSOR
SE-13
KPSS
RELEASE SWITCH PSV -P1
P1 PUMP PROPORTIONAL VALVE
: HIGH PRESSURE SENSOR
(FOR P1,P2 : 2pcs) PSV -P2
: INJECTOR P2 PUMP PROPORTIONAL VALVE
: E/G SPEED SENSOR CAN COMMUNICATION L6

C-8
: LOW PRESSURE SENSOR ENGINE CONTROLLER
(ATT : 7pcs, TRAVEL : 2pcs) ENGINE SPEED L7
COMMAND CURRENT
VOLTAGE 24V
PROPORTIONAL COMMAND CURRENT
21-4
MAIN CONTROL VALVE

L1
SE-29
ARM OUT DUMP DOWN FORWARD FORWARD LEFT ARM OUT

(8) (2) (4) (3) (6) (8) SV-13
P1 UNLOAD
SELECTOR VALVE
CONFLUX
BOOM UP
BOOM LOW SPEED
TRAVEL RIGHT
ARM 2 SPEED
ARM 1 SPEED
TRAVEL LEFT
N&B
BUCKET
P2 UNLOAD
OPTION
STRAIGHT
SWING
TRAVEL
SOL
P1 P2
(1) (3) (5) (7)
DIGGING UP REVERSE REVERSE RIGHT ARM IN
L2 SOLENOID VALVE
L3
L4
SWING MOTOR PARKING RELEASE
TRAVEL MOTOR 1,2 SPEED SELECT
BOOM CYLINDER
BOOM DOWN RECIRCULATION
BOOM CONFLUX
SWING PARKING BRAKE
SAFETY LOCK LEVER

TRAVEL 1,2 SPEED
TRAVEL STRAIGHT
ARM IN 2 SPEED
L5
P1 UNLOAD
P2 UNLOAD
ARM CYLINDER
ARM OUT CONFLUX
ARM IN CONFLUX
PSV PSV PSV PSV SV SV SV
-A -D -C -B -3 -1 -4
(7)
ARM IN
L6 BUCKET CYLINDER
DIGGING / DUMP CONFLUX
L7
PROPORTIONAL VALVE
SOLENOID VALVE ) BLOCK
21-5
21.1.2 UNLOAD VALVE CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
VALVE
SWING
BOOM
STRAIGHT
SOLENOID
TRAVEL
P2 UNLOAD
P2 P1
PILOT PILOT
(LEFT) (RIGHT) VALVE VALVE
OPTIONAL
PILOT VALVE
PILOT VALVE
FOR TRAVEL
LOW LOW
SE-11 PRESSURE PRESSURE
SE-10 SE-9 SENSOR SENSOR
SE-1~4 SE-5,7,8
pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 UNLOAD
PROPORTIONAL
VALVE PSV-D
MECHATRO
PILOT SECONDARY PRESSURE CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
(1) On starting any one of operations, the control pilot secondary pressure switches spools and enters in respective
low pressure sensors.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes
pilot signal and outputs command according to the input voltage to each unload pressure proportional valve.
(3) Each unload pressure proportional valves output pilot secondary pressure according to the command output by
mechatro controller and switches each unload spools.
(4) With this operation, the bleed opening according to lever manipulated movement is obtained, consequently the
pump pressure which is used to actuate each actuators are delivered and makes each actuator start operating.
21-6
21.1.3 POSITIVE CONTROL & P-Q CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
P2 UNLOAD
SOLENOID
TRAVEL
OPTIONAL
PILOT VALVE
P2 P1
SE-23 SE-22
SE-11
(LEFT) (RIGHT) PILOT PILOT

VALVE VALVE
PILOT VALVE
FOR TRAVEL
LOW LOW
PRESSURE PRESSURE
SE-10 SE-9 SENSOR SENSOR
SE-1~4 SE-5,7,8
pi
PILOT SIGNAL
PROCESS P2 PUMP P2 PUMP
PROPORTIONAL PROPORTIONAL
VALVE COMMAND VALVE PSV-P2
pi
pi
P1 PUMP P1 PUMP
PROPORTIONAL PROPORTIONAL
PILOT SIGNAL VALVE COMMAND VALVE PSV-P1
PROCESS
PILOT SECONDARY PRESSURE MECHATRO
CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
21-7
(1) Positive control

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

SECONDARY PRESSURE
SECONDARY PRESSURE
PUMP PROPORTIONAL
PUMP PROPORTIONAL
PILOT PRESSURE PUMP DELIVERY PRESSURE
21-8
21.1.4 BOOM UP CONFLUX CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT P2 P1
VALVE
LOW
PRESSURE
SENSOR
SE-3
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
BOOM UP PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-D
MECHATRO
CONTROLLER
pi : PROPORTIONAL VALVE
BOOM UP PILOT SECONDARY PRESSURE SECONDARY PRESSURE
(1) On starting boom up operation, boom up operating pilot pressure switches boom spool and boom up conflux
spool and is input to low pressure sensor.
pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves and P1 and
P2 unload proportional valves.
(3) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output
by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload pressure
control valve.
(4) With original hydraulic pressure command, boom main spool and boom up conflux spool are switched, and also
with the command by mechatro controller, P1 and P2 pumps and P1 and P2 unload valves are switched and
consequently the delivery oil on P1 pump side confluxes delivery oil on P2 pump side during boom up operation.
21-9
21.1.5 ARM IN RECIRCULATION & CONFLUX CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
TRAVEL LEFT
ARM 1 SPEED
ARM 2 SPEED
N&B
SELECTOR
BUCKET
OPTION
SWING
BOOM
VALVE
STRAIGHT
P2 UNLOAD
SOLENOID
TRAVEL
PILOT
VALVE
P2 P1
LOW
LOW
PRESSURE
PRESSURE
SENSOR
SE-1~6 SENSOR
SE-7
CONTROL PROCESS
FOR 2 SPEED
pi PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
ARM IN PILOT SECONDARY PRESSURE
P1 PUMP
PROPORTIONAL
VALVE PSV-P1

PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
P1 UNLOAD
pi PROPORTIONAL
VALVE PSV-D
pi
REVERSE PROPORTIONAL REVERSE PROPORTIONAL
VALVE CONTROL VALVE FOR ARM
PROCESS FOR ARM 2 SPOOL PSV-A
2 SPOOL
ARM PILOT SECONDARY
PRESSURE
P2 PUMP PRESSURE MECHATRO pi : PROPORTIONAL VALVE

CONTROLLER SECONDARY PRESSURE
21-10
(1) Recirculation and conflux (Low loading)

1) On starting arm-in operation, arm-in operating pilot secondary pressure is input to arm 1 spool and low
pressure sensor.
2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller
processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves,
P1 and P2 unload proportional valves and reverse proportional valve for arm-in 2 spool.
In case of combined operation, the pilot pressure other than arm-in operation is input to low pressure sensor
and the output voltage is input to mechatro controller. And the mechatro controller processes pilot signal
according to the combined operation and outputs command, which is different from the arm-in independent
operation, to P1 pump proportional valve, P1 unload proportional valve and reverse proportional valve for
arm-in 2 spool.
3) Primary pressure of reverse proportional valve for arm-in 2 spool is arm-in pilot secondary pressure and it
switches arm 2 spool by proportional secondary pressure according to command. (Arm 2 spool controls
recirculation rate and conflux rate.)
The other proportional valves output proportional secondary pressure according to command from mechatro
controller. These proportional valves change the delivery rate of P1, P2 pump, and switch P1, P2 unload
valve.
4) The arm 1 spool is switched according to original oil pressure command, and P1, P2 pumps, P1, P2 unload
spools and arm 2 spool are switched according to the command output by mechatro controller, and
consequently the return oil from the arm cylinder rod side is recirculated in P1 and P2 pumps delivery oil
during arm operation.
(2) Recirculation cut
The voltage output by high pressure sensor on P2 side is input to mechatro controller, and when the load is
raised during arm-in operation the mechatro controller processes a pilot signal according to the detected
pressure by high pressure sensor, in this time the command value outputs to the reverse proportional valve for
arm 2 spool so that the arm-in 2 speed spool is shifted to the recirculation cut position.
The reverse proportional valve for arm-in 2 spool outputs pilot secondary pressure according to the command
output by mechatro controller and switches arm 2 spool to recirculation cut position, and consequently
recirculation passage is blocked.
21-11
21.1.6 ARM-IN ANTI-CAVITATION CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT
VALVE
P2 P1
LOW
PRESSURE ACCEL
SENSOR POTENTIO
SE-7
pi pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2

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

pi
VALVE FOR ARM VALVE FOR ARM 2 SPOOL
2 SPOOL COMMAND PSV-A pi
ENGINE SPEED (COMMAND VALUE) MECHATRO

CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
(1) On starting arm-in operation, arm-in operating pilot secondary pressure switches arm 1 spool and is input to low
pressure sensor.
(2) The engine speed command output by accel potentiometer is input to mechatro controller.
(3) Low pressure sensor output voltage is input to mechatro controller, and the mechatro controller processes pilot
signal processing and outputs command according to the input voltage to P2 pump proportional valve and P2
unload proportional valve.
(4) And also outputs command according to input pressure output by potentiometer to reverse proportional valve
for arm 2 spool.
(5) Each proportional valves output pilot secondary pressure according to each command output by mechatro
controller, and consequently since the reverse proportional valve for arm 2 spool is controlled to spool stroke
according to engine speed and changes recirculation rate to prevent the cavitation from occurring even if pump
delivery rate is low due to low engine speed.
21-12
21.1.7 ARM-OUT CONFLUX CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT P2 P1
VALVE
LOW
PRESSURE
SENSOR
SE-8
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
ARM OUT PILOT SECONDARY PRESSURE

pi
P1 PUMP
PROPORTIONAL
VALVE PSV-P1

pi
P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

pi
P1 UNLOAD
PROPORTIONAL
VALVE PSV-D
MECHATRO
CONTROLLER
SECONDARY PRESSURE
(1) On starting arm-out operation, arm-out operating pilot pressure switches arm 1 spool and arm 2 spool and is
input to low pressure sensor.
pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves and P1 and
P2 unload proportional valves.
by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload pressure
control valves.
(4) With original hydraulic pressure command, arm 1 spool and arm 2 spool are switched and also with the
command output by mechatro controller, P1 and P2 pumps and P1 and P2 unload valves are switched, and
consequently the delivery oil on P2 pump side confluxes delivery oil on P1 pump side during arm-out operation.
21-13
21.1.8 BUCKET DIGGING (DUMP) CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT
VALVE P2 P1
LOW
PRESSURE
SENSOR
SE-1(2)
pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1
BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 UNLOAD
PROPORTIONAL
VALVE PSV-D
MECHATRO
BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
(1) On starting bucket digging (dump) operation, bucket digging (dump) operating pilot pressure switches bucket
spool and is input to low pressure sensor.
pilot signal and outputs command according to the input voltage to P1 pump proportional valve, and P1 unload
proportional valve.
by mechatro controller and changes P1 pump delivery rate and switches P1 unload valve.
21-14
21.1.9 SWING PRIORITY CONTROL
BOOM UP CONFLUX
P1 UNLOAD
PILOT
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
VALVE
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
P2 P1
LOW
PRESSURE
SENSOR
SE-5 SE-7
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
P1 PUMP
ARM IN PILOT SECONDARY PRESSURE PROPORTIONAL
pi PILOT SIGNAL VALVE PSV-P1
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
P1 UNLOAD
PROPORTIONAL
ARM IN PILOT SECONDARY PRESSURE VALVE PSV-D
pi
TRAVEL STRAIGHT TRAVEL STRAIGHT
PROPORTIONAL COMMAND
VALVE COMMAND PROPORTIONAL
VALVE PSV-C
SWING PILOT SECONDARY PRESSURE VALVE CONTROL VALVE FOR ARM
pi PROCESS FOR ARM 2 SPOOL PSV-A
2 SPOOL
MECHATRO pi : PROPORTIONAL VALVE

SWING PILOT SECONDARY PRESSURE CONTROLLER SECONDARY PRESSURE
(1) During arm-in operation, arm operating pilot secondary pressure switches arm 1 spool and is input to low
pressure sensor on starting swing operation (or arm-in operation during swing operation), and swing operation
pilot secondary pressure switches swing spool and is input to low pressure sensor.
pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves, P1 and P2
unload pressure proportional valves, travel straight valve and reverse proportional valve for arm 2 spool.
by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload spool, travel
straight spool, arm 2 spool.
(4) With original hydraulic pressure command, arm 1 spool and swing spool are switched and also with the
command by mechatro controller, P1 and P2 unload spools, travel straight spool and arm 2 spool are switched
enabling for two pump flow rates to be supplied to the arm cylinder head side, and consequently the return oil
on arm cylinder rod side is recirculated into arm cylinder head side.
(5) Because the return oil on the arm rod side is recirculated, the working pressure is raised and pump delivery rate
is used for swing operation by priority, and operated by the recirculated oil, making the operation with minimum
speed drop possible.
21-15
21.1.10 TRAVEL STRAIGHT CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
OPTIONAL
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
PILOT VALVE N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
P2 UNLOAD
SOLENOID
TRAVEL
(LEFT) (RIGHT) PILOT PILOT
VALVE VALVE P2 P1
PILOT VALVE
FOR TRAVEL
SE-11 LOW
SE-10 SE-9
PRESSURE
SENSOR
TRAVEL STRAIGHT SIGNAL
pi
PILOT SIGNAL TRAVEL STRAIGHT
PROCESS PROPORTIONAL
VALVE PSV-C

pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

pi
PILOT SIGNAL
PROCESS P1 UNLOAD
PROPORTIONAL
VALVE PSV-D
MECHATRO
PILOT SECONDARY PRESSURE CONTROLLER
SECONDARY PRESSURE
21-16
(1) Judgment travel straight

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

21-17
21.1.11 PRESSURE RELEASE CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
GAUGE CLUSTER PILOT
VALVE
P2 P1
SE-23 SE-22
ENGINE
PRESSURE
RELEASE
CONTROL
pi
ENGINE SPEED
CONTROL
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1
pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
pi PILOT SIGNAL
PROCESS P1 UNLOAD
PROPORTIONAL
VALVE PSV-D
MECHATRO
CONTROLLER SECONDARY PRESSURE
(1) Change mechatro controller to "PRESSURE DRAINING MODE" by operating switch on gauge cluster.
For detail of changing mode method, refer to "How to switch to "Pressure release mode"" on item 22.11.1.
(2) Once mechatro controller decides it as pressure release control, regardless of each input signal (operating pilot,
accel potentiometer, etc.) the mechatro controller;
1) Outputs minimum tilt angle command to P1, P2 pump proportional valves and fixes P1, P2 pump to minimum
tilt angle.
2) Outputs command of pressure release and outputs command of pressure release control to ECU and fixes
engine speed to pressure release control speed.
3) Outputs maximum command to P1 and P2 unload valves and each pilot secondary pressure fixes P1 and
P2 unload valves to the maximum opening.
21-18
(3) Mechatro controller senses output voltage from the main pump high pressure sensor, decides the pump
pressure and displays "DRAINING HYD. PRESS" or "FAIL DRAIN HYD. PRESS" on gauge cluster.
(4) Each pump delivery oil is unloaded to tank passage enabling for the remained pressure (trapped pressure) to
be released by operating each control lever and switching spool with the unload valve opened.
21-19
21.1.12 N&B SWITCH CONTROL (OPTION)
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
PRESSURE SENSOR N&B
FOR BREAKER SELECTOR
BUCKET
OPTION
SE-29
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
P2 P1
A MODE
B MODE
GAUGE CLUSTER
pi
B MODE SWITCH MECHATRO

CONTROLLER
pi : OUTPUT OF N&B SELECTOR SOLENOID
(1) Nibbler circuit

1) Select A mode through gauge cluster.
2) Nibbler display appears on gauge cluster.
3) The return oil from the nibbler passes through selector valve and option spool and led to tank line of main
control valve.
4) When selecting A mode through gauge cluster, the breaker pressure sensor has not function to output.
It is in normal when there is no output from sensor in A mode, and in cases of other than above, error display
is output to gauge cluster.
(2) Breaker circuit
1) Select B mode through gauge cluster.
2) Breaker display appears on gauge cluster.
3) The return oil from the breaker passes through selector valve and directly returns into hydraulic oil tank.
4) When selecting B mode through gauge cluster, the breaker pressure sensor outputs signal.
It is in normal when there is an output from sensor in B mode, and in cases of other than above, error display
is output to gauge cluster.
21-20
21.1.13 OPTION CONFLUX CONTROL (OPTION)
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
PILOT VALVE
TRAVEL
P2 P1
SINGLE / CONFLUX
LOW
SWITCH
PRESSURE
SENSOR
SE-11
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
OPTION PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

pi
PILOT SIGNAL
P1 UNLOAD
PROCESS PROPORTIONAL
VALVE PSV-D

pi
PILOT SIGNAL
PROCESS TRAVEL STRAIGHT
PROPORTIONAL
VALVE PSV-C
MECHATRO pi : PROPORTIONAL VALVE
OPTION PILOT SECONDARY PRESSURE CONTROLLER SECONDARY PRESSURE
(1) Select the Conflux with the aid of Conflux/Single switch.

(2) On starting option operation, option operating pilot pressure switches option spool and is input to low pressure
sensor.
pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional valves, P1 and
P2 unload pressure proportional valves and travel straight proportional valve.
(4) Each proportional valves output pilot proportional valve secondary pressure according to the command output
by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload valves and
travel straight valve of the control valve.
(5) The parallel passage on P2 side is connected to P1 port because of the travel straight valve switched and P1
pump delivery oil confluxes P2 pump delivery oil because of the P2 unload valve switched.
21-21
21.1.14 N&B SOLENOID RELIEF VALVE CONTROL
SOLENOID RELIEF
PSV-E
BOOM UP CONFLUX
VALVE
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
BOOM
VALVE
STRAIGHT
P2 UNLOAD
SOLENOID
TRAVEL
SOLENOID RELIEF
PILOT P2 P1
VALVE
VALVE
PSV-I
RELIEF VALVE
SOLENOID
OUTPUT
LOW
PRESSURE
SENSOR
SE-11
OPTION PILOT
SECONDARY PRESSURE
(1) Solenoid relief valve

Using solenoid relief valve, relief pressure is able to set in advance.
1) Using gauge cluster, setting pressure of A and B mode is selectable individually.
2) When optional operation is done, command value according to setting pressure which is selected with
solenoid relief valve is output from mechatro controller.
3) Each proportional valve outputs pilot proportional secondary pressure according to command value from
mechatro controller, and the pressure switches relief pressure.
21-22
21.2 MECHATRO CONTROLLER

21.2.1 SUMMARY OF MULTI DISPLAY
Electro-hydraulic conversion information is displayed on the multi display of the gauge cluster.
(1) Controls
GAUGE
CLUSTER
SAFETY
LOCK
LEVER
RIGHT
CONTROL
LEVER
STARTER SWITCH
ACCEL DIAL
KPSS WORK MODE

RELEASE SWITCH
SWING PARKING
BRAKE RELEASE
SWITCH
ENGINE
FUSE & ECU
MECHATRO RELAY BOX
CONTROLLER
A DETAIL A
(2) Gauge cluster
No. Name
11 1 Engine coolant temperature gauge
2 Fuel level gauge
22:00
3 Screen change switch
H
4 Buzzer stop switch
5 Work mode select switch
1
6 Washer switch
7 Wiper switch
2
3 8 Travel high speed, low speed select switch
9 Auto accel switch
10 10 Select switch
6
4 9 8 5 7 11 Multi display (LCD)
21-23
(3) KPSS work mode switch

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

• H mode: For heavy duty excavating work
• B mode: For works with breaker
• A mode: For demolition works with crusher
(Nibbler)
10:25
S
• The initial setting (default) of work mode had been set
to "S" mode at factory.
As for the work mode after the engine starts, the
mode that was used the last time engine was stopped
is automatically set.
Check that the selected mode conforms to the work
before starting work.
• Check that the attachment in use conforms to the
work mode before starting work. If not conformed,
select proper mode with the work mode select switch.
• The operation under improper work mode may cause
damage to machine.
Work mode Display Contents
S mode
10:25 "S mode"is suitable for standard digging and loading works and is in
fuel saving and is maintained well-balanced relations with workload.
H mode
10:25 "H mode"is suitable for heavy duty digging work which gives priority
to the workload at the high speed.
B mode
10:25 For the work with breaker, select "B mode" without fail.
A mode
10:25 For the work with crusher (nibbler), select "A mode".
21-24
1) Pump flow rate adjustment (A mode /B mode)

No. Switches 1 2 3 4
3 KPSS work mode select switch
4 Washer switch
5 Wiper switch
6 Travel speed select switch
7 Auto accel switch 5
8 Select switch 8 7 6
Fig. 21-1
According to some kind of attachment, it is required to change the flow rate for service circuit. Change the flow rate
in accordance with the procedure mentioned below.
In this machine, last set flow rate has been stored and the initial flow rate is 130L/min. The adjustment (increase or
decrease) of flow rate is changeable by 10L/min step.
Main screen Attachment mode (A mode)
10:25 Flow
rate 130 L/m
Flow
rate 100 L/m
Flow
rate 100 L/m
Enter
H A A
(a) (b) (d)
Increase/Decrease
In Breaker mode (B mode)
Flow Flow Flow

rate 130 L/m rate 100 L/m rate 100 L/m
Enter
B B
(c) (d)
Screen in Attachment/Breaker mode Increase/Decrease
A mode B mode When the conflux switch is tuned
on, the double flow rate is displayed.
Flow Flow
rate 130 L/m rate 130 L/m
A B
(b) (c)
1. Turn starter key switch on and display main screen (a).

2. The display on the left lower corner of screen is changed in order of "S" → "H" → "B" → "A" each time the
"MODE" switch (3) is pressed under the condition where main screen (a) is displayed.
3. Select "A" and A mode screen is displayed, and select "B" and B mode screen is displayed.
4. Press select switch (8) in A/B mode display screens (b)/(c) and the value of flow rate reverses in black and
the screen (d) is displayed. In this condition, press FEED (4)/ (5) and the flow rate value increases or
decreases.
5. Select the desired setting value and then press select switch (8) and the flow rate is set to the desired value.
21-25
(4) Maintenance screen displays

This screen displays the remaining time to the end of recommended replacement/change interval specified for
filter/oil.
For the initial set value of recommenced replacement/change time, see the following table.
Replacement interval
Item Default
Engine oil 500 Hr
Fuel filter 500 Hr
Hydraulic oil filter 1,000 Hr
S.E.ASIA 2,000 Hr
Hydraulic oil
OCEANIA 5,000 Hr
This menu is available for confirmation of the following items.

The maintenance screen changes each time the screen change switch is pressed.
1. Remaining time display to the engine oil change

This display shows the remaining time to the coming engine oil change. 492Hr
ENGINE OIL
H
2. Remaining time display to the coming fuel filter replacement

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

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

This display shows the remaining time to the coming hydraulic oil 1992Hr
change. HYD. OIL
H
• The display automatically changes to the main screen, if switch is not operated for 30 seconds.
• For the setting procedure of maintenance time to be performed to the coming oil change in each type and
filter replacement, see the 21.2.6 SET PROCEDURE OF MAINTENANCE SCHEDULE.
21-26
(5) Gauge cluster display

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

FAILURE
W009
WATER TEMP.
W006 LOW FUEL LEVEL
AUTO IDLE STOP DRAIN WATER SEPA W010 WARM AUTO WARMING UP
(OCEANIA ONLY)
WARM FINISH WARM-UP CLOGGED AIR FLTR W008 CHANGE ENG OIL
DATA HYDRAULIC SYSTEM

CPU COMMUNICATION ENGINE STOP CPU BACK UP MODE
ERROR
SWING BRAKE
W001 CHARGE ERROR
DISENGAGED
Error codes were stored as trouble history, and displayed on the monitor by the trouble history display function.
21-27
21.2.2 SELF DIAGNOSIS DISPLAY

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

(3) Self diagnosis display items

As-displayed clock (Usually main screen). When error occurred, specifies failed section and the failure type with
the aid of error code.
Alphabet: Decide system failure occurred.
10:25 B 01 3 Last 2nd and 3rd digits: Specifies failed section.
B013
Last 1 digit: Specifies failure type.
This failure symbol is displayed simultaneously with error code during failure diagnosis.
ERROR CODE
A B C D E F G H I K P R
Last 2,3 Controller Low pressure High pressure Proportional Proportional Solenoid Speed sensor Potentiometer Communication Battery relay Engine ECU Relay output
digits memory sensor sensor valve for valves valve for pumps valve etc
Boom up P1 pump P1 unload P1 pump Acceleration Battery relay Wiper ark
01 prevention relay
Torque Boom down P2 pump P2 unload P2 pump Swing parking Wiper ark forward
02 adjust data rotation relay
Unload Arm out Boom head Travel straight Travel 1,2 Angle sensor Wiper ark reverse
03 adjust data speed for shovel rotation relay
Arm in Option Angle sensors for Washer motor
04 selector shovel & ECU
Bucket Bucket stroke
05 digging limit
Bucket Arm 2 spool
06 dump for arm in
Swing
07
Engine coolant
08 temp. sensor
Travel right Fuel sensor
09
Refer to next page (Engine)
Travel left
10
Selector position CAN
11 detection communication
12
Swing flasher
13 right relay
Swing flasher
14 left relay
Travel alarm
15 relay
P1 side option AIS relay 2
16
P2 side option Engine stop
17 relay
Safety lock
18 lever relay
19
Adjustment
21 data sector 1
Adjustment
22 data sector 2
Hourmeter
23 sector 1
Hourmeter
24 sector 2
Proportional
25 valve adjust data
Cluster
31 communication
Refer to next page (Engine)
Larger than Larger than

0 normal range normal range
Transistor OFF CAN error
failure / Grounding
1 - short circuit
Wrong output Wrong output Transistor Transistor Over run
2 - ON failure ON failure
Disconnection Disconnection Disconnection Disconnection Transistor ON Disconnection Disconnection Time is over
failure /
3 - Disconnection
Power source Power source Power source Contact point is Power source
4 - short circuit short circuit short circuit melted and adhered short circuit
Wrong value
5
21-28
ECU failure code list

Failure Code Malfunctioned component Content of Failure [Class]/Limitation of output when failure occurs
20081 ADC monitoring ECU failure [1]
20082 Dfp_ADCMon A/D converter is abnormal in ECU. Engine is shut down
20084
20088
00291 Accelerator sensor 1 Analog signal input is defective. [5]
00292 SRC Defective analog input signal from controller is detected. -
Dfp_APP1
03838 Accelerator sensor Accelerator signal mutual comparison is defective. [5]
mutual diagnosis When there is deflection of 20% or more between CAN signal and analog signal, sensor detects it. -
Dfp_APPSync
01081 Atmospheric pressure sensor Atmospheric pressure sensor fails [4]
01082 Dfp_APSCD Defective operation of atmospheric pressure sensor in ECU (Disconnection, short circuit and characteristic defect) is detected. Engine power down
01021 Boost pressure sensor Boost pressure sensor failure [4]
01022 Dfp_BPSCD Defective operation of boost pressure sensor attached to engine (Disconnection, short circuit and characteristic defect) is detected. Engine power down
01101 Coolant temperature sensor Coolant temperature sensor failure [5]
01102 Dfp_CTSCD Defective operation of coolant temperature sensor attached to engine (Disconnection, short circuit and characteristic defect) is detected. Engine power down
05181 Q tune resistance Q tune resistance failure [8]
05182 SRCDfp_EngCD_TrqAdj Input failure of Q tune resistance is detected. -
06351 Cam single operation warning Crank sensor failure [3]
Dfp_EngMBackUp It is detected that crank sensor fails and engine is operated with the cam sensor. Engine power down
06361 Cam sensor Cam sensor failure [5]
06362 Dfp_EngMCaS1 Failure of cam sensor (Disconnection, short circuit, and damaged tooth) is detected. -
06371 Crank sensor Crank sensor failure [3]
06372 Dfp_EngMCrS1 Failure of crank sensor (Disconnection, short circuit, and damaged tooth) is detected. Engine power down
02281 Misalignment between cam and crank Misalignment between cam and crank [3]
Dfp_EngMOfsCaSCrS Misalignment between cam and crank is detected. Engine power down
00914 CAN accelerator CAN communication failure [7]
Dfp_FrmMngCANAPP It is detected that accelerator opening (APPREQ) received with CAN is defective. -
16744 APPREQ message time-out CAN communication failure [7]

Dfp_FrmMngTOAPPREQ Accelerator opening (APPREQ) signal is received by CAN. But it detects that the CAN -
cannot receive the signal.
20284 CAN transmission time-out CAN communication failure [7]
Dfp_FrmMngTxTO The transmission of CAN message is defective. -
06771 Glow relay power stage Glow relay failure [5]
06772 Dfp_GlwCD_Actr Failure of glow relay or wiring harness is detected. -
06774
06778
12311 SPI communication error ECU failure [1]
Dfp_HWEMonCom SPI (Serial peripheral interface): Serial communication malfunction between CPU and each internal IC occurs. Engine is shut down
12352 EEPROM ECU failure [5]
12354 Dfp_HWEMonEEPROM Defective reading and writing to EEPROM are detected. -
12358
16688 Recovery occurrence ECU failure [5]
Dfp_HWEMonRcyLocked Recovery (partial reset) occurred by ECU internal malfunction. -
16698 Recovery generation ECU failure [5]
Dfp_HWEMonRcySuppressed Recovery (partial reset) occurred by ECU internal malfunction. -
16708 Recovery generation ECU failure [5]
Dfp_HWEMonRcyVisible Recovery (partial reset) occurred by ECU internal malfunction. -
15421 CJ940 excessive voltage ECU failure [1]
Dfp_HWEMonUMaxSupply The supply voltage is excessive for power stage control IC. Engine is shut down
15432 CJ940 voltage is too low ECU failure [1]
Dfp_HWEMonUMinSupply The supply voltage is too low for power stage control IC. Engine is shut down
6511 Injector drive bank 1 Injector failure (ECU internal circuit) [1]
6512 Dfp_InjVlvBnk1A The injector drive circuit detected short circuit. Engine is shut down
6518
Dfp_InjVlvBnk1B The injector drive circuit detected disconnection. Engine is shut down
6532 Dfp_InjVlvBnk2A The injector drive circuit detected short circuit. Engine is shut down
6538
Dfp_InjVlvBnk2B The injector drive circuit detected disconnection. Engine is shut down
6551 Injector drive IC ECU failure [1]
6552 Dfp_InjVlvChipA IC which controls injector is malfunctioned. Engine is shut down
6554
6558
6561 Injector drive IC ECU failure [1]
6562 Dfp_InjVlvChipB IC which controls injector is malfunctioned. Engine is shut down
6564
6568
6571 Injector #1 Injector failure [1]
6574 Dfp_InjVlvCyl1A Short circuit is detected in injector or harness. Engine is shut down
6578
Dfp_InjVlvCyl1B Disconnection is detected in injector or harness. -
6598
Note) For detail of engine error code refer to "Section 51 ENGINE CHAPTER"
21-29
Failure Code Malfunctioned component Content of Failure [Class]/Limitation of output when failure occurs
6618

6638
20004 MPROP power stage MPROP failure [2]
20008 Disconnection and excessive load Disconnection or short circuit of MPROP or harness. Engine power down
Dfp_MeUnCDNoLoad
VB short Battery short circuit of MPROP or harness Engine power down
Dfp_MeUnCDSCBat
GND short circuit GND short circuit of MPROP or harness Engine power down
Dfp_MeUnCDSCGnd
14848 Supervision ECU failure [1]
Dfp_Montr Malfunction judgment by self-diagnosis function in ECU. Engine is shut down
16711 CAN A Pass off CAN communication failure [7]
Dfp_NetMngCANAOff Disconnection and short circuit of CAN communication line -
16731 CAN C Pass off CAN communication failure [7]
Dfp_NetMngCANCOff Disconnection and short circuit of CAN communication line -
198 Oil pressure switch Oil pressure switch failure [8]
Dfp_OPSCDPlaus1 Engine speed is high but sensor is OFF status. LOW IDLE
1008 Oil pressure switch Oil pressure switch failure [1]
Dfp_OPSCDPlaus2 Engine speed is high but sensor is OFF status. Engine is shut down
20051 Engine speed ECU failure [5]
Dfp_OvRMonSigA Recognized engine speed is defective. -
20411 DBV valve opening DBV valve opening [2]
Dfp_PRVMonMax It is recognized that DBV opened. Engine power down
20422 DBV kick off DBV valve is opened forcibly. [2]
Dfp_PRVMonMin Open valve forcible command is ordered for entering into Limp-home mode. Engine power down
20434 DBV valve is seized in closed position DBV valve is seized in closed position [1]
Dfp_PRVMonSig If you try to open valve forcibly, valve doesn't open. Engine is shut down
20441 Holding pressure of DBV Holding pressure of DBV is abnormal [1]
2-step is too high Holding pressure of DBV 2-step is higher than standard level. Engine is shut down
Dfp_PRVPresHi
20452 Holding pressure of DBV Holding pressure of DBV is abnormal [1]
2-step is too low Holding pressure of DBV 2-step is lower than standard level. Engine is shut down
Dfp_PRVPresLo
281 PTO accelerator sensor PTO failure for backup [2]
282 Dfp_PTOCD_APP Disconnection and short circuit of PTO or harness are detected. Engine power down
20111 Rail pressure sensor SRC Rail pressure sensor failure [2]
20112 Dfp_RailCD Disconnection and short circuit of rail pressure sensor or harness are detected. Engine power down
20121 Rail pressure sensor offset Rail pressure sensor failure [2]
20122 monitoring Zero-adjustment failure of rail pressure sensor. Engine power down
Dfp_RailCDOfsTst
20131 Rail pressure governor has deviation Rail pressure control failure [4]
(Nonattainment of target value) Rail pressure doesn't achieve target value. Engine power down
Dfp_RailMeUn0
(Nonattainment of target value & Despite fully pressurized feed of pump, rail pressure doesn't achieve target value. Engine is shut down
Fully pressurized feed of pump)
Dfp_RailMeUn1
(Pressure exceeds target value Despite fully closed pump, rail pressure is higher than target value. Engine power down
& Pump doesn't inject)
Dfp_RailMeUn2
20161 Rail pressure governor Rail pressure control failure [1]
(Real pressure is too low) Rail pressure is lower than standard value. Engine is shut down
Dfp_RailMeUn3
20171 Rail pressure governor Rail pressure control failure [2]
(Real pressure is too high) Rail pressure is higher than standard value. Engine power down
Dfp_RailMeUn4
11102 Shut-off pass test ECU failure [5]
11104 Dfp_SOPTst Emergency injection stop circuit doesn't operate. -
11108
10791 Sensor supply voltage monitor1 ECU failure [5]
10792 Dfp_SSpMon1 Failure of 5V power line which supplies power to sensor. -
10801 Sensor supply voltage monitor 2 ECU failure [5]
6201 Sensor supply voltage monitor 3 ECU failure [5]
20098 TPU monitoring ECU failure [1]
Dfp_TPUMon Failure of TPU in ECU Failure of Engine is shut down
Arithmetic circuit of rotational pulse
20108 SPIDfp_WdCom ECU failure [1]
Judgment of malfunction by self-diagnosis for ECU Error of watch dog Engine is shut down
Note) For detail of engine error code refer to "Section 51 ENGINE CHAPTER"
21-30
21.2.3 SERVICE DIAGNOSIS DISPLAY FUNCTION

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

2) After logo mark is displayed, the screen changes in service diagnosis mode.
The service diagnosis screen "Mode No.1", "Screen No.1" is displayed first.
The service diagnosis is classified into three modes, 1, 2, and 3, and the present mode is displayed in
"Screen No.1".
The screen number each mode can display differs. The screen number displayed by each mode is as
follows.
• Mode No.1 : Screen No.1~No.30
• Mode No.2 : Screen No.1, Screen No.31~No.40
• Mode No.3 : Screen No.1, Screen No.41~No.50
3) The screen changes each time each switch is pressed from now on.
Washer switch: Screen gains by 1 in order. (No.2→No.3→No.4→...)
Wiper switch: Screen loses by 1 in order. (No.24→No.23→No.22→...)
Auto idling switch: Service diagnosis number advances from No.1 to No.3, and then returns to No.1.
(No.1→No.2→No.3→No.1→...)
Travel 1, 2 speed switch: Service diagnosis number advances from No.3 to No.1, and then returns to
No.3. (No.3→No.2→No.1→No.3→...)
4) Turn key switch OFF and the display of service diagnosis mode is closed.
21-31
(2) Service diagnosis display screen (Example)

The service diagnosis display screen list is shown below. The conditions for display are H mode, engine low
speed and lever to neutral position.)
1) Service diagnosis mode No.1
No. Displays Contents No. Displays Contents
1 4
NO.1 NO.4 RELAY
MAIN CONT. P/N
YY22E00100F1 P/No. indication K-1 AIS RELAY 2 ON Indicated value
PROGRAM VERSION K-2 SAFETY RLY - Indicated value
1-VER 11.11 Program version indication K-3 ENG STOP OFF Indicated value
2-VER 00.00 MERIT controller program version KEY SWITCH ON Key switch
START SWITCH OFF Starter switch
SERVICE DIAG 1 Service diagnosis mode CHARGE LIVE Alternator
K-4 LOCK LEVER ON Indicated value
SWITCH OFF Switch
2 5
NO.2 ENG NO.5 PRESS.SENSOR
G-3 SPEED SET 1000 No load setting rpm B-1 BOOM RAISE
MEAS1 1000 Actual rpm 1 0.5V 0.0M Sensor voltage / Pressure converted value
MEAS2 1000 Actual rpm 2 (Engine controller) B-2 BOOM LOWER
G-5 ENG PRS. LIVE Engine oil pressure 0.5V 0.0M Sensor voltage / Pressure converted value
WATER TEMP 20 Coolant temperaturre sensor B-3 ARM OUT
MODE H Work mode 0.5V 0.0M Sensor voltage / Pressure converted value
H-1 ACCEL VOLT. 0.5V Potentiometer voltage B-4 ARM IN
POS. 0% Voltage % indication 0.5V 0.0M Sensor voltage / Pressure converted value
ECU OUTPUT 1.4V Accel output voltage to engine B-5 BUCKET DIG
controller 0.5V 0.0M Sensor voltage / Pressure converted value
B-6 BUCKET DUMP
0.5V 0.0M Sensor voltage / Pressure converted value
3 6
NO.3 SOL.VALVE NO.6 PRESS.SENSOR
F-1 POWER BOOST B-7 SWING
COMP. - Set value in computer 0.5V 0.0M Sensor voltage / Pressure converted value
MEAS. - Measured value B-9 TRAVEL(R)
SWITCH - Switch 0.5V 0.0M Sensor voltage / Pressure converted value
F-2 SWING-BRAKE B-10 TRAVEL(L)
COMP. OFF Set value in computer 0.5V 0.0M Sensor voltage / Pressure converted value
MEAS. OFF Measured value B-16 P1 OPT.
RELEASE SW OFF Switch 0.0V 0.0M Sensor voltage / Pressure converted value
F-3 1/2-TRAVEL B-17 P2 OPT.
COMP. OFF Set value in computer 0.0V 0.0M Sensor voltage / Pressure converted value
MEAS. OFF Measured value B-18 DOZER 1
SWITCH OFF Switch 0.0V 0.0M Sensor voltage / Pressure converted value
B-19 DOZER 2
0.0V 0.0M Sensor voltage / Pressure converted value
21-32
7 NO.7 P.SENSOR PROPO-V 16

NO.16 PRESS.SENSOR
C-1 PUMP P1 B-11 Option selector detect
0.5V 0.3M Sensor voltage / Pressure converted value 0.3V 0.0M Sensor voltage / Pressure converted value
C-2 PUMP P2 B-12
C-3 BOOM-HEAD (Over load alarm) B-13
C-4 BOOM-ROD
B-14
0.0V 0.0M
PROPO-VALVE Sensor voltage / Pressure converted value 0.0V 0.0M Sensor voltage / Pressure converted value
E-3 OPT RELIEF 1 B-15
COMP. 0mA 0.0M Set value in computer / Converted value from pressure 0.0V 0.0M Sensor voltage / Pressure converted value
MEAS. 0mA 0.0M Measured value / Converted value from pressure B-20
E-4 OPT RELIEF 2 0.0V 0.0M Sensor voltage / Pressure converted value
COMP. 0mA 0.0M Set value in computer / Converted value from pressure
MEAS. 0mA 0.0M Measured value / Converted value from pressure
8 NO.8 PROPO-VALVE
18
NO.18 DIGITAL INPUT
D-1 P1 UN-LOAD(BP-CUT) DI1 OFF ON/OFF indication
COMP. 750mA 3.0M Set value in computer / Converted value from pressure DI2 ON ON/OFF indication
MEAS. 750mA 3.0M Measured value / Converted value from pressure DI3 OFF ON/OFF indication
D-2 P2 UN-LOAD(BP-CUT) DI4 OFF ON/OFF indication
COMP. 750mA 3.0M Set value in computer / Converted value from pressure DI5 OFF ON/OFF indication
See
D-3 S-TRAVEL DI7 OFF ON/OFF indication
Mechatro
controller
connector
D-6 ARM IN-2-SPEED DI10 OFF ON/OFF indication
DI13 OFF ON/OFF indication
9 19 NO.19 DIGITAL INPUT
NO.9 PROPO-VALVE
E-1 P1 PUMP DI15 OFF ON/OFF indication
COMP. 417mA 1.0M Set value in computer / Converted value from pressure DI16 ON ON/OFF indication
MEAS. 417mA 1.0M Measured value / Converted value from pressure DI17 ON ON/OFF indication
POWER SHIFT 0mA Power shift DI18 OFF ON/OFF indication
FLOW RATE 20L Flow rate of pump P1 DI19 OFF ON/OFF indication
E-2 P2 PUMP DI20 ON ON/OFF indication
POWER SHIFT 0mA Power shift DI23 OFF ON/OFF indication
FLOW RATE 20L Flow rate of pump P2 DI24 OFF ON/OFF indication
10 20
NO.10 SENSOR,SWITCH NO.20 DIGITAL INPUT
H-9 FUEL LEVEL DI29 OFF ON/OFF indication
0.7V 97% Fuel level DI30 OFF ON/OFF indication
H-10 HYD.OIL TEMP DI31 OFF ON/OFF indication
0.0V 0 Hydraulic oil temperature DI32 OFF ON/OFF indication
GLOW - Glow switch DI33 ON ON/OFF indication
AIR FILTER LIVE Air filter clogging DI34 OFF ON/OFF indication
WATER SEPA. LIVE Water separator clogging DI35 OFF ON/OFF indication
ENG OIL FILTER - Engine oil filter clogging DI36 OFF ON/OFF indication
FRONT WINDOW OFF Front window open/close switch DI37 OFF ON/OFF indication
DOUBLE FLOW OFF Conflux/Single flow select switch DI38 OFF ON/OFF indication
KPSS SW OFF KPSS switch DI39 OFF ON/OFF indication
HEATER - Command from air heater DI40 OFF ON/OFF indication
ENG OIL LEVEL OK Engine oil level DI41 OFF ON/OFF indication
COOLANT LEVEL - Coolant level DI42 OFF ON/OFF indication
11 21
NO.11 SOL.VALVE NO.21 DIGITAL OUTPUT
F-4 OPT SELECT DO1 COMP. OFF Set value in computer
COMP. OFF Set value in computer MEAS. OFF Measured value
MEAS. OFF Measured value (Feed back value) DO2 COMP. OFF Set value in computer
MEAS. OFF Measured value
SPOOL POS. NIB Spool position DO3 COMP. OFF Set value in computer
SELECT SWITCH - Mode of selector valve MEAS. OFF Measured value
F-5 FAN PUMP DO4 COMP. OFF Set value in computer
COMP. - Set value in computer MEAS. OFF Measured value
MEAS. - Measured value DO5 COMP. OFF Set value in computer
F-6 MEAS. OFF Measured value
COMP. - Set value in computer DO6 COMP. OFF Set value in computer
MEAS. - Measured value MEAS. OFF Measured value
DO7 COMP. OFF Set value in computer
12 22
NO.12 POTENTIO. NO.22 DIGITAL OUTPUT
H-2 BOOM DO8 COMP. ON Set value in computer
2.5V 90 Sent value from sensor / Converted value from angle MEAS. ON Measured value
H-3 ARM DO9 COMP. OFF Set value in computer
2.5V 90 Sent value from sensor / Converted value from angle MEAS. OFF Measured value
21-33

23 27
NO.23 DIGITAL OUTPUT NO.27 MERIT SYSTEM
MEAS. OFF Measured value COMMUNICATION OFF Status of communication in MERIT controller
DO16 COMP. ON Set value in computer 0
MEAS. ON Measured value
DO18 COMP. ON Set value in computer 000000000
DO21 COMP. ON Set value in computer
24 28
NO.24 DIGITAL OUTPUT NO.28 ENG CONT.
DO22 COMP. OFF Set value in computer TRANS.COUNT. 0 Counted number of transmission error
MEAS. OFF Measured value RECEIVE COUNT. 0 Counted number of reception error
DO23 COMP. OFF Set value in computer DIAG STATUS 0 Diagnosis status
MEAS. OFF Measured value NUMBER OF DIAG 0 Numbers of error
DO24 COMP. OFF Set value in computer BOOST PRESS. 0 Boost pressure
MEAS. OFF Measured value BOOST TEMP. 0 Boost temperature
DO25 COMP. OFF Set value in computer BAROMETRIC P. 0 Atmospheric pressure
MEAS. OFF Measured value FUEL TEMP. 0 Fuel temperature
DO26 COMP. OFF Set value in computer FUEL CONS. 0 Fuel consumption
MEAS. OFF Measured value INTAKE TEMP. 0 Intake air temperature
DO27 COMP. OFF Set value in computer ENG PRESS. 0 Engine oil pressure
MEAS. OFF Measured value GLOW - Glow output from ECU
DO28 COMP. OFF Set value in computer ENG STOP - Engine stop command from ECU
MEAS. OFF Measured value TORQUE 500 Calculated torque of ECU
25
NO.25 WIPER SYSTEM
WIPER SW OFF Wiper switch
RISEUP SW OFF Wiper rise-up switch
REVERSE SW OFF Wiper reverse rotation switch
PREVENT ARC OFF Wiper motor ark prevention
CW MOTOR RLY OFF relay
CCW MOTOR RLY OFF Wiper normal rotation relay
WASHER SW OFF Wiper reverse rotation relay
MOTOR RELAY OFF Washer switch
Washer motor relay

1 33
NO.1 NO.33 BUCKET
MAIN CONT. P/N C-1 P1-PRES 0.3M Pump pressure sensor
YY22E00100F1 P/No. indication C-2 P2-PRES 0.3M Pump pressure sensor
PROGRAM VERSION E-1 P1-PSV 417mA Command current
1-VER 12.34 Program version indication E-2 P2-PSV 417mA Command current
2-VER 11.11 MERIT controller program version D-1 P1-UL(BPC) 750mA Command current
D-2 P2-UL(BPC) 750mA Command current
SERVICE DIAG 2 Service diagnosis mode D-3 S-TRAVEL 350mA Command current
B-5 BUCKET DIG 0.0M Bucket digging pressure sensor
B-6 BUCKET DUMP 0.0M Bucket dump pressure sensor
G-3 ENG SPEED 1000 Engine actual speed
POWER SHIFT 0mA Power shift current
31 NO.31 BOOM
34
NO.34 TRAVEL
C-1 P1-PRES 0.3M Pump pressure sensor C-1 P1-PRES 0.3M Pump pressure sensor
E-1 P1-PSV 417mA Command current E-1 P1-PSV 417mA Command current
D-1 P1-UL(BPC) 750mA Command current D-1 P1-UL(BPC) 750mA Command current
B-1 BOOM RAISE 0.0M Boom up pressure sensor D-3 S-TRAVEL 350mA Command current
B-2 BOOM LOWER 0.0M Boom down pressure sensor B-9 TRAVEL(R) 0.0M Travel right pressure sensor
G-3 ENG SPEED 1000 Engine actual speed B-10 TRAVEL(L) 0.0M Travel left pressure sensor
POWER SHIFT 0mA Power shift current Pi-P1 0.0M Pilot pressure at travel straight (P1 side)
Pi-P2 0.0M Pilot pressure at travel straight (P2 side)
G-3 ENG SPEED 1000 Engine actual rpm
POWER SHIFT 0mA Power shift current
32 35
NO.32 ARM,SWING NO.35 OPT
D-3 S-TRAVEL 350mA Command current D-3 S-TRAVEL 350mA Command current
D-6 ARM-IN-2 750mA Command current E-3 OPT RELIEF 0mA Command current
B-3 ARM OUT 0.0M Arm out pressure sensor B-16 P1 OPT 0.0M P1 side option pressure sensor
B-4 ARM IN 0.0M Arm in pressure sensor B-17 P2 OPT 0.0M P2 side option pressure sensor
B-1 BOOM RAISE 0.0M Boom up pressure sensor F-4 OPT SELECT - Optional selector SOL (Nibbler line)
B-7 SWING 0.0M Swing pressure sensor DOUBLE FLOW SW OFF Conflux/ Single selector switch
G-3 ENG SPEED 1000 Engine actual speed G-3 ENG SPEED 1000 Engine actual rpm
POWER SHIFT 0mA Power shift current POWER SHIFT 0mA Power shift current
21-34

1 43
NO.1 NO.43 MACHINE-INFORM.
MAIN CONT. P/N HOUR METER 3550 Hour meter of controller
YY22E00100F1 P/No. indication TRIP METER 3500 Trip meter of controller
PROGRAM VERSION OPERATION 3300 All accumulated operating time
1-VER 12.34 Program version indication TRAVEL 300 All accumulated traveling time
2-VER 11.11 MERIT controller program version SWING 3000 All accumulated swing time
HAMMER 100 All accumulated breaker operating time
SERVICE DIAG 3 Service diagnosis mode CRANE 100 All accumulated high-reach crane operating time
STARTER 1200 All accumulated starter operating time
41 44
NO.41 ADJUSTMENT 1 NO.44 MACHINE-INFORM.
ENG PUMP PRESS.
HI-IDLE 2450 Engine speed high idle TOTAL 10Hr Pump pressure distribution (%)
PUMP LEVEL1 24% 22% Total / In the last 10 hours
ACT I 519mA Current at pump adjustment LEVEL2 50% 50% Total / In the last 10 hours
9mA Current correction at pump adjustment LEVEL3 25% 25% Total / In the last 10 hours
PUMP P 34.6M Pressure at pump adjustment LEVEL4 1 % 3% Total / In the last 10 hours
ESS N 930 Engine speed sensor rpm
UN-LOAD WATER TEMP.
P1 580mA P1 unload corrective current TOTAL 10Hr Coolant temperature distribution (%)
P2 590mA P2 unload corrective current LEVEL1 24% 22% Total / In the last 10 hours
BOOM 0 0 Angle adjustment LEVEL2 50% 50% Total / In the last 10 hours
ARM 0 0 Angle adjustment LEVEL3 25% 25% Total / In the last 10 hours
OFFSET 0 0 Angle adjustment LEVEL4 1 % 3% Total / In the last 10 hours
INTER-B 0 0 Angle adjustment
21-35
(3) Service diagnosis data list

Preface and precaution
The following is the data decided as normal status after service diagnosis for every operation. Use these data
to decide normal/abnormal status.
• The values in following display are reference values with standard attachment attached machine.
• The value of pressure sensor is calculated taking variation into accounts. When compared to performance
check reference criteria, measure it with the aid of calibrated measuring instrument.
• The current of proportional valve is not the measured value, but command value. The measured value
should be confirmed by the value in the displayed value for each proportional valve.
• The current value of pump proportional valve is reference value because it varies according to pump
pressure and adjusted torque value.
• The value in display during operation shows the value in steady state, rather than, at start of operation.
• Check on machine after sufficiently warming up machine.
• The value in display may differ according to software version. Contact our dealer/distributor.
Operation No.1 : No operation Operation No.2 : No operation

H mode Hi idle S mode Hi idle
No.32 ARM, SWING No.32 ARM, SWING
C-1 P1-PRES 0.2~1.5 M C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 0.2~1.5 M C-2 P2-PRES 0.2~1.5 M
E-1 P1-PSV 350 mA E-1 P1-PSV 350 mA
D-1 P1-UL(BPC) 750 mA D-1 P1-UL(BPC) 750 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
D-6 ARM-IN-2 750 mA D-6 ARM-IN-2 750 mA
B-3 ARM OUT 0.0 M B-3 ARM OUT 0.0 M
B-4 ARM IN 0.0 M B-4 ARM IN 0.0 M
B-1 BOOM RAISE 0.0 M B-1 BOOM RAISE 0.0 M
B-7 SWING 0.0 M B-7 SWING 0.0 M
G-3 ENG SPEED 1970~2030 G-3 ENG SPEED 1870~1930
POWER SHIFT 0 mA POWER SHIFT 0 mA
Operation No.3 : Boom up in full lever operation & relief Operation No.4 : Boom up in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.31 BOOM No.31 BOOM

C-1 P1-PRES 32.0~35.8 M C-1 P1-PRES 11.0~16.0 M
C-2 P2-PRES 32.0~35.8 M C-2 P2-PRES 11.0~16.0 M
E-1 P1-PSV 385~495 mA E-1 P1-PSV 560~750 mA
E-2 P2-PSV 385~495 mA E-2 P2-PSV 450~550 mA
B-2 BOOM LOWER 0.0 M B-2 BOOM LOWER 0.0 M
21-36
Operation No.5 : Boom down in full lever operation & in

operation
H mode Hi idle
No.31 BOOM
C-1 P1-PRES 12.5~16.0 M
C-2 P2-PRES 0.2~1.5 M
E-1 P1-PSV 549 mA
E-2 P2-PSV 350 mA
D-1 P1-UL(BPC) 360 mA
D-2 P2-UL(BPC) 750 mA
B-1 BOOM RAISE 0.0 M
B-2 BOOM LOWER 3.0 M
G-3 ENG SPEED 1970~2030
POWER SHIFT 0 mA
Operation No.6 : Arm-in in full lever operation & relief Operation No.7 : Arm-in in full lever operation & in operation
C-1 P1-PRES 32.0~35.8 M C-1 P1-PRES 12.0~16.5 M
C-2 P2-PRES 32.0~35.8 M C-2 P2-PRES 12.0~16.5 M
E-1 P1-PSV 385~495 mA E-1 P1-PSV 550~700 mA
E-2 P2-PSV 385~495 mA E-2 P2-PSV 550~750 mA
21-37
Operation No.8 : Operation No.9 :

Arm-out in full lever operation & relief Arm-out in full lever operation & in operation
C-1 P1-PRES 32.0~35.8 M C-1 P1-PRES 12.0~18.0 M
C-2 P2-PRES 32.0~35.8 M C-2 P2-PRES 12.0~18.0 M
E-1 P1-PSV 385~495 mA E-1 P1-PSV 606~750 mA
E-2 P2-PSV 385~495 mA E-2 P2-PSV 606~750 mA
* Measure the values after a lapse of 5 minutes or after * Measure the values after a lapse of 5 minutes or after
release of low temperature mode release of low temperature mode

Swing in full lever operation & relief Swing in full lever operation & in operation
C-1 P1-PRES 0.2~1.5 M C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 28.0~35.8 M C-2 P2-PRES 8.0~13.0 M
E-2 P2-PSV 500~610 mA E-2 P2-PSV 642 mA
21-38

Bucket digging in full lever operation & relief Bucket digging in full lever operation & in operation
No.33 BUCKET No.33 BUCKET
C-1 P1-PRES 32.0~35.8 M C-1 P1-PRES 4.0~8.0 M
C-2 P2-PRES 0.2~1.5 M C-2 P2-PRES 0.2~1.5 M
E-1 P1-PSV 500~610 mA E-1 P1-PSV 750 mA
B-5 BUCKET DIG 3.0 M B-5 BUCKET DIG 3.0 M
B-6 BUCKET DUMP 0.0 M B-6 BUCKET DUMP 0.0 M

Bucket dump in full lever operation & relief Bucket dump in full lever operation & in operation
No.33 BUCKET No.33 BUCKET
C-1 P1-PRES 32.0~35.8 M C-1 P1-PRES 6.0~15.0 M
C-2 P2-PRES 0.2~1.5 M C-2 P2-PRES 0.2~1.5 M
E-1 P1-PSV 500~610 mA E-1 P1-PSV 650 mA
B-5 BUCKET DIG 0.0 M B-5 BUCKET DIG 0.0 M
B-6 BUCKET DUMP 3.0 M B-6 BUCKET DUMP 3.0 M
21-39

P2 side option in full lever operation & relief P2 side option in full lever operation & relief
A mode Hi idle B mode Hi idle
No.35 OPT No.35 OPT
C-1 P1-PRES 22.5~26.0 M C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 22.5~26.0 M C-2 P2-PRES 22.5~26.0 M
E-1 P1-PSV 480~590 mA E-1 P1-PSV 500 mA
E-2 P2-PSV 480~590 mA E-2 P2-PSV 665~750 mA
E-3 OPT RELIEF 0 mA E-3 OPT RELIEF 0 mA
B-16 P1 OPT 0.0 M B-16 P1 OPT 0.0 M
B-17 P2 OPT 2.0~2.6 M B-17 P2 OPT 2.0~2.6 M
F-4 OPT SELECT NIB F-4 OPT SELECT BRK
DOUBLE FLOW SW. ON DOUBLE FLOW SW. OFF
* Conflux switch is ON. Relief set pressure is value of * Conflux switch is OFF. Relief set pressure is value of
shipping. shipping.

Travel right in full lever operation & travel idling Travel left in full lever operation & travel idling
No.34 TRAVEL No.34 TRAVLE
C-1 P1-PRES 5.0~12.0 M C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 0.2~1.5 M C-2 P2-PRES 5.0~12.0 M
B-9 TRAVEL(R) 2.0~2.5 M B-9 TRAVEL(R) 0.0 M
B-10 TRAVEL(L) 0.0 M B-10 TRAVEL(L) 2.0~2.5 M
Pi-P1 0.0 M Pi-P1 0.0 M
Pi-P2 0.0 M Pi-P2 0.0 M
21-40
21.2.4 TROUBLE HISTORY DIAGNOSIS

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

1) Turn starter switch on.
2) Press buzzer stop switch for 10 seconds continuously 5 times and the trouble history screen is displayed.
(Example)
No errors NO ERROR
Error detected in the past
3) Transmit trouble history data (One or many) and hour meter to gauge cluster.
• Hour meter and 4 failure data are displayed on screen.
• In case of more than 4 failure data, 4 data is displayed at a time for 10 seconds by turns.
4) Paging (Up and down)
• Press washer switch ( ), and the item moves upward.
• Press wiper switch ( ), and the item moves downward.

5) Turn starter switch off, and the display is disappeared.
(2) How to delete contents of trouble history

1) Display trouble history screen.
2) Press work mode change switch and buzzer stop switch simultaneously for 10 seconds or more.
3) When "NO ERROR" is displayed, the deletion is completed.
4) Turn starter switch off.
All the stored items are erased. It is impossible to erase data partially.
21-41
21.2.5 TROUBLE DIAGNOSIS MODE

The recent control system includes many electrical systems and it makes troubleshooting very difficult.
The failure diagnosis mode is used to automatically specify the failed sections for the failures which can not be
detected through the use of self diagnosis function (the failure can be specified through the use of error code) like
disconnection and abnormal output. This is useful to save the time for troubleshooting.
(1) Function
There are two types of trouble diagnosis mode.
1) Trouble diagnosis mode 1: Used to diagnose unload system, pump system, travel straight system and
engine system.
2) Trouble diagnosis mode 2: Used to diagnose pilot system.
In any mode, with the attachment not moved, both directional valve and proportional valve are automatically
actuated, the sensor detects the machine status and the mechatro controller identifies the normal condition
or failed condition of the system.
For details of how to use, refer to "Chapter 46 TROUBLESHOOTING TROUBLE DIAGNOSIS MODE".
21-42
21.2.6 SET PROCEDURE OF MAINTENANCE SCHEDULE

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

switch switch select switch
Interval of replacement of parts is mentioned below. Washer

switch
• Engine oil : 500 Hr
• Fuel filter : 500 Hr
Select Wiper
• Hydraulic filter : 1,000 Hr switch switch
Auto accel Travel speed
• Hydraulic oil : 2,000 Hr (S.E.ASIA) switch select switch
• Hydraulic oil : 5,000 Hr (OCEANIA)
Procedure Operating Procedure Display on Multidisplay
After several seconds,

display is changed to 10:25
1 Turn starter key switch on. KOBELCO clock autmatically.
H
Press " " switch press once display

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

switch once and the display for the engine 250 Hr Press select switch 250 Hr
3 ENGINE OIL ENGINE OIL
oil change reverses. once more.
H
When required to adjust the interval to the coming

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

press " " buzzer stop switch once. 500 Hr To set the desired interval, 500 Hr
5 Press " " select switch once and the set ENGINE OIL press the select switch ENGINE OIL
time is stored. H
1. After displaying the display for setting by pressing the display change switch, set the respective maintenance
time for fuel filter, hydraulic oil filter and hydraulic oil while repeating the procedure 2 to 5.
2. The engine oil change time is displayed on the multi-display by 500 hours as a warning, but the buzzer does not
sound.
21-43
21.2.7 ADJUSTING PROCEDURE OF DISPLAY

(1) For operator
1) Auto idling stop (OCEANIA ONLY)

No. Switchs 1 2 3 4
3 KPSS work mode select switch
4 Washer switch
5 Wiper switch
6 Travel speed select switch
7 Auto accel switch 5
8 Select switch 8 7 6
Fig. 21-2
Main screen
SWITCH STATUS
10:25 CLOCK/CONTRAST
H
(a) (b)
AUTO IDLING STOP
(d)
AUTO WARM-UP AUTO IDLE STOP AUTO IDLE STOP
OFF OFF ON
FEED FEED FEED
(c)
(e)
AUTO IDLE STOP AUTO IDLE STOP
OFF ON
OFF ON OFF ON
1. Press select switch (8) in main screen (a) for operator and display "SWITCH STATUS CLOCK/CONTRAST"
select screen (b).
2. Press select switch (8) again and display "AUTO WARM-UP OFF" screen (c).
3. In operation of FEED (4), the "AUTO IDLE STOP OFF" screen (d) is displayed.
4. In operation of FEED (4), the color of "OFF" portion reverses and the "AUTO IDLE STOP OFF" screen
(e) is displayed.
5. Switch from "OFF" to "ON" in operation of FEED (4) and set it by pressing selector switch (8).
6. When auto idling is functioning, the "AUTO IDLE STOP" is displayed on the multi-display.
7. Turn starter key switch off once and store the auto idling stop setting as a memory.
21-44
2) Clock Adjustment Switches

1 Screen Change Switch
2 Buzzer Stop Switch
3 KPSS Work Mode Select Switch
4 Washer Switch
5 Wiper Switch
6 Travel Speed Select Switch
7 Auto Accel Switch
5
8 Select Switch 8 7 6
Main screen (a)

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

SWITCH STATUS ADJUST CLOCK Y M D H M Enter
CLOCK/CONTRAST ADJ CONTRAST 06 04 01 13 15
Select Year/Month/Day/Hour/Minute Increase/Decrese
1. Turn starter key switch on and display main screen (a) for operator, and then press select switch (8) and
display "SWITCH STATUS CLOCK/CONTRAST" select screen (b).
2. In operations of FEED (4) and FEED (5), move cursor to "CLOCK/CONTRAST" screen (c) and then
press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (d) is displayed.
3. In operations of FEED (4) and FEED (5), move cursor to "ADJUST CLOCK" and then press select
switch (8) and the "ADJUST CLOCK" screen (e) is displayed.
4. Select any of "Y•M•D•H•M" in operation of FEED (4) and FEED (5) and vary the values in operations
of FEED (4) and FEED (5).
5. After adjustment, press select switch (8) and the adjusted values are stored as memory and time setting is
completed, and then the screen returns to main screen (a).
21-45
3) Contrast Adjustment Switches

1 Screen Change Switch
2 Buzzer Stop Switch
3 KPSS Work Mode Select Switch
4 Washer Switch
5 Wiper Switch
6 Travel Speed Select Switch
7 Auto Accel Switch
5
8 Select Switch 8 7 6
Main screen
SWITCH STATUS
10:25 CLOCK/CONTRAST
H
(a) (b)
(c) (d) (a)

SWITCH STATUS ADJUST CLOCK
CLOCK/CONTRAST ADJ CONTRAST 10:25
H
(e) (f)
ADJUST CLOCK ADJ CONTRAST Enter
ADJ CONTRAST 55555
Adjustable range
11111~99999 Increase/Decrease
(Default 55555)
1. Turn starter key switch on and display main screen (a), and press select switch (8) and display "SWITCH
STATUS CLOCK CONTRAST" select screen (b).
2. In operations of FEED (4) and FEED (5), move cursor to "SWITCH STATUS CLOCK CONTRAST"
screen (c) and then press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (d) is
displayed.
3. In operations of FEED (4) and FEED (5), move cursor to "ADJUST CLOCK ADJ CONTRAST" and then
press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (e) is displayed.
4. Press select switch (8) and the "ADJ CONTRAST 55555" screen (f) is displayed.
5. Vary the values by pressing the desired figure in operations of FEED (4) and FEED (5).
The available setting range is in 9 steps from "11111" to "99999".
[Example] 11111 (faint) → 99999 (clear) * The initial set value is 55555.
6. Press select switch (8) and the adjusted values are stored as a memory and the contrast adjustment is
completed, and then the screen returns to main screen (a).
21-46
(2) Function for service

Following items are provided for adjustment of service function.
Item CONTENTS
Language Language selection
Rise-up wiper Wiper control change (When cab is changed)
Idle stop (OCEANIA ONLY) ON/OFF of auto idle stop (ON/OFF of adjustment for user) and time adjust
P1 option pressure sensor ON/OFF of self diagnosis for P1 option pressure sensor
P2 option pressure sensor ON/OFF of self diagnosis for P2 option pressure sensor
Swing alarm ON/OFF of swing alarm (ON/OFF of adjustment for user)
Left pedal for rotation of option Does left rotation pedal use?
attachment (Unload valve does not actuate because P4 pump is equipped in EU.)
Optional flow rate limitation, relief pressure limitation, combination of return
Setting of optional equipment
selector adjustment)
Engine speed ON/OFF of engine rpm display
Adjustment the type of the engine speed of auto deceleration runs up
Auto acceleration
abruptly.
Change of starter mode Change of start mode
Low temperature mode forcible
Low temperature mode release
release
Cylinders calibration Injection adjust mode of engine
Pressure release For pressure release
21-47
21.2.8 MECHATRO CONTROL EQUIPMENT

(1) C-1 Mechatro controller
1) Outside view
2 1 6 2 1 4 2 1 8 2 1
10
16
26
34
27 22 18 16 12 28 22
CN101 CN102 CN103 CN104
CN105 CN106 CN107 CN108 CN109

9 21 7 2 16 21 9 21 7 21
21
31 10 16 8 12 7 28 10 22 8
22 24 17 17 13 19 20 15 16
2) List of connectors
Connector No. Pin No. Port name Function Input/putput Signal level
CN101 1 GA 0V
2 A1 Boom up Input 0.5~4.5V
3 +5VA Power output 5V
5 A2 Boom down Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A3 Arm in Input 0.5~4.5V
11 A4 Arm out Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A5 Bucket digging Input 0.5~4.5V
17 A6 Bucket dump Input 0.5~4.5V
18 GA 0V
19 TXD1 Gauge cluster Transmission RS232C communication
20 RXD1 Reception RS232C communication
21 GP 0V
22 SHG1 Shield GND
23 TXD3 Down load Transmission RS232C communication
25 DL GND / OPEN(5V
26 GP 0V
27 CANH1 E/G ECU CAN communication
28 CANL1 E/G ECU CAN communication
29 DO 20 Spare Output GND / OPEN
30 DO 21 - Output GND / OPEN
31 DO 22 Spare Output GND / OPEN
32 DO 23 Rotary light (yellow) Output GND / OPEN
33 DO 24 Rotary light (green) Output GND / OPEN
34 DI 36 - Input GND / OPEN
21-48
CN102 1 GA 0V
2 A8 Travel right Input 0.5~4.5V
5 A9 Travel left Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A10 Accelation Input 0.5~4.5V
11 A13 P1 option Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A14 P2 option Input 0.5~4.5V
17 A27 Spare Input 0.5~4.5V
18 GA 0V
19 GA 0V
22 D1 37 Spare Input GND / OPEN
CN103 1 GA 0V
2 A Swing Input 0.5~4.5V
5 A11 P1 pump Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A12 P2 pump Input 0.5~4.5V
11 A15 Boom angle Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A16 Arm angle Input 0.5~4.5V
16 Reserved
21-49
CN104 1 GA 0V
2 A17 Boom head Input 0.5~4.5V
5 A18 Boom rod Input 0.5 4.5V
6 GA 0V
7 GA 0V
8 A19 Extra pressure source Input 0.5~4.5V
12 GA 0V
14 GA 0V
15 A22 Fuel level Input 0.5~4.5V
16 GP 0V
18 GA 0V
19 GA 0V
20 A24 Selector detection Input 0.5~4.5V
24 GA 0V
25 GA 0V
CN105 1 +24V Battery relay output side 20~32V
2 +24V Battery relay output side 20~32V
(sensor analog output)
3 +24V Battery relay output side 20~32V
4 DO 7 Travel 1,2 speed select valve Output 24V/OPEN
5 DO 8 Swing P/B select valve Output 24V/OPEN
6 DO 9 - Output 24V/OPEN
7 DO 11 Attachment boost select valve Output 24V/OPEN
8 GND Battery (-) 0V
10 D10+ OPT changeable relief 1 Output +0~800mA
11 D1+ P1 unload Output +0~800mA
12 D1- -0~800mA
13 D2+ P2 unload Output +0~800mA
14 D2- -0~800mA
15 D3+ Travel straight Output +0~800mA
16 D3- -0~800mA
17 D4+ Arm in Output +0~800mA
18 D4- -0~800mA
19 D5+ P1 pump Output +0~800mA
20 D5- -0~800mA
22 D10- OPT changeable relief 1 Output -0~800mA
23 D6+ P2 pump Output +0~800mA
24 D6- -0~800mA
25 D7+ - Output +0~800mA
26 D7- -0~800mA
27 D8+ - Output +0~800mA
28 D8- -0~800mA
29 D9+ - Output -0~800mA
30 D9- +0~800mA
31 +24V Battery direct connection 20~32V
21-50
CN106 1 +24V Battery relay secondary side 0 20~32V
2 SHGF Shield GND
3 F1+ - Output +24V 1.5A
4 F1- Output +24V 1.5A
5 F2+ Output +24V 1.5A
6 F2- Output +24V 1.5A
7 OIL - 0
8 OILG
9 D11+ OPT changeable relief 2 Output +0~800mA
10 D11- -0~800mA
11 D12+ Spare Output +0~800mA
12 D12- -0~800mA
14 D13- -0~800mA
16 D14- -0~800mA
19 D12- -0~800mA
20 E1+ E/G speed sensor Input XX~XXVp-p
21 E1- 0V
22 SHG3 Shiled GND
23 CANH2 - CAN communication
24 CANL2 CAN communication
CN107 1 DI 3 - Input +24V/OPEN
2 DI 8 Water separetor Input GND / OPEN
4 DI 10 Air filter Input GND / OPEN
5 DI 11 Stroke end check Input GND / OPEN
6 DI 12 Spare Input GND / OPEN
10 DI 20 ECU main relay Input GND / OPEN
12 DI 32 Hand control nibbler Input GND / OPEN
13 DI 38 Quick coupler Input GND / OPEN
14 DI 39 Extra pressure Input GND / OPEN
17 Reserved
21-51
CN108 1 DI 2 Key switch (ON) Input +24V / OPEN
2 DI 4 Spare Input +24V / OPEN
3 DI 5 Swing P/B release Input GND / OPEN
4 DI 6 E/G start Input +24V / OPEN
5 DI 7 High reach hoisting at fixed position Input GND / OPEN
6 DI 16 Wiper rise up Input GND / OPEN
7 DI 17 Wiper reverse Input GND / OPEN
9 DI 19 Nibbler open check SW Input GND / OPEN
10 DI 21 - Input +24V / OPEN
12 DI 23 Lever lock Input +24V / OPEN
13 DI 24 Hand control rotation / Input
clamp open or close GND / OPEN
14 DI 25 Front window open or close Input GND / OPEN
15 DI 26 Hand control breaker Input GND / OPEN
16 DI 27 Conflux/single select Input GND / OPEN
17 DI 29 Overload select Input GND / OPEN
18 DI 30 High reach (hoist at travel) Input GND / OPEN
19 Reserved
20 GP
21 DI 33 Charge Input ~12V / 12V~
24 Reserved Reserved
25 H1+ Accel signal 1 0~5V
26 H2- 0V
27 H2+ Accel signal 2 0~5V
28 H2- 0V
CN109 1 DO 1 Wiper arc prevention Output GND / OPEN
2 DO 2 Wiper normal moving Output GND / OPEN
3 DO 3 Wiper reserve moving Output GND / OPEN
4 DO 4 Washer motor Output GND / OPEN
5 DO 5 Bucket move limitation Output GND / OPEN
6 DO 6 Reserved Output GND / OPEN
7 DO 12 Rotary light (RH) Output GND / OPEN
8 DO 13 Swing flasher (RH) Output GND / OPEN
9 DO 14 Swing flasher (LH) Output GND / OPEN
10 DO 15 Travel alarm Output GND / OPEN
11 DO 16 Auto idle stop relay Output GND / OPEN
12 DO 17 Engine stop Output GND / OPEN
13 DO 18 Lever lock Output GND / OPEN
14 DO 19 Extra pressure release Output GND / OPEN
15 Reserved
16 GP IT controller 0V
17 TXD2 Tranmission RS232C communication
19 RTS Spare RS232C communication
20 CTS Spare RS232C communication
21 SHG2 Shiled GND
22 DO 10 - SV 24V/OPEN
21-52
(2) Gauge cluster (symbol C-2)

1) General view
MULTI
DISPLAY LCD
COOLANT
TEMPERATURE
GAUGE
FUEL LEVEL
GAUGE
MATED SIDE
AMP 040
HOUSING : 174044-2
TERMINAL : 173681-2
SCREEN CHANGE
SWITCH ETC.
BUZZER STOP SWITCH WORK MODE SWIHCH
2) Connector CN-600 (Harness side)
No. Item name Wire color No. Item name Wire color
Gauge cluster → Mechatro
GND source (+24V Battery Yellow /
1 controller (RS232C White 5
direct connection) Black
communication)
Mechatro controller → Gauge
2 cluster (RS232C Red 6 GND Black
communication)
Source (+24V starter switch
3 Reserved — 7 White
ON)
GND (RS232C
4 Reserved — 8 Black
communication)
3) Function
a. It processes signals by communication between the gauge cluster and the mechatro controller, displays
them in lamps, displays them in LCDs and actuates the buzzer.
b. It outputs coolant temperature signals, fuel level signals and panel switch signals to the mechatro
controller through the communication port.
4) Summary of display and drive item
No. Item Remarks

1 Monitar display LCD dot 120×168
2 Gauge display (Coolant temp., Fuel level) Stepping motor
3 —
4 Buzzer Piezo-electricity type
7 Work mode select switch
8 Back light LED
21-53
(3) Relay & fuse box (symbol E-1)

1) General view
(Overhead view of box)

LABEL INSIDE
Note) These circles indicate the parts

which are used in standard specification
1 10
1 14 1 14 1 12 1 3 1 3
CN16 CN17
20 20 CN4-1 17 CN5 15 6 2 6
CN2-1 CN2-2 2
11 22 1 3 1 3
13 26 13 26 9 20 CN14 CN15
1 13 1 7 2 6 2 6
1 9
CN4-2 1 3 1 3
17
CN3-1 CN3-2 12
6 12 3 CN12 CN13
1
2 6 2 6
12 24 8 16 1 CN1
1 2 1 2 CN2-3 2 1 2
CN8 CN9 2 4 CN10
3
LOCATION OF CONNECTORS (Seen from backside)
LOCATION OF RELAY & FUSE
LABEL OF RELAY & FUSE BOX

No. CODE IN CIRCUIT PARTS NAME
21-54
2) Circuit diagram
21-55
21-56
21-57
(4) High pressure sensor : YN52S00048P1
ECONOSEAL SERIES MARK (+)> SPECIFICATION :

3POLES CAP
MATING HOUSING174357-2 PRESSURE RANGE : 0 50 MPa
POWER SOURCE VOLTAGE : 5.0+0.5V DC
COMMON OUTPUT : 1/10Vs-9/10Vs
OUTPUT (+) (Vs=5V DC 0.5 4.5V DC)
POWER SOURCE (+) INSURANCE RESISTANCE : 100M OR MORE
HOUSING (BETWEEN CASING AND ALL IN/OUT
TERMINAL
TERMINALS AT 50V DC MEGGER)
PLASTIC POTTING CONDENSER
COVER
ELECTRIC CONNECTING DIAGRAM
DIE
CASING (Ex. Construction of internal controller)
FLEXIBLE BOARD
CIRCUIT DIAPHRAGM
O-RING P14 PIPE

JIS B2401 CLASS1B
THREAD
PF 3/8
Tightening torgue STRUCTURE
73.5N.m (54.2lbf.ft)
(5) Low pressure sensor : YX52S00013P1

Tightening torgue
Vout
29.4 34.3N.m (21.7 25.3lbf.ft)
PF1/4
Vcc GND
ELECTRIC CONNECTING DIAGRAM
(Ex. Construction of internal controller)
SPECIFICATION :
PRESSURE RANGE : 0 3.0 MPa
RATED VOLTAGE : 5.0+0.5V DC
OUTPUT CHARACTERISTIC INSURANCE RESISTANCE : 50M OR MORE
(BETWEEN CASING AND EACH TERMINAL AT
50V DC MEGGER)
21-58
22. HYDRAULIC SYSTEM
TABLE OF CONTENTS
22.1 SUMMARY.......................................................................................................................22-3
22.2 HYDRAULIC CIRCUITS AND COMPONENTS...............................................................22-4
22.3 COLOR CODING STANDARD FOR HYDRAULIC CIRCUITS........................................22-8
22.4 NEUTRAL CIRCUIT.........................................................................................................22-8 22
22.5 TRAVEL CIRCUIT ...........................................................................................................22-10
22.6 BUCKET CIRCUIT...........................................................................................................22-12
22.7 BOOM CIRCUIT ..............................................................................................................22-14
22.8 SWING CIRCUIT .............................................................................................................22-18
22.9 ARM CIRCUIT .................................................................................................................22-20
22.10 COMBINED CIRCUIT ......................................................................................................22-26
22.11 PRESSURE DRAINING (RELEASING) CIRCUIT ...........................................................22-30
22-1

SK125SR : YV05-04501~
S5YY2213E01
(OCE/S.E.ASIA)
SK135SRLC-2 : YH05-07001~
22-2
22.1 SUMMARY operability, safety, mass volume handling and low fuel
consumption.
The hydraulic circuits are built up with the following
functions and features in order to achieve easy
Table22-1
Perfor- Device
mance Function Features
Travel straight Travel straight at combined operation

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

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

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

Easy operability and safety
Pilot safety lock system Cut out of pilot circuit by safety lock lever.
Attachment
Lock valve (boom / arm) Protect boom and arm from unexpected drop (Natural fall).
Boom safety valve Prevention of boom falling when boom head side
and arm rod side pipings break
Multi control valve (Oceania) Changeable to 4 operating pattern with only 1 lever.
Pressurized hydraulic oil tank To prevent hydraulic oil from entering dust and to
promote self suction ability of pump
Suction strainer Remove dust on suction side.
Line filter ; pilot circuit To prevent pilot operating circuit from malfunctioning
Others
Return circuit To prevent hydraulic oil from contamination

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

Positive flow rate control Flow control by positive pilot control pressure
Boom up conflux circuit Speed up of boom up operation
Attachment
Arm conflux circuit Speed up of arm operation

Optimum operation by work mode select (H,S,A,B) Efficient operation in all work modes
Auto accel Reduce fuel consumption and noise by lowering engine

computer
Low fuel
speed when control lever is in neutral position.

Micro
22-3
22.2 HYDRAULIC CIRCUITS AND

COMPONENTS
STD. SCHEMATIC HYD. LINES YY01Z00069P1 (02)
Item Component name Part No. Model No.
Hyd. pump assy (OCE) YY10V00013F1 K7V63DTP174R-0E13-VC
1
Hyd. pump assy (S.E.ASIA) YY10V00009F1 K7V63DTP179R-0E13-VC
2 Control valve (main) YY30V00058F1 KMX13YD/B44904
3 Swing motor unit YY15V00016F1 M2X63CHB
4 Travel motor unit YY15V00015F1 GM21VX-A-45/75-2
5 Boom cylinder (RH & LH) YY01V00053F1 ø100×ø70×1092
6 Arm cylinder YY01V00054F1 ø115×ø80×1120
7 Bucket cylinder YY01V00055F1 ø95×ø70×903
8 Swivel joint YN55V00053F1
9 Pilot valve (ATT) YN30V00111F1 PV48K2017
10 Pilot valve (travel) YN30V00105F1 6TH6 NRZ
11 Inline filter YN50V00020F1 Y-457400
12 Suction strainer YN50V00025F2 SB281J0A022A
13 Solenoid valve assy YY35V00013F1 8KWE5A-30/G24WRX-827
14 Return filter YV52V01001F1 FZ1F183A001A
15 Air breather YN57V00004F1 AB0210GA008A
Multi control valve (STD) lever less YN30V00113F1
16
Multi control valve (OPT.) YF30V00009F1
17 Restrictor YN21V00005F3 07580-00000
The part numbers may be changed due to modification,

so use only the numbers for references.
22-4
22.2.1 STANDARD
D P
PSV1
SE-22
P
A1a1 a2
SE-23
A1
P PSV2
4
PH1 PH2
PSV-P1 PSV-P2
a3 a4
B FOR. FOR. A
SWING
A
REV. REV.
B
4 DB
PG
8 3
1
B DEE I HAC C
28.0MPa
MAIN PUMP TRAVEL RIGHT TRAVEL LEFT P D PA PB
Dr1
69kw 5.0MPa
/2000min-1 M
a3
B1
B3 Dr3 A3 11
PTO
(OCE SPEC.) A B
2 RIGHT
MU2 MAIN CONTROL VALVE P1 (P6) T1 (P5) T2 P2 LEFT
34.3MPa
15 12 CMR1
PTb CMR2 PBL
BUCKET DUMP
TRAVEL BUCKET DIGGING
P1 UNLOARD STRAIGHT TRAVEL LEFT SWING LEFT
PCb PAL SWING RIGHT
ARM OUT BOOM UP
AL ARM IN BOOM DOWN
14 CT2 CP2 BL
SE-8
SE-7
SE-4
SE-3
SE-2
SE-1
T3
TRAVEL RIGHT P2 UNLOAD
PAr CT1 PCa P P P P P P
CP1 BOOM 8 7 6 5 4 3 2 1
Br CONFLUX PB1
Ar
CCb Dr
HYD. TANK PBr PBs H M K
Pss SE-5 8 7 6 5 4 3 2 1
BOOM LCb LCs SWING P
SOL/V PAb PAs
P1 BLOCK LEVER
A1 LOCK As
SV-4
(ROD)Bb
37.8MPa Bs
PBa1
16
CRb
SWING
SV-1
A2 P/B
(HEAD)Ab
LCa 17 ATT.
PILOT
TRAVEL 37.8MPa ARM 1 PAa1 VALVE
1/2 SPEED
SV-3
A3 CHANGEOVER
BUCKET
CYLINDER
9 9
PBb
37.8MPa
LCc Aa (HEAD)
A4 PAc
BUCKET
7
CRa ARM
PLc2 CYLINDER P T P T
37.8MPa BOOM ARM
A5 P2 UNLOAD (ROD)Bc & BUCKET & SWING
Ba (ROD)
PSV-B (HEAD)Ac
37.8MPa
37.8MPa
6
TRAVEL
TRAVEL PBc PILOT VALVE P T
A6 STRAIGHT LCAT2
PSV-C
PAa2
ARM 2
LCAP2 OPTION
10
LCo
PAo
5
A7 P1 UNLOAD BOOM
PSV-D CYLINDER
PBa2 37.8MPa
Ao
Bo 3 6 4 1 5 2
A8 ARM 2 37.8MPa
PSV-A RIGHT TRAVEL FORWARD P P
17 PBo
RIGHT TRAVEL REVERSE
LEFT TRAVEL FORWARD
SE-9 SE-10
13 MU1
PBp1 P1 BY PASS
CUT
P2 BY PASS
CUT
PBp2 LEFT TRAVEL REVERSE
T2 P2
(P3) (P4)
17
YY01Z00069P1 02
22-5
22.2.2 N&B SPECIFICATION (OPTION)
NIBBLER & BREAKER

SPECIFICATION YY01Z00070P1 (01)
NO. PARTS PARTS No. MODEL No.
50 SELECTOR VALVE YB30V00018F1 VBY-181
51 STOP VALVE 24100P1006F1
52 PILOT VALVE YN30V00080F1 16030-00000
NOTE 1:This hydraulic circuit is used to add to standard circuit.

2:For using of nibbler confluence/single flow or breaker,
choosed condition and an order.
CHOOSED CONDITION
AN ORDER OF OUTPUT FOR
AN ORDER OF OUTPUT FOR PROPORTIONAL SOLENOID VALVE (W: , W/O:-)
CONFLUENCE/SINGLE FLOW PROPORTIONAL SOLENOID VALVE
CHANGEOVER SWITCH IN VALVE SELECTOR(ITEM 50)
(W: , W/O:-) P1 PUMP P2 PUMP TRAVEL P1 P2
STRAIGHT UNLOAD UNLOAD
CONFLUENCE FLOW OF NIBBLER CONFLUENCE ON
SINGLE FLOW OF NIBBLER CONFLUENCE OFF
BREAKER CONFLUENCE OFF
3:When using nibbler, according to specification of nibbler

installed, choose confluence or single flow by
"confluence/single flow changeover switch"
51
52
50
YY01Z00070P1 01
22-6
This page is blank for editing convenience.
22-7
22.3 COLOR CODING STANDARD 22.4 NEUTRAL CIRCUIT 22.4.3 PUMP POSITIVE FLOW CONTROL resulting in the reduction of tilt angle. Similarly,
when the servo piston moves rightward, the
FOR HYDRAULIC CIRCUITS This section describes the following. (1) Type :
Electric flow controlled variable displacement spool (652) is moved leftward by the feedback
Blue (1) Bypass cut valve and unload valve control
pump. lever.
Feed, drain circuit (2) Safety lock lever and pilot circuit The operation is maintained until the opening of
less than 0.44 MPa (64 psi) (2) Principle :
(3) Pump positive flow control spool sleeve is closed.
Green The current command I to the pump’s solenoid
(4) Pump P-Q (Pressure-Quantity) curve control proportional valve controls the delivery rate of the
Return, make up circuit, 22.4.4 PUMP P-Q CURVE CONTROL
0.44~0.59 MPa (64~86 psi) pump. OPERATION
22.4.1 OPERATION OF BY-PASS CUT VALVE
Purple AND UNLOADING VALVE HOUSED IN (3) Operation : (1) Type :
Secondary pilot pressure, CONTROL VALVE 1) Flow rate rise operation (Eg. P1 pump) Electrical flow control type variable pump
(including proportional vlave) By operating any of control levers, the
(1) By-pass cut valve (2) Principle :
0.59~5 MPa (86~725 psi) operating secondary pressure of pilot valve
On starting engine, P1 and P2 unloading Perform an operation of the value from pump high
Red rises, and the rising pressure is transformed to
proportional valves (PSV-D, PSV-B) output pressure sensor to P-Q curve control value, and
Primary pilot pressure, the rise of output voltage corresponding to the
secondary pressure according to the command send a command to the pump solenoid proportional
(including proportional vlave) pressure input by the low pressure sensor.
output by mechatro controller, and this pressure valve.
5 MPa (725 psi) Mechatro controller signal-processes this
exerts on PBp1 and PBp2 ports, and consequently (3) Operation :
Orange change of voltage, resulting in rise of command
the by-pass cut spool is switched to CLOSE side. The pump high pressure sensor converts the
Main pump drive pressure, current value I to the pump proportional
The by-pass cut spool is usually held on CLOSE pressure to the output voltage corresponding to the
5~34.3 MPa (725~4970 psi) solenoid valve and consequently the pump flow
side after the engine started. And it is switched to pump delivery pressure.
Blue tone rate rises. This is called "Positive Control
OPEN side only when failure occurred on pump The mechatro controller converts the voltage output
At valve operation System".
proportional valve and mechatro controller. by the high pressure sensor to the P-Q curve
Red valve As the pump command current value rises, the
(2) Unloading valve control value. On the other hand, select the pump
When solenoid proportional valve (reducing) secondary pressure of proportional solenoid
On starting engine, like by-pass cut valve, the positive control command current value from the
is operating valve also rises. On the regulator attached on
secondary pressures output by P1 and P2 low pressure sensor in lower order, and the values
Red solenoid the pump, the spool (652) through piston (643)
unloading proportional valves (PSV-D, PSV-B) are output to respective pump proportional valve as
In active and exciting is pushed leftward, and stops at the position
exert on PCb and PCa ports, consequently the P1 a command current.
Displaying the flow circuit and standby circuit when where being in proportion to the force of pilot
and P2 unloading valves are switched to OPEN With this operation, the pump power is controlled so
operating. spring (646).
side. as not to be exceed the engine power, therefore
Regarding the electrical symbols in this manual, refer to The tank port connected to the large bore of
engine dose not stall.
the electric circuit diagram. 22.4.2 SAFETY LOCK LEVER AND PILOT servo piston (532) opens, and the piston
CIRCUIT moves leftward by delivery pressure P1 of the
(1) Purpose : small bore resulting in the increase of tilt angle
To protect attachment from unexpected movement ( ).
for safety. The servo piston and spool (652) are
connected to feedback lever (611). Therefore
(2) Principle :
when servo piston moves leftward, the spool
Cut pressure source of pilot valve for operation.
(652) also moves rightward by means of
(3) Operation : feedback lever. With this movement, the
If the safety lock lever (red) is pushed forward after opening of spool sleeve closes gradually, and
the engine starts, the limit switch (SW-11) is turned the servo piston stops at the position the
on. The timer relay is actuated one second later opening closed completely.
which causes the solenoid (SV-4) of the solenoid
2) Flow rate reduction operation
valve block (13) to be energized and makes the
As the current value I of mechtro controller
pilot operating circuit to stand by.
reduces, the secondary pressure of solenoid
proportional valve reduces, and spool (652) is
moved rightward by the force of pilot spring
(646). With the movement of spool, the delivery
pressure P1 usually flows into the large bore of
piston through the spool.
The delivery pressure P1 flows in the small
bore of servo piston, but the servo piston
moves rightward due to the difference of area,
22-8
D P
PSV1
SE-22
P
A1a1 a2
SE-23
A1
P PSV2
4
PH1 PH2
PSV-P1 PSV-P2
a3 a4
B FOR. FOR. A
643 646 646 643 SWING
611 A
REV. REV.
B
4 DB
PG
A
8 3
652 A
611
652
1
B DEE I HAC C
28.0MPa
532 532
Dr1
69kw 5.0MPa
/2000min-1 M
a3
B1
B3 Dr3 A3 11
PTO
(OCE SPEC.) A B
2 RIGHT
34.3MPa
15 12 CMR1
PTb CMR2 PBL
BUCKET DUMP
PCb PAL SWING RIGHT
ARM OUT BOOM UP
AL ARM IN BOOM DOWN
14 CT2 CP2 BL
SE-8
SE-7
SE-4
SE-3
SE-2
SE-1
T3
CP1 BOOM 8 7 6 5 4 3 2 1
Br CONFLUX PB1
Ar
CCb Dr
Pss SE-5 8 7 6 5 4 3 2 1
SOL/V PAb PAs
P1 BLOCK LEVER
A1 LOCK As
SV-4
(ROD)Bb
37.8MPa Bs
PBa1
16
CRb
SWING
SV-1
A2 P/B
(HEAD)Ab
LCa 17 ATT.
PILOT
1/2 SPEED
SV-3
A3 CHANGEOVER
BUCKET
CYLINDER
9 9
PBb
37.8MPa
LCc Aa (HEAD)
A4 PAc
BUCKET
7
CRa ARM
37.8MPa BOOM ARM
Ba (ROD)
PSV-B (HEAD)Ac
37.8MPa
37.8MPa
6
TRAVEL
A6 STRAIGHT LCAT2
PSV-C
PAa2
ARM 2
LCAP2 OPTION
10
LCo
PAo
5
A7 P1 UNLOAD BOOM
PSV-D CYLINDER
PBa2 37.8MPa
Ao
Bo 3 6 4 1 5 2
A8 ARM 2 37.8MPa
17 PBo
LEFT TRAVEL FORWARD
SE-9 SE-10
13 MU1
PBp1 P1 BY PASS
CUT
P2 BY PASS
CUT
T2 P2
(P3) (P4)
17
YY01Z00069P1 02
Fig. 22-1 NEUTRAL CIRCUIT : Positive control function at safety lock lever down (unlocked position)
22-9
22.5 TRAVEL CIRCUIT 22.5.2 2-SPEED TRAVEL SOLENOID COMMAND

CIRCUIT AND AUTO 1st SPEED RETURN
This section describes the following.
FUNCTION
(1) Travel forward pilot simultaneous operation circuit
(1) Purpose :
(2) 2 speed travel solenoid command circuit and auto
Change travel motor speed with switch.
1-speed return function
(2) Principle :
(3) Travel main circuit
If the switch is turned, an electric signal is issued. It
(4) Travel motor function excites the 2-speed travel solenoid which in turn
converts the primary pilot pressure and the self
22.5.1 TRAVEL FORWARD PILOT
pressure to a tilting angle of the variable
SIMULTANEOUS OPERATION CIRCUIT
displacement motor.
(1) Purpose :
(3) Operation :
Light operating force and shockless operation
If the rabbit marked switch on the gauge cluster is
(2) Mechatronics :
pressed, the solenoid (SV-3) of the proportional
1) If the travel lever with damping mechanism is valve block (13) is excited and changes the
operated for travel right, left and forward proportional valve. Then the solenoid command
motions, the secondary pilot proportional pressure is issued from port A3, enters the P port of
pressure comes out of the 3, 1 ports of P/V (10). the travel motor (4), opens the oil passage to the
The higher of the pressures is selected, comes 2nd speed select piston, and causes the motor to
out of the 6, 5 ports and acts upon the low run in the 2nd speed tilting mode by its self
pressure sensors (SE-9) (SE-10). pressure. However, when the main circuit pressure
2) The pilot secondary pressure flows to PBr and rises above 27.3 MPa (3960 psi), the motor’s self
PBL ports of the control valve (2), moves the pressure pushes the 2nd speed select piston back
travel spool, and switches the main circuit. to the 1st speed.
3) The low pressure sensor output voltage is input
22.5.3 TRAVEL MAIN CIRCUIT
into mechatro controller. The mechatro
(1) Operation :
controller performs signal processing and
The delivery oil from Pump A1 and A2 ports by
outputs current corresponding to the increase
changing the travel spool with the operation of
of flow rate to P1 pump proportional valve
travel pilot flows in each A, B port on the left side of
(PSV-P1) and P2 pump proportional valve
travel motor (4) through C,D ports of swivel joint (8)
(PSV-P2), and at the same time the command
from AL, AR ports of C/V, and rotates the travel
current is output to P1 unloading valve (PSV-D)
motor.
and P2 unloading valve (PSV-B).
4) The secondary pressures output by P1 pump 22.5.4 TRAVEL MOTOR FUNCTION
proportional valve (PSV-P1) and P2 pump (1) Function :
proportional valve (PSV-P2) exert on pump
1) Prevents the motor from over running on a
regulator, actuating the pump on the delivery
slope.
flow rate increase side.
2) Check valve that prevents cavitation of the
5) The secondary pressure delivered in P1
hydraulic motor.
unloading valve (PSV-D) and P2 unloading
3) Shockless relief valve and anti cavitation valve
valve (PSV-B) is fed to PBp1, PCb, PBp2 and
when inertia force stops.
PCa ports provided in control valve (2).
The secondary pressure from proportional 4) High/Low 2 step speed change mechanism and
valve which has exerted on PBp1 and PBp2 auto 1st speed return at high load.
ports holds the by-pass cut spool on CLOSE 5) Travel parking brake.
side, like the operation in the lever neutral
position.
The secondary pressure from proportional
valve which has exerted on PCb and PCa ports
switches the unloading spool in CLOSE side.
22-10
D P
PSV1
SE-22
P
A1a1 a2
SE-23
A1
P PSV2
4
PH1 PH2
PSV-P1 PSV-P2
a3 a4
B FOR. FOR. A
SWING
A
REV. REV.
B
4 DB
PG
8 3
1
B DEE I HAC C
28.0MPa
Dr1
69kw 5.0MPa
/2000min-1 M
a3
B1
B3 Dr3 A3 11
PTO
(OCE SPEC.) A B
2 RIGHT
34.3MPa
15 12 CMR1
PTb CMR2 PBL
BUCKET DUMP
PCb PAL SWING RIGHT
ARM OUT BOOM UP
AL ARM IN BOOM DOWN
14 CT2 CP2 BL
SE-8
SE-7
SE-4
SE-3
SE-2
SE-1
T3
CP1 BOOM 8 7 6 5 4 3 2 1
Br CONFLUX PB1
Ar
CCb Dr
Pss SE-5 8 7 6 5 4 3 2 1
SOL/V PAb PAs
P1 BLOCK LEVER
A1 LOCK As
SV-4
(ROD)Bb
37.8MPa Bs
PBa1
16
CRb
SWING
SV-1
A2 P/B
(HEAD)Ab
LCa 17 ATT.
PILOT
1/2 SPEED
SV-3
A3 CHANGEOVER
BUCKET
CYLINDER
9 9
PBb
37.8MPa
LCc Aa (HEAD)
A4 PAc
BUCKET
7
CRa ARM
37.8MPa BOOM ARM
Ba (ROD)
PSV-B (HEAD)Ac
37.8MPa
37.8MPa
6
TRAVEL
A6 STRAIGHT LCAT2
PSV-C
PAa2
ARM 2
LCAP2 OPTION
10
LCo
PAo
5
A7 P1 UNLOAD BOOM
PSV-D CYLINDER
PBa2 37.8MPa
Ao
Bo 3 6 4 1 5 2
A8 ARM 2 37.8MPa
17 PBo
LEFT TRAVEL FORWARD
SE-9 SE-10
13 MU1
PBp1 P1 BY PASS
CUT
P2 BY PASS
CUT
T2 P2
(P3) (P4)
17
YY01Z00069P1 02
Fig. 22-2 TRAVEL CIRCUIT : Travel 2nd speed, RH & LH simultaneous operation.
22-11
22.6 BUCKET CIRCUIT <When lever is operated>

When the pressure 0.6MPa (87psi) is input to low
This section describes the following.
pressure sensor in STD specification (travel,
(1) Bucket digging pilot circuit
bucket, swing, arm), proportional voltage from low
(2) Auto accel operation pressure sensor inputs in mechatro controller, and
(3) Flow control in the work mode then the engine speed returns to the dial set
position corresponding to the lever operation.
22.6.1 PILOT CIRCUIT FOR BUCKET DIGGING
(1) Mechatronics : 22.6.3 STAND-BY CURRENT CONSTANT
CONTROL
1) When the operation for bucket digging is
performed, the pilot proportional secondary (1) Principle :
pressure is delivered through port 1 of the right When the engine speed is intermediate speed or
pilot V (9), flows to PAc port, and acts on the low lower, command current value to have the pump
pressure sensor (SE-1), and at the same time delivery rate constant is output.
the bucket spool is switched. (2) Operation :
2) The voltage output by low pressure sensor Even if the engine speed specified by acceleration
inputs in mechatro controller. The mechatro potentiometer is low speed, as the delivery rate
controller performs signal processing and corresponds to the intermediate speed, the
outputs current corresponding to the increase actuator moves earlier than the movement
of pump flow rate to pump proportional valve equivalent to the control lever angle rate in light
(PSV-P1) on the P1 pump side, and at the load operation.
same time the command current is output to P1
unloading valve (PSV-D).
In the following pages, the relation of operation
of low pressure sensor to both the increase of
pump flow rate and unloading proportional
valve is the same. Therefore the explanation is
omitted.
3) The secondary pressure output by P1 pump
proportional valve (PSV-P1) exerts on pump
regulator, actuating the pump onto the delivery
flow increase side.
4) The secondary pressure delivered in P1
unloading valve (PSV-D) is led to PBp1 and
PCb ports provided in control valve (2).
valve which has exerted on PBp1 port holds the
by-pass cut spool on CLOSE side, like the
operation in the lever neutral position.
valve which has exerted on PCb port switches
the unloading spool in CLOSE side.
22.6.2 AUTO ACCELERATION OPERATION

(1) Principle :
Auto acceleration actuates according to signals
from low pressure sensor.
(2) Operation :
<When lever is set to neutral position>
In the event where the sensor does not receive
signal for 4 seconds or more even though the
acceleration dial is set to MAX position, the engine
speed should be raised to 1000rpm.
22-12
D P
PSV1
SE-22
P
A1a1 a2
SE-23
A1
P PSV2
4
PH1 PH2
PSV-P1 PSV-P2
a3 a4
B FOR. FOR. A
SWING
A
REV. REV.
B
4 DB
PG
8 3
1
B DEE I HAC C
28.0MPa
Dr1
69kw 5.0MPa
/2000min-1 M
a3
B1
B3 Dr3 A3 11
PTO
(OCE SPEC.) A B
2 RIGHT
34.3MPa
15 12 CMR1
PTb CMR2 PBL
BUCKET DUMP
PCb PAL SWING RIGHT
ARM OUT BOOM UP
AL ARM IN BOOM DOWN
14 CT2 CP2 BL
SE-8
SE-7
SE-4
SE-3
SE-2
SE-1
T3
CP1 BOOM 8 7 6 5 4 3 2 1
Br CONFLUX PB1
Ar
CCb Dr
Pss SE-5 8 7 6 5 4 3 2 1
SOL/V PAb PAs
P1 BLOCK LEVER
A1 LOCK As
SV-4
(ROD)Bb
37.8MPa Bs
PBa1
16
CRb
SWING
SV-1
A2 P/B
(HEAD)Ab
LCa 17 ATT.
PILOT
1/2 SPEED
SV-3
A3 CHANGEOVER
BUCKET
CYLINDER
9 9
PBb
37.8MPa
LCc Aa (HEAD)
A4 PAc
BUCKET
7
CRa ARM
37.8MPa BOOM ARM
Ba (ROD)
PSV-B (HEAD)Ac
37.8MPa
37.8MPa
6
TRAVEL
A6 STRAIGHT LCAT2
PSV-C
PAa2
ARM 2
LCAP2 OPTION
10
LCo
PAo
5
A7 P1 UNLOAD BOOM
PSV-D CYLINDER
PBa2 37.8MPa
Ao
Bo 3 6 4 1 5 2
A8 ARM 2 37.8MPa
17 PBo
LEFT TRAVEL FORWARD
SE-9 SE-10
13 MU1
PBp1 P1 BY PASS
CUT
P2 BY PASS
CUT
T2 P2
(P3) (P4)
17
YY01Z00069P1 02
Fig. 22-3 BUCKET CIRCUIT : Bucket digging, Auto-accelation and Standby flow rate constant control
22-13
22.7 BOOM CIRCUIT

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

(1) Operation :
1) If boom up operation is performed, the
secondary pilot proportional pressure from the
right pilot valve (9) gets out of port 3 and acts
upon the low pressure sensor (SE-3). At the
same time, the pressure acts upon the PAb and
PB1 ports.
2) The secondary pressure which enters the PAb
port of C/V (2) shifts the boom spool. The
secondary pressure which enters the PB1 port
shifts the boom conflux spool.
22.7.2 BOOM UP 2 PUMPS CONFLUX MAIN

CIRCUIT IN C/V
(1) Purpose :
Boom up speed up
(2) Principle :
Confluxing oil from 2 pumps
(3) Operation :
1) The oil delivered through A1 port of P1 pump
flows into C/V (2) P1 port, and branches into
bypass circuit and parallel circuit. Since P1
unloading valve is closed, the boom spool is
moved and bypass circuit is closed, the oil
opens load check valve LCb through parallel
circuit and flows into boom spool.
2) Then the oil passes through boom spool, opens
lock valve of boom lock valve CRb, and is led
into H side of boom cylinder through C/V (2) Ab
port.
3) Meanwhile, the oil delivered from the A2 port of
the P2 pump enters the P2 port of C/V (2) and
due to shut off the P2 unloading valve, the oil
then passes through the parallel circuit and via
the restrictor on the circumference of the boom
conflux spool, pushes the load check valve
CCb open from the boom conflux circuit, and
combines the oil delivered by the P1 pump
internally.
4) The return oil from boom cylinder R side flows
into tank circuit through boom spool from C/V
(2) Bb port.
22-14
D P
PSV1
SE-22
P
A1a1 a2
SE-23
A1
P PSV2
4
PH1 PH2
PSV-P1 PSV-P2
a3 a4
B FOR. FOR. A
SWING
A
REV. REV.
B
4 DB
PG
8 3
1
B DEE I HAC C
28.0MPa
Dr1
69kw 5.0MPa
/2000min-1 M
a3
B1
B3 Dr3 A3 11
PTO
(OCE SPEC.) A B
2 RIGHT
34.3MPa
15 12 CMR1
PTb CMR2 PBL
BUCKET DUMP
PCb PAL SWING RIGHT
ARM OUT BOOM UP
AL ARM IN BOOM DOWN
14 CT2 CP2 BL
SE-8
SE-7
SE-4
SE-3
SE-2
SE-1
T3
CP1 BOOM 8 7 6 5 4 3 2 1
Br CONFLUX PB1
Ar
CCb Dr
Pss SE-5 8 7 6 5 4 3 2 1
SOL/V PAb PAs
P1 BLOCK LEVER
A1 LOCK As
SV-4
(ROD)Bb
37.8MPa Bs
PBa1
16
CRb
SWING
SV-1
A2 P/B
(HEAD)Ab
LCa 17 ATT.
PILOT
1/2 SPEED
SV-3
A3 CHANGEOVER
BUCKET
CYLINDER
9 9
PBb
37.8MPa
LCc Aa (HEAD)
A4 PAc
BUCKET
7
CRa ARM
37.8MPa BOOM ARM
Ba (ROD)
PSV-B (HEAD)Ac
37.8MPa
37.8MPa
6
TRAVEL
A6 STRAIGHT LCAT2
PSV-C
PAa2
ARM 2
LCAP2 OPTION
10
LCo
PAo
5
A7 P1 UNLOAD BOOM
PSV-D CYLINDER
PBa2 37.8MPa
Ao
Bo 3 6 4 1 5 2
A8 ARM 2 37.8MPa
17 PBo
LEFT TRAVEL FORWARD
SE-9 SE-10
13 MU1
PBp1 P1 BY PASS
CUT
P2 BY PASS
CUT
T2 P2
(P3) (P4)
17
YY01Z00069P1 02
Fig. 22-4 BOOM CIRCUIT : Boom up operation, Confluence function.
22-15
This section describes boom lower operation. 22.7.5 CONSTANT RECIRCULATION FUNCTION
(1) Boom down pilot circuit OF BOOM DOWN MAIN CIRCUIT
(2) Prevention of natural fall by lock valve and (1) Purpose :
actuation at lowering Prevention of cavitation during boom
lowering motion.
(3) Constant recirculation function of boom down main
circuit (2) Principle :
The oil returning from the boom cylinder head (H) is
22.7.3 BOOM DOWN PILOT CIRCUIT recirculated to the rod (R).
(1) Operation : (3) Operation :
1) If the boom down operation is performed, the When the oil is supplied to the boom cylinder rod
secondary pilot proportional pressure comes (R) side during boom down operation, the boom
out of port 4 of the right pilot valve (9) and acts moves faster than it should do in some cases by the
upon the low pressure sensor (SE-4). self weight of the attachment.
At the same time, the pressure acts upon the On that occasion, the circuit pressure on the rod (R)
PBb port of C/V (2). side is on the negative side.
2) The voltage output of the low pressure sensor The oil supplied to the boom cylinder rod (R) flows
(SE-4) enters the mechatro controller and into the A1 port of the P1 pump and the P1 port of
processed in it. C/V. The oil then passes through the boom spool
and goes out of the Bb port.
3) Then, the proportionl secondary pressure fed
On that occasion, the oil returning from the head
into C/V (2) PBb port and branches off in two
(H) goes through the recirculation path in the boom
lines and switches boom spool and releases
spool, pushes the check valve in the spool open, is
boom lock valve.
recirculated to the Bb port and is supplied to the rod
22.7.4 PREVENTION OF NATURAL FALL BY (R). When the (R) pressure is larger than the head
LOCK VALVE AND ACTUATION AT (H) pressure, the check valve in spool closes.
LOWERING Thereupon, the recirculation is stopped.
(1) Purpose :
Prevention of natural fall when the lever is neutral
(2) Principle :
The oil is prevented from returning to the boom
spool by the poppet seat of the boom lock valve.
(3) Operation :
In the boom down action, the selector valve is
changed over by the secondary proportional
pressure of PBb port. Then the poppet spring
chamber of the lock valve CRb gets through the
drain line (Dr) and makes the lock valve poppet
open.
When the boom lever is at neutral, the drain line on
the lock valve CRb poppet spring chamber is
closed which causes the poppet closed.
The result is that the oil returning from the boom
cylinder head (H) to the boom spool is held and
makes the leak from the boom spool zero.
Thus the boom cylinder is prevented from making a
natural fall.
22-16
D P
PSV1
SE-22
P
A1a1 a2
SE-23
A1
P PSV2
4
PH1 PH2
PSV-P1 PSV-P2
a3 a4
B FOR. FOR. A
SWING
A
REV. REV.
B
4 DB
PG
8 3
1
B DEE I HAC C
28.0MPa
Dr1
69kw 5.0MPa
/2000min-1 M
a3
B1
B3 Dr3 A3 11
PTO
(OCE SPEC.) A B
2 RIGHT
34.3MPa
15 12 CMR1
PTb CMR2 PBL
BUCKET DUMP
PCb PAL SWING RIGHT
ARM OUT BOOM UP
AL ARM IN BOOM DOWN
14 CT2 CP2 BL
SE-8
SE-7
SE-4
SE-3
SE-2
SE-1
T3
CP1 BOOM 8 7 6 5 4 3 2 1
Br CONFLUX PB1
Ar
CCb Dr
Pss SE-5 8 7 6 5 4 3 2 1
SOL/V PAb PAs
P1 BLOCK LEVER
A1 LOCK As
SV-4
(ROD)Bb
37.8MPa Bs
PBa1
16
CRb
SWING
SV-1
A2 P/B
(HEAD)Ab
LCa 17 ATT.
PILOT
1/2 SPEED
SV-3
A3 CHANGEOVER
BUCKET
CYLINDER
9 9
PBb
37.8MPa
LCc Aa (HEAD)
A4 PAc
BUCKET
7
CRa ARM
37.8MPa BOOM ARM
Ba (ROD)
PSV-B (HEAD)Ac
37.8MPa
37.8MPa
6
TRAVEL
A6 STRAIGHT LCAT2
PSV-C
PAa2
ARM 2
LCAP2 OPTION
10
LCo
PAo
5
A7 P1 UNLOAD BOOM
PSV-D CYLINDER
PBa2 37.8MPa
Ao
Bo 3 6 4 1 5 2
A8 ARM 2 37.8MPa
17 PBo
LEFT TRAVEL FORWARD
SE-9 SE-10
13 MU1
PBp1 P1 BY PASS
CUT
P2 BY PASS
CUT
T2 P2
(P3) (P4)
17
YY01Z00069P1 02
Fig. 22-5 BOOM CIRCUIT : Boom down operation & Prevention of natural boom falling.
22-17
22.8 SWING CIRCUIT since the bypass line is closed as the swing spool
is shifted, the oil pushes the load check valve LCs
This section describes the following operations.
open through the parallel circuit, enters the B port
(1) Swing left pilot circuit
of the swing motor via the As port of C/V (2), and
(2) Swing auto parking brake rotates the swing motor counterclockwise.
(3) Swing main circuit
22.8.4 SWING MOTOR CIRCUIT
(4) Swing motor circuit
(1) Anti cavitation circuit at swing deceleration
22.8.1 PILOT CIRCUIT FOR LEFT SWING (2) Shockless relief valve that prevents the swing
(1) Operation : motor from being reversed.
1) When the left swing operation is performed, the
pilot proportional secondary pressure is
delivered through port 5 of left pilot V (9), and
the secondary pressure acts on PAs port of C/V
(2), and simultaneously flows out from Pss port
of C/V and acts on low pressure sensor (SE-5).
2) The voltage output by the low pressure sensor
is input in the mechatro controller, and is signal
processed.
3) Then, the secondary pressure led into PAs port
of C/V (2) switches the swing spool.
22.8.2 SWING AUTO PARKING BRAKE

