Shop Manual Sk330 8pdf Compress 201 400

22.
HYDRAULIC SYSTEM
SE22 SE23 P MB MB P
P P
MAIN PUMP PSV1 a1 A1 A2 a2 PSV2
PH1 PH2
PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING
PG
VA VA DB
REG REG
1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT
a3
8
a4
Dr
5.0MPa
M A B
a5
195kw B1
/2100min-1 B3 Dr3 A3
PTO
(OCEANIA) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM 1
P P
2
P P
3 4 5 6 7
P P
8
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1
BR CP1
PCa K M H
AR
PBr CCb
PAs
Dr 1 2 3 4 5 6 7 8
SE5
BOOM LCb LCs Pss
SWING P
PBb PBs 16
As (OCEANIA)
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
LCAP2
SV-2 PBa2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 17
T2 P2
LC01Z00070P1 03
13
Fig. 22-11 COMBINED CIRCUIT : Swing / Arm in operation, swing priority function
22-29
22. HYDRAULIC SYSTEM
22.11 PRESSURE DRAINING (3) Operation :

(RELEASING) CIRCUIT 1) Pump proportional valve reduces the pump flow
rate to the minimum.
This section describes the following operations.
2) Unloading proportional valves (PSV-D, PSV-B)
(1) Pressure drain (releasing) pilot circuit
output secondary pressure and the secondary
(2) Pressure drain (releasing) main circuit
pressure flows in PCb, PCa ports of C/V(2) and
22.11.1 PRESSURE RELIEVING PILOT CIRCUIT switches the P1, P2 unloading valves to OPEN
position.
(1) Purpose :
To release the pressure in main circuit for piping 22.11.2 PRESSURE RELEASE MAIN CIRCUIT
repair works.
(1) Operation :
(2) Principle :
After the mode is switched to "Pressure Relief
Mode" with switch on gauge cluster, mechatro
controller outputs the following commands. When the hydraulic pressure releasing is
1) Minimum tilting command value to pump performed, make sure to place bucket on the
proportional valve (PSV-P1, PSV-P2). ground.
2) Output "Pressure relief control speed command When the operating lever is shifted to neutral during
value" at ECU. (Electric system) engine running, "DRAINING HYD. PRESS." is
3) Stand-by command value to P1, P2 unloading displayed on the gauge cluster while the mode
proportional valves switch is changed to pressure relieving mode. In
this time the intermittent buzzer sounds
How to switch to "Pressure release mode"
continuously. When right and left operating levers
1) Select the service diagnosis mode. are operated 4 or 5 times to their full stroke,
(Keeping pressing of the "BUZZER STOP pressure is relieved.
SWITCH" [ ] on gauge cluster, turn the starter After draining pressure is completed, turn off the
key on.) starter key and buzzer sound stops. If the pump
2) Select the service adjustment mode 1. pressure is determined to be more than 1 MPa (145
(Under the condition that "Screen No.1" of psi) by the output value of the high pressure sensor
"Service diagnosis mode 1" is indicated, or the high pressure sensors (SE-22,23) are
keeping pressing of the "BUZZER STOP broken, "FAIL DRAIN HYD. PRESS" is displayed
SWITCH", press the selector switch [ ] 3 and the buzzer sounds continuously. In that case,
times. When "LANGUAGE/LOGO", also the buzzer is not stopped unless the engine
"ADJUSTING MODE 1" and "PRESET BY key is turned to OFF. Repeat the pressure releasing
FACTORY" are displayed, press [ ] or [ ] procedure once again.
switch, and highlight "ADJUSTING MODE 1", (2) Hydraulics :
and then press "Selector Switch" again.) If the travel straight valve is turned to the pressure
3) When "ADJUSTING MODE 1" screen is release position, the oil delivered by each pump is
displayed, press [ ] or [ ] switch, and "DRAIN unloaded to the tank passage. If the spools are
HYD. OFF" screen appears. switched by pilot operation, the remaining pressure
from the actuators may be relieved to the tank
4) Press "Selector Switch" and highlight "OFF",
circuit, i.e. the main circuit pressure may be
and press [ ] switch to change to "DRAIN
released.
HYD. ON", and then press "Selector Switch"
again.
22-30
SE22 SE23 P MB MB P
P P
MAIN PUMP PSV1 a1 A1 A2 a2 PSV2
PH1 PH2
PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING
PG
VA VA DB
REG REG
1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT
a3
8
a4
Dr
5.0MPa
M A B
a5
195kw B1
/2100min-1 B3 Dr3 A3
PTO
(OCEANIA) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM 1
P P
2
P P
3 4 5 6 7
P P
8
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1
BR CP1
PCa K M H
AR
PBr CCb
PAs
Dr 1 2 3 4 5 6 7 8
SE5
BOOM LCb LCs Pss
SWING P
PBb PBs 16
As (OCEANIA)
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 17
T2 P2
LC01Z00070P1 03
13
Fig. 22-12 PRESSURE DRAIN (RELEASE) CIRCUIT : At pressure release mode.
22-31
[MEMO]
22-32
23. ELECTRIC SYSTEM
TABLE OF CONTENTS
23.1 ELECTRIC CIRCUIT DIAGRAM......................................................................................23-3

23.2 ELECTRICAL EQUIPMENT LIST....................................................................................23-7
23.3 HARNESS........................................................................................................................23-8
23.3.1 HARNESS LIST......................................................................................................23-8
23.3.2 INSTRUMENT PANEL ASSY.................................................................................23-9
23.3.3 CONTROLLER INSTALL........................................................................................23-10 23
23.3.4 TUNER INSTALL....................................................................................................23-10
23.3.5 UPPER ELECTRIC ASSY ......................................................................................23-11
23.3.6 UPPER HARNESS ASSY (1/6) ..............................................................................23-12
23.3.7 ENGINE HARNESS ASSY .....................................................................................23-25
23.3.8 UPPER HARNESS ASSY (FLOOR PLATE) (1/2)..................................................23-27
23.3.9 CAB HARNESS ASSY ...........................................................................................23-33
23.3.10 BOOM HARNESS ASSY........................................................................................23-36
23.3.11 INSTALLING BOOM LIGHT ...................................................................................23-36
23.3.12 INSTALLING UPPER LIGHT..................................................................................23-37
23.3.13 CAB LIGHT INSTALL .............................................................................................23-37
23.3.14 FLASHER LAMP INSTALL.....................................................................................23-38
23.3.15 ALARM ASSY.........................................................................................................23-38
Book Code No. S5LC2311E02
23-1
23. ELECTRIC SYSTEM
Issue Date of Issue Applicable Machines Remarks

SK330–8 : LC10-07001~ S5LC2311E01
First edition July, 2006 K
SK350LC–8 : YC10-03501~ (ASIA, OCE)
S5LC2311E02
Revision February, 2007 ↑ K
(ASIA, OCE)
23-2
23. ELECTRIC SYSTEM
23.1 ELECTRIC CIRCUIT DIAGRAM
DC-DC CONVERTER,
ROOM LIGHT TUNER
CIGARETTE LIGHTER
HORN, HORN RELAY
FUEL SUPPLY PUMP

ENG. CONTROLLER
ENG. CONTROLLER
RELAY, HOUR METER
KEY SW. STARTER RELAY

ACTUATOR POWER
APPLICABLE YN11-45001-
GAUGE CLUSTER
IT CONTROLLER
MACHINE No. YQ11-06001-
AUTO GREASE
CONTROLLER
CONTROLLER
CONTROLLER
LEVER LOCK
LC10-07001-
BATTERY RELAY
MECHATRO
MECHATRO
C-8 : ENGINE CONTROLLER ENG. HARNESS
YC10-03501-
BACK UP
BACK UP
SUPPLY
TUNER
ENG. SPEED SENSOR
FOR ECU
SH7 SHIELD
E-1 : FUSE & RELAY BOX
EGR VALVE 1
R-26 :
LEVER LOCK RELAY
EGR VALVE 2
SK330-8
SOLENOID,
HIGH REACH,
LMN/BH
AIR CON.
AIR CON.
RADIATOR COOLANT
LEVEL CONTROLLER,
FLASHER, REAR WORK
LIGHT, TRAVEL ALARM,
ONE WAY CALL
DC-DC CONVERTER
WORK LIGHT
GAUGE CLUSTER
WIPER, WASHER
CAB WORK LIGHT
CAB WORK LIGHT
ROOF WIPER
OPT. BUCKET CONTROL

OPT. 4
OPT. 1
OPT. 3
OPT. HAND CONTROL
AIR CON. (AMP.) SK350LC-8 ONLY
ENGINE CONTROLLER INJECTOR 1

CHECK CONNECTOR
SH1 SHIELD
INJECTOR 2
E-12 : E-12 :
BATTERY BATTERY SH2 SHIELD
STARTER CABLE
INJECTOR 3
SH3 SHIELD
E27 :
ACCEL REDUNDANT
R-1 : VOLUME
E-15 : BATTERY RELAY INJECTOR 4
FUSIBLE LINK
SH4 SHIELD
R-23 :
AUTO IDLE STOP RELAY 1 R-24 : R-25 : INJECTOR 5
AUTO IDLE ENG. EMERGENCY
STOP RELAY 2 STOP RELAY SH5 SHIELD
KEY ON
POSITION
INJECTOR 6
PREHEATING
SH6 SHIELD
START
TERMINAL
ENGINE START
ACC
OFF
ON
IN THE CASE OF
R-3 : SK330-8, SK350LC-8
GLOW RELAY GLOW
CYLINDER
DISCRIMINATION
G SENSOR
SW-1 : BOOST SENSOR

KEY SW.
E-2 :
ALTERNATOR
M-1 : C-1 :
STARTER MOTOR MECHATRO CONTROLLER COMMON RAIL
(TCO-60-2) PRESS. SENSOR
R-4 :
SAFETY RELAY
SUCTION
CONTROL VALVE
(FUEL PUMP (SCV))
C-6 :
R-2 : AUTO GREASE CONTROLLER
STARTER RELAY E-3 : HOUR METER
SHIELD FUEL PUMP SENSOR
CHARGE
KEY ON
PREHEATING
WATER TEMP SENSOR
C-5 :
CONTROL : (SENSOR POWER RADIATOR COOLANT SW-27 :
SOURCE, CPU) LEVEL CONTROLLER RADIATOR COOLANT LEVEL SW.
OUT SOURCE :
(PSV, SOL. MOTOR)
R-28 : ALTERNATOR RELAY
CONTROL : (SENSOR POWER

SOURCE, CPU)
WATCH IC TO 2/4
SW-28 :
(1/4)
WATER SEPARATOR SW.
LC03Z00036P1 02
23-3
23. ELECTRIC SYSTEM
C-1 : MECHATRO CONTROLLER (TCO-60-2)

FROM 1/4
SE-16 : ACCEL POTENTIO

PRESS. SENSOR
SE-1 : BUCKET DIGGING
C-8 : ENG. CONTROLLER

SE-2 : BUCKET DUMP
ENG. HARNESS
SE-3 : BOOM UP
POSITION
INJECTOR 1
SE-4 : BOOM DOWN
RELEASE
NORMAL
SW-4 :
TERMINAL SWING PARKING BRAKE RELEASE SW.
INJECTOR 2 SE-7 : ARM IN SV-1 :
SWING PARKING BRAKE SOL.
SE-8 : ARM UP
INJECTOR 3 SV-3 : TWO SPEED SELECT SOL.
SE-5 : SWING
SV-2 : POWER BOOST SOL.
IN CASE OF
INJECTOR 4 SK200-8, SE-9 : TRAVEL RIGHT PSV-B : P2 UNLOAD
SK210LC-8 PROPORTIONAL SOL.
SE-10 : TRAVEL LEFT PSV-C : TRAVEL PRIORITY

PROPORTIONAL SOL.
SE-22 : PUMP P1
PSV-D : P1 UNLOAD
PROPORTIONAL SOL.
SE-23 : PUMP P2
PSV-A : ARM TWO-SPEED INVERSE
PROPORTIONAL SOL.
SE-20: P1 OPT. PSV-P1 : PUMP P1

PROPORTIONAL SOL.
C-2 : GAUGE CLUSTER
SE-11 : P2 OPT.
PSV-P2 : PUMP P2
PROPORTIONAL SOL.
ENG. WATER TEMP INDICATOR

PSV-E : OPT RELIEF ADJUSTMENT
PROPORTIONAL SOL. 1
SE-15 : FUEL SENSOR PSV-H : ARM CUSHION

FUEL METER
PROPORTIONAL SOL.
PSV-I : OPT RELIEF ADJUSTMENT

PROPORTIONAL SOL. 2
OPT
SW-20 : POWER BOOST SW. RIGHT
SE-13 : ENG. SPEED SENSOR

SHIELD
SHIELD
DISPLAY BUZZER MODE WASHER

SELECT SW. STOP
ENTER DECEL TRAVEL WIPER

TO 3/4
2-SPEED
(2/4)
LC03Z00036P1 02
23-4
23. ELECTRIC SYSTEM

FROM 2/4
R-17 : EXTRA RELEASE RELAY

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

E-5 : HORN LOW
SW-10 : HORN SW. LEFT
SE-28 : EXTRA PRESS
EXTRA RELEASE SW-5 : HORN SW. RIGHT

EU(OPT)
(WIPER RELAY) OPT.
SW-15 : R-31 :
CONFLUX/SINGLE SELECT SW. PREVENT SPARK RELAY
R-29 :
WIPER MOTOR RELAY L-5 : ROOM LIGHT
OPT
M-3 : WIPER MOTOR
R-30 :
WIPER MOTOR REVERSING RELAY
SW-44 :
EXTRA PRESS. SW.
EU
E-14 : CIGARETTE LIGHTER

R-32 :
WINDOW WASHER MOTOR RELAY M-4 : WASHER MOTOR
SW-11 : R-26 : SV-4 :
LEVER LOCK LEVER LOCK CONTROL LEVER LOCK SOL. E-10 : E-11 :
SW. RELAY RECEIVER DRIER AIR COMPRESSOR CLUTCH
STOP R-6 :
REVERSE WORK LIGHT RELAY
GROUND
OUTPUT AIR CON.
AMP.
SW-19 : WIPER INTERLOCK SW.
SW-35 : HEAVY LIFT SW.
EU
COOLING
UNIT
SE-29 : R-8 : TRAVEL ALARM RELAY

OPT. SELECTOR DETECT SENSOR
E-13 :
TRAVEL ALARM
SV-13 : OPT. SELECTOR SOL.

SW-13 : TRAVEL ALARM SW.
OPT JAPAN: OPT

USA: STD
SW-12 : OCEANIA: STD
OVER LOAD ALARM SELECT SW-17 : ROOF WIPER SW.
POSITION
SW. E-7 : TUNER AM & FM
M-9 : ROOF WIPER MOTOR

OFF
ON
TERMINAL E-8 : SPEAKER LEFT

SE-26 :
PRESS. SENSOR : BOOM HEAD FM / AM
EU(FOR OVER LOAD ALARM)
E-9 : SPEAKER RIGHT
(BACK-UP)
EU
ROOF WIPER
TO 4/4
(3/4)
LC03Z00036P1 02
23-5
23. ELECTRIC SYSTEM
C-1 : MECHATRO CONTROLLER (TCO-60-2) C-1 : MECHATRO CONTROLLER (TCO-60-2)
FROM 3/4
C-6 : AUTO GREASE CONTROLLER

R-26 : SV-6 :
LEVER LOCK RELAY SW-33 : REVOLUTION
SE-24 : REVOLUTION RIGHT SOL
PRESS SENSOR : BOOM HEAD R-12 :
REVOLUTION RIGHT SW.
RIGHT RELAY
M-8 : GREASE MOTOR
SE-25 :
PRESS SENSOR : BOOM ROD E-2 :
ALTERNATOR
SV-7 :
SW-34: REVOLUTION
SE-17 : BOOM POTENTIO. R-13 : REVOLUTION LEFT SOL
REVOLUTION LEFT SW.
OPT. LEFT RELAY
AUTO GREASE
SE-19 : ARM POTENTIO. REVOLUTION N&B
L-6 : BOOM WORKING LIGHT

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

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

TRAVEL
FIXED
SW-41 :
OFF
TERMINAL
HIGH REACH
CRANE SW.
(FIXED)
(TRAVEL)
OPT.
HIGH REACH CRANE
SV-14 :
QUICK COUPLER OPERATION SOL. L-4 :
SWING FLASHER RIGHT & WORKING LIGHT 9P CONNECTOR
SWING FLASHER & WORKING LIGHT
SW-59 :
QUICK COUPLER SW-37 :
OPERATION SW. TRAVEL INDEPENDENT SW.
EU OPT. USA
QUICK COUPLER
DOWNLOAD
(4/4)
LC03Z00036P1 02
23-6
23. ELECTRIC SYSTEM
23.2 ELECTRICAL EQUIPMENT LIST

GROUP CODE NAME PARTS No. GROUP CODE NAME PARTS No. GROUP CODE NAME PARTS No.
MECHATRO CONTROLLER YN22E00214F1 L-1 BOOM WORK LIGHT (LH) YW80S00001F1 PRESSURE SENSOR :
C-1 SE-1 LC52S00019P1
(C) CONTROLLER
(TCO-60-2) (HARD) L-2 DECK WORK LIGHT (RH) YT80S00002F2 BUCKET DIGGING
C-2 GAUGE CLUSTER YN59S00021F2 SWING FLASHER (LH) & REAR PRESSURE SENSOR :
L-3 YM80S00001F1 SE-2
(L) LIGHT
AIR-CON CONTROLLER WORK LIGHT BUCKET DUMP
C-4 YN20M01468P1
(INCLUDING PANEL) SWING FLASHER (RH) & REAR SE-3 PRESSURE SENSOR : BOOM UP
L-4 YM80S00001F2
ENGINE COOLANT LEVEL WORK LIGHT PRESSURE SENSOR :
C-5 VHS834701230B SE-4
(SE) SENSOR
CONTROLLER L-5 ROOM LIGHT YT80S00001P1 BOOM DOWN
C-8 ENGINE CONTROLLER VH89661E0010 L-6 BOOM WORK LIGHT (RH) YW80S00001F1 SE-5 PRESSURE SENSOR : SWING
D-4 DIODE HARNESS ACCESSORY L-7 CAB WORK LIGHT FRONT (For SE.Asia) YT80S00002F2 SE-7 PRESSURE SENSOR : ARM IN
(M) MOTOR
D-5 DIODE ACCESSORY OF RELAY BOX M-1 STARTER MOTOR VHS281002894A SE-8 PRESSURE SENSOR : ARM OUT
D-6 DIODE M-3 WIPER MOTOR YN53C00012F2 SE-9 PRESSURE SENSOR : TRAVEL RH
D-9 DIODE M-4 WASHER MOTOR YN54C00001F1 SE-10 PRESSURE SENSOR : TRAVEL LH
(D) DIODE
D-10 DIODE M-9 ROOF WIPER MOTOR YN76S00005P1 SE-11 (PRESSURE SENSOR : P2 OPT.)
D-12 DIODE ARM 2 SPEED SE-13 E/G SPEED SENSOR VHS894101290A
D-13 DIODE PSV-A INVERSE YN35V00049F1 SE-15 FUEL SENSOR YN52S00045F1
D-14 DIODE PROPO.VALVE SE-16 ACCEL POTENTIOMETER YN52S00032P1
(P) PROPORTIONAL
D-15 DIODE P2 UNLOAD (YN35V00047F1) SE-20 (PRESSURE SENSOR : P1 OPT.) LC52S00019P1
SOLENOID VALVE
PSV-B YN35V00048F1
D-16 DIODE PROPO.VALVE SOLENOID SE-22 PRESSURE SENSOR : PUMP P1 YN52S00048P1
D-17 DIODE TRAVEL STRAIGHT VALVE ASSY SE-23 PRESSURE SENSOR : PUMP P2
PSV-C
E-1 FUSE AND RELAY BOX YN24E00016F2 PROPO.VALVE SWING PARKING
SV-1 YN35V00051F1
E-2 ALTERNATOR VHS270402500 P1 UNLOAD BRAKE SOL.
(SV) SOLENOID
PSV-D
E-3 HOUR METER YT58S00006P1 PROPO.VALVE POWER BOOST
SV-2 (YN35V00047F1) YN35V00050F1
E-5 HORN HIGH LC53S00001D1 P1 PUMP SOL
PSV-P1 YN35V00052F1 SOLENOID
E-6 HORN LOW LC53S00001D2 PROPO.VALVE (LC10V00014F1) TWO SPEED
SV-3 VALVE ASSY
E-7 TUNER AM/FM (For Oceania) YN54S00046P1 P2 PUMP PUMP SELECT SOL
PSV-P2
E-8 SPEAKER LEFT (For Oceania) YN54S00050P1 PROPO.VALVE SAFETY LOCK
SV-4
E-9 SPEAKER RIGHT (For Oceania) R-1 BATTERY RELAY YN24S00008F1 LEVER SOL
E-10 RECEIVER DRYER YN54S00041P1 R-2 STARTER RELAY VHS283001271A SW-1 KEY SWITCH YN50S00026F1
E-11 AIR-CON COMPRESSOR YX91V00001F1 R-3 GLOW RELAY VHS286201420A SWING PARKING BRAKE RELEASE
SW-4 YN50S00047P1
E-12 BATTERY YN72S00014P1 R-4 SAFETY RELAY YN24S00010P1 SWITCH
E-13 TRAVEL ALARM (For Australia) YN53S00004F1 R-5 HORN RELAY SW-5 HORN SWITCH (RH) YN50E00017P1
(E) ELECTRIC FITTINGS
E-14 CIGARETTE LIGHTER YN81S00003P1 R-6 WORKING LIGHT RELAY SW-7 E/G OIL PRESSURE SWITCH VHS835301471D
E-15 FUSIBLE LINK LC13E01175S002 R-8 TRAVEL ALARM RELAY (For Australia) SW-8 AIR FILTER CLOGGING SWITCH YR11P00008S005
E-27 ACCEL REDUNDANT VOLUME YN52S00052P1 R-10 CAB WORK LIGHT RELAY (For SE.Asia) SW-10 HORN SWITCH (LH) YN50E00017P1
R-19 FLASHER RELAY YY24S00001F1 SW-11 SAFETY LOCK LEVER SWITCH YN50S00041F1
R-23 AUTO IDLE STOP RELAY 1 YN24S00010P1 SW-13 TRAVEL ALARM SWITCH (For Australia) YN50S00040DF
R-24 AUTO IDLE STOP RELAY 2 (CONFLUX/SINGLE SELECT
SW-15 YN50S00040DD
R-25 ENGINE EMERGENCY STOP RELAY SWITCH)
(R) RELAY
(SW) SWITCH
R-26 LEVER LOCK RELAY SW-17 (SKYLIGHT WIPER SWITCH) YN50S00040D9
R-28 ALTERNATOR RELAY SW-19 WIPER INTERLOCK SWITCH YT50S00004P1
WIPER MOTOR RELAY SW-20 POWER BOOST SWITCH (RH) YN50E00017P1
R-29 YN24S00012P2
(NORMAL ROTATION) SW-21 POWER BOOST SWITCH (LH)
WIPER MOTOR RELAY SW-27 COOLANT LEVEL SWITCH VHS834601510A
R-30
(REVERSE ROTATION) SW-28 WATER SEPARATOR SWITCH VHS233002800A
WIPER MOTOR RELAY SW-55 BOOM WORK LIGHT SWITCH YN50S00040D1
R-31
(ARC PREVENTION)
R-32 WASHER MOTOR RELAY
NOTE : The parts number may be changed due to the improvement of machine, so use the number for reference only. LC03Z00036P1 02
23-7
23. ELECTRIC SYSTEM
23.3 HARNESS
23.3.1 HARNESS LIST
INDEX No. EQUIPMENT HARNESS

REMARKS
ASSY No. PART No.
GROUP ITEM NAME ITEM NAME
SE. ASIA OCEANIA SE. ASIA OCEANIA
3.2 INSTRUMENT PANEL ASSY YN17M00053F1 YN17M00054F1
3.3 CONTROLLER INSTALL (ENGINE) YN22E00220F1
CONTROLLER INSTALL YN22E00219F1
3.4 RADIO INSTALL YN54E00008F1 YN54E00017F1
3.5 UPPER ELECTRIC ASSY LC03E00008F1
3.6 UPPER HARNESS ASSY LC13E00031F1 1 HARNESS LC13E01184P3 UPPER
2 CABLE LC13E01145P2 BATTERY ~ BATTERY
UPPER FRAME
3 CABLE LC13E01176P2 BATTERY ~ RELAY

4 CABLE LC13E01245P1 BATTERY ~ GROUND
5 CABLE LC13E01175P2 STARTER
6 HARNESS LC13E01185P3 ECU HARNESS
48 CABLE LE13E01006P1 FLOOR GROUND
51 CABLE LC13E01177P1 ENGINE GROUND
54 CABLE LC13E01180P2 GLOW RELAY ~ STARTER RELAY
3.7 ENGINE HARNESS ASSY LC16E00010F1 1 HARNESS LC16E01029P2 ENGINE SUB
20 HARNESS LC16E01028P1 AIR CONDITIONER SUB
3.8 UPPER HARNESS ASSY LC13E00032F1 1 HARNESS YN13E01449P3 FLOOR
(FLOOR PLATE) 4 HARNESS LC13E01186P1 CAB SUB
9 CABLE LE13E01005P1 FLOOR GROUND
BOOM CAB
3.9 CAB HARNESS LC14E00023F1 1 HARNESS YN14E01102P3 CAB

3.10 BOOM HARNESS ASSY LC15E00008F1 1 HARNESS 2479Z3130D1 BOOM
3.11 BOOM LIGHT INSTALL LC80E00004F1
3.12 DECK LIGHT INSTALL YN80E00049F1
LIGHT
3.13 CAB LIGHT INSTALL YN80E00058F1 6 HARNESS YN02C01760P1 CAB LIGHT

3.14 FLASHER LAMP INSTALL LC80E00011F1
ALARM 3.15 ALARM ASSY YN53E00015F1
The parts number may be changed due to the improvement of machine, so use the number for reference only.
23-8
23. ELECTRIC SYSTEM
23.3.2 INSTRUMENT PANEL ASSY
TIGHTENING TORQUE
YN17M00053F1 (09) SE. Asia 1.5N.m (1.1lbf.ft)
INSTRUMENT PANEL ASSY TIGHTENING TORQUE SEMS BOLT TIGHTENING TORQUE
YN17M00054F1 (09) Oceania
5.2N.m (3.8lbf.ft) 5.2N.m (3.8lbf.ft)
ITEM PART NAME PART No. Q'TY REMARKS 2 PLACES INSTALL TO CAB
TAPPING SCREW
3-2 POTENTIO METER YN52S00032P1 1 TAPPING
SEMS BOLT DUCT ASSY SCREW
3-10 KEY SWITCH YN50S00026F1 1 K250 2 PLACES
TIGHTENING TORQUE TAPPING SCREW
4-2 CIGARETTE LIGHTER YN81S00003P1 1 2.8N.m (2.1lbf.ft) TIGHTENING TORQUE
5.2N.m (3.8lbf.ft)
5-2 HOUR METER YT58S00006P1 1
SECTION BB SECTION DD SECTION EE
10 GAUGE CLUSTER YN59S00021F2 1
46-3 SPEAKER YN54S00050P1 2
TIGHTENING TORQUE TIGHTENING TORQUE
TIGHTENING TORQUE 5.0N.m (3.7lbf.ft) 8.5N.m (6.3lbf.ft)
TIGHTENING TORQUE 5.0N.m (3.7lbf.ft) INSTALL SEMS BOLT
5.0N.m (3.7lbf.ft) INSTALL SEMS BOLT TO CAB
INSTALL SEMS BOLT
INSTALL SEMS TO CAB
TIGHTENING TORQUE TO CAB
4.1N.m (3.0lbf.ft) BOLT TO CAB
2 PLACES
SEMS BOLT
TIGHTENING TORQUE
4.1N.m (3.0lbf.ft)

23.5N.m (17.3lbf.ft) 5.0N.m (3.7lbf.ft)
3 PLACES
SEMS BOLT
SECTION AA
VIEW
SEMS BOLT
TIGHTENING TORQUE
5.0N.m (3.7lbf.ft)
TIGHTENING TORQUE
TIGHTENING TORQUE 0.43N.m (0.32lbf.ft) TIGHTENING TORQUE
. .
8.5N m (6.3lbf ft) 8 PLACES 5.0N.m (3.7lbf.ft)
5.0N.m (3.7lbf.ft) TIGHTENING TORQUE 4 PLACES
5.0N.m (3.7lbf.ft) 4.9N.m (3.6lbf.ft) SEMS BOLT TAPPING SCREW
SEMS BOLT TIGHTENING TORQUE INSTALL SEMS BOLT
SEMS BOLT
12.0N.m (8.9lbf.ft) TO CAB
INSTALL
SEMS BOLT
TO CAB
SEMS BOLT
4 PLACES
TIGHTENING TORQUE
5.0N.m (3.7lbf.ft)
SECTION CC
TIGHTENING TORQUE
5.2N.m (3.8lbf.ft)
SEMS BOLT VIEW
INSTALL TAPPING SCREW TIGHTENING TORQUE
TO A/C 5.0N.m (3.7lbf.ft)
23-9
23. ELECTRIC SYSTEM
23.3.3 CONTROLLER INSTALL 23.3.4 TUNER INSTALL
CONTROLLER INSTALL(ENGINE) YN22E00220F1 (03) YN54E00008F1 (03) SE. Asia

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

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

TIGHTENING TORQUE
2.8N.m (2.1lbf.ft)
VIEW VIEW
SEMS BOLT
TIGHTENING
TORQUE
2.8N.m (2.1lbf.ft)
VIEW
PASS CABLE THROUGH

TIGHTENING TORQUE THE HOLE FOR HOSE
2.8N.m (2.1lbf.ft) CLAMP CABLE
SEMS BOLT USING BACK OF
CLIP FLOOR PLATE
TIGHTENING TORQUE
5.0N.m (3.7lbf.ft)
SEMS BOLT
SEMS BOLT
TIGHTENING TORQUE
5.0N.m (3.7lbf.ft)
CLIP
CLIP
PUT SURPLUS
CABLE INTO CAB CLAMP CABLE WITH HARNESS
INSIDE TOGETHER
CONNECT CABLE WITH PASS CABLE THROUGH THE HOLE CABLE ARRANGEMENT
CAB SIDE ANTENNA FOR HARNESS
23-10
23. ELECTRIC SYSTEM
23.3.5 UPPER ELECTRIC ASSY
UPPER ELECTRIC ASSY LC03E00008F1 (02)
ITEM PART NAME PART No. Q'TY REMARKS

1 BATTERY RELAY YN24S00008F1 1
2 HORN LC53S00001D1 1 HIGH
3 HORN LC53S00001D2 1 LOW AFTER INSTALLING GLOW RELAY AND STARTER RELAY
TO BRACKET (A), ASSEMBLE THIS BRACKET
TIGHTENING TORQUE
23.5N.m (17.3lbf.ft)
SEMS BOLT
BRACKET
GLOW RELAY
HORN (LOW)
SEMS BOLT
HORN (HIGH)
TIGHTENING TORQUE
15.5N.m (11.4lbf.ft)
STARTER RELAY
B TERMINAL
NUT C TERMINAL
BATTERY RELAY BOX TIGHTENING TORQUE
17.5N.m (12.9lbf.ft)
2 PLACES
SEMS BOLT
TIGHTENING
TORQUE
10.7N.m (7.9lbf.ft)
TIGHTENING TORQUE
10.7N.m (7.9lbf.ft)
CONNECT SEMS BOLT
AFTER CHECKING CONNECT HARNESS AS SHOWN
GROUND
NO PAINT IS HERE TO AVOID SHORT CIRCUIT ON
SEMS BOLT HORN (HIGH)
POWER SOURCE WIRING
CONNECT HARNESS AS SHOWN HORN (LOW)
TO AVOID SHORT CIRCUIT ON
POWER SOURCE WIRING SEMS BOLT
INSTALL BOLT FROM
TIGHTENING TORQUE
FRONT SIDE
11.7N.m (8.6lbf.ft)
MAX
(BLACK) (BLACK)
(GREEN ORANGE) (GREEN ORANGE)
SECTION BB (BATTERY RELAY BOX)

VIEW (COVER INSTALL)
VIEW VIEW
23-11
23. ELECTRIC SYSTEM
23.3.6 UPPER HARNESS ASSY (1/6)

L-2 : SE-5 :
SE-28 :
UPPER HARNESS ASSY LC13E00031F1 (07) DECK WORKING PRESS. SENSOR : CLIP FIX WHITE TAPING POSITION
PRESS. SENSOR : SV-11 :
LIGHT RIGHT SWING
ITEM PART NAME PART No. Q'TY REMARKS EXTRA PRESS EXTRA PRESS.RELEASING SOL SW-28 :
SE-15 : NOTE 5
FUEL SENSOR WATER SEPARATOR SW.
1 HARNESS LC13E01184P3 1 UPPER TO TRAVEL ALARM
2 CABLE LC13E01145P2 1 BATTERY ~ BATTERY
PSV-P2 : PUMP 2 PROPORTIONAL SOL.
3 CABLE LC13E01176P2 1 BATTERY ~ RELAY
SE-23 : PRESS. SENSOR : PUMP P2
4 CABLE LC13E01245P1 1 BATTERY ~ GROUND
5 CABLE LC13E01175P2 1 STARTER SE-22 : PRESS. SENSOR : PUMP P1
6 HARNESS LC13E01185P3 1 ECU HARNESS PSV-P1 : PUMP 1 PROPORTIONAL SOL.
48 CABLE LE13E01006P1 1 FLOOR GROUND

