E80MSR

WORKSHOP MANUAL
ENGLISH

Print No. 604.13.421

Edition 02/2005
English - Printed in Italy

Printed by Studio ti - 14805

 INTRODUCTION

TO THE READER
• This manual has been written for a skilled technician, For any question or comment, or in case you no-
in order to give him the information necessary to repair tice a mistake in this manual content, please con-
this machine. tact:
NEW HOLLAND KOBELCO CONSTRUCTION
MACHINERY S.p.A.
Read this manual carefully for correct information
Strada di Settimo, 323
about repair procedures.
San Mauro Torinese (TO)
10099 ITALIA
PRODUCT SUPPORT
Fax. ++39 011 0077357

ADDITIONAL REFERENCE MANUALS

• In addition to this Workshop Manual, refer also to the
following:
Operation and maintenance instruction manual
Spare parts catalog

DESCRIPTION OF THE WORKSHOP • The “Hydraulic exavator” Workshop Manual contains

MANUAL the technical information necessary for machine serv-
ice and repair, the service equipment, the information
• This repair manual consists of one single volume, on maintenance standards, the removal and installing
identified with: procedures, and the disassembly and assembly pro-
E80MSR - Workshop Manual “Hydraulic exavator” cedures.

• The complete Workshop Manual for the model

E80MSR consists of the following volume identified by
print number as shown herebelow:

VOLUME MACHINE TYPE PRINT No.

Workshop Manual - “Hydraulic exavator” E80MSR 604.13.421
INTRODUCTION

AVOID ACCIDENTS
Most accidents, whether they occur in industry, on the farm, at home or on the highway, are caused by the failure of
some individuals to follow simple and fundamental safety rules or precautions. For this reason MOST ACCIDENTS
CAN BE PREVENTED by recognising the real cause and doing something about it before the accident occurs.
Regardless of the care used in the design and construction of any type of equipment there are conditions that cannot
be completely safeguarded against without interfering with reasonable accessibility and efficient operation.
Carefully read indications, cautions and safety warning quoted in the “SAFETY RULES” section.
A careful operator is the best insurance against an accident.
The complete observance of one simple rule would prevent many thousand serious injuries each year.
That rule is:
Never attempt to clean, oil or adjust a machine while it is in motion.

S ATTENTION
On machines having hydraulically, mechanically and/or cable controlled equipment (such as showels,
loaders, dozers, scrapers etc.) be certain the equipment is lowered to the ground before servicing, adjust-
ing and/or repairing.
If it is necessary to have the equipment partially or fully raised to gain access to certain items, be sure the
equipment is suitably supported by means other than the hydraulic lift cylinders, cable and/or mechanical
device used for controlling the equipment.

COPYRIGHT BY NEW HOLLAND KOBELCO CONSTRUCTION MACHINERY S.p.A.

Product Support - Documentation Centre

Strada di Settimo, 323 - 10099 S. Mauro T.SE (TO) ITALY

All rights reserved. Reproduction of text and illustrations in whole or in part, is strictly prohibited.
SAFETY PRECAUTIONS

0-1
SAFETY PRECAUTIONS

GENERAL SAFETY INFORMATION nor or moderate injury. It may also be used to

alert against possible damage to the machine
and its components and is represented as fol-
lows:
Do not operate or perform any maintenance on this
machine until all instructions found in the OPERA-
TOR’S MANUAL and this MANUAL have been thor- (4) It is very difficult to forecast every danger that may
oughly read and understood. occur during operation. However, safety can be en-
Improper operation or maintenance of this machine sured by fully understanding proper operating pro-
may cause accidents and could result in serious in- cedures for this machine according to methods
jury or death. recommended by Manufacturer.
Always keep the manual in storage. (5) While operating the machine, be sure to perform
If it is missing or damaged, place an order with an work with great care, so as not to damage the ma-
authorized our Distributor for a replacement. chine, or allow accidents to occur.
If you have any questions, please consult an autho-
(6) Continue studying the manual until all Safety, Oper-
rized our Distributor.
ation and Maintenance procedures are completely
(1) Most accidents, which occur during operation, are understood by all persons working with the ma-
due to neglect of precautionary measures and safe- chine.
ty rules. Sufficient care should be taken to avoid
these accidents. Erroneous operation, lubrication
or maintenance services are very dangerous and
may cause injury or death of personnel. Therefore
all precautionary measures, NOTES, DANGERS,
WARNINGS and CAUTIONS contained in the man-
ual and on the machine should be read and under-
stood by all personnel before starting any work with
or on the machine.
(2) Operation, inspection, and maintenance should be
carefully carried out, and safety must be given the
first priority. Messages of safety are indicated with
marks. The safety information contained in the
manual is intended only to supplement safety
codes, insurance requirements, local laws, rules
and regulations.
(3) Messages of safety appear in the manual and on
the machine : All messages of safety are identified
by either word of "DANGER", "WARNING" and
"CAUTION".
1) DANGER- Indicates an imminently hazardous
situation which, if not avoided, will result in
death or serious injury and is represented as
follows:

2) WARNING- Indicates a potentially hazardous

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

3) CAUTION- Indicates a potentially hazardous

situation which, if not avoided, may result in mi-

0-2
 SAFETY PRECAUTIONS

SAFETY PRECAUTIONS stands, capable of supporting the machine, before

performing any disassembly.

The proper and safe lubrication and maintenance

for this machine, recommended by Manufacturer, Do not operate this machine unless you have
are outlined in the OPERATOR’S MANUAL for the read and understand the instructions in the OP-
machine. ERATOR’S MANUAL. Improper machine opera-
Improper performance of lubrication or mainte- tion is dangerous and could result in injury or
nance procedures are dangerous and could result death.
in injury or death. Read and understand the MAN-
(6) Relieve all pressure in air, oil or water systems be-
UAL before performing any lubrication or mainte-
fore any lines, fittings or related items are discon-
nance.
nected or removed. Always make sure all raised
The serviceman or mechanic may be unfamiliar with components are blocked correctly and be alert for
many of the systems on this machine. This makes it possible pressure when disconnecting any device
important to use caution when performing service work. from a system that utilizes pressure.
A knowledge of the system and or components is im- (7) Lower the bucket, dozer, or other attachments to
portant before the removal or disassembly of any com- the ground before performing any work on the ma-
ponent. chine. If this cannot be done, make sure the bucket,
Because of the size of some of the machine compo- dozer, ripper or other attachment is blocked correct-
nents, the serviceman or mechanic should check the ly to prevent it from dropping unexpectedly.
weights noted in this manual. Use proper lifting proce- (8) Use steps and grab handles when mounting or dis-
dures when removing any components. Weight of com- mounting a machine. Clean any mud or debris from
ponents table is shown in the section ; steps, walkways or work platforms before using.
SPECIFICATIONS. Always face to the machine when using steps, lad-
The following is a list of basic precautions that must al- ders and walkways. When it is not possible to use
ways be observed. the designed access system, provide ladders, scaf-
folds, or work platforms to perform safe repair oper-
(1) Read and understand all Warning plates and decal
ations.
on the machine before Operating, Maintaining or
Repairing this machine. (9) To avoid back injury, use a hoist when lifting com-
ponents which weigh 20kg (45lbs) or more. Make
(2) Always wear protective glasses and protective
sure all chains, hooks, slings, etc., are in good con-
shoes when working around machines. In particu-
dition and are the correct capacity. Be sure hooks
lar, wear protective glasses when using hammers,
are positioned correctly. Lifting eyes are not to be
punches or drifts on any part of the machine or at-
side loaded during a lifting operation.
tachments. Use welders gloves, hood/goggles,
apron and the protective clothing appropriate to the (10)To avoid burns, be alert for hot parts on machines
welding job being performed. Do not wear loose fit- which have just been stopped and hot fluids in
ting or torn clothing. Remove all rings from fingers, lines, tubes and compartments.
loose jewelry, confine long hair and loose clothing (11)Be careful when removing cover plates. Gradually
before working on this machinery. back off the last two capscrews or nuts located at
(3) Disconnect the battery and hang a "Do Not Oper- opposite ends of the cover or device and carefully
ate" tag in the Operators Compartment. Remove ig- pry cover loose to relieve any spring or other pres-
nition keys. sure, before removing the last two capscrews or
nuts completely.
(4) If possible, make all repairs with the machine
parked on a level, hard surface. Block the machine (12)Be careful when removing filler caps, breathers and
so it does not roll while working on or under the ma- plugs on the machine. Hold a rag over the cap or
chine. Hang a "Do Not Operate" tag in the Opera- plug to prevent being sprayed or splashed by liq-
tors Compartment. uids under pressure. The danger is even greater if
the machine has just been stopped because fluids
(5) Do not work on any machine that is supported only
can be hot.
by lift, jacks or a hoist. Always use blocks or jack

0-3
SAFETY PRECAUTIONS

(13)Always use the proper tools that are in good condi- (21)Do not operate a machine if any rotating part is
tion and that are suited for the job at hand. Be sure damaged or contacts any other part during opera-
you understand how to use them before performing tion. Any high speed rotating component that has
any service work. been damaged or altered should be checked for
(14)Reinstall all fasteners with the same part number. balance before reusing.
Do not use a lesser quality fastener if replacements (22)Be careful when servicing or separating the tracks
are necessary. (crawlers). Chips can fly when removing or install-
(15)Repairs which require welding should be per- ing a track (crawlers) pin. Wear safety glasses and
formed only with the benefit of the appropriate ref- long sleeve protective clothing. Tracks (crawlers)
erence information and by personnel adequately can unroll very quickly when separated. Keep away
trained and knowledgeable in welding procedures. from front and rear of machine. The machine can
Determine type of metal being welded and select move unexpectedly when both tracks (crawlers)
correct welding procedure and electrodes, rods or are disengaged from the sprockets. Block the ma-
wire to provide a weld metal strength equivalent at chine to prevent it from moving.
least to that of the parent metal. Make sure to dis-
connect battery before any welding procedures are
attempted.
(16)Do not damage wiring during removal operations.
Reinstall the wiring so it is not damaged nor will be
damaged in operation of the machine by contacting
sharp corners, or by rubbing against some object or
hot surface. Do not connect wiring to a line contain-
ing fluid.
(17)Be sure all protective devices including guards and
shields are properly installed and functioning cor-
rectly before starting a repair. If a guard or shield
must be removed to perform the repair work, use
extra caution and replace the guard or shield after
repair is completed.
(18)The maintenance and repair work while holding the
bucket raised is dangerous due to the possibility of
a falling attachment. Don’t fail to lower the attach-
ment and place the bucket to the ground before
starting the work.
(19)Loose or damaged fuel, lubricant and hydraulic
lines, tubes and hoses can cause fires. Do not bend
or strike high pressure lines or install ones which
have been bent or damaged. Inspect lines, tubes
and hoses carefully. Do not check for leaks with
your hands. Very small (pinhole) leaks can result in
a high velocity oil stream that will be invisible close
to the hose. This oil can penetrate the skin and
cause personal injury. Use card-board or paper to
locate pinhole leaks.
(20)Tighten connections to the correct torque. Make
sure that all heat shields, clamps and guards are in-
stalled correctly to avoid excessive heat, vibration
or rubbing against other parts during operation.
Shields that protect against oil spray onto hot ex-
haust components in event of a line, tube or seal
failure must be installed correctly.

0-4
 SAFETY PRECAUTIONS

INDEX E80MSR

Title Index
No.
MAINTENANCE SPECIFICATIONS

OUTLINE 1

SPECIFICATIONS 2

ATTACHMENT DIMENSIONS 3

TOOLS 11

STANDARD MAINTENANCE TIME SCHEDULE 12

MAINTENANCE STANDARDS AND TEST PROCEDURES 13

MECHATRO CONTROL SYSTEM 21

HYDRAULIC SYSTEM 22
SYSTEM

ELECTRICAL SYSTEM 23

COMPONENTS SYSTEM 24

AIR-CONDITIONER SYSTEM 25

DISASSEMBLING & ASSEMBLING 31

DISASSEMBLING

ATTACHMENTS 32

UPPER SWING BODY 33

TRAVEL FRAME 34

41
TROUBLESHOOTING

MECHATRO CONTROL

HYDRAULIC SYSTEM 42

ELECTRICAL SYSTEM 43

ENGINE 44

51
E/G

ENGINE

0-5
SAFETY PRECAUTIONS

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

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

0-6
 1

1. OUTLINE
TABLE OF CONTENTS

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

1.1.1 PREPARATION BEFORE DISASSEMBLING ........................................................... 1-3
1.1.2 SAFETY IN DISASSEMBLING AND ASSEMBLING ................................................. 1-3
1.1.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT ......................... 1-3
1.1.4 ELECTRICAL EQUIPMENT ...................................................................................... 1-4
1.1.5 HYDRAULIC PARTS ................................................................................................. 1-5
1.1.6 WELDING REPAIR ................................................................................................... 1-5
1.1.7 ENVIRONMENTAL MEASURE ................................................................................. 1-5
1.2 INTERNATIONAL UNIT CONVERSION SYSTEM(Based on MARKS’ STANDARD
HANDBOOK FOR MECHANICAL ENGINEERS) .............................................................. 1-6

1-1
1. OUTLINE

1-2
 1. OUTLINE

1.1 GENERAL PRECAUTIONS FOR (2) Suspend warning tag "DO NOT OPERATE" from
the doorknob or the operating lever, and have a
REPAIRS
preliminary meeting before starting work.
1.1.1 PREPARATION BEFORE DISASSEM- (3) Stop the engine before starting inspection and
BLING maintenance to prevent the operator being caught
in machine.
Read Operator’s Manual
(4) Identify the location of a first-aid kit and a fire extin-
before disassembling

guisher, and also where to make contact in a state

(1) Understanding operating procedure of emergency.
Read OPERATOR’S MANUAL and this MANUAL
(5) Choose a hard, level and safe place, and place the
carefully to understand the operating procedure.
attachment on the ground securely.
(2) Cleaning machines
(6) Use a lifter such as a crane to remove heavy parts
Remove soil, mud, and dust from the machine be-
(20 kg [45 lbs] or more) from the machine.
fore carrying it into the service shop to prevent loss
of work efficiency, damage of parts, and difficulty in (7) Use proper tools, and replace or repair defective
rust prevention and dust protection while reassem- tools.
bling. (8) Support the machine and attachment with supports
(3) Inspecting machines or blocks if the work is performed in the lifted condi-
Identify the parts to be disassembled before start- tion.
ing work, determine the disassembling procedure 1.1.3 DISASSEMBLING AND ASSEMBLING HY-
by yourself considering the workshop situations DRAULIC EQUIPMENT
etc., and request procurement of necessary parts in
advance.
(4) Recording
Record the following items for communication and (1) Removing hydraulic equipment
prevention of recurring malfunction.
1) Before disconnecting pipes, release the hy-
1) Inspection date and place draulic pressure of the system, or open the re-
2) Model name, applicable machine number, and turn side cover and take out the filter.
hour meter read 2) Carefully drain oil of the removed pipes into a
3) Trouble condition, place and cause. containers without spilling on the floor.
4) Visible oil leakage, water leakage and damage 3) Apply plugs or caps on the pipe ends to avoid
5) Clogging of filters, oil level, oil quality, oil con- oil spillage and dust intrusion.
tamination and loosening of connections 4) Clean off the external surface of the equipment
6) Result of consideration if any problem exists before disassembling, and drain hydraulic and
based on the operation rate per month calculat- gear oil before placing it on the workbench.
ed from hour meter indication after the last in- (2) Disassembling hydraulic equipment
spection date. 1) Do not disassemble, reassemble or modify the
(5) Arrangement and cleaning in service shop hydraulic equipment without the permission of
1) Tools required for repair work. the manufacturer, who is not responsible for the
performance and function of the product after
2) Prepare space to place the disassembled parts.
modification.
3) Prepare oil containers for draining oil etc.
2) When disassembling and reassembling for un-
1.1.2 SAFETY IN DISASSEMBLING AND AS- avoidable reason, refer the work to qualified
SEMBLING personnel who have the specific knowledge or
completed the parts service training.
3) Provide matching marks to facilitate reassem-
WARNING
bling work.
(1) Wear appropriate clothes with long sleeves, safety 4) Before starting the work, read the manual of
shoes, safety helmet and protective glasses. disassembling procedure, if it is provided, and
decide whether the work can be performed by
yourself.

1-3
1. OUTLINE

5) Use the special jig and tools without fail if they

are specified.
6) If it is hard to remove a part according to the
Operation of the hydraulic equipment with-
procedure, do not try it by force but investigate
out filling hydraulic oil or lubricant or with-
the cause.
out performing air bleeding will result in
7) Place the removed parts in order and attach damage to the equipment.
tags to facilitate the reassembling.
8) Note the location and quantity of parts com- 3) Perform air bleeding of the hydraulic pump and
monly applied to multiple locations. slewing motor after loosening the upper drain
plug, starting the engine and keep it in low idle
(3) Inspecting parts
condition.
1) Ensure that the disassembled parts are free Complete the air bleeding when seeping of hy-
from seizure, interference and uneven contact. draulic oil is recognized, and tightly plug.
2) Measure and record wear condition of parts 4) Perform air bleeding of the travel motor and the
and clearance. hydraulic cylinders by running the engine for
3) If the problem is found in a part, repair or re- more than 5 minutes at low speed without load.
place it with a new one.
(4) Reassembling hydraulic equipment
1) Turn ON the ventilation fan or open windows to
Do not allow the hydraulic cylinder to bot-
maintain good ventilation prior to starting the
tom on the stroke end just after the mainte-
cleaning of parts.
nance.
2) Perform rough and finish cleaning before as-
sembling. 5) Perform air bleeding of pilot line by performing
3) Remove washing oil by air and apply clean hy- a series of digging, slewing and travel.
draulic or gear oil for assembling. 6) Check hydraulic oil level after placing the at-
4) Always replace the removed O-rings, backup tachment to the oil check position, and replen-
rings and oil seals with new ones by applying ish oil if necessary.
grease in advance.
5) Remove dirt and moisture from and perform de-
Level gauge
greasing on the surface where liquid gasket to Oil level lines (Level
be applied. located between the
two lines shows
6) Remove rust preventive agent from the new appropriate amount
of oil)
parts before use.
7) Fit bearings, bushings and oil seals using spe- 1.1.4 ELECTRICAL EQUIPMENT
cial jigs.
8) Assemble the parts utilizing matching marks.
9) Ensure all the parts are completely assembled
after the work. (1) Do not disassemble electrical equipment.
(5) Installing hydraulic equipment (2) Handle it carefully not to drop and give a shock.
1) Ensure hydraulic oil and lubricant are properly (3) Turn the key OFF prior to connecting and discon-
supplied. necting work.
2) Perform air bleeding when: (4) Disconnect the connector by holding it and press-
ing the lock. Do not pull the wire to apply force to the
1. Hydraulic oil changed
caulking portion.
2. Parts of suction side piping replaced
(5) Connect the connector and ensure it is completely
3. Hydraulic pump installed
locked.
4. Slewing motor installed
(6) Turn the key OFF prior to touching the terminal of
5. Travel motor installed starter or generator.
6. Hydraulic cylinder installed (7) Remove the ground (earth) terminal of battery
when handling tools around the battery or its relay.

1-4
 1. OUTLINE

(8) Do not splash water on the electrical equipment • Tighten the fitting at the specified torque.
and connectors during machine washing. Ensure no kink, tension, interference nor oil
(9) Check for moisture adhesion inside the waterproof leakage is recognized.
connector after pulling it out, since it is hard to re-
1.1.6 WELDING REPAIR
move moisture from the connector.
(1) Refer repair welding to qualified personnel accord-
If moisture adhesion is found, dry it completely be-
ing to the appropriate procedure.
fore the connection.
(2) Disconnect the ground (earth) cable of the battery
before starting the repair.
Failure to do so will cause damage to the electrical
Battery electrolyte is hazardous. equipment.
Battery electrolyte is dilute sulfuric acid. Exposure (3) Move away the articles in advance that may cause
of skin or eyes to this liquid will cause burning or fire if exposed to sparks.
loss of eyesight.
(4) Before starting the repair of the attachment, do not
If the exposure occurs, take the following emergen-
fail to cover the plated surface of the piston rod with
cy measures and seek the advice of a medical spe-
flameproof sheet to prevent it from being exposed
cialist.
to sparks.
• When skin exposed:
Wash with water and soap sufficiently. 1.1.7 ENVIRONMENTAL MEASURE
• When eyes exposed: (1) Run the engine at the place that is sufficiently ven-
Immediately wash away with city water continu- tilated.
ously for more than 10 minutes. (2) Industrial waste disposal
• When a large amount of the liquid flows out: Dispose of the following parts according to the rel-
Neutralize with sodium bicarbonate or wash evant regulations:
away with city water. Waste oil and waste container
Battery
• When swallowed:
Drink a large amount of milk or water. (3) Precautions for handling hydraulic oil
Exposure of eyes to hydraulic oil will cause inflam-
• When clothes exposed:
mation. Wear protective glasses before handling to
Immediately undress and wash.
avoid an accident. If an eye is exposed to the oil,
take the following emergency measures:
1.1.5 HYDRAULIC PARTS
• When an eye exposed:
Immediately wash away with city water suffi-
ciently till stimulative feeling vanishes.
(1) O-ring • When swallowed:
Do not let vomit, and receive medical treatment
• Ensure O-rings have elasticity and are not dam-
immediately.
aged before use.
• When skin exposed:
• Use the appropriate O-rings. O-rings are made
Wash with water and soap sufficiently.
of various kinds of materials having different
hardness to apply to a variety of parts, such as (4) Others
the part for moving or fixed portion, subjected to Use replacement parts and lubricants authorized as
high pressure, and exposed to corrosive fluid, the manufacturer's genuine parts.
even if the size is same.
• Fit the O-rings without distortion and bend.
• Always handle floating seals as a pair.
(2) Flexible hose (F hose)
• Use the appropriate parts. Different parts are
used depending on the working pressure even
the size of fitting and the total length of the hose
is same.

1-5
1. OUTLINE

1.2 INTERNATIONAL UNIT CON- (3) Derived Units

VERSION SYSTEM Table 1-3
(Based on MARKS’ STANDARD QUANTITY UNIT SYMBOL
HANDBOOK FOR MECHANI- Area square meter m2
CAL ENGINEERS) Volume cubic meter m3
Velocity meter per second m/s
Introduction
Acceleration meter per second squared m/s2
Although this manual includes International System of
Density kilogram per cubic meter kg/m3
Unit and Foot-Pound System of Units, if you need SI
unit, refer to the following international system of units. (4) Derived Units bearing Peculiar Designations
Given hereinafter is an excerpt of the units that are re-
lated to this manual. Table 1-4

1. Etymology of SI Unites QUANTITY UNIT SYMBOL FORMULA

French : Le Systeme International d’ Unites Frequency hertz Hz 1/s
English : International System of Units Force newton N kg • m/s 2
2. Construction of SI Unit System Pressure and
pascal Pa N/m2
Stress
Base units
Table 1-1 Energy, Work
Derived units and Quantity of joule J N•m
Supplemen of base units
Table 1-3 heat
SI units tary units
SI unit Table 1-2 Power watt W J/s
system Derived units Quantity of
Derived bearing peculiar coulomb C A•s
units designations electricity
Table 1-4
Electric poten-
Prefixes of SI tial difference,
(n-th power of 10, where n is an integer) Voltage, and volt V W/A
Table 1- 5
Electromotive
force
(1) Base units Quantity of
Table 1-1 static electricity
farad F C/V
and Electric
QUANTITY UNIT SYMBOL
capacitance
Length meter m
Electric
Mass kilogram kg ohm V/A
resistance
Time second s
celcius
Electric current ampere A Celcius
degree or C (t+273.15)K
Thermodynamic temperature
kelvin K degree
temperature Illuminance lux lx l m/m2
Amount of sub-
mol mol
stance
Luminous
candela cd
intensity

(2) Supplementary units

Table 1-2
QUANTITY UNIT SYMBOL
Plane angle radian rad
Solid angle steradian sr

1-6
 1. OUTLINE

(5) Prefixes of SI
Table 1-5
PREFIX SYMBOL MULTIPLICATION FACTORS
giga G 109
mega M 106
kilo k 103
hecto h 102
deca da 10
deci d 10–1
centi c 10–2
milli m 10–3
micro µ 10–6
nano n 10–9
pico p 10–12

(6) Unit Conversion

Table 1-6
QUANTITY Gravitational SI CONVERSION FACTOR
Mass kg kg
Force kgf N 1 kgf=9.807 N
Torque kgf•m N•m kgf•m=9.807 N•m
Pressure kgf/cm 2 MPa 1 kgf/cm2=0.09807 MPa
Motive
PS kW 1 PS=0.7355 kW
Power
Revolution rpm min–1 r/min *1

*1 Units that are allowed to use.

1-7
1. OUTLINE

[MEMO]

1-8
 2

2. SPECIFICATIONS
TABLE OF CONTENTS

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

2.2 MACHINE DIMENSIONS ................................................................................................... 2-4
2.2.1 3.72 m (12 ft-2 in) Boom + 1.8 m (5 ft-11 in) Arm + 0.28 m3 (0.37 cu•yd) Bucket .......... 2-4
2.3 WEIGHT OF COMPONENTS ............................................................................................. 2-5
2.4 TRANSPORTATION DIMENSION AND WEIGHT .............................................................. 2-7
2.5 SPECIFICATIONS AND PERFORMANCE ........................................................................ 2-10
2.5.1 SPEED AND CLIMBING CAPABILITY ..................................................................... 2-10
2.5.2 ENGINE ..................................................................................................................... 2-10
2.5.3 HYDRAULIC COMPONENTS ................................................................................... 2-10
2.5.4 WEIGHT .................................................................................................................... 2-10
2.6 TYPE OF CRAWLER ......................................................................................................... 2-11
2.7 TYPE OF BUCKET ............................................................................................................. 2-11
2.8 COMBINATIONS OF ATTACHMENT ................................................................................. 2-12
2.9 ENGINE SPECIFICATION ................................................................................................. 2-13
2.9.1 SPECIFICATIONS .................................................................................................... 2-13
2.9.2 ENGINE CHARACTERISTIC CURVE (ISUZU 4JG1) ............................................... 2-14

2-1
2. SPECIFICATIONS

2-2
 2. SPECIFICATIONS

2.1 NAME OF COMPONENTS

2-3
2. SPECIFICATIONS

2.2 MACHINE DIMENSIONS

2.2.1 3.72 m (12 ft-2 in) Boom + 1.8 m (5 ft-11 in) Arm + 0.28 m3 (0.37 cu•yd) Bucket
Unit: mm (ft-in)

* Marked dimensions do not include height of shoe lug.

2-4
 2. SPECIFICATIONS

2.3 WEIGHT OF COMPONENTS

Unit : kg (lbs)

Model 1.8 m (5 ft-11 in) Arm

Item + 450 mm (17.7 in) Shoe
Machine complete 8,000 (17,640)
1. Upper frame assy (including the following :) 3,815 (8,410)
1.1 Counterweight 820 (1,810)
Counterweight (Add-on) 400 (880)
1.2 Cab 191 (420)
1.3 Engine *250 (550)
1.4 Hydraulic oil tank *65 (143)
1.5 Fuel tank *59 (130)
1.6 Slewing motor (including reduction unit) 67 (150)
1.7 Control valve 63 (140)
1.8 Boom cylinder *92 (203)
1.9 Pin (2pcs. for mounting boom) 14 (31)
1.10 Pump 44 (97)
1.11 Radiator *39 (86)
1.12 Swing cylinder *59 (130)
1.13 Swing bracket 244 (538)
2. Lower frame assy (including the following :) 2,910 (6,420)
2.1 Slewing bearing 115 (250)
2.2 Travel motor (including reduction unit) 81 (180)×2
2.3 Upper roller 4 (9)×2
2.4 Lower roller 15 (33)×10
2.5 Front idler 44 (97)×2
2.6 Track tension adjuster 29 (64)×2
2.7 Sprocket 27 (59)×2
2.8 Swivel joint 21 (46)
2.9 Dozer blade 350 (770)
2.10 Dozer cylinder *60 (130)×2
2.11 Track link with 450 mm (17.7 in) shoes assy 421 (928)×2
3 Attachment 1,050 (2,315)
{3.72 m (12 ft-2 in) Boom + 1.80 m (5 ft-11 in) Arm + 0.28 m (0.37 cy•yd) bucket}
3.1 Bucket assy 200 (440)
3.2 Arm assy (including the following :) 330 (728)
3.2.1 Arm 190 (420)
3.2.2 Bucket cylinder *48 (106)
3.2.3 Idler link 17 (37)
3.2.4 Bucket link 8 (17)×2
3.2.5 Pin (2 pcs. for mounting bucket cylinder / 2 pcs. for mounting bucket) *18 (40)
3.3 Boom assy (including the following :) 514 (1,130)
3.3.1 Boom 390 (860)
3.3.2 Arm cylinder 72 (160)
3.3.3 Pin (Mounting arm • Mounting arm cylinder) 16 (35)
4. Lubricant and water (including the following :) 208 (460)
4.1 Hydraulic oil *102 (225)
4.2 Engine oil 9 (20)

2-5
2. SPECIFICATIONS

Model 1.8 m (5 ft-11 in) Arm

Item + 450 mm (17.7 in) Shoe
4.3 Fuel 83 (183)
4.4 Water 10 (22)

Numerical values marked * indicate the dry weight.

2-6
 2. SPECIFICATIONS

2.4 TRANSPORTATION DIMENSION AND WEIGHT

OVERALL DIMENSIONS OF MACHINE ON A TRAILER

OVERALL DIMENSIONS OF A COMPLETE MACHINE ON A TRAILER

Item Type 1.80 M (5 ft-11 in) Arm + 450 mm (17.7 in) shoes
Width m (ft-in) 2,320 (7’-7")
Weight kg (lb) 8,000 (17,640)

6,760 mm (22’-2”)
1,650 (5’-5”)
2,600 mm (8’-6”)
3,800 mm (12’-6”)
1,200 mm
(3’-11”)

OVERALL DIMENSIONS OF WITHOUT BOOM, ARM AND BUCKET

Type A : Shoe width L : Length H : Height W : Width Weight

Combination mm (ft-in) mm (ft-in) mm (ft-in) mm (ft-in) kg (lb)
Without boom, arm and 450 (17.7") 2,860 (9’-5") 2,600 (8’-6") 2,320 (7’-7") 5,860 (12,920)
bucket 600 (23.6") 2,860 (9’-5") 2,600 (8’-6") 2,470 (8’-1") 6,070 (13,380)

2-7
2. SPECIFICATIONS

OVERALL DIMENSIONS OF BOOM

Item Type 3.72 m (12 ft-2 in) Boom

Length × Height × Width 3.86 ×1.43 × 0.40
m (ft-in)
L×H×W (12’-8" × 4’-8" × 1’-4")
Weight kg (lb) 520 (1,150)

OVERALL DIMENSIONS OF ARM + BUCKET

Type 1.80 m (5 ft-11 in) Arm+ 2.07 m (6 ft-9 in) Arm+

Item 0.28 m3 (0.37 cu•yd) Bucket 0.22 m3 (0.29 cu•yd) Bucket

Length × Height × Width 3.34× 0.70 × 0.75 3.61 × 0.71 × 0.65

m (ft-in)
L×H×W (10’-4" × 2’-4" × 2’-6") (11’-10" × 2’-4" × 2’-2")
Weight kg (lb) 520 (1,150) 530 (1,170)

OVERALL DIMENSIONS OF ARM

Item Type 1.80 m (5 ft-11 in) Arm 2.07 m (6 ft-9 in) Arm
Length × Height × Width 2.37 × 0.53 × 0.36 2.64 × 0.53 × 0.36
m (ft-in)
L×H×W (7’-1" × 1’-9" × 1’-2") (8’-8" × 1’-9" × 1’-2")
Weight kg (lb) 320 (705) 340 (750)

2-8
 2. SPECIFICATIONS

OVERALL DIMENSIONS OF BUCKET

Type Hoe bucket

Length × Height × Width 0.98 × 0.89 × 0.75 0.98 × 0.89 × 0.85
L×H×W m (ft-in) (3’-3"× 2’-11"× 2’-6" ) (3’-3" × 2’-11" × 2’-9" )
Weight kg (lbs) 200 (440) 220 (490)
Bucket capacity m3 (cu•yd) 0.28 (0.37) 0.35 (0.45)

OVERALL DIMENSIONS OF DOZER

Length × Height × Width 1.62 × 0.45 × 2.32

m (ft-in)
L×H×W (5’-4" × 1’-6" × 7’-7" )
Weight kg (lb) 350 (770)

2-9
2. SPECIFICATIONS

2.5 SPECIFICATIONS AND PERFORMANCE

2.5.1 SPEED AND CLIMBING CAPABILITY

Model & Shoe spec. E80MSR

Item
Swing speed 12.5 {12.5}
Travel speed km/h 3.1 / 5.5
Gradeability % (degree) 70 (35)

2.5.2 ENGINE

Engine model ISUZU 4JG1NABGA

Type Water-cooled 4-cycle direct injection type engine
Number of cylinders-Bore × Stroke 4-95.4 mm × 107 mm (3.76 in × 4.21 in)
Total displacement 3,059 cc (187 cu•in)
Rated output / Rotation speed 40.5 kW (55 PS) / 2,100 rpm
Maximum torque / Rotation speed 19.1 kgf•m (139 ft•lbs) / 1,800 rpm
Starter 24 V / 3.2 kW
Alternator 24 V / 30A

2.5.3 HYDRAULIC COMPONENTS

Hydraulic pump Variable displacement axial piston+gear pump

Hydraulic motor (Slewing) Axial piston motor
Hydraulic motor (Travel) 2-speed axial piston motor
Control valve 8-spool control valve
Cylinder
Double action cylinder
(Boom, Arm, Swing and Bucket)
Oil cooler Air-cooled type

2.5.4 WEIGHT

Unit : kg (lbs)
Model & Shoe spec.
Iron shoe Rubber shoe
Item
Fully equipped weight 8,000 (17,640) 7,930 (17,500)
Upper structure 3,810 (8,400) ←
Lower machinery
2,910 (6,420) 2,840 (6,260)
(With 450 mm (17.7 in) grouser shoe)
Attachment
[ Boom + 1.80 m (5 ft-11 in) Arm 1,070 (2,360) ←
+0.28 m3 (0.37 cu•yd) bucket ]

2-10
 2. SPECIFICATIONS

2.6 TYPE OF CRAWLER

Shoe width Overall width of crawler Ground pressure
Shape
mm (in) mm (in) kgf/cm2 (psi)
Rubber crawler

450 (17.7) 2,320 (7’7" ) 0.36 (5.1)

Iron crawler

450 (17.7) 2,320 (7’7" ) 0.32 (4.5)

Iron crawler

600 (23.6) 2,470 (8’1" ) 0.28 (4.0)

Use grouser shoes 600 mm (23.6 in) or 450 mm (17.7 in) on rough ground (areas covered with rocks and gravel).
If you drive or excavate with other shoes, this may cause shoe bending, shoe bolt looseness, and track assembly
(link, roller, etc.) damage.

2.7 TYPE OF BUCKET

Hoe bucket Heaped Struck Outer width mm (ft-in) Number Availability
W or W/O Weight
capacity m3 With side Without side of of face
side cutter kg (lbs)
m (cu•yd) (cu•yd)
3
cutter cutter tooth shovel
STD 0.22 200
750 (2’6" ) 680 (2’3" ) 4 Yes Yes
0.28 (0.37) (0.29) (440)

2-11
2. SPECIFICATIONS

2.8 COMBINATIONS OF ATTACHMENT

Bucket Applicable Arm
Heaped capacity Struck 1.8 m (5 ft-1 in) 2.07 m (6 ft-9 in)
Type
m3 (cu•yd) m3 (cu•yd) Arm (STD) Arm
0.11 (0.14) 0.09 (0.12)
0.14 (0.18) 0.12 (0.16)
0.18 (0.24) 0.14 (0.18)
Hoe bucket
0.22 (0.29) 0.18 (0.24)
STD
0.22 (0.29)
0.28 (0.37)
0.35 (0.46) 0.26 (0.34)
V-bucket 0.24 (0.31) 0.16 (0.21)
Slope finishing
0.26 (0.34) 0.14 (0.18)
bucket
Breaker — —
Nibbler — —

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

• Use the attachments recommended. Reinforcement of arm allows to use it as nibbler and breaker.
The trouble due to the use in the condition "Use not allowed" described in the above table is not included in our
responsibility

• When bucket marked by has been attached or nibbler has been attached on long arm, the specified stability
may not be obtained. So add weight 400 kg (880 lbs) in add-on type as required.

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

2-12
 2. SPECIFICATIONS

2.9 ENGINE SPECIFICATION

2.9.1 SPECIFICATIONS

Model E80MSR
Engine model ISUZU 4JG1 NABGA
Type Diesel, 4-cycle water -cooled, in-line, Direct injection
Number of cylinder-Bore × Stroke 4-95.4mm (3.76 in) ×107 mm (4.21 in)
Total displacement 3,059 (187 cu•in)
Compression ratio 18.6
Rated out put 55 PS (40.5 kW) at 2,100 rpm
Maximum torque 19.1 kgf•m (138 lbf•ft) at 1,800 rpm
High idling 2,310±25rpm
Low idling 1,000±25rpm
Injection valve opening pressure 185 kgf/cm2 (2,632 psi)
Thermostat action Start 82C°(180°F)/Full open 95C°(203°F)
Firing order 1-3-4-2
Compression pressure 30 kgf/cm (427 psi) at 200 rpm
2

Lubrication oil pressure —

Fuel injection timing 10±1° before top dead point
Valve clearance Open Close
0.4 mm (0.016" ) 24.5° before top 55.5° after bottom
Intake valve
Valve clearance in cold condition dead point dead point
0.4 mm (0.016" ) 54° before top 26° after top
Exhaust valve
in cold condition dead point dead point
Starter capacity 3.2kW × 24 V
Generator capacity (Alternator) 24 V×30 A
Ø450 (17.7 in) suction type seven fans
Cooling fan drive method
V-belt drive, pulley ratio Crank / Fan=1.12
Full level 10.6 L (2.8 gal)
Engine oil quantity
Low level sensor actuation Oil filter, etc
Dry weight 250 kg (550 lbs)
Fuel consumption ratio 176 g / PS•h
Allowable inclination Front / Rear and Right / Left : 35°
Dimension (L × W × H) 760 mm × 610 mm × 710 mm (29.9 in × 24.0 in × 28.0 in)
Rotating direction Counterclockwise seeing from flywheel side

2-13
2. SPECIFICATIONS

2.9.2 ENGINE CHARACTERISTIC CURVE (ISUZU 4JG1)

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

2-14
 3
3. ATTACHMENT DIMENSIONS
TABLE OF CONTENTS

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

3.1.1 BOOM DIMENSIONAL DRAWING ........................................................................... 3-3
3.1.2 BOOM MAINTENANCE STANDARD ....................................................................... 3-4
3.2 ARM ................................................................................................................................... 3-6
3.2.1 ARM DIMENSIONAL DRAWING .............................................................................. 3-6
3.2.2 ARM MAINTENANCE STANDARDS ........................................................................ 3-9
3.3 BUCKET ............................................................................................................................ 3-12
3.3.1 BUCKET DIMENSIONAL DRAWING ....................................................................... 3-12
3.3.2 BUCKET DIMENSIONAL TABLE ............................................................................. 3-12
3.3.3 DETAIL DIMENSIONAL DRAWING OF LUG SECTION ........................................... 3-13
3.3.4 DETAIL DIMENSIONAL DRAWING OF BOSS SECTION ........................................ 3-14
3.4 DOZER ............................................................................................................................... 3-15
3.4.1 DOZER DIMENSIONAL DRAWING .......................................................................... 3-15
3.4.2 DOZER MAINTENANCE STANDARD ...................................................................... 3-16
3.5 SWING ............................................................................................................................... 3-18
3.5.1 SWING BRACKET DIMENSION ............................................................................... 3-18
3.5.2 SWING MAINTENANCE STANDARD ...................................................................... 3-19

3-1
3. ATTACHMENT DIMENSIONS

3-2
 3. ATTACHMENT DIMENSIONS

3.1 BOOM
3.1.1 BOOM DIMENSIONAL DRAWING

Fig. 3-1 Boom dimensional drawing

3.7 m (12'2") Boom Unit : mm (ft-in)

Code Item Dimension
A Boom length 3,715 (12'-2")
B Boom foot width 360 (14.2")
C Boom end inner width 215 (8.46")
D Boom end outer width 315 (12.4")
E Height of boom cylinder rod pin 781 (30.7")
F Height of arm cylinder (head side) pin 1,085.5 (3'-7")
G Distance between pins of boss R1,858.5 (6'-1")
H Distance between of pins of bracket R1,706.5 (5'-7")
I Arm cylinder (head side) inner width 100 (3.94")
J Inner width of bracket on the arm cylinder (rod side) mounting section 100 (3.94")
d1 Boom foot pin dia. Ø 60 (2.36")
d2 Boom cylinder (rod side) pin dia. Ø 70 (2.76")
d3 Pin dia. of arm end Ø 60 (2.36")
d4 Arm cylinder (head side) pin dia. Ø 60 (2.36")

3-3
3. ATTACHMENT DIMENSIONS

3.1.2 BOOM MAINTENANCE STANDARD

(1) Clearance of pin and bushing on boom section

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

Unit : mm (in)
Standard dimensions Clearance
Limi Service
Pos. Item Pin dia. tol- Bushing i.d. Standard Remedy
Pin dia. value for limit
erance tolerance value
repair value
+0.10
0.09~0.19
Ø60 (+0.0039)
A Boom foot (0.0035~
(2.3622) +0.03
0.0075)
–0.06 (+0.0012)
Replace
Boom cylinder Ø75 (-0.0024) 2.0 2.5
B bushing or
(Head side) (2.9528) -0.09 +0.25 (0.08) (0.1)
0.11~0.34 pin
Boom cylinder Ø70 (-0.0035) (+0.0098)
C (0.0043~
(Rod side) (2.7559) +0.05
0.0134)
Arm cylinder Ø60 (+0.0020)
*D
(Head side) (2.3622)
* Marked pin; Ground pin

3-4
 3. ATTACHMENT DIMENSIONS

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

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

Unit : mm (in)
Clearance X adjusted by shim Length under
Basic size
(total of both sides) pin neck
Pos
Item Repair Service Remedy
. Standard Dimen-
Code Size reference limit No.
value sions
valve valve
Boom 0.5 (0.02) 1.0 1.5 470
A-A Boom foot L1 360 (14.2) PL 1
Swing bracket or less (0.04) (0.06) (18.50)
Boom cylinder Boom cylinder 95 (3.74) 0.6~1.0 2.0 2.5 448
B-B L2 PL 2 Adjust-
(Head side) Swing bracket 102 (4.02) (0.02~0.04) (0.08) (0.10) (17.64)
ed by
Boom cylinder Boom cylinder 95 (3.74) 0.6~2.0 3.0 4.0 204
C-C L3 PL 3 shim
(Rod side) Boom 100 (3.94) (0.02~0.08) (0.12) (0.16) (8.03)
Arm cylinder Arm cylinder 95 (3.74) 0.6~1.0 2.0 2.5 198
D-D L4 PL 4
(Head side) Boom 100 (3.94) (0.02~0.04) (0.08) (0.10) (7.80)
Provide * indicates a full length as it has no under neck.

3-5
3. ATTACHMENT DIMENSIONS

3.2 ARM
3.2.1 ARM DIMENSIONAL DRAWING

3-6
 3. ATTACHMENT DIMENSIONS

Unit : mm (ft-in)
Code Item Dimension Code Item Dimension
1,800 2,070 180
C Arm length L Arm top end ←
(5'-11") (6'-9") (7.09")
R498 210
A point M Boss width ←
Distance between pins R483 (19.6") (8.27")
D
of boss and bracket (19.0") R495 100
B point N Bracket inner width ←
(19.5") (3.94")
Ø65 90
D1 I.D of boss ← O Bracket inner width ←
(2.56") (3.54")
Ø60 436.5
D2 I.D of boss ← P Link dimension ←
(2.36") (17.2")
380±0.5
Ø75
D3 I.D of boss ← Q Link dimension (14.7"±0. ←
(2.95")
0197")
R1,512.
Distance between pins of boss and Height between pins of boss and 15
E 5 ← R ←
bracket center (0.591")
(4'-12")
Distance between of boss and R240 Ø50
F ← d1 Pin dia. ←
boss (9.45") (1.97")
Height between pins of boss and 406.7 Ø50
G ← d2 Pin dia. ←
bracket (16.01") (1.97")
308.5 Ø60
A point d3 Pin dia. ←
Height between pins of 195 (12.1") (2.36")
H
boss and bracket (7.68") 222.5 Ø60
B point d4 Pin dia. ←
(8.76") (2.36")
180 Ø50
J Arm top end width (with bushing) ← d5 Pin dia. ←
(7.09") (1.97")
162
K Boss width ←
(6.38")

3-7
3. ATTACHMENT DIMENSIONS

This page is blank for editing convenience.

3-8
 3. ATTACHMENT DIMENSIONS

3.2.2 ARM MAINTENANCE STANDARDS

(1) Clearance of pin and bushing

Fig. 3-4 Clearance of pin and bushing on arm section

Unit : mm (in)
Standard value Clearance
Bushing Limit Service
Pos. Item Pin dia. tol- Standard Remedy
Pin dia. i.d. value for limit
erance value
tolerance repair value
+0.11
-0.06 (+0.0043)
A Arm point
(-0.0024) +0.21
-0.09 +0.12 (+0.0083)
Bucket link (-0.0035) (+0.0047)
B
(Bucket side) +0.05 +0.11
Idler link (+0.0020) (+0.043)
C
(Arm connection) +0.21
Bucket link Ø50 (+0.0083)
D
(Idler link side) (1.9685)
+0.25 +0.11
Bucket cylinder (+0.0098) (+0.0043)
D' Replace
(Rod side) +0.05 +0.34 2.0 2.5
bushing or
(+0.0020) (+0.001) (0.08) (0.1)
pin
+0.06 +0.20 +0.06
Bucket cylinder (+0.0024) (+0.0079) (+0.0024)
*E
(Bottom side) -0.09 +0.00 +0.29
(-0.0035) (+0.0000) (+0.0114)
+0.20 +0.14
Connecting part (+0.0079) (+0.0055)
F
of arm and boom +0.08 +0.29
Ø60 (+0.0032) (+0.0114)
(2.3622) +0.25 +0.11
Arm cylinder (+0.0098) (+0.0043)
*G
(Rod side) +0.05 +0.34
(+0.0020) (+0.0134)
* Marked pin; Ground pin

3-9
3. ATTACHMENT DIMENSIONS

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

Fig. 3-5 Clearance in thrust direction

3-10
 3. ATTACHMENT DIMENSIONS

Unit : mm (in)
Clearance X adjusted by shim
Basic size Pin length
(total of both sides)
Pos. Item Repair Di- Remedy
Standard Service
Code Size reference No. men-
value limit valve
valve sions
Arm 180 (7.09) 1.0 (0.04) 2.0 2.5 PL 330
A-A Arm point L1
Bucket 182 (7.17) or less (0.08) (0.10) 1 (13.0)
Link side — PL 330
B-B Bucket link L2
Bucket — 2 (13.0)
0.6 (0.02) 1.0 1.5
Idler link Arm 180 (7.09)
or less (0.04) (0.06) PL 246
C-C (Arm connec- L3 —
Link side 3 (9.69)
tion)
Bucket link —
Bucket link PL 246
Idler link L4 — Adjust-
(Idler link side) 0.6~1.0 2.0 2.5 4 (9.69)
D-D side ed by
(0.02~0.04) (0.08) (0.10)
Bucket link Rod side 85 (3.35) — — shim
L4'
(Cylinder side) Link side —
Bucket Bottom side 85 (3.35)
0.6~2.0 3.0 4.0 PL 168
E-E cylinder L5
Arm 90 (3.54) (0.02~0.08) (0.12) (0.16) 5 (6.61)
(Arm side)
Arm and boom Arm 210 (8.27) 0.6 (0.02) 1.0 1.5 PL 328
F-F L6
connection Boom 215 (8.46) or less (0.04) (0.06) 6 (12.9)
Arm cylinder Rod side 95 (3.74) 0.6~2.0 3.0 4.0 PL 186
G-G L7
(Arm side) Arm 100 (3.94) (0.02~0.08) (0.12) (0.16) 7 (7.32)

3-11
3. ATTACHMENT DIMENSIONS

3.3 BUCKET
3.3.1 BUCKET DIMENSIONAL DRAWING
(1) Hoe bucket

Bushing out dia.

3.3.2 BUCKET DIMENSIONAL TABLE

Unit : mm (ft-in)
Type Hoe Bucket
0.28 m3
Capacity
(0.37 cu•yd)
A 290 (11.4")
B R1,037 (3'-5")
C 650 (25.6")
D 238 (9.37")
E 182 (7.17")
F 750 (29.5")
G 550 (21.7")
H 566 (22.3")
I 190 (7.48")
Io 188 (7.40")
d1 Ø65 (2.56")
d2 Ø50 (1.97")

3-12
 3. ATTACHMENT DIMENSIONS

3.3.3 DETAIL DIMENSIONAL DRAWING OF LUG SECTION

3.3.3.1 FOR HOE BUCKET

SECTION BB

BOSS
2418P26830

SECTION AA
DETAIL OF PLATE

PLATE

BOSS
2418P27140

SHIM (t = 1.0)

DETAIL I
Fig. 3-6 Dimension of lug section

Unit : mm (ft-in)
Boss outer dia.

Boss outer dia.

Spring pin dia.
Pin hole dia.

Bush length

Screw hole
Boss width
Boss width
Screw dia.
thickness
Lug plate

Capacity of
Hole dia.

Type of
bucket
P.C.D

bucket
m3 (cu•yd)

A B C D E F G H J M N
50 19 53 65 8 110 19 110 28 91
Hoe bucket 0.28 (0.37) M12
(1.97") (1.748") (2.09") (2.56") (0.315") (4.33") (0.748") (4.33") (1.10") (3.58")

3-13
3. ATTACHMENT DIMENSIONS

3.3.4 DETAIL DIMENSIONAL DRAWING OF BOSS SECTION

II

SECTION II

Fig. 3-7 Dimension of boss section

Unit : mm (ft-in)
Capacity
Type of
of bucket ØA ØB ØC ØD E F ØG H I
bucket
m3 (cu•yd)
75.5±0.2
Hoe 0.28 82.6 54 80.5 23 38 13 10 2.5
(2.972"
bucket (0.37) (3.25") (2.13") (3.17") (0.906") (1.50") (0.512") (0.394") (0.0984")
±0.0078")

3-14
 3. ATTACHMENT DIMENSIONS

3.4 DOZER
3.4.1 DOZER DIMENSIONAL DRAWING

Fig. 3-8 Dozer dimensional drawing

Unit : mm (ft-in)
DIMENSION
DOZER
For 450mm For 600mm (24")
Code Name
(17.7") shoes shoes
A Blade width 2,320 (7'-7") ←
A' Blade width — 2,494 (8'2")
B Blade height 474 (18.7") ←
C Distance from dozer attaching pin center to cutting edge end R1,568 (4'-11") ←
D Inner width of dozer attaching bracket 653 (25.7”) ←
E Width of dozer attaching bracket 60 (2.36") ←
Distance from dozer attaching pin center to attaching pin on
F R969 (38.1") ←
dozer cylinder head side
G Attaching bracket inner width on dozer cylinder head side 82 (3.23") ←
d1 Dozer attaching pin dia. Ø50 (1.97") ←
d2 Attaching pin dia. on dozer cylinder head side Ø70 (2.76") ←

3-15
3. ATTACHMENT DIMENSIONS

3.4.2 DOZER MAINTENANCE STANDARD

Fig. 3-9 Dozer maintenance standard

(1) Clearance of pin and bushing

Unit : mm (in)
Standard value Clearance
Pos. Item Pin dia. Bushing i.d. Limit value Service Remedy
Pin dia. Clearance
tolerance tolerance for repair limit value
Dozer cylinder -0.06 +0.25 +0.11
A
(Rod side) Ø70 (-0.0024) (+0.0098) (+0.0043)
Dozer cylinder (2.7559) -0.12 +0.05 +0.37
B 1.2 Replace
(Head side) (-0.0047) (+0.0020) (+0.0015) 2.0
(0.05) bushing or
-0.06 +0.19 +0.12 (0.08)
or more pin
Ø50 (-0.0024) (+0.0075) (+0.0047)
C-C Dozer foot
(1.9685) -0.09 +0.06 +0.28
(-0.0035) (+0.0024) (+0.0110)

3-16
 3. ATTACHMENT DIMENSIONS

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

Unit : mm (in)
Clearance X adjusted by shim (total of
Basic size Pin length
both sides)
Pos. Item Repair ref- Di- Remedy
Standard Service limit
Code Size erence No. men-
value valve
valve sions
Dozer cylinder Rod side 80 (3.15) PL 167
A L1
(Rod side) Lower frame 82 (3.23) 1 (6.57)
2.0
Dozer cylinder Head side 80 (3.15) 1.0~2.0 3.0 PL 167 Adjusted
B L2 (0.08)
(Head side) Dozer 82 (3.23) (0.04~0.08) (0.12) 2 (6.57) by shim
or more
Dozer 60 (2.36) PL 118
C Dozer foot L3
Lower frame 63 (2.48) 3 (4.65)

3-17
3. ATTACHMENT DIMENSIONS

3.5 SWING
3.5.1 SWING BRACKET DIMENSION

Fig. 3-10 Swing bracket dimension

Unit : mm (in)
No. NAME DIMENTION
A Distance between swing center pin and boom foot pin 100 (3.94")
B Distance between boom foot pin and boom cylinder pin 365 (14.37")
C Distance between boom foot pin and boom cylinder pin 365 (14.37")
D Distance between swing center pin and swing cylinder pin R326 (12.83")
E Distance between swing center pin and swing cylinder pin 295 (11.61")
F Swing center inner width 378 (14.88")
F1 Swing center inner width 90.5 (3.56")
F2 Swing center inner width 84.5 (3.33")
G Boom foot inner width 360 (14.17")
H Inner width of boom cylinder attaching section 102 (4.02")
J Inner width of swing cylinder attaching section 83 (3.27")
d1 Swing center pin dia. Ø95 (3.74")
d2 Boom foot pin dia. Ø60 (2.36")
d3 Pin dia. of boom cylinder attaching section Ø75 (2.95")
d4 Pin dia. of swing cylinder attaching section Ø70 (2.76")

3-18
 3. ATTACHMENT DIMENSIONS

3.5.2 SWING MAINTENANCE STANDARD

(1) Clearance of pin and bushing

Unit : mm (in)
Standard value Clearance
Pos. Item Pin dia. Bushing i.d. Limit value Service Remedy
Pin dia. Clearance
tolerance tolerance for repair limit value
Swing cylinder 0.26–
A +0.150
(Rod side) Ø70 0.06
(+0.0059)
Swing cylinder (2.7559) -0.06 (0.010–
B 0 Replace
(Head side) (-0.0024) 0.002) 1.5 2.0
bushing or
Swing center -0.09 +0.80 0.17– (0.06) (0.08)
C pin
(Upper) Ø95 (-0.0035) (+0.0031) 0.08
Swing center (3.7402) +0.020 (0.007–
D
(Lower) (+0.0008) 0.003)

3-19
3. ATTACHMENT DIMENSIONS

(2) Clearance in thrust direction

Fig. 3-11 Clearance in thrust direction

3-20
 3. ATTACHMENT DIMENSIONS

Unit : mm (in)
Clearance X adjusted by shim
Basic size Pin length
(Total of both sides)
Pos. Item Repair ref- Di- Remedy
Standard Service limit
Code Size erence No. men-
value valve
valve sions
Rod side 80 (3.15)
Swing cylinder 0.5~0.9 2.0 2.5 PL 200
A-A Swing L1 Shim
(Rod side) 83 (3.27) (0.02~0.04) (0.08) (0.10) 1 (7.87)
bracket Adjust-
Swing cylinder Head side 80 (3.15) 1.0~0.5 PL 155 ment
B-B L2
(Head side) Upper frame 82 (3.23) (0.04~0.02) 2 (6.10)
Upper frame
83 (3.27)
Swing center bracket PL 157 Replace
C-C L3
(Upper) Swing 1.0 1.5 3 (6.18) washer
90.5 (3.56)
bracket 0.5 (0.02) (0.04) (0.06)
Upper frame 82 or less
Shim
Swing center bracket (3.23) 150
D-D L4 PL4 Adjust-
(Lower) Swing 84.5 (5.91)
ment
bracket (3.33)

3-21
3. ATTACHMENT DIMENSIONS

[MEMO]

3-22
 11. TOOLS
11
TABLE OF CONTENTS

11.1 TORQUE SPECIFICATIONS FOR CAPSCREWS & NUTS .............................................. 11-3

11.1.1 Metric Coarse Thread Standard Tightening Torque Values.
Make Certainto tighten all Capscrews & Nuts to proper torque values ...................... 11-3
11.1.2 Metric Fine Thread Standard Tightening Torque values
Make certainto tighten all Capscrews & Nuts to proper torque values ....................... 11-4
11.2 SCREW AND TOOL SIZES ............................................................................................... 11-5
11.2.1 Capscrew .................................................................................................................. 11-5
11.2.2 Capscrew (Socket bolt) .............................................................................................. 11-5
11.2.3 Setscrew ................................................................................................................... 11-6
11.3 TORQUE SPECIFICATIONS FOR JOINTS AND HOSES ................................................. 11-6
11.3.1 JOINTS FOR PIPING (O-RING SEALING TYPE) ...................................................... 11-6
11.3.2 HYDRAULIC HOSE (30 FLARE TYPE) ................................................................... 11-6
11.4 TORQUE SPECIFICATIONS FOR SLEEVE TYPE TUBE FITTINGS ................................ 11-7
11.4.1 SLEEVE TYPE TUBE FITTINGS ............................................................................... 11-7
11.4.2 PART NO. .................................................................................................................. 11-7
11.5 PLUGS ............................................................................................................................... 11-8
11.5.1 Plug for hydraulic pipe joint ........................................................................................ 11-8
11.5.2 Plug for hydraulic equipment ..................................................................................... 11-9
11.6 SPECIAL SPANNERS FOR TUBES .................................................................................. 11-10
11.7 SPECIAL TOOLS ............................................................................................................... 11-11
11.8 APPLICATION OF SCREW LOCKING AND SEALING COMPOUNDS ............................. 11-12
11.9 SUCTION STOPPER ......................................................................................................... 11-13
11.10 COUNTERWEIGHT LIFTING JIG ..................................................................................... 11-14
11.11 UPPER FRAME LIFTING JIG ............................................................................................. 11-15
11.12 ENGINE MOUNTING PEDESTAL ...................................................................................... 11-16
11.13 TRACK SPRING SET JIG ................................................................................................... 11-16

11-1
11. TOOLS

11-2
 11. TOOLS

11.1 TORQUE SPECIFICATIONS FOR CAPSCREWS & NUTS

The following Torque Specifications are provided for use when actual torque value of a fastener is not known. Check
the capscrews and nuts for their looseness and dropping off before the start of daily work and at the periodical main-
tenance. Retighten the loosened ones, and install new ones for the dropped off. For the new machine, the check
and retightening of them must be carried out at first 50 hours operation. For the replacement of them, make sure to
use the same size of manufacturer's genuine parts.
Refer to the table below for the tightening and retightening of capscrews.
• The table below is not applicable for the capscrews to fix the cover, etc., made of plastic. For the tightening
torque for such capscrews, consult with an authorized our Distributor. Over-tightening may cause damages on
the parts to be fixed.
• In case that the tightening torque is specified in the manual, use such torque values regardless to the table be-
low.
• Numerical indication on the capscrew head shows the classification for strength (e.g., 7 = 7 T). No indication is
provided for smaller size of capscrews, M 5 or less.

11.1.1 Metric Coarse Thread Standard Tightening Torque Values. Make Certain to tighten all Capscrews
& Nuts to proper torque values.

Torque value Unit : N•m (lbf•ft)

Classification 4.8T 7T 10.9T
Nominal size No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication
4.4±0.5 3.7±0.4 9.6±1.0 8.1±0.8 17.4±1.8 14.7±1.5
M6 P=1
(3.2±0.4) (2.7±0.3) (7.1±0.7) (6.0±0.6) (12.8±1.3) (10.8±1.1)
10.7±1.1 9.0±0.9 23.5±2.0 19.6±2.0 42.2±3.9 35.3±3.9
M8 P=1.25
(7.9±0.8) (6.6±0.7) (17.3±1.5) (14.5±1.5) (31.1±2.9) (26.0±2.9)
21.6±2.0 17.9±1.8 46.1±4.9 39.2±3.9 83.4±8.8 70.6±6.9
M10 P=1.5
(15.9±1.4) (13.2±1.3) (34.0±3.6) (28.9±2.9) (61.5±6.5) (52.1±5.1)
36.3±3.9 31.4±2.9 79.4±7.8 66.7±6.9 143±15 121±12
M12 P=1.75
(26.8±2.9) (23.2±2.1) (58.6±5.8) (49.2±5.1) (105±11) (89.2±8.9)
57.9±5.9 49.0±4.9 126±13 106±10 226±20 191±19
M14 P=2
(42.7±4.4) (36.1±3.6) (92.9±9.6) (78.2±7.4) (167±15) (141±14)
88.3±8.8 74.5±6.9 191±20 161±16 343±39 284±29
M16 P=2
(65.1±6.5) (55.0±5.1) (141±15) (119±12) (253±29) (209±21)
122±12 103±10 265±29 226±20 481±49 402±39
M18 P=2.5
(90.0±8.9) (75.8±7.2) (195±21) (167±15) (355±36) (297±29)
172±17 144±14 373±39 314±29 667±69 559±59
M20 P=2.5
(127±13) (106±10) (275±29) (232±21) (492±51) (412±44)
226±20 192±20 500±49 422±39 902±88 755±78
M22 P=2.5
(167±15) (142±15) (369±36) (311±29) (665±65) (557±58)
294±29 235±29 637±69 520±49 1160±118 941±98
M24 P=3
(217±21) (173±21) (470±51) (383±36) (856±87) (694±72)
431±39 353±39 941±98 765±78 1700±167 1370±137
M27 P=3
(318±29) (260±29) (694±72) (564±58) (1250±123) (1010±101)

11-3
11. TOOLS

Torque value Unit : N•m (lbf•ft)

Classification 4.8T 7T 10.9T
Nominal size No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication
588±59 490±49 1285±127 1079±108 2300±235 1940±196
M30 P=3.5
(434±44) (361±36) (948±94) (796±80) (1700±173) (1430±145)
794±78 667±69 1726±177 1451±147 3110±314 2610±265
M33 P=3.5
(586±58) (492±51) (1270±131) (1070±108) (2290±232) (1930±195)
1030±98 863±88 2226±226 1863±186 4010±402 3360±333
M36 P=4
(760±72) (637±65) (1640±167) (1370±137) (2960±297) (2480±246)

11.1.2 Metric Fine Thread Standard Tightening Torque values. Make certain to tighten all Capscrews &
Nuts to proper torque values.

Torque value Unit : N•m (lbf•ft)

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

11-4
 11. TOOLS

11.2 SCREW AND TOOL SIZES

11.2.1 Capscrew

Nominal B mm Nominal B mm
screw size screw size
Tool size Tool size
(d) (d)
M6 10 (M33) 50
M8 13 M36 55 d
M10 17 M42 65
M12 19 M45 70
(M14) 22 M48 75
M16 24 M56 85 B
(M18) 27 (M60) 90
M20 30 M64 95
(M22) 32 (M68) 100
M24 36 M72 105
(M27) 41 M76 110
M30 46 M80 115

Nominal B mm Nominal B mm
screw size screw size
Tool Tool d
Unified Unified
size size
(screw threads) (screw threads)
1/4–20UNC 11 3/4–10UNC 29
5/16–18UNC 13 7/8–9UNC 33
B
3/8–16UNC 14 1–8UNC 38
7/16–14UNC 16 1 1/8–7UNC 43
1/2–13UNC 19 1 1/4–7UNC 48
5/8–11UNC 24 1 1/2–6UNC 57

11.2.2 Capscrew (Socket bolt)

Nominal B mm Nominal B mm
screw size screw size d
Tool size Tool size
(d) (d)
M6 5 M20 17
M8 6 M24 19
M10 8 M30 22 B
M12 10 M36 27
M14 12 M42 32
M16 14 M48 36
(M18) 14

11-5
11. TOOLS

11.2.3 Setscrew

Nominal screw size B mm

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

11.3 TORQUE SPECIFICATIONS FOR JOINTS AND HOSES

11.3.1 JOINTS FOR PIPING (O-RING SEALING TYPE)

Nominal screw size Spanner size Tightening torque

(PF) (mm) N•m (lbf•ft)
1/8 14 17±2 (12±1)
1/4 19 36±2 (27±1)
3/8 22 74±5 (54±4)
1/2 27 108±9.8 (80±7)
3/4 36 162±9.8 (119±7)
1 41 255±9.8 (188±7)

11.3.2 HYDRAULIC HOSE (30° FLARE TYPE)

Nominal screw size Spanner size Tightening torque

(PF) (mm) N•m (lbf•ft)
1/8 17 15±2.0 (11±1)
1/4 19 29±4.9 (22±4)
3/8 22 49±4.9 (36±4)
1/2 27 78±4.9 (58±4)
3/4 36 118±9.8 (87±7)
1 41 137±15 (101±11)

NOTE : The application of the tightening torque is subject to a dry condition.

11-6
 11. TOOLS

11.4 TORQUE SPECIFICATIONS FOR SLEEVE TYPE TUBE FITTINGS

11.4.1 SLEEVE TYPE TUBE FITTINGS

Tube size Spanner size Tightening Torque

OD × Thickness (mm) (mm) N•m (lbf•ft)
10 × 1.5 19 44±4.9 (33±4)
15 × 2.0 27 147±20 (110±14)
18 × 2.5 32 177±20 (130±14)
22 × 3.0 36 216±20 (160±14)
28 × 4.0 41 275±29 (200±22)
35 × 5.0 55 441±44 (330±33)

11.4.2 PART NO.

SLEEVE NUT
B

d
d

Tube size Tube size Opposing flats(HEX)

ød ød B
6 6 14
8 8 17
10 10 19
12 12 22
15 15 27
18 18 32
22 22 36
28 28 41
32 32 50
35 35 55
38 38 60

11-7
11. TOOLS

11.5 PLUGS
11.5.1 Plug for hydraulic pipe joint
(1) Cap nut (Joint plug)

Applicable Opposing flats

A
tube T screw
O. D : A H1 H
6 M12 X 1.5 14 14
8 M14 X 1.5 17 17
10 M16 X 1.5 17 19
12 M18 X 1.5 19 22
H1 T screw H 15 M22 X 1.5 24 27
18 M26 X 1.5 27 32
22 M30 X 1.5 32 36
28 M36 X 1.5 38 41

(2) Plug (Tube plug)

Applicable
tube
O. D : A
A

6
8
10
12
Sleeve Nut
Type 15
joint body 18
22
28

(3) Nut

Applicable
D Screw
A

tube D screw Opposing flats

O. D : A
6 M12 X 1.5 14
8 M14 X 1.5 17
10 M16 X 1.5 19
12 M18 X 1.5 22
15 M22 X 1.5 27
18 M26 X 1.5 32
22 M30 X 1.5 36
28 M36 X 1.5 41
32 M42 X 1.5 50
35 M45 X 1.5 55
38 M48 X 1.5 60

11-8
 11. TOOLS

11.5.2 Plug for hydraulic equipment

(1) PF screw

B
O-ring
PF screw B mm Nominal O ring
PF1/4 19 1B P11
PF3/8 22 1B P14
PF1/2 27 1B P18
PF3/4 36 1B P24
PF screw PF1 41 1B P29

(2) PT screw

B
PT screw
PT screw B mm
PT1/8 5
PT1/4 6
PT3/8 8
PT1/2 10
PT3/4 14
PT1 17
PT1 1/4 22
PT1 1/2 22

(3) Plug for (F) flare hose

PF screw

PF screw B mm
PF1/4 14
60

PF3/8 17
PF1/2 22
PF3/4 27
Opposing flats B PF1 36

PF screw E mm F mm
PF PF1/4 14 19
60

screw
PF3/8 17 22
PF1/2 23 27
PF3/4 27 36
Opposing PF1 36 41
Opposing
flats F PF1 1/4 40 50
flats E

11-9
11. TOOLS

11.6 SPECIAL SPANNERS FOR TUBES

Applicable tube diameter HEX Dimensions of a special spanner
mm (in) mm mm (in)

70(2.76)

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

40(1.57) 12.7 (0.500 )

70(2.76)
42(1.65)

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

12.7 (0.500 )
22(0.866)

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

23 22
22 (0.866) 36 (0.906) (0.866)

12.7 (0.500 )

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

12.7 (0.500 )

80(3.15) 109(4.29)
15.5(0.610)

28 (1.10) 46 31 PA R T- N o . 35
(1.22) (1.38)

HEX46 19.05 (0.750 )

80(3.15) 109(4.29)
16.5(0.650)

33 35
32 (1.26) 50 (1.30) PA R T- N o .
(1.38)

HEX50 19.05 (0.750 )

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

41 45
35 (1.38) 55 (1.61) PA R T- N o .
(1.77)

HEX55 20 (0.787)

11-10
 11. TOOLS

11.7 SPECIAL TOOLS

No. Tools name Shape Use

B
R
Allen wrench C

L1
1 Nominal Pump suction

(0.394")
10
B : 10
L
Commercial tool length (L1) - cut length = Required length
40 (1.57 ) - 10 (0.39 ) = 30 (1.18 )

B
R
Allen wrench C
L1

2 Nominal Pump install

(0.433")
11

B : 14
L
Commercial tool length (L1) - cut length = Required length
56 (2.20 ) - 11 (0.43 ) = 45 (1.77 )

Cut

Spanner Nominal 32 (1.25") Slewing motor

3
S : 32 A, B port
S
D

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

73 (2.87 ) - 13 (0.51 ) = 60 (2.36 )

M10 X 22 Additional
threading for For slinging
4 Plug PF 3/4 M10 eye bolt
the slewing motor

PF 3/4 O-ring

Eye bolt For slinging

[15] (0.59)
18 (0.71)

5 M10 X 18 the slewing motor

[M8 X 15) & Flare hose
M10
[M8]

M8 Eye bolt
Plug
(Nominal tube dia.
6 22) Reference nut Flare hose
Reference Eye bolt
M8 X 18
Nut Additional threading
for M8 Eye bolt

4.4 (0.17")
Torx driver
(with tamper proof) For instrument R.H
7 Nose shape
T25 cover
(for M5)

11-11
11. TOOLS

11.8 APPLICATION OF SCREW LOCKING AND SEALING COMPOUNDS

(1) For general

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

(2) For specific location

No. Use Manufacturer Name Equivalent Applicable

(Manufacture : Loctite)
# 1901 Anti-seizure Cylinder
Three-bond # 1215 gray # 5699 Slewing motor
Sealing compound & adhesive

# 1211 white # 5301J Slewing motor

# 1303B # 211 Main pump
(Manufacture : Three-bond)
Loctite # 222 # 1344N Main pump
1
# 277 # 1307N Pilot valve
(Manufacture : Three-bond )
Loctite Parmatex 98D # 1121 Hydraulic oil tank : Hose
Sumitomo Chemi- Locktite # 515
Syano Bond P0-1 For slewing bearing : Seal
cal Co.,Lad. Three-bond # 1215
Showa-shell petro-
Shell Albania EP2 New Molyknock Grease 2 Swing bearing grease bath
leum

11-12
 11. TOOLS

11.9 SUCTION STOPPER

11.9.1 COMPONENTS

NO. NAME Q’ty

Suction Stopper Assy
1 Rod 1
2 Nut 1
3 Cover 1
4 O-Ring 1

Fig. 11-1 Components of suction stopper

11.9.2 DIMENSION

ROD COVER

Fig. 11-2 Dimension of suction stopper

11-13
11. TOOLS

11.10 COUNTERWEIGHT LIFTING JIG

Bracket for left side Bracket for right side

Material : Mild steel

Fig. 11-3 Counterweight lifting bracket

11-14
 11. TOOLS

11.11 UPPER FRAME LIFTING JIG

Fig. 11-4 Upper frame lifting jig

11-15
11. TOOLS

11.12 ENGINE MOUNTING PEDESTAL

547 (21.54 )
(0.827 ) 21 505 (19.88 ) 21 (0.827 )

(5.12 )
130
(11.81 )
300
(0.827 )

240(9.45 ) 265 (10.43 )

21

(11.02 )
280
21 (11.02 )
280

8
R15 2 )

(5.51 )
(6.2

140
200 (7.87 )
(0.827 )

250 240 (9.45 ) 265 (10.43 )

(9.84 ) 325 (12.8 )
(11.81 )
300

(5.12 )
130

505 (19.88 )
(0.827 ) 21 21 (0.827 )
547 (21.54 )
Material : Plywood or wooden plate

Fig. 11-5 Engine stand

11.13 TRACK SPRING SET JIG

Retainer nut

Retainer plate

Stand

Hydraulic jack

Base

Fig. 11-6 Track spring set jig

11-16
 12. STANDARD MAINTENANCE
TIME SCHEDULE
12
TABLE OF CONTENTS

12.1 STANDARD MAINTENANCE TIME SCHEDULE FOR EXCAVATOR ................................ 12-4

12.2 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF ENGINE ............... 12-15

12-1
12. STANDARD MAINTENANCE TIME SCHEDULE

12-2
 12. STANDARD MAINTENANCE TIME SCHEDULE

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

12-3
12. STANDARD MAINTENANCE TIME SCHEDULE

12.1 STANDARD MAINTENANCE TIME SCHEDULE FOR EXCAVATOR

(1) Standard maintenance time schedule
1) Units of working time : 6 minutes = 0.1 hour
2) Calculating method of standard maintenance time :
Maintenance time = working time × the number of workers
(working time = Maintenance time / the number of workers)
3) When more than one operation is going on :
a. Add each standard service time.
b. A pure time (readily started) is given except covers easily removed by hand.
c. Assy works include the following works marked with black dot • .
4) O/H : Basically the installing and removing operation are included.
5) Abbreviation in the table.

A/C : Air conditioner F hose : Flexible hose

ASSY : Assembly O/H : Over haul
ATT : Attachment SOL : Solenoid
BRG : Bearing SW : Switch
C/V : Control valve V : Valve
Cyl : Cylinder
E/G : Engine

(2) Classification of working code

No. Group Remarks

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

(3) Condition for standard service time of the engine

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

Work to Unit:
Group No. Location Unit Remark
be done hour
00 Bucket relation 2. Reference for bucket
01 Bucket ASSY Detach/attach 1 pc. Include adjustment 0.5
02 • Bucket attaching and detaching posi- Preparation 1 pc. 0.1
01 Attachment

tion
03 • Bucket attaching pin Detach/attach 1 Include omission of pin. 0.1
04 • Bucket drive pin Detach/attach 1 0.1
05 • Bucket sling and movement Preparation 1 pc. 0.1
06 Bucket (Single) O/H 1 pc. Not include attaching and 2.0
detaching.
07 • Tooth Replace 1 pc. 0.5

12-4
 12. STANDARD MAINTENANCE TIME SCHEDULE

Work to Unit:
Group No. Location Unit Remark
be done hour
08 • Side cutter Replace 1 pc. 1.0
09 • Bushing Replace 1 pc. 0.5
10 Arm relation 3. Reference for arm
11 Arm ASSY Detach/attach 1 pc. 1.0
12 • Bucket cylinder attaching and detach- Preparation 1 pc. 0.3
ing position and piping
13 • Bucket cylinder rod pin Detach/attach 1 pc. Include omission of pin. 0.1
14 • Bucket cylinder head pin Detach/attach 1 pc. Include omission of pin. 0.1
15 • Bucket cylinder assy Detach/attach 1 pc. 0.1
16 • Arm cylinder rod pin Detach/attach 1 pc. Include omission of pin. 0.1
17 • Boom top pin Detach/attach 1 pc. 0.1
18 • Arm sling and movement Detach/attach 1 pc. 0.1
30 Boom relation 4. Reference for boom
31 Boom ASSY Detach/attach 1 pc. 1.0
32 • Boom attaching and detaching posi- Preparation 1 pc. 0.1
tion
33 • Boom cylinder temporary slinging Preparation 1 pc. 0.1
34 • Boom cylinder rod pin Detach/attach 1 Include omission of pin. 0.1
35 • Boom cylinder piping Detach/attach 1 pc. 0.1
36 • Arm & bucket piping Detach/attach 1 pc. 0.2
37 • Boom assy temporary slinging Detach/attach 1 pc. 0.1
38 • Boom foot pin Detach/attach 1 Include omission of pin 0.2
01 Attachment

39 • Boom assy slinging Detach/attach 1 pc. 0.1

40 Arm cylinder attaching and detaching Detach/attach 1 pc. 0.3
41 • Arm cylinder piping Detach/attach 1 pc. 0.1
42 • Arm cylinder head pin Detach/attach 1 Include omission of pin 0.1
43 • Arm cylinder slinging Detach/attach 1 pc. 0.1
50 Boom cylinder attaching and detaching Detach/attach 1 pc. 0.3
51 • Boom cylinder piping Detach/attach 1 0.1
52 • Boom cylinder head pin Detach/attach 1 pc. 0.1
53 • Boom cylinder slinging Detach/attach 1 0.1
60 Bucket cylinder O/H 1 3.0
61 • Pin bushing Preparation 1 Include seal 1.0
70 Arm cylinder O/H 1 3.0
71 • Pin bushing Preparation 1 set Include seal 1.0
75 Boom cylinder O/H 1 3.0
76 • Pin bushing Preparation 1 Include seal 1.0
80 Swing portion 5. Reference for swing
81 Swing bracket assy Detach/attach 1 pc. After removing boom 0.4
82 • Swing cylinder rod pin Detach/attach 1 pc. 0.1
83 • Swing bracket slinging Detach/attach 1 pc. 0.1
84 • Swing center pin Detach/attach 1 0.1
85 Swing cylinder attaching and detaching Detach/attach 1 pc. After removing swing brack- 0.3
et
86 • Swing cylinder hose Detach/attach 2 0.2
87 • Swing cylinder head pin Detach/attach 1 0.1

12-5
12. STANDARD MAINTENANCE TIME SCHEDULE

Work to Unit:
Group No. Location Unit Remark
be done hour
88 Swing cylinder O/H 1 2.5
89 • Pin bushing Replace 1 Include seal 1.0
Others necessary works Detach/attach 1 set Panel assy (3) 0.1
01 Attachment

90 Dozer portion 6. Reference for dozer

91 Dozer assy Detach/attach 1 pc. 0.6
92 • Dozer cylinder hose Detach/attach 2 0.2
93 • Dozer cylinder rod pin Detach/attach 1 0.1
94 • Dozer attaching pin Detach/attach 2 0.2
95 Dozer cylinder O/H 1 pc. 2.5
96 • Pin bushing Replace 1 set Include seal 1.0
10 Cab relation 1. Reference for cable
11 Cab ASSY Detach/attach 1 pc. 1.5
12 • Front lower glass, floor mat Detach/attach 1 pc. 0.1
each
13 • Cab mounting bolts, nuts (front) Detach/attach 4 places 0.2
14 • Grille on seat rear side Detach/attach 1 pc. 0.2
15 • Grille on seat under side Detach/attach 1 pc. 0.1
16 • Air-con duct Detach/attach 2 0.2
17 • Coupler for cluster gauge (electric) Detach/attach 1 0.1
18 • Cab mounting bolts, nuts (rear side) Detach/attach 5 places 0.2
19 • Cab slinging Detach/attach 3 places 0.4
20 Guard relation 6. Reference for guard
21 Cover (1) Detach/attach 1 pc. 0.2
22 • Cover (1) slinging Detach/attach 1 pc. 0.1
23 Panel assy (2) Detach/attach 1 pc. 0.1
02 Cab & Guard

24 Cover assy (6) Detach/attach 1 pc. 0.1

25 Guard assy (40) Detach/attach 1 pc. 0.1
26 Guard assy (41) Detach/attach 1 pc. 0.1
27 Bonnet assy (65) Detach/attach 1 pc. 0.2
28 • Bonnet assy slinging Detach/attach 1 pc. 0.1
29 Cover (3) Detach/attach 1 pc. 0.1
30 Bracket (44) Detach/attach 1 pc. 0.1
31 Guard assy (7) Detach/attach 1 pc. 0.1
32 Cover assy (60) Detach/attach 1 pc. 0.1
33 Guard assy (11) Detach/attach 1 pc. 0.2
34 Guard assy (9) Detach/attach 1 pc. 0.1
35 Guard assy (8) Detach/attach 1 pc. 0.2
36 • Guard assy (8) slinging Detach/attach 1 pc. 0.1
40 Cover relation 7. Reference for cover
41 Cover (1) Detach/attach 1pc. 0.1
42 Cover (2) Detach/attach 1pc. 0.1
43 Cover (3) Detach/attach 1pc. 0.1
44 Cover (4) Detach/attach 1pc. 0.1
45 Cover (5) Detach/attach 1pc. 0.1
46 Cover (6) Detach/attach 1pc. 0.1

12-6
 12. STANDARD MAINTENANCE TIME SCHEDULE

Work to Unit:
Group No. Location Unit Remark
be done hour
50 Counter weight relation 5. Reference for counter
02 Cab & Guard

weight
51 Counter weight ASSY Detach/attach 1 pc. 0.4
52 • Counter weight lifting jig Detach/attach 1 set 0.1
53 • Counter weight temporary slinging Preparation 1 pc. 0.1
54 • Counter weight mounting bolt Detach/attach 1 pc. 0.1
55 • Counter weight slinging Detach/attach 1 pc. 0.1

00 Control relation

01 E/G control ASSY Detach/attach 1 pc. Include adjustment. 0.2

02 • Emergency stop knob (control) cable Replace 1 pc. 0.1
10 Intake relation 8. Reference for Air cleaner
11 Air cleaner ASSY Detach/attach 1 pc. 0.4
12 • Hose (2) Detach/attach 1 0.1
13 • Hose (1) Detach/attach 1 0.1
14 • Element Replace 1 0.1
20 Exhaust relation 9. Reference for muffler
21 Muffler ASSY Detach/attach 1 pc. 0.4
22 • U bolt Detach/attach 1 pc. 0.1
23 • Clamp ASSY Detach/attach 1 pc. 0.1
24 • Gasket Replace 1 pc. 0.1
30 Radiator relation 13. Reference for Radiator
31 Radiator ASSY Detach/attach 1 pc. 3.5
32 • Coolant (LLC) Replace 1 pc. 0.2
33 • • Concentration of coolant Measuring 1 pc. 0.2
03 Upper frame

34 • A/C condenser Detach/attach 1 pc. 0.2

35 • Stay Detach/attach 1 pc. 0.1
36 • Bracket Detach/attach 1 0.2
37 • Sub tank Detach/attach 1 pc. 0.1
38 • Fan guard Detach/attach 1 pc. 0.2
39 • Water hose (radiator→E/G) Detach/attach 1 0.2
40 • Radiator mounting bolts removing Detach/attach 1 pc. 0.2
41 • Under cover Detach/attach 1 pc. 0.1
42 • Hydraulic oil tank • suction stopper Detach/attach 1 pc. 0.2
43 • Hydraulic oil piping coupling Detach/attach 1 pc. 0.8
44 • Hydraulic oil piping Detach/attach 1 pc. 0.2
45 • Water hose (E/G→radiator) Detach/attach 1 0.2
46 • Radiator lifting or hoisting Detach/attach 1 pc. 0.2
50 Fuel relation 10. Reference for fuel tank
51 Fuel tank ASSY Detach/attach 1 pc. 1.5
52 • Fuel Replace 1 pc. 0.2
53 • Hose (water separator side) Detach/attach 2 0.1
54 • Water separator Detach/attach 1 pc. 0.1
55 • Tube (tank side) Detach/attach 1 0.1
56 • Connecting bracket between tanks Detach/attach 1 0.1
57 • Fuel tank installing bolts Detach/attach 1 pc. 0.2
58 • Tank slinging Detach/attach 1 pc. 0.2

12-7
12. STANDARD MAINTENANCE TIME SCHEDULE

Work to Unit:
Group No. Location Unit Remark
be done hour
Other necessary works Detach/attach 1 pc. Removing and installing 0.3
guard
Removing and installing bat- 0.2
tery
60 Hydraulic oil tank relation 11. Reference for hydraulic
oil tank
61 Hydraulic oil tank ASSY Detach/attach 1 pc. After removing fuel tank ; 3.5
62 • Hydraulic oil tank attaching and de- Detach/attach 1 pc. 0.1
taching position
63 • Return oil pipe on tank upper cover Detach/attach 1 pc. 0.4
64 • Hose on upper cover Detach/attach 1 pc. 0.2
65 • Cover Detach/attach 1 pc. 0.2
66 • Hydraulic oil Replace 1 pc. 0.4
67 • Other necessary works Detach/attach 1 pc. Multi C/V attaching bracket 0.2
movement
Multi pilot hose removing 0.4
and attaching
68 • Pilot drain hose Detach/attach 1 pc. 0.2
69 • Pump suction hose Detach/attach 1 0.4
70 • Mounting bolt Detach/attach 1 pc. 0.2
71 • Hydraulic oil tank slinging Detach/attach 1 pc. 0.2
72 • Return filter Replace 1 0.2
03 Upper frame

73 • Suction filter Cleaning 1 0.2

80 Pump relation After removing counter
weight
81 Pump ASSY Detach/attach 1 pc. 2.3
82 • Hydraulic oil tank cover Detach/attach 1 pc. 0.3
83 • Strainer & stopper Detach/attach 1 pc. 0.3
84 • Piping Detach/attach 1 set 0.8
85 • Guard Detach/attach 2 pc. 0.4
86 • Pump slinging Detach/attach 1 pc. 0.4
87 • Cleaning Cleaning 1 pc. 0.1
88 • Vent air Adjust 1 pc.
89 Pump ASSY O/H 1 pc. 3.0
Other necessary works Detach/attach 1 set Counter weight 0.4
90 Slewing motor unit relation After removing boom
91 Slewing motor ASSY Detach/attach 1 pc. 1.8
92 • Piping Detach/attach 1 set 0.6
93 • Drain hose clamp Detach/attach 1 0.2
94 • Mounting bolt Detach/attach 1 pc. 0.5
95 • Unit slinging Detach/attach 1 pc. 0.3
96 • Cleaning and sealant Cleaning 1 set 0.2
97 • Slewing motor O/H 1 pc. 3.0
98 • Slewing reduction gear O/H 1 pc. 3.5
100 Swivel joint relation 19. Reference for swivel
joint
101 Swivel joint ASSY Detach/attach 1 After removing boom 1.5
102 • Piping (Top part only) Detach/attach 1 set. 0.3

12-8
 12. STANDARD MAINTENANCE TIME SCHEDULE

Work to Unit:
Group No. Location Unit Remark
be done hour
103 • Stop gap Detach/attach 1 0.1
104 • Cover Detach/attach 1 0.2
105 • Joint & elbow Detach/attach 1 set 0.2
106 • Mounting bolt Detach/attach 1 set 0.2
107 • Swivel joint slinging Detach/attach 1 0.2
108 • Cleaning Cleaning 1 set 0.1
109 Swivel joint O/H 1 set Removing and installing 3.0
guard
Other necessary works Detach/attach 1 set Front attach ASSY 1.5
Detach/attach 1 set Lower piping 0.5
110 Multi control valve 15. Reference for multi C/V
111 • Multi C/V ASSY Detach/attach 1 After removing guard 1.0
Write hose name on multi C/V connect-
112 Detach/attach 1 set 0.2
ing hose
113 • Piping Detach/attach 1 set 0.4
114 • Mounting bolt Detach/attach 1 set 0.2
115 • Cleaning Cleaning 1 set 0.2
Other necessary works Detach/attach 1 set Guard 0.3
16. Reference for control
120 Main control valve
valve
121 Main control valve ASSY Detach/attach 1 pc. 1.5
122 • Attach tag to port name of pipe Preparation 1 pc. 0.5
03 Upper frame

123 • Piping Detach/attach 1 set 0.8

124 • Bracket mounting bolt Detach/attach 1 pc. 0.1
125 • Valve slinging Detach/attach 1 pc. 0.1
126 Main control valve ASSY O/H 1 set 5.0
Other necessary works Detach/attach 1 set Guard 0.3
Detach/attach 1 set Battery 0.2
Detach/attach 1 set Fuel tank ASSY 1.5
Detach/attach 1 set Multi C/V movement 0.5
130 Dozer control valve
131 Control V ASSY Detach/attach 1 0.5
• Write hose name on Control V con-
132 Detach/attach 1 set 0.1
necting hose
133 • Piping Detach/attach 1 set 0.1
134 • Mounting bolt Detach/attach 1 set 0.1
135 • Cleaning Cleaning 1 set 0.1
136 Control V ASSY O/H 1 set 1.0
140 Engine (E/G) mounting relation 14. Reference for engine
141 Engine ASSY Detach/attach 1 pc. After removing pump & radi- 1.5
ator
• Harness connector & grounding & ca-
142 Detach/attach 1 pc. 0.2
ble connection
143 • Fuel hose Detach/attach 1 pc. 0.1
144 • Others Detach/attach 1 set 0.4
145 • Mounting bolt Detach/attach 1 pc. 0.4
146 • Engine slinging Detach/attach 1 set 0.2

12-9
12. STANDARD MAINTENANCE TIME SCHEDULE

Work to Unit:
Group No. Location Unit Remark
be done hour
147 • Cleaning Cleaning 1 pc. 0.2
148 Engine O/H 1 set Reference for engine
Other necessary works Detach/attach 1 set Removing and installing 0.5
guard
Detach/attach 1 set Removing and installing 0.4
counter weight
Detach/attach 1 set Removing and installing 2.3
pump
Detach/attach 1 set Removing and installing air 0.4
cleaner
Detach/attach 1 set Removing and installing 0.4
03 Upper frame

muffler
Detach/attach 1 set Removing and installing 3.5
radiator
150 Upper frame 20 Reference for upper
frame
151 Upper frame ASSY Detach/attach 1 pc. After removing swivel joint 1.0
152 • Mounting bolt Detach/attach 1 set 0.3
153 • Upper frame slinging Detach/attach 1 pc. 0.3
154 • Cleaning Cleaning 1 pc. 0.2
155 • Sealant Apply 1 pc. 0.2
Other necessary works Detach/attach 1 set Cab 1.5
Detach/attach 1 set Guard 0.3
Detach/attach 1 set Counter weight 0.4
Detach/attach 1 set Boom 1.5
00 Travel relation 1. Reference for crawler
01 Track link ASSY Detach/attach One side Include adjustment of ten- 1.0
sion
02 • Track link attaching and detaching Preparation One side 0.1
position
03 • Master pin Detach/attach One side 0.4
04 • Track link extending and winding Detach/attach One side 0.4
05 Shoe plate Replace 1 pc. 0.4
04 Travel system

10 Upper roller relation 2. Reference for upper roller

11 Upper roller ASSY Detach/attach 1 After removing track link 0.2
12 Upper roller O/H 1 1.0
20 Lower roller relation 3. Reference for lower roller
21 Lower roller ASSY Detach/attach 1 0.2
22 Lower roller O/H 1 1.0
30 Front idler relation 4. Reference for front idler
31 Front idler ASSY Detach/attach One side After removing track link 0.5
32 Front idler ASSY slinging Detach/attach One side 0.2
33 Front idler ASSY Disassemble One side 0.2
34 Idler ASSY O/H One side 1.0
35 Idler adjuster ASSY O/H One side Replace spring 2.0

12-10
 12. STANDARD MAINTENANCE TIME SCHEDULE

Work to Unit:
Group No. Location Unit Remark
be done hour
36 • Grease cylinder O/H One side 0.5
40 Sprocket 5. Reference for sprocket
41 Sprocket Replace One side After removing track link 0.5
50 Travel motor relation 8. Reference for travel motor
51 Travel motor ASSY Detach/attach One side After removing track link 1.4
52 • Motor cover Detach/attach One side 0.1
53 • Hydraulic piping Detach/attach One side 0.7
54 • Motor mounting bolt Detach/attach One side 0.4
55 • Motor slinging Detach/attach One side 0.1
56 Motor cleaning Cleaning One side 0.1
57 Travel motor O/H One side 3.0
04 Travel system

58 Travel reduction gear O/H One side 3.0

60 Swivel joint relation
61 Pipe on swivel joint travel side Detach/attach 1 pc. 0.5
62 Swivel joint O/H 1 pc. Refer to Upper structure
100.
6. Refer to 6 Slewing bear-
70 Slewing bearing
ing removing and installing
71 Slewing bearing ASSY Detach/attach 1 pc. After removing upper flame 0.6
72 Slewing bearing mounting bolt Detach/attach 1 pc. 0.4
73 Slewing bearing slinging Detach/attach 1 pc. 0.2
80 Dozer relation
81 Dozer ASSY Detach/attach 1 pc. 0.6
81 • Dozer cylinder piping Detach/attach 1 pc. 0.2
82 • Dozer cylinder slinging Detach/attach 1 0.2
83 Dozer slinging Detach/attach 1 pc. 0.2
84 Dozer Cylinder O/H 1 2.0
Controller
C-1 Controller (KPSS) Replace 1 0.2
C-2 Gauge cluster Replace 1 0.2
C-4 Air conditioner Amplifier Replace 1 0.2
C-5 Power window controller (OPT) Replace 1 0.2
06 Electric equipments

Diode
D-1 Diode Replace 1 0.2
D-2 Diode Replace 1 0.2
D-3 Diode Replace 1 0.2
D-4 Diode Replace 1 0.2
D-5 Diode Replace 1 0.2
D-6 Diode Replace 1 0.2
D-7 Diode Replace 1 0.2
Electric equipments
E-1 Fuse box Replace 1 Include C1 controller remov- 0.3
ing and installing.