(1) Purpose :
Swing lock in neutral position and parking
(2) Principle :
Release mechanical brake only when required to
operate swing and arm in.
(3) Operation :
1) The swing parking system excites the swing
parking SOL (SV-1) usually if the key switch is
turned on and works by the action of the
mechanical brake.
2) The mechanical brake is released if the swing
parking solenoid is de-excited only when the
secondary operating pressure in the swing and
arm in actions acts upon any of the low
pressure sensors (SE-5, 7).
3) The swing parking solenoid (SV-1) is excited
five seconds after the pressure of the swing low
pressure sensors (SE-5) is reduced to zero.
In the case of arm in operation, the swing
parking solenoid (SV-1) is excited the moment
the pressure of the arm in low pressure sensor
(SE-7) is reduced to zero. This causes the
mechanical brake to operate.
22.8.3 SWING MAIN CIRCUIT

(1) Operation :
The oil delivered from the A2 port of the P2 pump
enters the P2 port of C/V (2) and is branched off into
the bypass line and the parallel circuit. However,
22-18
D P
PSV1
SE-22
P
A1a1 a2
SE-23
A1
P PSV2
4
PH1 PH2
PSV-P1 PSV-P2
a3 a4
B FOR. FOR. A
SWING
A
REV. REV.
B
4 DB
PG
8 3
1
B DEE I HAC C
28.0MPa
Dr1
69kw 5.0MPa
/2000min-1 M
a3
B1
B3 Dr3 A3 11
PTO
(OCE SPEC.) A B
2 RIGHT
34.3MPa
15 12 CMR1
PTb CMR2 PBL
BUCKET DUMP
PCb PAL SWING RIGHT
ARM OUT BOOM UP
AL ARM IN BOOM DOWN
14 CT2 CP2 BL
SE-8
SE-7
SE-4
SE-3
SE-2
SE-1
T3
CP1 BOOM 8 7 6 5 4 3 2 1
Br CONFLUX PB1
Ar
CCb Dr
Pss SE-5 8 7 6 5 4 3 2 1
SOL/V PAb PAs
P1 BLOCK LEVER
A1 LOCK As
SV-4
(ROD)Bb
37.8MPa Bs
PBa1
16
CRb
SWING
SV-1
A2 P/B
(HEAD)Ab
LCa 17 ATT.
PILOT
1/2 SPEED
SV-3
A3 CHANGEOVER
BUCKET
CYLINDER
9 9
PBb
37.8MPa
LCc Aa (HEAD)
A4 PAc
BUCKET
7
CRa ARM
37.8MPa BOOM ARM
Ba (ROD)
PSV-B (HEAD)Ac
37.8MPa
37.8MPa
6
TRAVEL
A6 STRAIGHT LCAT2
PSV-C
PAa2
ARM 2
LCAP2 OPTION
10
LCo
PAo
5
A7 P1 UNLOAD BOOM
PSV-D CYLINDER
PBa2 37.8MPa
Ao
Bo 3 6 4 1 5 2
A8 ARM 2 37.8MPa
17 PBo
LEFT TRAVEL FORWARD
SE-9 SE-10
13 MU1
PBp1 P1 BY PASS
CUT
P2 BY PASS
CUT
T2 P2
(P3) (P4)
17
YY01Z00069P1 02
Fig. 22-6 SWING CIRCUIT : Swing operation (LH)
22-19
22.9 ARM CIRCUIT with P2 pump delivery oil in the valve section,
and then is flowed into arm cylinder head (H)
This section describes the following operations.
side through Aa port of C/V (2).
(1) Arm in, light-load operating pilot circuit
3) The return oil from arm cylinder (R) side flows
(2) Arm in, light-load variable normal recirculation main
in Ba port of C/V (2) and passes through the Ba
circuit / internal conflux main circuit
port because the arm lock valve CRa is open,
22.9.1 ARM IN, LIGHT-LOAD OPERATING PILOT and is flowed into arm 2 spool through arm 1
CIRCUIT spool.
(1) Purpose : 4) Because arm 2 spool is switched to normal

Speed-up and Anticavitation when the arm is at recirculation position, causing restriction of
light loaded. passage to tank, the return oil from arm cylinder
(R) side flows into arm cylinder (H) side.
(2) Principle :
The oil returning from the arm cylinder rod (R) is • Because, at light load, the pressure in
recirculated variably to the head (H) at arm 2 spool cylinder rod (R) side is higher than that in
in C/V. the head (H) side, it opens the check valve
housed-in arm 2 spool and is recirculated in
(3) Operation :
the head (H) side, resulting in the speed up
1) When the arm in operation is performed, the
of arm-in operation at light load.
secondary pilot proportional pressure gets out
5) Cavitations prevention control in arm-in
of port 7 of the left pilot valve (9) and acts upon
operation
the low pressure sensor (SE-7).
Command current is output to arm 2 solenoid
At the same time, the pressure is branched off
proportional valve by signal processing of E/G
in two flows, acts upon the PAa1 port and the
speed and arm-in pilot pressure, accordingly
PLc2 port, changes over the arm spool and the
the arm 2 spool is switched to neutral
arm lock valve CRa. releases.
(cavitations prevention) position, resulting in
2) The output voltage by the low pressure sensor
cavitations prevention.
is input into mechatro controller, and is pilot
signal-processed, and is output to P1, P2 pump
Position of arm 2 spool
proportional valve (PSV-P1), (PSV-P2) and arm
2 inverse proportional valve (PSV-A). Neutral position
(Anticavitation position)
3) The secondary pressure from pilot proportional Normal recirculation position
valve, which is reduced by arm 2 inverse Recirculation

proportional valve (PSV-A) switches arm 2
spool.
From arm out
P/V
22.9.2 ARM-IN, LIGHT-LOAD VARIABLE
From arm 2 inverse
NORMAL RECIRCULATION, INTERNAL proportional valve
CONFLUX MAIN CIRCUIT
Reference :
(1) Operation : In light-load arm-in operation (normal recirculation,
1) The P2 pump delivery oil flows in travel left conflux), when the attachment to which the circuit in
section through P2 port of C/V (2) and is P1 pump side is applied is operated, the meter-in
branched off in by-pass circuit and parallel path of arm 2 spool is closed, resulting in single flow
circuit, but because arm 1 spool is switched, the operation.
delivery oil which goes through parallel circuit
opens load check valve LCa and is flowed into Spool position at arm in,
light load and combined operation
arm 1 spool. (This position is not shown in hydraulic diagram)
2) On the other hand, P1 pump delivery oil flows in Meter-in passage (Close)
Neutral position
P1 port of C/V (2), and the flows in travel
straight section and travel right tandem path.
Then because arm 2 spool was switched, the
delivery oil opens load check valve LCAT2,
Normal recirculation position
goes through arm 2 spool, and confluences Arm 2 spool
22-20
D P
PSV1
SE-22
P
A1a1 a2
SE-23
A1
P PSV2
4
PH1 PH2
PSV-P1 PSV-P2
a3 a4
B FOR. FOR. A
SWING
A
REV. REV.
B
4 DB
PG
8 3
1
B DEE I HAC C
28.0MPa
Dr1
69kw 5.0MPa
/2000min-1 M
a3
B1
B3 Dr3 A3 11
PTO
(OCE SPEC.) A B
2 RIGHT
34.3MPa
15 12 CMR1
PTb CMR2 PBL
BUCKET DUMP
PCb PAL SWING RIGHT
ARM OUT BOOM UP
AL ARM IN BOOM DOWN
14 CT2 CP2 BL
SE-8
SE-7
SE-4
SE-3
SE-2
SE-1
T3
CP1 BOOM 8 7 6 5 4 3 2 1
Br CONFLUX PB1
Ar
CCb Dr
Pss SE-5 8 7 6 5 4 3 2 1
SOL/V PAb PAs
P1 BLOCK LEVER
A1 LOCK As
SV-4
(ROD)Bb
37.8MPa Bs
PBa1
16
CRb
SWING
SV-1
A2 P/B
(HEAD)Ab
LCa 17 ATT.
PILOT
1/2 SPEED
SV-3
A3 CHANGEOVER
BUCKET
CYLINDER
9 9
PBb
37.8MPa
LCc Aa (HEAD)
A4 PAc
BUCKET
7
CRa ARM
37.8MPa BOOM ARM
Ba (ROD)
PSV-B (HEAD)Ac
37.8MPa
37.8MPa
6
TRAVEL
A6 STRAIGHT LCAT2
PSV-C
PAa2
ARM 2
LCAP2 OPTION
10
LCo
PAo
5
A7 P1 UNLOAD BOOM
PSV-D CYLINDER
PBa2 37.8MPa
Ao
Bo 3 6 4 1 5 2
A8 ARM 2 37.8MPa
17 PBo
LEFT TRAVEL FORWARD
SE-9 SE-10
13 MU1
PBp1 P1 BY PASS
CUT
P2 BY PASS
CUT
T2 P2
(P3) (P4)
17
YY01Z00069P1 02
Fig. 22-7 ARM CIRCUIT : Arm in (Light load) operation, Arm variable recirculation & Anti cavitation function
22-21
This section describes the following operations. 4) The return oil returns directly into tank circuit
(3) Arm in, heavy load operating pilot circuit because arm 2 spool is switched to
(recirculation cut) recirculation cut position.
(4) Arm in, heavy load operating sequence confluxed
main circuit
Recirculation cut position Neutral position
22.9.3 ARM IN, HEAVY LOAD OPERATING
PILOT CIRCUIT
(1) Operation : From arm out
P/V
1) In arm-in operation, when the heavy loading is
From arm 2 inverse
applied to arm and the P2 pump pressure proportional valve
increases to the set pressure, the voltage
output by P2 pump pressure sensor (SE-23) is
converted to signal (signal processing) by
mechatro controller, consequently the current
of arm 2 solenoid proportional valve is
controlled according to the load pressure and
the arm variable recirculation is cut.
When the recirculation is cut, internal
confluence is held similarly to that in light load
operation.
2) Left pilot valve actuation due to arm-in
operation is equivalent to that at light load
operation.
22.9.4 ARM IN, HEAVY LOAD OPERATING

RECIRCULATION CUT MAIN CIRCUIT
(1) Purpose :
Speed up for arm in operation
(2) Principle :
Cut the recirculation and reduce rod pressure.
(3) Operation :
1) P2 pump delivery oil flows in the travel left
section through P2 port of C/V (2) and
branched off in by-pass circuit and parallel
circuit. Consequently the arm spool is switched
and pushes and opens load check valve LCa
through parallel circuit, and flows in the arm
spool.
2) On the other hand, P1 pump delivery oil flows in
P1 port of C/V (2), and flow in travel right
tandem passage through travel straight section.
Then because arm 2 spool was switched, the
delivery oil opens load check valve LCAT2, and
confluences with P2 pump delivery oil in the
valve section, and is flowed into arm cylinder
head (H) side through Aa port of C/V(2).
3) The return oil from arm cylinder (R) side flows
in Ba port of C/V(2) and is flowed to arm lock
valve , but because the arm lock valve is open,
the return oil goes through arm lock valve CRa
and flows in arm 2 spool.
22-22
D P
PSV1
SE-22
P
A1a1 a2
SE-23
A1
P PSV2
4
PH1 PH2
PSV-P1 PSV-P2
a3 a4
B FOR. FOR. A
SWING
A
REV. REV.
B
4 DB
PG
8 3
1
B DEE I HAC C
28.0MPa
Dr1
69kw 5.0MPa
/2000min-1 M
a3
B1
B3 Dr3 A3 11
PTO
(OCE SPEC.) A B
2 RIGHT
34.3MPa
15 12 CMR1
PTb CMR2 PBL
BUCKET DUMP
PCb PAL SWING RIGHT
ARM OUT BOOM UP
AL ARM IN BOOM DOWN
14 CT2 CP2 BL
SE-8
SE-7
SE-4
SE-3
SE-2
SE-1
T3
CP1 BOOM 8 7 6 5 4 3 2 1
Br CONFLUX PB1
Ar
CCb Dr
Pss SE-5 8 7 6 5 4 3 2 1
SOL/V PAb PAs
P1 BLOCK LEVER
A1 LOCK As
SV-4
(ROD)Bb
37.8MPa Bs
PBa1
16
CRb
SWING
SV-1
A2 P/B
(HEAD)Ab
LCa 17 ATT.
PILOT
1/2 SPEED
SV-3
A3 CHANGEOVER
BUCKET
CYLINDER
9 9
PBb
37.8MPa
LCc Aa (HEAD)
A4 PAc
BUCKET
7
CRa ARM
37.8MPa BOOM ARM
Ba (ROD)
PSV-B (HEAD)Ac
37.8MPa
37.8MPa
6
TRAVEL
A6 STRAIGHT LCAT2
PSV-C
PAa2
ARM 2
LCAP2 OPTION
10
LCo
PAo
5
A7 P1 UNLOAD BOOM
PSV-D CYLINDER
PBa2 37.8MPa
Ao
Bo 3 6 4 1 5 2
A8 ARM 2 37.8MPa
17 PBo
LEFT TRAVEL FORWARD
SE-9 SE-10
13 MU1
PBp1 P1 BY PASS
CUT
P2 BY PASS
CUT
T2 P2
(P3) (P4)
17
YY01Z00069P1 02
Fig. 22-8 ARM CIRCUIT : Arm in (Heavy load) operation, Arm confluence & recirculation cut function
22-23
This section describes the following operations. 22.9.7 NATURAL FALL PROTECTION WITH ARM
(5) Arm out pilot circuit LOCK VALVE
(6) Arm out 2 pumps conflux main circuit (1) Purpose :
To prevent the arm from falling naturally by the
(7) Natural fall protection with arm lock valve
weight of the arm and bucket.
22.9.5 ARM OUT PILOT CIRCUIT (2) Principle :
(1) Operation : Complete seat of the return circuit against the arm
1) When the arm out operation is performed, the spool of the arm cylinder (R) side circuit.
secondary pilot proportional pressure gets out (3) Operation :
of port 8 of the left pilot valve (9), and acts upon 1) When the secondary pressure for arm
the low pressure sensor (SE-8). At the same operation disappears and the arm cylinder
time, the oil is branched off in two flows and act stops, the pressure on the rod (R) side passes
upon the PBa1 and PBa2 ports of C/V (2). through the selector of the lock valve from the
2) The operating proportional secondary pressure Ba port of C/V (2), acts the back pressure on
flowed in PBa1 port of C/V (2) switches the arm the lock valve CRa and seats the lock valve.
1 spool. 2) Since the oil flow into the arm spool from the
3) Then, the operating secondary pressure flowed lock valve is shut off completely, natural fall of
in PBa2 port of C/V (2) switches the arm 2 spool the arm due to oil leaks through the arm spool
valve. is prevented.
22.9.6 ARM OUT 2 PUMPS CONFLUX MAIN

CIRCUIT
(1) Purpose :
Arm out operation speed up.
(2) Principle :
The oil delivered by the P1 pump is confluxed with
that delivered by the P2 pump in C/V (2).
(3) Operation :
1) P1 pump delivery oil opens load check valve
(LCAT2) by switching arm 2 spool and
confluxes with P2 pump delivery oil just short of
the arm lock valve.
2) And, P2 pump delivery oil flows through arm 1
spool and confluences with P1 delivery oil,
opens lock valve of arm lock valve CRa with
free flow and is flowed into arm cylinder rod (R)
side through Ba port of C/V(2).
3) On the other hand, the return oil from arm
cylinder (H) side flows in Aa port, and returns
into tank circuit through arm 1 spool and arm 2
spool.
The return line which does not pass through
boost check valve is used for this return circuit
to reduce the pressure loss.
22-24
D P
PSV1
SE-22
P
A1a1 a2
SE-23
A1
P PSV2
4
PH1 PH2
PSV-P1 PSV-P2
a3 a4
B FOR. FOR. A
SWING
A
REV. REV.
B
4 DB
PG
8 3
1
B DEE I HAC C
28.0MPa
Dr1
69kw 5.0MPa
/2000min-1 M
a3
B1
B3 Dr3 A3 11
PTO
(OCE SPEC.) A B
2 RIGHT
34.3MPa
15 12 CMR1
PTb CMR2 PBL
BUCKET DUMP
PCb PAL SWING RIGHT
ARM OUT BOOM UP
AL ARM IN BOOM DOWN
14 CT2 CP2 BL
SE-8
SE-7
SE-4
SE-3
SE-2
SE-1
T3
CP1 BOOM 8 7 6 5 4 3 2 1
Br CONFLUX PB1
Ar
CCb Dr
Pss SE-5 8 7 6 5 4 3 2 1
SOL/V PAb PAs
P1 BLOCK LEVER
A1 LOCK As
SV-4
(ROD)Bb
37.8MPa Bs
PBa1
16
CRb
SWING
SV-1
A2 P/B
(HEAD)Ab
LCa 17 ATT.
PILOT
1/2 SPEED
SV-3
A3 CHANGEOVER
BUCKET
CYLINDER
9 9
PBb
37.8MPa
LCc Aa (HEAD)
A4 PAc
BUCKET
7
CRa ARM
37.8MPa BOOM ARM
Ba (ROD)
PSV-B (HEAD)Ac
37.8MPa
37.8MPa
6
TRAVEL
A6 STRAIGHT LCAT2
PSV-C
PAa2
ARM 2
LCAP2 OPTION
10
LCo
PAo
5
A7 P1 UNLOAD BOOM
PSV-D CYLINDER
PBa2 37.8MPa
Ao
Bo 3 6 4 1 5 2
A8 ARM 2 37.8MPa
17 PBo
LEFT TRAVEL FORWARD
SE-9 SE-10
13 MU1
PBp1 P1 BY PASS
CUT
P2 BY PASS
CUT
T2 P2
(P3) (P4)
17
YY01Z00069P1 02
Fig. 22-9 ARM CIRCUIT : Arm out operation, Confluence function
22-25
22.10 COMBINED CIRCUIT 22.10.2 BOOM UP / TRAVEL, MAIN CIRCUIT

This section describes only the difference in combined (1) Purpose :
operation. To insure straight travel movement during travel
operation even if the attachment is operated.
(1) Boom up / travel, pilot circuit
(2) Principle :
(2) Boom up / travel, main circit
The travel action and the attachment action are
22.10.1 BOOM UP / TRAVEL, PILOT CIRCUIT actuated by separate pumps.
(1) Operation : (3) Operation :
<Operation: Different point of pilot circuit from 1) P1 pump delivery oil flows through P1 port of C/
independent operation > V(2) and branches off in P1 parallel circuit and
1) The mechatro controller outputs command travel straight spool.
current to travel straight solenoid proportional P2 pump delivery oil flows through P2 port of C/
valve (PSV-C) after signal processing, and the V(2) and branches off in P2 tandem circuit and
solenoid valve outputs secondary pressure and travel straight spool.
acts on PTb port of C/V (2). 2) The delivery oil flowed into P1 parallel circuit of
2) Then the pressure of PTb port switches the P1 pump opens check valve CT1 and LCb and
travel straight valve one step. flows in boom spool, which exerts on boom up
operation.
The delivery oil flowed into travel straight spool
of P1 pump opens check valve CT2 because
the travel straight spool is shifted, and flows in
boom conflux spool and exerts on boom up
operation with the internal oil conflux.
(In travel straight operation, P1 pump delivery
oil exerts on swing operation of attachment.)
3) The delivery oil flowed into P2 tandem circuit of
P2 pump flows in left travel spool to travel
leftward.
The delivery oil flowed into travel straight spool
of P2 pump flows in right travel spool because
the travel straight spool is shifted and exerts on
the right travel operation.
(In travel straight operation, P2 pump delivery
oil exerts on travel operation.)
4) However, a portion of the flow is led to the travel
straight spool notch restriction. The speed of
attachments like travel, boom, etc. is adjusted
by the circuit of restriction.
22-26
D P
PSV1
SE-22
P
A1a1 a2
SE-23
A1
P PSV2
4
PH1 PH2
PSV-P1 PSV-P2
a3 a4
B FOR. FOR. A
SWING
A
REV. REV.
B
4 DB
PG
8 3
1
B DEE I HAC C
28.0MPa
Dr1
69kw 5.0MPa
/2000min-1 M
a3
B1
B3 Dr3 A3 11
PTO
(OCE SPEC.) A B
2 RIGHT
34.3MPa
15 12 CMR1
PTb CMR2 PBL
BUCKET DUMP
PCb PAL SWING RIGHT
ARM OUT BOOM UP
AL ARM IN BOOM DOWN
14 CT2 CP2 BL
SE-8
SE-7
SE-4
SE-3
SE-2
SE-1
T3
CP1 BOOM 8 7 6 5 4 3 2 1
Br CONFLUX PB1
Ar
CCb Dr
Pss SE-5 8 7 6 5 4 3 2 1
SOL/V PAb PAs
P1 BLOCK LEVER
A1 LOCK As
SV-4
(ROD)Bb
37.8MPa Bs
PBa1
16
CRb
SWING
SV-1
A2 P/B
(HEAD)Ab
LCa 17 ATT.
PILOT
1/2 SPEED
SV-3
A3 CHANGEOVER
BUCKET
CYLINDER
9 9
PBb
37.8MPa
LCc Aa (HEAD)
A4 PAc
BUCKET
7
CRa ARM
37.8MPa BOOM ARM
Ba (ROD)
PSV-B (HEAD)Ac
37.8MPa
37.8MPa
6
TRAVEL
A6 STRAIGHT LCAT2
PSV-C
PAa2
ARM 2
LCAP2 OPTION
10
LCo
PAo
5
A7 P1 UNLOAD BOOM
PSV-D CYLINDER
PBa2 37.8MPa
Ao
Bo 3 6 4 1 5 2
A8 ARM 2 37.8MPa
17 PBo
LEFT TRAVEL FORWARD
SE-9 SE-10
13 MU1
PBp1 P1 BY PASS
CUT
P2 BY PASS
CUT
T2 P2
(P3) (P4)
17
YY01Z00069P1 02
Fig. 22-10 COMBINED CIRCUIT : Boom up & Travel forward 1st speed operation, Travel straight function.
22-27
In this section, the independent operation is omitted 22.10.4 SWING / ARM IN, SWING PRIORITY MAIN
and describes difference in combined operation. CIRCUIT
(3) Swing / Arm in light load, pilot circuit (1) Purpose :
(4) Swing / Arm in, swing priority main circuit Stable swing speed.
(2) Principle :
22.10.3 SWING / ARM IN LIGHT LOAD, PILOT
Raise the oil pressure flowing to arm cylinder, and
CIRCUIT
give a priority of the delivery of P2 pump to swing
(1) Operation : operation.
1) On operating swing (left) and arm in motions (3) Operation :
simultaneously, mechatro controller outputs
1) The swing main circuit operates with P2 pump
command current to travel straight solenoid
flow. But on P2 pump circuit side, the flow goes
proportional valve (PSV-C) and arm 2 solenoid
to the swing circuit and arm circuit
inverse proportional valve (PSV-A) according to
simultaneously because the swing circuit and
signal processing, and this proportional valve
arm circuit are parallel. Then since the return oil
outputs secondary pressure, which acts on PTb
from arm cylinder rod (R) side is restricted in
port and PAa2 port of C/V(2).
the arm 2 spool because the arm 2 spool is
2) PTb port pressure switches the travel straight switched to forced recirculation position, the
spool 2 steps, and the PAa2 port pressure pressure of return oil is raised, causing the rise
switches the arm 2 spool to the forced of circuit pressure on the arm cylinder head (H)
recirculation position. side.
2) At the same time meter-in of arm 2 spool closes
and arm in conflux is therefore cancelled, and
delivery oil from P2 pump and P1 pump are
combined in the parallel circuit on P2 pump side
because the travel straight spool was switched.
The conflux oil of P1 and P2 delivery oil in high
pressure flows in swing side taking priority over
all others.
This operation is called "Swing Priority Circuit".
Position of forced recirculation

Meter-in passage (Close)
Neutral position
From
From arm out
arm 2 inverse P/V
proportional valve
Normal recirculation position
Arm 2 spool
22-28
D P
PSV1
SE-22
P
A1a1 a2
SE-23
A1
P PSV2
4
PH1 PH2
PSV-P1 PSV-P2
a3 a4
B FOR. FOR. A
SWING
A
REV. REV.
B
4 DB
PG
8 3
1
B DEE I HAC C
28.0MPa
Dr1
69kw 5.0MPa
/2000min-1 M
a3
B1
B3 Dr3 A3 11
PTO
(OCE SPEC.) A B
2 RIGHT
34.3MPa
15 12 CMR1
PTb CMR2 PBL
BUCKET DUMP
PCb PAL SWING RIGHT
ARM OUT BOOM UP
AL ARM IN BOOM DOWN
14 CT2 CP2 BL
SE-8
SE-7
SE-4
SE-3
SE-2
SE-1
T3
CP1 BOOM 8 7 6 5 4 3 2 1
Br CONFLUX PB1
Ar
CCb Dr
Pss SE-5 8 7 6 5 4 3 2 1
SOL/V PAb PAs
P1 BLOCK LEVER
A1 LOCK As
SV-4
(ROD)Bb
37.8MPa Bs
PBa1
16
CRb
SWING
SV-1
A2 P/B
(HEAD)Ab
LCa 17 ATT.
PILOT
1/2 SPEED
SV-3
A3 CHANGEOVER
BUCKET
CYLINDER
9 9
PBb
37.8MPa
LCc Aa (HEAD)
A4 PAc
BUCKET
7
CRa ARM
37.8MPa BOOM ARM
Ba (ROD)
PSV-B (HEAD)Ac
37.8MPa
37.8MPa
6
TRAVEL
A6 STRAIGHT LCAT2
PSV-C
PAa2
ARM 2
LCAP2 OPTION
10
LCo
PAo
5
A7 P1 UNLOAD BOOM
PSV-D CYLINDER
PBa2 37.8MPa
Ao
Bo 3 6 4 1 5 2
A8 ARM 2 37.8MPa
17 PBo
LEFT TRAVEL FORWARD
SE-9 SE-10
13 MU1
PBp1 P1 BY PASS
CUT
P2 BY PASS
CUT
T2 P2
(P3) (P4)
17
YY01Z00069P1 02
Fig. 22-11 COMBINED CIRCUIT : Swing / Arm in operation, swing priority function
22-29
22.11 PRESSURE DRAINING switches the P1, P2 unloading valves to OPEN

position.
(RELEASING) CIRCUIT
This section describes the following operations. 22.11.2 PRESSURE RELEASE MAIN CIRCUIT
(1) Pressure drain (releasing) pilot circuit (1) Operation :
(2) Pressure drain (releasing) main circuit
22.11.1 PRESSURE RELIEVING PILOT CIRCUIT

(1) Purpose : When the hydraulic pressure releasing is
To release the pressure in main circuit for piping performed, make sure to place bucket on the
repair works. ground.
(2) Principle : When the operating lever is shifted to neutral during

After the mode is switched to "Pressure Relief engine running, "DRAINING HYD. PRESS." is
Mode" with switch on gauge cluster, mechatro displayed on the gauge cluster while the mode
controller outputs the following commands. switch is changed to pressure relieving mode. In
1) Minimum tilting command value to pump this time the intermittent buzzer sounds
proportional valve (PSV-P1, PSV-P2). continuously. When right and left operating levers
2) Output "Pressure relief control speed command are operated 4 or 5 times to their full stroke,
value" at ECU. (Electric system) pressure is relieved.
3) Stand-by command value to P1, P2 unloading After draining pressure is completed, turn off the
proportional valves starter key and buzzer sound stops. If the pump
pressure is determined to be more than 1 MPa (145
How to switch to "Pressure release mode" psi) by the output value of the high pressure sensor
1) Select the service diagnosis mode. or the high pressure sensors (SE-22,23) are
(Keeping pressing of the "BUZZER STOP broken, "FAIL DRAIN HYD. PRESS" is displayed
SWITCH" [ ] on gauge cluster, turn the starter and the buzzer sounds continuously. In that case,
key on.) also the buzzer is not stopped unless the engine
key is turned to OFF. Repeat the pressure releasing
2) Select the service adjustment mode 1.
procedure once again.
(Under the condition that "Screen No.1" of
"Service diagnosis mode 1" is indicated, (2) Hydraulics :
keeping pressing of the "BUZZER STOP Unload spool is switched to open position, and the
oil delivered by each pump is unloaded to the tank
SWITCH", press the selector switch [ ] 3
passage.
times. When "LANGUAGE/LOGO",
If the spools are switched by pilot operation, the
"ADJUSTING MODE 1" and "PRESET BY
remaining pressure from the actuators may be
FACTORY" are displayed, press [ ] or [ ]
relieved to the tank circuit, i.e. the main circuit
switch, and highlight "ADJUSTING MODE 1",
pressure may be released.
and then press "Selector Switch" again.)
3) When "ADJUSTING MODE 1" screen is
displayed, press [ ] or [ ] switch, and "DRAIN
HYD. OFF" screen appears.
4) Press "Selector Switch" and highlight "OFF",
and press [ ] switch to change to "DRAIN
HYD. ON", and then press "Selector Switch"
again.
(3) Operation :
1) Pump proportional valve reduces the pump flow
rate to the minimum.
2) Unloading proportional valves (PSV-D, PSV-B)
output secondary pressure and the secondary
pressure flows in PCb, PCa ports of C/V(2) and
22-30
D P
PSV1
SE-22
P
A1a1 a2
SE-23
A1
P PSV2
4
PH1 PH2
PSV-P1 PSV-P2
a3 a4
B FOR. FOR. A
SWING
A
REV. REV.
B
4 DB
PG
8 3
1
B DEE I HAC C
28.0MPa
Dr1
69kw 5.0MPa
/2000min-1 M
a3
B1
B3 Dr3 A3 11
PTO
(OCE SPEC.) A B
2 RIGHT
34.3MPa
15 12 CMR1
PTb CMR2 PBL
BUCKET DUMP
PCb PAL SWING RIGHT
ARM OUT BOOM UP
AL ARM IN BOOM DOWN
14 CT2 CP2 BL
SE-8
SE-7
SE-4
SE-3
SE-2
SE-1
T3
CP1 BOOM 8 7 6 5 4 3 2 1
Br CONFLUX PB1
Ar
CCb Dr
Pss SE-5 8 7 6 5 4 3 2 1
SOL/V PAb PAs
P1 BLOCK LEVER
A1 LOCK As
SV-4
(ROD)Bb
37.8MPa Bs
PBa1
16
CRb
SWING
SV-1
A2 P/B
(HEAD)Ab
LCa 17 ATT.
PILOT
1/2 SPEED
SV-3
A3 CHANGEOVER
BUCKET
CYLINDER
9 9
PBb
37.8MPa
LCc Aa (HEAD)
A4 PAc
BUCKET
7
CRa ARM
37.8MPa BOOM ARM
Ba (ROD)
PSV-B (HEAD)Ac
37.8MPa
37.8MPa
6
TRAVEL
A6 STRAIGHT LCAT2
PSV-C
PAa2
ARM 2
LCAP2 OPTION
10
LCo
PAo
5
A7 P1 UNLOAD BOOM
PSV-D CYLINDER
PBa2 37.8MPa
Ao
Bo 3 6 4 1 5 2
A8 ARM 2 37.8MPa
17 PBo
LEFT TRAVEL FORWARD
SE-9 SE-10
13 MU1
PBp1 P1 BY PASS
CUT
P2 BY PASS
CUT
T2 P2
(P3) (P4)
17
YY01Z00069P1 02
Fig. 22-12 PRESSURE DRAIN (RELEASE) CIRCUIT : At pressure release mode.
22-31
[MEMO]
22-32
23. ELECTRIC SYSTEM
TABLE OF CONTENTS
23.1 ELECTRIC CIRCUIT DIAGRAM......................................................................................23-3

23.2 ELECTRICAL EQUIPMENT LIST....................................................................................23-8
23.3 HARNESS........................................................................................................................23-9
23.3.1 HARNESS LIST......................................................................................................23-9
23.3.2 INSTRUMENT PANEL ASSY.................................................................................23-10
23.3.3 CONTROLLER INSTALL (OCE/S.E.ASIA) ............................................................23-11 23
23.3.4 OPERATOR'S CONTROL (SWITCH INSTALL).....................................................23-12
23.3.5 UPPER ELECTRIC ASSY (OCE/S.E.ASIA)...........................................................23-13
23.3.6 UPPER HARNESS ASSY (1/8) (OCE/S.E.ASIA)...................................................23-14
23.3.7 UPPER HARNESS ASSY (FLOOR) (1/3) (OCE/S.E.ASIA) ...................................23-28
23.3.8 ENGINE HARNESS ASSY (OCE/S.E.ASIA)..........................................................23-35
23.3.9 CAB INSTALL (OCE/S.E.ASIA)..............................................................................23-36
23.3.10 WASHER TANK ASSY (OCE/S.E.ASIA)................................................................23-37
23.3.11 CAB HARNESS ASSY (OCE/S.E.ASIA) ................................................................23-38
23.3.12 BOOM HARNESS ASSY (OCE/S.E.ASIA).............................................................23-41
23.3.13 BOOM LIGHT INSTALL (OCE SPEC.)...................................................................23-41
23.3.14 UPPER LIGHT INSTALL (OCE/S.E.ASIA) .............................................................23-42
23.3.15 TRAVEL ALARM ASSY (OCE SPEC.)...................................................................23-42
23-1
23. ELECTRIC SYSTEM

SK125SR : YV05-04501~
S5YY2313E01
(OCE/S.E.ASIA)
SK135SRLC-2 : YH05-07001~
23-2
23. ELECTRIC SYSTEM
23.1 ELECTRIC CIRCUIT DIAGRAM
HORN,HORN RELAY
ENG.CONTROLLER
KEY SW.STARTER RELAY
GAUGE CLUSTER
DC-DC CONVERTER,
ROOM LIGHT TUNER
ENG.CONTROLLER
LUBRICATION OIL
AUTO GREASE
CONTROLLER
CONTROLLER
CONTROLLER
PRESS.SENSOR
RELAY,HOUR
LEVER LOCK
BATTERY RELAY
MECHATRO
MECHATRO
CIGARETTE
GLOW RELAY
BACK UP
LIGHTER
BACK UP
METER
TUNER
C-8:ENG.CONTROLLER ENG.HARNESS
E-1:FUSE & RELAY BOX

RDS/RAIL PRESS.
R-26: (NONUSE) BOOST PRESS.

LEVER LOCK RELAY SENSOR
WATER TEMP
SENSOR
CRANK SENSOR
LIGHT,TRAVEL ALARM,
OPT.HAND
CONTROL
OPT.4
AIR CON.(AMP.)
GAUGE CLUSTER
WIPER,WASHER
SOLENOID,LMN/BH
WORK LIGHT
CAB WORK LIGHT
CAB WORK LIGHT

AIR CON.
AIR CON.
ROOF WIPER
OPT.BACKET
CONTROL
OPT.1
OPT.3
FLASHER,REARWORK
RELEASE SW.(KPSS)
LEVEL CONTROLLER,
DC-DC CONVERTER
RADIATOR COOLANT
SH2 SHEILD
ONE WAY CALL

CAM SENSOR
SH3 SHEILD
E-12: E-12: INJECTOR 1

BATTERY BATTERY
STARTER CABLE
INJECTOR 2
INJECTOR 3
R-1: ACCEL REDUNDANT

BATTERY REAY POTENTIO
E-15: INJECTOR 4
FUSIBLE LINK
75A
R-23: MPROP
AUTO IDLE STOP RELAY 1 R-24: R-25:
AUTO IDLE STOP ENG.EMERGENCY STOP
RELAY 2 RELAY LUBRICATION OIL
KEY ON PRESS. SENSOR
G
N TIN
IO EA
SIT EH
PO PR
TERMINAL
O A O S
T
F C A
F C N R TERMINAL FOR SERVICE
T
R-3:
GLOW RELAY GLOW
R-53:
GLOW RELAY
SW-1: KEY SW. (ECU)
M-1:
STARTER MOTOR
C-1:
MECHATRO CONTROLLER(TCO-60-2)
R-2:
STARTER RELAY
R-4: SAFETY RELAY C-6:

AUTO GREASE
CONTROLLER
SH8 SHIELD
E-3:
HOUR METER
CHARGE
KEY ON
CONTROL:
(SENSOR,5V,CPU)
(PULL UP)
OUT SOURCE:
(PSV.SOL.MOTOR)
R-28:ALTERNATOR RELAY
TO(2/5)
(1/5)
YY03Z00022P1 (03)
23-3
23. ELECTRIC SYSTEM
C-1: MECHATRO CONTROLLER(TCO-60-2)
FROM (1/5)
SE-16:ACCEL POTENTIO
N
IO AL ASE
PRESS.SENSOR SIT ORM ELE
PO N R
TERMINAL
SW-4:
SE-1:BUCKET DIGGING SWING PARKING RELEASE SW.
SE-2:BUCKET DUMP SV-1:SWING PARKING BRAKE SOL.
SV-3:TWO-SPEED SELECT SOL.

SE-3:BOOM RAISING
PSV-B:P2 UNLOAD PROPORTIONAL SOL.

SE-4:BOOM LOWERING
PSV-C:TRAVEL PRIORITY PROPORTIONAL SOL.

SE-7:ARM IN
PSV-D:P1 UNLOAD PROPORTIONAL SOL.

SE-8:ARM OUT
PSV-A:ARM TWO-SPEED INVERSE PROPORTIONAL SOL.
SE-5:SWING
SE-9:TRAVEL RIGHT PSV-E:OPT RELIEF ADJUSTMENT

PROPORTIONAL SOL. 1
SE-10:TRAVEL LEFT PSV-I:OPT RELIEF ADJUSTMENT

PROPORTIONAL SOL. 2
SE-22:PUMP P1
N
IO AL ASE
SIT ORM ELE
PO N R SW-22:
TERMINAL
SE-23:PUMP P2 RELEASE SW. (KPSS)
E-38: RESISTOR
SE-20:P1 OPT.
C-2:GAUGE CLUSTER
PSV-P1:PUMP P1 PROPORTIONAL SOL.
SE-11:P2 OPT.
ENG.WATER TEMP METER
PSV-P2:PUMP P2 PROPORTIONAL SOL.
FUEL METER SE-15:FUEL SENSOR
SE-13:ENG.REVOLUTION SENSOR
SHIELD
SHIELD
DISPLAY BUZZER STOP MODE WASHER

SELECT SW.
ENTER DECEL TRAVEL WIPER TO(3/5)

2-SPEED
(2/5)
YY03Z00022P1 (03)
23-4
23. ELECTRIC SYSTEM
C-1:MECHATRO CONTROLLER(TCO-60-2)
FROM 2/5
SW-8:AIR FILTER RESTRICTION SW. R-5:HORN RELAY
E-5:HORN HIGH
E-6:HORN LOW
SW-36:WATER SEPARATOR
RESTRICTION SW. SW-10:HORN SW. LEFT
SW-5:HORN SW. RIGHT
(WIPER RELAY)
SW-15:
CONFLUX/SINGLE SELECT SW. R-31: R-29:
PREVENT SPARK WIPER MOTOR RELAY
RELAY L-5:ROOM LIGHT
M-3:
WIPER MOTOR
R-30:
WIPER MOTOR
REVERSING RELAY
R-32: E-14:CIGARETTE LIGHTER

M-4:
WINDOW WASHER WASHER MOTOR
MOTOR RELAY
E-1:
FUSE & RELAY BOX
R-26: E-11:
SW-11: LEVER LOCK SV-4:OPERATING E-10:
LEVER LOCK SOL. AIR COMPRESSOR
LEVER LOCK SW. RELAY RECEIVER DRIER CLUTCH
STOP R-6:
REVERSE WORK LIGHT RELAY
AIR CON.AMP.
(GROUND OUTPUT)
SW-19:WIPER INTERLOCK SW.
R-8:TRAVEL ALARM RELAY
E-13: COOLING
TRAVEL ALARM UNIT
SE-29:OPT.SELECT
DETECT SENSOR
SW-13:
TRAVEL ALARM SW
DOMESTIC,AUSTRALIA
SV-13:OPT.SELECTOR SOL. DOMESTIC OPT.
KCMA KCMA STD.
AUSTRALIA STD.
SW-17:ROOF WIPER SW.

POSITION
TERMINAL
M-9:ROOF WIPER MOTOR
ROOF WIPER
TO 4/5
(3/5)
YY03Z00022P1 (03)
23-5
23. ELECTRIC SYSTEM
C-1:MECHATRO CONTROLLER
FROM 3/5
E-7:TUNER AM & FM
C-6:AUTO GREASE E-8:SPEAKER LEFT

CONTROLLER
FM / AM
E-9:SPEAKER RIGHT
M-8:GREASE MOTOR (BACK UP)
E-2: WITH OUT EU

ALTERNATOR
OPT.
AUTO GREASE
C-1:MECHATRO CONTROLLER (TCO-60-2)
R-6:WORK LIGHT RELAY L-6:BOOM WORKING LIGHT RIGHT OCEANIA
L-1:BOOM WORKING LIGHT LEFT
L-2:FRAME WORKING LIGHT RIGHT 9P CONNECTOR

C-4:AIR-CON AMP
SW-55:
BOOM,DECK WORKING LIGHT SW.
R-19:
FLASHER RELAY
L-3:
SWING FLASHER LEFT
DOWNLOAD
L-4:
SWING FLASHER RIGHT
SWING FLASHER & WORKING LIGHT

E-16:ONE WAY CALL AMP
E-17:
ONE WAY CALL SPEAKER
OPT.
MIC ONE WAY CALL
TO 5/5
(4/5)
YY03Z00022P1 (03)
23-6
23. ELECTRIC SYSTEM
C-1:MECHATRO CONTROLLER (TCO-60-2)
R-26:
LEVER LOCK RELAY SV-6:
SW-33: REVOLUTION
R-12: REVOLUTION RIGHT SOL.
REVOLUTION RIGHT SW.
RIGHT RELAY
SV-7:
SW-34: REVOLUTION
R-13: REVOLUTION LEFT SOL.
REVOLUTION LEFT SW.
LEFT RELAY
REVOLUTION N&B
SW-29: SV-9:
NIBBLER NIBBLER OPEN SOL.
R-15:
NIBBLER OPEN SW.
OPEN RELAY
(CASE OF HAND CONTROL
NIBBLER CONNECT WITH 571)
(CASE OF HAND CONTROL

BRAKER CONNECT WITH 572)
SV-10:
SW-30: NIBBLER
NIBBLER CLOSE SOL.
EASY OPERATING R-16: CLOSE SW.
NIBBLER NIBBLER
CLOSE RELAY
(5/5)
YY03Z00022P1 (03)
23-7
23. ELECTRIC SYSTEM
23.2 ELECTRICAL EQUIPMENT LIST
GROUP CODE NAME PARTS No. GROUP CODE NAME PARTS No. GROUP CODE NAME PARTS No. GROUP CODE NAME PARTS No.
MECHATRO CONTROLLER YN22E00214F1 L-1 BOOM WORK LIGHT (LH) YW80S00001F1 R-1 BATTERY RELAY YN24S00008F1 SWING PARKING
(C) CONTROLLER
C-1 SV-1 YN35V00051F1

(TCO-60-2) (HARD) L-2 FRAME WORK LIGHT (RH) YT80S00002F2 R-2 STARTER RELAY ENGINE ACCESSORY BRAKE SOL.
(YY35V00013F1)
C-2 GAUGE CLUSTER YN59S00021F3 L-3 SWING FLASHER (LH) YY80S00001F1 R-3 GLOW RELAY 34390-00601 TWO SPEED
SV-3 SOLENOID YN35V00050F1
AIR-CON CONTROLLER L-4 SWING FLASHER (RH) R-4 SAFETY RELAY ACCESSOR OF RELAY BOX SELECT SOL
C-4 YN20M01468P2 VALVE ASSY
(INCLUDING PANEL) L-5 ROOM LIGHT YT80S00001P1 R-5 HORN RELAY YN24S00010P1 SAFETY LOCK
SV-4
(SV) SOLENOID
C-8 ENGINE CONTROLLER 32G87-01020 R-6 WORKING LIGHT RELAY LEVER SOL
R-8 TRAVEL ALARM RELAY SV-5 BUCKET DUMP CUT SOLENOID
(L) LIGHT
D-4 DIODE ACCESSORY OF FUSE RELAY BOX R-12 REVOLUTION RIGHT RELAY SV-6 REVOLUTION RIGHT SOLENOID -
D-5 DIODE R-13 REVOLUTION LEFT RELAY SV-7 REVOLUTION LEFT SOLENOID -
D-6 DIODE R-15 NIBBLER OPEN RELAY SV-9 NIBBLER OPEN SOLENOID -
D-9 DIODE R-16 NIBBLER CLOSE RELAY SV-10 NIBBLER CLOSE SOLENOID -
D-10 DIODE R-19 FLASHER RELAY YY24S00001F1 SV-13 OPT. SELECTOR SOLENOID
(R) RELAY
D-12 DIODE R-23 AUTO IDLE STOP RELAY 1 YN24S00010P1
D-13 DIODE R-24 AUTO IDLE STOP RELAY 2
(D) DIODE
D-14 DIODE R-25 ENGINE EMERGENCY STOP RELAY

D-15 DIODE R-26 LEVER LOCK RELAY
D-16 DIODE M-1 STARTER MOTOR 32G66-0010 R-28 ALTERNATOR RELAY SW-1 KEY SWITCH YN50S00029F1
D-17 DIODE M-3 WIPER MOTOR YN53C00012F2 WIPER MOTOR RELAY SWING PARKING BRAKE RELEASE
R-29 YN24S00012P2 SW-4 YN50S00047P1
(M) MOTOR
M-4 WASHER MOTOR (TANK ASSY) YT54C00003F1 (NORMAL ROTATION) SWITCH
M-8 GREASE MOTOR LC71V00001P1 WIPER MOTOR RELAY SW-5 HORN SWITCH (RH) YN50E00017P1
R-30
M-9 ROOF WIPER MOTOR YN76S00005P1 (REVERSE ROTATION) SW-8 AIR FILTER CLOGGING SWITCH YR11P00008S005
R-31 PREVENT SPARK RELAY SW-10 HORN SWITCH (LH) YN50E00017P1
R-32 WASHER MOTOR RELAY SW-11 SAFETY LOCK LEVER SWITCH YN50S00041F1
R-53 GLOW RELAY(ECU) SW-13 TRAVEL ALARM SWITCH YN50S00040DF
ARM 2 SPEED CONFLUX/SINGLE SELECT
SW-15 YN50S00040DD
PSV-A INVERSE YN35V00049F1 SWITCH
PROPO.VALVE SW-17 SKYLIGHT WIPER SWITCH YN50S00040D9
E-1 FUSE AND RELAY BOX YY24E00008F1 P2 UNLOAD (YY35V00013F1) SW-19 WIPER INTERLOCK SWITCH YT50S00004P1
PSV-B YN35V00048F1
E-2 ALTERNATOR 32G68-00100 PROPO.VALVE SOLENOID SW-22 KPSS RELEASE SWITCH YX50S00001F1
E-3 HOUR METER YT58S00006P1 TRAVEL STRAIGHT VALVE ASSY PRESSURE SENSOR : SW-26 CAB WORK LIGHT SWITCH YN50S00040D4
PSV-C SE-1 YX52S00013P1
E-5 HORN (HIGH) LC53S00001D1 PROPO.VALVE BUCKET DIGGING SW-29 NIBBLER OPEN SWITCH 2406P5872
E-6 HORN (LOW) LC53S00001D2 P1 UNLOAD PRESSURE SENSOR : SW-30 NIBBLER CLOSE SWITCH
(P) PROPORTIONAL
SOLENOID VALVE
PSV-D SE-2
E-7 TUNER AM/FM (OCEANIA) YN54S00046P1 PROPO.VALVE BUCKET DUMP SW-33 REVOLUTION RIGHT SWITCH YN03M01231P3
E-8 SPEAKER (LEFT) YN54S00050P1 OPT. RELIEF ADJU- SE-3 PRESSURE SENSOR : BOOM UP SW-34 REVOLUTION LEFT SWITCH
PSV-E -
(SW) SWITCH
(E) ELECTRIC FITTINGS
E-9 SPEAKER (RIGHT) STMENT PROPO. VALVE 1 PRESSURE SENSOR : WATER SEPARATOR
SE-4 SW-36 32G90-00300
E-10 RECEIVER DRYER YN54S00041P1 OPT. RELIEF ADJU- BOOM DOWN RESTRICTION SWITCH
PSV-I -
E-11 AIR-CON COMPRESSOR YX91V00001F1 STMENT PROPO. VALVE 2 SE-5 PRESSURE SENSOR : SWING SW-37 TRAVEL INDEPENDENT SWITCH YN50S00040DB
E-12 BATTERY 2484U171 P1 PUMP SE-7 PRESSURE SENSOR : ARM IN SW-55 BOOM WORK LIGHT SWITCH YN50S00040D1
PSV-P1 YN35V00052F1
E-13 TRAVEL ALARM YN53S00004F1 PROPO VALVE (YY10V00013F1) SE-8 PRESSURE SENSOR : ARM OUT
E-14 CIGARETTE LIGHTER YN81S00003P1 P2 PUMP PUMP ACCESORY SE-9 PRESSURE SENSOR : TRAVEL RH
PSV-P2
E-15 FUSIBLE LINK YY73S00003P1 PROPO VALVE SE-10 PRESSURE SENSOR : TRAVEL LH
(SE) SENSOR
E-16 ONE WAY CALL AMP 2447R145 SE-11 (PRESSURE SENSOR : P2 OPT.)
E-17 ONE WAY CALL SPEAKER 2479R2098 SE-13 E/G SPEED SENSOR ENGINE ACCESSORY
E-22 DC-DC CONVERTER YN77S00005F1 SE-15 FUEL SENSOR YN52S00045F1
SE-16 ACCEL POTENTIOMETER YN52S00032P1
SE-20 (PRESSURE SENSOR : P1 OPT.) YX52S00013P1
SE-22 PRESSURE SENSOR : PUMP P1 YN52S00048P1
SE-23 PRESSURE SENSOR : PUMP P2
SE-29 OPT. SELECTOR DETECT SENSOR YX52S00013P1
NOTE : The parts number may be changed due to the improvement of machine, so use the number for reference only. YY03Z00022P1 03
23-8
23. ELECTRIC SYSTEM
23.3 HARNESS
23.3.1 HARNESS LIST
DIVISION DRAWING No. HARNESS

ASSEMBLY No. DRAWING No. REMARKS
POSITION ITEM NAME CODE No. NAME
SK125SR/SK135SR(LC)-2 OCE SK125SR/SK135SR(LC)-2 S.E.ASIA SK125SR/SK135SR(LC)-2 OCE SK125SR/SK135SR(LC)-2 S.E.ASIA
3.2 INSTRUMENT PANEL ASSY YY17M00017F1 YY17M00018F1
3.3 CONTROLLER INSTALL YY22E00109F1
3.4 OPERATORS CONTROL (SWITCH INSTALL) YY03M00068F1 YY03M00070F1 7-6 CABLE YN17M01072P1
3.5 UPPER ELEC ASSY YY03E00006F1
3.6 UPPER HARNESS ASSY YY13E00040F1 1 HARNESS YY13E01166P2 UPPER
2 CABLE YY13E01144P1 BATTERY TO BATTERY
UPPER FRAME
3 CABLE YY13E01130P1 BATTERY TO GROUND

4 CABLE YY13E01139P1 BATTERY TO RELAY
5 CABLE YY13E01138P1 STARTER
6 HARNESS YY13E01148P1 ECU
7 CABLE LE13E01006P1 FLOOR GROUND
3.7 UPPER HARNESS ASSY YY13E00041F1 1 HARNESS YY13E01167P1 FLOOR

(FLOOR PLATE) 3 CABLE YY13E01005P1 FLOOR GROUND
4 HARNESS YY13E01054P1 CAB SUB
3.8 ENGINE HARNESS ASSY YY13E00005F1 1 HARNESS YY16E01009P1 ENGINE SUB

3.9 CAB INSTAL YY02C00007F1
3.10 WASHER TANK ASSY YY54C00001F1
CAB
3.11 CAB HARNESS YB14E00018F1 1 HARNESS YB14E01027P2 CAB
5 HARNESS YN14E01106P1 KEY SWITCH GROUND
BOOM 3.12 BOOM HARNESS ASSY YY15E00009F1 1 HARNESS YY15E01021P1
LIGHT
3.13 BOOM LIGHT INSTALL YN80E00011F1 YN80E00011F2 BOOM LIGHT (OCE SPEC.)
3.14 UPPER LIGHT INSTALL YY80E00008F1 UPPER LIGHT
ALARM 3.15 TRAVEL ALARM ASSY YY53E00002F1
The parts number may be changed due to the improvement of machine, so use the number for reference only.
23-9
23. ELECTRIC SYSTEM
23.3.2 INSTRUMENT PANEL ASSY
YY17M00018F1 (01) S.E.ASIA

INSTRUMENT PANEL ASSY
YY17M00017F1 (01)
OCE
ITEM PART NAME PART No. Q'TY REMARKS
1 INSTRUMENT PANEL ASSY YB17M00018F1 (02)
INSTRUMENT PANEL ASSY YB17M00019F1 (01)

CROSS TAPPING SCREW
1-10 GAUGE CLUSTER YN59S00021F3 1 1 T=5.2N.m (3.86 lbf.ft)
Install to A/C unit
2 SWITCH INSTALL YN50E00014F1 1 1 (01)
2-1 SWITCH YN50S00040D1 1 1 WORK LIGHT

DETAIL
T=TIGHTNING TORQUE
Install to cab FORWARD

T=5.0N.m (3.69 lbf.ft)
SEMS-BOLT Install to support of
electric device
T=5.0N.m (3.69 lbf.ft)
SEMS-BOLT
TAPPING SCREW
Install to cab
T=5.2N.m (3.86 lbf.ft) 2-1 SEMS-BOLT
T=5.0N.m (3.69 lbf.ft)
SEMS-BOLT 4 PLACES
Install to cab
SEMS-BOLT Install to cab

T=2.8N.m T=8.5N.m (6.27 lbf.ft)
(2.07 lbf.ft) SEMS-BOLT
1-10
SEMS-BOLT
T=8.5N.m (6.27 lbf.ft)
Install to cab Install to cab
T=5.0N.m (3.69 lbf.ft) T=12N.m (8.85 lbf.ft)
SEMS-BOLT SEMS-BOLT
TAPPING SCREW
T=5.2N.m (3.86 lbf.ft)
SEMS-BOLT
T=5.0N.m (3.69 lbf.ft)
SEMS-BOLT CROSS TAPPING SCREW

T=5.0N.m (3.69 lbf.ft) T=5.2N.m (3.86 lbf.ft)
SEMS-BOLT
T=4.1N.m (3.02 lbf.ft)
SEMS-BOLT
SEMS-BOLT T=5.0N.m (3.69 lbf.ft)
T=4.1N.m (3.02 lbf.ft) Install to cab
SEMS-BOLT
T=5.0N.m (3.69 lbf.ft)
SEMS-BOLT
T=23N.m (17 lbf.ft) FORWARD
Install to cab
FORWARD
23-10
23. ELECTRIC SYSTEM
23.3.3 CONTROLLER INSTALL (OCE/S.E.ASIA)
CONTROLLER INSTALL YY22E00109F1 (01) 4-1 4-2 Put in center of top cover

1 CONTROLLER INSTALL YB22E00021F1 - (02)
1-3 SWITCH YN50S00047P1 1
1-12 SWITCH YX50S00001F1 1 KPSS RELEASE UPPER HEXAGON NUT
Install horn in this direction
1-14 RESISTOR LC22E01001D1 1 TOOTHED LOCK WASHER
2 CONTROLLER INSTALL YY22E00087F1 - (01)
2-1 CONTROLLER Engine accessory 1 ECU HORN WASHER
2-2 CONTROLLER Engine accessory 1 COOLANT LEVEL

3 CONTROLLER YY22E00080F1 - (01) LOWER HEXAGON NUT
3-1 CONTROLLER YN22E00214F1 1 MECHATRO
3-2 SOFTWARE YY22E00080S002 1 1-3
4 RELAY BOX ASSY YY24E00009F1 - (01)
4-1 RELAY BOX ASSY YY24E00008F1 1 SECTION A-A
4-2 LABEL YY73E01009P1 1
T=TIGHTNING TORQUE
MACHINE FRONT
TYPE 8 RATING MARKING SIDE T= 1.7N.m (1.25 lbf.ft)
Assemble with nut of accessory
SEMS-BOLT
4 PLACES 1-3
T= 1.4N.m
T= 5.0N.m (3.69 lbf.ft) SEMS-BOLT

4 PLACES1-12 4-1 T= 5.0N.m (3.69 lbf.ft)
SEMS-BOLT RELAY BOX ASSY
T= 5.0N.m (3.69 lbf.ft)
1-14 3 PLACES
SEMS-BOLT
SEMS-BOLT
T= 5.0N.m (3.69 lbf.ft)
SEMS-BOLT
T= 3.2N.m (2.36 lbf.ft)
SEMS-BOLT
T= 5.0N.m (3.69 lbf.ft)
MECHATRO
CONTROLLER
SEMS-BOLT
5 PLACES 2-1
T= 23N.m (17 lbf.ft)
FORWARD
23-11
23. ELECTRIC SYSTEM
23.3.4 OPERATOR'S CONTROL (SWITCH INSTALL)
YY03M00070F1 (01) S.E.ASIA

OPERATOR'S CONTROL
YY03M00068F1 (01)
OCE 23.3.4.7-6 CABLE ; YN17M01072P1
)
A.
DI
2000
2 CONTROL BOX ASSY YB03M00036F1 (05)
R
NE
(IN
CONTROL BOX ASSY YB03M00035F2 (06)
2-7 LIMIT SWITCH YN50S00041F1 1 1

3 GRIP ASSY YN03M01974F1 1 1 (02) PLUS SIDE CLICK TYPE
3-1 GRIP ASSY YN03M02021F3 1 1 R/H NOTHING

BURIED CONDENSER 150PF
3-2 GRIP ASSY YN03M02021F1 1 L/H HORN
7 RADIO INSTALL YN54E00017F1 1 (02)
RADIO INSTALL YN54E00008F1 1

7-6 CABLE YN17M01072P1 1
T=TIGHTENING TORQUE
CONSOLE RH UPPER
3-1 3-2
THE SURPLUS
ANTENNA CABLE
IS PUT INTO THE PANEL.
7-6
CONNECT WITH THE ANTENNA ON THE CAB SIDE. CLAMPED USING
PILOT HOSE.
VIEW
CLAMPED USING HARNESS.
PASS IN THE HOLE FOR HORNESSES

CONTROL BOX 2-7
T=41.2 N.m (30.3 lbf.ft)
LEVER NUT
CHECK HOLE FOR LIMIT SWITCH
2 PLACES
BOLT
T= 5.0N.m (3.7 lbf.ft)
2 PLACES ADJUST THE CLEARANCE SO AS TO PROVIDE
4.5 0.5mm (0.177 0.020in) WHEN THE LIMIT
SWITCH IS POSITIONED AT THE STROKE END.
SPRING WASHER
2 PLACES
PLATE
BOLT
SEMS BOLT
PROCEDURE FOR ADJUSTING THE LIMIT SWITCH SECTION AA
T=23N.m (17 lbf.ft) APPLY GREASE ON SLIDING AREA.
23-12
23. ELECTRIC SYSTEM
23.3.5 UPPER ELECTRIC ASSY (OCE/S.E.ASIA)
UPPER ELECTRIC ASSY YY03E00006F1 (01) P-3 GROUND

P-17 GROUND
HORN HIGH ; E-5
ITEM PART NAME PART No. Q'TY REMARKS HORN LOW ; E-6
GND
1 BATTERY RELAY YN24S00008F1 1 SEMS-BOLT
CONNECT AS SHOWN T=10.7 N.m CONNECT AS SHOWN
2 HORN LC53S00001D1 1 HIGH SO AS TO AVOID SHORT (7.89 lbf.ft) SO AS TO AVOID SHORT
CIRCUIT ON POWER CIRCUIT ON POWER
3 HORN LC53S00001D2 1 LOW SOURCE LINE. SOURCE LINE.
TIGHTEN FROM THE FOWARD
T=TIGHTNING TORQUE
P-3 P-17
BLACK
E-6 : BLACK
HORN LOW
E-5 : GREEN/ GREEN/

HORN HIGH ORANGE ORANGE
SET THE GND
TERMINAL BETWEEN SET THE GND
THE HONE STAY AND TERMINAL BETWEEN
THE SEMS-BOLT THE HONE STAY AND
2 3 THE SEMS-BOLT
HIGH LOW
SECTION AA VEW
GLOW RELAY
SEMS-BOLT
T=2.9 N.m
(2.14 lbf.ft)
CLIP
SEMS-BOLT
T=11.7 N.m
(8.63 lbf.ft) MAX
VEW (BATTERY RELAY, GLOW RELAY)
23-13
23. ELECTRIC SYSTEM
23.3.6 UPPER HARNESS ASSY (1/8) (OCE/S.E.ASIA)
UPPER HARNESS ASSY YY13E00040F1 (04) TO ENG. REVOLUTION

FIX WHITE TAPING CLIP SENSER
ITEM PART NAME PART No. Q'TY REMARKS TO PUNP
POSITION CLIP ENG. SWING FLASHER RIGHT
1 HARNESS YY13E01166P2 1 UPPER GND CABLE
1-3 FUSE YY73S00003P1 1
1-4 BOX,FUSE LE73E00001S001 1 NOTES:
(1) TIGHTENING TORQUE OF
2 CABLE YY13E01144P1 1 BATTERY-BATTERY BATTERY TERMINALS ARE 3.4N.m. (2.5lbf.ft)
(2) TIGHTENING TORQUE OF
3 CABLE YY13E01130P1 1 BATTERY-GND GROUNDING CABLES ARE 10.7N.m. (7.89lbf.ft)
(3) UNLESS OTHERWISE SPECIFIED
4 CABLE YY13E01139P1 1 BATTERY-RELAY TIGHTENING TORQUE IS SHOWN BELOW.
M6 : 9.6N.m (7.08lbf.ft) SEMS-BOLT
5 CABLE YY13E01138P1 1 STARTER M8 : 23.5N.m (17.3lbf.ft) GND
M10 : 46.1N.m (34lbf.ft) SECTION AA TIGHTEN AFTER
6 HARNESS YY13E01148P1 1 SUB HARNESS (ECU) M12 : 79.4N.m (58.6lbf.ft) CHECKING NO PAINT.
(4) UNLESS OTHERWISE SPECIFIED, THE
INSTALLING PROCEDURE IS SHOWN BELOW. ECU HARNESS
7 CABLE LE13E01006P1 1 FLOOR GND CLIP 6
UPP HARNESS
CLIP
HARNESS
CLIP
SEMS-BOLT
SE-13 : STARTER FIX WHITE TAPING POSITION
E-13 :TRAVEL ALARM (OCE)
ENG. REVOLUTION CABLE TO STARTER MOTOR ANND
SE-5 : SENSOR TO ATT HARNESS ALTERNATON
SE-15 :FUEL SENSOR TO GLOW
PRESS SENSOR
: SWING SE-23 :PRESS SENSOR: PUMP P2 CLIP
FIX WHITE TAPING POSITION
PSV-P2 :PUMP 2 PROPORTIONAL SOL. SECTION BB
E-6 :HORN LOW
BATTERY CABLE
2
E-5 :HORN HIGH
SEMS-BOLT
PSV-P1 :PUMP 1 PROPORTIONAL SOL. GND
L-2 : TIGHTEN AFTER
FRAME WORKING SE-22 :PRESS SENSOR:PUMP P1 CHECKING NO PAINT.
LIGHT RIGHT
CLIP L-4 :SWING FLASHER RIGHT 3
FIX WHITE TAPING GND CABLE
TO HARNESS OF ATTACHED ENG.
POSITION
CLIP
SEMS-BOLT
FIX WHITE TAPING
POSITION
1 5
UPP HARNESS STARTER CABLE
4
CLIP BATTERY RELAY CABLE
L-10 :HIGH REACH
ROTARY LIGHT
FIX WITH THE CLIP FOR
DRAIN HOSE
UPP HARNESS CLIP DERAIL OF BATTERY
SEMS-BOLT
TO AIR FILTER RESTRICTION SW.

RECEIVER DRIER
SWING FLASHER LEFT
STARTER UPP HARNESS
CABLE DRAIN HOSE STARTER CABLE
L-3 :SWING FLASHER LEFT
SW-8 :AIR FILTER RESTRICTION SW.
7 E-10 :RECEIVER DRIER

FLOOR GND CABLE
SEMS-BOLT
GND TO BATTERY TO HIGH REACH
TIGHTEN AFTER ROTARY LIGHT
CHECKING NO PAINT. CLIP
SEMS-BOLT
VIEW
23-14
23. ELECTRIC SYSTEM
FIX AND PUT WHITE TAPING POSITION

OF UPP HARNESS AND ECU HARNESS
CONNECT WITH ENG. ACCESORIES HARNESS CLIP
TO GLOW CLIP
CLIP P-11 TO UNDER FLOOR FRAME GROUND

SEMS-BOLT MECHATRO CONTROLLER ; C-1
CLIP CLIP P-10,P-16 TO UNDER FLOOR FRAME GROUND
FIX A CONNECTOR SEMS-BOLT MECHATRO CONTROLLER ; C-1
BY A CLIP ON BRACKET FIX WHITE TAPING POSITION
KPSS RELEASE SWITCH ; SW-22
OPT. SELECTOR SWITCH SOLENOID ; SV-13
12 PIN TO FLOOR PLATE
UPPER P-4,P-15 TO UNDER FLOOR FRAME GROUND
16 PIN ECU HARNESS
BATTERY RELAY ; R-1
STARTER CABLE
UPP HARNESS GND FUSE & RELAY BOX ; E-1
UPP HARNESS SEMS-BOLT AIR FILTER CLOGGING SWITCH ; SW-8
CLIP ECU HARNESS GND DIODE ; D-4
SEMS-BOLT TIGHTEN AFTER
CONNECT TO CAB HARNESS
FIX WITH THE CLIP FOR DRAIN HOSE CHECKING NO PAINT
UPP HARNESS
P-2,P-9 TO UNDER FLOOR FRAME GROUND
LEVER LOCK SOLENOID ; SV-4
ECU HARNESS DECK WORK LIGHT ; L-2
CLIP TRAVEL 2 SPEED SOLENOID ; SV-3
FIX A UPP HARNESS TO ECU HARNESS FOWARD CLIP SEMS-BOLT
GND
DRAIN HOSE CLIP SWING PARKING SOLENOID ; SV-1
DETAIL aa FIX WHITE TAPING TIGHTEN AFTER CHECKING NO PAINT
WATER SEPALATER RESTRICTI ON SW. ; SW-36
POSITION P-1 ECU HARNESS GROUND
OPT. HAND CONTROL,
ENGINE CONTROLLER ; C-6 ENGINE CONTROLLER ; C-6
FOWARD CONNECT A HARNESS WITH IN CAP. VIEW XI
FIX WHITE TAPING POSITION SE-15 : FUEL SENSOR
CLIP FIX A CONNECTOR TO THE BRACKET
L-4 :SWIBG FLASHER RIGHT CLIP CLIP CLIP
TO ENG. REVOLUTION SENSOR

CLIP
SEMS-BOLT
CLIP
TO PUMP
SEMS-BOLT
E-13 :
TRAVEL ALARM (OCE) CLIP
TO ENG.
REVOLUTION SENSOR
CLIP
FIX A HARNESS
TO GUARD
TO TRAVEL ALARM
AND FUEL SENSOR
CLIP
FIX A CONNECTOR HAS TAG OF

"ALARM" ON BRACKET
FOWARD
VIEW (DETAIL OF TRAVEL ALARM INSTAL)

VIEW IX
23-15
23. ELECTRIC SYSTEM
SV-4 :
FIX WHITE TAPING POSITION OPERATING LEVER LOCK SOL.
FIX WHITE TAPING POSITION E-5 :HORN HIGH
CLIP
FIX WHITE TAPING POSITION SV-1 :
CLIP SWING PARKING BRAKE SOL.
SV-3 : TO WATER SEPALATER

TWO-SPEED SELECT SOL. RESTRICTION SW.
PSV-B :
P2 UNLOAD
CLIP PROPORTIONAL SOL.
TO WATER SEPALATER PSV-C :
FIX TO THE CONNECTOR RESTRICTION SW. TRAVEL PRIORITY
WITH CLIP REMAINING PROPORTIONAL SOL.
LENGHT OF THE WATER PSV-D : CLIP
E-6 :HORN LOW
SEPALATER RESTRICTI ON P1 UNLOAD FIX A HARNESS TO THE GUARD
SIDE HARNESS PROPORTIONAL SOL. FIX WHITE TAPING POSITION
CLIP
CLIP PSV-A :
ARM TWO-SPEED INVERSE CLIP
PROPORTIONAL SOL. FIX A HARNESS TO THE GUARD
SW-36 :
WATER SEPALATER
RESTRICTI ON SW.
FIX A CONNECTOR TO VIEW
THE BRACKET
FOWARD
L-2 :
FRAME WORKING CLIP
LIGHT RIGHT
DETAIL bb
CLIP
SMSE-BOLT
FIX WHITE TAPING POSITION FIX WHITE TAPING
POSITION VIEW
VIEW
FIX A CORRUGATERD TUBE NOT
VIEW FIX A HARNESS TO CONTACT LOCK OF CONNECTOR.
SE-1 : A CONNECTOR
PRESS SENSOR : FOR PIP BY A CLIP
SE-1 : BUCKET DIGGING. CLIP M-CONNECTOR
PRESS SENSOR : SE-7 :
SE-3 : BUCKET DIGGING. CLIP
PRESS SENSOR : PRESS SENSOR :
BOOM RAISING SE-3 : ARM IN
PRESS SENSOR :
BOOM RAISING SENSOR
SE-8 : SE-8 :
PRESS SENSOR : PRESS SENSOR :
ARM OUT ARM OUT
SE-4 : SE-4 :
PRESS SENSOR : CLIP
PRESS SENSOR : FIX WHITE TAPING POSITION FIX A HARNESS PART OF
BOOM LOWERING. BOOM LOWERING. INSTALL TO REMAIN HOLE WHITE TAPING WITH CLIP
TO HORN LOW
AND WATER OF CONTROL VALVE
SE-2 : SE-2 : SEPALATER CLIP
PRESS SENSOR : PRESS SENSOR : CLIP SE-5 :
PESTRICTION SW. SEMS-BOLT PRESS SENSOR : SWING
BUCKET DUMP BUCKET DUMP
CLIP
FOWARD FIX WHITE TAPING POSITION
FIX A CORRUGATERD CLIP

TUBE NOT CONTACT
LOCK OF CONNECTOR.
SE-7 :
PRESS SENSOR : M-CONNECTOR
ARM OUT
CLIP CLIP
FIX A HARNESS PART OF FIX A HARNESS PART OF
COULGATED FOR PRESS SENSOR OF CLIP
COULGATED FOR PRESS DETAIL dd
SENSOR OF CLIP
SENSOR
DETAIL cc : CASE OF MULCH DETAIL cc : CASE OF SENSOR BLOCK VIEW
23-16
23. ELECTRIC SYSTEM
FIX A HARNESS PART

OF COULGATED FOR
SOL. OF CLIP FIX A HARNESS TO THELUG
CLIP BY A CLIP
CLIP
FIX A HARNESS PART OF FIX A HARNESS TO THELUG BY A CLIP
PSV-P1 : FIX A HARNESS PART OF COULGATED COULGATED CLIP
PUMP P1 FOR SOL. OF CLIP FOR SOL. OF CLIP
PROPORTIONAL SOL. CLIP PSV-P1 : CLIP FIX A HARNESS PART FOR SOL. OF CLIP
PUMP P1 CLIP
PROPORTIONAL SOL.
PSV-P2 : PSV-P2 :
CLIP PUMP P2 PROPORTINAL SOL.
PUMP P2
CLIP PROPORTIONAL SOL.
SEMS-BOLT
TIGHTENING TORQUE 25.5N.m (18.8lbf.ft)
SEMS-BOLT
TIGHTENING TORQUE 25.5N.m (18.8lbf.ft) CLIP
SEMS-BOLT
CLIP TIGHTENING TORQUE 25.5N.m (18.8lbf.ft)
SEMS-BOLT
TIGHTENING TORQUE 25.5N.m (18.8lbf.ft)
VIEW
VIEW (DETAIL OF PUMP P1, P2 PROPORTICNAL SOL. INSTALL)
(DETAIL OF PUMP P1, P2 PROPORTICNAL SOL. INSTALL) (CASE OF PUMP AUTO EMERGENCY FUNCTION)
FIX A HARNESS PART OF COULGATED

FOR PRESS SENSOR OF CLIP FIX A HARNESS PART OF COULGATED
FOR PRESS SENSOR OF CLIP
SE-22 : CLIP
SE-23 : SE-22 : CLIP SE-23 :
PRESS SENSOR : PUMP P1 PRESS SENSOR : PUMP P1
PRESS SENSOR : PUMP P2 PRESS SENSOR : PUMP P2
VIEW
VIEW
(DETAIL OF PRESS SENSOR : PUMP P1, P2 INSTALL)
(DETAIL OF PRESS SENSOR : PUMP P1, P2 INSTALL) (CASE OF PUMP AUTO EMERGENCY FUNCTION)
23-17
23. ELECTRIC SYSTEM

USE NUT OF ATTACHED GLOW CLIP
TIGHTENING TORQUE SEMS-BOLT
3.2 ~ 4.4N.m (2.4 ~ 3.2 lbf.ft)
E-2 :
GLOW ALTERNATOR
FIX WHUTE TAPING POSITION TIGHTENING TORQUE

FIX A HARNESS BY A CLIP ON 4.9 ~ 6.9N.m (3.6 ~ 5.1 lbf.ft)
THE BRACKET B TERMINAL M-1 :
CLIP STARTER MOTOR
CLIP
FIX TO THE CONNECTOR WITH
CLIP REMAINING LENGTH OF THE
ENGREVOLUTION SENSOR SIDE
HARNESS ENG. GROUND CABLE
SE-13 :
ENG. REVOLUTION SENSOR TIGHTEN AFTER
FIX A CONNECTOR TO THE BRACKET CHECKING NO PAINT.
GND
WASHER
CLIP
SEMS-BOLT
CLIP
TIGHTENING TORQUE
38.2N.m (28.2 lbf.ft)
FIX WHITE TAPING POSITION STARTER CABLE
CLIP UPP HARNESS

FIX A UPP HARNESS
WITH A HARNESS OF
ATTACHED ENG.
E-11 :
AIR COMPRESSOR
FOWARD
E-2 : CLIP
VIEW ALTERNATOR
TWO TERMINALS ARM IN TOUCH WITH

USE NUT OF ATTACHED EACH OTHER TO THEIR BACK AND
STARTER MOTOR INSTAL AS DRAWING. CLIP
TO AIR COMPRESSOR FIX HARNESS BY
TIGHTENING TORQUE M-1 : A CLIP TO THE CONNECTOR
15.7 ~ 19.6N.m (11.6 ~ 14.5 lbf.ft) STARTER MOTOR VIEW
B TERMINAL BRACKET
FIX THE HARNESS WITH CLIP
UPP HARNESS AS THIS DRAWING.
AFTER CONNECT WITH
STARTER CABLE STARTER CABLE AIR COMPRESSOR SIDE HARNESS
R TERMINAL, CLIP
S TERMINAL UPP HARNESS FIX THE HARNESS
AS THIS DRAWING
CLIP
TO ALTERNATOR
CLIP
SEMS-BOLT
CLIP
CLIP
FIX WITH UPP HARNESS AND STARTER CABLE
SEMS-BOLT
FIX WITH THE I/C TUBE BRACKET
STARTER CABLE TIGHTENING TORQUE
39.2N.m (28.9 lbf.ft)
UPP HARNESS
VIEW
DETAIL OF STARTER MOTOR DETAIL OF AIR COMPRESSOR
23-18
23. ELECTRIC SYSTEM
FASTEN UPP HARNESS AND

ECU HARNESS ON
FLOOR HARNESS BY CLIP.
SW-22 : E-1 :
CLIP
E-1 : KPSS RELEASE SW. FUSE & RELAY BOX
FUSE & RELAY BOX
C-8 :
C-1 :
ENG. CONTROLLER
MECHATRO FLOOR HARNESS
CONTROLLER
CLIP CAB SUB HARNESS
CONNECT TO KPSS RELEASE SW.

FIX WHITE
TAPING POSITION "CNT-1" WITH TAG.
CONNECTOR OF CONNECT
TO FLOOR HARNESS
CLIP
FASTEN UPP HARNESS "CNT-2" WITH TAG. FIX A ECU HARNESS BY A CLIP
C-8 :
ON FLOOR HARNESS CONNECTOR OF CONNECT
ENGINE CONTROLLER
BY CLIP. CLIP TO FLOOR HARNESS
CLIP
CLIP
FASTEN UPP HARNESS ON
FLOOR HARNESS CAB SUB HARNESS BY CLIP
"CNT-5" WITH TAG. CLIP

CONNECTOR OF CONNECT
TO FLOOR HARNESS
ECU HARNESS
FLOOR HARNESS
UPPER HARNESS
SECTION CC
CLIP
FIX TO A FLOOR HARNESS
GROMMET ENG. CONTROLLER CONNECT CONNCTOR WITH "CN 4-1"CONNECT CONNCTOR WITH "CN 5"
PUT WHITE TAPING CHECK CONNECTOR TAG OF ITEM 1 : HARNESS
POSITION TOGETHER TAG OF ITEM 6 : HARNESS
UPP HARNESS
E-1 :
FUSE & RELAY BOX
ECU
HARNESS
FOWARD FOWARD
C-1 :
GROMMET R-19 : MECHATRO CONTROLLER
PUT WHITE TAPING POSITION TOGETHER FLASHER RELAY
E-14 : RESISTER
DETAIL OF FUSE & RELAY BOX CONNECTION. CONNECT CONNCTOR WITH "CN4-2" CONNECT CONNCTOR WITH "CN1"
CLIP TAG OF ITEM 1 : HARNESS TAG OF ITEM 1 : HARNESS
FIX UPPER HARNESS AND
FLOOR HARNESS TO STAND VIEW X VIII
CLIP CASE OF UNCONNECTION,
FASTEN UPP HARNESS ON BUNDLE AND FIX HARNESS
FLOOR HARNESS BY CLIP. C-1 :
MECHATRO CONTROLLER
1P CONNECTOR OF
CONNECT TO CAB HARNESS
CAB SUB HARNESS

16P CONNECTOR 17P CONNECTOR
31P CONNECTOR
28P CONNECTOR 24P CONNECTOR
VIEW X VII VIEW X IX
23-19
23. ELECTRIC SYSTEM

L-10 : HIGH REACH ROTARY LIGHT SW-8 :
FIX THE CONNECTOR WITH CLIP AIR FILTER RESTRICTION SW.
"L-10" TAG TO THE BRACKET L-3 : SWING FLASHER LEFT
E-10 :
RECEIVER DRIER
GROMMET FIX A HARNESS OF

WHITE TAPING POSITION
OF CLIP TO THE SWITCH.
CLIP
HOSE
CLIP CLIP
FIX WHITE TAPING
POSITION TO THE FAN GUARD
HARNESS
CLIP
FIX WITH THE FAN GUARD
AND CLIP TO SWING FLASHER LEFT CLIP
FIX A HARNESS
TO THE HOSE
TO RECEIVER DRIER,
CLIP AIR FILTER RESTRICTION SW.
FOWARD
FOWARD
VIEW X X
SE-29 : A CLIP DOES NOT HIT A RUBBER CAP.

M-CONNECTOR FIX A CORRUGATERD
PRESS SENSOR : FIX A HARNESS OF WHITE TAPING POSITION
TUBE NOT CONTACT
SELECTOR DETECTION OF CLIP TO THE SWITCH.
FOWARD LOCK OF CONNECTOR.
CLIP CLIP CONNECT A CONNECTOR SENSOR CLIP
WITH "SELECTOR TAG."
SEMS-BOLT
INSTALL TO REMAIN HOLE
CLIP
VIEW X OF CONTROL VALVE.
PLATE SW-8 :
SEMS-BOLT SV-13 : AIR FILTER
OPT SELECTOR SOL. FIX A HARNESS PART OF RESTRICTION SW.
CONNECT A CONNECTOR WHITE TAPING WITH CLIP
CLIP WITH "SELECTOR TAG."
FIX A HARNESS TO
HOSE METAL FITTING
BY A CLIP. CLIP
CLIP
SEMS-BOLT
WHEN THERE IS NO OPT OF SE-29, SV-13,
OR THERE IS REST HARNESS FOR SE-29, IT
BUNDLES AND FIXES HERE.
CLIP
VIEW X X I
VIEW X II
23-20
23. ELECTRIC SYSTEM
CLIP
FIX WHITE TAPING POSITION SEMS-BOLT
BATTERY RELAY CABLE
GROUND CABLE
STARTER CABLE
UPP HARNESS
VIEW VIII
R-3 :
ADJUST THE LOCK OF THE FUSE FIX FUSE BOX WITH THE BRACKET
GLOW RELAY CONNECT THE TERMINAL WITH "A" OF HARNESS
BOX COVER TO THE UPPER SIDE PLATE
SEMS-BOLT
BATTERY RELAY CABLE
FIX A 1P CONNECTOR NUT

TO THE BRACKET ROCK WASHER
FIX A 2P CONNECTOR
TO THE BRACKET CONNECT THE TERMINAL WITH "B" OF HARNESS
CONNECT THIS TERMINAL

WITH BATTERY RELAY CABLE
TIGHTENING TORQUE CLIP
7.8N.m (5.8 lbf.ft) MAX FIX WITH HARNESS FOR FUSE BOX AND BATTERY RELAY
BATTERY RELAY
CONNECT THIS TERMINAL WITH FUSE BOX CABLE AND STARTER CABLE
FIX A CONNECTOR TIGHTENING TORQUE 7.8N.m (5.8 lbf.ft) MAX
TO THE BRACKET
CLIP
SEMS-BOLT
STARTER CABLE
UPP HARNESS
INSERT HARNESS FOR SLIT OF INSULATION
SECTION DD
23-21
23. ELECTRIC SYSTEM
23.3.6.1 UPPER HARNESS (1/5) : YY13E01166P2
2
CAP
23-22
23. ELECTRIC SYSTEM
23-23
23. ELECTRIC SYSTEM
4
FUSE BOX
3
FUSE
23-24
23. ELECTRIC SYSTEM
23-25
23. ELECTRIC SYSTEM
23.3.6.1 UPPER HARNESS (5/5) : YY13E01166P2 23.3.6.2 BATTERY CABLE : YY13E01144P1
110 (4.3")
CAP AV60B CAP

BTC-135L(RED) BTC-135R(RED)
TERMINAL TERMINAL
BC818( ) BC816( )
23.3.6.3 BATTERY GROUNDING CABLE : YY13E01130P1
370 (14.6")
AV60B
TERMINAL
60-8
CAP TERMINAL TAPED IN TWO TURNS (JIS C 2805)
BTC-135L(BLACK) BC816
23.3.6.4 BATTERY RELAY CABLE : YY13E01139P1
950 (37.4")
YAZAKI7034-1283
CAP
WHITE TAPING
AV60B
CORRUGATE TUBE
TO BE INSTALLED TERMINAL
CAP TERMINAL 60-8
TAPED IN TWO TURNS
BTC-135R(RED) BC818 (JIS C 2805)
23.3.6.5 STARTER MOTOR CABLE : YY13E01138P1
(JIS D 5403)
BA710
(JIS C 2805) TERMINAL
2800 (9'2.2")
60-8
TERMINAL
AV60sq
CAP WHITE TAPING
YAZAKI7034-1283 CORRUGATE CORRUGATE TUBE
CAP TO BE INSTALLED IN TWO TURNS TO BE INSTALLED
23-26
23. ELECTRIC SYSTEM
23.3.6.6 ECU HARNESS : YY13E01148P1
23.3.6.7 FLOOR GROUND CABLE : LE13E01006P1
FLOOR PLATE UPPER FRAME GROUND CABLE

100 (3.94")
LA308 5B E E 5B E
1PAM
YAZAKI 7122-3010
23-27
23. ELECTRIC SYSTEM
23.3.7 UPPER HARNESS ASSY (FLOOR) (1/3) (OCE/S.E.ASIA)
UPPER HARNESS ASSY YY13E00041F1 (02)
ITEM PART NAME PART No. Q'TY REMARKS E-32 :

1 HARNESS YY13E01167P1 1 FLOOR PRESS SENSOR
DOZER
3 CABLE LE13E01005P1 1 FRAME GROUND NOTE
FLOOR HARNESS 1. ATTACHMENT OF WELDING CLIP WITHOUT
4 HARNESS YB13E01054P1 1 CAB SUB DIRECTIONS IS MADE INTO THE FOLLOWING.
CLIP
SW-1 : C-1 :
KEY SW. MECHATORO CONTROLLER E-1 : HARNESS
SE-16 : FUSE & RELAY BOX
ACCEL POTENTIO
TO TUNER
C-8 : HARNESS
ENG. CONTROLLER
FIX A CORRUGATERD TUBE
NOT CONTACT LOCK OF
CLIP
CLIP CONNECTOR.
M-CONNECTOR
PLATE
SENSOR
SENSOR
FIX A HARNESS PART OF
WHITE TAPING WITH CLIP SECTION CC (SECTION SENSOR INSTAL)
VIEW (DETAIL OF CONNECT TO PRESS SENSOR : DOZER)
SW-13 :
TRAVEL ALARM SW.
CASE OF TRAVEL ALARM SW-37 :
SW-30 : CONNECT WITH NAME INDEPENDENT TRAVEL SW.
FOWARD NIBBLER CLOSE SW. (GREEN TAPING) TUBE OF "ALARM" CONNECT WITH NAME TUBE OF "TRAVEL"
SW-10 :
HORN SW. LEFT (BLUE TAPING)
SW-34 :
REVOLUTION LEFT SW.(OPT)(RED TAPING) TO SLACK HARNESS SW-12 :
OF LEVER SW. OVER ROAD ALARM SELECT SW.
SIDE, THIS POSITION. CONNECT WITH NAME TUBE OF "OVER L"
SW-40 :
ROTARY LIGHT SW.
SW-1 : SW-11 : CLIP CONNECT WITH NAME TUBE OF "ROTARY"
KEY SW. LEVER LOCK SW. FIX A HARNESS OF SW SIDE
FIX A HARNESS WITH CAB CLIP

SIDE COVER ON CLIP CLIP FIX HARNESS BY A CLIP ON HOLE
FIX HARNESS BY A CLIP OF STAND BOAD.
SE-16 : ON NOLE OF STAND BOAD. FIX WHITE TAPING POSITION
ACCEL POTENTIO FASTEN FLOOR HARNESS
AND LEVER SW. HARNESS
CLIP
CAB HARNESS IT BUNDLES AND FIX WHITE TAPING POSITION
FIX WITH TILTED LEVER. FIX THE HARNESS FOR THE PLATE
AS SHOWN IN FIGURE WITH CLIP.
THROUGH THE HARNESS AT SEAT
FIX WHITE TAPING CLIP SIDE OF BRACKET.
POSITION SW-33 : CLIP
REVOLUTION RIGHT SW.
(OPT)(BLUE TAPING)
FIX A HARNESS WITH CLIP
CLIP SW-5 :
CAB SIDE COVER ON CLIP FIX WHITE TAPING POSITION
FIX HARNESS BY A CLIP HORN SW. RIGHT
ON HOLE OF SEAT STAND
CLIP
CLIP (OPT)(BLUE TAPING) E-7 : TUNER FIX WHITE TAPING POSITION
FASTEN WHITE TAPING POSITION OF SW-29 : FIX HARNESS BY A CLIP ON HOLE
HARNESS WITH CLIP SIDE BY PILOT
E-32 :
NIBBLER OPEN SW. OF SEAT STAND
HOUSE PRESS SENSOR
(GREEN TAPING)
FIX WHITE TAPING POSITION DOZER
VIEW VIEW VIEW
23-28
23. ELECTRIC SYSTEM
C-1 :
MECHATORO CONTROLLER
E-1 :
FUSE & RELAY BOX
CAB SUB HARNESS CLIP
CONNECT TO ROTATION PARKING CANCEL SW.AND

CONNECTOR WITH NAME TUBE OF "PARKING"
CLIP
C-8 :
ENG.CONTROLLER
REFERENCE DRAWING OF ASSEMBLING
TO RIGHT
INST-PANEL E-1 :
FUSE & RELAY BOX
C-1 :
TO IT CONTROLLER HARNESS MECHATORO
CONTROLLER
TO LEFT
INST-PANEL
CLIP
TO FUSE & RELAY BOX
GROMMET
CONNECT THE "CNT-1" TAG
OF CONNECTOR WITH ECU
HARNESS
FIX TO THE UPPER

PART OF PLATE WITH CONNECT THE "CNT-2" TAG
CLIP. OF CONNECTOR WITH UPP
FOWARD HARNESS
DETAIL OF FUSE & RELAY BOX CONNECTION CONNECT THE "CNT-5" TAG
CONNECT CONNECTOR WITH "CN2-2" OF CONNECTOR WITH UPP
CONNECT CONNECTOR WITH "CN2-1" TAG OF ITEM 1:HARNESS HARNESS
TAG OF ITEM 1:HARNESS
TO LEFT INST-PANEL
ROTATION PARKING
CANCEL SW.
TO RIGHT
INST-PANEL.
CONNECT CONNECTOR
WITH "CN12" TAG OF ITEM
1:HARNESS
4
CAB SUB HARNESS
22P CONNECTOR 28P CONNECTOR 22P CONNECTOR
34P CONNECTOR 1
FLOOR HARNESS
CONNECT CONNECTOR WITH "CN2-3"
CONNECT CONNECTOR WITH "CN3-1" TAG OF ITEM 1:HARNESS
VIEW TAG OF ITEM 4:HARNESS
CONNECT CONNECTOR WITH "CN3-2"
TAG OF ITEM 4:HARNESS TO UNDER FLOOR
VIEW SECTION AA (STAND RIGHT SIDE A INSIDE)
23-29
23. ELECTRIC SYSTEM
E-1 : FIX A CORRUGATED TUBE NOT CONTACT

FUSE & RELAY BOX M-CONNECTOR LOCK OF CONNECTOR
SE-20 :
E-22 : SENSOR
PRESS SENSOR : P1 OPT FIX HARNESS PART
1 DC-DC CONVERTER
OF WHITE TAPING
CLIP WITH CLIP FIX WHITE TAPING POSITION
FOWARD CLIP
M-4 :
CONNECT TO DC-DC WASHER MOTOR
4 TIGHTENING TORQUE
CONVERTER. 10.7N.m (7.9lbf.ft)
TIGHTEN AFTER
CHECKING NO PAINT
TO LEFT INST-PANEL LOCK WASHER
ROTATION PARKING CONNECT THE "CNT-4" TAG OF ITEM 1: HARNESS
CANCEL SW.
WASHER
WITH THE "CNT-4" TAG OF CAB HARNESS P-31
NUT
CONNECT TO CAB HARNESS FIX WHITE
CONNECT WITH TAPING POSITION
FIX WHITE TAPING POSITION GROUND CABLE CLIP
OF UPPER FRAME
CLIP
P-31 CONNECT TO FRAME GROUND
TUNER ; E-7 3
SE-10 :
REVOLUTION RIGHT SW. ; SW-33
PRESS SENSOR :
HORN SW. (RH) ; SW-5 TRAVEL LEFT
NIBBLER OPEN SW. ; SW-29 SE-9 :
REVOLUTION LEFT SW. ; SW-34 PRESS SENSOR :
HORN SW. (LH) ; SW-10 TRAVEL RIGHT
WASHER MOTOR ; M-4
SE-11 :
NIBBLER OPEN SW. ; SW-30 PRESS SENSOR :
CONNECT TO ECU HARNESS P2 OPT
ENG. CONTOROLLER HARNESS SHIELD
CLIP 1 CLIP TO THE FRONT SIDE OF FLOOR PLATE
FIX A CORRUGATED TUBE NOT CONTACT

M-CONNECTOR LOCK OF CONNECTOR VIEW FROM THE BACK SIDE OF FLOOR PLATE.
ONLY SEPARATE SENSOR

SE-20 : SWING N&B SPEC.
PRESS SENSOR : P1 OPT USES THE CLIP OF ITEM 6 FIX HARNESS PART
SE-33 : OF WHITE TAPING FLOOR HARNESS
CLIP WITH CLIP FIX WHITE TAPING POSITION
PRESS SENSOR : SEPARATE CLIP
M-4 :
TIGHTENING TORQUE WASHER MOTOR CAB SUB HARNESS
10.7N.m (7.9lbf.ft)
TIGHTEN AFTER
CHECKING NO PAINT
LOCK WASHER
WASHER
P-31
NUT
FIX WHITE TAPING
CONNECT WITH POSITION
GROUND CABLE CLIP
OF UPPER FRAME
3
SE-10 :
PRESS SENSOR :
TRAVEL LEFT
SE-9 :
PRESS SENSOR :
TRAVEL RIGHT
SE-11 :
PRESS SENSOR : FIX WHITE TAPING CLIP
P2 OPT POSITION.
CLIP 1 CLIP TO THE FRONT SIDE OF FLOOR PLATE

TO FRONT
VIEW FROM THE BACK SIDE OF FLOOR PLATE. (CASE OF SEPARATE SWING N&B) SECTION BB (PART OF FIX A HARNESS ON SEAT STAND)
23-30
23. ELECTRIC SYSTEM
23.3.7.1 FLOOR HARNESS (1/3) : YY13E01167P1
23-31
23. ELECTRIC SYSTEM
23-32
23. ELECTRIC SYSTEM
15. TO BE MAKE OF PART OF A HOW TO DRAWING.
TO MECHATRO CONTROLLER
TO FUSE & RELAY BOX
23-33
23. ELECTRIC SYSTEM
23.3.7.3 FLOOR GROUNDING CABLE : LE13E01005P1
100 (3.94")
1PAF
YAZAKI 7123-3010
23.3.7.4 CAB SUB HARNESS: YB13E01054P1
FUSE & WHITE TAPING WHITE TAPING

RELAY BOX
TO CAB
HARNESS
23-34
23. ELECTRIC SYSTEM
23.3.8 ENGINE HARNESS ASSY (OCE/S.E.ASIA) 23.3.8.4 ENGINE SUB CABLE : YY16E01009P1
ENGINE HARNESS ASSY YY16E00005F1 (01) (12.2")

ITEM PART NAME PART No. Q'TY REMARKS TERMINAL TERMINAL
4 CABLE YY16E01009P1 1 ENGINE SUB
T=TIGHTENING TORQUE
AV60B
Corrugate tube to be installed
SEMS-BOLT
T=38.2 N.m
(28.2 lbf.ft)
BRACKET
SEMS-BOLT FORWARD
T=51.9 N.m
(38.3 lbf.ft)
23-35
23. ELECTRIC SYSTEM
23.3.9 CAB INSTALL (OCE/S.E.ASIA) 23.3.9.1-1 CAB ASSY : YY02C00008F1
CAB INSTALL YY02C00007F1 (01)

T=TIGHTENING TORQUE
CONNECTS WITH A LIMIT SWITCH OF WIPER
1 CAB ASSY YY02C00013F1 (01)
1-1 CAB ASSY YY02C00008F1 (06)
1-1-26 SWITCH YT50S00004P1 1 WIPER INTER LOCK

1-1-49 HARNESS YN02C03098P1 1 ROOM LAMP
1-1-50 ANTENA YT54S00018F1 1
1-1-52 ROOM LIGHT YT80S00001P1 1
1-1-55 WIPER ASSY YN53C00012F2 1 R/U MOTOR
1-1-50
1-1-49
1
CONNECTS IT
WITH THE MAIN
BODY HARNESS
1-1-55
SEMS-BOLT
SECTION BB
6 PLACES WIPER MOTOR INSTOL
T=8
CONNECT WITH A SWITCH

1-1-49
THE CONNECT POINT

DISTANCE IS ADJUSTED
2~3mm WITH THE FRONT
WINDOW LOCKED
1-1-26
1-1-52
CONNECTS IT
WITH HARNESS
FRONT WINDOW
DETAIL bb DETAIL cc
23-36
23. ELECTRIC SYSTEM
23.3.9.1-49 HARNESS : YN02C03098P1 23.3.10 WASHER TANK ASSY (OCE/S.E.ASIA)
WASHER TANK ASSY YY54C00001F1 (01)

WRAP THE TAPE TO THE 1 WASHER TANK 2427U900 1
CONNECTOR BASE
TO INST-HARNESS 1-2 MOTOR YT54C00003F1 1
STRAIGHT WRAP THE TAPE TO THE

FEMALE CONNECTOR BASE
T=TIGHTENING TORQUE
WIPER INTERLOCK SWITCH
FORWARD T=46.5 N.m

(34.3 lbf.ft)
ROOM LAMP
SEMS-BOLT
CONNECTORS SELECTION TABLE

CONNECTOR PART No.
NAME MANUFUC.
(PIN NUM.) HOUSHING TERMINAL
PLATE
1
SUPPORT
PUT THE TUBE THROUGH A
HOLE OF THE TANK
TUBE
CLIP
HOSE LAYOUT UNDER FLOOR PLATE
GROMMET
CONNECTOR
WINDSHIELD WASHER
FORWARD
1-2
HOSE LAYOUT UPPER FLOOR PLATE WASHER TANK
23-37
23. ELECTRIC SYSTEM
23.3.11 CAB HARNESS ASSY (OCE/S.E.ASIA)
CAB HARNESS ASSY YB14E00018F1 (04)

1 HARNESS YB14E01027P2 1 CAB
5 HARNESS YN14E01106P1 1 KEY S/W GROUND
C-1 : E-1 :
MECHATRO CONTROLLER FUSE & RELAY BOX
CAB SUB HARNESS

SEMS BOLT
TIGHTENING TORQUE 4.4N.m (3.2 lbf.ft)
TIGHTEN AFTER CHECKING E-9 :
NO PAINT. SPEAKER RIGHT
THIGHTEN WITH THREE EYELET TERMINALS.
FIX WHITE TAPING
P-1,P-2 CAB HARNESS GROUND POSITION
CLIP
GAUGE CLUSTER CONNECT TO
CAB WORK LIGHT SW. UPPER HARNESS
AIR-CON UNIT CONNECT WITH CAB WORK LIGHT
CLIP
UPPER HARNESS (GND)
BOOM DECK WORK LIGHT SW. E-23 :
CAB WORK LIGHT FRONT 12V SOCKET CONNECT WITH ROOM LIGHT
WIPER INTERLOCK SW. E-14 : CAB HARNESS
HOUR METER CIGARETTE
WIPER MOTOR LIGHTER CONNECT WITH WIPER INTERLOCK SW.
FIX WHITE
CIGARETTE LIGHTER TAPING
12V POWER SOURCE SOCKET CLIP TO THE CUTTING HOLE
SKY ROOF WIPER (OPT) POSITION
SW-15 : ON THE DUCT
CONFLUX / SINGLE CHANGE SW. CLIP CLIP
CONFLUX / SINGLE FLOOR HARNESS
CAB WORK LIGHT
ROTARY LIGHT SELECT SW.
FIX WHITE TAPING
SW-55 : CONNECT TO
POSITION
BOOM , DECK WORKING CLIP CAB SUB HARNESS
5 LIGHT SW.
SW-1 :
KEY SW. E-8 : CONNECT "CNT-4" TAG TO
P-1 SPEAKER LEFT FLOOR HARNESS
1 P-2
C-2 : FLOOR HARNESS

GAUGE CLUSTER
CLIP
TO AIR
CLIP
CONDITIONER UNIT UPPER HARNESS
CLIP
DETAIL A
E-3 :
HOUR METER
SW-15 :
CONFLUX / SINGLE SELECT SW. SW-41 : SW-17 :
SW-55 : GREEN CONNECT WITH HIGH REACH CRANE SW. ROOF WIPER SW.
CONNECT WITH BOOM , DECK WORKING LIGHT SW. NAME TUBE OF "CONFLUX" BLACK CONNECT WITH NATURAL COLOR CONNECT WITH
M-3 : CAB WORK LIGHT BLUE CONNECT WITH NAME TUBE OF NAME TUBE OF NAME TUBE OF "WIPER"
WIPER MOTOR CLIP CAB SUB FRONT. "BOOM, DECK" "CRANE" TAGGED
FIX WHITE TAPING SW-26 :
CLIP TIE UP FLOOR HARNESS WITH TO AIR HARNESS TO ROOF WIPER
POSITION CAB WORK LIGHT SW.
CAB HARNESS USING CLIP CONDITIONER UNIT (OPT)
FIX WHITE TAPING NATURAL COLOR CONNECT WITH
E-14 :
POSITION NAME TUBE OF "CAB LIGHT"
CIGARETTE LIGHTER
CLIP E-14 :
FIX TO THE BRACKET CIGARETTE LIGHTER
WR B
(+) (-)
DETAIL B
DETAIL OF HOUR METER VIEW I
23-38
23. ELECTRIC SYSTEM
23.3.11.1 CAB HARNESS (1/2) : YB14E01027P2
E-8 : SPEAKER LEFT
TO ROOF WIPER
(OPT)
DOUBLE
SPLICE
WHITE TAPING
DOUBLE
TAPING AFTER SPLICE
BUNDLED TAPING
TO CAB WORKING LIGHT

TO CAB WORKING LIGHT FRONT
DOUBLE DOUBLE E-9 :

SPLICE SPLICE SPEAKER RIGHT
WHITE TAPING
E-23 :
12V SOCKET SHIELD UN-CONNECTED
TAPING TAPING
C-2 :
GAUGE CLUSTER
L-5 : ROOM LIGHT
TAPING WHITE TAPING

M-3 : WIPER METER
SW-19 :
WIPER INTERLOCK SW. DOUBLE
SPLICE
E-3 :
DOUBLE SW-17 :
TO CAB GND. SPLICE HOUR METER
SW-41 : ROOF WIPER SW-15 :
HIGH REACH SW. CONFLUX / SINGLE
TO ROTALY LIGHT
CRANE SW. SELECT SW.
C-4 : E-14 : SW-26 :
AIR CONDITIONER SW-55 :
TO HARNESS (FLOOR) CIGARETTE LIGHTER CAB WORK LIGHT
UNIT BOOM, DECK
WHITE TAPING SW.
TO HARNESS (UPP) WORKING LIGHT SW.
DOUBLE
SPLICE
WHITE TAPING
TAPING TAPING AFTER TAPING AFTER
BUNDLED BUNDLED
TAPING
TO CAB SUB HARNESS
23-39
23. ELECTRIC SYSTEM
23.3.11.1 CAB HARNESS (2/2) : YB14E01027P2 23.3.11.5 KEY SWITCH GROUND HARNESS : YN14E01106P1
23-40
23. ELECTRIC SYSTEM
23.3.12 BOOM HARNESS ASSY (OCE/S.E.ASIA) 23.3.13 BOOM LIGHT INSTALL (OCE SPEC.)
BOOM HARNESS ASSY YY15E00009F1 (01) INSTALLING BOOM LIGHT YN80E00011F1 (04)
ITEM NAME PARTS No. Q'TY REMARKS ITEM NAME PARTS No. Q'TY REMARKS
1 HARNESS YY15E01021P1 1 BOOM 1 LIGHT YW80S00001F1 1
FIX WHITE
TAPING POSITION
1 CLIP
CLAMP TO THE
TUBE FOR GREASE
L-1 :
BOOM WORKING LIGHT LEFT
TO UPP HARNESS
1
23.3.12.1 BOOM HARNESS : YY15E01021P1
TIGHTENING TORQUE : 18.6N.m (13.7 lbf.ft)

SECTION AA

23-41
23. ELECTRIC SYSTEM
23.3.14 UPPER LIGHT INSTALL (OCE/S.E.ASIA) 23.3.15 TRAVEL ALARM ASSY (OCE SPEC.)
UPPER LIGHT INSTALL YY80E00008F1 (01) TRAVEL ALARM ASSY YY53E00002F1 (01)
ITEM PART NAME PART No. Q'TY REMARKS ITEM PART NAME PART No. Q'TY REMARKS
1 LIGHT YT80S00002F1 1 1 ALARM YN53S00004F1 1
3 SWITCH YN50S00040DF 1
5 RELAY YN24S00010P1 1
T=TIGHTENING TORQUE
1
SEMS-BOLT
T=23.5N.m
(17.3 lbf.ft)
1
E-13 :
UPP HARNESS TRAVEL ALARM
CLIP
FIX TO THE CONNECTOR
3 WITH CLIP REMAINING LENGTH
E-13 : OF THE ALARM SIDE HARNESS.
TRAVEL ALARM
CONNECT WITH NAME VIEW
NUT (SUPPLIED WITH LIGHT) TUBE OF "ALARM"
T=18.6 N.m (13.7 lbf.ft)
VIEW 4
TRAVEL ALARM RELAY
(HOW TO INSTALL LIGHT AT RIGHT SIDE DECK)
RIGHT CONSOLE BOX

(DETAIL OF TRAVEL ALARM SW. INSTAL) DETAIL OF FUSE & RELAY BOX
23-42
24. COMPONENTS SYSTEM
TABLE OF CONTENTS
24.1 HYDRAULIC COMPONENTS .........................................................................................24-3

24.1.1 HYDRAULIC PUMP • REGULATOR ......................................................................24-3
24.1.2 CONTROL VALVE..................................................................................................24-17
24.1.3 PILOT VALVE (ATT)...............................................................................................24-57
24.1.4 PILOT VALVE (TRAVEL) .......................................................................................24-61
24.1.5 SWING MOTOR UNIT............................................................................................24-63
24.1.6 TRAVEL MOTOR ...................................................................................................24-75
24
24.1.7 SWIVEL JOINT.......................................................................................................24-87
24.1.8 CYLINDER..............................................................................................................24-89
24.2 ELECTRIC EQUIPMENT.................................................................................................24-95
24.2.1 ELECTRIC EQUIPMENT LIST ...............................................................................24-95
24.2.2 SPECIFICATION OF ELECTRIC EQIUPMENTS...................................................24-98
24-1

SK125SR : YV05-04501~
S5YY2413E01
(OCE/S.E.ASIA)
SK135SRLC-2 : YH05-07001~
24-2
24.1 HYDRAULIC COMPONENTS

24.1.1 HYDRAULIC PUMP • REGULATOR
24.1.1.1 SUMMARY
(1) Outside view and Hydraulic port
PSV1 MAX. FLOW RATE

ADJUSTING SCREW
2X4-M10
Dr1 Depth 16
A3
A2
a5
a4
A1
PSV2 B3
B1
EYE BOLT (M10) VIEW
4 4
a4 PSV1 PSV2 a5
a5
a6
2 2 PSV2 PSV1
MIN. FLOW RATE
ADJUSTING SCREW
Dr1 Dr1 B3 Dr1

B3
B1 3
B1
A3
a1 a2 Dr1 B3
a3
a3 Dr3
A1 A2 PH2
1 Dr3 Dr1
4-M12 Depth 18
Hydraulic ports
No. Parts Q'TY Code Ports name Size
1 Main pump assy 1 A1,2 Delivery port SAE 6000psi 3/4"
2 Regulator assy 2 B1 Suction port SAE 2500psi 2 1/2"
3 Gear pump assy(for pilot) 1 Dr1 Drain port PF1/2-19
4 Solenoid proportional reducing valve 2 PSV1,2 Servo assist port PF1/4-13
PH1,2 Pressure sensor port PF3/8-17
a1,a2 Gauge port PF1/4-15
a3 Gauge port PF1/4-14
a4,a5 Gauge port PF1/4-13
A3 Delivery port of gear pump PF1/2-19
B3 Suction port of gear pump PF3/4-20.5
Dr3 Drain port of gear pump PF3/8-15
Fig. 24-1 Hydraulic pump • regulator
24-3
(2) Hydraulic circuit diagram
(FRONT) PSV1 a1 A1 PH1 PH2 A2 a2 PSV2 (REAR)

(KR76-0E13-V) (KR76-0E13PV)
(KDRDE5K) (KDRDE5K)
Solenoid proportional Solenoid proportional
reducing valve (PSV-1) reducing valve (PSV-2)
a4 a5
Regulator
Regulator
Dr1
Gear pump for pilot
Main pump a3
B1 B3 Dr3 A3
PTO.
Gear Case
Fig. 24-2 Hydraulic circuit diagram of pump
(3) Specifications
Item Main pump Gear pump

Without PTO YY10V00009F1
Pump assy -
Parts No. With PTO YY10V00013F1
Single Pump YY10V00014F1 YY10V00015F1
Without PTO K7V63DTP179R-0E13-V
Pump model ZX10L7RZ2-07G
With PTO K7V63DTP174R-0E13-V
Max.displacement capacity cm3 65.2 X 2 10
Revolution Rated min-1(Clockwise seen from shaft end) 2000
Rated 34.3 (4980)
Pressure MPa (psi) 5.0 (725)
ATT boost pressure -
Max. flow L/min (gal/min) 130 (34) X 2 at 7.8MPa (1130 psi) 20 (5.3)
Max. input horse power kW (PS) 64.9 (88.3) 3.1 (4.2)
Max. input torque N.m (lbf.ft) 310 (229) 14.7 (10.8)
Part No. YM10V01002F2, YM10V01002F1
Model KR76-0E13-V, KR76-0E13PV
Regulator Control function Electric flow control, positive flow control
With solenoid proportional reducing valve
Others
(KDRDE5K-31/30C50-123)
Without PTO 82 (181)
Weight kg (lb)
With PTO 84 (185)
Note) Without PTO ................... S.E.ASIA SPEC.