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

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

POSITION
CLIP CLIP
CLIP CLIP CLIP CLIP
TO ENGINE SPEED SENSOR FIX WHITE TAPING
UPPER HARNESS POSITION
TO TRAVEL ALARM
ECU HARNESS
NOTES: (4) UNLESS OTHERWISE SPECIFIED, THE
(1) TIGHTENING TORQUE OF INSTALLING PROCEDURE IS SHOWN BELOW.
CLIP BATTERY TERMINALS ARE 3.4N.m (2.5lbf.ft). CLIP
(2) TIGHTENING TORQUE OF
GROUNDING CABLES ARE 10.7N.m (7.9lbf.ft).
(3) UNLESS OTHERWISE SPECIFIED
TIGHTENING TORQUE IS SHOWN BELOW. HARNESS
M8 : 23.5N.m (17.3lbf.ft)
M10 : 46.1N.m (34.0lbf.ft)
CLIP
M12 : 79.4N.m (58.6lbf.ft) (5) PLACE THE SLIT OF CORRUGATED TUBE
SECTION AA DOWNWARD AND INSTALL IT.
23-12
23. ELECTRIC SYSTEM
SEMS BOLT TIE UP CORRUGATED PART OF

CLIP HARNESS WITH PRESSURE SENSOR
USING PLASTIC TIE
TIGHTENING TORQUE SV-11 : SE-5 :
F TERMINAL
3.43N.m (2.5lbf.ft) EXTRA PRESS SOL. (OPT) FIX WITH HARNESS PRESS SENSOR : SWING
S TERMINAL USE NUT OF ATTACHED IN THE ELBOW
GLOW RELAY TIE UP HARNESS SE-29 :
WITH SOLENOID VALVE PRESS SENSOR :
GLOW RELAY ~ STARTER RELAY USING PLASTIC TIE FIX WITH THE CLIP SELECTOR DETECTION
GLOW RELAY (OPT)
SE-28 :
GLOW RELAY TIGHTENING TORQUE PRESS SENSOR :
C TERMINAL
CONNECT TO 3.8N.m (2.8lbf.ft) EXTRA PRESS (OPT)
2P CONNECTOR B TERMINAL USE NUT OF ATTACHED
FOR HARNESS STARTER RELAY
OF ATTACHED CLIP
FIX A HARNESS BY CLIP
CLIP ON SOL. BLOCK BEHIND
FIX WITH THE CLIP
CLIP
WHEN THERE IS NO OPTION
STARTER RELAY OF SE-28, 29, SV-13,
TIE UP THIS HOSE HERE CLIP
FIX A HARNESS OF CLIP
SV-13 : ON PIPE METAL FITTING
CLIP INSTALL THE LOCK OF
THE FUSE BOX COVER UPWARD OPT SELECTOR SOL
BATTERY RELAY VIEW

SEMS BOLT DETAIL C (EXTRA SOL. INSTALL)
CLIP
FIX TWO HARNESS
WITH CLIP
TIE UP CORRUGATED PART OF
CLIP HARNESS WITH SOLENOID VALVE
CONNECT THIS CONNECT THIS USING PLASTIC TIE
TERMINAL WITH TERMINAL WITH
PSV-P1 :
STARTER CABLE BATTERY CABLE PSV-P2 : PUMP P2 PROPORTIONAL SOL.
PUMP P1
PROPORTIONAL SOL. TIE UP CORRUGATED PART OF
7.8N.m (5.8lbf.ft) MAX 7.8N.m (5.8lbf.ft) MAX TO PUMP
HARNESS WITH PRESSURE SENSOR
USING PLASTIC TIE PROPORTIONAL SOL FIX WHITE TAPING POSITION
UPPER HARNESS
CLIP CLIP
STARTER CABLE
CLIP
BATTERY RELAY CABLE
CLIP
FIX WHITE TAPING
POSITION
CLIP
UPPER HARNESS FIX A HARNESS
SE-23 : ON GUARD
TO GUARD PRESS SENSOR :
CLIP SE-22 : PUMP P2
FIX CONNECTOR PRESS SENSOR :
TO THE BRACKET PUMP P1
VIEW (PUMP P1, P2 PROPORTIONAL SOL. INSTALL)

TO SWING FLASHER
2P 1P 3P (PRESS SENSOR : PUMP P1, P2 INSTALL) TO WATER SEPARATOR SW
VIEW
BATTERY RELAY
VIEW
23-13
23. ELECTRIC SYSTEM
CONNECT CONNECTOR WITH "CN4-1" CONNECT CONNECTOR WITH "CN5"

TAG OF ITEM 1 : HARNNESS TAG OF ITEM 6 : HARNNESS E-1 :
C-8 : ENGINE CONTROLLER
E-1 : FUSE & RELAY BOX FUSE & RELAY BOX
C-1 :
CAB SUB HARNESS
MECHATRO CONTROLLER
34P CONNECTOR 32P CONNECTOR 31P CONNECTOR C-8 :
ENGINE CONTROLLER CONNECT THE "CNT-2" TAGGED
WITH "CN-1F" TAG WITH "CN-3F" TAG WITH "CN-5F" TAG
CONNECTOR WITH FLOOR HARNESS
35P (A) CONNECTOR 35P (B) CONNECTOR
WITH "CN-2F" TAG WITH "CN-4F" TAG
VIEW
CONNECT WITH
C-1 : MECHATRO CONTROLLER CONNECT CONNECTOR CONNECT CONNECTOR
BLUE CONNECTOR TO
WITH "CN4-2" WITH "CN1"
ACCELERATION
TAG OF ITEM 1 : HARNNESS TAG OF ITEM 1 : HARNNESS
EMERGENCY VOLUME
SET A WHITE TAPING PART OF UPP HARNESS
TO WHITE TAPING PART OF FLOOR HARNESS.
AND FIX TO FLOOR HARNESS. CLIP
31P CONNECTOR 17P CONNECTOR CONNECT 1P CONNECTOR TO CAB SUB HARNESS R-19 :
16P CONNECTOR
TAG : CNT-3 FLASHER RELAY
28P CONNECTOR 24P CONNECTOR
FIX WHITE TAPING POSITION OF UPPER HARNESS
VIEW AND ECU HARNESS TO THE FLOOR HARNESS WITH CLIP
CLIP
CLIP
FLOOR HARNESS
TIE UP UPPER HARNESS,
FLOOR HARNESS,
ECU HARNESS AND
C-8 : CAB SUB HARNESS
ENGINE CONTROLLER
ECU HARNESS GROUND

ECU HARNESS, C-5 :
FIX WHITE TAPING GROMMET
UPPER HARNESS GROUND RADIATOR COOLANT
POSITION LEVEL CONTROLLER
CLIP TIGHTEN SEMS BOLT
AFTER CHECKING
SEMS BOLT NO PAINT IS HERE FIX WHITE
ECU HARNESS CLIP
6 PLACES TAPING POSITION FIX UPPER HARNESS AND
FLOOR HARNESS NOTE 2 FLOOR HARNESS TO THE
PUT WHITE TAPING STAND IN CASE OF
POSITION HERE UNCONNECTION, TIE UP
GROMMET HARNESS AND FIX HARNESS
CONNECT 1P CONNECTOR
TO CAB HARNESS (GND) UPPER HARNESS
P - 3 ECU HARNESS GROUND ENGINE CONTROLLER

UPPER HARNESS GROUND CHECK CONNECTOR
UPPER HARNESS ENGINE CONTROLLER
P - 2 ECU HARNESS GROUND
CHECKER (FOR OUTSIDE MONITOR) P - 10 / P - 11 UPPER HARNESS GROUND
THE EARTH OF UPP MECHATRO CONTROLLER
HARNESS DO THE CLIP
ECU HARNESS DISTRIBUTION PLAN FIX WHITE TAPING
TO REVERSE OF POSITION
ECU HARNESS P - 9 UPPER HARNESS GROUND FIX THE CONNECTOR
OPT SELECTOR CHANGEOVER SOLENOID WITHOUT INTERFERENCE
P - 16 UPPER HARNESS GROUND LEVER LOCK SOLENOID IN AIR-CON DUCT
DECK WORK LIGHT (RH) ATT. BOOST SOLENOID
PUT WHITE TAPING POSITION HERE SWING FLASHER (LH) TRAVEL 2 SPEEDS SOLENOID P - 14 UPPER HARNESS GROUND
"CNT-1" WITH TAG, CONNECTOR OF RADIATOR COOLANT LEVEL CONTROLLER
& REAR WORK LIGHT SWING PARKING SOLENOID
CONNECT TO FLOOR HARNESS
VIEW WATER SEPARATOR SWITCH P - 15 UPPER HARNESS GROUND
P - 1 ECU HARNESS GROUND SWING FLASHER (RH) RADIATOR COOLANT LEVEL SWITCH
ENGINE CONTROLLER & REAR WORK LIGHT AIR FILTER CLOGGING SWITCH
P - 18 UPPER HARNESS GROUND P - 13 UPPER HARNESS GROUND BATTERY RELAY (COIL)
CAB HARNESS (GROUND) FUSE & RELAY BOX DIODE (GLOW RELAY)
FLASHER RELAY GLOW RELAY (COIL)
FUSE & RELAY BOX CONNECTION
23-14
23. ELECTRIC SYSTEM
FASTEN WHITE TAPING PART OF

AIR CONDITIONER SUB HARNESS
AND UPP HARNESS OF CLIP
CLIP E-10 :
RECEIVER DRYER
FIX WHITE TAPING POSITION
CLIP
HARNESS WITH RECEIVER DRYER
USING PLASTIC TIE
UPPER HARNESS
SW-27 :
RADIATOR COOLANT LEVEL SW
AIR CON. HARNESS IS
CONNECTED TO UPP TIE UP CORRUGATED PART OF
HARNESS. HARNESS WITH RECEIVER DRYER
USING PLASTIC TIE
CLIP
AIR CONDITIONER CLIP
SUB HARNESS E-10 :
RECEIVER DRYER
STARTER CABLE
DETAIL F
CLIP
UPPER HARNESS
FIX UPP HARNESS AND
STARTER CABLE TO THE
STAY WITH CLIP. CLIP
SW-8 : TO BATTERY RELAY BOX E-10 :

AIR FILTER CLOGGING SW RECEIVER DRYER

CLIP
TO STARTER
CLIP HARNESS WITH SWITCH USING
PLASTIC TIE
CLIP
FIX WHITE TAPING

POSITION
VIEW
CLIP
FIX WHITE TAPING POSITION FIX WHITE TAPING POSITION
BATTERY RELAY BOX
BATTERY RELAY CABLE
CLIP
FIX A HARNESS OF
CLIP ON GUARD UPPER HARNESS
STARTER CABLE
VIEW
AIR FILTER CLOGGING SW. INST VIEW
23-15
23. ELECTRIC SYSTEM

28.5N.m (21.0 lbf.ft) NUT
28.5N.m (21.0lbf.ft)
CLIP CLIP
GLOW
INSTALL THE TERMINAL ALTERNATOR (B)
OF UPP HARNESS IN TIGHTENING TORQUE FIX A CONNECTOR
THIS DIRECTION. 3.2 ~ 4.4N.m (2.4 ~ 3.2lbf.ft) WITH CLIP ON BRACKET
ENGINE TO STARTER MOTOR
ACCESSORIES HARNESS
TO STARTER MOTOR AND GLOW
GROUND
ENGINE GROUND CABLE
FIX A CONNECTOR
CLIP ON BRACKET
CLIP
CLIP
CLIP
ENGINE SUB HARNESS

E
ENGINE
CLIP
SUB HARNESS CLIP
F FIX UPP HARNESS AND
ENG. SUB HARNESS BY CLIP
CLIP
FIX WHITE TAPING
POSITION
UPPER HARNESS
STARTER CABLE
CLIP
CLIP UPPER HARNESS ECU HARNESS CLIP FIX WHITE TAPING
VIEW (DETAIL OF ALTERNATOR) FIX WHITE TAPING POSITION
POSITION
ENGINE GROUND CABLE
VIEW VIEW
INSTALL THE TERMINAL OF

LEVEL GAUGE TUBE ENG. EARTH IN THIS DIRECTION
TIGHTENING TORQUE
12 ~ 15N.m (8.9 ~ 11.1lbf.ft)
INSTALL THE RUBBER CAP

SE-13 : ON UPPER SIDE
ENGINE SPEED SENSOR
GROUND
FIX A CONNECTOR TO BRACKET
ENGINE
NUT
ENGINE TIGHTEN AFTER
GROUND CABLE CHECKING
UPPER HARNESS NO PAINT IS HERE
M-1 : STARTER MOTOR STARTER CABLE NOTE 2
ECU HARNESS
TIGHTENING TORQUE
3.5 ~ 5.5N.m (2.6 ~ 4.1lbf.ft) VIEW
CLIP
C TERMINAL
SECTION BB
FIX WHITE TAPING
POSITION
CLIP FIX WHITE TAPING
STARTER CABLE FIX WHITE TAPING POSITION
ENGINE
POSITION CLIP SUB HARNESS
UPP HARNESS
CLIP
FIX A WHITE TAPING
OF HARNESS BY
VIEW
CLIP ON BRACKET UPPER HARNESS
DETAIL OF ENGINE SPEED SENSOR INSTALLATION DETAIL OF E
23-16
23. ELECTRIC SYSTEM
SW-56 :
CLIP FUEL SUPPLY AUTO STOP SW.(OPT)
FIX A 2P CONNECTOR ON BRACKET
L-2 :
DECK WORK
LIGHT (RH) CLIP
SE-15 : E-13 :
FUEL SENSOR TRAVEL ALARM
CONNECT A HARNESS FIX WHITE TAPING POSITION
INSIDE OF CAP CLIP
INSTALL THE "ALARM"
TAGGED CONNECTOR
ON BRACKET
UPPER FLAME
CLIP
CLIP
FIX A HARNESS IT THROUGH
UNDER THE BRACKET OF
CLIP SW-28 : FASTEN HARNESS
WATER SEPARATOR SW.
FIX WHITE TAPING
POSITION
CLIP
FIX TO UPP HARNESS
CLIP DETAIL A
FIX WHITE TAPING
POSITION
VIEW (DETAIL OF TRAVEL ALARM INSTALL)

VIEW
C-1 :
SV-3 :
MECHATRO CONTROLLER E-1 :
TWO-SPEED SELECT SOL.
PSV-B:P2 FUSE AND RELAY BOX SW-16 :
SV-1 : ARM TWO-SPEED INVERSE PROPORTIONAL SOL. FIX ENGINE ROOM LIGHT
SV-2 :
SWING PARKING BRAKE SOL. CONNECTOR TO THE BRACKET
POWER BOOST SOL. PSV-C :
SV-4 : TRAVEL STRAIGHT PROPORTIONAL SOL.
LEVER LOCK SOL. PSV-D :
P1 UNLOAD PROPORTIONAL SOL. CAB SUB HARNESS
PSV-A :
CONNECT TO ROTATION
WHITE TAPING POSITION ARM TWO-SPEED INVERSE PROPORTIONAL SOL.
PARKING RELEASE SW.
CLIP
FIX UPPER HARNESS AND "CNT-2" WITH TAG, CONNECTOR OF
ECU HARNESS TO THE FLOOR HARNESS CONNECT TO FLOOR HARNESS CLIP
FIX A HARNESS WITH
CLIP ON HOLE OF
FIX WHITE TAPING POSITION OF GUARD
UPPER HARNESS AND ECU HARNESS
TO THE FLOOR HARNESS
TIE UP UPPER HARNESS,
FLOOR HARNESS,
CLIP UPPER HARNESS
ECU HARNESS AND
FIX WHITE TAPING POSITION CAB SUB HARNESS
FLOOR HARNESS
ECU HARNESS
DETAIL B (DETAIL OF PSV BLOCK)

TO UNDER FLOOR
VIEW
23-17
23. ELECTRIC SYSTEM
23.3.6.1 UPPER HARNESS (1/4) : LC13E01184P3
SE-15 : FUEL SENSOR

TO BE INSTALLED ITEM 2 CAP.
E-6 :
HORN LOW
L-2 : SEALING PLUG TO BE SV-8 :
TAPING AFTER DECK WORKING ARM PUSH/
SUPPLY INSERTED IN TO ALL
BUNDLED LIGHT RIGHT PULL PORT
WITH SUPPLY SELECT SOL.
TAPING AFTER WITH
BUNDLED SW-56 :
FUEL SUPPLY
AUTO STOP SW. SE-13 :
ENGINE SPEED SENSOR
SEALING PLUG TO BE M-11 : SUPPLY
INSERTED IN TO ALL FUEL SUPPLY PUMP WITH
SEALING PLUG TO BE WHITE TAPING

WHITE TAPING
INSERTED IN TO ALL
TAPING SE-44 :
TAPING TAPING AFTER
WHITE TAPING SEALING PLUG TO BE EXTRA PRESS. SW SHIELD UNCONNECTED
BUNDLED
SEALING PLUG TO BE INSERTED IN TO ALL SEALING
INSERTED IN TO ALL PLUG
TAPING TAPING
SUPPLY TAPING
WITH SUPPLY SEALING PLUG TO BE
WITH INSERTED IN TO ALL
E-5 :
HORN HIGH SUPPLY SUPPLY
SEALING WITH WITH E-2 : ALTERNATOR
PLUG
SUPPLY SEALING PLUG TO BE
WITH INSERTED IN TO ALL SEALING PLUG
INSTALL CTB-5 (2 PIECES) TO BE INSERTED CAP TO BE INSTALLED
TO ENGINE SUB
IN TO ALL
SUPPLY SE-11 : SE-5 :
WITH EXTRA PRESS. BUCKET DUMP
RELEASING SOL CUT SOL WHITE TAPING
SE-28 : SUPPLY
TAPING PRESS. SENSOR WITH
EXTRA PRESS
DOUBLE
SPLICE SEALING PLUG TO BE
INSERTED IN TO ALL
TAPING L-1 :
BOOM WORKING LIGHT TAPING AFTER SE-5 :
SEALING PLUG TO BE PRESS SENSOR :
BUNDLED INSERTED IN TO ALL SWING
WHITE TAPING
SEALING SUPPLY TAPING AFTER
PLUG WITH BUNDLED WHITE TAPING
TAPING
WHITE TAPING
TAPING
INSTALL CTB-6 (2 PIECES)
WHITE TAPING
SEALING PLUG TO BE
INSERTED IN TO ALL
WHITE TAPING SUPPLY SUPPLY
SEALING WITH WITH
PLUG
SUPPLY
CORRUGATE TUBE WITH
TAPING TAPING SEALING
SEALING PLUG
SUPPLY SEALING PLUG TO BE PSV-F : OPT, RELIEF PSV-1 : OPT, RELIEF PV-16 :
PLUG SEALING PLUG TO BE
WITH INSTALL CTB-6 (2 PIECES) INSERTED IN TO ALL ADJUSTMENT ADJUSTMENT BUCKET CONTROL SOL
PROPORTIONAL SOL 1 PROPORTIONAL SOL 2 INSTALL CTB-6 (2 PIECES) INSERTED IN TO ALL
WHITE TAPING
SUPPLY SUPPLY SUPPLY
WITH WITH WITH
SW-8 :
SEALING PLUG TO BE AIR FILTER
INSERTED IN TO ALL CLOGGING SW.
SEALING PLUG TO BE WHITE TAPING

SECTION A-A INSERTED IN TO ALL SEALING PLUG TO BE SEALING PLUG TO BE SEALING PLUG TO BE
INSERTED IN TO ALL INSERTED IN TO ALL INSERTED IN TO ALL
23-18
23. ELECTRIC SYSTEM
23.3.6-1 UPPER HARNESS (2/4) : LC13E01184P3

SE-29 :
PRESS SENSOR :
SELECTOR DETECTION SEALING PLUG TO BE E-10 :
INSERTED IN TO ALL RECEIVER DRYER
(DIRECT CONNECTION)
SUPPLY
WITH
SV-4 : WHITE TAPING
OPERATING SW-27 :
LEVER LOCK SOL RADIATOR COOLANT LEVEL SW
SUPPLY CAP TO BE INSTALLED

SV-1 : SEALING PLUG TO BE
WITH R-1 :
SWING PARKING INSERTED IN TO ALL
SEALING PLUG TO BE BATTERY RELAY
BRAKE SOL.
INSERTED IN TO ALL STARTER TERMINAL C
SV-13 : OPT. SELECTOR SOL. R-3 :
GLOW RELAY (COIL)
PSV-P1 :
SV-3 : PUMP P1 PROPORTIONAL SOL.
TWO-SPEED SELECT SOL. SUPPLY
WITH
WHITE TAPING
CAP TO BE INSTALLED
SV-2 :
POWER BOOST SOL. INSTALL CTB-3
TAPING GLOW RELAY
TAPING
PSV-P2 : (COMMON)
PUMP P2
PROPORTIONAL SOL.
PSV-B : TAPING
WHITE TAPING
P2 UNLOAD
PROPORTIONAL SOL. DOUBLE
SE-23 : INSTALL CTB-3 SPLICE
PRESS SENSOR :
PUMP P2 WHITE TAPING
CAP TO BE INSTALLED
PSV-C :
TRAVEL STRAIGHT SE-22 : GLOW RELAY (NO)
PROPORTIONAL SOL. PRESS SENSOR :
PUMP P1
SUPPLY
SW-28 : WITH
WHITE TAPING
WATER SEPARATOR SW. R-1 :
PSV-D : BATTERY RELAY (COIL) R-2 :
P1 UNLOAD L-13 : STARTER RELAY (COIL)
PROPORTIONAL SOL. TRAVEL ALARM
SEALING PLUG TO BE L-3 :
INSERTED IN TO ALL SWING FLASHER LEFT
& REAR WORKING LIGHT
SUPPLY SEALING PLUG TO BE
WITH INSERTED IN TO ALL
WHITE TAPING SEALING PLUG TO BE
INSERTED IN TO ALL
TAPING AFTER
BUNDLED
SUPPLY
WITH
SUPPLY
WITH TAPING AFTER
BUNDLED TAPING
WHITE TAPING
PSV-A :
ARM TWO-SPEED SEALING PLUG TO BE
INVERSE INSERTED IN TO ALL
L-4 :
PROPORTIONAL SOL. SWING FLASHER RIGHT L-10 : WHITE TAPING
& REAR WORKING LIGHT HIGH REACH
ROTARY LIGHT
SUPPLY SUPPLY
WITH WITH
SEALING PLUG TO BE
INSERTED IN TO ALL SEALING PLUG TO BE SW-16 :
INSERTED IN TO ALL ENGINE ROOM LIGHT
23-19
23. ELECTRIC SYSTEM
WHITE TAPING
WHITE TAPING
R-19 :
FLASHER RELAY
DOUBLE
SPLICE
DOUBLE TO HARNESS (CAB) TO HARNESS (CAB SUB)

SPLICE
TAPING
DOUBLE TAPING
SPLICE
C-5 :
RADIATOR COOLANT LEVEL
CONTROLLER
DOUBLE
SPLICE
OPT. (HAND CONTROL) SUPPLY WITH C-1 : MECHATRO CONTROLLER

SUMITOMO 6409-0075
DOUBLE CAP TO BE INSTALLED 7034-1280
SPLICE
WHITE TAPING M-1 : STARTER MOTOR (TO C TERMINAL)
FRAME GND OF UNDER FLOOR
TAPING
TO FLOOR HARNESS
TO GLOW
WHITE TAPING
TAPING RED TAPING

TAPING WHITE TAPING
DOUBLE DOUBLE WIRE WIRE WIRE SIZE FROM CONNECTION TO

SPLICE SPLICE NO COLOR
DOUBLE
SPLICE
TO AIR-CONDITIONER SUB HARNESS
23-20
23. ELECTRIC SYSTEM
WIRE WIRE WIRE SIZE FROM CONNECTION TO WIRE WIRE WIRE SIZE FROM CONNECTION TO WIRE WIRE
WIRE SIZE FROM CONNECTION TO
NO COLOR NO COLOR NO COLOR
CONNECTORS SELECTION TABLE
CONNECTOR PART. NUMBER

NAME MANUFUC,
(PIN NUM,) HOUSING TERMINAL
SHIELDED
CABLE
(2 CORE)
23-21
23. ELECTRIC SYSTEM
23.3.6.2 BATTERY CABLE : LC13E01145P2 23.3.6.5 STARTER CABLE : LC13E01175P2
3.8 (0.15")
300 (11.8")
2870 (9'5")
16 ")
TERMINAL (0.63") 0. 33
50 (1.97") 50 (1.97") 8.4(
CAP 70 700 310 240 70
(0.89")
WHITE TAPING
22.5
YAZAKI 7034-1283 (2.76") (27.6") (12.2") (9.45") (2.76")
CORRUGATE TUBE
TO BE INSTALLED CAP TERMINAL
TERMINAL
WIRE No.35
TERMINAL TERMINAL
INSTALL CORRUGATE TUBE CAP TO BE
INSTALLED
CAP CAP
SUPPLY YAZAKI 7034-1283
WITH
23.3.6.3 BATTERY RELAY CABLE : LC13E01176P2 TERMINAL

WIRE No.36
260 (10.2") TAPED DOUBLY
CAP TAPING
YAZAKI 7034-1283
40 (1.57")
20 (0.79")
TWO TERMINALS ARE IN TOUCH WITH
EACH OTHER TO THEIR BACK AND
BUNDLED BY TAPING, CAP TO BE INSTALLED
TERMINAL DETAIL A
CAP TERMINAL
TAPED IN TWO TURNS
23.3.6.4 BATTERY GROUNDING CABLE : LC13E01245P1
440 (17.3")
40 (1.57")
TERMINAL
TERMINAL
CAP TAPED IN TWO TURNS
23-22
23. ELECTRIC SYSTEM
23.3.6.6 ECU HARNESS (1/2) : LC13E01185P3
DOUBLE DOUBLE DOUBLE

SPLICE SPLICE SPLICE
E-27:
TO FUSE & RELAY BOX ACCEL REDUNDANT
RESISTOR
WHITE TAPING
WHITE TAPING TO ENGINE CONTROL

HARNESS
INSTALL
WHITE TAPING
DOUBLE CORRUGATE
WHITE TAPING
SEALING
PLUG
SUPPLY WITH
SUMITOMO 6409-0073 TO HARNESS (FLOOR)
TAPING
SUPPLY WITH
SUMITOMO 6409-0603
TAPING
SUPPLY WITH
SUMITOMO 6409-0072
TAPING
WHITE TAPING
SH8 SHIELD UN-CONNECTED
WHITE TAPING
C-6 : ENGINE CONTROLLER
23-23
23. ELECTRIC SYSTEM
23.3.6-6 ECU HARNESS (2/2) : LC13E01185P3 23.3.6.7 FLOOR GROUNDING CABLE : LE13E01006P1
100 (3.94")
WIRE WIRE
WIRE WIRE
LA308 5B E E 5B E
NO COLOR NO COLOR
1PAM
YAZAKI 7122-3010
23.3.6.8 ENGINE GROUNDING CABLE : LC13E01177P1
450 (17.7")
TERMINAL TERMINAL
SHIELDED CABLE
(2 CORE)
CORRUGATED TUBE TO BE INSTALLED
23.3.6.9 RELAY CABLE : LC13E01180P2
TAPED DOUBLY
LE-SS 180 (7.09")
SHIELDED CABLE
(2 CORE)
CAP TO BE INSTALLED
LE-SS
SHIELDED CABLE
CAP
(2 CORE) YAZAKI 7034-1280
LE-SS
SHIELDED CABLE
(2 CORE)
SHIELDED CABLE
(2 CORE)
TERMINAL TERMINAL
HEAT SHRINKAGE TUBE TO BE INSTALLED
LE-SS
CONNECTORS SELECTION TABLE
SHIELDED CABLE
(2 CORE)
CONNECTOR PART. NUMBER CONNECTOR PART. NUMBER
LE-SS
NAME MANUFUC, NAME MANUFUC,
SHIELDED CABLE HOUSING TERMINAL HOUSING TERMINAL
(PIN NUM,) (PIN NUM,)
(2 CORE)
LE-SS
SHIELDED CABLE
(2 CORE)
23-24
23. ELECTRIC SYSTEM
23.3.7 ENGINE HARNESS ASSY
HARNESS (ECU)
ENGINE HARNESS ASSY LC16E00010F1 (02)
ENGINE ACCESSORY
FIX A HEATER HOSE AND
ITEM PART NAME PART No. Q'TY REMARKS AIR CON. ACCESSORY
FIX AN AIR CON. ACCESSORY HARNESS BY CLIP OF INT
1 HARNESS LC16E01029P2 1 ENGINE SUB HARNESS OF CLIP TO HOLE
OF AIR COMPRESSOR
20 HARNESS LC16E01028P1 1 AIR CONDITIONER SUB CLIP
B TERMINAL
FIX A HEATER HOSE AND
AIR CON. ACCESSORY
HARNESS BY CLIP
NEAR THE BRED.
CLIP
M-1 : STARTER MOTOR

REMOVE AND CANCEL
THE HARNESS OF
CONNECT AIR CON.
ATTACHMENT FOR
ACCESSORY HARNESS
C TERMINAL
WITH AIR CON. SUB
HARNESS
CLIP
TIGHTENING TORQUE INSTALL BOLT AND BOLT OF
25.5N.m (18.8lbf.ft) AIR COMPRESSOR TOGHETHER AIR CON. SUB HARNESS
STARTER CABLE
AIR CON. HARNESS IS CONNECTED

TO UPP HARNESS DETAIL OF AIR COMPRESSOR
TIGHTENING TORQUE
CLIP 25.5N.m (18.8lbf.ft) USE THE EXISITING BOLT
ENGINE GROUND CABLE TIGHTENING TORQUE
3.2 ~ 4.4N.m (2.4 ~ 3.2lbf.ft)
HARNESS (UPP)
CLIP
TIGHTENING TORQUE
ENG. COOLANT 46.1N.m (34.0lbf.ft)
THERMO SENSOR FIX WHITE TAPING POSITION
(FOR ECU) CLIP
INSTALL WASHER
COOLANT THRMO SENSOR (ECU) UNDER THE CLIP
TIGHTENING TORQUE
3.2 ~ 4.4N.m (2.4 ~ 3.2lbf.ft)
ALTERNATOR (B)

CLIP FIX A HARNESS WITH
CLIP ON BRACKET OF
ENG. ACCESSORY
CLIP
HARNESS
(ENGINE SUB)
ALTERNATOR (L, R)
SW-7 :
ENG. OIL PRESS. SW.
ENGINE SIDE
FIX THE PLATE TO
ENGINE BRACKET
TIGHTENING TORQUE
25.5N.m (18.8lbf.ft) E-2 : ALTERNATOR
SW-7 : (FOR PLATE FIX)

VIEW TIGHTENING TORQUE
ENGINE OIL PRESS SW
25.5N.m (18.8lbf.ft) DETAIL OF ALTERNATOR
23-25
23. ELECTRIC SYSTEM
23.3.7-1 ENGINE SUB-HARNESS : LC16E01029P2 23.3.7-20 AIR CONDITIONING SUB-HARNESS : LC16E01028P1
E-11 :
SW-7 : ENGINE OIL PRESS. SW. TO UPPER HARNESS TO AIR COMPRESSOR
WHITE TAPING WHITE TAPING
ENGINE COOLANT CONNECTORS SELECTION TABLE