12-11
12. STANDARD MAINTENANCE TIME SCHEDULE

Work to Unit:
Group No. Location Unit Remark
be done hour
E-2 Alternator Replace 1 Include bonnet assy remov- 1.0
ing and installing.
E-3 Hour meter Replace 1 0.2
E-5 Horn Replace 1 0.2
E-6 Cigar lighter Replace 1 0.2
E-7 Tuner AM & FM (OPT) Replace 1 0.2
E-7 Tuner AM Replace 1 0.2
E-8 Speaker left (OPT) Replace 1 0.2
E-9 Speaker right Replace 1 0.2
E-10 Receiver dryer Replace 1 Include gas sealing 0.3
E-11 Air compressor Replace 1 Include counter weight re- 0.5
moving and installing.
E-15 Socket Replace 1 0.2
E-17 DC-DC converter Replace 1 0.2
E-20 Buzzer Replace 1 0.2
E-21 Counter Replace 1 0.2
E-22 Sequence box Replace 1 0.2
E-23 Over load press. adjust unit Replace 1 0.2
Light
06 Electric equipments

L-1 Boom work light left Replace 1 Bulb 0.2

L-2 Work light right Replace 1 0.2
L-3 Room light Replace 1 0.2
L-4 CAB work light (OPT) Replace 1 0.2
L-5 CAB work light (OPT) Replace 1 0.2
L-11 Starter alarm lamp Replace 1 0.2
L-4 Starter alarm lamp Replace 1 0.2
Motor
M-1 Starter Replace 1 Include counter weight re- 1.0
moving and installing.
M-2 Governor Replace 1 Include counter weight re- 0.5
moving and installing.
M-3 Wiper motor (Non rise up) Replace 1 0.2
M-4 Washer motor Replace 1 0.2
M-5 Cable assy (P/W motor OPT) Replace 1 0.5
M-6 Power window lock motor (OPT) Replace 1 0.2
M-7 Power window lock motor (OPT) Replace 1 0.2
M-8 Skylight wiper motor (OPT) Replace 1 0.2
Proportionate valve
PSV-B P2 by-pass cut proportionate valve Replace 1 Include proportional valve 2.0
removing and installing.
PSV-C Travel straight proportionate valve Replace 1 Include proportional valve 2.0
removing and installing.
PSV-D P1 by-pass cut proportionate valve Replace 1 Include proportional valve 2.0
removing and installing.

12-12
 12. STANDARD MAINTENANCE TIME SCHEDULE

Work to Unit:
Group No. Location Unit Remark
be done hour
Relay
R-1 Battery relay Replace 1 0.2
R-3 Glow relay Replace 1 0.2
R-4 Safety relay Replace 1 Include guard (9) removing 0.4
and installing.
R-5 Wiper motor relay Replace 1 Include C1 controller remov- 0.3
ing and installing.
R-6 Washer motor relay Replace 1 0.3
R-7 Horn relay Replace 1 0.3
R-8 Work light relay Replace 1 0.3
R-10 Cab work light relay Replace 1 0.3
R-20 Timer Replace 1 0.3
R-28 Auto idle stop relay 1 Replace 1 0.3
R-29 Auto idle stop relay 2 Replace 1 0.3
R-30 Timer unit Replace 1 0.3
R-31 Counter relay Replace 1 0.3
R-32 Travel two-speed relay Replace 1 0.3
Sensor
SE-1 Pressure sensor (low pressure ; bucket Replace 1 0.2
06 Electric equipments

digging)
SE-2 Pressure sensor (low pressure ; bucket Replace 1 0.2
dump)
SE-3 Pressure sensor (low pressure ; boom Replace 1 0.2
up)
SE-4 Pressure sensor (low pressure ; boom Replace 1 0.2
down)
SE-5 Pressure sensor (low pressure ; swing Replace 1 0.2
left)
SE-7 Pressure sensor (low pressure ; arm in) Replace 1 0.2
SE-8 Pressure sensor (low pressure ; arm Replace 1 0.2
out)
SE-9 Pressure sensor (low pressure ; travel Replace 1 Include removing installing 0.4
right) guard on cab lower side.
SE-10 Pressure sensor (low pressure ; travel Replace 1 Include removing installing 0.4
left) guard on cab lower side.
SE-13 Engine speed sensor Replace 1 Include guard removing and 0.5
installing.
SE-14 Engine water temperature sensor Replace 1 0.2
SE-15 Fuel sensor Replace 1 Include guard removing and 0.3
installing.
SE-16 Accel potentio Replace 1 0.2
SE-17 Pressure sensor (high pressure : P3 Replace 1 0.2
pump)
Solenoid
SV-1 Swing parking SOL Replace 1 Include proportional valve 2.0
removing and installing.

12-13
12. STANDARD MAINTENANCE TIME SCHEDULE

Work to Unit:
Group No. Location Unit Remark
be done hour
SV-2 Conflux single flow switching SOL Replace 1 Include proportional valve 2.0
(OPT) removing and installing.
SV-3 2-speed travel SOL Replace 1 Include proportional valve 2.0
removing and installing.
SV-4 Lever lock SOL Replace 1 Include proportional valve 2.0
removing and installing.
Include proportional valve
SV-8 PQ shift SOL Replace 1 2.0
removing and installing.
Switch
SW-1 Key switch Replace 1 0.2
SW-2 Switch Replace 1 0.2
SW-3 2-speed travel switch Replace 1 0.2
SW-4 Slewing parking release switch Replace 1 0.2
SW-6 Engine water temperature switch Replace 1 0.2
SW-7 Engine oil pressure switch Replace 1 0.2
06 Electric equipments

SW-8 Clogged air filter switch Replace 1 0.1

SW-10 Horn switch Replace 1 0.2
SW-11 Lever lock switch Replace 1 0.3
SW-12 Heater switch (OPT) Replace 1 0.2
SW-13 Air conditioner switch Replace 1 0.2
SW-14 Power window switch (OPT) Replace 1 0.2
SW-15 Skylight wiper switch (OPT) Replace 1 0.2
SW-16 Work light switch (OPT) Replace 1 0.2
SW-17 Conflux-single flow select switch Replace 1 0.2
SW-18 OPT pedal pressure switch (1) Replace 1 Include removing installing 0.4
guard on cab lower side.
SW-19 OPT pedal pressure switch (2) Replace 1 Include removing installing 0.4
guard on cab lower side.
SW-20 Horn switch (R) (OPT) Replace 1 0.2
SW-23 Wiper interlock switch Replace 1 0.2
SW-26 Auto accel release switch Replace 1 0.2
SW-28 Overload indicate switch KCME STD Replace 1 0.2
SW-35 Pedal pressure switch Replace 1 0.2
SW-40 Auto accel stop select switch Replace 1 0.2
SW-30 Auto accel stop select switch Replace 1 0.2

12-14
 12. STANDARD MAINTENANCE TIME SCHEDULE

12.2 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF ENGINE

Introduction
This standard working time table provides time required for maintenance (if the work is carefully carried out) under
the following condition :
• Tools designated by us are used.
• Genuine parts are prepared.
• Correct working procedures are observed.
• The engine is mounted correctly to the machine.
(1) The working hours given in this table can not be applied because of special machine construction.
(2) Special equipments not listed in this table may be used for operation.
If such operations are performed, fill out reasons in the Claim Application Sheet in detail and submit it to us.

• Unit of maintenance time :

The maintenance time is given in 6 minutes = 0.1 hour in the decimal system.

MAINTENANCE
LOCATION OF WORK WORK TO BE DONE
TIME (Hr)
Engine body
Flywheel assy Detach & attach 0.9
• Including replacing of ring gear, etc.
Engine cushion rubber (both sides) Replace 0.4
Drain plug Replace 0.1
Engine assy Detach & attach 21.6
• Incl. overhaul of engine and cylinder body
Sealing plug Replace 0.2
Cylinder block drain cock assy Replace 0.1
Piston & conn rod (2 cycle) Detach & attach 11.2
Incl. Replacing parts (4 cycle) 13.9
Crank shaft rear oil seal Replace 0.2
Crank shaft pulley Detach & attach 0.8
• Incl. replacement of front oil seal
Oil pan Retighten 0.3
Oil pan Detach & attach 0.9
• Incl. overhaul of oil pump
Crank casing & oil pan Detach & attach 2.3
Incl. overhaul of oil pump and replacement of other parts
Oil pan level gauge guide tube Replace 0.1

Cylinder head
Valve clearance Adjust 0.5
Cylinder head cover Detach & attach 0.5
• Incl. retightening cylinder head
Cylinder head assy Detach & attach 7.9
• Overhaul of cylinder head, replacement of valve guide, etc.

12-15
12. STANDARD MAINTENANCE TIME SCHEDULE

MAINTENANCE
LOCATION OF WORK WORK TO BE DONE
TIME (Hr)
Valve timing mechanism
Locker arm & shaft assy Detach & attach 0.6
• Incl. overhauling rocker arm
Tappet Replace 5.4
Tappet chamber cover Detach & attach 0.4
Valve rocker stand Replace 0.4
Timing gear casing cover Detach & attach 1.2
• Incl. replacement of gear
Cam shaft Detach & attach 11.6
• Incl. replacement of bearing and tappet

Intake/exhaust system
Air intake hose Replace 0.3
Manifold fastening bolts Retighten 0.3
Inlet manifold Detach & attach 1.1
Exhaust manifold Detach & attach 0.7
Throttle valve assy Detach & attach 0.8
• Incl. overhaul of throttle valve
Intake shutter spring Replace 0.1
Intake shutter Detach & attach 0.5
• Incl. overhaul of intake shutter
Inlet pipe assy Detach & attach 0.2
Exhaust pipe adapt assy Detach & attach 0.2

Lubricating system
Oil filter element cover Detach & attach 0.5
• Incl. replacement of relief valve
Oil filter element (cartridge) Replace 0.2
Oil filter assy Detach & attach 0.6
• Incl. overhaul of oil filter
Oil filter oil pipe Detach & attach 0.1
Oil cooler assy (incl. replacement of one hose) Detach & attach 0.3
Oil cooler assy (2 hoses) Detach & attach 0.5
Oil cooler water hose Replace 0.1
Oil relief valve Replace 0.2

Fuel system
Injection time Adjust 0.3
Injection pump assy Detach & attach 2.8
• Incl. replacement of governor, feed pump, etc.
Injection pump overflow valve Replace 0.3
Fuel feed pump assy Detach & attach 1.0
• Incl. overhaul of pump and replacement of check valve
Feed pump strainer Detach & attach 0.3
• Incl. cleaning strainer

12-16
 12. STANDARD MAINTENANCE TIME SCHEDULE

MAINTENANCE
LOCATION OF WORK WORK TO BE DONE
TIME (Hr)
Injection pipe (2 pcs.) Detach & attach 0.1
Injection pipe (4 pcs.) 0.3
Injection pipe clip Replace 0.1
Nozzle leakoff pipe Replace 0.3
Priming pump Replace 0.4
Injection pump 0.1
Fuel cut solenoid Replace 0.1
Nozzle holder assy (1 pc.) Detach & attach 0.7
• Incl. replacement of nozzle (2 pcs.) Detach & attach 1.0
• Incl. replacement of nozzle (4 pcs.) Detach & attach 1.5
Fuel filter (cartridge) Replace 0.1
Fuel filter element Detach & attach 0.2
Fuel filter assy Detach & attach 0.6
Fuel filter overflow valve Detach & attach 0.4
Fuel pump (feed pump → filter) Replace 0.4
Fuel pipe (Filter → injection) Replace 0.4
Fuel return pipe Replace 0.4
Fuel hose Replace 0.2

Cooling water system

Fan belt Adjust 0.1
Fan belt Replace 0.1
Cooling fan Detach & attach 0.3
Water pump assy Detach & attach 1.2
• Incl. overhaul of pump
Water pipe and hose Detach & attach 1.0
• Incl. replacement of pipe and packings
Thermostat Detach & attach 0.6
• Incl. performance test

Electrical equipments of engine

Starter assy Detach & attach 0.6
Generator pulley Replace 0.6
Generator assy Detach & attach 0.7
Generator drive belt Replace 0.1
Voltage regulator Adjust 0.5
Voltage regulator Replace 0.1
Glow plug (2 pcs.) Replace 0.3
Glow plug (4 pcs.) Replace 0.4
Glow plug relay Replace 0.1

Switch unit relay

Ignition & starter switch Replace 0.2
Oil pressure unit Replace 0.1
Oil pressure switch Replace 0.1
Thermo unit Replace 0.2

12-17
12. STANDARD MAINTENANCE TIME SCHEDULE

MAINTENANCE
LOCATION OF WORK WORK TO BE DONE
TIME (Hr)
Control resistor Replace 0.2
Auto stop motor assy Detach & attach 0.2

12-18
13. MAINTENANCE STANDARD AND
TEST PROCEDURE
TABLE OF CONTENTS 13
13.1 HOW TO USE MAINTENANCE STANDARD AND PRECAUTIONS ................................. 13-3
13.2 PERFORMANCE INSPECTION STANDARD TABLE ....................................................... 13-4
13.3 MEASUREMENT OF ENGINE SPEED............................................................................... 13-6
13.3.1 MEASUREMENT OF ENGINE SPEED ..................................................................... 13-6
13.4 MEASUREMENT OF HYDRAULIC PRESSURE ............................................................... 13-7
13.4.1 PREPARING TO MEASURE HYDRAULIC PRESSURE .......................................... 13-7
13.4.2 PLACE TO INSTALL PRESSURE GAUGE .............................................................. 13-7
13.4.3 PRESSURE ADJUSTMENT POSITION ................................................................... 13-8
13.4.4 PROCEDURE FOR ADJUSTING RELIEF VALVE .................................................... 13-10
13.5 MEASURING TRAVEL PERFORMANCES ....................................................................... 13-11
13.5.1 TRAVEL SPEED ....................................................................................................... 13-11
13.5.2 DEVIATION OF TRAVEL .......................................................................................... 13-11
13.5.3 PERFORMANCES OF PARKING BRAKE ............................................................... 13-12
13.5.4 DRAIN RATE OF TRAVEL MOTOR .......................................................................... 13-13
13.6 MEASURING SLEWING PERFORMANCES ..................................................................... 13-14
13.6.1 SLEWING SPEED ..................................................................................................... 13-14
13.6.2 PERFORMANCE OF SLEWING BRAKE .................................................................. 13-14
13.6.3 PERFORMANCE OF SLEWING PARKING BRAKE ................................................. 13-15
13.6.4 DRAIN RATE OF SLEWING MOTOR .................................................................... 13-16
13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES ....................................... 13-17
13.7.1 OPERATING TIME OF CYLINDERS ........................................................................ 13-17
13.7.2 OIL TIGHTENESS OF CYLINDERS ........................................................................ 13-18
13.8 MEASURING PERFORMANCES OF SLEWING BEARING .............................................. 13-19
13.9 MECHATRO CONTROLLER "A" ADJUSTMENT ............................................................. 13-20
13.9.1 ENGINE CONTROL INPUT / OUT ........................................................................ 13-20
13.9.2 ENGINE CONTROL INSTALLATION ....................................................................... 13-20
13.9.3 E/G CONTROL EQUIPMENT ................................................................................... 13-21
13.9.4 ADJUSTMENT OF MECHATRO CONTORL ............................................................ 13-22

13-1
13. MAINTENANCE STANDARD AND TEST PROCEDURE

13-2
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.1 HOW TO USE MAINTENANCE STANDARD AND PRECAUTIONS

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

13-3
13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.2 PERFORMANCE INSPECTION STANDARD TABLE

The mode is already S mode when power is thrown. Unless otherwise specified, measure it on H mode.

Table 13-1

Measuring position Standard

value Inspection item
Hi Lo Unit Adjusting
point
Measuring
condition
Position Size Port
Cleanliness of hydraulic oil Hydraulic oil in tank NAS 8 +1 -1 Class Sampling
50 +5 -5 Atmospheric
Standard measuring

Hydraulic oil temperature Tank surface (122) (41) (23) ºC temp.

75 +15 -15 (ºF) 50ºC -10ºC
Water temperature Radiator surface
condition

(167) (59) (5) (122ºF 14ºF)

Lo idle 1020 +30 -30 LOW throttle
Engine speed

FULL throttle
Hi idle 2250 +30 -30 (Hi idle)
min -1 Adjusting
Decel Injection pipe 1050 +30 -30 not
(rpm) required
S mode 2100 +30 -30
FC mode 1800 +30 -30
Pilot primary pressure circuit G a4 37-34 (530-480) PR1 Hi idle
pump
RH and LH
valve pressure

P1 a1
Travel 305-300 (4340-4270) MR1 simultaneous
Main relief

P2 a2 operation
P1 a1 MR1 Boom up
Att. 305-300 (4340-4270)
P2 a2 MR1 Boom up
Dozer P3 a3 205-200 (2920-2840) MR3 Dozer up
H 335-300 (4760-4270) OR11 Nibbler close
N&B a1
R 335-300 (4760-4270) OR12 Nibbler open
Swing of H 335-253 (4760-3600) OR9 Swing LH
boom a1
R 335-265 (4760-3770) OR10 Swing RH
Over load relief valve pressure
High pressure circuit

H 335-300 (4760-4270) OR1 Bucket digging

Bucket a1
R PF1/4 335-300 (4760-4270) OR2 Bucket dump
H Main 335-265 (4760-3770) OR3 Boom up
Boom pump a1
R 335-300 (4760-4270) OR4 Boom down
Forward TR2 Simultaneous
RH a1 315-300 (4480-4270)
Reverse TR1 operation of
Travel kgf/cm 2 travel RH and
Forward TR4 LH (Without
LH a2 315-300 (4480-4270) (psi) port relief)
Reverse TR3
LH OR5 Slewing LH
Slewing a2 275-255 (3910-3630)
RH OR6 Slewing RH
H 335-300 (4760-4270) OR7 Arm in
Arm a2
R 335-300 (4760-4270) OR8 Arm out
H 280-200 (3980-2840) OR13 Dozer down
Dozer a3
R 280-200 (3980-2840) OR14 Dozer up
P2 bypass A B Performs proportionate
cut valve B 2, 8 Indicated calculation from actual
current readings display
Proportional valve block

Travel straight current No. Values which are

C 3, 0 11.5-9.5 (160-140) value calculated by converting
Secondary pilot
pressure circuit

valve pressure values in the

(mA) left figure to current
P1 bypass values are shown.
D C-1 Hard 2, 6 400 E/G Hi, Lever on
cut valve neutral position
Mechatro check
P2 bypass B controller SW. 2, 8
cut valve
Travel straight E/G Hi
valve C 3, 0 18-14.5 (260-210) 700 Lever on full
stroke
P1 bypass D 2, 6
cut valve

13-4
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

Table 13-2

Inspection item Standard Unit

value
1-speed 32.5 - 29.3
Sprocket revolution H mode
(RH, LH) 2-speed 58.8 - 53.2 min-1
S mode 2-speed 54.8 - 49.6 (rpm)
FC mode 2-speed 47.0 - 42.4
Up 2.4 - 3.0
Boom
Down 2.9 - 3.5
In 2.4 - 3.0
Arm
Out 2.3 - 2.9
Operating speed

Operating time of Digging 3.2 - 3.8

cylinder Bucket sec
(At H mode and no load) Dumping 1.6 - 2.2
Swing of LH 4.6 - 5.6
boom RH 4.2 - 5.2
Down 2.6 - 3.2
Dozer
Up 1.8 - 2.4
Slewing speed RH
(At H mode and no load) 4.6 - 5.2 sec / 1 rev
LH
Rubber 22.3 - 23.7
1-speed
Iron 23.0- 24.4
Travel speed sec / 20 m
Rubber 12.6 - 14.6
2-speed
Iron 13.1 - 15.1
Amount of travel 2-speed 0 - 240 mm / 20 m
deviation
Parking brake drift 1/5 Gradient 0 mm / 5min
Performance of Neutral position after degree
swing brake 180º full speed swing
Performance

Perormance of 1/5 Gradient 0 mm

swing parking brake
Tip of the bucket tooth 51
Boom cylinder 3
Att amount of drift mm / 5min (At no load)
Arm cylinder 3
Dozer cylinder 3
Amount of horizontal play at the bucket tooth 40 - 70 mm
(1.6 - 2.8) (in)

The port relifef valve No. PR1-PR8 on the control section are coincided with to (8) (4)
the following operation numbers in advance.
(1) Bucket digging (5) Swing left (5) (6) (4) (2)
(2) Bucket dumping (6) Swing right
(3) Boom raise (7) Arm in (7) (3)
(4) Boom lower (8) Arm out LH RH
Control lever
(a) Travel RH reverse LH (d) (b) RH
(b) Travel RH forward
(c) Travel LH reverse
(d) Travel LH forward
(c) (a)
Travel control pedal or lever

13-5
13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.3 MEASUREMENT OF ENGINE SPEED

13.3.1 MEASUREMENT OF ENGINE SPEED
(1) Warming up of engine PICK UP
Start engine to raise the coolant temperature of en-
gine to 40° to 80°C (104° to 176°F).
The E/G coolant temperature gauge is used to
measure. The range in white color shows the tem-
SPEED METER
perature of approx. 40° to 100°C (104° to 212°F),
so confirm that the measured value indicates the
temperature within the range of white color.
Engine water
temperature gauge

Fig. 13-1 Measurement of E/G speed

SERVICE DIAGNOSTIC DISPLAY

(2) Measuring with diesel engine speed meter

1) Install diesel engine speed meter pickup on and
of injection pipes on which the pickup can be
easily installed. (See Fig. 13-1)
2) Check E/G speed shown in Table Table 13-1 in
idling speed.
(3) Engine speed measured value through service di-
agnosis
Insert precision driver (-) into convex place indicat-
ed by arrow of hard check SW A , B in C-1 control-
Remove grommet, and you can
ler., then direct the arrow to A = 0, B = 2, and 3 find the following switch
digits in unit of 10 rpm are displayed on service di-
agnostic display of controller, HARD CHECK SW
Example : 2100 rpm→210 in display

INTERNAL ADJUSTMENT SW
HARD CHECK SW

Fig. 13-2 E/G speed measuring hard check SW

13-6
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.4 MEASUREMENT OF HYDRAULIC PRESSURE

13.4.1 PREPARING TO MEASURE HYDRAULIC PRESSURE
(1) Hydraulic equipment a2 a1
70 kgf/cm2 (1000 psi) pressure gauge : 1 unit A2 A1
500 kgf/cm2 (7100 psi) pressure gauge : 2 unit
(3 pcs in dozer specification)
A3
Pressure measuring equipment and instrument for
analysis : 1 set
(2) Measuring cleanliness of hydraulic oil

A4

After releasing air in the hydraulic oil tank, open the Dr2 B1
cover and sample oil in the hydraulic tank, and measure
with the instrument for analysis. If the measured value
Fig. 13-3 Gauge port on main pump
is higher than the reference value, replace the return fil-
ter or change the hydraulic oil.

13.4.2 PLACE TO INSTALL PRESSURE GAUGE

(1) Main circuit
Replace plugs PF 1/4 of main pump gauge ports
a1, a2 with plugs for pressure measurement, and
attach pressure gauge 500 kgf/cm2 (7100 psi).
(2) Dozer circuit
Replace dozer pump gauge plug PF1/4 a3 with
plug for pressure measurement, and attach pres-
sure gauge 500 kgf/cm2 (7100 psi).
PUMP
(3) Pilot circuit
Replace pilot gauge plug a4 with plug PF1/4 for
pressure measurement, and attach pressure gauge
70 kgf/cm2 (1000 psi).

Fig. 13-4 Gauge plug on dozer pump

PUMP

Fig. 13-5 Plug for pilot pressure measurement

13-7
13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.4.3 PRESSURE ADJUSTMENT POSITION

(1) Main control valve

Fig. 13-6 Outside view

(2) Control valve for dozer & extra

Dozer : STD
Extra : OPT

Fig. 13-7 Control valve for dozer

13-8
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

(3) Pilot relief valve

Pilot relief valve PR1 is built in main pump.

a2 a1
A2 A1

PR1
A3 PILOT RELIEF

A4

Dr2 B1

Fig. 13-8 Pilot relief valve position

(4) Slewing port relief
The slewing motor is equipped with plugs for pressure measurement, but the measurement is carried out using
gauge ports a1 and a2 . (See Fig. 13-8)

Dr
RELIEF VALVE
OR5-B PORT PLUG 2-PT 1/4
for pressure
measurement

PF3/8 (PLUG)
AIR RELEASE PORT

PORT RELIEF VALVE

OR6-A

Fig. 13-9 Slewing port relief position

13-9
13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.4.4 PROCEDURE FOR ADJUSTING RELIEF VALVE

(1) Pilot relief valve 660
Loosen nut (661) and adjust it with adjust screw
(660).

: 24 mm

: 6 mm
661
Pressure change T=2.94 N m
No. of turns of adjust screw MPa (psi) (22 lbf ft)
1/2 turn Approx.6.1 (880)

(2) Main relief valve Fig. 13-10 Pilot relief valve

(Travel section, ATT common section) 7 6
Loosen lock nut (7) and adjust it with adjust screw T=19.6 N m
(6). (14 lbf ft)

: 19 mm

: 4 mm

Pressure change
No. of turns of adjust screw MPa (psi) Fig. 13-11 Main relief valve
1/2 turn Approx.6.1 (880) (Travel section , ATT common section)

(3) Port relief valve (Boom, bucket, arm, boom swing, 8

T=19.6 N m
N&B sections)
(14 lbf ft)
Loosen lock nut (8) and adjust it with adjust screw
(7).
7
: 19 mm

: 4 mm Fig. 13-12 Port relief valve

(Boom, bucket, arm, sections)
Pressure change
No. of turns of adjust screw MPa (psi) 71
Approx.6.1 (880) T=39.2 N m (29 lbf ft)
1/2 turn

(4) Slewing port relief valve

When the adjusted pressure is 10 kgf/cm2 (142 psi)
or less, loosen nut (71) and adjust it with cap (90).

: 24, 27 mm

: 5 mm 90
When the pressure adjusted value is over 10 kgf/ Fig. 13-13 Slewing port relief valve
cm2 (142 psi), replace the relief valve assy.

13-10
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.5 MEASURING TRAVEL PERFORMANCES

13.5.1 TRAVEL SPEED
(1) Purposes
Measure the travel sprocket revolution and confirm
the performances between the hydraulic pump and
the travel motor of the travel drive system.
(2) Conditions
Operating oil temperature : 45~55°C (113~ 131°F)
Crawler on the right and left sides are tensioned
evenly.
(3) Preparation Fig. 13-14 One side lifted position
Install the reflection panel with a magnet to the trav-
el motor cover.
Slewing the upper frame through 90° as shown in
Fig. 13-14 and make the crawler on one side take
off the ground, using the attachment.
(4) Measurement
Engine revolution : Hi idle
2-speed travel switch : 1st and 2nd speed Fig. 13-15 Adhering position of reflection panel
Measuring points : Right and left
Sprocket revolution Unit : rpm
Method, example 1 : Measurement Standard Repairable
Service limit
Measure revolution with a stroboscope. item value level
Method, example 2 : H1 32.5~29.3 25.4~22.9 20.7~
RH
Measure the revolutions per minute visually. H2 58.8~53.2 45.9~41.5 37.5~
&
LH S2 54.8~49.6 42.7~38.7 35.0~
FC2 47.0~42.4 36.7~33.1 29.9~

13.5.2 DEVIATION OF TRAVEL

(1) Purpose
Measure the amount of deviation at 20 m (66 ft)
travel and confirm the horizontal balance between
the hydraulic pump and the travel motor of the trav-
el drive system.
(2) Condition
Hydraulic oil temperature : 45 ~ 55°C (113 ~ 131°F)
RH and LH crawler are tensioned evenly.
Plain, level and solid ground Fig. 13-16 Travel position
Engine revolution : Hi idle
(3) Preparation
1) Straight course more than 30 m (33 yard)
2) Travel position in which the bottom of the bucket
is lifted by about 30 cm (1 ft).
(4) Measurement 20 m (66 ft)
1) Measure the max. deviation distance of the cir-
cular arc in the 20 m (22 yard) length, excluding
Fig. 13-17 Measuring method
the preliminary run of 3~5 m (10~16 ft).
2) Operate the travel lever at the same time. Travel deviation Unit : mm/20m
Measurement Standard Repairable
item value level Service limit
A 240 (9’45") or less 480 (18’9") 720 (28.3")

13-11
13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.5.3 PERFORMANCES OF PARKING BRAKE

(1) purpose
Confirm that the parking brake holds a stopped
condition of the machine in a no-load travel position
and on a 1/5 gradient slope.
(2) Condition
A slope with 1/5 (Approx. 12 deg) gradient and a
stopped condition in a no-load travel position.
(3) Preparation
Place an angle meter on the shoe plate and confirm
that it makes an angle more than 12°. Fig. 13-18 Parking brake operating position
Hang a perpendicular in parallel with the guide
frame rib on the track frame and put a mark (match-
ing mark) on the shoe plate.
(4) Measurement
Five minutes after the engine stops, measure the
movement distance of the matching mark. C ANGLE METER
GUIDE FRAME

Fig. 13-19 Method of measurement

Parking brake Unit : mm/5min

Measuring Standard Repairable
position value level Service limit
C 0 1 (0.04 in) 2 (0.08 in)

13-12
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.5.4 DRAIN RATE OF TRAVEL MOTOR

(1) Purpose FORWARD 90
To measure the drain rate of the travel motor and to (3.54" )
Ø10
confirm the performances of the travel motor. Ø22 PIPE (0.394" )
(0.866" )
(2) Conditions 40
(1.57" )
Hydraulic oil temperature : 45~55°C (113~131°F) RIB “A”
STOPPER 150
Engine revolution : Hi idle “B” (5.10" )
(3) Preparation
1) Place a stopper under the RH and LH travel 60
sprockets. ROTARY DIRECTION (2.36")

2) Stop the engine and vent air from the hydraulic Fig. 13-20 Location of stopper applied to travel
oil tank. sprocket

3) Connect a hose with the drain port of the travel

motor and take drain in a container.
(4) Measurement; at Travel Lock

Unless you observe the rotary force direction at travel

lock, rib "A" may be broken by stopper "B" in some cas-
es.

1) Start the engine and relieve pressure at the full

stroke of the travel lever.
2) Measure the drain rate for 30 seconds of reliev- Fig. 13-21 Method of measuring the drain rate of
ing. travel motor
Take three measurements in the forward motion
Drain rate of
on each side at one time and make the mean val- travel motor Unit : L/30sec
ue the measured value. Measuring Standard Repairable
Service limit
position value level
Drain rate 3.4 (0.9 gal) 6.8 (1.8 gal) 10 (2.6 gal)

13-13
13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.6 MEASURING SLEWING PERFORMANCES

13.6.1 SLEWING SPEED
(1) Purpose
Measure the slewing time and confirm the perfor-
mances between the hydraulic pump and the slew-
ing motor of the slewing drive system.
(2) Conditions
Hydraulic oil temperature : 45~55°C (113~131°F)
Hard and level ground Fig. 13-22 Slewing speed measuring position
Engine : Hi idle
(3) Preparation Slewing speed Unit : sec/rev
The height of 1.5 m (5 ft) at which the bottom of the Measuring Standard Repairable Service
bucket matches the tip of the tooth on condition that position value level limit
Standard slewing 4.6~5.2 5.9~6.6 7.4~
the bucket is empty, the arm cylinder is most re-
tracted and the bucket is used for digging.
(4) Measurement
Slewing the machine by bringing the slewing lever
to its full stroke. Measure the time required to make
two turns after one turn of preliminary run and cal-
culate the time required for one turn.
Fig. 13-23 Slewing brake performance measuring
position

13.6.2 PERFORMANCE OF SLEWING BRAKE

(1) Purpose
Confirm the braking torque performances by the
slewing relief valve.
(2) Conditions
Hydraulic oil temperature : 45~55°C (113~131°F)
Hard and level ground
Engine : Hi idle
(3) Preparation
Measuring the length of the arc over the
1) A height of 1.5 m (5 ft) at which the bottom of the outer circumference of slewing race
bucket matches the tip of the tooth on condition Matching marks
on slewing race
that the bucket is empty, the arm cylinder is most B
retracted and the bucket is used for digging.
2) Put a mark (matching mark) on the outer circum-
ference of the slewing bearing of the upper frame
side and of the track frame side.
Erect two poles (flags) at the front and back of Matching marks on track frame
the extended line of the matching mark.
Fig. 13-24 Measuring position of slewing brake per-
formances

13-14
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

(4) Measurement
Slewing brake
1) When operating in regular slewing speed, by performance Unit : degree
shifting lever to neutral position at pole position Repairable
Standard value level Service limit
the slewing operation stops.
2) Calculate the slewing drift angle by the following
equation, after the upper slewing body stops, us-
ing the amount of deflection (m) of the matching
marks on the slewing race and the length (m) of
the circumference of the slewing race :
Amount of deflection of
Slewing drift matching marks [m (ft-in)]
angle ( ) = X 360
Circumferential length of
slewing race [m (ft-in)]

13.6.3 PERFORMANCE OF SLEWING PARKING BRAKE

(1) Purpose
To confirm the mechanical performances of the
slewing parking brake that is fitted to the inside of
the slewing motor.
(2) Conditions
On a slope with 1/5 (Approx. 12 deg.) gradient stop
the machine at right angles with the slope at the
height of 1.5 m (5 ft) at which the bottom of the
bucket matches the tip of the tooth on condition that
Fig. 13-25 slewing parking brake performance mea-
the bucket is empty, the arm cylinder is most re-
suring position
tracted and the bucket is operated for digging.
(3) Preparation
Measuring the length of the arc over the
Put the angle meter on the shoe plate and make
outer circumference of slewing race
sure that the angle is more than 12°. Matching marks
on slewing race
Put a matching mark over the outer circumference
C
of the slewing bearing on the upper frame side and
on the track frame side.
(4) Measurement
When five minutes has passed after the engine
stops, measure the length of the movement of the Matching marks on track frame
matching marks.
Fig. 13-26 Measuring position of slewing brake per-
formances
Performance of slewing
Parking brake Unit : mm/5min
Measuring Standard Repairable
position value level Service limit
C 0 1 (0.4 in) 2 (0.08 in)

13-15
13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.6.4 DRAIN RATE OF SLEWING MOTOR

(1) Purpose
Measure the drain rate of the slewing motor and
confirm the performances of the slewing motor.
(2) Conditions
Hydraulic oil temperature : 45~55°C (113~ 131°F)
Engine revolution : Hi idle
(3) Preparation
1) Stop the engine.
2) Vent air from inside the hydraulic oil tank.
3) Disconnect the slewing motor drain hose from its
end returning to the hydraulic oil tank and take oil
in a container.
4) Put a plug to the tank side.
(4) Measurement ; at Slewing Lock Fig. 13-27
1) Start the engine and put the side faces against Drain rate of
the inside of the right or left shoe plate. slewing motor Unit : L/30sec
Measuring Standard Repairable
2) Relieve the slewing motor at full stroke of the position value level Service limit
slewing motion. Drain rate 5.0 (1.3 gal) 12.5 (3.3 gal) 15 (4.0 gal)
3) Receive in a container the amount of drain accu-
mulated in 30 seconds of relieving.

13-16
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES

13.7.1 OPERATING TIME OF CYLINDERS
(1) Purpose
Measure the operating time of the boom, arm and
bucket and confirm the performances between the
hydraulic pump and the cylinder of the attachment
drive system.
(2) Conditions
Hydraulic oil temperature : 45~55°C (113~131°F)
Engine : Hi idle Fig. 13-28 Measuring position for bucket digging
Operating time excluding the cushion stroke and dump
(3) Preparation
Plain ground with the bucket empty.
(4) Measurement 1 ; Boom up and down
With the boom operating lever at full stroke, mea-
sure the required operating time of the bucket be-
tween the ground surface and its highest position.

Fig. 13-29 Measuring position for boom up and

down motions
When lowering the boom, allow the bucket onto a soft
ground or cushioning such as rubber tires ; never put
the bucket against concrete or other solid material.

Measurement 2 ; Arm in and out, bucket digging

and dump

In a position in which the tooth of the bucket rises to

a level of about 30 cm (1 ft) above ground, measure Fig. 13-30 Measuring position for arm in and out
the full stroke operating time required with the arm motions
and bucket operating levers at full stroke. Cylinder Operating
time Unit : sec
Measuring Standard Repairable
position value level Service limit
(1) 3.2-3.8 4.1-4.9 5.3-
(2) 1.6-2.2 2.0-2.8 2.9-
(3) 2.4-3.0 3.1-3.8 4.1-
(4) 2.9-3.5 3.7-4.5 4.8-
(7) 2.4-3.0 3.1-3.8 4.1-
(8) 2.3-2.9 2.9-3.7 3.9-
LH 4.6-5.6 5.9-7.2 7.7-
Swing
RH 4.2-5.2 5.4-6.7 7.1-
Dozer down 2.5-3.1 3.2-4.0 4.2-
Dozer up 1.8-2.4 2.3-3.1 3.2-

13-17
13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.7.2 OIL TIGHTENESS OF CYLINDERS

(1) Purpose
Confirm that the cylinder oil tight by checking the
moving length of the cylinder rods.
(2) Condition
Hydraulic oil temperature : 45~55°C (113~131°F)
Hard and level ground
Immediately after cylinders are replaced, bleed off
air from the cylinders, before checking for oil tight- Fig. 13-31
ness.
Cylinder Operating
The arm cylinder has moved 30 mm (1.2 in) from time Unit : mm (in / 5min)
the stroke end. (Off the cushioning range) Measuring Standard Repairable
position value level Service limit
(3) Preparation A 3 (0.12) 4 (0.16) 5 (0.2)
Keep the tip of the bucket at 1.5 m (5 ft) height, with B 3 (0.12) 4 (0.16) 5 (0.2)
the bucket empty and the arm cylinder is most re- C
tracted. [Provided the arm cylinder is extended by
D 43 (3.3) 64 (2.5) 85 (3.3)
30 mm (1.2 in).]
Dozer 5 (0.2) 8 (0.31) 10 (0.4)
(4) Measurement
Measure the items five minutes after the engine is
turned off.

13-18
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.8 MEASURING PERFORMANCES OF SLEWING BEARING

(1) Purpose
Measure the gap between the lower frame and the
bottom face of the slewing bearing and estimate the
degree of wear of the slewing bearing.
(2) Condition
Hard and level ground
The slewing bearing mounting bolts are not loos-
ened.
The slewing bearing is lubricated well, not making
abnormal sound during turning.
Fig. 13-32 How to measure the axial play of slewing
bearing
(3) Preparation
1) Install a dial indicator to the magnetic base and
fix it to the lower frame.
2) Direct the upper slewing body and the lower
frame toward the travel direction, bring the probe
of the dial indicator in contact with the bottom
surface of the outer race on the slewing body
side and set the reading at zero. Fig. 13-33 Measuring position I

(4) Measurement 1 (Measuring position I and II)

1) Measure the travel of the outer race in the axial
direction in position I [The arm at 90°~110° and
the crawler front lifted about 30 cm (1 ft)] and in
position II, using a dial indicator.

Fig. 13-34 Measuring position II

Axial play of
slewing bearing Unit : mm (in)
Measuring Standard Repairable
position value level Service limit
A 0.5~1.5 1.9~2.9
(0.02~0.06 in) (0.07~0.11 in) 3.0 (0.12 in)~

(5) Measurement 2 (Measuring position III)

1) With the arm cylinder most retracted and the
bucket dump, lift the tip of the tooth of the bucket
about 10 mm (0.4 in) and slewing the tip of the
bucket to the right and the left by man power.
But in this case, the gap of the attachment is in- Fig. 13-35 Measuring position III
cluded.
Right and left
movement of
the tip of bucket Unit : mm (in)
Measuring Standard Repairable
position value level Service limit
Bucket tiptoe 70 (2.8) 175 (6.9) 210 (8.3)

13-19
13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.9 MECHATRO CONTROLLER "A" ADJUSTMENT

13.9.1 ENGINE CONTROL INPUT / OUT

Fig. 13-36

13.9.2 ENGINE CONTROL INSTALLATION

FINE CAPSCREW M10 X 35

TIGHTENING TORQUE
65 N m (48 lbf ft)
Apply Loctite #242 or equivalent.

2 places
FINE CAPSCREW M10 X 20
TIGHTENING TORQUE
65 N m (48 lbf ft)
Apply Loctite #242 or equivalent.

SOCKET BOLT M6 X 25 SOCKET BOLT M10 X 35

TIGHTENING TORQUE TIGHTENING TORQUE
9.8 N m (7.2 lbf ft) 19.6 N m (14 lbf ft)
Apply Loctite #242 or equivalent.

SECTION BB

Fig. 13-37

13-20
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.9.3 E/G CONTROL EQUIPMENT

(1) Governor motor and C-1 controller REDUCTION GEAR SECTION
1) By operating accel dial, the input voltage change OIL SEAL MOTOR SECTION
is sensed by 14-8 pins of C-1 controller. OUTPUT SHAFT
2) The C-1 controller computes the input voltage,
and outputs command to governor motor (M-2),
and incline governor lever of engine to the swing
CAM
angle corresponding to access dial set value.
3) The limit switch in governor motor is set to a an- LIMIT
gle from motor rotation OFF to ON position SWITCH
(Starting point).
(2) Rotation sensor
1) Installing place
Engine flywheel housing
Opposing flat 19
2) Sensor attaching procedure SIGNAL (Yellow)
M16 X 1.5 Opposing flat 17
a. Apply Loctite #262 on pick-up thread section.
b. Tighten thread until it contacts flywheel ring
gear, and turn it back one and half turns.
GND (Black)
c. After turning it back one and half, check that
the tightening torque of nut is 2.5~3.5 kgf•m SWITCH PANEL
(18 ~ 25 lbf•ft).
d. After installation, check that the engine
speed meter measured value corresponds to Wark mode
the engine speed in service diagnostics selector switch
while operating engine.
e. Output voltage at 850 rpm : 4V (AC) or more
Output voltage at 2250 rpm : 20V (AC) or Buzzer stop switch

less
(3) Work mode selector switch
Press work mode selector switch, and the opera-
tion signal is sent to C-1 controller, and the work
mode is switched.
(4) Buzzer stop switch
When the error is detected by self-diagnosis, the C-
1 controller sends alarm by sounding buzzer, and
CPU lamp on gauge cluster flickers. And press
buzzer stop switch to stop buzzer sounding. Also,
when engine coolant temperature has risen or the
engine oil pressure has lowered, buzzer sounds.
But in this case the buzzer sounding does not stop.

13-21
13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.9.4 ADJUSTMENT OF MECHATRO CONTORL

(1) When adjustment of mechatro control is required;

CONTROLLER DISPLAY

Case "A" adjustment

Replacement of C-1 mechatro controller
GROMMET
Replacement of governor motor
A
Disassemble governor rod

A
C-1 MECHATRO CONTROLLER

(2) Preparation
a. Warm up engine.
b. Turn starter switch OFF to stop engine, and turn A/C switch OFF .
c. Pull operator seat forward fully and incline seat-back forward.
d. Remove plastic cover on the rear side, then mechatro controller appears.
(Remove 5 attaching bolts form plastic cover with driver +).

Check to be sure that the engine emergency stop lever knob in fully pressed down. If mechatro controller in ad-
justed in the condition where the knob is pulled out, the engine speed can not be set rightly.

(3) Adjustment

Mode display on
Procedure Movement of governor motor
gauge cluster
1. Remove grommet on upper surface of mechatro controller, and switch internal adjustment switch from RUN
to TEST .
FULL
STOP

During
adjustment

LEVER

In normal
pisition GOVERNOR
MOTOR
SECTION AA
Internal adjustment jumper pin (JP) switch

2. Turn starter switch ON .

H S FC A

Stop at the position

set by accel dial
Display lamp lights
on in order

13-22
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

Mode display on
Procedure Movement of governor motor
gauge cluster
3. Keep pressing buzzer stop switch for approx 5 to
A
10 seconds and release. S
H S Automatically run
Check that the display on this gauge cluster is as
to engine stop
the right. position (S)

4. After checking the right mode display, adjust the S

rod length so that the clearance A bet- ween gov- H S
ernor lever and engine stop set bolt in engine Stop at S position
side is 0.1 mm (0.0039 in). adjust rod (5) length
[TOOLS]
to 204 mm (8.03 in). Spanner 13 mm X 2
And, when the governor motor is replaced, con- Spanner 6 mm
Thickness gauge
firm that the right display is indicated, then insert
link rod.
5. Press buzzer stop switch once, and wait until the S A
mode is switched to the right display. S FC

Automatically run to the engine

available position A
6. After verification of the flowing mode, start en- A
gine. S FC
Then, any position of accel dial is allowable.

Stop at A position
7. Press buzzer stop switch once, and the mode is
Lo A
switched to the following, and governor lever Hi
H FC
moves from A position to low idling position, and
reading the engine speed to high idling automat-
ically.
(Required time : approx. 3 minutes.) Move from A position to Lo idling
position, and self-travels from Lo
position to high idling (H) position

Governor lever is set to the position of approx.

1700rpm~1900rpm. According to the command of
mechatro controller, the lever moves to the low
idling position after engine starts, then starts read-
ing out for self-travelling.

8. After completion of read out, wait until the mode Hi

display on gauge cluster switches to the follow- H S FC
ing.
After the display switches, the engine speed is (Approx.
A
returned automatically to the position set through 5 seconds) Hi
accel dial and adjustment is completed.
When mechatro controller is replaced, and start-
er key is turned on, CPU lamp starts flickering.
If CPU lamp is turned off after completion of "A"
adjustment, the adjustment is completd correctly.
But CPU lamp is flickering yet, the adjustment is
failed, readjust again.

13-23
13. MAINTENANCE STANDARD AND TEST PROCEDURE

(4) After completion of adjustment

a. Turn starter switch OFF to stop engine.
b. Switch internal adjustment JP switch from TEST to RUN position, and set hardware check B to 2.
(Note : When hardware check switch indicates "0-0", the mechatro controller displays error code.)
c. Press the blank side of auto accel switch to release auto accel, and after starting engine the speed increases
to high idling position, then check the engine speed at the status of H, S and FC position indicated on the
display of mechatro controller.
d. By switching work mode through switch panel, the mode display on gauge cluster is also switched. Then,
check that the engine speed changes.
e. After setting accel dial to low idling position, press the symbol side of auto accel switch to actuate auto accel
function.
f. Set accel dial to high idling, and check engine speed when running in auto accel position.
g. After verification of engine speed, set hardware check switch B on mechatro controller to "0", and attach
grommet.
h. Attach plastic cover as it was, and slide operator seat backward to move the seatback backward. Then,
check connector of speaker for disconnection.
(5) When adjustment of mechatro controller can not be performed.
1) After execution of procedure (7), H→S→FC is displayed, CPU lamp flickers, and adjustment can not be ex-
ecuted. ( "E01" is indicated on controller display.)
"A" (Display condition)
• While reading engine speed, the engine speed after stepping of governor motor is lower than that before
stepping in condition of engine speed 850rpm or high.
(Cause)
• The read-out of engine speed sensor is wrong.
(Corrective action)
• After measurement and adjustment of speed sensor voltage, carry out A adjustment.
High idling 3V or high (AC) (Voltage available for controller to read)
(When adjusting in factory, the voltage is set to 3V (AC) or high at high idling)
"B" (Display condition)
• When abnormal rotation (step-out) occurs on high idling side;
(Cause)
• Wrong connection of link rod of governor motor
(Corrective action)
• After verification of connection of link rod, perform "A" adjustment. [Rod length : 204 mm (0.031 in)]
When step-out occurs after adjustment, press buzzer stop switch once before stepping out as a temporary
repair, and it is switched to high idling temporarily.
2) The error code "E02" is indicated on the display of mechatro controller, but the adjustment cannot be exe-
cuted.
(Display condition)
• Engine speed is 300 rpm or lower, or 3000 rpm or higher.
(Cause)
• The read-out of engine speed sensor is wrong.
(Corrective action)
• After measurement and adjustment of speed sensor voltage, carry out "A" adjustment.
High idling 3V or high (AC)

13-24
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

3) When buzzer stop switch is pressed once to proceed from procedure (6) to (7), it does not proceed to pro-
cedure (7), but procedure (8) directly, and CPU lamp flickers and error code E01 is indicated on the display
on mechatro controller.
(Display condition)
• Engine speed is 420 rpm or low.
(Cause)
• Buzzer stop switch is pressed once before starting engine.
• The read-out of engine speed sensor is wrong. (or disconnection)
(Corrective action)
• Adjust mechatro controller again as the procedure.
• After measurement and adjustment of speed sensor voltage, perform "A" adjustment.
High idling 4V or high (AC)
4) When buzzer stop switch is pressed once to proceed from procedure (4) to (5), but it does not proceed to
procedure (5).
(Display condition)
• Limit switch signal (grounding) is not input from governor motor to controller.
(Cause)
• Failure of limit switch in governor motor
• Disconnection of connector or harness on governor motor
(Corrective action)
• Check that limit switch of governor motor goes ON and OFF.
• Check connector and harness from possible damage, and adjust it.
5) Others
Error code "E02" is indicated on the display of controller, and engine stops.
Engine oil pressure switch and harness are short-circuited.
(6) CPU lamp on gauge cluster flickers, or error code "E01" is indicated on display of controller.
When mechatro controller is replaced, and the adjustment of controller has failed, this display appears.
When the adjustment is completed normally, CPU lamp goes off, and error code "E01" also disappears.
To perform the adjustment of mechatro controller again, press starter switch once to turn the power OFF, and
turn starter switch on and perform the adjustment again.

13-25
13. MAINTENANCE STANDARD AND TEST PROCEDURE

[MEMO]

13-26
 21. MECHATRO CONTROL SYSTEM
TABLE OF CONTENTS

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

21.2 BOOM RAISE CONFLUX MECHATRO CONTROL SYSTEM ........................................... 21-7
21.3 SWING CUT VALVE CONTROL MECHATRO CONTROL SYSTEM ................................. 21-8 21
21.4 ARM IN / OUT CONFLUX MECHATRO CONTROL SYSTEM ........................................... 21-9
21.5 TRAVEL STRAIGHT MECHATRO CONTROL SYSTEM ................................................... 21-10
21.6 TRAVEL BOOST CONTROL SYSTEM ............................................................................ 21-12
21.7 MECHATRO CONTROL .................................................................................................... 21-14
21.7.1 TROUBLESHOOTING .............................................................................................. 21-14
21.7.2 SERVICE DIAGNOSTICS ......................................................................................... 21-15
21.7.3 COMPONENT MECHATRO CONTROL ................................................................... 21-17

21-1
21. MECHATRO CONTROL SYSTEM

21-2
 21. MECHATRO CONTROL SYSTEM

PREFACE
This manual describes the outline of electrical and hydraulic systems and equipment. For details, refer to electric
and hydraulic diagrams.

21-3
21. MECHATRO CONTROL SYSTEM

21.1 SUMMARY OF MECHATRO CONTROL SYSTEM

21-4
 21. MECHATRO CONTROL SYSTEM

21-5
21. MECHATRO CONTROL SYSTEM

OPERATIONS & MECHATRO CONTROL EQUIPMENT FUNCTIONS H/V; Pressure Volt

V/A; Volt Ampere
Mechatro control equipment
Hydraulic equipment
Solenoid valve H/V
H/V V/A (C/V spool)
(Current hydraulic pressure)

Slewing parking brake

Conflux/single change
Travel two-speed

Conflux/single change valve

Low pressure sensor

P1 by-pass cut valve

P2 by-pass cut valve

Travel two-speed select

Safety lock lever

Travel straight valve

Mechatro control

Governor motor
P2 by-pass cut

P1 by-pass cut
Travel booster

Travel straight
equipment

or pressure SW.

Controller
Operation side

In Out 1 2 3 8 4 B C D M2
Digging SE1
Bucket
Dump SE2
(conflux) Raise SE3
Boom Lower SE4
Independent operation

Slewing Left
(Cut valve SE5
control) Right
(conflux) In SE7
Arm
(conflux) Out SE8
Right SE9
Travel
Left SE10
Boom Left SW18,32
Hydraulic pressure

swing Right SW18,33

Operation side output signal

Close SW35
N&B
Open SW35
Bucket Digging SE1
SE9,10
/ Travel SE2
Dump SE9,10
Boom Raising SE3
SE9,10
/ Travel Lowering SE4
Combined operation

SE9,10
Left SE5
Swing SE9,10
/ Travel Right SE5
SE9,10
In SE7
Arm SE9,10
/ Travel Out SE8
SE9,10
Dozer Up SE9,10
/ Travel Down SE9,10
SW18
Boom swing Left SE9,10
/ Travel SW18
Right SE9,10
Safety lock SW-11ON
lever
Travel two- SW-3 ON
speed
Electric

Slewing parking SW-4 ON

brake release
Conflux/single SW-17ON
change
P3 pump boost-up SE-17 ON

21-6
 21. MECHATRO CONTROL SYSTEM

21.2 BOOM RAISE CONFLUX MECHATRO CONTROL SYSTEM

(1) Start boom raise operation, and the boom raise operation pilot pressure switches boom spool and boom conflux
spool, and inputs into low pressure sensor.
(2) The voltage output by low pressure sensor is input into mechatro controller, and the controller processes the
pilot signal and outputs the command corresponding to input voltage to P2 by-pass cut valve.
(3) P2 by-pass cut valve outputs pilot proportional valve secondary pressure corresponding to the command output
by mechatro controller, and switches P2 by-pass cut valve of control valve.
(4) Operation pilot pressure switches boom main spool and boom conflux valve. And the oil delivered by P1 and P2
pump is confluxed in P2 by-pass cut valve switched by mechatro control.

21-7
21. MECHATRO CONTROL SYSTEM

21.3 SLEWING CUT VALVE CONTROL MECHATRO CONTROL SYSTEM

(1) Start slewing operation, and the slewing pilot pressure switches slewing spool, and is input into low pressure
sensor.
(2) The voltage output by low pressure sensor is input into mechatro controller, and the controller processes the
pilot signal and outputs the command corresponding to input voltage to P2 by-pass cut valve.
(3) P2 by-pass cut valve outputs pilot proportional valve secondary pressure corresponding to the command output
by mechatro controller, and switches P2 by-pass cut valve of control valve.
(4) By switching slewing main spool with operation pilot pressure and switching P2 by-pass cut valve according to
mechatro control command, the slewing operation control is performed more gently.

21-8
 21. MECHATRO CONTROL SYSTEM

21.4 ARM IN / OUT CONFLUX MECHATRO CONTROL SYSTEM

(1) Start arm in and out operation simultaneously, and arm operation pilot pressure switches arm spool, and is input
into low pressure sensor.
(2) The voltage output by low pressure sensor is input into mechatro controller, and the controller processes the
pilot signal and outputs the command corresponding to input voltage to P1 by-pass cut valve.
(3) P1 by-pass cut valve outputs pilot secondary pressure corresponding to the command output by mechatro con-
troller, and switches P1 by-pass cut valve of control valve.
(4) By switching arm main spool with operation spool pressure and switching P1 by-pass cut valve according to
mechatro control command, the oil delivered by P1 and P2 pumps is confluxed during arm operation.

21-9
21. MECHATRO CONTROL SYSTEM

21.5 TRAVEL STRAIGHT MECHATRO CONTROL SYSTEM

21-10
 21. MECHATRO CONTROL SYSTEM

TRAVEL STRAIGHT SYSTEM

(1) Start ATTs work operations (boom, arm, bucket, slewing) in travel operation (right and left), and the pilot pressure
switches respective spools, and is input into respective low pressure sensors.

Boom raise operation is explained here.

(2) If mechatro controller receives the input satisfying the following combination shown in Figure, the controller de-
termines it as travel straight, and the travel straight signal turns on.
(3) After the travel straight signal has turned on, the signal is input to respective proportional valve corresponding
to the following commands.
(4) Operation pilot pressure switches boom main spool and boom conflux valve. And the oil delivered by P1 and P2
pump is confluxed in P2 by-pass cut valve switched by mechatro control.
Travel straight proportional command
Outputs switching command corresponding to boom raise pilot pressure
(ATT pilot pressure in high priority in operation)
P1 by-pass cut valve command
Outputs switching command corresponding to boom raise pilot pressure (ATT pilot pressure in high priority in
operation) and the pressure selected by travel left pilot pressure as high priority.
P2 by-pass cut vale command
Outputs switching command corresponding to boom raise pilot pressure (ATT pilot pressure in high priority in
operation) and the pressure selected by travel right pilot pressure as high priority.
(Reference) Operating condition where travel straight signal turns on

Boom Bucket Arm Slewing

In travel right operation —
In travel left operation — —

21-11
21. MECHATRO CONTROL SYSTEM

21.6 TRAVEL BOOST CONTROL SYSTEM

21-12
 21. MECHATRO CONTROL SYSTEM

TRAVEL BOOST SYSTEM

(1) At travel single-operation
If the pressure of either right travel remote control or left travel remote control exceeded the specified pressure,
main hydraulic pump controls the travel boost operation.
(2) At travel and attachments (Boom, Arm, Bucket, Slewing, Boom swing) simultaneous operation
If the pressure of either right travel remote control or left travel remote control exceeded the specified pressure,
main hydraulic pump controls the travel boost operation.

In these 1. and 2. cases, the travel boost control is executed by ordinary control.
(3) At travel and attachments driven with third pump (Dozer, Extra and so on) simultaneous operation
1) When travel and attachments, which are driven with third pump (Dozer, Extra and so on) are simultaneously
operated, P3 pump pressure is increased, and the pressure is input into high-pressure sensor (SE-17).
2) Output voltage of high-pressure sensor (SE-17) is input into mechatro controller (C1), and if the voltage ex-
ceeded the specified pressure, travel booster solenoid valve (SV-8) is switched into neutral position by com-
mand of mechatro controller.
3) PZ port pressure of main pump regulator returns into hydraulic tank. And this PZ port pressure drop releases
power boost control.

21-13
21. MECHATRO CONTROL SYSTEM

21.7 MECHATRO CONTROL

21.7.1 TROUBLESHOOTING
"CPU lamp on gauge cluster flickers", and "buzzer sounds intermittently". In this case, error code is displayed on
LCD at the center of C-1 controller.
Determines the fault location and corrective action referring to Error diagnostics shown in the following page.
And in case "CPU lamp lights on", and "buzzer sounds continuously", the display indicates the trouble on C-1 con-
troller.

C-1 MECHATRO CONTROLLER GAUGE CLUSTER

CPU LAMP
OFF : Normal
Red lamp flickers :
System error
Display error code on
C-1 controller.
Red lamp lights on :
C-1 conroller error

Table 21-1 Error Diagnostics

Error code Error diagnostic items Corrective action
E01 EEPROM date error
Readjust engine speed, or replace controller.
E02 Mechatro controller maladjustment
E03 Boom raise pressure sensor error
E04 Boom lower pressure sensor error
E05 Arm in pressure sensor error
E06 Arm out pressure sensor error
E07 Bucket digging pressure sensor error
Replace sensor or check harness between sensor and
E08 Bucket dump pressure sensor error
controller for possible damage.
E09 Swing pressure sensor error
E10 P3 pump pressure sensor error
E11 Travel right pressure sensor error
E12 Travel left pressure sensor error
E13 Accel dial error
E14 Travel boost-up selector coil error Replace solenoid valve or check harness between so-
E15 Swing parking selector coil error lenoid valve and controller for possible damage.
Replace battery relay or check harness between bat-
E16 Battery relay error
tery relay and controller for possible damage.
E17 P1 by-pass cut valve coil error
Replace by-pass cut valve or check harness between
E18 P2 by-pass cut valve coil error
by-pass cut valve and controller for possible damage.
E19 Travel straight valve coil error
E20 Governor motor current error Replace governor motor or check harness between
E21 Governor motor start point error governor motor and controller for possible damage.
Replace engine oil pressure switch or check harness
E22 Engine reverse rotation between engine oil pressure switch and controller for
possible damage.

21-14
 21. MECHATRO CONTROL SYSTEM

21.7.2 SERVICE DIAGNOSTICS

This service diagnostics is used to check equipment and harness when CPU lamp flickers, and errors are indicated
on C-1 controller LCD section, and also to determine normal / error according to the numeric values in "Service Di-
agnostics" displayed by switching hardware check switch (A) and (B). However, since the hardware check SWs (A)
and (B) are set to "0.0" in factory, the numeric value in C-1 controller LCD display indicated error code.

SERVICE DIAGNOSTICS DISPLAY ERROR CODE DISPLAY

Remove
grommet, and
you can find
the following
switches.

Hardware check SW (the left shows the "0.0" setting condition).

Turn the arrow at the center of switch and set it to numeric value.
Insert precision driver (-) in to convex indicated by arrow and turn
the arrow to set to numeric values.

Hardware
check SW Service diagnostics Contents of display Example
A B
Normal (without service
0 0 Error diagnostics (error code). —
diagnostics)
0 1 Engine speed set value Display 3 digits per 10 rpm 2.2.5 per 2250 rpm. 2.2.5
0 2 Engine speed measure value Display 3 digits per 10 rpm 2.2.5 per 2250 rpm. 2.2.5
Display key SW input condition in column 10. 24V → 1
Key SW input / battery relay 0V → 0
0 3
output Deexcite → 0
Display battery relay output condition in column 1. Excite → 1
H.S.FC
Mode SW input / auto accel SW Display mode SW input condition in column 10.
0 4 ON → 0
input Display auto accel SW input condition column 1.
OFF → 1
Display wiper SW in column 100 and washer SW in
Wiper SW washer SW / working ON → 1
0 5 column 10.
light SW OFF → 0
Display working light SW condition in column 1.
0 6 Accel dial voltage Accel dial input voltage (3 digits display). Eg. 2.34V 2.3.4
Governor motor position (%) calculated based on
0 7 Accel dial position accel dial voltage. 1.0.0
Example: for 4V or higher, the limit is 100%.
Display the present governor motor step number, Hi 1.0.0
0 8 Governor motor step number
integer 3 digits. Low 0.0.0
Hi 1.0.0
0 9 Governor motor position The present step number is displayed in %.
Low 0.0.0
1 0 Governor motor A phase current Motor coil A output current value 1.5.0
1 1 Governor motor B phase current Motor coil B output current value 1.5.0
Display governor motor limit SW input signal condi- Input → 1
1 2 Governor motor limit SW
tion in column 1. Release → 0

21-15
21. MECHATRO CONTROL SYSTEM

Hardware
check SW Service diagnostics Contents of display Example
A B
1 3 Boom raise pressure sensor
1 4 Boom lower pressure sensor
1 5 Arm out pressure sensor
1 6 Arm in pressure sensor
Value converted input from each pressure sensor
1 7 Bucket digging pressure sensor
to voltage 3.2.4
1 8 Bucket dump pressure sensor
Eg.: 3.24V
1 9 slewing pressure sensor
2 0 P3 pump pressure sensor
2 1 Travel right pressure sensor
2 2 Travel left pressure sensor
Excite → 1
Travel boost-up selector valve
Output command in column 10. Deexcite → 0
2 3 output
Display feedback condition in column 1. Hi input → 1
command / feedback
Lo input → 0
slewing parking selector valve Excite → 1
2 4 Output command in column 10.
output command / feedback Deexcite → 0
Battery relay output command / Hi input → 1
2 5 Display feedback condition in column 1.
feedback Lo input → 0
P1 by-pass cut valve command
2 6
current (Prop. valve C)
P1 by-pass cut valve feedback
2 7
current
P2 by-pass cut valve command Values each command current value (mA) is con-
2 8 6.0.0
current (Prop. valve A) verted Eg: 600mA
P2 by-pass cut valve feedback Values each feed back current (mA) is converted
2 9 6.0.0
current Eg.: 600mA
Travel straight prop. valve com-
3 0
mand current (prop. valve B)
Travel straight prop. valve
3 1
feedback current
Buzer stop SW./slewing flasher Display 0 condition in column 10. ON → 1
3 2
select SW. Display 0 condition in column 1. OFF → 0
Wiper motor relay/slewing flash- ON → 1
3 3 Display 0 in columns 100, 10, and 1 respectively.
er relay (Opt.) OFF → 0
Washer motor relay / working Washer motor relay command, working light relay
ON → 1
3 4 light relay / command. CPU lamp error command conditions in
OFF → 0
CPU lamp error command columns 100, 10 and 1 respectively.
Wiper operation command / Display wiper operation command, lever lock SW. ON → 1
3 5
lever lock SW. condition in columns 10 and 1 respectively. OFF → 0
Display internal adjustment JP SW condition in col- TEST → 1
3 6 Internal adjustment JP SW
umn 1. RUN → 0

21-16
 21. MECHATRO CONTROL SYSTEM

21.7.3 COMPONENT MECHATRO CONTROL

(1) C-1 Mechatronic controller

In adjusting operation

In normal operation

SECTION AA
(Internal adjustment JP switch)

Table 21-2 CN-11

Input
No. NAME Wire color Remarks
Output
11–1 Battery relay (R-1) (R-1) In WG
11–2 Slewing parking select solenoid valve (SV-1) Out V
11–3 Work mode select switch (SW-2) Out G
11–4 Washer switch (SW-2) Out BrW
11–5 Buzzer stop switch (SW-2) Out LgR
11–6 Work light switch (SW-2) Out LG
11–7 Wiper switch (SW-2) Out VG
11–8 Buzzer (SW-2) In Br
11–9 Earth GND (SW-2) Out GW
11–10 Engine oil pressure switch (SW-7) In O
11–11 P2 by-pass cut proportional valve (PSV-B) Out BO
11–12 Travel straight proportional valve (PSV-C) Out GB
11–13 P1 by-pass cut proportionate valve (PSV-D) Out BP
11–14 Travel boost-up select valve (SV-8) Out LR
11–15 Starter switch (SW-1) In P
11–16 Travel alarm stop SW./Hi-reach (SW-37) In WY
11–17 Slewing flasher select switch (SW-21) In Gr
11–18 Travel alarm relay (R-11) In BP

21-17
21. MECHATRO CONTROL SYSTEM

Table 21-2 CN-11

Input
No. NAME Wire color Remarks
Output
11–19 Wiper motor relay (R-5) Out GB
11–20 Flasher relay (KCMA only) (R-19) Out GL
11–21 Washer motor relay (R-6) Out GrL
11–22 Work light relay (R-8) Out BrY
11–23 CPU error lamp In PG
11–24 P2 by-pass cut proportional valve (PSV-B) Out GrR
11–25 Travel straight valve (PSV-C) Out GrB
11–26 P1 by-pass cut proportional valve (PSV-D) Out PW

Table 21-3 CN-12

Input
No. NAME Wire color Remarks
Output
12–1 Boom raise pressure sensor (GND) (SE-3) In BR
12–2 Boom raise pressure sensor (SE-3) In LgY
12–3 Boom raise pressure sensor (5V) (SE-3) In W
12–4 Boom lower pressure sensor (5V) (SE-4) In OB
12–5 Boom lower pressure sensor (SE-4) In LO
12–6 Boom lower pressure sensor (GND) (SE-4) In BrW
12–7 Arm in pressure sensor (GND) (SE-7) In BrY
12–8 Arm in pressure sensor (SE-7) In PG
12–9 Arm in pressure sensor (5V) (SE-7) In OL
12–10 Arm out pressure sensor (5V) (SE-8) In OW
12–11 Arm out pressure sensor (SE-8) In PL
12–12 Arm out pressure sensor (GND) (SE-8) In Gr
12–13 Bucket digging pressure sensor (GND) (SE-1) In BrR
12–14 Bucket digging pressure sensor (SE-1) In LgR
12–15 Bucket digging pressure sensor (5V) (SE-1) In RB
12–16 Opt. operatint switch In LO

21-18
 21. MECHATRO CONTROL SYSTEM

Table 21-4 CN-13

Input
No. NAME Wire color Remarks
Output
13–1 Bucket dump pressure sensor (GND) (SE-2) In BL
13–2 Bucket dump pressure sensor (SE-2) In LgW
13–3 Bucket dump pressure sensor (5V) (SE-2) In RL
13–4 P3 pump pressure sensor (5V) (SE-17) In YL
13–5 P3 pump pressure sensor (SE-17) In PL
13–6 P3 pump pressure sensor (GND) (SE-17) In BrB
13–7 Slewing pressure sensor (GND) (SE-5) In Br
13–8 Slewing pressure sensor (SE-5) In VG
13–9 Slewing pressure sensor (5V) (SE-5) In YG
13–10 Travel right pressure sensor (5V) (SE-9) In YL
13–11 Travel right pressure sensor (SE-9) In VY
13–12 Travel right pressure sensor (GND)) (SE-9) In BY

Table 21-5 CN-14

Input
No. NAME Wire color Remarks
Output
14–1 Governor motor A phase (M-2) Out G
14–2 Governor motor A phase (M-2) Out B
14–3 Governor motor A phase shield Out —
14–4 Travel left pressure sensor (GND) (SE-10) In BG
14–5 Travel left pressure sensor (SE-10) In Sb
14–6 Travel left pressure sensor (5V) (SE-10) In YR
14–7 Accel dial (5V) (SE-16) In WR
14–8 Accel dial (SE-16) In P
14–9 Accel dial (GND) (SE-16) In BW
14–10 Detects the P3 pump pressure sensor (SE-17) In O
14–11 Power supply 24V In RY
14–12 Governor motor B phase (M-2) Out R
14–13 Governor motor B phase (M-2) Out W
Dctccts the starting point of the governor
14–14 (M-2) Out V
motor
14–15 Lever lock switch (SW-11) Out WL
14–16 Flasher relay (KCMA only) (R-19) Out GrR
14–17 Work mode display (C-2) Out LO
14–18 Work mode display (C-2) Out L
14–19 Engine speed sensor (SE-13) In B
14–20 Engine speed sensor (SE-13) In W
14–21 Shield earth In —
14–22 Power supply GND Out B

21-19
21. MECHATRO CONTROL SYSTEM

(2) Gauge cluster

Amp SCCS connector

(Nippon AMP 040)
Housing 174044-2
Terminal 173681-2

VIEW I

Table 21-6 Connector 21

No. NAME Wire color No. NAME Wire color
1 Fuel sensor BrR 11 CPU trouble PG
Slewing parking release
2 Engine coolant temp. sensor YR 12 Lg
switch
3 Alternator (charge) WR 13 Over load GrB
4 Glow switch BrY 14 Spare 1
5 Engine oil pressure switch O 15 Spare 2
6 Engine coolant temp. switch GB 16 Mode display (Main controller) LO
7 Remaining fuel volume switch BrB 17 Mode display (Main controller) L
8 Air cleaner clogged switch BrL 18 Work light switch WB
9 Travel 1-2 speed switch LgB 19 Power supply (+24V) W
10 Buzzer signal Br 20 GND B

Table 21-7 Performances, lamp display and alarm

Display contents Input signal condition Buzzer
Input termi-
sounds or
No. Function nal No. Normal (OFF) Abnormal (ON)
not. *Note 1
1 Battery charge faulty CN21-3 1 0 No
2 Glow operation CN21-4 — 1 No
3 Engine oil pressure low CN21-5 — 0 Yes
4 Engine coolant temp. high temp. CN21-6 — 0 Yes
5 Fuel down CN21-7 800 or more 150 or less No
6 Air cleaner clogged CN21-8 — 0 No
7 Travel 2-speed operation CN21-9 — 1 No
8 Buzzer *Note 2 CN21-10 — 0 Yes
9 CPU trouble CN21-11 0 — No
10 Swing parking CN21-12 — 34 No
11 Over load alarm CN21-13 — 0 Yes
12 Spare 1 CN21-14 — 0 No
13 Spare 2 CN21-15 — 0 No
14 Work light (Back light) CN21-19 — 1 No

1. The buzzer sounds intermittently, 0.5 ± 0.2 sec : ON and 0.5 ± 0.2 sec : OFF when the battery charge is
short, or error Nos. 3, 4, 11 in the above Table occurred during normal operation.
2. The buzzer in error No.8 sounds only, and mechatro controller controls it.

21-20
 21. MECHATRO CONTROL SYSTEM

(3) Switch assy

CN22 CN23

CN23 Wire
No. NAME color
1 Power supply+5V G
CN22 2 Address input Di1 LgR
3 Address input Di2 LG
4 Address input Di3 VG
CN22
5 Date output DO1 BrW
CN23 6 GND B
7 NC -
8 NC -

No. NAME Wire

color
1 Back light + WB
CN23
View from rear side 2 Back light - B

(4) Governor motor (M-2)

NAME PLATE

Connection diaqram

Brown Red
(A) (B)

Orange Yellow MOTOR CONNECTOR

(A) (B) LIMIT SWITCH CONNECTOR

Limit switch operation range

Limit switch connector wiring diagram Motor connector wiring diagram

No. Lead color Connection

line No. Lead color Connection
line
5 White COM 1 Brown A
_
6 Red NO 2 Orange A
7 Yellow NC 3 Red B
_
4 Yellow B

21-21
21. MECHATRO CONTROL SYSTEM

[MEMO]

21-22
 22. HYDRAULIC SYSTEM

TABLE OF CONTENTS

22.1 SUMMARY ......................................................................................................................... 22-3

22.1.1 FUNCTION AND FEATURES OF HYDRAULIC CIRCUIT ......................................... 22-3
22.2 HYDRAULIC CIRCUITS AND COMPONENT MODELS ..................................................... 22-4 22
22.2.1 STANDARD SPECIFICATION ................................................................................... 22-5
22.2.2 BOOM & ARM SAFETY SPECIFICATION ................................................................. 22-6
22.2.3 EXTRA SPECIFICATION (OPT.) ............................................................................... 22-7
22.3 NEUTRAL CIRCUIT ........................................................................................................... 22-8
22.4 TRAVEL CIRCUIT ............................................................................................................. 22-10
22.5 BUCKET CIRCUIT ............................................................................................................. 22-12
22.6 BOOM CIRCUIT ................................................................................................................ 22-14
22.7 SLEWING CIRCUIT ........................................................................................................... 22-18
22.8 ARM CIRCUIT ................................................................................................................... 22-20
22.9 BOOM SWING CIRCUIT ................................................................................................... 22-24
22.10 NIBBLER & BREAKER CIRCUIT ....................................................................................... 22-26
22.11 COMBINED CIRCUIT (MULTIPLE CIRCUIT) ................................................................... 22-28
22.12 DOZER CIRCUIT .............................................................................................................. 22-32
22.13 TRAVEL AND DOZER CIRCUIT ....................................................................................... 22-34
22.14 CONTROL LINES .............................................................................................................. 22-36
22.15 UPPER & LOWER HYD. LINES ......................................................................................... 22-48
22.16 ATT HYD. LINES ............................................................................................................... 22-54

22-1
22. HYDRAULIC SYSTEM

22-2
 22. HYDRAULIC SYSTEM

22.1 SUMMARY
22.1.1 FUNCTION AND FEATURES OF HYDRAU-
The hydraulic circuits are built up with the following
LIC CIRCUIT
functions and features in order to achieve easy opera-
bility, safety mass volume handling and low fuel con-
sumption.
Table 22-1

Perfor-
Device Function Features
mance

• Travel straight • Travel straight at composite operation

• 2-speed travel changeover. • 2-speed changeover of travel speed.
• Auto parking brake • Automatic braking when parking
• Motor overrun protection • Secure people from danger caused by overrun-
Travel

ning of motor on the slope.

• Travel pilot operation • start and stop
Slow
• Travel boost-up • Travel speed up at traveling
• Reverse rotation protective function • Easy positioning to protect it from slewing
back when stops slewing.
Slewing

• Slewing priority circuit • operation of stable slewing speed, arm

Easy Operability and Safety

Easy
(simultaneous operation of arm digging and slanted leveeing, slewing press digging.
slewing motions)
• Automatic slewing parking brake. • Protect it from slewing drift on the slope.
• Hydraulic pilot control system. • Delicate operability.
Attachment

• Pilot safety lock system • Cut out of pilot circuit by safety lock lever.
• valve (boom / arm / boom swing)
Lock • Protect boom, arm and the boom swing from
natural drop when parking.

• Closed pressure type hydraulic oil tank • To prevent hydraulic oil from being contami-
nated and to promote self suction ability of
pump.
Others

• Suction strainer • Remove dust on suction side.

• Line filter : pilot circuit • To prevent pilot operating circuit from malfunc-
tioning
• Return circuit • To prevent hydraulic oil from fouling.
• Cooling hydraulic oil by oil cooler. • To prevent hydraulic oil from being deteriorated.

• Total power shift control variable displacement • Use engine power effectively with 2 variable
Mass handling capability

pump displacement pumps (delivery side)

Pump

• Boom raise conflux circuit • Speed up for boom raise operation.

Attachment

• Arm conflux circuit • Speed up for arm operation.

• Dozer circuit • Speed up the back-filling during dozing
Consumption

• Auto accel • Reduce fuel consumption and noise by lowering

computer
Low Fuel

Micro

The delay auto accelerator works when boom engine speed when control lever is in neutral
swing and N & B operate. position.

22-3
22. HYDRAULIC SYSTEM

22.2 HYDRAULIC CIRCUITS AND

COMPONENT MODELS
STANDARD SPECIFICATION E80MSR
No. NAME MODEL No.
1 PUMP ASSY (WITH GEAR PUMP) K3SP36B
2 CONTROL VALVE BCV75-A9
3 CONTROL VALVE KVS65-1
4 SLEWING MOTOR UNIT SG025E-096
5 TRAVEL MOTOR GM09VN
6 BOOM CYLINDER 110–70–916
7 ARM CYLINDER 95–65–813
8 BUCKET CYLINDER 80–55–735
9 SWING CYLINDER 105–65–594
10 DOZER CYLINDER 130–70–170
11 SWIVEL JOINT
12 PILOT VALVE (ATT) PV48M2061
13 PILOT VALVE (TRAVEL) PVD6PC4017A
14 PILOT VALVE
15 PROPORTIONAL VALVE BLOCK 8KWE5G-30/G24WR-821
16 RETURN FILTER FZJ3183S002A
17 CHECK VALVE Y2389
18 SUCTION STRAINER Y497500
19 INLINE FILTER YTD9986
20 BREATHER Y-382000
21 CONNECTOR
22 CONNECTOR
23 CHECK VALVE
24 STOP VALVE
25 SELECT VALVE

22-4
 22. HYDRAULIC SYSTEM

22.2.1 STANDARD SPECIFICATION

22-5
22. HYDRAULIC SYSTEM

22.2.2 BOOM & ARM SAFETY SPECIFICATION

22-6
 22. HYDRAULIC SYSTEM

22.2.3 EXTRA SPECIFICATION (OPT.)

22-7
22. HYDRAULIC SYSTEM

22.3 NEUTRAL CIRCUIT

This section describes the following.
1) Safety lock lever
2) Pump control

22.3.1 SAFETY LOCK LEVER AND PILOT CIRCUIT

(1) Purpose
To protect attachment from unexpected operation for
safety, however, dozer is outside of adaptation.
(2) Principle
Cut pressure source of pilot valve for operation.
(3) Operation
After engine starts, push down the safety lock lever
(red), and the limit switch (SW-11) is turned on, the pilot
operation circuit is changed to standby condition.

22.3.2 PUMP CONTROL

(1) Type
Total power shift control variable displacement pump
(2) Operation
1) Since the pump delivery flow rate is unloaded
when in neutral position, the pump delivery pres-
sure (P1, P2) is low, and the average pressure
(P1+P2) / 2 on compensating piston (621) stepping
section becomes small. Consequently the force of
spring (625, 626) becomes higher than the average
pressure, and the spool (652) is moved rightward.
And the passage to large bore of servo piston (532)
is connected with low pressure side and moves left-
ward, then tilting angle becomes larger, and pump
delivery flow rate increases.
2) Lever (611) rotates at a fulcrum of pin, and moves
with this operation, the feedback sleeve (651) right-
ward, then keep moving until the openings of spool
(652) and sleeve (651) are closed.

22-8
 22. HYDRAULIC SYSTEM

Neutral circuit safety lock lever ON 22-9

22. HYDRAULIC SYSTEM

22.4 TRAVEL CIRCUIT 22.4.3 TRAVEL MAIN CIRCUIT

This section describes the following. (1) Operation
With travel pilot operation, the travel speed is switched,
1) Travel forward pilot simultaneous operation circuit
and the oil delivered through A1 port of main pump
2) Travel 2 speed solenoid command circuit
passes through C/V P1-A1, flows into A port of travel
3) Travel main circuit motor (5) through C port of swivel joint (11) allowing
4) Travel motor function travel motor to perform the operation above mentioned.
5) Travel boost-up (Refer to "Travel Motor Function")

22.4.1 FORWARD PILOT SIMULTANEOUS OPERA- 22.4.4 TRAVEL MOTOR FUNCTION

TION CIRCUIT (1) Function
(1) Operation 1) Brake valve that prevents the motor from running
1) Start travel right and left at the same time with con- recklessly on a slope.
trol lever, and the pilot proportional secondary pres- 2) Hydraulic motor cavitation protective check valve.
sure is delivered through P/V (13) 2, 4 ports, at the 3) Shockless relief valve and anticavitation valve
same time select higher pressure and the higher when stopping it with the force of inertia.
pressure is delivered through 5, 6 ports, then acts
4) High and low speed 2 stage switching mechanism.
on low pressure sensors (SE9) (SE10).
5) Travel parking brake.
2) Pilot proportional secondary pressure flows into
Pd1, Pa1 ports of control valve, acts on travel 22.4.5 TRAVEL BOOST-UP
spool, and switches main circuit. (1) If the pressure of either low-pressure sensor (SE-9) or
3) The signal output by low pressure sensor is input to low-pressure sensor (SE-10) exceeds the specified
mechatro controller, and executes signal process- pressure, travel booster solenoid is switched. Conse-
ing. quently, the pressure is applied to pump PZ port; spring
(625) is compressed with piston (668), then the setting
22.4.2 TRAVEL MAIN CIRCUIT
value of pump power control is increased.
(1) Purpose
Change travel motor speed with switch.
(2) Principle
Electric signal because of switching excites travel 2
speed solenoid and pilot primary pressure varies
swash plate angle of variable motor.
(3) Operation
Press switches with rabbit and turtle marks on travel le-
ver grips, and the solenoid (SV-3) of proportional valve
block (15) is excited and is switched, and solenoid com-
mand is output by port 3 and sends to P port of travel
motor (5), opens oil passage to 2 speed piston, and
switches it to 2 speed tilting angle with self-pressure.

22-10
 22. HYDRAULIC SYSTEM

Travel circuit : Travel 2nd speed operation (Forward), travel boost-up 22-11
22. HYDRAULIC SYSTEM

22.5 BUCKET CIRCUIT 22.5.3 E/G OVERLOAD PROTECTION WITH PUMP

POWER CONTROL OPERATION
This section describes the following.
(1) Principle
1) Bucket digging pilot circuit
Total power shift control with pump pressure (P1+P2)/2
2) Auto accel operation
(2) Operation
3) E/G overload protection with pump power control op-
1) With increase of pump delivery pressure P1 or P2,
eration
(P1+P2)/2 pressure acts on compensating piston
4) Bucket digging main circuit
(621) stepping section by the function of restriction.
22.5.1 BUCKET DIGGING PILOT CIRCUIT 2) With bucket operation, the delivery pressure is
(1) Operation raised and pushes spool (652) leftward, and moves
Start bucket digging operation, and pilot proportional it to the position where the force of springs (625,
secondary pressure is output through port (1) of right pi- 626) balances the hydraulic pressure.
lot V (12), and flows into C/V (2) Pa3 port, and switches 3) With movement of spool (652) leftward, the oil pas-
bucket spool. sage to large bore of servo piston (532) opens, and
delivery pressure is led into it and pushes the piston
22.5.2 AUTO ACCEL OPERATION
rightward.
(1) Principle
4) Then, the tilting angle becomes smaller and reduc-
Start operating with signal output by low pressure sen-
es the delivery flow rate from the pump used to pro-
sor.
tect engine from overloading.
(2) Operation
[Lever in neutral position] 22.5.4 BUCKET DIGGING MAIN CIRCUIT
When the signal is not input to low pressure sensor for (1) Operation
4 seconds or more after turning accel dial to Max. posi- With pilot operation, the pressure oil switches bucket
tion, set engine speed to 1050 rpm. spool, and is fed into bucket cylinder H side through C/
[Lever in operation position] V A3 port. And the return oil from cylinder R side flows
When the pressure of 0.59 MPa (86 psi) or more is in- into tank circuit while being restricted by bucket spool
put to low pressure sensor in STD specification (travel, through C/V (2) B3 port.
bucket, boom, swing and arm), the proportional voltage
received from low pressure sensor is output to C1 con-
troller, and restores the E/G speed to the speed set by
accel dial with control lever operation.