With PTO ........................ OCE SPEC.
24-4
24.1.1.2 HYDRAULIC PUMP
24.1.1.2.1 CONSTRUCTION
(1) Main pump
Apply adhesive (Three Bond No.1305N)
533 789 733 732 532 214 548 531 702 792 901 954 724 717 723 402 151 981 983
535 534
806 808 152
953
211
490 255
256 04
261
Apply (sealub L101)
to the oil seal surface
circumferential
111 774
A A
127
710
406
123 Tightening torque
824 Flange socket
(4-M8X1.25)
17N.m (12.5 lbf.m)
251
212 271 153 468 156 466 157 313 124 711 116 312 886 314 401 467 141 272 113
727 723 Valve plate for clockwise rotation 732 05
Tightening torque Valve plate for c.clockwise rotation
Tightening torque
Item number Thread size
N.m (lbf.ft)
401, 402 M16 240 (177) 414
406 M6 12 (8.9)
326
533 M30 220 (162)
414 M10 57 (42) The grinding side is
O-ring seal side.
466 PF 1/4 36 (27)
467 PF 3/8 74 (55)
468 PF 1/2 110 (81)
490 NPTF1/16 8.8 (6.5)
531,532 M20X1.5 240 (177)
806 M12 60 (44) SECTION A-A (without PTO) SECTION A-A (with PTO)
808 M16 130 (96)
No. Parts Q'ty No. Parts Q'ty No. Parts Q'ty
111 Drive shaft (F) 1 272 Pump casing (R) 710 O-ring 1B G80 1
113 Drive shaft (R) 1 312 Valve block 711 O-ring 1B G95 1
116 Gear #1 1 313 Valve plate (R) 717 O-ring 1B G125 2
123 Roller bearing 2 314 Valve plate L 723 O-ring 1B P11 6
124 Needle bearing 2 326 Cover 724 O-ring 1B P8 12
127 Bearing spacer 2 401 Socket bolt M16X150 727 O-ring 1B P18 4
141 Cylinder block 2 402 Socket bolt M16X190 732 O-ring 1B P14 4
151 Piston 18 406 Socket bolt M6X16 733 O-ring 1B P28 2
152 Shoe 18 414 Socket bolt M10X20 774 Oil seal 1
153 Retainer plate 2 466 VP plug PF1/4 789 Back up ring; P14 2
156 Spherical bushing 2 467 VP plug PF3/8 792 Back up ring; G30 2
157 Cylinder spring 12 468 VP plug PF1/2 806 Nut M12 2
211 Shoe plate 2 490 Plug NPTF1/16 808 Nut M16 2
212 Swash plate 2 531 Tilting pin M20X1.5 824 Stop ring 2
214 Tilting bushing 2 532 Servo piston M20X1.5 886 Spring pin 4
251 Swash plate support 2 533 Plug M30 901 Eye bolt ; M10 2
255 Rotation lock pin 2 534 Stopper L 953 Socket screw ; M12X23 2
256 Set spring 2 535 Stopper S 954 Set screw ; M16 2
261 Seal cover (F) 1 548 Feed back pin 04 Gear pump 1
271 Pump casing F 1 702 O-ring 1B G30 05 PTO unit 1
The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
Fig. 24-3
24-5
(2) Gear pump (For pilot)
887
Front gear side Gear case side
SECTION X-X
(2 places)
710 700 354 351 Suction port : G3/4 887 433
Tightening torque : 74N.m
(54.5 lbf.ft)
Z
X
B3
X
434
X
A3
Delivery port : G1/2
311 Tightening torque :
312 X 53N.m (39 lbf.ft)
732 Dr3
a3 850
Dr3 Z
308 308 355
435 361 353 310 310 434 466

725
SECTION Z-Z
Drain port : G3/8
Tightening torque :
Tightening torque 34N.m (25 lbf.ft)
Tightening torque
N.m (lbf.ft)
312 M14X1.5 29 (21)
433, 434
M8 17 (13)
435
466 PF 1/4 16 (11)
No. Parts Q’ty No. Parts Q’ty

307 Poppet 1 433 Flange socket; M8×40 2
308 Seat 1 434 Flange socket; M8×55 2
309 Ring 1 435 Flange socket; M8×20 4
310 Spring 1 466 VP plug ; PF1/4 1
311 Adjust screw 1 700 Ring 1
312 Lock nut ; M14×1.5 1 710 O-ring 1
351 Gear case 1 725 O-ring ; 1B P11 1
353 Drive gear 1 732 O-ring ; 1B P16 1
354 Driven gear 1 850 Locking ring 1
355 Filter 1 887 Pin 2
361 Front case 1
24-6
(3) PTO gear case (OCE SPEC.)
125
711 468
118 825 710 728
117
126
326 262
115
128
826
414
435
886
885

115 Idle shaft 1 435 Flange socket ; M10×20 4
117 2nd gear 1 468 VP plug ; PF3/4 1
118 3rd gear 1 710 O-ring ; 1B G80 1
125 Ball bearing 2 711 O-ring ; 1B G85 1
126 Roller bearing 1 728 O-ring ; 1B P24 1
128 Bearing spacer 2 825 Snap ring 1
262 Cover 2 826 Snap ring 1
326 Gear case 1 885 Sprig pin 1
414 Capscrew ; M10×20 4 886 Pin 2
24-7
24.1.1.2.2 OPERATION
The pump assy is equipped with two pumps
arranged on the same axis that are connected with
gear (116) and distribute the rotating power to the REGULATOR
gear trains on a different axis. Thus the engine
rotation is transmitted to front shaft (111) that drives
the two pumps and, at the same time, drives the
auxiliary pump (OPT) arranged on another shaft. 116
The pump assy consists largely of the rotary group,
the main part of the pump that makes rotary on; the 111
swash plate group that changes the delivery rate;
the valve block group that selects between oil
suction and delivery ; and the PTO group that
transmits the drive power to the auxiliary pump.
(1) Rotary group
PTO GEAR CASE
The rotary group consists of shaft (111) (113),
cylinder block (141), piston (151), shoe (152), plate AUXILIARY PUMP
(153), spherical bushing (156), bearing spacer (OPT)
(127) and cylinder spring (157). Fig. 24-4 Construction of hydraulic pump
The shaft is supported by bearings (123) and (124)
at its both ends. The shoe, which is caulked to the
piston, forms a spherical joint and relieves it of
thrust force that is generated by load pressure.
Further, the piston is provided with a pocket so it
moves lightly on shoe plate (211), taking hydraulic
balance.
The sub group of the piston-shoe is pressed
against the shoe plate by the cylinder spring, via the
retainer plate and the spherical bushing, so that it
moves smoothly over the shoe plate. The cylinder
block (141) is also pressed against valve plate
(314) by the action of cylinder spring (157).
313
124
312
111
116
124
314
141
157
156
151
. 153
152
211
Fig. 24-5 Rotary group
24-8
(1) Swash plate group 532

The swash plate group consists of swash plate
(212), shoe plate (211), swash plate support (251),
531
lock pin (255), set spring (256), tilting bushing 214 211
(214), tilting pin (531), and servo piston (532). The 212
swash plate is the cylindrical part that is formed on
the opposite side of the shoe sliding surface and is
supported by the swash plate support. 251
The hydraulic force controlled by the regulator
flows into the hydraulic chamber that is provided on
both sides of the servo piston. This moves the
servo piston to the right and left. The result is that
the swash plate swings on the swash plate support
via the spherical part of the tilting pin and changes
Fig. 24-6 Swash plate group
the tilting angle (a).
(2) Valve block group
The valve block group consists of valve block (312),
valve plates (313 or 314), and spring pin (886). The 313
312
valve plates having two crescent-shaped ports are
installed to valve block (312) to feed oil and recycle
it from cylinder block (141). The oil switched over by 116
the valve plate is connected with the external pipe 111
by way of the valve block. 314
141
886
Fig. 24-7 Valve block group

(3) PTO group 117
The PTO group is composed of 1st gear (116), 2nd
gear (117) and 3rd gear (118). The 2nd and the 3rd 126
gear are supported by bearings (125) and (126)
respectively and installed to the valve block.
Now, if the shaft is driven by the engine, the cylinder
block rotates together by the spline linkage. If the
swash plate is inclined, the pistons arranged in the
cylinder block make reciprocating motion with
respect to the cylinder while rotating with the 118
cylinder block. If we keep an eye on a single piston,
125
it makes a motion away from the valve plate (oil
suction process) in the first 180°and a motion
toward the valve plate (oil delivery process) in the
125
remaining 180°. If the swash plate is not inclined
(zero tilting angle), the piston does not stroke i.e.
Fig. 24-8 PTO group
delivers no oil.
The shaft rotation is taken up by the 1st gear (116)
and transmitted to the 2nd gear (117) and the 3rd
gear (118), in that order, to drive the gear pump that
is linked to the 3rd gear.
24-9
24.1.1.3 REGULATOR
496 O-RING JIS B 2401 P20
325 079
624 627
631 A
643
B B
731
924
407
801
724
402
656
A 733
651 646
652 754 658 887 754
466
755
755 541 543
897 496 418 601
415 496 545
726 543
SECTION B-B
616 545 TIGHTENING TORQUE

Tightening torque
614 755 Item No. Thread size
N.m (lbf.m)
402,407 M6 12 (8.9)
875 541 415 M8 29 (21)
418 M5 6.9 (5.1)
724 708 466 PF 1/4 16 (12)
496 NPTF1/16 8.8 (6.5)
611 614 M14 1.5 27 (20)
801 M10 29 (21)
SECTION A-A
Fig. 24-9
24-10
No. Parts Q'ty No. Parts Q'ty

325 Valve casing 1 651 Sleeve 1
402 Socket bolt ; M6 X 16 4 652 Spool 1
407 Socket bolt ; M6 X 30 4 656 Block cover 1
415 Socket bolt ; M8 X 40 4 658 Plug with throttle 1
418 Socket bolt ; M5 X 12 2 708 O-ring : 1B G55 1
466 VP plug ; PF1/4 1 724 O-ring : 1B P8 5
496 Plug ; NPTF1/16 9 726 O-ring : 1B P12 1
541 Seat 2 731 O-ring : 1B G25 1
543 Stopper 1 2 733 O-ring : 1B P18 1
545 Ball 2 754 O-ring : 1B P10 2
601 Casing 1 755 O-ring : 1B P11 3
611 Feed back lever 1 801 Nut ; M10 1
614 Fulcrum plug 1 875 Pin 1
616 Prevention plug 1 887 Pin 1
624 Spring seat 1 897 Pin 1
627 Adjusting stem (Q) 1 924 Socket screw ; M10 X 20 1
631 Sleeve (For PF) 1 041 Sub-check valve 2
643 Pilot piston 1 079 Solenoid proportional reducing valve 1
646 Pilot spring 1
The codes in a rectangle represent adjust screws.
Do not tamper with the adjust screws as much as possible.
24-11
(1) Control function
Control function …… Electric flow control.
•Positive flow control.
(2) Summary
The regulator KR76-0E13-V for the in-line type axial piston pump K7V series is composed of the control
mechanism as mentioned below:
1) Electric flow control and positive flow control
The tilting angle of the pump (delivery rate) is controlled by controlling the current command value of the
solenoid proportional reducing valve attached to the regulator. The regulator makes positive flow control
(positive control) that increases the delivery rate as the secondary pressure of the solenoid proportional
reducing valve rises. Since this function permits the output power of the pump to be varied, it is possible to
attain optimum power according to the operating condition. Also, since the pump delivers only the necessary
oil flow, the machine does not consume excessive power.
(3) Explanation of operation

1) Flow rate electrical control
The pump delivery rate is controlled according to
Delivery flow rate Q
the command current value corresponding to the
movement of control devices. This relation is
shown in right figure.
2) Flow increasing action
As the command current I rises, the secondary
pressure of solenoid proportional reducing valve
(079) increases. This causes spool (652) to
Command current I
move via pilot piston (643) and stops where the
Fig. 24-10
hydraulic pressure pushing the spool rightwards
balances with the action of pilot spring (646).
If the spool (652) moves, port CL opens to the tank port. This causes the pressure of the large diameter part
of servo piston (532) to go away. This causes the servo piston (532) to the left by delivery pressure P1 of the
small diameter part, resulting in an increase in the tilting angle.
Feedback lever(611) is linked with the servo piston and sleeve(651). As the servo piston moves to the left, the
feedback lever rotates on point A which causes the sleeve to the right. As the servo piston moves to the right,
the feedback lever rotates on point A to move the sleeve to the right. The result is that the opening of the spool
sleeve begins to close gradually and the servo piston settles down when the opening of the spool sleeve
closes completely.
3) Flow decrease function
As the command current I decreases, the secondary pressure of the solenoid proportional valve decreases.
This causes the spool to move to the left.
When the spool(652) has moved, delivery pressure P1 reaches port CL via spool and is admitted to the large
diameter chamber of the servo piston. Delivery pressure P1 is admitted to the small diameter part of the servo
piston at all times. The servo piston moves rightward by areal difference to decrease tilting angle. As the servo
piston moves to the right, the feedback lever rotates on point A to move the sleeve to the left. The sleeve
keeps moving till the opening of the spool sleeve closes and settles down when the spool sleeve closes
completely.
24-12
079
651 652
627
643 DELIVERY
801
PRESSURE
P1
924
808 646
954 611
953
P1
DELIVERY
PRESSURE
806
532
LARGE TILTING ANGLE SMALL
HYDRAULIC CIRCUIT
(KDRDE5K) PSV
CL PORT
Fig. 24-11 Regulator operation
24-13
24.1.1.3.3 ADJUSTING THE REGULATOR

The regulator may be adjusted in terms of maximum
flow, minimum flow, horsepower (at emergency mode
control) control characteristics, flow control
characteristics using the adjust screw.
(1) Adjusting the maximum flow (See Fig. 24-3)
Adjust the maximum flow by loosening nut (808)
and by tightening set screw (954) (or loosening it).

Tightening set screw (954) decreases the delivery
rate, as indicated in Fig. 24-12.
Only the maximum flow varies, but other control
characteristics remain unchanged.
Adjust screw no. 954

No. of turns for tightening 1/4
Pilot pressure Pi (Input current I) No change Input current I (Pilot pressure Pi)
Fig. 24-12 Adjusting the max. delivery flow
Min. increase in delivery flow L/min 3.4
(2) Adjusting the minimum flow (See Fig. 24-3)

Adjust the minimum flow by loosening nut (808) and
by tightening socket screw (953) (or loosening it). Delivery flow rate Q
Tightening socket screw increases the delivery
rate, as indicated in Fig. 24-13.
Other control characteristics remain unchanged in
the same way as maximum flow adjustment, care
should be used of the fact that overtightening may
increase a required power at the maximum delivery
pressure (at relieving action).
Input current I (Pilot pressure Pi)
Fig. 24-13 Adjusting the min. delivery flow
Pilot pressure Pi (Input current I) No change
Min. increase in delivery flow L/min 2.9
(3) Adjusting the flow control characteristics (See Fig.

24-9)
Adjust them by loosening nut (801) and socket bolt
(924) (or loosening it). Socket bolt causes the

control chart to move to the right as shown in Fig.
24-14.

Increase Pilot pressure MPa 0.16
Input current I (Pilot pressure Pi)
Decrease in delivery flow L/min 10.1
Fig. 24-14 Adjusting the flow control
characteristics
24-14
24.1.1.3.4 CAUSES OF FAULT RESULTING FROM REGULATOR

When trouble due to this regulator occurs, disassemble
and inspect it referring to "Chapter UPPER
STRUCTURE"
(1) When the engine is overloaded,
Load every unit of pump, and check on pumps on
the right and left sides for possible damages. When
pumps on both sides are failed, check on them for
the following failures 1), 2). When pump on the one
side is failed, start checking from para. 3).
1) Check that the power shift command current I is
normal.
2) The power shift pressure is high.
• Check the dither of amp.
• Replace solenoid proportional reducing
valve.
3) Stick of spool (652) and sleeve (651)
• Disassemble and clean it.
4) Stick of pilot piston (643)
(2) The max. flow rate is not delivered.
1) Check that secondary pressure of solenoid
proportional reducing valve is normal.
2) Stick of pilot piston (643)
3) Stick of spool (652) and sleeve (651)
Note : When the damage of part is severe, replace the
part with new one.
24-15
24.1.1.4 CONTROL CURVE OF PUMP
250
[1] 49kW H mode at operating attachment
[2] 64kW H mode at traveling or optional working Input revolution ; 2000 min-1, 1800 min-1
[3] 44kW S mode at operating attachment Input horse power ; 64 kW
Input torque ; 303 N.m
200 Reference value in ( )
Two pumps are loaded at the same time
Delivery flow rate Q [ L/min ]
150
Q 2000min-1
(H mode)
1800min-1
(S mode)
100
[3] [2]
[1]
50
Min.Flow(at 2000min-1)
0 5 10 15 20 25 30 35 40
Delivery pressure Pd [MPa]
24-16
24.1.2 CONTROL VALVE
24.1.2.1 SPECIFICATIONS
24.1.2.1.1 OUTSIDE VIEW

PTb PCa
PBL
MU2
P2
P6 P5
P1
PCb PAL
T1
CT1 T2 CT2
PTb CMR1
P1 unload PCb PAL
CMR2 PL CP2
Travel PCb PAL Travel left PBL
straight
AL BL
CP1
Br Ar Travel PAr PB1 DR PCa
PBr PAr PB1 Boom CCb
right P2
Ab conflux unload
PAb Bb (ROD) LCb (HEAD) Bs
PBs As LCs
PBb PBs Swing
Boom PBb PAs
CRb
Pss
Pss CRa
Ac (HEAD) LCc Bucket
Bc PBc PAa1 Arm 1 PBa1
(ROD) LCa
PAc PBc PAa1 Aa
(ROD) LCo
MU1 PAa2
PBa2 Arm 2 PAa2 PAo PAo Option PBo
LCAT2 LCAP2 Ao Ba
(HEAD)
PBp1 PBp2 Bo
PAo PAa2
PAa2
PBa2
Arm 2 Option
PBo
PAc PBa1
Bucket Arm 1
(P3) (P4) PAb
PAa
Boom Swing
PBr PCa
Travel right P2 unload
T3
PTb PBL
Travel Travel left
straight
PBa2 PBo
A VIEW A
Fig. 24-15 Outside view
24-17
24.1.2.1.2 PORTS
Port size Tightening torque Ports Description

PF3/4 150~180 N•m (111~133 lbf•ft) (MU1), (MU2) Pluged
T3
Ar Right travel motor port (forward)
Br Right travel motor port (reverse)
AL Left travel motor port (forward)
BL Left travel motor port (reverse)
As Swing motor port (right)
Bs Swing motor port (left)
Ab Boom cylinder head side port (up)
Bb Boom cylinder rod side port (down)
Aa Arm cylinder head side port (in)
Ba Arm cylinder rod side port (out)
Ac Bucket cylinder head side port (digging)
Bc Bucket cylinder rod side port (dump)
Ao Optional pilot port
Bo Optional pilot port
PF1/2 98~120 N•m (72~89 lbf•ft) (P3), (P5) Pluged
(P4), (P6) Pluged
PF3/8 69~78 N•m (51~58 lbf•ft) PAa1 Arm 1 (in) pilot port
PBa1 Arm 1 (out) pilot port
PAb Boom (up) pilot port
PBb Boom (down) pilot port
PAc Bucket (digging) pilot port
PBc Bucket (dump) pilot port
PAL Travel left (forward) pilot port
PBL Travel left (reverse) pilot port
PAr Travel right (forward) pilot port
PBr Travel right (reverse) pilot port
PAs Swing (right) pilot port
PBs Swing (left) pilot port
PAa2 Arm 2 (in) pilot port
PBa2 Arm 2 (out) pilot port
PAo Option pilot port
PBo Option pilot port
DR Drain port
PF1/4 34~39 N•m (25~29 lbf•ft) Pss Swing pilot high pressure select port
PLc2 Lock valve select pilot port
PBp1 Bypass cut valve (P1 side) pilot port
PBp2 Bypass cut valve (P2 side) pilot port
(PL)
PB1 Boom (up) conflux pilot port
PTb Travel straight pilot port
PCa Unload valve (P2 side) pilot port
PCb Unload valve (P1 side) pilot port
M10 49~65N•m (36~48 lbf•ft) P1 Pump port (P1 side)
P2 Pump port (P2 side)
24-18
Port size Tightening torque Ports Description

M12 83~110N•m (61~81 lbf•ft) T1 Tank port 1
T2 Tank port 2
24.1.2.1.3 SPECIFICATIONS
Item Specifications
Model KMX13YD/B44004
Maximum flow rate [L/min (gal/min)] 130 (34)×2
Maximum set pressure [MPa (psi)] 37.8 (5480) (Pump port)/ 39.7 (5760) (Actuator port)
Main relief valve set pressure [MPa (psi)] Std 34.3 (4970) [at 30×2L/min (8×2gal/min)]
Overload relief valve set pressure [MPa (psi)] 37.8 (5480) [at 30L/min (8gal/min)]
24-19
24.1.2.2 CONSTRUCTION AND OPERATION
(1) Control valve
K
155 163 101

(P5)
P2
T1
T2 CT2
K
PAL PBL
PB1 PCa
PBs PAs
Pss
PAa1 PBa1
PAo PBc
PAp2
(P4)
166 161 161155 163164
SECTION A-A
154 567 155 163
(MU2) (P6) 102
P1
973 973
CT1
PTb POb
973 973
PBr PAr
PAb PBb
973 973
PAc PBc
973 973
PBa2 PAa2
PBp1
973
(P3)
161 164 163 155 161 161
SECTION B-B
Fig. 24-16 Section (1/6)
24-20
273x10
6
H H
P1 unload PCb PAL
Travel left
(Travel straight) 273x10
C C
PAr PB1 Boom conflux
Travel right (P2 unload)
D D
977
PBb PBs 978x2
Boom Swing
E Pss
E
PBc PAa1
Bucket Arm 1
F F
PAa2 PAo
Arm 2 MU1 Option
G PBp1 PBp2
G
H H
B A
(P3)
PAa2 PAo PAo
PBp1
PBp2
275x4
213
274x4
(P4)
(P3)
212
PBa2 PBo
273x10
273x10
24-21
202 P1 unload 201

Travel left
333 PCb PAL 333
331 331
336 339
328 327
325 325
331
601 331
MR
261 261
309 306
(PL)
159
166
157
161 AL
161
511
512
521
522
CP2
CMR2 551
556 561
561
561 BL
CMR1
556
522
512
307
261 264
331 PBL
325 205
326
336 SECTION C-C
331
333 PTb
202 Travel straight
201 Travel right Boom conflux 201

333 PAr PB1 333
331 331
339 336
327 322
AbR
325 321
602
331 331
261 261
166 305
164 DR 511
162 521
Ar CCb
306
551
511 561
521
CP1
551
551 561
561
166 Br
310
164
166
161
166 T3
264 261
331
PBr
205 325
SECTION D-D 328
336
331
PCa 333
P2 unload 202
24-22
203
333 Swing
331 PBs
339 Boom 204
320 PBb Pss 333
319 331
336
322
331 321
211 266
261 L 331
L 261
266
166
160
303
301
561 CRb 161
Ab As
(HEAD)
556 511
524 524
LCb LCs
514
551 556
561 561
521 Bb Bs
511 (ROD)
161
264
264
602
PAb
205 PAs 206
BbR
160 266
SECTION E-E
201
201 333
333 Bucket Arm 1
PBc PAa1
331
331 336
339 322
320 321
BcR
319 AaR 602
602 331
331 261
261
161
304
Bc Aa(HEAD)
(ROD)
511 511
521 521
LCc LCa 551
561
551
561 161
Ac 561
(HEAD) CRa 556
Ba(ROD)
524
514
156
PLc2 167
264 160x2
L 302
602 L
PAc PBa1 264
205 211
AcR
205
SECTION F-F
24-23
201
333
331 Arm 2 Option 201
333
339 PAa2 PAo
331
326 337
325
330
331
329
261 604
154 AoR 331
567 261
MU1
161 311
308
162
515
521 Ao
551 511
LCAP2
561 521
LCo
561 551
LCAT2
561
551
Bo
521
511 Ba(ROD)
162
162
162
264
PBa2 PBo 606
264
205
SECTION G-G
205 PaR
605 605
PBp1 PBp2
Bo
BoR
166 604
153
SECTION H-H
24-24
T2
P1 T1
511
521
CT1
551
561
511
C P2
(MU2)
521
CT2
E 551
561
162 SECTION J-J

278x5
160
266
207
267 267
528
527
T1
518
517
SECTION L-L
SECTION K-K
24-25
Tightening torque Tightening torque

N•m (lbf•ft) N•m (lbf•ft)
101 Casing A 1 309 P1 unload spool 1
102 Casing B 1 310 P2 unload spool 1
25~29 (18~21) 153 Plug 1 311 Option spool 1
220~250 (162~184) 154 Plug PF3/4 2 319 Spring 2
110~130 (81~96) 155 Plug PF1/2 4 320 Spring 2
13~17 (9.6~13) 156 Plug PF1/8 1 321 Spring 5
20~24 (15~18) 157 Plug PF1/4 MEC 1 322 Spring 4
34~39 (25~29) 159 Plug PT1/4 1 325 Spring 6
7.8~9.8 (5.8~7.2) 160 Plug PT1/16 MEC 5 326 Spring 1
161 O-ring : 1B G30 13 327 Spring 2
162 O-ring : 1B G25 6 328 Spring 3
163 O-ring : 1B P18 4 329 Spring 1
164 O-ring : 1B P15 4 330 Spring 1
166 O-ring : 1B P10 7 331 Spring seat 24
16~18 (11.8~13.3)
167 O-ring : 1B P8 1 333 Spacer bolt 12
Loctite #262
168 O-ring : 1B P11 1 336 Stopper 6

201 Cover 6 337 Stopper 1
203 Cover 1 511 Poppet 11
204 Sub cover 1 512 Poppet 2
207 Back pressure check valve cover 1 517 Poppet 1
9.8~14 (7.2~10.3) 211 Lock valve selector sub 2 518 Poppet 1
212 Plate 1 521 Spring 11
261 O-ring 12 524 Spring 3
264 O-ring : 1B G35 8 527 Spring 1
266 O-ring : 1B P7 4 528 Spring 1
267 O-ring : 1B 32 2 130~150 (96~111) 551 Plug 12
25~34 (18~25) 273 Socket bolt 40 130~150 (96~111) 556 Plug 5
98~120 (72~89) 274 Socket bolt 4 561 O-ring : 1B P20 17
9.8~14 (7.2~10.3) 278 Socket bolt 5 69~78 (51~58) 601 Main relief valve 1
301 Boom spool assy 1 69~78 (51~58) 602 Port relief valve 5
302 Arm 1 spool 1 69~78 (51~58) 604 Relief valve plug assy 2
303 Swing spool 1 98~120 (72~89) 605 Bypass cut valve 2
304 Bucket spool 1 69~78 (51~58) 606 Port relief valve 1
305 Boom conflux spool 1 140~180 (103~133) 973 Socket bolt 9
306 Travel spool 2 977 Name plate 1
307 Travel straight spool 1 978 Rivet 2
308 Arm 2 spool assy 1
24-26
(2) Main relief valve (601)
123 124 125 561 562 611 621 163 661 612
512 521 541 121 122 103 651 671
Fig. 24-22 Main relief valve

69~78 (51~58) 103 Plug ; M27 1 541 Seat 1
121 C-ring 1 561 O-ring 1
122 Spacer 1 562 Back up ring 1
123 C-ring 1 611 Poppet 1
124 Filter stopper 1 612 Spring seat 1
125 Filter 1 621 Spring 1
163 O-ring 1 651 Adjust screw 1
512 Plunger 1 661 O-ring 1
521 Spring 1 28~31 (21~23) 671 Lock nut ; M14 1
24-27
(3) Over load relief valve (602,606)
Fig. 24-23 Over load relief valve
Tightening Tightening
torque No. Parts Q’ty torque No. Parts Q’ty
69~78 (51~58) 101 Body ; M27 1 541 Seat 1
69~78 (51~58) 102 Plug ; M27 1 561 O-ring 1
161 O-ring 1 562 Backup ring 1
162 O-ring 1 563 O-ring 1
123 C-ring 1 564 Backup ring 1
124 Filter stopper 1 611 Poppet 1
125 Filter 1 612 Spring seat 1
301 Piston 1 621 Spring 1
511 Plunger 1 651 Adjust screw 1
521 Spring 1 661 O-ring 1
522 Spring 1 28~31 (21~23) 671 Lock nut ; M14 1
24-28
(4) Arm 2 spool (308)
317 340 361 371 351

350 371 361 340 317 308
Fig. 24-24 Arm 2 spool
Tightening
Tightening torque
torque No. Parts Q’ty No. Parts Q’ty
N•m (lbf•ft)
N•m (lbf•ft)
308 Spool 1 18~20 (13~15) Loctite #638 350 Plug 1
317 Plunger 2 18~20 (13~15) Loctite #638 351 Plug 1
371 Backup ring 2
(5) Boom spool (301)
301 317 340 361 371 350
Fig. 24-25 Boom spool
Tightening
Tightening torque
N•m (lbf•ft)
N•m (lbf•ft)
301 Spool 1 18~20 (13~15) Loctite #638 350 Plug 1
317 Plunger 1 361 O-ring 1
340 Spring 1 371 Backup ring 1
24-29
(6) Lock valve selector (211)
101
164
171
201
321
PLc A B Dr
166 541 167 511 161
Fig. 24-26 Lock valve selector
Tightening
Tightening torque
N•m (lbf•ft)
N•m (lbf•ft)
101 Casing 1 10~14 (7.4~10.3) 171 Socket bolt 3
161 O-ring 4 49~59 (36~44) 201 Plug 1
166 O-ring 1 511 Spool 1
167 O-ring 1 541 Sleeve 1
24-30
(7) Bypass cut valve (605)
! ! " "
2 2E
6 ,H

Fig. 24-27 Bypass cut valve

98~120 (72~89) 101 Plug 1 301 Plunger 1
201 Poppet 1 69~78 (51~58) 401 Plug 1
24-31
(8) Swing shuttle valve cover (204)
PBs
Pss
555
A
G1/4
SECTION B-B A
542 541
PBs G3/8
166
B B
Pss
554
202
PAs
SECTION A-A
Fig. 24-28 Swing shuttle valve cover
Tightening
Tightening torque
N•m (lbf•ft)
N•m (lbf•ft)
166 O-ring 1 542 Seat 1
202 Cover 1 25~29 (18~21) 554 Plug 1
541 Steel ball 1 7.9~9.8 (5.9~7.2) 555 Plug 1
24-32
24.1.2.2.2 HYDRAULIC CIRCUIT DIAGRAM
P1 T1 T2 P2
CMR1
(PL) CMR2
PTb PBL
Travel straight
PCb PAL Travel left
P1 unload
AL
CT2 CP2 BL
CT1
T3 Boom conflux
Travel right PAr PCa
P2 unload
CP1
Br
Ar PB1
PBr
CCb
PBs
LCb LCs Pss
Boom PAb PAs Swing

As
Bs
PBa1
(ROD) Bb
CRb LCa
PAa1
(HEAD) Ab
Arm 1
PBb
Aa (HEAD)
LCc
CRa
PLc2
Bucket PAc
Ba (ROD)
(ROD) Bc
(HEAD) Ac
LCo
PAo Option
PBc
LCAT2
LCAP2
PAa2
Arm 2 Ao
Bo
PBa2 PBo
(MU)
PBp1 PBp2
(P3) (P4)
Fig. 24-29 Hydraulic circuit diagram
24-33
(1) In neutral position
The hydraulic oil delivered by hydraulic pump P1 enters port P1 of control valve, and passes through unloading
valve P1 (309), low pressure circuit (D) and boost check valve (517), and returns to the hydraulic tank through
tank port T1. And when the operation of unloading valve is impossible due to failure of electric control system,
because the by-pass cut valve (605) located on the downstream of center by-pass passage (52) opens, the
hydraulic oil through hydraulic pump P1 port passes through travel straight spool (307), and then flows though
the center by-pass passage (52) which passes through travel right, boom, bucket and arm 2 and the by-pass cut
valve (605) on P1 side, and flows into low pressure circuit (D) and boost check valve (517), and then returns to
the hydraulic tank through tank port T1.
The hydraulic oil delivered by hydraulic pump P2 passes through unloading valve P2 (310), low pressure circuit
(D) and boost check valve (517) and returns to the hydraulic tank through tank port T1 similarly to the hydraulic
oil from hydraulic pump P1. And when the operation of unloading valve is impossible, because the by-pass cut
valve (605) located on the downstream of center by-pass passage (55) opens, the hydraulic oil through hydraulic
pump P2 port passes through main passage, and then flows though the center by-pass passage (55) which
passes through travel left, swing, arm 1 and option and the by-pass cut valve (605) on P2 side, and flows into
low pressure circuit (D) and boost check valve (517), and then returns to the hydraulic tank through tank port T1.
52
605 (D)
517
307
T1
T1
P2
P1
309
605
(D)
Connected to low
55 310 pressure circuit of
P2 side casing
Fig. 24-30 In neutral position
24-34
(2) Actuation in travel operation

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

A B
AL BL
CP2
306
327 325
PBL
PAL
(D)
Fig. 24-31 In left reverse travel (at PBL is pressurized)
24-35
2) In travel straight operation

When actuator other than travel operation and the travel operation are operated simultaneously in the said
item 1) "In travel independent operation" the pilot signal from the outside acts on port PTb and the travel
straight spool (307) moves upward.
With this operation, the hydraulic oil delivered by hydraulic pump P1 mainly flows from P2 to A and is used
for each actuator, and the hydraulic oil delivered by hydraulic pump P2 mainly flows from P2 to B and into
main passage, and is used for right and left travel operations as hydraulic oil realizing the actuator and travel
simultaneous operation. (Travel straight function) At circuit (I) position, a part of hydraulic oil delivered by
hydraulic oil P1 passes through circular notch on travel straight spool (307) and enters from P1 to B enabling
the hydraulic oil to be supplied from actuator side to travel side. And at circuit (II) position, the circular notch
on travel straight spool (307) closes and the pump line on the travel sides is independent from pump line on
actuator.
CMR2 P2 CMR2 P2
B B
CMR1
P1 CMR1
P1
A A
307 307
325 325
328 328
PTb PTb
P2 P1 P2 P1
PTb PTb
Dr Dr Dr Dr
B A
To each actuator B A
To travel right To each actuator
To travel right
Circuit (I) Circuit (II)
Fig. 24-32 Movement of travel straight spool
24-36
(3) Actuation in bucket operation

1) In bucket digging operation
On starting bucket digging operation, the pilot pressure enters port PAc, bucket spool (304) moves leftward
the force of springs (319)(320), and simultaneously the secondary pressure of solenoid proportional valve
[XI] acts on port PCb and switches unloading spool (309).
The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), pushes and opens load
check valve LCc (511), and flows through between the perimeter of bucket spool (304) and casing through
U-shaped passage, and supplied to bucket cylinder head side (H) through port (Ac).
In the meantime, the return oil from bucket cylinder rod side (R) passes through between the perimeter of
bucket spool (304) and casing, flows through low pressure circuit (D) and boost check valve (517), and
returns to the hydraulic tank through tank port T1.
53
PBc PAc
320
319
304
(D)
Bc LCc Ac
511
(R) (H)
Fig. 24-33 In bucket digging operation
24-37
2) In bucket dumping operation

On starting bucket dumping operation, the pilot pressure enters port PBc and bucket spool (304) moves
rightward the force of springs (319)(320), and simultaneously the secondary pressure of solenoid
proportional valve [XI] acts on port PCb and switches unloading spool (309). The hydraulic oil delivered by
hydraulic pump P1 flows into parallel passage (53), pushes and opens load check valve LCc (511), and flows
through between the perimeter of bucket spool (304) and casing through U-shaped passage, and supplied
to bucket cylinder rod side (R) through port (Bc).
In the meantime, the return oil from bucket cylinder head side (H) passes through between the perimeter of
bucket spool (304) and casing and flows through low pressure circuit (D’), boost check valve (517) and
53 (D)
PBc PAc
320
319
304
Bc 511 LCc Ac
(R) (H)
Fig. 24-34 In bucket dumping operation
24-38
(4) Boom
1) In boom up operation
On starting boom up operation, the pilot pressure enters port PAb and boom spool (301) moves rightward
against the force of springs (319) (320), and simultaneously the secondary pressure of solenoid proportional
valve [XI] acts on port PCa and switches unloading spool (309).
check valve LCb (511), and flows through between the perimeter of boom spool (301) and casing through
U-shaped passage, and supplied to bucket cylinder head side (H) through port (Ab).
In the meantime, the return oil from boom cylinder rod side (R) passes through between the perimeter of
boom spool (301) and casing, flows through low pressure circuit (D) and boost check valve (517), and
(R) (R)
(H) (H)
53
(D) Ab CRb 514 BH chamber
Bb 511 LCb
301
319
320
PAb PBb
Fig. 24-35 In boom up operation (Boom spool)
24-39
2) In boom up conflux operation

When boom up operation is performed, the pilot pressure also enters port PB1, and boom conflux spool
(305) is switched by pressure which counters against the force of springs (321) (322). Simultaneously,
secondary pressre of solenoid proportional valve [X2] acts on port PCa and switcheds unload spool (310).
The hydraulic oil delivered by hydraulic pump P2 passes through travel left spool and enters parallel passage
(56), and pushes and opens load check valve CP2, and flows through between the perimeter of boom
conflux spool (305) and casing from the A side of U-shaped passage, and pushes and opens conflux check
valve CCb (511) and enters port Ab through conflux passage inside of casing and confluents the hydraulic
oil from the hydraulic pump P1 side.
PB1
322
321
305
511
CCb
Conflux passage
To Ab port of P1 casing
56
Fig. 24-36 In boom up conflux operation (Boom conflux spool)
24-40
3) In boom down operation

On starting boom down operation, the pilot pressure enters port PBb and boom spool (301) moves leftward
against the force of springs (319) (320) and the secondary pressure of solenoid proportional valve [X1] acts
on PCb and switches unloading spool (309). And simultaneously the spool of lock valve selector (211) is
switched, and the poppet (514) is released because the spring chamber of lock valve poppet CRb (514) is
connected to the drain circuit.
The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), and pushes and opens
load check valve LCb (511), and flows through between the perimeter of boom spool (301) and casing
through U-shaped passage, and is supplied to boom cylinder rod side (R) through port (Bb).
In the meantime, the return oil from boom cylinder head side (H) enters the control valve through port (Ab).
Because the retention of lock valve poppet CRb (514) which is located on this side of boom spool (301) is
released, the lock valve poppet (514) pushes and opens. And then the return oil enters BH chamber and
passes through between the perimeter of boom spool (301) and casing, and flows through low pressure
circuit (D) and boost check valve (517), and the returns to the hydraulic tank through tank port T1. And a part
of the return oil flows into the inside of boom spool (301) through circular notch of boom spool (301). Since
the return oil contains sufficient pressure with the self weight of boom, arm, etc. the return oil passes through
inside passage of boom spool (301) and pushes and opens poppet (317) leftward as shown in the figure and
flows through the circular notch, and then supplied to boom cylinder rod (R) side again through port Bb.
(Boom recirculation function)
(R) (R)
(H) (H)
511 BH chamber
Bb 53 CRb 514
317 LCb Ab
301
319
320
PAb
PBb
(D)
Fig. 24-37 In boom down operation
24-41
(5) Arm operation

1) In arm out operation
When arm out operation is performed, the pilot pressure enters ports PBa1 and arm 1 spool (302) moves
rightward against the force of springs (321) (322). Simultaneously the secondary pressure of solenoid
proportional valve [X2] acts on port PCa and switches unloading spool (310).
And the pilot pressure also enters PBa2, and arm 2 spool (308) is switched against the force of springs (325)
(326) and the secondary pressure of solenoid proportional valve [X1] acts on port PCb and switches unload
spool (309).
check valve LCa (511), and flows into AR chamber through between the perimeter of arm 1 spool (302) and
casing through U-shaped passage.
In the meantime, the hydraulic oil delivered by hydraulic pump P1 flows through center by-pass passage (52)
and pushes and opens load check valve LCAT2 (511) and enters U-shaped passage, and pushes and opens
load check valve LCAP2 (515) provided with orifice, and flows into U-shaped passage. And then the
hydraulic oil flows through between the perimeter of arm 2 spool (308) and casing, and enters AR chamber
through casing inside passage (RR) and confluences the hydraulic oil from hydraulic pump P2 side.
The conflux hydraulic oil opens lock valve poppet CRa (514) and is supplied to arm cylinder rod side (R).
In the meantime, the return oil from arm cylinder head side (H) flows through between the perimeter of arm
1 spool (302) and casing and passes though low pressure circuit (D) and casing inside passage (HH) and
then flows into low pressure circuit (D) through between the perimeter of arm 2 spool (308) and casing.
The return oil in low pressure circuit (D) returns to hydraulic tank through tank port T1 passing through boost
check valve (517).
(H) (R)
CRa
514
511 Ba 302
Aa LCa
321
AR
322 chamber
211
P1
56
PAa1 PBa1 (D')
(D) LCAT2
Arm 1 LCAP2
P1
(D)
HH RH RR PAa2 PBa2
(D) Dr Dr
Arm 2 52
PBa2
[XR] To arm 1 spool
PAa2 Aa (HEAD)
53
Ba (ROD)
53
(MU1)
To bypass cut valve
326
325
308
515 LCAP2 LCAT2 511
Fig. 24-38 In arm out operation
24-42
2) In arm in operation (At light load: arm recirculation function)

When arm in operation is performed, the pilot pressure enters ports PAa1 and PLc2, and arm 1 spool (302)
moves rightward against the force of springs (321) (322). Simultaneously the secondary pressure of solenoid
proportional valve [X2] acts on port PCa and switches unloading spool (310). At the same time, since the
spool of lock valve selector (211) is switched, the spring chamber of lock valve poppet CRa (514) is
connected to the drain circuit and the retention of poppet (514) is released.
And the pilot pressure enters PAa2 through solenoid proportional valve [XR], and arm2 spool (308) moves
rightward against the force of springs (325) (326) and the secondary pressure of solenoid proportional valve
[X1] acts on port PCb and switches unloading spools (309). But in light load operation, because the solenoid
proportional valve [XR] actuates and arm 2 spool (308) stays in the position of circuit (I).
check valve LCa (511), and flows into port (Aa) through between the perimeter of arm 1 spool (302) and
casing through U-shaped passage. In the meantime, the hydraulic oil delivered by hydraulic pump P1 flows
through center by-pass passage (52) and pushes and opens load check valve LCAT2 (511) and enters U-
shaped passage, and also the oil from parallel passage (53) pushes and opens load check valve LCAP2
(515) provided with orifice and flows into U-shaped passage. And then the hydraulic oil flows through
between the perimeter of arm 2 spool (308) and casing from U-shaped passage and enters port (Aa) through
casing inside passage (HH) and confluences the hydraulic oil from hydraulic pump P2 side.
The conflux hydraulic oil is supplied to arm cylinder head side (H) through port (Aa).
In the meantime, the return oil from arm cylinder rod side (R) enters the control valve through port (Ba).
Because the retention of lock valve poppet CRa (514) which is located on this side of arm 1 spool (302) is
released, the return oil pushes and opens lock valve poppet CRa (514) and enters AR chamber. The return
oil in AR chamber flows through between perimeter of arm 1 spool (302) and casing, and flows through low
pressure circuit (D) and boost check valve (517). And finally, the oil returns to hydraulic oil tank through tank
port T1. The return oil in AR chamber is led to arm 2 spool (308) through casing inside passage (RR), but
because arm 2 spool (308) does not connect to low pressure passage (D) at circuit (I), the entire flow rate
flows into arm 1 spool (302).
Further more, the return oil from chamber AR passes through the perimeter of arm 1 spool (302) and casing,
and flows through casing inside passage (RH) and is led to the inside of arm 2 spool (308) through circular
notch (a) of arm 2 spool (308). In light load operation, since the return oil contains higher pressure than that
of arm cylinder head side (H) with the self weight of arm, etc. the hydraulic oil inside of arm 2 spool (308)
passes through check valve (317) and flows into casing inside passage (HH) and the supplied to arm
cylinder head side (H) again. (Arm recirculation function)
And a part of the return oil which was led to arm 2 spool (308) passes through check valve (319), and flows
through boost check valve (517) through low pressure circuit (D) and returns to the hydraulic tank through
tank port T1.
(H) (R)
CRa
Ba 514
Aa 511
LCa
302
321
AR
322 chamber 211
P1
56
PAa1
PBa1
(D')
Arm 1 (D) LCAT2 LCAP2
P1
HH (a) RH RR (D)
PAa2 PBa2
Arm 2 52 Dr Dr
PAa2
PBa2
[XR] 53 To arm 1 spool
Aa (HEAD)
(MU1) (D) Ba (ROD)
326 325
To bypass cut valve
308 317 515 Circuit (l)

LCAP2 LCAT2 511 319
Fig. 24-39 In arm in operation (At light load: arm recirculation function)
24-43
3) In arm in operation (In heavy load operation)

The arm recirculation function is effective in actuating arm cylinder quickly in light load operation, but in
heavy load operation (work required large power); the function causes the power loss. This control valve
selects the presence of recirculation function in light and heavy load operation with solenoid proportional
valve [XR]. (Variable recirculation function)
The flow path of hydraulic oil in heavy load operation, the path on the supply side to arm cylinder is the same
as that in light load operation, differs from that of return oil. In heavy load operation, solenoid proportional
valve [XR] actuates and arm 2 spool (308) is positioned to circuit (II). The return oil from arm cylinder rod
side (R) enters the control valve through port (Ba). Because the retention of lock valve poppet CRa (514)
which is located on this side of arm 1 spool (302) is released, the return oil pushes and opens lock valve
poppet CRa (514) and enters AR chamber. The return oil in AR chamber flows through between perimeter
of arm 1 spool (302) and casing, and flows through low pressure circuit (D) and boost check valve (517).
And finally, the oil returns to hydraulic oil tank through tank port T1. The return oil in AR chamber is led to
arm 2 spool (308) through arm 1 spool (302) and casing inside passage (RR). But because arm 2 spool (308)
is connected to low pressure passage (D) at circuit (II), the return oil passes through between the perimeter
of arm 2 spool (308) and casing and flows through boost check valve (517) through low pressure (D) and
The return oil from AR chamber passes through between the perimeter of arm 1 spool (302) and casing and
flows through casing inside passage (RH) and then is led to the inside of arm 2 spool (308) through circular
notch (a) of arm 2 spool (308). In heavy load operation, since the pressure on arm cylinder head side (H) is
higher than the rod side, the hydraulic oil in arm 2 spool (308) does not flow into casing inside passage (HH),
but flows through check valve (319) and passes through boost check valve (517) through low pressure (D)
and returns to the hydraulic tank through port T1.
(H) (R)
CRa 514
511 Ba
Aa LCa
321 302
AR
322 chamber 211
P1
56 (D')
PAa1 (D) LCAT2
PBa1 LCAP2
P1
Arm 1 PAa2 PBa2
Dr Dr
HH (a) RH RR (D)
Arm 2 52
PAa2 To arm 1 spool
PBa2 Aa (HEAD)
[XR] 53 Ba (ROD)
(MU 1) (D) To bypass cut valve
326 325
Circuit (ll)
308 317 515

LCAP2 LCAT2 511 319
Fig. 24-40 In arm in operation (In heavy load operation)
24-44
(6) Swing operation

On starting swing operation, the pilot pressure enters ports PAs or PBs, and swing spool (303) moves rightward
or leftward against the force of springs (321) (322), and simultaneously the secondary pressure of solenoid
proportional valve [X2] acts on port PCa and switches unloading spool (310).
At the same time, in the event that the pilot pressure acts on port PAs, the pilot pressure flows through shuttle
valve inside of cover (204) through the inside passage and then is led to port Pss. When the pilot pressure acts
on port PBs, the pilot pressure also flows through shuttle valve inside of cover (204) and then is led to port Pss.
The hydraulic oil delivered by hydraulic pump P2 flows into parallel passage (56), pushes and opens load check
valve LCs (511) and flows through between the perimeter of swing spool (303) and casing through U-shaped
passage and is supplied to swing motor A side or B side through port (As) or (Bs).
In the meantime, the return oil from swing motor A side or B side passes through between the perimeter of swing
spool (303) and casing through port (Bs) or (As) and flows through low pressure circuit (D) and boost check valve
(517), and then returns to the hydraulic tank through tank port T1.
204
PAs PBs
Pss
(D)
322
303 321
Bs 56 As
(D)
511
A B
Swing motor
Fig. 24-41 Swing operation
24-45
(7) Spool actuation for operation in option

This spool is used to control the attachment in option like Nibbler (Crusher), etc.
Where the pilot pressure acts on port PAo on operating the attachment in option, the pilot pressure enters ports
PAo, and option spool (311) moves against the force of springs (329) (330), and simultaneously the secondary
pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310).
The hydraulic oil delivered by hydraulic pump P2 flows through parallel passage (56) and pushes and opens
load check valve LCo (511), and flows through between the perimeter of option spool (311) and casing through
U-shaped passage and is supplied to actuator for attachment through port (Ao).
In the meantime, the return oil from actuator for attachment swing passes through between the perimeter of
option spool (311) and casing through port (Bo) and flows through low pressure circuit (D) and boost check valve
(517), and then returns to the hydraulic tank through tank port T1.
The operation where the pilot pressure acts on PBo port is the same as the above.
* The oil passage is branched toward the end side of control valve at the mid course from option spool (311) to
port Ao, but when N&B (Nibbler and Breaker) selector valve is provided on the end side of control valve, this
oil passage is used as passage to connect to N&B selector valve.
Oil passage to
N&B valve
Ao 511 Bo
LCo
311
604
56
330 329
PAo PBo
(D)
Fig. 24-42 Spool actuation for operation in option
24-46
(8) Lock valve operation

The lock valve is housed in between each port of the control valve connected to arm cylinder rod side (R) and
arm cylinder head side (H) and the arm spool and boom spool, and reduces the leaking due to holding pressure
caused by each cylinder.
1) At boom spool neutral position (Arm spool makes the same operation.)
When boom spool (301) is set to neutral position, spool (511) of lock valve selector is held on the left side
as shown in the figure. At this position, passages Sa and Sb are connected each other at the inside of
bushing (541) and on the perimeter of spool (511). Therefore in spring chamber (RH) of lock valve poppet,
the holding pressure receiving from boom cylinder head side (H) passes from passage Sa to bushing (541)
spool (511) and is connected through passage Sb, consequently the lock valve poppet (514) is kept pressed
the lower side as shown in the Fig. 24-51 and restricts the leaking to the minimum.
Lock valve selector
(a) (b) 541
Return oil from 511

boom cylinder head
CRb Sb PLc Dr
Ab 321
PLc Sa Sb Dr
RH CHAMBER
A A SECTION A-A
514
BH CHAMBER Sa
319
320
PBb
(D) Dr 301
Fig. 24-43 Lock valve operation (At boom spool neutral position)
24-47
2) In boom down operation ((In arm in operation)

Pilot pressure PBb for boom down operation acts on port PLc of lock valve selector, and the spool (511)
moves rightward as shown in the Fig. 25-52. After the spool (511) was moved, orifice (a) of bushing (541)
first closes and then passages Sa and Sb are blocked, and therefore the holding pressure receiving from
boom cylinder head side (H) does not act on spring chamber (RH) of lock valve poppet (514).
And after spool (511) was moved, the inside of bushing (541) is connected from port Dr to passage DR
through spring chamber (319).
With this actuation, spring chamber (RH) of lock valve poppet (514) is connected from orifice (b) of bushing
(541) to drain passage Dr through passage Sb, and the force which pushes lock valve poppet (514) down
as shown in the Fig. 24-52 is released. And since lock valve poppet (514) receives holding pressure from
boom cylinder head side (H) to the pressure receiving section in ring type which is made up of guide diameter
and seat diameter of lock valve poppet (514), and it is pushed upward and is open.
The said operation, in boom down operation, is performed before making the opening (meter out opening)
which is used to return the return oil from the boom cylinder head side of boom spool (301) to the tank open,
the operation has no effect on the operability of boom down operation.
In case of arm in operation, the same operation is performed because pilot pressure PAa1 of arm in acts on
lock valve selector port PLc2.
Lock valve selector
(a) (b) 541

Return oil from
boom cylinder head
511
Sb PLc Dr
CRb
Ab 321
RH CHAMBER PLc Sa Sb Dr
A A SECTION A-A
514
BH CHAMBER Sa
319
320
PBb
(D) Dr 301
Fig. 24-44 Lock valve selector operation (At boom down operation)
24-48
(9) By-pass cut valve

This by-pass cut valve is located on the most downstream of center by-pass passage (52) on P1 side and center
by-pass passage (55) on P2 side. And this by-pass cut valve controls the flow rate of hydraulic oil from each
center by-pass passage to low pressure passage (D).
1) In normal operation
On starting the engine, the secondary pressure of solenoid proportional valves [X1] and [X2] act on pilot
ports PBp1 and PBp2 of by-pass cut valve (605). This secondary pressure is the same as that actting on
pilot port PCb of P1 unloading spool (309) and pilot port PCa of P2 unloading spool (310).
The following explains the by-pass cut valve on P1 side, the operation of by-pass cut valve on P2 side is the
same. The secondary pressure of solenoid proportional valve [X1] enters PBp1 and plunger (301) moves
downward against the force of spring (302). The taper section at the top end of plunger (301) is seated on
the seat of plug (101), shutting off the spring chamber of poppet (201) and spring chamber (b) of plug (101).
The hydraulic oil from center by-pass passage (52) passes through the orifice of poppet (201) and enters
spring chamber (a) of poppet (201). Because spring chamber (a) of poppet (201) and spring chamber (b) of
plug (101) are disconnected, spring chamber (a) of poppet (201) is the same pressure as center by-pass
passage (52) and poppet (201) is pushed the seat section of casing shutting off center by-pass passage (52)
and low pressure passage (D).
Consequently, in normal operation, center by-pass passage (52) is always disconnected from low pressure
passage (D) and the hydraulic oil delivered by hydraulic pump P1 does not flow through center by-pass
passage (52), but returns to the hydraulic tank through P1 unloading spool (309).
[X1]
PBp1
301
302
(C) (b)
Dr
201 101
(D) (a)
52
Fig. 24-45 By-pass cut valve (In normal operation)
24-49
2) At the time when failure occurred

When the electric system is failed and consequently the secondary pressure of solenoid proportional valves
[X1] and [X2] is not produced, plunger (301) is moved upward by the force of spring (302). Since the taper
section at the top end of plunger (301) is lifted up from the seat section of plug (101), spring chamber (a) of
poppet (201) and spring chamber (b) of plug (101) are connected each other.
The hydraulic oil from center by-pass passage (52) passes through the orifice of poppet (201) and enters
spring chamber (a) of poppet (201). Because spring chamber (a) of poppet (201) and spring chamber (b) of
plug (101) are connected each other, the hydraulic oil in spring chamber (a) of poppet (201) passes through
from seat section of plug (101) to spring chamber (b) and flows into passage (Dr) through passage (c).
Consequently the pressure in spring chamber (a) of poppet (201) lowers, poppet (201) receives the pressure
of center by-pass passage (52) and is lifted up against the force of spring (202), and the hydraulic oil from
center by-pass passage (52) flows into low pressure passage (D) through poppet (201) of by-pass cut valve
(605). Therefore when the electric system is failed, P1 unloading spool (309) is shifted to the neutral position
and the passage to low pressure passage (D) is cut off, but because center by-pass passage (52) is
connected to low pressure passage (D) through by-pass cut valve (605), the abnormal rise of the pump
pressure is prevented.
PBp1
301
302
(C) (b)
Dr
101
201
(a)
(D)
202
52
Fig. 24-46 By-pass cut valve (In condition of failure)
24-50
(10)Boost check valve, By-pass check valve

1) Boost check valve
The boost check valve is located between low pressure passage (D) and tank port T1 and generates boost
pressure necessary for the low pressure passage.
a. In normal operation
The hydraulic oil from low pressure passage (D) moves the boost check valve (517) upward against the
force of spring (527), and returns to the hydraulic tank through tank port T1. At this time, the pressure
generated by spring (527) is used as the boost pressure for the low pressure passage.
528
527
T1
518
517
T2
(D)
Fig. 24-47 Boost check valve operation
24-51
2) By-pass check valve

Even if the pressure at tank port T1 goes up due to the sudden change of return flow rate, the by-pass check
valve actuates and prevents the pressure at tank port T1 from going up higher than the specified pressure,
and consequently the oil cooler and filter located between tank port T1 and the hydraulic tank are protected
from possible damage.
When the pressure at tank port T1 goes up to the pressure added by spring (528), by-pass check valve (518)
is pushed and opens against the force of spring (528), and the hydraulic oil in tank port T1 directly returns
to the hydraulic tank through tank port T2.
528
527
T1
518
517
T2
(D)
Fig. 24-48 By-pass check valve operation
24-52
24.1.2.3 CARTRIDGE TYPE SOLENOID PROPORTIONAL RELIEF VALVE FOR N&B
24.1.2.3.1 INSTALLATION OF CARTRIDGE TYPE SOLENOID PROPORTIONAL RELIEF VALVE

(1) Tools
TIGHTENING TORQUE
No. PARTS TOOLS
N•m (lbf•ft)
36mm
101 BODY 73.5±5 (54.2±3.7)
SPANNER and TORQUE WRENCH
PROPORTIONAL SOLENOID 32mm
801 15.7 (11.8)
(COIL FIXING NUT) SPANNER and TORQUE WRENCH
(2) Installation
Procedure Caution
1) When attaching cartridge to control valve, if the
cartridge can not be screwed in because connector of
solenoid valve interferes with the surrounding parts,
perform the procedure in the following items 2) ~ 4).
If no interference and so on is found, only procedure in
item 3) should be performed.
2) Hold the hexagonal section (Opposing flats: 36mm) of Do not remove nut, but only loosen.
body (101) and loosen coil fixing nut on the solenoid
(801) upper part for the coil section to be rotated freely.
COIL FIXING NUT
BODY (101)
3) Hold the hexagonal section (Opposing flats: 36mm) of Do not hold the parts other than body (101) for
body (101) and tighten it on the control valve. tightening.
Tightening torque: 73.5±5 N•m (54.2±3.7 lbt•ft)
4) Fit connector of solenoid valve to the proper position
and tighten coil fixing nut.
Tightening torque: 15.7 N•m (11.8 lbt•ft)
24-53
24.1.2.3.2 AIR BREATHING

(1) Tools
TIGHTENING TORQUE
No. PARTS TOOLS
N•m (lbf•ft)
PROPORTIONAL SOLENOID 17mm
801 23 (17)
(AIR BREATHING PLUG) SPANNER and TORQUE WRENCH
(2) Air breathing
Procedure Caution
1) Perform the operation in items 2) and 3) under the
condition where oil is flowing into control valve KMK
and consequently back pressure (R port pressure) is
produced.
2) Loosen air breathing plug of solenoid valve until the Be careful not to mistake it for pressure adjusting
hydraulic oil starts flowing out. screw fixing nut.
Air is flown out with hydraulic oil.

3) After hydraulic oil left flowing out for a while, tighten air
breathing plug.
Tightening torque: 23 N•m (17 lbt•ft)
24-54
24.1.2.3.3 OUTSIDE VIEW
M27x1.5
AIR BREEDER PLUG
WIDTH ACROSS FLATS 17 (1/2-20UNF-2B)
TIGHTENING TORQUE : 23N.m (17.6 lbf.ft)
MANUAL SCREW SEAL NUT

WIDTH ACROSS FLATS 12 (M6x1.0)
TIGHTENING TORQUE : 7.35 0.5N.m
(5.42 0.37 lbf.ft)
NUT
WIDTH ACROSS FLATS 32 (M22x1.5) WIDTH ACROSS FLATS 36 (M27x1.5)
TIGHTENING TORQUE : 15.7N.m TIGHTENING TORQUE : 73.5 5N.m
(11.6 lbf.ft) (54.2 3.7 lbf.ft)
USE THIS ACROSS FLATS FOR
WIDTH ACROSS FLATS 36 ATTACHING THIS VALVE TO THE CASING
TYPE OF CONNECTOR
EQUIVALENT TO AMP ECONOSEAL J SERIES
CONNECTORS MARK (+) CAP HOUSING
CAP HOUSING 174354-2

TERMINAL 173706-1
HYDRAULIC SYMBOL
SPECIFICATIONS
Working pressure range (Press. in port P) MPa (psi) 15~40 (2180~5800)
Max. working pressure (Press. in port T) MPa (psi) 1.0 (145)
Max. flow L/min (gal/min) 300 (79.3)
Rated current mA 700
Electrical specifications
Coil resistance 19.5 (at 20°C)
24-55
Across flats
for tightening 402
801 solenoid tube 701 403 202 401 204 304 305 102 303 301
assy
M22 X 1.5
1/2-20
M6 X 1.0
201 208 101 203 205 206 207 501 302 601
TIGHTENING TORQUE OF SOLENOID (801)
No. SIZE TIGHTENING TORQUE REMARKS
N.m (lbf.ft)
M16 X 1.0 44 (32.5) SOLENOID TUBE ASSY
M22 X 1.5 15.7 (11.6) COIL LOCK NUT
801
1/2-20 23 (17) AIR VENT PLUG
M6 X 1.0 7.35 0.5 (5.42 0.37) MANUAL SCREW SEAL NUT

No. Name Q’ty No. Name Q’ty
73.5±5 (54.2±3.7) 101 Body : M27×1.5 1 302 O-ring 1
102 O-ring 1 303 Back-up ring 1
110 (81.1) 201 Plug : M30×1.5 1 304 Spring 1
203 O-ring 1 401 poppet 1
204 Back-up ring 1 402 Spring 1
205 Filter 1 403 Spring 1
206 Filter stopper 1 501 Sheet 1
207 C-ring 1 601 Sheet 1
208 Sheet 1 701 O-ring 1
301 Plunger 1 801 Solenoid 1
24-56
24.1.3 PILOT VALVE (ATT)
24.1.3.1 OUTLINE
(1) Outside view
5-PF3/8
Single operating angle Single operating angle T=49.0 (36.1)
(Port 2, 4) (Port 1, 3)
The adjust nut

(opposing flats : 22) :
Fix adjust nut
(opposing flats : 22)
when the lever is installed by PF1/4
means of spanner or the like. T=29.4 (21.7)
Then tighten the mating lock
nut to 41 + 3 N.m (302.2 lbf.ft). T=Tightening torque
: N.m (lbf.ft)
VIEW A
Part No. YN30V00111F1

Model PV48K2004
Operating torque Refer to the curve below
Max. primary pressure 6.9 MPa (1000 psi)
Primary pressure 5.0 MPa (725 psi)
Rated flow 20 L/min (5.3gal/min)
Weight Approx. 1.9 kg (4.2 lbs)
A
PORT 1, 3 PORT 2, 4
(580)4.0 4.0(3.0) (580)4.0 4.0(3.0)

Secondary pressure [MPa (psi)]
Secondary pressure [MPa (psi)]

Operation torque [N.m (lbf.ft)]
Operation torque [N.m (lbf.ft)]

(464)3.2 (464)3.2
(435)3.0 3.0(2.2) (435)3.0 3.0(2.2)
SINGLE OPERATING TORQUE SINGLE OPERATING TORQUE
2.21(1.63) 2.29(1.69)
(290)2.0 2.0(1.5) (290)2.0 2.0(1.5)
SECONDARY PRESSURE SECONDARY PRESSURE
(145)1.0 1.0(0.74) (145)1.0 1.0(0.74)

0.94(0.69) 0.94(0.69)
(87)0.6 (87)0.6
0 0 0 0
0 1.1 2 4 6 7 0 1.12 4 6 8 9.4
PUSH ROD STROKE (mm) PUSH ROD STROKE (mm)
0 5 10 15 19 0 5 10 15 20 25
Operating angle (deg.) Operating angle (deg.)
P T
1 3 2 4
HYDRAULIC SYMBOL
24-57
24.1.3.2 CONSTRUCTION
Apply Loctite #277

312
302
501 Apply grease on
301 rotating and sliding sections.
Be careful the
Apply grease on top section
assembling direction
212
213
151
*246
*218-2
211
214
*218-1
216-2 216-1
241-2 241-1
201-2
Secondary 201-1
pressure 217
adjusting shim
101 221
PORT 2,4 PORT 1,3
Fig. 24-49 Pilot valve (ATT)
torque No. Name Q’ty torque No. Name Q’ty
101 Casing 1 *218-1 Seat 2
151 Plate 1 *218-2 Seat 2
201-1 Spool 2 221 Spring 4
201-2 Spool 2 241-1 Spring 2
211 Plug 4 241-2 Spring 2
212 Push rod 4 *246 Spring 4
213 Seal 4 47.1 (34.7) 301 Joint : M14 1
214 O-ring : 1B P20 4 302 Circular plate 1
216-1 Spring seat 2 68.6 (50.6) 312 Adjust nut : M14 1
216-2 Spring seat 2 501 Boots 1
217 Washer 2 (Shim) 4
Note) The parts marked * may not be equipped depending on valve type.
24-58
24.1.3.3 OPERATION
(1) Lever in neutral (See Fig. 24-50)
The action of spring (509) (for secondary pressure
setting) that determines the output pressure of the
pilot valve does not act upon spool (201).
Therefore, spool (201) (for return) is pushed up by
spring (221) [spring seat (216)]. The output ports
(2,4) connect with the T port. The result is that the
output pressure is equal to the tank pressure.
216
509
221
201
PORT (2,4) PORT (1,3)
Fig. 24-50 Lever in neutral

(2) When the pilot lever is tilted (See Fig. 24-51 )
When the lever is tilted and the push rod (511)
strokes, the spool (201) [spring seat (216)] moves
downward to make the port P to connect with the
port 2, 4, with the result that the oil of the pilot pump
flows to the port 2 ,4 to produce a pressure.

Fig. 24-51 When the lever is tilted
(3) Lever held (See Fig. 24-52)
When the pressure at ports (2,4) rises to a level
equivalent to the action of spring (509) that is set by
tilting the lever, the hydraulic pressure balances the
spring action. When the pressure of ports (2,4)
rises above a set value, ports (2,4) and the P port
close while ports (2,4) and the T port open. When
the pressure at ports (2,4) falls below a set value, 509
ports (2,4) and the P port open while ports (2,4) and
the T port close. Thus the secondary pressure is
T PORT
kept constant.
P PORT
PORT (2,4) PORT (1,3)

Fig. 24-52 When the lever is held
24-59
(4) Operation in the area where the tilting angle of the

lever is large.
(varies with the model)
If the lever is inclined beyond a certain angle on
certain models, the top end of the spool contacts
the bottom of the bore of the push rod. This keeps
the output pressure connected with the P port
pressure.
Furthermore, on a model in which a spring seat and
a spring are built in the push rod, the bottom of the
bore of the push rod contacts the spring if the lever
is turned beyond a certain angle. This causes the
secondary pressure gradient to change by the
spring action. Thereafter, the bottom of the bore of
the push rod contacts the top end of the spring seat,
keeping the output pressure connected with the P
port.
24-60
24.1.4 PILOT VALVE (TRAVEL)
24.1.4.1 OUTLINE
(1) Outside view
Tightening torque
Port size N.m (lbf.ft) Port name Function
1 LH travel forward port
2 LH travel reverse port
PF3/8 30 (22) 3 RH travel forward port
4 RH travel reverse port
T Tank port
5 LH travel pressure sensor port
PF1/4 16.7 (12.3) 6 RH travel pressure sensor port
P Pilot primary pressure port
(2) Specifications
P T
Item Specifications
Part No. YN30V00105F1
Type 6TH6NRZ
Primary pressure 4.9MPa (711psi)
Secondary pressure 0.54~2.35MPa (78~341 psi)
Rated flow 25 L/min (6.6 gal/min)
Weight Approx. 8kg (18 lbs)
1 5 2 3 6 4
Hydraulic symbol
(3) Performance characteristics

Secondary pressure
[MPa (psi)] Secondary pressure
2.35 + 0.15
(340 + 22)
0.54 + 0.1
(78 + 15) 0
1 30' 11 30' Pedal angle (degree)
(4.7 + 0.5) 2 30' 12 30'
6.4 + 0.64
7.7 + 0.77
(5.7 + 0.6)
12.7 + 1.27
(9.4 + 0.9)
Operating Operating torque
torque
[N.m (lbf.ft)] Control diagram
24-61
24.1.4.2 Construction and operation

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

T line
24-62
24.1.5 SWING MOTOR UNIT
24.1.5.1 SPECIFICATION
(1) General view
PB L,IP DP Port
Symbol Port name
size
THREAD FOR
EYE BOLT 2-M10 A,B Main port PF1/2
B DEPTH 18
DB Drain port PF3/8
GN C Make-up port PF3/4
PA PA,PB Pressure measuring port PF1/4
C PG Parking brake release port PF1/4
L Level gauge PF3/4
IP Filling port of gear PF3/4
PG DP Outlet port of gear oil PF1/2
A
DP2 Outlet port of gear oil PF1/2
AN C Dr GN Inlet povt of grease PF1/4
A,B
AN Air vent port PF1/4
PG
IP
DP2
B A
DP PB PA
AN Safety relief valve

C
DB
GN PG
Hydraulic diagram
24-63
(2) Specifications
Swing motor unit part No. YY15V00016F1

Type M2X63CHB-13A-36/285-60
Part No. YY15V00018F1
Hydraulic motor
Displacement cm (in ) / rev

3 3
60 (3.66)
Rated pressure MPa (psi) 28.0 (4060)
Braking torque N•m (lbf•ft) 314 (232)
Release pressure MPa (psi) 2.3 (334)
Relief set pressure MPa (psi) 28.0 (4060) at 110L/min (29 gal/min)
Weight kg (lbs) 29 (64)
Type RG06D19J2
Part No. YY32W00004F1
Reduction unit
Lubicate oil Gear oil SAE#90~#140 (API class GL-3~4 grade)

Lubicate oil volume L (gal) 1.65 (0.44)
Grease Extreme pressure lithum base #2 grease
Grease volume cm (in )
3 3
500 (30.5)
Total weight kg (lbs) 113 (249)
24-64
24-65
(1) Swing motor
992
451 452
303 131 444
b
A
351
355 SECTION A-A
051
401
488 469 (051-1)
468
106 487 444 433 981 390 438 452 980
391
Tightening forgue
303
472 Tightening Widfh
No. Size torque
across flat
451 . .
N m (lbf ft)
707
712 051 M33X1.5 177(131) 41
A 706
A 401 M16 240(177) 14
131
982
468 G1/4 36(27) 6
702
114 469 M22X1.5 108(80) 10
111
117 980 G3/8 1.7(1.3) 6
743 981 G3/4 4.4(3.2)
121 14
742 982 G1/4 0.9(0.66) 6
113
992 PT3/4 98(72) 14
123
116
117
301
432 471 443 106 101 491 304 437 124 122
24-66
101 Drive shaft 1 443 Roller bearing 1
106 Spacer 3 444 Roller bearing 1
111 Cylinder 1 451 Pin 2
113 Retainer (spherical bushing) 1 36 (27) 468 Plug : PF1/4 2
114 Cylinder spring 1 108 (80) 469 Plug : M22 2
116 Push rod 12 471 O-ring : 1B G80 1
117 Spacer 2 472 O-ring 1
121 Piston 9 487 O-ring : 1B P11 2
122 Shoe 9 488 O-ring : 1B P20 2
123 Set plate 1 491 Oil seal 1
124 Shoe plate 1 702 Brake piston 1
131 Valve plate 1 706 O-ring 1
301 Casing 1 707 O-ring 1
303 Casing 1 712 Brake spring 20
304 Front cover 1 742 Friction plate 3
351 Plunger 2 743 Separator plate 4
355 Spring 2 1.7 (1.2) 980 Plug : PF3/8 1
240 (177) 401 Socket bolt : M16×75 4 4.4 (3.3) 981 Plug : PF3/4 1
432 Snap ring 2 0.9 (0.6) 982 Plug : PF1/4 1
433 Ring 1 98 (72) 992 Plug : PT3/4 1
437 Snap ring 1 177 (131) 051 Relief valve : M33 2
438 Snap ring 1 051-1 O-ring : 1B G30 2
24-67
(2) Anti-reaction valve
171 101
401 (401-2) (401-1)
B
B1
A
A1
C C
151 161 A1,B1
SECTION C-C
Tightening torque
Tightening Widfh
No. Size torque
across flat
N.m (lbf.ft)
151 NPTF 1/16 9 (6.6) 4

171 M8 29 (21) 6
401 M22X1.5 69 (51) 24
Fig. 24-53
Tightening
torque No. Parts Q’ty
N•m (lbf•ft)
101 Casing 1
9 (6.6) 151 Plug : NPTF1/16 4
161 O-ring : 1B P22 2
29 (21) 171 Socket bolt : M8×60 6
29 (21) 401 Swing reactionless valve : M22 2
401-1 O-ring : 1B P20 2
401-2 Back-up ring 2
24-68
(3) Swing reduction unit
602 230 231 204 286 211 912 285 287 911 283 403 603 922
210
921
282
202
*
203
913
285
*
402
910
801
925
920
390
926
102
401
Apply Three Bond #1217 on . 915
201

102 Casing 1 402 Roller bearing 1
201 Pinion shaft 1 403 Needle bearing 3
202 Ring gear 1 98 (72) 602 Socket bolt : M12×100 8
203 No.2 planetary gear 4 603 Socket bolt : M12×135 2
204 No.2 sun gear 1 801 Oil seal 1
210 No.1 planetary gear 3 910 Spring pin 4
211 No.1 sun gear 1 911 Retaining ring 3
230 No.2 spider 1 912 Retaining ring 1
282 No.2 pin 4 915 Seal 1
283 No.1 pin 3 65 (48) 920 Adapter : PT1/2 1
285 Side plate t=1 7 108 (80) 921 Hose : PF1/2 1
286 Thrust washer t=2 1 108 (80) 922 Plug : PF1/2 1
287 Side plate t=2 3 925 relief fitting 1
401 Roller bearing 1 926 Grease nipple : PT1/4 1
24-69
24.1.5.3 OPERATION
24.1.5.3.1 OPERATION OF HYDRAULIC MOTOR

If the high pressure oil flows into the cylinder

through the inlet port (a) of valve plate (131), as
shown in the right figure, the hydraulic pressure
acts upon piston (121) and generates force F in the
axial direction.
The force F may be divided into force F1 vertical to
shoe plate (124) via shoe (122) and force F2 at right
angle with the shaft.
The force F2 is transmitted to cylinder block (111)
via pistons (121) and causes drive shaft to turn so
as to generate a rotation moment.
The cylinder block (111) has nine pistons equally
arranged. Rotation torque is transmitted to the drive
shaft by turns by pistons connected to inlet port of
high pressure oil. If the oil supply and discharge
directions are reversed, the drive shaft rotates in

the opposite direction.
Theoretical output torque T can be given by the
following equation. Low pressure oil High pressure oil
T= 2P XX q Pq ;; Effective differential pressure MPa
Displacement per revolution cc/rev
OUTLET INLET (a)
Fig. 24-54 Operation of hydraulic motor
24.1.5.3.2 VALVE CASING SECTION

(1) Operation of anti-cavitation check plunger
Because the motor of this type does not equip a
counterbalance valve, this motor may be rotated 351
beyond the oil feed.
To avoid cavitation due to the lack of oil feed, the
check valve (351) is equipped and the lack of oil is
made up.
C port
(Make-up port)
Control valve
Fig. 24-55 Operation of anti-cavitation check

plunger
24-70
(2) Operation of relief valve

Area A1 Orifice m Spring (321) Piston (303) Area A2
1) Operation during pressurizing Chamber g Dumping
chamber h
1. The pressure at the P and R ports are equal to
the tank pressure at the beginning as shown
P
inFig. 24-56.
R
Plunger (301) Area A3 Spring (322)
piston (302) Spring chamber
Fig. 24-56
2. Condition shown inFig. 24-57
m Spring (321) Pin (303) Area A2
When the P port is pressurized, a pressure is Chamber g Dumping chamber h
built up in the chamber g via the orifice m of
plunger (301). This pressure acts upon the
P
pressure-receiving area (A2 – A3) of the
piston (303) and generates the force which
pushes the piston rightward. And the piston R Area A3 Spring (322)
begins to move rightward when the pushing Plunger (301) Spring chamber
force balances with the spring (322) force. The
Fig. 24-57
pressure is called Pg1 at this point. The
pressure in the chamber g is kept the constant
pressure (Pg1) while the piston (303) is
moving rightward.
In this case, the relief pressure (P1) is
expressed as:

3. Condition shown inFig. 24-57

While the piston (303) is moving rightward, the
oil in the dumping chamber (h) is discharged
from the periphery slit of the piston (303) to the
R port.
In the middle of the rightward moving, the
function of dumping becomes stronger and
the pressure of chamber g rises gradually,
because the periphery slit of piston (303)
becomes smaller as the piston (303) moves
rightward.
As the equation (1) indicates, while the
pressure Pg1 is rising, the relief pressure (P1)
rises too.
24-71
4. Condition shown inFig. 24-58 m Spring (321) Pin (303) Area A2

Chamber g Dumping
After the piston reached to the stroke end, the chamber h
pressure of chamber g equals the pressure of
P port.
P
In this case, the relief pressure (PS) is
expressed as:
R
FSP1 Area A3 Spring (322)
PS = (2) Spring chamber
A1 A2 Plunger (301)
In the process of above mentioned paragraph Fig. 24-58
1 to 4, the relief pressure changes according
toFig. 24-59
2) Operation during pressure reducing
Relief pressure
After the pressurizing force against P port is
reduced to zero, the plunger (301) is pushed with
spring (321), and seated on seat. And the piston
(303) moves leftward by the force of the spring
(322). At this time, the oil is supplied immediately
from the R port to the dumping chamber (h) via
the periphery slit. And the piston (303) moves
Time
leftward promptly. As a result, the relief valve
Fig. 24-59 Relief valve operation diagram
returns to the initial condition.
(3) Operation of anti-reaction valve
ANTI REACTION
VALVE
ANTI REACTION
VALVE
Fig. 24-60 Hydraulic circuit diagram for anti-

reaction valve
1) Neutral condition
Fig. 24-60explains the relationship between the
neutral condition of the anti-reaction valve and
the hydraulic circuit. Now, let us consider a L
braking condition of the AM port.
k
322 313 321 311
Fig. 24-61 Neutral condition
24-72
2) When brake pressure occurs m n

If the pressure (P) is generated at the AM port, it
flows through the passage, the hole on the shaft
of seat (313), and the passage m of the plunger P=PS
(311). And the oil is led to the chamber n.
When the pressure P rises above the value (PS) L
set by spring (321), the plunger (311) pushes the
spring (321) and moves leftward.
322 313 321 311
The seat (313) is pushed with the plunger (311),
Fig. 24-62 When brake pressure occurs
and pushes a weak spring (322). As a result, the
seat (313) moves to left.
3) When anti-reaction valve is actuating p t
When an inertia load stops moving (Point Y
inFig. 24-64, a brake pressure (P) tries to fall.
When Ps becomes larger than P, the plunger P<PS
(311) moves towards the right return direction.
L
Seat (313) tries to move rightward by the action
of the spring (322). But the return of the seat k
makes a time delay with regard to the return of
322 313 g r 321 311
the plunger because the chamber p provides
Fig. 24-63 When anti-reaction valve is actuating
damping function by orifice g. Consequently, the
t of seat opens. This makes a passage of
connecting the both AM and BM ports of the
hydraulic motor, and the oil flows through L, t, r,
and k in order. As a result, the pressures at the
AM and BM ports become same pressure (PB)
rapidly, and the pressure changes to point Z Fig.
24-64.This prevents the swing motor stop
reaction which is caused by the closing pressure
of the AM port. Fig. 24-64 Pressure change diagram of anti-
reaction operation
24.1.5.3.3 OPERATION OF BRAKE

The cylinder (111) is jointed through the drive shaft

(101) and a gear. The rotation of separator plate (743)

is restricted in its circumferential direction by circular
grooves provided in the casing (301).
If the friction plate (742) restricted to the outer
circumference of the cylinder is pressed against the
casing (301) via the separator plate (743) and the brake
piston (702) by the force of the brake spring (712), the
frictional force is generated between the friction plate

(742) and the casing (301) and between the separator
plate (743) and the brake piston (702). This frictional
force restricts the drive shaft and applies the brake.
Fig. 24-65 Operation of brake chamber
In the meantime, when the brake release pressure
applied to the oil chamber formed between the brake
piston (702) and the casing (301) overcomes the spring
force, the brake is released as the brake piston (702)
moves until the friction plate (742) is separated from the
casing (301).
24-73
24.1.5.3.4 SWING REDUCTION UNIT

The transmitted power from swing motor drive shaft is

transmitted to the No.2 sun gear (204) of the 2nd stage
through No.1 sun gear (211) and No.1 carrier (231) of
1st stage.
Similarly, the power of No.2sun gear (204) is
transmitted to the drive shaft (201) through the No.2
carrier of 2nd stage.
The drive shaft (201) is supported in the casing (102) by

the two bearings (401) (402). To protect the bearings
from the metal powder of gear abrasion, the oil seal
(801) is equipped at the center of casing (301) because
the bearings are exposed to heavy load. And the

chamber A is lubricated with the inner oil of the ring
gear (202), the chamber B is lubricated with packed
grease.

Fig. 24-66 Operation of REDUCTION UNIT
24-74
24.1.6 TRAVEL MOTOR
24.1.6.1.1 General view
18-M16 X P2.0 Mounting surface of sprocket

20-M16 X P2.0
Oil filling port
(PF1/2)
A PF3/4
Oil level
D PF1/2 check port
(PF1/2)
Y Z
X
B PF3/4
Oil drain port
(PF1/2)
Oil filling port

P PF1/4 (PF1/2)
Oil level check port
(PF1/2)
VIEW Y
DIRECTION INLET OUTLET

(VIEW X) PORT PORT
CLOCK WISE A B Oil drain port
C . CLOCK WISE B A (PF1/2)
VIEW Z
Fig. 24-67 Travel motor (with reduction unit and brake valve)
24.1.6.1.2 SPECIFICATIONS
Part No. YY15V00015F1

Item
Type GM21VA-A-45/76-2
Revolution min-1 51.4/31.3
reduction unit Lubricant oil Gear oil SAE#90 GL4
Lubricant oil valume L (gal) 2.1 (0.55)
Max. displacement cc (cu•in)/rev 44.9/75.5 (2.74/4.61)
Max. speed min-1 2777/1688 (2nd/1st)
Hydraulic motor
System pressure MPa (psi) 34.32 (4976)
2 speed changeover
MPa (psi) 1.96~6.86 (284~995)
pressure
Brake torque N•m (lbf•ft) 206 (152)
Parking brake
Release pressure MPa (psi) 0.76 (110)
24-75
(1) Outline
HIGH LOW
SPEED SPEED 2-SPEED
CHANGE
PISTON
PARKING
BRAKE
REDUCTION 2-SPEED
UNIT CHANGE
PISTON
HYDRAULIC MOTOR
BRAKE VALVE
PARKING BRAKE
HIGH AND LOW SPEED SHOCKLESS
CHANGE MECHANISM RELIEF
LOAD CHECK VALVE KIT
VALVE
&
CONTROL VALVE ANTI
CAVITATION
VALVE
BREKE
VALVE
HYDRAULIC PUMP
HYDRAULIC CIRCUIT DIAGRAM
Fig. 24-68
24-76
24-77
(2) Hydraulic motor
116
115
135
324 112
336 139
328 109
325
326 341
331 377
354
327 301
330
380 383358
352 113
353 150
329
398 376
396 358 352 343 323

327
353
358 352
381 383
380 379
366 330
398 378 331
363 399 398 326
359 208 201 325
357 384 210
208 207 328
210
209 336
324
212
203
103
204 202
106
105
213 206
211 107
205
108
151
104
110
114
110
145 132
149
102
171
167
185
161
162
Fig. 24-69
24-78
No. NAME Q'TY No. NAME Q'TY No. NAME Q'TY

102 Shaft 1 185 Spring 1 341 Parallel pin 1
103 Swash plate 1 201 Valve seat 1 343 Socket bolt 10
104 Cylinder block 1 202 Valve 1 352 Plug 3
105 Piston 1 203 Sleeve 1 353 Ball 2
106 Shoe 1 204 Collar 1 354 Plug 5
107 Retainer plate 1 205 Plug 1 357 Plug 1
108 Thrust ball 1 206 Spring 1 358 O-ring 3
109 Timing plate 1 207 O-ring 1 359 O-ring 1
110 Washer 2 208 Back-up ring 2 363 Spool 1
112 Piston 1 209 O-ring 1 366 Spring 1
113 Spring 10 210 Back-up ring 2 376 Orifice 1
114 Spring 1 211 O-ring 1 377 Filter 1
115 Friction plate 3 212 O-ring 1 378 Ball 1
116 Separator plate 4 213 Shim 1 379 Plug 1
132 Oil seal 1 301 Rear flange 1 380 Plug 2
135 O-ring 1 323 Spool 1 381 Piston 1
139 O-ring 1 324 Plug 2 383 O-ring 2
145 THS snap ring 1 325 Washer 2 384 Orifice 2
149 Bearing 1 326 Plug 2 396 Plug 2
150 Bearing 1 327 Valve 2 398 Plug 8
151 Needle roller 3 328 Spring 2 399 Name plate 1
161 Piston 1 329 Orifice 2
162 Shoe 1 330 Spring 2
167 Pivot 2 331 O-ring 2
171 Parallel pin 2 336 O-ring 2
24-79
(3) Reduction unit
22 24
29
24
29
23
2
33
34 32 35
14
13
4
36
15
6
3 16
8
10
717
31 30
11
27
5
11
12
28
9
12
Fig. 24-70

1 Hub 1 16 Parallel pin (1) 3
2 Spindle 1 17 Parallel pin (2) 3
3 Spider (1) 1 22 Lock washer 2
4 Sun gear (1) 1 23 Shim 1
5 Planetary gear (1) 3 24 Bearing 2
6 Pin (1) 3 27 Needle bearing 3
7 Spider (2) 1 28 Needle bearing 3
8 Sun gear (2) 1 29 Floating seal 2
9 Planetary gear (2) 3 30 Plug 3
10 Pin (2) 3 31 O-ring 3
11 Thrust washer (1) 6 32 O-ring 1
12 Thrust washer (2) 6 33 O-ring 2
13 Thrust plate 1 34 Parallel pin 2
14 Cover 1 35 Socket bolt 12
15 Coupling 1 36 Snap ring 1
24-80
24.1.6.3 OPERATING DESCRIPTION
24.1.6.3.1 REDUCTION GEAR

(1) Function
This reduction gear unit is composed of two stage
planetary gear mechanism. The reduction gear
reduces the high speed of hydraulic motor and
converts it low-speed, high-torque rotation.
(2) Operating Description
The rotation of hydraulic motor shaft is transmitted
to sun gear (4) of the first stage which is linked with
shaft (102) in spline.
At that time, the hub (1) is rotated by the rotation of
the planetary gears (5). The hub (1) rotation is
transmitted to carrier (3) which connected to
planetary gears (5), and that causes sun gear (6)
rotation of the second stage.
The rotation of sun gear (6) is transmitted to the hub
via three planetary gears (7) of the second stage.
The generated rotation of reduction gear is output
Fig. 24-71
rotation.
24-81
24.1.6.3.2 HYDRAULIC DRIVES

(1) Function
1) Hydraulic Motor
This hydraulic motor is a swash plate type axial
piston motor, converting the hydraulic force from
the pump to rotary motion.
2) Brake Valve
a) Controls inertia when stopping the hydraulic
motor, in order to provide smooth stopping.
b) Prevents runaway rotation when the hydraulic
motor is rotated by external force.
This is done by preventing hydraulic
cavitation.
c) Prevents the generation of abnormally high
pressure when the hydraulic motor is stopped
suddenly.
3) Parking Brake
The parking brake prevents the hydraulic motor
from being rotated by external force while
stopped. A friction plate type mechanism is used,
constructed so as to form one unit with the
hydraulic motor.
4) High-Low 2-Speed Switching Mechanism
Switches the hydraulic motor between high
speed rotation with low torque, and low speed
rotation with high torque.
(2) Operating Principles and Description
1) Hydraulic Motor
Hydraulic fluid fed from the hydraulic pump
enters the GM motor through the rear flange
(101), passes through the brake valve and timing
plate (109) and enters the cylinder block (104).
This hydraulic fluid is fed only into one side of a
line connecting the upper and lower dead points
(Y1-Y2) of the piston stroke (105). The hydraulic
fluid pushes each of the pistons (105), creating
force F(=P×A). This force operates on the
Fig. 24-72
oblique surface of the swash plate (103). Force
F is separated into components F2 and F3
according to the angle of the oblique surface.
Of the two components, the radial component
force F3 generates torque (=F3×ri). The sum of
the torque T(= (F3×ri) of each of the pistons
(105) is the rotary force of the hydraulic motor.
This rotary force passes through the pistons
(105) and rotates the cylinder block (104) and
the shaft (102).
Fig. 24-73
24-82
2) Brake Valve
a) Operation (Brake released)
The pressure oil is led to through port (A),
opens valve (327), and led to port (C) on the
section side of hydraulic motor to rotate
hydraulic motor.
At the same time, the pressure oil enters
chamber (a) through orifice (329), and exerts
on the end of spool (323) to generate the
force. Then the force of spring (328) slides the
spool (323) placed on the neutral position
leftward.
The sliding of spool (323) forms the space
(passage) between spool (323) and rear
flange (301) with spool groove.
This passage is connected to port (D) and port
(B) of the return circuit of the hydraulic motor,
and the returns oil returns to tank side,
enabling hydraulic motor to rotate.
Fig. 24-74
Then, the sliding of spool (323) leads pressure
oil to port (E). The pressure oil led to port (E)
moves piston (112) of parking brake, and
releases parking braking force. (For details,
refer to item "Parking brake".)
If pressurized oil is supplied from port (B), the
movements of spool (323) and valve (327) are
reversed so that the hydraulic motor is rotated
reversely.
b) Self-traveling
While machine is being operated, as the travel
speed is increased due to steep slope, the oil
flow rate of the hydraulic motor is higher than
the supply flow rate of the hydraulic oil pump.
The rotation of the hydraulic motor in this case
is called a self-traveling. (Overrun) While self-
traveling, the pressure is lowered similar to the
stopping condition. Then brake valve is
moved similar to the stopping condition,
throttles passage in the return side of
hydraulic motor, and generate backing
pressure.
In addition, the force of inertia decreases the
revolution of hydraulic motor to revolution
having a balance with the supply flow rate of
pump.
Fig. 24-75
24-83
c) Stop / Stall (Braking Operation)

If pressurized oil supply through the port (A) is
suspended while traveling, the hydraulic force
to push up the spool (323) is lost, and the
spool (323) which is slid to left side, tries to
return to the neutral position due to the spring
(328) force. At that time, through the oil in the
chamber (a) tries to flow out to the port (A)
side through the orifice (329), its flow is
restricted and some back pressure is
generated by the throttle effect in the orifice
(329) controlling the return speed of the spool
(323). At the same time, the hydraulic motor
tries to rotate with its inertia force even though
the pressurized oil is suspended, and the
return oil from the hydraulic motor tries to
return to the port (B) side from the port (D)
through the passages on spool groove and
rear flange (301).
When the spool (323) entirely return to neutral Fig. 24-76
position, the passage on the hydraulic motor
of the oil return side is completely closed by
the spool (323), and the hydraulic motor
ceases its rotation. While machine working,
the brake valve smoothly stops rotation of-the
hydraulic motor which tries to rotate with its
inertia force, by means of throttling the return
side passage of the hydraulic motor,
generating back pressure due to shape of the
spool groove and controlling the return speed
of the spool.
On the other hand, when braking is operated,
the hydraulic motor tries to rotate with its
inertia force and to intake oil with its pumping
function. However, because the intake side is
closed its passage with the spool (323), the oil
supply is suspended. This causes cavitation in
the hydraulic motor. To prevent the cavitation,
the valve (327) is operated by very slight
negative pressure to open the passages of
port (A) side and intake port (C) of the
hydraulic motor.
And when pressurized oil is supplied through
the port (B), each motion of the mentioned
parts above becomes symmetrical right and
left to stop the hydraulic motor.
24-84
3) High-Low 2-Speed Switching Mechanism

a) Low Speed
When the pilot pressure is not supplied
through the port (P), the valve (363) is pushed
up to the upper position due to the spring
(366) force and pressurized oil through the
port (A) or (B), the pressurized oil is cut off at
port (C), and oil in the chamber (W) is

released into the drain (motor case) through Fig. 24-77
the valve (363).
Accordingly, the tilt angle of the swash plate
(103) becomes the maximum 1 resulting the
maximum stroke volume and low speed
rotation of the hydraulic motor.
b) High Speed
When the pilot pressure is supplied through
the port (D), it defeats the spring (366) force
and pressurized oil through the port (A) or (B)
to push down the valve (363) to lower position,
the pressurized oil at the port (C) is led to the
chamber (P) through the valve (363), and the
piston (161) pushes the swash plate (103) up

to the plane X and maintain it at its position.
Fig. 24-78
At that time, the tilt angle of the swash plate
becomes the minimum 2 resulting the
minimum stroke volume and high speed
rotation of the hydraulic motor.
c) Automatic shifting to low speed during high
speed operation
If the load is increased while high speed
operation, the oil pressure at the port (A) or (B)

is also increased. And when the oil pressure
reaches to specified pressure, it excesses the
pilot pressure, and the valve (363) is pushed
up to upper position, and oil in the chamber

(W) is released into the drain (motor case)
Fig. 24-79
through the valve (363).
At that time, the swash plate (103) gets touch
with the plane Y of spindle, and the tilt angle of
swash plate (103) becomes the maximum 1
and is maintained at its position resulting low
speed rotation.
24-85
24-86
24.1.7 SWIVEL JOINT
24.1.7.1 GENERAL VIEW
VIEW Y
VIEW Z
Fig. 24-80 General view of swivel joint
Item Specifications
Assy parts No. YN55V00053F1
Working pressure 34.3 MPa (4970 psi)
High pressure ports
Max. impact pressure 51.5 MPa (7470 psi)
A, B, C, D
Rated flow 255 L/min (67 gal/min)
Low pressure ports Working pressure 0.5 MPa (73 psi)
E Rated flow 50 L/min (13 gal/min)
Low pressure ports Working pressure 5 MPa (725 psi)
H, I Rated flow 30 L/min (8 gal/min)
Revolution speed 15 min-1 (15 rpm)
A, B, C, D (Body) PF1
A, B, C, D (Stem) PF3/4
Ports size
E PF1/2
F PF1/4
Length : L 368 mm (14.5")
Weight 25 kg (55 lbs)
24-87
2 places Apply Three Bond

#1805 to stem
2 places
VIEW Y
5 places
Tightening torque
30.4 N.m (22.4 lbf.ft)
Apply Loctite #242
SECTION HH
Tightening torque
30.4 N.m (22.4 lbf.ft)
Apply Loctite #242
Fig. 24-81 Construction
No. Name Q’ty No. Name Q’ty

1 Body 1 7 O-ring (G95 1A) 1
2 Stem 1 8 Capscrew (M8×20) 2
3 Thrust plate 1 9 Capscrew (M8×30) 3
4 Cover 1 12 Plug 1
5 Seal 5 13 O-ring 1
6 Seal 1
24.1.7.4 OPERATION
The swivel joint consists mainly of body (1) and stem (2) that rotate mutually, thrust plate (3) preventing both
components from falling off, cover (4) closing one side of body (1), seal (5) that partitions off the circuits and seal
assy (6) and O-ring (7) that prevent external leaks.
Four ports for the travel main circuits are provided on body (1) and stem (2). Further, four oil passing grooves are
arranged in the inner surface of body (1), with seal (5) fixed above and below the circumferential groove.
The body (1) and the stem (2) rotate mutually. The oil flowing in from body (1) or stem (2) keeps on flowing to stem
(2) or body (1) past the circumferential groove between body (1) and stem (2) ; the oil flow is never shut off because
of rotation. Further, an oil groove for lubrication that connects with the drain port is provided, in order to prevent the
body (1) from seizure with the stem (2).
This construction keeps on connecting the circuits between the swing bodies by means of a swivel joint.
24-88
24.1.8 CYLINDER
(1) General view
B A
n gth gth
n
d le d le
de te
xten rac
ly e et
Fu
l l ly r
Fu
Part No. and Manufacturing No.