THERMO SENSOR (FOR ECU)
WHITE TAPING PART. NUMBER
CONNECTOR
NAME MANUFUC,
(PIN NUM,) HOUSING TERMINAL
WHITE TAPING SEALING PLUG
TO UPP HARNESS
E-2 : ALTERNATOR
E-2 : ALTERNATOR
SEALING PLUG
23-26
23. ELECTRIC SYSTEM
23.3.8 UPPER HARNESS ASSY (FLOOR PLATE) (1/2)
SE-3 :
UPPER HARNESS ASSY LC13E00032F1 (10)
PRESS SENSOR :
NOTE : 1. ATTACHMENT OF WELDING CLIP WITHOUT DIRECTIONS IS
SE-4 :
PRESS SENSOR : BOOM RAISING
MADE INTO THE FOLLOWING.
ITEM NAME PARTS No. Q'TY REMARKS
BOOM LOWERING CLIP
1 HARNESS YN13E01449P3 1 FLOOR
SE-1 : HARNESS
4 HARNESS LC13E01186P1 1 CAB SUB HARNESS TO WASHER MOTOR PRESS SENSOR :
BUCKET DIGGING
9 CABLE LE13E01005P1 1 FLOOR HARNESS GROUND SE-2 :
PRESS SENSOR : SE-7 : SW-1 :
BUCKET DUMP PRESS SENSOR : KEY SW.
ARM IN
SE-8 : SW-16 :
PRESS SENSOR : ACCEL POTENTIO
E-1 : FUSE & RELAY BOX ARM OUT
SW-1 : KEY SWITCH
CLIP
USE THE HOLE OF SEAT FASTEN HARNESS BY CLIP CAB HARNESS
SE-16 : WITH BRACKET OF MULTI CLIP
STAND AND FIX HARNESS BUNDLE AFTER
ACCEL POTENTIO NOT USE CLIP CASE BY MULTI
WITH CLIP * CLIP HARNESS DIVERGES
FIX WHITE TAPING
DETAIL A : A CASE OF MULTI
POSITION
(For Oceania)
TO WASHER MOTOR
FIX A HARNESS ON SENSOR
BLOCK WITH CLIP
TO WASHER MOTOR
FIX A HARNESS TO CLIP OF
CLIP CAB SIDE COVER
VIEW
PUSH CONTROL LEVER MOST FRONTWARD
AND FIX THIS SLACK HARNESS WITH CLIP
SE-1 :
SW-12 :
PRESS SENSOR :
SW-35 : OVER LOAD ALARM SELECT SW.
BUCKET DIGGING
HEAVY LIFT SW. CONNECT SWITCH TO TAGGED
SE-8 : SE-2 : CONNECT SWITCH "OVER L" CONNECTOR
PRESS SENSOR : PRESS SENSOR : TO TAGGED "HEAVY"
ARM OUT SW-13 : CONNECTOR
SE-7 : SE-3 : BUCKET DUMP
PRESS SENSOR : PRESS SENSOR : TRAVEL ALARM SW.
BOOM RAISING IN CASE OF TRAVEL SW-40 :
ARM IN SE-4 :
FIX A CORRUGATERD ALARM SPEC., ROTARY LIGHT SW.
PRESS SENSOR : CONNECT SWITCH TO CONNECT SWITCH TO TAGGED "ROTARY"
TUBE NOT CONTACT
M-CONNECTOR BOOM LOWERING TAGGED "ALARM" CONNECTOR
LOCK OF CONNECTOR
DETAIL A : A CASE OF SENSOR TOWER CONNECTOR
SENSOR CLIP
(For SE. Asia) FIX A HARNESS
OF SW. SIDE
CLIP CLIP
FIX A HARNESS PART OF CLIP
SE-20 : PRESS SENSOR : P1 OPT WHITE TAPING WITH CLIP FIX A CLIP ON HOLE
OF STAND SIDE
TIGHTENING TORQUE 10.7N.m (7.9lbf.ft)
TIGHTEN AFTER CHECKING NO PAINT HERE CLIP
FIX A CLIP ON HOLE SW-20 :
NUT
FLOOR HARNESS GROUND OF STAND SIDE POWER BOOST SW. RIGHT
TO PRESS SENSOR, FASTEN FLOOR HARNESS
TUNER CONNECT WITH EARTH MULTI, (YELLOW TAPING)
CABLE OF UPPER WITH LEVER SW.
OVER LOAD ALARM SW. WASHER MOTOR SW-33 :
FRAME HARNESS
HEAVY LIFT SW. REVOLUTION RIGHT SW. (OPT)
TOGETHER
(RED TAPING)
TRAVEL INDEPENDENT CHANGE SW.
SE-10 : SW-5 :
ATT BOOST SW. (RH)
PRESS SENSOR : HORN SW. RIGHT (OPT) (BLUE TAPING)
HORN SW. (RH)
TRAVEL LEFT
ATT BOOST SW. (LH)
SE-9 :
HORN SW. (LH) PRESS SENSOR :
DC-DC CONVERTER TRAVEL RIGHT E-7 :
WASHER MOTOR TUNER CLIP
SE-11 : CLIP FIX WHITE TAPING
PRESS SENSOR : FIX WHITE TAPING POSITION
P2 OPT CLIP FIX A CLIP ON HOLE
POSITION
FIX WHITE TAPING OF SEAT SIDE
THROUGH THE HARNESS
POSITION
AT SEAT SIDE OF BRACKET
CLIP
FIX WHITE TAPING POSITION TO THE FRONT SIDE OF FLOOR PLATE
23-27
23. ELECTRIC SYSTEM
23.3.8 UPPER HARNESS ASSY (FLOOR PLATE) (2/2)
SW-10 : E-1 :
HORN SW. LEFT (OPT) (BLUE TAPING) FUSE & RELAY
SW-21 : BOX C-1 :
POWER BOOST SW. LEFT (OPT)
MECHATRO CONNECT THE "CNT-2" TAGGED
(YELLOW TAPING) C-8 : ENG. CONTROLLER CONTROLLER CONNECTOR WITH "UPPER HARNESS"
SW-34 :
REVOLUTION LEFT SW. (OPT)
(RED TAPING) CONNECT TO SWING
PARKING RELEASE SW.
CONNECT THE "CNT-4" TAGGED

CONNECTOR OF CAB HARNESS E-22 :
SW-11 : WITH "ITEM 1 HARNESS" DC-DC CONVERTER
LEVER LOCK SW.
CLIP
CONNECT TO CAB HARNESS
PUSH CONTROL LEVER

MOST FRONTWARD
AND FIX THIS SLACK CLIP
HARNESS WITH CLIP CONNECT TO
DC-DC CONVERTER
CLIP TO FLOOR PLATE
CLIP BACK SIDE
DETAIL OF WASHER MOTOR CONNECTION
CLIP TO RIGHT
FIX WHITE TAPING INST-PANEL
POSITION
CLIP
USE CLIP TO TIE UP WHITE TO UNDER
TAPING PART OF HARNESS FLOOR
WITH PILOT HOSE TOGETHER TO LEFT
VIEW INST-PANEL
TO IT CONTROLLER
CONNECT THE "CNT-1" TAGGED HARNESS
CONNECTOR WITH "ECU HARNESS"
C-1 :
CONNECT THE "CNT-3" TAGGED E-1 :
MECHATRO CONTROLLER
CONNECTOR OF CAB HARNESS CLIP FUSE & RELAY
WITH "UPPER HARNESS" BOX
CONNECT THE "CN2-1" CONNECT THE "CN2-2" CLIP
TAGGED CONNECTOR WITH TAGGED CONNECTOR WITH CLIP FIX WHITE TAPING POSITION
TIE UP "ITEM 1 HARNESS" WITH
"ITEM 1 HARNESS" "ITEM 1 HARNESS" TO THE PLATE WITH CLIP
"ITEM 12 HARNESS" USING CLIP
TO THE PLATE WITH CLIP CAB SUB HARNESS
CONNECT TO SWING
DETAIL OF FUSE & RELAY BOX CONNECTION PARKING RELEASE SW.
FIX TO THE UPPER PART CONNECT THE "CNT-2"

OF PLATE WITH CLIP TAGGED CONNECTOR
WITH "UPPER HARNESS"
CONNECT THE "CN3-2" TAGGED

CONNECTOR WITH "ITEM 4 HARNESS" CONNECT THE "CN2-3"
TAGGED CONNECTOR WITH
CONNECT THE "CN3-1" "ITEM 1 HARNESS"
TAGGED CONNECTOR WITH
"ITEM 4 HARNESS"
VIEW
FLOOR HARNESS
FIX TO THE LOWER PART

OF PLATE WITH CLIP
34P CONNECTOR 22P CONNECTOR 28P CONNECTOR 22P CONNECTOR TO UNDER

VIEW FLOOR
SECTION AA
23-28
23. ELECTRIC SYSTEM
23.3.8-1 FLOOR HARNESS (1/3) : YN13E01449P3
SE-9 :
PRESS SENSOR :
TRAVEL RIGHT
SW-1 :
KEY SW.
WHITE TAPING SUPPLY WITH

SW-39 :
NIBBLER OPEN AMP 1565123-1
WHITE TAPING
PRESSURE SW.
SUPPLY WITH
SUPPLY TAPING AFTER TAPING AFTER

WITH BUNDLED BUNDLED
SUPPLY WITH SUMITOMO 6409-0603
SE-11 :
PRESS SENSOR : WHITE TAPING
SEALING PLUG TO BE P2 OPT
INSERTED IN TO ALL
WHITE TAPING
TAPING
SE-10 :
PRESS SENSOR :
TRAVEL LEFT
SE-20 :
PRESS SENSOR : SE-16 :
P1 OPT ACCEL POTENTIO
TAPING AFTER
BUNDLED TO ECU HARNESS
WHITE TAPING
TAPING
WHITE TAPING WHITE TAPING
WHITE TAPING TAPING
SUPPLY WITH
WHITE TAPING
SUPPLY WITH DOUBLE TO UPPER HARNESS
SPLICE
AMP 1565123-1 WHITE TAPING
DOUBLE
SPLICE
SW-43 :
JIB PRESS SW.
TO FRAME GND. M-4 :
WASHER MOTOR
TAPING
SEALING PLUG TO BE
INSERTED IN TO ALL
SW-4 :
SWING RELEASE SW.
SE-8 : SE-1 :
PRESS SENSOR : PRESS SENSOR :
ARM OUT BUCKET DIGGING
SE-7 : SE-2 : E-1 :

PRESS SENSOR : PRESS SENSOR : FUSE & RELAY BOX
ARM IN BUCKET DUMP
SE-4 : SE-3 :
PRESS SENSOR : PRESS SENSOR :
BOOM LOWERING BOOM RAISING
23-29
23. ELECTRIC SYSTEM

"

$

#

!

" !"

23-30
23. ELECTRIC SYSTEM
23-31
23. ELECTRIC SYSTEM
23.3.8-4 CAB SUB-HARNESS : LC13E01186P1
TO HARNESS (UPPER)
E-1 :
FUSE & RELAY BOX
TO CAB HARNESS
23.3.8-9 FLOOR GROUNDING CABLE : LE13E01005P1
100 (3.94")
1PAF
YAZAKI 7123-3010
23-32
23. ELECTRIC SYSTEM
23.3.9 CAB HARNESS ASSY
CAB HARNESS ASSY LC14E00023F1 (06)
ITEM NAME PARTS No. Q'TY REMARKS E-1 :

1 HARNESS YN14E01102P3 1 CAB FUSE & RELAY BOX
C-1 :
MECHATRO CONTROLLER
CAB SUB HARNESS
E-23 :
12V SOCKET
E-9 :
SPEAKER RIGHT
CONNECT TO
FLOOR HARNESS
TIGHTENING TORQUE 4.4N.m CONNECT TO

E-14 : FIX WHITE CONNECT WITH CAB WORK LIGHT
TIGHTEN SEMS BOLT AFTER CAB SUB HARNESS
CIGARETTE TAPING
CHECKING NO PAINT IS HERE FIX WHITE CONNECT WITH ROOM LIGHT
LIGHTER POSITION
SEMS BOLT TAPING
CLIP CONNECT WITH WIPER INTERLOCK SW. CLIP
CAB HARNESS GROUND POSITION
GAUGE CLUSTER FIX TO CLIP ON THE DUCT
CAB WORK LIGHT SW. CAB HARNESS
AIR-CON UNIT
UPPER HARNESS (GND)
CLIP
BOOM DECK WORK LIGHT SW. FIX WHITE TAPING
CAB WORK LIGHT FRONT POSITION
WIPER INTERLOCK SW.
HOUR METER E-8 :
WIPER MOTOR SPEAKER LEFT
CIGARETTE LIGHTER
12V POWER SOURCE SOCKET SW-15 : FLOOR HARNESS
SKY ROOF WIPER (OPT) CONFLUX / SINGLE
CONFLUX / SINGLE CHANGE SW. CAB SUB CONNECT TO
SELECT SW.
CAB WORK LIGHT HARNESS UPPER HARNESS
SW-55 :
BOOM , DECK TO AIR
CONNECT WITH
FLOOR HARNESS WORKING CONDITIONER UNIT
CAB WORK LIGHT
LIGHT SW.
UPPER HARNESS
C-2 :
GAUGE CLUSTER
DETAIL A
CLIP
CLIP
SW-41 :
HIGH REACH CRANE SW.
E-3 : CONNECT THE SWITCH
HOUR METER WITH "CRANE" TAGGED
BLACK CONNECTOR
SW-15 :
SW-17 : SW-26 :
M-3 : CONFLUX / SINGLE SELECT SW.
ROOF WIPER SW. CAB WORK LIGHT SW.
WIPER MOTOR CONNECT THE SWITCH WITH "CONFLUX"
CONNECT THE SWITCH CONNECT THE SWITCH WITH "CAB LIGHT"
TAGGED GREEN CONNECTOR
WITH "WIPER" TAGGED TAGGED NATURAL COLOR CONNECTOR
SW-55 :
BOOM , DECK WORKING LIGHT SW. NATURAL COLOR
E-4 :
CONNECTOR E-4 :
CONNECT THE SWITCH WITH "BOOM, DECK" CIGARETTE LIGHTER
CIGARETTE LIGHTER
TAGGED BLUE CONNECTOR
TO AIR
CONDITIONER UNIT FIX TO THE BRACKET
FIX WHITE TAPING CLIP

POSITION
TIE UP FLOOR HARNESS WITH
CLIP
CAB HARNESS USING CLIP
WR B
DETAIL B
DETAIL OF HOUR METER
23-33
23. ELECTRIC SYSTEM
23.3.9-1 CAB HARNESS (1/2) : YN14E01102P3
E-8 : SPEAKER LEFT
DOUBLE
WHITE TAPING SPLICE
DOUBLE
TAPING AFTER SPLICE
BUNDLED
TO CAB WORKING LIGHT
TO CAB WORKING LIGHT
DOUBLE
SPLICE E-9 :
DOUBLE
SPLICE SPEAKER RIGHT
WHITE TAPING
TO ROOF WIPER
E-23 : SHIELD UN-CONNECTED
12V SOCKET
TAPING TAPING C-2 :
GAUGE CLUSTER
L-5 : ROOM LIGHT

TAPING WHITE TAPING
M-3 : WIPER METER
DOUBLE
SW-19 : SPLICE
WIPER INTERLOCK SW. E-3 :
DOUBLE SW-17 : HOUR METER
TO CAB GND. SPLICE ROOF WIPER
SW-41 : SW-15 :
SW.
HIGH REACH CONFLUX / SINGLE
CRANE SW. SELECT SW.
TO ROTALY LIGHT C-4 : E-14 :
TO HARNESS (FLOOR) CIGARETTE LIGHTER
AIR CONDITIONER UNIT WHITE TAPING SW-55 :
TO HARNESS (UPP)
DOUBLE BOOM, DECK
SPLICE
WORKING LIGHT SW.
SW-26 :
CAB WORK LIGHT
SW.
DOUBLE
SPLICE
WHITE TAPING
TAPING TAPING AFTER TAPING AFTER
BUNDLED BUNDLED
TAPING
TO CAB HARNESS
23-34
23. ELECTRIC SYSTEM
23.3.9-1 CAB HARNESS (2/2) : YN14E01102P3
23-35
23. ELECTRIC SYSTEM
23.3.10 BOOM HARNESS ASSY 23.3.11 INSTALLING BOOM LIGHT
BOOM HARNESS ASSY LC15E00008F1 (05) INSTALLING BOOM LIGHT LC80E00004F1 (04)
ITEM NAME PARTS No. Q'TY REMARKS ITEM NAME PARTS No. Q'TY REMARKS
1 HARNESS 2479Z3130D1 1 BOOM HARNESS 1 LIGHT YW80S00001F1 2
TO UPPER
HARNESS POINT THIS LAMP TO BUCKET BOTTOM CENTER.
INSTALL THE LAMP SO THAT THE LIGHT BEAM POINTS THE
BOTTOM OF BUCKET, IN THE CONDITION THAT AREM IS
23.3.10-1 BOOM HARNESS : 2479Z3130D1 EXTENDED FULLY (ARM OUT) AND BUCKET IS CLOSED FULLY. 1
YAZAKI
CAP : 7120-1010
TERMINAL : 7115-1050
TIGHTENING TORQUE
18.6N.m (13.7lbf.ft)
SECTION AA
YAZAKI
CAP : 7120-1010 YAZAKI
TERMINAL : 7115-1050 HOUSING : 7122-2810
BRANCH WITH SPLICE TERMINAL : 7114-2020
23-36
23. ELECTRIC SYSTEM
23.3.12 INSTALLING UPPER LIGHT 23.3.13 CAB LIGHT INSTALL
INSTALLING UPPER LIGHT YN80E00049F1 (01) CAB LIGHT INSTALL YN80E00058F1 (02) SE. Asia
ITEM PART NAME PARTS No. Q'TY REMARKS ITEM PART NAME PARTS No. Q'TY REMARKS
1 LIGHT YT80S00002F2 1 1 LIGHT YT80S00002F2 1
6 HARNESS YN02C01760P1 2
7 SWITCH YN50S00040D4 1
8 RELAY YN24S00010P1 1
6
bb
OPT WORK CONNECT TOINST-PANEL
LIGHT RELAY 8 HARNESS
7
CONNECT WITH
MAIN HARNESS
VIEW
VIEW
VIEW
aa
NOTE :
ITEM 1, TIGHTENING TORQUE 18.6N.m (13.7lbf.ft)
MAIN HARNESS TIGHTENING TORQUE

GROMMET
46.1N.m (34lbf.ft)
PAINT PANGIN SEAL
2 PLACES FROM SURFACE
CLIP
BUNDLE HARNESS AND
NUT (SUPPLIED WITH LIGHT) GROMMET TIE WITH CLIP
1 PAINT PANGIN SEAL SEMS-BOLT
FROM SURFACE TIGHTENING TORQUE
DETAIL aa 46.1N.m (34lbf.ft)
DETAIL bb
HOW TO INSTALL LIGHT AT RIGHT SIDE DECK
23-37
23. ELECTRIC SYSTEM
23.3.14 FLASHER LAMP INSTALL 23.3.15 ALARM ASSY
FLASHER LAMP INSTALL LC80E00011F1 (02) ALARM ASSY YN53E00015F1 (01)
ITEM PART NAME PARTS No. Q'TY REMARKS ITEM PART NAME PARTS No. Q'TY REMARKS
1 FLASHER LAMP YM80S00001F1 1 FOR LH 1 ALARM YN53S00004F1 1
2 FLASHER LAMP YM80S00001F2 1 FOR RH 3 SWITCH YN50S00040DF 1
4 RELAY YN24S00010F1 1
TIGHTENING
CONNECT WITH CONNECTOR OF SWING
TORQUE
FLASHER (SUPPLIED WITH UPP HARNESS) 23.5N.m
(17.3lbf.ft)
SEMS BOLT
E-13 :
TRAVEL ALARM
1
UPP
HARNESS
VIEW
1 2
SW-13 :
TRAVEL ALARM SW.
CONNECT WITH NAME TUBE OF "ALARM"
3
4
SHOWING REAR VIEW (C/W) TRAVEL ALARM RELAY
NOTE : TIGHTENING TORQUE OF ITEM 1 AND 2 TO BE UNDER 3~3.9N.m (2.2~2.9lbf.ft)

DETAIL OF FUSE & RELAY BOX
RIGHT CONSOLE BOX
23-38
24. COMPONENTS SYSTEM
TABLE OF CONTENTS
24.1 HYDRAULIC COMPONENTS .........................................................................................24-3

24.1.1 HYDRAULIC PUMP • REGULATOR ......................................................................24-3
24.1.2 CONTROL VALVE..................................................................................................24-21
24.1.3 PILOT VALVE (ATT)...............................................................................................24-59
24.1.4 PILOT VALVE (TRAVEL) .......................................................................................24-63
24.1.5 SWING MOTOR UNIT............................................................................................24-65
24.1.6 TRAVEL MOTOR ...................................................................................................24-75
24
24.1.7 SWIVEL JOINT.......................................................................................................24-89
24.1.8 CYLINDER..............................................................................................................24-91
24.2 ELECTRIC EQUIPMENT.................................................................................................24-97
24.2.1 ELECTRIC EQUIPMENT LIST ...............................................................................24-97
24.2.2 SPECIFICATION OF ELECTRIC EQIUPMENTS...................................................24-100
24-1

SK330–8 : LC10-07001~ S5LC2411E01
SK350LC–8 : YC10-03501~ (ASIA, OCE)
S5LC2411E02
(ASIA, OCE)
24-2
24.1 HYDRAULIC COMPONENTS

24.1.1 HYDRAULIC PUMP • REGULATOR
24.1.1.1 SUMMARY
(1) Outside view and Hydraulic port
5
EYE BOLT (M10)
a3 PSV2
Dr
A3 2X4-M12
Depth 22
A1 A2
B3
a4 VIEW
PSV1
MAX. FLOW RATE ADJUSTING SCREW
PH1 PH2
4 PSV1 4
PSV2 PSV2
MIN. FLOW MIN. FLOW RATE

2 2 ADJUSTING SCREW
RATE
ADJUSTING a3
SCREW
PH1 PH2 PH2 PH1
a4
a1 3 a1
a2
a2 B3
B3
B1
Dr B1
A3
Dr3 a5
A1 A2 5
1 A2
Dr3
Hydraulic ports
Q'TY Code Ports name Size
No. Parts
SE.Asia Oceania A1,2 Delivery port SAE 6000psi 1"
1 Main pump assy 1 B1 Suction port SAE 2500psi 2 1/2"
2 Regulator assy 2 Dr Drain port PF3/4-20
3 Gear pump assy(for pilot) 1 PSV1,2 Servo assist port PF1/4-13
4 Solenoid proportional reducing valve 2 PH1,2 Pressure sensor port PF3/8-17
5 PTO unit 1 a1~a4 Gauge port PF1/4-15
a5 Gauge port PF1/4-14
A3 Delivery port of gear pump PF1/2-19
B3 Suction port of gear pump PF3/4-20.5
Dr3 Drain port of gear pump PF3/8-15
Fig. 24-1 Hydraulic pump • regulator
24-3
(2) Hydraulic circuit diagram
(FRONT) PSV1 a1 A1 PH1 PH2 A2 a2 PSV2 (REAR)

(KDRDE5K) (KR3G-YTOK-HV) (KR3G-YTOK-HV) (KDRDE5K)
Solenoid proportional Solenoid proportional

reducing valve (PSV-1) reducing valve (PSV-2)
Regulator Regulator
a3 Dr a4
Engine Gear pump for pilot
a5
Main pump
B1 B3 Dr3 A3
PTO gear case
Fig. 24-2 Hydraulic circuit diagram of pump

(3) Specifications
Main pump
Item Gear pump
SE. Asia Oceania
Pump assy LC10V00014F1 LC10V00015F1 -
Parts No.
Single Pump LC10V00020F1 YN10V00014F3
Pump model K5V140DTP1K9R-YT0K-HV ZX10LGRZ2-07G
Max.displacement capacity cm3 140 X 2 10
Revolution Rated min-1(Clockwise seen from shaft end) 2100
Rated 34.3 (4980)
Pressure MPa (psi) 5.0 (725)
ATT boost pressure 37.8 (5480)
Max. flow L/min (gal/min) 294 (78) X 2 at 7.8MPa (1130 psi) 21 (5.5)
Max. input horse power kW (PS) 195 (265) 3.4 (4.6)
Max. input torque N.m (lbf.ft) 886 (653) 14.7 (10.8)
Part No. LC10V01005F1
Model KR3S-YTOK-HV
Regulator Electric flow control, positive flow control,
Control function
total power control at emergency mode and power shift control
Others With solenoid proportional reducing valve (KDRDE5K-31/30C50)

Weight kg (lb) 141 (310) 143 (315)
24-4
24.1.1.2 HYDRAULIC PUMP
24.1.1.2.1 CONSTRUCTION
(1) Main pump
953 806 789 532 Apply adhesive (Three Bond No.1305N) 724 901 808 954 717 151 152 211
886 214 548 531 702 792 534 A
535 732
717
261
406
824
774
111
B B
127
123
710 04
212
401 251 490 271 153 156 157 468 313 124 710 116 467 466 312 885 314 141 271 113
728 727 725
Tightening torque 05
Tightening torque
Item number Thread size
N.m (lbf.ft) 546
401 M20 430 (317) 414 326
406 M8 29 (21) 725
407 M6 12 (8.9) 727
414 M10 57 (42)
466 PF 1/4 36 (27)
467 PF 3/8 74 (55)
468 PF 3/4 170 (125)
490 NPTF1/16 8.8 (6.5)
531,532 M24X2 240 (177) 407 325
806 M16 130 (96) SECTION B-B SECTION B-B
VIEW A
808 M20 240 (177) SE.Asia Oceania
No. Parts Q'ty No. Parts Q'ty No. Parts Q'ty
111 Drive shaft (F) 1 314 Valve plate (L) 1 724 O-ring ; 1B P8 16
113 Drive shaft (R) 1 325 Sensor block 1 725 O-ring ; 1B P11 9
116 Gear #1 1 326 Cover 1 727 O-ring ; 1B P14 3
123 Roller bearing 2 401 Socket bolt ; M20X210 8 728 O-ring ; 1B P24 4
124 Needle bearing 2 406 Socket bolt ; M8X20 4 732 O-ring ; 1B P18 2
127 Bearing spacer 3 407 Socket bolt ; M6X55 3 774 Oil seal 1
141 Cylinder block 2 414 Socket bolt ; M10X20 4 789 Back up ring ; P18 2
151 Piston 18 466 VP plug ; PF1/4 2 792 Back up ring ; G35 2
152 Shoe 18 467 VP plug ; PF3/8 2 806 Nut ; M16 2
153 Retainer plate 2 468 VP plug ; PF3/4 4 808 Nut ; M20 2
156 Spherical bushing 2 490 Plug ; NPTF1/16 32 824 Snap ring 2
157 Cylinder spring 18 531 Tilting pin ; M24X2 2 885 Valve plate pin 2
211 Shoe plate 2 532 Servo piston ; M24X2 2 886 Spring pin 4
212 Swash plate 2 534 Stopper(L) 2 901 Eye bolt ; M10 2
214 Tilting bushing 2 535 Stopper(S) 2 953 Socket screw ; M16X35 2
251 Swash plate support 2 546 Spacer 2 954 Set screw ; M20 2
261 Seal cover (F) 1 548 Feed back pin 2 04 Gear pump 1
271 Pump casing 2 702 O-ring ; 1B G35 2 05 PTO unit 1
312 Valve block 1 710 O-ring ; 1B G95 2
313 Valve plate (R) 1 717 O-ring ; 1B G145 4
The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
Fig. 24-3
24-5
(2) Gear pump (For pilot)
700 354 351

Suction port : PF3/4 433
Tightening torque : 73.5N.m
(54.2 lbf.ft)
434
Delivery port : PF1/2

Tightening torque :
53N.m (39.1 lbf.ft)
311
312
732 307 850
434 355
Drain port : PF3/8 310 308 309 466
725
710 435 361 353 Tightening torque :
34.3N.m (25.3 lbf.ft)
No. Parts Q’ty No. Parts Q’ty

307 Poppet 1 361 Front case 1
308 Seat 1 433 Flange socket; M8×40 2
309 Ring 1 434 Flange socket; M8×55 2
310 Spring 1 435 Flange socket; M8×20 4
311 Adjust screw 1 466 VP plug ; PF1/4 1
312 Lock nut ; M14×1.5 1 700 Ring 1
351 Gear case 1 710 O-ring ; 1B G95 1
353 Drive gear 1 725 O-ring ; 1B P11 1
354 Driven gear 1 732 O-ring ; 1B P16 1
355 Filter 1 850 Locking ring 1
24-6
(3) PTO gear case (For Oceania)
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 (OPT)
that transmits the drive power to the auxiliary pump.
(1) Rotary group
PTO GEAR CASE
The rotary group consists of shaft(111), cylinder
OCEANIA
block (141), piston (151), shoe (152), plate (153), AUXILIARY PUMP
spherical bushing (156), and cylinder spring (157). (OPT)
The shaft is supported by bearings (123) and (124) Fig. 24-4 Construction of hydraulic pump
at its both ends. The shoe, which is caulked to the
piston, forms a spherical joint and relieves it of
thrust force that is generated by load pressure.
Further, the piston is provided with a pocket so it
moves lightly on shoe plate (211), taking hydraulic
balance.
The sub group of the piston-shoe is pressed
against the shoe plate by the cylinder spring, via the
retainer plate and the spherical bushing, so that it
moves smoothly over the shoe plate. The cylinder
block (141) is also pressed against valve plate
(313) by the action of cylinder spring (157).
313
124
312
111
116
124
314
141
157
156
151
. 153
152
211
Fig. 24-5 Rotary group
24-8
(1) Swash plate group 532

The swash plate group consists of swash plate
(212), shoe plate (211), swash plate support (251),
531
tilting bushing (214), tilting pin (531), and servo 214 211
piston (532). The swash plate is the cylindrical part 212
that is formed on the opposite side of the shoe
sliding surface and is supported by the swash plate
support. 251
The hydraulic force controlled by the regulator
flows into the hydraulic chamber that is provided on
both sides of the servo piston. This moves the
servo piston to the right and left. The result is that
the swash plate swings on the swash plate support
via the spherical part of the tilting pin and changes
Fig. 24-6 Swash plate group
the tilting angle (a).
(2) Valve block group
The valve block group consists of valve block (312),
valve plates (313 or 314), and valve plate pin (885). 313
312
The valve plates having two crescent-shaped ports
are installed to valve block (312) to feed oil and
recycle it from cylinder block (141). The oil switched 116
over by the valve plate is connected with the 111
external pipe by way of the valve block. 314
141
885
Fig. 24-7 Valve block group

(3) PTO group (For Oceania) 117
The PTO group is composed of 1st gear (116), 2nd
gear (117) and 3rd gear (118). The 2nd and the 3rd 126
gear are supported by bearings (125) and (126)
respectively and installed to the valve block.
Now, if the shaft is driven by the engine, the cylinder
block rotates together by the spline linkage. If the
swash plate is inclined, the pistons arranged in the
cylinder block make reciprocating motion with
respect to the cylinder while rotating with the 118
cylinder block. If we keep an eye on a single piston,
125
it makes a motion away from the valve plate (oil
suction process) in the first 180°and a motion
toward the valve plate (oil delivery process) in the
125
remaining 180°. If the swash plate is not inclined
(zero tilting angle), the piston does not stroke i.e.
Fig. 24-8 PTO group
delivers no oil.
The shaft rotation is taken up by the 1st gear (116)
and transmitted to the 2nd gear (117) and the 3rd
gear (118), in that order, to drive the gear pump that
is linked to the 3rd gear.
24-9
24.1.1.3 REGULATOR
PSV B PSV 418

413
079
757 D
439
438
725
730
a3
656 643
438 924
D
801
722 543 755 545 541 724 B 466, 755 708 644 646 645 728
VIEW C SECTION B-B
641 655 654 836 651 652 601

624
734 629
612 897 876 874 755 858 653
A 630
615 814
412 628
614 631 627

C
613
898 802
875
A 732
611 753
733
756
622 621 623 625 626 887 763
SECTION A-A
At start and
emergency mode
662 642 Tightening torque

Tightening torque
543 545 541 Item No. Thread size
466 N.m (lbf.ft)
At normal
412,413 M8 29 (21)
755 E 438,439 M6 12 (8.9)
418 M5 6.9 (5.1)
466 PF 1/4 36 (27)
496 496 NPTF1/16 8.8 (6.5)
755 E 630 M30X1.5 160 (118)
801 M8 16 (12)
SECTION E-E SECTION D-D 802 M10 19 (14)
Fig. 24-9
24-10
No. Parts Q'ty No. Parts Q'ty No. Parts Q'ty

412 Socket bolt ; M8X50 2 628 Adjusting screw (C) 1 732 O-ring ; 1B P16 1
413 Socket bolt ; M8X70 2 629 Cover (C) 1 733 O-ring 1
418 Socket bolt ; M5X12 2 630 Lock nut ; M30X1.5 1 734 O-ring ; 1B G25 1
438 Socket bolt ; M6X20 8 631 Sleeve (For PF) 1 753 O-ring ; 1B P9 1
439 Socket bolt ; M6X25 5 641 Pilot cover 1 755 O-ring ; 1B P11 7
466 VP plug ; PF1/4 3 642 Spool 1 756 O-ring ; 1B P26 1
496 Plug ; NPTF1/16 17 643 Pilot piston 1 757 O-ring ; 1B P12.5 1
541 Seat 2 644 Spring seat (Q) 1 763 O-ring ; 1B G35 1
543 Stopper 1 2 645 Adjusting stem (Q) 1 801 Nut ; M8 1
545 Ball 2 646 Pilot spring 1 802 Nut ; M10 1
601 Casing 1 651 Sleeve 1 814 Snap ring 1
611 Feed back lever 1 652 Spool 1 836 Snap ring 1
612 Lever (1) 1 653 Spring seat 1 858 Snap ring 2
613 Lever (2) 1 654 Return spring 1 874 Pin ; o 4X11.7L 1
614 Fulcrum plug 1 655 Set spring 1 875 Pin ; o 4X8L 2
615 Adjusting plug 1 656 Block cover 1 876 Pin ; o 5X8L 2
621 Compensating piston 1 662 Spring 1 887 Pin 1
622 Piston case 1 708 O-ring ; 1B G75 1 897 Pin ; o 5X19L 1
623 Compensating rod 1 722 O-ring ; 1B P6 3 898 Pin ; o 7.5X11L 1
624 Spring seat (C) 1 724 O-ring ; 1B P8 8 924 Socket screw ; M8X20 1
625 Outer spring 1 725 O-ring ; 1B P10 1 041 Sub-check valve 2
626 Inner spring 1 728 O-ring ; 1B P18 1 079 Solenoid proportional reducing valve 1
627 Adjusting stem (C) 1 730 O-ring ; 1B P22 1
The codes in a rectangle represent adjust screws.
Do not tamper with the adjust screws as much as possible.
24-11
(1) Control function
Control function …… Electric flow control.
•Positive flow control.
•Total horsepower control.
Emergency mode control.
•Hydraulic positive control.
•Hydraulic total horsepower control
(2) Summary
The regulator KR3S-YTOK for the in-line type axial piston pump K5V series is composed of the control
mechanism as mentioned below:
1) Electric flow control and positive flow control
The tilting angle of the pump (delivery rate) is controlled by controlling the current command value of the
solenoid proportional reducing valve attached to the regulator. The regulator makes positive flow control
(positive control) that increases the delivery rate as the secondary pressure of the solenoid proportional
reducing valve rises. Since this function permits the output power of the pump to be varied, it is possible to
attain optimum power according to the operating condition. Also, since the pump delivers only the necessary
oil flow, the machine does not consume excessive power.
2) Constant power control at emergency mode

When the electromagnetic proportional pressure-reducing valve cannot output the secondary pressure due
to the trouble, the spool for emergency mode is switched automatically, and the control is switched from
electric control to hydraulic control (emergency mode).
In emergency mode, the power shift command pressure Pf shifts the power set value. The power shift
pressure (secondary pressure of electromagnetic proportional pressure-reducing valve) is led to power
control section of regulator on each pump through pump inside passage and shifts respective control to the
same power set value.
In the power shifted condition, as self pump delivery pressure Pd1 rises, the pump tilt angle (delivery rate) is
automatically reduced; consequently the input torque is controlled to the constant value or less. (When the
speed is constant, the input power is also constant.)
This pump is controlled by Pd1 only regardless of another delivery pressure. Condition where the power is
controlled, the regulator of each pump is controlled to the different tilt angle (delivery rate). Consequently in
the condition where the power is controlled, the overloading of engine is automatically prevented regardless
of the loading of pump 2. And in normal condition, because the power shift pressure is 0MPa, the power
control is not worked.
With this mechanism, it is possible to obtain proper power for the working condition.
This regulator is made up of the above two kinds of control system, but when both controls are actuated
together, the low tilt angle (low delivery rate) command precede on mechanical operation described later.
(3) Explanation of operation

1) Flow rate electrical control
The pump delivery rate is controlled according to
Delivery flow rate Q
the command current value corresponding to the

movement of control devices. This relation is
shown in right figure.
Command current I
Fig. 24-10
24-12
a. Flow rate increase (See Fig. 24-11)

As the command current value I rises, the CL port :
Connect with large
secondary pressure P2 of electromagnetic diameter chamber of
servo piston
proportional pressure-reducing valve rises, and 652
by pressing pilot piston (643) in (A) direction it 646
stops at the position the secondary pressure P2 B 613
balances the pilot spring force (646). The D 876 F 897
movement of pilot piston is transferred to lever 2 875
(613) through pin (875), and rotates at (B) A 611
643
fulcrum in arrow direction. Furthermore the lever C
2 movement is transferred to feedback lever
(611) through pin (897) and rotates at (C) fulcrum E 532
in the same arrow direction as (B). Consequently (KDRDE5K) Psv A
the spool (652) connected to feedback lever

moves towards (D). When the spool moves
towards (D), the port CL connected to tank port
is open and the pressure in servo piston large
bore diameter chamber is released,
consequently the servo piston (532) moves
towards (E) according to delivery pressure Pd1
in small bore diameter piston chamber, resulting Pd1
in the rise of flow rate. Since the feed back lever CL port
is connected to the servo piston and spool, the a3
feed back lever rotates at (F) fulcrums with the Hydraulic circuit diagram
B
movement of the servo piston towards (E),
consequently the spool is returned to the original Fig. 24-11
position. With this movement, the opening of
spool sleeve gradually closes, and the servo
piston stops at the position the opening closes
completely.
24-13
b. Flow rate decrease (See Fig. 24-12)

As the command current value I is reduced, the
secondary pressure P2 of electromagnetic

proportional pressure-reducing valve is reduced, "
and by pressing pilot piston (643) in (G) direction
it stops at the position the pilot spring force (646)
balances the secondary pressure P2. The $
movement of pilot piston is transferred to lever 2
(613) through pin (875), and rotates at (H)
fulcrum in arrow direction. Furthermore the lever
#
2 movement is transferred to feedback lever !