22-12
 22. HYDRAULIC SYSTEM

Bucket circuit : Bucket digging operation 22-13

22. HYDRAULIC SYSTEM

22.6 BOOM CIRCUIT 22.6.2 BOOM RAISE 2 PUMPS CONFLUX MAIN CIR-
CUIT IN C/V
This section describes the boom raise conflux operation.
(1) Purpose
1) Boom raise pilot circuit
Boom raise speed up
2) Boom raise 2 pumps conflux main circuit in C/V
(2) Principle
22.6.1 BOOM RAISE PILOT CIRCUIT Confluxing oil from 2 pumps
(1) Operation (3) Operation
1) Start boom raise operation, and pilot proportional 1) The oil delivered through A1 port of P1 pump flows
secondary pressure from right pilot valve (12) is into C/V (2) P1 port, and branches into by-pass cir-
output through port (3), and acts on low pressure cuit and parallel circuit. However since the boom
sensor (SE3), and at the same time the pressure is spool is moved and by-pass circuit is closed, the oil
branched into 2 circuits and acts on Pa2 and Pc4 opens load check valve through parallel circuit and
port of C/V (2). flows into boom spool.
2) The voltage output by low pressure sensor is pro- 2) On the other hand, the oil delivered through A2 port
cessed by mechatro controller and outputs com- of P2 pump passes through C/V (2) P2 port, flows
mand current to P2 by-pass cut valve (PSV-B) and into travel straight section, and branches into by-
solenoid valve outputs proportional secondary pass circuit and parallel circuit. However, since P2
pressure and the pressure acts on C/V (2) Pd4 port. by-pass cut valve is switched and closed, the oil
3) Then, the secondary pressure fed into C/V (2) Pa2 passes through the outside of boom conflux spool
port switches boom conflux spool. And the solenoid from parallel circuit, opens load check valve from
proportional secondary pressure fed into Pd4 port boom conflux circuit, confluxes with oil delivered by
switches P2 by-pass cut valve. P1 pump inside, and flows into boom spool.
3) Then the oil passes through boom spool, opens
lock valve of boom lock valve, and is led into H side
of boom cylinder through C/V (2) A2 port.
4) The return oil from boom cylinder R side flows into
tank circuit through boom spool from C/V (2) B2
port.

22-14
 22. HYDRAULIC SYSTEM

Boom circuit : Boom raise (up) operation, conflux function 22-15

22. HYDRAULIC SYSTEM

This section describes the boom lower operation. [When boom lower operation pressure is not
1) Boom lower pilot circuit actuated]
2) Boom lower main circuit 1) Where the pilot pressure in boom lock valve relief
port Pb2’ is not actuated, the above needle valve is
3) Natural drop protection with boom lock valve
pushed back by the force of spring, and the back
22.6.3 BOOM LOWER PILOT CIRCUIT pressure of lock valve becomes equal to the return
(1) Operation pressure.
1) Start boom lower operation, and the pilot propor- 2) The area on back pressure side of lock valve is
tional secondary pressure is output through port (4) larger, the lock valve is completely seated, and the
of pilot valve, and acts on low pressure sensor oil in boom cylinder H side is stopped from return-
(SE4), at the same time branches into two circuits, ing, protecting the boom from natural drop.
then acts on C/V (2) Pb2 and Pb2' port.
2) The voltage output by low pressure sensor (SE4) is
input into mechatro controller.
3) Then, the proportional secondary pressure fed into
C/V (2) Pb2 port switches boom spool. And the pro-
portional secondary pressure flown into C/V (2)
Pb2' port releases boom lock valve.

22.6.4 BOOM LOWER MAIN CIRCUIT

(1) Operation
1) The oil delivered through A1 port of P1 pump pass-
es through C/V (2) P1 port and flows into travel
straight section, and branches into by-pass circuit
and parallel circuit. However since the boom spool
is moved and by-pass circuit is closed, the oil opens
load check valve through parallel circuit and flows
into boom spool.
2) The oil passes through outside of boom spool, and
flows into boom cylinder R side through C/V (2) B2
port.
3) On the other hand, the return oil boom cylinder H
side flows into C/V (2) A2 port, but since the boom
lock valve is open, it flows into boom spool.
4) Then the oil passes through orifices on boom spool
and returns into tank while restricting.

22.6.5 NATURAL DROP PROTECTION WITH BOOM

LOCK VALVE
(1) Operation
[When boom lower secondary pressure is actuated]
1) The control secondary pressure flown into relief
port Pb2' of boom lock valve pushes needle valve
on the rear side of the lock valve seat, and the back
pressure of lock valve flows into tank circuit through
port DR5 making the opening of valve easier.
2) The return oil from boom cylinder R side opens lock
valve, and flows into boom spool.

22-16
 22. HYDRAULIC SYSTEM

Boom circuit : Boom lower (down) operation 22-17

22. HYDRAULIC SYSTEM

22.7 SLEWING CIRCUIT 22.7.3 SLEWING MAIN CIRCUIT

This section describes the following operations. (1) Operation
The oil delivered through A2 port P2 pump passes
1) Slewing left pilot circuit
through C/V (2) P2 port and flows into travel straight
2) Slewing auto parking brake
section, and branches into by-pass circuit and parallel
3) Slewing main circuit circuit. However since the slewing spool is moved and
4) Slewing motor function by-pass circuit is closed, the oil opens load check valve
through parallel circuit and flows into B port of slewing
22.7.1 SLEWING LEFT PILOT CIRCUIT
motor through C/V (2) D2 port, and has slewing motor
(1) Operation rotated in counterclockwise.
1) Start slewing left operation, and pilot proportional
22.7.4 SLEWING MOTOR FUNCTION
secondary pressure through port (5) of left pilot
valve (12) is output, and acts on low pressure sen- (1) Anticavitation circuit when reducing slewing speed
sor (SE5), and at the same time the pressure is (2) Shockless relief to protect it from reverse rotation
branched into 2 circuits and acts on Pd2 and Pd2’
ports of C/V (2).
2) The voltage output by low pressure sensor is pro-
cessed by mechatro controller and outputs com-
mand current to P2 by-pass cut valve (PSV-B) and
solenoid valve outputs proportional secondary
pressure and the pressure acts on C/V(2) Pd4 port.
3) Then, the secondary pressure fed into C/V (2) P2
port switches slewing, spool. And the secondary
pressure fed into Pd2' port flows into PS' port
through check ball, then into PS' port, and acts on
load check valve for arm operation. In addition, the
solenoid proportional secondary pressure switches
P2 by-pass cut valve.

22.7.2 SLEWING AUTO PARKING BRAKE (P/B)

(1) Purpose
Slewing lock and parking in neutral position
(2) Principle
Release only when required to operate mechanical
brake.
(3) Operation
1) Slewing parking release SW-4 excites slewing
parking SOL (SV-1) by turning switch on.
2) Only when operation secondary pressure burring
slewing and arm digging operation acts on any of
low pressure sensors (SE5,7), it release the excita-
tion to slewing parking SOL.
3) After 5 seconds when the pressure of low pressure
sensor (SE5) from slewing operation has exhaust-
ed, the slewing parking SOL (SV-1) is excited. And
in case of arm digging operation, at the same time
when the pressure of pressure sensor (SE7) for
arm digging operation has been exhausted, the
slewing parking SOL (SV-1) is excited.

22-18
 22. HYDRAULIC SYSTEM

Slewing circuit : Slewing operation (Left) 22-19

22. HYDRAULIC SYSTEM

22.8 ARM CIRCUIT 4) In addition, the return oil from arm cylinder R side
flows into arm lock valve through D3 port, but since
This section describes the following operations.
the arm lock valve is open, it flows into arm spool.
1) Arm control pilot circuit
5) Then, the oil passes through orifices on arm spool
2) Arm in (digging) 2 pumps conflux main circuit
and returns into tank while restricting.
3) Natural drop protection with arm lock valve
22.8.3 NATURAL DROP PROTECTION WITH ARM
22.8.1 ARM CONTROL PILOT CIRCUIT LOCK VALVE
(1) Operation (1) Operation
1) Start arm in operation, and pilot proportional sec- [When arm in operation is indicated]
ondary pressure is output through port (7) of left pi- 1) The control secondary pressure flown into relief
lot valve (12), and acts on low pressure sensor port Pc3’ of arm lock valve pushes needle valve on
(SE7), and at the same time the pressure branches the rear side of lock valve seat, and the back pres-
into 2 circuits and acts on Pc3 and Pc3' ports of C/ sure of lock valve flows into tank circuit through
V (2). drain port DR3 making the opening of valve easier.
2) The voltage output by low pressure sensor (SE7) is 2) The return oil from arm cylinder R side opens lock
input into mechatro controller and the controller ex- valve, and flow into arm spool.
ecutes signal processing, and outputs command
[When arm in operation is not indicated]
current to P1 by-pass cut valve (PSV-D) and sole-
1) Where the pilot pressure in arm lock valve relief
noid valve outputs proportional secondary pressure
port Pc3' is exhausted, the above needle valve is
and the pressure acts on C/V (2) Pb4 port.
pushed back by the force of spring, and the pres-
3) Then, the secondary pressure fed into C/V (2) Pc3
sure of lock valve becomes equal to the return pres-
port switches arm spool. And the secondary pres-
sure due to back pressure of lock valve.
sure fed into Pc3' port releases arm lock valve. In
2) The area on back pressure side of lock valve is
addition, solenoid proportional secondary pressure
large, the lock valve is completely seated, and the
switches P1 by-pass cut valve.
oil in arm cylinder R side is stopped from returning,
22.8.2 ARM IN 2 PUMPS CONFLUX MAIN CIRCUIT protecting the arm from natural drop.
(1) Purpose
Arm in speed up
(2) Principle
Confluxing oil from 2 pumps in C/V (2)
(3) Operation
1) The oil delivered by P2 pump flows into travel
straight section through C/V (2) P2 port, and
branches into by-pass circuit and parallel circuit.
However since the arm spool is moved and by-pass
circuit is closed, the oil opens load check valve and
flows into arm spool.
2) On the other hand, the oil delivered by P1 pump
passes through C/V (2) P1 port and flows into travel
straight section, and branches into by-pass circuit
and parallel circuit.
However, since P1 by-pass cut valve is switched
and low pressure circuit is closed, the oil opens
load check valve and confluxes with oil delivered
from load check valve on P2 parallel circuit, and
flows into arm spool.
3) Then, the confluxed oil is fed into arm cylinder H
side through C/V (2) C3 port from arm spool.

22-20
 22. HYDRAULIC SYSTEM

Arm circuit : Arm in (digging) operation, conflux function 22-21

22. HYDRAULIC SYSTEM

This section describes the following operations.

1) Arm out pilot circuit
2) Arm out drop protection with arm lock valve

22.8.4 ARM OUT PILOT CIRCUIT

(1) Operation
1) Start arm out operation, and the pilot proportional
secondary pressure is output through port (8) of left
pilot valve (12), and acts on low pressure sensor
(SE8), at the same time acts on C/V (2) Pd3 port.
2) The voltage output by low pressure sensor (SE-8)
is processed by mechatro controller, and outputs
command current to P1 cut valve (PSV-D), and the
solenoid valve outputs secondary pressure and
acts on C/V Pb4 port.
3) Then, the secondary pressure fed into C/V (2) Pd3
port switches arm spool. And the solenoid propor-
tional secondary pressure flows into Pb4 port
switches P1 by-pass cut valve.

22.8.5 ARM OUT DROP PROTECTION WITH ARM

LOCK VALVE
(1) Purpose
Arm out speed up
(2) Operation
1) The oil delivered by P1 and P2 pumps flows in the
same way until the oil reaches to arm spool.
2) Then, the oil passes through arm spool opens arm
lock valve with free flow and flows into arm cylinder
R side through C/V (2) D3 port.
3) And, the return oil from arm cylinder H side flows
into C3 port, passes through periphery on arm
spool, and returns into tank circuit.

22-22
 22. HYDRAULIC SYSTEM

Arm circuit : Arm out (extend) operation, conflux function 22-23

22. HYDRAULIC SYSTEM

22.9 BOOM SWING CIRCUIT 22.9.3 RIGHTWARD DRIFT PREVENTION WITH

SWING LOCK VALVE
The following functions are explained.
(1) Purpose
1) Boom left swing pilot circuit
Prevents natural rightward projection by right swing.
2) Boom left swing main circuit
(2) Operation
3) Rightward drift prevention with swing lock valve
[Where boom swing secondary operating pressure is
22.9.1 BOOM LEFT SWING PILOT CIRCUIT available]

(1) Operation 1) If you step on the heel of the right hand foot pedal,
If you step on the toe of the right foot pedal, the second- the secondary pilot pressure comes out of the A
ary pilot pressure comes out of the B port of pilot valve port of pilot valve (14) and acts upon the pressure
(14) and acts on the low-pressure switch (SW18). At switch (SW18). At the same time, the oil is split into
the same time the pressure acts upon the Pa5 port of two streams and acts upon the Pb5 port and Pb5'
C/V (2). port of C/V (2).
2) If the secondary operating pressure enters the
22.9.2 BOOM LEFT SWING MAIN CIRCUIT
boom swing lock valve release port Pb5’, the back
(1) Operation pressure of the lock valve reaches the tank line
1) The oil delivered by the P1 pump enters the P1 port from the drain port DR8. This makes the lock valve
of C/V (2) and is split into the bypass line and the easy to open. Thus the oil returning from the H side
parallel line by means of the travel straight valve. of the arm cylinder opens the lock valve and enters
The oil then enters the boom swing spool. However the arm spool.
since the spool is shifted and the bypass cut is 3) If the pressure switch (SW18) is turned on by the
closed, the oil pushes open the load check valve by secondary operating pressure with the decelerator
way of the parallel line and enters the boom swing on, the decelerator is released. However, it returns
spool. to “ON” four seconds after the pressure switch is
2) Next, the oil enters the A5 port of C/V (2) via the turned off.
boom swing spool and is supplied to the H side of [Where boom swing operating secondary pressure
the boom swing cylinder from the A5 port of C/V (2). is not available]
3) In the meantime, the oil returning from the R side of 1) If pilot pressure disappears from the boom swing
the boom swing cylinder enters the B5 port of C/V lock valve release port Pb5', the lock valve is seat-
(2) and returns to the tank line. ed completely because the back pressure receiving
area of the lock valve is large. This prevents the oil
on the H part of the boom swing cylinder from re-
turning to the boom swing spool of C/V (2). This in
turn reduces oil leakage through the spool to zero
to prevent the swing motion from drifting to the
right.

22-24
 22. HYDRAULIC SYSTEM

Boom swing circuit : Boom swing operation (Left) 22-25

22. HYDRAULIC SYSTEM

22.10 NIBBLER & BREAKER CIRCUIT 22.10.3 BREAKER BLOWING PILOT CIRCUIT
The following functions are explained. (1) Operation
[Electrical]
1) Nibbler closing pilot circuit
2) Nibbler closing main circuit 1) Turn the conflux-single select switch to .
3) Breaker blowing pilot circuit [Hydraulic]
4) Breaker blowing main circuit 2) Press on the heel of the lefthand foot pedal. (Same
as for the nibbler closing)
22.10.1 NIBBLER CLOSING PILOT CIRCUIT
(1) Operation 22.10.4 BREAKER BLOWING MAIN CIRCUIT
[Electrical] (1) Operation
1) Blowing with the breaker only by the oil delivered by
1) If the conflux-single select switch is turned to ,
the P1 pump.
the conflux-single select solenoid (SV-2) of the pro-
portional valve block (15) is energized. This causes 2) If the selector valve (25) of the breaker return circuit
the primary pilot pressure to come out of port 2 and is changed over, the oil is brought directly to tank,
enters the Pd6 port of C/V (2). instead of returning to C/V (2).
[Hydraulic]
1) If you press on the toe of the lefthand foot pedal, the
secondary pilot pressure comes out of the B port of
pilot valve(14) and acts on the pressure switch
(SW35). At the same time, the pressure acts upon
the Pa6 port of C/V (2).
2) If the pressure switch (SW35) is turned on by sec-
ondary operating pressure with the decelerator on,
the decelerator is released, but returns to ON con-
dition four seconds after the pressure switch is
turned off.

22.10.2 NIBBLER CLOSING MAIN CIRCUIT

(1) Operation
1) The oil delivered by the P1 pump enters the P1 port
of C/V (2). The oil is then branched off to the bypass
line and the parallel line by means of the travel
straight valve and enters the N & B spool. Since the
spool is shifted, the bypass cut is closed. The oil
pushes the load check valve open and enters the N
& B spool.
2) Then, if the conflux-single select spool is changed
over, the oil delivered by the P2 pump enters the P2
port of C/V (2) and goes through the bypass line of
the P1 pump side by way of the bypass line of the
travel straight valve and the double-single select
valve.
The oil delivered by the P1 pump and the oil deliv-
ered by the P2 pump are combined together and
supplied to the H side of the nibbler cylinder by way
of the A6 port of C/V (2).
3) In the meantime, the oil returning from the R side of
the nibbler cylinder returns to the tank line by way
of the B6 port of C/V (2).

22-26
 22. HYDRAULIC SYSTEM

Nibber & Breaker circuit : Nibbler close operation when 2 pumps conflux switch ON 22-27
22. HYDRAULIC SYSTEM

22.11 COMBINED CIRCUIT

(MULTIPLE CIRCUIT)
This section describes only the difference in combined op- Whenever the travel pilot pressure exceeds the speci-
eration. fied pressure at simultaneous operations of travel and
1) Boom raise / travel, pilot circuit boom up, the travel boost control is executed.
When the travel operation and the arm, bucket, slewing
2) Boom raise / travel, main circuit
operations are simultaneously operated, also the travel
22.11.1 BOOM RAISE/TRAVEL, PILOT CIRCUIT boost control is executed.
(1) Operation
[Points which are differed from the independent opera-
tion]
1) With signal processing of mechatro controller, the
controller outputs command current to travel
straight valve (PSV-C) and P2 by-pass cut valve
(PSV-B) and P1 by-pass cut valve (PSV-D), and
this solenoid valve outputs secondary pressure,
then acts on C/V (2) PO, Pd4 and Pb4 ports.
2) Next, the electromagnetic proportional secondary
pressure which entered the Pd4 port of C/V(2)
changes the P2 bypass cut valve. The PO port
pressure changes the travel straight valve. The Pb4
port pressure changes the P1 bypass cut valve.

22.11.2 BOOM RAISE/TRAVEL, MAIN CIRCUIT

(1) Purpose
Travel straight operation is available even if the attach-
ment is operated during travel operation.
(2) Principle
The travel motion and attachment operations are per-
formed by respective pump.
(3) Operation
1) The oil delivered by P1 and P2 pumps flows into
travel straight section through C/V (2) P1, P2 ports.
The travel straight spool is moved and the oil deliv-
ered by P1 pump branches into P1 and P2 parallel
circuits. In addition, the oil delivered by P2 pump
branches into P1 and P2 by-pass circuits.
2) And, both travel operations are performed by by-
pass circuit, that is performed by the oil delivered by
P2 pump.
Since boom spool and other spool are operated
through parallel circuit, so oil delivered by P1 pump
is available.
3) However, a part of flow is connected through orifice
of travel straight spool and the travel and boom
(ATT) speeds are regulated by connection to this
orifice.

22-28
 22. HYDRAULIC SYSTEM

Conflux operation : Boom up / Travel 1st speed operation, in Travel straight function, travel boost-up 22-29
22. HYDRAULIC SYSTEM

This section describes difference in combined operation.

1) Slewing / Arm in, pilot circuit
2) Slewing / Arm in, slewing priority main circuit

22.11.3 SLEWING / ARM IN, PILOT CIRCUIT

(1) Operation
1) Start slewing left and arm in operation simulta-
neously, and with signal processing of mechatro
controller, the mechatro controller outputs com-
mand to P2 by-pass cut valve (PSV-B) and P1 by-
pass cut valve (PSV-D), and this solenoid valve out-
puts secondary pressure and acts on C/V (2) Pd4
and Pb4 ports. (These operations are the same as
that of the combined respective independent oper-
ation.)
2) Then, the higher pilot proportional secondary pres-
sure selected in slewing control side flows into C/V
(2) PS port, acts on load check valve for arm oper-
ation, and makes it less susceptible to the oil flow-
ing into arm spool.

22.11.4 SLEWING / ARM IN, SLEWING PRIORITY

MAIN CIRCUIT
(1) Purpose
Stable slewing speed
(2) Principle
It controls the oil flow from the P2 pump into the arm so
it is used for slewing action on a priority basis.
(3) Operation
1) The slewing main circuit functions with the delivery
of P2 pump, but in P2 pump circuit the slewing and
arm circuits are in parallel, therefore the oil flows
into slewing and arm sides at the same time.
However, in slewing operation, the selected higher
slewing pilot proportional secondary pressure limits
the opening of load check valve on arm side, allow-
ing to stop confluxing with oil by P2 side. Therefore,
the oil delivered by P2 pump flows into slewing side
in preference to arm side.
2) Arm in circuit functions with only P1 pump circuit,
but only when the pressure rise higher than the
pressure specified from arm in load check valve the
oil delivered by P1 and P2 pumps is confluxed.

22-30
 22. HYDRAULIC SYSTEM

Conflux operation : Slewing Arm in operation, in slewing priority function 22-31

22. HYDRAULIC SYSTEM

22.12 DOZER CIRCUIT

The following functions are explained.
1) Manual operation circuit
2) Auto accelerator independent circuit
3) Dozer lowering main circuit

22.12.1 MANUAL OPERATION CIRCUIT

(1) Function
Primary pressure pilot lock is disabled because of man-
ual lever operation. Therefore, the safety lock by the
access shutoff lock lever does not work.

22.12.2 AUTO ACCELERATOR INDEPENDENT CIR-

CUIT
(1) Function
Since the accelerator is not pilot-operated, the low-
pressure sensor does not work. Therefore, the auto ac-
celerator is not applicable. In reality, dozer operation is
combined with travel action. The auto accelerator func-
tion is released in travel action. Therefore, there is no
problem with the auto accelerator operation.

22.12.3 DOZER LOWERING MAIN CIRCUIT

(1) Function
1) If the dozer lever is operated, the oil supplied to the
dozer cylinder changes over the spool of the control
valve (3). Then the oil delivered from the A5 port of
the gear pump comes out of the A1 port of the doz-
er C/V, passes through the G port of the swivel joint
and is supplied to the H side of the dozer cylinder
(10).
2) The oil returned from the dozer cylinder passes
through the R side of the cylinder and the F port of
the swivel joint and returns to tank by way of the B1
port of C/V.

Bringing the dozer blade in contact with ground before

the engine stops:
Since the dozer control valve is operated manually, the
spool of it can be moved even when the engine is not
operating. Therefore, in case the engine should stop
with the dozer blade hoisted, the dozer blade falls by its
weight if the dozer lever is brought down. It is danger-
ous to put your feet under the dozer blade. For this rea-
son, do not fail to bring down the dozer blade to the
ground before the engine stops.

22-32
 22. HYDRAULIC SYSTEM

Dozer circuit : Dozer down operation 22-33

22. HYDRAULIC SYSTEM

22.13 TRAVEL AND DOZER CIRCUIT

This section describes a following function.
1) Hydraulic pump power shift control at simultaneous
operations of travel and dozer.

22.13.1 PUMP POWER SHIFT CONTROL AT SIMUL-

TANEOUS OPERATIONS OF TRAVEL AND
DOZER
(1) Operation
1) When the travel and dozer are simultaneously op-
erated, if the dozer working pressure exceeds the
specified pressure, the pressure is input into high-
pressure sensor (SE17).
2) Output voltage of high-pressure sensor (SE 17) is
input into mechatro controller (C1), and travel
booster solenoid valve (SV-8) is actuated by
mechatro controller’s command and spool is
switched.
3) Pilot pressure of travel boost solenoid valve (SV8)
acts on PZ port on a hydraulic pump regulator, and
hydraulic main pump power-reducing shift is exe-
cuted.

Only when travel and 3rd pump driven attachments like

dozer, extra and so on, are simultaneously operated,
the power shift control is actuated.

22-34
 22. HYDRAULIC SYSTEM

Travel & Dozer circuit : Travel 2nd speed (Forward) / dozer down operation 22-35
22. HYDRAULIC SYSTEM

22.14 CONTROL LINES

No. PARTS Q'ty PEMARKS No. PARTS Q'ty PEMARKS No. PARTS Q'ty PEMARKS No. PARTS Q'ty PEMARKS
(1) Pump control (3) 9 CAPSCREW 2 M8 X 25 16 CONNECTOR 1 PF1/4 L=75
1 INLINE FILTER 1 P/T block control lines 10 WASHER 2 M10 17 CLIP 5
2 CONNECTOR 1 PF3/8 1 BLOCK 1 11 WASHER 2 M8 18 ELBOW 3 4 3 3 PF1/4
3 ELBOW 3 PF3/8 2 CONECTOR 1 PF3/8 12 PLUG 1 PF1/4 19 ELBOW 5 PF1/4
4 PLUG 1 PF1/4 3 CONECTOR 2 3 PF1/4 20 CONNECTOR 2 3 PF1/4-PF3/8
5 ELBOW 1 PF3/8 4 CONECTOR 1 PF3/8 L=23 (6) N&B, Extra remo-con lines 21 ELBOW 4 PF1/4-PF3/8
6 TEE 1 PF3/8 5 ELBOW 3 PF3/8 N&B, Swing remo-con lines 22 TEE 2 3 PF3/8
7 TEE 1 2-PF3/8-PF1/4 6 ELBOW 3 PF1/4 1 HOSE ; L=2900 PF1/4 2 P/V A ; Swing RH P/V B ; Swing LH 23 CONNECTOR 1 PF1/4 0.8
8 CAPSCREW 2 M10 X 20 7 ELBOW 1 PF3/8 3 HOSE ; L=400 PF1/4 2 P/V P ; Primary pressure 24 CONNECTOR 1 0.6 Filter
9 WASHER 2 M10 9 TEE 1 PF3/8 4 HOSE ; L=420 PF1/4 1 P/V T ; Drain 25 CHECK VALVE 1
10 HOSE ; L=550 PF3/8 1 Dellivery relief 10 ELBOW 2 PF3/8-PF1/4 5 HOSE ; L=3200 PF1/4 1 P/V B ; Nibbler close 26 HOSE ; L=800 PF1/4 1 Pb5' ; Boom RH swing check open command
11 HOSE ; L=400 PF3/8 1 Pilot delivery 11 CAPSCREW 2 M8˜40 6 HOSE ; L=1750 PF1/4 1 P/V A ; Extra 27 HOSE ; L=1100 PF1/4 1
12 CONNECTOR 1 PF1- 25.4 12 WASHER 2 M8 7 CONNECTOR 2 PF1/4 L=23 29 HOSE ; L=900 PF1/4 2 DR4 ; Drain, DR3 ; Drain
13 HOSE 1 Suction 13 TEE 1 2 PF3/8 8 ELBOW 6 PF1/4 30 GROMMET 2
14 CLIP 2 14 ELBOW 1 PF3/8 9 CAPSCREW 4 M8 X 20 31 ELBOW — 1 PF3/8
15 ELBOW 1 PF3/4- 25.4 15 CONNECTOR 1 PF1/4 L=23 10 WASHER 6 M8 ELBOW 1 PF3/8
32
16 HOSE GUARD 2 L=250 11 CAPSCREW 4 M10 X 20 ELBOW — 1 PF3/8-PF1/4
17 CONNECTOR 1 PF1/4 (4) Att remote control lines 12 LOCK WASHER 4 M10 ELBOW 1 PF3/8
33
18 ELBOW 1 PF1/4 2 CONNECTOR 8 PF1/4 13 CAPSCREW 4 M10 X 25 CONNECTOR — 1 1 1 PF1/4-PF3/8
19 TUBE 1 3 CONNECTOR 2 PF1/4 with filter 14 WASHER 4 M10 TEE 1 PF1/4
34
20 HOSE ; L=650 PF1/4 1 Drain 4 CONNECTOR 2 PF3/8-PF1/4 15 ELBOW 2 PF1/4 with filter ELBOW — 1 1 1 PF1/4
5 HOSE ; L=1450 PF1/4 1 P/V P ; Primary pressure 16 PILOT VALVE 2 TEE 1 PF1/4
35
(2) SOL. valve control lines 6 HOSE ; L=2050 PF1/4 1 P/V P ; Primary pressure 17 LOCK ASSY 1 TEE — 1 1 1 PF1/4
2 CAPSCREW 2 M10 X 70 7 HOSE ; L=1400 PF3/8 1 P/V T ; Drain 18 PEDAL 2 ELBOW 1 PF1/4
36
3 WASHER 2 M10 8 HOSE ; L=1900 PF3/8 1 P/V T ; Drain 19 RUBBER 2 TEE — 1 1 1 PF1/4
4 ELBOW 1 PF3/8 9 HOSE ; L=2600 PF3/8 1 P/V T ; Drain 20 WASHER 4 M10 TEE 5 PF1/4
37
5 ELBOW 7 PF1/4 10 HOSE ; L=3450 RED 1 P/V 6 ; Slewing right 21 PLUG 2 PF1/4 ELBOW — 1 1 1 PF1/4
6 CONNECTOR 1 PF3/8 with filter 11 HOSE ; L=3450 BLUE 1 P/V 7 ; Arm in 22 PRESSURE SWITCH 2 TEE 1 PF3/8
38
8 ELBOW 2 PF3/8 12 HOSE ; L=3800 GREEN 1 P/V 8 ; Arm out 23 NUT 2 M10 TEE — 5 6 6 PF1/4
9 HOSE ; L=450 PF3/8 1 Sol. 4 ; lever lock primary press. 13 HOSE ; L=3600 GRAY 1 P/V 5 ; Slewing left 24 PIN 2 39 TEE — 2 2 2 PF3/8
10 HOSE ; L=3400 PF1/4 1 Sol C ; Travel priority command 14 HOSE ; L=3200 RED 1 P/V 1 ; Bucket digging 25 LOCK ASSY 1
11 HOSE ; L=850 PF1/4 1 Sol. 3 ; Travel 2speed changeover 15 HOSE ; L=2800 BLUE 1 P/V 2 ; Bucket dump 26 HOSE ; L=1800 PF1/4 1 P/V B ; Extra (8) Travel P/V remote control lines
12 HOSE ; L=1550 PF1/4 1 Sol.1 ; Panking brake primary press. 16 HOSE ; L=3200 GREEN 1 P/V 3 ; Boom up 27 HOSE ; L=2650 PF1/4 1 P/V A ; Nibbler open 1 HOSE ; L=400 PF1/4 1 P/V P ; Primary pressure
13 HOSE ; L=2600 PF1/4 1 Sol. D ; P1 bypass cut & arm conflux 17 HOSE ; L=2800 GLAY 1 P/V 4 ; Boom down 28 CONNECTOR 2 PF1/4-PT1/8 2 HOSE ; L=450 PF3/8 1 P/V T ; Drain
Sol. B ; P2 bypass cut command
14 HOSE ; L=3150 PF1/4 2 Sol. 2 ; Slewing flow conflux changeover 18 HOSE 2 29 HOSE ; L=500 PF1/4 1 P/V T ; Drain 3 HOSE ; L=2350 PF1/4 1 P/V 3 ; Travel LH reverse
15 HOSE ; L=3200 PF3/8 1 Drain 19 BOOT 2 4 HOSE ; L=3100 PF1/4 1 P/V 4 ; Travel RH forward
16 HOSE ; L=2700 PF3/8 1 A3 Pilot pump delivery 20 GROMMET 1 (7) Extra / Boom safty 5 ELBOW 4 PF1/4
18 TUBE 1 L=500 21 WASHER 1 M10 Boom safety Main control 7 CONNECTOR 1 PF1/4 with filter
19 GROMMET 2 22 CLIP 1 Boom / Arm safety valve lines 8 CONNECTOR 1 PF3/8-PF1/4
20 CLIP 8 23 CLIP 2 STD 9 PRESSURE SENSOR 2
21 RUBBER 1 L=290 24 CAPCREW 8 M6˜25 1 ELBOW 15 PF1/4 10 CAPSCREW 4 M8 X 25
22 RUBBER 2 L=100 25 CAPCREW 1 M10˜20 2 TEE 5 7 5 PF1/4 11 WASHER 4 M8
23 RUBBER 1 L=220 26 WASHER 8 M6 3 CONNECTOR 15 14 PF1/4 12 PILOT VALVE 1
24 CLIP 3 27 BUSHING 1 4 CONNECTOR 5 PF1/4 L=38 13 HOSE ; L=2250 PF1/4 1 P/V 3 ; Travel RH reverse
25 RUBBER 1 L=270 28 PILOT VALVE 2 5 PRESSURE SENSOR 4 14 HOSE ; L=3300 PF1/4 1 P/V 2 ; Travel LH forward
26 TUBE 1 L=750 6 CONNECTOR 1 PF1/4-PF3/8 L=84
27 TUBE 1 L=400 (5) Tower block control lines 7 HOSE ; L=1000 PF1/4 1 DR1 ; Drain
29 GROMMET 1 1 HOSE ; L=1000 PF1/4 1 B2 ; Bucket dump 8 HOSE ; L=1200 PF1/4 1 DR3 ; Drain
31 HOSE ; L=3700 PF1/4 1 SOL. A ; Travel boost-up press. 2 HOSE ; L=500 PF1/4 1 B4 ; Boom down 9 HOSE ; L=750 PF1/4 2 DR7 ; Drain
32 ELBOW 1 PF1/4-PF3/8 3 HOSE ; L=900 PF1/4 2 B6 ; Slewing right B7 ; Arm in 10 HOSE ; L=1650 PF1/4 1 DR6 ; Drain
PC3' ; Arm in check open command
33 TUBE 1 L=500 4 ELBOW 8 PF1/4 11 HOSE ; L=750 PF1/4 2 PS ; Slewing priority command for check close
35 SOLENOID VALVE 1 5 PRESSURE SENSOR 3 12 HOSE ; L=1050 PF1/4 1 PC4 ; Boom conflux command
Pb2' ; Boom down check open command
6 BLOCK 1 13 HOSE ; L=900 PF1/4 2 Pd2' ; Slewing priority command at slewing left
7 BRACKET 1 14 CONNECTOR 1 PF1/4 L=23
8 CAPSCREW 2 M10 X 25 15 CONNECTOR 2 PF1/4 L=60

22-36
 22. HYDRAULIC SYSTEM

No. PARTS Q'ty PEMARKS No. PARTS Q'ty PEMARKS No. PARTS Q'ty PEMARKS No. PARTS Q'ty PEMARKS
(9) Boom safety V. control lines
Boom / Arm safety V. contrl lines
1 HOSE ; L=4600 PF3/8 1 Boom H/V Pi1 ; Boom down command
2 HOSE ; L=4400 PF3/8 1 Arm H/V Pi1 ; Arm in command
3 HOSE ; L=3300 PF3/8 1 Boom H/V T ; Drain Arm H/V T ; Drain
5 HOSE ; L=1250 PF3/8 1 Drain
6 CONNECTOR 1
7 CONNECTOR 1 PF3/8 L=23
8 ELBOW 3 PF3/8
9 TEE 1 PF3/8
10 CAPSCREW 1 M12 X 20
11 WASHER 1 M12
15 CLIP 5 3
16 HOSE ; L=4500 PF3/8 1 Boom H/V T ; Drain
17 TUBE 3 2 L=1900
18 TUBE 1 L=2250
19 HOSE 1 L=3400 PF3/8
20 CLIP 11 3

(10) Swing / Extra SOL/V con. Lines

1 HOSE ; L=1700 PF1/4 1 S/V PP ; Solenoid primary pressure
2 WASHER 2 M10
3 HOSE ; L=950 PF1/4 1 Pa2 ; Extra
4 HOSE ; L=2000 PF1/4 1 Pa5 ; Swing LH
5 HOSE ; L=1950 PF1/4 1 Pb5' ; Swing RH
6 HOSE ; L=1850 PF1/4 1 S/V T ; Drain
8 CONNECTOR 3 PF1/4
9 ELBOW 6 PF1/4
10 ELBOW 1 PF1/4 with filter
11 BRACKET 1
12 CAPSCREW 2 M12 X 30
13 CAPSCREW 2 M10 X 70
14 WASHER 2 M12
15 HOSE ; L=600 PF1/4 1 Pb2 ; Extra
16 CONNECTOR 1 PF1/4 L=50
17 ELBOW 1 PF1/4
18 PILOT VALVE 1

22-37
22. HYDRAULIC SYSTEM

(1) PUMP CONTROL

S/V A
-PUMP

(2) SOL. VALVE CONTROL LINES

TIGHTENING TORQUE
TIGHTENING TORQUE 49N.m {36.2 lbf.ft}
49N.m {36.2 lbf.ft} TIGHTENING TORQUE
49N.m {36.2 lbf.ft}

22-38
 22. HYDRAULIC SYSTEM

(3) P/T BLOCK CONTROL LINES

(4) ATT P/V REMOTE CONTROL LINES

22-39
22. HYDRAULIC SYSTEM

(5) TOWER BLOCK CONTROL LINES (6) N&B, SWING REMOTE CONTROL LINES

22-40
 22. HYDRAULIC SYSTEM

(7A) MAIN CONTROL VALVE LINES: STD

22-41
22. HYDRAULIC SYSTEM

STD

22-42
 22. HYDRAULIC SYSTEM

(7B) MAIN CONTROL VALVE LINES : BOOM / ARM SAFETY (OPT)

: BOOM SAFETY (OPT)
: EXTRA & BOOM SAFETY (OPT)

F8 F8 F6~F8

F6~F8

F8

22-43
22. HYDRAULIC SYSTEM

BOOM / ARM SAFETY (OPT)

BOOM SAFETY (OPT)
EXTRA & BOOM SAFETY (OPT)ì

22-44
 22. HYDRAULIC SYSTEM

(8) TRAVEL P/V REMOTE CONTROL LINES

22-45
22. HYDRAULIC SYSTEM

(9) BOOM / ARM SAFETY VALVE CONTROL LINES : (OPT)

BOOM SAFETY VALVE CONTROL LINES : (OPT)

22-46
 22. HYDRAULIC SYSTEM

(10) SWING / EXTRA SOL. VALVE CONTROL LINES : (OPT)

22-47
22. HYDRAULIC SYSTEM

22.15 UPPER & LOWER HYD. LINES

No. PARTS Q'ty PEMARKS No. PARTS Q'ty PEMARKS No. PARTS Q'ty PEMARKS No. PARTS Q'ty PEMARKS
(1) Pump delivery 31 CLIP 1 7 CONNECTOR 1 PF3/8 (8) Lower hyd. lines
1 CONNECTOR 2 PF1/2 32 U BOLT 4 32 8 CONNECTOR 1 PF3/8 1 TUBE 1 18
2 GROMMET 1 33 CAPSCREW 1 M10 X 25 9 CONNECTOR 1 PF1/4 3 TUBE 1 18
3 TUBE : 50.8 1 Suction 34 CAPSCREW 1 M10 X 60 10 ELBOW 1 PF3/8 5 TUBE 1 18
4 HOSE 1 Suction 35 NUT 16 M8 11 ELBOW 1 PF3/8 6 TUBE 1 18
5 HOSE ; L=850 1 Delivery P1 36 CONNECTOR 1 PF3/8 7 TUBE 1 18
6 HOSE ; L=800 1 Delivery P2 37 ELBOW 1 PF3/8 (5) Extra hyd. line 8 TUBE 1 18
7 O RING 1 1A G55 38 TUBE 1 L=300 Upper dozer hyd. lines 9 TUBE 1 15
9 CLIP 4 39 TUBE 1 L=500 1 CONNECTOR 2 PF1/2 L=32 10 TUBE 1 15
10 CAPSCREW 2 M12 X 35 41 TUBE 1 L=1400 2 CONNECTOR 1 φ PF1/4 11 TUBE 1 10
11 LOCK WASHER 4 M12 3 ELBOW 2 PF1/2-PF3/8 12 CLAMP 2
12 CLIP 1 (3) Main C/V hyd. lines 4 TEE 1 2-PF1/2-PF1/4 13 CLAMP 2
13 ELBOW 2 PF3/4 1 CONNECTOR 1 PF1/2 L=32 5 PLUG 1 PF1/4 14 SPACER 2
14 O RING 2 1B P24 3 CONNECTOR 3 18-PF1/2 6 HOSE 1 PF3/8 L=1250 15 SPACER 2
15 CAPSCREW 1 M12 X 25 4 CONNECTOR 4 18-PF1/2 7 HOSE 1 PF3/8 L=1300 16 CAPSCREW 6 M8 X 40
16 CONNECTOR 1 12-M12 5 CONNECTOR 4 18-PF1/2 8 HOSE 1 PF1/2 L=1600 17 LOCK WASHER 6 M8
17 CONNECTOR 1 PF1/4 9 CONNECTOR 1 PF3/4 L=60 9 GUARD HOSE 1 L=1400 18 WASHER 4 M8
18 O RING 1 1B P11 10 ELBOW 1 PF3/4 10 TEE 1 PF1/4 19 TUBE 1
19 HOSE ; L=540 1 For surge cut 11 O RING 7 1B P18 11 HOSE 1 PF1/4 L=300 20 TUBE 1
20 WASHER 1 M12 12 O RING 2 1B P24 12 ELBOW 2 4 PF1/2 22 HOSE 1
21 PLUG 3 PF1/4 14 BRACKET 1 13 ELBOW 1 PF1/4 23 HOSE 2
22 CAPSCREW 2 M12 X 40 15 CAPSCREW 4 M8 X 20 14 CONNECTOR 1 PF1/4 L=23 24 CLAMP 2
23 SUPPORT 1 16 CAPSCREW 2 M12 X 25 15 CONNECTOR 1 PF1/2 L=60 25 HOSE 4 L=300
17 WASHER 4 M8 16 HOSE 1 PF1/2 L=3200 26 CONNECTOR 2
(2) Return hyd. lines 18 WASHER 2 M12 17 HOSE 1 PF1/2 L=3150 27 CLIP 4
1 TUBE 1 31.8 33 CLIP 2 18 TUBE 2 L=750 28 HOSE 1
2 TUBE 1 31.8 34 RUBBER 1 19 CONNECTOR 1 PF1/2
3 TUBE 1 31.8 36 HOSE 1 L=1180 18 20 TEE 1 PF1/2 (9) Swivel joint hyd. lines
4 CHECK VALVE 1 37 ELBOW 3 18-PF1/2 21 ELBOW 1 PF1/2-PF3/8 1 CONNECTOR 4 PF1/2- 18
5 COUPLIING 4 PF1/2 38 CONNECTOR 4 18-PF1/2 22 PRESSURE SENSOR 1 2 CONNECTOR 2 PF3/8- 15
6 COUPLIING 1 PF1/2 39 ELBOW 1 18-PF3/4 3 CONNECTOR 1 PF1/4- 10
7 HOSE 1 L=2300 PF3/4 40 CONNECTOR 1 18-PF3/4 (6) Swing cyl. hyd. lines 4 TEE 1 PF3/8- 15
8 HOSE 1 L=1450 PF3/4 41 SELECTOR VALVE 1 2 CONNECTOR 2 18-PF1/2 5 O RING 4 1B P18
9 HOSE 1 L=1500 PF3/4 42 HOSE 1 L=1200 18 3 ELBOW 1 2-PF1/4 6 O RING 3 1B P14
10 HOSE 1 L=1200 PF1/2 43 HOSE 1 L=1400 18 4 O RING 2 1B P18 7 O RING 1 1B P11
11 HOSE 1 L=1600 PF1/2 44 HOSE 2 L=1350 18 5 GREASE NIPPLE 1 PF1/8
12 HOSE 1 L=1800 PF3/8 45 HOSE 2 L=1550 18 6 CLIP 3 (10) Travel motor hyd. lines
13 HOSE 1 L=500 PF3/8 46 HOSE 1 L=1650 18 7 HOSE 1 L=900 PF1/4-PF3/8 1 CONNECTOR 4 PF1/2- 18
14 CONNECTOR 1 PF3/4 L=60 47 HOSE 1 L=1700 18 2 CONNECTOR 2 PF3/8- 15
15 TEE 1 PF3/4 48 HOSE 1 L=2950 18 (7) 3 CONNECTOR 2 PF1/4
Swing Br. group hyd. lines
16 ELBOW 3 PF3/4 49 HOSE 1 L=3900 18 4 O RING 2 1B P14
17 CONNECTOR 1 PF3/4 L=60 50 HOSE 1 L=3600 18 1 COVER 1
18 CONNECTOR 1 PF3/4 51 HOSE 1 L=3700 18 2 RUBBER 1 (11) Dozer cyl. hyd. lines
19 CONNECTOR 2 PF1/2 52 HOSE 1 L=3750 18 3 RUBBER 1 1 CONNECTOR 2 PF3/8
20 WASHER 8 M8 53 HOSE 1 L=3850 18 4 CLAMP 2
21 TEE 1 PF1/2 54 HOSE 1 L=3900 18 5 BUSHING 2
22 ELBOW 1 PF3/8-PF1/2 55 HOSE 1 L=3850 18 6 GROMMET 1
23 ELBOW 1 PF1/2 7 PLATE 1
24 TEE 1 PF3/8 (4) Swivel joint hyd. lines 8 CAPSCREW 4 M8 X 40
25 HOSE GURAD 1 L=600 1 CONNECTOR 1 PF1/2 L=41 9 CAPSCREW 2 M10 X 25
26 WASHER 2 M10 2 O RING 4 1B P18 10 LOCK WASHER 4 M8
27 CLIP 2 3 ELBOW 3 18-PF1/2 11 LOCK WASHER 2 M10
28 RUBBER 1 4 CONNECOTR 1 PF1/2 L=32 12 CLIP 3
29 BRACKET 1 5 CONNECOTR 1 18-PF1/2
30 CLAMP 1 6 TUBE 1

22-48
 22. HYDRAULIC SYSTEM

(1) PUMP HYD. LINES (2) RETURN HYD. LINES

22-49
22. HYDRAULIC SYSTEM

(3) UPPER MAIN C/V HYD. LINES : N&B (STD)

(4) SWIVEL JOINT HYD. LINES

22-50
 22. HYDRAULIC SYSTEM

(5A) UPPER DOZER HYD. LINES (5B)UPPER DOZER & EXTRA HYD. LINES : (OPT)

(6) SWING CYL. HYD. LINES

22-51
22. HYDRAULIC SYSTEM

(7) SWING BRACKET GROUP HYD. LINES: STD

: N&B & EXTRA & BOOM / ARM SAFETY

22-52
 22. HYDRAULIC SYSTEM

(8) LOWER HYD. LINES 9) SWIVEL JOINT HYD. LINES

(10) TRAVEL MOTOR HYD. LINES

(11) DOZER CYLINDER HYD. LINES

22-53
22. HYDRAULIC SYSTEM

22.16 ATT HYD. LINES

No. PARTS Q'ty PEMARKS No. PARTS Q'ty PEMARKS No. PARTS Q'ty PEMARKS No. PARTS Q'ty PEMARKS
(1A) LF42H00004F1 Boom hyd. lines 4 TUBE 1 21 LOCK WASHER 2 M10 17 CAPSCREW 2 M10 X 50
1 TUBE 2 5 TUBE 1 18 LOCK WASHER 2 M8
2 TUBE 1 6 HOSE 2 L=1200 (4A) LF42H00006F2 Boom cyl. hyd. lines 19 LOCK WASHER 4 M10
3 TUBE 1 7 HOSE 2 L=1100 2 TUBE 1 20 PLUG 1
4 TUBE 1 8 STOP VALVE 2 24100P1006F1 3 CONNECTOR 1 21 CONNECTOR 1
5 TUBE 1 9 CONNECTOR 2 22-PF3/4 4 ELBOW 1 22 TUBE 1 22
6 TUBE 2 10 TEE 2 3- 15 5 O RING 2 1B P18
7 CONNECTOR 2 11 PLUG 2 15 6 CLAMP 2 (5A) YT42H00003F1 Arm cyl. hyd. lines
8 PLUG 2 PF3/4 12 PLUG 2 15 7 CAPSCREW 2 M10 X 50 1 TUBE 1
9 CLAMP 10 13 NUT 2 8 LOCK WASHER 2 M10 2 HOSE 2 L=650
10 CLAMP 6 14 O RING 2 1B P24 9 GREASE NIPPLE 1 3 CONNECTOR 1
11 CLAMP 2 15 CLAMP 1 10 GREASE NIPPLE 1 4 CONNECTOR 1
12 CAPSCREW 16 M10 X 45 16 CLAMP 2 11 PLUG 1 5 O RING 3 1B P18
13 CAPSCREW 4 M10 X 55 17 CPASCREW 8 M8 X 25 12 TUBE 1 6 GREASE NIPPLE 1
14 LOCK WASHER 20 M10 18 CPASCREW 1 M8 X 40
19 CPASCREW 2 M10 X 45 (4B) LF42H00009F3 Boom safety with sensor (5B) YT42H00058F1 Arm safety cyl. hyd. lines
(1B) LF42H00005F3 Arm safety (OPT) 20 LOCK WASHER 9 M8 1 TUBE 1 22 1 TUBE 1 22
LF42H00005F2 Ext. (OPT) 21 LOCK WASHER 2 M10 3 TUBE 1 22 2 TUBE 1 22
LF42H00005F1 N&B + Ext. + Arm safety (OPT) 4 HOLDING VALVE 1 3 TUBE 1 22
1 TUBE 1 (3A) LF43H00005F1 Long arm hyd. lines 6 BAND 1 4 HOSE 2 L=650
2 TUBE 1 1 HOSE 2 L=1450 7 CONNECTOR 2 M30 X 1.5-PF1/2 5 HOLDING VALVE 1 YR28V00001F1
3 HOSE 1 1 PF3/8 L=2940 8 CONNECTOR 1 2-PF1/4 6 BAND 1
4 HOSE 1 1 PF3/8 L=3100 (3B) YT43H00039F1 Long arm N&B 9 ELBOW 1 PF1/4-PF3/8 7 BAND 1
5 BRACKET 1 1 1 TUBE 2 22 10 ELBOW 1 M30 X 1.5-PF1/2 8 CONNECTOR 2 M30 X 1.5-PF1/2
6 CONNECTOR 3 3 2-PF3/8 2 HOSE 2 L=1450 11 ELBOW 1 PF1/4-PF3/8 9 CONNECTOR 1 M30 X 1.5-M30 X 1.5
7 CLAMP 2 3 STOP VALVE 2 24100P1006F1 12 O RING 4 1B P18 10 CONNECTOR 1 PF1/4-PF3/8
8 CLAMP 8 4 CLAMP 2 13 GREASE NIPPLE 1 PT1/8 11 CONNECTOR 1 PT1/4-PF1/4
9 CLAMP 8 5 CONNECTOR 2 PF3/4-M30 X 1.5 14 GREASE NIPPLE 1 PT1/8 12 CONNECTOR 1 2-PF1/4
10 CAPSCREW 2 M8 X 40 6 O RING 2 1B P24 15 CLAMP 2 13 ELBOW 1 PF1/4-PF3/8
11 CAPSCREW 8 M10 X 35 7 CAPSCREW 8 M8 X 25 16 CAPSCREW 2 M8 X 50 14 O RING 5 1B P18
12 CAPSCREW 2 2 M10 X 60 8 CAPSCREW 2 M10 X 45 17 CAPSCREW 2 M10 X 35 15 GREASE NIPPLE 1 PT1/8
13 LOCK WASHER 2 M8 9 LOCK WASHER 8 M8 18 CAPSCREW 2 M10 X 50 16 CAPSCREW 2 M8 X 50
14 LOCK WASHER 10 8 2 M10 10 LOCK WASHER 2 M10 19 LOCK WASHER 2 M8 17 CAPSCREW 2 M10 X 35
15 CLIP 9 9 20 LOCK WASHER 4 M10 18 LOCK WASHER 2 M8
19 ELBOW 1 1 (3C) YT43H00045F1 Long N&B + Ext. 28 TUBE 1 22 19 LOCK WASHER 2 M10
1 TUBE 2 29 BAND 1
(2A) LF43H00002F1 Arm hyd. lines STD 2 TUBE 1 30 ELBOW 1 2-PF3/8 (6) YT43H00005F1 Bucket cyl. hyd. lines
1 HOSE 2 L=1200 3 TUBE 1 31 PRESSURE SENSOR 1 PF3/8 1 TUBE 1
4 TUBE 1 2 TUBE 1
(2B) LF43H00004F2 Arm hyd. lines N&B 5 TUBE 1 (4C) LF42H00007F2 Boom safety Boom cyl. OCEANIA 3 CONNECTOR 1
2 HOSE 2 L=1200 6 HOSE 2 L=1450 2 TUBE 1 22 4 ELBOW 1
3 STOP VALVE 2 7 HOSE 2 L=1350 3 TUBE 1 22 5 CLAMP 2
4 CONNECTOR 2 22-PF3/4 8 STOP VALVE 2 24100P1006F1 4 HOLDING VALVE 1 YR28V00001F1 6 CAPSCREW 2 M10 X 50
5 O RING 2 1B P24 9 CONNECTOR 2 22-PF3/4 5 BAND 1 7 LOCK WASHER 2 M10
6 CLAMP 2 10 TEE 2 3- 15 6 BAND 1 8 O RING 2 1B P18
7 CAPSCREW 8 M8 X 25 11 PLUG 2 15 7 CONNECTOR 2 M30 X 1.5-PF1/2 9 GREASE NIPPLE 1
8 CAPSCREW 2 M10 X 45 12 PLUG 2 15 8 ELBOW 1 PF1/4-PF3/8 10 GREASE NIPPLE 1
9 LOCK WASHER 8 M8 13 NUT 2 9 ELBOW 1 M30 X 1.5-PF1/2
10 LOCK WASHER 2 M10 14 O RING 2 1B P24 10 ELBOW 1 PF1/4-PF3/8 (7) LE43H00006F1 N&B connector
11 TUBE 2 15 CLAMP 1 11 O RING 4 1B P18 1 CONNECTOR 1
16 CLAMP 2 12 GREASE NIPPLE 1 PT1/8 2 PLUG 1
(2C) Arm hyd. lines N&B, Ext. (OPT) 17 CPASCREW 8 M8 X 25 13 GREASE NIPPLE 1 PT1/8 3 O RING 1 1B P24
1 TUBE 2 18 CPASCREW 1 M8 X 40 14 CLAMP 2
2 TUBE 1 19 CPASCREW 2 M10 X 45 15 CAPSCREW 2 M8 X 50
3 TUBE 1 20 LOCK WASHER 9 M8 16 CAPSCREW 2 M10 X 35

22-54
 22. HYDRAULIC SYSTEM

(1A) BOOM HYD. LINES : N&B

22-55
22. HYDRAULIC SYSTEM

(1B) BOOM HYD. LINES: N&B & EXTERA & ARM SAFETY (OPT)
: EXTERA (OPT)
: ARM SAFETY (OPT)

22-56
 22. HYDRAULIC SYSTEM

(2A) ARM HYD. LINES : 1.8M (STD) (3A) ARM HYD. LINES : 2.07M LONG (OPT)

(2B) ARM HYD. LINES : 1.8M N&B (STD) (3B)ARM HYD. LINES : 2.07M LONG N&B (OPT)

((2C) ARM HYD. LINES : 1.8M N&B & EXTRA (OPT) (3C)ARM HYD. LINES : 2.07M LONG N&B & EXTRA (OPT)

22-57
22. HYDRAULIC SYSTEM

(4A) BOOM CYLINDER HYD. LINES : STD

(5A) ARM CYLINDER HYD. LINES : (STD)

(4B) BOOM CYLINDER HYD. LINES : BOOM SAFETY WITH SENSOR (OPT) KCME

22-58
 22. HYDRAULIC SYSTEM

(5B) ARM CYLINDER HYD. LINES : ARM SAFETY (OPT) (6) BUCKET CYLINDER HYD. LINES : STD

(7) N&B CONNECTOR ASSY

22-59
22. HYDRAULIC SYSTEM

[MEMO]

22-60
 23. ELECTRICAL SYSTEM
TABLE OF CONTENTS

23.1 ELECTRICAL CIRCUIT DIAGRAM AND EQUIPMENT LIST .............................................. 23-3

23.2 HARNESS ........................................................................................................................ 23-7
23.2.1 HARNESS & CABLE LIST ......................................................................................... 23-7
23.2.2 HARNESS CONNECTION DRAWING ...................................................................... 23-8
23.2.3 CONTROLLER ASSY ............................................................................................... 23-9
23.2.4 INSTRUMENT PANEL ASSY .................................................................................... 23-13 23
23.2.5 UPPER ELECTRICAL ASSY ..................................................................................... 23-14
23.2.6 UPPER HARNESS ASSY ......................................................................................... 23-16
23.2.7 ENGINE HARNESS ASSY ........................................................................................ 23-22
23.2.8 FLOOR PLATE HARNESS ASSY .............................................................................. 23-24
23.2.9 CAB HARNESS ASSY .............................................................................................. 23-26
23.2.10 BATTERY .................................................................................................................. 23-31
23.2.11 CAB ASSY ................................................................................................................. 23-32
23.2.12 MOUNTING CAB ...................................................................................................... 23-34
23.2.13 MOUNTING LIGHT ................................................................................................... 23-34
23.2.14 MOUNTING BOOM LIGHT ....................................................................................... 23-34
23.2.15 MOUNTING CAB WORK LIGHT ............................................................................... 23-35
23.2.16 AIR CONDITIONER .................................................................................................. 23-37
23.2.17 MOUNTING FUEL PUMP .......................................................................................... 23-38
23.2.18 NAME PLATE INSTAL (ELECTRIC COMPONENT FOR AUTO IDLE STOP) .......... 23-39

23-1
23. ELECTRICAL SYSTEM

23-2
 23. ELECTRICAL SYSTEM

23.1 ELECTRICAL CIRCUIT DIAGRAM AND EQUIPMENT LIST

CONVERTER

CONVERTER
WASHER RELAY
CONTROLLER

CIGARETTE

FUEL PUMP
SE-16:ACCEL POTENTIO

MECHATRO

LIGHTER

KEY SW.
DC-DC
HORN
WIPER
PRESS. SENSOR(LOW) C-1:MECHATRO CONTROLLER
SE-1:BUCKET DIGGING
APPLICABLE : LF04-02001~ GREEN
E-1:FUSE BOX
BLACK
SE-2:BUCKET DUMP RED
WHITE M-2:GOVERNOR MOTOR
SHIELD

SE-3:BOOM RAISING
C-1:
MECHATRO ING
CONTROLLER ION AL EAT
SIT RM EH
PO NO PR

TERMINAL
SE-4:BOOM LOWERING C-2: SW-4:SLEWING PARKING RELASE SW.
GAUGE CLUSTER

TRAVEL ALARM

GAUGE CLUSTER

WIPER, WASHER

SOLENOID

WORK LIGHT

CAB WORK LIGHT

AIR CON. HEATER

AIR CON.

RESERVE
SE-7:ARM IN SV-1:SLEWING PARKING
BRAKE SOL.
E-14: E-14:
BATTERY BATTERY
SE-8:ARM OUT

SV-8:TRAVEL BOOST-UP SOL.

SE-5:SLEWING
SW-1: R-28:
STARTER KEY SW. ING AUTO IDLE STOP RELAY 1 PSV-C:TRAVEL PRIORITY
ION EAT E-21:COUNTER PROPOTIONAL SOL.
SIT EH
PO PR R-1:
TERMINAL

BATTERY RELAY SE-9:TRAVEL RIGHT

PSV-D:P1 BY-PASS CUT

PROPOTIONAL SOL.
R-3:
GLOW RELAY SE-10:TRAVEL LEFT
C-2: GLOW
GAUGE CLUSTER
SW-7: PSV-B:P2 BY-PASS CUT
ENG. OIL PRESS. SW. PROPOTIONAL SOL.
ENG. OIL
PRESS.
SW-26:
R-29: AUTO ACCEL RELEASE SW.
AUTO IDLE STOP RELAY 2
R-4: C-2:GAUGE CLUSTER
SAFETY RELAY M-1: SV-2:
STARTER MOTOR DOUBLE . SINGLE
R-30:TIMER UNIT SELECT SOL.

SV-3:TRAVEL TWO-SPEED
E-2: SOL.
ALTERNATOR SW-18:PEDAL PRESS. SW 1
SW-1: E-21:COUNTER R-31:COUNTER RELAY.
KEY SW.
E-22:SEQUENCE
BOX ASSY.
SW-35:PEDAL PRESS. SW 3
R-32:TRAVEL
L-11: TWO-SPEED RELAY
STARTER ALARM LAMP. SW-3:TRAVEL
C-2:
GAUGE CLUSTER TWO-SPEED SW.

ILLUMINATION E-3:HOUR METER

R-8:WORK LIGHT RELAY

C-1:MECHATRO CONTROLLER CHARGE

ENG.OIL PRESS. R-30:TIMER UNIT

SW-7:ENG. OIL PRESS. SW. SW-2:SWITCH ASSY
MODE(H)
R-30:TIMER UNIT.
ENG.WATER TEMP. SW-6:ENG. WATER TEMP. SW MODE(S)
SW-6:ENG. WATER TEMP. SW.
SW-40: SW-11:LEVER LOCK SW. SE-17:P3 PUMP
AUTO IDLE STOP SELECT SW. MODE(FC)
COOLANT THERMO
INDICATOR BUZZER STOP
SE-14:COOLANT THERMO SENSOR E-20:BUZZER
LIGHT
AIR CLEANER KEY ON
SW-8:AIR FILTER RESTRICTION SW.
R-28,29: WIPER
FUEL LEVEL AUTO IDLE STOP RELAY.
WASHER
FUEL METER
SE-15:FUEL SENSOR
GLOW
SW-1:STARTER KEY SW. SHORT CIRCUIT IN CASE OF TIMER UNIT.
TRAVEL TWO-SPEED
R-32:TRAVEL TWO-SPEED RELAY.
R-8:WORK LIGHT RELAY BACK LIGHT
SLEWING PARKING
SW-4:SLEWING PARKING BRAKE
RELEASE SW. SE-13:ENG. SPEED SENSOR
CPU ALLERGY
SHIELD

EU OPT.
OVERLOAD

SW-28:
OVER LOAD INDICATE SW.
MODE

SE-18:PRESS, SENSOR
BOOM HEAD
E-23:OVER LOAD PRESS ADJUST UNIT.
CONTROLLER EARTH TO 2/3

Fig. 23-1 23-3

23. ELECTRICAL SYSTEM

R-5:WIPER MOTOR
C-1: RELAY
MECHATRO CONTROLLER
M-3:WIPER MOTOR
FROM 1/3

SW-23:
WIPER INTERLOCK SW. E-10:RECEIVER E-11:AIR COMMPRESSOR
DRIER CLUTCH

R-6:WINDOW WASHER R-8:WORK LIGHT

RELAY AIR
MOTOR RELAY CONDITIONER
AMP.
M-4:WASHER MOTOR
L-3:ROOM LIGHT

SW-13:AIR CONDITIONER SW.

R-8:WORK LIGHT RELAY

R-30:TIMER UNIT
E-6:CIGARETTE LIGHTER
COOLING
R-20:TIMER UNIT
SV-4:OPERATING LEVER LOCK SOL.

SW-11:LEVER LOCK SW.

TIMER

R-7:HORN RELAY

E-5:HORN

R-11:TRAVEL ALARM RELAY

SW-10:HORN SW.(RIGHT)

E-13:TRAVEL ALARM

SW-25:BUZZER STOP SW.

(TRAVEL ALARM)
ASIA SW-27:ENGINE ROOM LIGHT SW. L-7:ENGINE ROOM LIGHT
SW-29:ROTARY LIGHT SW. L-10:ROTARY LIGHT

R-8:WORK LIGHT RELAY

EU STD. EU OPT.
L-1:BOOM WORKING LIGHT LEFT

WORKING L-2:WORKING LIGHT RIGHT M-11:FUEL PUMP

LIGHT ON C-1:MECHATRO M-9:FUEL PUMP
CONTROLLER
L-1:BOOM WORKING LIGHT RIGHT

C-4:AIR CONDITIONER AMP.

OPT.
C-2:GAUGE CLUSTER

SW-2:SWITCH ASSY

R-10:CAB WORK LIGHT RELAY

L-4:CAB WORKING LIGHT(FRONT 1)

L-5:CAB WORKING LIGHT(FRONT 2)

SW-16:WORK LIGHT SW. L-6:CAB WORKING LIGHT(FRONT 3)
SW-18:OPT. PEDAL PRESS SW. (1)
L-8:CAB WORKING LIGHT(FRONT 4) SW-17:DOUBLE . SINGLE
SELECT SW. SV-2:DOUBLE . SINGLE
L-9:CAB WORKING LIGHT(REAR) SELECT SOL.
OPT.

R-13:CAB WORK LIGHT RELAY

OPT.

L-14:SWING EXTRA SELECT

INDICATION LAMP

SV-6:SWING EXTRA SELECT SOL.

SW-34:SWING EXTRA SELECT SW.

R-21:SEQUENCE RELAY
OPT.

23-4 Fig. 23-2

 23. ELECTRICAL SYSTEM

STD.

E-17:DC-DC CONVERTER E-7:TUNER AM & FM

E-15:SOCKET E-9:SPEAKER RIGHT

E-8:SPEAKER LEFT

BACK UP

(OPT.)

NOTES:
1. Wire used to be
1) "AVSS" or "AVX" for 0.75 mm2 and 1.25 mm2.
2) "AVS" for 2 mm2, 5 mm2. WIRE COLOR CODING TABLE
3) "AV" for others. Sign Color Sign Color Sign Color Sign Color
2. Wires to be 0.75 mm2 unles otherwise specified. B Black W White Br Brown V Violet
3. Grounding for which wire color is not shown to G Green Y Yellow Lg Light Green
be performed with component case. L Blue P Pink Gr Gray
4. Number in square shows line No. R Red O Orange Sb Sky Blue

Fig. 23-3 23-5

23. ELECTRICAL SYSTEM

ELECTRIC EQUIPMENT LIST

Group Code Name Group Code Name Group Code Name

PROPORTIONAL
CONTROLLER C-1 MECHATRO CONTROLLER M-1 STARTER MOTOR PSV-B P2 BY-PASS CUT PROPOTIONAL SOL.
C-2 GAUGE CLUSTER M-2 GOVERNOR MOTOR PSV-C TRAVEL PRIORITY PROPOTIONAL SOL.

VALVE
C-4 AIR CONDITIONER CONTROLLER M-3 WIPER MOTOR PSV-D P1 BY-PASS CUT PROPOTIONAL SOL.

MOTOR
M-4 WASHER MOTOR
D-1 DIODE M-8 ROOF WIPER MOTOR (OPT.)
D-2 M-9 FUEL PUMP (AUTO AIR REMOVE) (OPT.) SW-1 KEY SWITCH
D-3 M-11 FUEL PUMP SW-2 SWITCH ASSY
DIODE

D-4 SW-3 TWO-SPEED SELECT SWITCH

D-5 R-1 BATTERY RELAY SW-4 SLEWING PARKING RELEASE SWITCH
D-6 (OPT.) R-3 GLOW RELAY SW-6 ENG. WATER TEMPERATURE SWITCH
D-7 (OPT.) R-4 SAFETY RELAY SW-7 ENG. OIL PRESS SWITCH
R-5 WIPER MOTOR RELAY SW-8 AIR FILTER ALARM SWITCH
E-1 FUSE BOX R-6 WASHER MOTOR RELAY SW-10 HORN SWITCH
E-2 ALTERNATOR R-7 HONE RELAY SW-11 LEVER LOCK SWITCH
E-3 HOUR METER R-8 WORK LIGHT RELAY SW-13 AIR CONDITIONER SWITCH
E-5 HORN R-10 CAB WORK LIGHT RELAY SW-15 ROOF WIPER SWITCH (OPT.)
E-6 CIGALETTE LIGHTER R-11 TRAVEL ALARM RELAY SW-16 WORK LIGHT SWITCH

RELAY
E-7 TUNER AM & FM R-13 CAB WORK LIGHT RELAY 2 (OPT.) SW-17 DOUBLE·SINGLE SELECT SWITCH
ELECTRIC FITTINGS

E-8 SPEAKER LEFT R-20 TIMER SW-18 PEDAL PRESSURE SWITCH ASSY (1)

SWITCH
E-9 SPEAKER RIGHT R-21 SEQUENCE RELAY (OPT.) SW-23 WIPER INTERLOCK SWITCH
E-10 RECEIVER DRIER R-28 AUTO IDLE STOP RELAY 1 SW-25 BUZZER STOP SWITCH (TRAVEL ALARM)
E-11 AIR COMMPRESSOR CLUTCH R-29 AUTO IDLE STOP RELAY 2 SW-26 AUTO ACCEL RELEASE SWITCH
E-13 TRAVEL ALARM R-30 TIMER UNIT SW-27 ENGINE ROOM LIGHT SWITCH
E-14 BATTERY R-31 COUNTER RELAY SW-28 OVERLDAD INDICATE SWITCH (OPT.)
E-15 POWER SOCKET R-32 TRAVEL TWO-SPEED RELAY SW-29 ROTARY LIGHT SWITCH (OPT.)
E-17 CONVERTER SW-34 SWING/EXTRA SELECT SWITCH (OPT.)
E-20 BUZZER SE-1 PRESSURE SENSOR (LOW) : BUCKET DIGGING SW-35 PEDAL PRESSURE SWITCH ASSY (3)
E-21 COUNTER (OPT.) SE-2 PRESSURE SENSOR (LOW) : BUCKET DUMP SW-40 AUTO IDLE STOP SELECT SWITCH
E-22 SEQUENCE BOXE (OPT.) SE-3 PRESSURE SENSOR (LOW) : BOOM UP
E-23 OVER LOAD ADJUST UNIT (OPT.) SE-4 PRESSURE SENSOR (LOW) : BOOM DOWN
SE-5 PRESSURE SENSOR (LOW) : SLEWING
L-1 BOOM WORKING LIGHT LEFT
L-1 BOOM WORKING LIGHT RIGHT SE-7 PRESSURE SENSOR (LOW) : ARM IN
L-2 WORKING LIGHT RIGHT SE-8 PRESSURE SENSOR (LOW) : ARM OUT
SENSOR

L-3 ROOM LIGHT SE-9 PRESSURE SENSOR (LOW) : TRAVEL RIGHT

L-4 CAB WORKING LIGHT FRONT (OPT.) SE-10 PRESSURE SENSOR (LOW) : TRAVEL LEFT
L-5 CAB WORKING LIGHT FRONT (OPT.) SE-13 E/G SPEED SENSOR
L-6 CAB WORKING LIGHT (FRONT 3) SE-14 E/G WATER TEMPERATURE SENSOR
L-7 ENGINE ROOM LIGHT SE-15 FUEL SENSOR
L-8 CAB WORKING LIGHT (FRONT 4) SE-16 ACCEL POTENTIO METER
L-9 CAB WORKING LIGHT (REAR) SE-17 PRESSURE SENSOR (HIGHT) : P3 PUMP
LIGHT

L-10 ROTARY LIGHT SE-18 PRESSURE SENSOR (HIGHT) : BOOM HEAD (OPT.)
L-11 STARTER ALARM LAMP
SOLENOID VALVE

SV-1 SLEWING PARKING BRAKE SOL.

SV-2 DOUBLE·SINGLE SELECT SOL. (OPT.)
SV-3 TRAVEL TWO-SPEED SELECT SOL.
SV-4 LEVER LOCK SOL.
SV-8 TRAVEL BOOST-UP SOL.
SV-6 SWING/EXTRA SELECT (OPT.)

23-6 Fig. 23-4

 23. ELECTRICAL SYSTEM

23.2 HARNESS
23.2.1 HARNESS & CABLE LIST

Index No. DWG. No. HARNESS

Device Item Name Name

2.3 Controller assy Harness

2.4 Instrument panel assy

Upper frame

2.5 Upper electric assy Harness

2.6 Upper harness assy Starter cable

Battery relay cable
Battery cable
Battery ground cable
Right guard harness
Main harness
Frame ground cable

2.7 E/G Harness E/G Sub harness

2.8 Floor plate harness assy Harness
Cable
2.9 Cab harness assy Left instrument panel harness
Right instrument panel harness
Cab right front harness
2.10 Battery

2.11 Cab Wiper harness

Cab

Curl code harness

Cab harness
Antenna
Room lamp harness

2.12 Mounting cab

2.13 Mounting deck light
2.14 Mounting boom work light Boom light Harness
Light

2.15 Mounting cab work light Fore light harness

2.16 A/C Conditioner

A/C

2.17 Mounting fuel pump

Upper
frame

2.18 Name plate instal

(Electric component for AIS)

Fig. 23-5 23-7

23. ELECTRICAL SYSTEM

23.2.2 HARNESS CONNECTION DRAWING

23-8 Fig. 23-6

 23. ELECTRICAL SYSTEM

23.2.3 CONTROLLER ASSY

No. Name
7 SWITCH ASSY
8 RELAY
22 TIMER
25 CONTROLLER
27 CAB HARNESS ASSY
27-3-1 INSTRUMENT PANEL HARNESS
27-3-2 FUSE
32 CONTROLLER
38 RELAY
40 COUNTER
44 RELAY
47 CAB HARNESS ASSY
47-8-1 INSTRUMENT PANEL HARNESS
47-8-2 FUSE

Fig. 23-7 Controller assy 23-9

23. ELECTRICAL SYSTEM

23.2.3-27-3-1 INSTRUMENT PANEL HARNESS : (1/3)

23-10 Fig. 23-8 Instrument panel harness (1/3)

 23. ELECTRICAL SYSTEM

23.2.3-27-3-1 INSTRUMENT PANEL HARNESS : (2/3)

Fig. 23-8 Instrument panel harness (2/3) 23-11

23. ELECTRICAL SYSTEM

23.2.3-27-3-1 INSTRUMENT PANEL HARNESS : (3/3)

23-12 Fig. 23-8 Instrument panel harness (3/3)

 23. ELECTRICAL SYSTEM

23.2.4 INSTRUMENT PANEL ASSY

No. Name
1 GAUGE CLUSTER
11 SPEAKER
19A R/H PANEL ASSY
19A-2 ACCEL POTENTIO DIAL
19A-3 KYE SWITCH
19A-4 MODE SELECT SWITCH
21 AUTO ACCEL RELEASE SWITCH
26 DC-DC CONVERTER
38 SOCKET
39 CONFLUX/SINGLE SELECT
40 OVERLOAD INDICATE SWITCH
41 ROTARY LIGHT SWITCH
46 HOUR METER
59A COVER ASSY
59A-4 CIGALETTE LIGHTER

Fig. 23-9 Instrument panel harness 23-13

23. ELECTRICAL SYSTEM

23.2.5 UPPER ELECTRICAL ASSY: (1/2)

UPPER ELECTRIC ASSY

No. Name Q'ty REMARK
1 BATTERY RELAY 1
2 HORN 1
7 ROOM LIGHT 1 E/G
10 SWITCH 1 E/G ROOM LIGHT
11 HARNESS 1 E/G ROOM LIGHT

23-14 Fig. 23-10 Upper electric assy (1/2)

 23. ELECTRICAL SYSTEM

UPPER ELECTRICAL ASSY: (2/2) 23.2.5.11 E/G ROOM LIGHT HARNESS

Fig. 23-11 Upper electric assy (2/2) 23-15

23. ELECTRICAL SYSTEM

23.2.6 UPPER HARNESS ASSY: (1/3)

UPPER HARNESS ASSY

No. Name Q'ty
1 STARTER CABLE 1
2 BATTERY RELAY CABLE 1
3 BATTERY CABLE 1
4 BATTERY GROUND CABLE 1
5 RIGHT GUARD HARNESS 1
6 MAIN HARNESS 1
7 FRAME GROUND CABLE 1

NOTE :
1. TIGHTENING TORQUE OF BATTERY TERMINAL
3.34 N.m (2.46 lbf.ft)
2. NOT SPECIFIED TORQUE FOR GND.
18.0 N.m (13.3 lbf.ft)

23-16 Fig. 23-12 Upper harness assy (1/3)

 23. ELECTRICAL SYSTEM

UPPER HARNESS ASSY: (2/3)

Fig. 23-12 Upper harness assy (2/3) 23-17

23. ELECTRICAL SYSTEM

UPPER HARNESS ASSY: (3/3)

23-18 Fig. 23-12 Upper harness assy (3/3)

 23. ELECTRICAL SYSTEM

23.2.6.6B MAIN HARNESS : (1/2)

Fig. 23-13 Main harness (1/2) 23-19

23. ELECTRICAL SYSTEM

23.2.6.6B MAIN HARNESS : (2/2)

23-20 Fig. 23-14 Main harness (2/2)

 23. ELECTRICAL SYSTEM

23.2.6-1 STARTER CABLE 23.2.6-4 BATTERY GROUND CABLE

Fig. 23-18
23.2.6-5 RIGHT GUARD HARNESS

Fig. 23-15
23.2.6-2 BATTERY RELAY CABLE

Fig. 23-22
23.2.6-7 FRAME GROUND CABLE

Fig. 23-16
Fig. 23-19
23.2.6-3 BATTERY RELAY CABLE

Fig. 23-17

23-21
23. ELECTRICAL SYSTEM

23.2.7 ENGINE WARNESS ASSY

E/G HAENESS ASSY

No. Name Q'ty
1 E/G SUB HARNESS 1

#$%& '

 
   
     
  !  "  

(%) %%

(%) %


#$%& $  #$%&
* $&+ $
+ (%) %%%

#$%& . #$%&
* 
, % -  -%  -+
, #

23-22 Fig. 23-20 Engine harness assy

 23. ELECTRICAL SYSTEM

23.2.7-1 ENGINE SUB HARNESS

Fig. 23-21 Engine sub harness 23-23

23. ELECTRICAL SYSTEM

23.2.8 FLOOR PLATE HARNESS ASSY 23.2.8-1 UNDER FLOOR HARNESS: (1/2)

FLOOR PLATE HARNESS ASSY

No. Name Q'ty
1 UNDER FLOOR HARNESS 1
3 GROUND CABLE 1

23-24 Fig. 23-22 Floor plate harness assy Fig. 23-23 Under floor harness (1/2)
 23. ELECTRICAL SYSTEM

23.2.8-1 UNDER FLOOR HARNESS: (2/2)

23.2.8-3 GROUND CABLE

100 (3.94 )
LA308 5B E E 5B E
1PAM
YAZAKI 7122-3010

Fig. 23-34 Ground cable

Fig. 23-13 Under floor harness (2/2) 23-25

23. ELECTRICAL SYSTEM

23.2.9 CAB HARNESS ASSY: (1/2)

CAB HARNESS ASSY

No. Name Q'ty
1 CAB RIGHT FRONT HARNESS 1
2 LEFT INSTRUMENT HARNESS —
7 RIGHT INSTRUMENT HARNESS 1
8 LEFT INSTRUMENT HARNESS 1

23-26 Fig. 23-15 Cab harness assy (1/2)

 23. ELECTRICAL SYSTEM

CAB HARNESS ASSY: (2/2)

Fig. 23-15 Cab harness assy (2/2) 23-27

23. ELECTRICAL SYSTEM

23.2.9-1 CAB INSTRUMENT HARNESS

23-28 Fig. 23-16 Cab instrument harness

 23. ELECTRICAL SYSTEM

23.2.9-2 LEFT INSTRUMENT PANEL HARNESS

Fig. 23-17 Left instrument harness 23-29

23. ELECTRICAL SYSTEM

23.2.9-7 RIGHT INSTRUMENT HARNESS

23-30 Fig. 23-18 Right instrument harness

 23. ELECTRICAL SYSTEM

23.2.10 BATTERY C. BATTERY, BATTERY INSTALL

A. BATTERY 95D31R

BATTERY INSTALL
No. Name Q'ty
1 PLATE 1
3 CAPSCREW 2
5 LOCK WASHER 2

Fig. 23-19 Battery

B. BATTERY: KCME
Fig. 23-21 Battery install

Part No. 2411U25

Model 95D31R

Voltage 12 V

Capacity (5hr) 64 Ah

Mass (with Liquid) 20.5 kg (45 lb)

Electrolyte amount Approx. 5.2 L (1.4 gal)

Specific gravity of
1.28 {at 20 C (68 F)}
electrolyte

Fig. 23-20 Battery

23-31
23. ELECTRICAL SYSTEM

23.2.11 CAB ASSY

CAB ASSY
No. Name Q'ty
2 FRONT WINDOW ASSY 1
2-8 WIPER ASSY 1
2-37 WIPER HARNESS 1
25 DOOR SWITCH 1
61 CURL CODE HARNESS 1
64 CAB HARNESS 1
65 ANTENNA 1
68 ROOM LAMP 1
189 ROOM LAMP HARNESS 1
195-3 INTER LOCK SWITCH 1

23-32 Fig. 23-22 Cab assy

 23. ELECTRICAL SYSTEM

23.2.11-2-37 HARNESS 23.2.11-61 CURL CODE HARNESS 23.2.11-64 CAB HARNESS

Fig. 23-24 Fig. 23-25

Fig. 23-23

23.2.11-2-65 ANTENNA

Fig. 23-26

23.2.11-189 ROOM LAMP HARNESS

Fig. 23-27

23-33
23. ELECTRICAL SYSTEM

23.2.12 MOUNTING CAB 23.2.13 MOUNTING LIGHT 23.2.14 MOUNTING BOOM LIGHT

MOUNTING CAB MOUNTING LIGHT MOUNTING BOOM LIGHT

No. Name Q'ty No. Name Q'ty No. Name Q'ty
4 WASHER TANK 1 1 LIGHT 1 1 LIGHT 2
2A BOOM LIGHT HARNESS —
2B BOOM LIGHT HARNESS 1

Fig. 23-28 Mounting cab

23.2.14.1-2-A BOOM LIGHT HARNESS

23.2.12-4 WINDOW WASHER TANK & PUMP

L=3400 (11´2 )

CB104
CAP · 7120-1010 1PAM
YAZAKI 7122-2810
TARMINAL 7114-2020

23.2.14.1-2-B BOOM LIGHT HARNESS

G CB104
CAP · 7120-1010

(1.2 )
30
Fig. 23-30

870 (34.3 )
Fig. 23-29
770 (30.3 ) 2970 (9´9 )
G
30 30 G
G
(1.2 ) (1.2 )
CB104
CAP · 7120-1010 1PAM
YAZAKI 7122-2810
TARMINAL 7114-2020
23-34 Fig. 23-32
 23. ELECTRICAL SYSTEM

23.2.15 MOUNTING CAB WORK LIGHT

MOUNTING CAB WORK LIGHT

(FOUR LIGHT, HARNESS ONLY)
No. Name Q'ty
6 SWITCH 1
18 FOUR LIGHT HARNESS 1

Fig. 23-33 Mounting cab work light 23-35

23. ELECTRICAL SYSTEM

23.2.15-18 FOUR LIGHT HARNESS

Fig. 23-34

23-36
 23. ELECTRICAL SYSTEM

23.2.16 AIR CONDITIONER

AIR CONDITIONER (A/C)

No. Name Q'ty
1 A/C ASSY 1
1-3 SENSOR 1
1-11 A/C CONDITONER 1
2 AIR DRYER ASSY 1
2-1 RECEIVER TANK 1
3 AIR COMPRESSOR 1
4 PANEL 1

23.2.16-3 AIR COMPRESSOR

Fig. 23-35 Air conditioner Fig. 23-36 Detail of compressor wiring 23-37
23. ELECTRICAL SYSTEM

23.2.17 MOUNTING FUEL PUMP

FUEL PUMP ASSY

MOUNTING FUEL PUMP
No. Name Q'ty
No. Name Q'ty
1 FUEL PUMP 1
1 FUEL PUMP ASSY 1

23-38 Fig. 23-37 Mounting fuel pump Fig. 23-38 Fuel pump assy
 23. ELECTRICAL SYSTEM

23.2.18 NAME PLATE INSTALL (ELECTRIC COMPONENT FOR AUTO IDLE STOP)

NAME PLATE INSTAL

No. Name Q'ty
1 SWITCH 1
2 LIGHT ASSY 1

Fig. 23-39 Cab switch instal

23-39
23. ELECTRICAL SYSTEM

[MEMO]

23-40
 24. COMPONENTS SYSTEM
TABLE OF CONTENTS

24.1 HYDRAULIC COMPONENTS ............................................................................................ 24-3

24.1.1 HYDRAULIC PUMP & REGULATOR ....................................................................... 24-3
24.1.2 PILOT VALVE (ATT) .................................................................................................. 24-13
24.1.3 PILOT VALVE (TRAVEL) .......................................................................................... 24-17
24.1.4 CONTROL VALVE .................................................................................................... 24-22
24.1.5 SWING MOTOR UNIT ............................................................................................... 24-57
24.1.6 TRAVEL MOTOR ...................................................................................................... 24-67
24
24.1.7 SWIVEL JOINT ......................................................................................................... 24-81
24.1.8 CYLINDER ............................................................................................................... 24-83
24.2 ELECTRIC EQUIPMENT ................................................................................................... 24-91
24.2.1 ELECTRIC EQUIPMENT LIST FOR KCMA, KCME .................................................. 24-91
24.2.2 ELECTRIC EQUIPMENT LIST FOR ASIA, OCEANIA ............................................. 24-94
24.2.3 SPECIFICATION OF ELECTRIC EQUIPMENTS ...................................................... 24-97

24-1
24. COMPONENTS SYSTEM

24-2
 24. COMPONENTS SYSTEM

24.1 HYDRAULIC COMPONENTS

24.1.1 HYDRAULIC PUMP & REGULATOR

24.1.1.1 SUMMARY
(1) General view and hydraulic port

Code Port name Size

A1, A2 Delivery port PF 3/4
A3 Delivery port PF 3/8
A4 Relief port PF 3/8
A5 Delivery port PF 1/2
a1, a2 Gauge port PF 1/4
a3 Air Bleed port PF1/4 Pz
B1 Suction port 48
B2 Suction port PF 1
Dr1, Dr2 Drain port PF 1/2 C2
P3 Power shift port of the pilot pump PF 1/4
Pf Power shift port of the Pilot Pressure PF 1/4
C2 Pcl port PF 1/4
Pz Power shift port PF 3/8

Fig. 24-1 Hydraulic pump & regulator

(2) Specifications
Table 24-1

Model K3SP36B-101R-2002
Displacement capacity cm3/rev 31.4 X 2
Main
pump Max. pressure MPa (psi) 29.4 (4270)
Max. flow L/min (gal/min) 66 (18) X 2
Purpose of use Dozer pressure source (A5) Pilot hydraulic pressure source (A3)
Attached Displacement capacity cm3/rev 23.1 9.5
gear
pump Max. pressure MPa (psi) 19.6 (2840) 3.4 (500)
Max. flow L/min (gal/min) 48.5 (13) 20 (5.3)
Revolution (min ) rpm
-1
Rate : 2100 (Clockwise as seen from the shaft), high idle : 2310
Weight kg (lbs) 44 (88)
Oil quantity L (gal) 1.0 (0.26)
Simultaneous total horsepower,
Power shift control of air-conditioner,
Control characteristics of regulator
Power shift control of the No.3 pumpVariable horsepower control
Power boost-up control for travel

24-3
24. COMPONENTS SYSTEM

24.1.1.2 CONSTRUCTION

Apply adhesive
(Three bond No.1303B)

Coat the circumference

of the oil seal with
adhesive
(Loctite No.222)

Fig. 24-2 Construction of hydraulic pump & regulator (1/2)

24-4
 24. COMPONENTS SYSTEM

SECTION VV
GEAR PUMP

SECTION WW SECTION XX

SECTION YY

SECTION ZZ

Fig. 24-3 Construction of hydraulic pump & regulator (2/2)

24-5
24. COMPONENTS SYSTEM

Table 24-2
No. NAME Q’ty No. NAME Q’ty
111 SHAFT 1 624 SPRING SEAT 1
114 COUPLING 1 625 SPRING 1
115 COLLAR 1 626 SPRING 1
123 ROLLER BEARING 1 627 ADJUST STEM (E1) 1
124 NEEDLE BEARING 1 630 LOCK NUT : M30 1
127 SPACER 1 641 SPRING COVER 1
141 CYLINDER BLOCK 1 651 SLEEVE 1
151 PISTON 10 652 SPOOL 1
152 SHOE 10 653 PIN 1
153 PLATE 1 654 PIN 1
156 SPHERICAL BUSHING 1 655 PIN (Pf PISTON) 1
157 SPRING 10 656 PIN 1
212 SWASH PLATE 1 660 ADJUST SCREW (R) 1
214 BUSHING 1 661 LOCK NUT : M14 × 1.5 1
215 PIVOT BALL 1 662 SPRING SEAT 1
216 PIVOT BALL 1 663 SPRING 1
271 CASING 1 664 POPPET 1
273 COVER 1 665 SEAT (R) 1
312 VALVE COVER 1 666 ADJUST SCREW (E) 1
313 VALVE PLATE 1 667 ADJUST STEM (E2) 1
401 SOCKET BOLT : M16 ×40 4 668 PISTON (E) 1
402 FLANGE SOCKET BOLT ; M8 × 16 2 700 O-RING : 1B G35 1
403 SOCKET BOLT : M16 × 70 1 701 O-RING : 1B G55 1
404 SOCKET BOLT : M6 × 20 9 702 O-RING : 1B G135 1
467 DRAIN PLUG : PF 1/2 1 705 O-RING : 1B P16 2
468 PLUG : PF1/4 1 706 O-RING : 1B P11 7
490 PLUG : NPTF1/16, Meck coated 14 707 O-RING : 1B P18 1
492 PLUG : PT1/8, Meck coated 1 708 O-RING 1
493 PLUG : PT3/8 1 709 O-RING : 1B P26 1
710 O-RING 1
508 ORIFICE SCREW : NPTF1/16 4 751 GASKET 1
531 TILTING PIN : M16 × 1.5 1 774 OIL SEAL 1
532 SERVO PISTON : M16 × 1.5 1 787 BACKUP RING 1
534 SET SCREW : M27 × 1.5 1 789 BACKUP RING 2
535 STOPPER 1 801 LOCK NUT : M8 1
541 SEAT 2 803 LOCK NUT : M27 × 1.5 1
543 STOPPER 2 824 SNAP RING 1
545 BALL 2 825 SNAP RING 1
548 FEED BACK PIN 1 885 SPRING PIN 2
611 FEED BACK LEVER 1 901 EYE BOLT : M8 1
621 COMPENSATING PISTON 1

24-6
 24. COMPONENTS SYSTEM

24.1.1.3 FUNCTION
(1) This pump is of split flow double-pump type capable of obtaining two independent delivery lines by branching off
the oil delivered from single cylinder block (141) to two delivery ports by the action of the valve plate (313). Fur-
ther, the pump has a common suction construction that integrates the suction of the gear pump at the rear end
and the suction of the main pump. The pump contains a relief valve for the gear pump for pilot pressure.
The pump consists mainly of :
The rotary group that makes rotary-movements, The swash plate group that changes the delivery rate, and the
regulator group that controls the tilting angle.