Stamp position
Fig. 24-82 General view of cylinder

(2) Specifications
Unit : mm (ft-in)
Center distance of pins

Part No. of Cylinder bore / Dry weight
Use Stroke Full extend B / Full Cushion
cylinder assy Rod Dia. kg (lbs)
retract A
ø100 / ø70 1,092 2,648 / 1,556 With cushion on
Boom YY01V00053F1 101 (223)
(3.94" / 2.76") (3-7) (8-8.3 / 5-1.3) rod side
ø115 / ø80 1,120 2,835 / 1,715 With cushion on

Arm YY01V00054F1 148 (326)
(4.53" / 3.15") (3-8.1) (9-3.6 / 5-7.5) both sides
ø95 / ø65 903 2,293 / 1,390 With cushion on

Bucket YY01V00055F1 98 (216)
(3.74" / 2.56") (2-11.6) (7-6.3 / 4-6.7) rod side
24-89
24.1.8.2 CONSTRUCTION AND FUNCTION
(1) Boom cylinder
T= Tightening torque ; N.m (lbf.ft)
(3.54"-0.012 )
(3.15"-0.012 )
2 4-M10 P1.5 TAP DP 17 MIN
0
26 4 25 2
0
90 -0.3
80 -0.3
0
0
T=206~216 (152~159)
Apply Loctite #242 T=14.7(10.8)
T=981 (724) T=1860 (1372) Apply Loctite #242
11 9,10 8 24 6 7 5 14 12,13 3 1 15 16 19 18 17 20,21 22 23 2 PT1/8
PT1/4
Fig. 24-83 Construction of boom cylinder
P/No YY01V00053F1
No. PARTS Q’ty No. PARTS Q’ty No. PARTS Q’ty
1 CYLINDER TUBE 1 10 BACKUP RING 1 19 DUST RING 1
2 PIN BUSHING 1 11 DUST WIPER 1 20 O-RING 1
3 PISTON ROD 1 12 O-RING: 1B G95 1 21 BACKUP RING 2
4 PIN BUSHING 1 13 BACKUP RING 1 22 PISTON NUT 1
5 ROD COVER 1 14 O-RING: 1B G100 1 23 SETSCREW: M8×16 1
6 BUSHING 1 15 CUSHION RING 1 24 SOCKET BOLT: M14 10
7 RETAINING RING 1 16 PISTON 1 25 WIPER PIN 2
8 BUFFER SEAL 1 17 SLIPPER SEAL 1 26 WIPER PIN 2
9 U-PACKING 1 18 WEAR RING 2
24-90
(2) Arm cylinder
T= Tightening torque:
32 2 N.m (lbf.ft)
32 4
(4.13"-0.012 )
)
0
(4.13"-0.012
105-0.3
0
0
105-0.3
0
2 4-M10 P1.5 TAP DP 17 MIN
T=343~363 (253~268)
Apply Loctite #242 T=14.7(10.8)
T=981 (724) T=1860 (1372) Apply Loctite #242
11 5 10,9 8 26 6 7 14 12,13 3 1 15 16 19 18 17 20,21 22 23 25 24
PT1/8
PT1/4
27,28,29,30,31
Fig. 24-84 Construction of arm cylinder
P/No YY01V00054F1
1 CYLINDER TUBE 1 12 O-RING : 1B G110 1 23 SET SCREW : M8 1
2 PIN BUSHING 2 13 BACK-UP RING 1 24 CUSHION PLUNGER 1
3 PISTON ROD 1 14 O-RING : 1B G115 1 25 STOP RING 1
4 PIN BUSHING 2 15 CUSHION RING 1 26 SOCKET BOLT : M16 10
5 ROD COVER 1 16 PISTON 1 27 CHECK VALVE 1
6 BUSHING 1 17 SLIPPER SEAL 1 28 SPRING 1
7 RETAINING RING 1 18 WEAR RING 2 29 SPRING SUPPORT 1
8 BUFFER SEAL 1 19 DUST RING 2 30 O-RING : 1B P14 1
9 U-PACKING 1 20 O-RING 1 31 PLUG : PT3/8 1
10 BACK-UP RING 1 21 BACK-UP RING 2 32 WIPER RING 4
11 DUST WIPER 1 22 PISTON NUT 1
24-91
(3) Bucket cylinder
T= Tightening torque ; N.m (lbf.ft)
PT1/8
PT1/8
2 4-M10 P1.5 TAPDP 17 MIN
T=206~216 (152~159) T=14.7(10.8)

Apply Loctite #242 T=981 (724) T=1860 (1372) Apply Loctite #242
)
26 4 11 9,10 8 24 6 7 5 14 12,13 3 1 15 16 19 18 17 20,21 22 23 25 2
(3.34"-0.012
85 0 (3.34"-0.012 )
0
0
-0.3
-0.3
85 0
Fig. 24-85 Construction of bucket cylinder
P/No YY01V00055F1
1 CYLINDER TUBE 1 10 BACKUP RING 1 19 DUST RING 2
2 PIN BUSHING 1 11 DUST WIPER 1 20 O-RING 1
3 PISTON ROD 1 12 O-RING: 1B G90 1 21 BACKUP RING 2
4 PIN BUSHING 1 13 BACKUP RING 1 22 PISTON NUT 1
5 ROD COVER 1 14 O-RING: 1B G95 1 23 SETSCREW: M8×16 1
6 BUSHING 1 15 CUSHION RING 1 24 SOCKET BOLT: M14 8
7 RETAINING RING 1 16 PISTON 1 25 WIPER PIN 2
8 BUFFER SEAL 1 17 SLIPPER SEAL 1 26 WIPER PIN 2
9 U-PACKING 1 18 WEAR RING 2
24-92
Hydraulic cylinder construction (See Fig. 24-83, Fig. 24-84, Fig. 24-85)
By construction the hydraulic cylinder consists mainly of cylinder tube assy (1), piston rod assy (3) that takes out the
motion of pistons reciprocating in the cylinder tube assy, and rod cover (5) that serves as both a lid and a guide.
Cylinder tube assy (1) is equipped with a piston mount (clevis) that connects piston rod assy (3) with other parts.
In addition to these main components, slipper seal (17) and ware ring (18) are located between, cylinder tube assy
(1) and piston rod assy (3) ; buffer seal (8), rod packing (9) and dust seal (11) are located between piston rod assy
(3) and rod cover (5) ; and an O-ring and a back-up ring are placed between cylinder tube assy (1) and rod cover (5).
If pressurized oil is fed alternatively to the oil inlet and
CUSHION RING (15) CHAMBER "A" PATH "B"
outlet provided in the cylinder, force acts on the piston TANK
which in turn causes the piston rod (3) to extend and PISTON (16)
retract. ROD (3)
ROD SIDE
HEAD
(1) Operation of cylinder with cushion
SIDE
1) Cushion on rod side
The cushion mechanism is provided to prevent (5)
CUSHION STROKE ROD COVER
the generation of shock when the moving speed
of piston (16) is not reduced and strikes rod Fig. 24-86 Cushion mechanism on the rod side
cover (5).
An oil in chamber "A" returns to the tank by RESTRICTED PATH "C"
passing through paths "B" and "C" at a fixed flow CLEARANCE "D" TANK
rate in a intermediate stroke state (Fig. 24-86) of

pressing bottom side. Next, in a state of just
before stroke end (Fig. 24-87), cushion ring (15)
plunges into path "B".
At this time, an oil in chamber "A" passes
clearance "D" and mouth gap "C", an oil flow
volume returning to tank suddenly drops and the
piston part movement slows down. Fig. 24-87 Cushioning action on the rod side

Fig. 24-88 Rod side cushion
24-93
2) Cushion on head side

PLUNGER
This construction is similar to the one of cushion
TANK
on rod side. In a state of intermediate stroke CHAMBER "A"
pressing rod side, an oil in chamber "A" returns
to tank by passing through paths "B" and "C" at a
fixed flow rate.
Next, in a state of just before stroke end, plunger
plunges into path "B". At this time, an oil in
chamber "A" path clearance "D" and restricted
PATH "B" CLEARANCE "D"
path "C", an oil flow volume returning to tank
E
suddenly drops and the piston part movement RESTRICTED PATH "C"
slows down. RESTRICTOR VALVE
SPRING
SPRING SEAT
PLUG
O-RING
DETAIL E
Fig. 24-89 Cushioning action on the head side
24-94
24.2 ELECTRIC EQUIPMENT

24.2.1 ELECTRIC EQUIPMENT LIST
Group Code Name Parts No.

C - 1 Mechatro controller YN22E00214F1
(C) Controller
C - 2 Gauge cluster YN59S00021F3

C - 4 Air-con controler (including panel) YN20M01468P2
C - 8 Engine controller 32G87-01020
D - 4 Diode Accessory of relay box

D - 5 Diode ↑
D - 6 Diode ↑
D - 9 Diode ↑
(D) Diode
D - 10 Diode ↑
D - 12 Diode ↑
D - 13 Diode ↑
D - 14 Diode ↑
D - 15 Diode ↑
D - 16 Diode ↑
D - 17 Diode ↑
E - 1 Fuse and Relay box YY24E00008F1
E - 2 Alternator 32G68-00100
E - 3 Hour meter YT58S00006P1
E - 5 Horn high LC53S00001D1
E - 6 Horn low LC53S00001D2
E - 7 Tuner AM / FM (OCEANIA) YN54S0046P1
(E) Electric fittings
E - 8 Speaker left YN54S00050P1

E - 9 Speaker right ↑
E - 10 Receiver dryer YN54S00041P1
E - 11 Air-con compressor YX91V00001F1
E - 12 Battery 2484U171
E - 13 Travel alarm YN53S00004F1
E - 14 Cigaratte lighter YN81S00003P1
E - 15 Fusible link YY73S00003P1
E - 16 One way call amp 2447R145
E - 17 One way call speaker 2479R2098
E - 22 DC-DC converter YN77S00005F1
L - 1 Boom work light (LH) YW80S00001F1
(L) Light
L - 2 Frame work light (RH) YT80S00002F2

L - 3 Swing flasher (LH) YY80S00001F1
L - 4 Swing flasher (RH) ↑
L - 5 Room light YT80S00001P1
24-95

M - 1 Starter motor 32G66-00100
(M) Motor
M - 3 Wiper motor YN53C00012F2

M - 4 Washer motor (Tank assy) YT54C00003F1
M - 8 Grease motor LC71V00001P1
M - 9 Roof wiper motor YN76S00005P1
PSV - A Arm 2 speed inverse propo. valve YN35V00049F1
PSV - B P2 unload propo. valve (YY35V00013F1) YN35V00048F1
PSV - C Travel straight propo. valve Solenoid valve assy ↑
(P) Proportional
solenoid valve
PSV - D P1 unload propo. valve ↑

OPT. Relif adjustment propo.
PSV - E — —
valve 1
OPT. Relif adjustment propo.
PSV - I — —
valve 2
PSV - P1 P1 pump propo. valve (YY10V00013F1) YN35V00052F1
PSV - P2 P2 pump propo. valve Pump accesory ↑
R - 1 Battery relay YN24S00008F1
R - 2 Starter relay Engine accessory
R - 3 Glow relay 34390-00601
R - 4 Safety relay Accessor of relay box
R - 5 Horn relay YN24S00010P1
R - 6 Working light relay ↑
R - 8 Travel alarm relay ↑
R - 12 Revolution right relay ↑
R - 13 Revolution left relay ↑
R - 15 Nibbler open relay ↑
(R) Reray
R - 16 Nibbler close relay ↑

R - 19 Flasher relay YY24S00001F1
R - 23 Auto idle stop relay 1 YN24S00010P1
R - 24 Auto idle stop relay 2 ↑
R - 25 Engine emergency stop relay ↑
R - 26 Lever lock relay ↑
R - 28 Alternator relay ↑
R - 29 Wiper motor relay (Normal rotation) YN24S00012P2
R - 30 Wiper motor relay (Reverse rotation) ↑
R - 31 Prevent spark relay ↑
R - 32 Washer motor relay ↑
R - 53 Glow relay (ECU) ↑
24-96

SE - 1 Pressure sensor : Bucket digging YX52S00013P1
SE - 2 Pressure sensor : Bucket dump ↑
SE - 3 Pressure sensor : Boom up ↑
SE - 4 Pressure sensor : Boom down ↑
SE - 5 Pressure sensor : Swing ↑
SE - 7 Pressure sensor : Arm in ↑
SE - 8 Pressure sensor : Arm out ↑
(SE) Sensor
SE - 9 Pressure sensor : Travel RH ↑

SE - 10 Pressure sensor : Travel LH ↑
SE - 11 Pressure sensor : P2 OPT. ↑
SE - 13 E/G speed sensor Engine accessory
SE - 15 Fuel sensor YN52S00045F1
SE - 16 Accel potentiometer YN52S00032P1
SE - 20 Pressure sensor : P1 OPT. YX52S00013P1
SE - 22 Pressure sensor : Pump P1 YN52S00048P1
SE - 23 Pressure sensor : Pump P2 ↑
SE - 29 Opt. selector detect sensor YX52X00013P1
SV - 1 Swing parking brake SOL. YN35V00051F1
(SV) Solenoid
SV - 2 — (YY35V00013F1) —
SV - 3 Two speed select SOL Solenoid valve assy YN35V00050F1
SV - 4 Safety lock lever SOL ↑
SW - 1 Key switch YN50S00029F1
SW - 4 Swing parking brake release switch YN50S00047P1
SW - 5 Horn switch (RH) YN50E00017P1
SW - 8 Air filter clogging switch YR11P00008S005
SW - 10 Horn switch (LH) YN50E00017P1
SW - 11 Safety lock lever switch YN50S00041F1
SW - 13 Travel alarm switch YN50S00040DF
SW - 15 Conflux/single select switch YN50S00040DD
(SW) Switch
SW - 17 Skylight wiper switch YN50S00040D9

SW - 19 Wiper interlock switch YT50S00004P1
SW - 22 KPSS release switch YX50S00001F1
SW - 26 Cab work light switch YN50S00040D4
SW - 29 Nibbler open switch 2406P5872
SW - 30 Nibbler close switch ↑
SW - 33 Revolution right switch YN03M01231P3
SW - 34 Revolution left switch ↑
SW - 36 Water separator restrlction switch 32G90-00300
SW - 37 Travel independent switch YN50S00040DB
SW - 55 Boom work light switch YN50S00040D1
24-97
24.2.2 SPECIFICATION OF ELECTRIC EQIUPMENTS
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
C-1
Maker Sinko Electric Co. Ltd
Controller
Rated voltage DC24V
YN22E00214F1
Weight 4.2 kg (9.3 lbs)
Mechatro controller
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
YF05 - 02001 ~
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
C-2
Maker Nippon seiki Co., Ltd
Controller
Rated voltage DC24V
YN59S00021F3
Insulation More than 3M at 500V megger
Gauge cluster
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
YF05 - 02001 ~
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
24-98
File No.
Name of part
Use
Applicable Machine
C-4
Controller

YN20M01468P2

Air-con Controller

YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
YF05 - 02001 ~
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
C-8
Controller
Weight 700g (711.5g)[1550 lbs]
32G87-01020
ECU Type : EDC16UC40
Engine controller BOSCH part No. : 0 281 B03 233
YV05 - 04501 ~ (978772-0627)
MHI part No. : 32F98-10115
YY05 - 12001 ~
YH05 - 07001 ~
(7.99")
(6.56")
E-1
Fuse capacity and circuit
Fuse & Relay box
YY24E00008F1
Fuse & Relay
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
Front side of machine
24-99
File No.
Name of part
Use
Applicable Machine
E-2
Alternator
32G68-00100
Generator
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
E-3
Hour meter Movement Quarts
Operating voltage 10~80VC
YT58S00006P1 GM terminal : 2962447
GM connector : 2962448
Service meter
LC10 - 07001 ~
YC10 - 03501 ~
YF05 - 02001 ~
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
E - 5, 6
Type Bottom L : Low sound
Horn H : High sound
Rated voltage DC24V
LC53S0001D1 (High) STAMP
Operating voltage range DC20~30V
LC53S0001D2 (Low)
Sound level 113+5dB(A)/2m
Warning sound
420+20Hz high sound
LC10 - 07001 ~ Basic frequency 350+20Hz low sound
YC10 - 03501 ~ Insulation resistance More than 3M /DC500V
YF05 - 02001 ~
YU05 - 02001 ~ o 8.5
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
24-100
File No.
Name of part
Use
Applicable Machine
E-7
Maker SOKEN Co,.Ltd.
Tuner
Part name AM/FM radio
YN54S00046P1
Radio (AM & FM)
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
E - 8, 9
Speaker (L/R) Maker SOKEN Co,.Ltd.
Model SOK104A004
YN54S00050P1
Rated input 10W
Radio
Impedance 8
LY01 - 00101 ~
Frequency 33.3Hz
LV02 - 00201 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
E - 10
Maker Sanden Corp.
Receiver dryer
Airtight test pressure 3.5MPa (508 psi)
YN54S00041P1
Pressure proof test pressure 5.3MPa (769 psi)
Air-con
Breaking test pressure 9.8MPa (1420 psi) Outlet (To unit)
LC10 - 07001 ~ 17% or over than the
Desiccant moisture
YC10 - 03501 ~ adsorption capability weight of desiccant
(Include initial absorption 2%)
YF05 - 02001 ~ Refrigerant HFC-134a
YU05 - 02001 ~
Inner volume/Desiccant 578cm3/300g Inlet (From condenser)
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
24-101
File No.
Name of part
Use
Applicable Machine
E - 11
Air-con compressor
!"#!"""
YX91V00001F1
$%&
Air-con
&"""'
YX03 - 01601 ~
() *
YX04 - 01773 ~
#+ &
YX05 - 02001 ~
,-#%".+ /
YN11 - 45001 ~

YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
YF05 - 02001 ~
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
E - 12
Type 95E41R-N100
Battery
Voltage 12V
2484U171
5 HR 80Ah
Power Capacity
20 HR 100Ah
YV03 - 02150 ~
Weight 26kg (57lbs)
LD03 - 01105 ~
YY03 - 04299 ~
YH03 - 02013 ~
YV04 - 03001 ~
LD04 - 01200 ~
YY04 - 06001 ~
YH04 - 03001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
407L 175W 250H

(16.02" 6.89" 9.84")
24-102
File No.
Name of part
Use
Applicable Machine
E - 13 GND AV 0.5 Black
Model BA3111A
Alarm
Rated voltage DC 12V~36V
YN53S00004F1 Power AV 0.5 Red / Green
Travel alarm AMP Econoseal J series Mark II water-proof

Housing : 174354-2 Harness seal : 172888-2
YN11 - 45001 ~ Terminal : 171661-1 Retainer : 1-174355-1
YQ11 - 06001 ~ VIEW A
LC10 - 07001 ~
YC10 - 03501 ~
Vinyl tube
YF05 - 02001 ~
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
E - 14
Cigarette lighter

!" #$
YN81S00003P1
% ,
*
Cigarette lighter -.
YN11 - 45001 ~
& '
YQ11 - 06001 ~
(%$

LC10 - 07001 ~ )
*'+#%
YC10 - 03501 ~
YF05 - 02001 ~
/ 0 *
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
E - 15
Type Slow blow fuse
Fusible link
Allowable current 80A
YY73S00003P1
Fuse
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
24-103
File No.
Name of part
Use
Applicable Machine
L-1
Light (Halogen)

YW80S00001F1
Boom work light (LH)
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
YF05 - 02001 ~
YU05 - 02001 ~

YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
L-2
Light (Halogen) Type BL84-200
Bulb DC 24V,70W
YT80S00002F2
Effective area of lens 71cm2
Frame work light (RH)
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
YF05 - 02001 ~
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
L - 3, 4
Light Bulb 24V,6W
VINYL TUBE
YY80S00001F1 (BLACK)
Swing flasher
(Right, left)
YF05 - 02001 ~
YU05 - 02001 ~
YV05 - 04501 ~ DRAIN HOLE
YAZAKI Part No.
YY05 - 12001 ~ 7322-2228
YH05 - 07001 ~
AV0.5B AV0.5B
24-104
File No.
Name of part
Use
Applicable Machine
L-5
Bulb 24V,5W Body
Light
Note) Equivalent to 2456Z322F1 Lens
YT80S00001P1
Room light
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
Bulb
YC10 - 03501 ~
YF05 - 02001 ~
YU05 - 02001 ~
SECTION A-A Door
YV05 - 04501 ~ Switch
YY05 - 12001 ~
YH05 - 07001 ~
M-1
Motor
32G66-00100
Starter motor
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
M-3
159800-5710
Motor Denso corp. P/No. (Motor only)
YN53C00012F2 Rated voltage 24V
Wiper motor Swing angle Applox. 80
LC10 - 07001 ~ Controller
YC10 - 03501 ~ Wiper motor 24V

YF05 - 02001 ~
YU05 - 02001 ~
YV05 - 04501 ~ Wiper sw
OFF-Stop
YY05 - 12001 ~ Stop signal ON-Start
YH05 - 07001 ~ Reverse signal

Electric diagram
M-4
Rated voltage DC 24V
Motor (Reservoir)
Injection flow 1.2L (0.32 gal) / min or more
YT54C00003F1
Capacity 1.5L (0.4 gal)
Window washer
Time rated Max. continuous 60 sec.
YF05 - 02001 ~
Injection nozzle 1 X 2 pcs.
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
PUMP
24-105
File No.
Name of part
Use
Applicable Machine
M-8 !&'(! #
Motor

LC71V00001P1
! "#
Auto greasing
!$$$
%
YN11 - 45001 ~ )-4
$
YQ11 - 06001 ~

#
YF05 - 02001 ~
- %
YU05 - 02001 ~ . % (3/%
YV05 - 04501 ~
/
0+)11 -201
YY05 - 12001 ~
// 2 !&'(!
YH05 - 07001 ~
)*
+) ) ,*
R-1
At start 24V2000A(0.1 sec) Terminal A
Relay Rated voltage / current At charge 28V120A(Continuous) VIEW A
YN24S00008F1 Exciting current 0.4A or less / 24V
Lock section
Battery relay Contact pressure 37.2N {8.4 lb} or more Terminal A
YN11 - 45001 ~ Closed circuit voltage 16V or less VIEW I
Terminal B
YQ11 - 06001 ~ Open circuit voltage 7V or less HOUSING AMP
GND terminal
LC10 - 07001 ~
174359-2
Insulation resistance 3M or more/500V megger RETAINER AMP
1-174360-7
YC10 - 03501 ~ TERMINAL AMP
171661-1
YF05 - 02001 ~ WIRE PROOF PLUG AMP
172888-2
YU05 - 02001 ~ VIEW Z Terminal L

YV05 - 04501 ~ Flowing direction of
main current
o 9 X 30L F HOUSING YAZAKI
YY05 - 12001 ~ Terminal A Terminal B Terminal B AVS 1.25G
Heart shrinkage tube 7123-4210-30
F TERMINAL YAZAKI
YH05 - 07001 ~ z
AVS 1.25B 7116-3251*
GND wire
WIRE PROOF PLUG
I Terminal B Terminal L 7157-3580-60
F HOUSING YAZAKI AVS 1.25L Terminal B
7123-4220-30
F TERMINAL YAZAKI
P coil 7116-3251
REAR HOLDER YAZAKI
7157-6801-30
H coil WIRE PROOF PLUG
7157-3580-60
Bracket groud
Circuit diagram
o 7.0 X 150L
Corrugete tube (Black)
Fusible link assy B o 7.0 X 150L

Fusible link assy A Corrugete tube (Black)
24-106
File No.
Name of part
Use
Applicable Machine
R-3
Relay
34390-00601
Glow relay
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
Specifications
Rated voltage DC24V
Exciting current 2.3A (AT 24V 20 )
Rated time 75 sec
Closing circuit volt. 16V MIN. Electric diagram
Opening circuit volt. 4V MAX.
Max. Permissible
200A
current
Weight 0.26kg (0.57lb)
Tightening torque M6NUT 2.45~3.43N.m (1.81~2.53lbf.ft)
for terminal M4BOLT 1.13~2.35N.m (0.83~1.73lbf.ft)
R - 5,6,8,12,13,15,
16,23,24,25,26,28 Maker Tyco Electronics
Maker's p/No. V23074-A2002-A403
Relay
Type Micro relay A
YN24S00010P1
Horn realy
Work light relay Contact 1C
Travel alarm relay * Accessory of relay box
Revolution right relay
Revolution left relay
Nibbler open relay
Nibbler close relay Pin assignment
Auto idle stop relay 1, 2
Engine emergency stop relay
Lever lock relay
Alternator relay
LC10 - 07001 ~
YC10 - 03501 ~
YF05 - 02001 ~
YU05 - 02001 ~
YV05 - 04501 ~
Terminal arrangement
YY05 - 12001 ~
YH05 - 07001 ~
24-107
File No.
Name of part
Use
Applicable Machine
R - 29,30,31,32,55
Maker Tyco Electronics
Relay
Maker's p/No. V23134-A0053-C643
YN24S00012P2
Type Relay
Wiper motor relay
Wiper motor reveing relay Rated voltage DC 24V
Prevent spark relay Contact 1C
Washer motor relay
* Accessory of relay box
Glow relay (ECU)
YN11 - 45001 ~
YQ11 - 06001 ~
Pin assignment
YF05 - 02001 ~
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
30 85 86 87 87a 30
87a
85 86
87
SE - 1 ~ 5, 7 ~ 11,20,29
Pressure range 0~3MPa (435 psi)
Pressure sensor
Allowable max. pressure 7.0MPa (1010 psi) O-ring
(Low pressure) (P11 1B)
Rated voltage 5+0.5V DC
YX52S00013P1 Vout
50M or more /DC50V megger HEX24
Bucket dig and dump, Insulation resistance
(Between Body terminal)
Boom up and down,
Swing,
Connection (Arrangement)
Arm in and out,
Travel RH and LH and other
Vcc GND
Opt. selector detect PF1/4
.
Tightening torque 29.4~34.3 N m
YF05 - 02001 ~
(21.7~25.3 lbf.ft)
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
24-108
File No.
Name of part
Use
Applicable Machine
SE - 15
Float operation
Fuel sending unit
Float Resistance
YN52S00045F1 +0.1
FULL 10 -0.6
Fuel level
3/4 (19)
YN11 - 45001 ~
1/2 32+5
YQ11 - 06001 ~
1/4 (49.5)
LC10 - 07001 ~
EMPTY 85 +10
0
YC10 - 03501 ~
YF05 - 02001 ~
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~ Machine side controller
Float
Electric diagram VIEW A
SE - 16
Total resistance value
Potentio meter
Effective electric angle
YN52S00032P1
Number of notches
Accel dial
Source voltage
YN11 - 45001 ~
YQ11 - 06001 ~ Notch part
LC10 - 07001 ~
Potentio
YC10 - 03501 ~
3MA JM II + AMP
YF05 - 02001 ~ Bracket HOUSING : 174359-2
YU05 - 02001 ~ TERMINAL : 171661-1
YV05 - 04501 ~ Dial

YY05 - 12001 ~
YH05 - 07001 ~
24-109
File No.
Name of part
Use
Applicable Machine
SE - 22, 23 Electric diagram (Arrangement)
Pressure range 0~50MPa (7250 psi)
Pressure sensor
Max. allowable press. 120MPa (17400 psi)
(High pressure)
Operating source voltage 5+0.5V DC
YN52S00048P1
100M or more/DC50V megger
P1 pump Insulation resistance
(Between casing and terminal)
P2 pump
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
P3/8 Source (+)
YC10 - 03501 ~ Tightening torque Output (+) Econo seal J series
YF05 - 02001 ~ : 73.5 N.m O ring P14 Common (+) (Mark II (+)
(54.2 lbf.ft) JIS B2401 3 pole
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
PSV - A, B, C, D
Proportional solenoid valve YN35V00049F1 YN35V00048F1 YN35V00050F1 YN35V00050F1
YN35V00051F1
Hydraulic solenoid valve
T=7N.m
Hydraulic symbol A5 to A8
(YY35V00013F1)
YN35V00048F1
YN35V00049F1
YV05 - 04501 ~
YY05 - 12001 ~ T2
YH05 - 07001 ~ A1
A8 A7 A6 A5 A4 A3 A2 A1
P2
P1
PSV-A PSV-B PSV-C PSV-B SV-3 SV-1 SV-4

T2
HYDRAULIC SYMBOL P1
P2
A8 A7 A6 A5 A4 A3 A2 A1
Arm 2 speed
P1 unload
Travel straight
P2 unload
Travel 1,2 speed
Swing parling
Lever lock
24-110
File No.
Name of part
Use
Applicable Machine
PSV - P1, P2
Solenoid Type KDRDE-5K AMP MARK II
Max. feed press 13.7MPa (1987 psi) HOUSING : 174354-2
YN35V00052F1 TERMINAL : 173706-1
Rated feed press 5.0MPa (725 psi) Orifice Spring
Pump P1, P2 HEX 10
Allowable back press 1MPa (145 psi) Spool T=7.4N.m
proportional valve (5.5lbf.ft)
Control pressure range 0~2.7MPa (392 psi)
YF05 - 02001 ~
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
Sleeve O-ring Solenoid Seal nut
YH05 - 07001 ~ 1B P20
SV - 1, 2, 3, 4
Rated pressure 5.0 MPa (725 psi)
Solenoid directional
Solenoid directional
valve (7 spool) assy pressure
Hydraulic symbol Solenoid proportional Dither current 100Hz,200mA P-P P1, P2, T, A1, A8 port PF3/8
valve Coil resistance 17.5 (at 20C)
A1 to A3 A2~A7 port PF1/4
AMP MARK II AMP MARK II
(YY35V00013F1) Connector specification HOUSING 174354-2
TERMINAL 173706-1
YN35V00050F1
YN35V00051F1
YF05 - 02001 ~
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
SW - 1 Auto return
Switch
Connection
YN50S00029F1 Terminal
Position
Starter switch
Auto return
YF05 - 02001 ~
YU05 - 02001 ~
YV05 - 04501 ~ VIEW A Terminal
YY05 - 12001 ~ arrangement
YH05 - 07001 ~
SW - 4
Single-pole double-throw
Switch Type (alternate) Insulation tape
R B W
YN50S00047P1 Rated DC30V, 10A
Swing parking brake Insulation resistance
release
Vinyl tube
YF05 - 02001 ~ YAZAKI
T No.
YU05 - 02001 ~ Contact construction : Position Red (2) 7122-2237
7114-2020
YV05 - 04501 ~ Swing parking release
YY05 - 12001 ~ Normal
YH05 - 07001 ~
White (3) Blue (1)
24-111
File No.
Name of part
Use
Applicable Machine
SW - 5, 10
)* +,
Switch , (-

YN03M01861F1
(Right grip)
! "# #$
% % &
YN03M01862F1 '$! (
(Left grip)
Horn
YF05 - 02001 ~
YU05 - 02001 ~ (( (, ./01,+ 23*" 4 (5
YV05 - 04501 ~ (( (, %#6,+ 7 "*8 7
6 4(( ( 9 '"5
YY05 - 12001 ~
YH05 - 07001 ~
SW - 8
Switch

YR11P00008S005

Air cleaner
Clogging switch
LC10 - 07001 ~
YC10 - 03501 ~
YF05 - 02001 ~
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
SW - 11
Switch

YN50S00041F1

Lock lever
LC10 - 07001 ~
YC10 - 03501 ~
YF05 - 02001 ~
YU05 - 02001 ~ !
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~ !
"#
SW - 13
Switch
Single pole single throw
YN50S00040DF Type (alternate)
Travel alarm More than 1M /
Insulation resistance DC500V megger UP
LC10 - 07001 ~
YC10 - 03501 ~
Terminal connector
YF05 - 02001 ~ Connector
Position
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
24-112
File No.
Name of part
Use
Applicable Machine
SW - 15
Switch
YN50S00040D3 Type (alternate)
Conflux / single flow More than 1M /
switching
LC10 - 07001 ~ Terminal connector
YC10 - 03501 ~ Connector
Position
YF05 - 02001 ~
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
SW - 17
Switch
Roof window wiper More than 1M /
switch
LC10 - 07001 ~ Terminal connector
YC10 - 03501 ~ Connector
Position
YF05 - 02001 ~
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
SW - 19
Switch
YT50S00004P1
Rated load 1A
Wiper inter lock
Voltage drop 0.2V or less
Insulation resistance 5M or more
LC10 - 07001 ~
YC10 - 03501 ~
Operation force Initial motion 0.8+0.3
0 kg
YF05 - 02001 ~
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~ Max. stroke
SW - 22
HOUSING : 6098-0258
Maker's part No. ET610N13
Switch TERMINAL : 8230-4282
YX50S00001F1 Rated DC 30V
KPSS release More than 100M /

Insulation resistance 500V megger
YF05 - 02001 ~ After fixing the wires by soldering,
insulate them with insulation tape. VIEW I
YU05 - 02001 ~ (all terminals)
YV05 - 04501 ~ Bundle with vinyl tape
YY05 - 12001 ~ or tape.
YH05 - 07001 ~
I
24-113
File No.
Name of part
Use
Applicable Machine
SW - 26
Switch
Cab work light switch More than 1M /
LC10 - 07001 ~
YC10 - 03501 ~
Terminal connector
YF05 - 02001 ~ Connector
Position
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
SW - 36
Switch
32G90-00300
Water separator
restrlction
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
SW - 37
Switch
YN50S00040DB Type (alternate)
Travel independent More than 1M /
YF05 - 02001 ~
YU05 - 02001 ~ Terminal connector
YV05 - 04501 ~ Position
Connector
YY05 - 12001 ~
YH05 - 07001 ~
24-114
File No.
Name of part
Use
Applicable Machine
SW - 55
Switch

YN50S00040D1
Boom work light switch
!"" %$
#
LC10 - 07001 ~
YC10 - 03501 ~
#
YF05 - 02001 ~ $

YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
24-115
[MEMO]
24-116
25. AIR-CONDITIONER SYSTEM
TABLE OF CONTENTS
25.1 BASIC SYSTEM OF AIR CONDITIONER (HVAC AIR CONDITIONER).........................25-3

25.1.1 AIR CYCLE.............................................................................................................25-3
25.1.2 AUTO AIR CONDITIONER SYSTEM OUTLINE ....................................................25-4
25.2 COMPONENT AND CONSTRUCTION ...........................................................................25-5
25.2.1 COMPONENT ........................................................................................................25-5
25.2.2 CONSTRUCTION...................................................................................................25-6
25.3 PIPING.............................................................................................................................25-9
25.3.1 AIR CONDITIONER................................................................................................25-9
25.3.2 AIR DRYER ASSY..................................................................................................25-12 25
25.4 FUNCTION ......................................................................................................................25-13
25.4.1 MECHANISM OF COOLING CIRCUIT...................................................................25-13
25.4.2 COOLING CIRCUIT................................................................................................25-15
25.4.3 COMPONENT PARTS ...........................................................................................25-16
25.5 DISASSEMBLY AND ASSEMBLY...................................................................................25-20
25.5.1 PRECAUTIONS TO BE EXERCISED IN OPERATION .........................................25-20
25.5.2 DISASSEMBLY AND ASSEMBLY OF UNIT ..........................................................25-21
25.6 CHARGING REFRIGERANT...........................................................................................25-25
25.6.1 PRECAUTIONS TO BE EXERCISED IN OPERATION .........................................25-25
25.6.2 OPERATING PROCEDURE...................................................................................25-26
25.6.3 CHARGING PROCEDURE ....................................................................................25-27
25.7 ELECTRIC CIRCUIT........................................................................................................25-32
25.7.1 WIRING DIAGRAM AND CONNECTORS .............................................................25-32
25.7.2 STRUCTURE AND OPERATION OF EACH FUNCTIONAL PARTS AND THE INSPECTION............. 25-34
25.8 TROUBLESHOOTING.....................................................................................................25-37
25.9 SELF DIAGNOSIS FUNCTION ON DISPLAY OF PANEL ..............................................25-44
25.9.1 POSITION OF INDICATION FOR FAILURE. .........................................................25-44
25.9.2 EXPLANATION OF INDICATION FOR FAILURE. .................................................25-44
25.9.3 EXPLANATION OF MONITOR MODE...................................................................25-46
25-1

E135BSR : YY05-12001~ S5YY2511E01
First edition July, 2007 K
E135BSRLC : YH05-07001~ (NHK)
↑
↑ September, 2007 SK135SRLC-2 : YH05-07001~ K
(North America)
SK125SR : YV05-04501~
↑
(OCE/S.E.ASIA)
SK135SRLC-2 : YH05-07001~
25-2
25.1 BASIC SYSTEM OF AIR CONDITIONER (HVAC AIR CONDITIONER)

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

• Heater
Inside air or outside air is taken in through intake port and the air is passing through filter and heat exchange is
performed with hot air (heating) at the heater core of air-con unit, and then the heated air blows off from grille
through duct.
• Cooler
Inside air or outside air is taken in through intake port and the air is passing through filter and heat exchange is
performed with cold air (dehumidifying and cooling) at the evaporator of air-con unit, and then the cooled air
blows off from grille through duct.
• Heater system
The heater recycles (circulates) the cooling water in the engine, and the hot water delivered by the engine flows
in the heater core of air-con unit and then heat exchange is performed.
The intake air is heated and the heated air blows off from the grille provided on the inside of cab.
The blow off air temperature is controlled by the temperature control switch on the control panel, and the
operation is controlled by air mixing damper on the air-con unit.
25-3
25.1.2 AUTO AIR CONDITIONER SYSTEM OUTLINE
AIR CONDITIONER CONTROL PANEL
COMPRESSOR
SOLAR RADIATION SENSOR COMPRESSOR DRIVE SOURCE
REFRIGERANT
AIR MIXED DAMPER SIGNAL PRESSURE SWITCH
AIR-CON BLOWER REVOLUTION SIGNAL
AIR OUTLET SWITCHING SIGNAL CONTROLLER
INNER AIR SENSOR
EVAPORATION SENSOR
INNER AIR AND OUTER AIR
SWITCHING SIGNAL
OUTER AIR INTAKE

MOTOR
VENT ACTUATOR
INNER AIR
MOTOR
ACTUATOR
AIR CONDITIONER UNIT FACE
FOOT MOTOR BLOWER

ACTUATOR CONTROLLER
25-4
25.2 COMPONENT AND CONSTRUCTION

25.2.1 COMPONENT
27
33 30
27-1
40
32
39
27-3 27-4
27-2
35
35-7 35-6
35-1
35-11
35-2 35-5
34 35-8
35-10
35-9
Fig. 25-1 Air-conditioner group
A/C ASSY YY20M00017F1 (04)
No. Parts Q’ty No. Parts Q’ty No. Parts Q’ty

27 Air-conditioner assy 1 33 Pulley 1 35–7 L hose 1
27–1 Air-conditioner unit 1 34 Condenser 1 35–8 L hose : Ø 15 1
27–2 Hose 2 35 Air dryer assy 1 35–9 S tube : Ø 16 1
27–3 Clamp 2 35–1 Receiver dryer 1 35–10 L tube : Ø 8.5 1
27–4 Filter 1 35–2 Bracket 1 35–11 D tube : Ø 12 1
30 Panel assy 1 35–5 S hose : Ø 24 1 39 Filter 1
32 Compressor 1 35–6 D hose 1 40 Solar radiation sensor 1
25-5
25.2.2 CONSTRUCTION
(1) Air conditioner unit
"'
"& "%
"$ ""
!
" !
"
#
!
"#
"!
! )

!'
!%
!&
!$
"
!!
Fig. 25-2 Air conditioner unit (1/2)
25-6
" $
$ !

#
#
!
$
!

,
- "
%

) &

%

!
+ $
$

'
" !

!
"
&
# &! %'
#"
$!
'
%& + &" $

% -
&
!
,
*

'
#

!
!
%%
Fig. 25-3 Air conditioner unit (2/2)
25-7
Air conditioner YN20M00107F2 (03)
No. Parts Q’ty No. Parts Q’ty No. Parts Q’ty

1 Screw M5×16 23 21 Expansion valve 1 43 Foot joint lever 1
2 Main harness 1 22 O-ring 1 44 MA mode lever 1
3 MA air mix 3 23 O-ring 2 45 Foot lever 1
4 Blower controller 1 24 Screw M5×40 2 46 Face lever cam 1
5 Upper casing 1 25 Thermistor 1 47 Vent lever cam 1
6 Air mix door 1 26 Thermistor holder 1 48 Face rod 1
7 Air mix lever 1 27 Heater core 1 49 Vent rod 1
9 Air mix door sub 1 28 Pipe holder 1 50 Foot rod 1
10 Air mix lever sub 1 29 Thermistor 1 54 Capscrew 1
11 Blower 1 31 Screw M4×30 9 60 Evaporator packing 1
12 Lever MA air mix 1 32 Upper casing 1 61 Casing packing A 1
13 Intake door 1 33 Lower casing 1 62 Casing packing B 1
14 MA intake lever 1 36 Foot door 1 63 O-ring 1
15 Intake lever 1 37 Vent door 1 77 Packing 1
16 Intake rod 1 38 Face door 1 78 Tube 1
17 Air mix rod 1 39 KK box upper packing 1 79 Tube 1
18 Air mix rod sub 1 40 KK-box lower packing 1 82 Tube 1
19 Relay 2 41 Vent lever 1 83 Bracket 1
20 Evaporator 1 42 Face lever 1 84 Lower casing 1
(2) Receiver dryer
REFRIGERANT 2
INLET
REFRIGERANT
OUTLET
2-M6
1
No NAME Q'TY
1 PRESSURE SWITCH 1
3 2 SIGHT GLASS 1
4 3 DESICCANT 1
4 SUCTION PIPE 1
5 5 FILTER 1
6 RECEIVER TANK 1
Fig. 25-4 Receiver dryer
25-8
25.3 PIPING
25.3.1 AIR CONDITIONER
JAM NUT FOR

40 TENSION PULLEY
T=46.1 (33)
30
D
27
A
L
B
25
C
25 E
26
53
4
INITIAL BELT TENSION
When the belt is pushed by the
force of 23N, adjust the
deflection of L
l part
partto
tobe
be3mm.
3mm.
26
53
58 69 61
NOTE 62
66
1. Apply oil for refrigerant R134a to the
O-rings of all air-conditioner hose fittings.
33
16
2. Refrigerant volume : 800 50g
3. T : Tightening torque N.m(lbf.ft) 33
6
60 33
22 9
10
32
A B
Fig. 25-5 Air conditioner piping (1/2)
25-9
53
12
8 26
8 65 13
25
63 2
1 1
2 5
54 X
5
53 51
52 50
55 5 64 53
8 67
24
53
X
15
39
C D
3
23
35
8 59
23
17
25
14
19
68
34
56
57
E
Fig. 25-6 Air conditioner piping (2/2)
25-10
Air conditioner YY20M000017F1 (04)
1 Hose : L = 2700 1 46.1 (33.0) 33 Pulley assy 1
2 Hose : L = 2800 1 34 Condenser 1
3 Bracket 1 35 Air dryer assy 1
4 V-belt 1 39 Filter 1
3.92~4.9 (2.9~3.6) 5 Clip 4 40 Solar radiation sensor 1
6 Sems bolt : M10×25 4 50 Connector 1
7 Sems bolt : M6×20 2 51 Connector 1
8 Sems bolt : M8×20 7 52 Clip 1
9 Capscrew : M8×100 4 46.1 (34.0) 53 Sems bolt : M10×20 5
10 Washer 4 54 Grommet 1
12 Tube for heater : L = 2400 1 55 Grommet 1
13 Tube for heater : L = 2400 1 4.4 (3.2) 56 Capscrew : M6×50 4
14 Tube for D hose : L = 2600 1 57 Washer 4
15 Tube for S hose : L = 2950 1 59 Bracket 1
16 Bracket 1 60 Pulley 1
17 Tube for L hose : L = 900 1 46.1 (34.0) 61 Capscrew : M10×25 1
19 Tube for L hose : L = 300 1 62 Washer 1
46.1 (34.0) 22 Sems bolt : M10×45 4 63 Support 1
23.5 (17.3) 23 Sems bolt : M8×25 6 64 Insulation 1
24 Clip 1 46.1 (34.0) 65 Sems bolt : M10×30 1
25 Clip 10 66 Nut 2
26 Clip 3 67 Bracket 1
27 Air conditioner assy 1 68 Bracket 1
30 Panel 1 70 Clip 1
32 Compressor assy 1
UNIT CONNECTION TUBE ASSY COMPRESSOR CONNECTION BOLT

UNIT CONNECTION BOLT S TUBE
AIR CONDITIONER ASSY S D HOSE
COMPRESSOR ASSY
RECEIVER CONNECTION BOLT

S HOSE
L TUBE
L HOSE
L HOSE CONDENSER
RECEIVER DRYER RECEIVER DRYER MOUNTING BRACKET
25-11
25.3.2 AIR DRYER ASSY
B
A
C
8 5
A
4 6 5
10 6
4 11
3
8
2
1 7
B C
Fig. 25-7
Air dryer assy YY96V00009F1 (01)

1 Receiver dryer 1 7 L hose 1
2 Bracket 1 8 L hose 1
20~25 3 Capscrew 2 9 S tube 1
(14.8~18.4)
8~12 (5.9~8.9) 4 Capscrew 2 10 L tube 1
5 S hose 1 11 D tube 1
6 D hose 1
25-12
25.4 FUNCTION
25.4.1 MECHANISM OF COOLING CIRCUIT
(2) Mechanism of Cooling
Item HFC-134a (R134a)
In the cooling process, the refrigerant that flows
Chemical formula CH2FCF3
through the cooling circuit changes its phases from Molecular weight 102.03
liquid to gas and vice versa during which process Boiling point -26.19 (-15.14 )
heat is transferred from the low temperature part Critical temperature 101.14 (214.05 )
Critical pressure 4.065 MPa (41.45kgf/cm2 1)
(compartment) to the high temperature part
Critical density 511 kg/m3 (31.9lb/ft3)
(outside of the vehicle). Density of saturated
1206 kg/m3 (75.3lb/ft3)
1) Kind of Refrigerant liquid[25 (77.0 )]
Many kinds of refrigerants that change in that Specific volume of saturated
0.0310 m3/kg (0.496ft3/lb)
vapor [25 (77.0 )]
way are available, but the following requirements Latent heat of
are needed for use in such applications: 197.5 KJ/kg {47.19kcal/kg}
vaporization [0 (32 )]
• Latent heat of vaporization (heat of Flammability Nonflammable
Ozone destruction
vaporization) is large. coefficient 0
• It is easy to liquefy (condense). (It dose not 1 : 1MPa (mega pascal) equals 10.1972kgf/cm2
require very high pressure for condensation.) (145psi)
• It is easy to gasify (evaporate). (It evaporates
sufficiently at not too low pressure, i.e. cools
down an object.)
• It has small specific heat. (Since the
refrigerant itself is cooled by the expansion
valve, the loss resulting from it must be held
down to a minimum.)
• It has a high critical temperature and a low
solidification point.
• It is stable chemically and does not corrode
and permeate into the circuit parts.
• It is free from toxicity, objectionable odor,
flammability and explosiveness and excels in
thermal conductivity and electric insulation.
• It has small specific volume.
• It is easy to find out leakage.
Out of refrigerants meeting the above-
mentioned requirements, ones having
characteristics that suit the intended cooling
unit are chosen and used. If a refrigerant
other that those designated is used,
sufficient refrigeration will not be performed
or the equipment in which the refrigerant is
used may be broken. Therefore, always use
a designated refrigerant for the cooling unit.
Table shows the principal characteristics of
the R134a refrigerant that is used in this
machine.
25-13
(3) Characteristics of Refrigerant (Fig. 25-8) PRESSURE

In general, the fluid (general term of gas and liquid) MPa(psi)
R134a
has the following qualities: 4(580)
1) As a gas under certain pressure is cooled down,

3(435)
it begins to condensate at a certain temperature LIQUID
to take a liquid state. The temperature at which
2(290)
condensation begins is unique to each
substance (fluid) at a given pressure. The 1(145) GAS
temperature determined by a given pressure is 0.5(75)
TEMPERATURE
called saturation temperature. [ ( )]
0 0 15 18 35 50 100
(32) (59)(64) (95) (122) (212.0)
2) Inversely to 1) above, the pressure at which a
gas condenses for a temperature is determined. Fig. 25-8 Pressure-temperature characteristics of
This pressure is called saturation pressure. R134a
Fig. 25-8 illustrates the relationships between
the saturation temperature and the saturation
pressure in the case of refrigerant R134a used in
the air-conditioner. At the temperature and the
pressure on the lower righthand side of the curve
in Fig. 25-8 the refrigerant take a gaseous state,
while at the temperature and the pressure on the
upper lefthand side of the curve, the refrigerant
takes a liquid state.
Let us think of a case where an air-conditioner is
operated in the midst of summer. As the
refrigerant evaporates, it absorbs evaporation
heat from the air of the compartment. In order to
cool the inside of the compartment down to 25°C
(77°F), the refrigerant must transform
(evaporate) from a liquid to a gaseous state at a
lower temperature. It can be seen from Fig. 25-8
that R134a under a pressure above the
atmospheric pressure is capable of cooling the
inside of the compartment sufficiently. (If a
refrigerant that requires a pressure below the
atmospheric pressure to cool it to a required
temperature is used, air is mixed into the circuits,
thereby deteriorating the performance of the
cooling unit.) In the process in which gaseous
refrigerant is brought back to a liquid state, the
refrigerant is cooled and condensed by the outer
air exceeding 35°C (95°F).
Accordingly the refrigerant is capable of
condensing at a pressure exceeding 1 MPa
(145psi), as seen from Fig. 25-8.
25-14
25.4.2 COOLING CIRCUIT

Fig. 25-9 illustrates the cooling circuit of the car air-
conditioner.
In this circuit diagram, the portion that cools the air of INSIDE OF COMPARTMENT(CAB)
the compartment is the evaporator. The object air is
cooled off by utilizing the fact that the refrigerant takes
heat off the surrounding area as evaporation heat as it
evaporates in the cooling circuit. Since the part at which EVAPORATOR EXPANSION
VALVE
vaporization of the refrigerant takes place is the BLOWER
evaporator, cooled air is constantly delivered to the
circumference of the evaporator by the blower fan. In INSIDE OF ENGINE
the meantime, liquid refrigerant (slightly wet vaporized S D ROOM
refrigerant) is fed into the evaporator, when "cooling" COMPRESSOR COOLING FAN
effect is attained.
For instance, in order to cool the air to 15°C (59°F), the
refrigerant can not absorb evaporation heat from the air RECEIVER
DRYER
unless it evaporates at a temperature lower that 15°C
(59°F). For that purpose, it can be seen from Fig. 25-8 CONDENSER
that the pressure of the refrigerant in the evaporator
must be less than 0.51 MPa (74psi). Fig. 25-9 Construction of cooling circuit
Furthermore, the cooling effect deteriorates unless the
feed rate of the refrigerant is controlled so that all of the
refrigerant supplied to the evaporator vaporizes and
turns into dry vapor.
Consequently, the cooling circuit is so constructed that
the evaporator can cool down an object (air in this case)
sufficiently (i.e. so as to decrease the pressure in the
evaporator) and that an adequate amount of refrigerant
can be fed to the evaporator.
The feed rate of the refrigerant is controlled by the
expansion valve, but the pressure in the evaporator is
held low by the throttling action of the expansion valve
and the suction action of the compressor. The
compressor acts as a pump that allows the refrigerant
to circulate. The compressive action of the compressor
and the heat exchange (heat radiation) action of the
condenser transform the refrigerant in a dry vapor state
back to a liquid state.
25-15
25.4.3 COMPONENT PARTS

(1) Evaporator (See Fig. 25-10.)
The evaporator is an important heat exchanger that
EVAPORATOR
absorbs the heat of the compartment air (object) by
the utilization of the latent vaporization heat of the
low-temperature, low-pressure liquid-state
refrigerant. Therefore, it is necessary that
satisfactory heat transfer between the object and
the refrigerant take place in the evaporator.
O-RING
To that end, the evaporator is equipped with fins on
the air side in order to increase the heat transfer
area of the air side and thereby perform excellent
thermal transfer between the refrigerant and the air.
The humidity in the air condenses as the air cools
down and adheres to the outside of the evaporator EXPANSION VALVE
as water drops. The cooling effect deteriorates if
the water drops freeze. Therefore, how to
discharge water is an important point. SOCKET BOLT M5X40(2 PCS.)
The amount of refrigerant supplied to the
evaporator is controlled by the expansion valve Fig. 25-10
which is described in the following. In order to attain
proper control, it is necessary to reduce the
pressure drop of the refrigerant of the evaporator.
Accordingly, reducing the pressure drop is one
element that makes the evaporator attain its full
performances.
(2) Expansion Valve
In order for the evaporator to fulfill its performances,
a proper amount of low-pressure low-temperature
liquid refrigerant must be fed to the evaporator.
If the feed rate is too low, the refrigerant completes
vaporization early in the evaporator which results in
deterioration of the cooling effect. If the feed rate is
too high, unvaporized liquid refrigerant returns to
the compressor (liquid back). This not only
deteriorates the cooling effect, but also damages
the compressor valves.
The expansion valve feeds the flowing high-
pressure high-temperature liquid refrigerant to the
evaporator as low-pressure low-temperature liquid
refrigerant (damp vapor of low dryness). The
expansion valve controls the feed rate of the
refrigerant at the same time.
25-16
Fig. 25-11 shows how the block type expansion

valve is constructed. The temperature sensing
DIAPHRAGM
part is provided in the shaft of the expansion
valve to directly detect the refrigerant
temperature at the outlet of the evaporator.
The diaphragm contains R134a in saturated REFRIGERANT
state. The pressure in the diaphragm changes EVAPORATOR OUTLET
SIDE
according to the temperature detected by the
sensor. The change in the pressure causes the SHAFT
force acting upon the diaphragm to vary
accordingly.
The high-pressure high-temperature liquid
refrigerant that is fed from the receiver side REFRIGERANT
INLET
reduces the pressure abruptly as it passes
through the valve (throttling action). On that
BALL
occasion, part of the refrigerant evaporates by VALVE
the very heat of the refrigerant and cooled off. SPRING
The result is that low-pressure low-temperature
damp refrigerant vapor is fed to the evaporator. Fig. 25-11 Block type expansion valve
The opening of the valve is determined by the
equilibrium between the pressure (low) of the
evaporator side, the action of the adjust spring
and the pressing force of the diaphragm (the
temperature of the refrigerant at the outlet of the
evaporator to be sensed by the thermowell). The
feed rate is controlled automatically so that
under the pressure in the evaporator, the
refrigerant is properly overheated (3~8 degrees
C) and goes out of the evaporator. This action is
carried out by sensing the refrigerant
temperature at the outlet of the evaporator as
against the inlet pressure of the evaporator and
consequently controlling the feed rate of the
refrigerant.
This means that if the refrigerant pressure drop
in the evaporator is excessive, it is difficult to
control the overheating or the feed rate of the
refrigerant. For this reason, the smaller the
pressure drop of the evaporator, the better.
The expansion valve senses the pressure and
the temperature at the outlet of the evaporator
and controls the overheating of the refrigerant
and the refrigerant supply to the evaporator more
Fig. 25-12 Expansion valve outside view
securely. The air-conditioner of this machine
adopts a block type expansion valve.
25-17
(3) Compressor (See Fig. 25-13.)

D HOSE
The compressor performs the following three
functions in the cooling circuit:
1) Suction action
S HOSE
2) Pumping action
3) Compressive action
1) The suction action, as combined with the
throttling action, works to decrease the
refrigerant pressure in the evaporator. This
permits the refrigerant to vaporize at low
temperature in order to perform cooling effect.
2) The pumping action serves to cause all the
refrigerant to circulate in the cooling circuit. This
enables enables continuous cooling.
3) The compressive action, as combined with the Fig. 25-13
action of the condenser which is mentioned
hereunder, transforms vaporized refrigerant
back to a liquid state again.
The saturation temperature gets higher as the
pressure increases. For instance, it becomes
possible to cool down the refrigerant by the use
of an outer air of 35°C (95°F) and liquefy it. The
compressive action of the compressor works to
turn low pressure vaporized refrigerant to high
pressure vapor refrigerant. The condenser then
serves to cool down the refrigerant. However,
since the compressive action takes place only for
a short period, the refrigerant hardly exchanges
heat with outer air. That is to say, it takes a near
form of thermally insulated compression, so that
the refrigerant discharged by the compressor
turns into high-temperature high-pressure vapor
and is delivered to the condenser.
(4) Condenser ( See Fig. 25-14.)
This is a heat exchanger that cools the vaporized
refrigerant at high temperature and high pressure
by the use of outer air and condenses the
refrigerant. The direction in which heat moves is
from the refrigerant to air, the opposite to the case
of the evaporator. Fins are equipped on the outer
air side to improve thermal transfer. If the
refrigerant is not cooled well by the condenser, the
air in the compartment can not be cooled
sufficiently by the evaporator. For that purpose, it is
necessary to secure ventilation required for the
cooling of the refrigerant.
Fig. 25-14 Condenser
25-18
(5) Receiver dryer ( See Fig. 25-15.)

REFRIGERANT SIGHT GLASS
1) Receiver Tank INLET
On the air-conditioner, the revolution of the REFRIGERANT
compressor varies greatly which causes the OUTLET
proper flow of refrigerant in the cooling circuit to
vary. It is the receiver tank that receives the
variations. When the cooling circuit does not
need much refrigerant, the receiver tank stores
extra refrigerant temporarily and supplies it when
the cooling circuit needs much refrigerant. The
PRESSURE SWITCH
receiver tank also stores an extra amount of
refrigerant to be used for filling balance and
supplement small amounts of leakage of the
refrigerant through penetration into rubber
hoses.
2) Dryer
If water is mixed in the cooling circuit, it
deteriorates the compressor valves and oil, DESICCANT
corrodes the metallic parts of the circuit or clogs
the circuit as the water freezes in the expansion SUCTION
valve. It is desirable that the amount of water PIPE
mixed in the refrigerant should be held below a
concentration of 30ppm. The air-conditioner
uses a molecular sieve as desiccant suited for FILTER
the circuit, in order to absorb water content that
intrudes into the circuit when the dryer is
installed or when refrigerant is charged.
3) Sight Glass
This is a inspection window with which the
refrigerant level in the circuit is determined, the RECEIVER
TANK
only means of confirming the inside of the circuit
visually.
4) Filter
5) Pressure Switch
This machine employs pressure switches of
high/low pressure type.
The pressure switch protects the circuit by Fig. 25-15
cutting off the power supply to the compressor
when high pressure increases abnormally high
[more than 3.14MPa (460psi) ].
The pressure switch also detects the leakage of
refrigerant by cutting the power supply to the
compressor when the pressure of the circuit falls
below 0.2MPa (28psi).
25-19
25.5 DISASSEMBLY AND ASSEMBLY

25.5.1 PRECAUTIONS TO BE EXERCISED IN OPERATION
(1) Special Refrigerator Oil
Unit : N.m (lbf.ft)
This air-conditioner uses special refrigerator oil
SP20 for use with new refrigerant R134a. Oils other PIPE FASTENING PART TIGHTENING TORQUE
than SP20 may not be used. Since SP20 tends to
D hose and compressor (M8 bolt) 19.6~24.5 (14~18)
absorb moisture and may corrode paint and resin,
the following points must be noted: D hose and condenser 19.6~24.5 (14~18)
1) Do not keep open all pipe connections on a new L hose and condenser 11.8~14.7 (8.7~11)
compressor and the component parts of the
L hose and receiver dryer (M6 bolt) 7.8~11.8 (5.8~8.7)
installed refrigeration circuit
(Remove valves and caps at the pipe openings L hose and air-conditioner unit 11.8~14.7 (8.7~11)
of the compressor, just before connecting pipes. S hose and air-conditioner unit 29.4~34.3 (22~25)
If you have removed a pipe joint for repair, put a
cap to both ports immediately.) Expansion valve 1.96~2.45 (1.4~1.8)
2) Use care so SP20 does not adhere to the

painted surface and resin parts. In case SP20 Unit : N.m (lbf.ft)
has adhered to such surfaces, wipe it off SCREW SIZE TIGHTENING TORQUE
immediately.
N4,T4 machine screw, M4 0.78~1.18 (0.58~0.87)
(2) The receiver dryer is filled with desiccant to absorb
moisture in the circuit. Therefore, remove the valve N5,T5 machine screw, M5 1.96~2.45 (1.4~1.8)
at the pipe port immediately before connecting M6 (mounting part of L hose joint) 7.85~11.8 (5.8~8.7)
pipes.
M6 (except mounting part of L hose joint) 9.8~11.8 (7.2~8.7)
(3) Tightening Torque
M8 (mounting part of S,D hose joints) 19.6~24.5 (14~18)
1) Pipe Joints
When connecting pipe joints, coat the O-ring with M8 (mounting part of A/C unit) 9.8~11.8 (7.2~8.7)
special oil (SP20) and fasten to the tightening
M8 (other than those mentioned above) 11.8~15.7 (8.7~12)
torque indicated in the table, using a double
spanner. M10 39.2~53.9 (29~40))
2) Screws and Bolts

Fasten to the tightening torque indicated in the
table REPLACED PARTS AMOUNT TO BE FILLED IN
(4) Amount of Oil for Compressor
EVAPORATOR 40 cc (2.4cu.in)
The compressor SD7H (HD type) is filled with
135cc (8.2cu•in) of oil. If the oil volume is small, CONDENSER 40 cc (2.4cu.in)
seizure at high revolution and shortening of service
Drain out the volume of oil left in
life will occur. If the oil volume is large, the cooling
COMPRESSOR the compressor to be replaced,
ability will be deteriorated.
from the new compressor.
Once the air-conditioner is operated, part of the oil
is dispersed in the refrigeration circuit. Therefore,
RECEIVER DRYER 20 cc (1.2cu.in)
when replacing the parts in right Table, adjust the oil
level to that of table. HOSES 20 cc (1.2cu.in)
(5) Before performing operation, stop the engine and
turn off all power supplies to the equipment related
to the air-conditioner.
(6) After the operation is over, confirm that all faults
have been repaired completely, by operating the
air-conditioner.
25-20
25.5.2 DISASSEMBLY AND ASSEMBLY OF UNIT

(1) Removing inner air filter

Slide the inner air filter leftward and remove it from
the unit.

Fig. 25-16
(2) Removing selector box
MODE ACTUATOR PLUS SCREW
Remove 6 plus screws, remove connector MAIN HARNESS
connected to the mode actuator on mode selector
box, and separate the mode selector box from the
unit.
CONNECTOR
(3) Removing main harness SELECTOR BOX
Pull out 3 harness clamps from the unit, and UNIT
disconnect all connected connectors and remove
harness on the body from the unit.
Fig. 25-17
(4) Removing upper unit case AIR MIX LEVER PLUS SCREW
1) Remove air MIX rod and air MIX rod sub from air
MIX lever.
2) Remove 12 plus screws which are used to install
the upper and lower unit casings.
Pull out the upper unit casing upward giving
attention to the thermistor harness so as not to
UPPER UNIT
be caught by the casing. CASING
AIR MIX
ROD SUB
AIR MIX
ROD SUB
LOWER UNIT CASING
Fig. 25-18
25-21
(5) Replacing blower controller UPPER UNIT CASING

1) Remove 2 plus screws and remove the blower
controller from the upper unit casing.
2) Install new blower controller by the reverse
procedure of removal.
* Do not disassemble the blower controller.
PLUS SCREW BLOWER CONTROLLER
Fig. 25-19
(6) Removing heater core
PIPE CLAMP
1) After draining the coolant, remove heater hose HEATER CORE
PLUS SCREW
from the heater core.
2) Remove 1 plus screw, and remove pipe clamp EVAPORATOR ASSY
which is used to secure the heater core and then BLOWER MOTOR
remove the heater core from the lower unit
casing.
3) Install it by the reverse procedure of removal.
(7) Replacing blower motor

1) Disconnect connector which is connected to the
blower motor and remove the blower motor from
the lower unit casing.
* Do not remove the fan from the blower motor.
LOWER UNIT CASING

2) Install it by the reverse procedure of removal.
Fig. 25-20
(8) Replacing evaporator and expansion valve
1) Take the evaporator with expansion valve off
EVAPORATOR
from the lower casing.
2) Remove evaporator sensor with sensor holder
from the removed evaporator. SENSOR HOLDER
3) Insert the sensor holder into the new evaporator 105mm
at the position shown in Fig. 25-21 and install the (4.1 inch)
evaporator sensor again.
11TH ROWS OF FIN
EVAPORATION SENSOR
Fig. 25-21
25-22
4) Remove 2 socket bolts M5×40 with Allen wrench

(4mm) and remove the expansion valve from the
EVAPORATOR
evaporator.
5) Fit O-ring (NF O-ring 5/8 and 1/2 one each) to
A
new evaporator.
* When assembling again, fit O-ring paying

attention so as not to be caught with others. O-RING
(Socket bolt M5×40 (2 pcs.) Tightening torque :
6.9N•m (5.1lbf•ft)
* Do not apply undue force to pipe of evaporator

outlet. This undue stress causes the leak of
refrigerant from "A" part of evaporator. EXPANSION VALVE
Moreover, when tube assembly (27-6) (see Fig.
25-1) connected with expansion valve is
SOCKET BOLT M5X40(2 PCS.)
disconnected from expansion valve, similar
careful work is necessary.
Fig. 25-22
(9) Replacing motor actuator

VENT ROD
1) Replacing mode actuator
FACE ROD
a) Remove connector connected to the motor
MA MODE
actuator. LEVER
CONNECTOR
b) Remove FACE rod and VENT rod which is PLUS SCREW
3PCS.
used to connect MA mode lever and mode
MODE
cam from the holder. ACTUATOR
c) Remove 3 plus screws and remove the
motor actuator with lever MA mode from the
unit.
d) Remove the lever MA mode from the
removed motor actuator, and install it on new Fig. 25-23
motor actuator by the reverse procedure of
removal.
2) Replacing air mixing actuator
AIR MIX ROD
a) Remove connector connected to the motor
MA AIR MIX LEVER
actuator.
b) Remove rod air MIX which is used to connect
the motor actuator and the lever MA air MIX. CONNECTOR

motor actuator with MA lever air MIX from the
unit.
d) Remove the MA lever air MIX from the
removed motor actuator, and install it on new
removal. PLUS SCREW 3PCS.
AIR MIX ACTUATOR
Fig. 25-24
25-23
3) Replacing inner and outer air switching actuator

MA INTAKE LEVER
a) Disconnect connector connected to the

motor actuator. INTAKE ROD
PLUS SCREW
b) Remove intake rod from MA intake lever. (3PCS.)

motor actuator with MA intake lever from the
CONNECTOR
unit.
d) Remove the MA intake lever from the
removed motor actuator, and install it on new
removal.
INNER AND OUTER AIR SWITCHING ACTUATOR
Fig. 25-25
25-24
25.6 CHARGING REFRIGERANT

25.6.1 PRECAUTIONS TO BE EXERCISED IN OPERATION
(1) Always assign a person in charge of handling refrigerant.
Refrigerant charge operation involves dangers as it handles high pressure gas. Always assign a person familiar
with how work is done for handling refrigerant.
• Wear protective goggles. (You may lose your sight if the refrigerant gets in your eyes.)
• The refrigerant in liquid state is at very low temperature [approx. -26°C (-15°F)]. Therefore, handle it
with care. (You may get a frostbite if the refrigerant is sprayed over your skin.)
(2) Storage and Transportation

1) Keep the service can (hereinafter called can) less than 40°C (104°F). Since high pressure gas of R134a is
filled in the can in a saturated liguefied state, the pressure in the can increases sharply as temperature rises.
The can may blast as the result.
It is for this reason why the can temperature must be kept below 40°C (104°F).
2) For storage, choose a cold dark place not exposed to direct sunlight.
3) If the can is placed near a fire source, it is subject to radiation heat and gets hot. This causes the inside
pressure to rise and may cause the can to blow out. Do not bring the can close to a fire.
4) The inside of the closed compartment gets very hot as the radiation heat of the sunlight enters the
compartment. The areas of the compartment which are exposed to direct sunlight may rise to a dangerous
temperature level. Do not bring the can into the compartment. Also, the inside of the trunk room may rise to
a dangerous temperature level even in the summer time. Use sufficient care, therefore, taking the above into
account.
5) Note that if the can has scratches, dents and distortion, the strength of the can will deteriorate.
1. Do not drop or knock on the can.
2. When transporting, loading or unloading cans and packages containing cans, do not throw or drop them.
6) Store cans beyond the reach of children.
(3) Charging
1) When warming the can in which refrigerant is charged, do not fail to open the service can valve and the low
pressure valve of the gauge manifold and warm the can in warm water of 40°C (104°F or below (to an extent
that you do not feel hot when you put your hand in the water.) If the can is put in hot water or heated by a
direct fire, the pressure of the can may rise sharply, thereby blowing off the can.
2) When charging refrigerant while running the engine, do not open the high pressure valve (HI) of the gauge
manifold in any case.
(4) Others
Reuse of service cans is prohibited by law; never use them again. Do not allow foreign matter to enter the air-
conditioner circuit. Air, water and dust are detrimental to the refrigeration cycle. Install the components of the air-
conditioner correctly and speedily. Pay full attention to the entry of water and dust.
• Be careful about overcharge of gas.

• Fasten pipes to the specified torque.
25-25
25.6.2 OPERATING PROCEDURE

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

30 min. for five minutes.
Begin vacuum Stop vacuum Check Fill in Check for Fill in
making making air-tightness refrigerant gas leak refrigerant
Lower than
-750mmHg Gauge indicates
abnormality
Charge refrigerant gas to a gauge
Check and correct joints pressure of 0.1MPa (14 psi)
(3) Tools
No. Parts Q’ty Sketch Service No. Parts Q’ty Sketch Service
Low pressure
4 Quick joint 1
Gauge side
1 1
manifold For service can
5 T joint 1
valve
Red :
high pressure side
Charging Blue : Service can
2 3 6 2 For service can
hose low pressure side valve
Yellow :
vacuum pump side
Vacuum
High pressure For vacuum
3 Quick joint 1 7 pump 1
side pump
adapter
25-26
25.6.3 CHARGING PROCEDURE
25.6.3.1 VACUUM MAKING OPERATION

(1) Connecting gauge manifold (See Fig. 25-26)
HIGH
1) Close the high pressure valve (HI) and the low LOW PRESSURE PRESSURE GAUGE
pressure valve (LO) of the gauge manifold. GAUGE GAUGE MANIFOLD
(CLOSED)LOW HIGH PRESSURE
2) Connect the charging hoses (red and blue) with PRESSURE VALVE VALVE(CLOSED)
the service valves of the compressor. RED
BLUE
Red hose :
High pressure side (HI) of the gauge HIGH
PRESSURE YELLOW
manifold→high pressure side (DIS) of SIDE
compressor DIS
LOW
Blue hose : PRESSURE
Low pressure side (LO) of gauge manifold→low SIDE
SUC
pressure side (SUC) of compressor
COMPRESSOR VACUUM PUMP(STOP)
Fig. 25-26
• Do not mistake the high pressure hose for the low
pressure hose in any circumstances when BLUE
connecting them. Put the hose in firmly till a clicking RED
sound is heard.
CHARGING
3) Connect the center valve of the gauge manifold
HOSE
with the charging hose of the vacuum pump. (GAS VALVE)
Fig. 25-27 Connecting gauge manifold
Some kinds of gauge manifolds are not equipped with

an open/close valve in the center.
25-27
(2) Vacuum making (See Fig. 25-28)

LOW PRESSURE VALVE(OPEN) (CLOSE)
1) Open the high pressure valve (HI) and the low HIGH PRESSURE VALVE(OPEN) More than (CLOSE)
pressure valve (LO) of the gauge manifold. 30 min
2) Turn on the switch of the vacuum pump and
make vacuum for more than 30 minutes. GAUGE MANIFOLD
3) When vacuum making for a specified duration
is over (degree of vacuum : less than - 750
mmHg), close the high pressure valve and the
low pressure valve of the gauge manifold.
DIS
4) Then turn off the vacuum pump.
(3) Air-tightness Check
Close the high pressure valve and the low pressure
valve of the gauge manifold, leave it as it is for more SUC
than five minutes and make sure that the gauge
indication does not return toward 0.
Fig. 25-28 Vacuum making operation
If the gauge indication goes toward 0, there is

somewhere that is leaking. Retighten pipe joints, make
vacuum again and make sure of no leakage.
25-28
25.6.3.2 GAS CHARGING OPERATION

(1) Charging from high pressure side (See Fig. 25-29.)
1) After making vacuum repeatedly, change the
charging hose (yellow) of the gauge manifold
from the vacuum pump to the service can.
2) Air purge
Open the service can valve. (However, close the
high and low pressure valves of the gauge AIR PURGE
manifold.) Then push the gas valve of the side CLOSE
service port on the low pressure side of the
SCREW DRIVER OPEN SERVICE
gauge manifold, using a screw driver, in order to CAN VALVE
YELLOW
let out the air in the charging hose by the
pressure of the refrigerant. (See Fig. 25-29.)
BLUE RED
(The operation ends when a hissing sound is
heard.)
Fig. 25-29 Gas charging operation

3) Open the high pressure valve of the gauge
manifold and charge in refrigerant. [Charge in
gaseous refrigerant to a gauge pressure of
0.1MPa (14psi).] LOW PRESSURE HIGH PRESSURE VALVE
After charging, close the high pressure valve of VALVE(CLOSE) (OPEN) (CLOSE)
RED FILL IN 1~1.5 CANS
the gauge manifold and the service and valve. BLUE OF REFRIGERANT
(See Fig. 25-30.)
DIS
YELLOW
SERVICE CAN
VALVE
• Do not run the compressor during this work, (OPEN) (CLOSE)
CHARGE
(Otherwise the refrigerant flow in reverse
direction which causes the service can and the SUC
hoses to rupture. This is very dangerous.)
(2) Checking for gas leak (High pressure side)
Check for gas leak in the cycle, using a gas leak
detector (electric type). Retighten and correct
leaking points.
• Always use the leak tester for R134a. (Do not use
one for flon gas service as it provides poor
sensitivity.)
25-29
(3) Charging from low pressure side (See Fig. 25-31)

1) Make sure that the high-pressure and low-
pressure valves of the gauge manifold and the
service can valve are closed. LOW PRESSURE HIGH PRESSURE
VALVE VALVE(CLOSE)
2) Start the engine and run the revolution to OPEN CLOSE
RED (CLOSE SECURELY)
WHEN AIR
1500±100rpm and fully close the cab door and BUBBLES IN THE
SIGHT GLASS
the windows. DISAPPEAR
YELLOW
DIS
3) Turn on the air-conditioner switch, set the fan BLUE
switch to Max and the temperature control switch
to cool Max. SERVICE CAN
VALVE(OPEN)
4) When charging gas, set the discharge pressure
SUC
of the compressor to 1.4~1.6 MPa (200~230psi).
COMPRESSOR SERVICE CAN
OPERATION (DO NOT TURN IT OVER)

(Low pressure side)
5) Open the low pressure valve of the gauge
SIGHT GLASS
manifold and the service can valve and fill in
refrigerant till air bubbles of the sight glass of the
receiver go away. (See Fig. 25-31)
[Total amount of gas to be charged :
800g±50g (1.76±0.11 lbs)]
6) When refrigerant charge is over, close the low
pressure valve of the gauge manifold and the
service can valve.
RECEIVER DRYER
• Do not open the high pressure valve of the

gauge manifold in any circumstances. Fig. 25-32 Receiver dryer
• Never place the service can upside down. (The
compressor valve may be scored because the
refrigerant is sucked in a liquid state.)
25-30
(4) Criterion for checking the amount of refrigerant

filled in
JUDGMENT OF REFRIGERANT LEVEL THROUGH THE SIGHT GLASS OF RECEIVER DRYER
After A/C is turned on, only a little

PROPER LEVEL bubbles are seen and thereafter light
milky white is seen.
After A/C is turned on,

OVERCHARGE no air bubbles are seen.
After A/C is turned on, continuous

UNDERCHARGE
air bubbles are seen.
• If the air-conditioner is run with poor refrigerant

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

When the refrigerant level has been checked,
disconnect the charging hoses from the
compressor in the following manner :
1. Press the "L" shape metal fitting of the charging
hose (blue) on the low pressure side against the
service valve of the compressor so the
refrigerant does not leak out and loosen the nut.
As soon as the nut has been removed,
disconnect the charging hose from the service
valve.
2. Leave the high pressure side as it is till the high
pressure gauge reading falls. [below 1MPa
(140psi)].
3. Disconnect the charge hose (red) on the high
pressure side the same way as on the low
pressure side.
25-31
25.7 ELECTRIC CIRCUIT

25.7.1 WIRING DIAGRAM AND CONNECTORS
JAE : JAPAN AVIATION ELECTRONICS
JAE JAE INDUSTRY, LTD.
HOUSING : IL-AG5-22D-S3C1 HOUSING : IL-AG5-14D-S3C1
TERMINAL : IL-AG5-C1-5000 TERMINAL : IL-AG5-C1-5000
MAKER : YAZAKI CORP.

MAKER : YAZAKI CORP. HOUSING No. : 7122-6060
HOUSING No. : 7123-6060-40 REAR HOLDER : 7157-6260-30
TERMINAL : 7116-2871 TERMINAL : 7114-2871
NIPPON AMP KK
170889-1
170003-5
PRESSURE SWITCH
(RECEIVER DRYER)
MAKER : SUMITOMO
HOUSING No. : 6189-0094
MAKER : YAZAKI CORP. HARNESS SEAL : 7160-8234
7120-8019 TERMINAL : 1500-0110
CP3.96MA
FUSE 20A LIGHT SWITCH
POWER SUPPLY FOR
NIGHT LIGHTING
MAKER : YAZAKI CORP. MAKER : YAZAKI CORP. A/C MAIN POWER

HOUSING No. : 7123-2249 FUSE 5A
HOUSING No. : 7123-6020 MAIN KEY SW POWER SUPPLY FOR
TERMINAL : 17111 TERMINAL : 7116-2871 COMPRESSOR CLUTCH
FUSE 15A
FUSE 5A
MAKER : YAZAKI CORP. MAKER : YAZAKI CORP.

HOUSING No. : 7123-2237 HOUSING No. : 7123-2228
TERMINAL : 17111 TERMINAL : 17111 FUSE BOX
MAKER : YAZAKI CORP.

JAE IL-AG5-7S-S3C1 HOUSING No. : 7123-2228
TERMINAL : AG5-C1-5000 TERMINAL : 17111
COMPRESSOR
NIPPON AMP KK 174056-2 JAE IL-AG5-7S-S3C1

TERMINAL : 175062-1 TERMINAL : AG5-C1-5000
JAE IL-AG5-7S-S3C1
TERMINAL : AG5-C1-5000 MAKER : YAZAKI CORP.
HOUSING No. : 7123-2249
TERMINAL : 17111
NOTE) 1. THe double chain lines indicate the wiring

on the excavator side. MACHINE SIDE WIRING (PARTS)
2. The connector colors indicate the cord colors seen
from the connecting part.
P W B R Y G L Br Lg O
LIGHT
PINK WHITE BLACK RED YELLOW GREEN BLUE BROWN GREEN ORANGE
Fig. 25-33 Electric diagram (1/2)
25-32
CCU (OPERATION PANEL + CONTROLLER)
EVA SENSOR
AIR INLET SENSOR
SUN SENSOR
MOTOR ACTUATER
(FOR AIR MIX)
MOTOR ACTUATER
BLOWER OFF RELAY (FOR MODE)
BLOWER MOTOR
BLOWER AMP
MOTOR ACTUATER
(REC/FRESH)
COMPRESSOR RELAY
AIR CONDITIONER SIDE

WIRING (PARTS) IN THE CAB
Fig. 25-34 Electric diagram (2/2)
25-33
25.7.2 STRUCTURE AND OPERATION OF EACH FUNCTIONAL PARTS AND THE INSPECTION
(1) Control panel and control unit
The control unit is integrated into control panel, and
processes the signal input by each sensor, etc. and
the signal input by each switch through control
panel with the function of the built-in micro
Fig. 25-35
computer, and comprehensively controls each
actuator (Inner and outer air flow select, air mix),
fan motor and compressor on the output side.
And the self-diagnosis performance is provided to
facilitate the trouble shooting.
(2) Blower controller (TKS-B215A1)

The power transistor shifts the fan motor into
variable speed with base current from the control B
unit.
TERMINAL NO.
CONTINUITY
1 2 3
CONTINUED Lg L
TESTER NOT CONTINUED
CONTINUED(DIODE PARALLEL
AND FORWARD DIRECTION FLOW)
In normal operation
1. Disconnect the connector of blower amplifier.
2. Check continuity between terminals on the
blower amplifier side.
Fig. 25-36
* The installing position is provided on the left side
of air-con unit.
25-34
(3) Relay
Four-electrode relay is used for the blower OFF
relay and compressor relay.
1) Blower OFF relay
The blower OFF relay turns on after receiving the
signal from the control amplifier.
When the blower OFF relay turns on, the source
voltage is supplied to the blower motor and the
blower motor starts running.
2) Compressor relay
The relay ON—OFF is tripped by the control
amplifier and electronic thermostat control. Fig. 25-37
3) Relay inspecting items
1. Relay (24-4PE)
2. Coil resistance: 320
3. Specified voltage: DC20V~30V
4. Be careful about the coil side of relay because
this relay has polarity.
5. Inspection: Inspect the continuity between 3
and 4 according to the conditions mentioned
below.
20~30V applied between terminals 1-2:
Continued
20~30V not applied between terminals 1-2: Not
continued
(4) Air mix actuator
Air mix actuator is installed at the center of air-con
unit, and opens and closes air mix damper through
the link.
The air mix actuator contains potentiometer which
is switched by being coupled to the shaft of
actuator.
When the target air mix door position is determined CONTROL AMPLIFIER MOTOR ACTUATOR
through the temperature control switch, the control LIMITER

COOL
unit reads the level of potentiometer of the actuator, POTENTIO 5V
and determines the rotating direction of motor in

POTENTIO
POTENTIO GND
either normal rotation or reverse rotation. Then as

the motor rotates, the contact point is moved, and HOT
when the contact point is detached or the output

signal of control unit turns OFF, the motor stops
rotating. Fig. 25-38
25-35
(5) The actuator for inner and outer

The actuator for inner and outer air flow select is
installed on the blower intake unit, and opens and
closes inner and outer air damper through the link.
The actuator for inner and outer air flow select

contains position detection switch which is
switched with the movement of shaft of the
actuator. AMPLIFIER MOTOR ACTUATOR
When the inner and outer damper position is set by

the inner and outer switch on the control panel, the
control unit reads the signal of the position
detection switch in the actuator and determines the INNER AIR SIDE
rotation direction of motor in either normal rotation OUTER AIR SIDE
or reverse rotation. Then as the motor rotates, the LIMITER
position detection switch also rotates and makes it

stop at the set position of the inner and outer air Fig. 25-39
damper.
(6) Evaporator sensor
This sensor is used to control the evaporator outlet
temperature with the compressor ON-OFF to
protect the evaporator from freezing, and this
evaporator sensor functions as a sensor of this
control.
• Evaporator sensor inspecting items
(Specification)
Terminal resistance : Fig. 25-40
at 0 degree C : 7.2 k
at 25 degree C : 2.2k
(7) Dual pressure switch
This dual pressure switch is attached on L-hose
and is used to turn OFF the compressor, and
employs dual type (for high and low pressure
control) to protect the cooler cycle from possible
failure at the time when abnormal pressure was
generated on the high pressure side.
Fig. 25-41
SPECIFICATION OF DUAL PRESSURE SWITCH
0.02MPa(2.9psi) 0.59MPa(86psi)
ON
OFF
0.20MPa(29psi) 3.14MPa(455psi)
(LOW PRESSURE SIDE) (HIGH PRESSURE SIDE)
(8) Solar radiation sensor

This solar radiation sensor, which is used to correct
the solar radiation to the auto air conditioner
detects the strength and solar orientation of
sunbeam after transforming them into current by
means of photo diode.
Inspection : Check for the continuity between
Fig. 25-42
terminals.
25-36
25.8 TROUBLESHOOTING
Air temperature does not fall. Note : M/A is motor

actuator
* is any of the
numbers 0 ~ 9.
If AUTO switch or A/C switch is pushed,
"HL.E" is indicated on the set temp. display of the panel.
NO YES
"HL.*" is shown on the set temp. . Connector for air mix M/A is
display of the panel. disconnected or in poor contact.
. Air mix M/A is failed.
NO YES . Main harness shows poor continuity.
A snow mark ( ) on A snow mark ( )
the panel is flashing. on panel is flashing. Inspect and correct or replace parts.
NO YES
. Inner air sensor or harness is disconnected or shorted. . Both inner air sensor and
. Inner air sensor connector is disconnected or in poor contact. evaporation sensor are
disconnected or shorted.
See section monitor mode. . Controller failed.
See section monitor mode.

Inspect and correct or replace parts.
A
NO YES
Blowout temp. falls if temp. is set . Evaporation sensor connector

at 18.0 (64.4 ) (COOLMAX) and the is disconnected or in poor contact.
blowout mode is changed to vent mode. . Evaporation sensor is disconnected or shorted.
NO YES Inspect and correct or replace parts.
Air mix damper is Cool air flowing

in COOLMAX. into inner air sensor Inspect and correct or replace parts.
NO YES
NO YES
If M/A is at stop halfway, Turn compressor clutch
eliminate cause, correct on and off. Inspect and
correct electric circuits. Controller is faulty Inspect duct or
and measure operating or inner air sensor eliminate cause for
force. (less than 14.7N : OK) is faulty. cool air intrusion.
Refer to Troubleshooting
for refrigeration cycle.
Inspect and replace.
NO YES
. Inspect, correct or replace M/A failed or controller

M/A lever link. is out of order.
. After cleaning lever link,
apply grease.
Replace.
25-37
Air temperature does not rise. Note : * is any of

the numbers 0 ~ 9.
HL.E is shown on the set temp. display of the panel.

NO YES
"HL. " is shown on the set temp.

* . Connector for air mix M/A is
display of the panel. disconnected or in poor contact.
. Air mix M/A is failed.
NO YES . Main harness shows poor continuity.
. Inner air sensor or harness is disconnected or shorted.
. Inner air sensor connector is disconnected or in poor contact. Inspect and correct or replace parts.
NO YES
NO YES
Blowout temp. rises at blowout
mode if temp. is set at
HOT MAX 32.0 (64.4 )
NO YES
Air mix damper is Warm air is flowing into

in HOT MAX. inner air sensor.
NO YES
NO YES
If M/A action is at stop, Inspect warm water piping.
eliminate cause, correct
Controller or Inspect duct or
and measure operating
inner air sensor eliminate causes
force. (less than 14.7N : OK)
is out of order. for warm air entry.
NO YES
Inspect and replace.
. Inspect, correct or M/A failed or controller

replace M/A lever link. is out of order.
. Clean lever link and apply grease.
Replace.
25-38
Blower motor does not run.
At air flow HI, battery voltage acts across

Note 1) both terminals (+) and (-) of blower motor.
NO YES
Battery voltage acts across red Blower motor fails.

(+) and body of blower motor.
NO YES Replace.
Inspect blower motor relay. Blower motor Approx. 10V acts across light green wire
Note 2) rotates if white / red wire and red wire of and grounding of blower amplifier.
blower motor relay are direct connected.
NO YES
NO YES
Controller is out of order. Remove blower amplifier and check for

Wire harness is Replace continuity across light green wire
faulty. Inspect and black wires ; you get continuity.
and correct or replace.
NO YES
Battery voltage acts across white /

red wire and body of blower motor relay. Eliminate cause Inspect and
and replace repair harness.
NO YES blower amplifier.
Inspect and repair Blower turns if orange wire of blower motor relay
harness or replace. is connected with ground.
NO YES
Replace relay. Inspect and correct harness

or replace controller.
Note 1) Measure with connector set.

Note 2) Always turn off air-conditioner, starter key switch and light switch before work.
25-39
Blower motor speed does not change.
CASE (1)
Note) is any of the
"HL. " is shown on the set temp. display of the panel.
* *
numbers 0 ~ 9.
NO YES
Replace blower . Inner air sensor or harness is disconnected or shorted.

amplifier controller. . Inner air sensor connector is disconnected or in poor contact.
CASE (2)
Does not blower motor speed

change because the setting mode
is other face mode?
YES NO
Is door or front window open? See CASE (1).
YES NO
The limiting or control operation See CASE (1).

is actuated by door switch or
front window switch.
25-40
Magnet clutch does not engage.
Snow mark ( ) lights

if A/C switch is pressed.
No Yes
Snow mark ( ) flickers and E is Voltage acts upon clutch.

shown on panel display.
No Yes
To A On page 25-37. Voltage is applied to Clutch faulty.

pressure switch harness.
No Yes
Voltage acts across white / green wire and Pressure switch is faulty or refrigerant
Ground (Black) connector connected to excavator. gas is under charged or overcharged.
No Yes
Refer to troubleshooting
for refrigeration cycle.
Inspect clutch Inspect air-conditioner
fuses. harness. No fault.
No Yes
Replace harness. Replace controller.
Inner air and outer air do not change over.
Inner / outer air mode display on

operation panel is flickering.
No Yes
M/A lever includes foreign matter Connector of inner/outer air

or is broken. M/A is disconnected or in poor
No Yes contact.
Or M/A failed or main harness failed.
M/A failed Remove foreign matter

and replace parts. Inspect or replace.
Replace
25-41
Modes do not change.
Mode display (Mark of person)

on operating panel is flickering.
No Yes
M/A rod does not disengage. Mode M/A connector is

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

by hand, it is heavy. (more than 19.6N.)
No Yes
M/A or controller is out of order. . Cam or damper shaft includes

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

. Clean cam and apply new grease.
25-42
Trouble with refrigeration cycle.
Both high and low pressures are lower.

Low pressure is higher.
NO YES
Air bubbles are seen in sight glass.
Air bubbles are seen in High pressure
sight glass. is lower.
NO YES
Cooling does not work Oil comes out from

if run at high speed. piping and parts. Compressor cylinder Compressor cylinder
does not get hot. gets very hot.
NO YES NO YES
Expansion valve Expansion valve Natural Gas leaks
is clogged or is frozen or leak from from pipe
maladjusted. intruded by water. hose. joints and Expansion valve is Compressor does
parts. maladjusted. not discharge well.
(too much open)
Adjust or replace After making
expansion valve. vacuum, refill Retighten
refrigerant Charge gas. or replace
and replace parts.
receiver. Replace Replace compres
expansion valve.
High pressure
is lower.
Air bubbles are seen in sight glass.
NO YES
High pressure gets Condenser is

lower slowly. fouled or clogged.
High pressure YES NO

circuit before
receiver is Air bubbles are hard to
clogged up. go out even if water
is poured on condenser.
Remove Clean
clogging or condenser. Air is mixed.
replace parts. Make vacuum and
refill refrigerant.
25-43
25.9 SELF DIAGNOSIS FUNCTION ON DISPLAY OF PANEL

The failure of motor actuator and each sensor can be identified on the display of panel.
25.9.1 POSITION OF INDICATION FOR FAILURE.
The error is indicated on 3 digits segment.
25.9.2 EXPLANATION OF INDICATION FOR FAILURE.

(1) Failure of Motor Actuator
1) HL.E is indicated on 3 digits segment.
Check harness or connector to motor actuator

for the air mix damper for disconnection.
2) MODE is flickering.
Check harness or connector to motor actuator

for the air outlet damper for disconnection.
3) R/F is flickering.
Check harness or connector to motor actuator for the inner and outer
air damper for disconnection.
Note) The above indication and flickering does not function if the
harness and connector were disconnected under the condition
the panel ON/OFF switch is ON.
After the failure was occured, if the panel ON/OFF switch is
turned ON, it functions.
After correction of failure, if the main switch is not switched from
OFF to ON the error indication and flickering are not released.
25-44
(2) Failures of sensors

1) HL.* is indicated on 3 digits segment.
Check the inner air sensor or the harness for disconnection

and short circuit, and also connectors for disconnection.
(* is any of the numbers 0 to 9.)
2) **E and mark are flickering.
(** is displayed leaving the present set temperature value.)
Check evaporator sensor or the harness for disconnection

and short circuit, and also connectors for disconnection.
Note) The above displays in items 1) and 2) are indicated by 3 digits segment when error occurred under the
condition the panel ON/OFF switch is ON.
And, after correction of failure if the panel ON/OFF switch is switched from OFF to ON, the error indication is
released.
(3) Communication error of control amplifier and panel

1) E is indicated on the only use segment of display.

25-45
25.9.3 EXPLANATION OF MONITOR MODE

When error of 25.9.2 (2) sensors is displayed, the monitor mode is available to identify the sensor condition
(disconnection, short circuit).
(1) Position of monitor mode indication
SEGMENT FOR ONLY MONITOR INDICATION

3 DIGITS SEGMENT
(2) Operation of monitor mode
SPEED UP AND DOWN

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

0 INNER AIR SENSOR
1 EVAPORATOR SENSOR
2 SOLAR RADIATION SENSOR
(Excluding above mentioned indications, for example "from 3 to 9 and from B to F" are not used at service work.)
5) The monitor display is terminated by pressing the inner and outer air flow select switch (R/F) and ON/OFF
switch for 1 second again, or turning off the main switch of excavator.
Notes)
1. The air conditioner is turned off while the monitor mode is in operation, and all switches are not available for
operation and setting until the monitor mode is cancelled.
2. Even if each sensor is corrected while the monitor mode is in operation, the error display is memorized.
Therefore turn on ON/OFF switch again, and the error display is disappeared.
25-46
(3) Contents of monitor mode display

Refer to the list of segment display exclusively used for monitor and the list of segments in three digits.
1) Example 1
THIRD SEGMENT
SECOND SEGMENT
When the segment exclusively used for monitor indicates 0
(displays the inner air sensor condition),
since the segment indicates 3F, the sensor is in normal
operating condition according to the list of 3 segments.
--> The inner air sensor is in normal operating condition.
2) Example 2

(displays the evaporator sensor condition),
since the segment indicates 00, the sensor is
in disconnection condition according to the list of 3 segments
--> The evaporator sensor is in disconnection condition.
3) Example 3

(displays the solar radiation sensor condition), since the
segment indicates FF,the sensor is in short-circuiting condition
according to the list of 3 segments.
-->The solar radiation sensor is in short-circuiting condition.
4) List of 3 segments
SECOND SEGMENT
INNER AIR SENSOR DISCONNECTION (0CH0 INDICATED)

EVAPORATOR SENSOR DISCONNECTION (0CH1 INDICATED)
SOLAR RADIATION SHORT-CIRCUITING (0CH2 INDICATED)
THIRD SEGMENT
EACH SENSOR IS NORMAL
SOLAR SENSOR 5V SIDE SHORT-CIRCUITING (C7H2 INDICATED)
INNER AIR SENSOR SHORT-CIRCUITING (F6H0 INDICATED)

EVAPORATOR SENSOR SHORT-CIRCUITING (F6H1 INDICATED)
25-47
[MEMO]
25-48
31. DISASSEMBLING AND ASSEMBLING
TABLE OF CONTENTS
31.1 EXPLAINING CHAPTER OF WHOLE DISASSEMBLY & ASSEMBLY...........................31-3

31.1.1 FORM FOR CHAPTER OF DISASSEMBLY & ASSEMBLY ..................................31-3
31.1.2 INDICATION OF TIGHTENING TORQUE .............................................................31-3
31
31-1

SK250-8: LQ12-06001~ S5YN3118E01
First edition October, 2006 K
SK260LC–8 : LL12-05001~ (ASIA, OCE)
↑ December, 2006 SK850LC: LY01-00101~ ↑ K
E235BSR : YF05-02001~ ↑
E235BSR(N)LC : YU05-02001~ (NHK)
↑
↑ ↑ SK235SRLC-2 : YU05-02001~ K
(North America)
E215B : YN11-45001~ ↑
↑ March, 2007 K
SK235SR-2 : YF05-02001~ ↑
↑ April, 2007 K
SK235SRLC-2 : YU05-02001~ (OCE)
SK200-8 : YN11-45001~ ↑
↑ ↑ K
SK250-8: LQ12-06001~ ↑
↑ May, 2007 K
E225BSR : YB05-03001~ ↑
↑ June, 2007 K
E225BSRLC : LA05-02001~ (NHK)
↑
↑ ↑ SK215SRLC : LA05-02001~ K
(North America)
E135BSR : YY05-12001~ ↑
↑ July, 2007 K
E135BSRLC : YH05-07001~ (NHK)
SK225SR : YB05-03001~ ↑
↑ ↑ K
SK225SRLC : LA05-02001~ (OCE)
SK460-8: LS10-02001~ ↑
↑ ↑ K
SK480LC–8 : YS10-01501~ (ASIA, OCE)
E215B : YN11-45001~ ↑
↑ ↑ K
E265B : LQ12-06001~ ↑
↑ ↑ K
↑
↑ ↑ ↑ K
(NHK Middle East)
E215B : YN11-45001~ ↑
↑ ↑ K
↑
↑ ↑ ↑ K
E385B : LC10-07001~ ↑
↑ August, 2007 K
E265B : LQ12-06001~ ↑
↑
↑ ↑ ↑ K
↑
↑ ↑ SK135SRLC-2 : YH05-07001~ K
(North America)
SK125SR : YV05-04501~
↑
(OCE/S.E.ASIA)
SK135SRLC-2 : YH05-07001~
31-2
31.1 EXPLAINING CHAPTER OF WHOLE DISASSEMBLY & ASSEMBLY

31.1.1 FORM FOR CHAPTER OF DISASSEMBLY & ASSEMBLY
This chapter is consist of 3-Section as follows.
(1) ATTACHMENTS .................................................................Chapter 32
1) Removing and Installing
2) Disassembling and Assembling
a. Cylinder
(2) UPPER STRUCTURE ........................................................Chapter 33
a. Hydraulic pump
b. Control Valve
c. Pilot Valve (ATT)
d. Pilot Valve (Travel)
e. Slewing Motor
f. Swivel Joint
(3) TRAVEL SYSTEM ..............................................................Chapter 34
a. Travel Motor
31.1.2 INDICATION OF TIGHTENING TORQUE

Tightening torque is indicated as follows, for example ;
T=98N•m(72 lbf•ft)
Tolerance is ±10% unless otherwise specified.
• Refer to "Chapter 11 TOOLS" for standard tightening torque.
31-3
[MEMO]
31-4
32. ATTACHMENT
TABLE OF CONTENTS
32.1 REMOVING AND INSTALLING.......................................................................................32-3

32.1.1 ATTACHMENT ASSY.............................................................................................32-3
32.1.2 BUCKET .................................................................................................................32-3
32.1.3 ARM........................................................................................................................32-6
32.1.4 BOOM.....................................................................................................................32-9
32.2 DISASSEMBLING AND ASSEMBLING...........................................................................32-13
32.2.1 CYLINDER..............................................................................................................32-13
32
32-1
32. ATTACHMENT

SK125SR : YV05-04501~
S5YY3213E01
(OCE/S.E.ASIA)
SK135SRLC-2 : YH05-07001~
PREFACE
(1) This Manual describes all the procedures from removing to attaching, arranging them by item.
(2) This Manual consists of 2 sections. "Removing and Installing", and "Disassembling and Assembling".
(3) The removing and installing can be performed in the procedure specified in Table of Contents, but in view of
actual repairing or time saving some process can be omitted.
(4) The removing and installing procedure does not completely cover all possible situations because of differences
of field condition and defective section.
(5) Please be aware that the procedure to be followed must be determined according to the above conditions.
When disassembly and assembly are required, select the necessary section, itemize the work contents with
good understanding, then starts working.
32-2
32. ATTACHMENT
32.1 REMOVING AND INSTALLING

32.1.1 ATTACHMENT ASSY
(D) ARM CYLINDER HEAD PIN (C) BOOM CYLINDER ROD PIN
4. BOOM (A) BOOM FOOT PIN
(E) ARM CYLINDER ARM CYLINDER

ROD PIN
(F) BOOM TOP PIN
(G) BUCKET CYLINDER

HEAD PIN
3. ARM
BUCKET CYLINDER
(J) BUCKET DRIVE PIN
(I) IDLER LINK PIN
IDLER LINK BUCKET LINK (H) BOOM CYLINDER
(H) BUCKET CYLINDER ROD PIN (K) BUCKET ATTACHING PIN HEAD PIN
Fig. 32-1 Front attachment and position
32.1.2 BUCKET
32.1.2.1 REMOVING BUCKET

(1) Put the machine in position to remove bucket.
Fig. 32-2 Position to remove bucket

(2) Removing pin (2)
BOSS SECTION
Expand slit of ring (1) with screwdriver, and remove
it. Push out the pin (2) with flat-blade screwdriver . DRIVER
1 2
SECTION OF BOSS
Fig. 32-3 Removing pin (2)
32-3
32. ATTACHMENT
(3) Removing bucket attaching pin (K)

Lift up bucket, position it so that bucket attaching
pin (K) is not loaded, adjust bucket link, and pull out
K
bucket attaching pin (K).
Fig. 32-4 Removing bucket attaching pin

(4) Removing bucket drive pin (J)
Put bucket on the ground, position it so that the
bucket drive pin (J) is not loaded, adjust bucket link, J
and pull out pin (J).
Store the removed pin (J) in original position again.
Fig. 32-5 Removing bucket drive pin
32.1.2.2 ATTACHING BUCKET

(1) Attaching bucket drive pin (J)
Attach bucket drive pin (J) first, then continue in the
reverse procedure of removing.
J
• When aligning the pin holes, do not put your

finger in the pin holes, but align them visually.
• Check the seals for damaged and replace as
necessary.
• When inserting the pin, coat the shaft with
grease.
Fig. 32-6 Attaching bucket
32-4
32. ATTACHMENT
32.1.2.3 PROCEDURE FOR ADJUSTING CLEARANCE

Adjustment of clearance between bucket and arm Apply rust preventive oil +1.0 +0.039"
251 -0.5 (9.88 -0.020" )
(1) Shift O-ring (3) toward the bucket boss, using a New bucket
spatula. (a→b) B
3 : O-RING
12 : WASHER
11 : CAPSCREW b a
(2) When adjusting clearance (B), bring the non-
adjusting side of the bucket in contact with the arm.
(3) Measure clearance (B) and check that it is within

1.0mm (0.04in). 7 : BUSHING
8 : PLATE
(4) Adjust clearance (B) where it is more than 1.0mm
Install pin (10) until the top
(0.04in). 9 : SHIM 10 : PIN of pin is even surface
with bushing.
(5) An average of 5 shims (9) of 1mm (0.04in)

thickness are set in the plate (8) fixed by the three
capscrews (11). The clearance can be decreased
Fig. 32-7 Adjusting clearance between bucket and
by 1mm (0.04in) if one shim is removed.
arm
: 22mm,
Tightening torque : 181N•m (133 lbf•ft)
(6) After adjustment, tighten the capscrews evenly.

• The gap exceeding the specified dimension
causes early wear.
(7) Operate the bucket and confirm that the total sum
of both clearance is within 1.0mm (0.04in).
(8) Replace O-ring (3) on its original position.
• When shifting O-ring (3) by means of a spatula, use

care so as not to damage O-ring (3).
• Remove shims (9), push out bushing (7) rightwards
by means of three capscrews (11) and adjust
clearance (B) so it settles within the standard value
evenly all round.
32-5
32. ATTACHMENT
32.1.3 ARM
32.1.3.1 REMOVING ARM

(1) Put the machine in position to remove arm.
Extend the arm cylinder, retract the bucket cylinder
and bring the arm down on the ground.
Fig. 32-8 Position to remove arm

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

Plug : Tools section 11.5.2-(4)
Tools section 11.5.2-(5)
OIL PAN
When the removal of bucket cylinder is not
required, skip to procedure (6). Fig. 32-9 Disconnecting piping of bucket cylinder
(3) Removing bucket cylinder rod pin (H) After adjustment of shim, the total gap
Loosen nut (9), remove capscrew M14×115 (8), should be within 0.6~1.0mm (0.02~0.04in).
SHIM
and push out pin (H).
9
: 22mm
8
G A
H D A
H SECTION D-D
Install plastic shims
to bucket link side.
D
PLASTIC SHIM STEEL SHIM

Fig. 32-10 Detail of bucket cylinder rod pin (H)
(4) Removing cylinder head pin (G)
Install plastic shims
Loosen nut (3), remove capscrew M16×130 (2), to bucket link side.
and push out pin (G). 3 2
SHIM
After adjustment of
shim, the total gap
should be within
: 24mm 0.6~1.0mm (0.02~0.04in).
SHIM Apply grease
to inner wall
of bushing
G
SECTION A-A
Fig. 32-11 Detail of bucket cylinder head pin (G)
32-6
32. ATTACHMENT
(5) Removing bucket cylinder

Sling tube of bucket cylinder with nylon sling, and
remove it.
Bucket cylinder weight : 82 kg (181 lbs)
Fig. 32-12 Slinging bucket cylinder

(6) Removing arm cylinder rod pin (E)
Apply grease to inner wall
Put a wooden block between the arm cylinder and of bushing
the boom. Install plastic shims 2
Loosen nut (3), remove capscrew M16×130 (4), to bucket link side.
SHIM
and push out arm cylinder rod pin (E). E
: 24mm
Retract arm cylinder rod, and return pin (E) to the 3

SHIM
original position (hole). After adjustment of shim, the total gap
should be within 0.6~2.0mm (0.02~0.08in).
SECTION B-B
E
BLOCK Fig. 32-13 Detail of arm cylinder rod pin (E)
(7) Removing boom top pin (F)

Loosen capscrew M12×45 (2), and pull out boom Tightening torque 144N.m (106 lbf.ft)
Apply loctite #242 to bolt.
top pin (F). 2 1
: 19 mm SHIM
Install plastic
shims to arm
Insert pin (F) into the original hole. side.
SHIM Apply grease

to inner wall
After adjustment of of bushing
shim, the total gap
should be within
0.5mm (0.02in).
F
SECTION A-A
Fig. 32-14 Detail of boom top pin (F)
32-7
32. ATTACHMENT
(8) Slinging arm assy

Sling arm with nylon sling and remove it.
Arm weight : 380 kg (838 lbs)
Fig. 32-15 Slinging arm assy
32.1.3.2 ATTACHING ARM

Instal the arm in the reverse order of removing, paying
attention to the following :
1) When aligning the pin holes, do not put your
2) Check the seals for damage and replace as
necessary.
3) When inserting the pin, coat the shaft with
grease.
4) Pin lock nut handling procedure
(0.02")
CLEARANCE
: 22, 24 mm
5) When installing the arm and the cylinder, inspect

the clearance in the thrust direction of the pins
and decide the thickness of shims by referring to
the Maintenance Standard.
6) Tightening torque
Tightening torque
Classfication Size
N.m lbf.ft
M12 115 84.8
Metric threads M14 144 106
M16 147 108
PF,PT threads 1/8" 16.7 12.3
32-8
32. ATTACHMENT
32.1.4 BOOM
32.1.4.1 PREPARATION FOR REMOVING AND ATTACHING BOOM

When removing and attaching boom in the position
shown in Fig. 32-16, to remove and attach boom foot
pin (A), removing and attaching of cab and guard are
required.
32.1.4.2 REMOVING BOOM

(1) Put the machine in position to remove boom.
Place top end of boom down on block, etc. giving
attention for arm cylinder rod not to be extended.
BLOCK
Fig. 32-16 Position to remove boom

(2) Lifting up boom cylinder temporarily
Remove the right and left boom cylinders one side
by one side according to the following procedure:
Lift up boom cylinder temporarily to prevent it from
A
dropping.
A
STAND
Fig. 32-17 Lifting up boom cylinder temporarily

(3) Press the boom cylinder rod pin (C)
Install plastic shim to cylinder side.
At the one side of pin (C), loosen nut (5), remove SHIM
capscrew (3) (M14×135), and remove collar (4). After adjustment of shim,
the total gap should be within
And push pin (C) to the end of boom boss. 0.6~2.0mm (0.02~0.08in).
SHIM
: 22 mm
4 3
(4) Preparing for disconnecting cylinder pipes

C
Retract the above mentioned cylinder rod, and 4
place one side of cylinder on stand. (See Fig. 32-
17) 5
SECTION A-A
Fig. 32-18 Detail of boom cylinder rod pin (C)
32-9
32. ATTACHMENT
(5) Disconnecting the arm cylinder and bucket cylinder A1

pipings A3
Release pressure from arm and bucket circuit and
bleed air in hydraulic tank, and then disconnect
A2
pipe at (A1), (A2), (A3), (A4) and 4 hoses.
HOSE (4 pieces)
A4
: 27, 36 mm
After disconnection of pipe, plug every pipe. 825 (32.5")

ARM (R)
)
BUCKET (H
ORS Plug : See Tools 11.5.2-(4). 795 (31.3")
ARM (R)
BUCKET (H)
100 (2.76
70
(3.9 ") AR
ARM (H) 4")
BU M (H)
100 (5.12")
CK
130
BUCKET (R) ET )
BUCKET (R
(3.9 )BBUUC
Apply Loctite #242.

825 (32.5")
(H)
4"))A CKKEE
5 (3 3. 7" ) ARM (H)

85
ARRM TT(
M(H(
H)) H))
SECTION CC VIEW I Fig. 32-19 Boom piping disconnection

H(
(6) Lifting up boom assy temporarily

Lift up boom with nylon sling so that boom foot pin
(A) is not loaded.
Weight of single boom :
SK125SR : 940 kg (2,070 lbs)
SK135SR-2 : 1,250 kg (2,760 lbs)
BLOCK
Boom assy temporary lift up procedure
(7) Removing boom foot pin (A) After adjustment of shim,

the total gap should be SHIM
1) Loosen nut (3) or washer (4) and remove within 0.5mm (0.02in).
capscrew (2). 2
2) Draw out pin (A).

A 4
3
Apply molybdenum addition
grease to inner wall of bushing.
Install plastic shim to boom side.
SECTION A-A
Fig. 32-20 Details of boom foot pin (A) section
32-10
32. ATTACHMENT
(8) Hoisting boom assy

Hoist and remove boom assy.
Weight of single boom :

SK125SR : 940 kg (2,070 lbs)
SK135SR-2 : 1,250 kg (2,760 lbs)
D
D
BLOCK
Boom assy hoisting procedure
(9) Completion of removal of front attachments

When the removing and attaching of cylinder are
not required, the work is finished. 2
(10)Removing and installing arm cylinder

F2
1) Lift up arm cylinder (2) with nylon sling so that
the head of cylinder is not loaded.
2) Disconnect hose (F1) and (F2) at position A. After adjustment of
After disconnection of hose, plug both ends of shim, the total gap
should be within F1
hose. 0.6~2.0mm (0.02~0.08in).
3 2 A
Install plastic shim to
Plug : TOOLS cylinder side. SHIM
11.5.2-(4) Plugs for ORS fitting SHIM
:27, 30, 32, 36 mm Apply grease
to inner wall
of bushing
3) Removing arm cylinder head pin (D)

Loosen nut (3), remove capscrew M16×130 (2) D
and pull out pin (D). SECTION D-D
Fig. 32-21 Removing arm cylinder
: 24mm
4) Removing arm cylinder (2)

Weight of arm cylinder : 140 kg (309 lbs)
32-11
32. ATTACHMENT
(11)Removing and installing boom cylinder

1) Release pressure from boom circuit and bleed
air in hydraulic tank.
2) Sling boom cylinder (2) using nylon sling
temporally not to act the weight of cylinder upon
the cylinder head. 2
3) Disconnect each two hoses (C2) and (C3). And
plug their both ends. 2
B
Plug : TOOLS 11.5.2-(4) Plugs for ORS fitting
: 27,32mm C3
C2
C3
Fig. 32-22 Removing and installing boom cylinder
4) Removing boom cylinder foot pin (B) After adjustment of shim,
(See Fig. 32-23,Fig. 32-24) the total gap should be within
0.6~2.0mm (0.02~0.08in).
Loosen nut (5), remove capscrews M10×20 (3) SHIM Apply grease
to inner wall
and pull out pin (B). of bushing
B B
: 17mm
5) Remove boom cylinder (2). 3

Weight of boom cylinder : 96 kg (212 lbs) Apply grease
to inner wall SHIM
6) Remove another boom cylinder the same way. of bushing
Install plastic shim
to cylinder side.
SECTION B-B
Fig. 32-23 Removing and installing boom cylinder

head pin (B)
32.1.4.3 ATTACHING BOOM

(1) Attaching boom foot pin (A)
First of all, insert boom foot pin (A) and install the
boom assy.
Attach it in the reverse procedure of removing,
paying attention to the following points.
A
1) When aligning the pin holes, do not put your
2) Check that the dust seals is not damaged and
replace as necessary.
3) When inserting the pin, coat the shaft with
grease.
4) M16 capscrew tightening torque : 279 (3.11) N•m
B
(205 lbf•ft)
5) When installing boom and cylinder, check the
clearance of mounting section in thrust direction,
Fig. 32-24 Boom foot pin (A)
and decide the thickness of shim according to
the maintenance standard.
Install plastic shim first, and insert iron shim into
remaining gap.
Regarding the position of shim, refer to Fig. 32-
20.
32-12
32. ATTACHMENT
32.2 DISASSEMBLING AND ASSEMBLING

32.2.1 CYLINDER
32.2.1.1 PREPARATION BEFORE DISASSEMBLY

Before assembly, secure a dustfree workshop and necessary equipment and facilities.
32.2.1.1.1 WORK AREA

The following working area is required for disassembly:
(1) Ample space
For the disassembly of the hydraulic cylinder, the cylinder tube and the piston rod must be drawn out. For this
reason, the first condition is that the working area is long enough for the work. In terms of width, it is also
necessary to keep sufficient space to disassembly, cleaning and measuring equipment are placed and the work
can be performed.
(2) Suitable working environment
The hydraulic cylinder is a precision-machined product that uses seals and packings made of rubber and plastic
materials. For this reason full care should be exercised so the hydraulic cylinder is free from dust, dirt, and in
particular, such hard particles as sand, metal chips, and weld slag (spatter). If the hydraulic cylinder is
assembled with hard particles adhered on such components as the cylinder tube and the piston rod, the tube
inner surface and the rod surface are scratched as the cylinder operates, consequently disabling it in worst
cases. Damage to the piston seals and the rod seals will result in oil leaks. For this reason, grinding and welding
operation should not be performed in the neighborhood of the working area to keep it clean.
32.2.1.1.2 APPARATUS
The following equipment are required for disassembly:
(1) Hoist or crane
The hoist or crane must be capable of carrying the cylinder in an assembled condition. It must also be capable
of making level and liner movement under load for retracting and extending the piston rod and the tube.
(2) Work bench
The work bench must have strength and rigi-dity capable of accommodating the total length of the cylinder in its
most retracted condition and of withstanding the repulsive force of the tightening torques of the cylinder head
and the piston nut. Since a vise is attached to the bench, the width of the work bench must be sufficiently large.
(3) Support stand
If the piston rod is fully extended in a free condition, the bushing and the seals may be damaged as the rod
bushing and the piston are twisted due to the weight of the rod. A stand is required to support the rod to prevent
damage of seals.
(4) Hydraulic source
A Hydraulic source is required for disassembly and assembly of the cylinder head and piston nut and for oil leak
tests after completion of assembly.
(5) Jet air source
It is used for drying after oil draining and cleaning of the cylinder.
(6) Cleaning bath, cleaning oil and detergent
(7) Oil pan and oil reservoir
An oil pan is necessary to contain oil drained from the cylinder and oil spilt during work.
An oil reservoir is required to collect oil spilt on the floor and waste oil.
(8) Others
Oil extracting hoses, wooden blocks, clean cloths and sawdust in which oil soaked are also necessary.
32-13
32. ATTACHMENT
32.2.1.1.3 NECESSARY TOOLS

Tools and jigs vary with types of cylinder, but it is necessary to prepare the tools in Table32-1 as a guideline.
Table32-1 List of Tools and Jigs
Tool / Jig Remarks Tool / Jig Remarks
Hammer 1. Steel hammer Spatula Metallic one with smooth corners.
2. Wooden or plastic mallet
Screwdriver A few types of large and small sizes Gimlet A sharp-point tool may be used in place of a
gimlet.
Chisel Flat chisel Special jig 1. For piston nut.
2. For inserting and reforming seal.
3. For inserting rod cover.
4. For press fitting bushing.
See para 32.2.1.9 for detail)
Vise One having an operation wide enough to Rust
hold cylinder head O.D. and tube remover
mounting pins (clevis)
Wrench 1. Eye wrench Measuring 1. Slide caliper
2. Allen wrench instruments 2. Micrometer
3. Extension pipe for wrenches
3. Cylinder gauge ( Fig. 32-25)
4. V-block
• For the details of special tools and jigs, refer to the back pages of this manual.
32.2.1.1.4 EXTERNAL CLEANING

The cylinder taken off the excavator has dust and
foreign matter, and grease is usually adhered to the
clevis part. For this reason, remove external soil and
contamination from the cylinder with water and steam Fig. 32-25 Cylinder gauge
before bringing it into the workshop.
• The following describes the construction of boom
cylinder. When disassembling and servicing the
cylinder, confirm the construction of cylinder
referring to Parts Manual.
32.2.1.1.5 DISCHARGING OIL

Place a wooden-block on the work bench and place the
WOODEN BLOCK
cylinder on it to prevent it from rotating. Charge air into
ports A and B alternately to actuate the piston rod till the
PORT B
hydraulic oil in the cylinder is drained out. At this time, V BLOCK
connect a suitable hose to each port so that the
hydraulic oil may not gush out. PORT A
AIR
OIL PAN
Fig. 32-26 Preparation
32-14
32. ATTACHMENT
32.2.1.2 CONSTRUCTION OF CYLINDER (GENERAL EXAMPLE OF CYLINDER)
32 2
32 4
2 4-M10 P1.5 TAP DP 17 MIN
11 5 10,9 8 26 6 7 14 12,13 3 1 15 16 19 18 17 20,21 22 23 25 24
PT1/8
PT1/4
27,28,29,30,31
Fig. 32-27 Construction of general cylinder
P/No YY01V00054F1
No. Parts name Q’ty No. Parts name Q’ty No. Parts name Q’ty
1 Cylinder tube 1 12 O-ring : 1B G110 1 23 Set screw : M8 1
2 Oiles bush 2 13 Back-up ring 1 24 Cushion plunger 1
3 Rod assy 1 14 O-ring : 1B G115 1 25 Stop ring 1
4 Oiles bush 2 15 Cushion ring 1 26 Socket bolt : M16 10
5 Rod cover 1 16 Piston 1 27 Check valve 1
6 DD-bushing 1 17 Slip seal 1 28 Spring 1
7 Retaining ring 1 18 Wear ring 2 29 Spring 1
8 Buffer seal 1 19 Dust ring 2 30 O-ring : 1B P14 1
9 U-packing 1 20 O-ring 1 31 Plug : PT3/8 1
10 Back-up ring 1 21 Back-up ring 2 32 Wiper ring 4
11 Dust seal 1 22 Piston nut 1
32-15
32. ATTACHMENT
32.2.1.3 DISASSEMBLY
• When disassembling and servicing the cylinder,
check the construction and the availability of
service parts as well as necessary tools and jigs
on separate Parts Manual.
• The figures in parentheses after part names
correspond to those in Fig. 32-27.
• The following explanation and quantities are for
a general use cylinder which has separated
piston and piston nut.
In case that piston and piston nut are combined,
the construction differs from separated type,
refer to the sentence in parenthesis.
32.2.1.3.1 REMOVING ROD COVER AND PISTON ROD

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

surface of the cylinder tube. Do not make use of the
outside piping as a locking means.
(2) Pull out piston rod (3) about 200mm (8in). Because
the piston rod is heavy, finish extending it with air
200mm
pressure after the above-mentioned oil draining (8")
operation.
(3) Loosen and remove socket bolts (26) of the rod
cover in sequence.
Fig. 32-28
Cover the extended piston rod (3) with cloths to prevent
it from being accidentally damaged during operation. ALLEN WRENCH 26
(4) Strike the corner of the rod cover flange by means

of a plastic mallet till rod cover (5) comes off.
Turn counterclockwise
5
Cover here with cloths
3
Fig. 32-29
32-16
32. ATTACHMENT
• At this time, the weight of piston rod (3) is loaded KNOCK THIS EDGE
on rod cover (5). Therefore, lift the top end of the WITH A PLASTIC MALLET.
LIFT HERE.
piston rod with a hoist to the extent that only the
rod weight may be held.
5
3
Fig. 32-30 Drawing out piston rod assy (2).
(5) Draw out the piston rod assy from cylinder tube (1). LIFT HERE. 1
PULL STRAIGHT
SIDEWAYS
Since the piston rod assy is heavy in this case, lift the HORIZONTALLY
tip of the piston rod (3) with a hoist and draw it out.
However, when piston rod (3) has been drawing out to
approximately two thirds of its length, lift it in its center OIL PAN
to draw it completely. However, since the plated surface
Fig. 32-31 Method of drawing out the piston rod
of piston rod (3) is lifted, do not use a wire rope which
assy
may score the surface, but use a strong cloth belt or a
rope.
(6) Place the removed piston rod on a horaizontal

wooden V-block.
PISTON ROD ASSY
• Cover a V-block with cloths.

WOODEN V-BLOCK
(PLACE CLOTHS)
Fig. 32-32 Method of placing the piston rod
(7) Remove wear ring (18) and dust ring (19) from 16
piston (16). Remove slide ring by
widening the slit toward
the arrow
19
18
Fig. 32-33 Remove wear ring (18) and dust ring (19)
32-17
32. ATTACHMENT
32.2.1.3.2 REMOVING PISTON ASSY

(1) Fix piston rod (3) by holding its clevis section in a 5 WOODEN BLOCK
vise. Fix the piston rod (3) securely as piston nut 3
(22) is tightened to a high torque. 16
22
• Note that the tightening torque differs with the type,

the working pressure and the mounting method of
the piston (16), though the rod diameter remains
the same.
• It is also necessary to place a suitable supporting
block near the piston (16). In case a V-block is
WOODEN V-BLOCK
used, put cloths or something over the rod to (PLACE CLOTHS)
prevent it from damage.
Fig. 32-34 How to loosen piston nut (22)
(2) Scrape off the caulked part of setscrew (23) of
DRILL
piston nut (22) by means of a hand drill and loosen
remove setscrew (23).
: 4 mm
22
23
Fig. 32-35 Removing setscrew (23)

(3) Loosen and remove piston nut (21).
Since piston nut (22) is tightened to a high torque, use TURN COUNTER
CLOCKWISE.
a hook wrench suitable for the outside diameter of 16
piston nut (22). Use care so the hook of the wrench is EYE WRENCH
22
positively fixed in the groove of the piston nut perimeter.
Fig. 32-36 How to loosen piston nut (22)
(4) Loosen piston (16) with a pin wrench as shown in

Fig. 32-37, utilizing the two holes in the side face of
the piston. If the O-ring (20) comes off, the piston
may be turned easily by hand. When removing the TURN COUNTER
last thread of the piston, hold the piston by hand to CLOCKWISE
receive the weight EYE WRENCH
3 16
Fig. 32-37 Removing piston (16)
If the piston is dropped with a bang, the O-ring seal face
on the piston interior may be damaged with the threads.
32-18
32. ATTACHMENT
(5) After removing cushion ring (15), separate rod

LIFT WITH A HOIST. STRIKE WITH
cover (5) from piston rod (3). If it is too hard to slide
A PLASTIC MALLET.
it, knock the flanged part of rod cover (5) with a
PULL STRAIGHT.
plastic mallet. But when drawing it out, lift rod cover
(5) by hoist and pull it straight horizontally.
NOTE:
DO NOT
DAMAGE
PISTON ROD
SURFACE.
Take care so rod bushing (6) and the lip of packings
(8,9,10,11) may not be damaged by thread of the piston
rod (3).
5 6 8 9,10 11 3
Fig. 32-38 Removing rod cover (5)
32.2.1.3.3 DISASSEMBLING PISTON ASSY

(1) Remove piston seal assy (17).