(611) through pin (897) and rotates at (I) fulcrum
in the same arrow direction as (H). Consequently '!()(*!+ , -
the spool (652) connected to the feedback lever
moves towards (J). When the spool moves
towards (J), the delivery pressure Pd1 is led in
servo piston large bore diameter chamber
through spool and port CL. The servo piston
small bore diameter chamber constantly
receives delivery the pressure Pd1,
consequently the servo piston moves towards ,
(K) according to the difference of area resulting
in the reduction of tilt angle, and finally the flow
rate is reduced. Since the feed back lever is % & &
connected to servo piston and spool, the feed .
back lever rotates at (L) fulcrum with the Fig. 24-12
movement of servo piston towards (K),
consequently the spool is returned to the original
position. With this movement, the opening of
spool sleeve gradually closes, and the servo
piston stops at the position the opening closes
completely.
2) Power control (In emergency mode)
When the load pressure rises, the pump tilt angle
is reduced preventing the overloading of engine
as shown in Fig. 24-13.

The operation of power control is the same as
the flow rate control, and is explained below.
Delivery output (Pd1)

Fig. 24-13
24-14
a. Overload prevention operation (See Fig. 24-14)

Because the delivery pressure Pd1 acts on the

compensating rod stepped section with the rise

of self pump delivery pressure Pd1 the $
compensating rod (623) is pushed towards (M),
and moves to the position the delivery pressure !
Pd1 balances the spring force of outer spring
& #
(625) and inner spring (626). The movement of
'
compensating rod is transferred to lever 1 (612)

through pin (875), and rotates at (N) fulcrum in
%
arrow direction. Furthermore the lever 1 (612)
"
movement is transferred to feedback lever (611) '
through pin (897) and rotates at (O) fulcrum in *+,,-+. & /
the same arrow direction as (N). Consequently
the spool (652) connected with feedback lever
moves towards (P). When the spool moves
towards (P), the delivery pressure Pd1 is led in
servo piston large bore diameter chamber
through spool and CL port. Since the delivery
pressure Pd1 is constantly led to servo piston
large bore diameter chamber, the servo piston &
moves towards (Q) according to the difference of
area, resulting in the reduction of tilt angle, '
consequently the flow rate is also reduced. Since !() )
0
the feed back lever is connected with servo
piston and spool, the feed back lever rotates at Fig. 24-14
(R) fulcrum with the movement of the servo
piston towards (Q), consequently the spool is
returned to the original position. With this
movement, the opening of spool sleeve
gradually closes, and the servo piston stops at
the position the opening closes completely.
24-15
b. Flow rate recovery operation (See Fig. 24-15)

897 876 625
Because the compensating rod (623) is pushed X 612 626
CL port : T S
towards (S) with the force of outer spring (625) Connect with large
diameter chamber of
and inner spring (626) with reduction of self servo piston G
pump delivery pressure Pd1, and moves to the 652
position the spring force of outer spring (625) H
and inner spring (626) balances the delivery
V J 875
pressure Pd1. The movement of compensating
623
rod is transferred to lever 1 (612) through pin 621
611
(875), and rotates at (T) fulcrum in arrow
direction. U
W
Furthermore the lever 1 (612) movement is
532
transferred to feedback lever (611) through pin (KDRDE5K) Psv A
(897) and rotates at (T) fulcrum in the same
arrow direction as (N). Consequently the spool
(652) connected to feedback lever moves
towards (V).
As the spool moves towards (V), CL port is open
and connected to tank port, the pressure of servo
piston large bore diameter chamber is released
and the servo piston (532) moves towards (W) Pd1
with delivery pressure Pd1 in small bore CL port
diameter chamber, and consequently the flow a3
rate is raised. Since the feed back lever is Hydraulic circuit daigram
connected to servo piston and spool, the feed B
back lever rotates at (X) fulcrum with the Fig. 24-15

movement of the servo piston towards (W),
consequently the spool is returned to the original
position.
With this movement, the opening of spool sleeve
gradually closes, and the servo piston stops at
the position the opening closes completely.
3) Priority mechanism of low tilt angle (low flow
rate) command
As the said explanation, the tilting commands of
flow rate control and power control are
transferred to feedback lever (611) and spool
(652) through the large bore section of lever 1
(612) and lever 2 (613), but because the pin (dia
5) is extruded in large bore (dia 9), pin (897) on
the side where making tilt angle smaller contacts
with it, consequently the bore (dia 9) of lever on
the side where larger tilt angle command is given
is free without contact with pin (897). In this
mechanical selecting manner, the command on
the side of low tilt angle of the flow rate control
and power control has a priority.
24-16
4) Power shift control

As shown in Fig. 24-16, the pump set power is
controlled according to the movement of control

by power shift pressure Pf.
As power pressure Pf rises, the compensating
rod (623) moves rightward through pin (898) and
compensating piston (621). Consequently like
the overloading prevention operation of power
control, the pump tilt angle becomes smaller and
the power setting value is reduced. Conversely,
if the power shift pressure Pf is reduced, the Delivery pressure (Pd1)
power set value is raised. Fig. 24-16
The power shift pressure Pf of this pump is
ordinary set to 0MPa, but in emergency mode,
the power shift pressure Pf is raised to 4.9MPa.
(710 psi)
24.1.1.3.3 ADJUSTING THE REGULATOR

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

rate, as indicated in Fig. 24-17.
Only the maximum flow varies, but other control
characteristics remain unchanged.
Adjust screw no. 954

No. of turns for tightening 1/4
Pilot pressure Pi (Input current I) No change Input current I (Pilot pressure Pi)
Fig. 24-17 Adjusting the max. delivery flow
Min. increase in delivery flow L/min (gal/min) 5.8 (1.5)
(2) Adjusting the minimum flow (See Fig. 24-3)

Adjust the minimum flow by loosening nut (806) and
by tightening socket screw (953) (or loosening it).
Tightening socket screw increases the delivery

rate, as indicated in Fig. 24-18.
Other control characteristics remain unchanged in
the same way as maximum flow adjustment, care
should be used of the fact that overtightening may
increase a required power at the maximum delivery
pressure (at relieving action).
Input current I (Pilot pressure Pi)
Fig. 24-18 Adjusting the min. delivery flow
Pilot pressure Pi (Input current I) No change
Min. increase in delivery flow L/min (gal/min) 4.6 (1.2)
24-17
(3) Adjusting the input horsepower

(At emergency mode)
Since the regulator is of total horsepower control
type, turn the adjust screws of both the front (No.1)
and rear (No.2) pumps when changing horsepower
set values. Adjust the horsepower settings of both
pumps to a same level. The pressure change
values by adjustment are based on two pumps
pressurized at the same time, and the values will by
halved when only one pump is loaded.
1) Adjusting the Outer Spring (See Fig. 24-9)
(At emergency mode)
Adjust it by loosening lock nut (630) and by

tightening adjust screw (628) (or loosening it).
Tightening the adjust screw shifts the control
chart to the right and increases the input
horsepower, as indicated in Fig. 24-19.
Since turning the adjust screw C (628) by N turns
changes the setting of the inner spring (626),
return the adjust screw C (627) by NX1.48 turns
at first. Delivery pressure (Pd1)
Fig. 24-19 Adjusting the input horsepower (1)
Increase delivery pressure MPa (psi) 2.06 (299)
Increase in input torque N.m (lbf.ft) 50 (36.9)
2) Adjusting the Inner Spring (See Fig. 24-9)

(At emergency mode)
Adjust it by loosening nut (802) and by adjust
screw (C) (627) (or loosening it). Tightening the

adjust screw increases the flow and then the
input horsepower, as indicated in Fig. 24-20. And
the input torque raises.

Increase inflow L/min (gal/min) 12 (3.2) Delivery pressre (Pd1)
Fig. 24-20 Adjusting the input horsepower (2)
Increase in input torque N.m (lbf.ft) 58.7 (43.3)
(4) Adjusting the flow control characteristics (See Fig.

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

control chart to move to the right as shown in Fig.
24-21.

Increase Pilot pressure MPa (psi) 0.18 (26)
Input current I (Pilot pressure Pi)
Decrease in delivery flow L/min (gal/min) 18.5 (4.9)
Fig. 24-21 Adjusting the flow control
characteristics
24-18
24.1.1.3.4 CAUSES OF FAULT RESULTING FROM REGULATOR

When trouble due to this regulator occurs, disassemble
and inspect it referring to "Chapter LC33-II"
(1) When the engine is overloaded,
Load every unit of pump, and check on pumps on
the right and left sides for possible damages. When
pumps on both sides are failed, check on them for
the following failures 1), 2). When pump on the one
side is failed, start checking from para. 3).
1) Check that the power shift command current I is
normal.
2) The power shift pressure is low.
• Check the dither of amp.
• Replace solenoid proportional reducing
valve.
3) Stick of compensating piston (621) and
compensating rod (623)
• Disassemble and clean it.
4) Stick of pin (898)
(2) The max. flow rate is not delivered.
1) Check that pilot differential pressure Pi is normal.
2) Stick of pilot piston (643)
3) Stick of spool (652)
4) Stick of pin (898)
Note : When the damage of part is severe, replace the
part with new one.
24-19
24.1.1.4 CONTROL CURVE OF PUMP
300 1471
(79) (1085)
2100min-1: Hmode Input revolution ;2100 min-1
Q Input horse power ;195 kW (265ps)
1900min-1: S Input torque ;886 N.m (653lbf.ft)
250
(66) [1]
Reference value in ( ).
[2] Two pumps are loaded at the same time
[3]
Delivery flow rate Q [ L/min ](gal/min)
200 981
(53) (724)
150
(40)
[1] 183kW (249ps) H mode at traveling or optional working
[2] 154kW (209ps) H mode at operating attachment
[3] 149kW (203ps) S mode at operating attachment
100 490
(26) (360)
Tin N.m (lbf.ft)

Input torque
50
(13)
Min.Flow(at 2100min-1)
0 5 10 15 Delivery 20 25 30 35 40[MPa]
(725) (1450) (2175) pressure (2900) (3625) (4350) (5075) (5800)(psi)
300 725mA Pd
1471
(79) 290L(77gal) (1085)
Q 2000min-1
300mA 12.0MPa [4] 156kW (212ps) (Pf=0MPa) (72 gal)
(1740psi) : At emergency mode
288L Input revolution ;2100 min-1 271L
250
(P t e
(76gal) Input horse power ;195 kW (265ps)

f= me
(66)
A
4. rg
Input torque ;886 N.m (653lbf.ft)

9M e
Pa ncy
[4]
I-Q Curve
)(7 m
Pd=7.8MPa at Qmax
10 od
Reference value in ( ).
Delivery flow rate Q [ L/min ](gal/min)
200 (1131psi) 981

ps e
Two pumps are loaded at the same time (724)

i)
(53)
Pf:Power shift pressure (Reference value)
23.8MPa
147L
150 (39gal)
(40)
100 490
(26) (360)
Tin N.m (lbf.ft)
38.0MPa
Input torque
Tin (5510psi)
50 84L
(13) (22gal)
Min.Flow(at 2100min-1)
400mA
30L
(8gal)
0 5 10 15 Delivery 20 25 30 35 40[MPa]
(725) (1450) (2175) pressure (2900) (3625) (4350) (5075) (5800)(psi)
Pd
0 1 2 3 Pilot pressure 4 [MPa]
(145) (290) (435) Pi (580)(ps)
24-20
24.1.2 CONTROL VALVE
24.1.2.1 SPECIFICATIONS
24.1.2.1.1 OUTSIDE VIEW

PTb
PBL
P2 CT2
CP2
CT1
P1
Pcb PAL
CT1 T1
T2
PTb P1 unload CT2
PCb PAL
Travel PL PCb Travel left PBL
PAL AL BL P2 unload
straight CMR1 CMR2 Ar CP2
USE FOR YN30V00101
Br PAr PCa
PBr Travel PAr PB1 Boom
F1
PB1
Ab right conflux CCb Bs
PAb CP1 (HEAD) As
Bb PBs Swing
Boom PBb PBs PAs
(ROD) Aa
PBb Pss
LCb CRb PC LCs
PAc Bucket PCc PBa1 Pss
Ac Bc PBc Arm 1 PLc2 CRa (HEAD) PAa1
PBa1
(HEAD) (ROD) Ba
LCc LCa
PCAP2 LCAT2 MU PBa2 PAo (ROD)
PAa2 Arm 2 PBa2 PAo Option PBo
Ao Bo
LCo
PBp1 PBp2
(P3) (P2)
PBa2 PAo
PBp1 PBp2
PAa2
Arm 2 Option
PBo
PAc PAa1
Bucket Arm 1
(P4) PAa
(P3) PAb
Boom Swing
PBr PCa
Travel right P2 unload
(T3)
PTb
Travel PBL Travel left
straight
PAa2 PBo
A
VIEW A
Fig. 24-22 Outside view
24-21
24.1.2.1.2 PORTS
Port size Tightening torque Ports Description

PF3/4 150~180 N•m MU
(111~133 lbf•ft) (T3) Pluged
PF1/2 98~120 N•m (P3) Pluged
(72~89 lbf•ft) (P4) Pluged
PF3/8 69~78 N•m PAa1 Arm 1 (in) pilot port
(51~58 lbf•ft) PBa1 Arm 1 (out) pilot port
PAb Boom (up) pilot port
PBb Boom (down) pilot port
PAc Bucket (digging) pilot port
PBc Bucket (dump) pilot port
PAL Travel left (forward) pilot port
PBL Travel left (reverse) pilot port
PAr Travel right (forward) pilot port
PBr Travel right (reverse) pilot port
PAs Swing (right) pilot port
PBs Swing (left) pilot port
PAa2 Arm 2 (in) pilot port
PBa2 Arm 2 (out) pilot port
PAo Option pilot port
PBo Option pilot port
DR Drain port
PF1/4 34~39 N•m Pss Swing pilot high pressure select port
(25~29 lbf•ft) PLc2 Lock valve select pilot port
PBp1 Bypass cut valve (P1 side) pilot port
PBp2 Bypass cut valve (P2 side) pilot port
PL Attachment boost port
PB1 Boom (up) conflux pilot port
PTb Travel straight pilot port
PCa Unload valve (P2 side) pilot port
PCb Unload valve (P1 side) pilot port
PCc Bucket (digging) stroke limiter pilot port
M12 83~110N•m P1 Pump port (P1 side)
(61~81 lbf•ft) P2 Pump port (P2 side)
T1 Tank port 1
T2 Tank port 2
M10 49~65 N•m Ar Right travel motor port (forward)
(36~48 lbf•ft) Br Right travel motor port (reverse)
AL Left travel motor port (forward)
BL Left travel motor port (reverse)
As Swing motor port (right)
Bs Swing motor port (left)
Ab Boom cylinder head side port (up)
Bb Boom cylinder rod side port (down)
Aa Arm cylinder head side port (in)
Ba Arm cylinder rod side port (out)
Ac Bucket cylinder head side port (digging)
Bc Bucket cylinder rod side port (dump)
24-22
Port size Tightening torque Ports Description

Ao Optional pilot port
Bo Optional pilot port
24.1.2.1.3 SPECIFICATIONS
Item Specifications
Model KMX15YD/B44031
Maximum flow rate [L/min (gal/min)] 294 (78) × 2
Maximum set pressure [MPa (psi)] 37.8 (5481) (Pump port)/ 39.7 (5757) (Actuator port)
Main relief valve set pressure [MPa (psi)] Std 34.3 (4970) [at 135×2 L/min (at 36×2 gal/min)]
When power boost pressure 37.8 (5480) [at 125×2 L/min (at 33×2 gal/min)]
Overload relief valve set pressure
39.7 (5757) [at 30 L/min (at 8 gal/min)]
(Boom head, Bucket head, Arm rod) [MPa (psi)]
Overload relief valve set pressure
37.8 (5481) [at 30 L/min (at 8 gal/min)]
(Boom rod, Bucket rod, Arm head) [MPa (psi)]
24-23
24.1.2.2 CONSTRUCTION AND OPERATION
(1) Control valve
J
154 164 101
P2
T2 T1
PAL PBL
YT1
J
PB1 PCa
YBG1
P2-20
PBs PAs
YS1
Pss
PBa1 PAa1
YA1
PAo PBo
YP1
(P4)
163 162 163 169 155 162
SECTION A-A
154 164
P1
102
973 973
PTb PCb
P1-20
973
973
PBr PAr
YT1
973
PAb PBb
YB 2
973 PBc 973

PCc
PAc
YK2
974 973
PAa2 PBa2
YA
G2
974
(P3)
162 162 169 155 163 162
SECTION B-B
Fig. 24-23 Section (1/6)
24-24
T2
H 273x10 273x10 H
PCb PAL
P1 unload
Travel left
(Travel straight)
C C
USE FOR YN30V00101F1

977 PAr
PB1 Boom conflux
Travel right (P2 unload)
D 978x2 D
PBs
Boom Swing
E PCc
PBb E
PBa1 Pss
Bucket
Arm 1
F F
PBa2 PA
PAo
Arm 2 MU Option
G G
K PBp1 PBp2
K
(P3) B A
PBa2 PAo
PBp1 PBp2
274x4
275x4
213
(P4)
(P3)
212
PAa2 PBo
273x10 273x10
24-25
$!#- &'# #'"+

&'# ,+()*+

&'# ()*+ !"#$%

$!#-

24-26
Swing 204
203 PBs
333 Boom
PBb Pss
333
331
336 331
322
321 336
603 AbR
331 322
211
261 321
266 266
160
160 331
514 261
303
524 As 161
CRb
556 162
164 Ab 163
511 511
521 523
LCb LCs
551 556
164 164
Bb
Bs 162
161
301
264 266
264
266
BbR 160 PAs 206
602 PAb
559 SECTION E-E
560 164 551
Bucket
208
209
PCc
216 201
333 Arm 1 333
331 PBa1
PBc
331
336 336
322 322
321 321
BaR
602 BcR 603
331 331
261 261
211
304 160
514
524
CRar
Bc 556
Ba 164
511 511
521 521
LCc LCa
551 551
164 164
Ac
162 Aa
161
264 302
603 PAc PAa1 264
205 AcR SECTION F-F 205
AaR 602
24-27
201
333 Arm 2 Option 201
331 PBa2 PAo 333
340
328 331
321
336
331
324
261
AoR 323
604
MU 331
308
162 261
162 311
162
511 Ao
521
LCAT2 511
551
164 521
515 LCo
521 LCAP2 551
551 164
164
Bo
162
161
604
BoR
264 264
PAa2 PBo
205
205
SECTION G-G
T2
161
P1
T1
511
521 163
CT1
551
163
164
162
P2 511
521
CT2
551
164
SECTION H-H
24-28
PBp1 PBp2
207
160 606 606
278x5 266
264 264
527 528 163

T2 T1
517
518
SECTION J-J
SECTION K-K
24-29
Tightening torque Tightening torque

N•m (lbf•ft) N•m (lbf•ft)
101 Casing A 1 321 Spring 5
102 Casing B 1 322 Spring 4
220~250 (162~184) 154 Plug PF3/4 3 323 Spring 3
110~130 (81~96) 155 Plug PF1/2 2 324 Spring 3
20~24 (15~18) 159 Plug PT1/4 MEC (Pre-coat bolt) 1 325 Spring 1
7.8~9.8 (5.8~7.2) 160 Plug PT1/16 MEC (Pre-coat bolt) 5 326 Spring 1
161 O-ring 7 327 Spring 3
164 O-ring 19 331 Spring seat 24
169 O-ring 2 16~18 (12~13) Loctite #262 333 Spacer bolt 12
201 Cover 5 336 Stopper 10
204 Sub cover 1 511 Poppet 11
205 Cover 6 512 Poppet 2
207 Back pressure check valve cover 1 515 Poppet 1
9.8~14 (7.2~10.3) 211 Lock valve selector sub 2 521 Spring 11
212 Plate 1 522 Spring 2
213 Plate 1 523 Spring 1
216 Piston 1 524 Spring 2
261 O-ring ; 1B G50 12 527 Spring 1
264 O-ring ; 1B G40 10 528 Spring 1
266 O-ring ; 1B P7 5 230~260 (170~192) 551 Plug 13
25~34 (18~25) 273 Socket bolt ; M8×25 40 130~150 (96~111) 552 Plug 2
98~120 (72~89) 274 Socket bolt ; M12×25 4 230~260 (170~192) 556 Plug 3
98~120 (72~89) 275 Socket bolt ; M12×35 4 559 Plug 1
25~34 (18~25) 278 Socket bolt ; M8×35 5 560 O-ring 1
301 Boom spool sub 1 562 O-ring ; 1B P20 2
302 Arm 1 spool 1 69~78 (51~58) 601 Main relief valve 1
303 Swing spool 1 69~78 (51~58) 602 Port relief valve 3
304 Bucket spool 1 69~78 (51~58) 603 Port relief valve 3
305 Boom conflux spool 1 69~78 (51~58) 604 Relief valve plug assy 2
306 Travel spool 2 98~120 (72~89) 606 Bypass cut valve 2
307 Travel straight spool 1 140~180 (103~133) 973 Socket bolt ; M14×160 8
308 Arm 2 spool sub 1 140~180 (103~133) 974 Socket bolt ; M14×140 2
309 P1 unload spool 1 977 Name plate 1
310 P2 unload spool 1 978 Rivet 2
311 Option spool 1
24-30
(2) Main relief valve (Two step relief) (601)
Fig. 24-29 Main relief valve (Two step relief)

69~78 (51~58) 103 Plug ; M27 1 562 Back up ring 1
104 Adjust screw 1 611 Poppet 1
121 C-ring 1 613 Stopper 1
122 Spacer 1 614 Piston 1
123 C-ring 1 621 Spring 1
124 Filter stopper 1 652 Adjust screw 1
125 Filter 1 661 O-ring 1
163 O-ring 1 663 O-ring 1
512 Plunger 1 664 O-ring 1
521 Spring 1 28~31 (21~23) 671 Lock nut ; M14 1
541 Seat 1 46~52 (34~38) 673 Lock nut ; M24 1
561 O-ring 1 1
24-31
(3) Over load relief valve (602,603)
Fig. 24-30 Over load relief valve

69~78 (51~58) 101 Body ; M27 1 541 Seat 1
69~78 (51~58) 102 Plug ; M27 1 561 O-ring 1
161 O-ring 1 562 Backup ring 1
162 O-ring 1 563 O-ring 1
123 C-ring 1 564 Backup ring 1
124 Filter stopper 1 611 Poppet 1
125 Filter 1 612 Spring seat 1
301 Piston 1 621 Spring 1
511 Plunger 1 651 Adjust screw 1
521 Spring 1 661 O-ring 1
522 Spring 1 28~31 (21~23) 671 Lock nut ; M14 1
24-32
(4) Arm 2 spool (308)
308 318 341 362 372 352

Fig. 24-31 Arm 2 spool

308 Spool 1 33~35 (24~26) Loctite #638 352 Plug 1
341 Spring 1 372 Buckup ring 1
(5) Boom spool (301)
301 317 340 361 371 350

Fig. 24-32 Boom spool

301 Spool 1 16~18 (12~13) Loctite #638 350 Plug 1
340 Spring 1 371 Buckup ring 1
(6) Travel straight spool (307)
307 361 371 350

Fig. 24-33 Travel straight spool

307 Spool 1 361 O-ring 1
16~18 (12~13) Loctite #638 350 Plug 1 371 Backup ring 1
24-33
(7) Lock valve selector (211)
101
164
171
201
321
PLc A B Dr
166 541 167 511 161
Fig. 24-34 Lock valve selector

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
24-34
(8) Bypass cut valve (606)
! ! " "
2 2E
6 ,H

Fig. 24-35 Bypass cut valve

98~120 (72~89) 101 Plug 1 301 Plunger 1
201 Poppet 1 69~78 (51~58) 401 Plug 1
202 Spring 1 402 O-ring 1
24-35
(9) Swing shuttle valve cover (204)

Fig. 24-36 Swing shuttle valve cover

166 O-ring 1 542 Seat 1
202 Cover 1 25~29 (18~21) 554 Plug 1
541 Steel ball 1 7.9~9.8 (5.9~7.2) 555 Plug 1
24-36
(10)Boost check valve (517)
104
107
102
101
Fig. 24-37 Boost check valve

101 Poppet 1 20~29 (15~21) Loctite #262 104 Plug 1
102 Poppet 1 107 Spring 1
24-37
24.1.2.2.2 HYDRAULIC CIRCUIT DIAGRAM

P1 T1 T2 P2
CMR1
PL CMR2
PTb PBL
Travel straight
PCb PAL Travel left
P1 unload
AL
CT2 CP2 BL
CT1
(T3) Boom conflux
Travel right PAr PCa
P2 unload
CP1
Br
Ar PB1
PBr CCb
PBs
Dr
LCb LCs Pss
Boom PAb PAs Swing

As
Bs
(RO D) Bb
PBa1
CRb LCa
(HE AD) Ab
PAa1 Arm 1
PBb
LC c Aa (HEAD)
Bucket PAc
CRa
(ROD) B c PLc2
(HEAD) Ac
Ba (ROD)
PCc
PBc
LCAT2
LCAP2 LCo
Arm 2 PAa2 PAo Option
Ao
Bo
PBo
PBa2
MU
PBp1 PB p2
(P3) (P4)
Fig. 24-38 Hydraulic circuit diagram
24-38
(1) In neutral position
The hydraulic oil delivered by hydraulic pump P1 enters port P1 of control valve, and passes through unloading
valve P1 (309), low pressure circuit (D) and boost check valve (517), and returns to the hydraulic tank through
tank port T1. And when the operation of unloading valve is impossible due to failure of electric control system,
because the by-pass cut valve (606) located on the downstream of center by-pass passage (52) opens, the
hydraulic oil through hydraulic pump P1 port passes through travel straight spool (306), and then flows though
the center by-pass passage (52) which passes through travel right, boom, bucket and arm 2 and the by-pass cut
valve (606) on P1 side, and flows into low pressure circuit (D) and boost check valve (517), and then returns to
the hydraulic tank through tank port T1.
The hydraulic oil delivered by hydraulic pump P2 passes through unloading valve P2 (310), low pressure circuit
(D) and boost check valve (517) and returns to the hydraulic tank through tank port T1 similarly to the hydraulic
oil from hydraulic pump P1. And when the operation of unloading valve is impossible, because the by-pass cut
valve (606) located on the downstream of center by-pass passage (55) opens, the hydraulic oil through hydraulic
pump P2 port passes through main passage, and then flows though the center by-pass passage (55) which
passes through travel left, swing, arm 1 and option and the by-pass cut valve (606) on P2 side, and flows into
low pressure circuit (D) and boost check valve (517), and then returns to the hydraulic tank through tank port T1.
(D)
Pss
606
517 52
306
YP1 YS1 YT1
YA1 YBG1
T1
P2
P1
P2-20
YAG2 YK2 Y B2 YT1
P1-20
309
310
55 606
(D)
PBc
Connected to low
pressure circuit of P2
PCc
side casing
Fig. 24-39 In neutral position
24-39
(2) Actuation in travel operation

1) In travel independent operation
On starting travel operation (forward) started, the hydraulic oil delivered by hydraulic pump P1 is fed into
travel right motor, and the hydraulic oil delivered by hydraulic pump P2 is fed into travel left motor. The pilot
pressure enters ports PAr and PAL, and the right and left travel spools (306) move rightward the force of
springs (323)(324) and the secondary pressure of solenoid proportional valves [X1] and [X2] acts on ports
PCb and PCa and switches unloading spools (309) (310).
The hydraulic oil delivered by hydraulic pump P1 passes through travel straight spool (307) and flows into
main circuit, and flows through between the perimeter of right travel spool (306) and casing and is fed into
A side of right travel motor through port Ar. The hydraulic oil delivered by hydraulic pump P2 flows through
between the perimeter of left travel spool (306) and casing and is fed into A side of left travel motor through
port Ar similarly to the stream of hydraulic oil delivered by hydraulic pump P1.
But in the meantime, the return oil from the B sides of left and right travel operations passes through between
the perimeter of right and left travel spools (306) and casing through ports Br and BL and flows into low
pressure circuit (D), boost check valve (517), and then returns to the hydraulic tank through tank port T1. On
traveling reverse (at the time when the pilot pressure actuates on ports PBr and PBL of control valve), the
actuation is similar to that in forward travel operation.