Fig. 24-4 Rotary group

(2) Rotary group (See Fig. 24-4)
The rotary group consists of shaft (111), cylinder block (141), piston (151), shoe (152), plate (153), spherical
bushing (156), and spring (157). The shaft is supported by bearings (123, 124) at its both ends. The shoe makes
a spherical joint caulked to the piston and relieves thrust load occurring by load pressure. Since the shoe slides
lightly on swash plate (212), it has a pocket that achieves hydraulic balance. The subgroup consisting of the pis-
ton and the shoe is pressed against swash plate (212) by spring (157) via the plate that slides smoothly on swash
plate (212). Likewise, the cylinder block is pressed against valve plate (313) by a spring.
Now, if the shaft is driven by the engine, the cylinder block (141) is driven (rotates) via a spline joint. If the swash
plate is tilted, the pistons arranged in the cylinder block make reciprocating motion relative to the cylinder while
rotating with the cylinder block. Now let us take a lock at a single piston : While the cylinder block makes one
turn, the piston moves away from valve plate (313) (the process of sucking oil) in 180° and moves close to valve
plate (313) (the process of deliverying oil) in the remaining 180°. The valve plate is provided with one suction
port and two delivery ports that are arranged in valve cover (312). The oil sucked into the cylinder block via the
suction port is branched off to two delivery ports of the valve plate and is connected to the external piping past
valve cover (312).

24-7
24. COMPONENTS SYSTEM

(3) Swash plate group (See Fig. 24-5)

The swash plate group consists of swash plate (212), pivot balls (215, 216), tilting bushing (214), tilting pin (531),
and servo piston (532). The swash plate (212) is supported by pivot balls (215, 216) on two spherical faces
formed on the opposite side of the shoe sliding surface. The regulator controls the supply and delivery of hy-
draulic oil to and from the large diameter chamber of the servo piston. The result is that the servo piston is moved
to the right and left. The swash plate swings pivot balls (215, 216) via the spherical part of tilting pin (531) and
changes the tilting angle ( ) or the delivery rate of the pump.

Fig. 24-5 Swash plate group

24-8
 24. COMPONENTS SYSTEM

(4) Regulator group

1) Summary (See Fig. 24-6 and Fig. 24-7)
The regulator group consists of feedback lever (611), compensating piston (621), springs (625, 626), pilot
sleeve (651), and pilot spool (652).
Thus it makes up a hydraulic servo mechanism consisting of servo piston (532) and a positional feedback.
The delivery pressures P1, P2 of the pump are combined in the regulator and changes the delivery rate of
the pump according to the level of he pressure as shown in Fig. 24-6. For this reason, the input torque is
kept nearly constant which realizes a total horsepower control, in order to prevent the engine from being
overloaded.
This pump system is equipped with one or two gear pumps at its rear end. The load pressures P3 Pf of the
pump enables power shift control that shifts the horsepower set as illustrated in the figure on the right.

DELIVERY RATE Q

DELIVERY PRESSURE (P1+P2)/2

Fig. 24-6 Power shift control chart
COMPENSATING PISTON (621)
No.3 PUMP SHIFTED PIN (P3 PISTON)(655)
HORSEPOWER PORT CHECK VALVES
PILOT REDUCED (541),(543),(545)
HORSEPOWER PORT
ORIFICE
SPOOL (652) (508)
SPRING (626)
PISTON (668)

PZ GAUGE
SPRING (625) PORT

SLEEVE (651)
FIXED PIN (653)
FEEDBACK LEVER
(611)
SERVO PISTON (532)
TILTING PIN (531)
FEEDBACK PIN (548)
SWASH PLATE (212) DRAIN PORT SUCTION PORT

Fig. 24-7 Functional explanation of regulator

2) Function of added total horsepower control (See Fig. 24-7)
If pump delivery pressure P1 or delivery pressure P2 rises, the mean pressure (P1+P2)/2 acts upon the
stepped section of compensating piston (621) by the action of four orifices (508). In this case, spool (652) is
pushed to the right and moves till the action of spring (625) and spring (626) balances the hydraulic force.
As the spool moves to the right, the oil path to the larger diameter part of servo piston (532) consisting of the
sleeve and the spool opens. This admits the delivery pressure to push the spool to the left.
The delivery pressure enters the check valve [seat (541), stopper (543), and ball (545)] from which the higher
of the pressures P1, P2 is put out selectively to the smaller diameter side of the servo piston so that the de-
livery pressure is admitted at all times. In the meantime, swash plate (212) and servo piston (532) are linked
together by tilting pin (531). This decreases the tilting angle which in turn decreases the delivery rate of the
pump, in order to prevent the engine from being overloaded. The action of the servo piston is transmitted to
feedback lever (611) via the feedback pin (548). The feedback lever turns on pin (653) that is fixed to casing
(271) and moves sleeve (651) to the right. The sleeve moves till the opening of the path to the larger diameter
part of the servo piston closes and stops just when the opening is closed.
If the pump delivery pressures P1, P2 decrease, the spool is pushed back by the action of springs (625, 626).

24-9
24. COMPONENTS SYSTEM

This connects the oil path for the larger diameter of the servo piston to the tank.
This moves the servo piston to the right by the oil pressure from the smaller diameter side. The result is that
the tilting angle ( ) increases which in turn increases the delivery rate of the pump.
Then the feedback lever turns on the pin which moves the sleeve to the left till it closes the opening of the
spool-sleeve.
3) Horsepower shift control function
The function is capable of power shift control that changes a set horsepower of the pump with the load pres-
sure P3 of the gear pump installed to the rear end of the pump as a command pressure, as shown by doted
lines in Fig. 24-8.
The power shift pressure P3 is admitted to the left end of pin (655). The spool moves to the right as load
pressure P3 of the No.3 pump rises. This decreases the tilting angle of the pump as mentioned above which
in turn decreases the horsepower set. Inversely, the horsepower set rises as pressure P3 falls.
Likewise, power shift control is possible if the pump horsepower is changed with load pressure Pf of the gear
pump installed to the rear end of the pump as a command pressure. Power shift pressure Pf acts upon the
mount (smaller diameter) of the compensating piston. As the load pressure of the pilot pressure pump rises,
the tilting angle ( ) of the pump decreases which in turn reduces the horsepower set as mentioned above.
Inversely, the horsepower set rises as the pressure Pf falls.
DELIVERY RATE Q

DELIVERY PRESSURE (P1+P2)/2

Fig. 24-8 Power shift control
4) With regard to power up port (Pz port)
This system is used to shift up the main pump set power when the gear pump for slewing and dozer opera-
tions (hereafter called "4th pump") is unloaded.
• Explanation of the system
When the 4th pump is loaded, the pump set power is set to the power close to power B shown in Fig. 24-9 to
prevent engine stalling. Consequently, when the 4th pump is unloaded, the set power is set to the power close
to power A automatically, and it is anticipated that the delivery rate down in the range of high pressure area
may cause a large speed down of this machine.

To avoid this problem, the set power close to power A changes as shown in by a function of pressure signal
onto Pz port, preventing the delivery rate down in the range of high pressure area.
DELIVERY RATE Q

DELIVERY RATE Q

Power B Power A Power B Power A

DELIVERY PRESSURE (Pa+Pb) DELIVERY PRESSURE (Pa+Pb)

In power up operation
Fig. 24-9 Pump P-Q curve

24-10
 24. COMPONENTS SYSTEM

24.1.1.4 ADJUSTING THE REGULATOR

The maximum flow and the horsepower control (630) (666)
characteristics may be adjusted by the adjust (HORSEPOWER CHARAC-
TER ADJUST SCREW E)
screws of the regulator. However, since they are set (801)
to optimum at shipment, use care so as not to (667) (INPUT HORSEPOWER
ADJUST SCREW) (E2)
tamper with these adjust screw in normal condition.

(803) (534) (MAX.FLOW ADJUST SCREW)

Fig. 24-10 Regulator adjust screws

(1) Adjusting the max. flow (See Fig. 24-10, Fig. 24-
11)

DELIVERY RATE Q
Loosen lock nut (803) and tighten (or loosen) set
screw (534) to adjust the flow. If the set screw (534)
is tightened 1/4 turn, the theoretical flow decreases
by approx. 0.7 cm3/rev. Only the max. flow changes
by it, leaving other control characteristics un-
changed.
DELIVERY PRESSURE (P1+P2)/2
Fig. 24-11 Max. flow adjustment
(2) Adjusting the horsepower control characteristics
(See Fig. 24-10, Fig. 24-12)
DELIVERY RATE Q

Adjust the spring by loosening lock nut (630) and

tightening (or loosening) adjust screw (E) (666). If
the adjust screw (E) is tightened 1/4 turn, the com-
pensating control start pressure rises by approx.
1.2 MPa (180 psi), as shown in Fig. 24-12 on the
right. If adjust screw (E) is rotated by N turns, a set
spring pressure changes also ; return the set screw DELIVERY PRESSURE (P1+P2)/2
(667) by N × 1.2 turns. Fig. 24-12 Adjusting the horsepower control char-
acteristics
(3) Adjusting the input horsepower
(See Fig. 24-10 and Fig. 24-13.)
DELIVERY RATE Q

Adjust the spring pressure by loosening lock nut

(801) and tightening (or loosening) set screw (667).
The flow increases as in the figure on the right if the
adjust screw is tightened. (The input horsepower
increases also.) If the set screw is tightened by 1/4
turn, the theoretical flow increases by approx.
2.5cm3/rev. DELIVERY PRESSURE (P1+P2)/2
Fig. 24-13 Adjusting the input horsepower

24-11
24. COMPONENTS SYSTEM

280psi 710±210psi
17.4±0.3G 17.1G
2.0MPa 4.9±1.5MPa Control chart of pump
Spec. with dozer
H mode 66±1L 65.6L 1640±71psi
17.0G A/C power cut pressure Dozer pump pressure
70 11.3±0.5MPa
(18) a Pf = 0MPa P3 = 1.96MPa
64.6L
S mode 9.3MPa b Pf = 3.4MPa P3 = 1.96MPa
2.9MPa

Pf 500 Pa
66.9L 64.9L c Pf = 0MPa P3 = 19.6MPa
Pf

Pf

Pf 0ps a P
= 0 ps i P
60

(0 Pa

(5 .4M
=3

=3

= 0 i)
430psi ( .4 M 1350P

(0 Pa
M
d Pf = 3.4MPa P3 = 19.6MPa

ps P ( 284 1 9 .6

0 P
(16)

ps
M
17.7G 17.1G

i) 3

i)
FC mode )

P
Delivery flow rate L/min (gal/min)

= 1 0psi MPa

3 = 80p Pa
(2 .6M
50
3=

3=
84 P
2470psi 2460psi

(2 6M
(13) 9

1.9 si)
(2 96M

80 Pa
0p a
9.0G 6.9G

1.

ps
si)
17.1MPa 17.0MPa

i)
)

34.2L 25.4L
40
(11) 2740psi
6.9G
12.5MPa 18.9MPa 4270psi
26.1L 25.1L 3.3G
30 29.4MPa
1540psi 1820psi
(8) 12.5L
7.0G 6.9G
10.6MPa
26.4L
20
(5) 4270psi
2.7G
29.4MPa
10 10.2L
(3) 29.4MPa
3970psi 27.3MPa 5.4L
4270psi
1.5G 5.7L
0 1.4G
4.9 (710) 9.8 (1420) 14.7 (2130) 19.6 (2840) 24.5 (3550) 29.4 (4270)
Pd1+Pd2
Delivery pressure MPa (psi)
2

24-12
 24. COMPONENTS SYSTEM

24.1.2 PILOT VALVE (ATT)

24.1.2.1 SUMMARY
(1) General view

SINGLE SINGLE
PORT 2
OPERATION OPERATION
ANGLE ANGLE
(PORT 2,4) (PORT 1,3) PORT 3

T PORT
P PORT

PORT 1
PORT 4

VIEW A

Max. primary pressure 6.9MPa (1,000 psi)

Rated flow 15 L/min (4.0 gal / min)
Weight 1.6 kg (3.5 lb)

A
PORT 1,3
50.0 4.9 4.9 50.0
Secondary pressure (MPa)
Secondary pressure psi

40.8 4.0 4.0 40.8

SINGLE OPERATION
3.43 TORQUE
35 3.09 +0.59
Operation torque

2.27{23.2}
31.5+60 0
Operation torque

30.6 3.0 SECONDARY 3.0 30.6

PRESSURE
2.29 23.3
2.16 22.0
20.4 2.0 2.0 20.4
19 1 1.86 0.1 1.73 17.6

10.2 1.0 1.0 10.2

+0.049
-0.074
1.16{11.8} 0.94 9.6
5.5 +0.50
-0.75 0.54 0.98{10.0}

0 0 0
0 1.1 2 4 5.5 6 6.5 7
Push rod stroke mm
0 5 10 15 19
Operation angle (deg.)

PORT 2,4
50.0 4.9 4.9 50.0
SINGLE
OPERATION
Secondary pressure psi

Secondary pressure (MPa)

TORQUE

40.8 4.0 4.0 40.8

SECONDARY
3.43 PRESSURE
Operation torque
Operation torque

35 3.09+0.59
0
31.5+60 3.0 3.0 30.6
30.6
2.37 24.1
2.34{23.8} 2.22 22.7
20.4 2.0 2.0 20.4
19 1 1.73 18.3
1.86 0.1

10.2 1.0 1.0 10.2

+0.049 0.94
-0.074
1.16{11.8}
9.6
5.5-0.75
+0.50 0.54 0.98{10.0}

0 0 0 0
0 1.1 2 4 6 7.5 8 8.5 9.4
Push rod stroke mm
0 5 10 15 20 25
Operation angle (deg.)

24-13
24. COMPONENTS SYSTEM

24.1.2.2 CONSTRUCTION

APPLY GREASE 312

ON ROTATIONAL
PART OF THE
UNIVERSAL JOINT
302 301
501

APPLY GREASE 1 3 2 4
213 ON TOP
511 HYDRAULIC SYMBOLS

507 151
RIGHT PILOT VALVE
PORT
OPERATION
510 NO.
211 1 BUCKET DIGGING
506 2 BOOM DOWN
3 BUCKET DUMP
214
216 4 BOOM UP

LEFT PILOT VALVE

503 508
PORT
OPERATION
NO.
221
509 1 SLEWING LEFT
2 ARM OUT
201 3 SLEWING RIGHT
4 ARM IN
217
SECONDARY 101
PRESSURE PORT 2,4 PORT 1,3
ADJUSTING SHIMS

Fig. 24-14 Pilot valve-Sectional view

Table 24-3
No. NAME Q’TY No. NAME Q’TY No. NAME Q’TY
101 CASING 1 217 WASHER 2 4 506 SPRING SEAT 2
151 PLATE 1 221 SPRING 4 507 SPRING SEAT 2
201 SPOOL 4 301 JOINT; M14 1 508 SPRING 2
211 PLUG 4 302 DISK 1 509 SPRING 2
213 SEAL 4 312 ADJUSTING NUT; M14 1 510 SPRING 4
214 O-RING; 1B P20 4 501 BELLOWS 1 511 PUSH ROD 4
216 SPRING SEAT 2 503 SPRING SEAT 2

24-14
 24. COMPONENTS SYSTEM

24.1.2.3 OPERATION
(1) Lever in neutral position (See Fig. 24-15)
In this case, the force of the secondary pressure
setting spring (509) that determines the output
pressure of the pilot valve is not transmitted to the
spool (201). Accordingly, the spool (201) is pushed
up by the return spring (221) and spring seat (216)
permitting the output port 2, 4 to connect with the
tank port T. This makes the output pressure equal
to the tank pressure.

Fig. 24-15 Lever in neutral position

(2) When the Lever is tilted (See Fig. 24-16)
When the lever is tilted, the push rod (511) strokes.
The spool (201) and 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 flow out to the port 2, 4, to produce a pres-
sure.

Fig. 24-16 When Lever is tilted

(3) The Lever being held (See Fig. 24-17)
When the lever is tilted till the pressure of the port
2, 4 rises to an oil pressure corresponding to the
set spring force, the hydraulic pressure is balanced
with the spring (509) force. And when the pressure
of the port 2, 4 rises above a set pressure, the port
P are closed and the port T are opened. When the
pressure of the port 2, 4 falls below a set pressure,
the port P are caused to open and the port T are
caused to close, thus holding the second pressure
constant.

Fig. 24-17 Lever being held

24-15
24. COMPONENTS SYSTEM

(4) Operation in the area where the tilting angle of the

lever is large. (varies with the model) If the lever is
inclined beyond a certain angle on certain models,
the top end of the spool contacts the bottom of the
bore of the push rod. This keeps the output pres-
sure 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.

24-16
 24. COMPONENTS SYSTEM

24.1.3 PILOT VALVE (TRAVEL)

24.1.3.1 OUTLINE
(1) General view

4-M8 X P1.25
T=16.7 N·m
(21.3 lbf·ft)

Back side
2-PF1/4
2-PF1/4 T=29.4 N·m
T=29.4 N·m (21.7 lbf·ft)
(21.7 lbf·ft)

4-PF1/4
T=29.4 N·m
(21.7 lbf·ft)

Hydraulic diagram

Fig. 24-18
(2) Specifications

Type PVD6PC4017A
Max.primary pressure 6.9MPa (1000 psi)
Rated flow 10 L/min (2.64 gal/min)
Weight 3.9 kg (8.6 lbs)

(3) Performance characteristics

Operation torque kgf·m (lbf·ft)

40.8 1.224
Operation torque
Secondary pressure kgf/cm2

Secondary pressure (MPa)

Operation torque (N·m)

30.6 0.918
0.916
24.0 0.600
20.4 0.612
0.570
0.524
10.2 0.306
5.5 Secondary pressure
Torque required (Damper)
0 0 18.9~2.8 N·m (13.9~2.07 lbf·ft)
Push rod stroke (mm) Push rod speed 0.0275 m/s
Actual required torque is the valve
operation torque shown in left diagram
Operation angle (deg)
adding to damper operation torque.
Fig. 24-19

24-17
24. COMPONENTS SYSTEM

Fig. 24-20 Assembly view of pilot valve (travel)

Tightening Tightening
torque No. Parts Q’ty torque No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
101 CASING 1 6.9 (5.1) 252 PLUG 6
102 CASING (Damper) 1 11.8 (8.7) 253 RO PLUG 2
191 SEAT 1 2 261 O-RING 3
192 SEAT 2 2 263 O-RING 2
193 BUSHING 2 2 8.8 (6.5) 271 CAPSCREW 4
194 BALL 2 301 SPOOL 4
201 COVER 2 311 SPRING SEAT 4
202 PLUG 4 313 WASHER 4
203 GREASE CUP 4 324 SPRING 4
210 SEAL 4 335 SPRING 4
211 O-RING 4 336 SPRING 4
212 O-RING 4 413 CAM SHAFT 2
213 O-RING 2 414 BUSHING 4
214 PUSH ROD 4 420 CAM 2
217 SHIM 4 471 BALL 4
218 SPRING SEAT 4 6.9 (5.1) 472 LOCK NUT 2
224 PISTON 4 501 BOOTS 2
225 BALL 12
29.4 (21.7) 251 RO PLUG 3

24-18
 24. COMPONENTS SYSTEM

24.1.3.2 FUNCTION

1. Reducing valve
(1) Neutral (Fig. 24-21)
Spool (301) is pushed up by spring (335) (for return)
via spring seat (311) and washer (215) and is locat-
ed in the neutral position as shown in the cross-sec-
tional view. Therefore, since the output port
connects only with port T by the spool select func-
tion, the pressures at output ports 1, 2 are equal to
that of port T.

311

335

301

PORT 2 (4) PORT 1 (3)

Fig. 24-21
(2) The control of the remote control valve is tilted from NEUTRAL
its neutral (Fig. 24-22) At the full stroke
If cam (420) is rotated clockwise in the cross–sec-
tional view, push rod (214) on port 1 is pushed
420
down. This moves the spool down via washer 1,
spring seat (for secondary pressure setting), spring
214
(324), washer 2 (217), and washer 3 (313) and con-
nects port P with port 1. The oil supplied by the pilot
pump runs to port 1 and generates pressure.
If the control lever (or pedal) is inclined and when
the pressure at port 1 rises to a level equivalent to
the action of the spring that sets the secondary
pressure, the hydraulic pressure acting on the 311
spool balances the spring action, thereby keeping 324
the output pressure at port 1 constant. The spool at
port 2 is held neutral ; the oil returning from the con- 217
trol valve is discharged via port T. 313
On some specifications, the push rod comes in di-
rect contact with the top of the spool in the neigh-
borhood of the maximum angle of the control. This
pushes in the spool forcibly which connects port P
with the output port and makes the pressures at PORT 2 (4) PORT 1 (3)
both ports equal. Fig. 24-22

24-19
24. COMPONENTS SYSTEM

2. Damping mechanism of the control

(1) Neutral
The push rod is pushed up by springs (336) via piston (224) (damping) and is located as shown in the cross-
sectional view.
(2) The control is inclined from its neutral position :
[Refer to the functional explanation (1) of damping]
If the cam is turned clockwise in the cross-sectional view, the push rod on the port 1 side is pushed down which
brings the piston down.
On that occasion, the oil in the damping piston chamber is discharged through the orifice. The pressure then
generated creates a damping force.
In the meantime, the push rod on the port 2 side moves up by the damping spring via the piston.
On that occasion, the oil in the tank chamber is sucked into the damping piston chamber through the ball checks
(3 places) that consists of bushing (223) and ball (225). The oil outside of the piston chamber gets out of the path
to port T, from the top end of the casing.

CAM

PUSH ROD

ORIFICE

PISTON

PISTON CHAMBER

If the lever is stroked in

the arrow direction from
its neutral, the oil in the
right-hand (left-hand)
piston chamber is
discharged from the
orifice. Damping force
occurs by the pressure
then generated.

BALL

PORT 2 (4) PORT 1 (3)

24-20
 24. COMPONENTS SYSTEM

(3) The control lever (or pedal) is inclined from its maximum angle to its opposite side :
[Refer to the functional explanation (2) of damping.]
On the cross-sectional drawing, if the cam is tilted in its full clockwise direction and then turned counterclockwise,
the push rod on the port 2 side is pushed down. This moves the piston down.
On that occasion, the oil in the damping piston chamber is discharged from the orifice of the piston. The pressure
then generated creates a damping force.
In the meantime, the push rod on the port 1 side moves spring (335) (for return) and damping spring (336) up-
wards.
The oil in the tank chamber is sucked into the damping piston chamber through the ball checks (3 places) con-
sisting of a bushing and a ball. The oil outside of the piston chamber gets out from the top end of the casing to
the path that leads to the tank port.
That is to say, the mechanism is so constructed that damping force acts on any tilting operations i.e. from neutral
to full tilting or from full tilting to neutral.

NEUTRAL
At the full stroke

CAM

PUSH ROD The oil outside of the piston

flows out of the path to the
T port, from the top end of
the casing
( at operation)

PISTON
Oil
When the lever is neutral DAMPING
to reverse direction, the SPRING
push rod is pushed up by
the damping spring.
( operation) The oil in the piston
chamber is discharged
The oil in the T line through the orifice.
is sucked into the The oil then created
damper generates a damping
chamber through the ball force.
check (3 places).
( at operation) ( at operation)
When the lever is operated RETURN
in the reverse direction SPRING
(from to state), the
left-hand piston serves as a
damper piston this time.

Damping force is
generated on both
at all times.

PORT 2 (4) PORT 1 (3)

24-21
24. COMPONENTS SYSTEM

24.1.4 CONTROL VALVE

24.1.4.1 SPECIFICATIONS
(1) General view and hydraulic ports

Fig. 24-23 General view and hydraulic ports (1/2)

24-22
 24. COMPONENTS SYSTEM

Item Spec. Tightening

Port torque Port
N·m name Description
Model BCV75 size
(lbf·ft)
Main relief valve set pressure 29.4 MPa (4270 psi) 78~88
PF3/4 T1 Tank port
(attach, travel) at 28 L/min (7.4 gal/min) (58~65)
P1 Pump A1 port
Over load relief valve
32.9 MPa (4760 psi) P2 Pump A2 port
set pressure A1 Travel right port (forward)
at 20 L/min (5.3 gal/min)
(OR-A2, A3, B2, B3, C3, D3) B1 Travel right port (reverse)
Pilot pressure (MAX) 3.5 MPa (508 psi) C1 Travel left port (reverse)
D1 Travel left port (forward)
A2 Boom up port
B2 Boom down port
59~69
PF1/2 C2 Slewing port (right)
(43~51)
D2 Slewing port (left)
A3 Bucket digging port
B3 Bucket dump port
C3 Arm in port
D3 Arm out port
B5 Boom swing rod port
A6 N&B head port
B6 N&B rod port
39~49
PF3/8 DR4 Drain port
(29~36)
PS Load check valve for slewing priority
pilot port
PS' Slewing priority command
P0 Travel straight spool select pilot port
Pa1 Travel right pilot port (forward)
Pb1 Travel right pilot port (reverse)
Pc1 Travel left pilot port (reverse)
Pd1 Travel left pilot port (forward)
Pa2 Boom up pilot port
Pb2 Boom down pilot port
Pb2' Boom lock valve release pilot port
Pc2 Slewing right pilot port
Pd2 Slewing left pilot port
Pd2' Higher pilot pressure select port for slewing
Pa3 Bucket digging pilot port
25~29 Pb3 Bucket dump pilot port
PF1/4 (18~22) Pc3 Arm in pilot port
Pc3' Arm lock valve release pilot port
Pd3 Arm out pilot port
Pb4 P1 bypass cut pilot port
Pc4 Boom conflux spool pilot port
Pd4 P2 bypass cut pilot port
Pa5 Boom swing LH pilot port
Pb5' Boom swing RH pilot port
Pa6 N&B close piot port
Pb6 N&B open pilot port
DR1 Drain port
DR2 Drain port
DR3 Drain port
DR5 Drain port
DR6 Drain port
DR7 Drain port
DR8 Drain port
Fig. 24-24 General view and hydraulic ports (2/2)

24-23
24. COMPONENTS SYSTEM

24.1.4.2 CONSTRUCTION

Fig. 24-25 Construction of control valve (1/6)

24-24
 24. COMPONENTS SYSTEM

Fig. 24-26 Construction of control valve (2/6)

24-25
24. COMPONENTS SYSTEM

Fig. 24-27 Construction of control valve (3/6)

24-26
 24. COMPONENTS SYSTEM

Fig. 24-28 Construction of control valve (4/6)

24-27
24. COMPONENTS SYSTEM

Fig. 24-29 Construction of control valve (5/6)

24-28
 24. COMPONENTS SYSTEM

Tightening Tightening
torque No. NAME Q'ty torque No. NAME Q'ty
N.m (lbf.ft) N.m (lbf.ft)
1 BODY A 1 59-69 (49-51 43 PLUG 1
2 O-RING 2 44 O-RING 1
3 O-RING; 1B P22 8 45 TAPER SOCKET PLUG 3
4 O-RING; 1B P16 4 46 STEEL BALL 1
6.8-7.0 (49-51) 6 SOCKET BOLT: M12 X 105 4 98-11 (7.2-8.0) 47 SOCKET BOLT: M6 X 40 42
7 TRAVEL STRAIGHT SPOOL 1 98-11 (7.2-8.0) 48 SOCKET BOLT: M6 X 90 9
8 TRAVEL SPOOL 2 49 LOAD CHECK VALVE 1
9 SLEWING SPOOL 1 39-49 (29-36) 50 PLUG: PF3/8 2
10 BOOM SPOOL 1 51 RETAINING RING 3
11 ARM SPOOL 1 52 O-RING 24
12 BUCKET SPOOL 1 53 O-RING: 1B P6 3
13 BOOM CONFLUX SPOOL 1 54 O-RING: 1B P8 1
14 P2 BYPASS CUT VALVE 1 55 O-RING: 1B P10 1
15 P1 BYPASS CUT VALVE 1 56 O-RING: 1B P11 5
16 PILOT COVER D 3 57 O-RING: 1B P14 12
17 PILOT COVER E 1 58 O-RING: 1B P15 23
18 PILOT COVER C 10 59 O-RING: 1B P18 7
19 PILOT COVER B1 10 59-69 (49-51) 60 MAIN RELIEF VALVE ASSY 1
39-49 (29-36) 20 PLUG; M18 X 1.5 22 39-49 (29-36) 61 OVER LOAD RELIEF VALVE 10
21 LOAD CHECK VALVE 12 59-69 (49-51) 62 PLUG: PF3/4 1
22 LOAD CHECK VALVE SPRING 13 63 O-RING: 1B P24 1
23 SPRING HOLDER A 13 98-12 (7.2-8.7) 64 TAPER SOCKET PLUG: NPTF1/16 3
24 SPRING HOLDER B 11 65 STOPPER PIN 1
25 SPOOL END 11 66 PILOT COVER F 1
26 SPRING 12 67 PISTON D 1
27 SPOOL END 2 68 PILOT TIE 1
28 LOCK VALVE 3 29-34 (22-25) 69 PIN GUIDE 1
29 NEEDLE VALVE (POPPET) 3 70 SPRING (For slewing priority) 1
30 LOCK VALVE ORIFICE 3 71 O-RING 1
31 LOCK VALVE SPRING B 3 72 O-RING 1
32 SPRING HOLDER 3 39-49 (29-36) 73 PLUG: GPF 3/8 2
33 PISTON GUIDE 3 98-11 (7.2-8.0) 74 SOCKET BOLT: M6 X 55 2
34 PISTON A 3 75 BACKUP RING 2
35 LOCK VALVE SPRING A 3 78 SPOOL; BOOM SWING 1
36 PISTON C 3 6.0-7.0 (49-51) 79 PLUG; PF1/2 3
39-49 (29-36) 37 SHUTTLE VALVE SOCKET 1 80 BODY CA 1
38 SHUTTLE VALVE SEAT 1 81 SPOOL; CONFLUX/SINGLE SW. 1
39 SPOOL END 1 82 SPOOL; N&B 1
40 CHECK VALVE 1 3.5-4.0 (25-29) 84 PLUG; PF1/4 2
39-49 (29-36) 41 PLUG; PF3/8 7 85 BODY BB 1
42 CHECK VALVE SPRING 1 86 SPOOL; DUMMY 1

Fig. 24-30 Construction of control valve (6/6)

24-29
24. COMPONENTS SYSTEM

24.1.4.3 HYDRAULIC CIRCUIT

(1) Hydraulic circuit and designation of main parts

Fig. 24-31 Hydraulic circuit and designation of main parts

24-30
 24. COMPONENTS SYSTEM

Table 24-4
No. Parts
7 Travel straight spool
8 Travel spool
9 Slewing spool
10 Boom spool
11 Arm spool
12 Bucket spool
13 Boom conflux spool
14 P2 bypass cut spool
15 P1 bypass cut & arm conflux spool
21 Load check valve
28 Lock valve (Boom, Arm, Boom swing)
51 P1 main passage
52 P1 bypass passage
53 P1 parallel passage
54 P2 main passage
55 P2 bypass passage
56 P2 parallel passage
58 Boom conflux passage
59 Arm conflux passage
60 Tank passage
61 Main relief valve assy
62 Over load relief valve assy
78 Boom swing spool
81 N&B single flow conflux changeover spool
82 N&B spool
83 N&B conflux passage

24-31
24. COMPONENTS SYSTEM

24.1.4.4 FUNCTIONAL EXPLANATION

(1) Neutral
P1 side
The oil delivered from hydraulic pump enters port P1 passage passes through port P1. It then flows into the con-
trol valve (C/V), passes through the land of travel straight spool (7) and flows into the P1 parallel passage (53)
and P1 bypass passage (52). In the neutral position, the bypass passage (52) on the P1 side is not shut off by
spool. Therefore the oil passes through the travel (right) → boom → bucket → P1 bypass cut & arm conflux spool
→ boom swing → P1 bypass passage of nibbler & breaker spool, in that order, and flows out of T1 port past the
tank passage (60). (Fig. 24-32)

Fig. 24-32 Operation (1) at neutral

24-32
 24. COMPONENTS SYSTEM

P2 side
The oil delivered from hydraulic pump enters port P2 passage passes through port P2. It then flows into the con-
trol valve (C/V), passes through the land of travel straight spool (7) and flows into the P2 parallel passage (56)
and P2 bypass passage (55). In the neutral position, the bypass passage (55) on the P2 side is not shut off by
spool. Therefore the oil passes through the travel (left) → slewing → arm → P2 bypass cut spool → P2 bypass
passage of N&B single flow / conflux changeover spool, in that order, and flows out of T1 port past the tank pas-
sage (60). (Fig. 24-33)

Fig. 24-33 Operation (2) at neutral

24-33
24. COMPONENTS SYSTEM

(2) Travel operation

1) Travel forward operation
If the travel straight operation is performed the secondary pilot pressure enters the spring chamber of the
Pal and Pd1 ports of the C/V from the travel pilot valve, and shifts the travel spool (8). The oil which flows
in from the pump port passes through the land of travel straight spool (7) and flows into the main paths (51),
(54) of travel spool (8). The oil which flows into the main paths (51, 54) is then supplied to the travel motor
from the A1 and D1 ports which are now open because the bypass paths (52, 55) are shut off by the spool
(8) which is shifted.
In the meantime, the oil returning from the travel motor flows into the C/V from the B1 and C1 ports and flows
into the tank path (60) which is now open as the travel spool (8) has been shifted.

Fig. 24-34 Functions at travel straight operation

24-34
 24. COMPONENTS SYSTEM

2) Travel reverse operation

If the travel reverse operation is carried out, the secondary pilot pressure enters the opposite side of the
chamber of the Pb1 and Pc1 ports from the travel pilot valve, and shifts the travel spool (8). The oil which
has flowed in from the pump port passes through the land of the travel spool (7) and flows to the main paths
(51), (54) of travel spool (8).
The oil which flows from the main paths (51), (54) is supplied to the travel motor from the B1 and C1 ports
which are now open, because the bypass paths (52), (55) are shut off by the spool (8) now shifted.
In the meantime, the oil returning from the travel motor flows into the C/V from the A1 and D1 ports and flows
to the tank path (60) which is now open as the travel spool (8) has been shifted.

Fig. 24-35 Functions at travel reverse operation

24-35
24. COMPONENTS SYSTEM

(3) Bucket operation

1) Bucket digging operation
If the bucket digging operation is performed, the secondary pilot pressure enters the spring chamber of the
Pa3 port of the C/V from the pilot valve and moves the bucket spool (12). When the bucket spool has been
shifted, the P1 bypass path (52) is shut off by the bucket spool (12). Therefore, the oil which has flowed in
from the P1 port flows into the P1 parallel path (53) arranged in the travel straight part. Now the passage
between the A3 port and the bridge path is opened as the bucket spool (12) has been shifted. Therefore, the
oil which has flowed into the P1 parallel path (53) passes through the load check valve (21) in the bucket
select section, and is fed to the head of the bucket cylinder by way of the bridge path and the A3 port.
Meanwhile, the oil which has returned from the cylinder rod flows into the B3 port, passes through the spool
notch which is opened as the bucket spool (12) is shifted, and flows out to the tank passage (60). As the
result, the bucket cylinder operates in the extending direction whereby the bucket performs digging opera-
tion.

Fig. 24-36 Functions at bucket digging operation

24-36
 24. COMPONENTS SYSTEM

2) Bucket dump operation

If the bucket dump operation is performed, the secondary pilot pressure enters the opposite side of the
spring chamber of the Pb3 port of the C/V from the pilot valve and shifts the bucket spool (12).
If the spool is shifted, the P1 bypass path (52) is shut off by the bucket spool (12). Therefore, the oil which
has flowed in from the P1 port flows into the P1 parallel path (53) provided in the travel straight spool.
When the bucket spool (12) is shifted, the line between the B3 port and the bridge path is opened. Therefore,
the oil which flows into the P1 parallel path (53) passes through the load check valve (21) of the bucket select
part, and is fed to the rod of the bucket cylinder by way of the bridge path and the B3 port.
In the meantime, the oil returning from the cylinder head flows into the A3 port and flows out to the tank pas-
sage (60) which is now open as the bucket spool (12) has been shifted. Therefore, the bucket cylinder op-
erates in the contracting direction in order to dump the bucket.

Fig. 24-37 Function at bucket dump operation

24-37
24. COMPONENTS SYSTEM

(4) Boom operation

1) Boom up operation
If the boom up operation is performed, the secondary pilot pressure enters the spring chamber of the Pa2
port of the C/V from the pilot valve and shifts the boom spool (10).
The P1 bypass path (52) is shut off by the boom spool (10) as the spool has been shifted. Therefore, the oil
which has flowed in from the P1 port flows into the P1 parallel path (53) provided in the travel straight spool.
The line between the A2 port and the bridge path is opened as the boom spool is shifted. Therefore, the oil
which has flowed into the P1 parallel path (53) passes through the load check valve (21) of the boom select
part and is fed to the head of the boom cylinder from the A2 port via the bridge path and the lock valve (28)
(free flowing condition). (Fig. 24-38)

Fig. 24-38 Boom up operation

24-38
 24. COMPONENTS SYSTEM

The secondary pilot pressure for boom up operation is branched off. At the same time, secondary pilot pres-
sure enters the spring chambers of the boom conflux spool (13) and the P2 bypass cut spool and shifts the
boom conflux spool (13) and the P2 bypass cut spool (14).(Fig. 24-39)
If the P2 bypass cut spool (14) is shifted the P2 bypass path (55) is cut off by the P2 bypass cut spool (14).
Therefore, the oil which has flowed in from the P2 port flows into the P2 parallel path (56) provided upstream
of the P2 bypass path (55).
The oil which has flowed into the P2 parallel path (56) flows into the boom conflux path (58) which is now
opened as the boom conflux spool (13) is shifted.
The oil which has flowed into the boom conflux path (58) passes through the load check valve (21) of the
boom select part and is fed to the boom cylinder head from the A2 port. (Fig. 24-38)
As the result, the oil flow at the P1 port is combined with that at the P2 port and is fed to the boom cylinder
head.
In the meantime, the oil which has returned from the cylinder rod flows into the B2 port and flows to the tank
path (60) which is now open as the boom spool (10) is shifted.
Consequently, the boom cylinder operates in the extending direction and raises the boom.

Fig. 24-39 Functions of the boom conflux spool and the P2 bypass cut spool

24-39
24. COMPONENTS SYSTEM

(5) Boom down operation

1) If the boom down operation is performed, the secondary pilot pressure enters the opposite side of the spring
chamber of the Pb2 port of the C/V from the pilot valve and shifts the boom spool (10).
If the boom spool is shifted, the P1 bypass path (52) is cut off by the boom spool (10). The oil which has
flowed in from the P1 port flows into the P1 parallel path (53) provided in the travel straight spool.
Part of the oil passes through the P1 bypass path (52) past the notch of the boom spool (10) and flows out
to the tank path (60).
Transfer of the boom spool opens the line between the B2 port and the bridge path. The oil which has flowed
into the P1 parallel path (53) passes through the load check valve (21) in the boom select part and is fed to
the boom cylinder rod by way of the bridge path and the B2 port.
In the meantime, the oil which has returned from the cylinder head flows into the A2 port and flows out to the
tank path (60) from the spool notch which is now open as the boom spool (10) is shifted. (Refer to Fig. 24-
41 for the functions of the lock valve.)
As the result, the boom cylinder operates in the contracting direction to lower the boom. (The boom cylinder
rod is not subject to the combined flow of the flow from the P1 port and that from the P2 port.)

Fig. 24-40 Functions at boom down operation

24-40
 24. COMPONENTS SYSTEM

(6) Function of lock valves (boom, arm and boom swing)

1) When the boom spool (10) is in neutral position, the pilot piston chamber C is connected with the drain path
via the pilot port Pb2 (for releasing the lock valve). The piston C (36) is therefore held by the spring.
2) The oil which has returned from the boom cylinder passes through the lock valve (28) and fills up the lock
valve chamber. Therefore, the needle valve [poppet valve (29)] is positively seated against the poppet seat,
while the lock valve is also firmly seated against the body seat.

Fig. 24-41 The hold condition of lock valve

3) The moment the boom spool (10) is shifted to the spring chamber side, the Pb2 port of the lock valve releas-
ing pilot line is pressurized. The piston A (34) is pressed by the piston C (36) and opens the needle valve
[poppet (29)]. On the occasion, the oil passes through the lock valve → lock valve chamber → pilot piston
chamber B → drilled hole A, in that order, and flows to the drain port DR5.
4) If the needle valve [poppet (29)] opens, the pressure of the lock valve chamber falls. The result is that the
oil returning from the cylinder opens the lock valve (28) and then runs directly into the tank path via the boom
spool (10).
5) If the boom spool (10) is brought back to neutral, the lock valve returns to a state whereby the lock valve is
positively seated against the body seat.

Fig. 24-42 Lock valve in open condition

24-41
24. COMPONENTS SYSTEM

(7) Slewing operation

1) Slewing left operation
If the slewing left operation is performed, the secondary pilot pressure from the pilot valve enters the spring
chamber of the Pd2 port of the C/V and shifts the slewing spool (9).
At the same time, the secondary pressure from the pilot valve enters the Pd2 port through the external piping
and flows into the slewing preference section via the shuttle valve. (Refer to Fig. 24-50 for the slewing priority
section.)
When the slewing spool (9) is shifted, the P2 bypass path (55) is shut off by the slewing spool (9). The oil
which has flowed in from the P2 port flows into the P2 parallel path (56) provided in the travel straight spool.
Part of the oil passes through the notch in the slewing spool (9) and the P2 bypass path (55), and flows out
to the tank passage.
Then, the proportional secondary pressure of the P2 bypass cut solenoid valve shifts the P2 bypass cut spool
(14) in the lower stream and cuts off the oil path. This causes all the oil flowing out to the P2 bypass path to
be fed to the slewing motor, in order to soften the slewing speed. If the slewing spool (9) is shifted, the line
between the D2 port and the bridge path is opened by the spool notch. As the result, the oil which has flowed
into the P2 parallel path (56) passes through the load check valve (21) in the slewing select part, and is fed
to the slewing motor via the bridge path and the D2 port.
In the meantime, the oil which has returned from the slewing motor flows into the C2 port and flows into the
tank path (60) from the spool notch which is now open as the slewing spool (9) is shifted. Consequently, the
slewing motor rotates counterclockwise.

Fig. 24-43 Function at slewing left operation

24-42
 24. COMPONENTS SYSTEM

2) Slewing right operation

If the slewing right operation is performed, the secondary pilot pressure from the pilot valve enters the op-
posite side of the spring chamber of the Pc2 port of the C/V and shifts the slewing spool (9). At the same
time, the secondary pressure from the pilot valve flows into the slewing priority section via the shuttle valve.
(Refer to Fig. 24-50 for the function of the slewing priority section.)
Shift of the slewing spool (9) causes the P2 bypass path (55) to be cut off. Therefore, the oil which has flowed
in from the P2 port flows into the P2 parallel path (56) provided in the travel straight spool.
Part of the oil passes through the notch of the slewing spool (9) and the P2 bypass path (55) and flows out
to the tank path (60).
Next, the secondary proportional pressure of the P2 bypass cut solenoid valve shifts the P2 bypass cut spool
(14) in the lower stream and cuts off the oil flowing out to the P2 bypass path. The result is that all the oil is
fed to the slewing motor to soften the slewing speed.
Shift of the slewing spool (9) causes the line between the C2 port and the bridge path to be opened by the
spool notch. The oil which has flowed into the P2 parallel path (56) passes through the load check valve (21)
in the slewing select section and is fed to the slewing motor by way of the bridge path and the C2 port.
In the meantime, the oil returning from the slewing motor flows into the D2 port and flows out to the tank path
(60) from the spool notch which is now open by the shift of the slewing spool (9).

Fig. 24-44 Functions at slewing right operation

24-43
24. COMPONENTS SYSTEM

(8) Arm operation

1) Arm in operation
If the arm in operation is performed, the secondary pilot pressure from the pilot valve enters the opposite
side of the spring chamber of the Pc3 port of the C/V and shifts the arm spool (11).
Shift of the arm spool (11) causes the P2 bypass path (55) to be cut off. Therefore, the oil pass path (55) to
be cut off. Therefore, the oil which has flowed in from the P2 port flows into the P2 parallel path (56) provided
in the travel straight spool.
Since the shift of the arm spool (11) causes the line between the C3 port and the bridge path to be open, the
oil which has flowed into the P2 parallel path (56) passes through the load check valve (21) in the arm select
part and is fed to the arm cylinder head by way of the bridge path and the C3 port. (Fig. 24-45)

Fig. 24-45 Function at arm in operation

24-44
 24. COMPONENTS SYSTEM

In the meantime, the mechatro control system causes the secondary pilot pressure (electromagnetic propor-
tional) to enter the spring chamber of the P1 bypass cut spool (15) and shifts the spool (15). (Fig. 24-46)
Shift of the P1 bypass cut spool (15) causes the P1 bypass path to be shut off. The oil which has flowed in
from the P1 port flows into the P1 parallel path (53) provided in the check valve built in the P1 bypass cut
spool (15) and upstream of the P1 bypass path (52).
The oil which has flowed into the check valve and the P1 parallel path (53) flows into the arm conflux path
(59) which is now open by the shift of the P1 bypass cut spool (15). (Fig. 24-46)
Thus the arm cylinder head is subject to the oil stream at P1 port and that at port P2 combined.
The oil which has flowed into the arm conflux path passes through the load check valve (21) in the arm select
section and is fed to the arm cylinder head from the C3 port. (Fig. 24-45)
In the meantime, the oil which has returned from the cylinder rod flows into the D3 port and flows out to the
tank path (60) from the spool notch which is now open by the shift of the arm spool via the lock valve (28).
(Refer to Fig. 24-41 for the functions of the lock valve.)
Consequently, the arm cylinder operates in the extending direction to cause the arm to dig.

Fig. 24-46 Functions of P1 bypass cut spool

24-45
24. COMPONENTS SYSTEM

2) Arm out operation

If the arm out operation is performed, the secondary pilot pressure from the pilot valve enters the spring
chamber of the Pd3 port of the C/V and shifts the arm spool (11). If the arm spool (11) is shifted, the P2 by-
pass path (55) is cut off by the arm spool (11). The oil which has flowed in from the P2 port flows into the P2
parallel path (56) provided in the travel straight spool.
If the arm spool (11) is shifted, the line between the D3 port and the bridge path is opened. The oil which has
flowed into the P2 parallel path (56) passes through the load check valve (49) in the arm select section and
is fed to the arm cylinder rod by way of the bridge path, the lock valve (28) and the D3 port (free flow state).
(Fig. 24-47)

Fig. 24-47 Functions at arm out operation

24-46
 24. COMPONENTS SYSTEM

In the meantime, the electromagnetic proportional secondary pilot pressure created by the mechatro control
system enters the spring chamber of the P1 bypass cut spool (15). (Fig. 24-48)
Since the P1 bypass path (52) is cut off by the shifted P1 bypass cut spool (15), the oil which has flowed in
from the P1 port flows into the check valve built in the P1 bypass cut spool (15) and into the P1 parallel path
(53) provided upstream of the P1 bypass path (52).
The oil which has flowed into the check valve and the P1 parallel path (53) flows into the arm conflux path
(59) which is now opened by the shifted P1 bypass cut spool (15). (Fig. 24-48)
The oil which has flowed into the arm conflux path (59) passes through the load check valve (21) in the arm
select section and is fed to the arm cylinder rod from the D3 port. (Fig. 24-47)
As the result, the arm cylinder rod is subject to the combination of the stream of the P1 port and the stream
of the P2 port. In the meantime, the oil returning from the cylinder head flows into the C3 port and flows out
to the tank path (60) which is now open by the shifted arm spool (11).
Consequently, the arm cylinder operates in the retracting direction to cause the arm to out.

Fig. 24-48 Functions of P1 bypass cut spool

24-47
24. COMPONENTS SYSTEM

(9) Combined operation

1) Simultaneous operation of travel and attachment(travel straight function)
The pilot line for a change signal of the travel straight spool (7) is normally (at neutral) connected with the
drain path by means of the travel straight solenoid valve. Therefore, the travel straight spool (7) is not
changed over.
If a combined operation of travel and attachment is performed, the travel straight solenoid valve is excited
by the mechatro control system. Therefore, the electromagnetic secondary pilot pressure enters the P0 port
of the C/V and shifts the travel straight spool (7).
If the travel straight spool (7) is shifted, the hydraulic oil supplied from the P1 port flows into the P1 and P2
parallel paths (53), (56) leading to the attachment select section. At the same time, the hydraulic oil flows
into both travel select sections via the orifice of the travel straight spool (7)
The hydraulic oil supplied from the P2 port flows into both travel select sections and at the same time flows
into the P1 and P2 parallel paths (53), (56) leading to the attachment select part, by way of the orifice of the
travel straight spool (7).
As the result, if the attachment select section is changed over when both travel select sections changed, the
hydraulic oil supplied to the P2 port acts mainly on both travel select sections, whereas the hydraulic oil sup-
plied to the P1 port acts mainly on the attachment select section. Consequently, the pressure variation of the
P2 port is small with limited branching of oil to both travel select sections. Consequently, the machine runs
straight without deviation and provides proper attachment action.

Fig. 24-49 Functions of travel straight spool

24-48
 24. COMPONENTS SYSTEM

2) Simultaneous operation of arm and swing actions (swing priority function)

If the arm and the swing actions are performed at the same time, the secondary pilot pressure from the swing
pilot valve flows out again from the Ps' port of the C/V and flows into the Ps port by way of the external piping.
The oil which has flowed into the Ps port pushes in the piston D (67) that is held by the spring (70) and press-
es the load check valve (49) provided in the P2 parallel path (56) of the arm select section, via the stopper
pin (65). As the result, the hydraulic oil from port P2 flows preferentially into the swing system at all times,
free from the size of the load to the arm cylinder.
If the swing operation is stopped, the secondary pilot pressure from the swing pilot valve does not flow into
the Ps port. Therefore, the piston (67) is pushed up by spring (70). This releases the force pressing the load
check valve (49) located in the P2 parallel path (56) of the arm select section.

Fig. 24-50 Closing the load check valve (49) by secondary swing pilot pressure

24-49
24. COMPONENTS SYSTEM

(10)Boom swing operation

1) Boom swing cylinder extending operation (Boom swing left)
If the boom swing cylinder extending operation is performed, the secondary pilot pressure from remote con-
trol valve enters the port of swing chamber and moves the boom swing (78). When the spool has been shift-
ed, the P1 bypass path (52) is shut off by the boom swing spool (78). Therefore, the oil which has flows in
from P1 port flows into the P1 parallel path (53).
However, part of the oil passes through the notch of the boom swing spool (78) from the P1 bypass path (52)
and flows out to the tank path (60). The passage between the A5 port and bridge path is opened as the boom
swing spool (78) has been shifted. Therefore, the oil which has flowed into the P1 parallel path (53) passes
through the load check valve (21) in the boom swing select section, and is fed to the head of the boom swing
cylinder from the A5 port via the bridge path and the lock valve (28). (Free flowing condition)
Meanwhile, the oil which has returned from the cylinder rod flows into the B5 port, passes through the spool
notch which is opened as the boom swing spool (78) is shifted, and flows out to the tank passage (60).
As the result, the boom swing cylinder operates in the extending direction.

P1 SIDE BYPASS
BYPASS (52)

TANK PASSAGE
LOCK VALVE (28)

NOTCH
NOTCH SPRING CHAMBER

FROM REMOTE
CONTROL VALVE
OFFSET

78 B5 A5
LOAD CHECK
BRIDGE PASSAGE VALVE (21)
P1 SIDE PARALLEL PASSAGE (53)

PART OF OIL FLOWS OUT ROD SIDE HEAD SIDE

FROM BYPASS PASSAGE
Fig. 24-51 Functions at boom swing cylinder extending operation

24-50
 24. COMPONENTS SYSTEM

2) Boom swing cylinder retracting operation (Boom swing right)

If the boom swing cylinder retracting operation is performed, the secondary pilot pressure from remote con-
trol valve enters (the opposite side) port of swing chamber and moves the boom swing spool (78). When the
spool has been shifted, the P1 bypass path (52) is shut off by the boom swing spool (78). Therefore, the oil
which has flows in from P1 port flows into the P1 parallel path (53).
However, part of the oil passes through the notch of the boom swing spool (78) from the P1 bypass path (52)
and flows out to the tank path (60). The passage between the B5 port and bridge path is opened as the boom
swing spool (78) has been shifted. Therefore, the oil which has flowed into the P1 parallel path (53) passes
through the load check valve (21) in the boom swing select section, and is fed to the rod of the boom swing
cylinder from the B5 port via the bridge path.
Meanwhile, the oil which has returned from the cylinder rod flows into the A5 port, passes through the spool
notch which is opened as the boom swing spool (78) is shifted, and flows out to the tank passage (60) via
lock valve.
As the result, the boom swing cylinder operates in the retracting direction. (Function of lock valve refer to 24-
41)

P1 SIDE BYPASS
BYPASS (52) NOTCH

TANK PASSAGE

NOTCH LOCK VALVE

SPRING CHAMBER

FROM REMOTE
CONTROL VALVE
OFFSET

B5 A5
LOAD CHECK
VALVE (21)
BRIDGE PASSAGE P1 SIDE PARALLEL PASSAGE (53)

PART OF OIL FLOWS OUT

ROD SIDE HEAD SIDE
FROM BYPASS PASSAGE
Fig. 24-52 Functions at boom swing cylinder retracting operation

24-51
24. COMPONENTS SYSTEM

(11)Nibbler and breaker operation

Here, only nibbler operation are described. Regarding breaker operation, refer to nibbler operation.
1) Nibbler cylinder extending operation
If the nibbler cylinder extending operation is performed, the secondary pilot pressure enters the spring cham-
ber of the Pa6 port of the C/V from the pilot valve and shifts the N&B spool (82).
The P1 bypass path (52) is shut off by N&B spool (82) as the spool has been shifted. Therefore, the oil which
has flowed in from the P1 port flows into the P1 parallel path (53).
The line between the A6 port and the bridge path is opened as N&B spool is shifted. Therefore, the oil which
has flowed into the P1 parallel path (53) passes through the load check valve (21) of the N&B select part and
fed to the head of the nibbler cylinder from the A6 port through the bridge path.
If the conflux / single switch operation is performed, the secondary pilot pressure enters the spring chamber
of the Pd6 port of the C/V and shifts the conflux / single switching spool (81).
The oil, which has flowed into the P2 parallel path (56) flows into the N&B conflux path (83) which is now
opened as the N&B conflux spool (81) is shifted.
The oil which has flowed into the N&B conflux path (83) passes through the load check valve (21) of the N&B
select part and is fed to the nibbler cylinder head from the A6 port.
As the result, the oil flow at the P1 port is combined with that at the P2 port and is fed to the nibbler cylinder
head.
In the meantime, the oil which has returned from the cylinder rod flows into the B6 port and flows to the tank
path (60) which is now open as the N&B spool (82) is shifted.
Consequently, the nibbler cylinder operates in the extending direction.

P2 SIDE PARALLEL PASSAGE(55)

P1 SIDE PARALLEL PASSAGE (53)

CONFLUX / SINGLE
SWITCHING SPOOL (81)

N&B SPOOL (82)

Pd6
TANK Pd6
PASSAGE(60)
Pa6

BRIDGE PASSAGE
B6 A6

P1 SIDE PARALLEL
N&B CONFLUX LOAD CHECK PASSAGE (53)
PASSAGE (83) VALVE (21)

R H

NIBBLER CYLINDER

Fig. 24-53 Function of nibbler cylinder extending operation

24-52
 24. COMPONENTS SYSTEM

2) Nibbler cylinder retracting operation

If the nibbler cylinder retracting operation is performed, the secondary pilot pressure enters the spring cham-
ber of the Pb6 port of the C/V from the pilot valve and shifts the N&B spool (82).
The P1 bypass path (52) is shut off by N&B spool (82) as the spool has been shifted. Therefore, the oil which
has flowed in from the P1 port flows into the P1 parallel path (53).
The line between the B6 port and the bridge path is opened as N&B spool is shifted.
Therefore, the oil which has flowed into the P1 parallel path (53) passes through the load check valve (21)
of the N&B select part and is fed to the rod of the nibbler cylinder from the B6 port through the bridge path.
In the meantime, the oil which has returned from the cylinder head flows into the A6 port and flows to the
tank path (60) which is now open as the N&B spool (82) is shifted.
Consequently, the nibbler cylinder operates in the retracting direction.

N&B SPOOL (82) P1 SIDE PARALLEL PASSAGE (52)

N&B CONFLUX
PASSAGE (83)

Pd6
Pa6

TANK
PASSAGE(60)
B6 A6

BRIDGE PASSAGE LOAD CHECK P1 SIDE PARALLEL

VALVE (21) PASSAGE (53)

R H

NIBBLER CYLINDER

Fig. 24-54 Function of nibbler cylinder retracting operation

24-53
24. COMPONENTS SYSTEM

(12)Function of main relief valve

1) The hydraulic oil P is filled up in the inner chamber A past the inside of the piston built in the plunger G and
the orifice B. The poppet F is securely seated against the socket which is also positively sealed against the
regulator body.

Fig. 24-55
2) When the hydraulic pressure at port P reaches a set pressure of the spring C, it acts upon the poppet F via
the piston and opens the poppet F. On that occasion, the hydraulic oil flows out to the tank passage past the
piston inside → the orifice B → the chamber A → the annular orifice D, and the passage E, in that order.

Fig. 24-56
3) If the poppet F opens, the pressure of chamber A falls. Then the plunger G opens and the pressure of port
P flows directly to the tank T passage through drilled hole H.

Fig. 24-57
4) If the pressure at port P falls below a set value of spring C, the poppet F is pressed against the seat by the
action of spring C. As the result, the pressure of chamber A equals that of port P. This presses the plunger
G against the socket seat and brings it back where it was. (Fig. 24-55)

24-54
 24. COMPONENTS SYSTEM

(13)Function of over road relief valve

1) Pressurized oil P is filled up in chamber A through the inside of the piston built in the plunger G and choke B.
The plunger G and the socket are sealed securely. The socket is sealed securely against the poppet as well.

Fig. 24-58
2) When the hydraulic pressure at port P arrives at a set value of spring C, it pushes the piston which in turn
opens the poppet F.
On that occasion, the hydraulic pressure goes through the inside of the piston → choke B → chamber A →
annular orifice D and drilled hole E goes around the outer circumference of the socket and flows out to the
tank passage.

Fig. 24-59
3) If the poppet F opens, the pressure of chamber A falls. Then the plunger G opens and the pressure of port
P flows directly to the tank T passage through drilled hole H.

Fig. 24-60
4) If the pressure at port P falls below a set value of spring C, the poppet F is pressed against the seat by the
action of spring C. As the result, the pressure of chamber A equals that of port P. This presses the plunger
G against the socket seat and brings it back where it was. (Fig. 24-58)

Fig. 24-61
5) Function of anti-cavitation
This function supplies oil from the T (tank) path in case negative pressure occurs at port P. When the tank
path pressure gets higher than that of port P, the socket is subject to a force that pushes it up. This creates
a space between the body seat and the socket. The oil from the T path (tank) flows into port P, and fills up
the space.

24-55
24. COMPONENTS SYSTEM

This page is blank for editing convenience.

24-56
 24. COMPONENTS SYSTEM

24.1.5 SLEWING MOTOR UNIT

24.1.5.1 SPECIFICATION
(1) General view

Fig. 24-62 General view of slewing motor unit

24-57
24. COMPONENTS SYSTEM

(2) Specifications
Table 24-5
Item Specifications
Slewing unit SG025E-126
Type Motor MFB40-330
Reduction unit RG025S-155-52
Working pressure MPa (psi) 24.5 (3360)
Reduction ratio 1:15.54
Output torque kN•m (lbf•ft) 2.32 (3170) at 24.5 MPa (3360 psi)
Braking torque N•m (lbf•ft) 185 (1.4)
Brake release pressure MPa (psi) 2.0 (280), Allowable 3.9 (570)
The rotating direction (as seen from the shaft end) A port in : Clockwise, B port in : Counterclockwise
Weight (Including reduction unit) kg (lbs) 67 (148)
Reduction unit lubricate oil Nisseki gearlube SP90 : 1.5L (0.40 gal)
Grease Shell alvania EP2 : 150cc (9.15 cu•in)

24.1.5.2 EXPLANATION OF CONSTRUCTION

(1) The rotary group of the swing motor consists of
a cylinder (M-19) which is integral with the drive Slewing unit
shaft and seven piston assy (M-21) arranged in
the cylinder bores. The cylinder (M-19) is sup-
ported by bearings (M-1) (M-6) on both ends.
Each piston assy (M-21) is guided by a return Swash plate type Two-stage planetary
axial piston motor gear reduction unit
plate (M-22) and retaining spring (M-20) so as to
slide smoothly on the cam plate (M-23).
The balance plate (M-10) is forced against the Mechanical brake
end of the cylinder by the force of the disc spring
(M-15) and the hydraulic force acting on the Relife valve
bushing (M-14).
A mechanical brake is installed between the cyl-
Make-up valve
inder exterior and the housing (M-26).
A relief valve to cushion hydraulic shock and a
backup valve to prevent cavitation are built in to By-pass valve
the cover (M-39).
Fig. 24-63
(2) The reduction gear system consists of two stage
planetary gears. The system decelerates high-
speed rotary motion of the slewing motor and
coverts it to low-speed large-torque motion in or-
der to rotate the pinion shaft.

24-58
 24. COMPONENTS SYSTEM

24.1.5.3 CONSTRUCTION
(1) Slewing motor

Fig. 24-64 Slewing motor

24-59
24. COMPONENTS SYSTEM

Tightening Tightening
torque No. Parts Q'ty torque No. Parts Q'ty
N•m (lbf•ft) N•m (lbf•ft)
M-1 TAPER ROLLER BEARING 1 M-22 RETURN PLATE 1
M-3 FRICTION PLATE 2 M-23 CAM PLATE 1
M-4 SEPARATOR PLATE 2 M-24 LEVEL GAUGE 1
M-5 SNAP RING 1 M-25 O-RING 1
M-6 NEEDLE BEARING 1 M-26 HOUSING 1
M-7 O-RING 1 M-27 COLLAR 1
M-8 O-RING 1 M-28 OIL SEAL 1
M-9 O-RING 1 M-30 BACKUP RING 2
M-10 BALANCE PLATE 1 M-31 O-RING : 1B P21 2
M-11 PISTON 2 M-33 BACKUP RING 2
M-12 TEFLON RING 2 M-34 O-RING : 1B P26 2
M-13 PLUG : PT 1/4 2 M-35 PARALLEL PIN 2
M-14 BUSHING 4 M-36 PLUG : PF 3/8 1
M-15 SCROWAVE 4 M-37 O-RING : 1B P14 1
M-16 TEFLON RING 4 M-38 SOCKET BOLT : M12 × 30 4
M-17 SPRING 13 M-39 COVER 1
M-18 PISTON 1 M-40 PLUG 1
M-19 CYLINDER 1 70 RELIEF VALVE ASSY 2
M-20 SUPPORT SPRING 1 100 BY-PASS VALVE ASSY 2
M-21 PISTON ASSY 7

24-60
 24. COMPONENTS SYSTEM

1) Relief & check valve assy (70)

Fig. 24-65 Detail of Relief & check valve assy

No. Parts Q'ty No. Parts Q'ty

70 RELIEF& CHECK VALVE ASSY 2 82 SEAT 2
71 LOCK NUT 2 83 POPPET 2
72 CAP 2 84 SPRING 2
76 BACKUP RING 2 85 O-RING 2
77 O-RING : 1B P26 2 86 SHIM 2
78 SPRING 2 87 PISTON 2
79 BUSHING 2 88 SLEEVE 2
80 CHECK 2 89 O-RING 2
81 SLEEVE 2 90 CAP 2

2) By-pass valve assy (100)

Fig. 24-66 Detail of by-pass valve assy (slewing shockless valve)

No. Parts Q'ty No. Parts Q'ty

100 BY-PASS VALVE ASSY 2 106 O-RING : 1B P21 2
101 SEAT 2 107 BACKUP RING 2
102 SLEEVE 2 108 CAP 2
103 POPPET 2 109 SPRING 2
104 BACKUP RING 2 110 POPPET 2
105 O-RING : 1B P14 2 111 SPRING 2

24-61
24. COMPONENTS SYSTEM

(2) Slewing reduction unit

Fig. 24-67 Slewing reduction unit

Tightening Tightening
torque No. Parts Q'ty torque No. Parts Q'ty
N•m (lbf•ft) N•m (lbf•ft)
R-1 PINION SHAFT 1 R-15 HOLDER 2 ASSY 1
R-2 COLLAR 1 R-16 NEEDLE BEARING 6
R-3 PLATE 1 R-17 SHAFT 2 3
R-4 TAPER ROLLER BEARING 1 R-18 SPUR GEAR 5 3
R-5 GEAR CASE 1 R-19 THRUST PLATE 2 6
R-6 PLUG : PT1/8 1 R-20 SPRING PIN : 8 × 15 3
R-7 OIL SEAL 1 R-21 HOLDER 2 1
R-8 TAPER ROLLER BEARING 1 R-22 COLLAR 2
R-9 PIN 2 R-23 RELIEF NIPPLE 1
R-10 RING GEAR 1 R-24 CONNECTOR 1
R-11 SPUR GEAR 4 1 R-25 ELBOW 1
R-12 SUN GEAR 1 R-26 HOSE 1
R-13 HOLDER 1 ASSY 1 R-27 PLUG 1
R-14 SOCKET BOLT : M12 × 95 6

24-62
 24. COMPONENTS SYSTEM

24.1.5.4 OPERATION
(1) Slewing motor
The pressure oil fed by the pump via the control valve, etc. enters the motor through port A (or port B) installed
on cover (M-39), and is discharged from port B (or port A).
Also the oil leaking through the sliding section or clearance returns to the tank through drain port Dr installed on
cover (M-39).
The pressure oil fed to port A goes through passage (b) inside of cover (M-39) and to the passage on bushing
(M-11) section installed cover, then is fed to piston bore (f) on the cylinder through balance plate (M-10) passage
(b) which contains crescent shaped port switching supply and discharge by 180 degrees of core rotation of mo-
tor, and cylinder (M-19) passage (e).
The pressure oil exerts on piston assy (M-21), then the piston assy is pushed against cam plate (M-23) through
a part of the shoe. Since the shoe sliding surface of cam plate (M-23) is inclined at a uniform angle, the pushing
force of piston assy (M-21) on which pressure oil is exerted is converted into sliding power for the shoe on the
swash plate.
In addition, the shoe bulb is similarly joined to universal joint. As a result, the shoe sliding power on the swash
plate is converted into rotating power through piston assy (M-21) and cylinder assy (M-19) and transmitted to
the motor output shaft section.
In this way, every piston assy (M-21) receives the pressure oil within the stroke from top dead point to bottom
dead point on a grade, the oil pressure is converted to rotating power to rotate cylinder assy (M-19), resulting in
discharging oil in the stroke from bottom dead end and top dead point.
The discharge line function in reverse of the supply line, and the oil is discharged from port B.
As described above, the hydraulic motor is operated, and the output torque of hydraulic motor is determined by
oil pressure, and speed of revolution by supply flow rate.
(2) Parking brake
Separator plate (M-4) is fitted to the external section of cylinder assy (M-19) with spline.
Friction plate (M-3) is fitted to housing (M-26).
When the primary pilot pressure of brake release port is Zero, brake piston (M-18) locks the cylinder (M-19) (out-
put shaft) which is rotated by the force of the spring (M-17) pushing separator plate and friction plate.
Conversely, when pressure of 1.96 to 3.92MPa (280 to 570psi) exerted on the brake relief port, brake piston
power exceeds the force of spring and strokes to the contact with cover end. Then space is generated between
mating parts, and the mechanical brake released.

Fig. 24-68

24-63
24. COMPONENTS SYSTEM

(3) Relief valve

1) Starting
With operation of the lever, the oil fed to port A at first escapes and is discharged to port B without obtaining
regular revolution because the force of inertia of the upper structure is larger. The hydraulic oil from port A
to passage (i) of relief valve, opens poppet (83), and is discharged to port B.
2) Braking (Cushion)
By returning the lever to neutral position, the return circuit of motor discharge oil close, and immediately after
this operation, the motor is rotated by the force of inertia resulting in pumping function, and the oil is sucked
from port A and discharged to port B side. Then, since the return circuit of the control valve is closed, the
pressure of port B is raised.
The raised pressure of port B opposes the spring (84-B) force and opens poppet (83-B), and check valve
(80-B) through passage (g) (h), and flows into passage (c). The movement stops while absorbing the force
of inertia in this process.
In the above-mentioned process of pressure increase, the oil at port B enters the piston (L) chamber past
the small orifice of poppet (83-A), and causes the piston (87) to move till it hits the cap (90). In this period,
the poppet (83-A) is already open, so that the cushion relief action operates first at a little lower pressure.
3) 2-step relief at braking
(shockless relief action)
The increased pressure at port B enters the piston chamber (L) past the path (t) of the poppet (83-B). The
poppet begins to move to the right slowly by the throttling effect of the inlet path and stops when it hits the
shoulder J of piston (87) and the stopper K of sleeve (88). It pushes the spring (84-B), acting as 2-step relief
that rises to a specified pressure. This absorbs impacts at starts and stops.

SHOULDER STOPPER K i PORT A SIDE

J OF PISTON OF SLEEVE g PORT B SIDE
B (A PORT)
PASSAGE t

A
(B PORT)

PISTON
CHAMBER
L At starting port A side 80-A 84-A 83-A
At braking (port Bside 80-B 84-B 83-B)

Fig. 24-69 Detail of relief valve (70)

(4) Make-up valve
1) Operation in half lever position
(When cushion relief valve does not function.)
After accelerating slewing of the upper structure, when the speed is being reduced by half-lever with the
function of control valve, the supply flow rate from pump to port A is lowered. But if the upper structure is
slewed at a comparatively high speed, the pressure in the (C) section is lowered to negative pressure making
lubrication necessary. However, when the pressure of port B is equal to or lower than the working pressure
of cushion relief valve the all oil of (C) section led through port B is discharged to the control valve.
As a result, the flow rate from the control valve (Since the valve is in the half-lever position, the flow rate from
pump is limited.) does not satisfy the specified oil quantity. To prevent this, the make-up check valve is in-
stalled to supply necessary oil into the (C) section.
2) Braking
(When cushion relief valve is functioned)
When the lever is moved to neutral position rapidly as described in item 1), the pump does not supply oil to
port A, but the upper structure is slewed by the force of inertia. In this case, the cushion relief valve on port
B side functions, and the oil from relief valve goes through the passage (g) (h) and opens make-up check
(80) valve on the port A side to flow into passage (b) (c). But the oil quantity is insufficient due to the leakage.
Therefore oil opens make-up check valve (80) through the make-up port, and flows into passage (b) (c) to
prevent cavitation.

24-64
 24. COMPONENTS SYSTEM

(5) By-pass valve (Slewing shockless valve)

1) Accelerating
At the moment of slewing operation, the high pressure oil in the "A" side flows instantly into the "B" side in-
stantly, but the high pressure oil enters the chamber on the back side of poppet A simultaneously. Then pop-
pet A moves rightward, resulting in the poppet A "Close" condition shown in Fig. 24-71
2) Braking
When braking, the pressure oil of B side is raised to high pressure, and the high pressure oil is bypassed
from B side to A side, but the high pressure oil enters the chamber on the back side of poppet B simulta-
neously.
The poppet B moves leftward, resulting in the poppet B "Close" condition.
3) Reverse rotation
After stopping the slewing of the upper structure, the motor is reverse-rotated by high pressure on the B side.
But while the motor is rotated inversely, the high pressure oil is by-pass from A side to B side to hold the
reverse rotation to one rotation or less, protecting the generation of reverse-rotation pressure.

Fig. 24-70 Poppet A "Open"

Fig. 24-71 Detail of poppet

24-65
24. COMPONENTS SYSTEM

(6) Slewing reduction gear

The power of the slewing motor output shaft is transmitted to spur gear 4 (R-11) on the 2nd stage through sun
gear (R-12) on the 1st stage and holder assy (R-13).
Similarly, the power is transmitted to pinion shaft (R-1) through spur gear 4 (R-11) on the 2nd stage and holder
assy 2 (R-15). The pinion shaft is supported by two bearing (R-4) (R-8) in gear case (R-5).
In addition, oil seal is installed at the center of gear case (R-5) to protect the bearing on the pinion shaft side of
which the load condition is difficult from the gear friction power, and the A chamber side is lubricated by oil in the
gear case, and the B chamber is lubricated by the grease sealed inside.

Fig. 24-72 Function of reduction unit

24-66
 24. COMPONENTS SYSTEM

24.1.6 TRAVEL MOTOR

24.1.6.1 CONSTRUCTION
(1) General view

D1

D2

FILLING PORT PF3/8

OIL LEVEL CHECK PORT PF3/8

DRAIN PORT PF3/8

VIEW Z
Fig. 24-73 Function of reduction unit

24.1.6.2 HYDRAULIC CIRCUIT

PORT NAME, SIZE

No. Ports Size
A Hydraulic oil filling / drain port
PF 1/2
B Hydraulic oil filling / drain port
D1 Drain port
PF 3/8
D2 Drain port
P 1st / 2nd speed select port PF 1/4

ROTATIONAL DIRECTION (Viewed from Z side)

INLET B PORT, OUTLET A PORT, CW
INLET A PORT, OUTLET B PORT, CCW

Fig. 24-74 Function of reduction unit

24-67
24. COMPONENTS SYSTEM

24.1.6.3 SPECIFICATIONS
Table 24-6
Type GM09VN-B-19/34-1
Reduction ratio 61.6
Reduction unit Output torque 1st / 2nd N•m (lbf•ft) 8530 (6,300) / 4630 (3,410)
Revolution speed 1st / 2nd rpm 30.5 / 53.8
Displacement 1st /2nd cc / rev (cu-in/rev) 34.4 (2.1) / 19.1 (1.17)
Operation press. MPa (psi) 29.4 (4,270)
Revolution speed 1st / 2nd rpm 1877 / 3312
Hydraulic motor
1, 2 speed select press. MPa (psi) 3.5 (500)
Auto 1, 2 speed select press. MPa (psi) 22.6 (3,200)
Drain press. MPa (psi) STD 0.2 (28), MAX. 0.69 (100)
Breaking torque N•m (lbf•ft) 97.1 (72)
Parking brake
Release press. MPa (psi) 0.47 (68)
Lube oil SAE #90 GL-4 L (gal) Approx.1.3 (0.34)
Weight kg (lb) 81 (179)

24-68
 24. COMPONENTS SYSTEM

24.1.6.4 CONSTRUCTION
(1) Basic construction of motor

Fig. 24-75
• Reduction gear
The reduction gear consists of a spur gear device (hereunder called 1st reduction gear) and a differential
gear device (hereunder called 2nd reduction gear) that employs a peri-cycloid tooth profile. The reduction
gear system reduces the high speed of the hydraulic motor and converts it to low-speed high torque rotation.
• Hydraulic motor
The hydraulic motor is of swash-plate axial piston type and converts the hydraulic pressure delivered by the
pump to rotary motion.
• Brake valve
The brake valve is composed of different valves. It stops the hydraulic motor smoothly, prevents the hydraulic
motor from over-running and prevents abnormally high pressure surges from occurring as the hydraulic mo-
tor is stopped jerkily.
• High-low 2-step speed select mechanism
The mechanism consists of a selector valve and a piston and changes the displacement capacity of the hy-
draulic motor in two steps.
• Parking brake
This is a friction plate type braking mechanism that is made integral with the hydraulic motor.

24-69
24. COMPONENTS SYSTEM

(2) Construction

Fig. 24-76

24-70
 24. COMPONENTS SYSTEM

(3) Parts list

Table 24-7
No. Parts Q'ty No. Parts Q'ty
1 HUB 1
PISTON KIT 1
SPINDLE KIT •PISTON ASSEMBLING PARTS 9
•SPINDLE ASSY 1 105 ••PISTON 1
2 ••SPINDLE 1 106 ••SHOE 1
3 ••HOLD FLANGE 1
19 •REAMER BOLT 3 •PISTON ASSEMBLING PARTS 1
161 ••PISTON 1
RV GEAR ASSEMBLING PARTS 1 162 ••SHOE 1
•RV GEAR KIT 1
4 ••RV GEAR A 1 102 SHAFT 1
5 ••RV GEAR B 1 103 SWASH PLATE 1
9 •CRANK SHAFT 3 104 CYLINDER BLOCK 1
12 •SPACER 6 107 RETAINER PLATE 1
22 •BEARING 6 108 THRUST BALL 1
23 •BEARING 6 109 TIMING PLATE 1
110 WASHER 2
6 INPUT GEAR 1 112 PISTON 1
113 SPRING 8
SPUR GEAR KIT 1 114 SPRING 1
7 •SPUR GEAR 3 115 FRICTION PLATE 2
116 SEPARATOR PLATE 2
FLOATING SEAL KIT 1 132 OIL SEAL 1
31 •FLOATING SEAL 2 135 O-RING 1
141 O-RING 1
8 COVER 1 146 SNAP RING 1
15 SHAFT 1 149 BEARING 1
17 PIN 28 150 BEARING 1
18 RING 1 151 BEARING (ROLLER) 3
20 SNAP RING 3 176 PIVOT 2
21 BEARING 2 177 PARALLEL PIN 2
24 SNAP RING 1 185 SPRING 1
25 SNAP RING 6
28 O-RING 2 REAR FLANGE ASSEMBLING PARTS 1
29 O-RING 1 •REAR FLANGE KIT 1
30 O-RING 1 201 ••REAR FLANGE 1
33 PLUG (WITH FLANGE) 1 223 ••SPOOL 1
34 PLUG 2 252 ••SOCKET PLUG 2
35 O RING 3 268 ••STEEL BALL 1
36 STEEL BALL 1 275 ••SOCKET PLUG 10
43 PARALLEL PIN 2 279 ••FILTER 1

24-71
24. COMPONENTS SYSTEM

Table 24-7
No. Parts Q'ty No. Parts Q'ty
280 ••ORIFICE 4 282 •PLUG 4
283 • • PLUG (WITH FLANGE) 1 284 •PLUG 2
286 ••PISTON 2 285 •O-RING 2
299 ••NAME PLATE 1 287 •VALVE 2
288 •SLEEVE 2
•SPOOL KIT 1 289 •PLUG 2
271 ••SPOOL 1 290 •SPRING 2
272 ••OIL STOPPER 1 291 •O-RING 2
221 •PLUG 2 292 •O-RING 4
224 •PLUG 2 293 •PISTON SEAL 2
225 •SPRING RETAINER 2 294 •BACKUP RING 4
227 •VALVE 2 295 •BACKUP RING 4
228 •SPRING 2 296 •STEEL BALL 2
230 •SPRING 2 297 •ORIFICE 2
236 •O-RING 2
238 •O-RING 6 242 PARALLEL PIN 2
281 •SPRING 1 245 SOCKET BOLT 6

24-72
 24. COMPONENTS SYSTEM

24.1.6.5 FUNCTIONAL EXPLANATION

(1) Reduction gear CRANK SHAFT (9)
SPUR GEAR (7)
1) Function
The reduction gear consists of a spur gear de-
vice (hereunder called 1st reduction gear) and a
differential gear device (hereunder called 2nd re-
duction gear) that employs a peri-cycloid gear
tooth profile. The reduction gear reduces the SHAFT (15)
high speed rotation of the hydraulic motor and
converts it to low-speed high torque rotation.
2) Functional explanation
2-1: 1st reduction gear
1. The rotary motion of the hydraulic motor is put
out of shaft (102). This rotation is transmitted
to input gear (6) that is linked to shaft (G) (15).
The input gear (6) meshes with three spur INPUT GEAR (6)
gears (7). Fig. 24-77
The speed of spur gears (7) is reduced and ro-
tate in the opposite direction. The reduction
gear composed of input gear (6) and spur gear
(7) is called 1st reduction gear. The reduction
ratio [i1] is as below :

i1 = Reduction ratio of 1st reduction gear

Zi = No. of teeth of input gear
Zs = No. of teeth of spur gear

2-2: 2nd reduction gear SPUR GEAR (7)

NEEDLE BEARING (23)
1. Spur gears (7) (3 pieces) are connected to re-
spective crankshafts (9). If spur gear (7) ro- ECCENTRIC BODIES ROTATION
tates, crankshaft (9) rotates in the same
direction and at the same revolution. This CRANK SHAFT (9)
causes the eccentric bodies A and B of crank- ROTATION
shaft (9) to make eccentric motion. (revolu-
tion). This eccentric motion (revolution) is
transmitted to RV gears A (4) and B [5] via
needle roller bearing (23).
RV gears A (4) and B (5) make eccentric mo-
tion in the same direction and at the same rev-
olution as the spur gears and the crankshafts.

ECCENTRIC MOTION
RV GEAR B (5)
RV GEAR A (4)
Fig. 24-78

24-73
24. COMPONENTS SYSTEM

2. The tooth face of RV gear A (4) and RV gear

B (5) meshes constantly with pins (17)(pin
number Zp). If RV gears A and B make eccen- HUB (1)
tric motion, the meshing point moves in se-
PIN (17)
quence as the gears turn. In a single eccentric
motion, pins (17) rotate with hub (1) by the dif-
ference between the number of teeth Zr of RV
RV GEAR A (4)
gears A, B and the number of pins Zp i.e. the OR RV GEAR B (5)
number of pins. The rotating direction of hub
(1) is the same as that of the eccentric motion CRANKSHAFT REVOLVING
of the RV gears. BODY SECTION
The hub (1) makes output rotation. The sec-
tion that is decelerated by the crankshafts, RV
gears, pins and hubs is called 2nd reduction
gear. The reduction gear (i2) of the 2nd reduc-
tion gear is as below :

i2 = Reduction ratio of 2nd reduction gear

Zr = No. of teeth of RV gear A, B
Zp = No. of pin

At half rotation (180 ) At one rotation

Fig. 24-79
2-3: Entire reduction gear
The motion of the entire reduction gear equals
the product that is made by multiplying the 1st
reduction gear with the 2nd reduction gear.
Therefore, if the hydraulic motor shaft makes
one turn, the total revolution (reduction ratio)
of the reduction gear is as follows:

i1 = Speed ratio of 1st reduction gear section.

i2= Speed ratio of 2nd reduction gear section.

24-74
 24. COMPONENTS SYSTEM

(2) Hydraulic drive

This article describes the hydraulic motor, the brake
valve and parking brake driven by hydraulic pres-
sure and the high-low 2-step select mechanism of
the hydraulic motor.
1) Functions
1. Hydraulic motor
The hydraulic motor is of swash-plate axial pis-
ton type and converts the force of the pressur-
ized oil to rotary motion.
2. Brake valve CYLINDER BLOCK (104)
1. The brake valve controls inertia force to stop
the hydraulic motor smoothly. PISTON (105)
2. The brake valve prevents the hydraulic motor SWASH PLATE (103)
from over running by external force acting on
the hydraulic motor i.e. prevents hydraulic SHAFT (102)
cavitation.
3. The brake valve prevents abnormally high
pressure surges that are generated as the hy-
draulic motor is stopped jerkily.
3. High-low 2-step speed select mechanism
The mechanism changes the hydraulic motor
output in two steps; high-speed low-torque and
low-speed high-torque. TIMING PLATE (109)
4. Parking brake
The parking brake prevents the hydraulic motor
at rest from being turned by external force. The
brake is of friction plate type that is assembled
integral with the hydraulic motor.
2) Functional Explanation
1. Hydraulic motor
The pressurized oil supplied by the hydraulic Fig. 24-80
pumps enters the rear flange (201) of the hy-
draulic motor. The pressurized oil passes
through the brake valve and the timing plate
(109) and is admitted into the cylinder block
(104). The pressurized oil is admitted only to the
one side of the line (Y1-Y2) that connects the top
dead point with the bottom dead point of the pis-
ton (105) stroke. The pressurized oil pushes
each piston (105) and generates force F (= P×A).
This force acts upon the tilted surface of swash
plate (103). The force F is split into components
F2, F3, depending upon the angle of the titled
surface. Out of them the radial component F3
generates torque = (F3 × ri). The total force of
torque of the pistons (105) T= (F3 × ri) equals
the rotary force of the hydraulic motor. This rotary
force causes the cylinder block (104) and the
shaft (102) to rotate via the pistons (105).

24-75
24. COMPONENTS SYSTEM

2. Brake valve
Ports A and B are the oil inlet and the outlet. The
following is an explanation in which hydraulic oil
(pressurized oil) is supplied to port A.
When hydraulic oil is supplied to port B, the di-
rection of flow and motion are reversed. The ro-
tating direction of the hydraulic motor is reversed
as well.
1. Normal action
If pressurized oil is supplied to port A by the
pumps, the hydraulic motor turns. Below is a
detailed explanation.
If the pressurized oil is supplied by the pumps, PARKING
the oil enters port A and opens the valve BRAKE
(227). The oil then passes through valve SPOOL (223)

(227), enters the hydraulic motor via port C

and gives rotating force to the hydraulic motor. SPRING a b
In the meantime, the oil enters port A, passes
through the orifice of spool (223) and the pipe-
line (a) and enters chamber (b). Spool (223)
moves to the left from its neutral position by
the hydraulic force of chamber (b). In that
case, a hydraulic oil passage is formed be-
tween ports D and B by the groove provided
on the spool (223).
The hydraulic oil discharged by the hydraulic
motor flows from port D to port B. Thus the hy-
draulic motor rotates, and the hydraulic oil re-
VALVE (227)
turns to the oil tank.
In the meantime, if spool (223) moves to the Fig. 24-81
left, the pressurized oil enters port E and the
oil flows into the parking brake and the 2-
speed select valve.