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

Fig. 32-39 Removing piston seal (17)
(2) Separate O-ring (20) and back-up ring (21) from
piston (16). 21 17-1 17-3 17-2
After removing two back-up rings (21), remove O- 16
ring (20). The back-up ring (21). comes off easily if
the slit on its circumference is extended. O-ring (20)
can be taken off by stretching it with an earpick-like
spatula.
20
Fig. 32-40 Removing back-up ring (21) and

O-ring(20)
32-19
32. ATTACHMENT
32.2.1.3.4 DISASSEMBLING ROD COVER ASSY

(1) Remove O-ring (10) and back-up ring (11).
SPATULA
Remove back-up ring (11) and O-ring (10) in that
order. Remove back-up ring (11) and O-ring (10) by 10
pulling and stretching them with an spatula like
earpick. 11
Fig. 32-41 Removing the outer circumferential seal

of rod cover (3)
(2) Remove buffer ring (6), U-ring (7) and back-up ring GIMLET
(8). Each seal is fixed in the groove on the bore and
removing in flawless is impossible.
8
Stab each seal with a gimlet and pull it out of the
3 7
groove.
6
Take care in this operation not to damage the grooves.
Fig. 32-42 Removing the inner circumferential seal

of rod cover (3)
(3) Remove wiper ring (9). When taking out wiper ring HAMMER SCREW- 3
(9), fix rod cover (3) in a vise. DRIVER
WOOD PIECE
WOOD PIECE
VISE
Fig. 32-43 Removing wiper ring (9)

(4) Remove circlip (7) and rod bushing (6). 7 6
After taking out snap ring (7) in the same way as 3
mentioned above, remove rod bushing (6). Rod
bushing (6) is impossible to remove as it is press
fitted in rod cover (3). Machine the bushing thin on SPATULA
a lathe, insert a steel spatula hard into the gap at
WOOD PIECE WOOD PIECE
the chamfered edge of the remaining bushing and
VISE
pry it up.
Center the work on a lathe sufficiently so the bushing Fig. 32-44 Removing rod bushing (6)
may be shave on a lathe as thin as possible.
32-20
32. ATTACHMENT
32.2.1.3.5 REMOVING PIN BUSHING

(1) Apply driver to wiper ring (32) of cylinder tube (1) PUSH WITH A PRESS.
and piston rod (3), and strike it by hammer lightly. JIG J
(2) Push out pin bushing (4) press fitted in cylinder tube
(1) and piston rod (3) with press.
24 BASE
Fig. 32-45 Drawing out pin bushing (24)
32.2.1.3.6 REMOVING CHECK VALVE (ARM CYLINDER ONLY)

(1) Using allen wrench, remove check valve plug (31),
27
and remove the internal parts (27, 28 and 29)
: 8 mm
28
29
31
30
Configuration of check valve

Fig. 32-46 Removing of check valve
32.2.1.4 CLEANING
(1) After disassembly the cylinder, wash all parts with
commercial detergent.
Never use benzene(gasoline, thinner, etc.) because it

may be damage the rubber, etc.
(2) Do not use the used oil seal, O-ring, back-up ring,
etc. even if they are not damaged after inspection.
(3) After cleaning, dry all parts by compressed air, and
put them on the working bench taking care not to
damage them.
32.2.1.5 ASSEMBLING PIN BUSHING

Start assembling the following sub assy
• Cylinder tube assy
• Piston assy
• Rod cover assy
32-21
32. ATTACHMENT
32.2.1.5.1 ASSEMBLING PIN BUSHING

(1) Press fit pin bushing (4) in cylinder tube (1) and PUSH WITH A PRESS
piston rod (3) respectively with press. 3
4
(2) Press fit wiper ring (32) in the upper and lower sides
of cylinder tube (1) and piston rod (3) respectively
with press.
• Before press fitting, apply grease on wiper ring and

boss hole. OIL HOLE LOCATION
• Before press fitting the pin bushing, align the Fig. 32-47 Press fitting of pin bushing (4)
position of oil hole.
32.2.1.5.2 ASSEMBLING OF PISTON ASSY

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

Since it is hard to deform seal ring (17-1) in room
temperature, immerse and soften it in hydraulic oil
heated about 150 to 180 C degrees. Therefore slip it in
piston seal groove quickly with fitting jig so as not to be
cooled. Fig. 32-48 Attaching seal ring (17-1)
To avoid burn, wear gloves when fitting the heated seal
ring (17-1), and fit it quickly. And the hydraulic oil must
be heated with electric heater. (Do not use fire. There is
a danger.)
(3) Shrink the seal ring (17-1) to the original size using
correcting jig.

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

Fig. 32-49 Correction of seal ring (17-1)

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

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

side. Fig. 32-50 Direction of components
32-22
32. ATTACHMENT
32.2.1.5.3 ASSEMBLING ROD COVER ASSY

(1) Press fit bushing (6) in rod cover (5) with bushing PRESS HERE. (STRAIGHT DOWN)
press-fitting jig (A). Then, fit snap ring (7) in the METAL
groove. Apply hydraulic oil on internal surface of 6 (MAKE O.D.SMALLER
rod cover (5). THAN ROD BUSHING O. D.)
GROOVE FOR
FIXING CIRCLIP (18)
Press bushing till bushing

The snap ring (7) can not be fitted when the bushing (6) comes in contact with
5
is not press-fitted fully to the stop end. this face.
(2) Apply grease to dust seal (24) or the hole of rod PRESS HERE. (STRAIGHT DOWN)
cover (16), and fit dust seal (24) to the bottom of the
hole. At this moment, press the metal ring of dust PRESS METAL
PRESSING JIG RING.
seal (24) with a jig.
24
RUBBER
CLIP
METAL RING
Fig. 32-51 Pressing in rod bushing (6)

(3) Fit buffer seal (8), back-up ring (10) and rod INSERT U-RING INTO GROOVE FROM THIS SIDE.
packing (9) in their grooves in that order. Before
setting packings, coat them with hydraulic oil (or
vaseline if not available). If you forget the coating,
the packings may be scored. When attaching seals,
deform them in a heart shape as illustrated.
• Rod packing (9) is harder than other packing and it

would be difficult to deform them in a heart shape.
In such a case, put a U-ring in the groove obliquely Fig. 32-52 Inserting a seal into the inner
by hand as deep as possible and push in the last circumference of rod cover.
part with a push bar till it is set with a click.
PUSH BAR (WOOD OR PLASTIC)
• Buffer seal (8) should be fitted taking care of the 12
fitting direction. The reverse fitting may cause 13
deformation, damage, etc. of the piston due to high Tube side
pressure generated between the buffer ring and rod 5
packing (9).
• If rod packing (9) is set upside down, the lip may be
damaged. Check that it is positioned correctly.
• Attach back-up ring (13) on the open air side of O-
ring (12). (See Fig. 32-53).
8
9
10
11
Fig. 32-53 How to fit rod packing (9)
32-23
32. ATTACHMENT
32.2.1.5.4 INSERTING ROD COVER ASSY TO PISTON ROD

Inserting rod cover (5) to piston rod assy by the
following procedure. INSERT GUIDE JIG (I) 5
(1) Fix piston rod assy on working bench. PUSH
(2) Install rod cover (5) on piston rod (3) with inserting
guide jig (I) as shown in Fig. 32-54 paying attention
3
for the lip section of rod packing not to be caught on
the stepped section.
Fig. 32-54 Inserting rod cover (5)
• For the rod the outer diameter of piston installing

section is small, insert spacer on the faucet section
of rod first, and attach inserting guide jig.
• Apply hydraulic oil on the inserting guide jig and
outer surface of piston rod lightly to make the
insertion smooth.
32.2.1.5.5 ASSEMBLING PISTON ASSY ONTO PISTON ROD

(1) Inset in cushion ring and install the piston assy to
piston rod (3).
(2) Apply hydraulic oil or grease to the inside of the
piston assembly and to the piston mounting part of CHECK THAT BACK-UP RING
piston rod (3). Then install the piston assembly as IS NOT THE GROOVE. 15 3
shown in Fig. 32-55, exercising care not to damage
O-ring (20) and the seal.
Always tighten the piston to a specified torque
TURN
CLOCKWISE
V BLOCK
20
PISTON ASSY HOLD THE POINT AS CLOSE TO
THE PISTON AS POSSIBLE
Fig. 32-55 Tightening piston assy
(3) Piston nut (22) till it gets tight.
Always tighten the piston nut (22) to a specified
torque (Refer to 32.2.1.7.3.)
22 HOOK WRENCH
Always correct the threads of the tapped hole in piston 1.0~1.5m

(3'3"~4'11") TURN CLOCKWISE
nut (22) before fixing piston nut, using a tap.
Fig. 32-56 Tightening piston nut (22)
32-24
32. ATTACHMENT
(4) Screw in and set setscrew (23). 23 ANTI-LOOSENING CAULKING

3
: 4mm
After tightening the setscrew to a specified torque
of 15 N•m (11 lbf•ft), caulk the two places of the
screw threads of the piston nut side to secure the
setscrew.
(5) Attach two wear rings (18) and dust rings (19). Take V BLOCK
off vinyl tape wound around the perimeter of piston 22
(16), apply high-quality grease (or vaseline) to wear
Fig. 32-57 Attaching setscrew (23)
ring (18) and dust ring (19) and attach the wear
rings in a manner that they may be coiled around 23 18 19
3
the groove. Set the wear rings about 90 degrees
apart with each other so that the 45 degree slits
may not point to the same direction.
22 V BLOCK
Fig. 32-58 Attaching wear ring (18)
32.2.1.5.6 OVERALL ASSEMBLY

(1) Place a V-block on a work bench (A wooden V-
1
block is preferable.). Place the cylinder tube assy
(1) on it and fix the assy by passing a wooden bar LIFT
through the clevis pin hole to lock the assy.
(2) Insert the piston rod assy into the cylinder tube
assy, while lifting and moving the piston rod assy
with a hoist. In this operation, apply hydraulic oil (or STRAIGHT PREVENT TURNING
vaseline) to the inner surface of the tube mouth and WITH WOODEN BAR.
the circumference of the piston. Align the center of
the piston rod assy with the center of the cylinder
tube assy and put it in straight forward. When Fig. 32-59 Inserting piston rod assy
inserting, make sure that wear rings (18), dust ring
(19) on the perimeter of the piston is not out of the
groove.
(3) Tighten socket bolt (26). Match the bolt holes of the 26
rod cover flange to the threaded holes in the
cylinder assy, and screw in socket bolts (26) one by PLACE CLOTH
one. Tighten the bolts to a specified torque, taking
care so the bolts may not be tightened unevenly.
See para. 32.2.1.7.3 for torque.
: 14 mm, 12 mm
ALLEN WRENCH
TURN CLOCKWISE
Fig. 32-60 Tightening socket bolts (26)
Take care so as not to damage the rod surface by
accidentally slip a wrench. Covering the rod surface
with cloth is recommended to prevent damage to it.
32-25
32. ATTACHMENT
32.2.1.6 INSPECTION AFTER ASSEMBLY

(1) No-load functional test
Place the cylinder level at no load, operate the
piston rod 5 to 6 strokes by the directional valve and DIRECTIONAL VALVE
make sure that it operates without failure. PUMP
• Do not raise the hydraulic pressure above the H R

maximum pressure of 34.3MPa (4974 psi) for the
cylinder of the machine.
• Grease coated on the O-rings and the seals of the
HYDRAULIC CYLINDER
rod cover may come out. Wipe it off and retest the
Fig. 32-61 External leak test
cylinder in such a case.
(2) Leak test MEASURE THE

1) Apply a test pressure to the retracting and INTERNAL LEAK.
extending sides of the cylinder for three minutes
independently, and check that the rod section
and the welds have external leaks and
permanent deformation. For an internal leak test,
connect the cylinder with a test unit as shown in
Fig. 32-62. FROM DIRECTIONAL VALVE
Fig. 32-62 Internal leak test
2) After completing the test, apply a plug to each

port and store the cylinder. (Fig. 32-63)
• For storage, place the cylinder on wooden V-

blocks and bring the cylinder to the most
retracted condition. Fig. 32-63 How to store the cylinder
32-26
32. ATTACHMENT
32.2.1.7 MAINTENANCE STANDARDS
32.2.1.7.1 INSPECTION AFTER DISASSEMBLY

Visually inspect all parts after cleaning to see that excessive wear, crack and other damage that are detrimental to
use are not present.
(1) Inspection Item
Table32-2
Part Name Inspecting Section Inspection Item Remedy
1. Neck of rod pin Presence of crack Replace.
2. Weld on rod hub Presence of crack Replace.
3. Stepped part to which
Presence of crack Replace.
piston is attached
4. Threads Presence of seizure Recondition or replace
Measure degree of bend (See
5. Bend Refer to (Table32-3)
Fig. 32-64)
Piston rod 6. Plated surface Check that:
1) Plating is not worn off to 1) Replace or replate
base metal
2) Rust is not present on plating. 2) Replace or replate
3) Recondition, replate or
3) Scratches are not present.
replace.
7. Rod Wear of O. D. Recondition, replate or replace.
8. Bushing at mounting part Wear of I. D. Replace.
1. Weld on bottom Presence of crack Replace.
2. Weld on head Presence of crack Replace.
Cylindertube 3. Weld on hub Presence of crack Replace.
4. Tube interior Presence of damage Replace if oil leak is seen.
5. Bushing at mounting part Wear on inner surface Replace.
1. Bushing 1) Wear on inner surface 1) See para. 32.2.1.7.2
Rod cover 2) Replace if score is deeper than
2) Flaw on inner surface
coating.
(2) Repair method

Check all seals and parts to see that they do not show excessive damage and wear. For correction of scores on
the piston rod, observe the following procedure:
1) Correct very fine longitudinal scratches with an oilstone. Replace the piston rod if the scratch is so deep as
may be caught by your nail.
2) In case of a smooth indention, recondition by removing the sharp area around the indention with an oilstone.
If the score or the indention is excessive, replace or replate the damaged part.
• Always regrind after replating. The thickness of the plating must be maximum 0.1mm (0.004in).
• In case plating is removed to the base metal during reconditioning with an oilstone, do not fail to replate the
surface.
32-27
32. ATTACHMENT
32.2.1.7.2 LIMIT OF SERVICEABILITY

Serviceability limits represent the limits of wear on the
sliding surfaces of the cylinder tube and the rod that
have no such damage as may degrade the sealing
effect.
(1) Clearance between piston rod and rod bushing
Replace the bushing if the clearance between the
piston rod and the rod bushing exceeds 0.25mm
(0.01in).
(2) Bend of piston rod
The allowable bend of the rod is maximum 1mm /
1m (0.04"/3’3"). For measurement, support both
ends of the parallel section of the piston rod with V-
blocks, set a dial indicator in the center between the
two V-block turn the piston rod, and read the
difference between the maximum and minimum Fig. 32-64 Measuring Method
deflection on the dial indicator.
Table32-3 shows an example of measurement.
Table32-3 Example of Measurement

Distance between Deflection of the dial indicator
V-blocks in the middle of the rod. Remedy
m (ft-in) mm (in)
1 (3’3") 1 (0.04") Replace
Even if the bend is within the above limit, the cylinder

may not operate smoothly because of localized bend.
Beware of it during function test after assembly.
Replace the rod if the cylinder makes a squeaking
noise or dose not operate smoothly.
32.2.1.7.3 TIGHTENING TORQUE
B A C Unit : N.m (lbf.ft)

A B C
Cylinder Piston nut
or [Piston] Socket bolt Setscrew
Boom 2841 (2095) 267 (200) 56.9 (42)
Arm 2841 (2095) 367 (270) 56.9 (42)
Bucket 2841 (2095) 267 (200) 56.9 (42)
32.2.1.7.4 VOLUME OF OIL LEAK

The oil leak rates as mentioned in 1.6 (2) of Inspection after Assembly are as shown in INSPECTION AFTER
ASSEMBLY32.2.1.6 (2).
Cylinder Volume of Internal Oil Leak

Boom 2.0cc (0.12 cu•in) or below / 10min
Arm 2.3cc (0.14 cu•in) or below / 10min
Bucket 1.9cc (0.11 cu•in) or below / 10min
32-28
32. ATTACHMENT
32.2.1.8 TROUBLESHOOTING
Table32-4
Trouble Failed Parts Cause Remedy
1. Oil leak through sliding 1. Rod packing 1. Foreign matter is trapped in the 1. Remove foreign matter.
surface of piston rod. Oil bore of rod packing
ring is formed on piston 2. Lips on outer and inner diameter 2. Replace rod packing.
rod, and the ring grows up surfaces of rod packing are scored.
to oil drops, and they drip. 3. Other back-up ring are failed. 3. Replace rod packing
2. Buffer seal 1. Foreign matter is trapped in the 1.Remove foreign matter.
bore of seal.
OIL LEAKS FROM HERE 2. Score is present on the bore of seal. 2. Replace buffer seal.
3. Other seals are failed. 3. Replace buffer seal.
3. Dust seal 1. Foreign matter is trapped in the 1.Remove foreign matter.
bore of seal.
2. Score is present on the bore of seal. 2. Replace dust seal.
3. Other seals are failed. 3. Replace dust seal.
4. Piston rod 1. Score is present on the sliding 1.Smooth out the sliding surface with
surface of piston rod. an oilstone. If leakage occurs even
if the sliding surface is finished
below 1.6S, rod packings may be
scored. Disassemble and inspect it
and replace rod packings as
required.
If leak will not stop by that
treatment, replace piston rod.
2. Hard chromium plating has peeled 2. Replate.
off
2. Oil leaks from the 1. O-ring 1. O-ring is damaged. 1. Replace O-ring.
circumference of rod cover. 2. Backup ring 1. Back-up ring is damaged. 1. Replace back-up ring.
3. Cylinder tube 1. Swelling of cylinder tube. 1. Replace cylinder tube.
OIL LEAKS FROM HERE

3. Oil leaks from welds. 1. Cylinder tube 1. Welds of cylinder are broken. 1. Replace cylinder tube.
WELDS
4. Cylinder falls by it-self. 1. Piston seal 1. Foreign matter is trapped in the 1. Remove foreign matter
[When the rod is loaded with sliding surface of slipper seal.
a static load equal to the 2. Score is present on the sliding 2. Replace seal ring.
maximum working pressure surface of slipper seal.
multiplied by the area of the 3. Other back-up rings are faulty.
cylinder bore, the maximum 2. Wear ring 1. Sliding surface of wear rings is 1. Replace wear ring.
movement of the piston is scored.
more than 0.5mm (0.02") in
3. O-ring 1. O-ring is damaged. 1. Replace O-ring.
ten minutes.]
32-29
32. ATTACHMENT
32.2.1.9 TOOLS AND JIGS LIST

The tool and jig list provides the materials and the dimensions of tools and jigs so that they may be utilized in
manufacturing in a service shop. Follow the directions given below in selecting, manufacturing and using the tools
and jigs.
(1) For the rod cover, piston nut and others that require
large tightening torques, use eye wrenches as
much as possible.
The tools and the jigs are so designed
dimensionally that they can withstand the
maximum tightening torques even if material
SS400 (JIS) is used. However, the hook of the tool
may be distorted if struck with a hammer. If such
occurs, apply reinforcement weld and finish it by
grinding. USE THIS PORTION.
(2) The pin section of pin wrenches and pin hook
Fig. 32-65
wrenches is loaded with large shearing force.
Therefore, take care when selecting pin material
and welding the pin to the body. It is recommended
to use the shank section of disused drills (Fig. 32-
65)
32.2.1.9.1 ALLEN WRENCH AND SPANNER WRENCH
Unit : mm (in)
For piston nut For check For 1/8 grease For 1/4 grease
CYLINDER For cover bolt
set screw valve plug nipple nipple
ARM 14 (0.55) 4 (0.16) 8 (0.32) 14 (0.55)
BOOM 12 (0.47) 4 (0.16) — 10 (0.39) 14 (0.55)
BUCKET 12 (0.47) 4 (0.16) — —
32.2.1.9.2 DUST SEAL PRESSING JIG

(FOR ROD COVER)
E
C1
C1
I
H J MATERIAL : SS400 (JIS)
F G
A
B
C
D
Fig. 32-66 Dust seal pressing jig

Table32-5
Unit : mm (in)
CYLINDER A B C D E F G H I J
84 89 92 106 5.5 25.5
ARM
(3.31) (3.50) (3.62) (4.17) (0.21) (1.00)
75 79 82 98 80 5 15 5
BOOM
(2.95) (3.11) (3.23) (3.86) (3.15) (0.20) 5 (0.59) (0.20) 25
75 74 77 93 (0.20) (0.98)
BUCKET
(2.76) (2.91) (3.03) (3.66)
32-30
32. ATTACHMENT
32.2.1.9.3 EYE WRENCH (FOR PISTON NUT)

MATERIAL : SS400 (JIS), FINISH BY GRINDING AFTER GAS CUTTING
C
B A
D
E
Plate thickness :
Fig. 32-67 Eye wrench

Table32-6
Unit : mm (in)
CYLINDER A B C D E F G T Common use bolts
91 150 80 11 300 55 30 12~15
ARM
(3.58) (5.91) (3.15) (0.43) (11.8) (2.17) (1.18) (0.47~0.59)
81 140 75 11 300 55 30 12~15
BOOM —
(3.19) (5.51) (2.76) (0.43) (11.8) (2.17) (1.18) (0.47~0.59)
76 135 65 11 300 55 30 12~15
BUCKET
(3.00) (5.32) (2.56) (0.43) (11.8) (2.17) (1.18) (0.47~0.59)
32.2.1.9.4 WRENCH (FOR PISTON)

MATERIAL : SS400 (JIS), FINISH BY GRINDING AFTER GAS CUTTING

Fig. 32-68 Wrench

Table32-7
Unit : mm (in)
CYLINDER A B C D E F G T Common use bolts
60 120 90 12 300 55 30 12~15
ARM
(2.36) (4.72) (3.54) (0.47) (11.8) (2.17) (1.18) (0.47~0.59)
45 105 75 12 300 55 30 12~15 M8×20(2 pcs.)
BOOM
(1.77) (4.13) (2.95) (0.47) (11.8) (2.17) (1.18) (0.47~0.59) (0.79)
40 100 80 12 300 55 30 12~15
BUCKET
(1.58) (3.94) (3.15) (0.47) (11.8) (2.17) (1.18) (0.47~0.59)
32-31
32. ATTACHMENT
32.2.1.9.5 ROD COVER FIXING JIG
MATERIAL : SS400 (JIS)

G
R0.5 About
(0.02") E F
5~10
R0.5 (0.02")
R10
(0.39")
D
C
B
Fig. 32-69 Rod cover fixing jig
Table32-8
Unit : mm (in)
CYLINDER A B C D E F G
70.5 75 75 .3±0.1 80 32 28.5 155

ARM
(2.78) (2.95) (2.965±0.0039) (1.26) (1.12) (6.10)
(3.150 )
60.5 65 65.3±0.1 70 22 28.5 150

BOOM
(2.38) (2.56) (2.571±0.0039) (0.87) (1.12) (5.91)
(2.756 )
55.5 60 60.3±0.1 65 32 28.5 155

BUCKET
(2.19) (2.36) (2.374±0.0039) (1.26) (1.12) (6.10)
(2.559 )
32.2.1.9.6 PISTON (SLIPPER) SEAL FIXING JIG

C MATERIAL : SS400 (JIS)
D
About 12 F
R10
(0.39") G
A
B
Fig. 32-70 Piston (slipper) seal fixing jig

Table32-9
Unit : mm (in)
114.5±0.1 116±0.1 105 95 28.0 63 96
ARM
(4.508±0.0039) (4.567±0.0039) (4.13) (3.74) (1.10) (2.48) (3.78)
99.5±0.1 101±0.1 90 80 23.0 63 90
BOOM
(3.917±0.0039) (3.976±0.0039) (3.54) (3.15) (0.90) (2.48) (3.54)
94.5±0.1 96±0.1 85 75 23.0 63 90
BUCKET
(3.720±0.0039) (3.780±0.0039) (3.35) (2.95) (0.90) (2.48) (3.54)
32-32
32. ATTACHMENT
32.2.1.9.7 PISTON SEAL HOLDING-DOWN JIG

C MATERIAL : SS400
R10
F (0.39")
E
HANDLE
D
G
A About 5~ 10
B
Fig. 32-71 Piston seal holding-down jig

Table32-10
Unit : mm (in)
125 133 117±0.1 46 75 10~15 100
ARM
(4.92) (5.24) (4.606±0.0039) (1.81) (2.95) (0.39~0.59) (3.94)
110 118 102±0.1 46 75 10~15 100
BOOM
(4.33) (4.65) (4.016±0.0039) (1.81) (2.95) (0.39~0.59) (3.94)
105 113 98±0.1 46 75 10~15 100
BUCKET
(4.13) (4.45) (3.858±0.0039) (1.81) (2.95) (0.39~0.59) (3.94)
32.2.1.9.8 PIN BUSHING PRESSING JIG
C1 (0.039") MATERIAL : SS400
Inner diameter : A1 A-20 (0.878")

A1
D
C
A
B
(Even if there is not the bore A1,

there is no problem.)
C1 E
(0.039")
F G H
I
Fig. 32-72 Pin bushing pressing jig

Table32-11
Unit : mm (in)
CYLINDER A B C D E F G H I
69.5 84.5±0.1 105 85 5.5±0.1 70 20 10 100

ARM
(3.327±0.0039) (4.13) (3.35) (0.217±0.0039) (2.76) (0.79) (0.39) (3.94)
(2.736 )
79.5 94.5±0.1 115 95 5.5±0.1 70 20 10 100

ROD SIDE
(3.720±0.0039) (4.53) (3.74) (0.217±0.0039) (2.76) (0.79) (0.39) (3.94)
(3.130 )
BOOM
69.5 84.5±0.1 105 85 5.5±0.1 70 20 10 100
HEAD SIDE
(3.327±0.0039) (4.13) (3.35) (0.217±0.0039) (2.76) (0.79) (0.39) (3.94)
(2.736 )
64.5 79.5±0.1 100 80 5.5±0.1 70 20 10 100

ROD SIDE
(3.130±0.0039) (3.94) (3.15) (0.217±0.0039) (2.76) (0.79) (0.39) (3.94)
(2.539 )
BUCKET
59.5 74.5±0.1 95 70 5.5±0.1 70 20 10 100
HEAD SIDE
(2.933±0.0039) (3.74) (2.76) (0.217±0.0039) (2.76) (0.79) (0.39) (3.94)
(2.343 )
32-33
32. ATTACHMENT
32.2.1.9.9 ROD BUSHING PRESSING JIG
MATERIAL : SS400 (JIS)

C1 (0.039")
A1 Inner diameter : A1 A-20 (0.878")

B
A
(Even if there is not the bore A1,

there is no problem.)
C1
(0.039") C D
E
Fig. 32-73 Rod bushing pressing jig

Table32-12
Unit : mm (in)
CYLINDER A B C D E
80 84.8±0.1 30 90 120
ARM
(3.339±0.0039) (1.14) (3.54) (4.72)
(3.150 )
75 74.8±0.1 30 90 120
BOOM
(2.945±0.0039) (1.14) (3.54) (4.72)
(2.953 )
65 64.8±0.1 30 90 120
BUCKET
(2.551±0.0039) (1.14) (3.54) (4.72)
(2.559 )
32-34
33. UPPER STRUCTURE
TABLE OF CONTENTS

33.1.1 OPERATOR SEAT .................................................................................................33-3
33.1.2 CAB ........................................................................................................................33-4
33.1.3 BATTERY ...............................................................................................................33-6
33.1.4 GUARD...................................................................................................................33-7
33.1.5 UNDER COVER .....................................................................................................33-14
33.1.6 FUEL TANK ............................................................................................................33-15
33.1.7 HYDRAULIC TANK ................................................................................................33-17
33.1.8 HYDRAULIC PUMP................................................................................................33-21
33.1.9 AIR CLEANER........................................................................................................33-26
33.1.10 MUFFLER...............................................................................................................33-28
33.1.11 COUNTERWEIGHT................................................................................................33-30
33.1.12 RADIATOR & OIL COOLER...................................................................................33-32
33.1.13 ENGINE ..................................................................................................................33-39
33.1.14 CONSOLE COVER ................................................................................................33-42
33
33.1.15 MULTI CONTROL VALVE (OCE SPEC.)...............................................................33-43
33.1.16 CONTROL VALVE..................................................................................................33-44
33.1.17 PILOT VALVE (FOR ATT) ......................................................................................33-47
33.1.18 PILOT VALVE (FOR TRAVEL)...............................................................................33-48
33.1.19 SWING MOTOR UNIT............................................................................................33-50
33.1.20 SWIVEL JOINT.......................................................................................................33-52
33.1.21 UPPER FRAME......................................................................................................33-55
33.2 DISASSEMBLING AND ASSEMBLING...........................................................................33-58
33.2.1 HYDRAULIC PUMP • REGULATOR ......................................................................33-58
33.2.2 CONTROL VALVE..................................................................................................33-78
33.2.3 PILOT VALVE (ATT)...............................................................................................33-109
33.2.4 PILOT VALVE (FOR TRAVEL)...............................................................................33-119
33.2.5 SWING MOTOR UNIT............................................................................................33-128
33.2.6 SWIVEL JOINT.......................................................................................................33-161
33-1
33. UPPER STRUCTURE

SK125SR : YV05-04501~
S5YY3313E01
(OCE/S.E.ASIA)
SK135SRLC-2 : YH05-07001~
PREFACE
(1) This Manual describes all the procedures from removing to installing, arranging them by item.
(2) This Manual consists [Removing and installing], and [Disassembling and assembling].
(3) The removing and installing can be performed in the procedure specified in Table of Contents, but in view of
(4) The removing and installing procedure does not completely cover all possible situations because of differences
(5) Recognize well that the service man must decide a work procedure before proceeding to repair. When deciding
the work procedure, choose an item that is needed, familiarize yourself with the contents of the work and itemize
the work procedure, before starting work.
(6) Disconnect the negative terminal of battery first, when the removing and the installing of the electric component
and wiring are performed.
(7) The explanatory note and figure of this manual may differ from the actual machine by the difference in
specification.
33-2
33. UPPER STRUCTURE

33.1.1 OPERATOR SEAT
33.1.1.1 REMOVAL
(1) Preparation for removal
1) Remove the head rest (A1-1) of the operator’s
seat (A1) to ease handling. A1-1
2) Move the whole control stand to its foremost A1

position.
3) Move the operator’s seat to its forward end.
4) Incline the reclining seat as forward as possible. B2
(2) Remove operator’s seat. (Include upper rail.) C1
1) With the above-mentioned condition, remove C2
C1
two cap screws (B2) M8×20 from the upper rail. C2
Then move the control stand to its rearmost end
and remove two capscrews (B2) M8×20.
: 6 mm
2) Remove the operator’s seat. [about 28kg (62
lbs).] 1
7
Carry out the following operations as required.
13
3) Remove seat belt (C1). 10
4) Remove armrest (A3)(A4).
5) Remove bracket assy (1), rail (7).
Fig. 33-1 Disassembling and Assembling seat
33.1.1.2 INSTALLATION
Install it in reverse procedure of removing according to A4
the tightening torque table.
Allen A5
Tightening position wrench Tightening torque A3
HEX (mm) N·m (lbf·ft)
Capscrew (B2) 6 23.5 (17.3)
Sems bolt (C2) 17 46.1 (34) A6
A2
Capscrew (A5) 13 23 (17)
A5
Sems bolt (A6) 13 23 (17) A1
Reference : Movement on rail

Upper rail …… Fixed on lower surface of seat
[Forward 80mm (0.26in), backward 80mm (0.26in)]
Lower rail …… Fixed on seat stand.
[Forward 60mm (0.19in), backward 60mm (0.19in)]
Amount of adjustment of seat height Fig. 33-2 Disassembling and Assembling armrest
[Up; 23mm (0.07in), down; 37mm (0.16in)]
Suspension stroke
[Up; 37.5mm (1.48in), down; 37.5mm (1.48in)]
33-3
33. UPPER STRUCTURE
33.1.2 CAB
33.1.2.1 REMOVAL
(1) Remove floor mat.

(2) Remove cover (1A-2)
Lift cover (1A-2) upwards and remove it. (Fixed with

2 clips)
(3) Remove cover assy (A1)
1) Loosen 4 sems bolts (A22) M6×16 and lift cover
assy (A1) up.
2) Disconnect each connector for both speakers.
Then remove cover assy (A1).
(4) Remove the harness connector (See Chapter 23)
1) Disconnect connectors of cab harness (CN-
515), (CN-518), (CN-71) (CN-72) and (CN-500)

at rear right of cab.
2) Disconnect antenna cable coming from backside
of tuner at rear left of cab. Fig. 33-3 Disassembly and assembly of cover (A7)
(5) Remove the plastic tube for the window washer and cover assy (A1)
from the rear left of cab.
A3
(6) Remove the right panel of cab A14
1) Remove 2 caps (A29) loosen 2 sems bolts (A40)
M6×30 and 1 sems bolt (A39) M6×16. And right
panels (A4) and (A4-3) are freed.
: TORX driver T30
2) Lift cover (A3) upwards and remove it. (Fixed A40 A22
with 3 clows and 2 clips) A29

3) Unfix 3 harness clips of inside on right panel (A4-
3). And free the harnesses connected to key A40
switch. A29
4) With harnesses are connected condition, install
key switch cover (A3) to bracket (A1) of rear cab
temporally. (See Fig. 33-5) A39 A4
A4-3
5) Disconnect harness connectors of work light
switch on right panel (A4), air conditioner panel A22
and cigarette lighter, and remove right panel (A4)
and (A4-3). (See Chapter 23)
6) Loosen sems bolts (A22) M6×16 and (A23)
M6×45 one each, and remove front panel (A5-2)
with air conditioner duct.
A5-2
: Plus driver
A23
Fig. 33-4 Disassembly and assembly of right panels

(A4-3), (A3) and (A5-2)
33-4
33. UPPER STRUCTURE
FUSE & A3
RELAY BOX Front
ASSY
A1
Fig. 33-5 Move switch cover assy

(7) Remove cab attaching bolt
1) 5 capscrews (A1) M12×65 and 1 capscrew (A3)
B4
M12×30. (Mark )
2) 4 nuts (B3) M16 (Mark )
(8) Slinging cab
1) Remove two plastic plugs at the front of the
ceiling of the cab. Then place a wire sling with A3
eye rings and a hook around the cab, as shown
in Fig. 33-7.
A1
2) Then lift up slowly avoiding interference with
surroundings. Fig. 33-6 Removing and installing cab mounting
Wire with hook ; bolts.
Length 1.5m (4ft 11in)×Dia. 8mm
(0.315in)×3pcs.
Weight of cab ; Approx. 250kg (550 lbs)
Install it in reverse order of removing according to the
Tightening Torque Table.
Allen Tightening torque EYE BOLT
Tightening position wrench
N·m (lbf·ft)
M10
HEX(mm)
Nut M16 (B4) 24 191 (140)
Capscrew (A1)(A3) 19 80 (66)
Torx driver
Sems bolt M6 (A39)(A40) (T30) 8.5 (6.3)
Sems bolt M6 (A22)(A23) Plus driver 5.0 (3.7)
Fig. 33-7 Slinging cab
33-5
33. UPPER STRUCTURE
33.1.3 BATTERY
33.1.3.1 REMOVING
(1) Open panel assy (1).
1) Unlock with starter switch key.
2) Open panel assy (1).
3) Keep panel assy open with stay.
(2) Remove battery cable
1) Remove cable (A4) [between the earth and
battery (–)].
(Always remove (-) terminal first and install it at
last.)
2) Remove cable (A2) [between battery (+) and (-)] 1
3) Remove cable (A3) [between battery (+) and Fig. 33-8 Opening and closing of panel assy (1)
battery relay]
A2
: 13 mm
A3
Follow the battery removal order.

Start removing battery from grounding side, and finish
attaching to grounding side. If this order is missed,
short-circuits may occur. A4
(3) Remove battery (B1) Fig. 33-9 Removing and installing battery cable
1) Loosen nut (A6) M10 and remove cover (A1) and
spacer (A5).
2) Loosen 2 capscrews (A3) M12×200.
: 17 mm
3) Remove plate (A2).
4) Remove battery (B1).
33.1.3.2 INSTALL
(1) Install the battery in the reverse order of removing. A1 A6
Hold down plate (A2) against battery (B1), and
tighten capscrew (A3).
: 19 mm,
Tightening torque : 10.8N•m (8.0 lbf•ft) A5
(2) Installing grounding cable A2

Install grounding cable (A4) last. Especially care A3
must be taken that the grounding face is free from B1
painting, rust, etc.
: 13 mm
Fig. 33-10 Removing battery
33-6
33. UPPER STRUCTURE
33.1.4 GUARD
33.1.4.1 PREPARATION FOR REMOVAL

(1) Remove guard in the following procedure
Remove the guards in the order of (H1) → (H3) → (H2) → (5) → (Set of 3) → (Set of 1) → (20) → (22) → (21)
→ (A1) → (B1) → (33),(34) → (C4) → (C1) → (C3) → (D1) → (C2) → (A12) → (29) → (27) → (E1,E2) → (36)
→ (F1).
34 D1
A1 33
36
C3 H3
E2
H1
5
B1
C2
C4 H2
C1 E1
Fig. 33-11 Arrangement of guard assy
33.1.4.2 REMOVE GUARD

(1) Remove bonnet assy (H1)
H1
1) Open bonnet (H1).
2) Remove snap pin (13) from head side of gas
cylinder (11) which is installed reverse side of
bonnet. And remove gas cylinder from bonnet
(H1). (See Fig. 33-15)
3) Remove 2 sems bolts (H5) M12X25.
4) Remove bonnet (H1).
H5
: 19 mm
Weight : 28kg (62 lbs)
Fig. 33-12 Removing bonnet assy (H1)

(2) Remove bonnet assy (H3)
H10
1) Remove 1 sems bolt (H9) M12X30.
2) Remove 2 sems bolts (H10) M12×25.
3) Remove bonnet assy (H3) together with duct H9
assy (H3-2). H3
: 19 mm
H10
33-7
33. UPPER STRUCTURE
(3) Remove bonnet assy (H2) H5

1) Remove 3 sems bolts (H5) M12×25. H2
2) Remove bonnet assy (H2).

H5
: 19 mm

(4) Remove bracket (5)
1) Remove 2 capscrews (16) M12×30.
2) Remove bracket (5). 16 10
: 19 mm
13 5
14
13
11
13
Fig. 33-15 Removing bracket (5)
(5) Remove bracket assy (3)
3
1) Remove 3 sems bolts (17) M12×25.
2) Remove bracket assy (3). 7
1
: 19 mm
5
8
17
17
4
2
17 3 9
Fig. 33-16 Removing bracket assy (3)
33-8
33. UPPER STRUCTURE
(6) Remove cover assy (1) (2) (4) (9), brackt assy (7)
and bracket (8). 17 17
2 1
1) Remove all tightened sems bolts (17) M12X25, 7
X
and remove cover assy, guard assy and bracket 7-2
22
in order of following. X
: 19 mm 17 17
4 17 17
a. Remove cover assy (2).
17 17 17 21
b. Remove cover assy (1).
c. Remove guard assy (4). 8 17
17
20
d. Remove cover assy (9).
e. Remove bracket (7).
9
f. Remove bracket (8).
(7) Removing bracket (20), (22) and cover assy (21)
1) Loosen 2 sems bolts (17) M12X25 which fasten
brackets (20) (22). And remove bracket (20),
(22) and cover assy (21) as assembled parts.
: 19 mm
Fig. 33-17 Removing cover assy (1),(2),(4),(9),

bracket assy (7) and bracket (8).
(8) Removing cover assy (A1), (A3), (A4)
1) Loosen all fastened sems bolts (A2) M12X20,
and remove cover assy in the following order.
A1
A2
: 19 mm
a. Remove cover assy (A1).
b. Remove covers (A3) and (A4) as assembled
parts.
A3 A2
A5
A2
A4
Fig. 33-18 Removing cover assy (A1),(A3),(A4)
33-9
33. UPPER STRUCTURE
(9) Remove panel assy (B1).

B3
B3
1) Remove 6 sems bolts (B3) M12×25. B3
2) Remove panel assy (B1). B1
: 19 mm
(10)Remove guard assy (33) and (34).
39
1) Remove 3 capscrews (39) M12×20.
2) Remove 3 sems bolts (17) M12×25. 33
39
3) Remove guard assy (33).
4) Remove 3capscrews (25) M12×20. 17
5) Remove guard assy (34).
: 19 mm 34
Fig. 33-19 Removing panel assy (B1) and guard

assy (33),(34)
(11)Remove cover assy (C4) and panel assy (C1) C15
C4
1) Remove 3 sems bolts (C15) M8×25.
2) Remove cover assy (C4). C8
C15
C1
3) Remove 2 sems bolts (C8) M12×30
C8
4) Remove a sems bolt (C14) M12×35.
6) Remove panel assy (C1).
: 13 mm, 19 mm
C14
C9
Fig. 33-20 Removing cover assy (C4) and panel

assy (C1)
(12)Remove fuel tank side panel assy (C3)
C3
C10
C10
Weight : 11.5kg (25 lbs)
: 19 mm
C9
Fig. 33-21 Removing panel assy (C3)
33-10
33. UPPER STRUCTURE
(13)Remove stay (D1)

D1
1) Remove 4 capscrews (D3) M12×55, (D4)
M12×75, (D8) M10×65 and (D9) M16×85. D9
2) Remove stay (D1).
: 17 mm, 19 mm, 24 mm
D8
D4
D3
Fig. 33-22 Removing stay (D1)
(14)Remove panel assy (C2) and bracket (32)
31 17
1) Remove 2 nuts (C13) M12.
Weight : 16kg (35 lbs) 32
17
3) Remove 2 sems bolts (17) M12×25. 18
28
4) Remove bracket (32) together with bracket (31). 17 17 C13
29
Weight : 10kg (22 lbs) C2
17
: 19 mm
16 27
(15)Remove box (29) and bracket assy (27)

1) Remove 2 sems bolts (17) M12×25. 18 16
17
2) Remove box (29).
3) Remove a sems bolt (17) M12×25. Fig. 33-23 Removing panel assy (C2), box (29),
4) Remove bracket assy (27) and bracket (28) as bracket assy (27)
assembled parts.
: 19 mm
33-11
33. UPPER STRUCTURE
(16)Remove cover assy (E1), (E2) E1

1) Remove 2 sems bolts (E4) M12×25 for attaching L/H
cover assy (E1), (E2).
2) Remove cover assy (E1). 4
3) Remove cover assy (E2).
: 19 mm 4
E2
R/H
E2
4
E1
Fig. 33-24 Removing cover assy (E1), (E2)
(17)Remove cover assy (36) 17
36
2) Remove cover assy (36).
: 19 mm
17
Fig. 33-25 Removing cover assy (36)
33-12
33. UPPER STRUCTURE
(18)Duct (F1) removal G12

1) Preparation
a. Remove counterweight. (See 33.1.11)
G15
b. Remove hydraulic oil hose which connects to
top of radiator oil cooler. (See Fig. 33-55)
2) Push filter assemblies (G15) in the direction of
24
arrow, and remove them.
3) Remove air cleaner hose (2) (7) and air cleaner
assy (1). (See 33.1.9 AIR CLEANER)
4) Remove battery relay from battery cover. In this
time, disconnect battery relay which has
remained harness connection with the battery
relay.
(See Detail of battery relay of 23.3.6 Electric
System)
5) Remove clip at side of radiator cap and remove
hose (G12) of sub tank.
6) Remove a sems bolt (F9) M12×30, and remove
F12
a capscrew (9) M12×30.
7) Remove 6 capscrews (F12) M8×20. F1
8) Sling duct (F1) to hoist and remove the duct.

: 13 mm, 19 mm
F9
F11
F12
Fig. 33-26 Removing duct assy (F1)
(1) Installing is done in the reverse order of removing.
(2) Tightening torque
Unit : N.m (lbf.ft)

Size Capscrew Sems bolt
M8 35.3 (26) 23 (17)
M10 46.5 (34) 46.5 (34)
M12 121 (90) 80 (59)
33-13
33. UPPER STRUCTURE
33.1.5 UNDER COVER
33.1.5.1 REMOVAL
(1) Remove under cover (1,2,3,4,5,6,9)
1) Remove any relevant sems bolts (8) M12×30.
2) Remove covers.
: 19 mm
5
2 1
8
4
1 8 8
1
8
6 8
8
8
3
9
8 8
8
Fig. 33-27 Removing under cover assy
(1) Install under cover (1,2,3,4,5,6,9)
: 19 mm
Tightening torque : 80 N•m (59 lbf•ft)
33-14
33. UPPER STRUCTURE
33.1.6 FUEL TANK

(1) Draining fuel. (See )
1) Unlock cap (B1) with a starter key and open it.
2) Loosen valve (A8) under the tank.
3) Draining fuel
Capacity of tank : 200L (53gal)
(2) Remove cover assy (36) and guard assy (34).
(See Fig. 33-19)
(3) Remove panel assy (C3). (See Fig. 33-21)
(4) Remove under cover (1),(2). (See Fig. 33-27)
(5) Remove the connector for fuel level sensor (A3).
(See Fig. 33-29)
B
(6) Remove fuel hose A
1) Loosen clip (20),(32) and draw out hoses (11)

and (12). 24
11
20 12
2) Put in plugs that match the hose bore. 24
33 17
16 32
DETAIL A
DETAIL B
Fig. 33-28 Removing fuel hose (11), (12) and
fuel filter assy
33.1.6.2 REMOVAL
(1) Remove 4 capscrews (A2) M16×35. B1
(2) Remove 2 capscrews (A7) M16×55.
A2
: 24 mm
B6
(3) Hook the wire to the lifting eye on the fuel tank assy
(B6) and remove the fuel tank.
(4) Remove shim (A14).
Record the shim locations. A3

A5
A8 A14
A7
Fig. 33-29 Removing fuel tank
33-15
33. UPPER STRUCTURE
Tank attaching bolt (A2) M16×35
Tank attaching bolt (A7) M16×55
: 24 mm, Apply Loctite #262

If the gap (looseness) between tank mount and frame

exceeds 1mm (0.04inch), adjust the gap with shim
(A14) and tighten capscrew (A2) to install the tank.

No. Name Q'ty N.m (lbf.ft) No. Name Q'ty N.m (lbf.ft)
A2 Capscrew 4 191 (140) A7 Capscrew 2 191 (140)
A5 Machine screw 5 1.96 (1.45) A8 Stop valve 1 34 (25)
When the stop valves (A8) was loosened, replace the seal tape with new one. On the occasion of this work, prevent
entry of dust.
33-16
33. UPPER STRUCTURE
33.1.7 HYDRAULIC TANK

(1) Remove panel assy (B1), guard assy (33)(34) and
bonnet assy (3).
(See Fig. 33-19 Fig. 33-13.)
(2) Release internal pressure of tank
Remove cap on air breather and push valve (head
of bolt) by your finger.

Keep pressing until the hissing sound stops.
Fig. 33-30 Bleeding internal pressure of tank
(3) Remove cover (B6).
1) Remove 6 sems bolts (B8) M10×25. B8
B8
: 17 mm B7 B6
2) Remove cover (B6).
3) Remove suction strainer (B1).
(4) Remove cover (B7).

1) Remove 6 sems bolts (B8) M10×25.
B
: 17 mm
2) Remove cover (B7). C
3) Remove filter element (B5). B5 B1
D
(5) Turn the handle of element assy (B), and

E
disassemble the removed filter element (B5).
Disassemble parts : (B), (C), (D), (E), (F) F
(6) Draining hydraulic oil
Place pump in tank and drain hydraulic oil.
Capacity of tank : 146 L (39gal)
Hyd.tank
Fig. 33-31 Remove cover (B6), (B7)
33.1.7.2 REMOVAL
(1) Draw out the suction hose (3)
Remove 2 clips (21) of the tank side and pull out
21
hose (3).
3 20
2 : Flat-blade screwdriver
Fig. 33-32 Removing the suction hose
33-17
33. UPPER STRUCTURE
(2) Disconnecting the main pipe return hose

Disconnect return hose (A2). Disconnect hose (A3)
returning to oil cooler.
: 41 mm
A2
(3) Disconnect pump drain hose (A5) of pump C/V

T2
: 27 mm A3
O/C S/M
OUT DB
(4) Disconnect makeup hose (A4) of swing motor. A5
: 27 mm
PUMP
Dr1 A4
Fig. 33-33 Removing main piping return hose
(5) Disconnecting pilot return hose
1) Remove pilot hose (23).
: 22 mm
2) Remove pilot hose (21).

21
: 22 mm 23
S/V
A23 T2
PT
3) Remove pilot hose (A23). C/V T
Dr
: 22 mm
Fig. 33-34 Removing pilot return hose

(6) Remove drain hose (2) of pilot pump PUMP Dr3
2
: 22 mm
Fig. 33-35 Removing pump drain hose
33-18
33. UPPER STRUCTURE
(7) Remove hydraulic tank attaching bolt

Remove 4 capscrews (A1) M16×50.
: 24 mm
Hyd. tank
(8) Slinging hydraulic oil tank

Place a wire sling, using the lifting plate on top of
the tank.
Tank weight : Approx : 105kg (232 lbs)
(9) Remove shim (A3).
Record the shim locations.
A3
A1
Fig. 33-36 Removing hydraulic tank
(1) Cleaning hydraulic oil tank
(2) Cleaning suction hose
(3) Cleaning mount of tank.
Installing is done in the reverse order of removing.
(4) Install 4 mounting capscrews (A1) M16×50.
(See Fig. 33-36.)
: 24 mm, Apply Loctite # 262

If the gap (looseness) between tank mount and frame

exceeds 1mm (0.04inch), adjust the gap with shim (A3)
and tighten capscrew (A1) to install the tank.
33-19
33. UPPER STRUCTURE
(5) Connection of suction hose (3)(See Fig. 33-32) O-RING

1) Apply PERMATEX on pipe side of hose
connection and insert it.
2) Put the hose with clip (21).
Tightening torque : 5.39 N•m (4.0 lbf•ft)
(6) Assembling return element
C
Assemble filter element by the use of element kit
(B5-400). (See Fig. 33-31,Fig. 33-37)
D
B1 SUCTION
1. Replace O-ring (C) and packing (F) with new ones STRAINER
YN50V00025F2
respectively. F
(7) Install return element (B5). (See Fig. 33-31) ELEMENT KIT
(B5-300)
(8) Installing suction strainer (B1) YV52V01001R300
(9) Tighten sems bolts (B8) M10×25 that attach tank
covers (B6), (B7).
M10 Tightening torque : 46.5 N•m (34 lbf•ft)
Fig. 33-37 Return element & suction strainer
Replace O-ring fitted on the back side of tank cover with

new one.
33-20
33. UPPER STRUCTURE
33.1.8 HYDRAULIC PUMP

(1) Release pressure in hydraulic oil tank.
B8
(See 33.1.7HYDRAULIC TANK)
(2) Remove six capscrews (B8) M10×25.
B6
(3) Remove cover (B6)
Suction
: 17 mm stopper
(4) Take out suction strainer.

(5) Install suction stopper.
Suction
For suction stopper, see chapter 11. Tools. strainer
(6) Remove counterweight (See 33.1.11)
Hyd.tank
Fig. 33-38 Suction stopper installing
33.1.8.2 REMOVAL
(1) Loosen sems bolts (17) M10×35 and remove half 12
clamp (12). And disconnect 2 hoses (1), (2) from 17 17
the delivery side.
C/V
1 12
: 17 mm C/V P1
P2
(2) Remove pilot pump suction hose (A4)
(See Fig. 33-40)
: 36 mm
(3) Remove suction hose (3) and drain hose (A5) 2 PUMP
1) Remove 4 capscrews (A15) M12×30. B1
: 10 mm
2) Remove elbow (A6) of suction hose (3) from A15
pump.
3) Remove drain hose (A5).
A2
A6
: 36 mm 21
3
20
A5
TANK
Fig. 33-39 Removing and installing of suction and

delivery hose
33-21
33. UPPER STRUCTURE
(4) Removing other hoses A2

1) Disconnect hoses of the following ports. A1
Hose Tool
Port No. Remarks A3
(mm)
Dr3 A2 22 Drain
Dr3
PSV1 A3
*Psv1 A1 22 Pilot primary pressure P1 side
S/V
Psv1 A3 22 Pilot pump delivery P1
Remove the parts marked * only if necessary. B3
2) Attach tags to hoses to identify.

3) Put a plug in the hoses and the pump. B1
A4
Fig. 33-40 Removing other hoses

(5) Remove connector !""#$
Remove 4 connectors of all pressure sensors and " !% " ! "#" !"&
proportional valves. '

' 0

() (
* +&+ & ,-&- .%&%/
Fig. 33-41 Removing connector
33-22
33. UPPER STRUCTURE
(6) Remove main pump 3 0

1) Put a wire sling on the hydraulic pump and
tension the wire sling a little. Loosen 8
capscrews (4) M10×30.
: 17 mm
2) Draw out the power take-off assy from the
flywheel housing slowly, adjusting the tension of
the wire rope. 4
On that occasion, the assembly is drawn out with
the insert NA (2-3) remaining on the flywheel 3
side.
2-6
3) Remove element (2-1) from the tip of the spline 2-4
shaft.
4) Remove 4 capscrews (2-6) M16×45 that fasten
insert R (2-4) and remove insert R (2-4). 2-7
: 14 mm 2-2
5) Remove hub (2-2)
If you loosen 2 set screws (2-7) M16×18, hub 2-5
2-3 1
comes off from the spline shaft of the pump. 2-8 2-1
: 8 mm Fig. 33-42 Removing pump
6) Remove 4 capscrews (2-5) M16×55 that fasten
the insert NA (2-3) with the engine side flywheel,
as necessary. Then remove and spring pin (2-8)
from insert NA (2-3).
: 14 mm
7) Removing bracket (1)
Loosen 2 capscrews (3) M16×50, and remove
bracket (4) from pump (0).
33-23
33. UPPER STRUCTURE
(1) Installing bracket (1)
Tighten bracket (1) with capscrew (3) and install
bracket temporarily.
: 14 mm
Apply Loctite #262
(2) Installing hub (2-2)
Put hub (2-2) into the pump spline till it enters 5mm
(0.12in) from the end face of the spline (See Fig.
33-43 Detail aa). Then install two set screws (2-7)
and fix them together.
: 8 mm
(3) Installing insert R (2-4)
Install insert R (2-4) into hub (2-2) by means of
capscrews (2-6).
: 14 mm
(4) Installing element (2-1)
Put element (2-1) into hub (2-2) and insert R (2-4).
(5) Installing insert NA (2-3)
Put spring pin (2-8) into insert NA (2-3) and install it
to the engine flywheel by means of capscrews (2-
5).
: 14 mm
(See Fig. 33-42 about above mentioned (1) ~ (5).)
33-24
33. UPPER STRUCTURE
(6) Installing the pump (See Fig. 33-42,Fig. 33-43)

Lift the pump with bracket (1). Place coupling (2) in
the groove of element (2-1) so as to receive insert
2-6
NA (2-3). 2
(7) Coat 8 capscrews (4) M10×30 with Loctite #262
and put them in place.
aa
: 17 mm
Tightening torque : 64.7N•m (48 lbf•ft) 2-7
T=110N.m (81 lbf.ft)
(8) Fasten hoses (1), (2) on the delivery side with half
clamp (12) and sems bolt (17) M10×35. 2-8 3
SPRING PIN
T=191N.m (141 lbf.ft)
(See Fig. 33-39) (4 places)
Apply Loctite #262
1
T=220N.m (162 lbf.ft)
: 17 mm Do not use Loctite
(The attached bolts are coated
4
Tightening torque : 57N•m (42 lbf•ft) with micro capsule coating)
T=64.7N.m (48 lbf.ft)
Apply Loctite #262
(9) Install suction hose (3) with 4 capscrews (A15)
M12×30. (SeeFig. 33-39) 4
5
: 10 mm (0.197")

(10)Install the hydraulic piping by referring to
"HYDRAULIC SYSTEM".
50 (1.97")
(11)Installing the hose (See Fig. 33-40) DRAIN HOLE (Bottom)
DETAIL aa VIEW I
Tool Tightening torque
Port
(mm) N m (lbf ft)
Fig. 33-43 Installing hydraulic pump
Cap nut Dr3 22 49 (36)
Cap nut Psv1 22 49 (36)
Cap nut B3 36 118 (87)
(12)Installing pressure sensor connector and

proportional valve connector.
(13)Remove suction stopper
(14)Install suction strainer
When the pump is replaced, replenish more than 1L

(0.26gal) of hydraulic oil from the drain port (Dr).
(15)Bleed air in pump

Dr
Bleed air by loosening the drain port (Dr).
(16)Check hydraulic oil level.
(17)Start engine and check it for oil leak and noise.
(18)Attach drain down pipe under engine muffler.
(19)Install counterweight.
(See 33.1.11)
Fig. 33-44 Bleed air port (Dr) in pump
33-25
33. UPPER STRUCTURE
33.1.9 AIR CLEANER

(1) Open bonnet assy (H1).
(See 33.1.4 GUARD)
(2) Open cover assy (E1).
(3) Remove 2 filters in front of radiator (G15).
(See Fig. 33-26)
(4) Unplug terminals on indicator (1-8) wiring.
(See Fig. 33-46)
Fig. 33-45 Preparation for removal
33.1.9.2 REMOVAL
(1) Pulling out hose (2).
1) Loosen clips (7), (8) on both sides of hose (2).
2) Pulling out hose (2)
: Flat-blade screw driver
dd
(2) Pulling out hose (4).
1) Loosen clip (8) on hose (4).
2) Pulling out hose (4).
: Flat-blade screw driver 3
(3) Remove air cleaner assy (1)
B
1) Loosen 4 sems bolts (12) M8×16
4
: 13 mm aa 1
2) Remove air cleaner assy (1) from bracket. 1 4
8
2
Alowance for
inserting hose 8
7 9
Fasten item 7 clip
in the drawing direction
TIGHTENING TORQUE : CLIP
RUBBER 5.9N.m (4.35 lbf.ft) Fasten item 6 clip
in the drawing direction
After connection of TIGHTENING TORQUE :
hose to tube, paste 5.9N.m (4.35 lbf.ft)
rubber to duct.
cc
Alowance for DETAIL aa INDICATOR
inserting hose
TIGHTENING TORQUE :
25 (0.98")
25
(0.98")
17.5N.m (12.9 lbf.ft) 4 places
Alowance for
inserting hose
30
(1.18")
(2)
Alowance for
inserting hose
CLIP
Fasten item 10 clip
CLIP in the drawing direction
Fasten item 8 clip in the drawing direction TIGHTENING TORQUE :
TIGHTENING TORQUE : 5.9N.m (4.35 lbf.ft) 5.9N.m (4.35 lbf.ft)
DETAIL cc DETAIL dd
VIEW B
Fig. 33-46 Removing air cleaner
33-26
33. UPPER STRUCTURE
(1) Installing is the reverse order of removing with REPLACING PARTS
attention paid to the following items:
ELEMENT ASSY, OUTER (1-3)
1) Put in air hoses (2), (3) to the end as shown in (YY11P00008S003)
Fig. 33-46.
ELEMENT ASSY, INNER (1-2) O-RING (1-6)
2) Tightening torque :
(YY11P00008S002) (YY11P00008S006)
No. Name Tightening torque N.m (lbf.ft)

1-8 Indicator 3.9 (2.9)
6,7 Clip 5.9 (4.4)
9 Sems bolt 17.5 (12.9)
33-27
33. UPPER STRUCTURE
33.1.10 MUFFLER

(1) Remove bonnet assy (A3) with exhaust tube (20).
(See Fig. 33-13)
A3
33.1.10.2 REMOVAL
(1) Remove hose (5).
12
1) Loosen clip (11) and remove hose (5). 13
(2) Remove U-bolt (4).
1) Remove 4 nuts (10) M8.
: 13 mm
2) Remove 2 U-bolts (4).
(3) Remove clamp assy (3)
1) Remove 2 capscrews (7) M10×35
: 17 mm 4
1
2) Separate clamp assy (3) from muffler (1).
(4) Removing other parts
1) Remove brackets (2) as necessary. 10
11
: 17 mm A 7
2) Remove exhaust tube (20) as necessary. 3
5 aa
: 17 mm A 6
8,9
Tightening torque: 68.6~98 N.m (51~72lbf.ft)
Tighten nut (11) till the no gap is here between
plates of clamp.
7 8 9
10
7,8,9 B
10mm (0.4 in) from
the tip of muffler slit
m
fro
in)
0 .8 lit
4~ s
(0. ler
3 B m m muff
10 of B
DETAIL aa 5~ e tip VIEW BB
th
C
A Procedure of fastening U-bolt
Fig. 33-48 Removing and installing the muffler
33-28
33. UPPER STRUCTURE
Installing is the reverse order of removing with attention
paid to the following items:
(1) Procedure of fastening U bolt (4) (See Fig. 33-48)
1) Tighten 4 nuts (A) till there is no space and make
sure that the dimension C is even all around.
2) Tighten nuts (A) to specified torque and confirm
the C dimensions on the right and left once
again.
3) Tighten nuts (B) to specified torque and make
sure that U bolts are not inclined.
(Decide C dimension after checking the piece-to-
piece variations in related parts.)
4) Tightening torque
Nut A : 8.8 N•m (6.5 lbf•ft)
Nut B : 10.8 N•m (8.0 lbf•ft)
(2) Installing clamp assy (3)
1) Place the end of clamp (3) 10mm (0.40in) away
from the tip of the muffler slit so the joint of clamp
does not extend over the slit in the muffler. (See
Fig. 33-48)
2) Install the clamp assy (3) in the illustrated
direction.
(3) Tightening torque :
No. Name Tightening torque N.m (lbf.ft)

6 Sems bolt 64.7 (47.7) (Apply Loctite #262)
13 Sems bolt 39.2 (28.9)
(4) Replacing parts
Name Part No.

Muffler (1) YY12P00012P1
33-29
33. UPPER STRUCTURE
33.1.11 COUNTERWEIGHT

(1) Removing bonnet assy
Remove bonnet (B1) located at upper of engine.
(See Fig. 33-12)
(2) Remove dumper bracket (A17).
(See Fig. 33-15)
(3) Remove covers (A3), (A9).
(See Fig. 33-13, Fig. 33-14)
(4) Installing of lifting jig
Remove plugs (A5) from counterweight, and install
right and left jigs (Refer to Chapter 11. Tools) for
lifting to counterweight.
Fig. 33-49 Lifting up counterweight
: 75 mm
33.1.11.2 REMOVAL
(1) Lifting up counterweight temporarily
A1
Hook wire rope to lifting jig, and lift it and stretch
wire rope to the degree where it is providing no A5
slack temporarily.
A3
Weight of counterweight ; A1
SK125SR : Approx. 2,840kg (6,260 lb) C11
A5
SK135SR-2 : Approx. 3,400kg (7,490 lb)
C3
Wire more than ø10 (0.39 inch) ;
1.5m (5ft)×2 pcs. B1
(2) Removing counterweight
1) Remove 4 capscrews (A1) M36×300.
: 55 mm C1
C2
2) Remove shim (A3), (A4). (Select)
ADDITIONAL
3) Remove counterweight (C11). A1
COUNTERWEIGHT
A2
(3) Removal of additional counterweight (Optional A1
A2
weight)
1) Attach 2 eye bolts to additional counterweight in Fig. 33-50 Removing counterweight
the same way of standard counterweight and
hoist it temporally.
Additional counterweight ; 585 kg (1,290 lb)
2) Loosen 3 capscrews (C1) M20×135 and remove
counterweight (B1).
: 30 mm
33-30
33. UPPER STRUCTURE
(1) Install counterweight in the reverse order of
removing.
A1
(2) Slinging counterweight A5
Check that the 4 attaching bolts can be screwed in
by hand.
A4
(3) Apply Loctite #262 on capscrews (A1), and tighten
them with washers (A5).
: 41 mm
(4) Remove lifting jigs, and attach plugs (A3).
A1
(5) Installation of additional counterweight (Optional A2
weight) Fig. 33-51 Fastening the counterweight attaching
1) Apply Loctite #262 to capscrews (C1) and capscrew
tighten them with washers (C2).
: 30mm
2) Loosen eye bolts and attach plugs (C3).
33-31
33. UPPER STRUCTURE
33.1.12 RADIATOR & OIL COOLER

(1) Bleed air from the hydraulic tank and install the
suction stopper.(See 33.1.7, and 33.1.8)
(2) Remove counterweight.
(See 33.1.11)
(3) Remove duct assy (F1). (See Fig. 33-26)
(4) Removing under cover installed on lower side of
radiator.
Remove under cover (1),(6),(9). (See Fig. 33-27)
(5) Drain down of radiator
Put container 18L (4.8gal) under drain valve hose
for draining water.
[Water capacity of radiator : 6.6L (1.7gal)]
Do not loosen the joints of the hoses related to the air-

conditioner. Otherwise the refrigerant leaks.
RECEIVER 23
DRYER
(6) Move air-conditioner condenser and receiver tank
8
1) Loosen 6 sems bolts (23) M8×25. 23
: 13 mm 7
2) Move a set of air-conditioner condenser and
17
receiver dryer.
25
14
19
AIR-CON CONDENSER
Fig. 33-52 Moving condensers and receiver dryer
33-32
33. UPPER STRUCTURE
33.1.12.2 REMOVAL
(1) Remove radiator stay (B1), (B4).
A1
: 19 mm B2
2) Remove 2 stays (B1), (B4).
B4
(2) Remove water hose (2),(3)
1) Loosen the 2 hose bands (17) for water hose (2). B2
: Flat-blade screwdriver B2
2) Remove hose (2).

B1
3) Loosen 2 hose band (17) on water hose (3).
B3
: Flat-blade screwdriver
4) Remove hose (3).
B3 B2
Fig. 33-53 Removing radiator assy

(3) Remove hoses (4)(5)(6) for inter-cooler 4
1) Remove a fixing U-bolt (19) from tube (7). 18
17 2 18
: 13 mm
17
2) Loosen sems bolt (21) M10×25. 20 17 B C 17
9 F
20 11 20
G 5
: 13 mm 17
E
3) Loosen tow hose bands (18) and remove hose 19
(4). 21
3 D
: Flat-blade screwdriver 8 7
4) Loosen hose bands (17),(18) and remove hose 17

17
(6). 6
: Flat-blade screwdriver 18
F
5) Loosen 2 hose bands (24) and remove hose (5). B
G
(4) Remove guard (8), (9) (See Fig. 33-54)
1) Remove 4 sems bolts (20) M8×20. C
2) Remove guard (8), (9). E
D
: 13 mm
Fig. 33-54 Removing hose for radiator/inter-cooler
33-33
33. UPPER STRUCTURE
(5) Disconnecting hydraulic oil tube (A8), (A9)

A21
1) Loosen 2 capscrews (A16) M12×55 for attaching
clamp (A17). A16
A17
2) Place an oil pan under the hose joint. Loosen 4
sems bolts (A21) M12×35, and remove hoses A9
(A8) and (A9).
(6) Remove radiator assy. (See Fig. 33-53)
A3
: 19 mm
TANK
: 19 mm
2) When lifting the engine fan, shift the radiator so A21
it does not interfere with the engine fan.
3) Plug up pipe ends with clean cloth, etc. A8
4) Removing radiator C/V

Place a wire sling in the lifting eyes of the radiator T1 A17
A16
assy and remove the assy by crane.
Weight : 74kg (163 lbs) Fig. 33-55 Removing hydraulic oil tube (A8), (A9)
33-34
33. UPPER STRUCTURE
(1) Installing is done in the reverse order of removing. Adjust the engine fan so its rear end
sticks out 32 5mm (1.3 0.2 in) from
And removed clips of hose should be clamped at the radiator shroud.
original position. 32 5 (1.3" 0.2")
(2) Install radiator assy B4

Place a wire sling in the lifting eyes of the radiator
and move it to original position temporally. And
install hydraulic hose, radiator hose and hose of
inter-cooler. Regarding Inserting width of hose.
(See Fig. 33-57)
(3) Radiator attaching bolt
Apply Loctite #262 on 4 semsbolts (A3) M12×35.
: 19 mm
(4) Installing radiator stays (A1), (A2)
Install radiator stays (A1), (A2) with 4 sems bolts B2 B3 B1 B2
TIGHTENING TIGHTENING TIGHTENING
(A3) M12×35. TORQUE
120.6N m.
TORQUE TORQUE
120.6N m (88.9 lbf ft) 120.6N.m (88.9 lbf.ft)
. .
Tighten circular hole side of stay (A1) to upper (88.9 lbf.ft) Apply Loctite # 262
or equivalent.
frame. 4 places
(5) Adjust the clearance between the fan and the The clearance between the fan and the radiator shroud should
be 20 5mm (0.79 0.2 in) along all circumferences.
radiator shroud all around the circumference, as
below :
Circumferential direction:
20±5mm (0.8in±0.2in)
32±5mm (1.3in±0.2in)
)
.6"
(6) Clean the plastering area of the insulation 23
0(
60
thoroughly before plastering it.

.
dia
n
Fa
(7) Making up hydraulic oil and LLC (Long Life

Coolant)
After completion of other installation, make up
hydraulic oil and water.
Coolant volume of engine body : 6 L (1.6gal)
Coolant capacity of radiator : 6.6 L (1.7gal) Fig. 33-56 Adjusting position of radiator
Hydraulic oil capacity of oil cooler : 2.1 L (0.55gal)
33-35
33. UPPER STRUCTURE
dd
cc
Fasten hose by clip

of guard.
Fasten hose by clip

bb of guard.
Fasten hose by
clip of guard
11 WATER SUB TANK ASSY HOSE
Fasten clip in the direction of drawing.
Tightening torque : 5.9N.m (4.35 lbf.ft)
17
4
27
(1.06") Fasten clip in the 18
50 direction of drawing.
(1.97") Tightening torque :
5.9N.m (4.35 lbf.ft)
Allowance for 21
(1.77")
(1.57")
inserting hose Tightening torque : 6 Allowance for
45
39.2N.m (30 lbf.ft) 7 17 inserting hose 40
Apply Loctite #262. Fasten clip in the direction of drawing. Allowance for
Tightening torque : inserting hose
VIEW III 5.9N.m (4.35 lbf.ft) 18
Fasten clip in the direction of drawing. Fasten clip in the
Tightening torque : 5.9N.m (4.35 lbf.ft) direction of drawing.
Tightening torque :
18 5.9N.m (4.35 lbf.ft)
3
6 2
(1.77")
Allowance for
(1.57")
45
inserting hose DETAIL bb 17

40
Fasten clip in the direction of drawing.

Fasten clip in the direction of drawing. Tightening torque :
Allowance for Tightening torque : 5.9N.m (4.35 lbf.ft)
inserting hose 17 Fasten clip in the direction of drawing. 5.9N.m (4.35 lbf.ft)
Tightening torque : 17
5.9N.m (4.35 lbf.ft)
VIEW IV
Fasten clip in the direction of drawing. 5 DETAIL cc

17 Tightening torque : 20 Tightening torque :
5.9N.m (4.35 lbf.ft) 19.6N.m (14.5 lbf.ft)
SECTION DD
Allowance for
inserting hose
D 35 (1.38")
Allowance for
inserting hose 3
(1.57")
(1.9
50
7")
40
40
(1.57")
Allowance for Allowance for

inserting hose inserting hose
D
2
4
6
VIEW V VIEW VI DETAIL dd
Fig. 33-57 Allowance of hose insertion
33-36
33. UPPER STRUCTURE
33.1.12.4 PROCEDURE OF DISASSEMBLING AND ASSEMBLING THE RADIATOR/INTER COOLER CORE

(1) Preparation for disassembly and assembly
28 28 19
1) Remove one under cover (1), (9) at the bottom of
the radiator.
(See Fig. 33-27)
2) Wait till the engine coolant cools down so you do
not get burned. Then remove the cap of the
radiator, drain the coolant by opening the drain
valve located at the lower of engine and receive
it in a container. 1 19 17
* In case of removing inter cooler only, the above
2
mentioned work is not necessary.
(2) Disassembly
1) Loosen each 6 capscrews (19) at head and
bottom of shroud, remove upper plate (17) and
lower plate (18).
2) Loosen 2 sems bolts (28) M10×30 attaching
radiator core.
3) After confirming that the coolant has been
A
drained out completely, loosen and remove only
the radiator side of hose bands (17) at the top
and bottom of the radiator. (See Fig. 33-54)
4) Lift and remove radiator core using lifting eyes
and hoist on the radiator core.
Confirm the missing of rubber bushing (27)
under the radiator core.
5) Loosen 2 sems bolts (28) M10×30 attaching the
DRAIN VALVE
top of the inter-cooler core.
6) Loosen and remove only the inter-cooler side of
hose bands (18) at the top and bottom of the 27
inter-cooler. (See Fig. 33-54)
MOUNTING OF
7) Lift and remove inter-cooler using lifting eyes and RADIATOR CORE FOOT
hoist on the inter-cooler.
Weight : 4.8kg (11 lbs)
Confirm the missing of rubber bushing under the
inter-cooler.
19
18
VIEW A
Fig. 33-58 Removing radiator and inter-cooler
33-37
33. UPPER STRUCTURE
10) Disconnection of oil cooler tube

Disconnect tube (A8), (A9) from upper and lower
of cooler, and drain hydraulic oil. (See Fig. 33-
55)
11) Lift cooler temporally using cooler head flange
for slinging.
12) Loosen 4 bolts (19) M8×25 attaching oil cooler.
13) Lift the oil cooler.
There is no predetermined sequential order in

removing radiator core, inter-cooler core and oil cooler.
Removing these components can be done as
necessary.
(3) Installing
33-38
33. UPPER STRUCTURE
33.1.13 ENGINE
33.1.13.1 PREPARATION FOR REMOVING

(1) Remove battery ground (See 33.1.3 BATTERY)
(2) Remove bonnet and guard (See 33.1.4 GUARD ) Remove under cover (See 33.1.5 UNDER COVER)
(3) Remove air cleaner hose (See 33.1.9 AIR CLEANER)
(4) Remove counterweight (See 33.1.11 COUNTERWEIGHT)
(5) Remove radiator hose and inter-cooler hose (See 33.1.12 RADIATOR & OIL COOLER)
(6) Remove fuel hose and heater hose, and if necessary disconnect air-con hose.
(7) If necessary, remove pump, muffler and radiator.
(8) Remove harness connector (Refer to ELECTRIC SYSTEM)
1) Remove E/G ground cable
2) Starter cable-Starter B terminal
3) Remove the connector that connects the upper harness with the engine and ECU harness.
4) Upper harness
CN-206-E/G sub harness
P1,P8-Alternator B terminal
CN-136-E/G speed sensor
CN-141, CN142-Pump proportional valve
CN-139, CN-140-P1,P2 pump pressure sensor
P5-Glow
P6-Starter motor B terminal
Prepare a stand, which withstands the weight of the engine assy and can place the removed engine firmly. (Refer
to Tools)
OIL FILTER
ELEMENT
THERMOSTAT
STARTER
ALTERNATOR
Fig. 33-59 Outside view of engine
33-39
33. UPPER STRUCTURE
33.1.13.2 REMOVAL
9
A
10
9
7 10
4
7
2
6 4
5
3
4
9 9
10 10 4
8
7 8
7
4
4
1
9
5 2 11
A
4 6 4
8 8
Fig. 33-60 Dismantling and mounting engine

(1) Loosen engine mounting bolt of flame
1) Loosen a nut (11) M18 and 2 capscrews (10) M18×150.
: 27 mm
2) Loosen 3 other capscrews (10) M18×150 and remove them.
: 27 mm
3) Remove each 4 plates (7).
4) Remove upper rubber mounts (4) 4 each.
(2) Slinging engine body
Prepare a stand, which withstands the weight of the engine assy and can place the removed engine firmly. (Refer
to "Tool".)
1) Sling engine hooking wire to lifting lugs on the front and rear sides.
Weight: Approx. 400 kg (882 lbs)
Wire: ø6 (0.236")×1m (3ft 3in) - 2pcs.
(3) Position engine on the stand stably.
33-40
33. UPPER STRUCTURE
Tightening torque
No. Name Remarks
N.m (lbf.ft)
Apply Loctite
5 Sems bolt 115 (84.8) #262
Apply Loctite
6 Sems bolt 115 (84.8) #262
Apply Loctite
10 Capscrew 226 (167) #271
33-41
33. UPPER STRUCTURE
33.1.14 CONSOLE COVER
33.1.14.1 REMOVAL
(1) Removing right-hand console cover
1) During pushing 4 locked claws of boot retaining
plate (4) with flat-blade screw driver, lift the plate
(4) and remove it.
2) Loosen 3 sems bolts (A5) M6×16.

: Plus screw driver
3) During lifting right upper console cover (A4-5)
up; disconnect connector of tuner and antenna.
Move boot (3) upwards and remove console
cover (A4-5).
• Removing of boot and lever is unnecessary. Fig. 33-61 Removing plate (4)
4) Loosen 3 sems bolts (15A) M6×16 and remove A5
lower console (3). A4-5
: Plus screw driver A5
(2) Removing left-hand console cover 15A

15B
1) Remove the boot retaining plate (4) in the same
way as right-hand console cover. (See Fig. 33- 4X 15B 3 15A
61) 15B
15C
2) Loosen 4 sems bolts (15B) M6×16.
: Plus screw driver
5X
3) Remove the left upper console cover (4X) in the
same way as right-hand console cover.
4) Loosen 2 sems bolts (15C) M6×16 while lifting
left under console cover (5X) up, and remove left
lower console cover.
Fig. 33-62 Removing console covers
Install it in reverse order of removing according to the
tightening torque table.
)$
Item Bolts Tightening torque N.m (lbf.ft)
15A~15C Sems bolt M6 5.0 (3.7)

A5 Sems bolt M6 5.0 (3.7)
A6 Sems bolt M8 23.5 (17.3)
Fig. 33-63 Removing left armrest
33-42
33. UPPER STRUCTURE
33.1.15 MULTI CONTROL VALVE (OCE SPEC.)

(1) Bleed pressure air in hydraulic oil tank (See 33.1.7
HYDRAULIC TANK)
(2) Remove under cover (3). (See 33.1.5 UNDER
COVER)
(3) Remove plate (A6) and panel assy (A2).
(See Fig. 33-20)
Fig. 33-64 Removing multi control valve
33.1.15.2 REMOVAL
(1) Attach tag on which hose name is entered to the
remote control hoses between multi control valve
0 2
and pilot V, and write numbers P1 to P8 on it.
P/V
See Tools 11.5 PLUG (3) P2
P6 P5
: 19 mm, 22 mm 6 5
P/V C4 P/V
(2) Attach tag on which hose name is entered to the
C3 C6 PBb
remote control hoses between multi control valve C/V
and main control valve, and write numbers C1 to C8 C1
PBs
C7 PAb C5 C/V
on it. C/V P1
See Tools 11.5 PLUG (3) PAa1 PAc PAc PBc
C/V C/V C/V C/V
1
: 19 mm, 22 mm
P/V PBa2
(3) Remove 4sems bolts (B15) M8×35, and remove C/V
multi control valve (0) from machine.
(1) Installing is done in the reverse order of removing
(2) Relations between pilot valve and multi control P3
valve hose 3
P/V
P/V Hose ISO Multi Mark-
Port Size Color Control pattern port ing P7
1 3/8 Red Bucket digging P1 1 7
2 3/8 Blue P8
Right side
Bucket dump P2 2 P/V

3 3/8 Green Boom up P3 3
4 3/8 Gray Boom down P4 4
8
P 1/4 Black Pilot primary - - P4
P/V
T 3/8 Black Drain - -
5 3/8 Gray Swing left P5 5
6 3/8 Red Swing right P6 6
Left side
4
7 3/8 Blue Arm in P7 7
P/V
8 3/8 Green Arm out P8 8
P 1/4 Black Pilot primary - - B15
T 3/8 Black Drain - -
Fig. 33-65 Removing hoses between main C/V, P/V
(3) Tightening torque and multi control valve
Tool Tightening torque

Tightening position
mm N.m (lbf.ft)
Sems bolt (B15) 13 35.3 (26.1)
33-43
33. UPPER STRUCTURE

(1) Remove cover assy (B1)
(See Fig. 33-19) 1
(2) Remove plate (C4), panel assy (C1).
(See Fig. 33-20)
(3) Remove panel assy (C13), bracket (31), box (29).
(See Fig. 33-21) 4
4
(4) Install the suction stopper to the hydraulic oil tank.
(5) Remove the hoses in Fig. 33-67 and Fig. 33-68.
Mark each hose with a port name before removing it. 2
Fig. 33-66 Removing the standard main control

valve
33.1.16.2 REMOVAL
(1) Remove 3 capscrews (4) M16×45, and remove
control valve (1) by hoist.
: 24 mm
Weight :Approx. 155kg (342 lbs)
(1) Installing is done in the reverse order of remove.
1) Install control valve by tightening 3 capscrews (4) M16×45.
: 24 mm
2)
Connector / Bolt Hose nut

Tread
size Ports Opposing Tightening Opposing Tightening Remarks
Name torque torque
flats N.m (lbf.ft) flats N.m (lbf.ft)
PF1/4 Pss,PLc2,PBp1,PBp2,(PL), ORS Joint 19 36 (27) 19 29 (21)
PB1,PTb,PCa,PCb
PF3/8 PAa1,PBa1,Pab,PBb,Pac, 22 74 (55) 22 49 (36)
PBc,PAL,PBL,Par,PBr,Pas,
PBs,PAa2,PBa2,Pao,Pbo,DR
PF3/4 (MU1), (MU2), Ab, Bb, Ao, Bo 36 162 (119) 36 118 (87)
Ar,Br,AL,BL,As,Bs,Aa,Ba,Ac,Bc
M10 P1,P2 Sems bolt 14 57 (42)
M12 T1,T2 17 96 (70)
(2) Check for oil leak and operation.
33-44
33. UPPER STRUCTURE
Functions Ports Ports on right front sides (on machine) Ports Functions
PBp1 P1 bypass cut

P2 bypass cut PBp2
PAa2 Arm 2 in
Option PAo Mu Make-up line
Bucket (R) relief valve
Arm (H) relief valve
PBC Bucket out
Arm 1 out PBa1
Swing (LH) PBs PBb Boom down

Boom (H) relief valve
Boom conflux PB1
PAr Travel right forward
Travel left forward PAL
Main relief valve
Tank return T2 Mounting surface PCb P1 unload
Ports on rear left sides (on machine)
Arm 2 out PBa2 LEFT RIGHT PBo Option
Bucket digging PAc Arm (R) relief valve
Bucket (H)relief valve PLc2 Arm in lock valve
Boom(R)relief valve PBa1 Arm out
Boom up PAb PAs Swing right
Travel right reverse PBr PCa P2 unload
Travel straight PTb PBL Travel left reverse

Mounting surface
Ports on bottom sides (on machine)
LEFT RIGHT
P2 pump P2
P1 pump P1
Fig. 33-67 Control valve ports (1/2)
33-45
33. UPPER STRUCTURE
Function Ports Ports on left side (on machine) Ports Function

FRONT REAR
Bucket dump BC SIDE SIDE
Boom up Ab AC Bucket digging
Bb Boom down
BR Travel right reverse
Travel right forward AR

Mounting
surface
Ports on right side (on machine)

REAR FRONT
SIDE SIDE
Option Bo Ao Option
Aa Arm 1 out
Arm 1 in Ba Pss Swing low pressure sensor
Swing left Bs As Swing right
Travel left reverse BL Dr Drain
AL Travel left forward

Mounting
surface
T1 Tank return
Fig. 33-68 Control valve ports (2/2)
33-46
33. UPPER STRUCTURE
33.1.17 PILOT VALVE (FOR ATT)

The removing procedure for right and left is the same,
so the preparation for left side is described here.
(1) Put attachment on ground, stop engine and release
pressure in tank.
(2) Remove left console cover (4X), 5X) assy referring
to Section 33.1.14CONSOLE COVER.
3
(3) Disconnect harness connector for horn at 2-1
position.
5
(4) Attach a tag to the hose to make assembly work
easier. *
Fig. 33-69 Installing and removing boot and lever

part
33.1.17.2 REMOVAL
(1) Remove hoses from your side to far side in order.
: 19 mm, 22 mm
(2) Move the boot (3) up and loosen nut (5).
(See Fig. 33-69)

: 22 mm

(3) Turn and loosen lever (2-1) tightened in pilot valve,
and remove lever assy in a set. (See Fig. 33-69) )*+ ) *
$% & ' !!&
(4) Remove 4 capscrews (A14) M6×25. (See Fig. 33- $& !!&
70) $&

: 5 mm ,$- .).
(5) Remove pilot valve. )*+ ) *
(6) Plug hose ends.
! " "
Plug PF1/4, PF3/8 (& & ' #
/0 / ! " "
Fig. 33-70 Pilot valve connector
Install it in the reverse order of removal and tighten it. Front of machine
T Arm (R) Boom (R)
: 5 mm T = 11.8 N•m (11 lbf•ft) capscrew (Green) T (Gray)
(A14) Bucket (R)
Swing (R) (Blue)
(Red)
Swing (L)
(Gray)
Make sure the tightening torque for capscrews, Bucket (H) P

(Red)
because pilot valve is made of aluminum. Arm (H) (Blue) P
Boom (H) (Green)
LEFT SIDE RIGHT SIDE
Fig. 33-71 Pilot valve port position (from upper
side)
33-47
33. UPPER STRUCTURE
33.1.18 PILOT VALVE (FOR TRAVEL)

(1) Release pressure in hydraulic oil tank (See 33.1.7
HYDRAULIC TANK)
(2) Remove under cover (3) (See 33.1.5 UNDER
COVER)
A1
(3) Remove floor mat (B1). A8
A2 A7
A6
A7
A5
B1
A8
Fig. 33-72 Removing floor mat, pedal and and lever
33.1.18.2 REMOVAL
(1) Separate the two pressure sensors SE-9 (A9) and A12
A9
SE-10 (A9) at the connector. A1
T : Tightening torque
: 24 mm N.m (lbf.ft)
SE-9
(2) Attach tag, and discount connectors and hoses 6
(A2), (A3), (A4), (A5) T=16.7 (12)
A9 5 T T=30 (22)
: 19 mm (P port) P
A2
: 19 mm, 22 mm (T port, 1~4 port)

3 A5
SE-10 PT
A2 PT T
(3) Plug hose ends C/V P
T=30 (22) 4
Plug PF1/4, PF3/8 PBr
A3
1
(4) Remove 4 sems bolts (A8) M8×20, and remove
2
C/V C/V
right and left pedals (A5), (A6). Opposing PAL
PAr
A5
PF3/8 flats 22 C/V
: 13 mm PF1/4 PAL
A3
(5) Remove 4 sems bolts (A7) M10×20 and remove
right and left lever (A1), (A2).
VALVE SIDE HOSE SIDE
: 17 mm
VALVE SIDE T PORT CONNECTOR
(6) Remove 4 sems bolts (A12) M10×30.
PF3/8
Opposing Opposing
: 17 mm flats 22 flats 19 Mark "F"
(7) Remove pilot valve lifting it upward. PF1/4 PF1/4 PF1/4
(8) Stop up holes with plugs PF1/4.
HOSE SIDE
PORT P PORT CONNECTOR
CONNECTOR (With filter)
Fig. 33-73 Installing and Removing pilot valve
33-48
33. UPPER STRUCTURE
Install it in the reverse order of removal and tighten it.
Sems bolt (A12)
: 17 mm T = 37 N•m (27.3 lbf•ft)

Sems bolt (A7)
: 17 mm T = 46.1 N•m (34.0 lbf•ft)

Sems bolt (A8)
: 13 mm T = 23.5 N•m (17.3 lbf•ft)

Pressure sensor
: 24 mm T = 16.7 N•m (12.3 lbf•ft)
33-49
33. UPPER STRUCTURE

(1) Park machine on firm level ground and place
attachment on ground.
(2) Remove bracket (5) for engine bonnet gas damper.
(See Fig. 33-15)
(3) Remove top cover of swing motor and guard assy
(1), (2), (4), (9), (7), (8). (See Fig. 33-17, Fig. 33-18)
(4) Operate the switch on gauge cluster and select the
pressure release mode, and then release the inner
pressure in circuit by operating control lever. (See
22.11 HYDRAULIC SYSTEM PRESSURE
DRAINING(RELEASING) CIRCUIT)
(5) Bleed air from the hydraulic oil tank and attach to
each hose a tag showing port name and other
information.
33.1.19.2 REMOVAL
(1) Remove hose. C/V A6
AS
1) Remove hose (A6) from the connector in the
C/V
makeup port C. 20 T3
C/V
: 36 mm BS
C
2) Remove hose (A4), (A7) from the elbow in the A4 A7
B
drain port DB. 21
TANK
: 27 mm A
S/J
3) Remove hose (18) from the elbow of the PG port E
DB
(For swing parking brake)
: 19 mm
PG
4) Remove 2 hoses (21), (22) from the connectors
of the A, B port. 18
S/V
: 32 mm A2
Put in plugs PF3/4, PF1/2, PF3/8 and PF1/4 into Fig. 33-74 Removing swing unit piping
the removed ports.
2
(2) Removing the swing unit
1) Loosen clip (5).
2) Remove 9 capscrews (7) M20×55. 3
: 30 mm
3) Remove two plastic caps (2) M10 at the top of
7
the swing motor and install eye bolts.
4) Put a wire sling in the eye bolts and remove the
swing motor unit. 5 1
Weight of swing motor unit ;
5
Approx. 113kg (249 lbs) (Include reduction assy)
Fig. 33-75 Removing swing unit
33-50
33. UPPER STRUCTURE
33.1.19.3 PREPARATION FOR INSTALL

(1) Clean mating surfaces of swing motor unit and upper frame.
Tools : spatula, wash oil
(2) Apply Loctite #515 on entire mounting surface of swing motor unit.
Install the swing motor unit in the reverse order of
disassembly, confirming the orientation of the swing
motor unit.
(1) Tighten 9 capscrews (7) M20×55.
: 30 mm
Tightening torque : 539N•m (400 lbf•ft) Apply
Loctite #262
(2) Fill inside from motor drain port to casing with
hydraulic oil before piping for drain
Apply Loctite #262 LEVEL GAUGE

Tightening torque :
539N.m (400 lbf.ft)
TUBE
7 9 PLACES
Put sealing tape on the both
sides of thread portion of
filling tube.
Fix drain hose with the plug at Tightening torque :
the end of drain hose over the 1 108 N.m (80 lbf.ft)
hole of upp frame bottom plate.
Coat all the mounting surface of

the swing motor with Loctite #515
equivalent.
DETAIL OF SWING MOTOR
UNIT ASSY MOUNT
Fig. 33-76 Installing swing motor unit
33.1.19.5 PREPARATION FOR DRIVE

(1) Before starting operation, check that gear oil #90 (API grade GL-4) level of swing reduction is sufficient.
Amount of oil : 1.65L (0.44gal)
(2) When starting operation, operate motor in low idling and at low speed for several minutes, and check it for
possible oil leak and noise.
33-51
33. UPPER STRUCTURE
33.1.20 SWIVEL JOINT

Remove boom piping hose
33.1.20.2 REMOVAL
(1) Remove travel motor hose and tube
1) Remove 2 hoses (A15). (E port : PF1/2)
: 27 mm, Tightening torque : 78.5 N•m (58 lbf•ft)

2) Remove tubes (A3), (A4). (C, D port : PF1)
: 36 mm, Tightening torque : 216 N•m (159 lbf•ft)

3) Remove tubes (A1), (A2). (A, B port : PF1)
: 36 mm, Tightening torque : 216 N•m (159 lbf•ft)

4) Remove 2 hoses (A16). (H,I port : PF1/4)
: 19 mm, Tightening torque : 29.4 N•m (22 lbf•ft)
A B
C D
(TRAVEL MOTOR) (TRAVEL MOTOR)
B (LOWER) REVERSE A, B, C, D-PF1 A (LOWER) REVERSE
(LH) (RH)
A (UPPER) FORWARD E-PF1/2 B (UPPER) FORWARD
H, I-PF1/4
A4
A2
SWIVEL JOINT
D
B
A16
A1 A I
C E
H
E A15
A3
A15 A16
Fig. 33-77 Removing piping (lower side)
33-52
33. UPPER STRUCTURE
(2) Disconnecting the hoses on the top part of swivel S/M

C/V C/V
joint DB Ar
Br
1) Remove drain hoses (A7). (E port : PF1/2) 23 A7
22
: 27 mm
Tightening torque : 78 N•m (58 lbf•ft) 2 2
C/V
2) Remove hoses (27), (23). BL 3 C/V
(C, D port : 1-14UNS) 27 AL
D E B 24
: 32 mm
Tightening torque : 137 N•m (101 lbf•ft) 1 1
3) Remove hoses (24), (22). A
C
(A, B port : 1-14UNS)
: 32 mm
4) Remove hose (19).
H
(Travel 2-speed change over port : PF1/4) 19 S/V
5 A3
: 19 mm
Tightening torque : 29 N•m (21 lbf•ft) Fig. 33-78 Disconnecting the hoses on the top part
of swivel joint
(3) Remove whirl-stop of swivel joint.
23 Tightening torque 22
1) Loosen the nut (23) M24. 157N.m (116 lbf.ft)
2) Remove a capscrew (22) M24×140.
in)
59
: 36 mm (0.
mm
15 At assembling,
this distance
should be 15mm (0.59in).
Fig. 33-79 Removing whirl-stop nut & the capscrew

(4) Remove joint for piping (See Fig. 33-77,Fig. 33-78) Tightening torque B28
6.8N.m (5 lbf.ft)
1) Remove 2 connectors (1). (F,G port)
Tightening torque B29
2) Remove elbow (5) (F port) for travel 2-speed 14.7N.m (11 lbf.ft)
change over. (PF1/4) To prevent from
entering water,
apply Loctite 572
: 19 mm or 577 around
(5) Remove seal (B25) this plate (B24).
B24
: 17 mm Before mounting the seal

(B25), apply adhesive to B25
2) Remove clip (B28). the adhering surface of S/J
and the upper frame.
3) Remove seal (B25). Fig. 33-80 Removing seal (B25)
33-53
33. UPPER STRUCTURE
(6) Remove sems bolts for installation

Attach eye bolt, lift it up temporarily, and remove 3
sems bolts (D2) M12×25.
: 19 mm EYE BOLT
(See 11.7 SPECIAL TOOLS No.9 Plug)
LOWER FRAME
D2
SEMS BOLT
M12 25
Loctite #262
T=108N.m D1
(80 lbf.ft) SWIVEL JOINT
Fig. 33-81 Removing sems bolts for installation

(7) Slinging the swivel joint
Weight : Approx. 63kg (139 lbs)
Piping tightening torque
Tightening torque N.m (lbf.ft)

Size Tool.
PF HEX O-ring type Hydraulic hose
Connector
1/4 19 36 (27) 29 (22)
3/8 22 74 (54) 49 (36)
1/2 27 108 (80) 78 (58)
3/4 36 162 (120) 118 (87)
1 41 255 (180) 137 (100)
1-14UNS 32 - 137 (100)
(2) Check for oil leak and the hydraulic oil level.
(3) Check for operating.
33-54
33. UPPER STRUCTURE
33.1.21 UPPER FRAME

(1) Remove attachment
(See chapter 32)
(2) Remove cab (See 33.1.2 CAB)
(3) Remove guard (See 33.1.4 GUARD)
(4) Remove counterweight
(See 33.1.11 COUNTERWEIGHT) Note)
(5) Remove swivel joint This part is left blank
(See 33.1.20 SWIVEL JOINT) because we had not received related information
from "Engineering Division".
Fig. 33-82 Temporarily lift upper frame
33.1.21.2 REMOVAL
(1) Lifting up upper frame temporarily
Attach 2 upper-frame hoisting jigs to attaching
holes of counterweight. Attach 2 chain blocks to

holes of boom foot pin and use these four points
and hoist upper-frame.

Fig. 33-83 Lifting up upper frame temporarily
(2) Marking match marks on swing bearing

Put match marks on upper frame and swing
bearing.
Fig. 33-84 Matching mark on swing bearing and

upper frame
33-55
33. UPPER STRUCTURE
(3) Removing upper frame attaching bolts

Remove 33 capscrews (B31) M16×85 and a
reamer bolt (B30) used to install swing bearing and
upper frame.
: 24 mm
(4) Slinging upper frame
Sling according to Fig. 33-82, and remove upper
frame and put it on a stand.
Weight : Approx. 5ton (11,000lbs)
Fig. 33-85 Removing upper frame attaching bolts
(1) Installing is done in the reverse order of removing. Apply Loctite #515 to the race surface
(2) Cleaning mating surfaces of upper frame and swing over the whole circumference (shaded area)
bearing. on the inside of capscrew.
(3) Apply Loctite #515 to the inside of the capscrews

on the contact surface.
(4) Slinging upper frame
Match marks and install it with a reamer bolt (B30)
and a washer (B6) temporarily.
Apply Loctite #262

equivalent (* mark 1 place).
T=256N.m (189 lbf.ft)
Confirm the reamer bolt positions referring to Fig. 33- B30,B31
87.
Fig. 33-86 Bearing mount
: 24 mm Apply Loctite #262 OUTER (S) ZONE POSITION

Apply Loctite #262 *
(5) Install swing bearing
Install 33 capscrews (B31) M16×85.
: 24 mm Apply Loctite #262

Install a reamer bolt (B30).
: 24 mm
Fig. 33-87 Reamer bolt position (*) Apply Loctite to

shaded area
33-56
33. UPPER STRUCTURE
33-57
33. UPPER STRUCTURE
33.2 DISASSEMBLING AND ASSEMBLING

33.2.1 HYDRAULIC PUMP • REGULATOR
33.2.1.1 HYDRAULIC PUMP
33.2.1.1.1 Structural exploded view

(1) Main pump
534
531,548 792
702
272
532 251
732 808
490 X A 954
B
255
W Z 256
402
Y
732
789 901
535
733
533
806 981 490
824 983
953 127
727
123 468
04 C
124
113 726
466 314 D
717
401 E
141
157
156 886 312
153
151,152 D
E
211 F
214
212 B
116
711
A 406
F 326 05
271 261
724 774 414
Y 710
726
Z W
X
467
732 111
C
313 724
886
Fig. 33-88 Structural exploded view of main pump
33-58
33. UPPER STRUCTURE
No. Name Q'ty No. Name Q'ty No. Name No.

111 Shaft(F) 1 272 Pump casing (R) 1 710 O-ring ; 1B G80 1
113 Shaft(R) 1 312 Valve block 1 711 O-ring ; 1B G95 1
116 1st gear 1 313 Valve plate (R) 1 717 O-ring ; 1B G125 2
123 Roller bearing 2 314 Valve plate (L) 1 723 O-ring ; 1B P11 6
124 Needle bearing 2 326 Cover 1 724 O-ring ; 1B P8 12
127 Bearing spacer 2 401 Socket bolt ; M16X150 2 727 O-ring ; 1B P18 4
141 Cylinder block 2 402 Socket bolt ; M16X190 2 732 O-ring ; 1B P14 4
151 Piston 18 406 Socket bolt ; M6X16 4 733 O-ring ; 1B P28 2
152 Shoe 18 414 Socket bolt ; M10X20 4 774 Oil seal 1
153 Retainer 2 466 VP plug ; PF1/4 2 789 Backup ring P14 2
156 Spherical bushing 2 467 VP plug ; PF3/8 2 792 Backup ring G30 2
157 Cylinder spring 18 468 VP plug ; PF1/2 4 806 Nut ; M12 2
211 Shoe plate 2 490 Plug ; NPTF1/16 9 808 Nut ; M16 2
212 Swash plate 2 531 Tilt pin ; M20X1.5 2 824 Stop ring 2
214 Tilting bushing 2 532 Servo piston ; M20X1.5 2 886 Spring pin 4
251 Swash plate support 2 533 Plug ; M30 2 901 Eye bolt ; M10 2
255 Lock pin 2 534 Stopper (L) 2 953 Socket screw ; M12X23 2
256 Set spring 2 535 Stopper (S) 2 954 Set screw ; M16 2
261 Seal cover (F) 1 548 Feed back pin 2 04 Gear pump 1
271 Pump casing (F) 1 702 O-ring ; 1B G30 2 05 PTO gear case (OCE Spec.) 1
The numbers in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
Tightening torque of bolt, plug, nut and servo piston
Tightening torque
No. Thread size
N.m (lbf.ft)
401,402 M16 240 (177)
406 M6 12 (8.9)
414 M10 57 (42)
466 PF 1/4 36 (27)
467 PF 3/8 74 (55)
468 PF 1/2 110 (81)
490 NPTF1/16 8.8 (6.5)
531,532 M20X1.5 240 (177)
533 M30 220 (162)
806 M12 60 (44)
808 M16 130 (95)
33-59
33. UPPER STRUCTURE
(2) Gear pump (For pilot)
887
Front gear side Gear case side
SECTION X-X
(2 places)
710 700 354 351 Suction port : G3/4 887 433
Tightening torque : 74N.m
(54.5 lbf.ft)
Z
X
B3
X
434
X
A3
Delivery port : G1/2
311 Tightening torque :
312 X 53N.m (39 lbf.ft)
732 Dr3
a3 850
Dr3 Z
308 308 355
435 361 353 310 310 434 466

725
SECTION Z-Z
Drain port : G3/8
Tightening torque :
Tightening torque 34N.m (25 lbf.ft)
Tightening torque
N.m (lbf.ft)
312 M14X1.5 29 (21)
433, 434
M8 17 (13)
435
466 PF 1/4 16 (11)

307 Poppet 1 433 Flange socket; M8×40 2
308 Seat 1 434 Flange socket; M8×55 2
309 Ring 1 435 Flange socket; M8×20 4
310 Spring 1 466 VP plug ; PF1/4 1
311 Adjust screw 1 700 Ring 1
312 Lock nut ; M14×1.5 1 710 O-ring 1
351 Gear case 1 725 O-ring ; 1B P11 1
353 Drive gear 1 732 O-ring ; 1B P16 1
354 Driven gear 1 850 Locking ring 1
355 Filter 1 887 Pin 2
361 Front case 1
33-60
33. UPPER STRUCTURE
33.2.1.1.2 Disassembly and assembly of main pump

(1) Tools
Tool Part
The right list shows the tools required for remove
and install. Name Size mm Size Item No.
4 M5 490
(2) Disassembling procedure 5 M6 406
Allen wrench
1) Selecting a place for disassembly. 6 M8 466, 953
• Choose a clean place. 8 M10 414, 467
10 M12 468
• Spread rubber sheet or cloth on work bench
to protect parts from damaging. 14 M16 401, 402
Eye wrench 19 M12 806
Socket wrench 24 M16 808
2) Cleaning Wrench ; Double
Remove dust and rust, etc. on pump surface with single 41 PF1
wash oil. Crescent wrench Medium size 1pc.
Driver Flat bladed 2pcs.

Hammer Plastic
Plier Snap ring
Steel bar 4X100
Torque wrench
3) Drain oil
REGULATOR
Drain out the oil in the pump casing by removing
drain port plug (468).
: 10 mm
• Drain out oil from the plug of the front pump

and the rear pump.
4) Removing regulator and PTO cover

Remove the socket bolts [414, 415 (See Fig. 33-
88, Fig. 33-106)]. Then remove the regulator and
the PTO cover (326).
: 6 mm, 8 mm
• Regarding the disassembly of the regulator,

refer to article of Regulator.
5) Removing gear pump

Remove the socket bolt (435). Then remove the
gear pump (04).
: 6 mm
6) Remove socket bolt (401),(402)
Loosen socket bolts (401),(402) that fasten
pump casing (271),(272) and valve block (312).
: 14 mm
Fig. 33-89 Remove socket bolt (401),(402)
33-61
33. UPPER STRUCTURE
7) Disassembling the pump casing and the valve

312 271
block
Place the pump level on a work bench with its
mounting surface of the regulator facing down.
Then separate pump casing (271) and valve
block (312).
• When facing the mounting surface of the

regulator down, place a rubber sheet on a
work bench so as not to score the mounting
surface.
Fig. 33-90 Disassembling the pump casing (271)
• When the pump casing has been separated and the valve block (312)
from the valve block, draw out the 1st gear
(116) at the same time.
8) Drawing out the cylinder assy %
Draw out cylinder block (141) out of pump casing
"##%
(271),(272) in parallel to shaft (111),(113). At the
same time draw out piston sub (151),(152), plate #!
(153), spherical bushing (156) and cylinder #$
spring (157).
• Use care so as not to score the sliding

surface of the cylinder block, spherical
bushing, shoe and the swash plate.
Fig. 33-91 Drawing out the cylinder assy

9) Remove seal cover (F)
406
Remove socket bolt (406) M8 and seal cover (F)
(261). 261
: 5 mm
• The seal cover (F) may be drawn out with

ease if it is taken out by flat bladed driver in
the notch of the seal cover (F).
• An oil seal is fitted to seal cover (F).
Therefore, use care so as not to score the oil
seal.
Fig. 33-92 Removing seal cover (F)(261)
33-62
33. UPPER STRUCTURE
10) Drawing out the shaft

Tap lightly the shaft end (111, 113) by means of a
plastic hammer and draw out the shaft from the
pump casings (271),(272).
Fig. 33-93 Drawing out the shaft (111), (113)

11) Remove shoe plate and swash plate
Draw out shoe plate (211) and swash plate (212) 271
from pump casings (271),(272). (272)
212
(211)
Fig. 33-94 Removing shoe (211) and swash plate

(212)
12) Insert wire into hole to keep pressing lock pin
(255) which locks swash plate support (251).
(See Fig. 33-95). And free the swash plate
support from locking, and rotate it in
counterclockwise. Then remove swash plate
support (251) from pump casing.
• When pressing with wire, do not mistake the

hole for lock release and small hole (oil
passage) on arc of swash plate support.
• Be careful of jumping out of lock pin and set
spring, during removal of swash plate Fig. 33-95 Removing swash plate support (251)
support.
13) Remove valve plate
Remove valve plate (313, 314) from valve block
(312).
312
• The valve plate may come off during the
operation under 7).
314
(313 :
Opposite Side)
Fig. 33-96 Removing valve plates (313), (314)
33-63
33. UPPER STRUCTURE
14) Remove other parts

If necessary, remove Q min-plug (533), stopper 534
(L) (534), stopper (S) (535), servo piston (532) 531
and tilting pin (531) from pump casing 272
532 808
(271),(272), and remove needle bearing (124)
from valve block (312).
• When removing the tilting pin, use care so as 533

535
not to score the head of the tilting pin, using 806
a jig.
• It is hard to separate the tilting pin from the
124
servo piston in some cases as Loctite is
coated on the mating part between them.
Use care so as not to score the servo piston
by applying undue force.
• Do not draw out needle bearings except
312
when their service life has ended.
• Do not loosen Q min-plug (533) of valve
block (312). A set flow rate changes.
Fig. 33-97 Removing other parts
(3) Installing procedure
1) Precautions to be exercised in installation
Assembly is a reverse order of disassembly, but
notice the following.
1. Repair scored parts at disassembly. Get
replacements ready beforehand.
2. Wash parts sufficiently in cleaning oil and dry
them with jet air.
3. Do not forget to coat the sliding areas and
bearings with clean hydraulic oil.
4. In principle, replace sealing parts such as O-
rings and oil seals.
5. Tighten socket bolts and plugs to specified
torques in this manual, using a torque
wrench.
6. Do not mix up front pump parts with rear
pump parts.
33-64
33. UPPER STRUCTURE
2) Installing swash plate support

Install set spring (256) and lock pin (255) in pump
casing (271). Then align swash plate support
(251) with spigot of pump casing, and rotate it in
clockwise. And fix swash plate support (251) with 251
lock pin.
• When the servo piston, the tilting pin, the

stopper (L), the stopper (S) and the Q min-
plug have been removed, install them to the
pump casing beforehand.
• When tightening servo piston and tilting pin,
use a jig so as not to damage the head of the
tilting pin and feedback pin.
Coat the screwed part with Loctite #262.
Fig. 33-98 Installing swash plate support (251)

3) Installing swash plate #
Install shoe plate (211) on swash plate (212). %#!
Then insert tilting bushing of swash plate into
tilting pin (531), and fix swash plate (212) and
shoe plate (211) to swash plate support (251)
properly.
• Confirm by the fingers of your both hands

that swash plate moves smoothly.
• The shaft be installed easily if grease is
applied to the sliding parts of swash plate
and swash plate support.
• Do not damage the sliding surface of shoe
plate. Fig. 33-99 Installing swash plate (212)
33-65
33. UPPER STRUCTURE
4) Installing shaft
Install shaft (111),(113) fitted with bearing (123),
bearing spacer (127) and snap ring (824), to
pump casing (271),(272).
251
123
127,824
111
Fig. 33-100 Installing shaft (111)

5) Installing seal cover
Assemble seal cover (F) (261) to pump casing
(271) and fix it with socket bolts (406). %
: 5 mm $
Tightening torque : 12 N•m (8.9 lbf•ft)
"$
• Coat the oil seal in seal cover (F) with a thin
film of grease.
• Handle the oil seal with sufficient care so it is
not scored.
Fig. 33-101 Installing seal cover F (261)

6) Inserting piston cylinder sub
Assemble the piston cylinder sub [cylinder block
141(151,152,157)
(141), piston (151), shoe (152), plate (153),
spherical bushing (156) and cylinder spring 156
(157)].
Align the spherical bushing with the cylinder 153
spline and insert them into the pump casing.
Fig. 33-102 Inserting piston cylinder sub

7) Installing valve plate
Install valve plate (313), (314) to valve block
(312) by aligning pin.
312
• Do not mistake the suction and delivery sides
of the valve plate.
314
(313 :
Opposite Side)
Fig. 33-103 Installing valve plates (313), (314)
33-66
33. UPPER STRUCTURE
8) Installing valve block 312 271

Install valve block (312) to pump casing 401
(271),(272) and fasten them together with socket
bolts (401).
: 14 mm
Tightening torque ; 240 N•m (177 lbf•ft)
• Work will be promoted if assembly is started

from the rear pump.
• Exercise care so as not to mistake the
Fig. 33-104 Installing valve block (312)
direction of the valve block (312). (Install it so
the regulator comes up as seen from the
front side and the suction flange comes on
the right.)
• Insert the 1st gear into the valve block
beforehand and connect it with the spline of
the shaft.
9) Installing gear pump REGULATOR
Install gear pump (04) and fasten them together
socket bolts (435).
: 6 mm,
Tightening torque ; 17 N•m (12.5 lbf•ft)
10) Installing regulator and PTO cover
Pinch feedback pin of tilting pin in feedback lever
of the regulator and PTO cover (326), install the
regulator and fasten socket bolt.
(See Fig. 33-106)
Socket bolt (415) …… For regulator Fig. 33-105 Installing regulator and PTO cover
: 6 mm,
Socket bolt (414) …… PTO Cover (326)
: 8 mm,
• Do not mistake the front regulator for the rear

regulator.
11) Installing drain port plug

The work is complete when drain port VP plugs
(468) have been set.
: 10 mm
33-67
33. UPPER STRUCTURE
33.2.1.1.3 Maintenance standards

(1) Replacement standards for abrasive parts
Replace or readjust parts that exceed the following standards of wear.
However, always replace such parts that show excessive damage on appearance.
Recommended
Standard
Part name and inspection item value Remedy
dimension
forreplacement
Clearance between piston and cylinder
0.032 0.056
bore Replace piston or cylinder.
(0.0013 ) (0.0022 )
(D-d)
Gap between piston and caulked part of
shoe 0 ~ 0.1 0.3
Replace piston shoe assy.
(0.004 ) (0.012 )
( )
Thickness of shoe 3.9 3.7
Replace piston shoe assy.
(t) (0.154 ) (0.146 )
Free height of cylinder spring 41.1 40.3
Replace cylinder spring.
(L) (1.618 ) (1.587 )
Combined height of retainer plate and
17.0 15.8
spherical bushing Replace spherical bushing or retainer plate.
(0.669 ) (0.622 )
(H-h)

(2) Repair standards for cylinder, valve plate and swash plate (shoe plate face)
Valve plate (sliding section) Surface roughness requiring

3-Z
Swash plate (shoe plate face) correction
Cylinder (sliding section) Standard surface roughness
Less than 0.4Z (lapping)
Roughness of each surface (correction value)
33-68
33. UPPER STRUCTURE
33.2.1.1.4 Troubleshooting
(1) Locating causes of troubles
The pump is usually fitted with a regulator, auxiliary valves and auxiliary pumps, and this makes fault location
extremely difficult. However, faults would be found out easily if the following check items were attended to.
1) Inspecting the filter and drain oil
Inspect the filter element to check for abnormal contaminations. Some metallic particles will be deposited on
it as the shoe and the cylinder wear off. In case metallic particles are found in large quantity, the elements
may be damaged. In that case check the drain oil in the pump casing as well.
2) Checking for abnormal vibration and sound
Check that the pump does not vibrate and make an abnormal sound.
Check that the hunting of the regulator and the attached valve’s relief valve’s are of regular frequency. In
case vibration and sound are abnormal, the pump may be making a cavitation or internally broken.
3) When two pumps are used
In case two single pumps or motors are used or when a double pump is used. change pump pipelines. This
will make clear that the pumps are faulty or the circuit after the pumps is faulty.
4) Pressure measurements
If the problem is related to control functions, avoid disassembling the pumps carelessly, but look for causes
by measuring pressures.
(2) Troubleshooting
1) Overloading to engine
Cause Remedy Remarks

1. Revolution and pressure are higher 1) Set pressure to specified value.
than set values.
2. Regulator torque is set higher than 2) Readjust regulator. 2) Refer to Regulator Manual.
normal.
3. Pump’s internal parts are seized or 3) Replace damaged parts. 3) Check filter and drain oil to see if
broken. abnormal wear particles are present.
4. Regulator is piped incorrectly. 4) Pipe regulator correctly.
2) Pump’s oil flow rate is extremely low and delivery pressure is not available.