Fig. 24-40 In left reverse travel (at PBL is pressurized)
24-40
2) In travel straight operation

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

Fig. 24-41 Movement of travel straight spool
24-41
(3) Actuation in bucket operation

1) In bucket digging operation
On starting bucket digging operation, the pilot pressure enters port PAc, bucket spool (304) moves leftward
the force of springs (321)(322), and simultaneously the secondary pressure of solenoid proportional valve
[XI] acts on port PCb and switches unloading spool (309).
The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), pushes and opens load
check valve LCc (511), and flows through between the perimeter of bucket spool (304) and casing through
U-shaped passage, and supplied to bucket cylinder head side (H) through port (Ac).
In the meantime, the return oil from bucket cylinder rod side (R) passes through between the perimeter of
bucket spool (304) and casing, flows through low pressure circuit (D) and boost check valve (517), and
returns to the hydraulic tank through tank port T1.
And when the flow rate of hydraulic oil delivered by hydraulic pump P1 with engine running in low idling is
low, the pilot signal from the outside enters port PCc and piston (216) moves rightward. With this actuation,
the maximum leftward stroke of bucket spool (304) is limited, consequently the area of passage between the
perimeter of bucket spool (304) and casing minimizes. Consequently the flow rate of return oil from bucket
cylinder rod side (R) reduces and bucket cylinder moving speed is limited preventing cavitation which may
be occurred on bucket cylinder head side (H). (Stroke limiter ON)
53
216
PAc
PCc PBc
Bc Ac
LCc
321 (D)
322 304 511
(R) (H)
Fig. 24-42 In bucket digging operation (Stroke limiter ON)
24-42
2) In bucket dumping operation

On starting bucket dumping operation, the pilot pressure enters port PBc and bucket spool (304) moves
rightward the force of springs (321)(322), and simultaneously the secondary pressure of solenoid
proportional valve [XI] acts on port PCb and switches unloading spool (309). The hydraulic oil delivered by
hydraulic pump P1 flows into parallel passage (53), pushes and opens load check valve LCc (511), and flows
through between the perimeter of bucket spool (304) and casing through U-shaped passage, and supplied
to bucket cylinder rod side (R) through port (Bc).
In the meantime, the return oil from bucket cylinder head side (H) passes through between the perimeter of
bucket spool (304) and casing and flows through low pressure circuit (D), and returns to the hydraulic tank
through tank port T1. The return oil does not pass through boost check valve (517).
Downstream of boost check valve

!"!

Fig. 24-43 In bucket dumping operation
24-43
(4) Boom
1) In boom up operation
On starting boom up operation, the pilot pressure enters port PAb and boom spool (301) moves rightward
against the force of springs (321) (322), and simultaneously the secondary pressure of solenoid proportional
valve [XI] acts on port PCa and switches unloading spool (309).
And the pilot pressure enters port PB1 and boom conflux spool (305) is switched against the force of springs
(325) (326) and the secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches
unloading spools (310).
check valve LCb (511), and flows through between the perimeter of boom spool (301) and casing through
U-shaped passage, and supplied to bucket cylinder head side (H) through port (Ab).
In the meantime, the return oil from boom cylinder rod side (R) passes through between the perimeter of
boom spool (301) and casing, flows through low pressure circuit (D) and boost check valve (517), and
returns to the hydraulic tank through tank port T1.
(R) (R)
(H) (H)
301 53 511 321

(D) 514 322
BH chamber
LCb CRb
Bb Ab
PAb PBb
Fig. 24-44 In boom up operation (Boom spool)
24-44
2) In boom up conflux operation

The hydraulic oil delivered by hydraulic pump P2 passes through travel left spool and enters parallel passage
(56), and pushes and opens load check valve CP2, and flows through between the perimeter of boom
conflux spool (305) and casing from the A side of U-shaped passage, and pushes and opens conflux check
valve CCb (511) and enters port Ab through conflux passage inside of casing and confluents the hydraulic
oil from the hydraulic pump P1 side.

Fig. 24-45 In boom up conflux operation (Boom conflux spool)
24-45
3) In boom down operation

On starting boom down operation, the pilot pressure enters port PBb and boom spool (301) moves leftward
against the force of springs (321) (322) and the secondary pressure of solenoid proportional valve [X1] acts
on PCb and switches unloading spool (309). And simultaneously the spool of lock valve selector (211) is
switched, and the poppet (514) is released because the spring chamber of lock valve poppet CRb (514) is
connected to the drain circuit.
The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), and pushes and opens
load check valve LCb (511), and flows through between the perimeter of boom spool (301) and casing
through U-shaped passage, and is supplied to boom cylinder rod side (R) through port (Bb).
In the meantime, the return oil from boom cylinder head side (H) enters the control valve through port (Ab).
Because the retention of lock valve poppet CRb (514) which is located on this side of boom spool (301) is
released, the lock valve poppet (514) pushes and opens. And then the return oil enters BH chamber and
passes through between the perimeter of boom spool (301) and casing, and flows through low pressure
circuit (D) and boost check valve (517), and the returns to the hydraulic tank through tank port T1. And a part
of the return oil flows into the inside of boom spool (301) through circular notch of boom spool (301). Since
the return oil contains sufficient pressure with the self weight of boom, arm, etc. the return oil passes through
inside passage of boom spool (301) and pushes and opens poppet (317) leftward as shown in the figure and
flows through the circular notch, and then supplied to boom cylinder rod (R) side again through port Bb.
(Boom recirculation function)
(R)
(R)
(H) (H)
53 511 321
317 514 322
301 BH chamber
LCb CRb
Bb Ab
PAb PBb
(D)
Fig. 24-46 In boom down operation
24-46
(5) Arm operation

1) In arm out operation
On starting arm out operation, the pilot pressure enters ports PBa1 and PBa2, and arm 1 spool (302) moves
rightward against the force of springs (321) (322), and simultaneously the secondary pressure of solenoid
proportional valve [X2] acts on port PCa and switches unloading spool (310).
And the pilot pressure also enters PBa2, and arm 2 spool (308) is switched against the force of springs (321)
(328) and the secondary pressure of solenoid proportional valve [X1] acts on port PCb and switches
unloading spools (309).
check valve LCa (511), and flows into AR chamber through between the perimeter of arm 1 spool (302) and
casing through U-shaped passage.
In the meantime, the hydraulic oil delivered by hydraulic pump P1 flows through center by-pass passage (52)
and pushes and opens load check valve LCAT2 (511) and enters U-shaped passage, and pushes and opens
load check valve LCAP2 (515) provided with orifice, and flows into U-shaped passage. And then the
hydraulic oil flows through between the perimeter of arm 2 spool (308) and casing, and enters AR chamber
through casing inside passage (RR) and confluences the hydraulic oil from hydraulic pump P2 side.
The conflux hydraulic oil opens lock valve poppet CRar (514) and is supplied to arm cylinder rod side (R).
In the meantime, the return oil from arm cylinder head side (H) flows through between the perimeter of arm
1 spool (302) and casing and passes though low pressure circuit (D’) and casing inside passage (HH) and
then flows into low pressure circuit (D’) through between the perimeter of arm 2 spool (308) and casing.
The return oil in low pressure circuit (D’) returns to hydraulic tank through tank port T1 without passing
through boost check valve (517).
(R) (H) 302

AR
322 321 chamber 514
211 CRar
511 LCa
Ba Aa
56
PBa1 PAa1 P1
(D')
Arm 1 (D) LCAT2 LCAP2
RH (D') P1
RR HH PAa2 PBa2
52 Dr Dr
(D')
Arm 2 To arm 1 spoo
Aa (HEAD)
PAa2 Ba
PBa2 (ROD)
To pilot cut valve
53
MU
515
328
321 308 511 LCAT2 LCAP2
Fig. 24-47 In arm out operation
24-47
2) In arm in operation (At light load: arm recirculation function)

On starting arm in operation, the pilot pressure enters ports PAa1 and PLc2, and arm 1 spool (302) moves
leftward against the force of springs (321) (322), and simultaneously the secondary pressure of solenoid
proportional valve [X2] acts on port PCa and switches unloading spool (310). At the same time, since the
spool of lock valve selector (211) is switched, the spring chamber of lock valve poppet CRar (514) is
connected to the drain circuit and the retention of poppet (514) is released.
And the pilot pressure enters PAa2 through solenoid proportional valve [XR], and arm2 spool (308) moves
leftward against the force of springs (321) (328) and the secondary pressure of solenoid proportional valve
[X1] acts on port PCb and switches unloading spools (309). But in light load operation, because the solenoid
proportional valve [XR] actuates and arm 2 spool (308) stays in the position of circuit (I).
check valve LCa (511), and flows into port (Aa) through between the perimeter of arm 1 spool (302) and
casing through U-shaped passage. In the meantime, the hydraulic oil delivered by hydraulic pump P1 flows
through center by-pass passage (52) and pushes and opens load check valve LCAT2 (511) and enters U-
shaped passage, and also the oil from parallel passage (53) pushes and opens load check valve LCAP2
(515) provided with orifice and flows into U-shaped passage. And then the hydraulic oil flows through
between the perimeter of arm 2 spool (308) and casing from U-shaped passage and enters port (Aa) through
casing inside passage (HH) and confluences the hydraulic oil from hydraulic pump P2 side.
The conflux hydraulic oil is supplied to arm cylinder head side (H) through port (Aa).
In the meantime, the return oil from arm cylinder rod side (R) enters the control valve through port (Ba).
Because the retention of lock valve poppet CRar (514) which is located on this side of arm 1 spool (302) is
released, the return oil pushes and opens lock valve poppet CRar (514) and enters AR chamber. The return
oil in AR chamber is led to arm 2 spool (308) through arm 1 spool (302) and casing inside passage (RR),
because arm 2 spool (308) connects to low pressure passage (D) at circuit (I) with small area, the partial
return oil flows between perimeter of arm 2 spool (308) and casing. The oil returns to hydraulic oil tank from
tank port T1 through low pressure passage (D) and via boost check valve (517). But the most of volume of
return oil flows into arm 1 spool (302).
The return oil from chamber AR passes through the perimeter of arm 1 spool (302) and casing, and flows
through casing inside passage (RH) and is led to the inside of arm 2 spool (308) through circular notch (a)
of arm 2 spool (308). In light load operation, since the return oil contains higher pressure than that of arm
cylinder head side (H) with the self weight of arm, etc. the hydraulic oil inside of arm 2 spool (308) passes
through check valve (317) and flows into casing inside passage (HH) and the supplied to arm cylinder head
side (H) again. (Arm recirculation function)
(R) (H) 302
AR
322 321 chamber 514
211 CRar 511 LCa
Ba Aa
56
PBa1 PAa1 P1
(D')
Arm 1 (D) LCAT2 LCAP2
(D') P1
RR 52 RH PAa2 PBa2
(D) HH Dr Dr
Arm 2
(a) To arm 1 spool
Aa (HEAD)
PBa2 PAa2
[XR] Ba
(ROD)
53 To pilot cut valve
MU Circuit (I)
317
328 515
308 (D)
321 319 511 LCAT2 LCAP2
Fig. 24-48 In arm in operation (At light load: arm recirculation function)
24-48
3) In arm in operation (In heavy load operation)

The arm recirculation function is effective in actuating arm cylinder quickly in light load operation, but in
heavy load operation (work required large power); the function causes the power loss. This control valve
selects the presence of recirculation function in light and heavy load operation with solenoid proportional
valve [XR]. (Variable recirculation function)
The flow path of hydraulic oil in heavy load operation, the path on the supply side to arm cylinder is the same
as that in light load operation, differs from that of return oil. In heavy load operation, solenoid proportional
valve [XR] actuates and arm 2 spool (308) is positioned to circuit (II). The return oil from arm cylinder rod
side (R) enters the control valve through port (Ba). Because the retention of lock valve poppet CRar (514)
which is located on this side of arm 1 spool (302) is released, the return oil pushes and opens lock valve
poppet CRar (514) and enters AR chamber. The return oil in AR chamber is led to arm 2 spool (308) through
arm 1 spool (302) and casing inside passage (RR). But because arm 2 spool (308) is connected to low
pressure passage (D) at circuit (áU), almost all the return oil passes through between the perimeter of arm
2 spool (308) and casing and flows through boost check valve (517) through low pressure (D) and returns
to the hydraulic tank through tank port T1.
The return oil from AR chamber passes through between the perimeter of arm 1 spool (302) and casing and
flows through casing inside passage (RH) and then is led to the inside of arm 2 spool (308) through circular
notch (a) of arm 2 spool (308). In heavy load operation, since the pressure on arm cylinder head side (H) is
higher than the rod side, the hydraulic oil in arm 2 spool (308) does not flow into casing inside passage (HH).
(R) (H) 302

AR
322 321 chamber 514
211
CRar
511 LCa
Ba Aa
56
PBa1
PAa1
P1
Arm 1 (D')
(D') (D)
LCAT2 LCAP2
RR 52 RH P1
(D) HH
PAa2 PBa2
Dr Dr
Arm 2 (a)
PBa2 PAa2 To arm 1 spool

[XR] Aa (HEAD)
53 Ba
(ROD)
MU To pilot cut valve
Circuit (II)
317
328 515
308 319 (D) LCAP2
321 511 LCAT2
Fig. 24-49 In arm in operation (In heavy load operation)
24-49
(6) Swing operation

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

Fig. 24-50 Swing operation
24-50
(7) Spool actuation for operation in option

This spool is used to control the attachment in option like Nibbler (Crusher), etc.
Where the pilot pressure acts on port PAo on operating the attachment in option, the pilot pressure enters ports
PAo, and option spool (311) moves against the force of springs (323) (324), and simultaneously the secondary
pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310).
The hydraulic oil delivered by hydraulic pump P2 flows through parallel passage (56) and pushes and opens
load check valve LCo (511), and flows through between the perimeter of option spool (311) and casing through
U-shaped passage and is supplied to actuator for attachment through port (Ao).
In the meantime, the return oil from actuator for attachment swing passes through between the perimeter of
option spool (311) and casing through port (Bo) and flows through low pressure circuit (D) and boost check valve
(517), and then returns to the hydraulic tank through tank port T1.
The operation where the pilot pressure acts on PBo port is the same as the above.
* The oil passage is branched toward the end side of control valve at the mid course from option spool (311) to
port Ao, but when N&B (Nibbler and Breaker) selector valve is provided on the end side of control valve, this
oil passage is used as passage to connect to N&B selector valve.

Fig. 24-51 Spool actuation for operation in option
24-51
(8) Lock valve operation

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

( )&%* +*

!" #

Fig. 24-52 Lock valve operation (At boom spool neutral position)
24-52
2) In boom down operation ((In arm in operation)

Pilot pressure PBb for boom down operation acts on port PLc of lock valve selector, and the spool (511)
moves rightward as shown in the Fig. 25-52. After the spool (511) was moved, orifice (a) of bushing (541)
first closes and then passages Sa and Sb are blocked, and therefore the holding pressure receiving from
boom cylinder head side (H) does not act on spring chamber (RH) of lock valve poppet (514).
And after spool (511) was moved, the inside of bushing (541) is connected from port Dr to passage DR
through spring chamber (321).
With this actuation, spring chamber (RH) of lock valve poppet (514) is connected from orifice (b) of bushing
(541) to drain passage Dr through passage Sb, and the force which pushes lock valve poppet (514) down
as shown in the Fig. 24-52 is released. And since lock valve poppet (514) receives holding pressure from
boom cylinder head side (H) to the pressure receiving section in ring type which is made up of guide diameter
and seat diameter of lock valve poppet (514), lock valve poppet (514) is pushed upward and is open.
The said operation, in boom down operation, is performed before making the opening (meter out opening)
which is used to return the return oil from the boom cylinder head side of boom spool (301) to the tank open,
the operation has no effect on the operability of boom down operation.
In case of arm-in operation, the operation is the same.
Return oil from RH CHAMBER

boom cylinder head
514 Lock valve selector
511
BH CHAMBER 541
Sb
CRb PLc
Ab Dr
(a) (b) 321
A A PLc Sa Sb Dr
SECTION A-A
Sa
321 322
PBb
(D)
301
Dr
Fig. 24-53 Lock valve selector operation (At boom down operation)
24-53
(9) By-pass cut valve

This by-pass cut valve is located on the most downstream of center by-pass passage (52) on P1 side and center
by-pass passage (55) on P2 side. And this by-pass cut valve controls the flow rate of hydraulic oil from each
center by-pass passage to low pressure passage (D).
1) In normal operation
On starting the engine, the secondary pressure of solenoid proportional valves [X1] and [X2] act on pilot
ports PBp1 and PBp2 of by-pass cut valve (606). This secondary pressure is the same as that actting on
pilot port PCb of P1 unloading spool (309) and pilot port PCa of P2 unloading spool (310).
The following explains the by-pass cut valve on P1 side, the operation of by-pass cut valve on P2 side is the
same. The secondary pressure of solenoid proportional valve [X1] enters PBp1 and plunger (301) moves
downward against the force of spring (302). The taper section at the top end of plunger (301) is seated on
the seat of plug (101), shutting off the spring chamber of poppet (201) and spring chamber (b) of plug (101).
The hydraulic oil from center by-pass passage (52) passes through the orifice of poppet (201) and enters
spring chamber (a) of poppet (201). Because spring chamber (a) of poppet (201) and spring chamber (b) of
plug (101) are disconnected, spring chamber (a) of poppet (201) is the same pressure as center by-pass
passage (52) and poppet (201) is pushed the seat section of casing shutting off center by-pass passage (52)
and low pressure passage (D).
Consequently, in normal operation, center by-pass passage (52) is always disconnected from low pressure
passage (D) and the hydraulic oil delivered by hydraulic pump P1 does not flow through center by-pass
passage (52), but returns to the hydraulic tank through P1 unloading spool (309).
[X1]
PBp1
301 302
(b)
(C)
Dr
201 101
(a)
(D)
52
Fig. 24-54 By-pass cut valve (In normal operation)
24-54
2) At the time when failure occurred

When the electric system is failed and consequently the secondary pressure of solenoid proportional valves
[X1] and [X2] is not produced, plunger (301) is moved upward by the force of spring (302). Since the taper
section at the top end of plunger (301) is lifted up from the seat section of plug (101), spring chamber (a) of
poppet (201) and spring chamber (b) of plug (101) are connected each other.
The hydraulic oil from center by-pass passage (52) passes through the orifice of poppet (201) and enters
spring chamber (a) of poppet (201). Because spring chamber (a) of poppet (201) and spring chamber (b) of
plug (101) are connected each other, the hydraulic oil in spring chamber (a) of poppet (201) passes through
from seat section of plug (101) to spring chamber (b) and flows into passage (Dr) through passage (c).
Consequently the pressure in spring chamber (a) of poppet (201) lowers, poppet (201) receives the pressure
of center by-pass passage (52) and is lifted up against the force of spring (202), and the hydraulic oil from
center by-pass passage (52) flows into low pressure passage (D) through poppet (201) of by-pass cut valve
(606). Therefore when the electric system is failed, P1 unloading spool (309) is shifted to the neutral position
and the passage to low pressure passage (D) is cut off, but because center by-pass passage (52) is
connected to low pressure passage (D) through by-pass cut valve (606), the abnormal rise of the pump
pressure is prevented.
PBp1
302
301
(b)
(C)
Dr
201 101
(a)
(D)
202
52
Fig. 24-55 By-pass cut valve (In condition of failure)
24-55
(10)Boost check valve, By-pass check valve

1) Boost check valve
The boost check valve is located between low pressure passage (D) and tank port T1 and generates boost
pressure necessary for the low pressure passage.
a. In normal operation
The hydraulic oil from low pressure passage (D) moves the boost check valve (517) upward against the
force of spring (527), and returns to the hydraulic tank through tank port T1. At this time, the pressure
generated by spring (527) is used as the boost pressure for the low pressure passage.
But the return oil used for the arm out and bucket dumping operation does not pass through boost check
valve (517), but returns from low pressure passage (D’) to hydraulic tank through tank port T1.
b. In make up operation
When supplying to make up the flow rate through low pressure passage (D) after the swing operation is
suspended, if the hydraulic oil quantity in low pressure passage (D) is not enough, the deficient hydraulic
oil is made up from hydraulic tank into low pressure passage (D).
When the deficient hydraulic oil in low pressure passage (D) is not sufficient, the pressure of low pressure
passage (D) is lowered. If the pressure of low pressure passage (D) is lowered to the pressure at tank port
T1, poppet (102) housed in boost check valve (517) receives the pressure at tank port T1 on the receiving
section in ring type which is made up of guide diameter and seat diameter of poppet (102), and is pushed
upward and opens, and the hydraulic oil flows from the hydraulic tank to low pressure passage (D) to make
up the deficient flow rate.

Fig. 24-56 Boost check valve operation
24-56
2) By-pass check valve

Even if the pressure at tank port T1 goes up due to the sudden change of return flow rate, the by-pass check
valve actuates and prevents the pressure at tank port T1 from going up higher than the specified pressure,
and consequently the oil cooler and filter located between tank port T1 and the hydraulic tank are protected
from possible damage.
When the pressure at tank port T1 goes up to the pressure added by spring (528), by-pass check valve (518)
is pushed and opens against the force of spring (528), and the hydraulic oil in tank port T1 directly returns
to the hydraulic tank through tank port T2.
527
528
(D') T2
518
T1
102
517
(D)
Fig. 24-57 By-pass check valve operation
24-57
This page is blank for editing convenience.
24-58
24.1.3 PILOT VALVE (ATT)
24.1.3.1 OUTLINE
(1) Outside view
5-PF3/8
Single operating angle Single operating angle T=49.0 (36.1)
(Port 2, 4) (Port 1, 3)
The adjust nut

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

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

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

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

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

0.94(0.69) 0.94(0.69)
(87)0.6 (87)0.6
1.17 (0.86) 1.17 (0.86)
0.98 (0.72) 0.98 (0.72)
0 0 0 0
0 1.1 2 4 6 7 0 1.12 4 6 8 9.4
PUSH ROD STROKE (mm) PUSH ROD STROKE (mm)
0 5 10 15 19 0 5 10 15 20 25
Operating angle (deg.) Operating angle (deg.)
P T
1 3 2 4
HYDLAULIC SYMBOL
24-59
24.1.3.2 CONSTRUCTION
Apply Loctite #277

312
302
501 Apply grease on
301 rotating and sliding sections.
Be careful the
Apply grease on top section
assembling direction
212
213
151
*246
*218-2
211
214
*218-1
216-2 216-1
241-2 241-1
201-2
Secondary 201-1
pressure 217
adjusting shim
101 221
PORT 2,4 PORT 1,3
Fig. 24-58 Pilot valve (ATT)
Tightening Tightening
torque No. Name Q’ty torque No. Name Q’ty
101 Casing 1 *218-1 Seat 2
151 Plate 1 *218-2 Seat 2
201-1 Spool 2 221 Spring 4
201-2 Spool 2 241-1 Spring 2
211 Plug 4 241-2 Spring 2
212 Push rod 4 *246 Spring 4
213 Seal 4 47.1 (34.7) 301 Joint : M14 1
214 O-ring : 1B P20 4 302 Circular plate 1
216-1 Spring seat 2 68.6 (50.6) 312 Adjust nut : M14 1
216-2 Spring seat 2 501 Boots 1
217 Washer 2 (Shim) 4
Note) The parts marked * may not be equipped depending on valve type.
24-60
24.1.3.3 OPERATION
(1) Lever in neutral (See Fig. 24-59)
The action of spring (509) (for secondary pressure
setting) that determines the output pressure of the
pilot valve does not act upon spool (201).
Therefore, spool (201) (for return) is pushed up by
spring (221) [spring seat (216)]. The output ports
(2,4) connect with the T port. The result is that the
output pressure is equal to the tank pressure.
216
509
221
201
PORT (2,4) PORT (1,3)
Fig. 24-59 Lever in neutral

(2) When the pilot lever is tilted (See Fig. 24-60 )
When the lever is tilted and the push rod (511)
strokes, the spool (201) [spring seat (216)] moves
downward to make the port P to connect with the
port 2, 4, with the result that the oil of the pilot pump
flows to the port 2 ,4 to produce a pressure.

Fig. 24-60 When the lever is tilted
(3) Lever held (See Fig. 24-61)
When the pressure at ports (2,4) rises to a level
equivalent to the action of spring (509) that is set by
tilting the lever, the hydraulic pressure balances the
spring action. When the pressure of ports (2,4)
rises above a set value, ports (2,4) and the P port
close while ports (2,4) and the T port open. When
the pressure at ports (2,4) falls below a set value, 509
ports (2,4) and the P port open while ports (2,4) and
the T port close. Thus the secondary pressure is
T PORT
kept constant.
P PORT
PORT (2,4) PORT (1,3)

Fig. 24-61 When the lever is held
24-61
(4) Operation in the area where the tilting angle of the

lever is large.
(varies with the model)
If the lever is inclined beyond a certain angle on
certain models, the top end of the spool contacts
the bottom of the bore of the push rod. This keeps
the output pressure connected with the P port
pressure.
Furthermore, on a model in which a spring seat and
a spring are built in the push rod, the bottom of the
bore of the push rod contacts the spring if the lever
is turned beyond a certain angle. This causes the
secondary pressure gradient to change by the
spring action. Thereafter, the bottom of the bore of
the push rod contacts the top end of the spring seat,
keeping the output pressure connected with the P
port.
24-62
24.1.4 PILOT VALVE (TRAVEL)
24.1.4.1 OUTLINE
(1) Outside view
Tightening torque
Port size N.m (lbf.ft) Port name Function
1 LH travel forward port
2 LH travel reverse port
PF3/8 30 (22) 3 RH travel forward port
4 RH travel reverse port
T Tank port
5 LH travel pressure sensor port
PF1/4 16.7 (12.3) 6 RH travel pressure sensor port
P Pilot primary pressure port
(2) Specifications
P T
Item Specifications
Part No. YN30V00105F1
Type 6TH6NRZ
Primary pressure 4.9MPa (711psi)
Secondary pressure 0.54~2.35MPa (78~341 psi)
Rated flow 25 L/min (6.6 gal/min)
Weight Approx. 8kg (18 lbs)
1 5 2 3 6 4
Hydraulic symbol
(3) Performance characteristics

Secondary pressure
[MPa (psi)] Secondary pressure
2.35 + 0.15
(340 + 22)
0.54 + 0.1
(78 + 15) 0
1 30' 11 30' Pedal angle (degree)
(4.7 + 0.5) 2 30' 12 30'
6.4 + 0.64
7.7 + 0.77
(5.7 + 0.6)
12.7 + 1.27
(9.4 + 0.9)
Operating Operating torque
torque
[N.m (lbf.ft)] Control diagram
24-63
24.1.4.2 Construction and operation

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

T line
24-64
24.1.5 SWING MOTOR UNIT
24.1.5.1 SPECIFICATION
(1) General view
Tightening
Symbol Port name Port size torque
N.m (lbf.ft)
A,B Main port SAE 3/4"
DB Drain port PF1/2 108 (80)
M Make-up port PF1 216 (159)
PA,PB Pressure measuring port 2-PF1/4 36 (27)
PR Parking brake release port PF1/4 36 (27)
Gear oil level gauge or
IP,L,AR Air breather port or PT3/4 98 (72)
Gear oil filling port
IP, L, AR
12- 22 Through
DB
B
PB
M
PR PA
A
THREAD FOR
EYE BOLT 2-M12
PR
DB
RELIEF VALVE
PB PA
M DB
A,B
M
PA PB PR
A B
Hydraulic diagram
24-65
(2) Specifications
Swing motor unit part No. LC15V00025F1

Type M5X180CHB-10A-60B/295
Displacement cm (in )
3 3 180.1 (11.0)
Working pressure MPa (psi) 32.4 (4700)
Max. pressure MPa (psi) 39.2 (5680)
Hydraulic motor
Working flow L/min (gal/min) 294 (77.7)

Braking torque N•m (lbf•ft) 860~1121 (634~827)
Brake release
MPa (psi) 2.4~5.0 (348~725)
pressure
Relief set pressure MPa (psi) 29.0 (4205)
Weight kg (lbs) 72.5 (160)
Anti- Part No. YN22V00014F4
reaction valve Type 2KAR6P72/240-712
block Weight kg (lbs) 2.5 (5.5)
Hydraulic motor assy weight kg (lbs) 75 (165)
Part No. LC32W00007F1
Speed reduction type Planetary 2-stage
Reduction unit
Reduction ratio 27.143

Lubricate oil Gear oil SAE90 (API class GL-4 grade)
Lubricate oil volume 7.4 L (1.96 gal)
Grease Extreme pressure lithum base #2 grease
Grease volume kg (lbs) Approx. 1.7 (3.7)
Weight kg (lbs) 371 (818)
Total weight kg (lbs) 446 (983)
24-66
(1) Swing motor
702 712
351
ARRENGEMENT OF BRAKE SPRING

355
401
488 469
051-1 051
100
151
162 052 161 171
303 984
A A 163 985 391 390 444
131
451
472 400-1
400-2
712 400 052
702 707 SECTION A-A
706
986
742
743
994
111
491 101
121 123 122 124 114 301 443
24-67

177 (130) 051 Relief valve ; M33-P1.5 2 69 (51) 400 Anti-reaction valve ; M22-P1.5 2
051-1 O-ring ; 1B G30 2 400-1 O-ring ; 1B P20 2
052 Anti-reaction valve sub 1 400-2 Backup ring 2
Casing for anti-reaction
100 1 431 (318) 401 Socket bolt ; M20×45 4
valve
101 Drive shaft 1 443 Roller bearing 1
111 Cylinder 1 444 Roller bearing 1
114 Spring plate 1 451 Pin 2
121 Piston 9 539 (398) 469 ROMH plug; M36-P1.5 2
122 Shoe 9 472 O-ring ; W1516,WG44 1
123 Set plate 1 488 O-ring ; 1B P34 2
124 Shoe plate 1 491 Oil seal 1
131 Valve plate 1 702 Brake piston 1
36 (27) 151 Plug ; PF1/4 2 706 O-ring ; W1516,WG42 1
161 O-ring ; 1B P11 2 707 O-ring ; W1516,WG45 1
162 O-ring ; 1B P12 2 712 Brake spring 14
163 O-ring ; 1B P6 2 742 Friction plate 3
29 (21) 171 Socket bolt ; M8×55 4 743 Separator plate 4
301 Casing 1 2.7 (2.0) 984 Plug ; PF1/2 1
303 Valve casing 1 5.6 (4.1) 985 Plug ; PF1 1
351 Plunger 2 0.9 (0.66) 986 Plug ; PF1/4 1
355 Spring 2 98 (72) 994 Plug ; PT3/4 1
390 Name plate 1
391 Rivet 2
24-68
(2) Swing reduction unit
34
22 11 27 25 24 3
4
SURFACE
5 OF LUBE OIL
10 3
23 6 20 35
7 8 3 VIEW
11 15
26 12
9 17 30 36, 37, 38, 39
14 31
3
28
29 18
33 32
13
21 19 16
2
1
DETAIL aa
aa

1 Pinion 1 21 Ring 1
2 Shaft 1 22 Thrust washer 6
3 #1 Sungear 1 23 Thrust washer 8
4 #1 Planetary pinion 3 24 Snapring 1
5 #1 Spider assy 1 25 Snapring 3
6 #2 Sungear 1 26 Spring pin 4
7 #2 Planetary pinion 4 539±54 (398±40)*1 27 Capscrew ; M20×200 12
8 Ring gear 1 28 Grease fitting 1
9 #2 Spider assy 1 29 Relief fitting 1
10 Shaft 4 69.1±4.4 (51±3)*2 30 Tube 1
11 Needle bearing 11 69.1±4.4 (51±3)*2 31 Elbow 1
12 Roller bearing 1 69.1±4.4 (51±3)*2 32 Plug 1
13 Roller bearing 1 33 Cap 2
14 Oil seal 1 279±30 (206±22)*1 34 Capscrew 2
15 Housing 1 35 Wire ø1.6×250 1
16 Oil seal 1 36 Shim ; t=0.1 1
17 Sleeve 1 37 Shim ; t=0.2 1
18 Sleeve 1 38 Shim ; t=0.3 1
19 Plate 1 39 Shim ; t=0.5 1
20 Plate 1
*1 : Apply Three Bond #1360K.
*2 : Apply seal tape or Loctite #577.
*3 : Apply Loctite #515.
24-69
24.1.5.3 OPERATION
24.1.5.3.1 OPERATION OF HYDRAULIC MOTOR

If the high pressure oil flows into the cylinder
through the inlet port (a) of valve plate (131), as Cylinder block (111)
shown on the figure on the right, the hydraulic

pressure acts upon piston (121) and creates force F2
F in the axial direction. F1
The force F may be divided into force F1 vertical to F

shoe plate (124) via shoe (122) and force F2 at right
angles with the shaft.
The force F2 is transmitted to cylinder block (111) Drive shaft (101)
via pistons (121) and causes drive shaft to turn so

as to produce a rotating moment.
The cylinder block (111) has nine pistons equally
arranged. Rotating torque is transmitted to drive
Valve
shaft by turns by pistons connected to inlet port of plate
high pressure oil. Shoe Shoe Piston
(131)
If the oil supply and discharge directions are plate

(122) (121)
(122)
reversed, the drive shaft rotates in the opposite
direction. Low pressure oil High pressure oil
Theoretical output torque T can be given by the

following equation.
P X q P ; Effective differential pressure MPa OUTLET INLET (a)
T=
2X q ; Displacement per revolution cc/rev
Fig. 24-62 Operation of hydraulic motor
24.1.5.3.2 VALVE CASING SECTION

(1) (1)Operation of anti-cavitation check plunger
Since the system using this type of motor is not
equipped with a valve having a counterbalance 351
function, the motor is rotated beyond the oil feed
rate in some cases.
The system has check plunger(351) and sucks in
deficient oil, in order to prevent cavitation from
occurring due to oil deficiency. M port
(Make-up port)
DIRECTIONAL VALVE
Fig. 24-63 Operation of anti-cavitation check

plunger
24-70
(2) Operation of relief valve Chamber h

Orifice m Spring (321) Piston I (302)
1) Consider where the relief valve is pressurized.
The pressure at the P, R ports is equal to the tank
pressure at the beginning, as shown in Fig. 24-
64. P
The relief valve begins to operates when the
hydraulic pressure that is determined by the Pressure R Chamber g
product of the pressure-receiving area A1 of receiving Plunger(301) A3 A2 Orifice n A4
area A1
plunger(301) and the pressure P balances the Fig. 24-64 Functional explanation of relief valve (1)
hydraulic pressure that is determined by the
product of the pressure-receiving area A2 of the Orifice m Spring (321) Chamber h
Pin (303) Piston I (302)
plunger(301) and the pressure Pg of chamber g.
Thereafter, the pressure of chamber g rises and
the piston 1 (302) begins to stroke. The load to
spring (321) increases by this movement of the P
piston.
As the result, the relief pressure P is raised and R
controlled in the pressure boost time t1 from P1 Plunger(301) Orifice n Chamber g
till Ps. Fig. 24-65 Functional explanation of relief valve (2)
This process is explained in the following in the
relationships between the movements of the Orifice m Spring (321) Chamber h
Pin (303) Piston I (302)
components shown in (2) to (4) of Fig. 24-
65~Fig. 24-67and the relief pressure :
a. Condition shown in Fig. 24-65.
P
If the P port of the relief valve is pressurized,
pressure is built up in chamber g via the
R
restrictor m of plunger (301). Orifice n
The hydraulic pressure acting on plunger Plunger(301) Chamber g
(301) increases and when it balances the load Fig. 24-66 Functional explanation of relief valve (3)
Fsp of spring (321), the relief valve performs Orifice m Spring (321) Pin (303) Piston I (302)
relieving action by the pressure P1.
This relationship is expressed as :
P1×A1=FSP1+Pg1×A2
where FSP1 : P
primary set load value of spring (321)
b. Condition shown in Fig. 24-66. R
The pressure of chamber g acts upon the Plunger(301) Orifice n Chamber g
pressure-receiving area A3-A4 of piston 1
Fig. 24-67 Functional explanation of relief valve (4)
(302). When the hydraulic pressure rises
above the load of spring (321), the piston 1
begins to move to the left.
On that occasion, since the machine turns to
the left while discharging the oil of chamber h
arranged between piston 1 and adjust plug
(401) into chamber g via orifice n provided in
piston 1 (302), chamber h serves as a
dumping chamber.
The load of the spring increases slowly till Fig. 24-68 Pressure boost characteristics
piston 1 reaches the end of the adjust plug.
The relief pressure P rises smoothly.
24-71
c. Condition shown in Fig. 24-67.