24-76
 24. COMPONENTS SYSTEM

2. Stop action (braking action)

If the oil supply is suspended, the hydraulic mo-
tor stops. More detailed functions are explained
below:
If the oil being supplied to port A is suspended,
the pressure at port A and chamber (b) falls. As
the pressure falls, spool (223) begins to shift
from left to right (toward the neutral position) by
the action of spring (228).
The passage between ports D and B is narrowed
as the spool (223) moves and shut off when the PISTON (286)
spool arrives at neutral.
In the meantime, the hydraulic motor keeps ro-
tating by inertia force even though the oil supply g
from port A is suspended. The hydraulic oil dis-
charged by the hydraulic motor is exhausted as VALVE
there is no passage for oil flowing out of port D. (287)
Thus, the hydraulic pressure from port D rises.
The hydraulic pressure thus boosted goes
f
through the orifice of the right hand valve (287)
and enters chamber (g) from chamber (f). The
piston (286) on the right moves to the left in the
b
illustration so the pressure does not rise. While SPOOL
(223)
the piston is moving, the pressure of chamber (f)
and (g) is lower than that of port D by the orifice
effect of valve (287).
SPRING (228)
In the meantime, the pressure difference causes
the valve (287) on the right to open.
The hydraulic oil runs from port D to port C.
When the piston (286) reaches the stroke end,
the pressure in chamber (g) and (f) rises to be
equal to the pressure of port D. The valve (287)
on the right is closed again. Since the passage Fig. 24-82
that allows the oil to flow from port D is shut off,
the pressure rises further.
Then, the valve (287) on the left opens. The hy-
draulic oil of port D flows to port C. The pressure
of port D falls as the inertia force decreases.
The valve (287) on the left is closed again. The
hydraulic motor stops rotating.
In this way, controlling the pressure at port D in
two steps allows the hydraulic motor to stop by
smooth braking action.

24-77
24. COMPONENTS SYSTEM

3. Self (over) run prevention function

If the hydraulic motor is forced to turn by exter-
nal force during normal running, self run (over
run) occurs. For instance, it occurs while the
excavator is going down on a slope. PARKING BRAKE
Now let us explain about the mechanism that (112)
SPOOL (223)
prevents such phenomenon from occurring.
If the hydraulic motor is forced to rotate by ex-
ternal force during normal run, the pressure of SPRING a b
(228)
the hydraulic oil being supplied (port A or B)
falls. If the pressure rises close to a level at
which the machine begins to run by itself, the
spool (223) begins to move to its neutral in the
middle.
As the spool (223) moves, the area of the pas-
sage that lets the hydraulic oil run from outlet
port D to port B of the hydraulic motor is made
smaller, with the result that the flow of the hy-
draulic oil from port D to port B is restricted. At
the same time, the pressure at port D (back
VALVE (227)
pressure) rises as well.
In this way, self run of the motor is prevented Fig. 24-83
by controlling the flow and the pressure of the
outlet port of the hydraulic motor.
(3) High-low 2-step speed select mechanism (auto 2-
step speed select mode)
1) Low-speed step
The low-speed step is the status in which pilot
pressure is not being supplied from port P. In this
case, the spool (271) is pressed to the left by the
force of spring (281) and by the pressure from
port A or B. The pressure of port F is shut off.
The hydraulic oil of chamber S is released to
drain (motor casing) via spool (271). The thrust
of piston (161) is small. The swash plate (103) is
located along the Y face.
At that time, the swash plate (103) takes the
maximum tilting angle 1. That is to say, the hy-
draulic motor takes the maximum displacement
capacity and rotates at low speed.

Fig. 24-84

24-78
 24. COMPONENTS SYSTEM

2) High-speed step
The high-speed step is the status in which a pilot
pressure of 3.43 MPa (500 psi) is supplied from
port P. In that case, the spool (271) is pressed to
the right, overcoming the force of spring (281)
and the pressure from port A or B. The pressure
of port F is led to chamber S via spool (271).
The thrust of piston (161) increases by the pres-
sure of chamber S. The piston (161) is pushed
up and held till swash plate (103) comes in con-
tact with face X.
On that occasion, the swash plate (103) takes
the minimum tilting angle 2. That is to say, the
hydraulic motor takes the minimum displace-
ment capacity and rotates at high speed.

Fig. 24-85
3) Functional explanation of automatic selection of
low-speed step while operating at high-speed
step
The pressure of A or B increases as load in-
creases at high speed step. When the pressure
reaches 22 MPa (3200 psi), the spool (271) is
pressed to the left, overcoming the pilot pressure
3.43 MPa (500 psi) of port P. The pressure of
chamber S is released to drain (motor casing) via
spool (271). In that case, the swash plate (103)
comes in contact with the Y face and takes the
maximum tilting angle 1. The angle is held,
with the result that the hydraulic motor rotates at
low speed.

Fig. 24-86

24-79
24. COMPONENTS SYSTEM

(4) Parking Brake

1) Machine is running:
If the pressure from the pumps is supplied to port
A or B, the spool (223) of the brake valve moves
to the right or the left. Port E opens, and the pres-
sure is led from port E to cylinder chamber C.
When the pressure reaches 0.47 MPa (68psi) or
over, the thrust of piston (112) overcomes the
force of spring (113). The piston (112) moves to-
ward rear flange (201). If the piston (112) loses
its pressing force against separator plate (116)
and friction plate (115), the friction plate (115) is
let free.
The friction plate (115) is engaged with cylinder
block (104) of the hydraulic motor. The result is
that the cylinder block (104) is freed from the
braking force. The hydraulic motor is freed to
run.
Fig. 24-87
2) Machine is not running:
If the pressure to port A or B is suspended, the
spool (223) of the brake valve moves to neutral.
Port E is shut off, and the pressure in cylinder
chamber C falls. When the pressure falls below
0.47 MPa (68psi), the hydraulic force of piston
(112) decreases below the force of spring (113).
Then the action of spring (113) causes the piston
(112) to be pressed against the separator plate
(116) and the friction plate (115). This pressing
force creates frictional force that makes braking
power. The friction plate (115) meshes with the
cylinder block (104) of the hydraulic motor. The
cylinder block (104) meshes with shaft (102) of
the hydraulic motor.
In this way, the hydraulic motor undergoes brak-
ing torque while the machine is at rest.

Fig. 24-88

24-80
 24. COMPONENTS SYSTEM

24.1.7 SWIVEL JOINT

24.1.7.1 GENERAL VIEW

Fig. 24-89 General view of swivel joint

24.1.7.2 SPECIFICATIONS
Table 24-8
Travel main port Working pressure 28.4 MPa (4120 psi)
A, B, C, D Max. impact pressure 38.2 MPa (5550 psi)
Dozer port Working pressure 20.6 MPa (2990 psi)
F, G Max. impact pressure 38.2 MPa (5550 psi)
Drain port
Max. working pressure 490 kPa (71 psi)
E
Pilot port
Working pressure 4.9 MPa (711 psi)
H
Revolution 15rpm
Weight 21kg (46 lbs)

24-81
24. COMPONENTS SYSTEM

24.1.7.3 CONSTRUCTION

T=Tightening torque : N·m (lbf·ft)

Note)
Fix seal (5) in the
perfectly degreased
seal groove without
applying grease.

SECTION K-K

T =30.4 (22) (Loctite #290) T =30.4 (22) (Loctite #290) VIEW M

SECTION J-J
Fig. 24-90 Construction
Table 24-9
No. Parts Q'ty No. Parts Q'ty
1 BODY 1 8 SOCKET BOLT : M8 × 20 2
2 STEM 1 9 SOCKET BOLT : M8 × 30 3
3 THRUST PLATE 1 12 PLUG : PT1/8 1
4 COVER 1 13 PLUG : PT3/8 2
5 SEAL ASSY 7 15 SEAL 2
7 O-RING : 1A G95 1

24.1.7.4 OPERATION
The swivel joint consists mainly of mutually rotating body (1) and stem (2), thrust plate (3) that prevents them from
coming off, cover (4) that plugs up one part of body (1), seals (5) that partitioning circuits, and O rings (6, 7) that
prevents oil from leaking out.
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 binding with the stem (2). Such construction of the swivel joint makes it possible to connect circuits
between the swing body and the lower travel body at all times.

24-82
 24. COMPONENTS SYSTEM

24.1.8 CYLINDER

24.1.8.1 SPECIFICATIONS
(1) General view

B
gth
l en h A
ed gt
t e nd len
e x t e d
Fu
lly rac
l y ret
l
Fu

Part No. and Manufacturing No.

Stamp position

Fig. 24-91 General view of cylincer

(2) Specifications
Unit : mm (ft-in)
Table 24-10
Cylinder bore/ Center distance of mounting pins Dry weight
Use Stroke Cushion
Rod Dia. Full extend B / Full retract A Kg (lbs)
110 / 70 916 2,291 / 1,375 With cushion on 95
Boom
(4.33"/2.76") (30.1") (7’6" / 4’6") rod side (210)
95 / 65 813 2,113 / 1,300 With cushion on 72
Arm
(3.74"/2.56) (32.0") (6’11" / 4’3") both sides (160)
80 / 55 735 1,855 / 1,120 48
Bucket Without
(3.15"/2.16") (28.9") (6’1" / 3’8") (100)
130 / 70 170 860 / 690 60
Dozer Without
(5.17"/2.76") (6.69") (33.9" / 27.2") (132)
105 / 65 594 1,629 / 1,035 With cushion on 71
Swing
(4.13"/ 2.56") (23.4") (5.4" / 3.5") both sides (157)

24-83
24. COMPONENTS SYSTEM

24.1.8.2 CONSTRUCTION AND OPERATION

24.1.8.2.1 CONSTRUCTION
(1) Boom cylinder

T=Tightening torque : N·m (lbf·ft) [screw size]

Press it in from both ends Press it in from both ends

of the boss so R2.5 (0.10") 27 of the boss so R2.5 (0.10")
holes face with each other holes face with each other
in the grease hole position. in the grease hole position.

24 23
25 26 28, 29
T=3.2 ± 0.6 (23 ± 4.3) [M10 X 1.5]

VIEW A-A

475

T=56.9 (42) [M12 X 1.75]

After tightening,fit it with punch
caulking on two portions.
T=830 (615) [M117 X 2]
Apply Three-bond #1901 on the thread 12 14 9,15 13
T=3000 (2210) [M52 X 2,HEX80]

8 3 7 11 6 4 9,10 5 2 1 16 17 19 18 20 21,22

With Detail of S
one hole

S
Fig. 24-92 Construction of boom cylinder

No. Parts Q’ty No. Parts Q’ty No. Parts Q’ty

1 CYLINDER TUBE ASSY 1 11 O-RING 1 21 SET SCREW 1
2 PISTON ROD ASSY 1 12 O-RING 1 22 STEEL BALL 1
3 ROD COVER 1 13 CUSHION SEAL 2 23 PIN BUSHING 2
4 BUSHING 1 14 COLLAR 1 24 WIPER RING 2
5 SNAP RING 1 15 BACKUP RING 1 25 PIN BUSHING 2
6 BUFFER RING 1 16 CUSHION BEARING 1 26 WIPER RING 2
7 U-RING 1 17 PISTON 1 27 BAND ASSY 2
8 WIPER RING 1 18 SEAL RING ASSY 1 28 BOLT 2
9 O-RING 2 19 SLIDE RING 2 29 WASHER 2
10 BACKUP RING 1 20 NUT 1

24-84
 24. COMPONENTS SYSTEM

(2) Arm cylinder

T=Tightening torque : N·m (lbf·ft) [screw size]

Press it in from both ends Press it in from both ends

of the boss so R2.5 (0.10") of the boss so R2.5 (0.10")
33 34 32 29 31 holes face with each other
holes face with each other
in the grease hole position. in the grease hole position.
T=39.8 (30)
30
[M12 X 1.75]

29

26 27 T=31.5 (23) [M10 X 1.5] 27

26

VIEW A-A

T=56.9 (42) [M12 X 1.75]

After tightening,fit it with punch
T=569 (420) [M100 X 2] caulking on two portions.
Apply Three-bond #1901 on the thread
T=2780 (2000) [M45 X 2, HEX70]

9 3 12 7,8 6 10,11 4 5 11,13 2 1 14 15 19 17 18 16 20 21 25 23 22 24

With
one hole

Face the slit to the piston side.

Fig. 24-93 Construction of arm cylinder

No. Parts Q’ty No. Parts Q’ty No. Parts Q’ty

1 CYLINDER TUBE ASSY 1 13 O-RING 1 25 SNAP RING 1
2 PISTON ROD ASSY 1 14 CUSHION BEARING 1 26 PIN BUSHING 4
3 ROD COVER 1 15 CUSHION SEAL 1 27 WIPER RING 4
4 BUSHING 1 16 PISTON 1 28 BAND ASSY 1
5 SNAP RING 1 17 SEAL RING ASSY 1 29 BAND 1
6 BUFFER RING 1 18 SLIDE RING 2 30 BOLT 2
7 U-RING 1 19 SHIM 1 31 WASHER 2
8 BACKUP RING 1 20 SET SCREW 1 32 PIPE HOLDER 1
9 WIPER RING 1 21 STEEL BALL 1 33 BOLT 1
10 O-RING 1 22 CUSHION BEARING 1 34 WASHER 1
11 BACKUP RING 3 23 CHSHION SEAL 1
12 O-RING 1 24 STOPPER 2

24-85
24. COMPONENTS SYSTEM

(3) Bucket cylinder

T=Tightening torque : N·m (lbf·ft) [screw size]

T=31.5 (23) [M10 X 1.5]

45 45

VIEW B-B VIEW A-A

T=16.2 (12) [M8 X 1.25]

After tightening,fit it with punch
caulking on two portions.
T=450 (330) [M82 X 2]
Apply Three-bond #1901 on the thread
T=1420 (1000) [M39 X 3,HEX60)
8 3 7 11 6 4 9,10 5 2 1 12 14 13 15,16

With
one hole

Fig. 24-94 Construction of bucket cylinder

No. Parts Q’ty No. Parts Q’ty No. Parts Q’ty

1 CYLINDER TUBE ASSY 1 9 O-RING 1 17 PIN BUSHING 1
2 PISTON ROD ASSY 1 10 BACKUP RING 1 18 WIPER RING 4
3 ROD COVER 1 11 O-RING 1 19 PIN BUSHING 1
4 BUSHING 1 12 PISTON 1 20 BAND ASSY 2
5 SNAP RING 1 13 SEAL RING ASSY 1 21 BAND 2
6 BUFFER RING 1 14 SLIDE RING 2 22 BOLT 4
7 U-RING 1 15 SET SCREW 1 23 WASHER 4
8 WIPER RING 1 16 STEEL BALL 1

24-86
 24. COMPONENTS SYSTEM

(4) Dozer cylinder

T=Tightening torque : N·m (lbf·ft) [screw size]

21 20 22 21 20
22

T=56.9 (42) [M12 X 1.75]

After tightening,fit it with punch
caulking on two portions.
T=1340 (990) [M135 X 2]
Apply Three-bond #1901 on the thread T=2900 (2140) [M55 X 2,HEX85]

9 3 12 7,8 6 10,11 4 5 2 1 13 14 15 16 17 18 19

With
one hole

Fig. 24-95 Construction of dozer cylinder

No. Parts Q’ty No. Parts Q’ty No. Parts Q’ty

1 CYLINDER TUBE ASSY 1 9 WIPER RING 1 17 NUT 1
2 PISTON ROD ASSY 1 10 O-RING 1 18 SET SCREW 1
3 ROD COVER 1 11 BACKUP RING 1 19 STEEL BALL 1
4 BUSHING 1 12 O-RING 1 20 PIN BUSHING 2
5 SNAP RING 1 13 PISTON 1 21 WIPER RING 4
6 BUFFER RING 1 14 SEAL RING ASSY 1 22 GREASE NIPPLE 2
7 U-RING 1 15 SLIDE RING 2
8 BACKUP RING 1 16 SHIM 1

24-87
24. COMPONENTS SYSTEM

(5) Swing cylinder

T=Tightening torque : N·m (lbf·ft) [screw size]
2-PF1/2 O RING PORT

27 28 T=17.2 (12.7) [M8 X 1.25] 34 33 T=26.3 (19.4) [M8 X 1.25] 28 27

30 31,32
29 PT1/4

T=57 (42) [M12 X 1.75]

T=735 (540) [M110 X 2] After tightening,fit it with punch
Apply Three-bond #1901 on the thread caulking on two portions.

T=2770 (2040) [M52 X 3,HEX80]

8 3 7 11 6 4 9,10 5 2 1 16 17 19 18 20 21,22 25 24 23 26

With
one hole CUSHION CUSHION
STROKE STROKE
12 14 9,15 13

Slit to be faced to piston side.

Fig. 24-96 Construction of swing cylinder

No. Parts Q’ty No. Parts Q’ty No. Parts Q’ty

1 CYLINDER TUBE ASSY 1 12 HOLDER 1 23 CUSHION BEARING 1
2 PISTON ROD ASSY 1 13 CUSHION SEAL 1 24 CUSHION SEAL 1
3 ROD COVER 1 14 COLLAR 1 25 SNAP RING 1
4 BUSHING 1 15 BACK UP RING 2 26 STOPPER 2
5 SNAP RING 1 16 CUSHION BEARING 1 27 BUSHING 2
6 BUFFER RING 1 17 PISTON 1 28 WIPER RING 4
7 U-RING 1 18 SEAL RING ASSY 1 29 GREASE NIPPLE 1
8 WIPER RING 1 19 SLIDE RING 2 30 PIPE ASSY 1
9 O-RING 1 20 NUT 1 31 SOCKET BOLT 4
10 BACKUP RING 1 21 SET SCREW 1 32 O-RING 1
11 O-RING 1 22 STEEL BALL 1 33 PIPE HOLDER 1

24-88
 24. COMPONENTS SYSTEM

Hydraulic cylinder construction (See Fig. 24-93)

The hydraulic cylinder is composed of three sections, cylinder tube assy (1), piston rod assy to transmit the motion
of piston (16) stroke in the tube, a rod cover (3) which serves as the cover and guide. Also, the cylinder tube assy
and piston rod assy (2) have piston mounting section (clevis) which are used to connect the other device. And, in
addition to these principal parts, seal ring assy (17), slide ring (18) and piston rod assy (2), buffer ring (6), U ring (7),
backup ring (8), and wiper ring (9) between piston rod assy (2) and rod cover (3), and O ring and backup ring be-
tween cylinder tube assy (1) and rod cover (3).

24.1.8.2.2 OPERATION
By feeding pressure oil through oil inlet and outlet on
cylinder alternately, the oil pressure exerts on the pis-
ton, and piston rod assy (2) starts moving the telescopic
motion (stroke).

Fig. 24-97 Cushion on the rod side

(1) Operation of cylinder with cushion
The hydraulic cylinder contains a shock absorber to
shock generated when the moving piston rod assy (2)
strikes rod cover (3) without speed reduction.

(Cushion on rod side) Fig. 24-98 Cushion on the rod side

When pressurizing the rod cover side, the oil in (A)
chamber returns to the tank in constant speed through
passage (B) in the midway of stroke. (Fig. 24-97)
As the end of the stroke approaches, the cylinder bear-
ing enters into passage (B), and the passage (B) is
throttle reducing oil quantity. As a result, the speed of
piston rod is also lowered. (Fig. 24-98) Fig. 24-99 Cushion on the head side

(Cushion on head side)

Like the cushion on the rod side, the piston end of the
piston rod enters into the cushion bearing, and passage
(B) is throttled. As a result, as the return oil level for (A)
chamber lowers, the speed of piston rod lowers, obtain- Fig. 24-100 Cushion on the head side
ing the effect of cushion. (Fig. 24-99 and Fig. 24-100)

24-89
24. COMPONENTS SYSTEM

This page is blank for editing convenience.

24-90
 24. COMPONENTS SYSTEM

24.2 ELECTRIC EQUIPMENT

24.2.1 ELECTRIC EQUIPMENT LIST

Group Code Name

C-1 MECHATRO CONTROLLER
CONTROLLER

C-2 GAUGE CLUSTER

C-4 AIR CONDITIONER CONTROLLER

D-1 DIODE
D-2 ↑
D-3 ↑
DIODE

D-4 ↑
D-5 ↑
D-6 ↑
D-7 ↑
E-1 FUSE BOX
E-2 ALTERNATOR
E-3 HOUR METER
E-5 HORN
E-6 CIGALETTE LIGHTER
E-7 TUNER AM & FM
ELECTRIC FITTINGS

E-8 SPEAKER LEFT

E-9 SPEAKER RIGHT
E-10 RECEIVER DRIER
E-11 AIR COMMPRESSOR CLUTCH
E-13 TRAVEL ALARM
E-14 BATTERY
E-15 POWER SOCKET
E-16 SLEWING EXTRA SELECT INDICATION
E-17 CONVERTER
E-20 BUZZER
E-21 COUNTER
E-A ANNTENA
L-1 BOOM WORKING LIGHT LEFT
L-1 BOOM WORKING LIGHT RIGHT
L-2 WORKING LIGHT RIGHT
L-3 ROOM LIGHT
L-4 CAB WORKING LIGHT FRONT (OPT.)
LIGHT

L-5 CAB WORKING LIGHT FRONT (OPT.)

L-6 CAB WORKING LIGHT (FRONT 3)
L-7 ENGINE ROOM LIGHT
L-8 CAB WORKING LIGHT (FRONT 4)
L-9 CAB WORKING LIGHT (REAR)
L-10 ROTARY LIGHT
L-11 STARTER ALARM LAMP

24-91
24. COMPONENTS SYSTEM

Group Code Name

M-1 STARTER MOTOR
M-2 GOVERNOR MOTOR
M-3 WIPER MOTOR
MOTOR

M-4 WASHER MOTOR

M-8 ROOF WIPER MOTOR (OPT.)
M-9 FUEL PUMP
M-11 FUEL TANK PUMP
R-1 BATTERY RELAY
R-3 GLOW RELAY
R-4 SAFETY RELAY
R-5 WIPER MOTOR RELAY
R-6 WASHER MOTOR RELAY
R-7 HORN RELAY
R-8 WORK LIGHT RELAY
R-10 CAB WORK LIGHT RELAY
RELAY

R-11 TRAVEL ALARM RELAY

R-13 CAB WORK LIGHT RELAY 2
R-20 TIMER
R-21 SEQUENCE RELAY
R-22 SWITCH SELECT RELAY
R-23 SLEW / SWING PRESERVATION RELAY
R-28 AUTO IDLE STOP RELAY 1
R-29 AUTO IDLE STOP RELAY 2
R-30 TIMER UNIT
R-31 COUNTER RELAY
SE-1 PRESSURE SENSOR (LOW) : BUCKET DIGGING
SE-2 PRESSURE SENSOR (LOW) : BUCKET DUMP
SE-3 PRESSURE SENSOR (LOW) : BOOM UP
SE-4 PRESSURE SENSOR (LOW) : BOOM DOWN
SE-5 PRESSURE SENSOR (LOW) : SWING
SE-7 PRESSURE SENSOR (LOW) : ARM IN
SENSOR

SE-8 PRESSURE SENSOR (LOW) : ARM OUT

SE-9 PRESSURE SENSOR (LOW) : TRAVEL RIGHT
SE-10 PRESSURE SENSOR (LOW) : TRAVEL LEFT
SE-13 E/G SPEED SENSOR
SE-14 E/G WATER TEMPERATURE SENSOR
SE-15 FUEL SENSOR
SE-16 ACCEL POTENTIO METER
SE-17 PRESSURE SENSOR (HIGHT) : P3 PUMP
SE-18 PRESSURE SENSOR (HIGHT) : BOOM HEAD
SV-1 SLEWING PARKING BRAKE SOL.
SV-2 DOUBLE•SINGLE SELECT SOL. (OPT.)
SOLENOID
VALVE

SV-3 TWO-SPEED SELECT SOL.

SV-4 LEVER LOCK SOL.
SV-8 TRAVEL BOOST-UP SOL.
SV-6 SLEW / EXTRA SELECT SOL.

24-92
 24. COMPONENTS SYSTEM

Group Code Name

PROPORTIONAL
PSV-B P2 BY-PASS CUT PROPOTIONAL SOL.
PSV-C TRAVEL PRIORITY PROPOTIONAL SOL.
VALVE

PSV-D P1 BY-PASS CUT PROPOTIONAL SOL.

SW-1 KEY SWITCH

SW-2 SWITCH ASSY
SW-3 TWO-SPEED SELECT SWITCH
SW-4 SLEWING PARKING RELEASE SWITCH
SW-6 ENG. WATER TEMPERATURE SWITCH
SW-7 ENG. OIL PRESS SWITCH
SW-8 AIR FILTER ALARM SWITCH
SW-10 HORN SWITCH (LEFT)
SW-11 LEVER LOCK SWITCH
SW-13 AIR CONDITIONER SWITCH
SW-15 ROOF WIPER SWITCH (OPT.)
SW-16 WORK LIGHT SWITCH (OPT.)
SW-17 DOUBLE•SINGLE SELECT SWITCH
SW-18 OPT. PEDAL PRESSURE SWITCH ASSY 1
SW-20 SLEW / SWING SELECT SWITCH
SWITCH

SW-21 SLEWING FLASHER SELECT SWITCH

SW-23 WIPER INTERLOCK SWITCH
SW-24 OVER LOAD SWITCH
SW-25 HYD. FLUID TEMPERATURE SWITCH
SW-26 AUTO ACCEL RELEASE SWITCH
SW-27 ENGINE ROOM LIGHT SWITCH
SW-28 OVERLOAD INDICATE SWITCH
SW-29 ROTARY LIGHT SWITCH
SW-30 SLEW / SWING PRESSURE SWITCH LEFT
SW-31 SLEW / SWING PRESSURE SWITCH RIGHT
SW-32 SLEW / SWING LEVER PRESSURE SWITCH LEFT
SW-33 SLEW / SWING LEVER PRESSURE SWITCH RIGHT
SW-34 SWING / EXTRA SWITCH
SW-35 PEDAL PRESSURE SWITCH
SW-37 BUZZER STOP SWITCH
SW-40 AUTO IDLE STOP SELECT SWITCH

24-93
24. COMPONENTS SYSTEM

24.2.2 ELECTRIC EQUIPMENT LIST FOR ASIA, OCEANIA

Group Code Name

C-1 MECHATRO CONTROLLER
CONTROLLER

C-2 GAUGE CLUSTER

C-4 AIR CONDITIONER CONTROLLER

D-1 DIODE
D-2 ↑
D-3 ↑
DIODE

D-4 ↑
D-5 ↑
D-6 ↑
D-7 ↑
E-1 FUSE BOX
E-2 ALTERNATOR
E-3 HOUR METER
E-5 HORN
E-6 CIGALETTE LIGHTER
E-7 TUNER AM & FM (OPT.)
E-7 TUNER AM
ELECTRIC FITTINGS

E-8 SPEAKER LEFT (OPT.)

E-9 SPEAKER RIGHT
E-10 RECEIVER DRIER
E-11 AIR COMMPRESSOR CLUTCH
E-12 HEATER (OPT.)
E-13 TRAVEL ALARM
E-14 BATTERY
E-14 BATTERY (OPT.1)
E-14 BATTERY (OPT.2)
E-16 CONVERTER (OPT.)
E-17 SOCKET
E-20 BUZZER
E-A ANTENNA
L-1 BOOM WORKING LIGHT LEFT
LIGHT

L-2 WORKING LIGHT RIGHT

L-3 ROOM LIGHT

M-1 STARTER MOTOR

M-2 GOVERNOR MOTOR
M-3 WIPER MOTOR
MOTOR

M-4 WASHER MOTOR

M-8 ROOF WIPER MOTOR (OPT.)
M-9 FUEL PUMP (OPT.)

24-94
 24. COMPONENTS SYSTEM

Group Code Name

R-1 BATTERY RELAY
R-3 GLOW RELAY
R-4 SAFETY RELAY
R-5 WIPER MOTOR RELAY
R-6 WASHER MOTOR RELAY
RELAY

R-7 HONE RELAY

R-8 WORK LIGHT RELAY
R-11 TRAVEL ALARM RELAY (OPT.)
R-20 TIMER UNIT
R-28 AUTO IDLE STOP RELAY 1
R-29 AUTO IDLE STOP RELAY 2

SE-1 PRESSURE SENSOR (LOW) : BUCKET DIGGING

SE-2 PRESSURE SENSOR (LOW) : BUCKET DUMP
SE-3 PRESSURE SENSOR (LOW) : BOOM UP
SE-4 PRESSURE SENSOR (LOW) : BOOM DOWN
SE-5 PRESSURE SENSOR (LOW) : SWING
SE-7 PRESSURE SENSOR (LOW) : ARM IN
SENSOR

SE-8 PRESSURE SENSOR (LOW) : ARM OUT

SE-9 PRESSURE SENSOR (LOW) : TRAVEL RIGHT
SE-10 PRESSURE SENSOR (LOW) : TRAVEL LEFT
SE-13 E/G SPEED SENSOR
SE-14 E/G WATER TEMPERATURE SENSOR
SE-15 FUEL SENSOR
SE-16 ACCEL POTENTIO METER
SE-17 PRESSURE SENSOR (HIGHT) : P3 PUMP
SV-1 SWING PARKING BRAKE SOL.
SOLENOID

SV-2 DOUBLE•SINGLE SELECT SOL. (OPT.)

VALVE

SV-3 TWO-SPEED SELECT SOL.

SV-4 LEVER LOCK SOL.
SV-8 TRAVEL BOOST-UP SOL.
PROPORTIONAL

PSV-B P2 BY-PASS CUT PROPOTIONAL SOL.

PSV-C TRAVEL PRIORITY PROPOTIONAL SOL.
VALVE

PSV-D P1 BY-PASS CUT PROPOTIONAL SOL.

24-95
24. COMPONENTS SYSTEM

Group Code Name

SW-1 KEY SWITCH
SW-2 SWITCH ASSY
SW-3 TWO-SPEED SELECT SWITCH
SW-4 SWING PARKING RELEASE SWITCH
SW-6 ENG. WATER TEMPERATURE SWITCH
SW-7 ENG. OIL PRESSURE SWITCH
SW-8 AIR FILTER ALARM SWITCH
SW-10 HORN SWITCH (LEFT)
SW-11 LEVER LOCK SWITCH
SWITCH

SW-12 HEATER SWITCH (OPT.)

SW-13 AIR CONDITIONER SWITCH
SW-15 ROOF WIPER SWITCH (OPT.)
SW-17 DOUBLE•SINGLE SELECT SWITCH
SW-18 OPT. PEDAL PRESSURE SWITCH ASSY 1
SW-19 OPT. PEDAL PRESSURE SWITCH ASSY 2
SW-20 HORN SWITCH (RIGHT) (OPT.)
SW-23 WIPER INTERLOCK SWITCH
SW-27 AUTO ACCEL RELEASE SWITCH
SW-37 BUZZER STOP SWITCH (TRAVEL ALARM) (OPT.)

1. The Part numbers and serial numbers of machine may be changed due to modification, so use only the numbers
for reference.

24-96
 24. COMPONENTS SYSTEM

24.2.3 SPECIFICATION OF ELECTRIC EQUIPMENTS

Code No.
Parts Name Specifications Description
Use
C-1
Controller
Mechatro conntroller

C-2
Controller
Gauge cluster

C-4
Controller
Air conditioner
controller

24-97
24. COMPONENTS SYSTEM

Code No.
Parts Name Specifications Description
Use
D-1~4, 6, 7, 8
Diode
Key switch relay
Battery relay
Gauge cluster
Pedal pressure switch

D-5
Diode
Glow relay

E-1
Fuse box
Fuse

24-98
 24. COMPONENTS SYSTEM

Code No.
Parts Name Specifications Description
Use
E-2
Alternator
Generator

E-3
Hour meter
Service meter

E-5
Horn
Warning sound

E-6
Cigar lighter
Cigar lighter

24-99
24. COMPONENTS SYSTEM

Code No.
Parts Name Specifications Description
Use
E-7
Tuner

Radio (AM&FM)

E-8, 9
Speaker
Radio

E-10
Receiver drier
Air conditioner

24-100
 24. COMPONENTS SYSTEM

Code No.
Parts Name Specifications Description
Use
E-11
Air compressor
Air conditioner

E-13
ALARM
TRAVEL ALARM

E-14
Battery
POWER

24-101
24. COMPONENTS SYSTEM

Code No.
Parts Name Specifications Description
Use
E-20
Buzzer
AUTO IDLE STOP

E-21
Counter
AUTO IDLE STOP

24-102
 24. COMPONENTS SYSTEM

Code No.
Parts Name Specifications Description
Use
L-1
Light (halogen)
Boom work light

L-2
Light (halogen)
Work light (R)

L-3
Light
Room light

L-11
Light
Starter alarm lamp

24-103
24. COMPONENTS SYSTEM

Code No.
Parts Name Specifications Description
Use
M-1
Motor
Starter motor

M-2
Motor
Governor motor

M-3
Motor
For wiper (STD)

24-104
 24. COMPONENTS SYSTEM

Code No.
Parts Name Specifications Description
Use
M-4
Motor (tank)
Window washer

M-8
Motor
For roof wiper (OPT)

24-105
24. COMPONENTS SYSTEM

Code No.
Parts Name Specifications Description
Use
M-9
Motor (pump)
Fuel pump

R-1
Relay
Battery relay

24-106
 24. COMPONENTS SYSTEM

Code No.
Parts Name Specifications Description
Use
R-3
Relay
Glow relay

R-4
Relay
Safety relay

24-107
24. COMPONENTS SYSTEM

Code No.
Parts Name Specifications Description
Use
R-5, 6, 7, 8, 10, 11, 13
21, 22, 23, 24, 25, 28, 31
Relay
Wiper motor, Washer
motor, Horn relay,
Work light relay,
Cab work light relay (OPT),
Travel aram relay (OPT)
Breaker relay (OPT)
Hand control rotating relay
(OPT)
Crusher open / close relay
(OPT)
R-20
Relay
Timer

R-30
Timer unit
Auto idle stop

24-108
 24. COMPONENTS SYSTEM

Code No.
Parts Name Specifications Description
Use
R-29
Relay
Auto idle stop relay 2

SE-1~5, 7~10
Pressure sensor
(Iow pressure)
Bucket digging, Dump,
Boom up, down,
Slewing R,L
Arm in, out, Travel R,L

SE-13
Speed sensor
E/G Speed sensor

SE-14
Water temperature
E/G Water temperature

24-109
24. COMPONENTS SYSTEM

Code No.
Parts Name Specifications Description
Use
SE-15
Fuel sensor
Fuel sending

SE-16
Potentio meter
Accel dial

SE-17
Pressure sensor Pressure range
0~500 kgf/cm2
(0~7110 psi)
(Hight pressure)
765 kgf/cm2
Max. allowable press.
P3 pump (10880 psi)
pressure Operating source voltage 5±0.5V DC
Insulation resistance More than 100M
Load resistance 10 k MIN

TERMINAL NO. CONNECTION

1 COM
2 OUTPUT (+)
3 POWER (+)

24-110
 24. COMPONENTS SYSTEM

Code No.
Parts Name Specifications Description
Use
SV-1~4, 8
Solenoid valve assy
Refer to hydraulic
symbol
PSV-B, C, D
Solenoid valve assy
Refer to hydraulic
symbol

24-111
24. COMPONENTS SYSTEM

Code No.
Parts Name Specifications Description
Use
SV-5,6
Solenoid valve
Swing/Extra select

SW-1
Switch
Starter switch

24-112
 24. COMPONENTS SYSTEM

Code No.
Parts Name Specifications Description
Use
SW-2
Switch
Mode select

SW-3
Switch
Travel 1,2-speed

SW-4
Switch
Swing parking release

24-113
24. COMPONENTS SYSTEM

Code No.
Parts Name Specifications Description
Use
SW-6
Switch
E/G Water
temperature switch
[105°C(221°F)]

SW-7
Switch
E/G Oil pressure
Switch

SW-8
Switch
Air filter
alarm switch

SW-10, 20
Switch
Horn

24-114
 24. COMPONENTS SYSTEM

Code No.
Parts Name Specifications Description
Use
SW, 34-10
Grip & switch
Control lever

SW-11
Switch
Lock lever

SW-13
Switch
Air conditioner
operation

24-115
24. COMPONENTS SYSTEM

Code No.
Parts Name Specifications Description
Use
SW-15
Switch
Roof wiper switch

SW-16
Switch
Work light (OPT.)

SW-17
Switch
Operation select

SW-18, 19, 30, 31, 32,

33, 35
Switch
Option pedal press

24-116
 24. COMPONENTS SYSTEM

Code No.
Parts Name Specifications Description
Use
SW-21
Switch
Swing flasher
select switch

SW-23
Switch
Wiper inter lock
YT02-04001~
YT03-05432~
YT04-07001~
LF04-02001~

SW-26
Auto accel release
switch
Auto accel release

SW-40
Switch
Auto idle stop

24-117
24. COMPONENTS SYSTEM

Code No.
Parts Name Specifications Description
Use
SW-37
Buzzer stop switch
Buzzer stop (OPT.)
(Travle aram)

24-118
 25. AIR-CONDITIONER SYSTEM
TABLE OF CONTENTS

25.1 CONSTRUCTION AND PIPING ......................................................................................... 25-3

25.1.1 CONSTRUCTION ..................................................................................................... 25-3
25.1.2 PIPING ...................................................................................................................... 25-4
25.2 CONSTRUCTION OF MAIN COMPONENTS .................................................................... 25-6
25.2.1 INTAKE UNIT ............................................................................................................ 25-6
25.2.2 AIR-CONDITIONER UNIT ......................................................................................... 25-7
25.2.3 RECEIVER DRYER ................................................................................................... 25-8
25.3 FUNCTION ......................................................................................................................... 25-9
25.3.1 MECHANISM OF COOLING CIRCUIT ..................................................................... 25-9 25
25.3.2 COOLING CIRCUIT .................................................................................................. 25-11
25.3.3 COMPONENT PARTS .............................................................................................. 25-12
25.4 DISASSEMBLY AND ASSEMBLY ..................................................................................... 25-16
25.4.1 PRECAUTIONS TO BE EXERCISED IN OPERATION ............................................. 25-16
25.4.2 REMOVAL AND INSTALLATION OF THE UNIT ....................................................... 25-17
25.5 CHARGING REFRIGERANT ............................................................................................ 25-21
25.5.1 PRECAUTIONS TO BE EXERCISED IN OPERATION ............................................. 25-21
25.5.2 OPERATING PROCEDURE ..................................................................................... 25-22
25.5.3 CHARGING PROCEDURE ....................................................................................... 25-23
25.6 ELECTRIC CIRCUIT .......................................................................................................... 25-28
25.6.1 WIRING DIAGRAM AND CONNECTORS ................................................................ 25-28
25.6.2 INSPECTING FUNCTIONAL PARTS ........................................................................ 25-30
25.7 TROUBLESHOOTING ....................................................................................................... 25-32

25-1
25. AIR-CONDITIONER SYSTEM

PREFACE
We have developed an air conditioner for excavating machine which uses new refrigerant (R134a) instead of the
R12 traditionally used for the air conditioner installed on excavating machines. The advantage of this new refrigerant
(R134a) is that the detrimental effect of the refrigerant on the global environment is far lower, and the destruction of
ozone layer does not occur. This new refrigerant R134a could not use on the traditionally used air conditioner be-
cause the characteristics of new R134a are different from that of R12. This manual provides basic knowledge and
precautions required to furnish services for the air conditioner using the new refrigerant R134a which is installed on
excavating machine.

25-2
 25. AIR-CONDITIONER SYSTEM

25.1 CONSTRUCTION AND PIPING

25.1.1 CONSTRUCTION
3

1
5

9 8

Fig. 25-1 Air-conditioner group

No. Part name Q'ty No. Part name Q'ty No. Part name Q'ty
1 AIR-CONDITIONER ASSY 1 5 FILTER ASSY 1 8–8 S TUBE: Ø16 1
1–1 AIR-CONDITIONER UNIT 1 8 AIR DRYER ASSY 1 9 CONDENSER 1
1–2 HARNESS 1 8–1 RECEIVER DRYER 1
1–3 SENSOR 1 8–2 BRACKET 1
1–4 PLATE 1 8–3 L HOSE 1
1–5 MACHINE SCREW 1 8–4 D HOSE 1
1–7 CAP 1 8–5 S HOSE: Ø24.5 1
3 COMPRESSOR 1 8–6 L HOSE: Ø15.5 1
4 PANEL 1 8–7 D TUBE: Ø12 1

25-3
25. AIR-CONDITIONER SYSTEM

25.1.2 PIPING
19
2 COMPRESSOR ASSY

T= Tightening torque 3
N m {lbf ft}

19
22 22
15 13

A
AIR-CONDITIONER UNIT

20 1
23
16
COMPRESSOR
CONDENSER
20
CONDENSER
23
11 17
14 32
26
9 21 RECEIVER TANK

33
8 36
OUT 35
4
27
28
B 7 25
37
10 IN
6 34
27
5
6
Bolt for tension pulley
31 T=45 {33.2}
OUT
27

IN
5
4

26
19 29
15
30

B A 11

12
9 21
10 24
38
8 20 21 7
24 9
18

Fig. 25-2 Installing air conditioner and heater

25-4
 25. AIR-CONDITIONER SYSTEM

Tightening Tightening
torque N•m No. Part name Q'ty torque N•m No. Part name Q'ty
(lbf•ft) (lbf•ft)
1 SUPPORT 1 20 WASHER 8
2 BRACKET 1 21 WASHER 3
3 PULLEY 1 22 LOCK WASHER 6
4 HOSE : L=2500 1 23 LOCK WASHER 6
5 HOSE : L=1950 1 46 (34) 24 NUT 2
6 TUBE : L=1400 1 24.5 (18) 25 CONNECTOR 1
7 TUBE : L=1500 1 26 TUBE : L=2100 1
8 TUBE : L=400 1 27 CLIP 4
9 TUBE : L=1900 1 28 GROMMET 1
10 TUBE : L=1250 1 29 GROMMET 1
11 CLIP 3 30 V-BELT 1
12 CLIP 1 31 CLIP 1
10.7 (8.0) 13 CAPSCREW : M8 X 100 4 46 (34) 32 CAPSCREW : M10 X 16 1
39 (29) 14 SEMS BOLT : M8 X 25 2 9.8 (7.2) 33 CLIP 1
10.7 (8.0) 15 CAPSCREW : M8 X 16 4 34 PIPE 1
4.4 (3.3) 16 CAPSCREW : M6 X 50 3 35 HOSE : L=150 1
4.4 (3.3) 17 NUT : M6 3 36 TUBE : L=100 1
18 CAPSCREW : M6 X 20 2 37 CLIP 2
19 WASHER 7 38 CLIP 1

25-5
25. AIR-CONDITIONER SYSTEM

25.2 CONSTRUCTION OF MAIN COMPONENTS

25.2.1 INTAKE UNIT

Fig. 25-3 Intake unit

25-6
 25. AIR-CONDITIONER SYSTEM

25.2.2 AIR-CONDITIONER UNIT

Fig. 25-4 Air-conditioner unit

25-7
25. AIR-CONDITIONER SYSTEM

No. Part name Q'ty No. Part name Q'ty No. Part name Q'ty
1 ACTUATOR 3 22 LEVER 1 45 BRACKET 2
2 VALVE 1 23 LEVER 3 46 HOSE 1
3 THERMISTOR 1 24 LEVER 3 47 BLOWER MOTOR 1
4 CLAMP 2 25 CAM 1 48 CASING 1
5 ROD HOLDER 2 26 ROD 1 49 CASING 1
6 SENSOR HOLDER 2 27 ROD 1 50 FILTER 1
7 CLAMP 1 28 ROD 1 51 LEVER 1
8 EVAPORATOR 1 29 DAMPER 1 52 LEVER 1
9 CASING 1 30 DAMPER 1 53 DAMPER 1
10 CASING 1 31 DAMPER 1 54 FLANGE PLATE 1
11 CASING 1 32 DAMPER 1 55 SENSOR 1
12 THERMAL INSULATION 1 33 DAMPER 1 56 SEMS BOLT 1
MATERIAL 34 DAMPER 1 57 GASKET 1
13 THERMAL INSULATION 1 35 HEATER CORE 1 58 O-RING 1
MATERIAL 36 CONTROLLER 1 59 O-RING 1
14 PACKING 1 37 RELAY 1 60 TAPPING SCREW 6
15 PACKING 1 38 CLAMP 1 61 TAPPING SCREW 13
16 PACKING 1 39 BAND 1 62 SCREW 30
17 BRACKET 1 40 DUCT CAP 1 63 SEMS BOLT 3
18 CLAMP 1 41 HARNESS 1 64 TAPPING SCREW 9
19 PLATE 1 42 RESISTER 1 65 SCREW 1
20 LEVER 2 43 CASING 1 66 CAPSCREW 2
21 LEVER 1 44 CASING 1 67 TAPPING SCREW 4

25.2.3 RECEIVER DRYER

REFRIGERANT
INLET 2
REFRIGERANT
OUTLET

2-M6
1

No. Part name Q'ty

1 PRESSURE SWITCH 1
2 SIGHT GLASS 1
3 DESICCANT 1
4 SUCTION PIPE 1
5 FILTER 1
6 RECEIVER TANK 1

Fig. 25-5 Receiver dryer

25-8
 25. AIR-CONDITIONER SYSTEM

25.3 FUNCTION
25.3.1 MECHANISM OF COOLING CIRCUIT
(1) Mechanism of Cooling
In the cooling process, the refrigerant that flows Item HFC-134a (R134a)
through the cooling circuit changes its phases from Chemical formula CH2FCF3
liquid to gas and vice versa during which process Molecular weight 102.03
heat is transferred from the low temperature part Boiling point -26.19 C (-15.14 F)
(compartment) to the high temperature part (out- Critical temperature 101.14 C (214.05 F)
side of the vehicle). Critical pressure 4.065 MPa (41.45 kgf/cm2)*1
1) Kind of Refrigerant Critical density 511 kg/m3 (31.9 lb/ft3)
Many kinds of refrigerants that change in that Density of saturated
1206 kg/m3 (75.3 lb/ft3)
way are available, but the following requirements liquid [25 C (77 F)]
are needed for use in such applications: Specific volume of
saturated vapor 0.0310 m3/kg (0.496 ft3/lb)
• Latent heat of vaporization (heat of vaporiza-
[25 C (77 F)]
tion) is large.
Latent heat of
• It is easy to liquefy (condense). (It dose not vaporization 197.5 KJ/kg {47.19 kcal/kg}
require very high pressure for condensation.) [0 C (32 F)]
• It is easy to gasify (evaporate). (It evaporates Flammabillty Nonflammable
sufficiently at not too low pressure, i.e. cools Ozone destruction coefficient 0
down an object.) *1 : 1 MPa (mega pascal) equals 10.1972 kgf/cm2
• It has small specific heat. (Since the refriger- (145 psi)
ant 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.
Out of refrigerants meeting the above-men-
tioned requirements, ones having character-
istics that suit the intended cooling unit are
chosen and used. If a refrigerant other that
those designated is used, sufficient refriger-
ation will not be performed or the equipment
in which the refrigerant is used may be bro-
ken. Therefore, always use a designated re-
frigerant for the cooling unit.
Table 1 shows the principal characteristics of
the R134a refrigerant that is used in this ma-
chine.

25-9
25. AIR-CONDITIONER SYSTEM

(2) Characteristics of Refrigerant (See Fig. 25-6.) PRESSURE

In general, the fluid (general term of gas and liquid) MPa (psi)
has the following qualities:
1) As a gas under certain pressure is cooled down,
it begins to condensate at a certain temperature LIQUID
to take a liquid state. The temperature at which
condensation begins is unique to each sub-
stance (fluid) at a given pressure. The tempera- GAS
ture determined by a given pressure is called
TEMPERA-
saturation temperature. TURE
[ C ( F)]
2) Inversely to 1) above, the pressure at which a
gas condenses for a temperature is determined. Fig. 25-6 Pressure-temperature characteristics of
This pressure is called saturation pressure. R134a
Fig. 25-6 illustrates the relationships between
the saturation temperature and the saturation
pressure in the case of refrigerant R134a used in
the air-conditioner. At the temperature and the
pressure on the lower righthand side of the curve
in Fig. 25-6, the refrigerant take a gaseous state,
while at the temperature and the pressure on the
upper lefthand side of the curve, the refrigerant
takes a liquid state.
Let us think of a case where an air-conditioner is
operated in the midst of summer. As the refriger-
ant evaporates, it absorbs evaporation heat from
the air of the compartment. In order to cool the in-
side 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. 25-6 that R134a under a
pressure above the atmospheric pressure is ca-
pable of cooling the inside of the compartment
sufficiently. (If a refrigerant that requires a pres-
sure below the atmospheric pressure to cool it to
a required temperature is used, air is mixed into
the circuits, thereby deteriorating the perfor-
mance of the cooling unit.) In the process in
which gaseous refrigerant is brought back to a
liquid state, the refrigerant is cooled and con-
densed by the outer air exceeding 35°C (95°F).
Accordingly the refrigerant is capable of con-
densing at a pressure exceeding 1 MPa (145
psi), as seen from Fig. 25-6.

25-10
 25. AIR-CONDITIONER SYSTEM

25.3.2 COOLING CIRCUIT

Fig. 25-7 illustrates the cooling circuit of the car aircon-
ditioner.
In this circuit diagram, the portion that cools the air of INSIDE OF COMPARTMENT
the compartment is the evaporator. The object air is
cooled off by utilizing the fact the refrigerant takes heat
off the surrounding area as evaporation heat as it evap-
EVAPORATOR EXPANSION
orates in the cooling circuit. Since the part at which va- VALVE
porization of the refrigerant takes place is the BLOWER

evaporator, cooled air is constantly delivered to the cir-

cumference of the evaporator by the blower fan. In the INSIDE OF ENGINE
ROOM
meantime, liquid refrigerant (slightly wet vaporized re- S D

frigerant) is fed into the evaporator, when "cooling" ef- COMPRESSOR COOLING FAN

fect 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 unless it evaporates at a temperature RECEIVER DRYER
lower that 15°C (59°F). For that purpose, it can be seen
CONDENSER
from Fig. 25-6 that the pressure of the refrigerant in the
evaporator must be less than 0.51 MPa (74psi).
Fig. 25-7 Construction of cooling curcuit
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 ex-
pansion 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 com-
pressor acts as a pump that allows the refrigerant to cir-
culate. The compressive action of the compressor and
the heat exchange (heat radiation) action of the con-
denser transform the refrigerant in a dry vapor state
back to a liquid state.

25-11
25. AIR-CONDITIONER SYSTEM

25.3.3 COMPONENT PARTS

(1) Evaporator (See Fig. 25-8.)
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 refriger-
O-RING
ant. Therefore, it is necessary that satisfactory heat EXPANSION
transfer between the object and the refrigerant take VALVE

place in the evaporator.

To that end, the evaporator is equipped with fins on SOCKET BOLT
M5 X 40 (2 pcs.)
the air side in order to increase the heat transfer
area of the air side and thereby perform excellent EVAPORATION
thermal transfer between the refrigerant and the air. SENSOR

The humidity in the air condenses as the air cools Fig. 25-8 evaporator
down and adheres to the outside of the evaporator
as water drops. The cooling effect deteriorates if
the water drops freeze. Therefore, how to dis-
charge water is an important point.
The amount of refrigerant supplied to the evapora-
tor is controlled by the expansion valve which is de-
scribed in the following. In order to attain proper
control, it is necessary to reduce the pressure drop
of the refrigerant of the evaporator. Accordingly, re-
ducing 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 refrigerant completes va-
porization 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 deterio-
rates the cooling effect, but also damages the com-
pressor valves.
The expansion valve feeds the flowing high-pres-
sure high-temperature liquid refrigerant to the
evaporator as low-pressure low-temperature liquid
refrigerant (damp vapor of low dryness). The ex-
pansion valve controls the feed rate of the refriger-
ant at the same time.

25-12
 25. AIR-CONDITIONER SYSTEM

Fig. 25-9 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 tempera-
ture at the outlet of the evaporator.
The diaphragm contains R134a in saturated REFRIGERANT
EVAPORATOR OUTLET
state. The pressure in the diaphragm changes
according to the temperature detected by the SIDE

sensor. The change in the pressure causes the SHAFT

force acting upon the diaphragm to vary accord-
ingly.
The high-pressure high-temperature liquid refig-
REFRIGERANT
erant that is fed from the receiver side reduces INLET
the pressure abruptly as it passes through the
valve (throttling action). On that occasion, part of BALL
the refrigerant evaporates by the heat of the re- BALVE
SPRING
frigerant and cooled off. The result is that low-
pressure low-temperature damp refrigerant va- Fig. 25-9 Block type expansion valve
por is fed to the evaporator.
The opening of the valve is determined by the
equilibrium between the pressure (low) of the
evaporator side, the action of the adjust spring
and the pressing force of the diaphragm (the
temperature of the refrigerant at the outlet of the
evaporator to be sensed by the thermowell). The
feed rate is controlled automatically so that un-
der the pressure in the evaporator, the refriger-
ant is properly overheated (3~8°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 re-
frigerant. For this reason, the smaller the pres-
sure 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. 25-10 Expansion valve outside view
securely. The air-conditioner of this machine
adopts a block type expansion valve.

25-13
25. AIR-CONDITIONER SYSTEM

(3) Compressor (See Fig. 25-11)

D HOSE
The compressor performs the following three func-
tions in the cooling circuit:
1) Suction action
S HOSE
2) Pumping action
3) Compressive action
1) The suction action, as combined with the throt-
tling action, works to decrease the refrigerant
pressure in the evaporator. This permits the re-
frigerant to vaporize at low temperature in order
to perform cooling effect.
2) The pumping action serves to cause all the re-
frigerant to circulate in the cooling circuit. This
enables continuous cooling.
3) The compressive action, as combined with the Fig. 25-11 Compressor
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. 25-12)
This is a heat exchanger that cools the vaporized
refrigerant at high temperature and high pressure
by the use of outer air and condenses the refriger-
ant. 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 com-
partment can not be cooled sufficiently by the evap-
orator. For that purpose, it is necessary to secure
ventilation required for cooling of the refrigerant.

Fig. 25-12 Condenser

25-14
 25. AIR-CONDITIONER SYSTEM

(5) Receiver Dryer (See Fig. 25-13) REFRIGERANT SIGHT GLASS

1) Receiver Tank INLET
On the air-conditioner, the revolution of the com- REFRIGERANT
pressor varies greatly which cause the proper OUTLET
flow of refrigerant in the cooling circuit to vary. It
is the receiver tank that receives the variations.
When the cooling circuit the variations. When the
cooling circuit does not need much refrigerant,
the receiver tank stores extra refrigerant tempo-
rarily and supplies it when the cooling circuit
PRESSURE SWITCH
needs much refrigerant. The 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 deterio-
rates the compressor valves and oil, corrodes DESICCANT
the metallic parts of the circuit or clogs the circuit
as the water freezes in the expansion valve. It is SUCTION PIPE
desirable that the amount of water mixed in the
refrigerant should be held below a concentration
of 30 ppm. The air-conditioner uses a molecular
sieve as desiccant suited for the circuit, in order FILTER
to absorb water content that intrudes into the cir-
cuit when the dryer is installed or when refriger-
ant is charged.
3) Sight Glass
This is a window with which the refrigerant level
in the circuit is determined, the only means of RECEIVER TANK
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 cut-
ting off the power supply to the compressor when Fig. 25-13 Receiver dryer
high pressure increases abnormally high [more
than 3.1 MPa (460 psi)].
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 0.2 MPa (28 psi).

25-15
25. AIR-CONDITIONER SYSTEM

25.4 DISASSEMBLY AND ASSEMBLY

25.4.1 PRECAUTIONS TO BE EXERCISED IN OPERATION
(1) Special Refrigerator Oil
Pipe Joints 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, D hose and condenser 19.6~24.5 (14~18)
the following points must be noted: L hose and condenser 11.8~14.7 (8.7~11)
1) Keep open all pipe connections on a new com- L hose and receiver dryer
7.8~11.8 (5.8~8.7)
pressor and the component parts of the installed (M6 bolt)
refrigeration circuit. L hose and air-conditioner unit 11.8~14.7 (8.7~11)
(Remove valves and caps at the pipe openings S hose and air-conditioner unit 29.4~34.3 (22~25)
of the compressor, just before connecting popes. Inlet of expansion valve 11.8~14.7 (8.7~11)
If you have removed a pipe joint for repair, put a Outlet of expansion valve 19.6~24.5 (14~18)
cap to both ports immediately). Pressure sensing part of
6.9~8.8 (5.0~6.5)
expansion valve
2) Use care so SP20 does not adhere to the paint-
ed surface and resin parts. In case SP20 has ad-
hered to such surfaces, wipe it off immediately.
Screws and Bolts Unit : N·m (lbf·ft)
(2) The receiver dryer is filled with desiccant to absorb
moisture in the circuit. Therefore, remove the valve Screw Size Tightening Torque
at the pipe port immediately before connecting N4, T4, machine screw, M4 0.78~1.18 (0.58~0.87)
pipes. N5, T5, machine screw, M5 1.96~2.45 (1.4~1.8)
(3) Tightening Torque M6 (mounting part of
7.85~11.8 (5.8~8.7)
L hose joint)
1) Pipe Joints (See the table "Pipe Joints" to the
M6 (except mounting part of
right.) 9.8~11.8 (7.2~8.7)
L hose joint)
When connecting pipe joints, coat the O ring with
M8 (mounting parts of
special oil (SP20) and fasten to the tightening 19.6~24.5 (14~18)
S,D hose joints)
torque indicated in the table, using a double M8 (mounting part of A/C unit) 9.8~11.8 (7.8~8.7)
spanner. M8 (other than those
1.18~15.7 (8.7~12)
2) Screws and Bolts (See the table "Screws and mentioned above)
Bolts" to the right.) N10 39.2~53.9 (29~40)
(4) Amount of Oil for Compressor (See the table
"Amount of Oil for Compressor" to the right.)
The compressor SD7H (HD type) is filled with Amount of Oil for Compressor
135cc (8.2 cu-in) of oil. If the oil volume is small,
Part to be Replaced Amount to be filled in
seizure at high revolution and shortening of service
life will occur. If the oil volume is large, the cooling Evaporator 40 cc (2.4 cu•in)
Condenser 40 cc (2.4 cu•in)
ability will be deteriorated.
Drain out the volume of oil left in
Once the air-conditioner is operated, part of the oil
Compressor compressor to be replaced, from
is dispersed in the refrigeration circuit. Therefore,
the new cpmpressor.
when replacing the parts in Table 4, adjust the oil
level to that of table.
(5) Before performing operation, stop the engine and
turn off all power supplies to the equipment related
to the air-conditioner.
(6) After the operation is over, confirm that all faults
have been repaired completely, by operating the
air-conditioner.

25-16
 25. AIR-CONDITIONER SYSTEM

25.4.2 REMOVAL AND INSTALLATION OF THE UNIT

(1) Removing the blower unit
1) Remove the connectors connected to the inner/
INNER / OUTER
outer air select motor actuator, the blower motor AIR MOTOR
and the blower controller. Also remove the har- ACTUATOR
CONNECTOR
ness from the blower casing.

HARNESS

EVAPORATOR
SENSOR BLOWER
CONTROLLER BLOWER MOTOR
CONNECTOR
CONNECTOR CONNECTOR

Fig. 25-14
2) Draw out the inner air filter from the intake cas- INTAKE
ing. Remove four cross-recessed screws T5 X INNER AIR FILTER CASING
MOUNTING
14 (T1) from the top of the intake casing, using a SCREWS
screwdriver. Then remove the intake casing. (4 pcs.)

3) Remove three cross-recessed screws T5 X 14 INTAKE

(T1) fastening the blower casing with the unit CASING
casing. Then separate the blower unit from the BLOWER
air-conditioner unit. CASING
MOUNTING
SCREWS
(3 pcs.)

UNIT BLOWER
CASING

Fig. 25-15
(2) Replacing the blower motor
BLOWER CASING
1) Disconnect the cooling hose that is connected
between the blower motor and the blower cas-
ing.
2) Remove three cross-recessed screws N5 X 16
(W) fixed from the bottom of the blower unit cas-
BLOWER MOTOR
ing. Then draw out the blower motor.
BLOWER
• Do not separate the fan from the blower mo-
CONTROLLER
tor.
COOLING HOSE
3) Assembly is the reverse order of disassembly.
(3) Replacing the blower controller BLOWER MOTOR
1) Remove two cross-recessed screws T4 X 14 BLOWER MOTOR
MOUNTING
(T1) fixed from the bottom of the blower unit cas- BLOWER
CONTROLLER SCREWS (3 pcs.)
ing and draw out the blower controller. MOUNTING
2) Install a new blower controller in the reverse or- SCREWS (2 pcs.)

der of removal. Fig. 25-16

• Do not disassemble the blower controller in
any circumstances.

25-17
25. AIR-CONDITIONER SYSTEM

(4) Removing the heater core

1) After discharging the cooling water, disconnect
the heater hose from heater core.
HEATER CORE
2) Remove one cross-recessed screw N5 X 16 (T2)
each for the AHC bracket fixing the heater core PIPE CLAMP
to the unit and for the pipe clamp. Then remove
the AHC bracket and the pipe clamp and draw
PIPE CLAMP
out the heater core from the unit casing. MOUNTING
SCREW (1 pc.)
3) Assembly is the reverse order of disassembly.
AHC BRACKET AHC MOUNTING
SCREW (1 pc.)

Fig. 25-17
(5) Removing the upper and lower parts of the air-con-
ditioner unit casing.
1) Draw out the connectors for the mode motor ac-
tuator and the evaporation sensor.
ROD 120
2) Separate the rod 120 from the rod holder that is REAR OF
UNIT CASING
fixed to the lever MAL1 on the mode motor actu- ROD HOLDER
ator. MOUNTING SCREW

3) Remove three cross-recessed screws N4 X 22 LEVER MAL1

BOTTOM OF
(T2) fastening the mode motor actuator that in- MOUNTING UNIT CASING
SCREW
stall the bottom of the unit casing to the back of
MOUNTING MODE MOTOR
the unit casing. Then separate the mode motor SCREW ACTUATOR
actuator.
4) Remove eleven cross-recessed screws N5 X 16 Fig. 25-18
(T2) that install the bottom of the unit casing to
the top of the unit casing.
TOP OF
Draw out the top of the unit casing upwards, us- UNIT CASING
ing care so the evaporator sensor cord is not ar-
rested by the casing.
• On that occasion, do the work with the heater
core off the unit casing. EVAPORATOR ASSY
EXPANSION
VALVE
EVAPORATION
SENSOR

BOTTOM OF
UNIT CASING

TOP / BOTTOM
UNIT CASING
MOUNTING
SCREWS (11 pcs.)

Fig. 25-19

25-18
 25. AIR-CONDITIONER SYSTEM

(6) Replacing the evaporator and the expansion valve

1) Remove the evaporator assy from the bottom of EVAPORATOR
the casing, together with the casing insulator and
the expansion valve.
2) Remove the upper and lower casing insulators
O-RING EXPANSION
from the evaporator assy and draw out the evap- VALVE
orator sensor with the sensor holder.
3) Remove the socket head cap screws M5 X 40 (2 SOCKET HEAD
CAPSCREW
pcs.) from the evaporator. Then separate the ex- M5 X 40 (2 pcs.)
pansion valve from the evaporator.

: 4 mm
EVAPORATION SENSOR
4) Attach O-rings (NFO-ring 5/8 and 1/2, one piece
each) to a new evaporator. Then install the ex- Fig. 25-20
pansion valve to it.

: 4 mm
Tightening torque 6.8 N•m (5.1 lb•ft)
• When attaching O-rings, use care so the O-
rings are not caught. 3rd row

(7) Installing the evaporator sensor

Install the evaporation sensor as shown in Fig. 5th and
6th rows
25-21.
• When installing the casing, exercise care so 13th and 14th rows
the sensor cord is not caught by the casing.
EVAPORATION SENSOR

Fig. 25-21
(8) Replacing the motor actuator
1) Replacing the mode motor actuator
Remove the connector fixed to the motor actua-
tor.
ROD 120
Remove the rod 120 linking the motor actuator REAR OF
UNIT CASING
with the mode cam, from the rod holder. ROD HOLDER
Remove three cross-recessed screws T4 X 14 MOUNTING
SCREW
(T1) fixing the motor actuator. Separate the mo- LEVER MAL1
tor actuator from the unit, together with the rod BOTTOM OF
MOUNTING UNIT CASING
holder and the lever MAL1. Remove the rod SCREW
holder and the lever MAL1 from the motor actu- MOUNTING MODE MOTOR
ator and install them to a new motor actuator. As- SCREW ACTUATOR
sembly is the reverse order of disassembly.
Fig. 25-22

25-19
25. AIR-CONDITIONER SYSTEM

2) Replacing the air mix motor actuator LEVER AM ROD 67

Disconnect the connector connected with the ROD HOLDER
motor actuator. LEVER MAL1
Separate the rod 67 linking the motor actuator AIR MIX MOTOR
ACTUATOR
with the lever AM, from the rod holder.
Remove three cross-recessed screws T4 X 14
(T1) fastening the motor actuator. Then remove
the motor actuator with the rod holder and the le-
ver MAL1, from the unit. Remove the rod holder
and the lever MAL1 from the motor actuator and
install them to a new motor actuator. Assembly is Fig. 25-23
the reverse order of disassembly.
3) Replacing the inner/outer air select motor actua-
tor
Disconnect the connector connected with the
motor actuator. LEVER MAL2
Separate the motor actuator with lever MAL2
from the unit.
Remove the lever MAL2 from the motor actuator
and install it to a new motor actuator, in the re-
INNER / OUTER AIR
verse order of disassembly. MOTOR ACTUATOR

Fig. 25-24

25-20
 25. AIR-CONDITIONER SYSTEM

25.5 CHARGING REFRIGERANT

25.5.1 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.

• Always 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) Hold 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. Therefore, never bring the can
close to a fire.
4) The inside of the closed compartment gets very hot as the radiation heat of the sunlight enters the compart-
ment. The areas of the compartment which are exposed to direct sunlight may rise to a dangerous temper-
ature level. Therefore, do not bring the can into the compartment. Also, the inside of the trunk room may rise
to a dangerous temperature level even in the summer time. Use sufficient care, therefore, taking the above
into account.
5) Note that if the can has scratches, marks and distortion, the strength of the can will deteriorate.
1. Do not drop or knock on the can.
2. When transporting, loading or unloading cans and packages containing cans, do not throw or drop them.
6) Store cans beyond the reach of children.
(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
Re-use 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.

25-21
25. AIR-CONDITIONER SYSTEM

25.5.2 OPERATING PROCEDURE

(1) Refrigerant charge into the air-conditioner consists mainly of "vacuum making operation" and "gas charge oper-
ation".
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 cir-
cuit, make vacuum and allow the water in the circuit to boil and vaporize. Water in the circuit is thus elimi-
nated.
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 lubricat-
ing 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 mim. for five minutes
Begin vacuum Stop vacuum Check Fill in Check for Fillin
making making air-tightness refrigerant gas leak refrigerant
Less than
-750mmHg

Gauge reading
wrong
Charge liquid gas to a gauge
Check and correct joints
pressure of 0.1 MPa (14 psi)
(3) Tools
Table 25-1
No. Part name Q'ty Sketch Service No. Part name Q'ty Sketch Service
Low pressure
4 Quick joint 1
Gauge man- side
1 1
ifold For service
5 T joint 1
can valve
Red: high
pressure side
Charging Blue: low pres- Service can For service
2 3 6 2
hose sure side valve can
Yellow: vacu-
um pump side

Vacuum
For vacuum
3 Quick joint 1 7 pump adapt- 1
pump
er

25-22
 25. AIR-CONDITIONER SYSTEM

25.5.3 CHARGING PROCEDURE

25.5.3.1 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
GAUGE GAUGE MANIFOLD
pressure valve (LO) of the gauge manifold.
(CLOSED)LOW
2) Connect the charging hoses (red and blue) with HIGH PRESSURE
PRESSURE VALVE
VALVE (CLOSED)
the service valves of the compressor.
BLUE RED
Red hose:
High pressure side (HI) of the gauge manifold → HIGH
PRESSURE YELLOW
high pressure side (DIS) of compressor SIDE
DIC
Blue hose:
LOW
Low pressure side (LO) of gauge manifold → low PRESSURE
pressure side (SUC) of compressor SIDE

COMPRESSOR VACUUM PUMP (STOP)

• Take care so as not to mistake the high pres- Fig. 25-25 Connecting gauge manifold
sure side for low pressure side and push it in till
BLUE
a click is heard.
RED
• Connect the end bent like "L" of the charging
hose with the service valve of the compressor.
CHARGING HOSE
If the charging hose is connected the opposite
way, the mini core valve of the compressor (MINI CORE VALVE)
does not open. (See Fig. 25-26)
Fig. 25-26 Connecting piping with compressor
3) Connect the middle valve of the gauge manifold
with the charging hose of the vacuum pump.

Some kinds of gauge manifolds are not equipped

with an open/close valve in the center.

25-23
25. AIR-CONDITIONER SYSTEM

(2) Vacuum Making (See Fig. 25-27.)

1) Open the high pressure valve (HI) and the low
pressure valve (LO) of the gauge manifold.
2) Turn on the switch of the vacuum pump and
make vacuum for more than 30 minutes. 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 pres-
sure valve of the gauge manifold.
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
than five minutes and make sure that the gauge in-
dication does not return toward zero.
Fig. 25-27 Vacuum making operation

If the gauge indication swings toward zero, there is

somewhere that is leaking. Retighten pipe joints,
make vacuum again and make sure of no leakage.

25-24
 25. AIR-CONDITIONER SYSTEM

25.5.3.2 GAS CHARGING OPERATION

(1) Charging from High Pressure Side (See Fig. 25-
28.)
AIR PURGE
1) After making vacuum repeatedly, change the
CLOSE
charging hose (yellow) of the gauge manifold
RED
from the vacuum pump to the service can.
Open the service can valve. (However, close the OPEN SERVICE CAN VALVE
SCREWDRIVER
high and low pressure valves of the gauge man- OR SOMETHING
ifold.) Then push the mini core valve of the side BLUE YELLOW
service port on the low pressure side of the
gauge manifold, using a screwdriver or some-
thing, in order to let out the air in the charging
Fig. 25-28 Gas charging operation
hose by the pressure of the refrigerant. (See Fig.
25-28.) (The operation ends when a hissing
sound is heard.)
2) Open the high pressure valve of the gauge man- LOW PRESSURE
VALVE (CLOSE) HIGH PRESSURE VALVE
ifold and charge in refrigerant. [Charge in gas- (OPEN) (CLOSE)
eous refrigerant to a gauge pressure of 0.1 MPa RED
FILL IN 1~1.5 CANS
(14 psi).] BLUE OF REFRIGERANT
After charging, close the high pressure valve of YELLOW
the gauge manifold and the service can valve.
(See Fig. 25-29.)
SERVICE CAN
VALVE
(OPEN) (CLOSE)
CHARGE

• Do not run the compressor in any case, (Other-

wise the refrigerant flow in reverse direction Fig. 25-29 Gas charging operation (High pressure
which causes the service can and the hoses to side)
rupture. This is very dangerous.)

(2) Checking for Gas Leakage

Check for gas leakage in the cycle, using a gas leak
detector (electric type). Retighten and correct leak-
ing points.

• Always use R134a for the leak tester. (The pres-

ently used from gas affects the sensitivity ad-
versely.)

25-25
25. AIR-CONDITIONER SYSTEM

(3) Charging from Low Pressure Side (See Fig. 25-30.)

1) Make sure that the high-pressure and low-pres-
HIGH PRESSURE
sure valve of the gauge manifold and the service LOW PRESSURE VALVE (CLOSE)
can valve are closed. VALVE (MUST BE CLOSED
(OPEN) (CLOSE) POSITIVELY)
2) Start the engine and run the revolution to 1500 RED
WHEN AIR BUBBLES
±100 rpm and fully close the cab door and the IN THE SIGHT GLASS
windows. DISAPPEAR YELLOW
3) Turn on the air-conditioner switch to Max and the BLUE
temperature control switch to cool Max. SERVICE CAN
VALVE (OPEN)
4) When charging gas, set the discharge pressure
of the compressor to 1.37~1.57 MPa (200~230
psi).
COMPRESSOR
5) Open the low pressure valve of the gauge mani- OPERATION SERVICE CAN
fold and the service can valve and fill in refriger- (DO NOT TURN IT OVER)
ant till air bubbles of the sight glass of the Fig. 25-30 Gas charging operation
receiver go away. (See Fig. 25-7.) (Low pressure side)
[Total amount of gas to be charged : 900~950 g
SIGHT GLASS
(1.8~1.9 lbs)]
6) When refrigerant charge is over, close the low
pressure valve of the gauge manifold and the
service can valve.

• Do not open the high pressure valve of the

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

25-26
 25. AIR-CONDITIONER SYSTEM

(4) Criterion for Checking the Amount of Refrigerant Judgment of refrigerant level through the sight glass
Filled in of receiver dryer
Refrigerant volume Description

(A) Proper

• If the air-conditioner is run with scant refriger- After the air conditioner is turned ON, little
ant R134a, it has adverse effect on the compres- bubbles appear. The refrigerant becomes
transparent, then turns a light milky white.
sor.
(B) Overcharged
• If the refrigerant is charged too much (over-
charged), the cooling performance is deterio-
After the air conditioner is turned ON, no
rated. Moreover, the circuit pressure gets bubbles appear.
abnormally high : Always keep a proper level. (C) Insufficient

(5) Detaching Gauge Manifold

When the refrigerant level has been checked, dis- After the air conditioner is turned ON,
bubbles appear continuously.
connect the charging hoses from the compressor in
the following manner : Bubbles : Refrigerant gas is mixed with
refrigerant fluid.
1) Press the "L" shape metal fitting of the charging
hose (blue) on the low pressure side against the No Bubbles : Whole refrigerant becomes fluid
service valve of the compressor so the refriger- and transparent.
ant does not leak out and loosen the nut. As soon
as the nut has been removed, disconnect the Cloudy : Refrigerant is separated from oil.
The fluid becomes a light milky
charging hose from the service valve.
white.
2) Leave the high pressure side as it is till the high
pressure gauge reading falls. [below 0.98 MPa
(140 psi)].
3) Disconnect the charge hose (red) on the high
pressure side the same way as on the low pres-
sure side.

25-27
25. AIR-CONDITIONER SYSTEM

25.6 ELECTRIC CIRCUIT

25.6.1 WIRING DIAGRAM AND CONNECTORS

Fig. 25-32 Electric diagram (1/2)

25-28
 25. AIR-CONDITIONER SYSTEM

Fig. 25-33 Electric diagram (2/2)

25-29
25. AIR-CONDITIONER SYSTEM

25.6.2 INSPECTING FUNCTIONAL PARTS

(1) Relay (24-4PE)
1) Coil resistance : 320 (across 1 and 2)
2) Operating voltage : DC20~30V
3) The coil of the relay has polarity : Care is need- As viewed from A
ed.
4) Turn on and off the power to the blower motor by
controlling the controller.
5) Check : Check conductance across 3 and 4 in
the following condition :
Apply 20~30V across terminals 1 and 2 : contin-
ue
No voltage applied across terminals 1 and 2 : dis-
Fig. 25-34 Relay
continue
(2) Inner air sensor (C44)
Resistance across terminals :
at 0°C (32°F) : 7.2 K 1/2
at 25°C (77°F) : 2.2 K 1/2
The inner air sensor is installed to the sensor brack-
et under the operator's seat. The temperature in the
cab is sensed by the thermistor. Changes in the re-
sistance according to temperature variations are
transmitted to the controller.
Fig. 25-35 Inner air temperature sensor
(3) Blower controller
The blower controller changes output voltages for
the motor according to signals emitted by the con-
troller.

Fig. 25-36 Blower controller

(4) Motor actuator
1) Operating voltage : DC20~30V
2) Operating temperature range : -30°C (-22°F) to
+75°C (167°F)
The motor is controlled by signals (pulses) put
out by the controller.

Fig. 25-37 Motor actuator

25-30
 25. AIR-CONDITIONER SYSTEM

(5) Pressure Switch (Attached to Receiver Dryer) PRESSURE SWITCH

1) Contents of checking (specification)
Low pressure side OFF pressure :
0.2 ± 0.02 MPa (28 ± 3 psi)
Low pressure side return pressure :
OFF pressure + 0.03 MPa (4.3 psi) or below
High pressure side OFF pressure :
3.1 ± 0.2 MPa (455 ± 28 psi)
High pressure side return pressure :
OFF pressure -0.59 ± 0.02 MPa (-85 ± 2.8psi)

Fig. 25-38 Pressure switch

LOW PRESSURE RETURN HIGH PRESSURE RETURN MPa (psi)

(26) (30) (31) (36) (310) (430) (480)
0.18 0.21 0.22 0.25 2.16 2.94 3.33

LOW PRESSURE OFF HIGH PRESSURE OFF

2) Performance
Low pressure side :
To prevent actuation of the compressor clutch
where refrigerant is deficient
High pressure side :
To prevent actuation of the compressor clutch
where pressure rises abnormally because of the
clogging of the refrigeration circuit, etc.
(6) Thermistor (C19)
1) Contents of checking (specification)
Resistance across terminals
at 0°C (32°F) : 7.2 K1/2
at 25°C (77°F) : 2.2 K1/2

Normally check that there is no shortcircuit or discon-

Fig. 25-39 Thermistor
nection.

2) Performance
In order to prevent freezing of the evaporator, the
blowoff air temperature of the evaporator is con-
trolled by turning the compressor clutch ON and
OFF. The thermistor operates as the sensor of
the control.

25-31
25. AIR-CONDITIONER SYSTEM

25.7 TROUBLESHOOTING
[ Temperature does not fall. ] Note) M/A : Motor actuator

If A/C switch is pushed, "HL.E" is indicated on the set temp. display of the panel.

NO YES

Connector for air mix M/A is

*
"HL. " is shown on the set temp. display of the panel.
disconnected or in poor contact.
Note) is any of the
NO YES *numbers 0 ~ 9. M/A is broken.
Main harness shows poor conductance.
** E on display.
A snow mark on the A snow mark on panel is flickering.
panel is flickering. Inspect and correct or replace parts.

NO YES NO YES

Inner air sensor or harness Both inner air sensor and

is disconnected or shorted. evaporation sensor are
Inner air sensor connector is disconnected or sohrted.
disconnected or in poor contact. Controller failed.

Inspect and correct or replace parts.

Blowout temp. falls if temp. is set

Evaporation sensor connector
at 18.0 (64.4 F) (COOLMAX) and the
is disconnected or in poor contact.
blowout mode is changed to vent mode.
Evaporation sensor is
NO YES disconnected or sohrted.

*1 Air mix damper is

in COOLMAX.
Chilly air flowing
into inner air sensor
Inspect and correct or replace parts.

NO YES NO YES

If M/A is at stop Turn compressor clutch Controller is faulty Inspect duct or

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

Inspect, correct or replace M/A is faulty or controller

M/A lever link. is out of order.
After cleaning lever link,
apply grease.
Replace.

25-32
 25. AIR-CONDITIONER SYSTEM

[ Temperature does not rise. ]

HL.E is shown on the set temp. display of panel.

NO YES

*
"HL. " is shown on the set temp. display of the panel. Note)
* is any of the numbers 0 ~ 9
NO YES

*2Blowout temp. rises at blowout Inner air sensor or harness

mode if temp. is set at is disconnected or shorted. Air mix M/A connector is off.
HOTMAX 32.0 C (89.6 F). Inner air sensor connector M/A is broken.
is off or in poor contact. Main harness shows
poor continuity.

Inspect and correct or replace parts.

Inspect and correct
NO YES
or replace parts.

*2 Air mix damper is Warm air is flowing into

at HOT MAX. inner sensor.

NO YES
NO YES
If M/A action is at Inspect warm water piping.
stop, eliminate cause, Controller or Inspect duct or
correct and measure inner air sensor eliminate causes
operating force. is out of order. for warm air entry.
(less than 1.5kgf : OK)
Inspect and replace.

NO YES

Inspect, correct or M/A failed or controller *2 : HOT-MAX

replace M/A lever link. is out of order. operating condition.
Clean lever link and apply grease.
Replace.

25-33
25. AIR-CONDITIONER SYSTEM

[ Blower motor does not run. ]

At air flow HI, battery voltage acts across Note) Measure with
both terminals (+) and (-) of blower motor. connector set.

NO YES

Battery voltage acts across red Blower motor fails.

(+) and body of blower motor.

Replace.
Note 1) Always turn off air- NO YES
conditioner, starter
key switch and light
switch before work.

Inspect blower motor relay. Approx. 10V acts across

Note 1 Blower motor rotates if white / blue / black (0.85) and
green (2.0) and red of blower earth of blower amplifier.
motor relay are direct connected.
NO YES
NO YES
Controller is out of order.

Wire harness is Battery voltage acts across Remove blower amplifier and check for
faulty. Inspect white / green (0.85) and continuity across blue / black (0.85)
and correct or replace. body of blower motor relay. and black wires ; you get continuity.

NO YES NO YES

Inspect and repair Blower turns if Eliminate cause Inspect and

harness or replace. brown / red of and replace repair
blower motor blower amplifier. harness.
relay is connected
with earth.

NO YES

Replace relay. Inspect and correct harness

or replace controller.

[ Blower motor speed does not change. ]

HL. Note) is any of the

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

NO YES

Air flow rate is constant regardless of readings. Inner air sensor and harness
are disconnected or shorted.
Inner sensor connector is
disconnected or in poor contact.
Replace blower
amplifier or controller. Inspect and correct or replace parts.

25-34
 25. AIR-CONDITIONER SYSTEM

[ Magnet clutch does not engage. ]

Snow mark lights if A/C switch is pressed

NO YES

Snow mark flickers and E is Voltage acts upon clutch.

shown on panel display.
NO YES

to B Terminal voltage present across Clutch faulty.

pressure switch harness.

NO YES Replace compressor.

Voltage acts across red and Pressure switch is faulty or gas

blue terminals of connector is under charged or overcharged.
connected to excavator.

NO YES

Inspect air-conditioner Inspect air-conditioner

and vehicle connector. harness. No fault.
Also clutch fuses.

NO YES

Replace harness. Replace controller.

[ Inner air and outer air do not change over. ]

Inner / outer air mode display on

operation panel is flickering.

NO YES

M/A lever includes Connector of inner/outer air M/A is

foreign matter disconnected or in poor contact.
or is broken. Or M/A failed or main harness failed.

NO YES
Inspect or replace.

M/A failed Remove foreign matter

and replace parts.

Replace

25-35
25. AIR-CONDITIONER SYSTEM

[ Modes do not change. ]

Mode display on operating

panel is flickering.

NO YES

M/A rod is linked. Mode M/A connector is not linked or

in poor contact or M/A failed or main
harness is faulty.
NO YES

Inspect or replace.
Repair. Each damper lever is linked.

NO YES

When rod is removed and cam is operated

Repair. by hand, it is heavy. (more than 2kgf.)

NO YES

M/A or controller is out of order. Cam or damper shaft includes

forein matter or is broken
Erroneous motion occurs due to
Repair. dirty grease.

Remove foreign matter or replace parts.

Clean cam and apply new grease.

25-36
 25. AIR-CONDITIONER SYSTEM

[ Trouble with refrigeration cycle. ]

Both high and low pressures are lower. Low pressure is lower.

Air bubbles are seen in sight glass. Air bubbles are High pressure
seen in sight glass. is lower.
NO YES

Cooling does not work Oil oozes out from Compressor Hot air Compressor
if run at high speed. piping and parts. cylinder does comes out of cylinder gets
not get hot. heater unit. very hot.
NO YES NO YES

Expansion Expansion Natural Gas leaks Expansion Water cock Compressor

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

Adjust or After making Charge gas. Retighten Replace Adjust or Replace

replace vacuum, refill or replace expansion replace compressor.
expansion refrigerant parts. valve. water cock.
valve. and replace
receiver.

High pressure is lower. If system is run continuously in HI idle,

it does not cool down or air flow decreases.

Air bubbles are seen in sight glass. Frost deposits.

NO YES

High pressure gets Condenser is Thermistor does

lower gradually. fouled or clogged. not cool off.

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

Remove Clean Air is mixed. Functions and Thermistor Thermistor Air

clogging condenser. Make vacuum performances is faulty or position is leaks
or replace and refill are normal. cord is faulty. out of
parts. refrigerant. Familiarize disconnected. Correct casing.
the user with position.
how to use it.

25-37
25. AIR-CONDITIONER SYSTEM

[MEMO]

25-38
 31. GENERAL DISASSEMBLY AND
ASSEMBLY
TABLE OF CONTENTS

31.1 GENERAL DISASSEMBLY AND ASSEMBLY .................................................................... 31-3

31.1.1 CONTENTS OF GENERAL DISASSEMBLY AND ASSEMBLY ................................. 31-3
31.1.2 SPECIFICATION OF TIGHTENING TORQUE .......................................................... 31-3

31

31-1
31. GENERAL DISASSEMBLY AND ASSEMBLY

31-2
 31. GENERAL DISASSEMBLY AND ASSEMBLY

31.1 GENERAL DISASSEMBLY AND ASSEMBLY

31.1.1 CONTENTS OF GENERAL DISASSEMBLY AND ASSEMBLY
This chapter is consist of three sections as follows.
(1) ATTACHMENT ............................................................................................................Index No. : 32
Part I : Removing and Installing Assembly
Part II: Disassembling and Assembling Components
1) Hydraulic cylinder
(2) UPPER SLEWING STRUCTURE.................................................................................Index No. : 33
Part I : Removing and Installing Assembly
Part II: Disassembling and Assembling Components
1) Hydraulic pump
2) Control Valve
3) Pilot Valve (ATT)
4) Pilot Valve (Travel)
5) Slewing Motor
6) Swivel Joint
(3) TRAVEL SYSTEM .........................................................................................................Index No. : 34
Part I : Removing and Installing Assembly
Part II: Disassembling and Assembling Components
1) Travel Motor

31.1.2 SPECIFICATION OF TIGHTENING TORQUE

Tightening torque is indicated as follows, for example;
T=100N•m (73.8 lbf•ft)
Tolerance is ± 10% unless otherwise specified.
• Refer Index No. 11 TOOLS for standard tightening torque.

31-3
31. GENERAL DISASSEMBLY AND ASSEMBLY

[MEMO]

31-4
 32. ATTACHMENTS
TABLE OF CONTENTS

32.1 REMOVING AND INSTALLING ......................................................................................... 32-3

32.1.1 ATTACHMENT AND COMPONENT ......................................................................... 32-3
32.1.2 BUCKET ................................................................................................................... 32-4
32.1.3 ARM .......................................................................................................................... 32-7
32.1.4 BOOM ....................................................................................................................... 32-9
32.1.5 SWING ..................................................................................................................... 32-14
32.1.6 DOZER ...................................................................................................................... 32-16
32.2 DISASSEMBLING AND ASSEMBLING ............................................................................ 32-17
32.2.1 CYLINDER ................................................................................................................ 32-17

32

32-1
32. ATTACHMENTS

PREFACE
(1) This Manual covers all the procedures from removing to attaching, arranging them by item.
(2) This manual consists of first part; 32.1 REMOVING AND INSTALLING, and second part; 32.2 DISASSEMBLING
AND ASSEMBLING.
(3) The removing and installing can be performed in the procedure specified in Table of Contents, but in view of
actual repairing or time saving some process can be omitted.
(4) The removing and Installing procedure does not completely cover all possible situations because of differences
of field condition and defective section.
(5) Please be aware that the procedure to be followed must be determined according to the above conditions.
When disassembly and assembly are required, select the necessary section, itemize the work contents with
good understanding, then start working.

32-2
 32. ATTACHMENTS

32.1 REMOVING AND INSTALLING

32.1.1 ATTACHMENT AND COMPONENT

SWING CYLINDER ROD PIN (M) SWING CYLINDER HEAD PIN (N)

BOOM CYLINDER HEAD PIN (B)

BOOM CYLINDER ROD PIN (C) SWING CENTER PIN (UPPER) (L1)
ARM CYLINDER HEAD PIN (D) BOOM INSTALL
(FOOT) PIN (A)
BOOM TOP PIN (F)

IDLER LINK BUCKET CYLINDER

ROD PIN (H) SWING CENTER PIN (LOWER) (L2)
PIN (I)
BUCKET ATTACHING BUCKET DRIVE PIN (J)
PIN (K)
BUCKET CYLINDER
ARM CYLINDER HEAD PIN (G)
ROD PIN (E)

DOZER CYLINDER ROD PIN (Q)

DOZER CYLINDER HEAD PIN (R)

DOZER PIN (P)

Fig. 32-1 Front attachment and position

32-3
32. ATTACHMENTS

32.1.2 BUCKET

32.1.2.1 REMOVING BUCKET

(1) Put the machine in position to remove bucket.