1. Regulator is out of order 1) Repair regulator. 1) Refer to Regulator Manual.
2. Pump’s internal parts are seized or 2) Replace damaged parts. 2) Check filter and drain oil.
broken.
3. Attached pump is out of order 3) Replace damaged parts. 3) Remove attached pump and check
shaft joint.
4. Attached valve is out of order. 4) Replace attached valve. 4) Refer to Manual for Attached Valve.
5. Regulator is piped incorrectly. 5) Pipe correctly.
33-69
33. UPPER STRUCTURE
3) Abnormal Sound and Vibration

1. Cavitation 1) Prevent cavitation. 1-1) The boost pressure is low.
Check that hydraulic oil is not 1-2) The attached pump is in trouble.
clouded. 1-3) The suction pipe is inhaling air.
1-4) The suction resistance is high.
2. Caulked part of shoe is broken. 2)Replace piston shoe and shoe
plate.
3. Cylinder is cracked 3) Replace cylinder.
4. Pump is installed improperly. 4) Correct installation.
5. Regulator is hunting. 5) Repair regulator, 5) See Regulator Manual.
6. Relief valve in attached valve is 6) Repair attached valve.
hunting.
33-70
33. UPPER STRUCTURE
33.2.1.2 REGULATOR
33.2.1.2.1 Structural exploded view
402
656
733
496 627
041 601
543 724 646
545 624
541
415 801
755 924
418
496
079
652 875
726
614
496 651 616
041
466 496 658
755 755
754
724
407 887
643
731 754
631 897
611 708
325
Fig. 33-106 Regulator exploded view
No. Name Q'ty No. Name Q'ty No. Name Q'ty

325 Valve casing 1 616 Prevention plug 1 731 O-ring ; 1B G25 1
402 Socket bolt ; M6X16 4 624 Spring seat 1 733 O-ring ; 1B P18 1
407 Socket bolt ; M6X30 4 627 Adjusting stem (Q) 1 755 O-ring ; 1B P11 3
415 Socket bolt ; M8X40 4 631 Sleeve (For Pi) 1 754 O-ring ; 1B P10 2
418 Socket bolt ; M5X12 2 643 Pilot piston 1 801 Nut ; M10 1
466 VP plug ; PF1/4 1 646 Pilot spring 1 875 Pin 1
496 Plug ; NPTF1/16 9 651 Sleeve 1 887 Pin 1
541 Seat 2 652 Spool 1 897 Pin 1
543 Stopper 2 656 Cover 1 924 Socket screw ; M10X20 1
545 Ball 2 658 Plug 1 041 Check valve sub 2
601 Casing 1 708 O-ring ; 1B G55 1 079 Solenoid proportional 1
611 Feed back lever 1 724 O-ring ; 1B P8 5 reducing valve
614 Fulcrum plug 1 726 O-ring ; 1B P12 1
The numbers in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
Tightening torque of bolt, plug and nut
Tightening torque
No. Thread size
N.m (lbf.ft)
415 M8 29 (21)
402,407 M6 12 (8.9)
418 M5 6.9 (5.1)
466 PF 1/4 16 (12)
496 NPTF1/16 8.8 (6.5)
614 M14X1.5 27 (20)
801 M10 29 (21)
33-71
33. UPPER STRUCTURE
33.2.1.2.2 Disassembly and assembly

(1) Tools
PARTS
The right list shows the tools required for remove TOOLS SIZE (mm)
and install. SIZE ITEM No.
4 M5 418, 496
(2) Disassembling procedure ALLEN WRENCH 5 M6 402,407
1) Selecting a place for disassembly. 6 M8 415,466
8 M10 801
• Choose a clean place. 12 M14 614
• Spread rubber sheet or cloth on work bench ADJUSTABLE

MIDDLE SIZE 1 pc.
WRENCH
to protect parts from damaging.
FLAT BLADE
SCREW DRIVER MIDDLE SIZE 1 pc.
2) Cleaning TORQUE WRENCH

Remove dust and rust, etc. on regulator surface STEEL BAR 4X100
with wash oil.
SOCKET BOLT M4X50 ADJUSTING STEM
3) 3) Remove regulator (See Fig. 33-106)

Remove socket bolts (415) and separate the
regulator from the pump body.
: 6 mm
Take care so as not to lose O-rings and check valve sub

(541), (543), and (545).
4) Remove ROH-plug
Remove ROH-plug (466) for a port of valve
casing (601). And remove ROH-plug (466) for
psv port too.
(In case of KR76-0E13PV)
5) Remove valve casing (Fig. 33-106)

Remove socket bolts (407) and remove valve
casing (325) with solenoid proportional reducing
valve (079).
: 5 mm
Fig. 33-107 Removing ROH-plug (466)
Fig. 33-108 Removing valve casing (325)
33-72
33. UPPER STRUCTURE
6) Remove cover (See Fig. 33-106)

Remove socket bolt (402) and cover (656).
: 5 mm
The cover is assembled with set screw (924) and hex

nut (801), but do not loosen them. If they are loosened,
the pressure settings change.
Fig. 33-109 Removing cover (656)

7) Remove Pi sleeve and pilot piston
(See Fig. 33-106)
Draw out sleeve (631) and pilot piston (643) from
the regulator body.
Fig. 33-110 Removing Pi sleeve (631) and pilot

piston (643)
8) Removing looseness prevention plug (616).
• Removing of looseness prevention plug may
cause damage of plug. (But in this case,
there is no functional problem.)
Fig. 33-111 Removing plug (616)
33-73
33. UPPER STRUCTURE
9) Remove fulcrum plug and feedback lever

(Fig. 33-106)
Remove fulcrum plug (614) and feedback lever
(611).
Fig. 33-112 Removing fulcrum plug and feedback

lever (611)
10) Drawing out the spool and the sleeve (See Fig.
33-106)
Draw out spool (652) and sleeve (651) from the
sleeve hole of the regulator casing.
Fig. 33-113 Removing spool (652) and sleeve (651)

11) Remove plunger, pilot spring and spring seat
(See Fig. 33-106)
Draw out plunger (627). Then take out pilot
spring (646) and spring (624).
The plunger comes off easily if an M4 bolt is used.
12) Drawing out the check valve (See Fig. 33-106)

The disassembly is complete when the check
valve [seat (541), ball (545), and stopper (543)]
have been drawn out. Fig. 33-114 Removing plunger (627),
pilot spring (646) and spring seat (624)
The check valves are placed on two places; the mating

surface of the pump casing and on the matching
surface of the valve casing.
Do not lose the parts because they are small.
33-74
33. UPPER STRUCTURE
(3) Installing procedure

Assembly is a reverse order of disassembly, but
notice the following.
• Do not fail to correct parts damaged during
disassembly and get replacement parts ready
beforehand.
• Entry of foreign matter causes faulty functions;
clean parts thoroughly, dry them with jet air and
work in a clean place.
• Do not fail to coat the sliding parts with clean
hydraulic oil, before proceeding to assembly.
• In principle, replace seals such as O-rings with
new ones.
• Using torque wrench, the bolts and plugs should
be tightened to the specified torques that is
indicated in "Maintenance Standard".
1) Placing the check valve (See Fig. 33-106)
Install the check valve to casing (601) [Seat
(541), ball (545) and stopper (543)].
Assemble the check valve into the matching surface of

the pump casing and the matching surface of the valve
casing.
2) Fitting the sleeve and the spool (See Fig. 33-

106)
Place sleeve (651) and spool (652) into the
sleeve hole of casing (601).
• Make sure the spool and the sleeve slide smoothly

in the casing without catching.
• Make sure the direction of the spool is correct.
Fig. 33-115 Fitting sleeve (651) and spool (652).

3) Installing feedback lever (See Fig. 33-106)
Insert pin (897) of feedback lever (611) into the
pin hole of the sleeve and fix the feedback lever
with fulcrum plug (614).
Operate the feedback lever and make sure that it does

not have much looseness and that it operates without
catching.
Fig. 33-116 Installing feedback lever (611)
33-75
33. UPPER STRUCTURE
4) Installing plug
Place the prevention plug (616).
Fig. 33-117 Installing plug (616)

5) Installing spring seat, pilot spring and plunger
(See Fig. 33-106)
Place spring seat (624), pilot spring (646) and
plunger (627) into the hole in the sleeve.
6) Installing cover (See Fig. 33-106)

Attach cover (656) to casing (601) and fasten
them together with socket bolts (402).
The cover is fitted with adjusting screw (924) and hex

Fig. 33-118 Installing spring seat (624),
nut (801).
pilot spring (646) and plunger (627)
7) Assembling the Pi sleeve and the pilot piston

(See Fig. 33-106)
Assemble Pi sleeve (631) and pilot piston (643)
into casing (601).
Fig. 33-119 Assembling the sleeve (631) and the

pilot piston (643).
33-76
33. UPPER STRUCTURE
8) Installing valve casing (See Fig. 33-106)

Attach valve casing (325) fitted with solenoid
proportional reducing valve (079) to casing (601)
and fasten them together with socket bolts (407).
Fig. 33-120 Installing valve casing (325)

9) Installing ROH-plug
Install ROH-plug (466) to A port of valve casing
(601). And install ROH-plug (466) to Psv port
too.
(In cased KR76-0E13PV)
This completes assembly.
Fig. 33-121 Installing ROH-plug (466)
33-77
33. UPPER STRUCTURE
33.2.2.1 SECTIONAL VIEW

K
155 163 101

(P5)
P2
T1
T2 CT2
K
PAL PBL
PB1 PCa
PBs PAs
Pss
PAa1 PBa1
PAo PBc
PAp2
(P4)
166 161 161155 163164
SECTION A-A
154 567 155 163
(MU2) (P6) 102
P1
973 973
CT1
PTb POb
973 973
PBr PAr
PAb PBb
973 973
PAc PBc
973 973
PBa2 PAa2
PBp1
973
(P3)
161 164 163 155 161 161
SECTION B-B
33-78
33. UPPER STRUCTURE
273x10
6
H H
P1 unload PCb PAL
Travel left
(Travel straight) 273x10
C C
PAr PB1 Boom conflux
Travel right (P2 unload)
D D
977
PBb PBs 978x2
Boom Swing
E Pss
E
PBc PAa1
Bucket Arm 1
F F
PAa2 PAo
Arm 2 MU1 Option
G PBp1 PBp2
G
H H
B A
(P3)
PAa2 PAo PAo
PBp1
PBp2
275x4
213
274x4
(P4)
(P3)
212
PBa2 PBo
273x10
273x10
33-79
33. UPPER STRUCTURE
202 P1 unload 201

Travel left
333 PCb PAL 333
331 331
336 339
328 327
325 325
331
601 331
MR
261 261
309 306
(PL)
159
166
157
161 AL
161
511
512
521
522
CP2
CMR2 551
556 561
561
561 BL
CMR1
556
522
512
307
261 264
331 PBL
325 205
326
336 SECTION C-C
331
333 PTb
202 Travel straight
201 Travel right Boom conflux 201

333 PAr PB1 333
331 331
339 336
327 322
AbR
325 321
602
331 331
261 261
166 305
164 DR 511
162 521
Ar CCb
306
551
511 561
521
CP1
551
551 561
561
166 Br
310
164
166
161
166 T3
264 261
331
PBr
205 325
SECTION D-D 328
336
331
PCa 333
P2 unload 202
33-80
33. UPPER STRUCTURE
203
333 Swing
331 PBs
339 Boom 204
320 PBb Pss 333
319 331
336
322
331 321
211 266
261 L 331
L 261
266
166
160
303
301
561 CRb 161
Ab As
(HEAD)
556 511
524 524
LCb LCs
514
551 556
561 561
521 Bb Bs
511 (ROD)
161
264
264
602
PAb
205 PAs 206
BbR
160 266
SECTION E-E
201
201 333
333 Bucket Arm 1
PBc PAa1
331
331 336
339 322
320 321
BcR
319 AaR 602
602 331
331 261
261
161
304
Bc Aa(HEAD)
(ROD)
511 511
521 521
LCc LCa 551
561
551
561 161
Ac 561
(HEAD) CRa 556
Ba(ROD)
524
514
156
PLc2 167
264 160x2
L 302
602 L
PAc PBa1 264
205 211
AcR
205
SECTION F-F
33-81
33. UPPER STRUCTURE
201
333
331 Arm 2 Option 201
333
339 PAa2 PAo
331
326 337
325
330
331
329
261 604
154 AoR 331
567 261
MU1
161 311
308
162
515
521 Ao
551 511
LCAP2
561 521
LCo
561 551
LCAT2
561
551
Bo
521
511 Ba(ROD)
162
162
162
264
PBa2 PBo 606
264
205
SECTION G-G
205 PaR
605 605
PBp1 PBp2
Bo
BoR
166 604
153
SECTION H-H
33-82
33. UPPER STRUCTURE
T2
P1 T1
511
521
CT1
551
561
511
C P2
(MU2)
521
CT2
E 551
561
162 SECTION J-J

278x5
160
266
207
267 267
528
527
T1
518
517
SECTION L-L
SECTION K-K
33-83
33. UPPER STRUCTURE

101 Casing A 1 309 P1 unload spool 1
102 Casing B 1 310 P2 unload spool 1
25~29 (18~21) 153 Plug 1 311 Option spool 1
220~250 (162~184) 154 Plug PF3/4 2 319 Spring 2
110~130 (81~96) 155 Plug PF1/2 4 320 Spring 2
13~17 (9.6~13) 156 Plug PF1/8 1 321 Spring 5
20~24 (15~18) 157 Plug PF1/4 MEC 1 322 Spring 4
34~39 (25~29) 159 Plug PT1/4 1 325 Spring 6
7.8~9.8 (5.8~7.2) 160 Plug PT1/16 MEC 5 326 Spring 1
161 O-ring : 1B G30 13 327 Spring 2
162 O-ring : 1B G25 6 328 Spring 3
163 O-ring : 1B P18 4 329 Spring 1
164 O-ring : 1B P15 4 330 Spring 1
166 O-ring : 1B P10 7 331 Spring seat 24
16~18 (11.8~13.3)
167 O-ring : 1B P8 1 333 Spacer bolt 12
Loctite #262
168 O-ring : 1B P11 1 336 Stopper 6

204 Sub cover 1 512 Poppet 2
207 Back pressure check valve cover 1 517 Poppet 1
9.8~14 (7.2~10.3) 211 Lock valve selector sub 2 518 Poppet 1
264 O-ring : 1B G35 8 527 Spring 1
266 O-ring : 1B P7 4 528 Spring 1
267 O-ring : 1B 32 2 130~150 (96~111) 551 Plug 12
25~34 (18~25) 273 Socket bolt 40 130~150 (96~111) 556 Plug 5
9.8~14 (7.2~10.3) 278 Socket bolt 5 69~78 (51~58) 601 Main relief valve 1
301 Boom spool assy 1 69~78 (51~58) 602 Port relief valve 5
302 Arm 1 spool 1 69~78 (51~58) 604 Relief valve plug assy 2
303 Swing spool 1 98~120 (72~89) 605 Bypass cut valve 2
304 Bucket spool 1 69~78 (51~58) 606 Port relief valve 1
305 Boom conflux spool 1 140~180 (103~133) 973 Socket bolt 9
306 Travel spool 2 977 Name plate 1
307 Travel straight spool 1 978 Rivet 2
308 Arm 2 spool assy 1
33-84
33. UPPER STRUCTURE
33.2.2.2 PREPARATION FOR DISASSEMBLY

(1) General precautions
1) As all the hydraulic components are precisely machined, it is essential to carry out disassembly and
reassembly in an especially clean location.
2) When handling the control valve, take special care to prevent the entry of foreign matter, such as dust or
sand.
3) Cap each port of the control valve before removing the valve from the machine. Before disassembly, confirm
that each cap is in place and then clean the exterior of the assembly.
Use a workbench. Lay a clean sheet of paper or rubber mat over the workbench.
4) When carrying or moving the control valve, hold the body, and never put pressure on a lever, an exposed
spool, or the end cover. Handle the valve with care.
5) Tests(for relief characteristics, leaks, overload valve setting, flow resistance, etc.) that are desired after
disassembly and reassembly require hydraulic testing apparatus.
For this reason, do not disassemble hydraulic units that you are capable of disassembling but cannot test or
adjust.
Prepare beforehand washing fluid, hydraulic oil, grease, etc. .
(2) Tools
Prepare the following tools before disassembling the control valve.
No. Tools Q’ty Remarks

a Vise 1
Box end 1 of each
b 19mm, 24mm, 27mm, 32mm
wrench size
1 of each
c Allen wrench 5mm, 6mm, 10mm, 12mm, 14mm, 22mm
size
d Spanner 1 32 mm
e Loctite #262 1
f Spatula 1
g Pincers 1
Adjustable
h 1
wrench
The figures in parentheses after part names in this
manual represent those item numbers in the structural
sectional drawing under Fig. 33-122 to Fig. 33-127.
(1) Place the control valve on a work bench so as to
locate back pressure check valve upwards.
Disassemble the valve in a clean place, and be careful

not to damage flange surfaces or plate mounting
surfaces.
Fig. 33-128 Preparation for disassembly
33-85
33. UPPER STRUCTURE
33.2.2.3.1 Disassembling P1 unload spool

(1) Loosen the socket bolts (273) and remove the
spring cover (202) and the O-ring (261) for P1
unload spool.
Fig. 33-129 Removing spring cover (202) for P1

unload spring cover
(2) Draw out, from casing B (102), as a assy of P1
unload spool (309), spring seat (331), springs
(325), (328), stopper (336) and bolt (333).
When drawing out the spool assy, use care so as not to

score casing B (102).
Fig. 33-130 Drawing out P1 unload spool assy (309)

(3) Fix the P1 unload spool assy with vise via a
protective plate (aluminum plate, etc.) and remove
bolt (333). Then separate spring seat (331), springs
(325), (328) and stopper (336) from P1 unload
spool (309).
Fig. 33-131 Disassembling P1 unload

spool assy (309)
33-86
33. UPPER STRUCTURE
33.2.2.3.2 Disassembling the travel spool (left travel and right travel)
spring cover (201) and the O-ring (261) for travel.
Fig. 33-132 Removing spring cover (201)

(2) Draw out the assy of travel spool (306), spring seat
(331), springs (325), (327), stopper (339) and bolt
(333) from casing A (101) or casing B (102).
When drawing out the spool assy, take care so as not

to score the casing A (101) or the casing B (102).
Fig. 33-133 Drawing out travel spool (306) assy

(3) Fix the travel spool assy with vise via a protective
plate (aluminum plate, etc.). Remove bolt (333) and
separate spring seat (331), springs (325), (327) and
stopper (339) from travel spool (306).
Fig. 33-134 Removing right travel spring cover

(201)
Fig. 33-135 Disassembling travel spool (306) assy
33-87
33. UPPER STRUCTURE
33.2.2.3.3 Disassembling the boom conflux spool

(1) Loosen socket bolts (273) and remove spring cover
(201) for boom conflux and O-ring (261).
(2) Draw out the assy of boom conflux spool (305),

spring seat (331), springs (321), (322), stopper
(339) and bolt (333) from casing A (101).

score casing A (101).
(3) Fix the boom conflux spool with vise via a protective
plate (aluminum plate, etc.) and remove bolt (333).
Then separate spring seat (331), springs (321),
(322) and stopper (339) from boom conflux spool
(305).
Fig. 33-137 Drawing out boom conflux spool (305)

assy
33.2.2.3.4 Disassembling the boom spool

(1) Loosen socket bolts (273) and remove spring cover
(203) for boom spool and O-ring (261), (266).
(2) Draw out the assy of boom spool (301), spring seat
(333) from casing B (102).

to score casing B (102).
33-88
33. UPPER STRUCTURE
(3) Fix the boom spool assy with vise via a protective
(320) and stopper (336) from boom spool (301). Do
not disassemble boom spool (301) further unless
there is special reason.
Fig. 33-139 Drawing out boom spool (301) assy
33.2.2.3.5 Disassembling the swing spool

spring cover sub (204) and the O-ring (261), (266)
for swing. Do not disassemble spring cover sub
(204) further unless there is special reason.
(2) Draw out the assy of swing spool (303), spring seat
(333) from casing A (101).
Fig. 33-140 Removing spring cover sub (204)

(3) Fix the swing spool assy with vise via a protective
(322) and stopper (336) from swing spool (303).
Fig. 33-141 Drawing out swing spool (303) assy
33-89
33. UPPER STRUCTURE
33.2.2.3.6 Disassembling bucket spool

(1) Loosen socket bolts (273) and remove bucket
spring cover (201) and O-ring (261).

(2) Draw out the assy of bucket spool (304), spring
seat (331), springs (319), (320), stopper (339) and
bolt (333) from casing B (102).

Fig. 33-143 Drawing out bucket spool (304) assy

(3) Fix the bucket spool assy with vise via a protective
(320) and stopper (339) from bucket spool (304).
33-90
33. UPPER STRUCTURE
33.2.2.3.7 Disassembling arm 1 spool

(1) Loosen socket bolts (273), and remove spring
cover (201) and O-ring (261) of arm 1 spool.
(2) Draw out the assembly which is consist of arm 1

spool (302), spring seat (331), spring (321, 322),
stopper (336) and bolt (333) from casing A (101).

Fig. 33-144 Removing arm 1 spring cover (201)
(3) Fix the arm 1 spool assy with vise via a protective
plate (aluminum plate etc.) and remove bolt (333).
Then remove spring seat (331), spring (321, 322)
and stopper (336) from arm 1 spool (302).
Fig. 33-145 Disassembling arm 1 spool (302) assy
33.2.2.3.8 Disassembling arm 2 spool

cover (201) and O-ring (261) of arm 2 spool.
(2) Draw out the assembly which is consist of arm 2

stopper (339) and bolt (333) from casing B (102).

Fig. 33-146 Removing arm 2 spring cover (201)
(3) Fix the arm 2 spool assy with vise via a protective
and stopper (339) from arm 2 spool (308). Do not
disassemble arm 2 spool (308) further unless there
is special reason.
Fig. 33-147 Disassembling arm 2 spool (308) assy
33-91
33. UPPER STRUCTURE
33.2.2.3.9 Disassembling option spool

cover (201) and O-ring (261) of option spool.
(2) Draw out the assembly which is consist of option

stopper (337) and bolt (333) from casing A (101).

Fig. 33-148 Removing option spring cover (201)
(3) Fix the option spool assy with vise via a protective
and stopper (337) from option spool (311).
Fig. 33-149 Drawing out option spool assy (311)
33.2.2.3.10 Disassembling travel straight spool

spring cover (202) and the O-ring (261) for travel
straight.
(2) Draw out the assy of travel straight spool (307),

spring seat (331), springs (325), (328), stopper
(336) and bolt (333) from casing B (102).

Fig. 33-150 Drawing out travel straight spool (307)
to score the casing B (102).
assy
(3) Fix the travel straight spool assy with vise via a
protective plate (aluminum plate, etc.). Remove
bolt (333) and separate spring seat (331), springs
(325), (328) and stopper (336) from travel straight
spool (307).
33-92
33. UPPER STRUCTURE
33.2.2.3.11 Disassembling P2 unload spool

cover (202) of P2 unload spool and O-ring (261).
(2) Draw out the assembly which is consist of P2

unload spool (310), spring seat (331), spring (325),
(328), stopper (336) and bolt (333) from casing A
(101).

Fig. 33-151 Removing P2 unload spring cover (202)
(3) Fix the P2 unload spool assy with vise via a

protective plate (aluminum plate etc.) and remove
bolt (333). Then remove spring seat (331), spring
(325), (326) and stopper (336) from P2 unload
spool (310).
Fig. 33-152 Drawing out P2 unload spool assy (310)
33.2.2.3.12 Removing spool covers

(1) Travel, boom, bucket, arm 1, arm 2 and option
Loosen socket bolts (273) and remove spool cover
(205) and O-ring (264).
(2) Swing
Loosen socket bolts (273) and remove spool cover
(206) and O-ring (264), (266). Do not disassemble
spool cover (206) further unless there is special
reason.
Fig. 33-153 Removing spool cover (205),(206)
33-93
33. UPPER STRUCTURE
33.2.2.3.13 Removing relief valve and plug assy for relief valve hole
(1) Remove the main relief valve (601) and overload
relief valve (602), (606) and relief hole plug (604)
from the casing.
• Distinguish overload relief valve between (602) and

(606) with a tag to prevent them from being
confused during reassembly, as they are the same
in appearance and shape but differ in pressure
setting.
Fig. 33-154 Removing main relief valve (601)
• Regarding the disassembly of the relief valves
themselves, do not disassemble it.
Fig. 33-155 Removing overload relief valve (602)

and (606)
Fig. 33-156 Removing plug assy (604) for relief

valve hole
33-94
33. UPPER STRUCTURE
33.2.2.3.14 Removing by-pass cut valve

(1) Remove by-pass cut valve (605) from the casing.
Remove the by-pass cut valve, giving particular

attention to the poppet (605-201) and spring (605-202)
which may be remained on the inside of casing.
Fig. 33-157 Removing by-pass cut valve (605)
33.2.2.3.15 Removing lock valve selector valve sub

(1) Loosen socket bolt (211-171) and remove lock
valve selector valve sub (211) from the casing.
Further disassembly of the lock valve selector sub
is not allowed.
Fig. 33-158 Removing lock valve selector sub (211)
33.2.2.3.16 Removing back pressure check valve

(1) Loosen socket bolt (278) and remove back
pressure check valve (207) from the casing.
Fig. 33-159 Removing back pressure check valve

cover (207)
33-95
33. UPPER STRUCTURE
(2) Remove springs (527), (528), boost check valve

poppet sub (517) and by-pass check valve poppet
(518) from the casing. The further disassembly of
boost check valve poppet sub (517) is not allowed.
Replace control valve so that the spool cover face

directs downward.
When replacing, take care so as not to score the spool

cover.
Fig. 33-160 Removing boost check valve sub (517)
and by-pass check valve poppet (518)
33.2.2.3.17 Removing plate

(1) Loosen socket bolts (274), (275) and remove plates
(212), (213).
(2) After removing plates, remove all O-rings (161),
(164) remained on the casing side.
Fig. 33-161 Removing plate (212),(213)
33-96
33. UPPER STRUCTURE
33.2.2.3.18 Removing check valve

(1) Remove plugs of load check valve, conflux check
valve, etc. and then remove poppet (511) and
spring (521).
(2) Load check valve on the swing section
Remove plug (556) and then remove poppet (511)
and spring (524).
The plug and spring in use differ from the above (1). Do
not mix the parts when assembling parts again.
(3) Load check valve on arm 2 section Fig. 33-162 Removing plug (551),(556)
and spring (521).
The poppet in use differs from the above (1). Do not mix
the parts when assembling parts again.
(4) Lock valve

and spring (524).
Fig. 33-163 Removing poppet (511),(512),(514),(515)
The plug, poppet and spring in use differ from the

above (4). Do not mix the parts when assembling parts
again.
(5) Main relief valve

and spring (522).
The plug, poppet and spring in use differ from the

above (5). Do not mix the parts when assembling parts
again.
The plugs in which the procedure for disassembly is not

included in the above procedure are usually used to
block auxiliary holes and holes caused by casting. Do
not disassemble further if unnecessary.
33.2.2.3.19 Disassembling casing

Further disassembly of the casing is not allowed.
33-97
33. UPPER STRUCTURE
33.2.2.3.20 Inspection after disassembly

Thoroughly clean all disassembled parts with wash oil, and dry them with jet air. Place each part on a clean sheet
of paper or cloth for inspection.
(1) Control valve
1) Inspect the entire surface of each part for burrs, scratches, cuts, and other defects.
2) Confirm that the O-ring groove surface of the casing or the block is free from foreign matter, dents or rust.
3) If the check valve seat of the casing or the block has dents or damage on its surface, smooth it by lapping.
Take care not leave lapping compound behind in the casing or block.
4) Confirm that O-ring or the outer circumference of the sliding part of a manual spool is free from scratches,
dents, and the like. Remove any small defects with an oil stone or lapping compound.
5) Manually confirm that all sliding and fitted parts move smoothly. Confirm that all grooves and passages are
free from foreign matter.
6) Replace any broken or deformed spring with new one.
7) Of a relief valve malfunctions, repair it by following the relief valve disassembly and reassembly procedures.
8) Replace all O-ring with new ones.
(2) Relief valve

1) Make sure that the poppet and the seat surface at the tip of the seat are without fault and that the contact
surface is even all over.
2) Manually confirm that the main poppet slides smoothly onto and off the seat.
3) Confirm that the outer circumference of the main poppet and the inner circumference of its seat are free from
defects such as scratches.
4) Confirm that each spring is free from breakage, deformation, and excessive wear.
5) Confirm that the orifices of the main poppet and its seat are not clogged.
6) Replace all O-rings with new ones. (Between casing and seal)
33.2.2.4 REASSEMBLY
(1) Here, only the reassembly procedures are described. Regarding drawings, refer to the disassembly procedures.
(2) Figures in parentheses after part names in this instruction represent those item numbers in the structural
sectional drawing. (Fig. 33-122 to Fig. 33-127)
(3) Precautions on reassembling O-ring
1) Confirm that O-rings are free from defects caused by poor handling.
2) Apply thin coat of grease or hydraulic oil to O-rings and their mating parts.
3) Do not stretch O-rings to the extent that they become permanently set.
4) When installing O-rings, do not roll them into place. Twisted O-rings do not easily untwist by themselves after
installation, and can cause oil leaks.
5) Use a torque wrench to tighten each attaching bolt. Tighten to the specified torque in "Maintenance
Standards."
33-98
33. UPPER STRUCTURE
33.2.2.4.1 Installing check valve

(1) Load check valve, conflux check valve, and so on
Attach poppet (511) and spring (521) in place, place O-ring (561) in plug (551) and tighten them to the specified
torque. (8 places)
(2) Load check valve of swing section
torque. (1 place)
(3) Load check valve of arm 2 section
torque. (1 place)
(4) Lock valve section
torque. (2 places)
(5) Main relief valve section
torque. (2 places)
Take care to prevent misassembling of parts and assembling position error because the parts in (1) to (5) are similar
in shape.
33.2.2.4.2 Assembling plate

(1) Place O-rings (161), (164) in casing.
(2) Attach plates (212), (213) and tighten socket bolts (274), (275) to the specified torque.
Replace control valve so that this plate face directs downward.
33.2.2.4.3 Assembling back pressure check valve

(1) Attach boost check valve poppet sub (517), by-pass check valve poppet (518) and springs (527), (528).
(2) Attach O-rings (267) in back pressure check valve cover, attach it to casing A (101) and tighten socket bolt (278)
to the specified torque.
33.2.2.4.4 Assembling lock valve selector sub

(1) Attach lock valve selector sub (211) to the casing and tighten socket bolt (211-171) to the specified torque.
33.2.2.4.5 Assembling by-pass cut valve

(1) Attach by-pass cut valve (605) to casing and tighten it to the specified torque.
Take care to prevent drop of poppet (605-201) and spring (605-202) when attaching by-pass cut valve.
33-99
33. UPPER STRUCTURE
33.2.2.4.6 Assembling relief valve and relief valve hole plug assembly
(1) Tighten main relief valve (601), port relief valves (602), (606) and relief valve hole plug assembly (604) in
respective place to the specified torque.
Assemble it giving attention to the label attached when disassembling to prevent mistake because the port relief
valves (602), (606) are similar in shape.
33.2.2.4.7 Assembling P2 unload spool

(1) Hold the mid section of P2 unload spool (310) with vise provided with protection plate (aluminum plate, etc.), fit
spring seat (331), springs (325), (328) and stopper (336) and tighten bolt (333) to the specified torque.
• Apply Loctite #262 when tightening bolt (333).

• Take care not to deform P2 unload spool (310) because of careless over clamping.
(2) Place P2 unload spool assembly in item (1) in casing A (101).
Place P2 unload spool assembly in casing A (101) carefully. Do not squeeze it into place.
(3) Attach spring cover (202) with O-ring (261) attached to the spring side of P2 unload spool assembly and tighten
socket bolt (273) to the specified torque.
33.2.2.4.8 Assembling travel straight spool

(1) Hold the mid section of travel straight spool (307) with vise provided with protection plate (aluminum plate, etc.),
fit spring seat (331), springs (325), (328) and stopper (336) and tighten bolt (333) to the specified torque.

• Take care not to deform travel straight spool (307) because of careless over clamping.
(2) Place travel straight spool assembly in item (1) in casing B (102).
Place travel straight spool assembly in casing B (102) carefully. Do not squeeze it into place.
(3) Attach spring cover (202) with O-ring (261) attached to the spring side of travel straight spool assembly, and
tighten socket bolt (273) to the specified torque.
33-100
33. UPPER STRUCTURE
33.2.2.4.9 Assembling spool in option

(1) Hold the mid section of spool in option (311) with vise provided with protection plate (aluminum plate, etc.), fit

• Take care not to deform option spool (311) because of careless over clamping.
(2) Place spool assembly in option in item (1) in casing A (101).
Place option spool assembly in casing A (101) carefully. Do not squeeze it into place.
(3) Attach spring cover (201) with O-ring (261) attached to the spring side of spool assembly in option and tighten
33.2.2.4.10 Assembling arm 2 spool

(1) Hold the mid section of arm 2 spool (308) with vise provided with protection plate (aluminum plate, etc.), fit spring
seat (331), springs (325), (326) and stopper (339) and tighten bolt (333) to the specified torque.

• Take care not to deform arm 2 spool (308) because of careless over clamping.
(2) Place arm 2 spool assembly in option in item (1) in casing B (102).
Place arm 2 spool assembly in casing B (102) carefully. Do not squeeze it into place.
(3) Attach spring cover (201) with O-ring (261) attached to the spring side of arm 2 spool assembly and tighten
33.2.2.4.11 Assembling arm 1 spool

(1) Hold the mid section of arm 1 spool (302) with vise provided with protection plate (aluminum plate, etc.) and fit

• Take care not to deform arm 1 spool (302) because of careless over clamping.
(2) Place arm 1 spool assembly in item (1) in casing A (101).
Place arm 1 spool assembly in casing A (101) carefully. Do not squeeze it into place.
(3) Attach spring cover (201) with O-ring (261) attached to the spring side of arm 1 spool assembly, and tighten
33-101
33. UPPER STRUCTURE
33.2.2.4.12 Assembling bucket spool

(1) Hold the mid section of bucket spool (304) with vise provided with protection plate (aluminum plate, etc.), fit

• Take care not to deform bucket spool (304) because of careless over clamping.
(2) Place bucket spool assembly in item (1) in casing B (102).
Place bucket spool assembly in casing B (102) carefully. Do not squeeze it into place.
(3) Attach spring cover (201) with O-ring (261) attached to the spring side of bucket spool assembly and tighten
33.2.2.4.13 Assembling swing spool

(1) Hold the mid section of swing spool (303) with vise provided with protection plate (aluminum plate, etc.), fit spring

• Take care not to deform swing spool (303) because of careless over clamping.
(2) Place swing spool assembly in item (1) in casing A (101).
Place swing spool assembly in casing A (101) carefully. Do not squeeze it into place.
(3) Attach spring cover sub (204) with O-rings (261), (266) attached to the spring side of swing spool assembly and
33-102
33. UPPER STRUCTURE
33.2.2.4.14 Assembling boom spool

(1) Hold the mid section of boom spool (301) with vise provided with protection plate (aluminum plate, etc.), fit spring

• Take care not to deform boom spool (301) because of careless over clamping.
(2) Place boom spool assembly in item (1) in casing B (102).
Place boom spool assembly in casing B (102) carefully. Do not squeeze it into place.
(3) Attach spring cover (203) with O-rings (261), (266) attached to the spring side of boom spool assembly and
33.2.2.4.15 Assembling boom conflux spool

(1) Hold the mid section of boom conflux spool (305) with vise provided with protection plate (aluminum plate, etc.),
fit spring seat (331), springs (321)(322) and stopper (336) and tighten bolt (333) to the specified torque.

• Take care not to deform boom conflux spool (305) because of careless over clamping.
(2) Place boom conflux spool assembly in item (1) in casing A (101).
Place boom conflux spool assembly in casing A (101) carefully. Do not squeeze it into place.
(3) Attach spring cover (202) with O-ring (261) attached to the spring side of boom conflux spool assembly and
33.2.2.4.16 Assembling travel spool (travel right and left)

(1) Hold the mid section of travel spool (306) with vise provided with protection plate (aluminum plate, etc.), fit spring

• Take care not to deform travel spool (306) because of careless over clamping.
(2) Place travel spool assembly in item (1) in casing A (101) or casing B (102).
Place travel spool assembly in casing A (101) or casing B (102) carefully. Do not squeeze it into place.
(3) Attach spring cover (201) with O-ring (261) attached to the spring side of travel spool assembly and tighten
33-103
33. UPPER STRUCTURE
33.2.2.4.17 Assembling P1 unload spool

(1) Hold the mid section of P1 unload spool (309) with vise provided with protection plate (aluminum plate, etc.), fit

• Take care not to deform P1 unload spool (309) because of careless over clamping.
(2) Place P1 unload spool assembly in item (1) in casing A (101).
Place P1 unload spool assembly in casing A (101) carefully. Do not squeeze it into place.
(3) Attach spring cover (202) with O-ring (261) attached to the spring side of P1 unload spool assembly and tighten
33.2.2.4.18 Assembling spool cover, and so on

(1) Travel, boom, bucket, arm 1, arm 2, option
Place O-ring (264) in spool cover (205) and tighten socket bolt (273) to the specified torque.
(2) Swing
Place O-rings (264), (266) in spool cover (206) and tighten socket bolt (273) to the specified torque.
33-104
33. UPPER STRUCTURE
33.2.2.5.1 Inspection of components
Part name Inspection item Criterion and remedy

Casing 1) Look for scratches, rusting and corrosion. 1) If any of the following parts are damaged,
replace the casing.
• Sliding part of casing hole and spool,
particularly the land, to which holding
pressure is applied.
• Area of sealing part that is in contact with
O-ring.
• Sealing and seating part of main or
overload relief valve.
• Area of seating part or sliding part of
poppet.
• Sealing part of plug.
• Defects of other parts that seem to
prevent normal function.
Spool 1) Look for scratches, galling, rusting and 1) If a detectable defect with your fingernail is
corrosion. found on the sliding part of the outer
circumference, replace the spool.
2) Insert the spool in the casing bore, and 2) If the spool damages the O-ring or does
move it while turning it. not move smoothly, repair or replace the
spool.
Poppet If spring is damaged, replace it.
1) Look for damage on the poppet and the 1) If the seat of poppet or spring are
spring. damaged, correct or replace it.
2) If the poppet moves lightly without
2) Insert the poppet in the casing, and move catching, it is normal.
it.
Spring and related parts 1) Look for rust, corrosion, deformation, and 1) If damaged heavily, replace.
breakage of the spring, spring seat,
stopper, spacer bolt and cover.
Main relief valve 1) Look for rust and damage on outer 1) Replace.
Port relief valve surface.
By-pass cut valve 2) Inspect the contact face of the valve seat. 2) If damaged, replace.
3) Inspect the O-ring, backup ring, and seal. 3) As a general rule, replace all parts with
new ones. (Between casing and seal)
33-105
33. UPPER STRUCTURE
(1) If an abnormal condition is noticed, check to see if the problem is with the control valve itself, one of the main
pumps, the gear pump, or a circuit. To this end, you will need to measure pilot pressure, pump delivery pressure,
load pressure, etc. If any part of the system is to be disassembled for inspection, follow the disassembly and
reassembly procedures in this manual.
(2) Dust is the enemy of hydraulic components. Pay strict attention to protection from dust. If any part of the system
is to be disassembled, take dust protection measures beforehand.
(3) Moving parts must be handled with care. If they are damaged, smooth the damage using an oil stone or the like.
(4) Take care not to damage the contact face of O-rings. A damaged contact face will certainly cause oil leaks.
33.2.2.6.1 Control valve
Trouble Cause Remedy

1. Travel does not 1) Malfunctioning main relief valve. 1) Check travel relief valve pressure
occur. • Foreign matter between main poppet • Disassemble and clean. If damaged
Slow to start up and seat. heavily, replace the assy as a unit.
(or poor power).
• Same as above.
Slow response.
• Foreign matter between poppet and • Correct sticking part with oil stone.
seat.
• Replace spring.
• Sticking main poppet.
• Remove foreign matter.
• Broken or deformed spring.
• Readjust, and tighten lock nut to
• Clogged main poppet throttle. specified torque.
• Loosened adjusting screw.
2. Machine does not 1) Malfunctioning travel straight valve. 1) Check pilot pressure.
move straight during • Sticking spool. • Correct sticking part with oil stone.
simultaneous
• Replace spring.
operation of travel
• Broken or deformed spring. • Remove foreign matter.
and attachment.
• Clogged small hole in spool.
2) Malfunctioning main relief valve. 2) Remove main relief valve.
33-106
33. UPPER STRUCTURE

3. Excessive natural 1) Excessive clearance between casing and 1) Replace spool.
falls of attachment spool.
under its own weight 2) Spool is not completely in neutral position. 2) Check secondary pilot pressure.
when spool is in • Foreign matter between casing and • Disassemble, clean and smooth
neutral. spool, or sticking spool. sticking part with oil stone.
• Broken or deformed spring. • Replace spring.
• Clogged pilot circuit. • Remove foreign matter.
3) Malfunctioning overload relief valve. Refer 3) Check overload relief valve pressure.
to item 1. 1) above. (See 33.2.2.3.20 (2))
(See 33.2.2.3.20 (2)) • Clean and check damage on seat
• Foreign matter between valve seat and surface.
casing.
4) Lock valve function is faulty. 4) Replace
(Arm, boom)
• Foreign matter between poppet seat • Disassemble, clean.
and casing. • Correct stuck part with oil stone or
• Poppet is stuck. replace.
• Replace spring.
• Broken or deformed spring. • Replace lock valve selector assy.
• Selector spool is stuck.
4. When raising 1) Malfunctioning load check valve. 1)
attachment, at first it • Foreign matter between poppet and • Disassemble and clean. If heavily
drops. casing. damaged, replace control valve.
• Correct sticking part with oil stone.
• Replace spring.
• Sticking poppet.
• Broken or deformed spring.

5. Bucket, boom, arm or 1) Malfunctioning main spool. 1) Check secondary pilot pressure.
swing does not • Excessive clearance between casing • Replace spool.
operate. and spool. • Disassemble and clean.
Slow to start up (or
• Foreign matter between casing and • Correct stuck part with oil stone.
poor power).Slow
spool.
response. • Replace spring.
• Sticking spool.
• Broken or deformed return spring.

• Clogged pilot circuit.
2) Malfunctioning main relief valve. Refer to 2) Check main relief valve pressure. Refer to
item 1. 1) above. item 1. 1) above.
(See 33.2.2.3.20 (2)) (See 33.2.2.3.20 (2))
3) Malfunctioning overload relief valve. Refer 3) Check overload relief valve pressure.
to item 1. 1) above. (See 33.2.2.3.20 (2))
(See 33.2.2.3.20 (2))
33-107
33. UPPER STRUCTURE

6. Boom conflux does 1) Malfunctioning conflux valve. 1) Measure pilot pressure.
not operate. • Excessive clearance between casing • Replace spool.
and spool. • Disassemble and clean.
• Foreign matter between casing and • Correct stuck part with oil stone.
spool.
• Replace spring.
• Sticking spool.
• Broken or deformed return spring.

• Clogged pilot circuit.
33.2.2.6.2 Relief valve

1.No pressure rise. Main or pilot poppet of relief valve is sticking Check for foreign matter on each poppet.
and valve is open, or there is foreign matter Confirm that each component slides
on valve seat. smoothly.
If failure is found, replace it in an assembly.
2. Unstable relief Main or pilot poppet of relief valve seat is If failure is found, replace it an assembly.
pressure. damaged.
3. Incorrect relief 1) Wear due to foreign matter. 1) Replace damaged assembly
pressure setting. 2) Loosened locknut or adjusting screw. 2) Adjust pressure.
4. Oil leak. Confirm that each component operates
smoothly. Replace damaged or worn
1) Damaged seat. component.
Damaged O-ring. 1) If failure is found, replace it an assembly.
2) Sticking component due to foreign matter. 2) Confirm that there are no scratches,
scores, or foreign matter present before
reassembling.
If failure is found, replace it an assembly.
33-108
33. UPPER STRUCTURE
33.2.3 PILOT VALVE (ATT)
33.2.3.1 CROSS-SECTIONAL VIEW
312
302
Apply grease on
rotating and
501
Apply grease on 301 sliding sections.
Be careful the
top section assembling
212 direction
213
151
* 246
* 218-2
211
214
* 218-1
216-2 216-1
241-2 241-1
201-2
201-1
217
Secondary
pressure 101 221
adjusting shim
Designed value
t=0.4 (0.061 in),
1 pc
PORT PORT
2,4 1,3
Fig. 33-164 Pilot valve (For ATT)
Apply loctite #277 to areas marked

101 Casing 1 *218-1 Seat 2
151 Plate 1 *218-2 Seat 2
201-1 Spool 2 221 Spring 4
201-2 Spool 2 241-1 Spring 2
211 Plug 4 241-2 Spring 2
212 Push rod 4 *246 Spring 4
213 Seal 4 47.1 (35) 301 Joint : M14 1
214 O-ring ; 1B P20 4 302 Circular plate 1
216-1 Spring seat 2 68.6 (51) 312 Adjust nut : M14 1
216-2 Spring seat 2 501 Boots 1
217 Washer 2 (Shim) 4
Note) The parts marked * might not be equipped depending on valve type.
33-109
33. UPPER STRUCTURE
(1) Plug each port of pilot valve, and clean it with
kerosine. 501
P port : PF1/4
1~4 and T port : PF3/8
(2) Fix pilot valve with vise via a protective plate
(Alminum plate etc.), and remove boots (501).
Fig. 33-165 Removing boot (501)

(3) Remove adjusting nut (312) applying spanners to
adjusting nut (312) and circular plate (302).
312
: 22mm, 32mm
302
Fig. 33-166 Removing adjusting nut (312)

(4) Remove circular plate (302)
302
: 32mm
Fig. 33-167 Removing circular plate (302)
Fig. 33-168 Circular plate is removed
33-110
33. UPPER STRUCTURE
Fig. 33-169 Installing Jig A

(5) Turn joint (301) in counterclockwise with Jig A to
remove.
Jig A : See page 33-118.
: 24mm
301
When the force of return springs (221) is strong, never

loosen joint (301). If loosened, it might result in jumping
out of plate (151), plug (211) and push rod (212).
Remove joint (301) pressing plate (151) downward with
two fingers. Fig. 33-170 Removing joint (301)
(6) Remove plate (151)

• When the force of return springs (221) are 151
strong, press plate to let it come up slowly.
Fig. 33-171 Removing plate (151)

• When the force of return springs (221) are weak,
plug is left in casing (101) due to sliding
resistance of O-ring (214).
Pull plug (211) out with a driver.
To prevent personal injury, plug (211) must be removed

slowly and evenly until the return spring (221) force is
completely released.
211
33-111
33. UPPER STRUCTURE
(7) Remove push rod (212), plug (211), pressure

reducing valve assy (spool), return springs (221)
from casing (101). 212
211
Record combination of port holes on casing and the 221

pulled out parts. The stroke differs according to
direction.
101
Fig. 33-173 Removing push rod, plug, pressure

reducing valve and spring
(8) Push springs (241-1), (241-2) in the range of 7mm
(0.276in) that the movement of spring seats (216- 216-1
216-2
1), (216-2) and shift the seats (216) in a side
direction, and remove spools (201-1), (201-2)
through the larger hole of seat.
Never push down spring seat (216-1) in 7mm (0.276in)

or more. (For port 1,3)
201-1
Never push down spring seat (216-2) in 9.4mm
201-2
(0.370in) or more. (For port 2,4)
Fig. 33-174 Removing spool (201)
(9) Remove spool (201-1), (201-2), spring seats (216-
1), (216-2), spring (241-1), (241-2) and washer 241-1 216-1
(217). 241-2 216-2
217
201-1
201-2
Fig. 33-175 Disassembling pressure reducing valve

(10)Remove spring (*246), spring seat (*218-1), (*218-
2) from push rod (212). *218-1 *246 214
*218-2
The parts marked * might not be equipped depending

on valve type.
212
211
Fig. 33-176 Disassembling push rod
33-112
33. UPPER STRUCTURE
(11)Pull out push rod (212) from plug (211).

(12)Remove O-ring (214) from plug (211).
212
Fig. 33-177 Removing push rod (212)

(13)Remove inside seal (213) from plug (211) with
small driver.
213
Fig. 33-178 Removing seal (213)
33.2.3.3 CLEANING PARTS

(1) Clean parts with wash oil roughly.
(2) Clean parts with wash oil completely.
(3) Dry parts by swabbing clean rag.
(4) Apply rust preventives on parts.
33.2.3.4 ASSEMBLING
(1) Fit washer 2 (217), springs (241-1), (241-2), spring
seats (216-1), (216-2) to spool (201-1), (201-2). 201-1 241-1 216-1
216-2
201-2 241-2
217
Fig. 33-179 Assembling pressure reducing valve
33-113
33. UPPER STRUCTURE
(2) Push spring (241-1), (241-2) in the range of that the

movement of spring seats (216-1), (216-2) in a side 216-1
direction, and install spools (201-1) through the 216-2
larger hole of spring seat. (See Fig. 33-174)
Never push down spring seat (216-1) in 7mm (0.276in)

or more. (For port 1,3)
Never push down spring seat (216-2) in 9.4mm 201-1
(0.370in) or more. (For port 2,4) 201-2
Fig. 33-180 Installing spools (201-1), (201-2)

(3) Place spring (221) into ports 1,3 of casing (101),
and then install pressure reducing valve assy in it. PRESSURE REDUCING
VALVE ASSY
Place springs (221) into ports 2,4 and install it.
221
Install the removed respective assy into respective

holes. 101
Fig. 33-181 Installing pressure reducing valve assy

(4) Fit O-ring (214) and seal (213) into plug (211).
• Apply hydraulic oil on surface of push rod. 211
214 213
PLUG (211)
SEAL (213)
-RING (214)
PUSH ROD
(212) Apply hydraulic oil
For the assembling

direction of seal (213). Fig. 33-182 Installing O-ring (214) and seal (213)
(5) Insert push rod (212) in plug (211) and install spring
(*246) and spring seat (*218-1) to push rod (212) on
port 1,3 side.
And install spring seat (*218-2) to push rod on port
2,4 side.
The parts marked * might not be equipped depending

on valve type.
212 211 246 218-1
Fig. 33-183 Assembling push rod, spring (246) and
seat (218)
33-114
33. UPPER STRUCTURE
(6) Fit plug (211) assy to casing (101).

1) When the force of spring (211) is weak, it stops
at the position where it is pushed in by the sliding
resistance of O-ring (214).
101 211
Fig. 33-184 Installing plug assy

2) When the force of spring (221) is strong, attach
plate (151) and press 4 push rods by hand at the 301
same time, and tighten joint (301) temporarily.
• Install spool (201) straight and evenly into the
hole of casing (101).
• Take care so that plug (211) and plate (151) do
not jump out of casing (101).
151
Fig. 33-185 Installing plug assy and plate (151)

(7) Install joint (301) on casing (101) with jig A securely.
Jig A : See page 33-118.
Tightening torque : 47.1 N•m (35±2.2 lbf•ft)
101
A
Fig. 33-186 Installing joint (301)
33-115
33. UPPER STRUCTURE
(8) Install circular plate (302) to joint (301)
• Screw it in until it comes in contact with 4 push rods 312

(212) equally.
• The exceeding of screw in may cause malfunction
of machine. 302
(9) Screw adjusting nut (312) in until it touches circular

plate (302), and tighten it applying spanner to stop
circular plate returning.
Fig. 33-187 Installing circular plate (302)
: 32mm
: 22mm
• Apply Loctite #277 to threads of joint.
(10)Apply heat-resisting grease to joint (301) rotating
section and the top of push rod (212).
(11)Cover it with boots. GREASE
(12)Spray rust preventives through each port and

attach plug respectively.
301
212
Fig. 33-188 Applying grease to joint section and

push rod
33-116
33. UPPER STRUCTURE
Check item Standard Remarks

When leakage quantity reaches to 1000cc/ min.
or more where handle is set in neutral position,
Conditions
or to 2000cc/min. or more in operation, replace
Leakage Primary pressure 2.94 MPa (426 psi)
spool with new one.
Hydraulic oil viscosity 23 cSt
If leaked, even if the spool is replaced, replace
pilot valve assy with new one.
When the wear of sliding section is 10 more
This condition may be the same as the
Spool than the that of non sliding section, replace it
above.
with new one.
Push rod When the wear of top is 1mm (0.04in) or more, replace it with new one.
When looseness of 2mm (0.08in) or more on
In case of the looseness due to the
Looseness of control circular plate (302) on control section and joint
loosening on tightening section, adjust
section section (301) due to wear is produced, replace
it.
them with new ones.
When trouble such as noise, hunting, drop of
primary pressure, etc. has occurred in op-
eration, and it does not restore after taking
Stability of operation
corrective action according to below 33.2.3.6 (
TROUBLESHOOTING), replace pilot valve
assy with new one.
• O-ring, etc. should be replaced with new one at every disassembling.

• If socket bolt (125) was loosened, seal washer (121) should be replaced.
It is very difficult to find defective section. The following table explains the several estimated causes. For repair, refer
to the estimated causes and corrective actions.
The following table explains general phenomenon, estimated causes and corrective actions. However, most
machine problems are not caused by the failure of only one part, but involve relations with other parts. Therefore
corrective action other than those described in this table is often required. The following table does not cover causes
and corrective actions for all the troubles. So it may be necessary to perform further investigation of troubles and
causes.
Trouble Cause Remarks

1) Primary pressure is insufficient. 1) Secure primary pressure.
2) Secondary pressure springs (241) are
2) Replace with new ones.
broken or fatigued.
Secondary pressure
3) Clearance between spool (201) and
does not rise . 3) Replace spool (201).
cas-ing (101 ) is abnormally large.
4) Disassembly and reassembly or
4) Handle has a looseness.
replace handle section.
1) Sliding parts are caught. 1) Repair the unsmoothed section.
Secondary pressure is
2) Tank line pressure varies. 2) Bring pressure directly to oil tank.
unstable.
3) Air has mixed into pipeline. 3) Bleed air by operating it several times.
Secondary pressure is 1) Tank line pressure is high. 1) Bring pressure directly to oil tank.
high 2) Sliding parts are caught. 2) Correct.
33-117
33. UPPER STRUCTURE
33.2.3.7 JIG
(1) Jig for removing and installing joint (301)
(1)
Material ; SCM415 (N)
Carburizing and Quenching
(2) BUSHING
Material ; S45C
SECTION AA
A A
Installing condition on joint
* (1) and (2) are tight fitted
Sectional drawing of jig
Material ; SCM415 (N)

Carburizing and Quenching
Q'ty ; 2
Detail of bushing
33-118
33. UPPER STRUCTURE
33.2.4 PILOT VALVE (FOR TRAVEL)
T=Tightening torgue
N.m (lbf.ft) 12-o
12-o
7-h
12-o
12-y
5 12-y
12-x 12-x
13
6 8
f
d
Loctite 262 10
g
T=3
g
14
q 11
T=5 (3.7) r 15
u
t T=4 (3)
7-i T=30 (22)
15
7-k T=1.2 (0.9)
7-h u
15 t T=4 (3)
7-j t 14
u
r
q
17 21 T=5 (3.7)
Loctite 262 21
21
z
r 21
w' T=3~5 (2.2~3.7)
Fig. 33-189 Exploded view of pilot valve

5 Rubber boots 2 12-x Seal ø14×20×3 6
6 Foot pedal (Switch plate) (2) 12-y Wiper ring 6
6-d Switch plate 2 13 Damper spring 4
6-f Regulation screw M8×28 4 14 Check valve kit (2)
6-g Set screw M5×8 4 14-q Plug M8 2
7 Retaining plate kit (1) 14-r Ball M6, 35 2
7-h Plate 1 15 Orifice (4)
7-i Capscrew M10×20 2 15-u Plug M6 4
7-j Shaft 2 15-t Orifice M6, ø0.6 4
7-k Set screw M4×10 2 17 Shuttle valve kit (2)
8 Flange kit 4 17-w’ Shuttle valve & orifice 2
10 Control spool 4 17-r Ball M6, 35 2
11 Return spring 4 17-z Orifice M5, ø0.8 2
12 Damper flange kit (4) 21 Plug 4
12-o Damper plunger ø14 4
33-119
33. UPPER STRUCTURE
33.2.4.2 DISASSEMBLY AND ASSEMBLY

(1) Boot replacement

The pilot control unit does not need to be removed from

the machine to perform this operation.
1) Remove both faulty boots.

(using a flat screw driver if necessary)
2) Replace both boots with a new one.
* Reassembly :

• First fit the lower part of the rubber boot on

the retaining plate between the 2 switch
plates
• Then put the lower part in the external
groove of the retaining plate
• Finish by fitting the upper part of the rubber
boot on the switch plate.
Fig. 33-190
(2) Switch plate removal
1) Remove :

• The pilot control unit from the machine.
• Both rubber boots (See 33.2.4.2 (1))
2) Remove the screw locking the axis using a 2mm
socket wrench. (See Fig. 33-191 No.1)
* Reassembly :
• Apply a droplet of Loctite #262 on the

locking screw thread.
• Torque :1.2 N•m (0.89 lbf•ft)
3) Fit a M3 screw on the switch plate axis in order

to remove it
(Using pliers if necessary). (See Fig. 33-191
No.2)

* Reassembly :
• Position the axis so that the hole is aligned
with the locking screw as shown on the
picture (See Fig. 33-191 No.3)
4) Mark out the position of the switch plate before
removing it.
Fig. 33-191
5) Repeat the operation for the second switch plate.
6) Reassemble parts in reverse order.
33-120
33. UPPER STRUCTURE
(3) Switch plate adjustment
If the switch plate is replaced, it is necessary to adjust

the regulation screws.

1) Unscrew the 2 locking screws using a 2,5mm

socket wrench (See Fig. 33-192)
* Reassembly :
locking screw thread.
• Torque :3 N•m 2.2 (lbf•ft)
2) Set the switch plate horizontally.
3) Screw on simultaneously both regulation screws
using a flat screw driver (5,5×150) until feeling Fig. 33-192
some resistance.
Do not misadjust the two damping screws. (See Fig.

33-193)
Regulation Damping screws
screws to already adjusted
4) Tighten the locking screws to hold the regulation adjust and glued
screws in position.
5) Repeat the operation for the second switch plate
making sure both switch plates are parallel. (See
Fig. 33-192) SWITCH PLATE
The figure is shown
from the backside.
(4) Retaining plate removal
Fig. 33-193
1) Remove
• Both switch plates (See 33.2.4.2 (2))
2) Unscrew simultaneously both screws holding the
retaining plate using a 8mm socket wrench.
(See Fig. 33-194)
* Reassembly :
• Apply a droplet of Loctite #262 on the screw
thread.
• Torque :30 N•m (22 lbf•ft)
Fig. 33-194
33-121
33. UPPER STRUCTURE
3) Lift the retaining plate to remove it.

(See Fig. 33-195)
* Reassembly :
• Use the retaining plate to insert the 4 guides
into the body simultaneously and
perpendicularly.
(See Fig. 33-195 left side)
5) Drain the pilot control unit (See 33.2.4.3).
Fig. 33-195
(5) Damping plunger seals replacement
1) Remove
• Both rubber boots. (See 33.2.4.2 (1))
• The retaining plate (See 33.2.4.2 (4))
WIPER RING
2) Remove the wiper ring of the damping plunger
1 2 DAMPER PLUNGER
(1).
(See Fig. 33-196 No.1) Fig. 33-196
* Reassembly :
• Replace with a new wiper ring.

Always place the damping plunger prior to the wiper

ring, and make sure the wiper ring is correctly
positionned.
3) Remove the damping plunger (2).

(Fig. 33-196 No.2)
Fig. 33-197
4) Using a needle, remove the seal placed inside

the body (See Fig. 33-198 No.3, 4)
* Reassembly :
• Replace with a new seal and grease it.
3 4
Fig. 33-198
33-122
33. UPPER STRUCTURE
• Squeeze the seal between your fingers to

obtain a 8-shape.
(See Fig. 33-199 No.5)
• Insert the seal within the groove with your
fingers (lip in bottom position).
(See Fig. 33-199 No.6, 7)
• Push the seal against the side using the 5 6
round head of a small socket wrench. (Fig.
33-199 No.8)
During the reassembly, make sure the seal is correctly

positionned, and pay attention not to damage nor twist
it. 7 8
5) Repeat the operation for the other 3 assemblies. Fig. 33-199
6) Extract the damping springs from the body (using

flat nose pliers).
7) Inspect the damping springs. If defects are
detected, replace the 4 springs.
(6) Guide/plunger and regulation unit replacement
1) Remove
• The retaining plate (See 33.2.4.2 (4)) DAMPER
PLUNGER
2) Guide/plunger replacement :
BODY
• Insert the end of a thin screwdriver between
the guide and the body, carefully lift the guide
to remove it from the body.
Hold the guides with the other hand during the

extraction operation to limit the effect of the return
spring.
3) Remove the guide / plunger assembly.

4) Repeat the operation for the other 3 sub-
assemblies.
5) Visually check that the guides / plungers are in
good condition. If defects are present, replace
the 4 sub-assemblies.
Fig. 33-200
33-123
33. UPPER STRUCTURE
6) Guide/plunger and relulation unit replacement

• Extract the regulation units from the body
(using flat nose pliers).
• Inspect the regulation units. If defects are
detected on the parts, replace the 4 units.
7) Return spring replacement :
• Extract the return springs from the body
(using flat nose pliers).
Fig. 33-201
• Inspect the return springs. If defects are
detected, replace the 4 springs.
Fig. 33-202
(7) Throttle kit replacement
1) Remove
• The pilot control unit from the machine
• The retaining plate (See 33.2.4.2 (4))
• The damping plungers and springs (See
33.2.4.2 (5))
Fig. 33-203
33-124
33. UPPER STRUCTURE
2) Unscrew the screw using a 3mm socket wrench.

(See Fig. 33-203)
* Reassembly :
• Apply a droplet of Loctite #262 on the screw
thread
• Screw on until it sets just above the body.
(See Fig. 33-204)
3) Unscrew the throttle using a 3mm socket
wrench.
* Reassembly :
4) Repeat the operation for the other 3 assemblies.
SCREW
5) Replace with new screws and new throttles.
THROTTLE
Fig. 33-204
(8) Shuttle valve kit removal
1. Remove the pilot control unit from the machine
The pilot control unit does not need to be disassembled

to perform this operation.
2) Unscrew the shuttle valve using a 4mm socket

wrench. (See Fig. 33-205 and Fig. 33-206)
* Reassembly :
• Thoroughly clean the body to remove any
trace of loctite. Fig. 33-205

shuttle valve thread.
Wait for 8 hours before using the machine to let the

Loctite #242 dry completely.
Fig. 33-206
33-125
33. UPPER STRUCTURE
3) Turn the body upside down to remove the shuttle

valve and the ball. (See Fig. 33-208)
4) Unscrew the throttle using a 2,5mm socket
wrench.
* Reassembly:
• Hand tighten.
5) Repeat the operation for the other
subassemblies.
6) Inspect the shuttle valves, balls and throttles. If
defects are detected, replace all the assemblies.
Fig. 33-207

Fig. 33-208
(9) Check valve kit removal
1) Remove the pilot control unit from the machine
The pilot control unit does not need to be disassembled

to perform this operation.
2) Unscrew the check valve plug using a 4mm

socket wrench.
(See Fig. 33-209)
* Reassembly :
• Drain the pilot control unit
(See 33.2.4.3)
Fig. 33-209
• Torque :5 N•m (3.7lbf•ft)
3) Turn the body upside down to remove the ball.
4) Repeat the operation for the second check valve
kit.
5) Inspect the check valve plugs, O-rings and balls.
If defects are detected, replace all the
assemblies. (See Fig. 33-210)
CHECK VALVE
PLUG
BALL
Fig. 33-210
33-126
33. UPPER STRUCTURE
33.2.4.3 DRAIN OF HYDRAULIC PILOT CONTROL UNIT

(1) When removing the retaining plate, the throttle kit or
the shuttle valve kit, it is necessary to drain the pilot
unit.
(2) Reassemble the pilot unit control completely.
(3) Install the pilot unit control in the machine.
(4) Slightly unscrew the check valve plug using a 4mm
socket wrench. (See Fig. 33-211)
(5) Switch on the machine.
(6) Operate gently the pedal until the bubbles
disappear.
(7) Tighten the check valve plug.
• Torque : 5 N•m (3.7 lbf•ft)
(8) Repeat the operation for the other check valve plug.
Fig. 33-211
33-127
33. UPPER STRUCTURE
(1) Swing motor
992
451 452
303 131 444
b
A
351
355 SECTION A-A
051
401
488 469 (051-1)
468
106 487 444 433 981 390 438 452 980
391
Tightening forgue
303
472 Tightening Widfh
No. Size torque
451 N.m (lbf.ft) across flat
707
712 051 M33X1.5 177(131) 41
A 706
A 401 M16 240(177) 14
131
982
468 G1/4 36(27) 6
702
114 469 M22X1.5 108(80) 10
111
117 980 G3/8 1.7(1.3) 6
743 981 G3/4 4.4(3.2)
121 14
742 982 G1/4 0.9(0.66) 6
113
992 PT3/4 98(72) 14
123
116
117
301
432 471 443 106 101 491 304 437 124 122
Fig. 33-212 Swing motor
33-128
33. UPPER STRUCTURE
101 Drive shaft 1 443 Roller bearing 1
106 Spacer 3 444 Roller bearing 1
111 Cylinder 1 451 Pin 2
113 Retainer (spherical bushing) 1 36 (27) 468 VP plug : PF1/4 2
114 Cylinder spring 1 108 (80) 469 RO plug : M22 2
116 Push rod 12 471 O-ring : 1B G80 1
117 Spacer 2 472 O-ring 1
121 Piston 9 487 O-ring : 1B P11 2
122 Shoe 9 488 O-ring : 1B P20 2
123 Plate 1 491 Oil seal 1
124 Shoe plate 1 702 Brake piston 1
131 Valve plate 1 706 O-ring 1
301 Casing 1 707 O-ring 1
303 Casing 1 712 Brake spring 20
304 Front cover 1 742 Friction plate 3
351 Plunger 2 743 Separator plate 4
355 Spring 2 1.7 (1.2) 980 Plug : PF3/8 1
240 (177) 401 Socket bolt : M16×75 4 4.4 (3.3) 981 Plug : PF3/4 1
432 Snap ring 2 0.9 (0.6) 982 Plug : PF1/4 1
433 Ring 1 98 (72) 992 Plug : PT3/4 1
437 Snap ring 1 177 (131) 051 Relief valve : M33 2
438 Snap ring 1 051-1 O-ring : 1B G30 2
33-129
33. UPPER STRUCTURE
(2) Swing reduction unit
602 230 231 204 286 211 912 285 287 911 283 403 603 922
210
921
282
202
*
203
913
285
*
402
910
801
925
920
390
926
102
401
Apply Three Bond #1217 on . 915
201
Fig. 33-213 Sectional view of swing reduction unit

102 Casing 1 402 Roller bearing 1
201 Pinion shaft 1 403 Needle bearing 3
202 Ring gear 1 98 (72) 602 Socket bolt : M12×100 8
203 No.2 planetary gear 4 603 Socket bolt : M12×135 2
204 No.2 sun gear 1 801 Oil seal 1
210 No.1 planetary gear 3 910 Spring pin 4
211 No.1 sun gear 1 911 Retaining ring 3
282 No.2 pin 4 915 Seal 1
283 No.1 pin 3 65 (48) 920 Adapter : PT1/2 1
285 Side plate t=1 7 108 (80) 921 Hose : PF1/2 1
286 Thrust washer t=2 1 108 (80) 922 Plug : PF1/2 1
287 Side plate t=2 3 925 relief fitting 1
401 Roller bearing 1 926 Grease nipple : PT1/4 1
33-130
33. UPPER STRUCTURE
33.2.5.2 DISASSEMBLY AND ASSEMBLY OF SWING MOTOR
33.2.5.2.1 TOOLS AND JIGS

(1) Spanner wrench
OPPOSING
NAME SIZE APPLICABLE PARTS TOOL
FLATS mm
CAPSCREW M6 10 Selector valve for brake Spanner, Socket wrench
SOCKET BOLT M8 6 Swing shockless valve block Allen wrench
SOCKET BOLT M16 14 Valve casing Allen wrench
PLUG M22 10 RO plug Allen wrench
PLUG PF1/4 6 ROH plug Spanner, Socket wrench
ATTACHING SCREW M22 24 Swing shockless valve Spanner, Socket wrench
ATTACHING SCREW M33 41 Relief valve Spanner, Socket wrench
(2) Other tools and jigs
SPECIFICATION
REMARKS
TOOLS
For snap ring For ø35 (1.38") shaft
Pliers
For Locking ring For ø80 (3.15") hole
Screwdriver Flat-bladed type, medium size 2 pcs.
Steel bar 10×8×200 or so 1pc. (0.394"×0.315"×7.87" )
Hammer Plastic hammer Iron hammer 1 each
Torque adjusting range
Torque wrench
• For 0.09~24kgf•m (0.65~174 lbf•ft)
Slide hammer bearing puller
Brake piston drawing tool Fig. 33-214
2 X 7 (0.276")
(1.57")
40
M10 SCREW ON BOTH ENDS

(EFFECTIVE THREAD
LENGTH 20 (0.787") 40 (1.57")
100 (4")
250 (10")
BORE DIA. 11
(0.433")
10 (0.4")
2 X NUT M10
M10
123 (4.84")
200 (7.87")
Fig. 33-214 Brake piston drawing tool
33-131
33. UPPER STRUCTURE
33.2.5.2.2 DISASSEMBLY PROCEDURE

(1) Cleaning the swing motor
Place a wire sling around the motor, lift it up and
clean it. After cleaning, dry it with jet air.
Put plugs into all ports to prevent foreign matter from

entering the motor and clean the motor to be free from
dirt and dust.
(2) Draining out lube oil

Drain out the oil from the drain port of casing (301).
(3) Fixing the motor to the work bench.
Direct the shaft end of the drive shaft (101) down
and fix it on a bench convenient for disassembly.
On that occasion, leave a matching mark on the
mating part between casing (301) and valve cover
(303).
303
Choose a clean place. Place a rubber sheet or a cloth 301

on the work bench. Exercise care so as not to damage
parts.
Fig. 33-215 Fixing the motor to the work bench and
putting a matching mark
(4) Remove relief valve
Loosen relief valve (051) and separate it from valve 303
cover (303). 051
: 41 mm
(5) Remove swing shockless valve block
Loosen socket bolt (V171) and separate swing
shockless valve block (052) from valve casing
(303).
: 6 mm
(6) Removing the anti-cavitation check plunger Fig. 33-216 Removing relief valve
Separate RO plug (469) from valve casing (303)
V171 052 303
and draw out spring (355) and plunger (351).
: 10 mm
Exercise care so as not to score the plunger seat.
Fig. 33-217 Removing swing shockless valve block
33-132
33. UPPER STRUCTURE
(7) Remove valve casing and valve plate

Loosen socket bolt (401) and separate valve casing
(303) from casing (301).
[If the socket bolt (401) are loosened, the valve 401
casing floats off casing (301) by the force of brake
spring (712)].
303
Then separate valve plate (131) from valve casing
(303). 301
: 14 mm
Fig. 33-218 Removing valve casing No.1

Work with care so the valve seat does not come off from
the valve casing.
(In some cases, the valve plate is adhered on the
cylinder side.)
When inserting a screwdriver or something between
the matching surfaces, use care so as not to score the
matching surfaces.
(8) Remove brake spring

303
Draw out brake spring (712) from brake piston
(702).
712
301
Fig. 33-219 Removing valve casing No.2

(9) Remove brake piston
Draw out brake piston (702) from casing (301),
using a jig (slide hammer).
702
Hold it upright, utilizing the bolt holes in the brake

301
piston.
Fig. 33-220 Removing brake piston
33-133
33. UPPER STRUCTURE
(10)Remove cylinder
301
Place the motor level and draw out the cylinder
(111) from the drive shaft (101). Then draw out
piston (121), retainer plate (123), spacer (117) and
shoe plate (124).
• Use care when drawing out the cylinder as push rod

(116) tends to come off. Exercise care so as not to
score the sliding surfaces of the cylinder, retainer
111
and shoe.
Fig. 33-221 Removing cylinder
• In case the shoe plate does not come off, remove it
after the work sequence (12).
(11)Remove separator plate

Draw out friction plate (742) and separator plate 437
(743) from casing (301).
304
301
Fig. 33-222 Removing snap ring

(12)Remove front cover
Take off snap ring (437) with pliers and separate
front cover (304) from casing (301).
304
• When drawing out the front cover, take care so as

not to score the sliding surface of the oil seal.
• You may remove the front cover with the drive shaft.
301
Fig. 33-223 Removing front cover
33-134
33. UPPER STRUCTURE
(13)Remove drive shaft

Separate drive shaft (101) from casing (301) by
lightly tapping the end face of the valve casing side
(303) of drive shaft (101), using a plastic mallet.
Use care so as not to score the sliding surface of the oil

seal.
(14)Remove shoe plate 101 301

Draw out shoe plate (124) from the housing side of Fig. 33-224 Removing drive shaft
roller bearing (443) of casing (301) by lightly
tapping it with a steel rod.
(15)Remove inner race of roller bearing (443)

Remove snap ring (432) and spacer (106) from

drive shaft (101) and draw out the inner race of
roller bearing (443) by means of a press.

You may knock on the inner race of the roller bearing

with a steel bar, but knock on it evenly all around so the
bearing is not damaged.

Do not use the removed bearing again.
Fig. 33-225 Removing inner race of roller bearing

(16)Remove oil seal
Draw out oil seal (491) from front cover (304),
utilizing the jig.
304
(491)
Do not reuse the removed oil seal.

Fig. 33-226 Removing oil seal

(17)Remove roller bearing

SLIDE HAMMER
Separate roller bearing (444) from valve casing
101
(303), using a slide hammer bearing puller.
444
303
Do not reuse the removed bearing.
Fig. 33-227 Removing roller bearing (444)
33-135
33. UPPER STRUCTURE
33.2.5.2.3 ASSEMBLY PROCEDURE

(1) Holding casing
301
Place the casing (301) facing its valve casing (303)
downward.
Fig. 33-228 Holding casing

(2) Installing inner race of roller bearing
Fit snap ring (432) and spacer (106) to drive shaft
(101), insert the inner race of roller bearing (443),
and shrinkage fit the inner race.
Put spacer (106) in and fix snap ring (432).
444
101
Beware of the orientation of the inner race of the roller 106

bearing.

Fig. 33-229 Installing roller bearing (443)

432

Fig. 33-230 Installing snap ring (432)

(3) Shrinkage fitting inner race of roller bearing (444)
Shrinkage-fit the inner race of roller bearing (444) to
drive shaft (101). Then fit snap ring (433). 444
(4) Installing outer race of roller bearing (443)

Place drive shaft (101) with roller bearing (443) on
its output shaft, and insert the drive shaft into casing
101
(301). Then lightly knock on the outer race of roller
bearing (443) via a steel bar, using a hammer.
Knock on the outer circumference of the outer race

Fig. 33-231 Shrinkage fitting inner race
evenly all round till it stops at the step of the casing.
of roller bearing (444)
33-136
33. UPPER STRUCTURE
(5) Insert oil seal

Put oil seal (491) into front cover (304), using a jig.
• Be careful about the direction of the oil seal.

• Fix the oil seal till it stops at the step of the casing.
304 (491)
Fig. 33-232 Inserting oil seal

(6) Fit O-ring
Fit O-ring (471) to casing (301). 471
301
Fig. 33-233 Fitting O-ring
Wind protective tape
101
Fig. 33-234 Wind tape around the spline of the drive

shaft
33-137
33. UPPER STRUCTURE
(7) Installing front cover

Fit front cover (304) to casing (301) by lightly 304
tapping the cover with a plastic mallet
Coat the lip of the oil seal with a thin film of grease and
put it in with care so as not to score the lip of it. (Wind
tape on the spline of the drive shaft so the lip of it is not
scored by the spline.)
Tap the outer circumference evenly round to prevent it
from being scored.
Fig. 33-235 Installing front cover
(8) Fitting the snap ring
Fit snap ring (437) to casing (301), using pliers. 124
(9) Put shoe plate (124) into casing (301).
Put the larger chamfer side of the shoe plate into the
301
casing side.
Coat the matching surface with a thin film of grease to
prevent the shoe plate from falling off.
Fig. 33-236 Inserting shoe plate

(10)Insert push rod
Put push rod (116) in cylinder (111).
111
Use care so as not to score the sliding surface of the
cylinder.
(Put two push rods into one hole.)
116
Fig. 33-237 Inserting push rod

(11)Installing retainer
113
Then mount retainer (113) fitted with spacer (117)
on the cylinder.
117
Fig. 33-238 Installing retainer
33-138
33. UPPER STRUCTURE
(12)Installing the piston sub assy to the plate

123
Set piston sub assy (121,122) to plate (123).
121,122
Fig. 33-239 Installing the piston sub assy to the

plate
(13)Assembling the piston sub assy into the cylinder
121,122,123
Assemble piston sub assy (121,122) with plate 111
(123) into cylinder (111) and insert it in place,
aligning it with the spline of drive shaft (101).
The drive shaft can be set easily if the phase of the

retainer (113) and the cylinder spline is matched.
101
Fig. 33-240 Assembling the piston sub assy into the

cylinder
(14)Installing separator plate and friction plate
743
Replace casing (301) so front cover (304) side
faces down. Then Assemble separator plate (743)
and friction plate (742) into casing (301), in that
order.
Fit four separate plates and three friction plates.
301
Assemble four notches in the gear teeth of friction plate

so the same phases are aligned up and down.
Fix notches in the four claws of separator plate in the
position in Fig. 33-241. Fig. 33-241 Installing separator plate
742
301

Fig. 33-242 Installing friction plate
33-139
33. UPPER STRUCTURE
(15)Fit O-ring
707 (706)
Fit O-rings (706)(707) to casing (301).
In that case, coat the O-rings with grease beforehand. 301

This will prevent the O-rings from breaking when
inserting brake piston.
Fig. 33-243 Fitting O-ring

(16)Installing brake piston
Fit brake piston (702) to casing (301). 702
301
Install the brake piston so four slits of it are positioned
as shown in the figure on the right. (Match the M8
screws to the figure on the right.)

Fig. 33-244 Installing brake piston

If brake piston is hard to enter because of the

resistance of the O-rings, screw in socket bolt M8 into
the brake piston and knock on it evenly by means of a
plastic mallet.
(17)Installing brake spring

702 712
Fit brake spring (712) to brake piston (702).
At that time, make sure that the spring is set snugly in

the spotface of the brake piston.
Fig. 33-245 Installing brake spring
33-140
33. UPPER STRUCTURE
(18)Insert outer race of roller bearing

Insert the outer race of roller bearing (444) into
valve casing (303), knocking it lightly by means of a
steel bar.
444
303
Knock on the outer circumference of the outer race
evenly around and fix it so it stops at the step of the
valve casing.
Fig. 33-246 Inserting outer race of roller bearing

(19)Installing valve plate
Assemble valve plate (131) into valve casing (303)
and then fit O-ring (472) in place.
Coat the contact surface of the valve plate with a thin

film of grease. (To prevent it from falling off.)

Fig. 33-247 Installing valve plate

(20)Installing valve casing
Attach valve casing (303) to casing (301) and
fasten it with socket bolt (401).
: 14 mm
303
• Beware of the direction of the valve casing. 301

• Be careful so the valve plate does not come off.
• Use care so the brake spring does not fall down.
• Fasten the socket bolts evenly all around. Fig. 33-248 Installing valve casing
(21)Fitting plunger
Place plunger (351) and spring (355) into valve 401 351
casing. Fasten RO plug (469) with O-ring (488) into
valve casing.
: 10 mm
Make sure that the plunger moves smoothly.

355(488,469)
Fig. 33-249 Fitting plunger
33-141
33. UPPER STRUCTURE
(22)Installing relief valve

Fit backup ring (162) and O-ring (161) to relief valve 303
051 (051-1)
(051) and fasten the relief valve against valve
casing (303).
: 41 mm
(23)Installing plugs (464),(468)
Fit O-ring (487) to plug (468), attach it to valve
casing (303), fit O-ring (485) to plug (464) and
fasten it against casing (301). Fig. 33-250 Installing relief valve
: 19 mm
(24)Installing swing shockless valve block
052(V161) 303
Fit O-ring (V161) to the swing shockless valve V171
block. Then fasten the valve block against valve
casing (303) with socket bolts (V171).
: 6 mm
Fig. 33-251 Installing swing shockless valve block
33-142
33. UPPER STRUCTURE
33.2.5.3 DISASSEMBLY AND ASSEMBLY OF SWING REDUCTION UNIT

(1) Tools
NAME REMARKS
Allen wrench Opposing flats 6,10mm
Socket wrench
Adjust wrench
Double ended wrench
Hammer
Plastic mallet
Screwdriver
Torque wrench
Liquid packing Three-Bond #1104B
Oil container for shrinkage fit work 80~100°C (176~212°F)
(2) Jigs
1) Oil seal fitting jig 2) Roller bearing (401) removing jig
3) Roller bearing (402) fitting jig
33-143
33. UPPER STRUCTURE
33.2.5.3.2 DISASSEMBLY PROCEDURE

(1) Remove swing motor unit and drain oil
Remove the swing motor unit from the machine,
loosen plug (902) at the oil outlet, discharge the
gear oil and place the unit on a work bench.
Receive gear oil in a clean container and inspect for the

presence of worn particles.
(2) Remove hydraulic motor

Loosen socket bolts (602) and remove the
hydraulic motor.
: 10 mm
(3) Remove No.1 sun gear (211)
211
Fig. 33-252 Removing No.1 sun gear

(4) Remove No.1 carrier assy
Remove the No.1 carrier assy with the No.1
planetary gear (210) and others.
210
Fig. 33-253 Removing No.1 carrier assy
33-144
33. UPPER STRUCTURE
(5) Disassembly No.1 carrier assy
Put a matching mark on each of the planetary gears

and pins so combination and pairing do not change.
1) Remove snap ring (911). Then remove side plate 911

(287) at the top.
287
2) Remove No.1 planetary gear (210) and needle
bearing (403). Fig. 33-254 Removing snap ring
403 210
Fig. 33-255 Removing needle bearing

3) Remove side plate (285) under the planetary
gear. 285
Fig. 33-256 Removing side plate

4) After removing three No.1 planetary gears (210),
remove thrust washer (286) in the center.
286
• Do not remove No.1 pin (283) from No.1 carrier

(231) unless there is anything wrong.
• If the No.1 pin is removed, you need a special
caulking tool at reassembly.
However, make sure that the ø2(0.079") oil hole of 2 (0.079")
(OIL HOLE)
No.1 pin (283) is directed outwards with respect to
the center of No.1 carrier (231).
(Refer to Fig. 33-257 below.)
Fig. 33-257 Removing thrust washer
33-145
33. UPPER STRUCTURE
(6) Remove No.2 sun gear (204)
204
Fig. 33-258 Removing No.2 sun gear

(7) Remove No.2 carrier assy
No.2 CARRIER ASSY
Fig. 33-259 Removing No.2 carrier assy

(8) Disassembly No.2 carrier assy
282,910
Do not disassemble the No.2 carrier assy further unless 203,285

there is anything wrong. In this condition, inspect the
parts according to the inspection procedure specified
under 33.2.5.4.2 (1).
As mentioned above, it is recommended that the No.2
carrier assy be replaced as a pair, but in case part of it
must be replaced for an unavoidable reason, do it as
below:
Fig. 33-260 Removing No.2 pin
1) Push spring pin (910) in further and draw out
No.2 pin (282).
Do not reuse the removed No.2 pin.
2) Draw out No.2 planetary gear (203) and side

plate (285) sideways.
33-146
33. UPPER STRUCTURE
(9) Remove ring gear (202) 202

The bottom of the two holes is provided with M12
screw threads to draw out the ring gear. Utilise
motor mounting socket bolts (602) to draw it out.
: 10 mm
Fig. 33-261 Removing ring gear

(10)Separate snap ring (913) from drive shaft (201).
(11)Remove drive shaft
913
Support the flanged part of the drive shaft so the
shaft end faces down and place the drive shaft on a
work bench. Draw out the shaft downwards, while 201
tapping the center of it with a plastic mallet.
• Do not disassemble it further unless there is

anything wrong.
At this stage, inspect the parts according to the
Fig. 33-262 Removing snap ring
inspection procedure specified under 33.2.5.4.2
(1).
As mentioned above, we recommend that the drive
shaft assy be replaced as a set. In case part of it
must be replaced for an unavoidable reason, do as
follows:
• If nothing faulty is discovered on inspection at this
stage, no further disassembly is needed.
33-147
33. UPPER STRUCTURE
(12)Remove roller bearing

As shown on Fig. 33-263 on the right, support the PRESS
drive shaft assy, and draw out bearing seal (915) JIG 2
and roller bearing (401), using a press.
• Roller bearing (402) is left in the casing. Since the

shaft falls down, use care so as not to damage it.
• The removed oil seal and the bearing seal can not
be used again.
915
401
Fig. 33-263 Removing roller bearing

(13)Remove oil seal (801) from casing (102).
102
801
Fig. 33-264 Removing oil seal
33-148
33. UPPER STRUCTURE
33.2.5.3.3 ASSEMBLY PROCEDURE

(1) Assembly drive shaft assy
1) Insert bearing seal 402
801
Insert bearing seal (915) into drive shaft (201). 102
GREASE
401
915
201
Fig. 33-265 Assembling drive shaft
2) Press-fitting roller bearing
Coat the inside of roller bearing (401) with GREASE
sufficient grease and press it into the drive shaft,
using a press. Set the inner race firm into the
shaft by knocking on the steel bar, till the
hammer springs back. Then apply grease so it
reaps as shown in Fig. 33-266.
• Grease :EP type

201
(Shell Alvania grease EP2)
Fig. 33-266 Applying grease to roller bearing
• Roller bearing (401) has a bank in the middle. Push
grease in to both sides before assembling the
bearing into the shaft.
(2) Place casing (102) on a level bench.

(3) Installing drive shaft assy
Lift the drive shaft assy upright, using the screw in
the end of the shaft and put it into the casing.
Thread size : M10, Depth 20mm
201
102
Lightly tap the outer race of the bearing so it is
completely level. If the outer race is tilted, it does not
enter by light tapping in some cases. On such occasion,
pull it out once, place it level and do the job once again.
Fig. 33-267 Installing drive shaft assy
(4) Place the casing by supporting the flanged part so
the shaft end faces down.
(5) Installing oil seal
Insert oil seal (801) into casing (102).
• Use the jig 1) under 33.2.5.2.1 (2).

• Place the oil seal level and fix it so the lip is not
scored.
33-149
33. UPPER STRUCTURE
(6) Press-fitting roller bearing

Insert roller bearing (402) by using the jig that holds
JIG
down both the inner race and the outer race and
also using a press.
Always use the jig 33.2.5.2.1 (2) and set it properly.
402
Fig. 33-268 Press-fitting roller bearing

(7) Fit snap ring (913) 913
(8) Fitting the oil filling plug
Fill up the oil inlet with grease, wind seal tape
around plug (902) and set it to the casing.
Grease : EP type (Shell Alvania EP2)
Grease volume : about 500cc (31 cu•in)
: 6 mm
Fig. 33-269 Fitting snap ring

(9) Assembly No.2 carrier assy
230 285 282 203
1) Place side plate (285) by matching it to the pin
holes.
2) Put No.2 planetary gear (203) in.
3) Check the hole location, peeping through it from
above. Match the No.2 pin (282) with the hole for
spring pin (910) and the hole in the No.2 carrier
910
and set the pin, while tapping it lightly.
(10)Apply liquid packing to the matching surface Fig. 33-270 Assembling No.2 carrier assy
between casing (102) and ring gear (202).
Three-Bond #1104B
33-150
33. UPPER STRUCTURE
(11)Installing ring gear

Install ring gear (202) to casing (102), checking the
location of the matching marks and temporarily
fasten them together by means of four capscrews 202
or socket bolts M12×100. (Tightening torque :
78N•m (58 lbf•ft) or over). Always place plain 102
washers on the bolts so the matching surface of the
motor is not scored.
: 19mm or : 10mm
Fig. 33-271 Installing ring gear

(12)Installing No.2 carrier assy
Install the No.2 carrier assy into the ring gear.
No.2
(13)Installing No.2 sun gear CARRIER
Put in No.2 sun gear (204). ASSY
Fig. 33-272 Installing No.2 carrier assy

(14)Assembly No.1 carrier assy
204 286 211 285 287 283 403 210
1) Place No.1 carrier (231) on a level bench. 231
2) Make sure that all three ø2(0.079" ) oil holes of
No.1 pin (283) are directed outwards with
respect to the center of No.1 carrier (231), as
shown in the figure.
2 (0.079")
(OIL HOLE)
Fig. 33-273 Assembling No.1 carrier assy
231
3) Installing thrust washer

Put in thrust washer (286) in the center.
286
Fig. 33-274 Installing thrust washer
33-151
33. UPPER STRUCTURE
4) Installing side plate

Put in side plates (285).
286
The upper and lower side plates differ in thickness; take

care so as not to mistake one for another.
403
285
Fig. 33-275 Installing side plate and needle bearing

5) Installing needle bearing and No.1 planetary
gear
Fit needle bearing (403) and No.1 planetary gear
(210).
210
Fig. 33-276 Installing planetary gear

6) Installing side plate
Put side plate (287) in and fit snap ring (911).
'
&%
Fig. 33-277 Installing side plate and snap ring
(15)Installing No.1 carrier assy
No.1 CARRIER ASSY
Assemble the No.1 carrier assy. Make sure that
thrust washer (286) in the center sits in the convex
part of No.2 sun gear (204). 286
204
Fig. 33-278 Installing No.1 carrier assy
33-152
33. UPPER STRUCTURE
(16)Installing No.1 sun gear

Assemble No.1 sun gear (211).
211
(17)Apply liquid packing
Remove the temporarily fastened bolts and coat the
mounting surface of the hydraulic motor of ring gear
202
(202) with liquid packing (Three-Bond #1104B).
(18)Installing hydraulic motor
Fit snap ring (912) to the drive shaft of the hydraulic
motor, lower it vertically, assemble the hydraulic
motor in place, while matching it with the spline
position and fasten it with socket bolt (602).
: 10 mm Fig. 33-279 Installing No.1 sun gear

(19)Wind seal tape around oil drain plug (902) and fit it
to the casing.
: 6 mm
(20)Filling oil
Fill in gear oil through the oil inlet.
Lubricating oil: SAE#90~#140, API class GL3~4
(Shell Spirax 90EP filled up at shipping)
Lubricant volume : 1.7L (0.45gal)
Temporarily fit the level bar to the pipe and check the
level.
33-153
33. UPPER STRUCTURE
33.2.5.4.1 SWING MOTOR

(1) Replacement standards for parts
If part are worn out beyond the below standards, replace or recondition them. However if they show excessive
damage on their surface, replace them.
Recommended
Standard
Value for
Item Dimension Remedy
replacement
mm (in)
mm (in)
Clearance between piston and cylinder
bore (D-d)
0.016 0.046
Replace piston or cylinder.
d D (0.00063) (0.00181)
Gap between piston and caulked part of

shoe ( )
0 0.3
Replace piston and shoe assembly.
(0.012)
Thickness of shoe (t)
4.0 3.8
Replace piston and shoe assembly.
(0.157) (0.150)
t
Assembled height of shoe plate and

retainer (H-h)
5.5 5.0 Replace a spherical bushing and a

H (0.217) (0.197) retainer plate as a pair.
h
Thickness of friction plate
3.5 3.1
Replace.
t (0.138) (0.122)
33-154
33. UPPER STRUCTURE
(2) Standard for correcting sliding surfaces

If the surface roughness of the sliding surface of a part exceeds the following standard, correct it or replace the
part.
Standard for correcting sliding surfaces

STANDARD SURFACE SURFACE ROUGHNESS
NAME OF PART
ROUGHNESS REQUIRING CORRECTION
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)
• Lap each sliding surface to a standard roughness level or finer.

• If the sliding surface of the cylinder block, valve plate, retaining plate or spherical bushing is roughened, replace
parts in pairs.
33-155
33. UPPER STRUCTURE
33.2.5.4.2 REDUCTION UNIT

(1) Parts inspection and replacement standards
1) If pitching is seen on the tooth surface of the sun gear, the planetary gear and the ring gear;
(Single pit is more than ø1mm(0.039in) and the area occupancy of all pits is more than 5%.)
2) Oil seal
Replace the oil seal if the lip face of it is scored and worn.
Always replace when the reduction gear is disassembled for inspection or some reason.
3) Drive shaft roller bearing (Front side)
Inspect as below without drawing it out from the drive shaft:
1. Inspect the race surface and the rollers as far as you can see and make sure that there is no pitching
and flaking.
2. Inspect the following as well:
a. The gear oil does not contain large worn particles.
b. Large worn particles are not deposited between the roller and the retainer.
c. The bearing turns smoothly by hand.
Replace it if there is any fault on the above inspection.
Do not reuse the bearings drawn out of the shaft.
4) Drive shaft roller bearing (Rear side)
Replace the bearing if the race surface and the rollers show pitching and flaking.
5) No.2 planetary gear
Check for the circumferential gap between the No.2 planetary gear and the No.2 pin without disassembling
the No.2 carrier assy. Replace the planetary gear if the gap is more than 0.5.
6) Thrust plate and thrust washers
Replace the gear if the sliding surface in contact with the No.2 sun gear is extremely scored.
7) If pitching and flaking are seen on the rolling surfaces of the needle cage and the No.1 pin that support the
No.1 planetary gear; Replace such faulty parts.
33-156
33. UPPER STRUCTURE
(2) Table of parts to be replaced together
marks represent such parts that must be replaced together.

marks represent such parts that should preferably be replaced together.
Replace the inner race and the outer race of the roller bearing together.
#

"

!
!"

# $

!"

!

"
33-157
33. UPPER STRUCTURE
33.2.5.5.1 SWING MOTOR

(1) Hydraulic motor does not rotate.
TROUBLE CAUSE REMEDY

Pressure does not rise. 1. Relief valve in circuit is not set correctly. 1. Set to correct value.
2. Malfunction of relief valve. 2.
2-1 Correct the stuck areas or replace the
2-1 Sticking plunger.
plunger.
2-2 Orifice on plunger is clogged. 2-2 Disassemble and clean.
3. Plunger seat is faulty. 3. Check the seat surface and replace the
plunger if scored.
4. Swing shockless valve seat is faulty. 4. Replace the swing shockless valve
cartridge or block.
Pressure rises. 1. Overload 1. Eliminate overload.
2. Moving parts are seized. 2. Inspect and repair piston, shoe and
cylinder valve plate.
3. Brake release pressure is not working on 3. Check circuit and correct it.
the motor
4. Brake piston is stuck. 4. Disassemble and check.
5. Friction plate is seized. 5. Disassemble, check and repair.
Replace one that is seized.
(2) Rotating direction is opposite.

Rotating direction is 1. Motor's assembling direction is reversed. 1. Assemble correctly.
opposite.
2. Piping inlets and outlets are reversed. 2. Pipe correctly.
(3) Revolution does not rise to set value.

Revolution does not rise 1. Oil inflow is deficient. 1. Check pump's delivery rate and circuits to
to set value motor.
2. Oil leaks are excessive due to high 2. Lower oil temperature.
temperature.
3. Sliding surfaces are worn or broken. 3. Replace.
(4) Brake torque is insufficient.

Brake torque is 1. Friction plate is worn. 1. Disassemble and check. Replace if wear
insufficient. is beyond standard value.
2. Brake piston is stuck. 2. Disassemble and check.
3. Brake release pressure is not released. 3. Check and correct circuit.
4. Spline of friction plate is broken. 4. Disassemble and check.
Replace broken part.
33-158
33. UPPER STRUCTURE
(5) The swing motor drifts much.

Check the drain rate of the hydraulic motor. If it is less than 200cc/min(12cu•in/min), you should think that the
motor is not faulty.

The swing motor drifts 1. Relief valve malfunctions. 1.
much when it is actuated Same as (1). Same as (1).
by external torques. (e.g. 2. Plunger seat is faulty. 2. Replace.
Machine is on a slope.) 3. Seat of the swing shockless valve is no 3. Replace the swing shockless valve
good. cartridge or block.
(6) Oil leaks

1) Oil leak from oil seal

Oil leaks from oil seal 1. Lip of seal contains dirt and damaged. 1. Replace oil seal.
2. Shaft is damaged or worn. 2. Shift the lip and shaft positions or replace
oil seal.
3. Casing inner pressure has risen 3. Repair drain piping if clogged up.
abnormally high, with the result that lip of
oil seal has turned up.
4. Shaft is rusted. 4. Disassemble and correct.
2) Oil leak from matching surface

Oil leak from matching 1. O-ring is missing. 1. Set O-ring correctly and assemble it.
surface 2. O-ring has a scratch. 2. Replace.
3. Seal surface has a scratch. 3. Disassemble and correct.
4. Bolt is loose or broken. 4. Tighten to specified torque or replace.
33-159
33. UPPER STRUCTURE
33.2.5.6 REDUCTION UNIT
1) Reduction unit does not turn.
Hydraulic motor inlet pressure has risen. Overloaded Reduce the motor of load.
Reduction unit is broken. Replace reduction unit.
Parking brake of the hydraulic Inspect the release

motor is not released. pressure and the brake.
Check the release

Hydraulic motor inlet pressure has not risen. command pressure.
Rotating sound is heard from

Motor shaft is broken. Replace hydraulic motor.
hydraulic motor.
Reduction unit is broken. Replace reduction unit.
Rotating sound is not heard from

Pump and valve are out of order. Check for fault and correct.
hydraulic motor.
2) Oil leakage
Oil leaks through matching surface. Liquid packing is not applied. Disassemble and apply
liquid packing.
Bolts are not fastened tight. Disassemble, apply liquid

The matching surface is moving packing and reassemble
because of loosening. as specified.
The matching surface is scored. Replace faulty parts.
Oil leaks from shaft. Oil seal is scored. Disassemble reduction

unit and replace oil seal.
3) Temperature is high.
Temperature of reduction unit casing is high. The gear oil is not filled up or Check oil level and fill oil
the oil level is low. up to a specified level.
The amount of grease is small. Fill up grease.
Gear and bearing are damaged. Replace reduction unit.
33-160
33. UPPER STRUCTURE
33.2.6 SWIVEL JOINT
33.2.6.1 CONSTRUCTION VIEW
2 places Apply Three Bond

#1805 to stem
2 places
VIEW Y
5 places
Tightening torque
30.4 N.m (22.4 lbf.ft)
Apply Loctite #242
SECTION HH
Tightening torque
30.4 N.m (22.4 lbf.ft)
Apply Loctite #242
Fig. 33-280 Construction of swivel joint
No. Part name Q’ty No. Part name Q’ty

1 Body 1 7 O-ring (G95 1A) 1
2 Stem 1 8 Socket bolt (M8×20) 2
3 Thrust plate 1 9 Socket bolt (M8×30) 3
4 Cover 1 12 Plug 1
5 Seal 5 13 O-ring (P80) 2
6 Seal assy 1
33-161
33. UPPER STRUCTURE
33.2.6.2.1 Tools
No. Tool Name Used for Remarks

Hammer 1. Steel hammer
a
2. Wooden or plastic mallet
b Rubber mat Disassembly 750 mm (30in) square or more
Wrench Assembly 1. Allen wrench
c 2. Double-ended and single-ended wrench
3. Extension pipe
d Torque wrench Assembly 98 N•m (72 lbf•ft)
Pin Grind the tip of "a nail" to shape
as a screwdriver.
e Disassembly
Spatula Make from a hack-saw blade
Disassembly Approx. 120mm (4.72in)

f
Assembly
Remove the edge completely

Vinyl tape and make corner round smooth.
Disassembly
g Vise Vise movable over 150mm (6in)
Assembly
h Loctite # 242
i Lubricating oil Hydraulic oil or vaseline
j Cleaning oil
33.2.6.2.2 Apparatus
(1) Hoist or crane
The lifting device should be capable of lifting the swivel joint assy.
(2) Work bench
The work bench should have an area of 1.2m×1.5m (4ft×5ft).
(3) Others
Also prepare cloth, wooden block and oil pan.
33.2.6.2.3 Cleaning outside

Clean the swivel joint to be free from dirt and dust, using steam and cleaning oil.
• Keep all ports plugged up while cleaning.
33-162
33. UPPER STRUCTURE
33.2.6.2.4 Disassembly
The part numbers used in this disassembly procedure 2
correspond to those of a construction drawing in Fig. 1
33-280. 4
9
(1) Removing cover
1) Mark cover (4) and body (1) with matching marks
for convenient reassembly.
2) Place a V-block on a work bench, place a swivel
joint set on the side, fix it and loosen socket bolt
ALLEN WRENCH
(9) by means of a pipe and wrench. Alternately,
the swivel joint may be fixed by holding stem (2) V-BLOCK PIPE
in a vise.
: 6 mm Fig. 33-281 Removing cover (4)

3) Remove cover (4) from body (1) and draw out O-
ring (7) from cover (4).
%
"
Fig. 33-282 Removing O-ring (7)

(2) Removing thrust plate
Loosen socket bolt (8) fastening thrust plate (3), in
the same manner as the removing of the above-

mentioned cover.
: 6 mm

When removing thrust plate (3) by fixing body (1),

support stem (2) so it may not fall down.

Fig. 33-283 Removing thrust plate (3)

(3) Removing stem Wooden block for Secure with hands. 1 BODY
Place body (1) on a V-block. Put a wooden block protector
against stem (2) via the body so about half of the 2 STEM
stem is covered by the wooden block and knock it
out using a mallet.
By hitting out the stem over about 1/2 from the
body, it can be easily pulled out by hand.
Stem weight : 10.5 kg (23 lbs)
WORK BENCH V-BLOCK

Fig. 33-284 Drawing out stem (2)
33-163
33. UPPER STRUCTURE
(4) Removing sealing parts

SPATULA (f)
1) Remove rings (13) of seal assemblies (6) and (5)
with spatula (f).
13
Pay attention to the body (1) not to be damaged by the

top edge of spatula (f).
Fig. 33-285 Removing O-ring (13)

2) Pierce slipper ring of seal assemblies (6) and (5)
with pin (e) and remove them from the seal SLIPPER RING
groove. Fig. 33-286 shows only one pin, but use
two pins to remove it securely.
BACKUP RING
DETAIL (6)
O-RING
GROOVE
SEAL (6) PIN (e) SEAL GROOVE

ASSY
OIL GROOVE
SEAL (5) SEAL GROOVE
Fig. 33-286 Removing out seal assy (5)(6)
33.2.6.2.5 Assembly
Prior to assembly, clean each parts (excluding the O-
ring and seal), and arrange in the sequence of
assembly.
Apply grease on the groove of seal to be installed on
seal assembly (6) and O-ring (13).
(1) Assembling seals to body
1) Apply hydraulic oil to O-ring (13) thinly and insert
it in O-ring groove.
Check the twist of O-ring
33-164
33. UPPER STRUCTURE
2) Slipper ring is assembled, after first inserting the

backup ring, by slightly-distorting the shape as
shown in Fig. 33-287. Also after inserting all of
the seals, be certain that these are installed in
the seal groove by use of the spatula.
3) Assemble seal (5) by the same procedure above
mentioned.
Fig. 33-287 Inserting slipper ring (6)

Remove grease, hydraulic oil and vaseline from the
groove of seal.
And insert seal (5).
Seals (5) have no back-up ring.
(2) Assembling stem

Press in by applying your weight by your hands.
Lightly coat the outer circumference of stem (2) and
the inner surface of body (1) with grease or vaseline
and slowly insert stem (2) into body (1).
2 STEM
• If stem (2) is pressed in too fast, the seal may be

damaged. Do it slowly. O-RING 13
• The clearance between body (1) and stem (2) is 1 BODY

SEAL ASSY 6
about 0.1mm (0.004in). Push stem straight along
the shaft center. SEAL 5
WORK BENCH
Fig. 33-288 Inserting stem (2)

(3) Assembling thrust plate
& !
1) While holding stem (2) and body (1), match the
hole of thrust plate (3) and the stem (2) hole.
2) Next, after removing any oil from the thread of
socket bolt (8), coat it with Loctite #242 and
tighten to stem (2).
: 6 mm,
Fig. 33-289 Tightening socket bolt (8)
33-165
33. UPPER STRUCTURE
(4) Assembling cover

1
After installing O-ring (7) to cover (4) and aligning MATCHING MARK
the matching marks of the cover (4) and body (1),
coat socket bolt (9) with Loctite #242 and tighten it 9
which will then complete assembly.
4
: 6 mm,
ALLEN WRENCH
PIPE
Fig. 33-290 Tightening socket bolt (9)
33-166
33. UPPER STRUCTURE
33.2.6.3.1 Inspection procedure and remedy
Interval Check Item Checking Procedure Remedy

Seal for oil leakage Replace O-ring or dust seal , if any oil
2,000hr Check oil leakage outside
outside leakage can be found.
4,000hr All sealing parts Replace all sealing parts such as slipper
In principle, seal with back-up ring and O-ring.
disassemble All sliding parts
and check re- Check abnormal wear, scoringor
Repair or replace referring to their
gardless of corrosion caused by foreignmatters or
limit of service.
oil leakage or seizure.
not.
When All parts Repair or replace referring to their limit of
Check them for seizure, foreignmatters,
disassembled service.
abnormal wear, anddefect of seals.
for repair O-rings and dust seal should be replaced.
33.2.6.3.2 Service limit of the parts
Parts Maintenance Standards Remedy

Sliding surface with
Plating worn or peeled due to seizure or contamination. Replace
sealing sections
Sliding surface between 1) Worn abnormally or damaged more than 0.1mm
Replace
body and stem other than (0.004in) in depth due to seizure or contamination.
Body, Stem sealing sections 2) Damaged less than 0.1mm (0.004in) in depth. Smooth with oilstone.
1) Worn more than 0.5mm (0.02in) or abnormality. Replace
Sliding surface with thrust 2) Worn less than 0.5mm (0.02in). Smooth
plate 3) Damage due to seizure or contamination repairable
Smooth
within wear limit 0.5mm (0.02in).
1) Worn more than 0.5mm (0.02in) or abnormality. Replace
Sliding surface with thrust 2) Worn less than 0.5mm (0.02in). Smooth
Cover
plate 3) Damage due to seizure or contamination
Smooth
repairable within wear limit 0.5mm (0.02in).
33-167
33. UPPER STRUCTURE
Parts Maintenance Standards Remedy

1) Protruded excessively from seal groove.