The machine does not travel to the left further
when piston 1 (302) arrives at the end of
adjust plug (401). Therefore, the relief valve
keeps its normal relieving action whereby the
relief pressure is held at P2.
In the processes 1 to 3 above, the relief
pressure changes as shown in Fig. 24-68.
2) Function when the relief valve pressure is
reduced
Let us consider the pressure of the P port is
reduced.
When the pressure at port P is reduced to zero,
the pressure of chamber g falls to the tank
pressure level. The result is that the plunger
(301) which is now open moves to the left and is
seated on seat (341). At the same time, the
piston 1 (302) moves to the right by the action of
spring (321) and returns to the condition of Fig.
24-64.
(3) Operation of anti-reaction valve
Fig. 24-69 Hydraulic circuit diagram for anti-

reaction valve.
1) Neutral condition :
Fig. 24-69 illustrates the relationship between
the neutral condition of the anti-reaction valve
and the hydraulic circuits. Now, let us consider a
L
braking condition in which brake pressure
generates on the AM port side.
k
322 313 321 311
Fig. 24-70 Neutral condition
2) When brake pressure occurs : m n
If pressure (P) generates at the AM port, it
passes through the passage L, the hole on the
shaft of seat (313) and the passage m of plunger P=PS
(311) and is led to the n chamber.
L
When the pressure P rises above a value (Ps)
set by spring (321), plunger (311) compresses
spring (321) and shifts it to the left. 322 313 321 311
Seat (313) compresses weak spring (322) as
Fig. 24-71 When brake pressure occurs
pushed by plunger (311) and moves to the left.
24-72
3) At anti-reaction action p t
When inertia load stops moving (point Y Fig. 24-
73), brake pressure (P) tries to fall.
When P<Ps, plunger (311) moves toward the P<PS
right return side by the action of spring (321). L
Seat (313) tries to move to the right by the action
of spring (322), but since chamber p provides k
damping action by orifice g, the return of the seat 322 313 g r 321 311
makes a time delay with regard to the return of
Fig. 24-72 At anti-reaction action
the plunger.
Consequently, seat t opens. This makes a P Y
passage connecting the AM port and BM ports or
PS
both ports of the hydraulic motor by way of
→t→r→k. The result is that the pressures at the
AM and BM ports become equal (Pb), falling into PB
X
the condition at point Z in Fig. 24-73. Z
This prevents the hydraulic motor from swing T
shock by the closing pressure of the AM port. Fig. 24-73 Pressure change diagram of anti-
reaction operation
24.1.5.3.3 OPERATION OF BRAKE SECTION

The cylinder (111) is jointed by drive shaft (101) and a
spline. Separator plate (743) is fixed in its
circumferential direction by circular grooves provided in
casing (301).
Now, if the friction plate (742) splined to the outer 702
circumference of the cylinder is pressed against casing 712 743
(301) via separator plate (743) and brake piston (702)
742
by the action of brake spring (712), frictional force is
created between friction plate (742) and casing (301)
111 301
and between separator plate (743) and brake piston
(702). The frictional force bounds the drive shaft to 301 101
brake the motor.
Fig. 24-74 Operation of swing brake
In the meantime, when brake release pressure applied
to the oil chamber formed between brake piston (702)
and casing (301) overcomes the spring force, the brake
is released as brake piston (702) moves till friction plate
(742) is separated from casing (301).
24-73
24.1.5.3.4 SWING REDUCTION UNIT

The swing reduction unit is used to reduce the rotating Ring gear (Fixed) Planetary shaft
speed which is transmitted by the hydraulic motor and
to convert it to the strong turning force (torque).
This swing speed reduction unit is equipped with
Spider
planetary speed reducing mechanism.
The planetary mechanism is made up of sun gear, Sun gear
planetary pinion, planetary shaft, spider and ring gear,
as shown in Fig. 24-75.
For the operation of the 1st stage planetary, the

hydraulic motor rotates #1 sun gear (3). Sun gear (3) is
engaged with planetary pinion (4) and rotates, but since Planetary pinion
ring gear (8) is fixed, planetary pinion (4) revolves about Fig. 24-75 Planetary mechanism
sun gear (3) with the planetary shaft and spider (5). Swing motor
The role of spider is to hold the planetary pinion and 4 3

planetary shaft and transmits the power from the 8
planetary pinion to the spider through the planetary
shaft. 5
The #1 spider (5) is linked with #2 sun gear (6) by the 6
involute spline, and transmits the power to the 2nd 9
stage planetary mechanism.
For the operation of the 2nd stage planetary, the power Housing
is transmitted to #2 sun gear (6)→#2 planetary pinion 7
(7)→#2 spider (9) similarly to the 1st stage. The #2 Bearing
spider (9) is linked with pinion shaft (2) by the involute 2
spline, and pinion (1) is engaged with the swing gear
fixed on the undercarriage (lower frame) and rotates.
Bearing 1
Fig. 24-76 Function of reduction unit
24-74
24.1.6 TRAVEL MOTOR
24.1.6.1 SPECIFICATION
(1) Appearance
PRESSURE MEASUREMENT PORT

2-G (PF)1/4
(MB,MA)
PILOT PORT
G(PF) 1/4 (P)
BEARING CENTER
VALVE PORT
2-G (PF) 1
(VA,VB)
DRAIN PORT
2-G (PF)1/2
18-M24 (D1,D2)
G (PF) 3/4
FILL PORT
LEVEL PORT OIL LEVEL
G (PF) 3/4
DRAIN PORT VIEW Y
Fig. 24-77 Travel motor
Rotation direction
Tightening
Oil inlet Oil outlet Rotation direction Port
Port size torque Function
port port (Viewed from valve port side) name
N•m (lbf•ft)
VA VB Right (Clockwise) P PF1/4 36 (26.6) Pilot (2 speed changeover) port
VB VA Left (counter clockwise) D1, D2 PF1/2 98.1 (72.4) Drain port
VA, VB PF1 255 (188) Motor drive port
MA, MB PF1/4 29.4 (21.7) Pressure measurement
24-75
(2) SPECIFICATIONS

TRAVEL MOTOR UNIT
Type M4V290 / 170F-RG6.5F
Part No. —
Type —
Reduction ratio 40.467
Reduction unit Number of reduction stages 2
Lube oil capacity L (gal) 9.5 (2.5)
Lube oil capacity specification Gear oil SAE90API GL4 or GL5
Weight kg (lbs) —
Type M4V290 / 170F
cc/rev
Max. displacement 290.7 (17.7)
(cu•in/rev)
cc/rev
Min. displacement 170.1 (10.4)
(cu•in/rev)
Relief valve set pressure MPa (psi) 35.0 (5075)
Travel motor
2 peed changeover pilot
MPa (psi) 5.0 (725)
pressure
Parking brake torque N•m (lbf•ft) 902 or more (665)
Parking brake release pressure MPa (psi) Less than 1.54 (223)
Working 0.2 (29)
Allowable drain pressure MPa (psi)
Surge 0.98 (142)
Weight kg (lb) —
Unit weight (with oil) kg (lb) 399 (880)
24-76
24.1.6.2.1 TRAVEL MOTOR
Fig. 24-78 Travel motor
No. NAME No. NAME No. NAME

1 Casing 21 Breake piston 41 Restrictor spring (brake valve)
2 NPT 1/16 plug 22 D-ring (small dia.) 42 G1/8 plug
3 Oil seal 23 D-ring (big dia.) 43 O-ring 1B P8
4 Retaining ring IRTW68 24 Rear cover 44 Check valve
5 Expander plug MB800-040 25 NPT 1/16 plug (MEC) 45 Check valve spring
6 Shifter piston 26 Spool assy (M4V RBV) 46 M6 restrictor (0.6)
7 Piston seal 27 Spring holder (M4V RBV) 47 O-ring 1B P12.5
8 Steel ball 25 28 Spring (M4V150RBV) 48 M8 restrictor (0.8)
9 Shaft 29 M42 plug (4V RBV) 49 O-ring 1B P15
10 Bearing HR32209J 30 O-ring 1B G40 50 O-ring 215.57×2.62
11 Pivot 31 Pilot valve spool dia. ø10 (M4V290) 51 Bearing HR32207C
12 Swash plate 32 Pin (MRC03) 52 Shim
13 Cylinder block 33 Spring holder (MRC03) 53 Parallel pin M68×12
14 Cylinder spring 34 Spring (MRC03) 54 Valve plate
15 Spring holder 35 G3/8 pilot valve plug 55 Brake spring
16 Ball joint 36 O-ring 1B P14 56 HEX. socket head bolt M18×50
17 Shoe retainer 37 Connector (MRC03) 57 Overload relief valve ORV-240L
18 Piston assy 38 G1/4 plug 58 Coupling
19 Separating plate 39 O-ring 1B P11 59 Retaining ring C-type 40
20 Friction plate 40 Restrictor (brake valve) 60 G1/2 plug
61 O-ring 1B P18
24-77
24.1.6.2.2 REDUCTION UNIT
Fig. 24-79 Reduction unit
No. NAME No. NAME No. NAME

1 Housing 11 Thrust washer 2 21 Spring pin 6×36
2 Bearing 245BA35S1GS 12 Needle bearing FBNP-608660 22 Sun gear 1
3 Ring gear 13 Carrier pin 2 23 Thrust plate
HEX. socket head bolt
4 14 Spring pin 10×50 24 Cover
M18×110
HEX. socket head bolt
5 Floating seal 368 15 Sun gear 2 25
M10×30
6 Shim 16 Carrier 1 26 Plug G3/4
7 Lock washer 17 Planetary gear 1 27 O-ring 1B P24
8 Support ring 18 Thrust washer 1
9 Carrier 2 19 Needle bearing FBNP-406040
10 Planetary gear 2 20 Carrier pin 1
24-78
24.1.6.3 MAKEUP OF TRAVEL MOTOR

The travel motor consists mainly of the rotary group that generates rotating power, the parking brake that prevents
the machine from moving by itself while it is parked, the variable displacement mechanism that switches over the
motor capacity to the large or small mode, the overload relief valve that is built in the rear cover, and the brake valve
(counterbalance valve) that controls the hydraulic circuits.
(1) Rotary group
Cylinder block (13) is inserted in the gear tooth grooves of the spline of shaft (9) that is supported by bearings
(10, 51) at it both ends. The cylinder block (13) is pressed against rear cover (24) with valve plate (54) by the
action of spring (14).
9 piston assy (18) slide over shoe plate (12), while stroking in cylinder block (13).
A bearing retainer is arranged at the end face of piston assy (18) to reduce the sliding resistance. The action of
spring (14) is transmitted to spring retainer (15), ball joint (16), and shoe retainer (17) and presses the end face
of piston assy (18) against shoe plate (12) so the piston assy moves close to the surface of shoe plate (12).
(2) Parking brake

Seven separator plates (19) and six friction plates (20) are inserted by turns in the spline grooves in the outer
surface of cylinder block (13) and are pressed against casing (1) by the action of 14 springs (55) via brake piston
(21).
(3) Variable displacement mechanism

The variable displacement mechanism consists of pivot (11) supporting shoe plate (12) that is put in two
semispherical concaves provided in shoe plate tilting piston (6) that tilts shoe plate on pivot (11) tilting stopper
(H) supporting the piston at a certain position; the pilot valve that admits the pressurised oil to the tilting piston
(6) by an external command; and three check valves (44) that take out the highest of the external command
activated pilot pressure, the motor inlet pressure and the motor outlet pressure and that sends it to the pilot valve.
(4) Overload relief valve

The overload relief valve consists of socket (57-1) that has valve seat (57-3) metallically seating rear cover (24)
of the motor and screwed up in rear cover (24) valve (57-2) engaged with socket (57-1) that is tangential in
contact with valve seat (57-3) by the action of adjust spring (57-9) connecting piston (57-4) that is inserted in
valve (57-2) and serves also as an oil path to pilot body (57-6) piston (57-7) that is put in pilot body (57-6) and
pressed against plug (57-5) and shim (57-8).

!
!
!
!
!

Fig. 24-80 Construction of overload relief valve
24-79
(5) Brake valve portion

1) Spool
By shifting the spool (26), the discharged oil from hydraulic motor is automatically shut off or restricted
according to the condition and give the effect of holding, accelerating, stopping and counterbalance
operations.
2) Check valve (built in the spool)

This valve is located in the oil supplying passage to hydraulic motor, and at the same time functions to lock
oil displacement. Therefore, this valve serves as not only a suction valve but also a holding valve for
hydraulic motor.
Spool control pressure : 0.59~0.95 MPa (86~138 psi)

Check valve cracking pressure : 0.015 MPa (2.2 psi)
CHECK VALVE
Fig. 24-81 Brake valve portion
24-80
24.1.6.4 FUNCTIONS OF TRAVEL MOTOR

(1) Motor
High pressure oil delivered from hydraulic pump is led to inlet port that is provided in the brake valve portion and,
through the rear cover (24) and valve plate (54), led to cylinder block (13).
As shown in Fig. 24-82 (a), high pressure oil is supplied to the pistons which are on one side of the line Y–Y that
connects upper and lower dead points and produces force F1.
F1=P×A (P : pressure, A : area of piston section)
The swash plate (12) with inclined angle of divides this force F1 into thrust force F2 and radial force F31-F34
(or F35). (Fig. 24-82 (b)) This radial force is applied to axis Y-Y as turning force and generate drive torque of T.
T=r1•F31+r2•F32+r3•F33+r4•F34
(In case high pressure oil is applied to five pieces of pistons, r5 F35 should be added.)
This drive torque is transmitted via cylinder block (13) to driving shaft (9).
Fig. 24-82
(2) Parking Brake
Parking brake is released when high pressure oil, selected by the brake valve portion that is connected directly
to the rear cover (24), is applied to the brake piston (21). Otherwise the braking torque is always applied.
This braking torque is generated by the friction between the separating plates (19), inserted into the casing (1),
and friction plates (20), coupled to cylinder block (13) by the outer splines.
When no pressure is activated on the brake piston (21), it is pushed by the brake springs (55) and it pushes
friction plates (20) and separating plates (19) towards casing (1) and generates the friction force which brakes
the rotation of cylinder block (13) and hence the shaft (9).
Fig. 24-83 Parking brake portion
24-81
(3) Capacity Control Mechanism

Fig. 24-84 typically shows the capacity control mechanism.
When high speed pilot line is charged with the pressure PA that overcome the spring (34), the spring (34) is
compressed and spool (31) shifts to the right to connect the port P and port C.
Then, the highest pressure is selected by the check valve (44) from inlet and outlet pressure of the motor and
high speed pilot line pressure and pushes shifter piston (6). As a result, swash plate (12) turns around the line
L which connect the two pivots (11) as shown by dotted lines. The turn stops at the stopper (1-1) of casing and
swash plate (12) keeps the position.
In this case, the piston stroke become shorter and motor capacity become smaller and motor rotates faster,
around 1.71 times, by the same volume of oil.
When no pressure is in the high speed pilot line PA, spool (31) is pushed back by the spring (34) and pressure
that pressed the shifter piston (6) is released to the hydraulic tank through restrictor (46).
Here, nine pistons are there and they equally spaced on the swash plate (12). The force that summed up those
of pistons comes to almost the center of the swash plate (12) as shown. Since the pivots (11) are off-set by S
from the center, the rotating force of product S and the force moves swash plate (12) to the former position and
the speed returns to low.
When the power demand exceeds the engine power, such as in steep slope climbing or turning at high speed
mode, the system step down to the low speed automatically. The mechanism is that: pump pressure is led to the
port PB (Fig. 24-84) and this pressure activate on pin (32). When the pressure at PB exceeds predetermined
value, spool (31) returns to the left by the counter-pressure against pin (32) and the pressure on the shifter piston
(6) through port C is released to the tank and the motor comes to low speed.
When PB goes down, the spool (31) moves to the right and the speed become high.
TO COUNTERBALANCE VALVE
(BRAKE VALVE)
HIGH SPEED PILOT LINE

(EXTERNAL PILOT)
LOAD
APPLICATION POINT
Fig. 24-84 Capacity control Mechanism
24-82
(4) Function of overload relief valve

Two pieces of overload valves are located at cross-over position in the counterbalance circuit of brake valve and
have the following functions:
1) When hydraulic motor starts, keep the driving pressure below predetermined value and while accelerating,
bypasses surplus oil to return line.
2) When stopping the motor, keep the brake pressure, that develops on the outlet side of motor, under the
predetermined value to stop the inertial force.
3) To accelerate sharply while starting, and to mitigate the braking shock while stopping. For these purposes,
the developed pressure is kept comparatively low for a short period, then keep the line pressure as normal
value. While the pressure is low, meshing of reduction gears, crawler and sprocket etc. can be smoothly
done and the shock are absorbed.
When starting, "A" port pressure of overload valve increases, this pressure is applied to the effective diameter
of valve (57-2) which seats on the valve seat (57-3) and, at the same time, is delivered, via small hole, to the
connecting piston (57-4) located inside the valve (57-2) and the piston bore pressure increases up to "A" port
pressure. The valve (57-2) opposes to adjusting spring (57-9) by the force of the pressure exerted on the area
difference between valve seat's effective diameter and piston bore and keep the predetermined pressure.
When hydraulically braking, the piston (57-7) is at the left position by the driving pressure, and when "A" port
pressure increases, the pressure is applied also to the piston (57-7) through the small hole in the valve (57-2)
and piston (57-7) moves rightward until it touches the cap (57-5). In this while, the valve (57-2) maintains "A"
port pressure at comparatively low against the adjusting spring (57-9) force and exhaust oil to "B" port side. After
the piston reached to the plug, the valve acts the same as at starting.
CAP
CONNECTING PISTON (57-5)
PORT B (57-4)
VALVE SEAT
(57-3)
PORT A
VALVE ADJUSTING SPRING PISTON

SMALL HOLE (57-2) (57-9) (57-7)
Fig. 24-85 Function of overload relief valve
24-83
(5) Function of brake valve

1) Holding operation (see Fig. 24-86)
When the control valve is at neutral position, VA and VB ports are connected to the tank, and the spring (28)
located on both spool ends holds the spool (26) at central position. Therefore, the passages from VA to MA
and VB to MB are closed, which result in closing MA and MB ports connected to hydraulic motor.
Since the passage to parking brake is connected to the tank line, the brake cylinder pressure is equal to the
tank pressure and the brake is applied by the springs. Thus, the rotation of the motor is mechanically
prevented. If external torque is exerted on the motor shaft, the motor would not rotate as usual by this parking
brake.
In case the brake should be released for some reason, pressure is built on MA or MB port. But, due to oil
leakage inside hydraulic motor or so, high-pressure oil escapes from the closed circuit and motor rotates a
bit. So, the cavitation tends to occur in the lower pressure side of the closed circuit. Then, the check valve,
built in the spool (26), operates to avoid the cavitation and opens the passage from VA to MA or from VB to
MB. Then the oil equivalent to the leakage is sucked from the tank line to the closed circuit.
SPRING SPRING
Fig. 24-86 Holding Operation
24-84
2) Accelerating operation (see Fig. 24-87)

When VA and VB ports are connected respectively to pump and tank by operating the control valve, hydraulic
oil from pump is forwarded through VA port to push open the check valve provided inside spool (26), and oil
flows to motor via MA port to rotate the motor.
Therefore, the pressure increases and negative brake is released by the pressure supplied from pump. At
the same time, the pressure of pilot chamber increases to push and move the spool (26) leftwards,
overcoming the spring (28) force. Thus, the return line from MB to VB opens to rotate the motor.
In case inertia load is too big to start rotation, accelerating pressure reaches the set pressure of relief valve
and high pressure oil is being relieved while the motor gains the rotational speed. As the rotational speed
goes up, the relieved volume decreases, and finally the motor rotates at a fixed speed.

Fig. 24-87 Accelerating Operation
24-85
3) Stopping operation (see Fig. 24-88)

Returning the control valve to neutral position while running the motor, the oil supply is cut off and VA and
VB ports are connected to the tank line. Then the pressure of the pilot chamber located on both spool ends
become equal, and the spool (26) returns to the neutral position by spring (28) force. Thus, the passage from
MA to VA is closed.
Owing to the inertia force of the load, the hydraulic motor tends to continue the rotation. Here, the motor
functions as a pump and forwards the oil to MB port but the passage is blocked and MB port pressure
increases. Then the relief valve opens to relieve the pressure and rotational speed decelerates and at last
the motor stops.
Negative brake release pressure is gradually lowered due to the restrictor and finally the brake works and
the motor is mechanically stopped.

Fig. 24-88 Stopping operation
24-86
4) Counterbalance operation (see Fig. 24-89)

Counterbalance operation is required to decelerate slowly the hydraulic motor while absorbing inertia force.
In case the hydraulic oil is gradually decreased from pump to VB port, the drive shaft of hydraulic motor tends
to rotate faster than that matched to the volume of oil supply. Consequently, the pilot chamber pressure on
MB to VB side decreases and the spring (28) force moves the spool (26) leftwards towards neutral position.
Therefore, the area of passage from MA to VA becomes smaller and the pressure on MA side rises due to
increased resistance in the passage and the motor receives hydraulic braking effect.
If the motor rotates slower than that matched to the volume of supplied oil, the pilot chamber pressure on
VB port increases, and spool (26) moves rightwards to enlarge the area of passage from MA to VA.
Therefore the braking effect becomes smaller and the rotational speed of motor is controlled to correspond
to the volume of supplied oil. In order to give stable counterbalance operation, the restrictors (40) are set in
the pilot chamber to damp the spool (26) movement.
The parking brake is released during pressure adjusting action of the spool (26).
CHECK VALVE CHECK VALVE WITH RESTRICTOR

WITH RESTRICTOR
PILOT CHAMBER PILOT CHAMBER
SPRING
SPRING
Fig. 24-89 Counterbalance operation
24-87
24.1.6.5 FUNCTION OF REDUCTION GEAR

Reduction unit slows down the rotating speed of motor

and converts motor torque to strong rotating force.
This reduction unit utilizes two stages, planetary
reduction system.
Planetary reduction system consists of sun gear,
planetary gears, (planetary) carriers, and ring gear.
When the sun gear (s) is driven through input shaft,
planetary pinions (b), rotating on their center, also
move, meshing with fixed ring gear (a), around sun
gear (s).
This movement is transferred to carrier (k) and deliver
the torque.
This mechanism is called planetary gear mechanism.

Fig. 24-90 Planetary gear mechanism

See Fig. 24-91 on the right.
a
When the sun gear S1 is driven by input shaft,
planetary action occurs among gears S1, a and b and
b d
revolution of gear b transfers the rotation of carrier K1
to second sun gear S2, and also evokes planetary
action between gear S2, a and d. S1 S2
This time, because carrier K2 is fixed to frame, gear d
drives ring gear a and then ring gear a rotates to drive
sprocket.
K1 K2
Fig. 24-91 Two stages reduction gear
24-88
24.1.7 SWIVEL JOINT
24.1.7.1 GENERAL VIEW
VIEW Y
VIEW Z
Fig. 24-92 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)
F Rated flow 30 L/min (8 gal/min)
Revolution speed 15 min-1 (15 rpm)
A, B, C, D (Body) PF1
A, B, C, D (Stem) PF3/4
Ports size
E PF1/2
F PF1/4
Length : L 368 mm (14.5")
Weight 25 kg (245 lbs)
24-89
2 places Apply Three Bond

#1805 to stem
2 places
VIEW Y
5 places
Tightening torque
30.4 N.m (22.4 lbf.ft)
Apply Loctite #242
SECTION HH
Tightening torque
30.4 N.m (22.4 lbf.ft)
Apply Loctite #242
Fig. 24-93 Construction
No. Name Q’ty No. Name Q’ty

1 Body 1 7 O-ring(G95 1A) 1
2 Stem 1 8 Capscrew (M8×20) 2
3 Thrust plate 1 9 Capscrew (M8×30) 3
4 Cover 1 12 Plug 1
5 Seal 5 13 O-ring 2
6 Seal 1
24.1.7.4 OPERATION
The swivel joint consists mainly of body (1) and stem (2) that rotate mutually, thrust plate (3) preventing both
components from falling off, cover (4) closing one side of body (1), seal (5) that partitions off the circuits and seal
assy (6) and O-ring (7) that prevent external leaks.
Four ports for the travel main circuits are provided on body (1) and stem (2). Further, four oil passing grooves are
arranged in the inner surface of body (1), with seal (5) fixed above and below the circumferential groove.
The body (1) and the stem (2) rotate mutually. The oil flowing in from body (1) or stem (2) keeps on flowing to stem
(2) or body (1) past the circumferential groove between body (1) and stem (2) ; the oil flow is never shut off because
of rotation. Further, an oil groove for lubrication that connects with the drain port is provided, in order to prevent the
body (1) from seizure with the stem (2).
This construction keeps on connecting the circuits between the swing bodies by means of a swivel joint.
24-90
24.1.8 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. 24-94 General view of cylinder

(2) Specifications
Unit : mm (ft-in)
Center distance of
Part No. of Cylinder bore / pins Dry weight
Use Stroke Cushion
cylinder assy Rod Dia. Full extend B / Full kg (lbs)
retract A
ø140 / ø100 1,550 3,651 / 2,101 With cushion on
Boom LC01V00044F1 269 (593)
(5.51" / 3.94") (5'1") (11'12" / 6'11") rod side
SE.Asia LC01V00054F2 ø170 / ø120 1,788 4,281/ 2493 With cushion on
Arm 504 (1,111)
Oceania LC01V00054F1 (6.69" / 4.72") (5'10") (14'1" / 8'2") both sides
SE.Asia LC01V00055F2 ø150 / ø100 1,193 3,005 / 1,812 With cushion on
Bucket 265 (584)
Oceania LC01V00055F1 (5.91" / 3.94") (3'11") (9'10" / 5'11") rod side
24-91
24.1.8.2 CONSTRUCTION AND FUNCTION
(1) Boom cylinder
T= Tightening torque ; N.m (lbf.ft)

25 24 12 T=367 (271) 22 23
B
-0.5
-0.5
130 0
130 0
With hole
DETAIL B (1 place) DETAIL C
T=8000 (5900)
T=56.9 (42.0)
9 8 7 6 3 4 5 11 10 2 1 13 14 16 17 18 19 15 20 21
Slit
Orientation of cut off part
of cushion bearing (13)
Fig. 24-95 Construction of boom cylinder
P/No LC01V00044F1
No. Parts Q’ty No. Parts Q’ty No. Parts Q’ty
1 Cylinder tube 1 10 O-ring 1 19 Slide ring 2
2 Piston rod 1 11 Buckup ring 1 20 Set screw; M14 1
3 Rod cover 1 12 Socket bolt; M18×80 12 21 Steel ball 1
4 Bushing 1 13 Cushion bearing 1 22 Pin bushing 1
5 Snap ring 1 14 Cushion seal 1 23 Wiper ring 2
6 Buffer ring 1 15 Piston 1 24 Pin bushing 1
7 U-ring 1 16 Seal ring 1 25 Wiper ring 2
8 Buckup ring 1 17 Buckup ring 2
9 Wiper ring 1 18 Slide ring 2
24-92
(2) Arm cylinder

T=711 (524)
29 28 12 28 29
B
-0.5
-0.5
140 0
140 0
DETAIL B
Stake 2 places after tightening

T=96.6(71)
T=17000(12540)
22
9 7,8 6 4 5 3 12 10,11 2 1 13 15 16 19 21 23 27 25 24
14 17 18 20 26
With hole
(1 place)
Orientation of cut
off part of cushion
bearing (13)
SLIT SLIT
Fig. 24-96 Construction of arm cylinder
LC01V00054F2 SE.Asia
P/No
LC01V00054F1 Oceania
1 Cylinder tube 1 11 Buckup ring 1 21 Piston nut 1
2 Piston rod 1 12 Socket bolt; M22×95 12 22 Set screw; M16 1
3 Rod cover 1 13 Cushion bearing 1 23 Steel ball 1
4 Bushing 1 14 Cushion seal 1 24 Cushion bearing 1
5 Snap ring 1 15 Piston 1 25 Cushion seal 1
6 Buffer ring 1 16 Seal ring 1 26 Stopper 2
7 U-ring 1 17 Buckup ring 2 27 Snap ring 1
8 Buckup ring 1 18 Slide ring 2 28 Pin bushing 2
9 Wiper ring 1 19 Slide ring 2 29 Wiper ring 4
10 O-ring 1 20 Shim 1
24-93
(3) Bucket cylinder
24 23 12 T=520 (384) 23 24
B
-0.5
-0.5
130 0
130 0
DETAIL B
Stake 2 places after tightening

T=56.9(42)
T=10000(7376)
21
9 8 7 6 3 4 5 12 11,10 2 1 13 14 15 16 17 18 19 20 22
With hole
(1 place)
Orientation of cut off part

of cushion bearing (13)
Fig. 24-97 Construction of bucket cylinder
LC01V00055F2 SE.Asia
P/No
LC01V00055F1 Oceania
1 Cylinder tube 1 9 Wiper ring 1 17 Slide ring 2
2 Piston rod 1 10 O-ring 1 18 Slide ring 2
3 Rod cover 1 11 Buckup ring 1 19 Shim 1
4 Bushing 1 12 Socket bolt; M20×95 12 20 Piston nut 1
5 Snap ring 1 13 Cushion bearing 1 21 Set screw; M14×2 1
6 Buffer ring 1 14 Piston 1 22 Steel ball 1
7 U-ring 1 15 Seal ring 1 23 Pin bushing 4
8 Buckup ring 1 16 Buckup ring 2 24 Wiper ring 4
24-94
HYDRAULIC CYLINDER CONSTRUCTION (See Fig. 24-95)

By construction the hydraulic cylinder consists mainly of cylinder tube assy (1), piston rod assy (2) that takes out the
motion of pistons reciprocating in the cylinder tube assy, and cylinder head (3) that serves as both a lid and a guide.
Cylinder tube assy (1) is equipped with a pin mount (clevis) that connects piston rod assy (2) with other parts.
In addition to these main components, seal ring (16) and back-up ring (17) are located between cylinder tube assy
(1) and piston rod assy (2); buffer ring (6), U-ring (7) back-up ring (8) and wiper ring (9) are located between piston
rod assy (2) and cylinder head (3); and an O-ring (10) and a back-up ring (11) are placed between cylinder tube assy
(1) and cylinder head (3)
If pressurized oil is fed alternatively to the oil inlet and Cushion bearing (13) Chamber "A" Passege "B"
outlet provided in the cylinder, force acts on the piston Tank
which in turn causes the piston rod (2) to extend and Piston (15)
Rod (2)
retract.
Rod side
Head side
(1) Operation of cylinder with cushion
1) Cushion on rod side
The cushion mechanism is provided to prevent Rod cover (3)
Cushion stroke
the generation of shock when the moving speed
of piston (15) is not reduced and strikes cylinder Fig. 24-98 Cushion mechanism on the rod side
head (3).