Fig. 32-2 Position to remove bucket

(2) Removing pin (2)
Expand slit of ring (1) with driver, and remove it.
Push out the pin (2) with driver (–).

SECTION AA

Fig. 32-3 Removing pin (2)

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

Fig. 32-4 Removing bucket attaching pin

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

Fig. 32-5 Removing bucket drive pin

32-4
 32. ATTACHMENTS

32.1.2.2 ATTACHING BUCKET

(1) Attaching bucket drive pin (J)
Attach bucket drive pin (J) first, then continue in the
reverse procedure of the pulling out.

• When aligning the pin holes, do not put your fin-

ger in the pin holes in any circumstances, but
align them visually.
• Check that the seals are not scored and replace
a faulty one if necessary.
• When inserting the pin, coat the shaft with
grease.
Fig. 32-6 Attaching bucket

32-5
32. ATTACHMENTS

32.1.2.3 PROCEDURE FOR ADJUSTING CLEARANCE

Adjustment of clearance between bucket and arm
1) Shift O-ring (3) toward the bucket boss, using a
spatula. (a→b)
2) When adjusting clearance (B), bring the non-ad-
justing side of the bucket in contact with the arm.
3) Measure clearance (B) and check that it is within
1.0 mm (0.04 in).
4) Adjust clearance (B) where it is more that 1.0
mm (0.04 in).
5) An average of 5 shims (8) of 1mm (0.04 in) thick-
ness are set in each of the three M12 × 45 bolts
(10). The clearance can be adjusted by 1mm
(0.04 in) if one shim is removed.

: 19 mm
Tightening torque : 59 N•m (43 lbf•ft)
6) After adjustment, tighten the bolts evenly.
• The gap exceeding the specified dimension
causes a rapid progress of wear.
7) Operate the bucket and confirm that the total Fig. 32-7 Adjusting clearance between bucket and
sum of both clearances are within 1.0 mm (0.04 arm
in)
8) Refit O-ring (3) to its original position.

• When shifting O-ring (3) by means of a spatula, use

care so as not to score O-ring (3).
• Remove shims (8), push out bushing (7) rightwards
by means of three bolts (10) and adjust clearance
(B) so it falls within the standard value evenly all
round.
• Check the clearance at 120 hours' intervals in nor-
mal operation. Shorten these intervals in special
hard operation. Adjust the intervals as necessary.

32-6
 32. ATTACHMENTS

32.1.3 ARM

32.1.3.1 REMOVING ARM

(1) Put the machine in position to remove arm. Fold
arm, and the bucket cylinder is retracted and the
arm is put on the ground.

Fig. 32-8 Position to remove arm

(2) Separating piping of bucket cylinder
Release pressure of hydraulic tank, place oil pan to
prepare for oil leaking, and separate pipes.

Plug both section of separated pipes.

Plug : M30

When the removal of bucket cylinder is not required

skip to procedure (6).
Fig. 32-9 Separating piping of bucket cylinder
(3) Removing bucket cylinder rod pin (H) Insert resin shim into bucket link side.
1) Loosen nut (9), remove capscrew M12 × 100 (8), SHIM RESIN SHIM

and push out pin (H). After adjustment of shim, the total gap
should be within 0.6~1.0 mm (0.02~0.04 in).
: 19 mm SHIM

2) Retract cylinder rod.

DUST SEAL
SECTION DD

SHIM RESIN SHIM

Insert resin shim into bucket link side.

Fig. 32-10 Detail of bucket cylinder rod pin (H)

(4) Removing cylinder head pin (G) Insert resin shim into bucket link side.
Loosen nut (3), remove capscrew M12 × 100 (2), SHIM RESIN SHIM
and push out pin (G). After adjustment of shim, the total gap
should be within 0.6~2.0 mm (0.02~0.08 in).
: 19 mm SHIM

SECTION AA
Fig. 32-11 Detail of bucket cylinder head pin (G)

32-7
32. ATTACHMENTS

(5) Removing bucket cylinder

Sling tube of bucket cylinder with nylon sling, and
remove it.
Bucket cylinder weight : 44 kg (97 lbs)

Fig. 32-12 Slinging bucket cylinder

(6) Removing arm cylinder rod pin (E)
Insert resin shim into cylinder side.
Loosen nut (4), remove capscrew (3), and push out SHIM RESIN SHIM
arm cylinder rod pin (E). After adjustment of shim, the total gap
should be within 0.6~2.0 mm (0.02~0.08 in).
: 22 mm
SHIM
Retract arm cylinder rod, and return pin (E) to the
original position (hole).

SECTION BB

Fig. 32-13 Detail of arm cylinder rod pin (E)

(7) Removing boom top pin (F) Insert resin shim into cylinder side.
Loosen remove capscrew (12), and pull out boom SHIM RESIN SHIM
top pin (F).
Put block between arm cylinder and boom. After adjustment of shim, the total gap
should be within 0.5 mm (0.02 in).
: 19 mm
SHIM
Insert pin (F) into the original hole.
(8) Slinging arm assy
Sling arm with nylon sling and remove it.
Arm weight : 200 kg (440 lbs) (with bucket cylinder)
:150 kg (330 lbs) (without bucket cylinder)
SECTION AA

Fig. 32-14 Detail of boom top pin (F)

32-8
 32. ATTACHMENTS

32.1.3.2 ATTACHING ARM

(1) Attaching boom top pin (F)
Attach boom top pin (F) first, and continue in the re-
verse procedure of the removing.

• When aligning the pin holes, do not put your fin-

ger in the pin holes in any circumstances, but
align them visually.
Fig. 32-15 Slinging arm assy
• Check that the dust seals is not scored and re-
place a faulty one if necessary.
• When inserting the pin, coat the shaft with
grease.

32.1.4 BOOM

32.1.4.1 PREPARATION FOR REMOVING AND ATTACHING BOOM

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

WOOD
BLOCK

Fig. 32-16 Position to remove boom

32.1.4.2 REMOVING BOOM

(1) Put the machine in position to remove boom. Place
top end of boom down on block, etc. giving atten-
tion for arm cylinder rod not to be extracted.
(2) Lifting up boom cylinder temporarily
Lift up boom cylinder temporarily to prevent it from
dropping.

Fig. 32-17 Lifting up boom cylinder temporarily

32-9
32. ATTACHMENTS

(3) Removing boom cylinder rod pin (C) Insert resin shim into bucket link side.
Loosen nut (7), remove capscrew (3), and push out RESIN SHIM
IRON SHIM
pin (C).
After adjustment of shim, the total
(4) Preparing for separating cylinder pipes gap should be within 0.6~2.0 mm
(0.02~0.08 in).
Retract boom cylinder rod side, and place one side SHIM
of cylinder on block (See Fig. 32-17)

SECTION AA
Fig. 32-18 Detail of boom cylinder rod pin (C)
(5) Separating piping of arm cylinder and bucket cylin-
der
Release pressure in hydraulic tank, and separate
pipe at section E-E.

: 36 mm
After separation of pipe, plug every pipe.
Plug : M30

SECTION EE

Boom piping separation

32-10
 32. ATTACHMENTS

(6) Lifting up boom assy temporarily

Lift up boom cylinder with nylon sling so that boom
foot pin (A) is not loaded.

Weight of boom assy : 400 kg (880 lbs)

(7) Removing boom foot pin (A)

Total clearance of both sides to be
Remove capscrew (2) for locking boom foot pin (1) 0.1~0.5mm (0.00394~0.0197in) or
and pull out pin (1). less after adjusting by shims.
Apply grease.
1=(A)

3
Fig. 32-19 Details of boom foot pin (A)section

Fig. 32-20 Removing pin (A) using slide hammer

32-11
32. ATTACHMENTS

(8) Slinging boom assy

Sling and remove boom assy.

Weight of boom assy : 400 kg (880 lbs)

(9) Completion of removal of front attachments

When the removing and attaching of cylinder are
not required, the work is finished. Opposing flats 27

(10)Removing arm cylinder A

Opposing flats 27
Disconnect hose at A section, and plug both ends.
Plug 4-1 Opposing flats 36

Opposing flats 36
: 36 mm
Tightening torque : 216 N•m (160 lbf•ft) Insert resin shim
into cylinder side.
RESIN SHIM
: 27 mm IRON SHIM

Tightening torque : 108 N•m (80 lbf•ft)

(11)Removing arm cylinder head pin (D)
Loosen nut (3), remove capscrew (2)and pull out
pin (D)

SHIM
After adjustment of shim, the
total gap should be within
0.6~1.0 mm (0.02~0.04 in)

Fig. 32-21 Removing arm cylinder

32-12
 32. ATTACHMENTS

(12)Removing boom cylinder

Disconnect hose at B section. Plug both ends. Opposing flats 36
plug 4-1

: 36 mm
Tightening torque : 216 N•m (160 lbf•ft)
(13)Removing boom cylinder foot pin (B)
Loosen capscrew (4) and pull out pin (B).
Opposing flats 36

Fig. 32-22 Removing boom cylinder

32.1.4.3 ATTACHING BOOM

(1) Attaching boom foot pin (A)
(A)
Attach it in the reverse procedure of removing pay-
ing attention to the following points.

• When aligning the pin holes, do not put your finger

in the pin holes in any circumstances, but align (B)
them visually.
Fig. 32-23 Boom cylinder head pin (B)
• Check that the dust seals is not scored and replace
a faulty one if necessary. PLASTIC SHIM IRON SHIM

• When inserting the pin, coat the shaft with grease. PIN (B)

• Tightening torque
M10 : 65.7 N•m (48.5 lbf•ft)
• Pin lock nut handling procedure
(0~0.02)
0~0.5

SHIM
Total clearance of both sides to be
• To attach shim, fit resin shim on operating side and 0.6~1.0mm (0.02~0.04in) or less after
CAPSCREW adjusting by shims.
iron shim on the outside, and reduce the space.
Fig. 32-24 Attaching boom cylinder head pin

32-13
32. ATTACHMENTS

32.1.5 SWING

32.1.5.1 REMOVAL OF SWING BRACKET AND CYLINDER

(1) Preparation for removal
1) To make the removing work easy, swing by around 30° for leftward.
2) Remove cover (D1) then disconnect the hoses of bucket cylinder, arm cylinder and boom cylinder, and apply
plugs to all the openings.

: 27 mm

32.1.5.2 REMOVAL OF SWING BRACKET (A9)

(1) Removing the capscrew (C5) that is preventing the rod pin (C1) of swing cylinder (C) from coming out, remove
the pin (C1).

: 19 mm
(2) Install the boom foot pin (D) to the original position on swing bracket (A1), then temporarily lift it up.
(3) Removing two capscrews (E3) those are preventing the pin (E1) (E2) from coming out, remove the pin (E1) (E2).

: 24 mm
(4) Remove the swing bracket (A1).
Weight of swing bracket : 240kg (529 lb)

32.1.5.3 REMOVAL OF SWING CYLINDER (C)

(1) Disconnect 2 connecting hoses for the swing cylinder.

: 22 mm
(2) Removing the capscrew (C5) that is preventing the head side pin (C2) of swing cylinder from coming out, remove
the pin (C2).

: 19 mm
(3) Take out the swing cylinder (C) from the machine front side.
Weight of swing cylinder : 71kg (156 lb)

D1

E1 C5
A1 C1

D E3

E2
C

C2

C5

Fig. 32-25 Parts for swing

32-14
 32. ATTACHMENTS

32.1.5.4 INSTALLATION OF SWING BRACKET AND CYLINDER

Installation is performed in the reverse order of removal, including the following workings.
(1) Check the dust seal for damages, and replace the faulty dust seal to new one.
(2) Referring to the Chapter LF03 "ATTACHMENT DIMENSIONS" replace the worn-out pin and bush to new ones.
(3) Before inserting the pin, apply grease to the shaft area.
(4) Referring to Fig. 32-26, apply Loctite #242 and tighten the capscrew and nuts to prevent the pin from coming out.
(5) Refer to Fig. 32-26 for the shim adjustment at pin installing portion.
(6) For the adjustment for clearance, insert resin shim first, then adjust the clearance with iron shims.

To be face the groove of

washer to the lower side.

B
D D
A

A D D

C C

Clearance to be 0.5mm
(0.0197in) or less after
SECTION C-C adjusting with shims.
Total clearance of both
sides to be 0.5~0.9mm
(0.0197~0.0354in) or less
after adjusting with shims.

(0.04"~0.06")
Total clearance of
3.0 (0.02")

1.0~1.5
both sides to be
0.1~0.5mm
(0.00394~0.0197in)
or less after
adjusting with
SECTION A-A SECTION B-B shims. SECTION D-D

Fig. 32-26 Sectional view of installing pin

32-15
32. ATTACHMENTS

32.1.6 DOZER

32.1.6.1 REMOVAL
(1) Put a support of appropriate height under the
mounting side of dozer body, and make the dozer
at a stable condition not to exert any load to the pin
(P).
(2) Disconnect the hydraulic hose and apply a plug to
the connecting portions.

: 22 mm
(3) Apply a nylon sling to the dozer cylinder (C1), and
R Q C2, C3
lift it up slightly not to exert any load to the Pin (Q)
C1
of rod side.
(4) Remove the capscrew (C2) and nuts (C3) those are
preventing the pin (Q) from coming out. Remove
the pin (Q), and support the cylinder (C1) with wood
block, etc.

: 19 mm
(5) Remove the capscrew (B2) and nuts (B3) those are SUPPORT P B2, B3
preventing the dozer body fixing pin (Q) from com- Fig. 32-27 Removing / Installing dozer
ing out, and remove the two pins (P).

: 19 mm
(6) Gradually move the machine to backward to re-
move the dozer.
Weight of dozer assy

Standard 283kg (624 lb)

With cutting edge 300kg (661 lb)

(7) If necessary, remove the dozer cylinder by means

of removing the pin (R) of head side.
Weight of dozer cylinder : 55kg (121 lb)

32.1.6.2 INSTALLATION
The installation is carried out with the reverse order of
the removal paying attention to the following.
(1) Referring to the Chapter LF03 "ATTACHMENT DI-
MENSIONS" replace the worn-out bushings and
dust seals to new ones.
(2) Before installing pin (P), (Q) and (R), apply grease NUT
to their shaft area. 0.5~1.0
(0.02"~0.04")
(3) Referring to Fig. 32-28, install the nuts for capscrew
STOPPER
to prevent the pin from coming out. CAPSCREW

Fig. 32-28 Tightening proceduers for nuts

: 19 mm

32-16
 32. ATTACHMENTS

32.2 DISASSEMBLING AND ASSEMBLING

32.2.1 CYLINDER

32.2.1.1 PREPARATION BEFORE DISASSEMBLE

Before disassembly, it is necessary to keep a dustfree workshop and facilities.

32.2.1.1.1 WORK AREA

The following working area is required for disassembly :
(1) Ample space
For disassembly of the hydraulic cylinder, the cylinder tube and the piston rod must be extracted. Therefore, the
first prerequisite is that the working area must have sufficient space for such work. It is also necessary that the
space have amply space widthwise to accommodate disassembly, cleaning and measuring facilities.
(2) Suitable working environment
The hydraulic cylinder is a precision-machined product incorporating seals and packings made of rubber and
plastic materials. For this reason, care should be used so that the hydraulic cylinder is free from dust, dirt, sand,
metal chips weld slag and other hard substance. If the hydraulic cylinder is assembled without being aware of
hard particles stuck on the cylinder tube and the piston rod, the tube inner surface and the rod surface may be
scratched as the cylinder operates, thereby disabling it in worst cases. Damage to the piston seals and the rod
seals will result in oil leaks. For this reason, grinding and welding operation should be avoided near the working
area to keep it clean.

32.2.1.1.2 APPARATUS
The following equipment are required for disassembly :
(1) Hoist or crane
The hoist or crane must be capable of carrying the cylinder in an assembled condition. It must also be capable
of marking level and liner movement under load for inserting and extracting the piston rod and the tube.
(2) Work bench
The work bench must have strength and rigidity capable of accommodating the total length of the cylinder in its
most retracted condition and of withstanding the repulsive force of the tightening torques of the cylinder head
and the piston nut. Since a vise is attached to the bench, the width of the work bench must be sufficiently large.
(3) Support stand
If the clevis part of the piston rod is fully extended in a free condition, the bushing and the seals may be damaged
as the rod bushing and the piston are twisted due to the weight of the rod. A stand is required to support the rod
to prevent such.
(4) Hydraulic source
A Hydraulic source is required for disassembly and assembly of the cylinder head and piston nut and for oil leak
tests after completion of assembly.
(5) Jet air source
It is used for drying after oil draining and cleaning of the cylinder.
(6) Cleaning bath, cleaning oil and detergent
(7) Oil pan and oil reservoir
An oil pan is necessary to contain oil drained from the cylinder and oil spilt during work.
An oil reservoir is required to collect oil spilt on the floor and waste oil.
(8) Others
Oil extracting hoses, wooden skids, rag and sawdust in which oil soaked are also necessary.

32-17
32. ATTACHMENTS

32.2.1.1.3 TOOLS NEEDED

Tools and jigs vary with types of cylinder, but it is necessary to prepare the tools in Table 32-1 as a guideline.
Table 32-1
Tool/Jig Remarks Tool/Jig Remarks
1.Steel hammer A sharp-point tool may be used in place
Hammer Gimlet
2.Wooden or plastic mallet of a gimlet.
Screwdriver A few types of large and small sizes 1. For fitting seal ring
2. For pushing seal ring
Jig
Chisel Flat chisel 3. For inserting bushing
4. For press-fitting wiper ring
One having an operation wide enough to
1. Slide calipers
Vise hold cylinder head O.D. and tube mount-
Measuring 2. Micrometer
ing pins (clevis)
instruments 3. Cylinder gauge (Fig. 32-29)
1.Hook wrench
Wrench 4. V-block
2.Extension pipe for wrenches

For the details of special tools and jigs, refer to the back pages of this manual.

32.2.1.1.4 EXTERNAL CLEANING

The cylinder taken off the excavator has dust and
foreign matter, and grease is usually adhered to the
clevis part. For this reason, remove external soil
and contamination from the cylinder with water and
Fig. 32-29 Cylinder gauge
steam before bringing it into the workshop.
• The following describes the construction of arm
cylinder (with cushions on both sides). When
disassembling and servicing the cylinder, con-
firm the construction of cylinder referring to
Parts Manual.

Fig. 32-30 Discharging oil

32.2.1.1.5 DISCHARGING OIL

Place a wooden-block on the work bench and mount the cylinder on it to prevent it from rotating. Charge air into
ports A and B alternately to actuate the piston rod till the hydraulic oil in the cylinder is drained out. At this time,
connect a suitable hose to each port so that the hydraulic oil may not gush out.

32-18
 32. ATTACHMENTS

32.2.1.2 CONSTRUCTION OF CYLINDER (AN EXAMPLE OF ARM CYLINDER)

T = Torque : N•m (lbf•ft) (Thread)

Press it in from both ends Press it in from both ends

of the boss so R2.5 (0.10") of the boss so R2.5 (0.10")
33 34 32 28 31 holes face with each other
holes face with each other
in the grease hole position. in the grease hole position.
T=39.8 (30)
30
[M12 X 1.75]

29

26 27 T=31.5 (23) [M10 X 1.5] 27 26

VIEW A-A

T=56.9 (42) [M12 X 1.75]

After tightening,fit it with punch
T=569 (420) [M100 X 2] caulking on two portions.
Apply Three-bond #1901 on the thread
T=2780 (2050) [M45 X 2, HEX70]

9 3 12 7,8 6 10,11 4 5 11,13 2 1 14 15 19 17 18 16 20 21 25 23 22 24

With
one hole

Face the slit to the piston side.

Pay attention to the direction of the slit.

Fig. 32-31 Construction of cylinder (An example of arm cylinder)

No. NAME Q'ty No. NAME Q'ty No. NAME Q'ty

1 CYLINDER TUBE ASSY 1 13 O-RING 1 25 SNAP RING 1
2 PISTON ROD ASSY 1 14 CUSHION BEARING 1 26 PIN BUSHING 4
3 ROD COVER 1 15 CUSHION SEAL 1 27 WIPER RING 4
4 BUSHING 1 16 PISTON 1 28 BAND ASSY 1
5 SNAP RING 1 17 SEAL RING ASSY 1 29 BAND 1
6 BUFFER RING 1 18 SLIDE RING 2 30 BOLT 2
7 U-RING 1 19 SHIM 1 31 WASHER 2
8 BACKUP RING 1 20 SET SCREW 1 32 PIPE HOLDER 1
9 WIPER RING 1 21 STEEL BALL 1 33 BOLT 1
10 O-RING 1 22 CUSHION BEARING 1 34 WASHER 1
11 BACKUP RING 3 23 CHSHION SEAL 1
12 O-RING 1 24 STOPPER 2

32-19
32. ATTACHMENTS

32.2.1.3 DISASSEMBLING
• Before starting disassembling and servicing,
confirm the construction and supply parts refer- 0 mm
, 20
rox )
ring to Parts Manual in the separate volume, and App (8"
also required tools and jig.
• Figures noted just after the "Part name" corre-
spond to the number stated in Fig. 32-31 Arm
cylinder. Other cylinders may have some differ-
ent parts. Fig. 32-32 Removing piston rod

32.2.1.3.1 REMOVING ROD COVER AND PISTON ROD

(1) Fix the tube installing pin side using a vise. (Fig. 32- CHISEL
30) (Meet the width of chisel with
the groove width, flatten the
lock washer)

Take care not to damage the cylinder tube and ma-

chined surface.
Never use external pipe to stop turning.

Fig. 32-33 Flatten the slit lock

(2) Pull piston rod (2) out about 200 mm (8 in).
If pipe does not
Use air to push piston rod (2) out after draining the found, strike this
oil because of the weight of piston rod (2). portion with hammer.
Turn counter
(3) Flatten the lock on slit section installed between rod 1.0 clockwise
(3’ ~1.5
cover (3) and cylinder tube (1) with chisel and ham- 3"~ mm
4’1
1")
mer.
Cover this portion
(4) Lift up cylinder rod section with nylon sling tempo- with cloth.
rarily.
(5) Then, hook a wrench to rod cover (3), turn it coun-
terclockwise and remove it.
Special tool : Refer to Table 32-11. Fig. 32-34 Removing rod cover
(6) After putting threads out of mesh, remove the end
of rod cover (3) using plastic hammer.

Sling

In this case, apply the hoisting force equivalent to the

weight of piston rod, because the weight of piston rod Pull it straight out
horizontally
weights upon the rod cover.

OIL PAN

Fig. 32-35 Pulling piston rod out

32-20
 32. ATTACHMENTS

(7) Place pulled out piston rod assy (2) on the wooden
V-block horizontally.

WOODEN V-BLOCK
(cover with cloth.)

Fig. 32-36 Placing piston rod assy

(8) Remove slide ring (18)
Expand the slit portion in 45
degrees and remove.

Fig. 32-37 Removing slide ring

32.2.1.3.2 REMOVING PISTON ASSY

(1) Fix piston rod (2) grasping the installing pin portions
WOODEN BLOCK
with vise. Then fix it in strength so that it can with-
stand the tightening torque for piston rod 2) be-
cause the piston rod (2) is secured with large
tightening torque.

WOODEN V-BLOCK
Cover with cloth.

Fig. 32-38 Fixing piston rod assy

(2) Shave off the caulked section on set screw (20) DRILL
with hand drill, loosen set screw and take out steel
ball (21).

STEEL BALL

Fig. 32-39 Removing setscrew

32-21
32. ATTACHMENTS

(3) Remove nut section of piston with a closed wrench. EYE WRENCH
Special tool : See Table 32-12 1.0
(3’ ~1.5
3"~ m
• Since the piston section (16) is tightened by high 4’1
1")
torque, use the closed wrench closely fitted to
the width across flat.
Turn counter
• Approx. 1.5 times or higher of torque is required clockwise
to loosen piston nut. So prepare power wrench
equipped with hydraulic jack or hydraulic cylin-
der, if possible.

PLATE

PISTON ROD WIPER RING

PIN BUSHING

Fig. 32-40 Removing piston nut

(4) Removing cushion bearing on the retraction side. THREADED CUSHION BEARING (22)
PART
1) Remove snap ring (25). Strike it lightly being
STOPPER (24)
careful not to damage cushion bearing and pis-
(DIVIDE INTO
ton rod. 2 PORTIONS)

2) Move cushion bearing (22) to threaded side, and

remove stopper (24) (two pieces type).
CUSHION SEAL (23)
3) Pull out cushion bearing (22).
4) Expand slit (1 place) of cushion seal (23) and re- SNAP RING (25)
move it. PISTON ROD (2)
SLITTING
(1 PLACE)

Fig. 32-41 Disassembling cushioning bearing

(5) Removing cushion bearing on extension side.
1) Pull out cushion bearing (14).
2) Expand slit (1 place) on cushion seal (15) and re-
CUSHION SEAL (15) CUSHION BEARING (14)
move it.

SLITTING (1 PLACE)

Fig. 32-42 Disassembling cushioning bearing

32-22
 32. ATTACHMENTS

32.2.1.3.3 DISASSEMBLING PISTON ASSY

Removing piston seal HAMMER

1) Remove slide ring (18) by hand. SEAL RING (17)

SLIDE RING (18)
2) Cut seal ring (17) with driver (-) and hammer as
shown in the right figure. WOODEN PIECE

3) Pull out O-ring with spatula. VISE

4) Strictly prohibited to use pulled out seal parts.

O-RING

Fig. 32-43 Disassembling piston assy

32.2.1.3.4 REMOVING ROD COVER ASSY

Remove rod cover assy from piston rod (2). If it is Strike with a
too difficult to remove, strike flange section of rod plastic mallet Lift here
cover (3) with plastic hammer.
Hang the rod cover assy with crane and remove it
straight horizontally.

Pull straight
Care should be taken not to damage the bushing (4) lip
section of link and seal with screw of piston rod (2)
when pulling out rod cover (3).

Fig. 32-44 Removing rod cover assy

32.2.1.3.5 DISASSEMBLING ROD COVER ASSY

(1) Removing buffer ring
BUFFER RING (6)
1) Buffer ring (6) (Teflon made seal) is fitted on the O-RING AND
BACK-UP RING
inside of rod cover (3). Pierce with pointed tool (10, 11) (11, 13)
on the seal, raise it, insert spatula and take it out. WIPER
RING (9)
• Strictly prohibited to use the removed seal.

BUSHING (4)
SNAP RING (5)

U RING (7) AND BACK-UP RING (8)

Fig. 32-45 Construction of rod cover assy

32-23
32. ATTACHMENTS

(2) Removing U-ring (7), backup ring (8) and wiper ring
BUFFER RING ASSY
(9)
(SQUARE RING + SLIDE RING)
1) Remove U-ring (7) and backup ring (8) with driv-
er, etc. SQUARE RING
(PROJECTION)
2) The wiper ring (9) is press-fitted.
Pierce with driver, etc. on rubber and strike and
remove it with driver.
SLIDE RING
• Strictly prohibited to use removed seal. (SLITTING)

SNAP RING

Fig. 32-46 Direction of buffer ring

(3) Removing bushing (4)
Push with a press
Raise snap ring (5) with hooked bar and take it out
from cylinder rod cover. And press out bushing (4) JIG
with jig. If it is too difficult to take it out with jig, use
lathe to remove it.
ROD COVER (3)

BUSHING (4)

JIG

Fig. 32-47 Removing bushing

32-24
 32. ATTACHMENTS

(4) Removing pin bushing WIPER RING (27)

1) Remove wiper ring (27).
2) The pin bushing (26) of piston rod (2) is pressfit- Push with a press
ted, so press it out with a press applying a plate PLATE
to the section.

Where it is impossible to press it out, cut it with gas BASE

burner.

(5) Cleaning
1) After completion of cylinder disassembly, clean
all the parts with detergent.
Fig. 32-48 Drawing out pin bushing (rod & tube)
Apply hydraulic oil on them and cover them to
store.
Leaving them in the as-disassembled condition
causes rust, adherence of dust, etc., which may
cause malfunction after assembling.

Do not use volatile agents (gasoline and thinner) as

they deteriorate rubber.

2) Replace all of U-ring, wiper ring, O-ring and

backup ring as a general rule.

32-25
32. ATTACHMENTS

32.2.1.4 INSTALL
Start install with the sub assy listed below :
• Cylinder tube assy
• Piston rod assy
• Rod cover assy
• Piston assy

32.2.1.4.1 ASSEMBLING CYLINDER TUBE ASSY, PISTON ROD ASSY

(1) Apply hydraulic oil on the head in which pin bushing
Push with a press
is inserted and on the pin bushing hole of rod.
(2) Press pin bushing (26) into cylinder tube (1) and
piston rod (2), using a press.
(3) Insert wiper ring (27) in both sides.

OIL HOLE LOCATION

PLATE

PISTON ROD
WIPER RING

PIN BUSHING

Fig. 32-49 Pressing in pin bushing (rod & tube)

32-26
 32. ATTACHMENTS

32.2.1.4.2 ASSEMBLING ROD COVER ASSY

(1) Press fit bushing (4) in rod cover (3) applying plate Push with a press straight down
on the section. After press-fitting, check that the
bushing is not projected from the end surface (A).
(See Fig. 32-50)
(2) Fit snap ring (5). PLATE

(3) Fit backup ring (8) on U-ring groove.

(4) Apply hydraulic oil on U-ring (7) and fit it on the U-
ring groove.

• The U-ring is harder than other seals, so fit it in the

groove by hand first, then press in with pushing bar
Fig. 32-50 Pressing in bushing
until it is fitted with a click.
• Fitting U-ring paying attention to the direction.
PUSH BAR
• After fitting backup ring (8) and U-ring (7), check
that they are free from the permanent set.

Fig. 32-51 Fitting U-ring

(5) Installing buffer ring assy
SLIDE RING SQUARE RING
Buffer ring assy (6) is equipped with square ring GROOVE ROOT
SECTION Depress slide ring
and slide ring. in U shape to fit.
1) Fit square ring on the groove.
2) Depress slide ring in U shape by hand to house
it in groove, and fit it pushing out to periphery.

BUFFER RING ASSY (6)

(SQUARE RING + SLIDE RING)
• Depress it R 6 mm (0.24 in) or more, because if the
depressed R is too small, it may remain wrinkled. SQUARE RING (PROJECTION)

• After fitting, check that it is free from wrinkles.

• Fit it giving attention to the seal fitting direction. Re-
verse fitting produces high pressure between U- SLIDE RING
(SLITTING)
ring and seal and may cause the deformation of rod SNAP RING (5)

cover. Fig. 32-52 Installing buffer ring assy (6)

• Fit slide ring so that the groove matches to the root
section of square ring.

(6) Fit snap ring (5)

32-27
32. ATTACHMENTS

(7) Press fit wiper ring (9) by means of Jig Table 32-8. Push with a press

JIG

RUBBER
METAL RING CLIP

Fig. 32-53 Pressing in wiper ring

(8) Fit backup ring (11) and O-rings (10), (13). O-RING AND
(Attention should be paid to the fitting order.) BACK-UP RING
(10, 11) (11, 13)

Fig. 32-54 Fixing back-up ring and O-ring

32.2.1.4.3 ASSEMBLING PISTON ASSY

(1) Installing seal ring assy SEAL RING PRESSING JIG SEAL RING (17)
1) Fit O-ring so as not to be distorted. PISTON (16)
2) Press in seal ring (17) referring to Jig Table 32-8,
Table 32-6.

PUSH

O-RING

Fig. 32-55 Installing the seal ring (17)

3) Since the seal ring (17) is extended when fitting, CORRECTION JIG
press it referring to Correction jig Table 32-9.

PUSH

Fig. 32-56 Correcting the seal ring (17)

32-28
 32. ATTACHMENTS

4) Fitting slide ring (18) Expand 45 deg. slit

Fit it from rod side expanding slit by both hands. section in direction
specified by arrow and
• Expand slit in minimum. fit the ring.
If expansion is exceeded, the ring cannot be
fitted.
• Slit is mutually shifted 90 degree.

Fig. 32-57 Installing the slide ring (18)

32.2.1.4.4 INSTALLING ROD COVER ASSY ON ROD

(1) Fix piston rod assy on work bench.
(2) Apply grease (or hydraulic oil) on outside of piston
rod (2), inner surface of buffer ring (6), U-ring (7),
backup ring (8), wiper ring (9) and bushing (4), and
slide rod cover assy on piston rod (2) taking care
not to damage the lip of wiper ring (9).
It may not slide smoothly due to frictional resistance
of U-ring. In this case, sling rod cover assy horizon- Fig. 32-58 Installing rod cover assy
tally with crane, and push it striking flange of rod
ROD COVER PRESSING JIG
cover with mallet.
PISTON ROD ROD COVER

While pushing, be careful that the rod cover assy is not PUSH
rotated to piston rod (2).

Fig. 32-59 Pressing rod cover

32.2.1.4.5 INSTALLING PISTON ASSY ON ROD

(1) Fitting cushion bearing (14) on the extension side.

Before attaching piston (nut ) (16), fit cushion bearing CUSHIONING CUSHIONING BEARING (14)
SEAL (15)
(14). If the piston nut is attached, the bearing can not be
fitted. CUT OUT
FLAT SECTION
1) Expand slit of cushion seal (15) and insert it into
groove piston rod (2). SLITTING (1 PLACE)

Fig. 32-60 Fitting cushion bearing (14)

on the extension side
Insert cushion seal (15) directing the cut out toward the
thread side of rod as shown in Figure.

2) Fit cushion bearing (14) .

Fit cushion bearing (14) directing the flat section toward

as shown in Figure.

32-29
32. ATTACHMENTS

(2) Fitting cushion bearing (22) on retraction side CUSHION BEARING (22)
THREADED
1) Fit cushion seal (23) in groove directing the cut- PART STOPPER (24)
(DIVIDE INTO
out toward the thread side. 2 PORTIONS)
2) Assemble cushion bearing (22) directing the flat FLAT
SECTION
section toward as shown in Figure.
3) Fit stopper (24) in groove. PISTON CUSHION SEAL (23)
ROD (2)
4) Push cushion bearing (22) to stopper (24) fully, SNAP
CUT
OUT
and strike and fit snap ring (25). RING (25) SLITTING
(1 PLACE)

Fig. 32-61 Fitting cushion bearing (22) on retraction

side
Strike snap ring with plastic hammer being careful not
to damage rod (2) and cushion bearing (22).

(3) Tightening piston nut EYE WRENCH

1) Insert shim (19) and piston (nut) (16) into rod,
and tighten piston (nut) (16) to the specified
torque.
Special tool : See Table 32-12
Tightening torque : See Fig. 32-68.

Fig. 32-62 Tightening piston nut (16)

2) Put steel ball (21) in and tighten setscrew (20). CAULK

: Tightening torque : See Fig. 32-69.

3) Caulk 2 places on outer surface with punch. PUNCH

SETSCREW (20)

STEEL BALL
Fig. 32-63 Caulking set screw of piston nut

32-30
 32. ATTACHMENTS

32.2.1.4.6 OVERALL INSTALL

(1) Place a V-block on a rigid work bench (A wooden V Bar used to prevent rotation
block is preferable.) Mount the cylinder tube assy (Wood is preferable) or fix with vise
(1) on it and fix the assy by barring a bar through the
attaching pin hole to lock the assy. (Fig. 32-64)
(2) Insert piston rod (2) into cylinder tube (1) while Lift it lever
hanging and moving it with crane. Then, apply hy-
draulic oil on tube lip inner side and piston outer
surface and insert horizontally aligning the center of
piston rod and center of cylinder tube.
• Also, the use of fork lift makes inserting easier.
• Insert piston into tube being careful that seal ring PISTON
and slide ring are not caught in the stepped sec- Apply Three-Bond #1901
tion of tube.
Fig. 32-64 Installing piston rod

SLIT

ROD COVER (3)

CHISEL

Fig. 32-65 Bending lock of slit

(3) Apply Three Bond #1901 on thread section of rod SET SPACE
cover and hydraulic oil on O-ring (12), rotate rod
cover assy (3) by hand. Screw in 2 or 3 threads first,
then tighten it to the specified torque with hook
spanner wrench.
(4) Bend slit of cylinder tube toward cutout of rod cover
(3) to lock.
(5) Tighten band for piping on both sides equally to the PIPE HOLDER
specified torque in order not to have a set space.
Tightening torque : SET SPACE BAND BOLT
See 32.2.1.7 "TIGHTENING TORQUE".
• Fix port section of cylinder pipe with wrench, etc.
on main body and install pipe for cylinder, and
rubber hose, nipple, etc. Installation without fixa-
tion may cause bending of port plate, conse-
quently oil leakage, and interference with body.
SET SPACE SET SPACE

Fig. 32-66 Installing band for piping

32-31
32. ATTACHMENTS

32.2.1.5 MAINTENANCE STANDARDS

(1) Inspection after disassembly
1) Inspection
Table 32-2
Part Name Inspecting Section Inspection Item Remedy
1. Neck of rod pin Presence of crack Replace.
2. Stepped part to which pis-
Presence of crack Replace.
ton is attached
3. Threads Presence of seizure Recondition or replace
4. Bend Measure degree of bend Refer to rod bend
5. Plated surface Check that :
Piston rod
1) Plating is not worn off to base 1) Replace.
metal
2) Rust is not present on plating. 2) Replace.
3) Scratches are not present. 3) Recondition or replace
6. Rod Wear of O. D. Recondition or replace
7. Bushing at mounting part Wear of I. D. Replace.
1. Weld on bottom Presence of crack Replace.
2. Tube at mounting part Presence of crack Replace.
Cylinder tube
3. Tube interior Scratches are not present. Replace if oil leak is seen.
4.Bushing at mounting part Wear of I. D. Replace.
1) Wear of I. D.
Rod cover 1.Bushing Replace.
2) Flaw on inner surface

(2) Maintenance standards

Replace sliding parts and seal parts according to the following.
1 Bushing ....................................... Where 1/4 of circumference is worn in red copper color.
2 Seals and slide ring ..................... Replace them when cylinder is disassembled.
3 Pin bushing ................................. Where severe scuffing is produced
4 Piston rod .................................... Where the bent 0.5 mm/m or more is produced
(3) Inspection after assembling
Table 32-3
No-load perfor- When operating 5 time or more in full stroke at no-load, it operates smoothly with no
mance inspection abnormality.
Dimensional
Check the fully retracted length and stroke specified in drawing.
inspection
After applying test pressure specified in drawing to each stroke end for 3 minutes or
Pressure inspection
more, it is free from loosening, permanent set and oil leaking.
No-load perfor- Check rod section for oil leaking.
mance inspection (Refer to Criterion of oil leak quantity on rod section in proceeding page.)
Oil leak quantity unit mL (cc) / 10min
Oil leak Oil leak Oil leak
I. D. mm (in) I. D. mm (in) I. D. mm (in)
quantity quantity quantity
Internal leakage 32 (1.26) 0.4 100 (3.94) 4.0 160 (6.30) 10.0
inspection 40 (1.57) 0.6 125 (4.92) 5.6 180 (7.09) 12.6
50 (1.97) 1.0 140 (5.51) 6.0 200 (7.87) 15.6
63 (2.48) 1.6 220 (8.66) 20.0
80 (3.15) 2.3 250 (9.84) 22.0

32-32
 32. ATTACHMENTS

(4) CRITERION OF OIL LEAK QUANTITY ON ROD SECTION

Determine according to the oil ring condition produced on rod after 20 strokes in oil temperature 20°C (68°F) to
40°C (104°F). When oil ring is changed to A condition, it is in abnormality. Refer to 32.2.1.9 "Troubleshooting",
and take a measure.
OIL RING

Reject Accept

Fig. 32-67 Oil ring condition on rod section

32.2.1.6 GENERAL TOOL

Table 32-4
No. Tools name Q'TY

1 Flat-bladed screw driver 1

2 Allen key wrench 1 set

3 Vise 1

Spanner (see page II-1-18)

4 1 set
(for piston nut)

5 Punch 1

6 Torque wrench 1 set

7 Hammer (Plastic mallet) 1

8 Adjustable wrench 1

9 Spatula 1 pair

32-33
32. ATTACHMENTS

32.2.1.7 TIGHTENING TORQUE

(1) Piston nut

Cylinder name Opposing flat A Tightening torque

Boom 80 mm 3000 N·m (2210 lbf·ft)
Arm 70 mm 2780 N·m (2050 lbf·ft)
Bucket 60 mm 1420 N·m (1050 lbf·ft)
Dozer 85 mm 2900 N·m (2140 lbf·ft)
Swing 75 mm 2510 N·m (1850 lbf·ft)

Fig. 32-68
(2) Setscrew
CAULK
Cylinder name Opposing flat Tightening torque
Boom PUNCH
6 mm 56.9 N·m (42 lbf·ft)
Arm
Bucket 4 mm 16.2 N·m (12 lbf·ft)
Dozer 6 mm 56.9 N·m (42 lbf·ft) SETSCREW

Swing 5 mm 31.4 N·m (23 lbf·ft)

STEEL BALL

Fig. 32-69
(3) Rod cover

Cylinder name Tightening torque HOOK WRENCH PIPE

Boom 834 N·m (615 lbf·ft)

Arm 569 N·m (420 lbf·ft)
Bucket 450 N·m (330 lbf·ft)
Dozer 1343 N·m (990 lbf·ft)
Swing 736 N·m (540 lbf·ft)

Fig. 32-70
(4) For piping

Piping band Pipe holder

Cylinder
name Opposing flat Tightening Opposing flat Tightening
torque torque
Boom
Arm 19 mm
17 mm 31.5 N·m 39.8 N·m
Bucket (23 lbf·ft) (29 lbf·ft)
Dozer
PIPE HOLDER PIPING BAND BOLT
Swing

Fig. 32-71

32-34
 32. ATTACHMENTS

32.2.1.8 TOOL AND JIGS LIST

(1) Seal ring fitting jig ( I )
Material : Mild steel

Fig. 32-72
Table 32-5
Unit : mm (in)
Applicable cylinder D0 D1 (D2) D3 L0 (L1) L2
Boom 111 (4.3701) 110 (4.3307) 86 (3.39) 96 (3.78) 100 (3.94) 72 (2.83) 24 (0.9449)
Arm 96 (3.7795) 95 (3.7401) 71 (2.80) 81 (3.19) 100 (3.94) 72 (2.83) 23(0.9055)
Bucket 81 (3.1890) 80 (3.1496) 56 (2.20) 66 (2.60) 100 (3.94) 72 (2.83) 20 (0.7874)
Dozer 131 (5.1575) 130 (4.1181) 111 (4.37) 116 (4.57) 99 (3.90) 66 (2.60) 28 (1.1024)
Swing 106 (4.1732) 105 (4.1339) 81 (3.19) 91 (3.58) 100 (3.94) 72 (2.83) 23 (0.9055)

(2) Seal ring fitting jig ( II )

Material : Nylon or acrylic resin

Fig. 32-73
Table 32-6
Unit : mm (in)
Applicable cylinder D0 D1 L
Boom 112 (4.41) 104 (4.09) 100 (3.9370)
Arm 97 (3.82) 89 (3.51) 100 (3.9370)
Bucket 82 (3.23) 74 (2.91) 100 (3.9370)
Dozer 132 (5.20) 124 (4.88) 100 (3.9370)
Swing 107 (4.21) 99 (3.9) 100 (3.9370)

32-35
32. ATTACHMENTS

(3) Bushing press-fit jig

Material : Mild steel

Fig. 32-74
Table 32-7
Unit : mm (in)
Applicable cylinder D0 D1 (D2) D3 L0 (L1)
Boom 75 (2.9528) 69.5 (2.74) 68 (2.68) 95 (3.74) 65.5 (2.58) 59.5 (2.3425)
Arm 70 (2.7559) 64.5 (2.54) 63 (2.48) 90 (3.54) 65.3 (2.57) 53.3 (2.0984)
Bucket 60 (2.3622) 54.5 (2.15) 53 (2.09) 80 (3.15) 20.5 (0.807) 8.5 (0.3346)
Dozer 75 (2.9528) 69.5 (2.74) 68 (2.68) 95 (3.74) 65.5 (2.58) 59.5 (2.3425)
Swing 70 (2.3622) 64.5 (2.54) 63 (2.48) 90 (3.54) 65.5 (2.58) 53.5 (2.1063)

(4) Wiper ring (rod cover) press-fit jig

Material : Mild steel

finishing unless otherwise specified.

Fig. 32-75
Table 32-8
Unit : mm (in)
Applicable cylinder D0 D1 D3
Boom, Dozer 70 (2.7559) 78.5 (3.0905) 95 (3.74)
Bucket 55 (2.1654) 63.5 (2.5000) 80 (3.15)
Arm & Swing 65 (2.5591) 73.5 (2.8937) 90 (3.54)

32-36
 32. ATTACHMENTS

(5) Seal ring straightening jig

Material : Mild steel

finishing unless
otherwise specified.

Fig. 32-76
Table 32-9
Unit : mm (in)
Applicable cylinder D0 (D1) L0 (L1)
Boom 110 (4.3307) 130 (5.12) 120 (4.72) 40 (1.57)
Arm 95 (3.7401) 115 (4.53) 120 (4.72) 40 (1.57)
Bucket 80 (3.1496) 100 (3.94) 120 (4.72) 40 (1.57)
Dozer 130 (5.1181) 150 (5.91) 120 (4.72) 40 (1.57)
Swing 105 (4.1339) 125 (4.92) 120 (4.72) 40 (1.57)

(6) Piston insert jig

Material : Mild steel

Split into 2 portions with

2 to 3 mm (0.08~0.12 ) cutter.

finishing unless otherwise specified.

Fig. 32-77
Table 32-10
Unit : mm (in)
Applicable cylinder ØA ØB ØC D E
Boom 122 (4.80) 110 (4.3307) 113 (4.4488) 67 (2.64) 42 (1.65)
Arm 107 (4.21) 95 (3.7401) 98 (3.8583) 67 (2.64) 42 (1.65)
Bucket 92 (3.62) 80 (3.1496) 83 (3.2677) 62 (2.44) 37 (1.46)
Dozer 142 (5.59) 130 (5.1181) 133 (5.2362) 72 (2.83) 47 (1.85)
Swing 117 (4.61) 105 (4.1399) 108 (4.2520) 67 (2.64) 42 (1.65)

32-37
32. ATTACHMENTS

(7) Hook wrench

Material : Chromium-vanadium steel, hardness HRc 36 – 4

Fig. 32-78
Table 32-11
Unit : mm (in)
Applicable
A B C t D r f L
cylinder
Boom 130 (5.1181) 12 (0.4724) 5 (0.1969) 15 (0.591) 2 (0.0787) 86 (3.39) 12 (0.472) 380 (15.0)
Arm 120 (4.7244) 12 (0.4724) 4.5 (0.1772) 15 (0.591) 2 (0.0787) 80 (3.15) 12 (0.472) 380 (15.0)
Bucket 100 (3.9370) 10 (0.3937) 4.5 (0.1772) 15 (0.591) 2 (0.0787) 68 (2.68) 9 (0.354) 320 (12.6)
Dozer 150 (5.9055) 12 (0.4724) 5 (0.1969) 15 (0.591) 2 (0.0787) 96 (3.78) 12 (0.472) 460 (18.1)
Swing 130 (5.1181) 12 (0.4724) 5 (0.1969) 15 (0.591) 2 (0.0787) 93 (3.66) 12 (0.472) 380 (15.0)

(8) Eye wrench

Tolerance of A : 0.3 mm~0.8 mm

(0.0118"~0.0315") Straight in Material : Mild steel
this area FInish by grinding after gas cutting

Fig. 32-79
Table 32-12
Unit : mm (in)
Applicable L=300 (11.8) L=500 (19.7)
Size A
cylinder B1 B2 t B1 B2 B3 t
Boom 80 (3.1496) 110 (4.33) 78 (3.07) 28 (1.10) 122 (4.80) 107 (4.21) 87 (3.43) 28 (1.10)
Arm 70 (2.7559) 95 (3.74) 67 (2.64) 25 (0.984) 104 (4.09) 90 (3.54) 78 (3.07) 25 (0.984)
Bucket 60 (2.3622) 95 (3.74) 67 (2.64) 16 (0.630) 104 (4.09) 90 (3.54) 78 (3.07) 16 (0.630)
Dozer 85 (3.3465) 115 (4.53) 83 (3.27) 28 (1.10) 127 (5.00) 112 (4.41) 92 (3.62) 28 (1.10)
Swing 75 (2.9528) 110 (4.33) 78 (3.07) 28 (1.10) 122 (4.80) 107 (4.21) 87 (3.43) 28 (1.10)

32-38
 32. ATTACHMENTS

32.2.1.9 TROUBLESHOOTING
Failure on hydraulic cylinder and corrective action
It is very difficult to find defective section. The following table explains general phenomenon, estimated causes
and corrective actions.
For repair, refer to the estimated causes and corrective actions.
However, Most machine problems are not caused by the failure of only one part, but involve relations with other
parts.
Therefore corrective action other than those described in Table is often required. Please contact us to pursue
the problems and causes further and to take appropriate corrective action.

Items Phenomenon
Oil leakage from piston rod sliding section
1
(For criterion, refer to Table 32-3.)
2 Oil leakage from rod cover set section
3 Oil leakage from pipe and cylinder tube weld zone
4 Malfunction

Items Phenomenon Related parts Abnormalities Measures and corrective actions

1) Remove flaws with oil stone to make the surface
smooth. If oil is leaking after making rod surface
smooth (1.5S or less), disassemble it and check
Flaw and rust on slid-
seals of U ring, etc. that it is free from flaw.
ing surface.
2) In case the flaw is too wide to repair with oilstone,
Piston rod replace seals of U ring and wiper ring, etc. and
bearing parts of piston rod.
1) Plate it again, or replace piston rod.
2) At the same time, check seals and bearing parts
Plating is peeled.
of piston rod for possible damage, if damaged,
replace it.
Foreign matter is 1) Remove foreign matter.
caught in inner bore
2) Replace defective packing.
and outer surface.
Flaw on inner bore
1) Replace it.
and outer surface.
Oil leakage from
1) May be a burning caused by adiabatic compres-
1 piston rod slid- sion due to the remained air.
A part of lip and
ing section
groove is carbonized 2) After replacement of packing, release air com-
(burned). pletely through operation in low pressure and low
speed and start cylinder operating.
Rod packing 1) Replace it.
(Buffer ring, 2) May be service life expired, deterioration of hy-
U ring) Rubber packing is de- draulic oil and high temperature.
teriorated. Or lip sec- a) Change hydraulic oil with new one.
tion is damaged. b) Check hydraulic oil temperature. (Temperature
80°C or less is preferable.)
c) Be certain that temperature is not locally raised.
1) Replace it.
2) Extraordinary high pressure may be applied to
The protrusion of
packing.
packing heel section is
a) Check pressure at operating.
too large.
b) Where buffer ring is fitted, it may be damaged.
Check buffer ring for possible damage.

32-39
32. ATTACHMENTS

Items Phenomenon Related parts Abnormalities Measures and corrective actions

1) Replace rod packing at the same time as a rule.
(Where buffer ring is fitted, it is preferable to re-
place it at the same time.)
Backup ring Large deformation
2) It may be caused by extraordinary high pressure.
In this case, check it using the same procedure
as the above packing heel.
Foreign matter is
1) Remove foreign matter.
caught on lip section
Wiper ring Lip is damaged.
Or there is another 1) Replace it.
Oil leakage from abnormal damage.
1 piston rod slid- Worn, and the space
ing section between bearing and
piston rod exceeds the
maximum clearance. 1) Replace it.
Bearing (Refer Item 32.2.1.5
(Bushing) (2) "Maintenance
Standard".)
1) Replace it.
Large flaw on sliding
2) Check piston rod for possible damage at the
surface
same time.
Flaw and rust on seal 1) Remove flaw and rust with oilstone.
Rod cover
fitting surface 2) In case it is too large to repair, replace rod cover.
1) Remove foreign matter.
2) Replace damaged O-ring.
3) Inspect inner surface of tube.
If flaw and rust are detected, make it smooth with
Foreign matter is oil stone.
O-ring caught in inner bore 4) Inspect groove of rod cover.
and outer surface. - do -
5) Inspect backup ring.
Replace deformed or incompletely fit O-
ring.Check O-ring for above failure. If failed, re-
place it.
Deformed and
Backup ring 1) Replace it with O-ring
Oil leakage from incomplete fitting
2 rod cover set 1) Disassemble rod cover, check O-ring and back-
section up ring for possible damage.
If damaged, replace it.
Rod cover Loosen 2) Check thread ridges of tube and rod cover for
possible damage.
3) After inspection, tighten it to the specified torque.
(See Item 32.2.1.4 "Install".)
Loosen, elongation 1) Replace all bolts, and tighten them to the speci-
Bolt
and damage fied torque.
1) Replace it with new one.
The oil leakage from set section may be caused
Cylinder tube Abnormal expansion by the production of extraordinary high pressure.
Check tube for expansion and deformation, and
also circuit pressure for possible error.

32-40
 32. ATTACHMENTS

Items Phenomenon Related parts Abnormalities Measures and corrective actions

1) Replace it.

Oil leakage from • Crack is progressed and ruptured mechani-

Cylinder tube, cally.
pipe and cylin-
3 pipe (hollow Crack on weld zone
der tube weld • The rupture is very dangerous. So when
piston rod)
zone crack has been detected, stop operating im-
mediately and replace the parts with new
one.
• The weld on crack for repair is ineffective.

Bending exceed the

1) Replace it with new one.
specified deformation.
Piston rod Seal and sliding parts may be damaged.
(See Item 32.2.1.5 (2)
Cylinder tube Check for possible damage. If damaged, replace
"Maintenance Stan-
it.
dard".)
Malfunction 1) Replace it with new one.
Cylinder tube Dent Check seal and sliding parts for possible dam-
Unsmooth age same as the above.
operation 1) Replace it with new one.
Wear or damage on
Check seal and sliding parts for possible dam-
Piston rod sliding parts Foreign
age same as the above.
Cylinder tube matter is caught in pis-
2) Remove foreign matter.
sliding parts ton and cylinder head
Check seal and sliding parts for possible dam-
sliding section.
age same as the above.
1) Replace it with new one.
Piston seal Flaw, wear, etc. Check inner surface of cylinder tube for possible
4 damage.
1) Remove flaw and rust with horning and oilstone
Internal to make it flat.
leakage Flaw and rust on inner
Cylinder tube If it is too large to repair, replace cylinder tube
Piston rod is surface
with new one.
extended and 2) Replace piston seal with new one.
retracted of itself 1) Tighten it to the specified torque.
or abnormally Piston nut Insufficient tightening (See Item 32.2.1.4.5 "Installing piston assy on
drops in rod".)
operation.
Valves Leakage from valve 1) Inspect the leaking quantity and repair it.
And the speed
does not rise to
the specified
speed. Hydraulic oil is expanded and contracted with change of temperature and pressure.
Consequently the cylinder is also extended and retracted, so care must be taken in
order not to mistake this for internal leakage. Check it for internal oil leakage in the
constant temperature and pressure conditions.

32-41
32. ATTACHMENTS

Items Phenomenon Related parts Abnormalities Measures and corrective actions

1) Remove air.
a) If cylinder is not equipped with air bleed port ;
Release air by extending and retracting it at low
speed several times.
b) If cylinder is equipped with air bleed port ;
Unload so that the internal pressure is not raised,
The operation is Air is remained in
Air loosen air breather and release air completely.
unstable. cylinder.
(Reference)
When cylinder has stopped in an emergency,
cylinder may be extended and contracted slight-
ly. This phenomenon is caused by the pressure
of hydraulic oil, and easily occurs on the cylinder
of which the stroke is longer.
Great shock
4 when changed The space between fit- 1) Measure dimension of pin and pin bushing, if it
Pin bushing
from / to exten- ting section and pin exceeds the specified dimension, replace it with
Pin
sion to / from re- bushing is too large. new one.
traction.
Insufficient
Noise Lubrication 1) Lubricate.
lubrication
when cylinder is
Pin bushing Scuffing on engaged
worked. 1) Replace it with new one, and lubricate.
Pin section

Hydraulic oil is expanded and contracted with change of temperature and pressure.
Consequently the cylinder is also extended and retracted, so care must be taken in
order not to mistake this for internal leakage. Check it for internal oil leakage in the
constant temperature and pressure conditions.

32-42
 33. UPPER SLEWING BODY
TABLE OF CONTENTS

33.1 REMOVING AND INSTALLING ......................................................................................... 33-3

33.1.1 CAB ........................................................................................................................... 33-3
33.1.2 OPERATOR SEAT .................................................................................................... 33-5
33.1.3 BATTERY .................................................................................................................. 33-6
33.1.4 INSTRUMENT PANEL .............................................................................................. 33-7
33.1.5 COUNTERWEIGHT .................................................................................................. 33-9
33.1.6 GUARD ..................................................................................................................... 33-10
33.1.7 UNDER COVER ........................................................................................................ 33-14
33.1.8 AIR CLEANER .......................................................................................................... 33-15
33.1.9 MUFFLER ................................................................................................................. 33-17
33.1.10 FUEL TANK .............................................................................................................. 33-18
33.1.11 HYDRAULIC TANK ................................................................................................... 33-20
33.1.12 PUMP ........................................................................................................................ 33-23
33.1.13 RADIATOR & OIL COOLER ..................................................................................... 33-27
33.1.14 ENGINE ..................................................................................................................... 33-31
33
33.1.15 MULTI CONTROL VALVE ........................................................................................ 33-35
33.1.16 CONTROL VALVE .................................................................................................... 33-38
33.1.17 PILOT VALVE (FOR ATT) ......................................................................................... 33-39
33.1.18 PILOT VALVE (FOR TRAVEL) .................................................................................. 33-40
33.1.19 SWING UNIT ............................................................................................................. 33-41
33.1.20 SWIVEL JOINT ......................................................................................................... 33-43
33.1.21 UPPER FRAME ......................................................................................................... 33-45
33.2 DISASSEMBLING AND ASSEMBLING ............................................................................ 33-47
33.2.1 HYDRAULIC PUMP • REGULATOR ......................................................................... 33-47
33.2.2 CONTROL VALVE .................................................................................................... 33-59
33.2.3 PILOT VALVE (ATT) ................................................................................................. 33-73
33.2.4 PILOT VALVE (TRAVEL) .......................................................................................... 33-83
33.2.5 SWING MOTOR UNIT ............................................................................................... 33-89
33.2.6 SWIVEL JOINT .......................................................................................................... 33-103

33-1
33. UPPER SLEWING BODY

PREFACE
(1) This manual describes all the procedures from removing to installing, arranging them by item.
(2) This Manual consists of first part; 33.1 Removing and installing, and second part; 33.2 Disassembling and as-
sembling.
(3) The removing and installing can be performed in the procedure specified in Table of Contents, but in view of
actual repairing or time saving some process can be omitted.
(4) The removing and installing procedure does not completely cover all possible situations because of differences
of field condition and defective section.
(5) Please be aware that procedure to be followed must be determined according to the above conditions.
When disassembly and assembly are required, select the necessary section, itemize the work contents with
good understanding, then starts working.

33-2
 33. UPPER SLEWING BODY

33.1 REMOVING AND INSTALLING

33.1.1 CAB

33.1.1.1 REMOVAL
(1) Remove floor mat Rotate 90 degrees
(2) Remove the following parts for air-con cover. to remove.
GROMMET BOLT(1-9)
1) 5 bolts (1-9) for catch (24) COVER
24
2) Cover (1)
3) Grille under front seat CATCH (24) BRACKET
4) Duct from duct (14) to under right duct on cab in- 14
side.
1
: Cross recessed screw driver GRILLE

: 13 mm
FLOOR MAT

Fig. 33-1 Detaching and attaching air conditioner

cover
(3) Remove the following parts for harness and con- CURL CODE
FOR ROOM LAMP
nector. FOR WINDOW
1) Antenna cable from back side of tuner GROMMET WASHER

2) Harness for room lamp

DOOR SW
3) Harness on cab front right side
ANTENNA
4) Harness for gauge cluster CAB LIGHT
HARNESS
5) Harness for cab light
6) Harness on front right side of cab for power win- GROMMET
dow. (OPT) To instrument panel

(4) Remove window washer tube TO TUNER

GROMMET
(5) Remove the following parts for cab mounting bolt
A1
TUBE Remove
1) 5 capscrews (A1) M10 M10 X 5 pcs.
washer tube
2) 4 nuts M16 TUBE
at floor

3) Sems-bolt (B2) M10, 2 pcs on lower section of

hand rail
NUT
: 17 mm, 24 mm M16 X 4 pcs.
Ø30 (1.18")
HOLE FOR HAND RAIL
Fig. 33-2 Removing and attaching harness connec-
tor and cab mounting bolts

33-3
33. UPPER SLEWING BODY

(6) Slinging cab

1) Remove 2 plastic plugs on front side of cab ceil-
ing, and attach eye bolts M10, and hook wire 3 M10
places, 2 lifting eye, on rear left side. EYE BOLT LIFTING EYE

2) Then lift up slowly avoiding interference with sur-

roundings.
Wire with hook :
Length 1.5 m (4ft 11 in) × Dia. 8 mm (0.315 in)×
3 pcs.
Weight of cab : Approx 200 kg (440 lbs)

Fig. 33-3 Slinging cab

33.1.1.2 INSTALLATION
Mount it in reverse procedure of Dismouting according to the tightening torque table.
Tightening
Tool torque
Tightening position Hex. mm N·m (lbf·ft)
Lower section of hand rail
Sems-bolt (B2) 17 46 (34)
Nut M16 24 191 (140)
Capscrew (A1) 17 46 (34)

33-4
 33. UPPER SLEWING BODY

33.1.2 OPERATOR SEAT

33.1.2.1 REMOVAL
(1) Remove seat. (Include upper rail.)
1) Remove four M8 capscrews (15) in the upper
rail. SEAT
2) Remove seat. M8X16
15
[Approx.15kg (33 lbs) with upper rail]

: 6 mm

(2) Remove slide on lower rail of seat.

UPPER RAIL
1) Remove four capscrews (15) M8. 4
2) Remove support (4).
3) Remove four capscrews (8) M8.
4) Remove lower rail (3).

: 6 mm LOWER RAIL
3 15
M8X16
(3) Remove seat stand (1).
M8X30
1) Remove four capscrews (9) M10. 18
2) Remove seat stand (1).
M8X16 13
: 8 mm 15 M8X25
Weight of seat stand : 17 kg (37 lbs) PLATE (STOPPER)
1
M10X25
9

Floor plate
Fig. 33-4 Dismounting and mounting seat

33.1.2.2 INSTALLATION
Install it in reverse procedure of removing according to the tightening torque table.
Tool Tightening
Tightening position wrench torque
mm N·m (lbf·ft)
Capscrew (9) 8 46 (34)
Capscrew (15) 6 24 (17)

Reference : Movement on rail

Upper rail ... Fixed on lower surface of seat
(Forward 80, backward 80)
Lower rail ... Fixed on seat stand.
Height adjustment lever (L.H)
Seat raise 23mm (0.91 inch)
Seat lower 37mm (1.5 inch)

33-5
33. UPPER SLEWING BODY

33.1.3 BATTERY

33.1.3.1 REMOVE
(1) Open box (82) (See GUARD Fig. 33-22)
1) Open it with engine key. 82

2) Open cover. KEY

3) Fix it with stay

Fig. 33-5
(2) Remove 3 battery cables
1) Cable (between ground and battery (-)) (Always
STAY
remove (-) terminal first and install it at last.)
2) Cable (between battery (+) and (-))
3) Cable (between battery and (+) battery relay) BATTERY
RELAY
: 13 mm

Follow the battery removal order.

Start removing battery from grounding side, and finish
1) 2) 3)
attaching to grounding side. If this order is missed,
short-circuits may occur. Fig. 33-6 Grounding cable for main body

(3) Remove battery (B1)

1) Remove 2 attaching bolts (A2) M10.

: 17 mm
2) Remove cover (A1)
3) Remove battery (B1)

33.1.3.2 INSTALL
(1) Install counterweight in the reverse procedure of
A2
removing.
Battery attaching bolt
A1
: 17 mm
Tightening torque : 11 N•m (8.0 lbf•ft)
(2) Installing grounding cable B1
Install grounding cable last. Especially care must
be taken that the grounding face is free from paint-
ing, rust, etc.

: 13 mm
Fig. 33-7 Removing battery

33-6
 33. UPPER SLEWING BODY

33.1.4 INSTRUMENT PANEL

33.1.4.1 PREPARATION FOR REMOVAL

Remove terminal (-) from battery.

33.1.4.2 REMOVAL
(1) Remove RH, LH instrument panel
1) Remove 8 sems-bolts (12) M5.
: Cross recessed screw driver
2) Lift instrument panel 12 12

3) Remove two connectors and antenna cable on

rear side of left instrument panel
1. 8P connector for air-con panel 12
12

Fig. 33-8 Around of instrument panel

4) Remove four connectors on rear side of right CAP 12
panel 12 M5 X 16
12
1. 6P connector for key switch 12
2. 3P connector for accel dial
3. 2P & 8P connectors for switch panel
4. Other switch 28
12

28
28 M5 X 16

TUNER ANTENNA CABLE

Fig. 33-9 Removing instrument panel

(2) Remove control box
A13 PILOT VALVE
1) Remove four (4) sems-bolts (4), (19) M8 on M8 X 25
right and left sides. PILOT
SUPPORT
ASSY
2) Separate control box from support. VALVE
19 M8 X 25
4 M8
: 13 mm A20
M6 X 16
Weight : Left control box 8.5 kg (19 lbs) and right
control box 7 kg (15 lbs) including pilot valve.
SUPPORT

SEAT STAND
Remove hose referring to Item Hydraulic System. Fig. 33-10 Removing control box

33-7
33. UPPER SLEWING BODY

33.1.4.3 INSTALLATION
Install it in reverse procedure of removing according to the tightening torque table.

Tool Tightening
Tightening position torque
Hex. mm N·m (lbf·ft)
Sems-bolt (4), (19) 13 24 (17)
Sems-bolt (12) cross recessed 2.6 (2.0)
screw driver

33-8
 33. UPPER SLEWING BODY

33.1.5 COUNTERWEIGHT

33.1.5.1 PREPATATION FOR REMOVAL

(1) Removing bonnet assy.
Remove bonnet on engine. (See Fig. 33-20 )
(2) Remove cover (3) (See GUARD Fig. 33-21)
(3) Preparing slinging jig
Remove C7 plug, and attach weight slinging jig
(See Chapter Tools.) to counterweight.

: 36 mm

Fig. 33-11 Lifting up counterweight

33.1.5.2 REMOVAL
(1) Lifting up counterweight temporarily
Hook wire rope to slinging jig, and lift it and stretch A1
wire rope to the degree where it is providing no LIFTING HOLE
slack temporarily. C7
Weight of counterweight :
Approx. 820 kg (1800 lbs)
C3 C3
Wire more than ø10 (0.394") :
C2 SHIM
1.5 m (4 ft 11 in) × 2 pcs.
(2) Removing counterweight
1) Remove 1 capscrew (C1) M20 × 70. SHIM

2) Remove 2 capscrews (C3) M20 × 130.

: 30 mm
C2
3) Remove shim.
C1

Fig. 33-12 Removin counterweight

33.1.5.3 INSTALLATION
(1) Install counterweight in the reverse procedure of re-
moving.
(2) Install shim as it was
(3) Slinging counterweight
Check that 3 attaching bolts can be screwed in by
hand.
(4) Apply Loctite #262 on capscrews (C1, C3), and
tighten them with washers (C2).

: 30 mm
Tightening torque : 490 N•m (361 lbf•ft)
(5) Remove slinging tools, and attach plugs (C7). Fig. 33-13 Attaching bolts counterweight

33-9
33. UPPER SLEWING BODY

33.1.6 GUARD

33.1.6.1 PREPARATION FOR REMOVAL

(1) Remove guard in the following procedure. 1
7 2 (6)
For removing equipment Items (1) to (8).
82 5
For dismounting engine, Items (9) to (13).
(2) All the locked equipment, open them using starter
key. 6

81

8,9

Fig. 33-14 Guard assy

33.1.6.2 REMOVE GUARD

(1) Remove cover assy (1) 1 COVER ASSY
1) Open cover assy (1) and lift it up.
2) Remove two nuts (26) M12.
3) Remove cover assy (1).

: 19 mm
Weight : 12.7 kg (27.7 lbs)
26 NUT M12
Fig. 33-15 Removing cover assy (1)
(2) Remove panel assy (2) 24
1) Remove two sems-bolts (24) M12 × 25.
2) Remove two nuts (26).
3) Remove panel assy (2). 2
PANEL
: 19 mm 24 ASSY
Weight : 12 kg (26.4 lbs)
26

SHIM

Fig. 33-16 Removing panel assy (2)

33-10
 33. UPPER SLEWING BODY

(3) Remove cover assy (6) 25 SEMS-BOLT

1) Remove two capscrews (38) M12 × 45. M20 X 30

2) Remove a sems-bolts (25) M12 × 30. 6 COVER ASSY

24
3) Remove three sems-bolts (24) M12 × 25. SEMS-BOLT
4) Remove cover assy (6). M12 X 25

: 19 mm
24 38
Weight : 7 kg (15 lbs)
CAPSCREW
M25 X 45
Fig. 33-17 Removing cover assy (6)
(4) Remove bracket assy (7)
24
1) Remove three sems-bolts (24) M12 × 25. 7
2) Remove a capscrew (73) M12 × 25.
3) Remove bracket assy (7). 73

: 19 mm
Weight : 15.5 kg (34 lbs)

Fig. 33-18 Removing bracket assy (7)

(5) Remove bracket assy (81) 25
1) Remove four sems-bolts (25) M12 × 30. STRIKER
2) Remove bracket (81).

: 19 mm 81
Weight : 13.5 kg (30 lbs)

Fig. 33-19 Removing bracket (81)

(6) Remove bonnet assy (5)
1) Remove two sems-bolts (25) M12 × 30. 5

2) Lift up bonnet assy (5) together with hinge (22)

with nylon sling.

: 19 mm
Weight : 22 kg (48 lbs) 25

22 23

Fig. 33-20 Removing bonnet assy (5)

33-11
33. UPPER SLEWING BODY

(7) Remove cover (3)

COUNTERWEIGHT
1) Remove four capscrws (66) M10 × 25. 3 COVER 66
2) Remove cover (3).

: 17 mm
• Then remove counterweigtht (A1).
• (See 33.1.5 COUNTERWEIGHT.)
The removing procedures (1) through (7) for
guards and counterweight is available for re-
moving hydraulic equipment, but to remove
engine and all guards together, the perfor-
mance of procedures (8) through (13) are re-
(A1)
quired.

Fig. 33-21 Removing cover (3)

(8) Remove box (40)
71 82
1) Open cover assy and remove it. COVER ASSY
2) Remove battery.
(See 33.1.3 BATTERY Fig. 33-7)
3) Remove four sems-bolts (71) M10 × 25.
4) Remove box (82).

: 13 mm Fig. 33-22 Removing box (82)

Weight : 19 kg (42 lbs)
(9) Remove cover assy (59) 68
1) Remove two sems-bolts (68) M8 × 20.
2) Remove cover assy (59).
9
8
: 19 mm 59

11

60

Fig. 33-23 Guard assy (inside) and removing cover

assy (59)

33-12
 33. UPPER SLEWING BODY

(10)Remove cover assy (60) 24

Remove two sems-bolts (71) M10 × 25, then cover
assy (60). 24
60
: 17 mm
11
(11)Remove guard assy (11)
71
Remove a sems-bolts (25) M12 × 30 and two sems-
bolts (24) M12 × 25.

: 19 mm
Weight : 7 kg (15 lbs)

25
SEMS BOLT
M12 X 30

Fig. 33-24 Removing guard and cover assy (11), (60)

(12)Remove guard assy (9)
24
Remove four sems-bolts (24) M12 × 25 and guard
GUARD
assy (9). ASSY
24 9
: 19 mm
SEMS BOLT
Weight : 5 kg (11 lbs) M12 X 25

Fig. 33-25 Removing guard assy (9)

(13)Remove guard assy (8)
1) Remove 3 sems-bolts (25) M12 × 30
2) Lift up guard assy (8) with nylon sling.
8
: 17 mm 25 25
SEMS-BOLT
Weight : 45 kg (100 lbs) M20 X 30

Fig. 33-26 Removing guard assy (8)

33.1.6.3 INSTALLATION
(1) Installing is done in the reverse order of removing.
(2) Tightening torque

: 19 mm M12 79 N•m (59 lbf•ft)

: 17 mm M10 66 N•m (48 lbf•ft)

33-13
33. UPPER SLEWING BODY

33.1.7 UNDER COVER

33.1.7.1 REMOVAL
(1) Remove under cover (1, 2, 3, 4, 5, 6, 7, 8)
1) Remove sems-bolts (9) M12 × 25.
2) Remove covers

: 19 mm

7
2
8

9
1 9
9 6
9
9

9 9
5
4
9 3 9
Fig. 33-27 Removing under cover assy

33.1.7.2 INSTALLATION
(1) Install under cover (1, 2, 3, 4, 5, 6, 7, 8)

: 19 mm
Tightening torque : 79 N•m (59 lbf•ft)

33-14
 33. UPPER SLEWING BODY

33.1.8 AIR CLEANER

33.1.8.1 PREPARATION FOR REMOVAL

(1) Opening bonnet assy (5) 5
1) Unlock it with starter key.
2) Open bonnet (5) and support it with stay (15).
15

Fig. 33-28 Opening bonnet assy (5)

(2) Opening cover assy (4) STAY 15
(3) Unplug terminals on indicator lines (5-5)
(See Fig. 33-31)

4
COVER ASSY

Fig. 33-29 Opening cover assy (4)

33.1.8.2 REMOVAL
(1) Pulling out hose (2)
1) Loosen clip (8) on air cleaner side. 8 CLIP
2) Pulling out hose (2)
: Flat-blade screw driver

2 HOSE

Fig. 33-30 Pulling out hose (2)

33-15
33. UPPER SLEWING BODY

(2) Pulling out hose (1)

1) Loosen clip (8) on air cleaner side.
2) Pulling out hose (1) 1 HOSE
5-5 8 CLIP
: Flat-blade screw driver
(3) Remove air cleaner assy (5) 5
TERMINAL AIR CLEANER ASSY
1) Remove 2 capscrews (14) M8 × 20
2) Remove air cleaner assy (5) together with brack- 4 BRACKET
et (4).

: 13mm 14 M8 X 20
Fig. 33-31 Pulling out hose (1)

33.1.8.3 INSTALLATION
(1) Installing is done in the reverse order of removing.
FILTER ELEMENT
(2) Spare parts for deteriorated elements

O-RING

Fig. 33-32

33-16
 33. UPPER SLEWING BODY

33.1.9 MUFFLER

33.1.9.1 PREPARATION FOR REMOVAL

(1) Open bonnet assy (5). (See Fig. 33-20)
64
(2) Remove cover (3). (See Fig. 33-21)
(3) Remove sems-bolt (64), then cover (42).

42 COVER

Fig. 33-33 U-bolt a nut (As seen from pump)

33.1.9.2 REMOVAL
(1) Remove U-bolt (5).
1) Remove four nuts (9) M8.
5 U-BOLT
2) Remove two U- bolts (5).
A 2 MUFFLER

: 13 mm E/G parts
9 CAPSCREW
LOCK NUT M8
Fasten in with
T=10.8 N·m
pump bracket together
(8.0 lbf·ft)
9
NUT M8
T=8.8 N·m
(6.5 lbf·ft) 9

Fig. 33-34 Removing U-bolt (5)

(2) Remove clamp assy (6) CAPSCREW M10 X 35
T=83 N·m (61 lbf·ft)
1) Remove two capscrews (7) M10 × 35 7
2) Separate clamp assy (6) from muffler (2). CLAMP
NUT M8 9 ASSY 6
A
: 17 mm
WASHER
EX TUBE 3 NUT
GASKET 4

Fig. 33-35 Removing clamp assy (6)

33.1.9.3 INSTALLATION
(1) Installing is done in the reverse order of removing
M8 lock nut Tightening torque : 10.8 N•m (8.0 lbf•ft)
M8 nut Tightening torque : 8.8 N•m (6.5 lbf•ft)
M10 capscrew Tightening torque : 83 N•m (61 lbf•ft)
(2) Replacing parts
2. Muffler assy

33-17
33. UPPER SLEWING BODY

33.1.10 FUEL TANK

33.1.10.1 PREPARATION FOR REMOVAL

(1) Draining fuel. A3
1) Open cap (A3).
2) Loosen plug assy (A4) under the tank. 12
Installing position (See Fig. 33-38)
6
3) Draining fuel 14 11
Capacity of tank : 100 L (26 gal)
10
(2) Remove hose (6, 7) 7
1) Loosen clip (12) and pull out hoses (6, 7) 12
2) Plug hoses.
(3) Remove connector for level sensor (B5). 1
WATER SEPARATOR

Fig. 33-36 Removing fuel hose (6, 7)

(4) Remove water separator (1)
1 WATER SEPARATOR
1) Remove two sems-bolts (14) M8 × 30 ISUZU NO.
897218-6470
2) Remove water separator (1).

: 13 mm
(5) Remove tube (10)
Loosen clip (11) and pull out tube (10).

Fig. 33-37 Removing water separator (1)

33-18
 33. UPPER SLEWING BODY

33.1.10.2 REMOVAL
(1) Removing bracket (B3) used to secure two tanks. B4 A3
1) Remove two sems bolts (B4) M12 × 25.
2) Remove bracket (B3) and shim (If used). B3

: 19 mm
(2) Remove fuel tank assy (A1)
1) Remove four capscrews (B1) M16 × 30.
2) Sling and remove fuel tank assy. B7
Weight : 59 kg (130 lbs) B5
B6
: 24 mm

B1
T=216 N·m
(160 lbf·ft)
CAPSCREW
M16 X 30
A1

A4
Fig. 33-38 Removing fuel tank

33.1.10.3 INSTALLATION
(1) Installing is done in the reverse order of removing.
Tank attaching bolt M16 × 30

: 24 mm
Apply Loctite #262
Tightening torque : 216 N•m (160 lbf•ft)
Sems-bolt (B4) M12 × 25
Tightening torque : 67 N•m (49 lbf•ft)
Machine screw (B7) M5 × 12
Tightening torque : 2.0 N•m (1.5 lbf•ft)

Special attention must be paid not to drop tightening tools in far side when tightening installing bolts.

33-19
33. UPPER SLEWING BODY

33.1.11 HYDRAULIC TANK

33.1.11.1 PREPARATION FOR REMOVAL

(1) Slewinging upper structure 45 degrees.
Slewing upper structure to make the removal of
suction hose for pump installed under tank easier.

Fig. 33-39 Slewinging upper structure 45 degrees

(2) Bleeding internal air of tank Push
Press cap by finger to bleed internal air.

Keep pressing until the hissing sound stops.

Fig. 33-40 Bleeding internal air of tank
(3) Removing hydraulic pipe on the upper cover of
tank.
1) Remove two nuts M8 for coupling (5). 12

2) Open the gap and remove the coupling.

(4) Remove hose (12)
11
5
: 22 mm
(5) Remove hose (11)

: 27 mm

Fig. 33-41 Removing hydraulic pipe on the upper

cover of tank
(6) Remove cover (A6) A6
1) Remove six cpscrews (A12) M10×20
2) Remove cover (A6). A12

WASHER
: 17 mm

Fig. 33-42 Removing cover (A6)

33-20
 33. UPPER SLEWING BODY

(7) Emptying hydraulic oil

Place pump in tank and drain hydraulic oil.
Capacity of tank : Approx. 80 L (21 gal)

Care should be taken that pump does not damage suc-

tion strainer.

Fig. 33-43 Emptying hydraulic oil

33.1.11.2 REMOVAL
(1) Draw out the suction hose (4)
1) Remove two (2) clips (9) on tank side through
under side of slewing frame.
2) Pulling out hose (4).
: Flat-blade screwdriver HYDRAULIC OIL TANK

9 4
Fig. 33-44 Draw out the suction hose (4)
(2) Disconnecting pilot return hose (DR)
Disconnect 7 pilot drain hoses on rear side of tank.

Fig. 33-45 Disconnecting pilot return hose (DR)

33-21
33. UPPER SLEWING BODY

(3) Remove hydraulic tank attaching bolt

Remove four capscrews (1) M16 × 35.

: 24 mm
(4) Slinging hydraulic oil tank
Hook wire to neck of tank upper cover.
1
Tank weight : Approx. 65 kg (143 lbs) Tightening torque :
216 N·m (160 lbf·ft) 1
Apply Loctite #262 Tightening torque :
216 N·m (160 lbf·ft)
Apply Loctite #262

Fig. 33-46 Removing hydraulic tank attaching bolt

33.1.11.3 INSTALLATION
(1) Cleaning hydraulic oil tank
(2) Cleaning suction hose
(3) Cleaning mount of tank
Installing is done in the reverse order of removing.
(4) Attaching bolt
Apply Loctite #262

: 24 mm
Tightening torque : 216 N•m (160 lbf•ft)

Fig. 33-47 Slinging hydraulic oil tank

(5) Connection of suction hose O-RING
Apply PERMATEX on pipe side of hose connection
and insert it.
(6) Clip (9)
Tightening torque : 5.4 N•m (4.0 lbf•ft)
(7) Tank cover attaching bolt
M10 Tightening torque : 46.1 N•m (34 lbf•ft)

SUCTION
RETURN FILTER STRAINER
REPAIR KIT

O-RING

Fig. 33-48 Element & Filter

33-22
 33. UPPER SLEWING BODY

33.1.12 PUMP

33.1.12.1 PREPARATION FOR REMOVAL

(1) Remove counterweight. BREATHER
(2) Release pressure in hydraulic oil tank. A6 A12
CAPSCREW
(See item "Hydraulic oil tank") T=46.1 N·m (34 lbf·ft)
(3) Remove six capscrews (A12) M10.
(4) Remove cover (A6)
SUCTION SUCTION
STRAINER STOPPER
: 17 mm
(5) Take out suction strainer.
(6) Install suction stopper.
For suction stopper, see Chapter "Tools".

Pump can be removed even when counterweight is not HYDRAULIC

OIL TANK
removed. But removal of counterweight facilitates
working, and the working time is also reduced. Fig. 33-49 Hydraulic oil tank

(7) Remove two capscrews (71) M10.

(8) Remove cover (60).
(9) Remove a sems bolt (25) M12 and two sems bolts COVER
(24) M12. 24 SEMS-BOLT

(10)Remove guard (11) assy. 60

: 17 mm, 19 mm 71
11
(11)Disconnect drain down pipe installed under engine
muffler.
25

Fig. 33-50 Removing guard

33.1.12.2 REMOVAL
(1) Loosen cap nuts of hoses (5), (6) and remove 2
hoses from delivery sides (A1), (A2). 6

: 36 mm
(2) Remove suction flange
1) Remove four socket bolts (10) M12. 5
HYDRAULIC
2) Remove flange (3) of suction hose (4) from pump OIL TANK
(B1).
PUMP

40 mm
(1.57 in) : Special service tool No.6-1 of opposing 3

frats 10 mm
10

CLIP CLIP
4
If slewing is operated while leaving clip of suction hose
on flange side loosened, it can not be tightened. Fig. 33-51

33-23
33. UPPER SLEWING BODY

(3) Removing other hoses

1) Disconnect hoses of the following ports.
A3
(See Fig. 33-52) A1 *A5
A2 A5
Dr1
Port Size Tool Connected Remarks
to
Dr1 PF1/2 27 Tank Drain
HOSE
Dr2 PF1/2 27 Plug

Pf PF1/4 19 Tank Air-con power P3 A4 Pz

shift port
B2
P3 PF1/4 19 A5 Do not have
to remove it. Pf

A3 PF3/8 22 Inlet of Delivery port

in-line filter
B1
A4 PF3/8 22 Outlet of Relief port
in-line filter Dr2
Delivery port (PLUG)
Dozer
*A5 PF1/2 27
C/V-P for dozer Fig. 33-52 Pump port (with dozer)
Suction port
B2 PF1 41 Tank for dozer
Pz PF3/8 19 SOL. Block Power shift port

2) Attach tags to hoses to identify.

(4) Remove main pump
Clockwise
1) Attach eye bolt (M8) on upper surface of pump.
2) Lift it with wire lightly.
3) Remove 2 socket bolts (4) M16 × 35.
4) Pull pump horizontally and remove it.

EYE BOLT
45 mm
(1.77 in): Special service tool No.6-2 of 14 mm
(For bolts on upper side)
Weight of pump : Approx. 44 kg (97 lbs)
I

Tightening torque :
4 191 N·m (140 lbf·ft)
Apply Loctite #262

Fig. 33-53 Removing pump

33-24
 33. UPPER SLEWING BODY

33.1.12.3 INSTALLATION
Installing pump in the reverse procedure of removal fol-
lowing the specification for tightening torque and seal-
ant.
(1) Apply grease on spline of input shaft.
Apply
Grease ; Shell Retinax AM
grease
(General-purpose extreme-pressure molybdenum
disulfide grease)
(2) Hook wire to eye bolts (M8) on upper surface of
pump and lift it.
(3) Insert pump spline section.

4
Fig. 33-54 Installing pump
(4) Apply sealant on suction port (B2) for dozer and fix
it with hose connecting clip. 6
Sealant : Permatex #98D B2 port is omitted
in this Drawing
Socket screw driver 7 mm
Tightening torque : 4.4 N•m (3.3 lbf•ft)
(5) Apply sealant on socket bolt (4) and mount pump
with it.
Sealant : Loctite #262
5
: 14 mm HYDRAULIC
OIL TANK
(* Special service tool No.6-2)
PUMP
Tightening torque =191 N•m (140 lbf•ft)
(6) Install the suction flange (3) mounting socket bolts
(10) M12 (4 pcs.)

: 10 mm
(* Special service tool No.6-1)
Tightening torque =98 N•m (72 lbf•ft) 3

(7) Installation

Tightening
Tool torque
Tightening position
Hex. mm N·m (lbf·ft) 10
Cap nut A1, A2 36 118 (87)
CLIP
Cap nut Dr1 27 78 (58) CLIP
Cap nut Pf, Pz 19 29 (22)
Cap nut A3 22 49 (36) Fig. 33-55 Hose installing
Cap nut A4 22 49 (36)
Cap nut A5 27 78 (58)
*
(8) Install a water drain pipe under the engine muffler.

33-25
33. UPPER SLEWING BODY

(9) Remove suction stopper

a2 a1
(10)Mounting suction strainer
(11)To bleed air in pump, loosen plugs on pressure
measuring ports a1, a2 and a3.

: 19 mm
(12)Check hydraulic oil level.
(13)Start engine and check it for oil leakage and noise. a3

Fig. 33-56 Release air in pump

(14)Install guards

Tool Tightening
Tightening position torque
Hex. mm N·m (lbf·ft)
Capscrew (71) 17 66 (48)
COVER
Sems-bolt (24), (25) 19 79 (59) 64
24

60

71
11

After replacing pump, be sure to fill hydraulic oil of 1L 25

(0.26 gal) or more.

Fig. 33-57 Guard installing

33-26
 33. UPPER SLEWING BODY

33.1.13 RADIATOR & OIL COOLER

33.1.13.1 PREPARATION FOR REMOVAL

Connection of hoses for air-con should not be loosened and removed. Refrigerant may be leaked.

B9 SUB TANK

HOSE

B6 RADIATOR HOSE (UPPER)

B5
SHROUD · BRACKET
RADIATOR
HOSE
(LOWER) CAP M8 X 20
T=28 N·m
(21 lbf·ft)
4 GUARD
4-M12 X 30
Loctite #262
T=120 N·m DRAIN COCK
(88 lbf·ft) STAY

M10 X 25
T=57 N·m
(42 lbf·ft)

Fig. 33-58 Relative drawing of radiator

(1) Remove counterweight 3 HOSE
(2) Bleeding internal air of hydraulic oil tank
(3) Remove cover of suction strainer, and adjust oil
quantity so that oil level becomes lower than the re- 2 HOSE
turn tube level.
7
(4) Remove air cleaner hose
Refer to 33.1.8 AIR CLEANER 7
1) Loosen two bands (7).
2) Pulling out hose (2).
Fig. 33-59 Removing hose
3) Pulling out hose (3).
: Flat-blade screwdriver
(5) Removing under cover installed on lower side of ra-
diator.
1) Remove four sems bolts (A9) M12 × 25.
2) Remove cover (A5).