Replace
(With back-up ring)

2) Slipper ring 1.5mm (0.06in) narrower than seal groove,

or narrower than back-up ring.
Replace
Slipper ring
(With back-up ring)
1.5mm (0.02in)
(max.)
BACKUP RING
3) Worn unevenly more than 0.5mm (0.02in)
0.5mm (0.02in) Replace

(max.) (With back-up ring)
33-168
33. UPPER STRUCTURE
33.2.6.3.3 Inspection after assembly

After completion of assembly, inspection for oil leakage,
pressure resistance, etc., using a device as shown in
Fig. 33-291.
(1) High pressure port (A,B,C,D and F port)
Install a directional valve and pressure gauge to the

stem side port and body side port respectively, and
while watching the pressure gauge (for high
pressure) installed on the body side and also by
regulating high pressure relief valve (7), gradually

increase the pressure and when the pressure has
reached 1.5 times the maximum working pressure,
close stop valve (3) and lock in the hydraulic oil in
the swivel. Keep stop valve (6) on the low pressure
relief valve side closed at this time.
Check that it is free from looseness, deformation,
breakage, etc. under three minutes pressurizing.
And, the oil leakage must be checked for the first 1
minute, and if there be a pressure drop for any
reason, the pressure drop should be in 10% of the
trapped pressure.
This checking must be carried out for every circuit.

Fig. 33-291 Hydraulic circuit for inspection
equipment
(2) Low pressure port (E port)

Similar to the high pressure port, install a directional
valve and pressure gauge on each port of the stem &# ' (

side and body side. )'%
Open stop valve (6) on the side of low pressure
relief valve (5) and while watching the pressure
!
gauge (for low pressure) connected to the body
" ! " *
side and also by regulating low pressure relief valve
+%,- . /
(5), gradually increase the pressure and check for
outside leakage with a color check at a pressure of !
0.49MPa (71psi). " ! "

## .0 1 % /

!
$ %
33.2.6.3.4 Troubleshooting

1. External leakage of hydraulic oil Defective O-ring & seal Replace all seals.
2. Internal leakage of hydraulic oil 1) Defective slipper seal 1) Replace all seals.
2) Sliding face worn excessively 2) Replace assy.
3. Swivel stem seized 1) Stem and body seized 1) Grind and hone.
Replace assy, if stem and body are too loose
and causing oil leakage.
2) Inappropriate swivel stopper bracket 2) Reinstall
Secure 2~3mm (0.08~0.12in) allowance for
bolt stopper.
4. Loose swivel stem and cover Socket bolt tightened insufficiently. Retighten.
33-169
33. UPPER STRUCTURE
[MEMO]
33-170
34. TRAVEL SYSTEM
TABLE OF CONTENTS

34.1.1 TRAVEL SYSTEM .................................................................................................34-3
34.1.2 CRAWLER..............................................................................................................34-3
34.1.3 UPPER ROLLER ....................................................................................................34-7
34.1.4 LOWER ROLLER ...................................................................................................34-13
34.1.5 FRONT IDLER (IDLER ADJUSTER ASSY) ...........................................................34-20
34.1.6 SPROCKET ............................................................................................................34-29
34.1.7 TRAVEL MOTOR ..................................................................................................34-32
34.1.8 SWING BEARING ..................................................................................................34-34
34.2 REMOVAL AND INSTALLATION OF TRAVEL MOTOR UNIT .......................................34-38
34.2.1 CONSTRUCTION OF TRAVEL MOTOR ...............................................................34-38
34.2.2 TOOLS AND JIGS ..................................................................................................34-43
34.2.3 PREPARATION FOR DISASSEMBLY ...................................................................34-47
34.2.4 ASSEMBLY ............................................................................................................34-63
34.2.5 MAINTENANCE STANDARD.................................................................................34-79
34
34-1
34. TRAVEL SYSTEM

SK125SR : YV05-04501~
S5YY3413E01
(OCE/S.E.ASIA)
SK135SRLC-2 : YH05-07001~
PREFACE
(1) This Manual describes all the procedures from removing to attaching, arranging them by item.
(2) This Manual consists of first part. Removing and attaching, and sequel. Disassembling and assembling.
(3) The removing and attaching can be performed in the procedure specified in Table of Contents, but in view of
(4) The removing and attaching procedure does not completely cover all possible situations because of differences
(5) Please be aware that the procedure to be followed must be determined according to the above conditions.
When disassembly and assembly are required, select the necessary section, itemize the work contents with
good understanding, then starts working.
34-2
34. TRAVEL SYSTEM

34.1.1 TRAVEL SYSTEM
8. SWING BEARING
2. CRAWLER
7. TRAVEL MOTOR
5. FRONT IDLER 6. SPROCKET
GUARD LOWER FRAME
GREASE NIPPLE OF THE 3. UPPER ROLLER
TRACK SPRING ADJUSTER 4. LOWER ROLLER
Fig. 34-1 Designation and location of undercarriage
34.1.2 CRAWLER
34.1.2.1 REMOVING CRAWLER

(1) Position the machine to remove crawler.
(2) Pushing out master pin.
1) Find the master pin and place it in its removing/
fixing position in Fig. 34-3.
2) Loosen the grease nipple and slacken crawler.
: 19 mm
• When loosening the grease nipple of the adjuster,

Fig. 34-2 Crawler removing position
do not loosen it more than one turn.
• Where grease does not come out well, move the
machine back and forth. The over loosening of
grease nipple may cause it to jump out incurring
danger of injury. So be careful not to over loosen
the grease nipple.
3) Pushing out master pin

Apply jig on master pin and strike it out with a
mallet.
(Refer to Fig. 34-7 Press fitting of master pin)

When using a big hammer, wear protective goggles
Fig. 34-3 Removing/fixing position of master pin
and a long-sleeved uniform so you do not injure
yourself by flying objects.
34-3
34. TRAVEL SYSTEM
(3) Removing crawler

REMOVING
Put attachment on ground so that weight is not MASTER PIN
loaded to the lower frame, and remove track link
assy rotating sprocket.
Crawler end section may fall on the ground just before

extending it on the ground incurring danger of injury.
Please keep well away from the equipment.
Fig. 34-4 Removing crawler
34.1.2.2 INSTALLING
(1) Checking crawler installation direction.
Place the track links on the ground so they
converge, facing the front idler, as shown in the

figure on the right.
(2) Installing crawler

1) Preparation for installation
Treat paint flaking protection with care not to
damage lower flame.
Fig. 34-5 Installing direction of crawler
2) Winding crawler
Insert a crowbar into the master pin hole, lift the
lower frame 1 to 2cm above the ground level by
holding it by hand so the machine body weight is
not exerted on the shoe. Retract the sprocket to
help push the back winding of the crawler.
(3) Preparation for press fitting master pin

1) Preparing for installation
Put square wood under the shoe plate.
2) Aligning master pin holes
Aligning master pin holes through fine Fig. 34-6 Winding crawler
adjustment turning sprocket.
• When using a big hammer, exercise care so you

are not injured by flying objects the same way as
when pushing out the master pin.
• Coat the master pin with molybdenum disulfide
grease, before pressing it in.
(4) Press fitting of master pin Press fitting jig

Apply press fitting jig on master pin, and strike it on master pin
with a mallet to press fit. Fig. 34-7 Press fitting of master pin
34-4
34. TRAVEL SYSTEM
(5) Adjusting crawler tension (See Fig. 34-8)

After installing, adjust tension of crawler.
: 19 mm

Fig. 34-8 Adjusting crawler tension
FLAT SHOE
2
1-6
1-1
1-8
1-4
1-3
1-8 TRAIANGLE SHOE
2 GROUSER SHOE 7
1-7 2
1-1
9
1-5 7
1-2 1-7 7
1-2
Fig. 34-9 Track link assy and shoe plate
SK125SR / SK135SR-2 SK135SRLC-2

YY60D00028F1 YY60D00029F1
Shoe assy
Shoe assy
YY60D00028F2 YY60D00029F2
YY60D00028F3 YY60D00029F3
YY60D00028F4 YY60D00029F4
YY60D00028F5 YY60D00029F5
No. NAME Q'TY No. NAME Q'TY
.
1 LINK ASSY YY62D00015F1 1 1 1 1 1 .
1 LINK ASSY YY62D00015F2 1 1 1 1 1
1-1 .. TRACK LINK R 44 44 44 44 44 1-1 .. TRACK LINK R 46 46 46 46 46
1-2 .. TRACK LINK L 44 44 44 44 44 1-2 .. TRACK LINK L 46 46 46 46 46
1-3 .. BUSHING 43 43 43 43 43 1-3 .. BUSHING 45 45 45 45 45
1-4 .. PIN 43 43 43 43 43 1-4 .. PIN 45 45 45 45 45
1-5 .. MASTER BUSHING 1 1 1 1 1 1-5 .. MASTER BUSHING 1 1 1 1 1
1-6 .. MASTER PIN 1 1 1 1 1 1-6 .. MASTER PIN 1 1 1 1 1
1-7 .. COLLAR 2 2 2 2 2 1-7 .. COLLAR 2 2 2 2 2
1-8 .. SEAL 86 86 86 86 86 1-8 .. SEAL 90 90 90 90 90
2 . SHOE 500mm 44 2 . SHOE 500mm 46
. SHOE 600mm 44 . SHOE 600mm 46
. SHOE 700mm 44 . SHOE 700mm 46
. SHOE 500mm 44 . SHOE 500mm 46
. SHOE 800mm 44 . SHOE 800mm 46
7 . BOLT YY60D01004P1 176 176 176 7 . BOLT YY60D01004P1 184 184 184
. BOLT YY60D01008P1 176 176 . BOLT YY60D01008P1 184 184
9 . NUT LP60D01002P1 176 176 176 176 176 9 . NUT LP60D01002P1 184 184 184 184 184
34-5
34. TRAVEL SYSTEM
34.1.2.4 MAINTENANCE STANDARD
F E
D D G
B
Fig. 34-10
Unit : mm (in)
REPAIRAB SERVICE
No. ITEM STANDARD VALUE REMEDY
LE LEVEL LIMIT
A Link pitch 171.45 ± 0.1 (6.750 ± 0.0039) 175 (6.89) 179 (7.05) Replace the link
B O.D. of bushing ø 50.65 ± 0.05 (1.994 ± 0.002) ø 47 (1.85) ø 45 (1.77) assy if the service
C Height of link 89 ± 0.3 (3.504 ± 0.012) 84 (3.31) 82 (3.23) limit is exceeded
Basic
Tolerance Fit Fit
dimension
Interference between bushing + 0.11
D Interference
and link ø 50.67 (+0.004) Interference
Shaft 0.05
(1.995) + 0.05 0
(0.0020) Replace
(+0.002)
+ 0.1
Interference
Interference between track pin ø 33.50 (+0.004) Interference
E Shaft 0.05
and link (1.319) - 0.05 0
(0.0020)
(-0.002)
+ 0.03
Interference
Interference between master ø 33.30 (+0.001) Interference
F Shaft 0.05 Replace Link
pin and link (1.311) + 0.088 0
(0.0020)
(+0.003)
8 (0.32) 10 (0.39)
G Clearance between links 1.5 (0.06) (both side) Replace
(both side) (both side)
H Tightening torque of shoe bolt 412 ± 39 N•m (304 ± 28.8 lbf•ft) Reassembly
34.1.2.5 TOOLS AND JIGS

(1) Tightening tools
Unit : mm (in)
NAME OPPOSING FLATS
24 (0.945)
Socket
(2) Jig
NAME SHAPE
Master pin fixing jig for iron

crawler
34-6
34. TRAVEL SYSTEM
34.1.3 UPPER ROLLER
34.1.3.1 UPPER ROLLER ASSY
ASSY YY64D00004F1 (LC) (01)
No. YY64D00016F1 (STD) (01)
ITEM NAME Q'ty REMARKS

1 ROLLER ASSY 2 4 YY64D01002F1
CAPSCREW (SEMS
2 2 4 M20×P2.5×110
SCREW)
3 NUT 2 4
4 WASHER 4 8
34.1.3.2 REMOVING
Remove crawler (Above mentioned).
3 4 3 4
(2) Removing upper roller (1)
1) Remove nuts on support tightening section, and 1
also remove capscrew (2) M20×110. 1
: 30 mm 2
2
(STD SPEC.) (LC SPEC.)
Fig. 34-11 Removing upper roller
34.1.3.3 INSTALLING
(1) Inspection
Before reassembling, check it that it rotates smooth COUNTER-
manually and for leak. SINKING
(2) Installing upper roller (1)

1) To install the upper roller, turn up socket bolts (2)
toward the center of machine.
2) Insert it until collar comes in contact with support.
3) Fit it directing the countersinking mark of shaft

CENTER OF MACHINE
end upward.
4) Apply Loctite #262 on capscrew M20×110, and

tighten it to the specified torque.
: 30 mm
2 1 3,4
Fig. 34-12 Installing upper roller
34-7
34. TRAVEL SYSTEM
ROLLER ASSY PART NO. YY64D01002F1

No. NAME Q'TY No. NAME Q'TY 11 T=21.6 24.5 N.m (16 18.1lbf.ft)
7 9 T=65.7 N.m (48 lbf.ft) 7 3 2
1 ROLLER 1 FLOATING SEAL 1
2 SHAFT 1 8 O RING : 1A G55 1
3 COLLAR 1 9 SOCKET BOLT 2
4 PLATE 1 10 SNAP RING 1
5 COVER 1 11 PLUG PT1/8 1
6 BUSHING 1
10 8 5 4 6 1
Fig. 34-13 Construction of upper roller

(1) Disassembly 10
9
1) Draining out oil
4 11
Remove plug (11) and drain out oil. 8
5
: 6mm
1
2) Removing snap ring (10)

Mount the end face inside upper roller (1) on
stand jig (f) and separate snap ring (10), using
snap ring pliers.
f
3) Removing cover (5)
Take off cover (5) upwards, utilizing the screwed
hole for the plug.
4) Removing O-ring (8)

Separate O-ring (8) from cover (5). Fig. 34-14 Construction of upper roller
5) Removing plate (4)

Loosen 2 socket bolts (9) and draw out plate (4)
from roller (1).
h
: 10mm
2
6) Removing shaft (2)
Put the extrusion jig (h) against the end face of
7
shaft (2) and push shaft (2) with collar (3) for
floating seal (7), using a press or hammer. 3
Fig. 34-15 Extruding shaft
34-8
34. TRAVEL SYSTEM
7) Removing floating seal (7).

Take out floating seal (7) from roller (1). 7
Fig. 34-16 Taking out floating seal

8) Removing floating seal (7). 2
Remove from collar (3), floating seal (7) that is
located on the side from which shaft (2) was
g
disassembled. 7
6
1
Collar (3) is press fitted into shaft (2). Therefore do not
3
disassemble it. f
Fig. 34-17 Removing floating seal and extruding

bushing
9) Removing bushing (6)
Push with press (e)
Since the bushing is thin, machine it on a lathe or
scrape it off, take care so as not to damage the
bore of roller (1). i
If the bushing is not worn much, mount upper
roller (1) on jig (f), insert jig (g) into the end face
6
of bushing (6) and push it out with a press.
1
(2) Assembly
Assembly of the upper roller is done in the reverse
order of disassembly.
1) Place upper roller (1) on the top end face of jig
f
(f), with its floating seal setting side facing down.
2) Confirm that the outer surface of bushing (6) is Fig. 34-18 Pushing in bushing
not scuffed and coat the outer surface of the
inserting side of the bushing, with molybdenum
2
disulfide grease.
7
3) Put jig (i) into bushing (6) and press it in, using
7
the bore of the bushing and the bore of the roller
1
as guides.
If you fail in this operation by pressing the bushing

unevenly, the bushing is distorted and gets
unserviceable. In that case, do not re-use the bushing Fig. 34-19 Fixing floating seal
as it may develop malfunctioning after assembly.
34-9
34. TRAVEL SYSTEM
4) Installing floating seals (7)

Two floating seals (7) make a pair. Attach one
floating seal to retainer fixed in shaft (2), and
2
another to the inside of upper roller (1).
3
7
• Prior to placing floating seal (7) in, apply
engine oil lightly to seal surface.
1
5) Inserting shaft (2)
Coat shaft (2) with a thin film of oil and insert it
into upper roller (1).
6) Installing plate (4) Fig. 34-20 Inserting shaft

Mount upper roller (1) on the stand jig (f) and
10
attach plate (4) to the end face of the shaft with 9
11
bolt (9). 4
8
: 8mm, 5
Tightening torque : 65.7N•m (48 lbf•ft)
1
7) Installing O-ring (8)

Fit O-ring (8) to the groove of cover (5).
• Apply grease to O-ring.
8) Installing cover (5) f

Attach cover (5) to upper roller (1). Use a press
in this operation as a press fit is used.
9) Installing snap ring (10)

Fix snap ring (10) into upper roller (1), using
snap ring pliers.
Fig. 34-21 Installing cover
10) Filling oil

Fill in 20cc (1.22cu•in) of engine oil API grade
CD #30 through the plug hole in cover (5). 5
11) Installing plug (11) 1

Wind seal tape around plug (11) and screw it into
the plug hole of cover (5).
: 6mm,
Tightening torque :
21.6~24.5N•m (16~18.1 lbf•ft)
f
• After assembling the upper roller, confirm that

oil is not leaking from it and that it rotates
smoothly by hand.
Fig. 34-22 Filling oil
34-10
34. TRAVEL SYSTEM
2(0.079")
D
A
E
F
B C
Unit : mm (in)
REPAIRABLE SERVICE
LEVEL LIMIT
A Dia. ø 99 (3.9) ø 94 (3.7) ø 90.5 (3.56)
B Width 140 (5.51) — —
C Installing length 60 (2.36) — — Replace
D Shaft dia. ø 40 (1.576 ) — —

Basic
Tolerance Fit Fit
dimension
Clearance between - 0.025
E
shaft and bushing (-0.00098) Clearance Clearance
ø 38 (1.496) Shaft
- 0.050 0.7 (0.028) 1.0 (0.039) Replace bushing
(-0.0020)
+ 0.025
Interference between Interference Clearance
F ø 42 (1.654) Hole (+0.00098)
roller and bushing 0 0.01 (0.0004)
0
Tightening torque of
G 65.7 N•m (48 lbf•ft)
socket bolt
Oil Engine oil API grade CD #30, 20cc (1.22cu•in) Refill
Roller rotation Roller rotates smoothly by hand. Reassembly
34-11
34. TRAVEL SYSTEM

Unit : mm
NAME OPPOSING FLATS
30
Socket
Allen wrench 6,8
(2) Jigs
Unit : mm (in)
No. NAME SHAPE
100 (3.94)
+ +
85 1(3.35 0.04 )
f Stand jig
160 (6.30)
1C (0.04) 1C (0.04)
)
)
(1.50 -0.001
(1.50 -0.001
40-0.025
53 (2.09)
38-0.025
0
For extruding
0
g
bushing
(1.58) 40 60 (2.39) 30 (1.18)
130 (5.12)
36 (1.42)
For extruding
h
(1.18)
shaft
38 -0.025
42 -0.025
(1.50-0.001)
(1.65-0.001)
57 (2.24)
0
0
Bushing fixing
i
jig
(0.08) 2 50 (1.97)
100 (3.94)
34-12
34. TRAVEL SYSTEM
34.1.4 LOWER ROLLER
34.1.4.1 LOWER ROLLER ASSY
ROLLER STD YY64D00026F1

ASSY LC(HD) YY64D00028F1
ITEM NAME Q'TY REMARKS
1 LOW ROLLER 14 12 YY64D00027F1
2 CAPSCREW 56 48 M16X75 (P=2.0)
2
Apply Loctite #262 1
T=279N.m (206 lbf.ft)
Fig. 34-23 Lower roller assy and track guide
34.1.4.2 REMOVAL
1) Loosen the tension of the crawler, lift up the
lower frame by the front attachment and stop the
engine in that condition.
2) Place a safety block (wood) at the front and back
of the lower frame. SAFETY BLOCK
(WOOD BLOCK)
(2) Remove lower roller
Remove capscrews (2) and remove lower roller (1). Fig. 34-24 Preparation for removal
: 24 mm,
Weight of lower roller : Approx. 25kg (55 lbs)
Fig. 34-25 Installing lower roller
(1) Installation of lower roller
Coat mounting capscrews (2) with Loctite #262 and
fasten all 4 capscrews temporarily. Then tighten
them to a specified torque.
: 24 mm,
(2) Adjusting tension of crawler
Tighten grease nipple and fill it with grease.
: 19 mm,
34-13
34. TRAVEL SYSTEM
3 15 764
LOWER ROLLER YY64D00027F1
8
No. NAME Q'TY REMARKS

1 ROLLER 1
2 SHAFT 1
3 BUSHING 2
4 PIN 2 2
5 FLOATING SEAL 2
6 O-RING 2 1A G45 Fig. 34-26 Construction of lower roller
7 COLLAR 2
8 PLUG 2 PT1/4

(1) Disassembly
1) Drain oil L
Remove plug (8) and drain out oil.
: 6mm 7
2) Removing pin (4) 4

Put both ends of lower roller assy on the V-
shaped blocks (K), apply push-out bar (L) on
upper end face of pin (4), and push pin (4) out
striking with mallet.
K
3) Removing collar (7), O-ring (6)

Put lower roller on jig (M) for repair stand so that
the shaft (2) is perpendicularly located, apply
Fig. 34-27 Pushing out collar fixing pin (4)
push-out jig (P) on shaft end on upper side, and
push shaft (2) until the O-ring (6) separate from
collar (7) with press or mallet, and take out collar
(7) and O-ring (6). JIG P
6
7
4) Removing shaft (2)
In addition, push out and remove shaft (2) 1
together with the lower collar (7) and O-ring (6).
2
JIG M
The shaft (2) extrusion operation may cause the
remaining lube oil to flow out. Prepare an oil container
beforehand.
Fig. 34-28 Removing shaft (2), collar (7), O-ring (6)
34-14
34. TRAVEL SYSTEM
5) Removing collar (7), O-ring (6)

Remove O-ring (6) from shaft (2) that was drawn 5
out in the previous paragraph.
6) Removing floating seal (5)

Remove floating seal (5) from collar (7). 7
7) Removing floating seal (5)

Remove floating seal (5) from roller (1).
Fig. 34-29 Removing floating seal (5)

8) Removing bushing (3)
Since thickness of bushing (3) is thin [thickness
is 2.0mm (0.079in)], remove it through lathe or
N
strip it with care not damage inner hole of roller.
When the wear of bushing is not large, place
1
upper roller (1) on jig (M) for repair stand and
apply the end of push-out jig on the end face of
bushing (3) end, and push it out striking it with 3
mallet.
JIG M
Hammer the inside surface of roller lightly so as not to

damage the surface. Put the extrusion jig (N) uniformly Fig. 34-31 Extruding bushing (3)
over the circumference of bushing (3) and extrude it
perpendicularly little by little.
34-15
34. TRAVEL SYSTEM
(2) Installing 6 2
1) Attach O-ring (6) to one side
Install O-ring (6) to groove on shaft.
• Grease O-ring.
• Replace O-ring with new one without fail at Fig. 34-32 Attach O-ring (6) to one side
reassembling.
2) Press fitting bushing (3)

Align inner hole of roller (1) and bushing (3) and JIG Q
press fit it vertically in capacity of press fit load,
5ton (11000 lbs), in the condition that bushing 3
push-in jig (Q) is inserted into bushing (3).
• Apply molybdenum disulfide grease on press-

fit section of bushing, and press fit it in
ordinary temperature.
• Bushing which fails to press-fit because of the
one-side pressing should not be fitted. Fig. 34-33 Press fitting bushing (3)
3) Press fitting collar (7) PRESS

Fit O-ring (6) to the one side of shaft (2) mating
pin hole of collar (7) on which floating seal (5) is PIN HOLE
fit with pin hole of shaft (2) in advance. Use the 5
7
press of capacity 17 ton (37500 lbs) or more.
PIN HOLE
2 6
• Care should be taken not to damage O-ring
(6) while press-fitting collar (7) to shaft (2).
4) Inserting pin (4) Fig. 34-34 Press fitting collar (7)

Press-fit pin (4) to pin hole on aligning pin holes
of shaft (2) and collar (7).
5 4
6 7
Fig. 34-35 Inserting pin (4)
34-16
34. TRAVEL SYSTEM
5) Attach floating seal (5) to roller side

Fit floating seal (5) to inner holes on both ends of
roller (1).
1
5
• Check that the seal surface is free from flaws,
rusts, etc. before reusing the floating seal.
2
6) Inserting roller (1)
7
Insert roller (1) from the side where collar (7), 6
O-ring (6) is not press-fitted to the shaft (2).
Fig. 34-36 Inserting roller (1)
PRESS
Install O-ring (6) to groove on shaft.
PIN HOLE
• Grease O-ring.
7
• Replace O-ring with new one without fail at
reassembling. PIN HOLE
6
8) Press fitting collar (7)
Press-fit collar (7) to shaft (2).
2
• Press-fit collar (7) on aligning pin (4) hole.
9) Inserting pin (4)

Press-fit pin (4) in to the pin hole mating pin hole
of collar (7) with pin hole on the end side of shaft
(2).
Fig. 34-37 Installing O-ring (6), collar (7)

10) Filling oil
Remove plug (8) and fill in 150cc (9.2cu•in) of
engine oil API grade CD #30.
11) Check it for leakage 8
Before tightening plug (8), check it for leakage in TIGHTENING
TORQUE
the condition of air pressure 0.2 MPa (29 psi). 21.6~24.5N.m
12) Installing plug (8) (16~18.1 lbf.ft)
Apply oil resistant sealant on plug (8), and
tighten it in the plug hole on the collar (7) end 7
face.
: 6 mm,
Tightening torque : 21.6~24.5 N•m Fig. 34-38 Installing filling oil plug (8)
(16~18.1 lbf•ft)
After assembling the lower roller, confirm that oil is not

leaking and that the roller rotates smoothly by hand.
34-17
34. TRAVEL SYSTEM
C C H
-0.5
+
ce 2.5
Clearan 0.020)
(0.09 8
D
B
E
A
Fig. 34-39 Lower roller (Track roller)
Unit : mm (in)
REPAIRABLE SERVICE
LEVEL LIMIT
A O.D. of flange ø 170 (6.70) — — Reinforcement weld,
B Tread dia. ø 140 (5.51) ø 132 (5.20) ø 126 (4.96) repair or replace
C Flange width 19 (0.748) 14 (0.551) 11 (0.433)
Basic
Tolerance Fit Fit
dimension
Clearance between
- 0.060
D shaft and bushing
ø 50 (-0.00236) Clearance Clearance
(Wrapped bushing) Shaft Replace bushing
(1.96850) - 0.090 0.7 (0.276) 1.0 (0.394)
(-0.00354)
+ 0.030
Interference between ø 57 Interference Clearance
E Hole (+0.00118)
roller and bushing (2.24409) 0 0.01 (0.0004)
0
F Oil Engine oil API grade CD #30, 150cc (9.2 cu•in) Refill
Execute air leak test at 0.2MPa (28psi)
H Plug (8)
before tightening the plug.
Roller rotation Rotates smoothly by hand. Reassembly
34-18
34. TRAVEL SYSTEM

Unit : mm
NAME OPPOSING FLATS
24
Socket
Allen wrench 6
(2) Jig
Unit : mm (in)
No. NAME SHAPE
K V-block
100(3.94)
pin (4)
(0.551)
L
14
extrusion rod
16 (0.630)
200(7.87)
Bushing
N
extrusion rod
290(11.4)
140(5.51)
M Stand jig
(4.33)
110
270(10.6)
Shaft
P
(1.93)
extrusion jig
49
(0.98)
25
70(2.76)
70(2.76)
Bushing
45(1.77)
Q
fixing jig
+0.1
50 0
(1.97 +0.004
0 )
34-19
34. TRAVEL SYSTEM
34.1.5 FRONT IDLER (IDLER ADJUSTER ASSY)
34.1.5.1 FRONT IDLER ASSY
FRONT IDLER ASSY YY52D00010F1 APPLY LOCTITE #262 OR EQUIVALENT

T=115N.m (84.8 lbf.ft) 1-2
No. NAME Q'TY REMARKS 1,1-1
1-4
1 FRONT IDLER ASSY 2 YY52D00011F1
1-1 IDLER ASSY 1 YY52D00007F1
1-2 IDLER ADJUSTER ASSY 1 YY54D00003F1
1-3 GREASE NIPPLE 1
1-4 CAPSCREW 2 M12X35
1-3
T=58.8 9.6N.m
(43.4 7.08 lbf.ft)
Fig. 34-40 Front idler assy
34.1.5.2 REMOVING
Remove crawler. (Above mentioned)
(2) Removing idler assy

Sling idler assy, and push it forward with bar.
Weight of front idler assy : 127kg (280 lbs) BAR
Keep away from the front side of front idler.
(3) Installing
(4) Where idling assy (1-1) has to be separated

Loosen capscrew (1-4), and separate idling assy
(1-1) from idler adjuster assy (1-2).
Fig. 34-41 Removing and installation the front idler
: 19 mm 1-1
Weight of idler assy : 69kg (152 lbs)
Weight of idler adjuster assy : 58kg (128 lbs)
• The separated idling assy (1) should be placed

on square timbers.
1-2
1-4 1-3
Fig. 34-42 Separating idling assy (1-1) from idler

adjuster
34-20
34. TRAVEL SYSTEM
34.1.5.3 IDLER ASSY
IDLER ASSY YY52D00007F1 1

No. NAME Q'TY REMARKS 8
1 YY52D00006P1 4
1 IDLER 6
2 SHAFT 1 5
3 BUSHING 2
4 COLLAR 2 LP52D01009P1
5 PIN 2
7
6 FLOATING SEAL 2 2
7 O-RING 2 1A G55 3
8 PLUG 2 PT1/8
Fig. 34-43 Idler assy
34.1.5.3.2 REMOVING AND INSTALLING

(1) Removing 5
R
1) Drain oil
Remove plug (8) on the side of collar (4) to drain.
: 5 mm
2) Removing pin (5)

Apply pin push bar (jig R) to the top of pin, and
push out striking bar (jig R) lightly by hammer. Fig. 34-44 Removing pin (5)
PUSH WITH PRESS

3) Removing collar (4)
Put idler (1) on stand (U), apply push-out jig (S) 2
S
on shaft (2), push out shaft (2) with collar (4), 4
then remove collar (4). 1
U
4
Fig. 34-45 Removing collar (4)

4) Removing collar (4) from shaft (2) PUSH WITH PRESS
If removal of collar (4) on the opposite side is
S
required, turn over front idler and proceed with
the procedure described in Par. 3). 2
4
Fig. 34-46 Removing collar (4)
34-21
34. TRAVEL SYSTEM
5) Removing bushing (3) 3

1 T
With idler (1) mounted on the stand, tap bushing
(3) lightly by hammer, while placing the bushing
drawing rod (T) against the end face of bushing
(3) evenly all round, till it comes out.
6) Removing floating seals (6)

Take out floating seals (6) from idler (1), collar
(4). If you intend to re-use floating seals (6), U
confirm that there is no scoring and rusting on
the contact surface and store the floating seals
Fig. 34-47 Removing bushing (3)
in pairs by placing card board between the
sealing faces.
7) Removing O-ring (7)

Separate O-ring (7) from shaft (2).
(2) Assembly PUSH WITH
3 PRESS V
1) Pressing in bushing (3)
1
Align inner hole of idler (1) and bushing (3) and
press fit it vertically with press so that jig (V) for
bushing press-fitting is inserted into bushing (3).

Fit O-ring (7) to O-ring groove on shaft (2).
Fig. 34-48 Pressing in bushing (3)
• Apply grease to O-ring
3) Installing collar (4) PRESSING

Press fit the O-ring (7) installed side of shaft (2)
into collar (4), and drive pin (5). 2
4) Installing floating seal (6)

4
Fit the half of floating seal (6) on each side of
5
collar (4) and idler (1).
5) Inserting idler (1)

Fig. 34-49 Installing collar (4), shaft (2)
Insert floating seal (6) fitted side of idler (1) into
shaft (2). 2
6
6) Installing floating seal (6)

Fit floating seal (6) on the other side of idler (1). 1
Fig. 34-50 Inserting idler (1) and installing floating

seal (6)
34-22
34. TRAVEL SYSTEM
7) Installing collar (4)

Fit the half of floating seal (6) on the other collar 8 4
(4), press fit it in shaft (2), and drive pin (5) in with 5
hummer.
8) Filling oil•Inspection 1
Fill in 200cc (12.2cu•in) of engine oil API grade
CD #30 through the plug hole of collar (4), wind
seal tape and tighten plug (8).
: 5 mm
Fig. 34-51 Installing collar (4) and filling oil
• After installing the idler assy to the idler
adjuster assy, make certain that no oil leaks
from floating seal and plug (8) and that idler
(1) rotates smoothly.
34.1.5.3.3 MAINTENANCE STANDARD
132 1.5(5.20 0.059)

C
F
D
E
B
A
Fig. 34-52 Front idler
Unit : mm (in)
REPAIRABLE SERVICE
LEVEL LIMIT
A Dia. of idler projection ø 496 (19.5) — —
B Tread dia. ø 456 (18.0) ø 450 (17.7) ø 448 (17.6) Replace
C Flange width 68 ± 1 (2.677±0.04) 63 (2.48) 60 (2.36)
Basic
Tolerance Fit Fit
dimension
Clearance between shaft and - 0.03
D
bushing ø 60 (-0.00118) Clearance Clearance
Shaft Replace
(2.36220) - 0.06 1.5 (0.059) 2.0 (0.079)
bushing
(-0.00236)
- 0.03 Clearance
Interference between idler and ø 64 Interference
E Hole (-0.00118) 0.01
bushing (2.51969) 0
0 (0.0004)
F Oil Engine oil API grade CD #30, 200cc (12.2cu•in) Refill
Idler rotation Rotates smoothly by hand Reassemble
34-23
34. TRAVEL SYSTEM

Unit : mm
NAME OPPOSING FLATS
24
Socket
Allen wrench 5
(2) Jigs
Unit : mm (in)
No. NAME SHAPE
(0.591)
(1.18)
15
30
R Pin striking jig
(0.591)
105(4.13) 15
300(11.8)
S Shaft push out jig

(2.32)
59
(0.630)
16
300(11.8)
T Bushing drawing rod
Approx.150
(5.91)
Approx.600
(23.6)
U Stand
Approx.
400
(15.7)
2
(0.787)
70(2.76)
20
75(2.95)
Bushing press fitting

V
55(2.17)
jig
60 -0.030
-0.060
(2.36 -0.001
-0.002 )
103(4.06)
W Collar press fitting jig
(1.18)
30
34-24
34. TRAVEL SYSTEM
34.1.5.4 IDLER ADJUSTER ASSY
IDLER ADJUSTER ASSY YY54D00003F1 2 4 3 5 1 8 7 6 9

1 GREASE CYLINDER 1
2 BRACKET 1
3 NUT 1
4 SPRING PIN 1 6X63
5 SPRING 1
10 Apply grease to bleed air.
6 PISTON 1
7 O-RING 1 1B G90
Fig. 34-53 Idler adjuster assy
8 U-PACKING 1
9 PIN 2
10 COVER 1
34.1.5.4.2 DISASSEMBLY AND ASSEMBLY

(1) Disassembly
M30
HOLDING-DOWN NUT
1) Spring set special jig
Before disassembling and assembling the idler RETAINER PLATE
adjuster assy, prepare spring setting jig (V).
Capacity of hydraulic jack : more than 20 tons
(44000 lbs)
V
: 46 mm
HYDRAULIC JACK
Large power is needed to set the spring. Prepare a

BASE
special jig before disassembly and assembly.
Fig. 34-54 Spring set special jig (V)
2) Preparation for working
Place a hydraulic jack between the jig base and
the stand. 2
Loosen the holding-down nuts of the jig and draw

out the retainer plate upward.
: 46 mm
3) Draw out grease cylinder (See Fig. 34-53)
Draw out piston (6) from grease cylinder (1) of 5
the idler adjuster assy.
4) U-packing (8), O-ring (7) (See Fig. 34-53)
U-packing (8) and O-ring (7) from grease
cylinder (1).
V
5) Slinging work idler adjuster
Set the idler adjuster assy on the stand of the jig, Fig. 34-55 Slinging work idler adjuster
with its bracket side facing up.
34-25
34. TRAVEL SYSTEM
6) Fixing idler adjuster assy

Fit retainer plate to bracket (2), tighten holding- 3
down nuts alternately, and secure idler adjuster
assy.
: 46 mm HOLDING-DOWN NUT
RETAINER PLATE
4
Fig. 34-56 Fixing idler adjuster assy
7) Compression of spring (5) #
Remove spring pin (4), press spring (5) lifting it
with jack so that nut (3) can be turned freely, and
remove nut (3).
: Bar ø7.5×120
: 85 mm
Fig. 34-57 Compression of spring (5)

8) Removing bracket (2)
Allow the hydraulic jack to retract slowly till the
spring is extended to its free length. Remove the
retainer plate and take off bracket (2), cover (10). RETAINER PLATE
The free length of the spring : 427 mm (16.8 in)
2
10
Fig. 34-58 Removing retainer plate, bracket (2)

9) Removing spring (5), grease cylinder (1)
Hook lifting eye nut (W) to screw M45×P3 on
9
grease cylinder (1) top end and hoist it. Then,
remove the set of grease cylinder (1) and spring
(5) using crane from the jig.
Remove spring (5), grease cylinder (1), in that
#
order.
Fig. 34-59 Removing spring (5), grease cylinder (1)
34-26
34. TRAVEL SYSTEM
(2) Assembly
Assembly is done in the reverse order of W
disassembly. 1
1) Installing spring (5), grease cylinder (1)
Insert grease cylinder (1), collar (7) into spring
5
(5) and attach lifting eye nut (W) to screw
M45×P3 at the tip of the grease cylinder. Lift the
grease cylinder by crane and erect it in the
center of the jig stand upright.
Fig. 34-60 Attach spring (5) and grease cylinder (1)

2) Fixing idler adjuster assy
to the jig
Install bracket (2), cover (10) on top of spring (5).
Center the rod of grease cylinder (1) and the
holes in bracket (2). Attach the retainer plate and
four holding-down nuts. Fasten the nuts evenly
all round and fix the idler adjuster assy to the jig
body.
(See Fig. 34-64)
: 46 mm
3) Compressing spring (5) and tightening nut (3)
HOLDING-
Extend the hydraulic jack, compress spring (5) to
DOWN NUT
a set length and screw in nut (3) to the screwed
part at the tip of grease cylinder (1). RETAINER
PLATE
Set length of the spring : 354.8mm (14.0in)
2
4) Installing spring pin (4)
4
Tighten nut (3) till the holes for locking spring
3
pins (4) are aligned. Then fit spring pin (4).
10
: 70 mm
1
Fig. 34-61 Compression of spring (5), and attaching

nut (3) and spring pin (4)
5) Removing idler adjuster assy
Remove idler adjuster assy from jig.
Fig. 34-62 Removing idler adjuster assy
34-27
34. TRAVEL SYSTEM
6) Installing U-packing (8), O-ring (7)

1 8 7 6
Fit U-packing (8) and O-ring (7) to grease
cylinder (1).
• Grease U-packing (8) and O-ring (7).
7) Filling grease cylinder (1) with grease.

Fill up grease in cylinder (1), remove the grease
nipple from piston (6) to discharge the inside air,
and press in the piston by hand. GREASE NIPPLE
• Direct grease nipple hole downward to make Fig. 34-63 Grease cylinder (1)
air discharge easier.
8) Installing grease nipple

Tighten grease nipple to piston (6).
: 19 mm,
34.1.5.4.3 MAINTENANCE STANDARD
No. ITEM STANDARD VALUE

A Installed length of spring 354.8mm (14.0 in)
B Free length of spring Approx. 427mm 16.8 in)
C Stroke 39.4mm (1.55in)
D Set length 686mm (27.0in)
E Outside view of piston Nor scoring and rusting
Tightening torque of
F 59N•m (43 lbf•ft)
grease nipple
X E
aa F
C Apply grease to bleed air
A,B
D
X
INSTALL A SPRING WHOSE STARTING POINT AT BRACKET SIDE TO BE 35 DEGREE.
U-PACKING
8 O-RING 35
7 BRACKET
DETAIL aa
SECTION XX
Fig. 34-64
34-28
34. TRAVEL SYSTEM
34.1.6 SPROCKET
34.1.6.1 REMOVING
Remove crawler referring to "34.1.2 CRAWLER",
lift up crawler frame with attachment, and put it on
square timbers to float and stabilize.

(2) Removing sprocket
Loosen 18 capscrews (3) M16×45, for the
attaching of the sprocket by means of a socket and
remove the sprocket (1).
Weight of sprocket : 39kg (86 lbs)
: 24 mm
Fig. 34-66 Removing sprocket
34.1.6.2 INSTALLING
(1) Check before installing
Check the mating portion of the travel reduction unit
and the sprocket, eliminate burrs and
contamination thoroughly and install the sprocket.
(2) Installing sprocket temporarily

Coat the sprocket attaching capscrews with Loctite
#262 and fasten the sprocket temporarily.
(3) Installing sprocket completely

Remove the wooden blocks under the truck frame,
bring the machine down on the ground and tighten
the sprocket.
: 24 mm
Fig. 34-67 Installing sprocket completely
34-29
34. TRAVEL SYSTEM
34.1.6.3 MAINTENANCE STANDARD (YY51D01006P1)
86.69mm NUMBER OF
PITCH 21
(3.4130in) TEETH
SPECIFICATION
ø50.67mm 581.669
ROLLER DIA. PITCH DIA.
(1.9950in) (22.9in)
Unit : mm (in)
171.45 -+1 (6.750 -+0.039 ) B

86.69 62 +0.5
-
)
(3.4130 8.4(0.3307)
97)
(0.
(0.1 5
R5 7)
R
19
R
..55 39) R225
2255(1.00 (1.00 .5
R 39
)
R5
R5 97) (0.1
(0.1 97)
R5 .197
(0.1 R5
C
(0
97)
(22.9 81.669
)
34
(1.3386)
)
D5
P.C.
Fig. 34-68 Sprocket
Unit:mm (in)
REPAIRABLE SERVICE
No. NAME STANDARD VALUE REMEDY
LEVEL LIMIT
ø 594±3 Reinforcement weld,
A O.D. of sprocket ø 586 (23.1) ø 584 (23.0)
(23.4±0.118) repair or replace.
B Width of sprocket teeth 60 (2.36 ) 54 (2.13) 52 (2.05) Replace.
Reinforcement weld,
C O.D. of sprocket bottom ø 510 (20.1) ø 502 (19.8) ø 500 (19.7)
repair or replace.

(1) Tools
Unit : mm
NAME OPPOSING FLATS
24
Socket
34-30
34. TRAVEL SYSTEM
(2) Sprocket tooth profile gauge : W
Unit : mm (in)
R5 7)
9
.1
(0
8.4 (0.3307)
.0 .5
171.45 +-1 (6.750 +-0.039 )
9)
(1 R25
03
7)
R5
19
(0.
+0.5
-62
R5 197)
.5 )
25 039
(0.
.0
(1
R
)
197
(0. 5
R
.4130)
86.69 (3
Fig. 34-69 Tooth profile gauge (Full scale)
34-31
34. TRAVEL SYSTEM
34.1.7 TRAVEL MOTOR
34.1.7.1 TRAVEL MOTOR
INSTALL ASSY YY53D00006F1

1 TRAVEL MOTOR ASSY 2 YY53D00007F1
2 CAPSCREW 40 M16X45
2
APPLY LOCTITE #262
OR EQUIVALENT
TIGHTENING TORQUE:
279 N.m(206 lbf.ft)
Fig. 34-70 Installing travel motor
34.1.7.2 REMOVING
Remove crawler, lift up crawler frame using
attachment, and put it on square timbers to float
and stabilize.
(2) Removing cover (1)
Remove sems bolt (4) M12×25 and also remove
covers (1).
4
: 19 mm
1
(3) Preparation of oil pan
(4) Removing hydraulic pipe
Release pressure from travel circuit, and bleed air Fig. 34-71 Removing and installing cover (1)
in hydraulic oil tank, then remove all pipes
connecting to travel motor. Then plug up all pipes
and joint section to protect them from entry of dust.
: 19mm, 27mm, 36mm

Refer to "Hydraulic pipe plug" 5.1
(See Chapter 11. TOOLS)
"Plug for flare hose" 5.2 (3) (See Chapter 11.
TOOLS)
Fig. 34-72 Removing and installing hydraulic pipe
34-32
34. TRAVEL SYSTEM
(5) Removing sprocket

Removing eighteen (one side) capscrews (3A)
M16×45.
: 24 mm
3A
Fig. 34-73 Removing and installing sprocket
(6) Loosening travel motor attaching bolts (3) REMOVE PIPES (DISCONNECT)
Apply match marks on travel motor and crawler
frame, and remove twenty (one side) capscrews (3)
M16×45.
: 24 mm
Fig. 34-74 Removing and installing travel motor

attaching bolts
(7) Slinging travel motor assy
Sling travel motor with nylon sling applied on the
side close to sprocket installing section and remove
the motor.
Weight of motor : About. 103kg (227 lbs)
Fig. 34-75 Slinging travel motor
34.1.7.3 INSTALLING
Installing of the travel motor piping is performed in the TOOLS TIGHTEING
NAME SIZE HEX NO.
TORQUE REMARKS
reverse order of removal. N.m(lbf.ft)
1) Cleaning SEMS BOLT M12 19 6 83.4 (61) APPLY

Check that contact surface of travel motor and LOCTITE
crawler frame is free from burr and stain. CAPSCREW M16 24 3 279 (206) #262
2) Tightening torque FLARELESS 10X1.5 19 - 49(36)

NUT FOR -
Tighten capscrew and hydraulic pipes to the PIPES, 15X2.0 27 118(87)
torque specified in "Tightening Torque". SLEEVE 22X3.0 36 - 216(159)
PF1/4 19 - 29.4(21.7)
3) Fill inside from motor drain port to casing with HOSE
CAP PF1/2 27 - 78.5(57.9)
hydraulic oil before piping for drain. When
PF1/4 19 - 36.3(27)
starting operation, operate motor in low idling
CONNECTOR PF1/2 27 - 108(80)
and at low speed for several minutes, and check -
PF3/4 36 162(119)
it for possible oil leakage and noise.
34-33
34. TRAVEL SYSTEM
34.1.8 SWING BEARING
34.1.8.1 SWING BEARING ASSY
SWING BEARING ASSY YY40F00008F1

No. NAME Q'TY REMARKS INNER S ZONE
POSITION OF
1 SWING BEARING 1 YY40F00009F1
SWING BEARING
2 CAPSCREW 36 M16XP2.0X45
LOCTITE #262
OR EQUIVALENT
2
TO BE APPLYD
T=279N.m SECTION AA
(206 lbf.ft)
Fig. 34-76 Swing bearing assy
34.1.8.2 REMOVING
(1) Matchmarks

Remove upper structure, apply matchmarks on
inner race of swing bearing and lower frame.

(2) Remove 36 capscrews (2) M16×45 for installation
inner race.
: 24 mm
(3) Removing grease

Remove grease in grease bath.
Fig. 34-77 Matchmarks
(4) Removing swing bearing

Attach eyebolt on swing bearing and sling it.

Weight of swing bearing : 150kg (331 lbs)

Fig. 34-78 Removing and installing swing bearing
34-34
34. TRAVEL SYSTEM
34.1.8.3 INSTALLING
(1) Cleaning
Clean it completely so that installing surfaces of
swing bearing and lower frame are free from dust INNER S ZONE
POSITION OF
and dirt. SWING BEARING
(2) Installing
Install swing bearing on lower frame meeting the
matchmarks and positioning the S mark on inner
race as shown in Fig. 34-79.
(3) Temporary fastening of inner race
Coat the threads of the capscrews (2) with Loctite
#262 and tighten all the capscrews (2) temporarily.
: 30 mm
(4) Regular tightening of inner race
Tighten the capscrews (2) at 180 degrees intervals
alternately to a specified torque. Fig. 34-79 Location of S mark on swing bearing
: 24 mm,
(5) Filling grease
Fill grease bath with 8.2kg (18 lbs) of Nihon grease 1
(NIHON GREASE CO.LTD EP-2K) or equivalent. LOCTITE #262 OR 2
EQUIVALENT
TO BE APPLIED
T=279N.m (206 lbf.ft) SECTION AA
Fig. 34-80 Removing and installing capscrew (2)
6
SWING BEARING YY40F00009F1
1 1-2
No. NAME Q'TY No. NAME Q'TY
9
1 OUTER RACE 1 4 RETAINER 105
1-3
1-2 PLUG 1 5 SEAL 1 3,4
1-3 TAPER PIN 1 6 SEAL 1
5
2 INNER RACE 1 9 GREASE NIPPLE(PT1/8) 1 2
3 BALL 105
Fig. 34-81 Sectional view of swing bearing

(1) Disassembly
1) Remove seal (5) fitted in the groove in the outer EYE BOLT
6 2
circumference under inner race (2) and seal (5) 1-3
fitted in the groove in the inner circumference on
1
top of outer race (1) and place them level on a
SQUARE WOODEN
square wooden block or something. BLOCK
2) Remove taper pin (1-3), using a hammer and an
extrusion rod. 1-2
3) Remove plug (1-2), utilizing an pull bolt inserted 5
in the screwed hole (M10) in the center of the
plug and using a puller. Fig. 34-82 Disassembling swing bearing
34-35
34. TRAVEL SYSTEM
4) While rotating outer race (1) little by little, take out

ball (3) and retainer (4) through plug hole, in that
order.
"
!
Fig. 34-83 Removing balls (3) and retainers (4)
(2) Installing
1) Thoroughly degrease the groove for seal (5)
located on the inner surface of outer race (1) and
the groove for seal (5) located on the outer
surface of inner race (2). Coat the grooves with
adhesive Cyano Bond PX-3000 and fit seal (5).
Then direct the seal (5) side downward and
place it on wood blocks horizontally.
2) Lower outer race (1) to the position where upper

surface of inner race (2) and lower portion of seal
groove is mated, put adjusting washer under Fig. 34-84 Fitting balls (3)
outer race (1) so that outer raceway surface of
ball (3) aligns with inner raceway, and support it. EYE BOLT
3) Insert ball (3) and retainer (4), on which grease
is applied, through plug (1-2) hole on outer race
(1), alternately. HOOKED ROD
To insert ball (3) and retainer (4), use a push rod, etc., 4
to protect persons from injury from inserting fingers into SQUARE
plug hole. WOODEN BLOCK
Fig. 34-85 Fitting retainer (4)
4) Fit plug (1-2) to outer race (1) while checking it
for direction and position of taper pin hole.
5) Coat seal (5) with adhesive Cyano Bond PX-
3000, and apply Cyano Bond PO-X to joint of
seal and glue seal together.
6) After completion of assembly, caulk the edge of
taper pin (1-3) by punching.
7) Check that grease nipple (9) is properly fitted,
and fill it with grease. Then, check bearing for
smooth rotation and flaws on seal lip portion.
• Shell Albania EP#2 ; 140cc (8.54cu•in)

Maintenance standard concerning wear of swing bearing is described in the section 13.6 MEASURING SWING
PERFORMANCES of "Maintenance Standard and Test Procedure" in this manual.
34-36
34. TRAVEL SYSTEM
34-37
34. TRAVEL SYSTEM
34.2 REMOVAL AND INSTALLATION OF TRAVEL MOTOR UNIT

34.2.1 CONSTRUCTION OF TRAVEL MOTOR
34.2.1.1 CROSS-SECTIONAL VIEW OF TRAVEL MOTOR ASSEMBLY

Fig. 34-86 Cross-sectional view of travel motor unit assembly (1/2)
34-38
34. TRAVEL SYSTEM

Fig. 34-87 Cross-sectional view of travel motor unit assembly (2/2)
34-39
34. TRAVEL SYSTEM
34.2.1.2 EXPLODED VIEW OF REDUCTION UNIT
24
22
29
24
29
23
33
32
34 35
14
13
4
36
15
6
16
3
8
10
7 17
30
31
11
27
5
11
12
28
9
12
Fig. 34-88
34-40
34. TRAVEL SYSTEM
34.2.1.3 EXPLODED VIEW OF HYDRAULIC MOTOR
116
115
135
324 112
336 139
328 109
325
326 341
331 377
354
327 301
330
380 383358
352 113
353 150
329
398 376
396 358 352 343 323

327
353
358 352
381 383
380 379
366 330
398 378 331
363 399 398 326
359 208 201 325
357 384 210
208 207 328
210
209 336
324
212
203
103
204 202
106
105
213 206
211 107
205
108
151
104
110
114
110
145 132
149
102
171
167
185
161
162
Fig. 34-89
34-41
34. TRAVEL SYSTEM
No. NAME Q'TY No. NAME Q'TY No. NAME Q'TY

1 HUB 1 105 •••PISTON 1 213 •SHIM 1
2 SPINDLE 1 106 •••SHOE 1
CARRIER 1 ASSY 1 104 •CYLINDER BLOCK 1 REAR FLANGE ASSY 1
3 •CARRIER 1 1 107 RETAINER PLATE 1 •REAR FLANGE KIT 1
5 •PLANETARY GEAR 1 3 108 THRUST BALL 1 ••SPOOL ASSY 1
6 •CARRIER PIN 1 3 109 TIMING PLATE 1 323 •••SPOOL 1
11 •THRUST WASHER 1 6 110 WASHER 2 326 •••PLUG 2
16 •PARALLEL PIN 1 3 112 PISTON 1 327 •••VALVE 2
27 •NEEDLE ROLLER BEARING 3 113 SPRING 10 330 •••SPRING 2
CARRIER 2 ASSY 1 114 SPRING 1 331 •••O-RING 2
7 •CARRIER 2 1 115 FRICTION PLATE 3 301 ••REAR FLANGE 1
9 •PLANETARY GEAR 2 3 116 MAITING PLATE 4 324 •PLUG 2
10 •CARRIER PIN 2 3 132 OIL SEAL 1 325 •WASHER 2
12 •THRUST WASHER 2 6 135 O-RING 1 328 •SPRING 2
17 •PARALLEL PIN2 3 139 O-RING 1 329 •ORIFICE 2
28 •NEEDLE ROLLER BEARING 3 145 SNAP RING 1 336 •O-RING 2
4 SUN GEAR 1 1 149 BALL BEARING 1 352 •PLUG 3
8 SUN GEAR 2 1 150 BALL BEARING 1 353 •BALL 2
13 THRUST PLATE 1 151 NEEDLE ROLLER 3 354 •HEXAGON SOCKET PLUG 5
14 COVER 1 PISTON ASSY 1 357 •PLUG 1
15 COUPLING 1 161 •PISTON 1 358 •O-RING 3
22 LOCK WASHER 2 162 •SHOE 1 359 •O-RING 1
23 SHIM 1 167 PIVOT 2 363 •SPOOL 1
24 ANGULAR BALL BEARING 2 171 PARALLEL PIN 2 366 •SPRING 1
FLOATING SEAL KIT 1 185 SPRING 1 376 •ORIFICE 1
29 •FLOATING SEAL 2 377 •FILTER 1
30 PLUG 3 RELIEF ASSY 2 378 •BALL 1
31 O-RING 3 201 •VALVE SEAT 1 379 •PLUG 1
32 O-RING 1 202 •VALVE 1 380 •PLUG 2
33 O-RING 2 203 •SLEEVE 1 381 •PISTON 1
34 PARALLEL PIN 2 204 •COLLAR 1 383 •O-RING 2
35 HEXAGON SOCKET BOLT 12 205 •PLUG 1 384 •ORIFICE 2
36 SNAP RING FOR HOLE 1 206 •SPRING 1 396 •HEXAGON SOCKET PLUG 2
207 •O-RING 1 398 •HEXAGON SOCKET PLUG 8
102 SHAFT 1 208 •BACK-UP RING 2 399 •NAME PLATE 1
103 SWASH PLATE 1 209 •O-RING 1 341 PARALLEL PIN 1
CYLINDER & PISTON KIT 1 210 •BACK-UP RING 2 343 HEXAGON SOCKET BOLT 10
•PISTON KIT 1 211 •O-RING 1
••PISTON ASSY 9 212 •O-RING 1
34-42
34. TRAVEL SYSTEM
34.2.2 TOOLS AND JIGS

(1) Standard tools
NAME SIZE Q'TY

2.5 (For M5), 3 (For M6),
4 (For NPTF1/16), 5 (For PF1/8),
HEXAGON WRENCH 1 each
6 (For PF1/4), 8 (For M10, PF3/8),
10 (For M12, PF1/2)
SOCKET WRENCH
(Ratchet handle) Barrel type 1
(JIS B 4641)
Dial type : Approx. 50N
TORQUE WRENCH Dial type : Approx. 100N
1 each
(JIS B 4650) Dial type : Approx. 300N
Dial type : Approx. 560N
TORQUE WRENCH ADAPTER 1 each
HEXAGON SOCKET Opposite side : 24mm, 41mm 1 each
EXTENSION BAR
150mm 1
(JIS B 4637)
HAND HAMMER Various kinds 1 each
PLASTIC HAMMER Approx. L=400mm 1 each
FLAT-BLADE SCREWDRIVER Approx. 50mm
1
(JIS B 4609) Approx. 150mm
For shafts
SNAP RING PLIERS 1 each
For holes
CUTTING PLIER
200mm 1
(JIS B 4623)
Lifting load 2940N (662 lb) or more 1
Eyeboly (For M16) (2)
LIFTING TOOL Eyeboly (For M12) (3)
Eyeboly (For PF1/2) (2)
Wire with hook (1)
RECEPTACLES Volume : W450×D300×H120mm 2
LEATHER GLOVES 1 pair
(2) Bolts
No. NAME TYPE / DIMENSIONS Q'TY

HEXAGON SOCKET
1 CAPSCREW Approx. M12 (P1.5)×40mm 2
(JIS B 1176)
34-43
34. TRAVEL SYSTEM
(3) TIGHTENING TORQUE
APPLICATION BOLT•NUT OPPOSING TIGHTENING

ITEM FLATS Q'TY TORQUE
NAME SIZE (mm)
(No.) N•m (lbf•ft)
30,357 PLUG PF1/2 10 4 98.1 (72.4)
HEXAGON SOCKET
35 M10 (P1.5) 8 12 66.7 (49.2)
CAPSCREW
203 SLEEVE PF1/2 24 2 98.1 (72.4)
205 PLUG PF1/4 6 2 29.4 (21.7)
324 PLUG M36 (P1.5) 41 2 441 (325)
HEXAGON SOCKET M12
343 10 10 102 (75.2)
CAPSCREW (P1.75)
352 PLUG PF1/8 5 3 12.3 (9.07)
HEXAGON SOCKET
354 NPTF1/16 4 5 9.81 (7.24)
CAPSCREW
380 PLUG PF3/8 8 2 58.8 (43.4)
HEXAGON SOCKET
396 PT1/4 6 2 29.4 (21.7)
CAPSCREW
HEXAGON SOCKET
398 PT1/8 5 6 12.3 (9.07)
CAPSCREW
(4) Tools
NAME SIZE APPLICATION ITEM (No.)

Product disassembly /
GENERAL WORK BENCH
assembly
WASHING TANK For rough and finish washing Product / parts washing
24 : Press capacity
9800N (2205 lb) or more
104 : Press capacity
PRESS MACHINE 24, 104, 149
1960N (441 lb) or more
149 : Press capacity
1960N (441 lb) or more
Heating capacity : over 100°C (212°F)
HEATING TANK 149
Volume : 500×500×500 (19.7"×19.7"×19.7") or more
Pressure : 0.29~0.49MPa
COMPRESSED AIR For drying washed parts
(42~71 psi)
34-44
34. TRAVEL SYSTEM
(5) Jigs
No. NAME No. NAME

Working bench for travel motor Inserting jig for lock washer
1 5
This is used to carry out the work for assembly and For inserting lock washer (22) into spindle (2).
disassembly of travel motor easy and safe.
Retainer metal (I) Press fit jig for main bearing
2 6
• For inserting spring (114), washer (110) and

snap ring(145) into cylinder block (104).
• For removing spring (114) from cylinder block For press fitting angular ball bearing (24) into hub
(104). (1).
Retainer metal (II) Steel rod (I)
3 7
For removing ball bearing (149) from or inserting it For removing angular ball bearing (24) from hub
onto shaft (102). (1).
Press fit jig for oil seal Long eye bolt
USE "A"
HUB M16
4 8
HUB M10
SPINDLE M16
"A" GM MOTOR M16
For press fitting oil seal (132) into the oil seal hole
the spindle (2). For lifting the GM motor, spindle (2) and hub (1).
34-45
34. TRAVEL SYSTEM
No. NAME No. NAME

Slice Floating seal (F/S) fitting tool (II)
9 11
For removing timing plate (109) from rear flange For installing floating seal (29) to hub (1) and
(301). spindle (2).
Floating seal (F/S) fitting tool (III)
Floating seal (F/S) fitting tool (I)
10 12
For installing floating seal (29) to hub (1).

For installing floating seal (29) to spindle (2).
34-46
34. TRAVEL SYSTEM
34.2.3 PREPARATION FOR DISASSEMBLY
34.2.3.1 GENERAL PRECAUTIONS FOR DISASSEMBLY
• Internal parts are covered with hydraulic fluid and gear oil during disassembly and are slippery.
If a part slips out from your hand and falls, it could result in bodily injury or could damage the part.
Be very careful for handling.
• It combustibles such as white kerosene are used for washing parts, be careful for handling.
These combustibles are easily ignited, and could result in fire or injury.
Be careful for handling.
(1) Before disassembling, perform inspections and confirm clearly the indication of no abnormality, which may be
occurring, and work according to the disassembly procedure.
(2) All parts are manufactured precisely.
Be careful for handling.
Avoid rough contact or drop of parts.
(3) Do not bang or remove parts forcefully.
Such act could cause burs or damages on the parts, which leads to failure of assembling or inferior performance.
(4) If you leave parts disassembled parts or with partially disassembling, rust could develop on the parts due to
moisture or dirt.
If you have to interrupt the work before completion, take measures to protect against rust or dust.
(5) Place a counter mark on mating faces of parts when disassembling.
(6) Tidy removed parts when disassembling so as not to damage or lose the parts while working.
(7) As a rule, once any type of seal are disassembled, they should be replaced with new ones even if they show no
signs of damage.
You should ready new parts before disassembling.
New parts shall be provided prior to disassembling.
(8) The photographs and drawings contained in the manual are of representative models.
However, disassembly procedure is not affected even if the disassembled product are different from this manual.
34.2.3.2 CLASSIFICATION OF DISASSEMBLY

This travel motor assembly consists of hydraulic motor, reduction unit, brake valve, and parking brake as one
assembly.
The disassembly works consist of the following items basically.
Select the required parts to disassemble between hydraulic motor, reduction unit, brake valve, and parking brake.
Decide the order of parts to be disassembled, and perform a service work according to the respective maintenance
procedure.
Don't perform unnecessary disassembly.
34-47
34. TRAVEL SYSTEM
34.2.3.3 DISASSEMBLY PROCEDURE
(1) Cleaning travel motor. (15) Disassemble brake valve section on rear fiange.
(2) Place travel motor. (16) Disassemble the 2-speed selector valve.
(3) Drain lubricating oil. (17) Disassembling the piston.
(4) Remove cover. (18) Disassembling the check ball.
(5) Remove thrust plate. (19) Disassembling the parking brake.
(6) Remove 1st stage planetary gears. (20) Disassemble hydraulic motor.
(7) Remove coupling. (21) Take out spring from cylinder block .
(8) Remove 2nd stage planetary gears. (22) Pull out shaft (102).
(9) Remove lock washer. (23) Remove the ball bearing (149) inner race.
(10) Remove hub. (24) Remove the ball bearing (149).
(11) Remove floating seal. (25) Remove spindle.
(12) Remove angular ball bearing. (26) Rough cleaning of every part.
(13) Remove rear flange. (27) Finish clean.
(14) Remove parts installing rear flange.
34.2.3.4 WEIGHT OF COMPONENT
NAME Weight [kg (lbs)]

TRAVEL MOTOR ASSY Approx. 145 (320)
HUB Approx. 46 (101)
SPINDLE Approx. 27 (60)
CARRIER 1 ASSY Approx. 12 (26)
CARRIER 2 ASSY Approx. 24 (53)
REAR FLANGE ASSY Approx. 13 (29)
34-48
34. TRAVEL SYSTEM
34.2.3.5 REMOVING
(1) Cleaning travel motor
1) Tighten the eye bolts into the tapped holes of the EYE BOLT
spindle (2).
Eye bolt ; M16 2
Fasten two eye bolts into the tapped holes for the
spindle so they are located diagonally opposite to one
another.
2) Place a wire sling in the eye bolts, lift the travel

motor by hoist, and carry in to the cleaning bath. Fig. 34-90 Attaching eye bolt
Travel motor assy weight :
Approx. 144kg (320 lbs)
3) Clean the travel motor with a car brush.
Since soil and sand are entered in the clearance

(where the floating seal is fixed) between hub (1) and

spindle (2), clean it with particular care.
Fig. 34-91 Cleaning travel motor

(2) Installing travel motor
1) Placing travel motor on working bench.
Align threaded holes of hub (1) and working bench, and

place travel motor in fixing hole of working bench
slowly.
Fig. 34-92 Placing travel motor on working bench

2) Fix travel motor with two socket bolts on working
bench.
: 14 mm
Tighten 2 socket bolts securely. Failure to tighten

securely, when the travel motor is reversed, it falls and
causes injury.
Fig. 34-93 Fixing travel motor on working bench
34-49
34. TRAVEL SYSTEM
(3) Draining lubricating oil.
If you want to disassemble only the rear flange, go to 35, 31

(6) 1).
1) Turn over the travel motor.

30
Loosen plug (30) slowly to avoid spurt of lubricating oil.

2) Loosen and remove two socket plugs (30) to
release inner pressure.
: 10 mm
When draining out the lubricating oil, place a container

under the work bench.
4) Draw out the lube oil by reversely turning the

travel motor slowly.
5) Remove O-rings (31) from removed plugs.
EYE BOLT (PT1/2)

Do not reuse removed O-ring (31).
14
(4) Removing cover.
1) Turn over the travel motor.
2) Remove ten socket bolts (35).
: 10 mm
3) Because sealant is applied between cover (14)
and hub (1), hit upward the corner of cover with
a hammer using soft metal to protect the cover. Fig. 34-95 Removing cover (14)
The cover (14) may jump and remove suddenly by

hitting. Be careful not to drop the cover to avoid injury.
13
4) Place a hook and a wire sling on the PT eye
bolts, lift it up and remove cover (14).
(5) Removing thrust plate
1) Removing thrust plate (13)
Fig. 34-96 Removing thrust plate (13)
34-50
34. TRAVEL SYSTEM
(6) Removing 1st stage reduction gear

1) Remove sun gear 1 (4) by hand.
Be careful not to drop sun gear 1(4) it could be slippery

by lubricant.
2) Fasten 3 eyebolts to the tapped holes of carrier

1 (3). And attach wire slings and hook in the eye
bolts. Lift the carrier (1) assembly with hoist.
Fig. 34-97 Removing sun gear 1 (4)
When carrier (1) assembly is lifted with hoist, the edge

of planetary gear 1 (5) may damage the internal teeth
of hub (1).
3
Align center line of hub (1) with that of carrier 1
assembly, lift carrier 1 slowly and straightly.
Fig. 34-98 Removing carrier 1 (3) Assy

(7) Removing coupling
1) Remove coupling (15) from shaft (102) 15
(8) 2nd stage reduction gear removal

1) Fasten three eyebolts to the tapped holes of
carrier 2 (7).
Place a wire sling and hook in the eyebolts, lift
carrier 2 assembly by crane. Fig. 34-99 Removing coupling (15)
When carrier 2 assy is lifted by crane, the edge of 7

planetary gear 2 (9) could damage the internal teeth of
hub (1).
Lift up slowly, and carefully.
2) Remove sun gear 2 (8) by hand.
Be careful not to drop sun gear 2 (8).

Fig. 34-100 Removing carrier 2 assy (7)
If could be slippery by lubricant.
34-51
34. TRAVEL SYSTEM
(9) Removing lock washer

1) Fix hub (1) and workbench with using three holes
(ø14) of hub (1).
Fig. 34-101 Removing hub (1) and lock washer

2) Put a flathead screwdriver into the clearance
between two lock washers (22), and widen the
clearance.
Place the tip of the screwdriver to the one end of
the lock washers (22), tap it by hammer, and
remove two lock washers (22).
22
(10)Removing hub
Fig. 34-102 Removing lock washer (22)
1) Remove the hexagon socket bolts, which fixed
hub (1) and workbench. 1
2) Fasten two eyebolts on the tapped holes of
spindle (101).
Place a wire sling and hook in the eyebolts. Lift
hub (1) by crane.
Lift up hub (1) slowly and carefully.

If hub (1) is inclined against spindle (2), for the
interference, wire sling or eyebolts could be
destroyed and hit the worker. If hub (1) does not Fig. 34-103 Removing hub (1)
come out smoothly, do not pull forcefully. Instead,
use other tools such as press machine.
(11)Removing floating seal

1) Grasp inner side of floating seal (29) and lift it up
by hand.
Use work gloves to prevent from cutting hands at the

edge of floating seal (29). If lifting up by hand is difficult 29
by mudpack or such reason, use flat head screwdriver
as a lever. Fig. 34-104 Removing floating seal (29)
34-52
34. TRAVEL SYSTEM
(12)Removing angular ball bearing

1) Put a steel rod on the inner race of angular
bearing (24), tap 3 or 4 points evenly to take care 24
not to damage the bearing.
• Do not remove the angular ball bearing (24), except

for replacing the bearing.
When the outer race of angular ball bearing (24)
separates from fitness hub (1), angular ball bearing
(24) falls from hub (1 ).
Fig. 34-105 Removing angular ball bearing (24)
• Please place a container under the workbench and
cover with the rubber mat on it so that angular ball
bearing (24) does not get damage. 324
(13)Removing rear flange

1) Turn over GM motor. (Rear flange (301) is on
top.)
This work is carrying out to remove easily the pugs

(324) at the following work.
Do not loosen the plugs (324) if the inside of rear flange
Fig. 34-106 Removing plugs (324)
assembly is not disassembled.
2) Temporarily loosen plugs (324) (2 plugs). 380

3) Temporarily loosen plugs (380) (2 plugs).
352,357

4) Temporarily loosen plugs (352) (2 plugs).

Fig. 34-107 Removing plugs (380), (352), (357)

5) Temporarily loosen plugs (357).
This work is carrying out to remove easily the pug (357)

at the following work.
Do not loosen the plug (357) if the inside of rear flange
34-53
34. TRAVEL SYSTEM
6) Temporarily loosen relief valve assy (203 others)

(2pcs).
7) Loosen the relief valve assemblies (203 others)
(2 pcs).
203
Fig. 34-108 Temporarily loosen

relief valve Assy (203)
8) Remove the relief valve assemblies (203 others)
(2 pcs).
Do not reuse O-ring (207), (209), (212) and backup ring

(208), (210) which have been removed.
203
Fig. 34-109 Removing the relief valve Assy (203)

9) Loosen and remove hexagon socket bolts (343)
(10 pcs) from rear flange (301).
: 8 mm
10) Remove rear flange (301) from spindle (2).

!"!
Fig. 34-110 Removing socket bolts (343)
Hold rear flange (301) with both hands, hold up rightly
and gently, and remove it. !
Timing plate (109) could fall off and get damaged
during this work.
11) Removing ten springs (113).

'!"
12) Removing parallel pins (341) from spindle (2). !
13) Removing O-ring (27), (30) from spindle (2).
Do not reuse O-ring (27), (30) which have been

removed. Fig. 34-111 Removing rear flange (301)
34-54
34. TRAVEL SYSTEM
14) Pull out parallel pins (34) (2 pcs) from spindle

(2).
Fig. 34-112 Removing parallel pins (34)

15) Remove O-ring (32), (33) (2 pcs) from spindle
(2).
Do not reuse O-ring (32), (33) which have been

removed.
Fig. 34-113 Removing O-ring (32), (33)

(14)Removing the rear flange fittings
1) Place rear flange (301) on a work bench, with the
mating surface for spindle (2) facing up.
2) Remove timing plate (109) from rear flange
(301).
301(341)
If it is hard to remove the rear flange in some cases as

the mating surface of it is stuck with oil, insert a spatula
into the draft groove of the mating surface on the rear 150
flange side and hold the timing plate up. Then the rear
Fig. 34-114 Removing ball bearing (150)
flange comes off. If a sharp tool like screwdriver is put
into the mating surface, the mating surface is scored,
causing an oil leakage ; do not use sharp tools.
3) Remove parallel pins (341) from rear flange

(301).
4) Remove ball bearing (150) from rear flange
(301).
34-55
34. TRAVEL SYSTEM
(15)Removing the brake valve from the rear flange.

1) Remove two plugs (324) from rear flange (301).
: 36 mm
301
2) Remove O-ring (336) from plug (324).
324(336)

3) Remove two spring retainer (325) and two
springs (328) from rear flange (301).
4) Remove spool (323) from rear flange (301).
301
To remove spool (323), place your hand on one part of

328
the plug port of rear flange (301) and tilt it down. Then
spool (323) falls down. Hold the tip and remove it.
323 328 325

Fig. 34-116 Removing spool (323)
(16)Disassemble the 2-speed selector valve
1) Remove plug (357) from rear flange (301).
: 10 mm
357(359)
301

2) Remove spool (363) and spring (366) from rear
flange (301).
301
363,366
Fig. 34-118 Removing spool (363) and spring (366)
34-56
34. TRAVEL SYSTEM
(17)Removing piston 380(383)

1) Remove plugs (380) (2 pcs) from rear flange
(301).
Do not reuse removed O-ring (383) 301

3) Remove piston (381) from rear flange (301).
381

(18)Disassembling ball check part
1) Remove plugs (352) (2 pcs) from rear flange
(301).
Do not reuse O-ring (358) which have been removed.
352

3) Remove steel balls (353) from rear flange (301).
When it is hard to remove steel balls (353), remove

them using the magnet etc.
353
Fig. 34-122 Removing ball (353)
34-57
34. TRAVEL SYSTEM
(19)Disassembling parking brake
PROTECT COVER
The sudden blowing of compressed air may cause AIR HOSE

parts to fly out incurring the danger of injury. Cover
piston (112) for protection.
1) Blow jet air into the passage hole for the parking
brake of the spindle (2) and remove the piston
(112) from the spindle (2).
2 112
Fig. 34-123 Blowing jet air
2) Remove O-ring (135),(139) from piston (112).
112
(135,139)
Do not reuse removed O-ring (135), (139).
(20)Disassembling the hydraulic motor section
When placing the travel motor on its side, oil spills ;

place a container under the travel motor.
1) Lay down the travel motor through 90 degrees.
2) Drain out the oil of the travel motor. 104(103,106,115,116)
3) Hold cylinder block (104) by hand, turn it both
ways a few times alternately and separate shoe
(106) from swash plate (103).
If cylinder block (104) is drawn out in that condition,

shoe (106) stays with swash plate (103). Then parts
(pistons, shoes, etc.) attached to cylinder block (104)
come off from cylinder block (104) and fall into spindle
(2). Care should be used about it. Fig. 34-125 Removing cylinder block (104)
4) Hold the cylinder block (104) and remove the

shaft (102).
Also, friction plate (115) and separator plate (116) are

also removed with cylinder block (104).
34-58
34. TRAVEL SYSTEM
5) Remove friction plate (115) and separator plate 106

(116), (117) attached on the removed cylinder 105
block (104). 107
6) Remove piston assy [piston (105) and shoe 110
(106)] and retainer plate (107) from cylinder 104
block (104).
108
• When removing the cylinder block, hold the retainer
plate (107) by both hands and remove it with the
piston assy.
• Cylinder block (104) and piston assy [piston (105)
and shoe (106)] are the minimum parts unit as
cylinder & piston kits. When they have to be
replaced, replace the cylinder & piston kit as a set. 116 115
(Refer to the parts manual.)
Fig. 34-126
7) Remove the piston assy (105),(106) from

retainer plate (107). [Nine pistons]
8) Remove thrust ball (108) from cylinder block
(104).
9) Draw out washer (111) from cylinder block (104).
10) Remove three needle rollers (151) from cylinder
block (104).
151
104
Fig. 34-127 Removing roller (151)
34-59
34. TRAVEL SYSTEM
(21)Remove spring from inside of cylinder block.

1) Place cylinder block (104) on the press bench. 104
145(110)
• Do not remove the spring except when spring is
replaced.
• When removing the spring, align the Jig (I) with the
washer in order to prevent the cylinder block from
being damaged by contact.
• Put a plastic sheet over the sliding surface of the
cylinder block so as not to damage it. Fig. 34-128 Removing snap ring (145)
2) Place the retainer metal jig (I) on washer (110)

and remove snap ring (145) from the snap ring
groove of cylinder block (104) by means of snap
114(110)
ring pliers, while holding down the jig (I).
104
If the press is loosened too suddenly, the spring jumps

out and injure yourself. Always loosen the press slowly.
3) Loosen the press slowly till the spring action is

released.
Fig. 34-129 Removing spring (114)
4) Remove the snap ring (145), washer (110),
spring (114), and washer (110) from inside the
cylinder block (104).
(22)Removing out shaft (102).
1) Removing swash plate (103) from spindle (2).
When removing it, check that pivot (167) is not adhered

on swash plate. 2(103,167)
2) Draw out shaft (102) from spindle (2). On that 149

occasion, the inner race of ball bearing (149)
comes off with the shaft.
102
3) Draw out two pivots (167), two parallel pins (171)
and the outer race of ball bearing (149) from Fig. 34-130 Removing shaft (102)
spindle (2).
4) Draw out the 2-speed switch piston assy [piston 162
(161) and shoe (162)] and spring (185) from
spindle (2). 161
185
Fig. 34-131 Removing 2-speed switching

piston assy
34-60
34. TRAVEL SYSTEM
(23)Removing ball bearing (149)

Ball bearing (149) is removed only when replacing.

1) Place holder (II) on the press bench and put shaft
(102) into the holder (II).
2) Remove ball bearing (149) from shaft (102) by
pressing on the shaft end with press.
Fig. 34-132 Removing ball bearing (149)

Do not reuse the removed ball bearing (149).
(24)Removing spindle fittings

1) Remove shim (23) from spindle (2).
23
Fig. 34-133 Removing shim (23)

2) Remove floating seal (29) from spindle (2).
Do not reuse floating seal (29) which have been

removed.
29

3) Remove oil seal (132) from spindle (2).
Do not reuse oil seal (132) which have been removed.

Fig. 34-135 Removing oil seal (132)
34-61
34. TRAVEL SYSTEM
(25)Rough washing of parts.

2
1) Distinguish the four parts ; hub (1), spindle (2), 3,7
cover (8), and rear flange (101) from other parts 301
(hereafter called built-in parts).
2) Put the hub, spindle, cover and rear flange in a
cleaning bath and clean them.
• Soil and sand are adhered to the outer surface of

parts in some cases ; clean them and remove soil
1(14)
and sand from the parts.
• Wash oil is combustible. Be careful not to cause fire Fig. 34-136 Rough washing of parts
and get burns.
• Before cleaning stained parts, immerse them in
wash oil until dust and stain become soft and are
floated to protect them from damaging when
cleaning.
3) Put the built-in parts in a rough cleaning

container containing wash oil and clean the
parts.
(26)Finish cleaning
1) Put parts in a finish cleaning container containing
wash oil and clean them well, turning them 3,7
slowly.
2) Blow parts with dry air to remove cleaning oil.
• Blow compressed air in the inner surface of hub (1),

spindle (2) and hold flange (3) to dry in the dust free
and dry conditions. After drying, apply hydraulic oil
to every part.
Fig. 34-137 Finish cleaning
• Inner surface of rear flange (101), hydraulic motor
components, and RV gear assy are to be dried
naturally in the dust free and dry conditions. After
drying every part, apply hydraulic oil to every part.
• Use care not to damage the surface of twenty four
pins (17) or lose them while handling.
Fig. 34-138 Finish cleaning
34-62
34. TRAVEL SYSTEM
34.2.4 ASSEMBLY
34.2.4.1 GENERAL PRECAUTIONS FOR ASSEMBLY

(1) Assembly it by reversing the procedure of disassembly.
(2) Assemble it in clean air condition.
(3) Don’t use cloth gloves during assembly.
(4) Replace or repair the damaged parts during disassembly according to the instructions in the "Maintenance
standard".
Replace O-ring, oil seal, etc. with new one.
(5) Clean every part sufficiently, and blow them with compressed air don’t use waste cloth.
(6) Prior to assembling, apply clean hydraulic oil to moving and sliding portions of hydraulic motor valve.
(7) Tighten bolt and plug to the specified torque using torque wrench.
(8) Replace reamer bolt with new ones. If it is unavoidably reused, remove completely the adhesive agent on
reamer bolt, repair flaws on bolt seat surface with oilstone, and degrease it.
(9) Prior to assembling, apply grease to lip portions of O-ring, oil seal, and floating seal to protect it from being
damaged, and to moving section and sliding section.
(10)After assembly, plug every port to protect the entry of dust, etc.
34.2.4.2 PREPARATORY ARRANGEMENT FOR ASSEMBLY

(1) After replacing parts with new ones, adjust the pre-load of bearing and thickness of snap ring without fail.
1) When the following parts are replaced, the pre-load adjustment of bearing is required.
HUB (1)
SPINDLE (2)
Bearing (24)
Where replacing the above parts, the previously adjusted parts should be used. If unadjusted parts are used, the
travel motor moves abnormally, causing early breakage.
34-63
34. TRAVEL SYSTEM
34.2.4.3 ASSEMBLING PROCEDURE

(1) Assembling hub
PRESS
1) Place hub (1) on the press bench.
2) Place angular ball bearing (24) on hub (1), and HUB
press in by using the main plate and a press PRESS TOOL
machine. FOR BALL BEARING
3) Turn over hub (1).
4) Insert angular ball bearing (24) into hub (1) in the
same way 2). BALL BEARING
PRESS STAND
PRESS BENCH
Make sure that the installing direction of angular ball Fig. 34-139 Inserting ball bearing (24)
bearing (24) is correct.
5) Apply grease on the O-ring of floating seal (29),

and fit the O-ring into the floating seal groove on F/S INSTALLATION
TOOL (II)
hub (1).
F/S INSTALLATION
TOOL (III)
• When applying grease to the O-ring, remove the O-
ring from floating seal (29), and then, apply grease
thinly to entire surface.
FLOATING SEAL
• Use floating seal installation tool (I) and (II).
Make sure to keep the parallel tolerance 1mm
HUB
(0.039") to end surface of the groove.
If not, it could cause seizure on floating seals (29)
or oil leak.
Fig. 34-140 Installing floating seal (29)

(2) Assembling spindle F/S INSTALLATION TOOL(II)
1) Apply grease on the O-ring of floating seal (29),
and fit the O-ring into the floating seal groove on
spindle (2).
F/S INSTALLATION
TOOL(III)
When applying grease to the O-ring, remove the O-ring

from floating seal (29), and then, apply grease thinly to
entire surface.
Use floating seal installation tool (II) and (III).
FLOATING SEAL
Make sure to keep the parallel tolerance 1mm (0.039")
SPINDLE
to end surface of the groove.
Fig. 34-141 Installing floating seal (29)
If not, it could cause seizure on floating seals (29) or oil
leak.
2) Install eyebolts to spindle (2) so they are

symmetrically positioned.
34-64
34. TRAVEL SYSTEM
3) Fix spindle (2) on workbench with two hexagon

socket bolts, which should locate symmetrically.
Tighten the hexagon bolts securely.

Failure to do so could result in injury if GM motor is
inverted and falls.
2
Fig. 34-142 Installing spindle (2)

(3) Clearance adjustment procedure for angular ball
bearing C
If any of hub (1), angular ball bearing (24) or spindle (2)

is replaced, clearance adjustment should be
conducted.
If not, angular ball bearings (24) could break in short
period.
1) Insert lock washers (22) for measuring the

dimensions, and measure the distance C. Fig. 34-143 Measurement dimension C
2) Measure the distance D.
D
Rotate hub assembly for stabilizing the distance D.
3) Select one of the classified shim (23) which

makes the distance "C - D" from -0.17 to
-0.13mm (-0.0051"~0.0067").
Shim (23) thickness shall be refer to the following
table.
ITEM T (mm) ITEM T (mm)

A 0.9 (0.035") G 1.5 (0.059") Fig. 34-144 Measurement dimension D
B 1.0 (0.040") H 1.6 (0.063")
C 1.1 (0.043") I 1.7 (0.067")
D 1.2 (0.047") J 1.8 (0.071")
E 1.3 (0.051") K 1.9 (0.075")
F 1.4 (0.055") L 2.0 (0.079")
4) Attach shim (23) to spindle (2).
23
Fig. 34-145 Installing shim (23)
34-65
34. TRAVEL SYSTEM
(4) Assembling hub

1) Insert hub (1) into angular ball bearing (24)
assembled in spindle (2) with keeping both
center axes parallely.
Fig. 34-146 Assembling hub

2) Fix hub (1) to the workbench with three long
hexagon socket bolts.
3) Put steel rod on the inner race of angular ball
bearing (24) located on reduction gear, and tap
softly by hammer to stabilize angular ball bearing
(24).
Fig. 34-147 Fix hub (1) to the workbench

4) Place lock washers (22) to the groove of spindle
(2).
5) Fit lock washers (22) into the groove of spindle

(2) by using installation tool 22
Fig. 34-148 Fitting lock washer (22)

Insert lock washers (22) fully into the groove so as not
to interfere with carrier 2 (7).
6) Remove the long hexagon socket bolts, which fix

hub (1) and the workbench.
7) Rotate hub (1) two or three times.
Contacting state between both sliding surface of

floating seal (29) will be improved by rotating spindle 22
(2), and prevent initial oil leak.
Fig. 34-149 Fitting lock washer (22)
8) Turn over spindle (2).
34-66
34. TRAVEL SYSTEM
(5) Assembling spindle fittings

1) Drive oil seal (132) into spindle (2) by using the
holder (III) to prevent it from being inclined.

Apply lithium grease around the lip portion of oil seal

(132) when mounting.
Be careful in the inclusion direction of oil seal (132).
2) Install two parallel pins (171) into the pin holes of

spindle (2).
3) Apply lithium grease to hemispherical surface of Fig. 34-150 Installing oil seal (132)
two pivots (167), and fit it into parallel pins (171)
of spindle (2).
4) Apply lithium grease to spring (185), and install
spring (185) into the piston kit (piston (161) and
shoe (162)).
5) Apply hydraulic fluid to the sliding surface of the
piston kit, install it into the piston hole of spindle
(2).
162
6) Install two parallel pins (34) into the pin holes of
spindle (2).
161
Fig. 34-151 Installing piston (161) and shoe (162)
(6) Assembling shaft

Wear thick leather groves in handling the heated ball

bearing (149).

1) Put ball bearing (149) in a heating tank to heat it
at 90 to 110°C [194 to 230°F] for ten minutes and
then insert it onto shaft (102).
Fig. 34-152 Installing ball bearing (149)
2) Turn the workbench 90 degrees.

3) Insert shaft (102) to spindle (2).
Take care not to scratch or cut the lip portion of oil seal
(132) in place with the splined foremost end of shaft
(102). 102
Fig. 34-153 Installing shaft (102)
34-67
34. TRAVEL SYSTEM
(7) Install oil seal (132)

1) Turn over travel motor.
2) Coat the lip of the oil seal with lithium grease and
fix oil seal (132) into the oil seal hole in spindle 132
149
(2), using retainer metal and a hammer. (OUTER RACE)
3) Assemble the outer race (with roller) of bearing
2
(149) into spindle (2).
Fig. 34-154 Pressing oil seal (132)

4) Insert swash plate (103) into spindle (2).
Apply lithium grease on swash plate (103) where

mating surface of spindle (2). 103
Make sure that the locating pivots (167) of spindle (2)
enter pivots' holes of swash plate (103).
(8) Assembling cylinder block interior
Fig. 34-155 Installing swash plate (103)
• The sharp edge of snap ring (145) is turned and put

into the entrance side of cylinder block (104). 110
• Washer (110) which touches snap ring (145) turns
and puts its sharp edge side into snap ring side.
114
1) Insert washer (110), spring (114), washer (110)
and snap ring (145) in that order into cylinder
block (104).
104
2) Place cylinder block (104) on the press bench.
Fig. 34-156 Inserting spring (114)

When mounting snap ring (145), if the tip of the pliers
slips out of the hole of snap ring (145), snap ring (145)
could jump out.
109
Press force of spring (114) is 1128N (254 lb) or more.

Protect by covering cylinder block (104) with a vinyl
sheet so the contact surface with timing plate (109) of 145
cylinder block (104) does not become damaged.
104
3) Place holder (I) on washer (110), and while
Fig. 34-157 Installing snap ring (145)
clamping with the press, fit snap ring (145) in the
snap ring groove of cylinder block (104) with the
snap ring pliers.
34-68
34. TRAVEL SYSTEM
(9) Assembling hydraulic motor

1) Put three rollers (151) into the holes of cylinder
block (104) and place washers (111) and thrust
balls (108) on them.
2) Fit nine piston assy to retainer plate (107).
151
After fixing it, immerse the whole unit in hydraulic oil. 104
3) Fit retainer plate (107) and 9 piston assy to Fig. 34-158 Installing rollers (151)
cylinder block (104).
Match retainer plate (107) with the spherical part of

thrust ball (108) and install them.
105,106 107
4) Assemble cylinder block (104) fitted with swash
108
plate (103), thrust ball (108), washer (111),
111
retainer plate (107), piston assy (105), (106) and 104(151)
roller (151), to shaft (102) that is placed level. (to
make a hydraulic motor assy)
Fig. 34-159 Assembling piston assy and
retainer plate (107)
5) Installing cylinder block (104) into shaft (102).
Install cylinder bock (104) into the spline of shaft (102)

by aligning the spine hole with the spline of shaft (102).
104
Fig. 34-160 Installing cylinder block (104)

6) After installing cylinder block (104), turn it by
hand and make sure that it fits properly.
If not, inspect it.
Cylinder block (104) is not flattered after installing it.

If cylinder block (104) is flattered, thrust ball (108) is
separated and GM motor does not rotate normally.
104 102
Fig. 34-161 Check for play of cylinder block (104)
34-69
34. TRAVEL SYSTEM
(10)Installing parking brake.

115
104
Immerse friction plate (115) in hydraulic oil before fitting

it.
1) Assemble separator plate (117) into the inner

groove of spindle (2) that houses cylinder block
(104).
2) Assemble three friction plates (115) and
separator plates (116), by turns, into the outer
groove of cylinder block (104) and into the inner Fig. 34-162 Fitting friction plate and
groove of spindle (2). On that occasion, fix the separator plate
friction plates first and then the separator plates.
3) Fit O-rings (135),(139) to the O-ring grooves of
piston (112). In that case, coat O-rings (135),
(139) with a thin film of grease.
4) Fitting piston (112) into spindle (2).
112
• If it is hard to fit the piston (112) into the spindle (2)
(135,139)
due to the resistance of O-rings (135),(139), lightly
tap the end face of the piston (112), using a plastic 2
mallet.
Fig. 34-163 Fitting piston (112)
• Take care so as not to score the O-rings when
installing the piston (112).
(11)Attaching two-speed spool

1) Insert spring (366) and spool (363) into rear
flange (301).
2) Fit O-ring (359) to plug (357). 363
(366)
Apply grease to O-ring (359).

Fig. 34-164 Inserting spring (366) and spool (363)
3) Attach plug (357) to rear flange (301).
4) Temporarily tighten plug (357) into rear flange
(301) by hexagon wrench.
34-70
34. TRAVEL SYSTEM
(12)Attaching ball check part

1) Fit two O-rings (358) to two plugs (352).
2) Insert steel ball (353) into rear flange (301).
353
Fig. 34-166 Installing steel ball (353)

3) Temporarily tighten plugs (352) into rear flange
Fig. 34-167 Temporally fastening plug (352)

(13)Attaching piston
2) Insert piston (381) into rear flange (301).
381
Fig. 34-168 Installing piston (381)

3) Temporarily tighten plugs (380) into rear flange
Fig. 34-169 Temporally fastening plug (380)
34-71
34. TRAVEL SYSTEM
(14)Assembling brake valve parts in rear flange

1) Insert spool (323) into rear flange (301).
Apply hydraulic fluid to spool (323) and insert spool

(323) into rear flange (301).
To insert spool (323), align the hole of rear flange (301)
with spool shaft center so as to prevent the inner
surface of rear flange (301) and the outer surface of
323
spool (323) from being damaged due to interference.
Otherwise internal leaks will occur after reassembly,
Fig. 34-170 Installing spool (323)
resulting in performance deterioration of GM motor.
3) Attach .washer (325) (2 pcs) and spring (328) (2

pcs) to plug (324) (2 pcs).
336
324
Fig. 34-171 Installing O-ring (336)
4) Attach plug (324) (2 pcs) to rear flange (301).
When attach plug (324) to rear flange (301), insert

carefully so as not to deform spring (328).
5) Temporarily tighten plug (324) (2 pcs) into rear

flange (301).

(15)Assembling rear flange mounted parts
1) Apply hydraulic fluid to ball bearing (150), and fit
ball bearing (150) into rear flange (301).
2) Insert two parallel pins (341) in the pin holes of
rear flange (301).
3) Apply grease to the mating face of timing plate
(109) in contact with rear flange (301) of timing
plate (109).
150
Fig. 34-173 Installing ball bearing (150)
34-72
34. TRAVEL SYSTEM
4) Fit timing plate (109) on rear flange (301) using

parallel pins (341) as the guide.
Fitting of timing plate (109) is carried out until timing

plate (109) adheres to rear flange (301).
Adhesion prevents from dropping timing plate (109)
from rear flange (301) when mounting rear flange (301)
on spindle (2). 109
Fig. 34-174 Installing timing plate (109)

5) Mount ten springs (113) on the hole of rear flange 113
(301).
Apply grease to springs (113) in order to prevent from

dropping springs (113) from rear flange (301).
Fig. 34-175 Installing spring (113)

(16)Assembling rear flange
1) Fit O-rings (32), (33) (2pcs) in the O-ring grooves
of spindle (2).
Fit O-ring (32) without applying grease.

If reassembled with grease applied, the grease may
bleed from mating face of rear flange (301) and spindle
(2) when GM motor is running.
2) Put 1.0 litters of hydraulic fluid in spindle (2).

Fig. 34-176 Installing O-ring (32), (33)
3) Install rear flange (301) on spindle (2) so that two
parallel pins (34) on spindle (2) enter the pin
holes in rear flange (301).
4) Temporarily tighten hexagon socket bolts (343)
(10 pcs) into spindle (2) by hexagon wrench.
Fig. 34-177 Installing rear flange (301)
34-73
34. TRAVEL SYSTEM
(17)Tightening bolts
1) Tighten hexagon socket bolt (343) (10 pcs) with
the specified torque.
Tightening torque :
102±15.7 N•m (75±11 lbf•ft)
Fig. 34-178 Tightening hexagon socket bolt (343)

2) Tighten plugs (324) with the specified torque.
Tightening torque :
441±39.2 N•m (325±29 lbf•ft)
Fig. 34-179 Tightening plug (324)

Tightening torque :
58.8±9.81 N•m (43±7 lbf•ft)

Tightening torque :
12.3±2.45 N•m (9±2 lbf•ft)
34-74
34. TRAVEL SYSTEM

Tightening torque :
98.1±19.6 N•m (72±14 lbf•ft)

(18)Attaching relief valve assembly
1) Attach relief valve assembly (203 others) (2 pcs)
to rear flange (301).
Fig. 34-183 Installing relief valve assy

2) Tighten relief valve assembly (203 others) (2
pcs) with the specified torque.
Tightening torque :
98.1±19.6 N•m (72±14 lbf•ft)
(19)Assembling 2nd stage planetary gears

1) The workbench is rotated and the reduction-
gears side is turned upward. Fig. 34-184 Tightening relief valve assy
2) Attach san gear 2 (8) to carrier 2 (7).
3) Fasten three eyebolts to the tapped holes of
carrier 2 (7).
Place a wire sling and hook in the eyebolts, place
carrier 2 assembly slowly in hub (1).
When inserting carrier (2) assembly, take care so as not

to damage internal teeth of hub (1) by the egge of
planetary gears 2 (9).
Fig. 34-185 Installing carrier 2 assy
34-75
34. TRAVEL SYSTEM
PIPING PORT
Place carrier 2 (7) so that planetary gears 2 (9) should

be located as the left illustration.
HOLE OF 1st-2nd
SPEED PISTON
Fig. 34-186
(20)Attaching coupling
1) Attach coupling (15) to shaft (102). 15
Fig. 34-187 Installing coupling (15)

(21)Assembling 1st stage planetary gears
1) Place carrier (1) assembly slowly in hub (1).
When inserting carrier (1) assembly, take care so as not

to damage internal teeth of hub (1) by the edge of
planetary gears 1 (5).
Fig. 34-188 Installing carrier 1 assy

2) Insert sun gear 1 (4) with aligning spline portion
to coupling (15) first, then gear portion second.
If the gear portion of sun gear 1 (4) does not engage

with planetary gears 1 (5), lift carrier (1) assembly until
the spline of sun gear 2 (8) is disengaged.
Insert sun gear 1 (4) first, then engage the spline of sun
gear 2 (8).
Fig. 34-189 Installing sun gear 1 (4)
34-76
34. TRAVEL SYSTEM
3) Place thrust plate (13) on carrier 1 (3).
Fig. 34-190 Installing thrust plate (13)

(22)Assembling cover
1) Apply "Loctite #515" to the mating surface of hub
(1) for cover (14).
"Loctite #515" should be applied around the mating

surface without discontinuation.
Fig. 34-191 Apply Loctite #515

2) Fasten two eyebolts to the tapped holes (PF1/2)
of cover (14).
Place a wire sling and hook in the eyebolts, place
cover (14) on hub (1) with aligning the position of
bolt holes.
Fig. 34-192 Installing cover (14)

3) Apply "Loctite #242" to hexagon socket bolt (35)
(12 pcs).
Tighten hexagon socket bolts (35) (12 pcs) with
the specified torque.
Tightening torque :
66.7±3.92 N•m (49±3 lbf•ft)
Fig. 34-193 Installing hexagon socket bolt (35)
34-77
34. TRAVEL SYSTEM
(23)Filling lubrication oil

1) Fill gear oil (lubrication oil) into the filling port.
Supply 2.1 litters of gear oil.
Fig. 34-194 Filling lubrication oil

2) Attach plugs (30) to ports of cover (14), tighten
them with the specified torque.
Tightening torque : 98.1±19.6 N•m
98.1±19.6 N•m (72±14 lbf•ft)
(24)Removing reassembled GM motor from the

workbench
1) Turn the workbench upside down.
(The motor side of GM motor is turned up.)
2) Remove the bolts securing GM motor to the
workbench.
3) Fasten two eyebolts (Ml6) to spindle (2). Fig. 34-195 Removing reassemble travel motor
4) Place a wire sling and hook in the eyebolts,
remove GM motor from the workbench with the
crane.
34-78
34. TRAVEL SYSTEM
34.2.5 MAINTENANCE STANDARD
34.2.5.1 PART MAINTENANCE STANDARD

(1) Replace all seals
Seal parts (O-ring, oil seal floating seal) should be replaced once disassembled even though no damage is
observed.
(2) Maintenance criteria for wearing parts
1) Replace any parts if they have severe damage on appearance.
2) Replace any parts if they have the following abnormalities.
REFERENCE ALLOWANCE
No. PARTS TROUBLE
VALUE VALUE
1 HUB • Severe damage on appearance.
• Pitting on ring gear teeth. — —
• Abnormal wear such as scoring.
2 SPINDLE • Severe damage on appearance.
— —
• Abnormal wear such as scoring.
3,7 CARRIER ASSY • Abnormal wear such as scoring.
— —
others
4 SUN GEAR 1 • Pitting on ring gear teeth.
8 SUN GEAR 2 • Flaking on the outer race for needle roller — —
5 PLANETARY GEAR 1 bearing.
9 PLANETARY GEAR 2
24 ANGULAR BALL • Dent, flaking or uneven wear on contact
— —
BEARING surface.
301 REAR FLANGE • Many scratch on sliding surfaces between
— —
spool (323) and piston (381).
102 SHAFT • Abnormal wear on contact surface between
oil seal (132). — —
• Abnormal wear on spline.
103 SWASH PLATE • Mark of sticking. — —
104 CYLINDER BLOCK • Abnormal wear on spline.
• Abnormal wear on bore surface.
— —
• Scratch or uneven wear on sliding surface
with timing plate (109).
105 PISTON ASSY • Abnormal clearance in the axial direction Clearance Clearance
106 PISTON between piston (105) and shoe (106). 0.05mm 0.15mm
SHOE • Abnormal wear on shoe (106). (0.002") (0.006")
107 RETAINER PLATE • Uneven wear on sliding surface with shoe
(106).
— —
• Scratch or uneven wear on sliding surface
with thrust ball (108).
108 THRUST BALL • Uneven wear on sliding surface with
— —
retainer plate (107).
109 TIMING PLATE • Sticking or uneven wear on sliding surface. — —
115 FRICTION PLATE • Uneven wear on both contact surface. Braking torque Braking torque
116 MAITING PLATE 206N•m 206N•m
• Specified torque cannot be obtained.
(152 lbf•ft) (152 lbf•ft)
• Mark of sticking. or over or over
105 PISTON • Scratch on sliding surface. — —
34-79
34. TRAVEL SYSTEM
REFERENCE ALLOWANCE
No. PARTS TROUBLE
VALUE VALUE
149 BALL BEARING • Dent, flaking or uneven wear on contact
— —
150 surface.
161 1st-2nd SPEED PISTON KIT • Uneven wear on both sliding surface.
162 PISTON • Abnormal wear on shoe (162). — —
SHOE
323 SPOOL • Abnormal and uneven wear on the outer
363 circumference. — —
• Severe scratch on the circumference.
381 PISTON • Severe scratch on the circumference. — —
34-80
34. TRAVEL SYSTEM
34.2.5.2 PERFORMANCE CONFIRMATION TEST

After servicing GM motor, perform the following tests by the following procedure.
(1) Required measuring devices
1 Press gauge for 3.43MPa (500psi) 2 pcs.

2 Graduated cylinder for 5L (1.32gal) 1 pc.
3 Stopwatch 1 pc.
(2) Test procedure
1 GM motor mounting / Mount GM motor to body (frame section) and connect piping.
piping
The track shoe must not be attached here at this time.
(This is because for conducting the performance test (no-load operation) of GM motor.)
NOTE :
1. When connecting piping, connect so that the pressure gauge (main circuit)
can be mounted and drain volume of the hydraulic motor can be measured.
2. When mounting GM motor, do not strike with the hammer etc., but rather
mount gently using the bolt holes.
2 Break-in operation of Speed ranges Revolving speed of GM motor Pressure Rotation direction Running time
GM motor
Low speed 10min-1
No-load CW-CCW Min.1 min each
High speed 20min-1
3 GM motor performance
confirmation test
1 Pre-test preparatory operation

Hydraulic fluid temperature : 45~55 (113~131 )
Perform preparatory operation until
approximately the following temperature. Hub external temperature : 40~80 (104~176 )
2 Confirmation test
Passing GM motor drive pressure : Max. 1.57MPa (230psi) / at 10min-1
Measure the following items to criteria
decide with the motor passes or Hydraulic motor drain volume : Max. 1.2L/min (0.32gal/min)
fails the test. / at 10min-1
Good No good
Attach the track shoe Disassemble and adjust again
34-81
34. TRAVEL SYSTEM
Relief set pressure is low. Set it correctly.
No Check that motions other than

Pump fails.
pressure travel are okay and remedy if
out of order.
Directional valve is out of order. Check if spool is normal and

repair if necessary.
Motor does
not start. If spool or valve is seized, replace
Brake valve is out of order. spool. On other cases, repair.
Replace motor or check hydraulic

Hydraulic motor fails. oil. If faulty, replace hydraulic oil.
Pressure is okay.
Gear (in reduction unit) is broken. Replace motor.
Motor is overloaded. Eliminate load.
Orifice of parking brake passage is blocked. Remove the foreign materials from orifice.
Correct surface with grindstone,

Scratches on matching face
Through emery paper, etc.
matching faces
Bolts loosened Check after retightening
Plug is loosened Retighten

From casing
Casing cracked by stone, etc. Replace motor.
Oil leaks.
Sliding surface is worn. Replace motor.
From floating seal
Deterioration occurs to O-rings. Replace motor.
Bolts are loosened. Retighten
From hydraulic
motor O-ring is damaged. Replace O-ring.
Seal face is scored. Correct with grindstone, pa-per, etc.
Motor has poor volumetric efficiency. Replace motor.
Replace brake valve.

Machine slides down on a slope. Internal leakage from brake valve increased (Replace rear flange.)
Parking brake is not working.

Spring is broken. Replace spring.
Replace friction plate and
Friction plate is worn.
separator plate.
Orifice of passage is clogged. Clean oil passage and orifice.
34-82
34. TRAVEL SYSTEM
Gear oil is short. Refill to a proper level.
Surface temperature of Replace parts of reduction unit

Pitching occurs to bearing and gear.
reduction unit casing is high. and gear oil.
Hydraulic oil intruded into gear casing. Replace oil seal and gear oil.
It occurs at low pressure.
Delivery rate differs on RH and LH motors. Repair pump.

Machine zigzage.
Drain rate differs on RH and LH motors. Replace rotary section of timing plate.
It occurs at high pressure.

Delivery rate differs on RH and LH motors. Repair pump and regulator.
Replace motor rotary section of

Drain rate differs on RH and LH motors. timing plate.
RH and LH brake valves moves Replace parts of brake valve.

differently. (Replace rear flange.)
Relief pressure of either the RH

Set pressure to a correct level.
or LH control valve is low.
The delivery rate of the pump is low.