An oil in chamber "A" returns to the tank by
passing through passage "B" at a fixed flow rate
in a intermediate stroke state (Fig. 24-98) of
pressing head side. Next, in a state of just before
stroke end (Fig. 24-99), cushion ring (13)
plunges into passage "B".
At this time, an oil in chamber "A" passes
clearance "D" and mouth gap "C", an oil flow
volume returning to tank suddenly drops and the
piston part movement slows down. Fig. 24-99 Cushioning action on the rod side
2) Cushion on head side (See Fig. 24-100)
This construction is similar to the one of cushion
on rod side. In a state of intermediate stroke

pressing rod side, an oil in chamber "A" returns
to tank by passing through passage "B" at a fixed
flow rate.
Next, in a state of just before stroke end, cushion
bearing (22) plunges into passage "B". At this
time, the oil in chamber "A" flows only through
clearance "D" and mouth gap "C" of cushion seal
(23). So the returning oil volume drops suddenly
and the piston movement slows down.

Fig. 24-100 Cushion mechanism on the head side
24-95
24-96
24.2 ELECTRIC EQUIPMENT

24.2.1 ELECTRIC EQUIPMENT LIST
Group Code Name Parts No.

C - 1 Mechatro controller YN22E00214F1
(C) Controller
C - 2 Gauge cluster YN59S00021F2

C - 4 Air-con controler (including panel) YN20M01468P1
C - 5 Radiator coolant level controller VHS834701230
C - 8 Engine controller VH89661E0010
D - 4 Diode Harness accessory
D - 5 Diode Accessory of relay box
D - 6 Diode ↑
D - 9 Diode ↑
↑
(D) Diode
D - 10 Diode
D - 12 Diode ↑
D - 13 Diode ↑
D - 14 Diode ↑
D - 15 Diode ↑
D - 16 Diode ↑
D - 17 Diode ↑
E - 1 Fuse and Relay box YN24E00016F2
E - 2 Alternator VHS270402500
E - 3 Hour meter YT58S00006P1
E - 5 Horn high LC53S00001D1
E - 6 Horn low LC53S00001D2
(E) Electric fittings
E - 7 Tuner AM / FM (for Oceania) YN54S00046P1

E - 8 Speaker left (for Oceania) YN54S00050P1
E - 9 Speaker right (for Oceania) ↑
E - 10 Receiver dryer YN54S00041P1
E - 11 Air-con compressor YX91V00001F1
E - 12 Battery YN72S00014P1
E - 13 Travel alarm (for Australia) YN53S00004F1
E - 14 Cigarette lighter YN81S00003P1
E - 15 Fusible link LC13E01175S002
E - 27 Accel redundant volume YN52S00052P1
L - 1 Boom work light (LH) YW80S00001F1
L - 2 Deck work light YT80S00002F2
L - 3 Swing flasher (LH) & work light unit YM80S00001F1
(L) Light
L - 4 Swing flasher (RH) & work light unit YM80S00001F2

L - 5 Room light YT80S00001P1
L - 6 Boom work light (RH) YW80S00001F1
L - 7 Cab work light (for SE.Asia) YT80S00002F2
L - 9 Boom cyl. light (for SE.Asia) YT80S00002F1
24-97

M - 1 Starter motor VHS281002894A
(M) Motor
M - 3 Wiper motor YN53C00012F2

M - 4 Washer pump motor YN54C00001F1
M - 9 Roof wiper motor YN76S00005P1
Arm 2 speed inverse propo.
PSV - A YN35V00049F1
(P) Proportional
valve
solenoid valve
(YN35V00047F1)
PSV - B P2 unload propo. valve YN35V00048F1
Solenoid valve assy
PSV - C Travel straight propo. valve ↑
PSV - D P1 unload propo. valve ↑
PSV - P1 P1 pump propo. valve (YN10V00023F1) YN35V00052F1
PSV - P2 P2 pump propo. valve Pump ↑
R - 1 Battery relay YN24S00008F1
R - 2 Starter relay VHS283001271A
R - 3 Glow relay VHS286201420A
R - 4 Safety relay YN24S00010P1
R - 5 Horn relay ↑
R - 6 Working light relay ↑
R - 8 Travel alarm relay (for Australia) ↑
R - 9 Cab working light relay (for SE.Asia) YN24S00010P1
(R) Reray
R - 19 Flasher relay YY24S00001F1

R - 23 Auto idle stop relay 1 YN24S00010P1
R - 24 Auto idle stop relay 2 ↑
R - 25 Engine emergency stop relay ↑
R - 26 Lever lock relay ↑
R - 28 Alternator relay ↑
R - 29 Wiper motor relay (Normal rotation) YN24S00012P2
R - 30 Wiper motor relay (Reverse rotation) ↑
R - 31 Wiper motor relay (Arc prevention) ↑
R - 32 Washer motor relay ↑
R - 45 Boom cyl. working light relay (for SE.Asia) YN24S00010P1
24-98

SE - 1 Pressure sensor : Bucket digging LC52S00019P1
SE - 2 Pressure sensor : Bucket dump ↑
SE - 3 Pressure sensor : Boom up ↑
SE - 4 Pressure sensor : Boom down ↑
SE - 5 Pressure sensor : Swing ↑
SE - 7 Pressure sensor : Arm in ↑
(SE) Sensor
SE - 8 Pressure sensor : Arm out ↑

SE - 9 Pressure sensor : Travel RH ↑
SE - 10 Pressure sensor : Travel LH ↑
SE - 11 (Pressure sensor : P2 OPT.) ↑
SE - 13 E/G speed sensor VHS894101290A
SE - 15 Fuel sensor YN52S00045F1
SE - 16 Accel potentiometer YN52S00032P1
SE - 20 (Pressure sensor : P1 OPT.) LC52S00019P1
SE - 22 Pressure sensor : Pump P1 YN52S00048P1
SE - 23 Pressure sensor : Pump P2 ↑
SV - 1 Swing parking brake SOL. YN35V00051F1
(SV) Solenoid
SV - 2 Power boost SOL (YN35V00047F1) YN35V00050F1

SV - 3 Two speed select SOL Solenoid valve assy ↑
SV - 4 Safety lock lever SOL ↑
SW - 1 Key switch YN50S00026F1
SW - 4 Swing parking brake release switch YN50S00047P1
SW - 5 Horn switch (RH) YN50E00017P1
SW - 7 E/G oil pressure switch VHS835301471D
SW - 8 Air filter clogging switch YR11P00008S005
SW - 10 Horn switch (LH) YN50E00017P1
SW - 11 Safety lock lever switch YN50S00041F1
(SW) Switch
SW - 13 Travel alarm switch (for Australia) YN50S00040DF

SW - 15 (Conflux/single select switch) YN50S00040DD
SW - 17 (Skylight wiper switch) YN50S00040D9
SW - 19 Wiper interlock switch YT50S00004P1
SW - 20 Power boost switch (RH) YN50E00017P1
SW - 21 Power boost switch (LH) ↑
SW - 26 Cab work light switch (SE.Asia) YN50S00040D4
SW - 27 Coolant level switch VHS834601510A
SW - 28 Water separator switch VHS233002800A
SW - 55 Boom, deck work light switch YN50S00040D1
24-99
24.2.2 SPECIFICATION OF ELECTRIC EQIUPMENTS
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
C-1
Maker Sinko Electric Co. Ltd
Controller
Rated voltage DC24V
YN22E00214F1
Weight 4.2 kg (9.3 lbs)
Mechatro controller
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
C-2
Maker Nippon seiki Co., Ltd
Controller
Rated voltage DC24V
YN59S00021F2
Insulation More than 3M at 500V megger
Gauge cluster
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
C-4
Controller
YN20M01468P1

Air-con Controller
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
24-100
File No.
Name of part
Use
Applicable Machine
C-5
Rated voltage DC24V
Controller
Maker's (Hino) P/No. S8347-01230
VHS834701230
Controller
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
Hino P/No. : 82580-8050A

(YAZAKI : 7382-1680)
Hino P/No. : 82580-8870A
(YAZAKI : 7283-1080)
Measurement circuit Pin arrangement
C-8
Controller Maker's P/No. 89661-E0010
VH89661E0010 Rated voltage 24V (DC)
Engine controller Working voltage 16~32V (DC)
Operating voltage
LC10 - 07001 ~ (at starter ON) 9~32V (DC)
YC10 - 03501 ~ Back-up source
(reference value) 5mA MAX (BAT=24V)
Connector 167 pins Male
24-101
File No.
Name of part
Use
Applicable Machine
E-1
Fuse capacity and circuit
Fuse & Relay box
YN24E00016F2
Fuse & Relay
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
Front side of machine
E-2
Alternator M6
B terminal
VHS270402500
B
Generator
LC10 - 07001 ~
YC10 - 03501 ~
4 pin connector (Water proof)

Terminal arrangement Hino P/No. 82560-2390
(Eqivalent to sumitomo 6188-0631 )
VIEW B
Connector
Hino P/No. 82580-8640
(Eqivalent to sumitomo 6189-0351)
E-3
Hour meter Movement Quarts
Operating voltage 10~80VC
YT58S00006P1 GM terminal : 2962447
GM connector : 2962448
Service meter
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
24-102
File No.
Name of part
Use
Applicable Machine
E - 5, 6
Type Bottom L : Low sound
Horn H : High sound
Rated voltage DC24V
LC53S0001D1 (High) STAMP
Operating voltage range DC20~30V
LC53S0001D2 (Low)
Sound level 113+5dB(A)/2m
Warning sound
420+20Hz high sound
YN11 - 45001 ~ Basic frequency 350+20Hz low sound
YQ11 - 06001 ~ Insulation resistance More than 3M /DC500V
LC10 - 07001 ~
YC10 - 03501 ~ o 8.5
E-7
Maker SOKEN Co,.Ltd.
Tuner
Part name AM/FM radio
YN54S00046P1
Radio (AM & FM)
(Oceania)
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
E - 8, 9
Maker SOKEN Co., Ltd.
Speaker
Maker parts No. SOK104A004
YN54S00050P1
Rated input 10W
Radio
Impedance 8
LY01 - 00101 ~
Frequency 33.3Hz
LC10 - 07001 ~
YC10 - 03501 ~
E - 10
Maker Sanden Corp.
Receiver dryer
Airtight test pressure 3.5MPa (508 psi)
YN54S00041P1
Pressure proof test pressure 5.3MPa (769 psi)
Air-con
Breaking test pressure 9.8MPa (1420 psi) Outlet (To unit)
YN11 - 45001 ~ Desiccant moisture 17% or over than the
weight of desiccant
YQ11 - 06001 ~ adsorption capability (Include initial absorption 2%)
LC10 - 07001 ~ Refrigerant HFC-134a
YC10 - 03501 ~ Inner volume/Desiccant 578cm3/300g Inlet (From condenser)
24-103
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 ~
E - 12
Type 115F51
Battery
Voltage 12V
YN72S00014P1
Capacity (5HR) 96Ah
Power
Weight (Incl. fluid) Approx. 26.5kg (58.4 lbs)
YN11 - 45001 ~
Electrolyte Approx. 6.7 L (1.77 gal)
YQ11 - 06001 ~
LC10 - 07001 ~ Negative
terminal
Positive
terminal
YC10 - 03501 ~
(0.67")
(0.67")
Taper
Taper
17
17
17.9 19.5
(0.705") (0.768")
502 (19.76")
180 (7.09")
210 (8.27")
215 (8.47")
24-104
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
(Australia) Terminal : 171661-1 Retainer : 1-174355-1
YN11 - 45001 ~ VIEW A

YQ11 - 06001 ~
LC10 - 07001 ~ Vinyl tube
YC10 - 03501 ~
E - 14
Cigarette lighter
!" #$
YN81S00003P1
% , *
Cigarette lighter -.
YN11 - 45001 ~
& '
(%$
YQ11 - 06001 ~
LC10 - 07001 ~
) * '+#%
YC10 - 03501 ~
/ 0 *
E - 15
Fusible link

LC13E01175S002
Fuse
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
E - 27
Resistance 2
Rated voltage DC 5V
Resister for emergency
Resistance 2 TOCOS
(Potentio meter) Parts E-27 RA30YME20FB202
YN52S00052P1
Engine emergency After soldering,
insulate this part
volume with heat shrinkable tube
Clip
YN11 - 45001 ~
Adhesive
YQ11 - 06001 ~
LC10 - 07001 ~
Fix this resistance with tape HOUSING : 172131-5
YC10 - 03501 ~ PVC tube (Black) TERMINAL : 170340-1
Dial
VIEW I
24-105
File No.
Name of part
Use
Applicable Machine
L - 1, 6
Light (Halogen)

YW80S00001F1
Boom work light (LH, RH)
LC08 - 06201 ~
YC08 - 03001 ~
LC09 - 06201 ~
YC09 - 03701 ~
YN11 - 45001 ~

YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
L - 2,7
Light (Halogen) Type BL84-200
Bulb DC 24V,70W
YT80S00002F2
Effective area of lens 71cm2
Deck work light
Cab working light front
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
L-3
Meker Knight beam (Imasen)
Light
Type BL46-146
YM80S00001F1
Bulb DC 24V, 25W
Flasher lamp (LH)
Lighting cycle 90 times / min
Rear work light
YN11 - 45001 ~
AV0.85 W
YQ11 - 06001 ~ AV0.85 Y REAR WORKING
LC10 - 07001 ~ SWING LIGHT LIGHT
YC10 - 03501 ~ AMP PART NO.
HOUSING : 174259-2
L-4 TERMINAL : 171661-1
AV0.85 R
Light HARNESS SEAL : 176886-2 AV0.85 B SWING LIGHT
LOCK PLATE : 1-174260-1 GND
YM80S00001F2 VIEW I
Flasher lamp (RH)
Rear work light
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
SECTION A-A
24-106
File No.
Name of part
Use
Applicable Machine
L-5
Bulb 24V,5W Body
Light
Note) Equivalent to 2456Z322F1 Lens
YT80S00001P1
Room light
YT02 - 04001 ~
YT03 - 05293 ~
YT04 - 07001 ~ Bulb
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~ SECTION A-A Door
Switch
YC10 - 03501 ~
M-1 B Terminal : M8X1.25
Rated output DC 24V, 15kW A
Motor
Yazaki P/No.
VHS281002894A Terminal : 7114-6047
Pinion gear
Connector : 7282-3013-30 (Black)
Starter motor Hino P/No. : 82580-6720
YN11 - 45001 ~ Mating connector
Hino P/No. : 82580-6730
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
VIEW A
M-3
159800-5710
Motor Denso corp. P/No. (Motor only)
YN53C00012F2 Rated voltage 24V
Wiper motor Swing angle Applox. 80
YN11 - 45001 ~ Controller
YQ11 - 06001 ~ Wiper motor 24V
LC10 - 07001 ~
YC10 - 03501 ~
Wiper sw
OFF-Stop
Stop signal ON-Start
Reverse signal
Electric diagram
M-4
Rated voltage DC 24V
Motor (Reservoir)
Injection flow 600cc (0.16 gal) / min or more
YN54C00001F1
Capacity 1.5L (0.4 gal)
Window washer
Injection pressure 88.3 kPa (12.8 psi) or more
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
24-107
File No.
Name of part
Use
Applicable Machine
R-1
At start 24V2000A(0.1 sec) Terminal A
Relay Rated voltage / current At charge 28V120A(Continuous) VIEW A
YN24S00008F1 Exciting current 0.4A or less / 24V
Lock section
Battery relay Contact pressure 37.2N {8.4 lb} or more Terminal A
YN11 - 45001 ~ Closed circuit voltage 16V or less VIEW I
Terminal B
YQ11 - 06001 ~ Open circuit voltage 7V or less HOUSING AMP
GND terminal
LC10 - 07001 ~
174359-2
Insulation resistance 3M or more/500V megger RETAINER AMP
1-174360-7
YC10 - 03501 ~ TERMINAL AMP
171661-1
WIRE PROOF PLUG AMP
172888-2
VIEW Z Terminal L
Flowing direction of
main current F HOUSING YAZAKI
o 9 X 30L
Terminal A Terminal B Terminal B Heart shrinkage tube 7123-4210-30
AVS 1.25G
F TERMINAL YAZAKI
AVS 1.25B 7116-3251*
z GND wire
WIRE PROOF PLUG
I Terminal B Terminal L 7157-3580-60
F HOUSING YAZAKI AVS 1.25L Terminal B
7123-4220-30
F TERMINAL YAZAKI
P coil 7116-3251
REAR HOLDER YAZAKI
7157-6801-30
H coil WIRE PROOF PLUG
7157-3580-60
Bracket groud
Circuit diagram
o 7.0 X 150L
Corrugete tube (Black)
Fusible link assy B o 7.0 X 150L

Fusible link assy A Corrugete tube (Black)
R-2 Length of coupler harness

Hino P/No. S2830-01271A
Relay (From outlet to coupler)
Rated voltage DC24V L=215mm
VHS283001271A
Rated time 30 sec 18 o4 MAX
Starter relay Vynil tube (Red)
Exciting current 3A or more (at 20 )
YN11 - 45001 ~
Min operating voltage DC18V or less (at 20 )
YQ11 - 06001 ~
Insulation resistance 1M or more
LC10 - 07001 ~
YC10 - 03501 ~ Black
Blue
Vynil tube (Red) M6
Terminal C Terminal B
Electric diagram
E (AVX 0.85mm2 Black)

E (AVX 0.85mm2 Blue)
Tape
M6
24-108
File No.
Name of part
Use
Applicable Machine
R-3
Hino P/No. S2862-01420A
Relay
VHS286201420A
Rated load 100A flow
Glow relay
Min. operating voltage DC 18V or less
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
S terminal
YC10 - 03501 ~
(Red)
Name plate
F terminal
Connector
090 II Non water-proof male 2P blue
SW terminal Hino P/No. 82580-7320A
Yazaki P/No. 7282-1020-90
Mating connector
090 II Non water-proof female 2P
Hino P/No. 82580-7330A
L terminal Yazaki P/No. 7383-1020-**
Electric diagram
R - 4,5,6,8,9,23,
24,25,26,28,45 Maker Tyco Electronics
Maker's p/No. V23074-A2002-A403
Relay
Type Micro relay A
YN24S00010P1
Safety relay
Horn realy Contact 1C
Work light relay * Accessory of relay box
Travel alarm relay
Cab working light relay
Auto idle stop relay 1, 2
Engine emergency stop relay Pin assignment
Lever lock relay
Alternator relay
Wiper motor relay
Washer motor relay
Boom cyl. working light relay
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
Terminal arrangement
24-109
File No.
Name of part
Use
Applicable Machine
R - 19
Relay
YY24S00001P1 UPPER
Flasher relay
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
TERMINAL NUMBER
R - 29,30,31,32
Maker's P/No. V23134-A0053-C643
Relay
Parts name Relay
YN24S00012P2
Rated voltage DV 24V
Wiper motor relay
Washer motor relay Contact 1C
YN11 - 45001 ~ * Accessory of relay box
YQ11 - 06001 ~
Pin assignment
LC10 - 07001 ~
YC10 - 03501 ~
SE - 1 ~ 5, 7 ~ 11,20
Pressure sensor
(Low pressure)
!
LC52S00019P1
Bucket dig and dump,
( )* +, - "$$-+"
Boom up and down, ' +, -
" "*+- "$$-+" .-(/-
Swing, +- $(/ $ "$$-+"$ 0"1*$% 2 3#45653#&
+- $(/ 2 4545#
Arm in and out, & " 0-7 &4 %"/ /(+-
Travel RH and LH and other 3 "1+ 1+ 0( $-** *-(/ 2 45656#&
YN11 - 45001 ~ "8-
YQ11 - 06001 ~ "# $%
&' && .&!
LC10 - 07001 ~
YC10 - 03501 ~
SE - 13
Output voltage 2.8V or more
Speed sensor
Clearance 1.0mm
VHS894101290A Sumitomo : 090-II (4P : B)
E/G speed sensor P/No. : 6188-0265
Hino. P/No.
YN11 - 45001 ~ Sensor side : 82580-6120A (B)
Harness side : 82580-6130A (B)
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
M16 x 1 Hex. : 17
Hex. : 22
Tightening torque : 47N.m (34.7 lbf.ft)
24-110
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 ~
Machine side controller
Float
Electric diagram VIEW A
SE - 16
Total resistance value
Potentio meter
Effective electric angle
YN52S00032P1
Number of notches
Accel dial
Source voltage
YT02 - 04001 ~
Notch part
YT03 - 05293 ~
YT04 - 07001 ~ Potentio
YN11 - 45001 ~ 3MA JM II + AMP
Bracket
YQ11 - 06001 ~ HOUSING : 174359-2
TERMINAL : 171661-1
LC10 - 07001 ~
YC10 - 03501 ~ Dial
SE - 22, 23 Electric diagram (Arrangement)

Pressure range 0~50MPa (7250 psi)
Pressure sensor
Max. allowable press. 120MPa (17400 psi)
(High pressure)
Operating source voltage 5+0.5V DC
YN52S00048P1
100M or more/DC50V megger
P1 pump Insulation resistance
(Between casing and terminal)
P2 pump
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~ Source (+)
P3/8
YC10 - 03501 ~ Tightening torque Output (+) Econo seal J series
: 73.5 N.m O ring P14 Common (+) (Mark II (+)
(54.2 lbf.ft) JIS B2401 3 pole
24-111
File No.
Name of part
Use
Applicable Machine
PSV - A, B, C, D
Proportional solenoid valve
Hydraulic solenoid valve
Hydraulic symbol A5 to A8
(YN35V00047F1)
YN35V00048F1
YN35V00049F1
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
HYDRAULIC SYMBOL
Arm 2 speed
P1 unload
Travel straight
P2 unload
Attachment boost
Travel 1,2 speed
Swing parking
Lever lock
PSV - P1, P2
Solenoid Type KDRDE-5K AMP MARK II
Max. feed press 13.7MPa (1987 psi) HOUSING : 174354-2
YN35V00052F1 TERMINAL : 173706-1
Rated feed press 5.0MPa (725 psi) Orifice Spring
Pump P1, P2 HEX 10
Allowable back press 1MPa (145 psi) Spool T=7.4N.m
proportional valve (5.5lbf.ft)
Control pressure range 0~2.7MPa (392 psi)
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
Sleeve O-ring Solenoid Seal nut
1B P20
SV - 1, 2, 3, 4
Rated pressure 5.0 MPa (725 psi)
Solenoid directional
Solenoid directional
valve (8 spool) assy pressure
Hydraulic symbol Solenoid proportional Dither current 100Hz,200mA P-P P1, P2, T, A1, A8 port PF3/8
valve Coil resistance 17.5 (at 20C)
A1 to A4 A2~A7 port PF1/4
AMP MARK II AMP MARK II
(YN35V00047F1) Connector specification HOUSING 174354-2
TERMINAL 173706-1
YN35V00050F1
YN35V00051F1
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
24-112
File No.
Name of part
Use
Applicable Machine
SW - 1 Auto return
Switch
Connection
YN50S00026F1 Terminal
Position
Starter switch
Auto return
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~ VIEW A Terminal
YC10 - 03501 ~ arrangement
SW - 4
Single-pole double-throw
Switch Type (alternate) Insulation tape
R B W
YN50S00047P1 Rated DC30V, 10A
Swing parking brake Insulation resistance
release
Vinyl tube
YN11 - 45001 ~ YAZAKI
T No.
YQ11 - 06001 ~ Contact construction : Position Red (2) 7122-2237
7114-2020
LC10 - 07001 ~ Swing parking release
YC10 - 03501 ~ Normal
White (3) Blue (1)
SW - 5, 10, 20, 21
)* +,
Switch , (-

YN03M01861F1
(Right grip)
! "# #$
% % &
YN03M01862F1 '$! (
(Left grip)
Horn, ATT Power boost
YN11 - 45001 ~
YQ11 - 06001 ~ (( ( , ./01,+ 23*" 4 ( 5
LC10 - 07001 ~ (( ( , %#6,+ 7 "*8 7
6 4(( ( 9 '"5
YC10 - 03501 ~
SW - 7
Type Normal close
Switch
Working pressure 39.2~58.8kPa (5.7~8.5psi)
VHS835301471D
Rating DC 24V/12W
E/G oil pressure switch More than 100M / 090 II Water proof connector
Insulation resistance DC500V megger
YN11 - 45001 ~ Color : Black
Hino P/No. : 82580-6830
YQ11 - 06001 ~ Yazaki P/No. : 7383-1114
LC10 - 07001 ~
YC10 - 03501 ~
24-113
File No.
Name of part
Use
Applicable Machine
SW - 8
Switch
YR11P00008S005

Air cleaner
Clogging switch
YT02 - 04001 ~
YT03 - 05293 ~
YT04 - 07001 ~
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
SW - 11
Switch
YN50S00041F1

Lock lever
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~ !
!

"#
SW - 13
Switch
Single pole single throw
YN50S00040DF Type (alternate)
Travel alarm (Australia) More than 1M /
Insulation resistance DC500V megger UP
YN11 - 45001 ~
YQ11 - 06001 ~ Terminal connector
LC10 - 07001 ~ Position
Connector
YC10 - 03501 ~
SW - 15
Switch
YN50S00040DD Type (alternate)
Conflux / single flow More than 1M /
switching (OPT)
YN11 - 45001 ~ Terminal connector
YQ11 - 06001 ~ Position
Connector
LC10 - 07001 ~
YC10 - 03501 ~
24-114
File No.
Name of part
Use
Applicable Machine
SW - 17
Switch
YN50S00040D9 Type (alternate)
Roof window wiper More than 1M /
switch (OPT)
YN11 - 45001 ~ Terminal connector
YQ11 - 06001 ~ Position
Connector
LC10 - 07001 ~
YC10 - 03501 ~
SW - 19
Switch
YT50S00004P1
Rated load 1A
Voltage drop 0.2V or less
Wiper inter lock
Insulation resistance 5M or more
YN11 - 45001 ~
Operation force Initial motion 0.8+0.3
0 kg
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
Max. stroke
SW - 26
Switch
YN50S00040D4 Type (alternate)
Cab work light switch More than 1M /
YN11 - 45001 ~
YQ11 - 06001 ~ Terminal connector
LC10 - 07001 ~ Position
Connector
YC10 - 03501 ~
SW - 27
Purpose Coolant level detection
Switch
Working temperature -40 ~130
VHS834601510A
Coolant level switch Hino P/No. : 82580-71708
Sumitomo P/No. : 6188-0110
YN11 - 45001 ~
Electrode side
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~ CONNECTOR
Housing side
(To ground) Mating connector
M18, P=1.5 Hino P/No. : 82580-71808
Sumitomo P/No. : 6189-0189
24-115
File No.
Name of part
Use
Applicable Machine
SW - 28
Switch
VHS233002800A
Fuel filter
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~ Fuel outlet
Fuel inlet
YC10 - 03501 ~
Deposit container
Drain
Water proof connector

Yazaki 7383-7028-40
SW - 55
Switch

YN50S00040D1
Boom work light switch
!"" %$
#
YN11 - 45001 ~
YQ11 - 06001 ~ #
LC10 - 07001 ~ $

YC10 - 03501 ~
24-116
25. AIR-CONDITIONER SYSTEM
TABLE OF CONTENTS
25.1 BASIC SYSTEM OF AIR CONDITIONER (HVAC AIR CONDITIONER).........................25-3

25.1.1 AIR CYCLE.............................................................................................................25-3
25.1.2 AUTO AIR CONDITIONER SYSTEM OUTLINE ....................................................25-4
25.2 COMPONENT AND CONSTRUCTION ...........................................................................25-5
25.2.1 COMPONENT ........................................................................................................25-5
25.2.2 CONSTRUCTION...................................................................................................25-6
25.3 PIPING.............................................................................................................................25-9
25.3.1 AIR CONDITIONER................................................................................................25-9
25.3.2 AIR DRYER ASSY..................................................................................................25-11 25
25.4 FUNCTION ......................................................................................................................25-12
25.4.1 MECHANISM OF COOLING CIRCUIT...................................................................25-12
25.4.2 COOLING CIRCUIT................................................................................................25-14
25.4.3 COMPONENT PARTS ...........................................................................................25-15
25.5 DISASSEMBLY AND ASSEMBLY...................................................................................25-19
25.5.1 PRECAUTIONS TO BE EXERCISED IN OPERATION .........................................25-19
25.5.2 DISASSEMBLY AND ASSEMBLY OF UNIT ..........................................................25-20
25.6 CHARGING REFRIGERANT...........................................................................................25-24
25.6.1 PRECAUTIONS TO BE EXERCISED IN OPERATION .........................................25-24
25.6.2 OPERATING PROCEDURE...................................................................................25-25
25.6.3 CHARGING PROCEDURE ....................................................................................25-26
25.7 ELECTRIC CIRCUIT........................................................................................................25-32
25.7.1 WIRING DIAGRAM AND CONNECTORS .............................................................25-32
25.7.2 STRUCTURE AND OPERATION OF EACH FUNCTIONAL PARTS AND THE INSPECTION ..........25-34
25.8 TROUBLESHOOTING.....................................................................................................25-37
25.9 SELF DIAGNOSIS FUNCTION ON DISPLAY OF PANEL ..............................................25-44
25.9.1 POSITION OF INDICATION FOR FAILURE. .........................................................25-44
25.9.2 EXPLANATION OF INDICATION FOR FAILURE. .................................................25-44
25.9.3 EXPLANATION OF MONITOR MODE...................................................................25-46
25-1

SK330–8 : LC10-07001~ S5LC2511E01
SK350LC–8 : YC10-03501~ (ASIA, OCE)
S5LC2511E02
(ASIA, OCE)
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
35-8 35-6
35-11
35-1
35-2 35-5
34 35-7
35-10 35-9
Fig. 25-1 Air-conditioner group
A/C ASSY LC20M00033F1 (07)

27 Air-conditioner assy 1 33 Pulley 1 35–7 L hose 1
27–1 Air-conditioner unit 1 34 Condenser 1 35–8 L hose : Ø 15.5 1
27–2 Hose 2 35 Air dryer assy 1 35–9 S tube : Ø 16 1
27–3 Clamp 2 35–1 Receiver dryer 1 35–10 L tube : Ø 8.5 1
27–4 Filter 1 35–2 Bracket 1 35–11 D tube : Ø 12 1
30 Panel assy 1 35–5 S hose : Ø 24.5 1 39 Filter 1
32 Compressor 1 35–6 D hose 1 40 Solar radiation sensor 1
25-5
25.2.2 CONSTRUCTION
(1) Air conditioner unit
49
47
48
46 44
31
42 31
41
50
3 1
45 1
A
1 32 43
39
37
38
36
40
B
2
33
Fig. 25-2 Air conditioner unit (1/2)
25-6
14 16
6 1 1 31
1
5
15
1
31
62
1 3
1 1
D
E 4
7
28 1
A 1 1
27
1
20
26
13
C 60
11
29
23
21 22
24 82
24
83
51 54 79
9 63
78 23 C 84 61
17
E
18
31
D
B
10
19
12
1 25
3
31
77
Fig. 25-3 Air conditioner unit (2/2)
25-7
AIR-CON UNIT YN20M00107F2 (03)