: 19 mm
COVER A5

A9

Fig. 33-60 Removing under cover

33-27
33. UPPER SLEWING BODY

(6) Drain down of radiator D HOSE 9

Put container 18 L (4.8 gal) under drain cock hose (AIR-CON) A6
Tightening torque :
for draining water. Tightening torque : 4.4 N·m (3.3 lbf·ft)
4.4 N·m 17, 20, 23
(7) Remove washer tank (3.3 lbf·ft)
16, 20, 23 Tightening torque :
1) Pulling out hose. 39 N·m (29 lbf·ft)
CAPSCREW CONDENSER 14
2) Move washer tank. M6 X 60 3 pcs. SEMS-BOLT
RECEIVER M8 X 25 2 pcs.
(8) Move air-con condenser (A6) TANK
1
1) Remove three capscrews (16) M6 × 50. WASHER TANK
11
2) Remove two sems-bolts (14) M8 × 25.
15
S HOSE
3) Move A/C condenser (A6) (AIR-CON)
8

: 10 mm, 13 mm 10
L HOSE (AIR-CON)

(9) Move receiver tank

1) Remove two capscrews (15) M8 × 16 which are Fig. 33-61 Removing air condenser
used to install regulator tank with bracket.
2) Move receiver tank

: 13 mm

33.1.13.2 REMOVAL
(1) Remove radiator stay CAP
1) Remove two capscrews (A2) M10 × 25.
2) Remove stay (A1). STAY

: 17 mm
A1 CAPSCREW
(2) Remove bracket (B2) T=120 N·m
(88 lbf·ft) M10 X 25
1) Remove four capscrews (B17) M8 × 20. B17 T=57 N·m
A2 (42 lbf·ft)
2) Remove bracket (B2).
DRAIN COCK
4-M8
: 13 mm B2 COOLER MOUNTING BOLT
Fig. 33-62 Removing radiator stay (A1) & brackt
(3) Remove sub tank (B9) B9 SUB TANK
1) Loosen clip on one side of hose (B11) and pull
out hose.
2) Lift sub tank (B9) directing upward, and remove B3 BRACKET
B11 HOSE
it from bracket (B3).
TO RADIATOR

Fig. 33-63 Removing sub tank

33-28
 33. UPPER SLEWING BODY

(4) Remove guard (B4) B19 CAPSCREW

1) Remove three capscrews (B19) M8. B4

2) Remove guard (B4).

B6
: 13 mm B12
(5) Remove water hose (B6)
1) Loosen the hose band (B12).
2) Remove hose (B6).
C1
: Flat-blade screwdriver
(6) Remove main radiator (C1)
Remove four capscrews (A3) M12 × 30.

: 19 mm
CAPSCREW
: 19 mm M12 X 30
Loctite #262
T=120 N·m
(88 lbf·ft)
A3

Fig. 33-64 Removing radiator

(7) Removing connection coupling for hydraulic oil 5
cooler. M8
1) Remove 4 bolts M8 of coupling (5) just below the
radiator.
2) Put oil pan under the coupling (5), remove cou-
pling and let oil out.
(8) Disconnecting hydraulic oil pipe Fig. 33-65 Removing coupling
1) Shift radiator outward.
2) Plug up pipe ends with rag, etc.
(9) Disconnecting water lower hose (B5)
1) Loosen the hose band (B13).
2) Pulling out hose (B5).
RADIATOR
OIL COOLER

Remove the hose while sliding the radiator little by little. B5

B13
(10)Removing radiator
Remove radiator assy by power of men or with
crane.
Weight : 48 kg (106 lbs) Fig. 33-66 Removing water lower hose (B5)

33-29
33. UPPER SLEWING BODY

33.1.13.3 INSTALLATION
(1) Installing is done in the reverse order of removing.
(2) Install radiator assy
Lift up radiator by power of men or with crane,
match the holes for water hose and hydraulic oil
pipe and also the position respectively, and assem-
RADIATOR
ble them temporarily. CENTER
However, water hose insert standard 30 ± 2 mm
(1.18 ± 0.08 in)
Hydraulic oil pipe insert standard 30 ± 2 mm
7.5
(1.18 ±0.08 in)

8
(3) Radiator attaching bolt
Apply Loctite #262 on 4 capscrews (A3) M12, and
tighten it with washer respectively.

: 19 mm
Tightening Torque : 120 N•m (88 lbf•ft)
FAN CENTER
Adjust chip-clearance to be
20mm for all around.

(4) Making up hydraulic oil and LLC

After completion of other installation, make up hy-
draulic oil and water. See pages 4-7 in Operator's
Manual.

Tighten it with
attaching bolts
of radiator
3 shroud.
T=8.1 N·m
(6.0 lbf·ft)

Fig. 33-67 Installing radiator

33-30
 33. UPPER SLEWING BODY

33.1.14 ENGINE

33.1.14.1 PREPARATION FOR REMOVING

(1) Remove guard (See Fig. 33-14~Fig. 33-26.)
(2) Remove counterweight (See Fig. 33-11~Fig. 33-13.)
(3) Remove battery ground (See Fig. 33-7)
(4) Remove air cleaner hose (See Fig. 33-30)
(5) Remove radiator hose (See Fig. 33-64~Fig. 33-66.)
(6) Remove fuel hose and heater hose, and if necessary air-con hose.
(7) If necessary, remove pump, air cleaner, muffler and radiator.
(8) Remove harness and connector

1) Starter cable Starter B terminal

E/G sub harness terminal
CN357M
M-2
CN-351F E/G sub
2) Main harness
CN-352M harness
CN-363F

3) Engine grounding cable

Prepare a stand which withstands the weight of the engine assy and should be able to place the removed engine
firmly.

33-31
33. UPPER SLEWING BODY

E/G LIFTING FITTING

GROUND
E/G OIL PRESSURE SW
E/G OIL FILTER
E/G SPEED SENSOR E/G GROUND CABLE T=79 N·m
8 PIN CONNECTOR (59 lbf·ft)
CN-352M
BRACKET 2 E/G SUB HARNESS

TO ALTERNATOR
1 PIN CONNECTOR
TO E/G SPEED CN-351F
SENSOR
TIGHTEN CABLE TOGETHER WITH
CAPSCREW OF GROUND
Torque : 40 N·m (30 lbf·ft)

E/G OIL PRESSURE SW

Torque : 40 N·m (30 lbf·ft)
Apply Loctite #262

8 PIN CONNECTOR
CN-363F
SEMS-BOLT
Torque : 9.6 N·m (7.1 lbf·ft)

SAFETY RELAY
CLIP
TO MAIN HARNESS
DETAIL I

PT3/8 (PLUG)
FOR HEATER
HOSE
Clamp the white 4-M10 X 1.25
E/G WATER
tape portion
TEMPERTURE
SW [105 C (221 F)]

33-32
 33. UPPER SLEWING BODY

WATER
TEMPERTURE
FUEL FILTER FUEL RETURN (OUT)
SENSOR
M16 X 1.5
E/G LIFTING
FITTING

Clamp the white

tape portion

M-1
STARTER
MOTOR

A/C
COMPRESSOR

FUEL FEED (IN) STARTER CABLE

M-2
STEPPING (GOVERNOR) MOTOR

Connect with
the starter motor RUBBER CAP S
CN-357M
1PAM-58Y STARTER CABLE
B
TO E/G SUB
HARNESS M

DETAIL OF STARTER MOTOR TERMINAL

33-33
33. UPPER SLEWING BODY

33.1.14.2 REMOVAL

6 6 CAPSCREW
M18 X 90
T=225 N·m (170 lbf·ft)
1 Apply Loctite #271

2 BRACKET
10 CAPSCREW
M10 X 35
T=43 N·m (32 lbf·ft)
Apply Loctite #271
8
3 4

4 RUBBER MOUNT

3
12

5
5
12 SHIM
7 5
5 RUBBER
7
7 7 NUT

(1) Removing attaching bolt to frame

1) Remove four nuts (7) M18.
2) Remove rubber mount (5) and shim (12).
3) Remove four capscrews (6) M18 × 90.

: 27 mm
(2) Slinging engine body
1) Sling engine hooking wire to lifting lugs on the front and rear sides.
Weight : Approx. 250 kg (550 lbs)
Wire : ø6 (0.236") × 1 m (3 ft 3 in)-2 pcs.
(3) Position engine on the mount stable.

33.1.14.3 INSTALLATION
(1) Installing is done in the reverse order of removing. For tightening torque and Loctite, refer to above figure.

33-34
 33. UPPER SLEWING BODY

33.1.15 MULTI CONTROL VALVE

33.1.15.1 PREPARATION FOR REMOVAL

(1) Bleed pressure air in hydraulic oil tank (See Fig. 33- 24
40.)
(2) Remove cover assy (1) (See Fig. 33-15)
2
(3) Remove cover assy (2) (See Fig. 33-16)
(4) Remove cover assy (6) (See Fig. 33-17) A

(5) Shift bracket (1) for multi control valve if necessary.

(See Fig. Fig. 33-68) 22 15 Nut

(6) Tag harness and remove it. 1 3

(7) Attach tag to hose between multi control valve and
main C/V, and write numbers C1 to C8 on it. 10
11
Remove hose on multi control valve side, and plug
connection. Plug No. 4-3 SECTION A-A

Fig. 33-68 Removing bracket for multi control valve

33.1.15.2 REMOVAL
(1) Attach tag on which hose name is entered to the re-
mote control hoses between multi control valve and
pilot V, and write numbers P1 to P8 on it.
(2) Remove hoses P1 to P8 on multi control valve side
and plug connection, Plug No.4-3
(3) Remove four capscrews (22) M8 × 20.
(4) Remove multi control valve (24).

: 13 mm
(5) Removing and shifting bracket (1) for multi control Fig. 33-69 Connection between multi control valve
valve. and main C/V
1) Remove two capscrews (11) M12 × 85 and re-
move clamp (3).

: 19 mm
2) Remove two capscrews (15) M10 × 25 and
bracket (2).
3) Remove three capscrews (10) M10 × 30.

: 17 mm
4) Move bracket (1).

33-35
33. UPPER SLEWING BODY

33.1.15.3 INSTALLATION
(1) Installing is done in the reverse order of removing
(2) Relations between pilot valve and multi control
valve hose.

Hose ISO Multi Mark-

P/V port Operation pattern port ing
Size Collar
1 1/4 Red Bucket digging P1 1
2 1/4 Blue Bucket dump P2 2
Right 3 1/4 Green Boom up P3 3
side 4 1/4 Gray Boom down P4 4
P 1/4 Black Pilot primary
T 3/8 Black Drain
5 1/4 Gray Swing left P5 5
6 1/4 Red Swing right P6 6 Fig. 33-70 Connection between P/V and multi con-
Left 7 1/4 Blue Arm in P7 7 trol valve
side 8 1/4 Gray Arm out P8 8
P 1/4 Black Pilot primary
T 3/8 Black Drain

33.1.15.4 LEVER CHANGE PROCEDURE OF MULTI CONTROL VALVE

(1) Changing from "Multi valve" to "Lever less multi Specification of Multi valve with lever
valve" 19 20, 21
1) Lower attachment to ground level and check that 18
the engine stops. Then bleed hydraulic system 16
pressure and internal pressure of oil tank. 17 9 10, 13
11
(Refer to 33.1.11 HYDRAULIC TANK.) 6
15
2) Remove bolt (9) and adjust lever (29) to the po-
sition of operating pattern for "Lever less multi
12 29
valve". 4
8
3) Remove six capscrews (11) and two capscrews
7
(12).

: 5 mm
4) Remove "Multi valve" kit, and install "Lever less
Fig. 33-71
multi valve"kit
• Then replace O-rings (7) and (8) with new C/V assy with multi
ones. No. Name Q’ty
And apply grease before installation, and REPARE KIT WITH MULTI 1s
check that it is not twisted. 4 •
COVER 1
• Put capscrew (28) to the bolt hole provided 6 •
DUST SEAL 1
on the side farther away from the center.
7 •
O-RING 1
8 •
O-RING 1
: 5 mm 9 •
BOLT 1
Tightening torque : 42 N•m (31 lbf•ft) 10 •
CAPSCREW 2
5) Tighten capscrew (11) to the specified torque.
12 •
SOCKET BOLT 2

(Apply Loctite #242.)

13 •
WASHER 2
15 •
PIN 1
: 5 mm 16 •
CASE 1
Tightening torque : 42 N•m (31 lbf•ft)
17 •
SPRING 1

6) Check that it is set to regular switching pattern

18 •
KNOB 1

while operating excavator slightly.

19 •
KNOB 1
20 •
MACHINE SCREW 1
21 •
WASHER 1
29 •
LEVER 1

33-36
 33. UPPER SLEWING BODY

(2) Change from "Lever less multi valve" to "Multi Specification of Leverless multi valve
valve". 8 28 27 11
1) Stop engine, remove "Lever less multi valve" kit
by the reverse procedure, and change kit to
"Multi valve". 7

• Apply grease slightly on the lip of dust seal,

item (6).
2) Check that the lever can be changed to respec-
tive pattern easily while operating excavator
slightly.
Fig. 33-72

Multiless C/V assy

No. Name Q’ty
MULTILESS PEPARE KIT 1s
7 • O-RING 1
8 • O-RING 1
11 • CAPSCREW 2
27 • COVER 1
28 • SOCKET BOLT 1

33-37
33. UPPER SLEWING BODY

33.1.16 CONTROL VALVE

33.1.16.1 PREPARATION FOR REMOVAL

(1) Remove cover assy (1) (See Fig. 33-15) and bonnet assy (5) (See Fig. 33-20)
(2) Remove panel assy (2) (See Fig. 33-16) and cover (3) (See Fig. 33-21)
(3) Remove cover assy (60) (See Fig. 33-17) and guard assy (11) (See Fig. 33-24)
(4) Release air in hydraulic oil tank, open cover of suction element of hydraulic oil, and lower the level.
(See Fig. 33-49)

33.1.16.2 REMOVAL
(1) Removing hoses for each piping
Attach tag on hose, and write port name on it, then
remove hoses.
(2) Remove control valve
1) Remove 4 capscrews (2) M12 × 30 from upper
frame.
2) Remove bracket (1) together with control valve.
3) Three capscrews (2) M12 × 30 from bracket.

: 19 mm
4) Weight : 70 kg (154 lbs)

2
2

Fig. 33-73 Removing main control valve

33.1.16.3 INSTALLATION
(1) Installing is done in the reverse order of remove.

: 19 mm
M12 Tightening torque : 121 N•m (89 lbf•ft)
(2) Make certain that attachment moves normally in operation.
(3) Check oil level and that it is free from oil leakage.

33-38
 33. UPPER SLEWING BODY

33.1.17 PILOT VALVE (FOR ATT)

33.1.17.1 PREPARATION FOR REMOVING

The removing procedure for right and left is the same,
so the preparation for left side is described here. PANEL ASSY

(1) Put attachment on ground, stop engine and release

26
pressure in tank. 25
(2) Remove panel assy referring to Section 4. Instru-
ment Panel.
(3) Remove one sems-bolt (12) M5 from lower side of
control box.
: Cross recessed screw driver
(4) Remove cover on outer surface.
(5) Remove sems-bolt (25) and rubber sheet (26) se- 12

curing cover and control box on inner surface. Fig. 33-74 Removing instrument panel
: Cross recessed screw driver BOOTS
(6) Remove cover on inner surface.
16
: Cross recessed screw driver
(7) Remove harness connector for horn.
PILOT VALVE
(8) Attach tag to hoses for identification.
T=29 N·m
(22lbf·ft)
T=29 N·m PF1/4
(22lbf·ft)
PF1/4 Opposing
VALVE SIDE
Opposing flats 19
flats 22
MARK “ F ”
PF3/8
PF1/4
1-4, 5-8 PORT AND
HOSE SIDE P PORT (WITH FILTER)
T PORT CONNECTOR CONNECTOR

Fig. 33-75 Pilot valve connector

33.1.17.2 REMOVAL
(1) Remove hoses from your side to far side in order.
FRONT OF THE MACHINE
: 19 mm, 22 mm
BOOM (R)
(2) Shift boots. ARM (R)
BUCKET (R)
(3) Remove four socket bolts (A1) M6.

: 5 mm
SWING (R)
(4) Remove pilot valve.
(5) Plug hose ends. Plug PF1/4
BUCKET (H)
SWING (L) BOOM (H)
ARM (H)
LEFT SIDE RIGHT SIDE

Fig. 33-76 Pilot valve port position (for upper side)

33.1.17.3 INSTALLATION
Install it in the reverse order of removal and tighten it to the below tightening torque.

: 5 mm T=11 N•m (8.0 lbf•ft)

: 19 mm T=29 N•m (22 lbf•ft)

: 22 mm T=49 N•m (36 lbf•ft)

33-39
33. UPPER SLEWING BODY

33.1.18 PILOT VALVE (FOR TRAVEL)

33.1.18.1 PREPARATION FOR REMOVING

(1) Release pressure in hydraulic oil tank
(2) Remove under cover (See 33.1.7 UNDER COVER)
(3) Remove floor mat

33.1.18.2 REMOVAL
(1) Disconnect pressure sensors connectors at two
places from under floor harness.
(2) Remove two pressure sensors.

: 19 mm
7
(3) Disconnect lead cable CA103 for travel 1,2 speed
at two places from under floor harness.
(4) Attach tag, and disconnect connectors and hoses. Lead cable for
travel 1,2 speed
10
: 19 mm (P port) Connect to under
floor harness
: 19 mm (T port, 1~4 port) PF1/4
with CA103 plug
(5) Plug hose ends PRESSURE PRESSURE SENSOR
Plug PF1/4 SENSOR

(6) Remove four capscrews (7) M10

T
(7) Remove right and left levers. CONNECTORS
P
(8) Remove four socket bolts (10) M10. 4

: 8 mm 3
2
(9) Remove four sems-bolts (9) M10 and remove two
plate (18) 1 GROMMET
25 24
: 17 mm
(10)Remove pilot valve lifting it upward.
(11)Stop up holes with blank plugs PF1/4, 3/8.

33.1.18.3 INSTALLATION
Install it in the reverse order of removal and tighten it to Opposing
the below tightening torque. PF3/8 flats 22
PF1/4
: 19 mm, 22 mm T=29 N•m (22 lbf•ft)

: 8 mm T=46 N•m (34 lbf•ft)

VALVE SIDE HOSE SIDE
: 17mm T=46 N•m (34 lbf•ft) VALVE SIDE T port connector

Pressure sensor PF3/8 Opposing

Opposing flats 22 MARK F
flats 22 PF1/4 PF1/4
: 19 mm T=29 N•m (22 lbf•ft)
PF1/4

HOSE SIDE
1-4 port connector P port connector
Fig. 33-77 Installing and Removing pilot V

33-40
 33. UPPER SLEWING BODY

33.1.19 SLEWING UNIT

33.1.19.1 PREPARATION FOR REMOVING

(1) Park machine on flat and solid ground and put at-
tachment and dozer on ground.
(2) Stop engine and release pressure in circuit operat-
ing dozer lever.
(3) Release internal pressure through bleeder of hy-
draulic oil tank.
(4) Remove boom as necessary to make work easier.
(Refer to chapter of Attachment.)
(5) Remove cab if necessary to make work easier.
(Refer to Chapter of Upper structure.)
(6) Remove cover under engine.
(7) Attach tag to hose.

Fig. 33-78 Slewing unit piping

33.1.19.2 REMOVAL
(1) Remove hose.
1) Two hoses from tee of MU port.
1
: 36 mm
Tightening torque : 118 N•m (87 lbf•ft)
2) One hose from tee of Dr port.
9
: 22 mm
Tightening torque : 49 N•m (36 lbf•ft)
3) One hose from elbow of PG port (for slewing
parking brake). 8
: 19 mm
Tightening torque : 29 N•m (22 lbf•ft)
4) Two hose from tee of A, B ports.

: 32 mm
(* Special service tool No. 6-3)
Tightening torque : 147 N•m (110 lbf•ft) Fig. 33-79 Removing slewing unit

5) Install PF1/2 plug

Plug No.4-2-1

33-41
33. UPPER SLEWING BODY

(2) Loosen one capscrew (9) M10 from under side of

upper frame and remove drain hose clip (8) for re-
duction unit.

: 17 mm
Tightening torque : 46 N•m (34 lbf•ft)
(3) Remove eight the slewing unit mounting socket
bolt (1) M16 × 50.
Allen key socket wrench : 14 mm
Tightening torque : 279 N•m (210 lbf•ft)
Loctite #262 (Three Bond #1350)
(4) Remove Tee of slewing motor MU port and plug up
holes with plug used as eye bolt.

: 36 mm
Tightening torque : 162 N•m (120 lbf•ft)
Plug No. 6-4, Eye bolt No. 6-5
(5) Hook sling to eye bolts attached on MU port. Weight
of swing unit : Approx. 70 kg (150 lbs)

33.1.19.3 PREPARATION FOR INSTALL

(1) Clean mating surfaces of slewing unit and upper frame.
Tools : spatula, cleaning fluid
(2) Apply sealant on entire mounting surface of slewing unit.
Sealant : Loctite # 515 (Three Bond #1215)

33.1.19.4 INSTALLATION
Installing is done in the reverse order of removing

Fill inside from motor drain port to casing with hydraulic oil before piping for drain

33.1.19.5 PREPARATION FOR DRIVE

(1) Before starting operation, check that gear oil (#90 grade GL-4) level of slewing reduction is sufficient.
Amount of charge : 1.5 L (0.40 gal)
(2) When starting operation, operate motor in low idling and at low speed for several minutes, and check it for pos-
sible oil leakage and noise.
(3) Confirm proper functions.

33-42
 33. UPPER SLEWING BODY

33.1.20 SWIVEL JOINT

33.1.20.1 PREPARATION FOR REMOVE

(1) Remove attachment assy
A22
(Refer to 3. ATTACHMENT DIMENSIONS) A23
(2) Remove cab (See 33.1.1 CAB)
B6
(3) Remove guard (See 33.1.6 GUARD)
B3 B3
(4) Removing hoses on undercarriage A22
(See Chapter : Undercarriage) B7
B4
(5) Remove slewing reduction unit if necessary.
6
(See 33.2.5 SLEWING MOTOR UNIT) B10
B9
B1

B3
A20
11 1

B11
7
Fig. 33-80 Removing hose and joint

33.1.20.2 REMOVAL
(1) Remove travel motor hose C3
1) Remove hose (A22). (D port) CAPSCREW

2) Remove hose (A22). (A port) C5 M16

3) Remove hose (A23). (C port) T=157 N·m
(120 lbf·ft)
4) Remove hose (A20). (B port)
(2) Disconnect drain hose from pipe (B7).
(3) Disconnect 2-speed travel hose from joint 1. Fig. 33-81 Removing whirl-stop nut & the capscrew
(4) Remove dozer hose. (6), (7) (Port F, G)
CAPSCREW B4
(5) Remove whirl-stop of swivel joint. M8 X 25
T=9 N·m
1) Loosen the nut (C5) M16. B7 (6.5 lbf·ft)
2) Remove a capscrew (C3) M16 × 110.
PLATE B2
: 24 mm
(6) Remove joint for piping DUST COVER B1

1) Remove three elbows (B3), (B6).

2) Remove connector (B1), (B4).. Fig. 33-82 Removing dust cover (B1)

3) Remove connector for travel 2-speed change

over (B9).

: 27 mm, 19 mm
(7) Remove dust cover (B1)
1) Remove four capscrews (B4) M8 × 25.
2) Remove plate (B2).
3) Remove dust cover (B1).

: 13 mm

33-43
33. UPPER SLEWING BODY

(8) Remove socket bolt for installation

Attach eye bolt on pipe (B7), lift it up temporarily,
and remove three (3) socket bolts (2) M8 × 20.

: 6 mm
B7

BALL POINT
ALLEN KEY
WRENCH 2
SOCKET BOLT
M8 x 20
Loctite #262
T=35 N·m
(26 lbf·ft) 1
SWIVEL JOINT

Fig. 33-83 Removing socket bolt for installation

(9) Slinging the swivel joint
Weight : Approx. 21kg (46 lbs)

Fig. 33-84 Slinging swivel joint

33.1.20.3 INSTALLATION
(1) Installing is done in the reverse order of removing.
Piping tightening torque
Thread dia. Tool Tightening torque
PF HEX O-ring type Hydraulic hose
36 N·m 29 N·m
1/4 19 (27 lbf·ft) (22 lbf·ft)
74 N·m 49 N·m
3/8 22 (54 lbf·ft) (36 lbf·ft)
108 N·m 79 N·m
1/2 27 (80 lbf·ft) (58 lbf·ft)

(2) Check for oil leakage and the hydraulic oil level.
(3) Check for operating.

33-44
 33. UPPER SLEWING BODY

33.1.21 UPPER FRAME

33.1.21.1 PREPARATION FOR REMOVAL

(1) Remove attachment
(Refer to 3. ATTACHMENT DIMENSIONS)
(2) Remove cab (See 33.1.1 CAB)
(3) Remove guard (See 33.1.6 GUARD)
(4) Remove counterweight
(See 33.1.5 COUNTERWEIGHT)
(5) Remove swivel joint. 8
(Perform the steps (1) thru (7) of 33.1.20 SWIVEL
JOINT)

Fig. 33-85 Temporarily lift upper frame

33.1.21.2 REMOVAL
(1) Lifting up upper frame temporarily
MATCH
Hook one sling to slewing bracket on front side and MARK
two chain blocks to both side of guard (8) on rear
side and raise it up temporarily at three points.
Wire rope : ø16 (0.630") × 2.5 m (8 ft 2 in),1 pcs.
ø16 (0.630") × 1.5 m (4 ft 11 in),2 pcs.
Chain block : 750 kg (1650 lbs) 2 pcs.
(2) Marking match marks on slewing bearing
Mark match marks on upper frame and slewing
bearing.
Fig. 33-86 Matching mark on slewing bearing and
upper frame
(3) Removing upper frame mounting bolts
Remove twenty capscrews M16 × 90 and three
reamer bolts used to install slewing bearing and up-
per frame.

: 24 mm
(4) Slinging upper frame
Sling according to Fig. 33-85, and remove upper
frame and put it on a stand resistant to the weight.
Weight : Approx. 1,500 kg (3310 lbs)

Fig. 33-87 Removing upper frame mounting bolts

33-45
33. UPPER SLEWING BODY

33.1.21.3 INSTALLATION
(1) Installing is done in the reverse order of removing. Apply Loctite #515 or equivalent torace
(2) Cleaning mating surfaces of upper frame and slew- surface of the inside of capscrew to only
perimeter specified by slanting line.
ing bearing.
(3) Applying Loctite #515 on mating surface.
(4) Slinging upper frame
Match marks and install it with three reamer bolts
temporarily. Apply Loctite #262
T=157 N.m (120 lbf.ft)
5
Fig. 33-88 Bearing mount
Confirm the reamer bolt positions referring to Fig. 33-
OUTER S ZONE POSITION
89.

(5) Install slewing bearing

Install twenty capscrews (5) M16 X 90.

: 24 mm Apply Loctite #262

Tightening torque : 157 N•m (120 lbf•ft)

Fig. 33-89 Reamer bolt position (*)

Apply Loctite on section specified by slanting lines

33-46
 33. UPPER SLEWING BODY

33.2 DISASSEMBLING AND ASSEMBLING

33.2.1 HYDRAULIC PUMP • REGULATOR

33.2.1.1 STRUCTURAL EXPLODED VIEW

33-47
33. UPPER SLEWING BODY

Table 33-1
* : Apply Loctite #222
Tightening Tightening
torque No. Name Q’ty torque No. Name Q’ty
N•m (lbf•ft) N•m (lbf•ft)
111 SHAFT 1 624 SPRING SEAT 1
114 COUPLING 1 625 SPRING 1
115 COLLAR 1 626 SPRING 1
123 ROLLER BEARING 1 627 ADJUST STEM (E1) 1
124 NEEDLE BEARING 1 157 (120) 630 LOCK NUT : M30 1
127 SPACER 1 641 SPRING COVER 1
141 CYLINDER BLOCK 1 651 SLEEVE 1
151 PISTON 10 652 SPOOL 1
152 SHOE 10 653 PIN 1
153 PLATE 1 654 PIN 1
156 SPHERICAL BUSHING 1 655 PIN (Pf PISTON) 1
157 SPRING 10 656 PIN 1
212 SWASH PLATE 1 660 ADJUST SCRW (R) 1
214 BUSHING 1 29.4 (22) 661 LOCK NUT : M14 × 1.5 1
215 PIVOT BALL 1 662 SPRING SEAT 1
216 PIVOT BALL 1 663 SPRING 1
271 CASING 1 664 POPPET 1
273 COVER 1 665 SEAT (R) 1
312 VALVE COVER 1 666 ADJUST SCREW (E) 1
313 VALVE PLATE 1 667 ADJUST STEM (E2) 1
235 (170) 401 SOCKET BOLT : M16 × 40 4 668 PISTON (E) 1
29.4 (22) 402 FLANGE SOCKET BOLT ; M8 × 16 2 700 O-RING : 1B G35 1
235 (170) 403 SOCKET BOLT : M16 × 70 1 701 O-RING : 1B G55 1
11.8 (8.7) 404 SOCKET BOLT : M6 × 20 9 702 O-RING : 1B G135 1
108 (80) 467 DRAIN PLUG : PF 1/2 1 705 O-RING : 1B P16 2
36.3 (27) 468 PLUG : PF1/4 1 706 O-RING : 1B P11 7
8.8 (6.5) 490 PLUG : NPTF1/16, Meck coated 14 707 O-RING : 1B P18 1
98.1 (72) 492 PLUG : PT1/8, Meck coated 1 708 O-RING 1
44 (33) 493 PLUG : PT3/8 1 709 O-RING : 1B P26 1
710 O-RING 1
8.8 (6.5) 508 ORIFICE THREAD : NPTF1/16 4 751 GASKET 1
98.1 (72) 531 TILTING PIN : M16 × 1.5 1 774 OIL SEAL* 1
98.1 (72) 532 SERVO PISTON : M16 × 1.5 1 787 BACKUP RING 1
534 SET SCREW : M27 × 1.5 1 789 BACKUP RING 2
535 STOPPER 1 15.7 (12) 801 LOCK NUT : M8 1
541 SEAT 2 127 (94) 803 LOCK NUT : M27 × 1.5 1
543 STOPPER 2 824 SNAP RING 1
545 BALL 2 825 SNAP RING 1
548 FEED BACK PIN 1 885 SPRING PIN 2
611 FEED BACK LEVER 1 901 EYE BOLT : M8 1
621 COMPENSATION PISTON 1

Bold No. shows adjusting screw and nut. Don’t touch these parts. Turning these parts causes losing of proper ad-
justment.

33-48
 33. UPPER SLEWING BODY

33.2.1.2 REMOVAL AND INSTALLATION

(1) Tools
Tool name Dimension
The following list shows the tools required for re-
move and install. Allen wrench Opposing flats 4, 5, 6, 8, 10, 14 mm
Eye wrench
(2) General precautions for remove Socket wrench Opposing flats 27 mm
1) Work in clean area. Wrench with double
heads (single head)
2) Spread rubber sheet or cloth on work bench to Adjust wrench Medium size 1 pc.
protect parts from damaging. Screw driver Flat-bladed screw driver 1 pc.
3) Remove dust and rust, etc. on pump surface with Hammer Plastic mallet 1 pc.
wash oil. Plier For snap ring TSR-160
Steel bar for key
Steel bar Approx. 10 X 8 x 200
• Following explanations and illustrations describe
(0.40" X 0.31 X 0.79")
the Hydraulic pump, which doesn't equip the
One that may be fastened to
power up port. Assembly and disassembly of Torque wrench
specified torque
power up port is described later.

(3) Removal GEAR PUMP

1) Letting oil out
Remove drain plug (467) and let oil out of casing 402
(271).
312
: 27 mm
2) Remove coupling (114)
Remove socket bolts (402) used to fasten valve
cover (312) and gear pump, remove gear pump,
and remove coupling (114) from inside of valve
cover (312).

: 6 mm
3) Remove valve cover (312) Fig. 33-90 Remove coupling (114)
Remove socket bolt (401) used to fasten valve
cover (312) and casing (271). 401

: 14 mm 271

312

Fig. 33-91 Remove socket bolt (401)

33-49
33. UPPER SLEWING BODY

2. Remove valve cover (312) from casing (271).

271

312

Fig. 33-92 Remove valve cover (312)

4) Remove valve plate (313)
Remove valve plate (313) from inside of casing
(271). 271

313

Fig. 33-93 Remove valve plate (313)

5) Remove cylinder assy and swash plate (212)
Remove cylinder block (141), piston (151), plate 271
(153), spherical bushing (156), spring (157) and
swash plate (212) from casing (271). 212 151
• Also, special attention must be paid not to
damage sliding surface of cylinder block
(141), spherical bushing (156), shoe (152),
swash plate (212), etc.

153 141 (156, 157)

Fig. 33-94 Remove cylinder assy and swash plate
(212)
6) Remove pivot ball (215), (216)
Remove pivot ball (215), (216) from casing 271
(271).

215

216
Fig. 33-95 Remove pivot ball (215), (216)

33-50
 33. UPPER SLEWING BODY

7) Remove shaft (111)

Remove snap ring (825) from casing (271) and
remove shaft (111) striking shaft end with plastic 271
hammer.
• Then, special attention must be paid not to
damage oil seal (774) fitted on casing (271). 111
(825)

Fig. 33-96 Remove shaft (111)

8) Remove spring (625), (626) and spring seat
(624)
641 (624, 625, 626)
Remove socket bolt (404), then remove spring
cover (641), spring (625) spring (626) and spring
seat (624).

: 5 mm

• Never loosen lock nuts (630), (801) of spring cover

(641). If loosened, the set value of regulator may be
changed.
Fig. 33-97 Remove spring (625),(626) and spring
• The regulator is made up of small precision parts,
seat (624)
so care should be taken not to lose and damage
any of them when remove and install.

9) Remove feed back lever (611)

Remove socket bolt (404) and cover (273). Then 611
remove feed back lever (611) from casing (271).

: 5 mm

271

Fig. 33-98 Remove feed back lever (611)

33-51
33. UPPER SLEWING BODY

10) Remove spool sub assy and compensation pis-

ton (621)
651 (621),(652)
Remove sleeve (651), spool (652), and compen-
sation piston (621).

Fig. 33-99 Remove spool sub assy and compensa-

tion piston (621)
11) Remove pin (655)
Remove plug (468), then remove pin (655).
468 (655)
: 6 mm
12) Remove servo piston sub assy
Since the set screw (534) installed on servo pis-
ton sub-assy is screw used to regulate flow rate
of regulator, it should not be removal if not re-
quired.
If required to removal, remove set screw (534)
with lock nut (803), stopper (535), servo piston
(532) and tilt pin (531).

: 19 mm, : 41 mm

Fig. 33-100 Remove pin (655)

• Lock nut (803) and set screw (534) are not allowed
to be removal unnecessarily. A set flow rate chang- 271 531 532 535 803
es.
534
• Since servo piston (532) and tilt pin (531) are ap-
plied Three Bond, it is not allowed to removal them.
• Care must be taken not to damage servo piston fix-
ing tilt pin when remove.

Fig. 33-101 Remove servo piston sub assy

33-52
 33. UPPER SLEWING BODY

13) Remove valve cover (312) 661

660
If necessary, remove relief valve lock nut (661), 705
adjusting screw (660), spring seat (662), spring 663
662
(663), poppet (664), seat (665) and needle bear- 664
CHECK VALVE SUB 665
ing (124). RELIEF VALVE
541
: 22 mm 545 706
543
508
706
508
508
706
508
• Relief valve are not allowed to be removal unnec- 706
essarily. A set pressure relief rate changes. 541
545
543
• Strictly prohibited to pull out needle bearing (124)
other than when the life time is exceeded. 271 124

312
14) Remove check valve sub and orifice thread
(508)
Remove check valve sub (541), (543), (545) and
orifice thread (508) from casing (271)

: 4 mm
• Use wrench taking care not to damage orifice
thread (508) when remove.

Fig. 33-102 Remove valve cover (312), and remove

check valve sub-assy and orifice thread (508).
15) Power up port (Pz port)
a. Pull pistion of power up using M4 thread. Put a
match mark on set position of lock nut etc. for
convenience of reassembly.

b. Lossen hexagon nut (803). This nut is tightened

by torque 98N•m (72lbf•ft).

33-53
33. UPPER SLEWING BODY

c. Loosen adjusting stem E2 (667).

d. This completes the disassembly of power up

port. And after pump assembling, assemble
power up port in the reverse order of disassem-
bling.

(4) General precautions to be exercised in installation

Installation is basically the reverse order of remov-
al, but exercise care of the following.
1) Repair scored parts at disassembly, get replace-
ment ready beforehand.
2) Clean every parts with wash oil, and dry them
before attaching.
3) Do not forget to coat the sliding areas and bear-
ings with clean hydraulic oil.
4) In principle, replace sealing parts such as O-
rings, oil seals, and gasket.
5) Tighten bolt and plugs to specified torques in
Service Standard, using a torque wrench.
(5) Install 271 531 532 535 803
1) Installing servo piston sub assy 534
When lock nut (803), set screw (534), stopper
(535), servo piston (532) and tilt pin (531) have
been removed, attach those parts on casing
(271) first.

Fig. 33-103 Installing servo piston sub assy

• Fasten servo piston (532) and tilt pin (531) stopping

tilt pin. And apply Three Bond #1303B on threaded
section.

: 14 mm
Tightening torque : 9.8 N•m (7.2 lbf•ft)
• After tightening, check that servo piston (532)
moves smoothly.

33-54
 33. UPPER SLEWING BODY

2) Installing drain plug (467)

Attach drain plug (467) and O-ring (707) first on
casing (271).

: 27 mm 707
Tightening torque : 108 N•m (80 lbf•ft) 467

Fig. 33-104 Installing drain plug (467)

3) Installing shaft (111)
Set shaft (111) on which bearing (123), spacer
(127) and snap ring (824) are fitted on casing
111
(271), and fit snap ring (825) on it.
123(127,824)

271
• Insert shaft (111) completely striking outer race of
bearing (123) with plastic hammer using steel bar.
Be careful not to strike shaft (111) with plastic ham-
mer.
• Fit shaft taking care not to damage oil seal (774).

Fig. 33-105 Installing shaft (111)

4) Assembling pivot ball (215), (216)
Fit pivot ball (215) on right side and pivot ball
215
(216) on left side directing top cover installing
216
surface of casing (271) upward.
• Diameter of pivot ball (215) is smaller, and
271
equipped with O-ring (710) and backup ring
(787).

Fig. 33-106 Assembling pivot ball (215), (216)

5) Installing swash plate (212)
Fit tilt bushing (214) to tilt pin (531) top end and
install the swash plate (212) on casing (271).
• Before installing swash plate (212), apply 212
214
grease on the surface where pivot balls
(215), (216) side.
271

Fig. 33-107 Installing swash plate (212)

33-55
33. UPPER SLEWING BODY

6) Installing pin (655)

655
Fit pin (655) on casing (271) and attach plug
271
(468) with O-ring (706).

: 6 mm
Tightening torque : 36 N•m (27 lbf•ft)

Fig. 33-108 Installing pin (655)

7) Assembling compensation piston (621)
Install compensation piston (621) on casing
(271). 621

271

Fig. 33-109 Assembling compensation piston (621)

8) Assembling sleeve (651) and spool (652)
Install sleeve (651) and spool (652) on casing
(271).
271
651
(652)

Fig. 33-110 Assembling sleeve (651) and spool

(652)
9) Installing feed back lever (611) and cover (273)
Install feed back lever (611) to tilt pin (531), in- 273 611
stall cover (273) aligning with pin and tighten
socket bolt (404).

: 5 mm
Tightening torque : 11.8 N•m (8.7 lbf•ft) 271

Fig. 33-111 Installing feed back lever (611) and cov-

er (273)

33-56
 33. UPPER SLEWING BODY

10) Installing spring cover (641)

Install spring (625), spring (626) and spring seat
(624), and install spring cover (641) on casing
271
(271) with socket bolt (404). 641
(624,625,626)

: 5 mm
Tightening torque : 11.8 N•m (8.7 lbf•ft)

Fig. 33-112 Installing spring cover (641)

11) Installing piston cylinder sub assy
Assemble cylinder assy [cylinder block (141), 271
piston (151), shoe (152) plate (153), spherical
151,152
bushing (156) and spring (157),] and install it on
casing (271) meeting the spline phases of spher-
ical bushing (156) and cylinder block (141).
12) Installing needle bearing (124) and relief valve
When needle bearing (124) and relief valve have
been removed, attach those parts on valve cover
(312) first. 153 141
(156,157)
13) Installing check valve sub and orifice thread
Fig. 33-113 Installing piston cylinder sub assy
(508)
When check valve sub assy [seat (541), stopper
(543), ball (545)] and two orifice threads (508)
have removed, attach those parts on casing
(271) and valve cover (312) first.
14) Installing valve cover (312)
Install valve equipped with valve plate (313) on
casing (271) and tighten socket bolt (401). 401
271

: 14 mm
Tightening torque : 235 N•m (173 lbf•ft)
• Then, apply grease on installing surface of
valve cover (312) and valve plate (313) to
protect it from slipping out.

312
(313)

Fig. 33-114 Installing valve cover (312)

15) Installing gear pump
Set coupling (114) from rear side of pump to the
inside, install gear pump, and tighten flange
socket bolt (402).

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

402
Fig. 33-115 Installing gear pump

33-57
33. UPPER SLEWING BODY

33.2.1.3 MAINTENANCE STANDARD

(1) Replacement standards for parts

Recommended
Standard
Part name and inspection item value for Remedy
dimension
replacement

Clearance between piston

0.036 0.056
(151) and cylinder (141) d D Replace piston or cylinder.
(0.0014") (0.0022")
bore (D-d)

Gap between piston (151)

0~0.1 0.3
and caulked part of shoe Replace piston shoe assy.
(0.004") (0.012")
(152) ( )

3.9 3.7
Thickness of shoe (152) (t) Replace piston shoe assy.
t
(0.154") (0.146")

Free height of spring (157) 31.0 29.9

Replace spring.
(L) (1.22") (1.14")
L

Combined height of plate

19.0 18.3 Replace or spherical
(153) and spherical bush-
h H (0.748") (0.720") bushing and plate.
ing (156) (H-h)

(2) Repair standards for cylinder, valve plate and swash plate (shoe plate face)

Valve plate (sliding section) Surface roughness requiring

3-Z
Swash plate (shoe plate face) correction
Cylincer (sliding section) Standard surface roughness
Less than 0.4Z (lapping)
Roughness of each surface (correction value)

33-58
 33. UPPER SLEWING BODY

33.2.2 CONTROL VALVE

For part names and marks used in this explanation, refer to Section "Construction of Control valve" explained in
Chapter "Equipment System" in attached sheet.

33.2.2.1 PREPARATION FOR CONSTRUCTION

(1) General precautions
The disassembling and assembling should be performed in shop as a rule. If it is unavoidably necessary to dis-
assemble, it must be carried out by authorized personnel following the precautions described below.
1) Place
The hydraulic equipment is machined in precision, and space in each section is very narrow. So select clean
place and be careful so that dust, sand, etc. are not entered inside when disassembling and assembling.
2) Preliminary investigation
Before disassembling, understand the construction and operation of control valve thoroughly.
3) Cleaning
Cap each port of the control valve before removing the valve from the machine. Before disassembly, confirm
that each cap is in place and then clean the exterior of the control valve assy.
Use an appropriate workbench. Lay a clean sheet of paper, rubber mat, or the like over the workbench.
4) Rust prevention and sealing
After disassembling, apply rust preventives on all parts or seal to protect them from rusting.
5) Transportation
In case control valve is required to carry or transport, it is prohibited to support control valve by applying sup-
port to pilot cover section, relief valve and overload relief valve.
6) Handling
Even if movement of control valve parts is not smooth, never strike it or handle forcibly.
7) Hydraulic testing device
After completion of assembly, various tests (relief characteristic, leak test, overload pressure setting, perfor-
mance test, etc.) are required. Hydraulic testing device is therefore required. But it is not allowed to disas-
semble equipment which can be disassembled mechanically, but can not be adjusted through test.
(2) Tools (Excluding general tools.)
Prepare the following tools before disassembling the control valve.
Table 33-2
No. Tool name Q’ty Remarks
a Vise 1
b Mouth plate 2 For vise (Copper plate)
c 1 of each size 4, 5, 8, 10, 12 mm

d 1 of each 19, 21, 22, 30 mm

e 1 of each 13,19, 21, 22, 30 mm

f Tweezers 1
g Magnet 1
h Torque wrench 1 For 0~69 N•m (0~51 lbf•ft)
i Others Proper Q’ty Wash oil, hydraulic oil,grease, tag, oil marking ink, etc.

33-59
33. UPPER SLEWING BODY

(3) Placing on work bench

Place it on work bench directing slewing priority section upward.

Swing priority section

X X
Z
Y Y

TRAVEL STRAIGHT

TRAVEL(L)

SWING

ARM

BOOM CONFLUX CUT VALVE

VALVE

CONFLUX SINGLE
SWITCH

SECTION XX (Back of machine)

TRAVEL(R)

BOOM

BUCKET

CUT VALVE 1
ARM CONFLUX
VALVE
BOOM SWING

NIBBLER & BREAKER

SECTION YY (Front of machine)

Fig. 33-116 Placing on work bench and cross-section

33-60
 33. UPPER SLEWING BODY

33.2.2.2 DISASSEMBLY
(1) Pulling out travel straight spool (7), travel right and SWING PRIORITY SECTION PILOT COVER D (16) FOR ARM
left spool (8), slewing spool (9) and bucket spool BOOM TRAVEL (L)
CONFLUX SPOOL (8)
(12), conflux / single sw. spool (81) and N&B spool SPOOL(13) SLEWING TRAVEL
(REVERSE SIDE) SPOOL (9) STRAIGHT
(82). (Spool without lock valve) SPOOL (7)
(See Fig. 33-117, Fig. 33-118.)
1) Remove two socket bolts (47) of each spool,
then washer (49) and pilot cover C (18).
(See Fig. 33-118)

: 5 mm

P1 BY-PASS PILOT COVER

• Then, special care must be taken that O-ring (52) of CUT SPOOL (15) TRAVEL (R)
D (16) FOR BOOM SPOOL (8)
BUCKET SPOOL (12)
pilot cover C (18) does not slip out.
VIEW Z of Fig.33-117
2) Hold each spool with spring (26) section, pull it Fig. 33-117 Position of spool without lock valve
out slowly in parallel to spool hole, and remove
spool assy from body (1), (80).

• Don't disassemble spool assy. If it is damaged, re-

place it.
• When two types of spool have been removed, at-
tach tag and record the position before disassem-
bling.

(2) Pulling out P2 by-pass cut spool (14), P1 by-pass SOCKET

TRAVEL SPOOL RIGHT (8) O-RING (52) BOLT (47)
cut spool (15) and boom conflux spool (13).
TRAVEL SPOOL LEFT (8) SPRING (26)
(Spool without lock valve.)
(See Fig. 33-117, Fig. 33-119.)
1) Remove two socket bolts (47) of each spool,
then washer (49) and pilot cover C (18).
(See Fig. 33-119) PILOT
COVER C (18)
: 5 mm
Fig. 33-118 Pulling out travel right and left spool
(section BB)
• Then, special care must be taken that O-ring (52) of
pilot cover C (18) does not slip out.

33-61
33. UPPER SLEWING BODY

2) Hold each spool with spring (26) section, pull it P2 BY-PASS

out slowly in parallel to spool hole, and remove CUT SPOOL (14)
BOOM CONFIUX O-RING (52)
spool assy from body (1). SPOOL (13) SOCKET
BOLT (47)
3) Pull out boom conflux spool (13) in the reverse PILOT
COVER C (18)
direction.

• Don't disassemble spool assy. If it is damaged, re-

place it.
• When two types of spool have been removed, at- P1 BY-PASS CUT SPOOL (15)
tach tag and record the position before disassem-
Fig. 33-119 Pulling out P2 by-pass cut spool,
bling.
P1 by-pass cut spool and boom conflux spool
(section EE)
(3) Pulling out boom spool (10) and boom swing spool BOOM SPOOL (10) SPRING (26)
(78). PILOT COVER D (16)
(Spool with lock valve.) (See Fig. 33-120.) PISTON A (34)

1) Remove three (3) socket bolts (48).

: 5 mm SOCKET BOLT (48)

2) Remove pilot cover D (16). Since pilot cover D is O-RING
equipped with piston guide (33), piston A (34), pi- (52)

ton C (36), and lock valve spring A (35), remove O-RING PISTON C (36)
(59)
POPPET (29) PISTON LOCK VALVE
as equipped-pilot cover D. O-RING (53) GUIDE (33) SPRING A (35)

Fig. 33-120 Example of pulling out boom spool

(section CC)
• Special care must be taken that O-rings (52), (53),
(59) on bottom of pilot cover D (16) and poppet (29)
do not slip out.
• Take care not to damage piston guide (33) protrud-
ed from the bottom of pilot cover D (16).

3) Spring section (26) of each spool is disposed, so

hold spool with the spring (26) section, pull it out
slowly in parallel to spool hole, and remove spool
assy from body (1), (76).

• Don't fail to pull spool assy out from spring side.

• If spool assy is damaged, don't disassemble it.
Replace it.

33-62
 33. UPPER SLEWING BODY

(4) Pulling out arm spool (11) (See Fig. 33-121.)

ARM SPOOL (11)
Same procedure as boom spool (10).
PILOT COVER D (16)
1) Remove three (3) socket bolts (48).

: 5 mm
2) Remove pilot cover D (16). Since pilot cover D is
equipped with piston guide (33), piston A (34),
piston C (36), and lock valve spring A (35), re-
move as equipped-pilot cover D (16).

Fig. 33-121 Pulling out arm spool

(5) Disassembling lock valve pilot cover D (16) PILOT COVER D (16)
(SeeFig. 33-122.) PISTON C (36)
O-RING (58)
1) Remove pilot cover D (16).

LOCK VALVE (28) PISTON A (34) PLUG (20)

( )
RESTRICTOR (30),
Keep poppet (29) carefully because it is slipped out SPRING B (31), PISTON GUIDE (33)
SPRING HOLDER (32),
easily. RETAINER RING (51) POPPEET (29) SPRING A (35)

Fig. 33-122 Disassembling lock valve pilot cover D

2) Hold pilot cover D (16) with vise, and remove (16)
plug (20).

: 8 mm

• Don't hold on port surface with vise.

• Take care not to damage piston guide (33) project-
ed from the bottom of pilot cover D (16).

3) Take out piston C (36), spring A (35) and piston

A (34) with pin set or magnet through the plug
hole where it has been removed.

• Record the direction of Piston C (36) has been in-

stalled.
• Don't disassemble piston guide C (33). If it is dam-
aged, replace a set of pilot cover D (16).

4) Take out a set of lock valve (28), restrictor (30),

spring B (31) spring holder (32) and retainer ring
(51) from control valve body with magnet.

Don't disassemble lock valve (28). If it is damaged, re-

place a set of lock valve body.

33-63
33. UPPER SLEWING BODY

(6) Disassembling shuttle valve (See Fig. 33-123) SHUTTLE

VALVE STEEL SHUTTLE VALVE
1) Remove two places socket bolts (47). SOCKET (37) BALL (46) SEAL (38) O-RING (52)

: 5 mm
2) Remove pilot cover E (17).

Then, special care must be taken that O-ring (52) of pi-

lot cover E (17) does not slip out. SOCKET BOLT (47)

PILOT COVER E (17)

3) Fix pilot cover E (17) in a vise and remove shuttle
valve socket (37).

: 21 mm
Fig. 33-123 Disassembling shuttle valve

• When pilot cover E (17) is required to be held, don't

hold on port surface with vise.
• Don't disassemble shuttle valve socket (37). If it is
damaged, replace a set of shuttle valve socket (37),
shuttle valve seat (38) and steel ball (46).

(7) Disassembling slewing priority section

(See Fig. 33-124.) SOCKET BOLT (74)

1) Remove two places socket bolts (74). PILOT

O-RING (71) COVER (66)
: 5 mm PILOT BODY (68)
2) Remove pilot cover F (66), spring (70), piston D PISTON GUIDE (69)
(67) and pilot body (68).
STOPPER PIN (65)
PISTON
SPRING (22) D (67)

LOAD
Then, special care must be taken that O-ring (71) and CHECK
piston D (67) of pilot caver F (66) does not slip out. VALVE (49)

3) Take out stopper pin (65) with tweezers or mag-

net. SPRING (70)
4) Removing pin guide (69).
O-RING (72)

: 13 mm O-RING (58)

5) Take out load check valve (49) and spring (22)

with tweezers or magnet.
Fig. 33-124 Disassembling slewing priority section

33-64
 33. UPPER SLEWING BODY

(8) Disassembling load check valve (21)

O-RING (58)
(See Fig. 33-125.)
1) Hold control valve body and remove 13 plugs PLUG (20)
(20). LOAD CHECK VALVE (21)
SPRING (22)
: 8 mm
2) Take out load check valve (21) and spring (22)
with tweezers or magnet.

For load check valve (21) of arm switching section, dis-

assemble slewing priority section first. [Refer to (7) Dis-
assembling slewing priority section.]

LOAD CHECK VALVE (21) SPRING (22)

PLUG (20)

Fig. 33-125 Removing load check valve

(Example of section BB)
(9) Remove main relief valve (60) and over load relief
valve (61)
1) Hold control valve body and remove a main relief
valve (60). (See Fig. 33-126.)
Opposing flats 30
: 30 mm
2) Remove ten places over load relief valves (61).
(See Fig. 33-127.)
MAIN RELIEF
: 22 mm VALVE (60)
Fig. 33-126 Removing main relief valve (section AA)

Opposing flats 22
• Remove main relief valve (60) and overload relief
valve (61) taking care not to apply tools on hexago-
nal section in opposing flats 19 mm. OVER LOAD
RELIEF
• Attach tag on removed overload relief valve (61), VALVE (61)
and record the position before disassembling.
• Handle the removed main relief valve and overload
relief valve taking care not to damage on the seat. OVER LOAD
RELIEF VALVE (61)
• Main relief valve and overload relief valve are very
Fig. 33-127 Removing over load relief valve
essential for safety operation, and also readjust-
(Example of section CC)
ment of pressure is very difficult, so don't disassem-
ble them. If damaged, replace the assy.

33-65
33. UPPER SLEWING BODY

(10)Remove N&B valve body (80) and boom swing

valve body (76). (See Fig. 33-128.)
BODY (80)
1) Hold control valve body (1) directing optional
valves upward, and mark with marking ink to BODY (76) SOCKET BOLT(6)
avoid mistakes of assembly. SPOOL (78) SPOOL (81)(82)
2) Remove four socket bolts (6) with allen wrench..
MARKING
: 10 mm O RING
(2)(3)
3) Remove N&B valve body (80) and boom swing
valve body (76).

• Remove end cover taking care so that O-rings (2),

(3) on mating surface are not slipped out.
• Handle it taking care not to cause damage, such as
flaws and dents, on mating surface. BODY(1)

(11)Removing other parts

In addition, remove pilot cover B1 (19), plugs (41), Fig. 33-128 Removing N&B valve and boom swing
(43), (45), (50), (62), (64) and (73), backup ring valve
(75), etc. as required.

33.2.2.3 ASSEMBLY
Here, only the assembly procedures are described.
Regarding drawings, refer to the disassembly procedures.
(1) Precautions on installing
1) Cleaning the parts
Before using parts for assembly, clean all of them with clean cleaning oil.
2) O-ring, seals
a. Confirm that O-ring and seals are free of forming defects or defects caused by poor handling.
b. Lubricate O-ring, seals and sealing surfaces with sufficient grease or hydraulic oil.
c. Fit O-ring taking care not to make a distortion. If it is distorted, it may cause oil leakage.
3) Handling
Even if sliding parts and engaging parts are not operated smoothly, never strike them and handle forcibly.
4) Preliminary preparation
Before assembling, prepare structural drawing and check number of parts to avoid mistakes and missing of
parts.
5) Tightening torque
Tighten socket bolts and screws in each section to the specified torque with torque wrench.
(2) Assembling boom swing valve body (76) and N&B valve body (80) (See Fig. 33-128.)
1) Hold body (1) directing mating surface upward, and fit O-rings (2), (3).

• Check that mating surface is free from dust and O-ring is securely fitted on the groove.
• Don't apply hydraulic oil or grease on O-rings (2), (3) fitted on mating surface.

2) Install boom swing valve body (76) and N&B valve body (80) meeting positions marked when disassembling.

33-66
 33. UPPER SLEWING BODY

3) Tighten four socket bolts (6) to the specified torque.

: 10 mm
Tightening torque : 66.7~68.6 N•m (49~51 lbf•ft)

• Don't tighten four socket bolts (6) at a time, but tighten them evenly in order by separating in several
times.
• Check that body (1), boom swing valve (76) and N&B valve body (80) are fitted rightly.

(3) Assembling Main relief valve and over load relief valve (See Fig. 33-126, Fig. 33-127.)
1) Hold body (1), and tighten main relief valve (60) to the specified torque.

: 30 mm
Tightening torque : 58.8~68.6 N•m (43~51 lbf•ft)
2) Tighten ten over load relief valve (61) to the specified torque.

: 22 mm
Tightening torque : 39.2~49.0 N•m (29~36 lbf•ft)

• Install over load relief valve (61) to the original position with reference to the tag attached when disas-
sembling.
• Install main relief valve (60) and overload relief valve (61) taking care not to apply tools on hexagonal
section in opposing flats 19 mm.

(4) Assembling thirteen load check valves

(See Fig. 33-125.)
1) Hold body (1) to the position where every load check valve (21) can be inserted, and install load check valve
(21) and spring (22).
2) Fit O-ring (58) on plug (20) and tighten it to the specified torque.

: 8 mm
Tightening torque : 39.2~49.0 N•m (29~36 lbf•ft)
(5) Assembling slewing priority section (See Fig. 33-124.)
1) Hold body (1) directing slewing priority section upward, and install load check valve (21) and spring (22).
2) Tighten pin guide (69) on which O-rings (58), (72) are installed to the specified torque.

: 13 mm
Tightening torque : 29.4~34.3 N•m (22~25 lbf•ft)
3) Insert stopper pin (65) into pin guide (69).
4) Insert pilot body (68) on pin guide (69) and fit O- ring (71) to the groove.

Insert pilot body (68) into pin guide (69) taking care not to damage O-ring (72).

5) Install piston (67) and spring (70) on pilot cover F (66), and tighten two socket bolts (74) together with wash-
ers (49) to the specified torque.

: 5 mm
Tightening torque : 9.8~10.8 N•m (7.2~8.0 lbf•ft)

33-67
33. UPPER SLEWING BODY

Check that the O-ring is securely fitted on the groove.

(6) Assembling shuttle valve (See Fig. 33-123.)

1) Hold pilot cover E (17) on the side face other than the port surface with vise, tighten shuttle valve socket (37)
on which O-rings (55), (57) are fitted to the specified torque.

: 21 mm
Tightening torque : 39.2~49.0 N•m (29~36 lbf•ft)

Then, Tighten it slowly taking care not to damage O-rings (55), (57) of shuttle valve socket (37).

2) Fit O-ring (52) on faucet joint, install pilot cover E (17) on which shuttle valve socket (37) is installed on the
faucet joint of body (1).

Check that the O-ring is securely fitted on the faucet joint.

3) Tighten two socket bolts (47) together with washer (49) to the specified torque.

: 5 mm
Tightening torque : 9.8~10.8 N•m (7.2~8.0 lbf•ft)
(7) Assembling lock valve pilot caver D (See Fig. 33-122.)
1) Hold pilot cover D (16) on the side face other than the port surface with vise, insert piston A (34), spring A
(35) and piston C (36).

• Place the groove side face of piston C (36) into the piston A (34).
• Care should be taken not to damage piston guide (33) protruded from pilot cover D (16).

2) Tighten plug (20) on which O-ring (58) are installed to the specified torque.

: 8 mm
Tightening torque : 39.2~49.0 N•m (29~36 lbf•ft)
3) Hold body (1) on side face other than port surface with vise directing lock valve (28) upward, and insert a set
of lock valve (28) and needle valve [poppet (29)] into body (1).
(8) Assembling boom spool, arm spool and boom swing spool (78). (Spool with lock valve) (See Fig. 33-120, Fig.
33-121.)
1) Hold body (1) on side face other than port surface with vise in the condition where spool assy can be installed
through upper side, and insert boom spool assy, arm spool assy and boom swing spool assy into body (1)
paying attention to the directions.

When it is hard to insert spools into body, insert it getting in and out slowly.

2) Install pilot cover D (16) on body (1) slowly meeting piston guide (33) protruded from the bottom with needle
valve [poppet (29)].

33-68
 33. UPPER SLEWING BODY

Then, check that O-rings (52), (53), (59) are securely fitted on the groove.

3) Tighten three socket bolts (48) together with washer (49) to the specified torque.

: 5 mm
Tightening torque : 9.8~10.8 N•m (7.2~8.0 lbf•ft)
(9) Assembling P2 by-pass cut spool, P1 by-pass cut spool and boom conflux spool (Spool without lock valve)
(See Fig. 33-119.)
1) Insert every spool assy into body (1) taking care the directions.

When it is hard to insert spools into body, insert it getting in and out slowly.

2) Fit pilot cover C (18) on faucet joint of body (1).

Then, check that O-ring (52) is securely fitted to the faucet joint.

3) Tighten two socket bolts (47) together with washer (49) to the specified torque.

: 5 mm
Tightening torque : 9.8~10.8 N•m (7.2~8.0 lbf•ft)
(10)Assembling travel straight spool, travel R/L spool, swing spool, and bucket spool, conflux / single sw. spool and
N&B spool.
(Spool without lock valve) (See Fig. 33-118, Fig. 33-128.)
1) Insert every spool assy into body (1), (80) taking care the directions.

When it is hard to insert spools into body, insert it getting in and out slowly.

2) Fit pilot cover C (18) on faucet joint of body (1), (80).

Then, check that O-ring (52) is securely fitted to the faucet joint.

3) Tighten two places socket bolts (47) together with washer (49) to the specified torque.

: 5 mm
Tightening torque : 9.8~10.8 N•m (7.2~8.0 lbf•ft)
(11)Installation of other parts
In addition, install all the removed parts such as pilot cover B1 (19), plugs (41), (43), (45), (50), (62), (64) and
(73), backup ring (75), etc.

33-69
33. UPPER SLEWING BODY

33.2.2.4 MAINTENANCE STANDARDS

INSPECTION OF COMPONENTS

Part name Inspection item Criterion and remedy

Body 1) Check scratches, rusting, corrosion. 1) If any of the following parts are damaged,
replace the component as a unit.
• Sliding part of spool, particularly the land,
to which holding pressure is applied.
• Part of seal pocket or flange through
which spool is inserted.
• Area of sealing part that is in contact with
O-ring.
• Seat of main relief valve, overload relief
valve and lock valve.
• Defects of other parts that seem to harm
normal function.
Spool 1) Check scratches, galling rusting, corro- 1) Replace if there are scratches (which can
sion. be caught by your nail) on the outer sur-
face.
2) Insert the spool in the body, and move it 2) If the spool does not move smoothly, re-
while turning it. pair or replace the spool.
Load check valve 1) Damage to the load check valve or the 1) Correct or replace if the seat is incom-
load check valve spring plete.
Spring and related parts 1) Check rust, corrosion, deformation, and 1) If damaged severely, replace.
breakage of the spring, spring seat, plug
and cover.
Spool seal and related 1) Check external oil leakage. 1) Replace.
parts
Main relief valve Over 1) Check rust and damage on outer surface. 1) Replace.
load relief valve 2) Inspect the contact face of the valve seat. 2) If damaged, replace.

33-70
 33. UPPER SLEWING BODY

33.2.2.5 TROUBLESHOOTING
(1) When you find a malfunction or a fault, inspect whether or not it comes from the control valve, pump, motor or
hydraulic circuits. For this purpose it is necessary to measure pilot pressure, pump discharge pressure and load
pressure. If any part of the control valve is removed and inspected, do it according to the above mentioned re-
moving and installing procedures.
(2) Dust is extremely harmful to hydraulic components.
Use care so as not to allow dust from intruding inside. Take dustproofing measures in case any part of the control
valve is to be removed.
(3) Handle the moving part prudently. If a flaw is detected, even a small flaw, remove it with oilstone, or replace it
with new one. After repair, clean it.
(4) Handle surfaces of O-rings so as not to score them as scoring will result in oil leakage.

Trouble Cause Remedy

1. ATT does not move. 1) Malfunctioning relief valve 1) Measure relief valve pressure
Slow to start up (or • Foreign matter between plunger and • Replace assy. *
poor power). seat. * • Replace assy. *
Slow response.
• Foreign matter between poppet and • Replace assy. *
seat. *
• Replace assy. *
• Sticking plunger. *
• Replace assy. *
• Broken or deformed spring. *
• Replace it and tighten lock nut to the spec-
• Clogged piston orifice. * ified torque.
• Loosened adjusting screw. • Disassemble and clean. If the flaw is se-
2) Foreign matter caught between body and vere, replace body and spool with new
spool or sticking. ones.
2. Excessive natural fall 1) Excessive clearance between control 1) Replace spool.
of cylinder under its body and spool. 2) Measure secondary pilot pressure.
own weight when 2) Spool is not completely in neutral position. • Remove and clean. If it is stuck, replace
spool is in neutral.
• Foreign matter between body and both the control body and the spool as
spool, or sticking spool. a pair.
• Broken or deformed spring. • Replace spring.
3) Malfunctioning over load relief valve. Re- 3) Measure over load relief valve pressure.
fer to item * above. Refer to item * above.
3. When extending 1) Malfunctioning load check valve. 1)
boom cylinder, at first • Foreign matter caught between load • Disassemble and clean. If the flaw is
it retracts. check valve and body. severe, replace body and load check
• Sticking load check valve. valve with new ones.
• Broken or deformed spring. • Disassemble and clean. If the flaw is
severe, replace body and load check
valve with new ones.
• Replace spring.

If such faults as those marked * should occur, always replace the relief valve assy.

33-71
33. UPPER SLEWING BODY

This page is blank for editing convenience.

33-72
 33. UPPER SLEWING BODY

33.2.3 PILOT VALVE (ATT)

33.2.3.1 CONSTRUCTION

APPLY GREASE 312

ON ROTATIONAL
PART OF THE
UNIVERSAL JOINT
302 301
501

APPLY GREASE
213 ON TOP
511

507 151

510
211
506

214
216

503 508

221
509

201

217
SECONDARY 101
PRESSURE PORT 2,4 PORT 1,3
ADJUSTING SHIMS

Fig. 33-129 Pilot valve (ATT)

Table 33-3
Item Thread size Tightening Torque Table
N•m (lbf•ft)
301 M14 47.1 (34.7)
302, 312 M14 68.6 (50.6)

Table 33-4
No. NAME Q’TY No. NAME Q’TY No. NAME Q’TY
101 CASING 1 217 WASHER 2 4 506 SPRING SEAT 2
151 PLATE 1 221 SPRING 4 507 SPRING SEAT 2
201 SPOOL 4 301 JOINT; M14 1 508 SPRING 2
211 PLUG 4 302 DISK 1 509 SPRING 2
213 SEAL 4 312 ADJUSTING NUT; M14 1 510 SPRING 4
214 O-RING; 1B P20 4 501 BELLOWS 1 511 PUSH ROD 4
216 SPRING SEAT 2 503 SPRING SEAT 2

33-73
33. UPPER SLEWING BODY

33.2.3.2 DISASSEMBLY & ASSEMBLY

(1) Tools

No. Tool Name Remarks

15~100N m class
a Torque wrench
(10~75 )
b Screw driver ( ) W= 2 ~ 3, 4 ~ 5
c Screw driver ( )
d Wrench 22mm and 32mm

(2) Jig
Special jig : for disassembling and assembling the joint (301)
(See Fig. 33-130).

BUSHING

1. Material :
Ø29 (1.14 ) SCM415 N SECTION AA
Carburizing and Quenching
Ø26.5 (1.04 )

23.5 (0.925 )
(Opposing flats) 2. Material : S45C

A A
(0.512 )
13

Ø19 (0.748 )
69 (2.72 )
54 (2.13 )
50 (1.97 )
46 (1.81 )
25 (0.984 )

(0.669 )

Installing condition on joint

17

12 )
(0.5 3
R1

Ø23 (0.906 )

Ø27 (1.06 )
0.5 X 15˚
(0.0197 )

Ø31 (1.22 )
R
5.
8

15.5 6.5
(0

*1 and 2 are tight fitted. (0.256 )

.2

(0.61 ) R
12.5 (0.492 )

28

(0. 4.5 C0.5

17
)

7) (0.0197 )
(0.374 )
9.5

C0.5
11.6 (0.457 ) (0.0197 )
Ø16 Material :
(0.63 ) Detail of bushing SCM415 N
Sectional drawing of jig A Carburizing Hardening
Q'ty : 2

Fig. 33-130 Special jig

33.2.3.3 Disassembling procedure

33.2.3.3.1 General cautions for disassembly

(1) Since all the parts are very precisely manufactured, carefully handle them without causing collision with each
other or dropping.
(2) Perform the work carefully without hammering or using excessive force even if the part is sticking. Otherwise
burrs may be produced or the part is damaged, leading to oil leakage or performance deterioration.
(3) When leaving the parts in the disassembled condition, always take rust preventive and dust protective mea-
sures. Otherwise rust may be produced on the parts due to humidity or dust.

33-74
 33. UPPER SLEWING BODY

33.2.3.3.2 Disassembly
(1) Plug each port of pilot valve, and clean it with kero-
501
sine.
P port : PF1/4
1~4 and T port : PF3/8
(2) Fix pilot valve with vise via a protective plate (Almi-
num plate etc.), and remove boots (501).

Fig. 33-131 Removing boot (501)

(3) Remove adjusting nut (312) applying spanners to
adjusting nut (312) and circular plate (302).

: 22 mm, 32mm 312

302

Fig. 33-132 Adjusting nut (312) removal

(4) Remove circular plate (302).

: 32 mm 302

Fig. 33-133 Removing circular plate (302)

Fig. 33-134 Circular plate is removed

33-75
33. UPPER SLEWING BODY

Fig. 33-135 Installing Jig A

(5) Turn joint (301) in counterclockwise with Jig A to re-
move. JIG A
Jig A : Refer to Fig. 33-130 Special jig on page, 33-
74.
301
: 24 mm

When the force of return springs (221), is strong, never

loosen joint (301). If loosened, it might result in jumping
out of plate (151), plug (211) and push rod (212).
Remove joint (301) pressing plate (151) downward with Fig. 33-136 Removing joint (301)
two fingers.

(6) Remove plate (151).

• When the force of return springs (221) are
strong, press plate to let it come up slowly.

151

Fig. 33-137 Removing plate (151)

• When the force of return springs (221) are weak,
plug is left in casing (101) due to sliding resis-
tance of O-ring (214).
Pull plug (211) out with a driver (–).

To prevent personel injury, plug (211) must be removed

slowly and evenly until the return spring (221) force is
211
completely released.
Fig. 33-138 Removing plug (211)

33-76
 33. UPPER SLEWING BODY

(7) Remove push rod (511), plug (211), pressure re-

ducing valve assy (spool), return springs (221) from
511
casing (101).

211
221

Record combination of port holes on casing and the

pulled out parts. The stroke differs according to direc- 101
tion.

Fig. 33-139 Removing push rod, plug, pressure re-

ducing valve and spring
(8) Push springs (508) in the range of that the move-
ment of spring seats (216), (503) and shift the seats
(216) in a side direction, and remove spools (201)
through the larger hole of seat.

201

Never push down spring seat (216) in 6 mm (0.236 in)

or more.

Fig. 33-140 Removing spool (201)

(9) Remove spool (201), spring seats (216), (503),
spring (508), (509) and washer (217). 201 217

Fig. 33-141 Disassembling pressure reducing valve

(10)Remove spring (*510), spring seat (*506), (*507)
from push rod (511). 510
214

The parts marked * may not be equipped depending on

valve type.

511

211

Fig. 33-142 Disassembling push rod

33-77
33. UPPER SLEWING BODY

(11)Pull out push rod (511) from plug (211).

(12)Remove O-ring (214) from plug (211).

511

Fig. 33-143 Removing push rod (511)

(13)Remove inside seal (213) from plug (211) with
small driver.

213

Fig. 33-144 Removing seal (213)

33.2.3.4 Assembling procedures

33.2.3.4.1 CLEANING PARTS

(1) Clean parts with wash oil roughly.
(2) Clean parts with wash oil completely.
(3) Dry parts by swabbing clean rag.
(4) Apply rust preventives on parts. 201

217

Fig. 33-145 Assembling pressure reducing valve

33-78
 33. UPPER SLEWING BODY

33.2.3.4.2 Assembly
(1) Fit washer 2 (217), springs (508), (509), spring
seats (216), (503) to spool (201).
(2) Push spring (508), (509) in the range of that the
movement of spring seats (216), (503) in a side di-
rection, and install spools (201) through the larger
hole of spring seat. (See Installing spools (201).)

Never push down spring seats (216) in 6 mm (0.236 in) 201

or more.

Fig. 33-146 Installing spools (201)

(3) Place spring (221) into ports 1,3 of casing (101),
221
and then install pressure reducing valve assy in it. 101
Place springs (221) into ports 2,4 and install it.

Install the removed respective assy into respective

holes.

PRESSURE REDUCING
VALVE ASSY

Fig. 33-147 Installing pressure reducing valve assy

(4) Fit O-ring (214) and seal (213) into plug (211).
• Apply hydraulic oil on surface of push rod. 211
214
PLUG (211) 213
SEAL (213)

O-RING (214)

PUSH ROD (511)

Apply hydrailic oil

For the assembling

direction of seal (213). Fig. 33-148 Installing O-ring (214) and seal (213)

33-79
33. UPPER SLEWING BODY

(5) Insert push rod (511) in plug (211) and install spring
(*510) and spring seat (*506) to push rod (511) on *510
port 1,3 side.
And install spring seat (*507) to push rod on port
2,4 side.

The parts marked * may not be equipped depending on

valve type.
511
*506
211

Fig. 33-149 Assembling push rod, spring (510) and

seat (506)
(6) Fit plug (211) assy to casing (101).
1) When the force of spring (211) is weak, it stops 101
at the position where it is pushed in by the sliding
resistance of O-ring (214).

211

Fig. 33-150 Installing plug assy

2) When the force of spring (221) is strong, attach
plate (151) and press 4 push rods by hand at the
same time, and tighten joint (301) temporarily.
301
• Install spool (201) straight and evenly into the
hole of casing (101).
• Take care so that plug (211) and plate (151) do
not jump out of casing (101).

151

Fig. 33-151 Installing plug assy and plate (151)

(7) Install joint (301) on casing (101) with jig A securely.
Jig A : Refer to Fig. 33-130 Special jig on page, 33-
74.
Tightening torque : 47±3 N•m (35±2.2 lbf•ft)

101
JIG A

Fig. 33-152 Installing joint (301)

33-80
 33. UPPER SLEWING BODY

(8) Install circular plate (302) to joint (301)

• Screw it in until it comes in contact with 4 push 312

rods (511) equally.
• The exceeding of screw in may cause malfunc- 302

tion of machine.

(9) Screw adjusting nut (312) in until it touches circular

plate (302), and tighten it applying spanner to stop
circular plate returning.
Fig. 33-153 Installing circular plate (302)
: 32 mm

: 22 mm
• Apply Loctite #277 to threads of joint.
Tightening torque : 69±5 N•m (51±3.6 lbf•ft)
GREASE
(10)Apply heat-resisting grease to joint (301) rotating
section and the top of push rod (511).
(11)Cover it with boots.
(12)Spray rust preventives through each port and at- 301
tach plug respectively.
511
Fig. 33-154 Applying grease to joint section and
push rod

33-81
33. UPPER SLEWING BODY

33.2.3.5 Maintenance standard

Maintenance item Standard Remarks

Amount of leakage Replace with a complete set of pilot valve when Condition :
the amount of leakage reaches more than 1000 Primary pressure : 2.94MPa (427 psi)
cc/min (61 cu•in/min) or 2000 cc/min (122 cu•in/ Oil viscosity : 23 mm2/s
min) at the neutral position of the handle or dur-
ing operation, respectively.
Spool Replace with a complete set of pilot valve when The wear condition to the left is con-
an amount of wear at the sliding section is more sidered to correspond to the above
than 10 µm (0.0004") in comparison with the amount of leakage.
non-sliding section.
Push rod Replace when a wear amount of the tip is more than 1 mm (0.04").

Unnecessary play in Replace when a play more than 2 mm(0.079") A play generated by loosening of tight-
operation section due to wear and so on is found on the disk (302) ening portion should be adjusted.
or joint section (301) of the operation section.
Action stability Replace with a complete set of pilot valve when
abnormal noise, hunting or primary pressure
drop is generated during operation and the trou-
ble cannot be remedied according to Section
33.2.3.6 TROUBLESHOOTING.

Replace seal such as O-ring with new ones after every disassembly.

33.2.3.6 TROUBLESHOOTING

Phenomenon Possible Cause Corrective action

Secondary pressure 1) Primary pressure is insufficient. 1) Secure primary pressure.
does not rise. 2) Springs (508, 509) are broken or fa- 2) Replace with new ones.
tigued.
3) Clearance between spool (201) and 3) Replace assembly.
casing (101) is abnormally large.
4) Play of handle portion is too much. 4) Disassembly and reassembly or re-
place handle portion.
Secondary pressure is 1) Sliding parts are caught. 1) Correct.
unstable. 2) Tank line pressure varies. 2) Return directly to oil tank.
3) Air has contained into pipeline. 3) Release air.
Secondary pressure is 1) Tank line pressure is high. 1) Return directly to oil tank.
high. 2) Sliding parts are caught. 2) Correct.

33-82
 33. UPPER SLEWING BODY

33.2.4 PILOT VALVE (TRAVEL)

33.2.4.1 CONSTRUCTION

Fig. 33-155 Pilot valve (Travel)

Torque Torque
No. Name Q’ty No. Name Q’ty
N•m (lbf•ft) N•m (lbf•ft)
101 CASING 1 29.4 (22) 251 RO PLUG 3
102 CASING (DAMPER) 1 6.9 (5.1) 252 PLUG 6
191 SEAT 1 2 253 RO PLUG 2
192 SEAT 2 2 261 O-RING 3
193 BUSHING 2 2 263 O-RING 2
194 STEEL BALL 2 8.8 (6.5) 271 SOCKET BOLT 4
201 COVER 2 301 SPOOL 4
202 PLUG 4 311 SPRING SEAT 4
203 GREASE CUP 4 313 WASHER 4
210 PACKING 4 324 SPRING 4
211 O-RING 4 335 SPRING 4
212 O-RING 4 336 SPRING 4
213 O-RING 2 413 CAM SHAFT 2
214 PUSH ROD 4 414 BUSHING 4
217 SHIM 4 420 CAM 2
218 SPRING SEAT 4 471 STEEL BALL 4
224 PISTON 4 6.9 (5.1) 472 SET SCREW 2
225 STEEL BALL 12 501 BELLOWS (BOOTS) 2

33-83
33. UPPER SLEWING BODY

33.2.4.2 DISASSEMBLY AND ASSEMBLY

(1) Special jig for disassembly and assembly
Special jig 1(for removal of bushing)
(2) Precautions for disassembly and assembly
1) Disassemble and assemble the pilot valve paying attention to the rust protection fordust, dirt, etc. in order
not to allow them to enter in.
2) Handle parts carefully not to damage
3) Write down the installing positions of respective part during disassembly, and assemble respective part to
the position as they were before.
(3) Disassembly
1) Stop respective port (P, T, 1, 2, 3, 4, 5 and 6) of the valve with plugs and clean the outer surface.
2) Fix the cleaned valve with vise.
3) Remove bellows (501) from cover (201).
4) Remove set screw (472).

: 6 mm
5) Contact pry bar (ø7 or less) to one end of cam shaft (413), and strike it slightly with a hammer.
6) Remove cam (420).
7) Remove socket bolt (271).

: 6 mm
8) Remove cover (201).
9) Remove the casing upper assy, and fix the assy with vise, again.
10) Draw push rod (214) out of plug (202).
11) Remove plug (202) with grease cup (203), packing (210) and O-ring (212).
12) Remove piston (224).
13) Remove damping spring (336) from the casing.
14) Take out spring seat (218) from casing (102) with pincette.
15) Take out steel ball (225) using magnet.
16) Fix the lower casing assy with vise, and take out O-rings (211,213) from casing (101).
17) Remove reduction unit valve assy and return spring (335) from casing (101).
18) Place cover (201) on the flat bench transverse, apply bushing (414) to special jig 1, strike it lightly with ham-
mer, and draw the bushing out.

CENTERING HOLE IS ALLOWABLE

(SMALLER THAN Ø2 mm)
-0.0157")
(Ø0.3937" -0.0118"

-0.0118")
(Ø0.315" -0.008"
Ø10 -0.3
-0.4

Ø8 -0.2
-0.3
30˚

(0.787")
20 2 (0.008")

30
(1.181")
Fig. 33-156 Special jig 1

33-84
 33. UPPER SLEWING BODY

19) For disassembly of the reduction unit valve assy first push spring seat (311) in and shift the spring seat cross-
wise making secondary pressure spring (324), remove it from spool (301) passing through the large hole.
• Handle the assembled unit as a assy.

Fig. 33-157
20) Separate spool (301), spring (324) for secondary pressure setting, shim (217) and washer.
• Handle the assembled unit as a assy. And there may be unit on which washer is not installed.
21) Remove grease cup (203) from plug (202).
22) Remove O-ring (212) from plug (202).
(4) assembly
1) Clean all parts before assembly, and dry them by means of compressed air. Do not use rag.
• Repair the parts damaged when being disassembled, clean them, apply oil to the moving section, and
install the same parts on the positions where they are before.
• Replace every O-ring and packing with new ones.
2) Install washer (313), shim (217), spring (324) for resetting the secondary pressure, and spring seat on spool
(301) in order.
3) Pass spool (301) through the larger hole of spring seat (311), push the spring seat in , and install it making
the spring for the secondary pressure flex and shifting the spring seat crosswise.
4) Fix casing (101) with vise, and place spring (335) for return in casing (101).
5) Place the reduction unit subassy described in Articles 2) and 3) in casing (101).
• Install them on the positions as they were before.
• When placing the reduction unit subassy in, pay attention to the spool lower end so as not to bring into
contact with the corner of the casing.

Pay attention to the

corner of the casing

Fig. 33-158
6) Place O-rings (211,213) in casing (101).
7) Fix upper casing (102) with vise and place the steel ball in it.

33-85
33. UPPER SLEWING BODY

8) Place spring seat (218) in casing (102) with tweezers.

9) Place damping spring (336) in casing (102).
10) Install piston (224).
11) Place O-ring (212) in plug (202).
12) Place packing (210) in plug (202).
• Pay attention to the direction when placing the packing in.
• Apply grease slightly before placing packing in.

Packing

Fig. 33-159
13) Place grease cup (203) in plug (202).
14) Install push rod (214) on plug (202).
15) Place the push rod subassy which is sub-assembled by the procedures in Articles 11) to 14) in casing (102).
16) Put cover (201) on the flat work bench, press bushing (414) with special jig 1, and press fit the bushing strik-
ing lightly.
17) Fix the lower cover assy which is assembled by the procedures in Articles 2) to 6) with vise, and install the
upper cover assy which is assembled by the procedures in Articles 7 to 15) on it.
18) Install cover (201) on casing (102).
19) Tighten socket bolt (271) to the specified torque.
20) Install cam (420) on cover (201).
21) Insert cam shaft (413) from the outside pressing cam (420).
22) Apply Loctite #241 or equivalent to the thread of socket bolt.
23) Tighten socket set bolt (472) to the specified torque.
24) Incline cam (420), apply grease to the top end of push rod (214), and fill grease cup (203) of plug (202) with
grease.
25) After fitting the top end of bellows (501) in cam (402), fit the lower side in the groove of cover (201).

33-86
 33. UPPER SLEWING BODY

33.2.4.3 CAUSE OF FAILURES AND CORRECTIVE ACTION

Phenomenon Causes Corrective action

Secondary pressure 1) Insufficient primary pressure 1) Secure primary pressure.
does not rise. 2) Permanent set of spring (324) for setting 2) Replace it with new one.
of secondary pressure
3) The gap between spool and casing is too 3) Replace it with complete remote control
large. valve.
4) The control section is loosened. 4) Replace parts of control section.
Secondary pressure is 1) Sliding part is not smooth. 1) Repair unsmooth section.
unstable. 2) Variation of pressure of tank line 2) Return oil to oil tank directly.
3) Air contamination in piping 3) Bleed air by operating several times.
Secondary pressure is 1) Pressure of tank line is high. 1) Return oil to oil tank directly.
high. 2) Sliding part is not smooth. 2) Repair unsmooth section.
Damping does not work. 1) Air is accumulated in piston chamber. 1) Bleed air by operating several times.
2) Sliding part is not smooth. 2) Repair unsmooth section.
3) Permanent set of damping spring (336) 3) Replace it with new one.
4) Gap between damping piston (224) and 4) Replace it with complete remote control
casing (damper) (102) is too large. valve.
5) Malfunction of check valve 5) Disassemble and check on check valve
section.
6) Orifice of damping piston (224) is too 6) Replace damping piston.
large.
Damping torque is 1) Sliding part is not smooth. 1) Repair unsmooth section.
heavy. 2) Orifice of damping piston (224) is 2) Repair or replace damping piston.
clogged.

33-87
33. UPPER SLEWING BODY

This page is blank for editing convenience.

33-88
 33. UPPER SLEWING BODY

33.2.5 SLEWING MOTOR UNIT

33.2.5.1 CONSTRUCTION
(1) Slewing motor composition

Slewing motor assy

34 36,37
33 35 38
Swash plate type Two-stage planetary
axial piston gear reduction unit
motor

Mechanical brake

Relief valve

Makeup valve
31
Bypass valve
30

39
100

13 70 14 16
15 17

11,12

10
18

9
8

7 19
6
20
5
21
4
22
3
23

40

24,25

26

1 28 27

Fig. 33-160 Slewing motor

33-89
33. UPPER SLEWING BODY

Torque Torque
No. Parts Q’ty No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
1 TAPERED ROLLER BEARING 1 22 RETURN PLATE 1
3 FRICTION PLATE 1 23 CAM PLATE 1
4 SEPARATOR PALATE 2 24 LEVEL GAUGE 1
5 SNAP SING 2 25 O-RING 1
6 NEEDLE BEARING 1 26 HOUSING 1
7 O-RING 1 27 COLLAR 1
8 O-RING 1 28 OIL SEAL 1
9 O-RING 1 30 BACK UP RING 2
10 BALANCE PLATE 1 31 O-RING : 1B P21 2
11 PISTON 1 33 BACK UP RING 2
12 TEFLON RING 2 34 O-RING : 1B P26 2
13 PLUG ; PT 1/4 2 35 PARALLEL PIN 2
14 BUSHING 2 36 PLUG : PF3/8 1
15 SCROLL WAVE 4 37 O-RING : 1B P14 1
16 TEFLON RING 4 38 SOCKET BOLT : M12 × 30 4
17 SPRING 4 39 COVER 1
18 PISTON 13 40 PLUG 1
19 CYLINDER 1 70 RELIEF VALVE ASSY 2
20 RETAINING SPRING 1 100 BY-BASS VALVE ASSY 2
21 PISTON ASSY 7

1) Relief & check valve assy (70)

71 72 76 77 78 79 80 81 82 No. Parts Q’ty No. Parts Q’ty

70 RELIEF & 2 82 SEAT 2
CHECK VALVE ASSY 83 POPPET 2
71 LOCK NUT 2 84 SPRING 2
72 CAP 2 85 O-RING 2
76 BACK UP RING 2 86 SHIM 2
77 O-RING ; 1B P26 2 87 PISTON 2
78 SPRING 2 88 SLEEVE 2
79 BUSHING 2 89 O-RING 2
90 89 88 87 85 86 84 83
80 CHECK SEAT 2 90 CAP 2
Detail view of relief & check valve assy 81 SLEEVE 2

2) By-pass valve assy (100)

101 102 103 104 105 106 107

No. Parts Q'ty No. Parts Q'ty

100 BY-PASS VALVE ASSY 2 106 O-RING : 1B P21 2
101 SEAT 2 107 BACK UP RING 2
102 SLEEVE 2 108 CAP 2
103 POPPET 2 109 SPRING 2
104 BACK UP RING 2 110 POPPET 2
105 O-RING : 1B P14 2 111 SPRING 2

111 110 109 108

Detail view of by-pass valve assy (slewing shockless valve)

33-90
 33. UPPER SLEWING BODY

(2) Slewing reduction unit

12 13 14

11

10
16
9
17

18
8
15
19
7
20
6
1 21

22
27
23

4
26
3
2
1

25
24
Fig. 33-161 Slewing reduction unit

Torque Torque
No. Parts Q’ty No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
1 PINION SHAFT 1 15 HOLDER 2 ASSY 1
2 COLLAR 1 16 NEEDLE BEARING 6
3 PLATE 1 17 SHAFT 2 3
4 TAPER ROLLER BEARING 1 18 SPUR GEAR 5 3
5 GEAR CASE 1 19 THRUST PLATE 2 6
6 GREASE NIPPLE 1 20 SPRING PIN : 8 × 5 3
7 OIL SEAL 1 21 HOLDER 2 1
8 TAPER ROLLER BEARING 1 22 COLLAR 2
9 PIN 2 23 RELIEF NIPPLE 1
10 RING GEAR 1 24 CONNECTOR 1
11 SPUR GEAR 4 1 25 ELBOW 1
12 SUN GEAR 1 26 HOSE 1
13 HOLDER 1 ASSY 1 27 PLUG 1
14 SOCKET BOLT : M12 × 95 6

33-91
33. UPPER SLEWING BODY

33.2.5.2 DISASSEMBLY AND ASSEMBLY OF SLEWING MOTOR

(1) Disassembly 70
1) Remove the relief assy (70).