The pump regulator does not work Repair the regulator.
correctly.
The pump has a large amount of Repair or replace the pump.
Speed does not go up.
external leakage.
The volumetric efficiency is bad.
Internal leakage. Replace rotary section of timing plate.
Set pressure of relief valve is low. Replace relief valve.
Abnormal sound is heard. Motor or reduction unit is broken. Replace motor or reduction unit.
Piping vibrates. Clamp piping.
34-83
34. TRAVEL SYSTEM
The speed does not Malfunction of high pressure selector Check it.
change from low to high. check valve. If necessary, repair or replace it.
Check that spool operates normally,

Malfunction of speed change valve. and if necessary, repair or replace it.
Pilot pressure is low. Set the pressure to the specified value.
Check it.
Malfunction of 2-speed change piston If necessary, repair or replace it.
Remove the foreign materials from

Orifice of 2-speed passage is clogged.
orifice.
The speed does not change Check that the spool operates normally.
Malfunction of selector valve
from high to low. If necessary, repair or replace it.
Check it.
Malfunction of 2-speed change piston If necessary, repair or replace it.
34-84
46. TROUBLE SHOOTING
(BY ERROR CODES)
TABLE OF CONTENTS
46.1 JUDGMENT OF ACTUAL THING AT SITE .....................................................................46-3

46.2 CLASSIFICATION OF FAILURE AND TROUBLESHOOTING .......................................46-4
46.3 THE BLOWN FUSE OF MECHATRO CONTROLLER....................................................46-4
46.4 TROUBLESHOOTING BY ERROR CODE......................................................................46-4
46
46-1
46. TROUBLE SHOOTING (BY ERROR CODES)

SK125SR : YV05-04501~
S5YY4613E01
(OCE/S.E.ASIA)
SK135SRLC-2 : YH05-07001~
46-2
Preface
Troubleshooting provides process locating for the
cause of trouble in the order that trouble occurred. This
manual describes how to solve the specific
phenomenon systematically as early as possible. For
troubleshooting concerning the inside of equipment,
refer to troubleshooting for each manual of equipment.
Fig. 46-1 Attending the field to verify actual thing.
46.1 JUDGMENT OF ACTUAL THING AT SITE

(1) Get to the site as quickly as possible.
Verify model, serial number, situation of trouble and
field, and notify person of arrival time.
(2) Verify background of trouble occurred
1) Model name and serial number
2) Kind of attachment
Check that the combination of attachment is
proper or that the operating method is not
unreasonable.
3) Operating time by hour-meter
4) History of trouble occurred and additional works.
5) Recurrence of past trouble, or problems on the
Fig. 46-2 Verifying background of trouble occurred.
additional works.
(3) How to diagnose trouble
1) Verify defective part
2) Make the condition of trouble again
3) Where defective parts can not be verified,
surmise causes systematically.
4) Verify reasons for surmise
5) Report methods, procedure, and period for
repairing to user.
(4) Explanation of the cause of trouble
1) Explain the cause of trouble to clients. For
example, oil leak through piston is caused by
Fig. 46-3 Confirm the symptoms of the trouble.
flaws on the piston rod. And the method of using
the machines should be explained so that the
same kind of trouble does not reoccur.
2) Treatment of damaged parts
The damaged parts to be claimed and returned
are evidence so they should be handled with
care. Protect them from entry of water, soils, etc.
into port of hydraulic unit, etc. and return them.
And also use care not to flaw and damage those Fig. 46-4 Diagnosing fail by means
surfaces. troubleshooting.
46-3
46.2 CLASSIFICATION OF FAILURE AND TROUBLESHOOTING

Classify failures into the following 3 types and carry out the troubleshooting.
No. Classes of failure Troubleshooting

A When error code after self-diagnosis is displayed Carry out troubleshooting according to the error
on gauge cluster code.
B When no failure is detected currently but error code When it is hard to recreate the failure situation, cancel
after self diagnosis is remained in trouble history the data in the history and reproduce the failed
situation or suppose the cause according to the
troubleshooting by error code, and then repair it.
C When error code after self diagnosis is not • Carry out troubleshooting according to instructions
displayed or is not remained in the history in Chapter 47 "TROUBLESHOOTING BY
TROUBLE".
• Carry out troubleshooting according to instructions
in Chapter 48 "TROUBLE DIAGNOSIS MODE".
46.3 THE BLOWN FUSE OF MECHATRO CONTROLLER

If the fuse of mechatro controller has blown, the following display appears on the gauge cluster.
(1) The blown fuse of mechatro controller
a. Blown fuse 5A of mechatro controller :
"DATA COMMUNICATION ERROR" is displayed on the gauge cluster in the condition where the controller
program is not executed.
b. Blown fuse 20A of mechatro controller
The controller functions normally but the power supply applied when the controller drives the solenoid, etc.
stops.
Many error codes are displayed on the gauge cluster.
D013, D023, D033, D063,
E013, E023, F021
46.4 TROUBLESHOOTING BY ERROR CODE

When error code was displayed on the gauge cluster with the aid of self-diagnosis display function, carry out the
troubleshooting referring to applicable page in the contents of error codes.
Error Code Trouble Described

page
A025 Pump propo. valve adjustment (B adjustment) is not adjusted yet or is failed. 46-7
A035 Unload valve adjustment (C adjustment) is not adjusted yet or is failed. 46-7
A215 Written data of ROM adjustment data is incorrect. 46-8
A225 Writing of ROM adjustment data is incorrect. 46-8
A235 Written data of ROM hour meter data is incorrect. 46-9
A245 Writing of ROM hour meter data is incorrect. 46-9
A255 Writing of proportional valve adjustment data is incorrect. 46-10
B012 Incorrect output of boom up pressure sensor 46-10
B013 Disconnection of boom up pressure sensor 46-11
B014 Short-circuit of boom up pressure sensor 46-11
B022 Incorrect output of boom down pressure sensor 46-12
B023 Disconnection of boom down pressure sensor 46-12
B024 Short-circuit of boom down pressure sensor 46-13
B032 Incorrect output of arm out pressure sensor 46-13
46-4

page
B033 Disconnection of arm out pressure sensor 46-14
B034 Short-circuit of arm out pressure sensor 46-14
B042 Incorrect output of arm in pressure sensor 46-15
B043 Disconnection of arm in pressure sensor 46-15
B044 Short-circuit of arm in pressure sensor 46-16
B052 Incorrect output of bucket digging pressure sensor 46-16
B053 Disconnection of bucket digging pressure sensor 46-17
B054 Short-circuit of bucket digging pressure sensor 46-17
B062 Incorrect output of bucket dump pressure sensor 46-18
B063 Disconnection of bucket dump pressure sensor 46-18
B064 Short-circuit of bucket dump pressure sensor 46-19
B072 Incorrect output of swing pressure sensor 46-19
B073 Disconnection of swing pressure sensor 46-20
B074 Short-circuit of swing pressure sensor 46-20
B092 Incorrect output of travel right pressure sensor 46-21
B093 Disconnection of travel right pressure sensor 46-21
B094 Short-circuit of travel right pressure sensor 46-22
B102 Incorrect output of travel left pressure sensor 46-22
B103 Disconnection of travel left pressure sensor 46-23
B104 Short-circuit of travel left pressure sensor 46-23
B113 Disconnection of pressure sensor of optional selector positioning 46-24
B114 Short-circuit of pressure sensor of optional selector positioning 46-24
B162 Incorrect output of P1 optional side pressure sensor 46-25
B163 Disconnection of P1 side optional pressure sensor 46-25
B164 Short-circuit of P1 side optional pressure sensor 46-26
B172 Incorrect output of P2 optional side pressure sensor 46-26
B173 Disconnection of P2 side optional pressure sensor 46-27
B174 Short-circuit of P2 side optional pressure sensor 46-27
C012 Incorrect output of P1 pump pressure sensor 46-28
C013 Disconnection of P1 pump pressure sensor 46-28
C014 Short-circuit of P1 pump pressure sensor 46-29
C022 Incorrect output of P2 pump pressure sensor 46-29
C023 Disconnection of P2 pump pressure sensor 46-30
C024 Short-circuit of P2 pump pressure sensor 46-30
C033 Disconnection of boom head pressure sensor 46-31
C034 Short-circuit of boom head pressure sensor 46-31
D012 Failure of output transistor ON at P1 unload proportional valve 46-32
D013 Disconnection of P1 unload proportional valve 46-32
D022 Failure of output transistor ON at P2 unload proportional valve 46-33
D023 Disconnection of P2 unload proportional valve 46-33
D032 Failure of output transistor ON at travel straight proportional valve 46-34
D033 Disconnection of travel straight proportional valve 46-34
D062 Failure of output transistor ON at arm in high speed proportional valve 46-35
D063 Disconnection of arm in high speed proportional valve 46-35
E012 Failure of output transistor ON at P1 pump proportional valve 46-36
E013 Disconnection of P1pump proportional valve 46-36
E022 Failure of output transistor ON at P2 pump proportional valve 46-37
E023 Disconnection of P2 pump proportional valve 46-37
46-5

page
F021 Failure of output transistor OFF and GND short of swing parking SOL valve 46-38
F023 Failure of output transistor ON and disconnection of swing parking SOL valve 46-38
F031 Failure of output transistor OFF and GND short of travel 1-2 speed SOL valve 46-39
F033 Failure of output transistor ON and disconnection of travel 1-2 speed SOL valve 46-39
F041 Failure of output transistor OFF and GND short of optional selector SOL valve 46-40
F043 Failure of output transistor ON and disconnection of optional selector SOL valve 46-40
G032 Overrun of speed sensor of direct input Mechatro-controller 46-41
G033 Disconnection of speed sensor of direct input Mechatro-controller 46-41
G042 Overrun of speed sensor of direct input Mechatro-controller and received data from E/G controller. 46-42
G043 Disconnection of speed sensor of direct input Mechatro-controller and received data from E/G controller. 46-43
H013 Disconnection of acceleration potentio 46-44
H014 Power short-circuit of acceleration potentio 46-44
H091 Failure of GND short-circuit of fuel sensor 46-45
H093 Disconnection of fuel sensor 46-45
I111 Received error of CAN1 communication (passive error) 46-46
I113 Received error of CAN1 communication (time-out) 46-46
I313 Received error of cluster communication (time-out error) 46-47
K014 Adhesion of battery relay terminal 46-47
R014 Failure of arc prevention relay of wiper motor 46-48
R024 Failure of normal rotation relay of wiper motor 46-48
R034 Failure of reverse rotation relay of wiper motor 46-49
R044 Failure of washer motor relay 46-49
R134 Failure of swing right flasher relay 46-50
R144 Failure of swing left flasher relay 46-50
R154 Failure of travel alarm relay 46-51
R164 Failure of auto idling stop relay 2 46-51
R174 Failure of engine forcible stop relay 46-52
R184 Failure of lever lock relay 46-53
46-6
Table46-1
Error code A025
Trouble Not yet adjusted engine or failed adjustment of pump proportional valve (B adjustment)
Judging Pump proportional valve adjustment is missed. Or it is impossible to set the adjusting value within
condition the adjusting range.
Symptom Deviated from the rated output, but no problem in normal operation
Control in the
Workable with the default proportional valve output.
event of failure
Returned in
The pump proportional valve adjustment is completed normally.
normal condition
Service Screen No. 9 E-1 P1 PUMP
diagnosis Screen No. 9 E-2 P2 PUMP
checking screen Screen No.
Checking object Checking contents and remedy
1 •Checking Carry out pump adjustment (B adjustment).
When"ERROR PUMP" was displayed during adjustment, refer to the section
"Adjustment procedure - Measures to be taken with the adjustment failed"
2 • Mechatro controller Check that the error is corrected after replacement of controller.
3
Table46-2
Error code A035
Trouble Not yet adjusted unload valve or failed adjustment of unload valve (C adjustment)
Judging The adjustment of unload valve is missed. Or the adjusting value can not be set in the adjusting
condition range.
Symptom It is not normal output, but no problem in normal operation
Control in the
Work with the aid of output by default proportional valve.
event of failure
Returned in
The adjustment of unload valve is completed normally.
normal condition
Service Screen No. 8 D-1 P1 UN-LOAD (BP-CUT)
diagnosis Screen No. 8 D-2 P2 UN-LOAD (BP-CUT)
1 •Checking Carry out adjustment of unload valve (C adjustment).
When"ERROR PUMP" was displayed during adjustment, refer to the section
"Adjustment procedure - Measures to be taken with the adjustment failed"
3
46-7
Table46-3
Error code A215
Trouble The data of ROM adjustment is written incorrectly.
Judging
Check adjustment data, and judge the content of memory is correct or not. (Trouble history only)
condition
Symptom No affect.
Control in the
Control at side of correct memory data.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Service Screen No.
diagnosis Screen No.
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3
Table46-4
Error code A225
Trouble The data of ROM adjustment is written incorrectly.
Judging
Check adjustment data, and judge the data is correct or not.
condition
Control in the
Control can be done by default value.
event of failure
Returned in
normal condition
Service Screen No.
2
3
46-8
Table46-5
Error code A235
Trouble The data of ROM hourmeter is written incorrectly.
Judging
Check hourmeter memory, and judge the data is correct or not. (Trouble history only)
condition
Symptom No affect.
Control in the
Control at side of correct memory data.
event of failure
Returned in
normal condition
Service Screen No.
2
3
Table46-6
Error code A245
Trouble The data of ROM hourmeter is written incorrectly.
Judging
Check hourmeter memory, and judge the data is incorrect.
condition
Symptom The hour meter data which was judged as error is taken as 0 Hr. No problem in normal operation
Control in the
Normal control is available.
event of failure
Returned in
normal condition
Service Screen No.
2
3
46-9
Table46-7
Error code A255
Trouble The data of proportional valve adjustment is written incorrectly.
Judging
Check proportional valve adjustment data, and judge the data is incorrect.
condition
Control in the
Using fixed value of proportional valve correction data, usual control is done.
event of failure
Returned in
normal condition
Service Screen No.
2
3
Table46-8
Error code B012
Trouble Boom up pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the sensor after
condition starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The boom up operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 5 B-1 BOOM RAISE
1 • Boom up pressure sensor When B012 is cancelled and other error occurs by turning starter switch on
SE-3 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom up When B012 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-126F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
46-10
Table46-9
Error code B013
Trouble Boom up pressure sensor’s wiring disconnects.
Judging
The input voltage from boom up pressure sensor is less than 0.1V.
condition
Symptom All operation speed slows down.
Set proportional valve output rate of P1 and P2 pumps to constant current.
Control in the
(Current value in all operation is neutral.)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
1 • Boom up pressure sensor When B013 is cancelled and other error occurs after exchanging the
SE-3 connector with other sensor.
2 • Wiring between boom up When B013 is displayed after the connector is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-101F
Table46-10
Error code B014
Trouble Boom up pressure sensor’s power source is shortcut.
Judging
The input voltage from boom up pressure sensor is 4.7V or more.
condition
Control in the
event of failure
Returned in
normal condition
1 • Boom up pressure sensor When B014 is cancelled and other error occurs after exchanging the
2 • Wiring between boom up When B014 is displayed after the connector is exchanged with other sensor.
CN-101F
46-11
Table46-11
Error code B022
Trouble Boom down pressure sensor outputs error
Symptom The boom down operability becomes poor.
Control in the
Normal control
event of failure
Service Screen No. 5 B-2 BOOM LOWER
1 • Boom down pressure sensor When B022 is cancelled and other error occurs by turning starter switch on
2 • Wiring between boom down When B022 is displayed after turning the starter switch on after the connector
Table46-12
Error code B023
Trouble Boom down pressure sensor’s wiring is disconnecting.
Judging
The input voltage from boom down pressure sensor is 0.1V or less.
condition
Control in the
event of failure
Returned in
normal condition
1 • Boom down pressure sensor When B023 is cancelled and other error occurs after exchanging the
2 • Wiring between boom down When B023 is displayed after the connector is exchanged with other sensor.
CN-101F
46-12
Table46-13
Error code B024
Trouble Boom down pressure sensor’s power source is shortcut.
Judging
The input voltage from boom down pressure sensor is 4.7V or more.
condition
Control in the
event of failure
Returned in
normal condition
1 • Boom down pressure sensor When B024 is cancelled and other error occurs by turning starter switch on
2 • Wiring between boom down When B024 is displayed after turning the starter switch on after the connector
Table46-14
Error code B032
Trouble Arm-in pressure sensor outputs error
Control in the
Normal control
event of failure
Service Screen No. 5 B-3 ARM OUT
1 • Arm-out pressure sensor When B032 is cancelled and other error occurs by turning starter switch on
2 • Wiring between arm-out When B032 is displayed after turning the starter switch on after the connector
46-13
Table46-15
Error code B033
Trouble Arm-out pressure sensor’s wiring is disconnecting.
Judging
The input voltage from arm-out pressure sensor is 0.1V or less.
condition
Control in the
event of failure
Returned in
normal condition
1 • Arm-out pressure sensor When B033 is cancelled and other error occurs after exchanging the
2 • Wiring between arm-out When B033 is displayed after the connector is exchanged with other sensor.
CN-101F
Table46-16
Error code B034
Trouble Arm-out pressure sensor’s power source is shortcut.
Judging
The input voltage from arm-out pressure sensor is 4.7V or more.
condition
Control in the
event of failure
Returned in
normal condition
1 • Arm-out pressure sensor When B034 is cancelled and other error occurs by turning starter switch on
2 • Wiring between arm-out When B034 is displayed after turning the starter switch on after the connector
46-14
Table46-17
Error code B042
Trouble Arm-in pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the arm-in
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The arm-in operability becomes poor.
Control in the
Normal control
event of failure
Service Screen No. 5 B-4 ARM IN
1 • Arm-in pressure sensor When B042 is cancelled and other error occurs by turning starter switch on
2 • Wiring between arm-in When B042 is displayed after turning the starter switch on after the connector
Table46-18
Error code B043
Trouble Arm-in pressure sensor’s wiring is disconnecting.
Judging
The input voltage from arm-in pressure sensor is 0.1V or less.
condition
Control in the
event of failure
Returned in
normal condition
1 • Arm-in pressure sensor When B043 is cancelled and other error occurs after exchanging the
2 • Wiring between arm-in When B043 is displayed after the connector is exchanged with other sensor.
CN-101F
46-15
Table46-19
Error code B044
Trouble Arm-in pressure sensor’s power source is shortcut.
Judging
The input voltage from arm-in pressure sensor is 4.7V or more.
condition
Control in the
event of failure
Returned in
normal condition
1 • Arm-in pressure sensor When B044 is cancelled and other error occurs by turning starter switch on
2 • Wiring between arm-in When B044 is displayed after turning the starter switch on after the connector
Table46-20
Error code B052
Trouble Bucket digging pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the bucket
condition digging pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The bucket digging operability becomes poor.
Control in the
Normal control
event of failure
Service Screen No. 5 B-5 BUCKET DIG
1 • Bucket digging pressure sensor When B052 is cancelled and other error occurs by turning starter switch on
2 • Wiring between bucket digging When B052 is displayed after turning the starter switch on after the connector
46-16
Table46-21
Error code B053
Trouble Bucket digging pressure sensor’s wiring is disconnected.
Judging
The input voltage from bucket digging pressure sensor is 0.1V or less.
condition
Control in the
event of failure
Returned in
normal condition
Table46-22
Error code B054
Trouble Bucket digging pressure sensor’s power source is shortcut.
Judging
The input voltage from bucket digging pressure sensor is 4.7V or more.
condition
Control in the
event of failure
Returned in
normal condition
46-17
Table46-23
Error code B062
Trouble Bucket dump pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the bucket dump
Symptom The bucket dump operability becomes poor.
Control in the
Normal control
event of failure
Service Screen No. 5 B-6 BUCKET DUMP
CN-125F
and repair it if necessary.
Table46-24
Error code B063
Trouble Bucket dump pressure sensor’s wiring is disconnected.
Judging
The input voltage from bucket dump pressure sensor is 0.1V or less.
condition
Control in the
event of failure
Returned in
normal condition
46-18
Table46-25
Error code B064
Trouble Bucket dump pressure sensor’s power source is shortcut.
Judging
The input voltage from bucket dump pressure sensor is 4.7V or more.
condition
Control in the
event of failure
Returned in
normal condition
Table46-26
Error code B072
Trouble Swing pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the swing
Symptom The swing operability becomes poor.
Control in the
Normal control
event of failure
Service Screen No. 6 B-7 SWING
1 • Swing pressure sensor When B072 is cancelled and other error occurs by turning starter switch on
2 • Wiring between swing When B072 is displayed after turning the starter switch on after the connector
46-19
Table46-27
Error code B073
Trouble Swing pressure sensor’s wiring is disconnected.
Judging
The input voltage from swing pressure sensor is 0.1V or less.
condition
Control in the
event of failure
Returned in
normal condition
Table46-28
Error code B074
Trouble Swing pressure sensor’s power source is shortcut.
Judging
The input voltage from swing pressure sensor is 4.7V or more.
condition
Control in the
event of failure
Returned in
normal condition
46-20
Table46-29
Error code B092
Trouble Travel right pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the travel right
Symptom The travel right operability becomes poor.
Control in the
Normal control
event of failure
Service Screen No. 6 B-9 TRAVEL (R)
1 • Travel right pressure sensor When B092 is cancelled and other error occurs by turning starter switch on
2 • Wiring between travel right When B092 is displayed after turning the starter switch on after the connector
Table46-30
Error code B093
Trouble Travel right pressure sensor’s wiring is disconnected.
Judging
The input voltage from Travel right pressure sensor is 0.1V or less.
condition
Control in the
event of failure
Returned in
normal condition
46-21
Table46-31
Error code B094
Trouble Travel right pressure sensor’s power source is shortcut.
Judging
The input voltage from Travel right pressure sensor is 4.7V or more.
condition
Control in the
event of failure
Returned in
normal condition
Table46-32
Error code B102
Trouble Travel left pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the travel left
Symptom The travel left operability becomes poor.
Control in the
Normal control
event of failure
Service Screen No. 6 B-10 TRAVEL (L)
1 • Travel left pressure sensor When B102 is cancelled and other error occurs by turning starter switch on
2 • Wiring between travel left When B102 is displayed after turning the starter switch on after the connector
46-22
Table46-33
Error code B103
Trouble Travel left pressure sensor’s wiring is disconnected.
Judging
The input voltage from Travel left pressure sensor is 0.1V or less.
condition
Control in the
event of failure
Returned in
normal condition
Table46-34
Error code B104
Trouble Travel left pressure sensor’s power source is shortcut.
Judging
The input voltage from Travel left pressure sensor is 4.7V or more.
condition
Control in the
event of failure
Returned in
normal condition
46-23
Table46-35
Error code B113
Trouble Option selector position detect pressure sensor’s wiring is disconnected.
Judging
The input voltage from option selector position detect pressure sensor is 0.1V or less.
condition
Symptom When B mode is selected, option selector valve error is indicated.
Control in the
Normal control
event of failure
Returned in
normal condition
Service Screen No. 16 B-11
1 • Option selector position When B113 is cancelled and other error occurs by turning starter switch on
detect pressure sensor after exchanging the connector with other sensor.
SE-29 Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between option When B113 is displayed after turning the starter switch on after the connector
selector position detect is exchanged with other sensor.
CN-104F
Table46-36
Error code B114
Trouble Option selector position detect pressure sensor’s wiring is disconnected.
Judging
The input voltage from selector position detect pressure sensor is 4.7V or more.
condition
Symptom When B mode is selected, option selector valve error is indicated.
Control in the
Normal control
event of failure
Returned in
normal condition
Service Screen No. 16 B-11
1 • Option selector position When B114 is cancelled and other error occurs by turning starter switch on
detect pressure sensor after exchanging the connector with other sensor.
SE-29 Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between option When B114 is displayed after turning the starter switch on after the connector
selector position detect is exchanged with other sensor.
CN-104F
46-24
Table46-37
Error code B162
Trouble P1 side option pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the P1 side
condition option pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The P1 side option operability becomes poor.
Control in the
Normal control
event of failure
Service Screen No. 6 B-16 P1 OPT.
1 • P1 side option pressure sensor When B162 is cancelled and other error occurs by turning starter switch on
2 • Wiring between P1 side option When B162 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor. Check wiring for possible failure according to
CN-304F the wiring checking procedure and repair it if necessary.
Table46-38
Error code B163
Trouble P1 side option pressure sensor’s wiring is disconnected.
Judging
The input voltage from P1 side option pressure sensor is 0.1V or less.
condition
Symptom The P1 side option does not work. All operation speed slows down.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the (Hydraulic pump emergency mode)
event of failure Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
But normal control is done when the left control pedal selection is ON.
Returned in
normal condition
46-25
Table46-39
Error code B164
Judging
The input voltage from P1 side option pressure sensor is 4.7V or more.
condition
Symptom The P1 side option does not work. All operation speed slows down.
Control in the (Hydraulic pump emergency mode)
event of failure Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
But normal control is done when the left control pedal selection is ON.
Returned in
normal condition
Table46-40
Error code B172
Trouble P2 side option pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the P2 side
condition option pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The P2 side option operability becomes poor.
Control in the
Normal control
event of failure
pressure sensor and controller is exchanged with other sensor. Check wiring for possible failure according to
CN-303F the wiring checking procedure and repair it if necessary.
46-26
Table46-41
Error code B173
Judging
The input voltage from P2 side option pressure sensor is 0.1V or less.
condition
Symptom The selection of conflux does not work. All operation speed slows down.
Control in the
event of failure
Returned in
normal condition
Table46-42
Error code B174
Judging
The input voltage from P2 side option pressure sensor is 4.7V or more.
condition
Symptom The selection of conflux does not work. All operation speed slows down.
Control in the
event of failure
Returned in
normal condition
46-27
Table46-43
Error code C012
Trouble P1 pump pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the P1 pump
Symptom The P1 pump operability becomes poor.
Control in the
Normal control
event of failure
Service Screen No. 7 C-1 PUMP P1
1 • P1 pump pressure sensor When C012 is cancelled and other error occurs by turning starter switch on
2 • Wiring between P1 pump When C012 is displayed after turning the starter switch on after the connector
Table46-44
Error code C013
Trouble P1 pump pressure sensor’s wiring is disconnected.
Judging
The input voltage from P1 pump pressure sensor is 0.1V or less.
condition
Control in the
P1 pump pressure is controlled to 25 MPa.
event of failure
Returned in
normal condition
46-28
Table46-45
Error code C014
Trouble P1 pump pressure sensor’s power source is shortcut.
Judging
The input voltage from P1 pump pressure sensor is 4.7V or more.
condition
Control in the
event of failure
Returned in
normal condition
Table46-46
Error code C022
Trouble P2 pump pressure sensor outputs error.
Judging After starter switch ON and engine does not start yet. And the input voltage from the P2 pump
Symptom The P2 pump operability becomes poor.
Control in the
Normal control
event of failure
46-29
Table46-47
Error code C023
Trouble P2 pump pressure sensor’s wiring is disconnected.
Judging
The input voltage from P2 pump pressure sensor is 0.1V or less.
condition
Control in the
event of failure
Returned in
normal condition
Table46-48
Error code C024
Trouble P2 pump pressure sensor’s power source is shortcut.
Judging
The input voltage from P2 pump pressure sensor is 4.7V or more.
condition
Control in the
event of failure
Returned in
normal condition
46-30
Table46-49
Error code C033
Trouble Boom head pressure sensor’s wiring is disconnected.
Judging
The input voltage from boom head pressure sensor is 0.1V or less.
condition
Symptom Overload alarm is not actuated.
Control in the
Normal control
event of failure
Returned in
normal condition
Service Screen No. 7 C-3 BOOM-HEAD
1 • Boom head pressure sensor When C033 is cancelled and other error occurs by turning starter switch on
2 • Wiring between boom head When C033 is displayed after turning the starter switch on after the connector
Table46-50
Error code C034
Trouble Boom head pressure sensor’s power source is shortcut.
Judging
The input voltage from boom head pressure sensor is 4.7V or more.
condition
Symptom Overload alarm is not actuated.
Control in the
Normal control
event of failure
Returned in
normal condition
Service Screen No. 7 C-3 BOOM-HEAD
1 • Boom head pressure sensor When C034 is cancelled and other error occurs by turning starter switch on
2 • Wiring between boom head When C034 is displayed after turning the starter switch on after the connector
46-31
Table46-51
Error code D012
Trouble P1 unload proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Option conflux can not be done.
Control in the
event of failure
Returned in
normal condition
1 • P1 unload proportional valve When D012 is cancelled and other error occurs by turning starter switch on
PSV-D after exchanging the connector with other sensor.
2 • Wiring between P1 unload When D012 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
Table46-52
Error code D013
Trouble P1 unload proportional valve’s wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 150mA or less, judging is not done.)
Symptom Option conflux can not be done.
Control in the
event of failure
Returned in
normal condition
PSV-D after exchanging the connector with other sensor.
46-32
Table46-53
Error code D022
Trouble P2 unload proportional valve and output transistor ON are failure.
Judging
condition
Symptom Independent operations of boom up and of bucket digging/dump become slow.
Control in the
event of failure
Returned in
normal condition
PSV-B after exchanging the connector with other sensor.
Table46-54
Error code D023
Trouble P2 unload proportional valve’s wiring is disconnected.
Symptom Independent operations of boom up and of bucket digging/dump become slow.
Control in the
event of failure
Returned in
normal condition
PSV-B after exchanging the connector with other sensor.
46-33
Table46-55
Error code D032
Trouble Travel straight proportional valve and output transistor ON are failure.
Judging
condition
Symptom Travel deviation occurs by combined operation of travel and attachment.
Control in the
Set Travel straight proportional valve output to 0mA.
event of failure
Returned in
normal condition
Service Screen No. 8 D-3 S-TRAVEL
1 • Travel straight proportional valve When D032 is cancelled and other error occurs by turning starter switch on
PSV-C after exchanging the connector with other sensor.
2 • Wiring between Travel straight When D032 is displayed after turning the starter switch on after the connector
Table46-56
Error code D033
Trouble Travel straight proportional valve’s wiring is disconnected.
Symptom Travel deviation occurs by combined operation of travel and attachment.
Control in the
Set Travel straight proportional valve output to 0mA.
event of failure
Returned in
normal condition
Service Screen No. 8 D-3 S-TRAVEL
1 • Travel straight proportional valve When D033 is cancelled and other error occurs by turning starter switch on
PSV-C after exchanging the connector with other sensor.
2 • Wiring between Travel straight When D033 is displayed after turning the starter switch on after the connector
46-34
Table46-57
Error code D062
Trouble Arm-in spool 2 proportional valve and output transistor ON are failure.
Judging
condition
Symptom Operability of combined operation with arm-in becomes poor.
Control in the
Set Arm-in spool 2 proportional valve output to 0mA.
event of failure
Returned in
normal condition
Service Screen No. 8 D-6 ARM IN-2-SPEED
1 • Arm-in spool 2 proportional valve When D062 is cancelled and other error occurs by turning starter switch on
PSV-A after exchanging the connector with other sensor.
2 • Wiring between Arm-in spool 2 When D062 is displayed after turning the starter switch on after the connector
Table46-58
Error code D063
Trouble Arm-in spool 2 proportional valve’s wiring is disconnected.
Symptom Operability of combined operation with arm-in becomes poor.
Control in the
Set Arm-in spool 2 proportional valve output to 0mA.
event of failure
Returned in
normal condition
Service Screen No. 8 D-6 ARM IN-2-SPEED
1 • Arm-in spool 2 proportional valve When D063 is cancelled and other error occurs by turning starter switch on
PSV-A after exchanging the connector with other sensor.
2 • Wiring between Arm-in spool 2 When D063 is displayed after turning the starter switch on after the connector
46-35
Table46-59
Error code E012
Trouble P1 pump proportional valve and output transistor ON are failure.
Judging
condition
Control in the
event of failure
Service Screen No. 9 E-1 PUMP P1
1 • P1 pump proportional valve When E012 is cancelled and other error occurs by turning starter switch on
PSV-P1 after exchanging the connector with other sensor.
When replacing of connector is executed, turn off power source once.
2 • Wiring between P1 pump When E012 is displayed after turning the starter switch on after the connector
Table46-60
Error code E013
Trouble P1 pump proportional valve’s wiring is disconnected.
Control in the
event of failure
46-36
Table46-61
Error code E022
Trouble P2 pump proportional valve and output transistor ON are failure.
Judging
condition
Control in the
event of failure
Table46-62
Error code E023
Trouble P2 pump proportional valve’s wiring is disconnected.
Control in the
event of failure
46-37
Table46-63
Error code F021
Trouble Swing parking solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Judging
The feed-back signal is grounding level while exciting command is output.
condition
Symptom Swing parking is not available.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is 24V level while exciting command is output.
normal condition
Service Screen No. 3 F-2 SWING-BRAKE
1 • Swing parking solenoid valve When F021 is cancelled and other error occurs by exchanging the connector
SV-1 for other solenoid valve. Check solenoid valve unit for possible failure. If
failure found, replace it.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between swing parking When F021 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
Table46-64
Error code F023
Trouble Swing parking solenoid valve and output transistor ON are failure, and disconnection.
Judging
The feed-back signal is 24V level while exciting command is not output.
condition
Symptom Swing parking is not available or is leaving available.
Control in the
Normal control
event of failure
Returned in
normal condition
Service Screen No. 3 F-1 POWER BOOST
1 • Swing parking solenoid valve When F023 is cancelled and other error occurs by exchanging the connector
SV-1 for other solenoid valve.
2 • Wiring between swing parking When F023 is displayed after the connector is exchanged with other solenoid
46-38
Table46-65
Error code F031
Travel 1, 2 speed solenoid valve and output transistor OFF are failure, and grounding is short-
Trouble
circuit.
Judging
condition
Symptom Travel 2 speed is not obtainable.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is 24V level while exciting command is output.
normal condition
Service Screen No. 3 F-3 1/2-TRAVEL
1 • Travel 1, 2speed solenoid valve When F031 is cancelled and other error occurs by exchanging the connector
2 • Wiring between travel 1, 2speed When F031 is displayed after the connector is exchanged with other solenoid
Table46-66
Error code F033
Trouble Travel 1, 2 speed solenoid valve and output transistor ON are failure, and disconnection.
Judging
condition
Symptom Travel 2 speed is not obtainable or is keeping 1 speed.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is grounding level while exciting command is not output.
normal condition
Service Screen No. 3 F-3 1/2-TRAVEL
1 • Travel 1, 2speed solenoid valve When F033 is cancelled and other error occurs by exchanging the connector
2 • Wiring between travel 1, 2speed When F033 is displayed after the connector is exchanged with other solenoid
46-39
Table46-67
Error code F041
Option selector solenoid valve and output transistor OFF are failure, and grounding is short-
Trouble
circuit.
Judging
condition
Symptom Option selector valve does not change to breaker side.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is ground level while exciting command is output.
normal condition
Service Screen No. 11 F-4 OPT SELECT
1 • Option selector solenoid valve When F041 is cancelled and other error occurs by exchanging the connector
2 • Wiring between option selector When F041 is displayed after the connector is exchanged with other solenoid
Table46-68
Error code F043
Trouble Option selector solenoid valve and output transistor ON are failure, and disconnection.
Judging
condition
Option selector valve does not change to breaker side or it does not change from breaker to
Symptom
nibbler.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is ground level while exciting command is not output.
normal condition
Service Screen No. 11 F-4 OPT SELECT
1 • Option selector solenoid valve When F043 is cancelled and other error occurs by exchanging the connector
2 • Wiring between option selector When F043 is displayed after the connector is exchanged with other solenoid
46-40
Table46-69
Error code G032
Trouble Mechatro controller direct input speed sensor is overrun.
Judging
Engine rpm input is 3000rpm or more. (Only trouble history)
condition
Symptom Operate without problem.
Control in the
Receive rpm from engine controller and control the rpm.
event of failure
Returned in
normal condition
Service Screen No. 2 G-3 MEAS 1 (for mechatro controller)
diagnosis Screen No. 2 G-3 MEAS 2 (receive from engine controller)
1 • Engine speed sensor Measure the resistance between terminals of speed sensor.
SE-13 Normal value: 1.6~2.0k
2 • Wiring between engine speed Check wiring for possible failure according to the wiring checking procedure
sensor and controller and repair it if necessary.
CN-136F Especially check wiring for false disconnection and noise included.
CN-106F
(Controller is broken by only applying power to grounding of signal.)
Table46-70
Error code G033
Trouble Mechatro controller direct input speed sensor, Disconnection
Judging
Voltage of alternator is 12V or more, and speed sensor indicates excess low engine rpm.
condition
Control in the
Receive rpm from engine controller and control the rpm.
event of failure
Returned in
normal condition
2 • Wiring between engine Check wiring for possible failure according to the wiring checking procedure
speed sensor and controller and repair it if necessary.
CN-136F
CN-106F
46-41
Table46-71
Error code G042
Mechatro controller direct input speed sensor and received data from engine controller are
Trouble
overrun.
Judging
Engine rpm input is 3000rpm or more. (Only trouble history)
condition
Control in the
Normal control
event of failure
Returned in
normal condition
• Wiring between engine Check wiring for possible failure according to the wiring checking procedure
2
CN-136F Especially check wiring for false disconnection and noise included.
CN-106F
3 • Wiring between ECU engine Check wiring for possible failure according to the wiring checking procedure
pressure sensor and controller Especially check wiring for false disconnection and noise included.
Check that the error is corrected after replacement of controller.
4 • Mechatro controller
5 • Engine controller Check that the error is corrected after replacement of controller.
46-42
Table46-72
G043
(When cranking is executed for five seconds or more, this error code might be displayed. In case
Error code that the engine does not start, check by the engine failure diagnosis table of "Section 47.3
ENGINE RELATED TROUBLESHOOTING". Execute the following check when the error code
G043 is displayed after starting the engine.)
Mechatro controller direct input speed sensor and received data from engine controller are
Trouble
disconnected.
Judging Voltage of alternator is 12V or more, and speed sensor and receipt data from engine controller
condition indicate excess low engine rpm.
Symptom Engine speed down may cause extension by abrupt loading.
Control in the
Enter 0 rpm for engine speed. Enter 0 for ESS power shift command.
event of failure
Returned in
normal condition
• Wiring between engine Check wiring for possible failure according to the wiring checking procedure
2
CN-136F
CN-106F
3 • Wiring between ECU engine Check wiring for possible failure according to the wiring checking procedure
pressure sensor and controller
Check that the error is corrected after replacement of controller.
4 • Mechatro controller
5 • Engine controller Check that the error is corrected after replacement of controller.
46-43
Table46-73
Error code H013
Trouble Accel potentiometer is disconnected.
Judging
The input voltage from accel potentiometer is 0.1V or less.
condition
Symptom LOW idling is fixed.
Control in the
LOW idling is fixed.
event of failure
Returned in
normal condition
Service Screen No. 2 H-1 ACCEL VOLT.
1 • Accel potentiometer Measure the resistance between terminals of speed sensor. 1.6~2.4k
SE-16 Turn the potentiometer and measure resistance between signal and GND.
2 • Wiring between accel Check wiring for possible failure according to the wiring checking procedure
potentiometer and controller and repair it if necessary.
CN-402F
CN-102F
Table46-74
Error code H014
Trouble Accel potentiometer’s power source is shortcut.
Judging
The input voltage from accel potentiometer is 4.7V or more.
condition
Symptom LOW idling is fixed.
Control in the
LOW idling is fixed.
event of failure
Returned in
normal condition
Service Screen No. 2 H-1 ACCEL VOLT.
1 • Accel potentiometer Measure the resistance between terminals of accel potentiometer.
SE-16 1.6~2.4k
Turn the potentiometer and measure resistance between signal and GND.
2 • Wiring between accel Check wiring for possible failure according to the wiring checking procedure
potentiometer and controller and repair it if necessary.
CN-402F
CN-102F
46-44
Table46-75
Error code H091
Trouble Fuel sensor grounding is short-circuited.
Judging
The input voltage from fuel sensor is 0.1V or less.
condition
Symptom Warning for low fuel level is indicated.
Control in the
Fuel level becomes 0%.
event of failure
Returned in
normal condition
Service Screen No. 10 H-9 FUEL LEVEL
1 • Fuel sensor potentiometer Move fuel sensor and measure the resistance between terminals of fuel
SE-15 sensor.
EMPTY 95 ~ FULL 5
2 • Wiring between fuel Check wiring for possible failure according to the wiring checking procedure
CN-152F
CN-104F
Table46-76
Error code H093
Trouble Fuel sensor’s wiring is disconnection.
Judging
The input voltage from fuel sensor is 4.7V or more.
condition
Symptom Warning for low fuel level is indicated.
Control in the
Fuel level becomes 0%.
event of failure
Returned in
normal condition
Service Screen No. 10 H-9 FUEL LEVEL
1 • Fuel sensor potentiometer Move fuel sensor and measure the resistance between terminals of fuel
SE-15 sensor.
EMPTY 95 ~ FULL 5
2 • Wiring between fuel Check wiring for possible failure according to the wiring checking procedure
CN-152F
CN-104F
46-45
Table46-77
Error code I111
Trouble Reception of CAN1 communication is abnormal. (Passive error)
Judging
Reception from engine controller can not receive correctly.
condition
Symptom It has been affected little.
Control in the
Keep the last receiving condition.
event of failure
Returned in
normal condition
Service Screen No.
1 • Wiring between ECU Check wiring for possible failure according to the wiring checking procedure
and controller and repair it if necessary.
CN-3F (There is a possibility of false disconnection.)
CN-101F
Table46-78
Error code I113
Trouble Reception of cluster communication is abnormal. (Time-out error)
Judging
Reception from gauge cluster can not receive correctly. It has been affected little.
condition
Symptom It has been affected little.
Control in the
It can be operated in condition that coolant temperature is 20°C.
event of failure
Returned in
normal condition
Service Screen No. 2 G-5 WATER TEMP
1 • Wiring between ECU Check wiring for possible failure according to the wiring checking procedure
CN-3F
CN-101F
46-46
Table46-79
Error code I313
Trouble Reception of cluster communication is abnormal. (Time-out error)
Judging
Reception from gauge cluster can not receive correctly.
condition
Symptom Switch operation of gauge cluster can not be done.
Control in the
Keep the condition after immediately key-on is operated.
event of failure
Returned in
normal condition
Service Screen No.
1 • Wiring between gauge cluster Check wiring for possible failure according to the wiring checking procedure
CN-600F
CN-101F
Table46-80
Error code K014
Trouble Battery relay contact welded
Judging The power 24V is continuously supplied to controller for 40 seconds or more while the key switch
condition ON signal turned OFF
The power on the battery relay secondary side does not turn OFF even if the key switch is turned
Symptom
OFF.
Control in the
Normal control with key switch OFF
event of failure
Returned in Turn key switch ON.
normal condition Or when the power supply 24V to mechatro controller is stopped
Service Screen No. 4 K-1 AIS RELAY 2
diagnosis Screen No. 4 K-3 KEY SWITCH OFF
1 • Battery relay Turn key switch off and disconnect the connector (CN-256F) on the battery
R-1 relay coil. If 24V power lives on battery relay secondary side, check on battery
CN-256F relay for failure and replace it if failed.
Turn off the key switch, and remove the connector (CN-256F) on the battery
• Auto idle stop relay 2 relay coil side. If power of battery relay on secondary side falls, remove either
R-24 auto idling stop relay 2 or alternator relay.
2
• Alternator relay The failure may be occurred in case where the power falls after the relay was
R-28 removed, and therefore check on the relay unit and replace it with new one if
failed.
3 • Wiring between auto idle stop When K014 is left displayed with the relay removed
relay/alternator relay and Check that no power 24V is produced on relay (-) line according to the wiring
controller checking procedure and replace it if necessary.
CN-109F, CN2-1 When no failure found after checking on wiring and K014 is left displayed
• Fuse& relay box Replace fuse/relay box.
E-1
46-47
Table46-81
Error code R014
Trouble Wiper motor arc prevention relay error
Judging The mechatro controller output line to wiper motor arc prevention relay is short-circuited with the
condition power source.
Symptom Wiper does not move.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 25 PREVENT ARC
1 • Wiper motor arc prevention relay When error is cancelled after removing wiper motor arc prevention relay, check relay
R-31 unit for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between wiper motor arc When R014 is left displayed with the relay removed
prevention relay and controller Check that no power 24V is produced on relay (-) line according to the wiring
CN-109F, CN2-1 checking procedure and replace it if necessary.
• Fuse & relay box When no failure found after checking on wiring and R014 is left displayed
E-1
Replace fuse/relay box.
Table46-82
Error code R024
Trouble Wiper motor forward rotation relay error
Judging The mechatro controller output line to wiper motor forward rotation relay is short-circuited with the
Symptom Wiper does not move.
Control in the
event of failure
Returned in
normal condition
Service Screen No. 25 CW MOTOR RLY
1 • Wiper motor forward rotation When error is cancelled after removing wiper motor forward rotation relay, check relay
relay unit for failure, replace it with new one if failed.
R-29 When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between wiper motor When R024 is left displayed with the relay removed
forward rotation relay and Check that no power 24V is produced on relay (-) line according to the wiring
CN-109F, CN2-1 When no failure found after checking on wiring and R024 is left displayed
•Fuse & relay box
E-1
46-48
Table46-83
Error code R034
Trouble Wiper motor reverse rotation relay error
Judging The mechatro controller output line to wiper motor reverse rotation relay is short-circuited with the
Symptom Wiper does not move after forward rotation.
Control in the
event of failure
Returned in
normal condition
Service Screen No. 25 CCW MOTOR RLY
1 • Wiper motor reverse rotation When error is cancelled after removing wiper motor reverse rotation relay,
relay check relay unit for failure, replace it with new one if failed.
R-30 When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between wiper motor When R034 is left displayed with the relay removed
forward rotation relay and Check that no power 24V is produced on relay (-) line according to the wiring
CN-109F, CN2-1 When no failure found after checking on wiring and R034 is left displayed
•Fuse & relay box
E-1
Table46-84
Error code R044
Trouble Washer motor relay error
Judging
The mechatro controller output line to washer motor relay is short-circuited with the power source.
condition
Symptom Washer motor does not move.
Control in the
event of failure
Returned in
normal condition
Service Screen No. 25 MOTOR RELAY
1 • Washer motor relay When error is cancelled after removing washer motor relay, check relay unit for failure,
R-32 replace it with new one if failed.
2 • Wiring between washer motor When R044 is left displayed with the relay removed
relay and controller Check that no power 24V is produced on relay (-) line according to the wiring checking
CN-112F, CN2-1 procedure and replace it if necessary.
•Fuse & relay box When no failure found after checking on wiring and R044 is left displayed
E-1
46-49
Table46-85
Error code R134
Trouble Swing flasher right relay error
Judging The mechatro controller output line to swing flasher right relay is short-circuited with the power
condition source.
Symptom Right swing flasher does not light.
Control in the
event of failure
Returned in
normal condition
Service Screen No. 22 D13
1 • Swing flasher relay When error is cancelled after removing connector (CN-74F) of swing flasher relay,
R-19 check relay unit for failure, replace it with new one if failed.
When resistance between relays (HB) and (HC) is 0 , it is in abnormal condition.
2 • Wiring between swing flasher When R134 is left displayed with the relay removed
relay and controller Check that no power 24V is produced on relay (-) line (as shown right upper
CN-74F, CN-109F figure C) according to the wiring checking procedure and replace it if
necessary.
Table46-86
Error code R144
Trouble Swing flasher left relay error
Judging The mechatro controller output line to swing flasher left relay is short-circuited with the power
condition source.
Symptom Left swing flasher does not light.
Control in the
event of failure
Returned in
normal condition
1 • Swing flasher relay When error is cancelled after removing connector (CN-74F) of swing flasher relay,
R-19 check relay unit for failure, replace it with new one if failed.
When resistance between relays (HB) and (HC) is 0 , it is in abnormal condition.
2 • Wiring between swing flasher When R144 is left displayed with the relay removed
relay and controller Check that no power 24V is produced on relay (-) line (as shown right upper
CN-74F, CN-109F figure B) according to the wiring checking procedure and replace it if
necessary.
46-50
Table46-87
Error code R154
Trouble Travel alarm relay error
Judging
The mechatro controller output line to travel alarm relay is short-circuited with the power source.
condition
Symptom Travel alarm does not actuate.
Control in the
event of failure
Returned in
normal condition
1 • Travel alarm relay When error is cancelled after removing of travel alarm relay, check relay unit for failure,
R-8 replace it with new one if failed.
2 • Wiring between travel alarm When R154 is left displayed with the relay removed
relay and controller Check that no power 24V is produced on relay (-) line according to the wiring
•Fuse & relay box When no failure found after checking on wiring and R154 is left displayed.
E-1 Replace fuse/relay box.
Table46-88
Error code R164
Trouble Auto idle stop relay 2 relay error
Judging The mechatro controller output line to auto idle stop relay 2 is short-circuited with the power
condition source.
Power source for mechatro controller often turns off.
Symptom
Auto idle stop relay 2 does not actuate.
Control in the
event of failure
Returned in
normal condition
Service Screen No. 4 K-1 AIS RELAY 2
1 • Auto idle stop relay 2 relay When error is cancelled after removing of auto idle stop relay 2, check relay unit for
R-24 failure, replace it with new one if failed.
2 • Wiring between auto idle When R164 is left displayed with the relay removed
stop relay 2 and controller Check that no power 24V is produced on relay (-) line according to the wiring checking
CN-109F, CN2-2 procedure and replace it if necessary.
•Fuse & relay box When no failure found after checking on wiring and R164 is left displayed.
46-51
Table46-89
Error code R174
Trouble Engine forcibly stop relay error
Judging The mechatro controller output line to engine forcibly stop is short-circuited with the power
condition source.
When key switch is turned off but engine does not stop.
Symptom
Engine auto idle stop function does not actuate.
Control in the
event of failure
Returned in
normal condition
Service Screen No. 4 K-3 ENG STOP
1 • Engine forcibly stop relay When error is cancelled after removing of engine forcibly stop relay, check
R-25 relay unit for failure, replace it with new one if failed.
2 • Wiring between engine When R174 is left displayed with the relay removed
forcibly Check that no power 24V is produced on relay (-) line according to the wiring
stop relay and controller checking procedure and replace it if necessary.
CN-109F, CN2-2 When no failure found after checking on wiring and R174 is left displayed.
• Fuse & relay box Replace fuse/relay box.
E-1
46-52
Table46-90
Error code R184
Trouble Safety lock lever relay error
Judging The mechatro controller output line to safety lock lever relay is short-circuited with the power
condition source.
Symptom Safety lock lever timer does not actuate.
Control in the
event of failure
Returned in
normal condition
Service Screen No. 4 K-4 LOCK LEVER
1 • Safety lock lever relay When error R184 is cancelled after removing of safety lock lever relay, check
R-26 relay unit for failure, replace it with new one if failed.
2 • Wiring between safety lock When R184 is left displayed with the relay removed
lever relay and controller Check that no power 24V is produced on relay (-) line according to the wiring
• Fuse & relay box When no failure found after checking on wiring and R184 is left displayed.
46-53
[MEMO]
46-54
47. TROUBLESHOOTING
(BY TROUBLE)
TABLE OF CONTENTS
47.1 HYDRAULIC SYSTEM ....................................................................................................47-3

47.2 ELECTRIC SYSTEMS .....................................................................................................47-27
47.2.1 WIRING CHECKING PROCEDURE ......................................................................47-27
47.2.2 TROUBLE...............................................................................................................47-30
47.3 ENGINE RELATED TROUBLESHOOTING ....................................................................47-33
47
47-1
47. TROUBLESHOOTING (BY TROUBLE)

E135BSR : YY05-12001~ S5YY4711E01
E135BSRLC : YH05-07001~ (NHK)
↑
(North America)
SK125SR : YV05-04501~
↑
(OCE/S.E.ASIA)
SK135SRLC-2 : YH05-07001~
47-2
47.1 HYDRAULIC SYSTEM

Preface:
The troubleshooting for the failures shown below is explained here.
Identify the failure and trouble and carry forward the troubleshooting in order of the failure item number.
(1) All controls do not function/slow

(2) Engine down/stalled
(3) Move at lever neutral position
(4) Poor fine operability
(5) Slow boom up, insufficient power
(6) Slow boom down, insufficient power for lifting up body
(7) Slow arm in, insufficient power
(8) Slow independent arm out (in the air)
(9) Slow bucket digging
(10)Slow bucket dumping
(11)Swing operation not functioned/slow
(12)Noise during swing operation
(13)Swing on a slope drifts when control lever is in neutral position
(14)Swing drifts when swing operation is stopped
(15)Slow travel speed/weak
(16)Travel deviation
(17)Travel 1st/2nd speed not changed
(18)Travel parking on a slope is not held
(19)Travel does not run straightly when both crawlers and attachment operated simultaneously.
(20)Slow breaker (crusher) operation, weak power
(21)Option selector valve malfunction: not switched to breaker circuit
(22)Option selector valve malfunction: not switched to nibbler (crusher) circuit
47-3
(1) All controls do not function/slow
No. Sections Contents/normal value Corrective action, others

1 Fuse Check fuse No.4 If the fuse is blown out, check on
(10A) the short-circuited section.
2 Safety lever lock Carry out service No.4 K-4 switch: Check action of switch by tester,
switch diagnosis Push down the lever and it turns on, push or check that the power voltage
up and it turns off. is lowered by pushing the lever
down.
3 Safety lever lock Check that the Measure both terminals of solenoid Check solenoid unit for possible
switching solenoid is switched connector. 24V by pushing the lever down, failure.
correctly 0V by pushing it up Check harness for possible
failure.
4 Safety lever lock relay Carry out service No.4 K-4 lock lever: Check action of relay by tester
diagnosis Push down the lever and it turns off, push
up and it turns on.
5 Pilot pressure sensor •Stop engine stop and key is on position. Check 5V power for controller
All pilot low pressure sensors are 0MPa to
0.1MPa.
6 Solenoid valve for Measure pressure of About 0MPa by pushing the lever up, and Replace solenoid valve
safety lock lever solenoid A1 port 4MPa or more by push it down.
7 Pilot line filter Disassemble and Check filter for clogging Clean filter
check it visually
8 Pilot gear pump Measure pilot primary Check that it is 4MPa or more in high idling Check gear pump and the relief
pressure at gear valve for possible failure
pump
9 Multi control valve (in Change position Since all are blocked due to poor switching
case that travel is performance, check that the lever select
operable) pattern is set to the proper position.
10 Actual measuring Carry out service •No.8 D-1 P1 unload valve (cut valve) In case where the reading is
current value of P1/P2 diagnosis D-1 P2 unload valve (cut valve) largely differed from the actually
unload proportional •See Service Diagnosis Data List measured value, check
valve Operation No.3 Boom up full lever & relief proportional valve and controller
for possible failure.
11 Secondary pressure of Measure the Check that P1/P2 unload secondary Replace proportional valve
P1, P2 unload proportional valve pressures are within the range of 0.5 to
proportional valve secondary pressure 1.2MPa in boom up full lever and high
directly at the ports A7 idling operation
and A5 of 7 sections
solenoid block
12 Actual measuring Carry out service •No.9 E-1 P1 pump In case where the reading is
current value of P1/P2 diagnosis. E-2 P2 pump largely differed from the actually
pump proportional •See Service Diagnosis Data List measured value, check
valve Operation No.18 Travel right full lever & proportional valve and controller
idling for possible failure.
Operation No.19 Travel left full lever &
idling
13 Secondary pressure of Measure the pump Check that pump proportional valve Replace proportional valve
pump proportional proportional valve secondary pressure is 2.7MPa or more in
valve secondary pressure right (left) travel full lever and high idling
directly in idling operation
operation. (Ports a3, Right travel: P1 pump proportional valve
a4) Left travel: P2 pump proportional valve
47-4

14 Main relief pressure Carry out service •See Service Diagnosis Data List Measure the relief pressure
diagnosis Operation No.3 Boom up full lever & relief actually
15 Check set pressure Check that P1 and P2 pump pressures are Reset or replace
32MPa in boom up full lever, high idling
and H mode operation.
16 Pump regulator Visual check When removing, free from abnormal Replace
resistance against sliding.
Free from abnormal damage, etc on
outside surface
Spring free from breakage, damage, etc.
17 Pump Visual check When removing, inside parts (cylinder Replace
block, piston, valve plate, shaft, etc.) are
free from abnormal resistance against
sliding, abnormal damage, etc.
(2) Engine down/stalled

current value of P1/P2 diagnosis E-2 P2 pump largely differed from the actually
pump proportional valve •See Service Diagnosis Data List measured value, check
Operation No. 1 Operation is nil proportional valve and controller
2 Secondary pressure of Measure the pump Check that P1/P2 pump proportional Replace proportional valve
P1, P2 pump proportional valve valve pressures are within the range of
proportional valve secondary pressure 0.5 to 1.0MPa in control lever neutral
directly (Ports a3, a4) and high idling operation.
3 Pressure sensor of P1, Check pressure •See Service Diagnosis Data List Check pressure sensor and
P2 pump Operation No. 1 Operation is nil replace it if necessary
Operation No.3 Boom up full lever &
relief
resistance against sliding
outside surface
Spring free from breakage, damage,
etc.
block, piston, valve plate, shaft, etc.)
are free from abnormal resistance
against sliding, abnormal damage, etc.
(3) Move at lever neutral position

1 Pilot pressure sensor Carry out service Check that targeted pilot pressure of Check remote control valve
diagnosis sensor is 0MPa in high idling
2 Remote control valve Check targeted remote Check that spool is free from abnormal Replace
control valve damage and spring is free from
breakage
3 Main spool Check targeted spool Check that spool is free from abnormal Replace
visually damage and spring is free from
breakage
4 Over load relief valve Check targeted spool Free from dust entered in port relief Replace
visually valve. Seat is free from abnormality
47-5

5 Lock valve poppet Check targeted poppet Seat is free from abnormality Replace
(in case of boom and visually
arm)
6 Lock valve selector Exchange lock valve Check that the trouble is reversed Replace
(in case of boom and selector of boom/arm
arm) and boom/arm
7 Holding valve spool for Check that smooth Free from abnormal resistance against Replace
boom sliding of spool in sleeve sliding Do not pull spool out of sleeve
(in case of boom) forcibly.
8 Holding valve relief Check targeted spool Filter free from abnormal Replace
valve for boom visually contamination
(in case of boom)
9 Cylinder Check targeted cylinder Make sure of no problem of seals by Replace cylinder or seals
visually disassembling and investigation
(4) Poor fine operability

1 Pressure sensor Carry out service •See Service Diagnosis Data List Replace pressure sensor
diagnosis Operation No. 1 Operation is nil
•All low pressure sensors are 0MPa to
0.1MPa
valve Operation No. 1 Operation is nil proportional valve and controller
3 Secondary pressure of Measure the Check that P1/P2 unloads secondary Replace proportional valve
unload proportional proportional valve pressures is within the range of
valve secondary pressure 2.7MPa or more in control lever neutral
directly at the ports A7 and high idling operation
solenoid block
Operation No. 1 Operation is nil proportional valve and controller
P1, P2 pump proportional valve valve pressures are within the range of Check regulator
proportional valve secondary pressure 0.5 to 1.0MPa in control lever neutral
directly. (Ports a3, a4) and high idling operation
6 Slow return check valve Visual check Check that slow return check valve Clean and replace
of pilot line installed on pilot line is free from dust
(in case of boom up or entered
arm out)
47-6
(5) Slow boom up, insufficient power

1 Boom up pressure Carry out service •See Service Diagnosis Data List Check and replace pressure
sensor diagnosis Operation No.3 boom up full lever and sensor
relief Check remote control valve
2 Remote control valve Measure directly remote Check that pressure is 3.0MPa or more Check remote control valve
control pressure of in boom up full lever and high idling When equipped with multi
boom up operation control valve, check it while
changing lever pattern
3 Pump pressure sensor Carry out service •See Service Diagnosis Data List When there is difference
diagnosis for P1, P2 Operation No.4 boom up full lever and between P1 and P2 pump
pump pressures in in operation pressures, check high pressure
operation. sensor.
valve Operation No.3 Boom up full lever & proportional valve and controller
relief for possible failure.
P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary pressure 0.5~1.2MPa in boom up full lever and
directly at the ports A7 high idling operation
solenoid block
Operation No.4 boom up full lever & in proportional valve and controller
operation for possible failure.
proportional valve secondary pressure 1.8 to 3.0MPa in boom up full lever and
directly (Ports a3, a4) high idling operation
8 P2 by-pass cut valve Visual check No problem for sliding ability of main Clean and replace
<Trouble> poppet and no contamination on orifice
Only P2 pressure is low. No problem for sliding ability of internal
piston (Check it through PBp2 port.)
breakage
10 Lock valve poppet Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
Both P1 and P2 Free from abnormal damage, etc on damage)
pressures are low. outside surface
11 Conflux check valve Visual check When removing, free from abnormal Replace
Only P2 pressure is Free from abnormal damage, etc on damage)
high. outside surface
12 Holding valve for boom Visual check When removing, free from abnormal Replace
(poppet) resistance against sliding (Check on the casing side for
<Trouble> Free from abnormal damage, etc on damage)
Both P1 and P2 outside surface
pressures are high.
47-7

13 Boom spool Visual check When removing, free from abnormal Replace
Only P1 pressure is Spring is free from breakage. damage)
high.
14 Check boom spool and Disassembly and Free from abnormal resistance against Replace spool assembly
recirculation investigation sliding
<Trouble> Spring is free from breakage.
Only P1 pressure is low.
15 Conflux spool Visual check When removing, free from abnormal Replace
Only P2 pressure is Spring is free from breakage. damage)
high. Free from abnormal damage, etc on
outside surface
16 Main relief valve Check set pressure •See Service Diagnosis Data List Reset or replace
<Trouble> Operation No.3 boom up full lever and
Relief pressure is low. relief
17 Over load relief valve Visual check (Head Pressure is 32MPa or more in boom up When only relief pressure of
<Trouble> side) full lever and high idling. Free from boom up is low, replace valve
Relief pressure is low. dust entered in over load relief valve.
Seat is free from abnormality
(6) Slow boom down/insufficient power for lifting up body

1 Boom down pressure Carry out service •See Service Diagnosis Data List Check and replace pressure
sensor diagnosis Operation No.5 boom down full lever sensor.
& in operation Check remote control valve.
2 Remote control valve Measure remote control Check that pressure is 3.0MPa or more Check remote control valve
pressure of boom down in boom down full lever and high idling When equipped with multi
directly operation control valve, check it while
changing lever pattern.
3 Actual measuring Carry out service P1 unload valve (cut valve) In case where the reading is
current value of P1 diagnosis •See Service Diagnosis Data List largely differed from the actually
unload proportional Operation No.5 boom down full lever & measured value, check
valve in operation proportional valve and controller
4 Secondary pressure of Measure the Check that P1 unload secondary Replace proportional valve
P1 unload proportional proportional valve pressures are within the range of 0.8 to
valve secondary pressure 1.2MPa in boom down full lever and
directly at the ports A7 of high idling operation
7 sections solenoid
block.
pump proportional valve Operation No.5 boom down full lever measured value, check
& in operation proportional valve and controller
6 Secondary pressure of Measure the pump Check that P1 pump proportional valve Replace proportional valve
P1 pump proportional proportional valve pressures are within the range of 2.0 to
valve secondary pressure 2.5MPa in boom down full lever and
47-8

7 Actual measuring Carry out service Check that the value is not change •Check pressure sensor of
current value of travel diagnosis regardless of operation travel
straight proportional •See Service Diagnosis Data List •In case where the reading is
valve Operation No. 1 Operation is nil largely differed from the
Operation No.18 Travel right full lever actually measured value, check
& idling proportional valve and
Operation No.19 Travel left full lever & controller for possible failure.
idling
8 Travel straight Measure directly the High idling pressure is 0.8MPa or less Replace proportional valve
proportional valve travel straight regardless neutral/operation
secondary pressure proportional valve
secondary pressure.
breakage
10 Lock valve poppet Visual check When removing, free from abnormal Replace
Boom down is low. Free from abnormal damage, etc on damage)
outside surface
11 Holding valve (poppet) Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding Free from (Check on the casing side for
Boom down is slow. abnormal damage, etc on outside damage)
surface
12 Boom spool Visual check When removing, free from abnormal Replace
Boom down is slow. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
13 Check boom spool and Disassembly and Free from abnormal resistance against Replace spool assembly
Machine can not be
lifted by supporting with
boom.
15 Over load relief valve Visual check Free from dust entered in port relief Replace
<Trouble> valve.
Machine can not be Seat is free from abnormality
lifted by supporting with
boom.
(7) Slow arm in, insufficient power

1 Arm in pressure sensor Carry out service •See Service Diagnosis Data List Check and replace pressure
diagnosis Operation No.6 arm in full lever and sensor
pressure control pressure of arm in arm in full lever and high idling When equipped with multi
in operation control valve, check it while
47-9

diagnosis for P1, P2 Operation No.7 arm in full lever and in between P1 and P2 pump
pump pressures in operation pressures, check high pressure
operation. sensor
valve Operation No.6 Arm in full lever & proportional valve and controller
proportional valve secondary pressure 1.2MPa in arm in full lever and high
directly at the ports A7 idling operation.
solenoid block.
Operation No.7 Arm in full lever & in proportional valve and controller
P1, P2 pump proportional valve valve pressures are 2.0MPa or more in
proportional valve secondary pressure arm in full lever and high idling
directly. (Ports a3, a4) operation. (Secondary pressure is
affected by oil temperature and
attachment weight)
8 Actual measuring Carry out service •See Service Diagnosis Data List In case where the reading is
current value of arm in diagnosis Operation No. 1 Operation is nil largely differed from the actually
spool 2 proportional Operation No.6 Arm in full lever & measured value, check
valve relief proportional valve and controller
Operation No.7 Arm in full lever & in for possible failure.
operation
9 Secondary pressure of Measure directly the Check that secondary pressure of Replace proportional valve
arm in spool 2 proportional valve proportional valve secondary
proportional valve secondary pressure at pressures are within the range of
the ports A8 (arm 2 following
spool) of 7 sections Lever neutral: 0MPa
solenoid block. Motion in the air: 1.7 to 2.2MPa
Arm in relief: 2.5MPa or more
idling
11 Secondary pressure of Measure directly the 0.8MPa or less in high idling operation Replace proportional valve
travel straight proportional valve regardless of neutral/operation
proportional valve secondary pressure at
the ports A6 (travel
straight) of 7 sections
solenoid block
47-10

breakage
14 Over load relief valve Visual check (Head Pressure is 32MPa or more in arm in When only relief pressure of arm
<Trouble> side) and relief. in is low, replace valve
P1, P2 pressure is low. Free from dust entered in over load
relief valve.
Seat is free from abnormality
15 Over load relief valve Visual check (Rod side) Pressure is 32MPa or more in arm out When only relief pressure of arm
<Trouble> and relief. out is low, replace valve
relief valve.
Seat is free from abnormality.
16 Arm 1 spool Visual check When removing, free from abnormal Replace
P1, P2 pressure is high. Free from abnormal damage, etc on damage)
outside surface
P1, P2 pressure is high Free from abnormal damage, etc on damage)
or low. outside surface
18 Check arm 2 spool and Disassembly and Free from abnormal resistance against Replace spool assembly
Arm in power is poor.
19 Check lock valve poppet Visual check Free from abnormal resistance against Replace
<Trouble> sliding (Check on the casing side for
Both P1, P2 pressures Free from abnormal damage, etc on damage)
are high. outside surface
(8) Slow independent arm out (in the air)

1 Arm out pressure Carry out service •See Service Diagnosis Data List Check and replace pressure
sensor diagnosis Operation No.8 arm out full lever and sensor
control pressure of arm in arm out full lever and high idling When equipped with multi
out operation control valve, check it while
diagnosis for P1, P2 Operation No.9 arm out full lever and between P1 and P2 pump
pump pressures in in operation pressures, check high pressure
operation. sensor
valve Operation No.8 Arm out full lever & proportional valve and controller
47-11

proportional valve secondary pressure 1.2MPa in arm out full lever and high
directly at the ports A7 idling operation
solenoid block
Operation No.9 Arm out full lever & in proportional valve and controller
proportional valve secondary pressure 1.5 to 2.7MPa in arm out full lever and
(Secondary pressure is affected by oil
temperature and attachment weight)
idling
the ports A6 (travel
solenoid block
breakage
12 Over load relief valve Visual check (Rod side) Pressure is 32MPa or more in arm out When only relief pressure of arm
<Trouble> and relief. out is low, replace valve
relief valve. Seat is free from
abnormality
P2 pressure is high. Free from abnormal damage, etc on damage)
outside surface
outside surface
47-12

15 Check arm 2 spool and Disassembly and Free from abnormal resistance against Replace spool assembly
recirculation investigation (spring sliding
<Trouble> side) Spring is free from breakage.
Both P1, P2 pressures
are low.
16 Check lock valve poppet Visual check Free from abnormal resistance against Replace
<Trouble> sliding (Check on the casing side for
(9) Bucket digging is slow

1 Bucket digging pressure Carry out service •See Service Diagnosis Data List Check and replace pressure
sensor diagnosis Operation No.12 bucket digging full sensor
lever and relief Check remote control valve
control pressure of in bucket digging full lever and high When equipped with multi
bucket digging idling operation control valve, check it while
diagnosis for P1, P2 Operation No.13 Bucket digging full between P1 and P2 pump
pump pressures in lever and in operation pressures, check high pressure
operation. sensor
unload proportional Operation No.12 Bucket digging full measured value, check
valve lever & relief proportional valve and controller
valve secondary pressure 1.2MPa in bucket digging full lever and
directly at the ports A7 high idling operation
solenoid block
pump proportional valve Operation No.13 Bucket digging full measured value, check
lever & in operation proportional valve and controller
P1 pump proportional proportional valve pressures is 2.7MPa or more in bucket
valve secondary pressure digging full lever and high idling
directly (Ports a3) operation.
current value of travel diagnosis Operation No.12 Bucket digging full largely differed from the actually
straight proportional lever & relief measured value, check
valve proportional valve and controller
9 P2 by-pass cut valve Visual check No problem for sliding ability of main Clean or replace
47-13

breakage
Operation No.3 Boom up full lever and
relief
12 Travel straight spool Visual check When removing, free from abnormal Replace
outside surface
13 Bucket spool Visual check When removing, free from abnormal Replace
14 Over load relief valve Check targeted spool Free from dust entered in over load Replace
visually relief valve.
(10)Bucket dump is slow

1 Bucket dump pressure Carry out service •See Service Diagnosis Data List Check and replace pressure
sensor diagnosis Operation No.14 Bucket dump full sensor
control pressure of in bucket dump full lever and high When equipped with multi
bucket dump idling operation control valve, check it while
diagnosis for P1, P2 Operation No.15 Bucket dump full between P1 and P2 pump
pump pressures in lever and in operation pressures, check high pressure
operation. sensor
unload proportional Operation No.14 Bucket dump full measured value, check
valve lever & relief proportional valve and controller
P1 unload proportional proportional valve pressures are within the range of
valve secondary pressure 0.5~1.2MPa in bucket dump full lever
directly at the ports A7 and high idling operation. Replace
and A5 of 7 sections proportional valve
solenoid block
pump proportional valve Operation No.15 Bucket dump full measured value, check
Carry out service lever & in operation proportional valve and controller
diagnosis. for possible failure.
P1 pump proportional proportional valve pressures is 2.7MPa or more in bucket
valve secondary pressure dump full lever and high idling
directly (Ports a3) operation.
47-14

current value of travel diagnosis Operation No.14 Bucket dump full largely differed from the actually
straight proportional lever & relief measured value, check
valve proportional valve and controller
9 Secondary pressure of Measure directly the Check that travel straight secondary Replace proportional valve
travel straight proportional valve pressure is 2.7MPa or more in bucket
proportional valve secondary pressure at dump full lever and high idling
the ports A6 (travel operation
solenoid block
10 P2 by-pass cut valve Visual check No problem for sliding ability of main Clean and replace
piston (Check it through PBP2 port.)
breakage
<Trouble> Operation No.3 Boom up full lever and
outside surface
14 Bucket spool Visual check When removing, free from abnormal Replace
visually relief valve.
(11)Swing does not move/slow

1 Swing pressure sensor Carry out service •See Service Diagnosis Data List Check and replace pressure
diagnosis Operation No.11 Swing full lever and sensor
in operation Check remote control valve
control pressure of in boom up full lever and high idling When equipped with multi
swing operation control valve, check it while
3 Swing parking brake Carry out service No.3 F-2 SWING-BRAKE Check swing pressure sensor
solenoid diagnosis Lever neutral: COMP ON, MEAS ON Check harness
Swing: COMP OFF, MEAS OFF
Swing parking brake Measurement of Lever neutral: 0MPa Replace solenoid valve
4
solenoid solenoid valve A2 port In operation: 4MPa or more
5 Shuttle valve Visual check No contamination on spool cover Clean or replace
<Trouble> (short side) and orifice
Pilot pressure is low. No damage on spool cover (long side)
and shuttle
47-15

6 Pump pressure sensor Carry out service •See Service Diagnosis Data List Check high pressure sensor
diagnosis for P2 pump Operation No.11 Swing full lever and
pressures in operation in operation
unload proportional Operation No.11 Swing full lever & in measured value, check
valve operation proportional valve and controller
valve secondary pressure 1.2MPa in swing full lever and high
directly at the ports A5 of idling operation
7 sections solenoid
block
current value of P2 diagnosis largely differed from the actually
Operation No.11 Swing full lever & in proportional valve and controller
P2 pump proportional proportional valve pressure is 2.7MPa or more in swing
valve secondary pressure full lever and high idling operation
directly (Ports a3, a4)
(Check this trouble by Operation No.18 Travel right full lever actually measured value, check
only swing operation) & idling proportional valve and
idling
(Check this trouble by the ports A6 (travel
only swing operation) straight) of 7 sections
solenoid block
breakage
P2 pressure is low. Free from abnormal damage, etc on damage)
outside surface
15 Swing spool Visual check When removing, free from abnormal Replace
outside surface
16 Swing relief valve Check set pressure •See Service Diagnosis Data List Reset or replace
<Trouble> Operation No.10 Swing full lever and
47-16

17 Swing motor Visual check Inner parts (cylinder block, piston, Replace
valve brake etc) are to be free from
abnormal resistance against sliding.
outside surface (brake plate etc)
18 Swing reduction gear oil Take sample oil from Sampling oil does not include a lot of Disassemble and inspect
swing reduction gear metal powder. reduction gear
drain
19 Swing reduction Visual check Tooth surface is not worn abnormally Replace
and is not chipped.
(12)Noise occurred at swing operation

Swing: COMP OFF, MEAS OFF
2 Measurement of Lever neutral: 0MPa Replace solenoid valve
solenoid valve A2 port In operation: 4MPa or more
3 Boost check valve Visual check When removing, free from abnormal Replace
(Sound of cavitation at resistance against sliding
stopping) Spring is free from breakage.
4 By-pass check valve Visual check When removing, free from abnormal Replace
(Sound of cavitation at resistance against sliding
stopping) Spring is free from breakage.
5 Swing motor Visual check Disassemble and inspect abnormal Replace
(Brake valve/friction wear and scuffing
plate)
6 Swing motor piston Visual check When removing, free from abnormal Replace
7 Swing reduction gear oil Take sample oil from Sampling oil does not include a lot of Disassemble and inspect
swing reduction gear metal powder. reduction gear
drain.
8 Swing reduction Visual check Tooth surface has no abnormally worn Replace
and chipped.
(13)Swing drifts on a slope while swing control lever is in neutral position

1 Swing pressure sensor Carry out service •Engine stop & starter key ON Check and replace pressure
diagnosis All pilot low pressure sensors are sensor
within range of 0 to 0.1MPa.
breakage
Swing: COMP OFF, MEAS OFF Check parking brake release
switch
4 Measurement of Lever neutral: 0MPa Replace solenoid valve
solenoid valve A2 port In operation: 4MPa or more
5 Swing motor Visual check Disassemble and inspect abnormal Replace
(Brake valve/friction wear and scuffing
plate)
47-17

6 Parking brake Visual check Piston and friction plate do not have Replace
abnormal resistance against sliding
Free from spring damage
(14)Swing drifts at stopping

1 Shuttle valve Visual check No contamination on spool cover Clean or replace
<Trouble> (short side) and orifice. No damage on
Pilot pressure is low spool cover (long side) and shuttle.
2 Swing pressure sensor Carry out service •Engine stop & starter key ON Replace pressure sensor
diagnosis All pilot low pressure sensors are
within range of 0 to 0.1MPa.
3 Swing relief valve Check set pressure •See Service Diagnosis Data List Reset or replace
<Trouble> Operation No.10 Swing full lever and
4 Anti-reaction valve Visual check Free from dirt entering Clean or replace
Sliding part should be free from foreign
matter entering, abnormal damage and
wear.
breakage
6 Swing motor Visual check Inner parts (cylinder block, piston, Replace
valve brake etc) are to be free from
abnormal resistance against sliding.
47-18
(15)Travel speed is slow/poor

1 Travel right and left Carry out service •See Service Diagnosis Data List Check and replace pressure
pressure sensor diagnosis Operation No.18 Travel right full lever sensor
and idling Check remote control valve
Operation No.19 Travel left full lever
and idling
control pressure of in travel right (left), forward (reverse)
travel right and left full lever and high idling operation
valve Operation No.18 Travel right full lever proportional valve and controller
& idling for possible failure.
idling
proportional valve secondary pressure followings in travel right (left), forward
directly at the ports A7 (reverse) full lever and high idling
and A5 of 7 sections operation
solenoid block Travel right (P1 unload): 0.5 to 1.0MPa
Travel left (P2 unload): 0.5 to 1.0MPa
Operation No.18 Travel right full lever proportional valve and controller
idling
6 Secondary pressure of Measure the pump Check that P1/P2 unload secondary Replace proportional valve
P1, P2 pump proportional valve pressures are within the range of
directly (Ports a3, a4) (reverse) full lever and high idling
operation
Travel right (P1 pump): 2.7MPa or
more
Travel left (P2 pump): 2.7MPa or more
7 Actual measuring Carry out service Check that the value is not change •Check voltage of low pressure
current value of travel diagnosis regardless of operation sensor other than sensor for
straight proportional •See Service Diagnosis Data List travel
valve Operation No. 1 Operation is nil •In case where the reading is
Operation No.18 Travel right full lever largely differed from the
& idling actually measured value, check
Operation No.19 Travel left full lever & proportional valve and
idling controller for possible failure
proportional valve secondary pressure
breakage
Check sealing ability of shuttle valve
and entry of dust in orifice
47-19

outside surface
11 Travel spool Visual check of targeted When removing, free from abnormal Replace
<Trouble> spool resistance against sliding (Check on the casing side for
Pump pressure is high. Free from abnormal damage, etc on damage)
outside surface
12 Travel motor relief valve Check set pressure Check P1 and P2 pump pressures are If P1 is low, right travel motorÅfs
32MPa or more in right and left travel relief valve is failed.
levers full lever (relief operation at If P2 is low, left travel motorÅfs
locked crawler belt) and high idling relief valve is failed.
13 Travel motor Visual check Inner parts (piston, cylinder block, Replace
valve plate, brake valve spool) are to
be free from abnormal resistance
against sliding.
14 Parking brake in travel Visual check When removing, free from abnormal Replace
motor resistance against sliding
No sticking on friction plate and
separator plate
15 Travel reduction gear oil Take sample oil from Sampling oil does not include a lot of Disassemble and inspect
travel reduction gear metal powder. reduction gear
drain
16 Travel reduction Visual check Tooth surface is not worn abnormally Replace
and is not chipped.
(16)Travel deviation

1 Travel right and left Carry out service •See Service Diagnosis Data List Check and replace pressure
pressure sensor diagnosis Operation No.18 Travel right full lever sensor
and idling Check remote control valve
Operation No.19 Travel left full lever
and idling
control pressure of in travel right (left), forward (reverse)
travel right and left full lever and high idling operation
3 Actual measuring Carry out service Check that the value is not change •Check voltage of low pressure
current value of travel diagnosis regardless of operation sensor other than sensor for
straight proportional •See Service Diagnosis Data List travel
valve Operation No. 1 Operation is nil •In case where the reading is
Operation No.18 Travel right full lever largely differed from the
& idling actually measured value, check
Operation No.19 Travel left full lever & proportional valve and
idling controller for possible failure.
proportional valve secondary pressure
47-20

valve Operation No.18 Travel right full lever proportional valve and controller
idling
directly at the ports A7 (reverse) full lever and high idling
and A5 of 7 sections operation
solenoid block Travel right (P1 unload): 0.5 to 1.0MPa
Travel left (P2 unload): 0.5 to 1.0MPa
Operation No.18 Travel right full lever proportional valve and controller
idling
8 Secondary pressure of Measure the pump Check that P1/P2 unload secondary Replace proportional valve
P1, P2 pump proportional valve pressures are within the range of
directly (Ports a3, a4) (reverse) full lever and high idling
operation
Travel right (P1 pump): 2.7MPa or
more
Travel left (P2 pump): 2.7MPa or more
9 Exchange P1 for P2 Exchange delivery pipe Check the direction of deviation If the direction is changed,
of P1 for P2 inspect a pump. If the direction
is not changed, inspect a valve
and travel unit.
breakage
Check sealing ability of shuttle valve
and entry of dust in orifice
outside surface
Spring is free from breakage
12 Travel spool Visual check of targeted When removing, free from abnormal Replace
<Trouble> spool resistance against sliding (Check on the casing side for
Pump pressure is high. Free from abnormal damage, etc on damage)
outside surface
13 Travel motor relief valve Check set pressure Check P1 and P2 pump pressures are If P1 is low, right travel motorÅfs
32MPa or more in right and left travel relief valve is failed.
levers full lever (relief operation at If P2 is low, left travel motorÅfs
locked crawler belt) and high idling relief valve is failed.
Replace as necessary
47-21

14 Travel motor Visual check Inner parts (piston, cylinder block, Replace
valve plate, brake valve spool) are to
be free from abnormal resistance
against sliding.
15 Travel reduction gear oil Take sample oil from Sampling oil does not include a lot of Disassemble and inspect
travel reduction gear metal powder. reduction gear
drain
16 Travel reduction Visual check Tooth surface is not worn abnormally Replace
and is not chipped.
outside surface
etc.
block, piston, valve plate, shaft, etc.)
are free from abnormal resistance
against sliding, abnormal damage, etc.
(17)Travel 1/2 speed cannot be switched

(In case of the traveling under heavy loading (for example traveling on a slope or traveling on a soft ground), the
speed may sometimes does not change from 1st to 2nd because this machine equips the function of automatic
speed change.)

1 Travel 1/2 speed Carry out service Switch travel 1/2 speed to 2nd speed Check pressure sensor
switching solenoid diagnosis No.3 F-3 1/2-TRAVEL Check harness
Lever neutral COMP OFF, MEAS OFF Check travel 1/2 speed switch
Travel operation COMP ON, MEAS on gauge cluster
ON
2 Travel 1/2 speed Measure A3 port Lever neutral: 0MPa Replace solenoid valve
switching solenoid pressure on solenoid In operation: 4MPa or more
valve
3 1/2 speed switching Visual check Check that spool is free from abnormal Replace
spool in travel motor damage and spring is free from (Check on the casing side for
breakage damage)
4 1/2 speed switching Visual check Free from entry of dust Remove dust or replace
orifice in travel motor
5 Tilting piston in travel Visual check Free from abnormal wear on piston Replace
motor and seal (Check on the casing side for
damage)
(18)Machine does not stay on a slope in traveling

1 Pilot pressure sensor Carry out service •Engine stop & starter key switch is ON Check pressure sensor and
diagnosis Targeted pilot low pressure sensor is replace as necessary
in range of 0 to 0.1MPa Check remote control valve
breakage
47-22

3 Parking brake in travel Visual check When removing, free from abnormal Replace
motor resistance against sliding
etc.
4 Orifice of passage for Visual check Free from entry of dust Remove dust or replace
parking brake in travel
motor
(19)Machine does not travel straight in simultaneous operation of traveling and attachment

1 Actual measuring Carry out service No.8 D-3 S-TRAVEL is should be •Check voltage of low pressure
current value of travel diagnosis COMP 590mA and MEAS 560 to sensor other than travel sensor
straight proportional 620mA in both travel full lever and in •In case where the reading is
valve boom up full lever at high idling largely differed from the
actually measured value, check
proportional valve and
controller for possible failure.
2 Secondary pressure of Measure directly the Check secondary pressure is within Replace proportional valve
travel straight proportional valve range of 1.8 to 2.2MPa in both travel
proportional valve secondary pressure full lever and in boom up full lever at
high idling
resistance against sliding (Check on the casing side for
Free from abnormal damage, etc on damage)
outside surface
(20)Breaker works slowly and power is poor (In case of conflux, check p1 unload/pump and travel straight)

1 Pressure sensor for Carry out service •See Service Diagnosis Data List Check and replace pressure
optional attachment diagnosis Operation No.16 P2 side OPT full senso
2 Remote control valve Measure directly remote Check that pressure is 2.1MPa or more Check remote control valve0
control pressure of in optional attachment full lever and
travel right and left high idling operation
3 Actual measuring Carry out service •See Service Diagnosis Data List •In case where the reading is
current value of P1/P2 diagnosis Operation No.16 P2 side OPT full largely differed from the
unload proportional lever and relief actually measured value, check
valve proportional valve and
proportional valve secondary pressure 1.2MPa
directly at the ports A7
solenoid block
5 Actual measuring Carry out service •See Service Diagnosis Data List •Check voltage of low pressure
current value of travel diagnosis Operation No.16 P2 side OPT full sensor other than sensor for
straight proportional lever & relief optional attachment
valve •In case where the reading is
largely differed from the
actually measured value, check
proportional valve and
47-23

6 Secondary pressure of Measure directly the Check that travel straight secondary Replace proportional valve
travel straight proportional valve pressure is 2.7MPa or more in optional
proportional valve secondary pressure at attachment full lever and high idling
the ports A6 (travel operation
solenoid block
7 P1 by-pass cut valve Visual check No problem for sliding ability of main Clean or replace
8 Relief pressure Check set pressure •See Service Diagnosis Data List Reset or replace
Operation No.16 P2 side OPT full
lever and relief
(Set value of factory shipment is
24.5MPa.)
9 Remote control valve Check targeted remote Check sealing ability of shuttle valve Replace
control valve and entry of dust in orifice.
outside surface
11 Spool for optional Visual check When removing, free from abnormal Replace
attachment resistance against sliding (Check on the casing side for
<Trouble> Free from abnormal damage, etc on damage)
P1, P2 pressures are outside surface
high. Spring is free from breakage.
visually relief valve
(21)Selector valve for option malfunctions: Breaker circuit is not obtained.

(Indication of failure is displayed. For reference, see "Table47-1 Action of optional selector solenoid valve")

1 N&B selector spool Visual check When removing, free from abnormal Replace
outside surface
2 N&B selector solenoid Screw for emergency Check that the error indication is Replace solenoid valve
disappeared by turning emergency
screw
3 N&B selector solenoid Carry out service •No.11 F-4 Option selector is B mode Check solenoid valve
diagnosis COMP ON, MEAS ON Check harness
Spool position BRK
Selector switch BRK
4 N&B selector pressure Carry out service •No.16 B-11 Check pressure sensor
sensor diagnosis Data List Check harness
3.0MPa at B mode and 0.0MPa at A
mode
47-24
(22)Selector valve for option malfunctions: Nibbler circuit is not obtained.

(Indication of failure is displayed. For reference, see "Table47-1 Action of optional selector solenoid valve")

1 N&B selector spool Visual check When removing, free from abnormal Replace
outside surface
2 N&B selector solenoid Carry out service •No.11 F-4 Option selector is A mode Check solenoid valve
diagnosis COMP OFF, MEAS OFF Check harness
Spool position NIB
Selector switch NIB
47-25
Table47-1 Action of optional selector solenoid valve

Optional Selector
Safety lock Safety lock selector valve
Engine Work Spool Failure diagnosis
No. lever SW's lever relay's valve detecting Warning display
condition mode position display
input output COMP. pressure
MEAS. sensor
1 Running ON OFF A OFF Nibbler Normal — —
2 "SELECTOR VALVE [F042] displayed
Running ON OFF A ON Breaker Normal
FAILURE" simultaneously
3 "SELECTOR VALVE
Running ON OFF A OFF Breaker Normal —
FAILURE"
4 Running ON OFF A ON Nibbler Normal — [F042] displayed
5 Running ON OFF B ON Breaker Normal — —
6 "SELECTOR VALVE [F043] displayed
Running ON OFF B OFF Nibbler Normal
FAILURE" simultaneously
7 "SELECTOR VALVE
Running ON OFF B ON N&B Normal —
FAILURE"
8 Running ON OFF B OFF Breaker Normal — [F043] displayed
9 "SELECTOR VALVE
Running ON OFF — — — Failure [B113] displayed
FAILURE"
10 Stopping — — — — — — — —
11 — OFF — — — — — — —
12 — — ON — — — — — —
47-26
47.2 ELECTRIC SYSTEMS

47.2.1 WIRING CHECKING PROCEDURE
Check for continuity between connector terminals, CONNECTOR
presence or absences of short-circuit with other wires,
and presence or absences of short-circuit with machine
body grounding.
WIRE
(1) Checking for disconnection between connectors.
(When both ends measurement is easy because of
TESTER
short distance between connectors,)
Measure the resistance using tester.
Pull out opposite connector first.
When the resistance is zero (0), it is in normal
condition.
(When both ends measurement is difficult because

of long distance between connectors,)
Measure the resistance using tester. JUMPER
Pull out opposite connector first. WIRE
Where the resistance is zero (0), if the terminal on
one side is connected to frame body grounding with TESTER
jumper wire, it is in normal condition. FRAME BODY GROUNDING
The resistance is 1M or more when the terminal
on one side is not connected to frame body
grounding with jumper wire, it is in normal condition.
(2) Checking for presence or absence of short-circuit

with machine body
When the resistance is 1M or more, it is in normal
condition.
TESTER
FRAME BODY GROUNDING
(3) Checking for presence or absence of short-circuit

between wirings.
When the resistance is 1M or more, it is in normal
condition. TESTER
47-27
(4) Checking connector terminal for contact

Insert male terminal into female terminal unit, and INSERT
then check that the inserting force is equivalent to
other female terminals. MALE TERMINAL FEMALE TERMINAL
If looseness is there, replace the female terminal
with new one.
Clean the dirt terminal.
Do not insert the male terminal the thickness differs. It

may cause loose connection.
(5) Caution which should be paid in measuring voltage

When measuring the power supply to electric
equipment at connector position with the grounding
terminal contained inside of connector, measure
the voltage between grounding inside of connector
and power terminal.
When measuring the voltage between frame body
grounding and power source, the disconnection of
wiring to grounding inside of connector cannot be
identified.
Since the voltage may vary between with connector
connected and with connector not connected.
Measure the voltage with each connector
connected whenever possible.
(6) Checking the general view of connector CRIMPED
PART
a. Check the terminal crimped condition.
Pull one electric cable with the about 3kg force,
RUBBER
and make sure that the cable does not come out PLUG
RECEPTACLE.
of the terminal. CONTACT
When came out, replace the terminal and crimp PLUG

SEALING
it again. (is housed in plug)
b. Check connector for imperfect insertion DOUBLE LOCK

PLATE FOR PLUG
Check that all top ends form a line on the same DOUBLE LOCK
PLATE FOR CAP
position as seen from the connector engaged
side. CAP
When moved along, push it in further through TAB.CONTACT

wire inserting hole. RUBBER PLUG
c. Check connector for intruding of water.

Pull out the connector and check that the inside
is free from intruding of water.
When water intruding is found, check rubber plug
for damage and also that the sealing is fitted
properly.
47-28
(7) When abnormality occurs at intervals

When the abnormality situation can not be
reoccurred during checking operation, try the
following operations.
a. Check that variable of display exists or not on the
service diagnosis screen while shaking the
harness or giving shock by operating the
machine.
b. Check that variables of resistance and voltage
exist or not using tester while shaking the
harness.
c. Turn starter switch on and apply electricity
continuously, and check it again after the
temperature of wiring and equipment was raised.
(8) Checking on body grounding
Check attaching bolts of grounding terminal for
loosening.
And also check that there is no loose connection
due to corrosion.
There are multiple groundings like centralized

grounding box shown in the figure and battery
grounding, engine grounding, horn grounding fixed
together with horn, body grounding placed on
attaching section of boom working light.
Block of grounding is located
under floor plate of cab.
47-29
47.2.2 TROUBLE
(1) Engine does not stop.
(2) "CPU DATA COMMUNICATION ERROR" is displayed on multi display.
(3) Auto accel does not actuate. (The engine speed does not automatically slow down.)
(4) Auto accel does not actuate. (The engine speed does not automatically speed up.)
(5) Wiper does not function.
47-30
(1) Engine does not stop.

1 Starter key switch Check signal of starter No.4 K-3 Key switch Check continuity between
key switch ON by OFF at starter key switch OFF position terminals of starter switch using
carrying out service ON at starter key switch ON position tester
diagnosis.
2 Engine forcible stop When ON is displayed No.4 K-3 Key switch Check on engine forcible stop
relay with the starter switch OFF at starter key switch OFF position relay
OFF, then pull out R-25 ON at starter key switch ON position
engine forcible stop
relay and carry out the
service diagnosis.
3 Wiring Voltage between line 0V when starter switch is OFF Check harness
No.62 among starter Check diode D-9 between
switch, engine forcible starter switch and auto idling
stop relay, mechatro stop relay 1
controller and the body
grounding
(2) "CPU DATA COMMUNICATION ERROR" is displayed on multi display.

1 Fuse No.1 fuse (5A) Not blown fuse Check harness
Replace fuse
2 Mechatro controller Accel control Engine speed varies according to Check mechatro controller and
accel potentiometer operation. replace as necessary
(Use remote control because the auto
accel function is working.)
3 Wiring Transmission circuit line See "WIRING CHECKING Repair wiring
No.770 from mechatro PROCEDURE"
controller to gauge
cluster
4 Gauge cluster Gauge cluster Replace gauge cluster
(3) Auto accel does not actuate. (The engine speed does not automatically slow down).

1 Engine coolant Check engine coolant No.2 G-5 WATER TEMP Replace engine coolant sensor
temperature temperature by carrying Auto accel does not work in the
out service diagnosis. temperature -15°C or less.
Warm up and raise the coolant
temperature to – 15°C or more
2 Gauge cluster Indication of auto accel Mark "Display/not display" for auto Replace gauge cluster
accel switches by auto accel switch
operation on gauge cluster.
3 Low pressure sensor Service diagnosis Each control pressure of No.5 and Check low pressure sensor
No.6 is in the range of 0~0.1MPa at
control lever neutral position.
(4) Auto accel does not actuate. (The engine speed does not automatically speed up.)

1 Low pressure sensor Service diagnosis Each control pressure of No.5 and Check low pressure sensor
No.6 is raised with control lever
operated.
47-31
(5) Wiper does not function
Wiping range of
forward and
reverse movements
Wiper motor
Rise up (storing) position Rise up limit switch's ON range
Upper reversing position Reverse limit switch's ON range
Lower reversing position

1 Fuse Check fuse No.20 Replace fuse
2 SW-19: Service diagnosis No.19 D125 Check wiper interlock switch
Wiper interlock switch Wiper switch display (D125) is OFF with front window closed. and repair it if necessary
Check according to "WIRING
CHECKING PROCEDURE" and
repair it if necessary
3 Rise up limit switch built- Service diagnosis No.25 Wiper system Check according to "WIRING
in wiper motor CHECKING PROCEDURE"
Reverse limit switch Switch action in operation
Normal condition
Rise up limit switch ON OFF OFF
Reverse limit switch ON ON OFF
4 R-31: Service diagnosis No.25 Wiper system

Arc prevention relay
When started by forward rotation: STOP START (STOP) (REVERSE) (STOP) (FORWARD)
R-29: Arc prevention relay OFF ON ON ON ON OFF ON ON ON OFF ON
Forward rotation relay Forward rotation relay OFF ON ON ON ON OFF OFF OFF OFF OFF ON
R-30: Reverse rotation relay OFF OFF OFF OFF OFF OFF ON ON ON OFF OFF
Check that the relay is worked as shown in the table. Check that the relay is excited.
Reverse rotation relay * When the limit switch does not change in OFF after 4 seconds Check relay & fuse box and replace it
from the wiper startup, turn OFF all relay's outputs. if necessary.
47-32
47.3 ENGINE RELATED TROUBLESHOOTING
Checking
Filters Liquid Leak, clogging
Air leak between turbocharger and intake manifold

Factors
Leak, clogging of fuel system and intruding of air

Contamination of water and fuel with oil
Breather hose crushed or clogged
Fan belt slipped, fan pulley worn
Poor or deteriorated battery

Shortage of fuel level
Improper fuel in use

Air cleaner clogged
Fuel filter clogged
Oil level of oil pan

Oil filter clogged
Muffler clogged
Engine oil leak
Coolant level
Trouble
Poor start ability (Take a long time)

Faulty starting
Faulty engine starting/engine does not rotate.

Faulty engine starting/engine rotates but no
exhaust gas (No fuel injection)
Faulty engine starting/exhaust gas is emitted

but engine does not start (With fuel injection)
Poor output Insufficient
Engine poor run-up (Low follow-up ability)

rotation
Rotation in bad condition (hunting)

Engine stalled during operation.
Output is lowered.
Overheating
Exhaust smoke is black
Exhaust smoke is white
Larger oil consumption (or blue exhaust gas)
Other failures
Early contamination of oil

Larger fuel consumption
Intruding of oil in coolant, back flow, reduction
of coolant quantity
Hydraulic pressure down (Monitor lights up)
Oil quantity increased. (Intruding of water and fuel)
Vibration
47-33
Checking Electric equipment

Shovel side Shovel side Engine side
Loose mounting bolts, damage of mounting rubber

Factors
Radiator core clogged/fin clogged and crushed

Peeling of space insulation around radiator
Loose connection of battery cable terminal

Failure of radiator pressure cap
Failure of hydraulic system

Startup circuit wiring
Starter switch key
Hydraulic switch
Starter motor
Battery relay
Safety relay
Glow relay
Glow plug
Alternator
Trouble

Faulty starting



rotation

Output is lowered.
Overheating
Other failures

of coolant quantity
Vibration
47-34
Intake and Cooling

Fuel system exhaust system Lubrication system
system
Factors
Seizing and interference of turbocharger

Seal of turbocharger worn, damaged
Turbocharger oil drain tube clogged
Leak and crush of hydraulic piping
Failure of thermostat (Not open)

Fuel leak into the head cover
Improper fuel injection time
Failure of regulator valve
Damage of water pump

Failure of supply pump
Failure of relief valve

Failure of oil pump
Failure of injector
Trouble

Faulty starting



rotation

Output is lowered.
Overheating
Other failures

of coolant quantity
Vibration
47-35
Engine body
Factors
Wear and damage of rear oil seal and seal surface

Damage and seizing of piston and connecting rod
Damage of engine oil cooler core and O-ring
Damage of cylinder head and head gasket
Wear and failure of valve and valve guide
Wear of piston ring and liner, ring stick

Strainer clogged, damage of oil pipe
Failure of injection holder sleeve
Damage of flywheel gear

Hole due to cavitation
Damage of dumper
Trouble

Faulty starting



rotation

Output is lowered.
Overheating
Other failures

of coolant quantity
Vibration
47-36
48. TROUBLESHOOTING
(TROUBLE DIAGNOSIS MODE)
TABLE OF CONTENTS
48.1 TROUBLE DIAGNOSIS MODE .......................................................................................48-3
48
48-1
48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)

SK330–8 : LC10-07001~ S5YN4818E01
SK350LC–8 : YC10-03501~ (ASIA, OCE)
SK200–8 : YN11-45001~
↑ August, 2006 ↑ K
SK210LC–8 : YQ11-06001~
SK250-8 : LQ12-06001~
↑ October, 2006 ↑ K
SK260LC-8 : LL12-05001~
E235BSR : YF05-02001~ ↑
E235BSR(N)LC : YU05-02001~ (NHK)
E215B : YN11-45001~ ↑
↑ March, 2007 K
SK235SR-2 : YF05-02001~ ↑
↑ April, 2007 K
SK235SRLC-2 : YU05-02001~ (OCE)
SK200-8 : YN11-45001~ ↑
↑ ↑ K
SK250-8: LQ12-06001~ ↑
↑ May, 2007 K
E225BSR : YB05-03001~ ↑
↑ June, 2007 K
E225BSRLC : LA05-02001~ (NHK)
↑
↑ ↑ SK215SRLC : LA05-02001~ K
(North America)
E135BSR : YY05-12001~ ↑
↑ July, 2007 K
E135BSRLC : YH05-07001~ (NHK)
SK225SR : YB05-03001~ ↑
↑ ↑ K
SK225SRLC : LA05-02001~ (OCE)
E215B : YN11-45001~ ↑
↑ ↑ K
E265B : LQ12-06001~ ↑
↑ ↑ K
↑
↑ ↑ ↑ K
(NHK Middle East)
E215B : YN11-45001~ ↑
↑ ↑ K
↑
↑ ↑ ↑ K
E385B : LC10-07001~ ↑
↑ August, 2007 K
E265B : LQ12-06001~ ↑
↑
↑ ↑ ↑ K
↑
↑ ↑ SK135SRLC-2 : YH05-07001~ K
(North America)
SK125SR : YV05-04501~
↑
(OCE/S.E.ASIA)
SK135SRLC-2 : YH05-07001~
48-2
48.1 TROUBLE DIAGNOSIS MODE

The trouble diagnosis mode is used to automatically specify the failed sections for the troubles which can not be
detected by auto diagnosis function (the trouble can be specified by error code) like disconnection, abnormal output.
(1) Function
There are two types of trouble diagnosis mode.
1) Trouble diagnosis mode 1: Used to diagnose unload system, pump system, travel straight system and
engine system.
2) Trouble diagnosis mode 2: Used to diagnose pilot system.
In any mode, with the attachment not operated, both selector valve and proportional valve are automatically
actuated, the sensor detects the machine condition and the mechatro controller identifies the normal
condition or failed condition of the system.
(2) How to use and flow chart
The operation is performed through gauge cluster.
No.1 Select service adjustment select screen.
(Switch starter key on while pressing buzzer stop switch and press select switch three times while pressing
buzzer stop switch on the service diagnosis screen No.1.)
No.2 Select Trouble diagnosis mode
(Move the cursor to the desired position with screen change switch " ", and press the select switch.)
No.3 Select either "DIAG MODE 1" or "DIAG MODE 2"
(Move the cursor to the desired position with screen change switch " ", and press the select switch.)
No.4 Go ahead the operation according to the instructions on the screen of cluster gauge.
No.1 No.2 No.3

SELECT SWITCH
LANGUAGE/LOGO 8 FAULT DIAG MODE DIAG MODE 1
BUZZER STOP SWITCH
ADJUSTING MODE 1 DIAG MODE 2
PRESET BY FACTORY
FEED SCREEN CHANGE SWITCH
CASE OF DIAG MODE 1
SENSOR CHECK START ENG LOWER BOOM DIAG MODE 1

ENGINE SPEED
RELEASE LOCK In diagnosis
CHECK 0000 rpm
PRESSURE
C-1 00.0M C-2 00.0M
TO GROUND LEVER START operation
PROPO-VALVE About 15 minutes
E-1 005mA E-2 005mA
D-1 300mA D-2 300mA
For the diagnosing items, see Table 48-1.

When required to stop in diagnosis
Turn engine on operation, press the buzzer stop switch
manually. BACK TO No.3 and the operation is forcedly stopped.
The data at the time of judgment

can be confirmed with the select
RESULT OF DIAGNOSIS RESULT OF DETAIL switch.
When
DIAG MODE 1 not failed, DIAG MODE 1 1 P1 UNLOAD
ENGINE SPEED
0000 rpm
END ENGINE STOP OK O K PRESSURE
C-1 00.0M C-2 00.0M
PROPO-VALVE
E-1 005mA E-2 005mA
DATA END FEED D-1 300mA D-2 300mA
The other judgments can be

Engine stops confirmed with the feed button.
automatically. RESULT OF DIAGNOSIS
When failed,
DIAG MODE 1 RESULT 1 1 P1 UNLOAD
ENGINE SPEED
P1 UN-LOAD PSV NG 0000 rpm
P1 UN-LOAD SPOOL NG NG PRESSURE

C-1 00.0M C-2 00.0M
PROPO-VALVE
DATA END FEED DATA END FEED E-1 005mA E-2 005mA
D-1 300mA D-2 300mA
The suspected trouble sections are displayed in order of

possibility. The suspected three sections in maximum are
BACK TO No.3 displayed. When desired to see other suspected trouble sections,
press feed " " button. For diagnosis results and corrective
actions to be taken, see Table 48-2.
Notes:
1. When the trouble diagnosis mode is operating, lower the attachment and put the bucket on the ground. If the machine failed; the unexpected touch to the lever may move the
attachment and it causes injury or death.Because the bucket-grounded/bucket-not-grounded can not be automatically identified, do not fail to start operating the trouble diagnosis
mode after making sure of the bucket-grounded condition.
2. Before executing the trouble diagnosis mode, check each pressure sensor proportional valve and select valve for possible abnormality.
Check that the commands of proportional valve and select valve do not largely differ from the actually measured values through the service diagnosis.
The preliminary investigation of electric system makes the time saving and high precision diagnosis possible.
3. For the diagnosis results and the corrective actions to be taken, usually occurred troubles are taken as an example. When multiple troubles are occurred at the same time, there is a
case no accordance of diagnosis obtained. In this case, contact our dealer/distributor.
4. When the trouble diagnosis mode is executing, the error display with self-diagnosis and warning does not appear. If necessary, examine the presence or absence of trouble referring
to the trouble history.
48-3
No.4 CASE OF DIAG MODE 2
SENSOR CHECK START ENG

ENGINE SPEED
LOWER BOOM DIAG MODE 2
CHECK 0000 rpm
PRESSURE
C-1 00.0M C-2 00.0M
TO GROUND START
PROPO-VALVE
E-1 005mA E-2 005mA
D-1 300mA D-2 300mA
Turn engine on
Example: Case of boom up
manually. AT CONTROL LEVER IS
NEUTRAL WHEN FINISHING OF
DIAGNOSIS IS REQUIRED.
BOOM UP BOOM UP
OK BACK TO No.3
PRESSURE 0.0 MPa PRESSURE 1.5 MPa PRESSURE 3.0 MPa
SEARCHABLE OPERATION
Boom up
Boom down
In the normal condition, OK is
Bucket digging displayed when the control
lever is moved to stroke end.
Bucket dump
Arm in
Arm out
Swing
Travel right
Travel left
P1 side option
P1 side option
Notes:
1. When the trouble diagnosis mode is operating, lower the attachment and put the bucket on the ground. If the machine failed; the unexpected touch to the lever may move the
attachment and it causes injury or death. Because the bucket-grounded/bucket-not-grounded can not be automatically identified, do not fail to start operating the trouble diagnosis
mode after making sure of the bucket-grounded condition. Place the bucket on the ground between both crawlers.
2. In the case of "DIAG MODE2", pump pressure is unloaded with unload valve in order not to actuate attachment.
When trouble diagnosis is performed, if the pump pressure is generated, the engine stops and "UN-LOAD PSV NG" is displayed. Check the troubled section according to indication.
3. When the trouble diagnosis mode is executing, the error display with self-diagnosis and warning does not appear. If necessary, examine the presence or absence of trouble referring
to the trouble history.
Table48-1 Failure diagnosis Mode-1/Diagnosis item

No. Display Contents of diagnosis
Is normal pressure generated in the condition that the flow rate at P1 side is minimum and
1 1 P1 UNLOAD
the unloading valve is in the emergency position?
Is normal pressure generated in the condition that the minimum flow rate is relieved at P1
2 2 P1 UNLOAD
side?
Is normal pressure generated in the condition that the unload valve is fully opened, and P1
3 3 P1 UNLOAD
side flow rate is minimum?
Is normal pressure generated in the condition that the unload valve is in emergency position,
4 1 P2 UNLOAD
and P2 side flow rate is minimum?
Is normal pressure generated in the condition that the minimum flow rate is relieved at P2
5 2 P2 UNLOAD
side?
Is normal pressure generated in the condition that the unload valve is fully opened, and P2
6 3 P2 UNLOAD
Is normal pressure generated in the condition that the flow rate at P1 side is emergency and
7 1 P1 PUMP
Is normal pressure generated in the condition that the unload valve is emergency, and P1
8 2 P1 PUMP
9 3 P1 PUMP
and P1 side flow rate is maximum?
Is normal pressure generated in the condition that the flow rate at P2 side is emergency and
10 1 P2 PUMP
Is normal pressure generated in the condition that the unload valve is emergency, and P2
11 2 P2 PUMP
12 3 P2 PUMP
and P2 side flow rate is maximum?
48-4
Table48-1 Failure diagnosis Mode-1/Diagnosis item

No. Display Contents of diagnosis
Is normal pressure generated in the condition that P1 side flow rate is minimum, unload
13 1 TRAVEL-S
valve is emergency position and travel straight is stroked fully?
Is normal pressure generated in the condition that P2 side flow rate is minimum, unload
14 2 TRAVEL-S
valve is emergency position and travel straight is stroked fully?
Is rated engine speed obtained in the condition that P1 side flow rate increases little by little
15 1 P1 ENGINE
when P1 side flow rate is relieved?
Is rated engine speed obtained in the condition that P2 side flow rate increases little by little
16 2 P2 ENGINE
when P2 side flow rate is relieved?
When pump regulator does not have "Total power control of Emergency mode", "1 P1 PUMP" of No.7 and "1 P2
PUMP" of No.10 are not given a diagnosis.
Table48-2 Failure diagnosis Mode-1/Diagnosis and Remedy

Diagnosis (Display) Possible cause Remedy
Check each pressure sensor by
SENSOR CHECK Disconnection of pressure sensor, Short
service diagnosis and replace it if
NG circuit, Abnormal output
necessary
Secondary pressure is excessive high against
the command Check P1 unload proportional valve
P1 UN-LOAD PSV NG
Secondary pressure is excessive low against and replace it if necessary
the command
Stuck at full-stroke side Check P1 unload spool and replace it
P1 UN-LOAD SPOOL NG
Stuck at neutral side if necessary
the command Check P2 unload proportional valve
P2 UN-LOAD PSV NG
the command
Stuck at full-stroke side Check P2 unload spool and replace it
P2 UN-LOAD SPOOL NG
Stuck at neutral side if necessary
Stuck at closing side Check P1 by-pass cut valve and
P1 B-P CUT NG
Stuck at neutral side replace it if necessary
Stuck at closing side Check P2 by-pass cut valve and
P2 B-P CUT NG
the command Check P1 pump proportional valve
P1 PUMP PSV NG
the command
Delivery rate is excessive large against the Check P1 pump regulator and replace
command it if necessary.
P1 PUMP NG
Delivery rate is excessive small against the Check P1 pump and replace it if
command necessary.
the command Check P2 pump proportional valve
P2 PUMP PSV NG
the command
48-5
Table48-2 Failure diagnosis Mode-1/Diagnosis and Remedy

Diagnosis (Display) Possible cause Remedy
Delivery rate is excessive large against the Check P2 pump regulator and replace
command it if necessary.
P2 PUMP NG
Delivery rate is excessive small against the Check P2 pump and replace it if
command necessary.
the command Check travel straight proportional
S-TRAVEL PSV NG
Secondary pressure is excessive low against valve and replace it if necessary
the command
Stuck at full-stroke side Check travel straight spool and
S-TRAVEL SPOOL NG
PUMP 1 PRESS. SENSOR Check P1 high pressure sensor and
Pressure is recognized lower than it is
NG replace it if necessary
PUMP 2 PRESS. SENSOR Check P2 high pressure sensor and
Pressure is recognized lower than it is
NG replace it if necessary
Set pressure decreases Check main relief valve and replace it
MAIN RELIEF NG
Set pressure increases if necessary
Check engine and replace it if
ENGINE NG Output is lowered
necessary
Check engine speed sensor and
E/G R SENSOR NG Characteristics is misaligned
replace it if necessary
48-6
51. ENGINE
PREFACE
This service manual explains the single engine. Note that this manual is edited without
modification by based on the service manual of MITSUBISHI HEAVY INDUSTRIES, Ltd.
51
51-1
51. ENGINE

E135BSR : YY05-12001~ S5YY5111E01
E135BSRLC : YH05-07001~ (NHK)
↑
(North America)
SK125SR : YV05-04501~
↑
(OCE/S.E.ASIA)
SK135SRLC-2 : YH05-07001~
51-2

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HYDRAULIC EXCAVATOR

Book Code No.S5YY0013E01

2) WARNING- Indicates a potentially hazardous

The proper and safe lubrication and maintenance

2007-12 & ASSEMBLING

1.1 GENERAL PRECAUTIONS FOR MAKING REPAIRS ......................................................1-4

Book Code No. S5YN0118E01

Issue Date of Issue Applicable Machines Remarks

prepare for accidents and fire.

5) For parts which are required to use jig and

(6) Unit Conversion Table

QUANTITIES JIS SI REMARKS

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

Book Code No. S5YY0213E01

Issue Date of Issue Applicable Machines Remarks

2.1 NAME OF COMPONENTS

   

   

2.3 WEIGHT OF COMPONENTS

Marks * show dry weight.

1100 (3'7") 7070 (23'2") 3480 (11'5")

2.4.2 DIMENSIONS OF ATTACHMENT

(2) Arm and bucket

Type 2.38m (7ft-10in) Arm + 2.84m (9ft-4in) Arm +

Type Hoe bucket

Type Hoe bucket

2.5 SPECIFICATIONS AND PERFORMANCE

Engine model MITSUBISHI D04FR-74kW

2.5.3 HYDRAULIC COMPONENTS

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

2.6 TYPE OF CRAWLER

2.7 TYPE OF BUCKET

2.8 COMBINATIONS OF ATTACHMENT

0.24 (0.31) 0.20 (0.26)

SK135SR(LC)-2 Bucket Available Arm

0.24 (0.31) 0.20 (0.26)

2.9 ENGINE SPECIFICATIONS

Applicable machine SK125SR / SK135SR-2 / SK135SRLC-2

2.9.2 ENGINE CHARACTERISTIC CURVE

ENGINE SPEED (min-1)

Fuel consumption volume

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

Book Code No. S5YY0313E01

Issue Date of Issue Applicable Machines Remarks

3.1.2 BOOM MAINTENANCE STANDARD

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

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

2.38m (7ft-10in) ARM YY12B00433F1 Unit : mm (ft-in)

3.2.2 ARM MAINTENANCE STANDARD

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

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

PL1 PL3 PL6

Fig. 3-7 Bucket dimensional drawing

No. NAME No. NAME

3.3.2 BUCKET DIMENSIONAL TABLE

3.3.3 LUG SECTION DIMENSIONAL DRAWING

Roughness of counterbore bottom X

Fig. 3-8 Dimension of lug section

Screw hole P.C.D

$