1 Screw M5×16 23 21 Expansion valve 1 44 MA mode lever 1
2 Main harness 1 22 O-ring 1 45 Foot lever 1
3 MA air mix 3 23 O-ring 2 46 Face lever cam 1
4 Blower controller 1 24 Screw M5×40 2 47 Vent lever cam 1
5 Upper casing 1 25 Thermistor 1 48 Face rod 1
6 Air mix door 1 26 Thermistor holder 1 49 Vent rod 1
7 Air mix lever 1 27 Heater core 1 50 Foot rod 1
8 Lower casing 1 28 Pipe holder 1 51 Plate 1
9 Air mix door sub 1 29 Thermistor 1 54 Screw 1
10 Air mix lever sub 1 31 Screw M4×30 9 60 Casing packing A 1
11 Blower 1 32 Upper casing 1 61 Casing packing B 1
12 Lever MA air mix 1 33 Lower casing 1 62 Casing packing C 1
13 Intake door 1 36 Foot door 1 63 O-ring 1
14 MA intake lever 1 37 Vent door 1 77 Packing 1
15 Intake lever 1 38 Face door 1 78 Tube 1
16 Intake rod 1 39 KK box upper packing 1 79 Tube 1
17 Air mix rod 1 40 KK-box lower packing 1 82 Tube 1
18 Air mix rod sub 1 41 Vent lever 1 83 Bracket 1
19 Relay 2 42 Face lever 1 84 Lower casing 1
20 Evaporator 1 43 Foot joint lever 1
(2) Receiver dryer
REFRIGERANT 2
INLET
REFRIGERANT
OUTLET
2-M6
1
No NAME Q'TY
1 PRESSURE SWITCH 1
3 2 SIGHT GLASS 1
4 3 DESICCANT 1
4 SUCTION PIPE 1
5 5 FILTER 1
6 RECEIVER TANK 1
Fig. 25-4 Receiver dryer
25-8
25.3 PIPING
25.3.1 AIR CONDITIONER
35 6
7
JAM NUT FOR
TENSION PULLEY
T=46.1 (33)
50
33 3
10 13 6
17
54
14
25 21
1 22
INITIAL BELT TENSION 5 23
49 25
When the belt is pushed
by the force of 27N,
51
adjust the deflection N
of N part to be 5mm 4 15 25
9
10
11
6 12
52 25
3
32
25
57
6 58 50
52
E 30
D
40
27
C
B
A
25
1
12 E
25
16
2 25
25
39 25
25
8
34
8
56
1 59
2 25
24 24
53
8
5 24
8 5 18
8
6
2
6 6
20
8 55 11
C A B
Fig. 25-5
1. Apply oil for refrigerant R134a to the O-rings of all air-conditioner hose fittings.
2. Refrigerant volume : 900±50 g (2±0.1 lbs)
3. Tightening torque : T=N•m (lbf•ft)
25-9
Air conditioner LC20M00033F1 (07)
torque No. Parts Q’ty torque No. Parts Q’ty
1 Hose : L = 4150 1 24 Clip 3
2 Hose : L = 3050 1 25 Clip 13
3 Bracket 2 27 Air conditioner assy 1
4 V-belt 1 30 Panel 1
3.92~4.9 (2.9~3.6) 5 Clip 4 32 Compressor assy 1
46.1 (34.0) 6 Sems bolt : M10×25 7 33 Pulley assy 1
4.9 (3.6) 7 Sems bolt : M6×20 2 34 Condenser 1
10.7 (7.9) 8 Sems bolt : M8×20 5 35 Air dryer assy 1
23.5 (17.3) 9 Capscrew : M8×100 4 39 Filter 1
10 Washer 6 40 Solar radiation sensor 1
11 Tube for S hose : L = 2450 1 49 Connector 1
12 Tube for heater : L = 3300 1 23.5 (17.3) 50 Sems bolt : M8×25 4
13 Tube for L hose : L = 1800 1 51 Clip 1
14 Tube for D hose : L = 2100 1 52 Clip 2
15 Tube for L hose : L=180 1 53 Bracket 1
16 Tube for heater : L = 1800 1 23.5 (17.3) 54 Capscrew : M8×20 2
17 Bracket 1 55 Grommet 1
18 Hose : L = 130 1 56 Grommet 1
3.92~4.9 (2.9~3.6) 20 Clip 2 4.4 (3.2) 57 Capscrew : M6×50 4
21 Bracket 1 58 Washer 4
46.1 (34.0) 22 Capscrew : M10×50 3 59 Tube for L hose : L=100 1
23 Washer 3 46.1 (34.0) 60 Sems bolt : M10×20 2
UNIT CONNECTION TUBE ASSY COMPRESSOR CONNECTION BOLT

UNIT CONNECTION BOLT D TUBE (11)
D D HOSE (6)
27 AIR CONDITIONER ASSY S
S TUBE (9)
32 COMPRESSOR ASSY
RECEIVER CONNECTION BOLT
S HOSE (5)
L TUBE (10)
L HOSE (8) L HOSE (7) 34 CONDENSER

Note :
Numbers in ( ) shows the number in Fig. 25-6. 35 RECEIVER DRYER RECEIVER DRYER MOUNTING BRACKET
25-10
25.3.2 AIR DRYER ASSY
A
5
8
A
C
5
6
6
B
4
5
3
10 3
2 11
8
9
1
6 5
7
B C
Fig. 25-6
Air dryer assy LC96V00019F1 (02)
torque No. Parts Q’ty torque No. Parts Q’ty
1 Receiver dryer 1 7 L hose 1
2 Bracket 1 8 L hose 1
3 Capscrew : M8×25 2 9 S tube 1
4 Capscrew : M6×25 2 10 L tube 1
5 S hose 1 11 D tube 1
6 D hose 1
25-11
25.4 FUNCTION
25.4.1 MECHANISM OF COOLING CIRCUIT
(2) Mechanism of Cooling
Item HFC-134a (R134a)
In the cooling process, the refrigerant that flows
Chemical formula CH2FCF3
through the cooling circuit changes its phases from Molecular weight 102.03
liquid to gas and vice versa during which process Boiling point -26.19 (-15.14 )
heat is transferred from the low temperature part Critical temperature 101.14 (214.05 )
Critical pressure 4.065 MPa (41.45kgf/cm2 1)
(compartment) to the high temperature part
Critical density 511 kg/m3 (31.9lb/ft3)
(outside of the vehicle). Density of saturated
1206 kg/m3 (75.3lb/ft3)
1) Kind of Refrigerant liquid[25 (77.0 )]
Many kinds of refrigerants that change in that Specific volume of saturated
0.0310 m3/kg (0.496ft3/lb)
vapor [25 (77.0 )]
way are available, but the following requirements Latent heat of
are needed for use in such applications: 197.5 KJ/kg {47.19kcal/kg}
vaporization [0 (32 )]
• Latent heat of vaporization (heat of Flammability Nonflammable
Ozone destruction
vaporization) is large. coefficient 0
• It is easy to liquefy (condense). (It dose not 1 : 1MPa (mega pascal) equals 10.1972kgf/cm2
require very high pressure for condensation.) (145psi)
• It is easy to gasify (evaporate). (It evaporates
sufficiently at not too low pressure, i.e. cools
down an object.)
• It has small specific heat. (Since the
refrigerant itself is cooled by the expansion
valve, the loss resulting from it must be held
down to a minimum.)
• It has a high critical temperature and a low
solidification point.
• It is stable chemically and does not corrode
and permeate into the circuit parts.
• It is free from toxicity, objectionable odor,
flammability and explosiveness and excels in
thermal conductivity and electric insulation.
• It has small specific volume.
• It is easy to find out leakage.
Out of refrigerants meeting the above-
mentioned requirements, ones having
characteristics that suit the intended cooling
unit are chosen and used. If a refrigerant
other that those designated is used,
sufficient refrigeration will not be performed
or the equipment in which the refrigerant is
used may be broken. Therefore, always use
a designated refrigerant for the cooling unit.
Table shows the principal characteristics of
the R134a refrigerant that is used in this
machine.
25-12
(3) Characteristics of Refrigerant (Fig. 25-7) PRESSURE

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

3(435)
it begins to condensate at a certain temperature LIQUID
to take a liquid state. The temperature at which
2(290)
condensation begins is unique to each
substance (fluid) at a given pressure. The 1(145) GAS
temperature determined by a given pressure is 0.5(75)
TEMPERATURE
called saturation temperature. [ ( )]
0 0 15 18 35 50 100
(32) (59)(64) (95) (122) (212.0)
2) Inversely to 1) above, the pressure at which a
gas condenses for a temperature is determined. Fig. 25-7 Pressure-temperature characteristics of
This pressure is called saturation pressure. R134a
Fig. 25-7 illustrates the relationships between
the saturation temperature and the saturation
pressure in the case of refrigerant R134a used in
the air-conditioner. At the temperature and the
pressure on the lower righthand side of the curve
in Fig. 25-7 the refrigerant take a gaseous state,
while at the temperature and the pressure on the
upper lefthand side of the curve, the refrigerant
takes a liquid state.
Let us think of a case where an air-conditioner is
operated in the midst of summer. As the
refrigerant evaporates, it absorbs evaporation
heat from the air of the compartment. In order to
cool the inside of the compartment down to 25°C
(77°F), the refrigerant must transform
(evaporate) from a liquid to a gaseous state at a
lower temperature. It can be seen from Fig. 25-7
that R134a under a pressure above the
atmospheric pressure is capable of cooling the
inside of the compartment sufficiently. (If a
refrigerant that requires a pressure below the
atmospheric pressure to cool it to a required
temperature is used, air is mixed into the circuits,
thereby deteriorating the performance of the
cooling unit.) In the process in which gaseous
refrigerant is brought back to a liquid state, the
refrigerant is cooled and condensed by the outer
air exceeding 35°C (95°F).
Accordingly the refrigerant is capable of
condensing at a pressure exceeding 1 MPa
(145psi), as seen from Fig. 25-7.
25-13
25.4.2 COOLING CIRCUIT

Fig. 25-8 illustrates the cooling circuit of the car air-
conditioner.
In this circuit diagram, the portion that cools the air of INSIDE OF COMPARTMENT(CAB)
the compartment is the evaporator. The object air is
cooled off by utilizing the fact that the refrigerant takes
heat off the surrounding area as evaporation heat as it
evaporates in the cooling circuit. Since the part at which EVAPORATOR EXPANSION
VALVE
vaporization of the refrigerant takes place is the BLOWER
evaporator, cooled air is constantly delivered to the
circumference of the evaporator by the blower fan. In INSIDE OF ENGINE
the meantime, liquid refrigerant (slightly wet vaporized S D ROOM
refrigerant) is fed into the evaporator, when "cooling" COMPRESSOR COOLING FAN
effect is attained.
For instance, in order to cool the air to 15°C (59°F), the
refrigerant can not absorb evaporation heat from the air RECEIVER
DRYER
unless it evaporates at a temperature lower that 15°C
(59°F). For that purpose, it can be seen from Fig. 25-7 CONDENSER
that the pressure of the refrigerant in the evaporator
must be less than 0.51 MPa (74psi). Fig. 25-8 Construction of cooling circuit
Furthermore, the cooling effect deteriorates unless the
feed rate of the refrigerant is controlled so that all of the
refrigerant supplied to the evaporator vaporizes and
turns into dry vapor.
Consequently, the cooling circuit is so constructed that
the evaporator can cool down an object (air in this case)
sufficiently (i.e. so as to decrease the pressure in the
evaporator) and that an adequate amount of refrigerant
can be fed to the evaporator.
The feed rate of the refrigerant is controlled by the
expansion valve, but the pressure in the evaporator is
held low by the throttling action of the expansion valve
and the suction action of the compressor. The
compressor acts as a pump that allows the refrigerant
to circulate. The compressive action of the compressor
and the heat exchange (heat radiation) action of the
condenser transform the refrigerant in a dry vapor state
back to a liquid state.
25-14
25.4.3 COMPONENT PARTS

(1) Evaporator (See Fig. 25-9.)
The evaporator is an important heat exchanger that
EVAPORATOR
absorbs the heat of the compartment air (object) by
the utilization of the latent vaporization heat of the
low-temperature, low-pressure liquid-state
refrigerant. Therefore, it is necessary that
satisfactory heat transfer between the object and
the refrigerant take place in the evaporator.
O-RING
To that end, the evaporator is equipped with fins on
the air side in order to increase the heat transfer
area of the air side and thereby perform excellent
thermal transfer between the refrigerant and the air.
The humidity in the air condenses as the air cools
down and adheres to the outside of the evaporator EXPANSION VALVE
as water drops. The cooling effect deteriorates if
the water drops freeze. Therefore, how to
discharge water is an important point. SOCKET BOLT M5X40(2 PCS.)
The amount of refrigerant supplied to the
evaporator is controlled by the expansion valve Fig. 25-9
which is described in the following. In order to attain
proper control, it is necessary to reduce the
pressure drop of the refrigerant of the evaporator.
Accordingly, reducing the pressure drop is one
element that makes the evaporator attain its full
performances.
(2) Expansion Valve
In order for the evaporator to fulfill its performances,
a proper amount of low-pressure low-temperature
liquid refrigerant must be fed to the evaporator.
If the feed rate is too low, the refrigerant completes
vaporization early in the evaporator which results in
deterioration of the cooling effect. If the feed rate is
too high, unvaporized liquid refrigerant returns to
the compressor (liquid back). This not only
deteriorates the cooling effect, but also damages
the compressor valves.
The expansion valve feeds the flowing high-
pressure high-temperature liquid refrigerant to the
evaporator as low-pressure low-temperature liquid
refrigerant (damp vapor of low dryness). The
expansion valve controls the feed rate of the
refrigerant at the same time.
25-15
Fig. 25-10 shows how the block type expansion

valve is constructed. The temperature sensing
DIAPHRAGM
part is provided in the shaft of the expansion
valve to directly detect the refrigerant
temperature at the outlet of the evaporator.
The diaphragm contains R134a in saturated REFRIGERANT
state. The pressure in the diaphragm changes EVAPORATOR OUTLET
SIDE
according to the temperature detected by the
sensor. The change in the pressure causes the SHAFT
force acting upon the diaphragm to vary
accordingly.
The high-pressure high-temperature liquid
refrigerant that is fed from the receiver side REFRIGERANT
INLET
reduces the pressure abruptly as it passes
through the valve (throttling action). On that
BALL
occasion, part of the refrigerant evaporates by VALVE
the very heat of the refrigerant and cooled off. SPRING
The result is that low-pressure low-temperature
damp refrigerant vapor is fed to the evaporator. Fig. 25-10 Block type expansion valve
The opening of the valve is determined by the
equilibrium between the pressure (low) of the
evaporator side, the action of the adjust spring
and the pressing force of the diaphragm (the
temperature of the refrigerant at the outlet of the
evaporator to be sensed by the thermowell). The
feed rate is controlled automatically so that
under the pressure in the evaporator, the
refrigerant is properly overheated (3~8 degrees
C) and goes out of the evaporator. This action is
carried out by sensing the refrigerant
temperature at the outlet of the evaporator as
against the inlet pressure of the evaporator and
consequently controlling the feed rate of the
refrigerant.
This means that if the refrigerant pressure drop
in the evaporator is excessive, it is difficult to
control the overheating or the feed rate of the
refrigerant. For this reason, the smaller the
pressure drop of the evaporator, the better.
The expansion valve senses the pressure and
the temperature at the outlet of the evaporator
and controls the overheating of the refrigerant
and the refrigerant supply to the evaporator more
Fig. 25-11 Expansion valve outside view
securely. The air-conditioner of this machine
adopts a block type expansion valve.
25-16
(3) Compressor (See Fig. 25-12.)

D HOSE
The compressor performs the following three
functions in the cooling circuit:
1) Suction action
S HOSE
2) Pumping action
3) Compressive action
1) The suction action, as combined with the
throttling action, works to decrease the
refrigerant pressure in the evaporator. This
permits the refrigerant to vaporize at low
temperature in order to perform cooling effect.
2) The pumping action serves to cause all the
refrigerant to circulate in the cooling circuit. This
enables enables continuous cooling.
3) The compressive action, as combined with the Fig. 25-12
action of the condenser which is mentioned
hereunder, transforms vaporized refrigerant
back to a liquid state again.
The saturation temperature gets higher as the
pressure increases. For instance, it becomes
possible to cool down the refrigerant by the use
of an outer air of 35°C (95°F) and liquefy it. The
compressive action of the compressor works to
turn low pressure vaporized refrigerant to high
pressure vapor refrigerant. The condenser then
serves to cool down the refrigerant. However,
since the compressive action takes place only for
a short period, the refrigerant hardly exchanges
heat with outer air. That is to say, it takes a near
form of thermally insulated compression, so that
the refrigerant discharged by the compressor
turns into high-temperature high-pressure vapor
and is delivered to the condenser.
(4) Condenser ( See Fig. 25-13.)
This is a heat exchanger that cools the vaporized
refrigerant at high temperature and high pressure
by the use of outer air and condenses the
refrigerant. The direction in which heat moves is
from the refrigerant to air, the opposite to the case
of the evaporator. Fins are equipped on the outer
air side to improve thermal transfer. If the
refrigerant is not cooled well by the condenser, the
air in the compartment can not be cooled
sufficiently by the evaporator. For that purpose, it is
necessary to secure ventilation required for the
cooling of the refrigerant.
Fig. 25-13 Condenser
25-17
(5) Receiver dryer ( See Fig. 25-14.)

REFRIGERANT SIGHT GLASS
1) Receiver Tank INLET
On the air-conditioner, the revolution of the REFRIGERANT
compressor varies greatly which causes the OUTLET
proper flow of refrigerant in the cooling circuit to
vary. It is the receiver tank that receives the
variations. When the cooling circuit does not
need much refrigerant, the receiver tank stores
extra refrigerant temporarily and supplies it when
the cooling circuit needs much refrigerant. The
PRESSURE SWITCH
receiver tank also stores an extra amount of
refrigerant to be used for filling balance and
supplement small amounts of leakage of the
refrigerant through penetration into rubber
hoses.
2) Dryer
If water is mixed in the cooling circuit, it
deteriorates the compressor valves and oil, DESICCANT
corrodes the metallic parts of the circuit or clogs
the circuit as the water freezes in the expansion SUCTION
valve. It is desirable that the amount of water PIPE
mixed in the refrigerant should be held below a
concentration of 30ppm. The air-conditioner
uses a molecular sieve as desiccant suited for FILTER
the circuit, in order to absorb water content that
intrudes into the circuit when the dryer is
installed or when refrigerant is charged.
3) Sight Glass
This is a inspection window with which the
refrigerant level in the circuit is determined, the RECEIVER
TANK
only means of confirming the inside of the circuit
visually.
4) Filter
5) Pressure Switch
This machine employs pressure switches of
high/low pressure type.
The pressure switch protects the circuit by Fig. 25-14
cutting off the power supply to the compressor
when high pressure increases abnormally high
[more than 3.14MPa (460psi) ].
The pressure switch also detects the leakage of
refrigerant by cutting the power supply to the
compressor when the pressure of the circuit falls
below 0.2MPa (28psi).
25-18
25.5 DISASSEMBLY AND ASSEMBLY

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

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

Fasten to the tightening torque indicated in the
table REPLACED PARTS AMOUNT TO BE FILLED IN
(4) Amount of Oil for Compressor
EVAPORATOR 40 cc (2.4cu.in)
The compressor SD7H (HD type) is filled with
135cc (8.2cu•in) of oil. If the oil volume is small, CONDENSER 40 cc (2.4cu.in)
seizure at high revolution and shortening of service
Drain out the volume of oil left in
life will occur. If the oil volume is large, the cooling
COMPRESSOR the compressor to be replaced,
ability will be deteriorated.
from the new compressor.
Once the air-conditioner is operated, part of the oil
is dispersed in the refrigeration circuit. Therefore,
RECEIVER DRYER 20 cc (1.2cu.in)
when replacing the parts in right Table, adjust the oil
level to that of table. HOSES 20 cc (1.2cu.in)
(5) Before performing operation, stop the engine and
turn off all power supplies to the equipment related
to the air-conditioner.
(6) After the operation is over, confirm that all faults
have been repaired completely, by operating the
air-conditioner.
25-19
25.5.2 DISASSEMBLY AND ASSEMBLY OF UNIT

(1) Removing inner air filter

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

Fig. 25-15
(2) Removing selector box
MODE ACTUATOR PLUS SCREW
Remove 6 plus screws, remove connector MAIN HARNESS
connected to the mode actuator on mode selector
box, and separate the mode selector box from the
unit.
CONNECTOR
(3) Removing main harness SELECTOR BOX
Pull out 3 harness clamps from the unit, and UNIT
disconnect all connected connectors and remove
harness on the body from the unit.
Fig. 25-16
(4) Removing upper unit case AIR MIX LEVER PLUS SCREW
1) Remove air MIX rod and air MIX rod sub from air
MIX lever.
2) Remove 12 plus screws which are used to install
the upper and lower unit casings.
Pull out the upper unit casing upward giving
attention to the thermistor harness so as not to
UPPER UNIT
be caught by the casing. CASING
AIR MIX
ROD SUB
AIR MIX
ROD SUB
LOWER UNIT CASING
Fig. 25-17
25-20
(5) Replacing blower controller UPPER UNIT CASING

1) Remove 2 plus screws and remove the blower
controller from the upper unit casing.
2) Install new blower controller by the reverse
procedure of removal.
* Do not disassemble the blower controller.
PLUS SCREW BLOWER CONTROLLER
Fig. 25-18
(6) Removing heater core
PIPE CLAMP
1) After draining the coolant, remove heater hose HEATER CORE
PLUS SCREW
from the heater core.
2) Remove 1 plus screw, and remove pipe clamp EVAPORATOR ASSY
which is used to secure the heater core and then BLOWER MOTOR
remove the heater core from the lower unit
casing.
3) Install it by the reverse procedure of removal.
(7) Replacing blower motor

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

2) Install it by the reverse procedure of removal.
Fig. 25-19
(8) Replacing evaporator and expansion valve
1) Take the evaporator with expansion valve off
EVAPORATOR
from the lower casing.
2) Remove evaporator sensor with sensor holder
from the removed evaporator. SENSOR HOLDER
3) Insert the sensor holder into the new evaporator 105mm
at the position shown in Fig. 25-20 and install the (4.1 inch)
evaporator sensor again.
11TH ROWS OF FIN
EVAPORATION SENSOR
Fig. 25-20
25-21
4) Remove 2 socket bolts M5×40 with Allen wrench

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

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

outlet. This undue stress causes the leak of
refrigerant from "A" part of evaporator. EXPANSION VALVE
Moreover, when tube assembly (27-6) (see Fig.
25-1) connected with expansion valve is
SOCKET BOLT M5X40(2 PCS.)
disconnected from expansion valve, similar
careful work is necessary.
Fig. 25-21
(9) Replacing motor actuator

VENT ROD
1) Replacing mode actuator
FACE ROD
a) Remove connector connected to the motor
MA MODE
actuator. LEVER
CONNECTOR
b) Remove FACE rod and VENT rod which is PLUS SCREW
3PCS.
used to connect MA mode lever and mode
MODE
cam from the holder. ACTUATOR
c) Remove 3 plus screws and remove the
motor actuator with lever MA mode from the
unit.
d) Remove the lever MA mode from the
removed motor actuator, and install it on new Fig. 25-22
motor actuator by the reverse procedure of
removal.
2) Replacing air mixing actuator
AIR MIX ROD
a) Remove connector connected to the motor
MA AIR MIX LEVER
actuator.
b) Remove rod air MIX which is used to connect
the motor actuator and the lever MA air MIX. CONNECTOR

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. 25-23
25-22
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. 25-24
25-23
25.6 CHARGING REFRIGERANT

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

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

• Fasten pipes to a specified torque.
25-24
25.6.2 OPERATING PROCEDURE

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

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

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

an open/close valve in the center.
25-26
(2) Vacuum making (See Fig. 25-27)

LOW PRESSURE VALVE(OPEN) (CLOSE)
1) Open the high pressure valve (HI) and the low HIGH PRESSURE VALVE(OPEN) More than (CLOSE)
pressure valve (LO) of the gauge manifold. 30 min
2) Turn on the switch of the vacuum pump and
make vacuum for more than 30 minutes. GAUGE MANIFOLD
3) When vacuum making for a specified duration
is over (degree of vacuum : less than - 750
mmHg), close the high pressure valve and the
low pressure valve of the gauge manifold.
DIS
4) Then turn off the vacuum pump.
(3) Air-tightness Check
Close the high pressure valve and the low pressure
valve of the gauge manifold, leave it as it is for more SUC
than five minutes and make sure that the gauge
indication does not return toward 0.
Fig. 25-27 Vacuum making operation
If the gauge indication swings toward 0, there is

somewhere that is leaking. Retighten pipe joints, make
vacuum again and make sure of no leakage.
25-27
25.6.3.2 GAS CHARGING OPERATION

(1) Charging from high pressure side (See Fig. 25-28.)
1) After making vacuum repeatedly, change the
charging hose (yellow) of the gauge manifold
from the vacuum pump to the service can.
2) Air purge
Open the service can valve. (However, close the
high and low pressure valves of the gauge AIR PURGE
manifold.) Then push the gas valve of the side CLOSE
service port on the low pressure side of the
SCREW DRIVER OPEN SERVICE
gauge manifold, using a screw driver, in order to CAN VALVE
YELLOW
let out the air in the charging hose by the
pressure of the refrigerant. (See Fig. 25-28.)
BLUE RED
(The operation ends when a hissing sound is
heard.)
Fig. 25-28 Gas charging operation

3) Open the high pressure valve of the gauge
manifold and charge in refrigerant. [Charge in
gaseous refrigerant to a gauge pressure of
0.1MPa (14psi).] LOW PRESSURE HIGH PRESSURE VALVE
After charging, close the high pressure valve of VALVE(CLOSE) (OPEN) (CLOSE)
RED FILL IN 1~1.5 CANS
the gauge manifold and the service and valve. BLUE OF REFRIGERANT
(See Fig. 25-29.)
DIS
YELLOW
SERVICE CAN
VALVE
• Do not run the compressor during this work, (OPEN) (CLOSE)
CHARGE
(Otherwise the refrigerant flow in reverse
direction which causes the service can and the SUC
hoses to rupture. This is very dangerous.)
(2) Checking for gas leak (High pressure side)
Check for gas leak in the cycle, using a gas leak
detector (electric type). Retighten and correct
leaking points.
• Always use the leak tester for R134a. (Do not use
one for flon gas service as it provides poor
sensitivity.)
25-28
(3) Charging from low pressure side (See Fig. 25-30)

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

(Low pressure side)
5) Open the low pressure valve of the gauge
SIGHT GLASS
manifold and the service can valve and fill in
refrigerant till air bubbles of the sight glass of the
receiver go away. (See Fig. 25-30)
[Total amount of gas to be charged :
900g±50g (2.0±0.11 lbs)]
6) When refrigerant charge is over, close the low
pressure valve of the gauge manifold and the
service can valve.
RECEIVER DRYER
• Do not open the high pressure valve of the

gauge manifold in any circumstances. Fig. 25-31 Receiver dryer
• Never place the service can upside down. (The
compressor valve may be scored because the
refrigerant is sucked in a liquid state.)
25-29
(4) Criterion for checking the amount of refrigerant

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

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

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

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

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

When the refrigerant level has been checked,
disconnect the charging hoses from the
compressor in the following manner :
1. Press the "L" shape metal fitting of the charging
hose (blue) on the low pressure side against the
service valve of the compressor so the
refrigerant does not leak out and loosen the nut.
As soon as the nut has been removed,
disconnect the charging hose from the service
valve.
2. Leave the high pressure side as it is till the high
pressure gauge reading falls. [below 1MPa
(140psi)].
3. Disconnect the charge hose (red) on the high
pressure side the same way as on the low
pressure side.
25-30
25-31
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. 25-32 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. 25-33 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. 25-34
computer, and comprehensively controls each
actuator (Inner and outer air flow select, air mix),
fan motor and compressor on the output side.
And the self-diagnosis performance is provided to
facilitate the trouble shooting.
(2) Blower controller (TKS-B215A1)

The power transistor shifts the fan motor into
variable speed with base current from the control B
unit.
TERMINAL NO.
CONTINUITY
1 2 3
CONTINUED Lg L
TESTER NOT CONTINUED
CONTINUED(DIODE PARALLEL
AND FORWARD DIRECTION FLOW)
In normal operation
1. Disconnect the connector of blower amplifier.
2. Check continuity between terminals on the
blower amplifier side.
Fig. 25-35
* The installing position is provided on the left side
of air-con unit.
25-34
(3) Relay
Four-electrode relay is used for the blower OFF
relay and compressor relay.
1) Blower OFF relay
The blower OFF relay turns on after receiving the
signal from the control amplifier.
When the blower OFF relay turns on, the source
voltage is supplied to the blower motor and the
blower motor starts running.
2) Compressor relay
The relay ON—OFF is tripped by the control
amplifier and electronic thermostat control. Fig. 25-36
3) Relay inspecting items
1. Relay (24-4PE)
2. Coil resistance: 320
3. Specified voltage: DC20V~30V
4. Be careful about the coil side of relay because
this relay has polarity.
5. Inspection: Inspect the continuity between 3
and 4 according to the conditions mentioned
below.
20~30V applied between terminals 1-2:
Continued
20~30V not applied between terminals 1-2: Not
continued
(4) Air mix actuator
Air mix actuator is installed at the center of air-con
unit, and opens and closes air mix damper through
the link.
The air mix actuator contains potentiometer which
is switched by being coupled to the shaft of
actuator.
When the target air mix door position is determined CONTROL AMPLIFIER MOTOR ACTUATOR
through the temperature control switch, the control LIMITER

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

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

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

signal of control unit turns OFF, the motor stops
rotating. Fig. 25-37
25-35
(5) The actuator for inner and outer

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

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

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

stop at the set position of the inner and outer air Fig. 25-38
damper.
(6) Evaporator sensor
This sensor is used to control the evaporator outlet
temperature with the compressor ON-OFF to
protect the evaporator from freezing, and this
evaporator sensor functions as a sensor of this
control.
• Evaporator sensor inspecting items
(Specification)
Terminal resistance : Fig. 25-39
at 0 degree C : 7.2 k
at 25 degree C : 2.2k
(7) Dual pressure switch
This dual pressure switch is attached on L-hose
and is used to turn OFF the compressor, and
employs dual type (for high and low pressure
control) to protect the cooler cycle from possible
failure at the time when abnormal pressure was
generated on the high pressure side.
Fig. 25-40
SPECIFICATION OF DUAL PRESSURE SWITCH
0.02MPa(2.9psi) 0.59MPa(86psi)
ON
OFF
0.20MPa(29psi) 3.14MPa(455psi)
(LOW PRESSURE SIDE) (HIGH PRESSURE SIDE)
(8) Solar radiation sensor

This solar radiation sensor, which is used to correct
the solar radiation to the auto air conditioner
detects the strength and solar orientation of
sunbeam after transforming them into current by
means of photo diode.
Inspection : Check for the continuity between
Fig. 25-41
terminals.
25-36
25.8 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
force. (less than 14.7N : OK) inner air sensor eliminate causes
is out of order. for warm air entry.
NO YES
Inspect and replace.
. Inspect, correct or M/A failed or controller

replace M/A lever link. is out of order.
. Clean lever link and apply grease.
Replace.
25-38
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

Shop Manual Sk330 8pdf Compress 201 400

Uploaded by

Copyright:

Available Formats

Shop Manual Sk330 8pdf Compress 201 400

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Shop Manual Sk330 8pdf Compress 201 400

Uploaded by

Copyright:

Available Formats

22.

22.11 PRESSURE DRAINING (3) Operation :

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

Book Code No. S5LC2311E02

Issue Date of Issue Applicable Machines Remarks

23.1 ELECTRIC CIRCUIT DIAGRAM

FUEL SUPPLY PUMP

KEY SW. STARTER RELAY

CAB WORK LIGHT

CAB WORK LIGHT

OPT. BUCKET CONTROL

AIR CON. (AMP.) SK350LC-8 ONLY

ENGINE CONTROLLER INJECTOR 1

SW-1 : BOOST SENSOR

CONTROL : (SENSOR POWER

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

SE-16 : ACCEL POTENTIO

SE-1 : BUCKET DIGGING

C-8 : ENG. CONTROLLER

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

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

ENG. WATER TEMP INDICATOR

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

PSV-I : OPT RELIEF ADJUSTMENT

SE-13 : ENG. SPEED SENSOR

DISPLAY BUZZER MODE WASHER

ENTER DECEL TRAVEL WIPER

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

R-17 : EXTRA RELEASE RELAY

E-5 : HORN HIGH

SE-28 : EXTRA PRESS

EXTRA RELEASE SW-5 : HORN SW. RIGHT

E-14 : CIGARETTE LIGHTER

SW-35 : HEAVY LIFT SW.

SE-29 : R-8 : TRAVEL ALARM RELAY

SV-13 : OPT. SELECTOR SOL.

OPT JAPAN: OPT

SW. E-7 : TUNER AM & FM

M-9 : ROOF WIPER MOTOR

TERMINAL E-8 : SPEAKER LEFT

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

C-6 : AUTO GREASE CONTROLLER

L-6 : BOOM WORKING LIGHT

(CASE OF HAND CONTROL

EASY OPERATING NIBBLER

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

23.2 ELECTRICAL EQUIPMENT LIST

INDEX No. EQUIPMENT HARNESS

3 CABLE LC13E01176P2 BATTERY ~ RELAY

3.9 CAB HARNESS LC14E00023F1 1 HARNESS YN14E01102P3 CAB

3.13 CAB LIGHT INSTALL YN80E00058F1 6 HARNESS YN02C01760P1 CAB LIGHT

23.3.2 INSTRUMENT PANEL ASSY

TIGHTENING TORQUE TIGHTENING TORQUE

23.3.3 CONTROLLER INSTALL 23.3.4 TUNER INSTALL

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

INSTALL THE CONER

SECTION AA SEMS BOLT

PASS CABLE THROUGH

23.3.5 UPPER ELECTRIC ASSY

UPPER ELECTRIC ASSY LC03E00008F1 (02)