: 27 mm
2) Remove the by-pass valve (100).

: 8 mm
100

Install it in the original position.

Fig. 33-162 Removing relief valve assy and by-pass

valve
3) Apply match mark on cover (39) and housing
39
(26).

26

MATCHING
MARK

Fig. 33-163 Maching marks on cover and housing

4) Remove socket bolt (38). 39
: 10 mm

26
38

Fig. 33-164 Removing cover mounting bolts

5) Lift up and remove cover (39).

39

Fig. 33-165 Removing cover

33-92
 33. UPPER SLEWING BODY

6) Remove snap ring (5) with plier.

7) Remove inner race of needle bearing (6).

Fig. 33-166 Removing bearing (6) inner race

8) Remove the O-ring (9).

Fig. 33-167 Removing O-ring (9)

9) Remove the balance plate (10).

10

Fig. 33-168 Removing balance plate (10)

10) Remove the bushing (14) with a teflon ring (16)
on it, and the scroll wave (15).

14

Fig. 33-169 Removing bushing (14) and scrollwave

(15)

33-93
33. UPPER SLEWING BODY

11) Remove spring (17) from brake piston (18).

Fit spring in the original position.

17

18

Fig. 33-170 Removing spring (17)

12) Remove brake piston (18). 18

The O-ring (7) (8) make it difficult to slide the piston (18)
easily from the housing (26). For this reason, use
tapped hole (M6) provided in the piston (18) to remove
it, as shown in the Fig. 33-171.
Fig. 33-171 Removing brake piston (18)
13) Remove the separator plate (4) and friction
plate (3).

Fig. 33-172 Removing separator plate (4) and fric-

tion plate (3)
14) Remove cylinder assy (19) from housing (26).

19
• Oil seal (28) and outer race of taper roller bearing
(1) are left in housing.
• Take care not to damage the sliding surface on up-
per section of cylinder housing.
26
• Assemble piston bore of cylinder (19) and piston
assy (21) in the same original combination.
Fig. 33-173 Removing cylinder assy (19)

33-94
 33. UPPER SLEWING BODY

15) Remove the outer race of tapered roller bearing

1
(1) from the housing.

Fig. 33-174 Removing outer race of tapered roller

bearing (1)
16) Remove oil seal (28) from housing (26) with
driver and hammer.
• The reuse of the removed oil seal is not al-
lowed.

28

26

Fig. 33-175 Removing oil seal (28)

17) Removing the cylinder assy.
1. Attach an gear puller to two positions of the
inner race of the tapered roller bearing (1)
and to the splined end of the cylinder (19),
and pull out the inner race along with the col-
lar (27). 27

Fig. 33-176 Pulling inner race of tapered roller bear-

ing (1)
2. Remove the cam plate (23), piston assy (21)
and return plate (22) together from the cylin-
der (19).

23

22

21
Fig. 33-177 Removing cam plate (23), piston assy
(21) and return plate (22)

33-95
33. UPPER SLEWING BODY

3. Remove cam plate (23) from the piston assy

(21) as is by sliding it on sliding surface of
piston assy (21).
21
23

• Handle cam plate with care so as not to damage its

sliding surface.

Fig. 33-178 Removing cam plate (23)

4. Remove retaining spring (20) from cylinder
(19).

19 20

Fig. 33-179 Removing retaining spring (20)

(2) Installation
Install slewing motor unit in the reverse procedure
of disassembling.
1) Jigs
Jig used for installing is not provided with part
number.

Jigs Dimensions Jigs Dimensions

(1.1909"±0.0039")

C1
(1.0039±0.0039)
35 (1.38")

(0.04")
30.25±0.1

25.5±0.1

(1.9488"±0.0039")

(2.4350" -0.00591")

Press-fitting jig
(1.1417"±0.0039")

-0.15"
49.5±0.1
29±0.2

+0

61.85 +0

for inner race Press-fitting jig

of tapered 3 for oil seal (28)
(0.008") (0.08") 2
roller bearing (1) 60 (2.36") 10.5 (0.413")
75 (2.95") (0.5315" +0.0039
-0 ) 155 (6.10")
13.5 +0.1
-0

)
R3 18"
.1
)

(0
30.3 (1.19")
(0.9921"+0.0039"
(0.8720")

)
(0.689")

22.15

(+0.0059"
(1.06")

+0.1
17.5
27

+0.15"

-0
25.2-0
-0

-0

Press-fitting jig
Seal protector
for collar (27) 7
(0.276") 50 (1.97") 25 (0.984")

60 (2.36") 45 (1.77")

33-96
 33. UPPER SLEWING BODY

2) Assembling relief assy 70

Fit relief assy (70) to cover (39).
39
: 27 mm
Tightening torque : 39 N•m (29 lbf•ft)

Fig. 33-180 Assembling relief assy (70)

3) Confirming correct assembly A,B release
Open the brake release port, apply a pilot pres- Rotate spline by
(inlet / outlet ports)
sure of 1.96 MPa (280 psi) to the P port and con- 19.6 to 29.4 N·m
(14 to 22 lbf ·ft)
firm that the output shaft rotates more than 1 turn with torque
smoothly by 19.6~29.4 N•m (14~22 lbf•ft) torque. wrench.
In case the output shaft does not rotate, disas-
semble it again and readjust.

Apply pressure 1.96 MPa

(280 psi) to brake release
port (PF 1/4)
Fig. 33-181 Confirming correct assembly

33-97
33. UPPER SLEWING BODY

33.2.5.3 DISASSEMBLY AND ASSEMBLY OF SLEWING REDUCTION UNIT

(1) Removal
1) Remove the sun gear (12) and then remove the
15
holder 1 assy (13).
• Because the shafts in the holder 1 assy (13)
are press-fit in the holder (1), and caulked at
the end, further removal of the assy is impos-
sible.
20

Fig. 33-182 Removing spring pin (20)

2) Remove spur gear 4 (11) and then remove the
holder 2 assy (15).
3) Removing the holder 2 assy (15).
1. Drive the spring pin (20) through the holder 2
assy (15).
• The spring pin (20) cannot be reused.
2. Holding spur gear 5 (18) with your hand, re- 18
move the shaft 2 (17) from holder 2 (15).

17
Fig. 33-183 Removing shaft (17)
4) Remove the ring gear (10).
• The mating surface between the ring gear (10)
and the gear case (5) is coated with liquid 10
packing (Three Bond #1215, gray) to prevent
oil leakage. Use the notch in the gear case (5)
5
to remove the ring gear (10).
5) Removing the collar (16).
Remove the collar (16) from the shaft (1) by tap-
ping the collar with a screwdriver and hammer.

Fig. 33-184 Removing ring gear (10)

6) Removing the shaft (1) assy.
Place blocks about 300 mm (12 in) high under PRESS
the flange of the gear case (5) to allow removal
of the shaft (1) and push the end of the shaft with
a hydraulic press to remove the shaft (1), collar
(2), plate (3) and taper roller bearing (4) as an as-
5
sy.

Do not remove any further, unless the bearings etc. are Fig. 33-185 Removing shaft (1) assy
abnormal.

7) Remove the oil seals (7) from the gear case (5).
• Do not reuse the oil seals.

33-98
 33. UPPER SLEWING BODY

(2) Installation
• The jigs to be used for installation are shown be-
low.

Unit : mm (in)
Oil seal (7) press-fitting jig Seal protector Remarks
Ø50 15˚
(1.97")
• Heat vinyl chloride tube in hot

(0.591") (0.272") (0.591") (1.18")

15 6.9 15 30

±0.1 (0.00394")
water and inset it onto the pinion
shaft to from a seal protector.49

150 (5.91")
C2
(0.08")

85 (3.34")
(0.118") 3

0"
(2.5512" -0.0079" )
0
Ø64.8-0.2 15˚

Ø89 -0.2 -0.0079"

-0.5 (3.5039" -0.0197" )

Ø119 (4.69") Ø60

(2.56")

1) Apply grease to the rollers of the taper roller

bearing (4).
• Grade : SHELL ALVANA EP2 or equivalent
(grease for extreme pressure duty) GREASE
• Quantity : About 150cc (9.15 cu•in)

Fig. 33-186 Applying grease to taper roller bearing

(4)
2) Press-fitting the oil seal (7) 5
Degrease the oil seal position on the gear case SEAL
(5) and the oil seal (7). Apply liquid packing PRESS-
7 FITTINGH
(Three Bond #1211, white) to the outside of the JIG
oil seal. Using the seal press-fitting jig and a
hand press, install the oil seal (7) on the gear
case (5).
• After press-fitting, apply grease to the oil seal
lips. Fig. 33-187 Press-fitting oil seal (7)

33-99
33. UPPER SLEWING BODY

3) Place the gear case (5) with the output shaft side 1
facing upward, and install the pinion shaft (1)
assy into the gear case (5). 4
• Use the seal protector to prevent the spline of
the pinion shaft (1) from damaging the lips of SEAL
PROTECTOR
the oil seal (7).
5

Fig. 33-188 Installing pinion shaft (1) assy

4) Installing the taper roller bearing (8)
Place gear case (5) directing pinion shaft down-
ward, warm collar (22) of taper roller bearing to
temperature adding +50°C (122°F) to the room
temperature and fit it.
22

Fig. 33-189 Installing taper roller bearing (8)

5) Installing the collar (22) Adjust the clearance
The nominal thickness of the collar (22) is 7.0 0.06 mm (0.0024 in)
mm (0.2756 in). Adjust this thickness so that the
clearance between the collar (22) and the groove
COLLAR (22)
in the shaft (1) is 0.06 mm (0.0024 in).
TAPER ROLLER
BEARING (8)
SHAFT (1)

Fig. 33-190 Adjusting clearance between collar (22)

and shaft (1)

33-100
 33. UPPER SLEWING BODY

6) Installing the ring gear (10).

• Degrease the mating surface between the
gear case (5) and the ring gear (10) and the
pin (9).
• Apply liquid packing (Three Bond #1215, gray)
to the area of the gear case (5) inside the bolt
circle, and install the ring gear (10) on the gear
case (5).
• Apply sealant equally so that the thickness
projecting from nozzle is about 1.5 mm (0.06 Fig. 33-191 Applying liquid packing to gear case (5)
in) in diameter.
10

Fig. 33-192 Installing ring gear (10)

7) Installing the holder 2 assy (15)
1. Install the needle bearing (16) in spur gear 5
(18). Install this assy together with the thrust
plate 2 (19) into holder 2 (21), and insert the
shaft 2 (17) into the spur gear.
• Apply hydraulic oil to the inside diameter of 15
spur gear 5 (18), needle bearing (16) and the
outside diameter of the shaft 2 (17).

17
Fig. 33-193 Installing holder assy 2 (15)
2. Drive the spring pin (20)

Drive spring pin facing the split to gear side.

Beware of the direction

of spring pin.
20
GEAR SIDE

15
Caulk two point with a punch.
Fig. 33-194 Driving spring pin (20)

33-101
33. UPPER SLEWING BODY

8) Carefully mesh the holder 2 assy (15) in the in-

ternal teeth of the ring gear (10), and the spline
of the pinion shaft (1) with its mating part. In this
condition, insert the holder 2 assy (15) while 15
turning it.
9) Carefully mesh spur gear 4 (11) in the spur gear
5 (18).

11
Fig. 33-195 Inserting holder 2 assy (15)
10) Installing the holder 1 assy (13)
1. Carefully mesh the holder 1 assy (13) in the
internal teeth of the ring gear (10), and holder
1 (13) in the teeth of sun gear (12). In this
condition, insert the holder 1 assy (13) while
turning it slowly.
2. Place sun gear (12) in while engaging with 13
planet gear of holder 1 assy (13) slowly.
11) Turn the holder 1 assy (13) with your hand to
confirm that the pinion shaft rotates smoothly.

Fig. 33-196 Inserting holder 1 assy (13)

33.2.5.4 MAINTENANCE STANDARDS

Parts Maintenance
Replace if harmful wear, pitting, peeling, scratch, etc. are found on the tooth
Gear, Pinion
face.
Replace if harmful wear, indentation, etc. are found on the spline portion,
there is a backlash on the pin portion (For holder 1 assy, loosening of caulk-
Holder 1, 2 assy
ing, for holder 2 assy, wear of pin bore), or the needle bearing is worn mak-
ing a backlash.
Even if the bearing works normally, when the "Hour meter" arrives to the
time in 3000 hours, replace them with new ones.
Even through the "Hour meter" is within 3000 hours, when the rolling contact
Taper roller bearing,
surface of needle bearing is flawed while removing, replace them with new
Needle bearing
ones.
And if possible we will recommend that you replace bearings with new ones
because they will often be damaged during removing.
When the lip is damaged, replace it with a new one.
Oil seal And even if there is no leak, replace seal every 3000 hours.
Also, replace it with new ones without fail while installation.
Other parts Replace parts worn or damaged with new ones.

33-102
 33. UPPER SLEWING BODY

33.2.6 SWIVEL JOINT

33.2.6.1 CONSTRUCTION

12 T=Tightening torque : N·m (lbf·ft)

M
C D

G
2

15
Note)
Fit completely-degreased
seal saay (5) and seal (15)
in seal groove without
H application of oil and
grease.
D
SECTION K-K
C
J
G F
B 5

A
C
B F A
G
1 A E B
F
D G C
H D

7 K K
E
H
9 13 4 3 8 J
T = 30.4 (22) T = 30.4 (22) VIEW M
(Loctite #290) (Loctite #290)
SECTION J-J
Fig. 33-197 Construction
Table 33-5
No. Parts Q’ty No. Parts Q’ty No. Parts Q’ty
1 BODY 1 5 SEAL ASSY 7 12 PLUG : PT1/8 1
2 STEM 1 7 O-RING ; 1A G95 1 13 PLUG : PT3/8 2
3 THRUST PLATE 1 8 SOCKET BOLT : M8 × 20 2 15 SEAL 2
4 COVER 1 9 SOCKET BOLT : M8 × 30 3

33-103
33. UPPER SLEWING BODY

33.2.6.2 DISASSEMBLY AND ASSMBLY

33.2.6.2.1 TOOLS
Table 33-6
Code Tool Name Used for Remarks
1. Steel hammer
a Hammer
2. Wooden or plastic hammer
b Rubber mat Disassembly 500 mm (20 in) square or more
Assembly 1. Allen wrench
c Wrench 2. Double-ended and single-ended wrench
3. Extension pipe
d Torque wrench Assembly 98 N•m (72 lbf•ft)
Grind the tip of "a nail"
to shape as a screwdriver.
e Pin Disassembly

Made from a hack-saw blade

Disassembly Approx. 120 mm (5 in)

f Spatula
Assembly

Remove the edge completely

Vinyl tape and make corner round smooth.

Disassembly
g V block or vise Vises movable over 150 mm (6 in)
Assembly
Thrust plate,
h Loctite #290
Cover
i Lubricating oil Hydraulic oil or Vaseline
j Cleaning oil

33.2.6.2.2 APPARATUS
(1) Hoist or crane
The lifting device should be capable of lifting the swivel joint assembly.
(2) Work bench
The work bench should have an area of 1.2 m × 1.5 m (4ft × 5ft)
(3) Others
Also prepare rag, wooden block and oil container.

33.2.6.2.3 CLEANING
Clean the swivel joint to remove dirt, dust, etc. using steam, wash oil, etc.
• Never fail to plug up every port before starting cleaning

33-104
 33. UPPER SLEWING BODY

33.2.6.2.4 DISASSEMBLY
The part numbers used in this disassembly procedure 1
correspond to those of a construction drawing in Fig. MATCHING MARK
33-197. 9
(1) Removing cover
4
1) Place a V-block on a work bench, mount a swivel
joint set on the side, fix it and loosen capscrew
(9) by means of allen wrench.

: 6 mm
• Apply match mark on cover (4) and body (1).
ALLEN
• Alternately the swivel joint may be fixed by hold- WRENCH
V-BLOCK
ing stem (2) in a vise. PIPE
2) Remove cover (4) from body (1) and draw out O-
ring (7) from cover (4).
Fig. 33-198 Removing cover (4)
(2) Removing thrust plate 7 O-RING
Loosen socket bolts (8) fastening thrust plate (3), in
the same manner as the removing of the above-
mentioned cover.

: 6 mm

4 COVER
Fig. 33-199 Removing O-ring (7)
When removing thrust plate (3) by fixing body (1), sup- 1 BODY
port stem (2) so it may not fall dawn.
3 THRUST PLATE
8 CAPSCREW

PIPE

2
STEM

Fig. 33-200 Removing thrust plate (3)

(3) Extraction of stem 1 BODY
Place body (1) on a V-block. Put a wooden block
against stem (2), then knock it out using a hammer.
By hitting out the stem over about 1/2 from the
body, it can be easily pulled out by hand. Weight of
stem ; About 11kg (24 lbs)
WOODEN V-BLOCK
BLOCK 2 STEM

Work bench

Fig. 33-201 Drawing out stem (2)

33-105
33. UPPER SLEWING BODY

(4) Removing seals

1) Stick pin (e) to seal (15) and remove seal (15).
Fig. 33-202 shows the use of one pin, but by us-
ing two pins, this can be extracted with more
sureness.

15
(SEAL RING)
PIN (e)

Fig. 33-202 Taking out seal (15)

2) Pull out back-up ring from the O ring groove with SPATULA (f)
the aid of a spatula.

1 BODY (BACK-UP RING)

Use the tip of the spatula taking not to harm the body
(1).

3) Stick pin (e) to slipper ring and remove seal assy

(5) in the same procedure as seal (15). Then re- Fig. 33-203 TAKING OUT SEAL (15)
move back-up ring by means of spatula (f).

SLIPPER RING

BACK-UP RING
GROOVES
Detail of seal assy (5) FOR SEAL ASSY

PIN (e) GROOVES FOR

SEAL
HYDRAULIC OIL
ASSY
5 GROOVES
FOR SEAL ASSY

Fig. 33-204 Taking out seal assy (5)

33-106
 33. UPPER SLEWING BODY

33.2.6.2.5 ASSEMBLY
Prior to assembly, clean each parts (excluding the O-
ring and seal), and arrange in the sequence of assem-
bly.
(1) Assembling seals to body
1) Install seal (15) (back-up ring and seal ring in or-
der) into the seal groove. In this time, deform and
fit the seal ring as shown in Fig. 33-205. And af-
ter inserting entire seal section, fit it in seal
groove completely with spatula.
2) After deform slipper ring of seal assy (5) as
shown in Fig. 33-205, install back-up ring. And
after inserting entire seal section, fit it in seal Fig. 33-205 Inserting seal ring (15)
groove completely with spatula.

Before fitting seal (15) and seal assy (5), check that
seal groove is free from hydraulic oil, vaseline, grease,
etc.

(2) Assembling stem

Press in by applying your weight
Lightly coat the outer circumference of stem (2) and by your both hands.
the inner surface of body (1) with grease or vaseline
and slowly insert stem (2) into body (1).
2 STEM

• If stem (2) is pressed in too fast, the seal may be

damaged. Do it slowly. SEAL 15
• The clearance between body (1) and stem (2) is 1 BODY
about 0.1 mm (0.004 in). Push stem straight along
the shaft center. SEAL ASSY 5
WORK BENCH

Fig. 33-206 Inserting stem (2)

(3) Assembling thrust plate 8 3 2
1) While holding stem (2) and body (1), match the
hole of thrust plate (3) and the stem (2) hole.
2) Next, after removing any oil from the thread of
socket bolts (8), coat it with Loctite #290 and
tighten to stem (2).

: 6 mm
Tightening torque : 30.4 N•m (22 lbf•ft)
Fig. 33-207 Tightening socket bolts (8)

33-107
33. UPPER SLEWING BODY

(4) Assembling cover 1

After installing O-ring (7) to cover (4) and aligning
MATCHING MARK
the matching marks of the cover (4) and body (1),
9
and tighten socket bolts (9) with Loctite #290 and
tighten it which will then complete assembly. 4

: 6 mm
Tightening torque : 30.4 N•m (22 lbf•ft)

ALLEN WRENCH
V-BLOCK
PIPE

Fig. 33-208 Tightening socket bolts (9)

33-108
 33. UPPER SLEWING BODY

33.2.6.3 MAINTENANCE STANDARDS

33.2.6.3.1 USABLE LIMIT OF PARTS

Table 33-7
Parts Maintenance Standards Remedy
Sliding surface with sealing Plating worn or peeled due to seizure or contamina-
Replace
sections tion.
1) Worn abnormality or damaged more than 0.1 mm
Sliding surface between Replace
(0.004 in) in depth due to seizure or contamination.
body and stem other than
Smooth with oil
Body, Stem sealing sections 2) Damaged more than 0.1 mm (0.004 in) in depth.
stone.
1) Worn more than 0.5 mm (0.02 in) or abnormality. Replace
Sliding surface with thrust 2) Worn less than 0.5 mm (0.02 in). Smooth
plate 3) Damage due to seizure or contamination remedia-
Smooth
ble within wear limit 0.5 mm (0.02 in).
1) Worn more than 0.5 mm (0.02 in) or abnormality. Replace
Sliding surface with thrust 2) Worn less than 0.5 mm (0.02 in). Smooth
Cover
plate 3) Damage due to seizure or contamination remedia-
Smooth
ble within wear limit 0.5 mm (0.02 in).
1) Extruded excessively from seal groove square
ring.

EXTRUSION Replace
(With back-up
ring)

BACK-UP RING

2) Slipper ring 1.5 mm (0.06 in) narrower than seal

groove, or narrower than back-up ring.

Slipper ring Replace

Seal ring (With back-up
1.5 mm (max.)
ring)
(0.06 in)

BACK-UP RING
3) Worn more than 0.5 mm (0.02 in).

0.5 mm (max.) Replace

(0.02 in) (With back-up
ring)

33-109
33. UPPER SLEWING BODY

33.2.6.3.2 INSPECTION AFTER ASSEMBLY

After completion of assembly, inspection for oil leakage, 1
pressure resistance, etc., using a device as shown in
the figure right.
(1) High pressure port 9 Connect to
Install a changeover valve and pressure gauge to body side

the stem side port and body side port respectively,

and while watching the pressure gauge (for high
2
pressure) installed on the body side and also by
Connect to
regulating high pressure relief valve (7), gradually stem side
increase the pressure and when the pressure has
reached 1.5 times the maximum working pressure, 3
close stop valve (3) and lock in the hydraulic oil in
8
the swivel. Keep stop valve (6) on the low pressure
relief valve side closed at this time.
Apply high pressure for 3 minutes, and check the
7
looseness, deformation and breakage on every
parts.
Pressure down should be within 10% of closing
pressure.
These inspections are performed on every circuit.

6 5
Fig. 33-209 Hydraulic circuit for inspection equip-
ment
(2) Low pressure port (Drain port, return port, etc.)
Item Description Remarks
Similar to the high pressure port, install a
High and Low Pressures
changeover valve and pressure gauge on each port 1 Pressure Gauge are required.
of the stem side and body side. 2 Swivel Joint
Open stop valve (6) on the side of low pressure re- 3 Stop Valve
lief valve (5) and while watching the pressure Relief Valve for Setting Pressure :
5 low pressure 0.49 MPa (71 psi)
gauge (for low pressure) connected to the body
6 Stop Valve
side and also by regulating low pressure relief valve
Setting Pressure :
(5), gradually increase the pressure and check for Relief Valve for [Max. operating pressure
7
outside leakage with a color check at a pressure of high pressure 25.5 MPa
0.49 MPa (71 psi). (3700 psi) X 1.5 times]
8 Directional Valve
• The maximum working pressure stands for pres-
9 Piping, etc.
sure of hydraulic excavator equipped with swivel
joint.

33-110
 33. UPPER SLEWING BODY

33.2.6.3.3 TROUBLESHOOTING
Table 33-8
Trouble Cause Remedy
1. External leakage of hydraulic oil Defective O-ring Replace all seals.
2. Internal leakage of hydraulic oil 1) Defective slipper seal 1) Replace all seals.
2) Sliding face worn excessively 2) Replace assy.
3. Swivel joint seized 1) Stem and body seized 1) Grind and hone.
Replace assy, if stem and body are too loose
and causing oil leakage.
2) Setting failure of swivel stopper 2) Reinstall
bracket Secure 2~3 mm (0.08~0.12 in) allowance for
bolt stopper.
4. Loose swivel stem and cover Socket bolt tightened insufficiently. Retighten to specified torque.

33-111
33. UPPER SLEWING BODY

[MEMO]

33-112
 34. TRAVEL SYSTEM
TABLE OF CONTENTS

34.1 REMOVING AND INSTALLING ......................................................................................... 34-3

34.1.1 COMPONENTS OF TRAVEL SYSTEM .................................................................... 34-3
34.1.2 CRAWLER ................................................................................................................ 34-3
34.1.3 UPPER ROLLER ...................................................................................................... 34-7
34.1.4 LOWER ROLLER (TRACK ROLLER) ...................................................................... 34-12
34.1.5 FRONT IDLER (IDLER ADJUSTER ASSY) .............................................................. 34-19
34.1.6 SPROCKET .............................................................................................................. 34-28
34.1.7 TRAVEL MOTOR ...................................................................................................... 34-30
34.1.8 SLEWING BEARING ................................................................................................. 34-33
34.2 DISASSEMBLING AND ASSEMBLING ............................................................................ 34-37
34.2.1 TRAVEL MOTOR ...................................................................................................... 34-37

34

34-1
34. TRAVEL SYSTEM

PREFACE
(1) This Manual describes all the procedures from removing to attaching, arranging them by item.
(2) This Manual consists of first part; 34.1 Removing and Installing assy, and second part; 34.2 Disassembling and
assembling.
(3) The removing and Installing can be performed in the procedure specified in Table of Contents, but in view of
actual repairing or time saving some process can be omitted.
(4) The removing and Installing procedure does not completely cover all possible situations because of difference
of field condition and defective section.
(5) Please be aware that the procedure to be followed must be determined according to the above conditions.
When disassembly and assembly are required, select the necessary section, itemize the work contents with
good understanding, then starts working.

34-2
 34. TRAVEL SYSTEM

34.1 REMOVING AND INSTALLING

34.1.1 COMPONENTS OF TRAVEL SYSTEM

8. SLEWING BEARING
2. CRAWLER

7. TRAVEL MOTOR

5. FRONT IDLER
6. SPROCKET
GREASE NIPPLE OF THE
TRACK SPRING ADJUSTER LOWER FRAME

4. LOWER ROLLER
3. UPPER ROLLER
Fig. 34-1 Designation and location of undercarriage

34.1.2 CRAWLER

34.1.2.1 REMOVING CRAWLER

(1) Position the machine to remove crawler.
(2) Pushing out master pin.
1) Set master pin to positions shown in the figure.
2) Slacken crawler

: 19 mm

• When loosening the grease nipple of the adjuster,

do not loosen it more than one turn. Fig. 34-2 Crawler removing position

• Where grease does not come out well, move the Projection
Master pin
machine back and forth. The over loosening of
grease nipple may cause it to jump out incurring
danger of injury. So be careful not to over loosen
the grease nipple.

3) Pushing out master pin

Apply jig on master pin and strike it out with a
mallet.

Master pin
drawing jig

• If you use a big hammer, wear a long-sleeved gar- Fig. 34-3 Pushing out master pin
ment and protective goggles to protect yourself
from flying objects.

34-3
34. TRAVEL SYSTEM

(3) Removing crawler

Put attachment on ground so that weight is not Removing
master pin
loaded to the lower frame, and remove track link
assy rotating sprocket.

Crawler end section may fall on the ground just before

extending it on the ground incurring danger of injury.
Please keep well away from the equipment. Fig. 34-4 Removing crawler

34.1.2.2 INSTALLING
Installing is done in the reverse order of removing.
(1) Checking crawler installation direction.
Place the track links on the ground so they con- Front
idler side
verge, facing the front idler, as shown in the figure
on the right.

Fig. 34-5 Installing direction of crawler

(2) Installing crawler
1) Preparation for installation
Treat paint flaking protection with care not to
damage lower flame.
2) Winding crawler
Insert bar into master pin hole, lift lower frame up
1 or 2 cm (0.4 in~0.8 in) using attachment and
hold it, then turn sprocket in rearward positioning
the machine so that the weight is not loaded to
shoe.

Fig. 34-6 Winding crawler

(3) Preparation for press fitting master pin
1) Preparing for installation
Put wood block under the shoe plate.
2) Aligning master pin holes
Aligning master pin holes through fine adjust-
ment turning sprocket.

Connecting
position of master pin
Fig. 34-7 Preparation for press fitting master pin

34-4
 34. TRAVEL SYSTEM

(4) Press fitting of master pin

Apply press fitting jig on master pin, and strike it
with a mallet to press fit.

• If you use a big hammer, wear a long-sleeved gar-

ment and protective goggles to protect yourself
from flying objects.
• Coat the master pin with molybdenum disulfide
grease, before pressing it in. Master pin fixing jig

Fig. 34-8 Press fitting of master pin

(5) Adjusting crawler tension (See Fig. 34-9)
After installing, adjust tension of crawler.

: 19 mm

PROPER TENSIONING A DIMENSION

Iron crawler 200~230 mm
(8 in~9 in)
Rubber crewler 140~150 mm
(5 in~6 in)
A

Fig. 34-9 Adjusting crawler tension

34.1.2.3 CONSTRUCTION

No. Name Q'ty

7
SHOE ASSY 2
4
• TRACK LINK ASSY 1X2 3
1 • • TRACK LINK (R.H) 39 X 2 7
2 • • TRACK LINK (L.H) 39 X 2 8
3 • • BUSHING 38 X 2
4 • • PIN 38 X 2
11 1
5 • • MASTER BUSHING 1X2 5

6 • • MASTER PIN 1X2 8

2
7 • • SEAL 76 X 2 6
8 • • MASTER COLLAR 2X2
9
9 • SHOE 39 X 2
10 • SHOE BOLT 156 X 2
11 • SHOE NUT 156 X 2

10

Fig. 34-10 Shoe assy

34-5
34. TRAVEL SYSTEM

34.1.2.4 MAINTENANCE STANDARD

Track link assy

F E
G
D B

(2.87")

(3.50")
73

89
57 (2.24")
A

I
Fig. 34-11

Unit : mm (in)
REPAIR-
SERVICE
No. ITEM STANDARD VALUE ABLE REMEDY
LIMIT
LEVEL
A Link pitch 155.6±0.1(6.126±0.0039) 160 (6.30) 164 (6.46) Replace the link
B O.D. of bushing Ø41 (1.6142 ) Ø37 (1.46) Ø36 (1.42) assy if the service
C Height of link 75±0.15 (2.9528±0.0059) 69 (2.72) 67 (2.64) limit is exceeded.
Basic di-
Tolerance Fit Fit
mension
Interference between +0.214
D Interfer-
bushing and link Ø41 (+0.0084 ) Interfer-
Shaft ence 0.05
(1.6142) +0.174 ence 0
(0.0020) Replace
(+0.0069)
+0.15
Interfer-
Interference between Ø24 (+0.008) Interfer-
E Shaft ence 0.05
track pin and link (0.9449) 0 ence 0
(0.0020)
(0)
-0.05
Interfer-
Interference between Ø24 (-0.0020) Interfer-
F Shaft ence 0.05 Replace Link
master pin and link (0.9449) -0.08 ence 0
(0.0020)
(-0.0032)
Clearance between
G 1.6 (0.06) 8 (0.32) 10 (0.39) Replace
links (both sides)
H STD shoe plate 26 (1.02) 15 (0.59) 13 (0.51) Replace
Tightening torque of
I 294 N•m (220 lbt•ft) Retighten
shoe bolt

34.1.2.5 TOOLS AND JIGS

No. JIGS SHAPE

a Master pin fixing jig

34-6
 34. TRAVEL SYSTEM

34.1.3 UPPER ROLLER

34.1.3.1 UPPER ROLLER ASSY

No. Parts Q'ty Remarks 4 4

1 CAPSCREW 2 M16 X 90 IDLER SIDE
2 NUT 2 M16
3 ROLLER ASSY 2
4 WASHER 4 2 1

3
Fig. 34-12 Upper roller assy

34.1.3.2 REMOVING
(1) Preparation for removal
Remove crawler (see 34.1.2.1).
(2) Removing upper roller (3)
1) Remove nuts on support tightening section, and
also remove cap screw M16 X 90.
(1)
: 24 mm M16 X 80

Fig. 34-13 Removing upper roller

34.1.3.3 INSTALLING
Installing is done in the reverse order of removing.
(1) Inspection IDLER SIDE

Before reassembling, check it that it rotates smooth 3

Countersinking
manually and for leakage. 2

Up

SUPPORT 1 Apply Loctite #262

COLLAR T=279 N·m (210lbf·ft)
Fig. 34-14 Installing upper roller
(2) Installing upper roller (3)
1) Fit it directing nut toward idler side.
2) Insert it until collar comes in contact with support.
3) Fit it directing the countersinking mark of shaft
end upward.
4) Apply Loctite #262 on capscrew M16 X 90, and
tighten it to the specified torque.

: 24 mm
Tightening torque : 279 N•m (210 lbf•ft)

Fig. 34-15 Installing upper roller (3)

34-7
34. TRAVEL SYSTEM

34.1.3.4 CONSTRUCTION

10 7 8 1 5 6 11
2
No. Parts Q'ty No. Parts Q'ty
1 ROLLER 1 7 O-RING ; G45 1A 1
2 SHAFT 1 8 SOCKET BOLT
3 PLATE 1 ; M8 X M22 2
4 COVER 1 9 SNAP RING 1
5 BUSHING 1 10 PLUG 1
6 FLOATING SEAL 1 11 COLLAR 1

9 4 3
Fig. 34-16 Construction of upper roller

34.1.3.5 DISASSEMBLY AND ASSEMBLY

(1) Disassembly 8 9
1) Draining out oil 3
Remove plug (10) and drain out oil. 10
7
: 5 mm 4
2) Removing snap ring (9)
Mount the end face inside upper roller (1) on 1
stand jig (f) and separate snap ring (9), using
snap ring pliers.
3) Removing cover (4)
Take off cover (4) upwards, utilizing the screwed f
hole for the plug.
4) Removing O-ring (7)
Separate O-ring (7) from cover (4).
5) Removing plate (3)
Loosen two socket bolts (8) and draw out plate
(3) from upper roller (1). Fig. 34-17 Removing snap ring (9), cover (4), O-ring
(7), plate (3)
: 6 mm
6) Removing shaft (2) Push with press
Put the extrusion jig (g) against the end face of
shaft (2) and lightly extrude shaft (2) with retainer
for floating seal (6), using a press or hammer. g

Press machine capacity : 10 ton class.

2

Fig. 34-18 Extruding shaft (2)

34-8
 34. TRAVEL SYSTEM

7) Removing floating seal (6).

6
Take out floating seal (6) from upper roller (1).

Fig. 34-19 Taking out floating seal (6)

8) Removing floating seal (6).
2
Take out, from retainer, floating seal (6) that is lo-
cated on the side from which shaft (2) was dis-
parted. 6

RETAINER

Retainer is press fitted into shaft (2). Therefore do not

disassemble it.
Fig. 34-20 Taking out floating seal (6)
9) Removing bushing (5).
Since the thickness of bushing is thin, remove it
Push-out bar
through lathe or strip it. When the wear of bush-
ing is too small, place upper roller (1) on jig (f) for
repair stand and apply push-out bar on the end
face of busing (5), and push it out by striking it 5
with mallet.

Fig. 34-21 Extruding bushing (5)

(2) Assembly Push with press
Assembly of the upper roller is done in the reverse
order of disassembly. h
1) Pressing the bushing (5).
Align inner hole of roller (1) and bushing (5) and 5
press fit it vertically with press so that jig (h) for
bushing push-in jig (h) is inserted into bushing 1
(5). f

Fig. 34-22 Pushing in bushing (5)

If you fail in this operation by pressing the bushing un-

evenly, the bushing is distorted and gets unserviceable.
In that case, do not re-use the bushing as it may devel-
op malfunctioning after assembly.

34-9
34. TRAVEL SYSTEM

2) Installing floating seals (6).

6
Two floating seals (6) make a pair. Attach one 2
floating seal to retainer fixed in shaft (2), and an-
6 1
other to the inside of upper roller (1).
• Prior to placing floating seal (6) in, apply en-
gine oil lightly to seal surface.
COLLAR

Fig. 34-23 Fixing floating seal (6)

3) Inserting shaft (2).
Coat shaft (2) with a thin film of oil and insert it
into upper roller (1).
2
4) Installing plate (3).
Mount upper roller (1) on the stand jig (f) and at-
tach plate (3) to the end face of the shaft with
socket bolt (8). In that case, coat the screwed
1
part of socket bolt (8) with Loctite #242 before-
hand.
: 6 mm
Tightening torque : 33 N•m (25 lbf•ft)
Fig. 34-24 Pressing the shaft (2)
5) Installing O-ring (7). 9
8
Fit O-ring (7) to the groove of cover (4). 7
4
•Apply grease to O-ring.
3
6) Installing cover (4). 1
Attach cover (4) to upper roller (1). Use a press
in this operation as a press fit is used.
7) Installing snap ring (9).
Fix snap ring (9) into upper roller (1), using snap
ring pliers. f

Fig. 34-25 Installing plate (3), O-ring (7), cover (4),

snap ring (9)
8) Filling oil
Fill in 20 cc (1.22 cu•in) of engine oil API grade
CD#30 through the plug hole in cover (4). 10
9) Installing plug (10). 4
Place seal tape around plug (10) and screw it
1
into the plug hole of cover (4).
: 5 mm
Tightening torque : 23 N•m (17 lbf•ft)
• After assembling the upper roller, confirm that
oil is not leaking from it and that it rotates f
smoothly by hand.

Fig. 34-26 Filling oil

34-10
 34. TRAVEL SYSTEM

34.1.3.6 MAINTENANCE STANDARD

(1.34")
34
A D C

E
Fig. 34-27 Upper roller

Unit : mm (in)
REPAIR-
SERVICE
No. ITEM STANDARD VALUE ABLE REMEDY
LIMIT
LEVEL
A Tread dia. Ø82 (3.23) Ø73 (2.87) Ø70 (2.76) Rainforcement weld,
B Tread width 102 (4.02) 95 (3.74) 92 (3.62) repair or replace
Basic di-
Tolerance Fit Fit
mension
Clearance between -0.025
C
shaft and bushing Ø32 (-0.00098 ) Clearance Clearance
Shaft
(1.2598) -0.050 0.7 (0.028) 1.0 (0.04) Replace bushing
(-0.00197)
0 Clearance
Interference between Ø36 Interfer-
D Hole -0.03 0.01
roller and bushing (1.4173) ence 0
(-0.0012) (0.0004)
Tightening torque of
E 33 N•m (25 lbt•ft) Apply Loctite #242
socket bolt
Oil Engine oil API grade CD #30, 20 cc (1.22 cu•in) Replenish.
Roller rotation Roller rotates smoothly by hand. Reassembly.

34.1.3.7 TOOL AND JIGS

Unit : mm (in)
No. JIGS SHAPE No. JIGS SHAPE

For extruding
g
shaft

f Stand jig

Bushing fixing
h
jig

34-11
34. TRAVEL SYSTEM

34.1.4 LOWER ROLLER (TRACK ROLLER)

34.1.4.1 LOWER ROLLER ASSY

No. Parts Q'ty Remarks

1 LOWER ROLLER 10
2 CAPSCREW 40 M14 X 55

2 1
Apply Loctite #262
T=181 N·m (130 lbf·ft)
Fig. 34-28 Lower roller assy

34.1.4.2 REMOVAL
(1) Where crawler is removed
1) Preparation for removal
Loosen grease nipple to slacken the link. Put
wood blocks on the front and rear sides of under
section of lower frame, and stabilize the ma-
chine.
2) Removing lower roller
Remove capscrew (2) M14 X 55.

: 22 mm
Fig. 34-29 Holding up the lower frame
Weight of lower roller : Approx.15 kg (33 lbs)
(2) Where crawler is installed.
1) Preparation for removal
Slacken crawler, and stop engine keeping lower
frame lifted up with front attachment.
2) Put safe blocks under the front and rear sides of
lower frame.
3) Remove lower roller
Remove capscrews (2) in the same procedure
as that shown in Fig. 34-28.

Fig. 34-30 Removing lower roller

34.1.4.3 INSTALLATION
(1) Securing lower roller temporarily
Apply Loctite #262 on 4 capscrews (2) and tighten GREASE NIPPLE
them temporarily.

: 22 mm
(2) Securing lower roller regularly.
Tighten capscrews (2) to the specified torque.
(3) Adjusting tension of crawler.
Tighten grease nipple and fill it with grease.

Fig. 34-31 Adjusting tension of crawler

34-12
 34. TRAVEL SYSTEM

34.1.4.4 CONSTRUCTION

T=23 N·m (17 lbf·ft)

8
No. Parts Q'ty
1 ROLLER 1
2 SHAFT 1
3 BUSHING 2
4 PIN 2
5 SEAL 2
6 O-RING 2
7 COLLAR 2
8 PLUG 2 1 2 3 5 6 4 7
Fig. 34-32 Construction of lower roller

34.1.4.5 DISASSEMBLY AND ASSEMBLY

(1) Disassembly
1) Drain oil
14
Remove plug (8) and drain out oil. (0.551")
J
: 6 mm
2) Removing pin (4) 4
Put both ends of lower roller assy on the V-
shaped blocks (K), apply push-out bar (j) on up-
per end face of pin (4), and push pin out striking
K
with mallet.

Fig. 34-33 Drawing out collar fixing pin (4)

3) Removing collar (7), O-ring (6) Push with press Push with press
Put lower roller on jig (m) for repair stand so that
the shaft is perpendicularly located, apply push-
P P
out jig (P) on shaft end on upper side, and push
shaft (2) until the O-ring separate from collar (7) 7 7
with press or mallet, and take out collar (7) and
O-ring (6). 6 6
4) Removing shaft (2)
In addition, push out and remove shaft (2) to-
gether with the lower collar (7) and O-ring (6). 2 2

m m

The shaft (2) extrusion operation may cause the re-

maining lube oil to flow out and contaminate the floor.
Prepare an oil container beforehand.

Fig. 34-34 Removing shaft (2), collar (7), O-ring (6)

34-13
34. TRAVEL SYSTEM

5) Removing collar (7), O-ring (6) 5

Insert shaft (2) with collar (7) and O-ring (6) re-
moved in the said procedure into roller (1) direct-
ing the collar (7) side upward, and take out collar
(7) and O-ring (6) from shaft (2) in the same pro-
cedure as that described in Item 3). 7

6) Removing floating seal (5)

Take out floating seal (5) from collar (7). Fig. 34-35 Taking out floating seal (5)
7) Removing floating seal (5)
Take out floating seal (5) from roller (1).
5

Fig. 34-36 Taking out floating seal (5)

8) Removing bushing (3)
Since thickness of bushing (3) is thin, remove it
a
through lathe or strip it with care not damage in-
n
ner hole of roller. When the wear of bushing is 16 (0.63")
200 (8")

not large, place upper roller (1) on jig (m) for re-
pair stand and apply the end of push-out jig on
the end face of bushing (3) end, and push it out
striking it with mallet.
3

Hammer the inside surface of roller lightly so as not to m

damage the surface. Put the extrusion jig (n) uniformly
over the circumference of bushing (3) and extrude it lit- Fig. 34-37 Extruding bushing (3)
tle by little.

(2) Installing
6 2
1) Attach O-ring (6) to one side
Install O-ring (6) to shaft groove.
•Apply grease to O-ring.
•Replace O-ring with new one.
Fig. 34-38 Attach O-ring (6) to one side

34-14
 34. TRAVEL SYSTEM

2) Press fitting bushing (3)

Push with press
Align inner hole of roller (1) and bushing (3) and q
press fit it vertically in capacity of press fit load,
3600kg (7940 lbs), in the condition that bushing
push-in jig (g) is inserted into bushing (3). 3
• Apply molybdenum disulfide grease on press-
fit section of bushing, and press-fit it in ordi-
1
nary temperature.
• Bushing which fails to press-fit because of the
one-side pressing should not be fitted.
Fig. 34-39 Press fitting bushing (3)
3) Press fitting collar (7)
Fit O-ring to the one side of shaft (2) mating pin 5

hole of collar (7) on which floating seal (5) is fit 4

with pin hole of shaft (2) in advance.
• Care should be taken not to damage O-ring
(6) while press-fitting collar (7) to shaft. 2
4) Inserting pin (4)
Press-fit pin (4) to pin hole on aligning pin holes
of shaft (2) and collar (7).
6 7
Fig. 34-40 Inserting pin (4)
5) Attach floating seal (5) to roller side
Fit floating seal (5) to inner holes on both ends of
roller (1).
• Check that the seal surface is free from flaws,
rusts, etc. before reusing the floating seal.
1
6) Inserting roller (1)
Insert roller (1) from the side where collar (7), O-
ring (6) is not press-fitted to the shaft (2).

Fig. 34-41 Inserting roller (1)

34-15
34. TRAVEL SYSTEM

7) Installing O-ring (6)

Press
Install O-ring (6) to shaft groove.
•Apply grease to O-ring.
•Replace O-ring with new one. Pin
7
8) Press fitting collar (7)
Press-fit collar (7) to shaft (2).
6
•Press-fit collar (7) on aligning pin (4) hole.
9) Inserting pin (4)
Press-fit pin (4) described in to the pin hole mat-
ing pin hole of collar (7) with pin hole on the end 2
side of shaft (2).

Fig. 34-42 Installing O-ring (6), collar (7)

10) Filling oil 8
Remove plug (8) and fill in 90 cc (5.49 cu•in) of Tightening torque :
engine oil API grade CD#30. 23 N·m (17 lbf·ft)

11) Check it for leakage

Before tightening plug (8), check it for leakage in
the condition of air pressure 0.2 MPa (28 psi).
12) Installing plug (8)
Apply oil resistant sealant on plug (8), and tight-
en it in the plug hole on the collar (7) end face. 7

: 6 mm
Tightening torque : 23 N•m (17 lbf•ft) Fig. 34-43 Installing filling oil plug (8)

After assembling the lower roller, confirm that oil is not

leaking and that the roller rotates smoothly by hand.

34-16
 34. TRAVEL SYSTEM

34.1.4.6 MAINTENANCE STANDARD

C 95 (3.74)
G

(0.945")
24
ØD
ØB
ØA

199 (7.83")
Before tightening plug,
apply oil resistant sealant on it.
Tightening torque 23 N·m (17 lbf·ft)
Fig. 34-44 Lower roller (Track roller)

Unit : mm (in)
REPAIRABLE
No. ITEM STANDARD VALUE SERVICE LIMIT REMEDY
LEVEL
A O.D. of flange Ø147 (5.79) — — Reinforce-
ment weld.
B Tread dia. Ø120 (4.72) Ø110 (4.33) Ø106 (4.17) repair or re-
place
C Flange width 17.5 (0.689) 12 (0.472) 10 (0.394)
Basic di-
Tolerance Fit Fit
mension
Clearance between
-0.060
D shaft and bushing
Ø40 (-0.00236) Clearance Clearance
(Coiled bushing) Shaft Replace
(1.57480) -0.090 0.7 (0.028) 1.0 (0.39)
bushing
(-0.00354)
+0.025
Interference between Ø44 (+0.00098) Interference Clearance
E Hole
roller and bushing (1.73228) -0.020 0 0.01 (0.0004)
(-0.00079)
Oil Engine oil API grade CD #30, 90 cc (5.49 cu•in) Replenish.
Reassem-
Roller rotation Rotates smoothly by hand.
bly.
Clearance between
G Keep 2.5±0.5 (0.09843±0.01969) space.
roller and collar

34-17
34. TRAVEL SYSTEM

34.1.4.7 TOOL AND JIGS

Unit : mm (in)
No. JIGS SHAPE

k V-block

Pin (4)
l
extrusion rod

Bushing
n
extrusion rod

m Stand jig

Shaft
p
extrusion jig

Bushing
q
fixing jig

34-18
 34. TRAVEL SYSTEM

34.1.5 FRONT IDLER (IDLER ADJUSTER ASSY)

34.1.5.1 FRONT IDLER ASSY

700 IRON SHOE (27.6")

205 495 IRON SHOE (19.5")

(8.07")
1 116 270+STROKE 31.8
No. Parts Q'ty Remarks (4.57") (10.6") (1.25")

1 IDLER ASSY 2 ")

7.6
(1
2 IDLER ADJUSTER 2
3 GREASE NIPPLE 2
4 CAPSCREW 4 M12 X 30
4 2 3
Apply Loctite #262 Grease nipple is
or equivalent positioned on the outside
T=115 N·m (85 lbf·ft) T=58.8 N·m (43 lbf·ft)

Fig. 34-45 Front idler assy

34.1.5.2 REMOVING
(1) Preparation for removal
Remove crawler. (Above mentioned)
(2) Removing front idler assy
Sling idler assy, and push it forward with pry-bar.
Weight of front idler assy : 146 kg (320 lbs)
PRY-BAR

Keep away from the front side of front idler.

(3) Installing
Installing is done in the reverse order of removing.
(4) Where idling assy (1) has to be separated
Loosen capscrew (4), and separate idler assy (1)
from idler adjuster assy (2).

: 19 mm

Weight of idler assy : 45 kg (99 lbs) Fig. 34-46 Removing and installation the front idler
Weight of idler adjuster assy : 49 kg (110 lbs) assy
• The separated idler assy should be placed on
1
wood blocks.

4
3

Fig. 34-47 Separating idler assy (1) from idler ad-

juster assembly

34-19
34. TRAVEL SYSTEM

34.1.5.3 IDLER ASSY

34.1.5.3.1 CONSTRUCTION

No. Parts Q'ty Remarks

1 8
1 IDLER 1
4
2 SHAFT 1
3
3 COLLAR 2
4 BUSHING 2 2
5 PIN 2 16 X 78
5
6 SEAL 2
7
7 O-RING 2 1A G45
6
8 PLUG 2 PT1/8 Storage procedure

Fig. 34-48 Idler assy

34.1.5.3.2 REMOVING AND INSTALLING

(1) Removing 5
R
1) Drain oil
Remove plug (8) on the side of collar (3) to drain
idler assy of oil.

: 5 mm
2) Removing pin (5)
Apply pin push bar (jig R) to the top of pin, and
take out striking bar (jig R) lightly by hammer.
Fig. 34-49 Removing pin (5)
3) Removing collar (3) Push with press
Put idler (1) on repair stand (U), apply push-out
jig (S) on shaft (2), push out shaft (2) with collar S
2
(3), then remove collar (3).
3
1

U
3

Fig. 34-50 Removing collar (3)

4) Removing collar (3) from shaft (2) Push with press
If removal of collar (3) on the opposite side is re-
quired, turn over front idler and proceed with the S
2
procedure described in Item 3).
3

Fig. 34-51 Removing collar (3)

34-20
 34. TRAVEL SYSTEM

5) Removing bushing (4)

With idler (1) mounted on the stand, tap bushing 4
T
(4) lightly by hammer, while placing the bushing 1
drawing rod (T) against the end face of bushing
(2) evenly all round, till it comes out.
6) Removing floating seals (6)
Take out floating seals (6) from idler (1), collar
(3). If you intend to re-use floating seals (6), con-
firm that there is no scoring and rusting on the U
contact surface and store the floating seals in
Fig. 34-52 Removing bushing
pairs by placing thick paper between the sealing
faces.
7) Removing O-ring (7)
Separate O-ring (7) from shaft (2).
(2) Assembly Push with press
1) Pressing in bushing (4) 4 V 1
Align inner hole of idler (1) and bushing (4) and
press-fit it vertically with press so that jig (V) for
bushing press-fitting jig (V) is inserted into bush-
ing (4).
2) Installing O-ring (7)
Fit O-ring (7) to O-ring groove on shaft (2).
Fig. 34-53 Pressing in bushing (4)
• Apply grease to O-ring.
3) Installing collar (3) (See Fig. 34-54) Pressing
Press-fit the O-ring installed side of shaft into col-
2
lar (3), and drive pin (5).

3
5

Fig. 34-54 Installing collar (3), shaft (2)

4) Installing floating seal (6) 2
Fit the half of floating seal (6) on one side of col- 6
lar (3) and idler (1).
1
5) Inserting idler (1)
Insert floating seal (6) fitted side of idler (1) into
shaft (2).
6) Installing floating seal (6)
Fit floating seal (6) on the other side of idler (1).
Fig. 34-55 Inserting idler (1) and installing floating
seal (6)

34-21
34. TRAVEL SYSTEM

7) Installing collar (3)

8 2
Fit floating seal (6) on the other collar (3), press- 3
5
fit it in shaft, and drive pin (5) in with mallet.
8) Filling oil • Inspection
1
Fill in 150~160 cc (9.15~9.76 cu•in) of engine oil
API grade CD#30 through the plug hole of collar,
place the screwed part of plug (8) with seal tape
and put in plug (8).

: 5 mm Fig. 34-56 Installing collar (3) and filling oil

• After mounting the idler assy to the idler ad-
juster assy, make certain that no oil leaks
from floating seal and plug (8) and that idler
(1) rotates smoothly.

34.1.5.3.3 MAINTENANCE STANDARD

104 (4.09")
C

F
C

E D
A B
A B

DETAIL TREAD PORTION

Fig. 34-57 Front idler

Table 34-1
Unit : mm (in)
REPAIRABLE
No. ITEM STANDARD VALUE SERVICE LIMIT REMEDY
LEVEL
A Dia. of idler projection Ø446 (17.6) Ø440 (17.3) Ø438 (17.2)
B Tread dia. Ø400 (15.8) Ø394 (15.5) Ø392 (15.4) Replace.
C Flange width 43 (1.69) 38 (1.50) 36 (1.42)
Basic di-
Tolerance Fit Fit
mension
Clearance between -0.050
D
shaft and bushing Ø50 (-0.00197) Clearance Clearance
Shaft
(1.96850) -0.075 1.5 (0.059) 2.0 (0.079) Replace
(-0.00295) bushing
-0.03
Interference between Ø57 (-0.0012) Interference Clearance
E Hole
roller and bushing (2.2441) -0.02 0 0.01 (0.0004)
(-0.0008)
Oil Engine oil API grade CD #30, 150~160 cc (9.15~9.76 cu•in) Replenish.
Reassem-
Roller rotation Rotates smoothly by hand.
ble

34-22
 34. TRAVEL SYSTEM

34.1.5.3.4 TOOLS AND JIGS

Unit : mm (in)
No. JIGS SHAPE

Pin
R
striking jig

Shaft
S
push out jig

Bushing
T
drawing rod

About 80 (3.15")
About 400
(15.7")

U Repair stand
About
250
(9.84")
2 pcs

Bushing
V
Press fitting jig

34-23
34. TRAVEL SYSTEM

34.1.5.4 IDLER ADJUSTER ASSY

34.1.5.4.1 CONSTRUCTION

4
3
No. Parts Q'ty Remarks
1 GREASE CYLINDER 1 2
2 BRACKET 1 10
3 NUT 1 SPECIAL M36 X P3
4 SPRING PIN 1
5 SPRING 1 5
6 PISTON 1
7 O-RING 1 1B G50
8 OIL SEAL 1
9 PIN 2 1
10 COVER 1
8 9
11 GREASE NIPPLE 1
7
6
9
11

Fig. 34-58 Idler adjuster assy

34.1.5.4.2 DISASSEMBLY AND ASSEMBLY

(1) Disassembly M30
Holding-down nut
1) Spring set special jig
Before disassembling and assembling the idler Retainer plate
adjuster assy, prepare spring setting jig (V).

Capacity of hydraulic jack : more than 10 tons

V
(22000 lbs)

: 46 mm Hydraulic jack

BASE
Large power is needed to set the spring.
Prepare a special jig before disassembly and assembly. Fig. 34-59 Spring set special jig (V)

2) Preparation for working

Place a hydraulic jack between the jig base and
the stand.
Loosen the holding-down nuts of the jig and draw
out the retainer plate upward.

: 46 mm
3) Draw out grease cylinder (See Fig. 34-58)
Draw out piston (6) from grease cylinder (1) of 5

the idler adjuster assy.

4) Removing oil seal (8), O-ring (7) (See Fig. 34-58)
Taken out oil seal (8) and O-ring (7) from grease
cylinder (1). V
5) Slinging work idler adjuster Fig. 34-60 Slinging work idler adjuster
Set the idler adjuster assy on the stand of the jig,
with its bracket side (2) facing up.

34-24
 34. TRAVEL SYSTEM

6) Fixing idler adjuster assy

Fit retainer plate to bracket (2), tighten holding-

down nuts alternately, and secure idler adjuster
assy.

: 46 mm
  

 

Fig. 34-61 Fixing idler adjuster assy

7) Compression of spring (5) #
Remove spring pin (4), press spring (5) lifting it
with jack so that nut (3) can be turned freely, and
remove nut (3).

: 46 mm

Fig. 34-62 Compression of spring (5)

8) Removing bracket (2)
Allow the hydraulic jack to shrink slowly till the
spring is extended to its free length. Remove the
retainer plate, and take off bracket (2) and cover  
(10).
The free length of the spring : about 320 mm
(12.6 in) 
: 46 mm

Fig. 34-63 Removing retainer plate, bracket (2)

9) Removing spring (5), grease cylinder (1)
Hook lifting eye nut (W) to screw M36 X P3 on
9 
grease cylinder (1) top end and hoist it. Then, re-
move the set of grease cylinder (1) and spring (5)
using crane from the jig.
Remove spring (5), grease cylinder (1), in that
#
order.

Fig. 34-64 Removing spring (5), grease cylinder (1)

34-25
34. TRAVEL SYSTEM

(2) Assembly
Assembly is done in the reverse order of disassem- 9
bly. 
1) Installing spring (5), grease cylinder (1)
Insert grease cylinder (1) into spring (5) and at- #
tach lifting eye nut (W) to screw M36 X P3 at the
tip of the grease cylinder. Lift the grease cylinder
by crane and erect it in the center of the jig stand
upright.
2) Fixing idler adjuster assy
Fig. 34-65 Mounting spring (5) and grease cylinder
Install bracket (2) and cover (10) on top of spring
(1) to the jig
(5). Center the rod of grease cylinder (1) and the
holes in bracket (2). Attach the retainer plate and
four holding-down nuts. Fasten the nuts evenly
all round and fix the idler adjuster assy to the jig
body.

: 46 mm
3) Compressing spring (5) and tightening nut (3)
  
Extend the hydraulic jack, compress spring (5) to   
a set length and screw in nut (3) to the screwed
part at the tip of grease cylinder (1).

Set length of the spring : 270 mm (10.63 in) 

4) Installing spring pin (4) 

Tighten nut (3) till the holes for locking spring 
pins (4) are aligned. Then fit spring pin (4).



: 46 mm

: 55 mm Fig. 34-66 Compression of spring (5), and attaching

nut (3) and spring pin (4)
5) Removing idler adjuster assy
Remove idler adjuster assembly from jig.

Fig. 34-67 Removing idler adjuster assy

34-26
 34. TRAVEL SYSTEM

6) Installing oil seal (8), O-ring (7)


Fit oil seal (8) and O-ring (7) to grease cylinder
(1). &
• Apply grease to oil seal (8) and O-ring (7). %
7) Filling grease cylinder (1) with grease. $
Fill grease cylinder (1) with grease, remove
grease nipple from piston (6), and press piston
by hand to discharge air through grease nipple
hole.
• Direct grease nipple hole downward to make 
air discharge easier. Fig. 34-68 Grease cylinder (1)
8) Installing grease nipple (11)
Tighten grease nipple (11) to piston (6).

: 19 mm
Tightening torque : 58.8 N•m (43 lbf•ft)

34.1.5.4.3 MAINTENANCE STANDARD

No. ITEM STANDARD VALUE H

A Installed length of mm 270 (10.63 in)

spring
B Free length of spring mm About 320 (12.6 in)
C Stroke mm 31.8 (1.25 in)
D Set length mm 495 (19.49 in)
Outer circumference No scoring and rusting
E of piston
Tightening torque of A, B, (C)
F grease nipple 58.8 N.m (43 lbt.ft)

Close contact length of spring 235 (9.25 in) H

Fig. 34-69

34-27
34. TRAVEL SYSTEM

34.1.6 SPROCKET

34.1.6.1 REMOVING
(1) Preparation for removal
Remove crawler referring to 34.1.2 "Crawler", lift up
crawler frame with attachment, and put it on wood
blocks to float and stabilize.
(2) Removing sprocket
Loosen twelve capscrews (2) (M14) for the mount-
ing of the sprocket by means of a socket and re-
move the sprocket.
Weight of sprocket : 28 kg (62 lbs)
Fig. 34-70 Preparation for removal
: 22 mm


Fig. 34-71 Removing sprocket

34.1.6.2 INSTALLING
(1) Check before installing
Check the mating portion of the travel reduction
gear and the sprocket, eliminate burrs and contam-
ination thoroughly and install the sprocket.
(2) Securing sprocket temporarily.
Coat the sprocket mounting capscrews with Loctite
#262 and fasten the sprocket temporarily.
(3) Securing sprocket completely
Take out wood blocks placed under track frame,
and tighten capscrews to the specified torque.

: 22 mm
Tightening torque : 181 N•m (134 lbf•ft) Fig. 34-72 Securing sprocket completely

34-28
 34. TRAVEL SYSTEM

34.1.6.3 MAINTENANCE STANDARD (2404N267)

Table 34-2

PRINCIPAL PAR- PITCH 78.7 mm (3.10 in) NUMBER OF TEETH 21

TICULARS ROLLER DIA. Ø41 (1.61 in) PITCH DIA. 527.9 (20.78 in)

4 (0.157")

)
94"
4 (0.157")
10
(0.3
(0
.3
10 ")
9 4

20.64
64

(0.813")
20.813")
(0.

7.9
4")
P.C.D 52
(20.783

Fig. 34-73 Sprocket

Table 34-3
Unit : mm (in)
No. ITEM STANDARD VALUE REPAIRABLE LEVEL SERVICE LIMIT REMEDY
Reinforcement weld,
A O.D. of sprocket Ø540 (21.260 ) 534 (21.0) 532 (20.9)
repair or replace
B Width of sprocket teeth 38 (1.4961 ) 32 (1.26) 30 (1.18) Replace.
Reinforcement weld,
C I.D. of sprocket Ø487 (19.2) 481 (18.9) 479 (18.9)
repair or replace

34.1.6.4 SPROCKET TOOTH PROFILE GAUGE

Fig. 34-74 Tooth profile gauge

34-29
34. TRAVEL SYSTEM

34.1.7 TRAVEL MOTOR

34.1.7.1 TRAVEL MOTOR

Apply Loctite #262

2 T=181 N·m (130 lbf·ft)

3
D2 (PF 3/8) Apply Loctite #262
or equivalent
T=279 N·m (210 lbf·ft)
B (PF 1/2)

P (PF 1/4)

A (PF 1/2)

VIEW I D1 (PF 3/8)

Fig. 34-75 Installing travel motor

No. Parts Q'ty Remarks

1 SPROCKET 2 2404N267
2 CAPSCREW 24 M14 X 35
3 CAPSCREW 24 M16 X 40
4 TRAVEL MOTOR ASSY 2

34.1.7.2 REMOVING
(1) Preparation for removal 
Remove crawler, lift up crawler frame using attach-
ment, and put it on wood blocks to float and stabi-
lize.
(2) Removing cover (1) %
Remove capscrew (7) and also remove covers (1).

: 19 mm

Fig. 34-76 Removing and installing capscrew (7)

34-30
 34. TRAVEL SYSTEM

(3) Preparation of oil pan

(4) Removing hydraulic pipe
Bleed air in hydraulic oil tank, remove all pipes con-
necting to travel motor. Then plug up all pipes and
joint section to protect them from entry of dust.

: 19 mm, 22 mm, 24 mm, 27 mm, 32 mm

Plug (See section 11.5)

Fig. 34-77 Removing and installing hydraulic pipe

(5) Removing sprocket
Removing twenty four capscrews (2) M14 X 35.

: 22 mm

Fig. 34-78 Removing and installing sprocket

(6) Loosening travel motor mounting bolts Remove pipes (Disconnect)
Apply match marks on travel motor and lower
frame, and remove twenty four capscrews (3) M16
X 40.

: 24 mm

Fig. 34-79 Removing and installing travel motor

mounting bolts
(7) Slinging travel motor assy
Sling travel motor with nylon sling applied on the
side close to sprocket installing section and remove
the motor.

Weight of motor Approx.90 kg (198 lbs)

Fig. 34-80 Slinging travel motor

34-31
34. TRAVEL SYSTEM

34.1.7.3 INSTALLING
Installing of the travel motor piping is performed in the reverse order of removal.
1) Cleaning
Check that contact surface of travel motor and track frame is free from burr and stain.
2) Tightening torque
Tighten capscrew and hydraulic pipes to the specified torque.
3) Fill inside from motor drain port to cashing with hydraulic oil before piping for drain. When starting operation,
operate motor in low idling and at low speed for several minutes, and check it for possible oil leakage and
noise.

Parts Size Tools No. Tightening Torque N•m(lbf•ft) Remarks

M14 22 2 181 (134)
Capscrew Apply loctite #262
M16 24 3 279 (210)
Flareless nut Ø10 X 1.5 19 — 49 (36)
for pipes, Ø15 X 2.0 27 — 118 (87)
sleeve Ø18 X 2.5 32 — 147 (110)
PF1/4 19 P 36.3 (27)
Connector PF3/8 22 D1,D2 73.6 (54)
PF1/2 27 A,B 108 (80)

34-32
 34. TRAVEL SYSTEM

34.1.8 SLEWING BEARING

34.1.8.1 SLEWING BEARING ASSY

2
FRONT A A

SECTION A-A
Inner S mark position
of slewing bearing

Fig. 34-81 Slewing bearing assy

No. Parts Q'ty Remarks

SLEWING BEAR-
1 1 2425U261F1
ING
2 CAPSCREW 30 M16 X 90

34.1.8.2 REMOVING
(1) Matchmarks
Slewing bearing
Remove upper structure, apply matchmarks on in-
ner race of slewing bearing and lower frame. Outer race

(2) Remove thirty capscrews (2) M16 X 90 for installa-

Inner race
tion inner race.
Matchmarks
: 24 mm
(3) Drawing out grease
Remove grease in grease bath.
Fig. 34-82 Matchmarks
(4) Removing slewing bearing
Attach eyebolt on slewing bearing (1) and sling it. Slewing bearing
Weight of slewing bearing : 110 kg (240 lbs) Eye bolt

Grease bath

Fig. 34-83 Removing and installing slewing bearing

34-33
34. TRAVEL SYSTEM

34.1.8.3 INSTALLING
(1) Cleaning
Clean it completely so that installing surfaces of
slewing bearing and lower frame are free from dust
and stain.
(2) Installing
Install slewing bearing on lower frame meeting the
FRONT
matchmarks and positioning the S mark on inner A A
race as shown in the figure.
(3) Temporary fastening of inner race
Coat the threads of the capscrews (2) with Loctite
#262 and tighten all the capscrews (2) (24 pcs) to
an extent that they are fastened temporarily.

: 24 mm Inner S mark position

of slewing bearing
(4) Regular tightening of inner race
Fasten the capscrews (2) (24 pcs) at 180 degrees Fig. 34-84 Location of S mark on slewing bearing
intervals alternately and tighten them up to a spec-
2
ified torque. Apply Lpctite #262 or equiva-
lent to be applied
: 24 mm T=279 N·m (210 lbf·ft)
Tightening torque : 279 N•m (210 lbf•ft)
1
(5) Filling grease
Fill grease bath with 5 kg (11 lbs) of grease NLGI-
2 (molybdenum disulfide grease) or equivalent.
SECTION A-A
Fig. 34-85 Removing and installing capscrew (2)

34.1.8.4 CONSTRUCTION

  


Fig. 34-86 Cross-section

No. Parts Q'ty No. Parts Q'ty

1 OUTER RACE 1 6 SEAL 1
2 INNER RACE 1 7 GREASE NIPPLE
3 BALL 84 (PT1/8) 1
4 RETAINER 84 8 TAPER PIN 1
5 SEAL 1 9 PLUG 1

34-34
 34. TRAVEL SYSTEM

34.1.8.5 DISASSEMBLY AND ASSEMBLY

(1) Disassembly   
 
1) Take out seal (5) fitted in the groove in the outer 
circumference under inner race (2) and seal (6)
fitted in the groove in the inner circumference on
top of outer race (1) and place them level on a
  
wood blocks or something.
2) Draw out taper pin (8), using a hammer and an
extrusion rod.

3) Draw out plug (9), inserting a pull bolt in the 
screwed hole of the plug and using a puller.
Fig. 34-87 Removing slewing bearing
4) While rotating outer race (1) little by little, take out 
ball (3) and retainer (4) through plug hole, in that
order.

"
!
Fig. 34-88 Removing balls (3) and retainers (4)

34-35
34. TRAVEL SYSTEM

(2) Installing
1) After cleaning grooves for seal (6) on inner sur-
face on the upper side of outer race (1), and for
seal (5) on the outer surface of inner race (2), ap-
ply adhesive agent Cyano-bond PO-1, fit seal 1
(5), and place them on a surface plate.
Push rod 6
2) Lower outer race (1) to the position where upper
surface of inner race (2) and lower portion of seal 2
groove are mated, put adjusting washer under
outer race (1) so that raceway surface of ball (3) Wood rod 53
agrees, and support it. Fig. 34-89 Fitting balls (3)
3) Insert ball (3) and retainer (4), on which grease
Eye blte
is applied, through plug (9) hole on outer race
(1), alternately.

Hooked rod

To insert ball (3) and retainer (4), use a push rod, etc.,
to protect persons from injury from inserting fingers into
plug hole. 4

4) Fit plug (9) to outer race (1) while checking it for Wood blocks
direction and position of taper pin hole. Fig. 34-90 Fitting retainer (4)
5) Apply adhesive agent Cyano-bond PO-1 to seal
(7), and fit it to groove of outer race (1).
6) Check that grease nipple (7) is properly fitted,
and fill it with grease. Then, check bearing for
smooth rotation and flaws on seal lip portion.

34.1.8.6 MAINTENANCE STANDARD

Maintenance standard concerning wear of slewing bearing is described in the item 13.6"Measuring Swing Perfor-
mance" in the section 13. "Maintenance Standard and Test Procedure" in the separate volume.

34-36
 34. TRAVEL SYSTEM

34.2 DISASSEMBLING AND ASSEMBLING

34.2.1 TRAVEL MOTOR

34.2.1.1 CONSTRUCTION
(1) General view

D1

B
D2
OIL LEVEL CHECK PORT PF3/8 FILLING PORT PF3/8

DRAIN PORT PF3/8

VIEW Z
Fig. 34-91
HYDRAULIC CIRCUIT

PORT NAME AND SIZE

No. Ports Size
A Hydraulic oil filling / drain port
PF 1/2
B Hydraulic oil filling / drain port
D1 Drain port
PF 3/8
D2 Drain port
P 1st / 2nd speed select port PF 1/4

ROTATIONAL DIRECTION (Viewed from Z side)

INLET B PORT, OUTLET A PORT, CW
INLET A PORT, OUTLET B PORT, CCW

Fig. 34-92

34-37
34. TRAVEL SYSTEM

(2) Exploded view

1) Exploded view of reduction unit

21

31
19
3
2
17
21

30 5
43
12
23
9
23 18
12 34
4
8 35
22 29
28

6
7
25 15
25
20
22
35 33
36
24

2) Exploded view of hydraulic motor

"#

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

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

34-38
 34. TRAVEL SYSTEM

(3) Parts list

No. Parts Q'ty No. Parts Q'ty

1 HUB 1 PISTON KIT 1
• PISTON ASSEMBLING PARTS 9
SPINDLE KIT 105 • • PISTON 1
• SPINDLE ASSY 1 106 • • SHOE 1
2 • • SPINDLE 1
3 • • HOLD FLANGE 1 • PISTON ASSEMBLING PARTS 1
19 • REAMER BOLT 3 161 • • PISTON 1
162 • • SHOE 1
RV GEAR ASSEMBLING PARTS 1
• RV GEAR KIT 1 102 SHAFT 1
4 • • RV GEAR A 1 103 SWASH PLATE 1
5 • • RV GEAR B 1 104 CYLINDER BLOCK 1
9 • CRANK SHAFT 3 107 RETAINER PLATE 1
12 • SPACER 6 108 THRUST BALL 1
22 • BEARING 6 109 TIMING PLATE 1
23 • BEARING 6 110 WASHER 2
112 PISTON 1
6 INPUT GEAR 1 113 SPRING 8
114 SPRING 1
SPUR GEAR KIT 1 115 FRICTION PLATE 2
7 • SPUR GEAR 3 116 SEPARATOR PLATE 2
132 OIL SEAL 1
FLOATING SEAL KIT 1 135 O-RING 1
31 • FLOATING SEAL 2 141 O-RING 1
146 SNAP RING 1
8 COVER 1 149 BEARING 1
15 SHAFT 1 150 BEARING 1
17 PIN 28 151 BEARING (ROLLER) 3
18 RING 1 176 PIVOT 2
20 SNAP RING 3 177 PARALLEL PIN 2
21 BEARING 2 185 SPRING 1
24 SNAP RING 1
25 SNAP RING 6 REAR FLANGE ASSEMBLING PARTS 1
28 O-RING 2 • REAR FLANGE KIT 1
29 O-RING 1 201 • • REAR FLANGE 1
30 O-RING 1 223 • • SPOOL 1
33 PLUG (WITH FLANGE) 1 252 • • SOCKET PLUG 2
34 PLUG 2 268 • • STEEL BALL 1
35 O-RING 3 275 • • SOCKET PLUG 10
36 STEEL BALL 1 279 • • FILTER 1
43 PARALLEL PIN 2 280 • • ORIFICE 4

34-39
34. TRAVEL SYSTEM

No. Parts Q'ty No. Parts Q'ty

283 • • PLUG (WITH FLANGE) 1 284 • PLUG 2
286 • • PISTON 2 285 • O-RING 2
299 • • NAME PLATE 1 287 • VALVE 2
288 • SLEEVE 2
• SPOOL KIT 1 289 • PLUG 2
271 • • SPOOL 1 290 • SPRING 2
272 • • OIL STOPPER 1 291 • O-RING 2
221 • PLUG 2 292 • O-RING 4
224 • PLUG 2 293 • PISTON SEAL 2
225 • SPRING RETAINER 2 294 • BACKUP RING 4
227 • VALVE 2 295 • BACKUP RING 4
228 • SPRING 2 296 • STEEL BALL 2
230 • SPRING 2 297 • ORIFICE 2
236 • O-RING 2
238 • O-RING 6 242 PARALLEL PIN 2
281 • SPRING 1 245 SOCKET BOLT 6
282 • PLUG 4

34-40
 34. TRAVEL SYSTEM

34.2.1.2 TOOLS AND JIGS

(1) Standard tools

Tools Size Q'ty Application item (No.)

Torque wrench Nominal 450 Dial type 1 284
Torque wrench Nominal 1800 Dial type 1 33, 34, 221, 245, 282, 289
Torque wrench Nominal 5500 Dial type 1 19, 224
Allen wrench Nominal 5 1 284
Allen wrench Nominal 6 1 34
Allen wrench Nominal 8 1 33, 34, 221
Allen wrench Nominal 10 1 245, 282
Socket Nominal 5 Inset square 12.7 1 284
Socket Nominal 8 Inset square 12.7 1 33, 34, 221
Socket Nominal 10 Inset square 12.7 1 245, 282
Socket Nominal 22 Inset square 12.7 1 289
Socket Nominal 36 Inset square 12.7 1 19, 224
Extention bar Inset square 12.7 1 19
Spanner Round shaped powerful spanner 36 1 224
Hammer Nominal 12 1 1, 21
Plastic hammer L=300 (12") or so 1 8, 102
Snap ring pliers For shaft 1 24, 25
Snap ring pliers For bore 1 20, 145
Center punch Ø9.5 X 100 (0.374" X 4" ) 1 1
Pin punch Ø3 X 150 (0.127" X 6" ) 1 21
Lifting tool Hook, wire rope 1 Set 1,2 for lifting
Car washing brush 1 Cleaning the parts
Wire brush 1 Cleaning the parts
Vat for general use
Lubricant, draining hydraulic oil
Container W450 X D300 X H120 3
ball (36, 268, 296) retainer
(W18" X D12" X H5" )
Paint marker Oil base white 1 For matching mark
Metal screen basket 1 17
Rubber mat 1
Leather gloves 1 Pair 149
Jug For hydraulic oil, For lubricant. 2 Oil filling

34-41
34. TRAVEL SYSTEM

(2) Tools

Tools Size Application item (No.) Q'ty

General work bench Disassembly and assembly 1 set
Cleaning bath For rough cleaning and finish cleaning Cleaning the parts 1 set
Work bench for press Pressing capacity 200 kg (441 lb) or over 104, 149 1 set
Heating capacity 100°C (212°F) or over
Heating bath 149 1 set
Size 500 X 500 X 500 (20" X 20" X 20")
Portable electric drill
Electric drill 1 1
[Max. drill depth Ø10 (0.394")]
Drill Ø2 (0.0787") 1 1
Disassembly 161,162,163, 112
Compressed air Pressure 0.29~0.49 MPa (43~71 psi)
Drying after cleaning
Lathe 3 1 set

(3) Measuring instrument

Tools Size Application item (No.) Q'ty

Measurement range : 0.04~0.3 mm For snap ring (20)
Thickness gauge 2
(0.0016~0.012 in) thickness adjustment
Measured range : 0~25 mm (0~0.98 in) For snap ring (20)
Outside micrometer 1
Minimum graduation : 0.01 mm (0.0004 in) thickness adjustment
Measured range : 0~25 mm (0~0.98 in) For bearing (21)
Single depth micrometer 1
Minimum graduation : 0.01 mm (0.0004 in) pre-load adjustment

34-42
 34. TRAVEL SYSTEM

(4) Jigs
1) Working bench for travel motor
This is used to carry out the work for assembly
and disassembly of travel motor easy and safe.

2) Fixing metal
This is used to connect spindle (2) and hub (1).

3) Retainer metal (I)

This is used to insert spring (114), washer (110),
snap ring (145) into cylinder block (104).

4) Retainer metal (II)

This is used to pull out bearing (149) from shaft
(102).

34-43
34. TRAVEL SYSTEM

5) Retainer metal (III)

This is used to press-fit oil seal (132) into oil seal
fitting hole of spindle (2).

6) Retainer metal (IV)

Apply it on outer race of bearing (22) fitted on
crankshaft (9) of RV gear assy, then strike it to in-
sert RV gear assy securely.

7) Jig for adjusting the preload to the bearing

This is used to press-fit bearing (21) in hub (1),
and also used to measure clearance of bearing
(21) in shaft direction.

8) Steel rod (I)

This is used to remove ring (18) from hub (1).

34-44
 34. TRAVEL SYSTEM

9) Eye bolt for PF

This eye bolt is used to remove cover (8) from
hub (1) with wire and crane.
Screw size : PF3/8

PF3/8

10) Long eye bolt

This eye bolt is used to sling up travel motor,
spindle (2) and hub (1).

Application "A"
Hub M14
Spindle M16
"A"
Travel motor M16

11) Spatula
This is used to remove timing plate (109) from
rear flange (201).

12) Pin punch

This is used to remove outer race of bearing
(21).

34-45
34. TRAVEL SYSTEM

13) Jig for removing cover

This is used to remove cover (8) from hub (1).

14) Floating seal fitting tool (I)

This is the tool that is used to assemble floating
seal (31) to hub (1).

15) Floating seal fitting tool (II)

This is the tool that is used to assemble floating
seal (31) to spindle (2) and hub (1).

16) Floating seal fitting tool (III)

This is the tool that is used to assemble floating
seal (31) to spindle (2).

34-46
 34. TRAVEL SYSTEM

34.2.1.3 TIGHTENING TORQUE

Application Bolt • Nut Opposing flats Tightening torque

Item (No.) Parts Size (mm) N•m (lbf•ft)
19 Reamer bolt M24 P2.0 36 794 ± 49(586 ± 36)
33 Plug (with flange) PF3/8 8 59 (43)
34 Plug PF3/8 8 59 (43)
221 Plug PF3/8 8 59 (43)
224 Plug M30 P1.5 36 353 (260)
245 Socket bolt M12 P1.75 10 102 (75)
282 Plug PF1/2 10 98 (72)
284 Plug PF1/8 5 12.3 (9.0)
289 Plug PF1/2 22 98. (72)

34.2.1.4 WEIGHT

Parts Weight [kg (lb)]

Travel motor assy Approx. 81 (179)
Hub 19 (41)
Spindle 27 (60)
Rear flange assy 9.7 (21)

34-47
34. TRAVEL SYSTEM

34.2.1.5 DISASSEMBLY
(1) Preparation
Prepare as below before disassembly :
1) Preparation of work bench
Prepare a work bench for the travel motor.
The work bench must be sufficiently solid to disassemble and assemble the internal components of the travel
motor and sufficiently spacious to place components so components do not fall or move during operation.
Place a rubber or plastic sheet on the work bench.
2) Preparation of tools and materials
Prepare those tools and materials listed under Article. 34.2.1.2.
(2) General precautions to be exercised at work

• The internal components are wet with hydraulic oil and slippery during disassembly :
Handle them with care because you may be injured by the fall of components may or components may be
damaged.
• Such flammables as clear kerosene are used to clean components. Handle flammables as they are easy to
be caught a fire.

1) Before disassembly, decide inspection points and check the nature of the trouble.
2) Handle the components with care as they are finished to high precision. Take care so as not to hit and drop
the components.
3) If the components are struck or twisted by force during disassembly, they develop burrs or broken in some
cases. This makes the components unable to be reassembled or deteriorates the performances. Therefore,
handle them with care and patience.
4) If components are left separated or in the midst of disassembly, they develop rusting by humidity and dust.
Take rust and dust prevention treatment in case work is suspended halfway.
5) During disassembly, leave a matching mark on the mating face of each component.
6) Arrange disassembled components in order as the work proceeds so they are not damaged or lost during
work.
7) It is a rule to replace seals once disassembled. (even though they are not scored on an appearance) Get new
seals ready before disassembly.
8) Photos and illustrations shown are typical models. Although they may differ from those in use, they do not
affect the disassembly procedure.

34-48
 34. TRAVEL SYSTEM

(3) Removing
1) Cleaning travel motor
1. Tighten the eye bolts into the tapped holes of the
spindle (2).

• Fasten two eye bolts into the tapped holes for the
spindle so they are located diagonally opposite to
one another.

2. Place a wire sling in the eye bolts, lift the travel

motor by hoist, and carry in to the cleaning bath.
3. Clean the travel motor with a car brush.

• Since soil and sand are entered in the clearance

(where the floating seal is fixed) between hub (1)
and spindle (2), clean it with particular care.

1 2

2) Installing travel motor

1. Fix travel motor with two socket bolts on working
bench.

• Align threaded holes of hub (1) and working bench

and place travel motor in fixing hole of working
bench slowly.

Tighten up the socket bolts rigidly. Unless tightened rig-

idly, the components drop as the travel motor is turned
over and cause bodily injuries.

34-49
34. TRAVEL SYSTEM

3) Draining oil.
1. Turn over the travel motor.
2. Loosen one plug (33) and two plugs (34).

• If the plug (33), (34) is removed and the travel mo-

tor is reversed, oil spills. Stop loosening the plug
when it can be turned by hand.

3. Turn over the travel motor.

33, 34

• When draining out the oil, place a container under

the work bench.

4. Remove one plug (33) and two plugs (34) from

34
the cover (8) and drain out the oil. OIL FILL PORT
(PF3/8)
5. Remove O-ring (35), one plug (33) and two plugs
(34).
6. Remove O-ring (35) from two plugs (34).

• Do not reuse removed O-ring (35).

33 DRAIN PORT (PF3/8)

4) Removing cover.
1. Turn over the travel motor.
2. Mark on the mating surface between hub (1) and
cover (8), using marker paint.

8 1

34-50
 34. TRAVEL SYSTEM

3. Find the mating part of ring (18), and punch at a 18

point of the outside of the hub, approximately 20
mm (0.8 in) inward from the tip of ring (18) for
drilling purpose.

(Mating part) (0.

8") COVER (8) RING (18)

2
(0.08")

HUB

4. Drill through a 2mm (0.08 in) hole from the out- 18

side of hub (1) toward ring (18) using electric drill.

• Put a drill against the punched hole and drill it

through so the ring takes off the cover as it is
pushed by the drill.
• Wipe off the metal chips produced by drilling so
they do not score the parts to be removed.

5. Put a steel bar into the hole and push ring (18). 18

• In that case, the tip of the ring (18) stands out above
the cover (8) as pressed by a steel bar.

6. Hold the tip of ring (18) sticking out of the cover 8

(8) and draw the ring (18) out of the ring groove
of the hub (1).

18 1

34-51
34. TRAVEL SYSTEM

7. Fix two bolts inside of jig to the plug holes of drain

(33)(34).

• In case the cover (8) is hard to remove because of

the resistance of the O-ring (29), lift it up while light-
ly tapping the outer rim of the cover by means of a
plastic mallet.

8 COVER REMOVING JIG

8. Tighten two bolts outside of jig then two bolts (in-

stalled in plug holes) inside of jig float with cover
(8).
9. Remove O-ring (29) from cover (8).

• Do not reuse removed O-ring (29).

8 (29)

5) Removing input gear. 15

1. Remove snap ring (24) from shaft (15).

• When the snap ring is removed, the tip of the pliers

slips from the snap ring hole and the snap ring
jumps up in some cases. Be careful not to slip the
pliers.

24

34-52
 34. TRAVEL SYSTEM

2. Remove input gear (6) from shaft (15). 36 6

15

6) Removing spur gear 9, 25

1. Remove two snap rings (25) from crank-shaft (9).

• When the snap ring is removed, the tip of the pliers

slips from the snap ring hole and the snap ring
jumps up in some cases. Be careful not to slip the
pliers.

2. Remove three spur gears (7) from crank-shaft 7

(9).

3. Remove three snap rings (25) from crank-shaft 9

(9).

• When the snap ring is removed, the tip of the pliers

slips from the snap ring hole and the snap ring
jumps up in some cases. Be careful not to slip the
pliers.

25

34-53
34. TRAVEL SYSTEM

7) Removing shaft 15
1. Remove shaft (15) from shaft (102).

8) Removing rear flange 289

1. Turn over the travel motor

• This work is intended to remove the plug easily

when removing the inside of the rear flange.
• On that occasion, loosen the plug so it can be re-
moved by hand.
• Do not loosen the plug if you do not remove the in-
side of the rear flange.

2. Loosen two plugs (282)

3. Loosen two plugs (289)
4. Loosen two plugs (224)
5. Loosen six socket bolts (245) from rear flange
(201).

245

34-54
 34. TRAVEL SYSTEM

6. Remove rear flange (201) from spindle (2). 201

• Hold the rear flange by both hands, hold it up gently

upright and remove it.
Forced prying or striking it may cause timing plate
(109) to fall and damage it.

7. Remove parallel pins (43) from spindle (2).

43

8. Remove O-ring (28),(30) from spindle (2).

• Do not reuse removed O-ring (28), (30).

30 28

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34. TRAVEL SYSTEM

9) Removing the rear flange fittings

1. Place rear flange (201) on a work bench, with the
mating surface for spindle (2) facing up.
2. Remove timing plate (109) from rear flange
(201).

• If it is hard to remove the rear flange in some cases

as the mating surface of it is stuck with oil. Insert a
spatula into the draft groove of the mating surface
on the rear flange side and hold the timing plate up.
201 109
Then the rear flange comes off. If a sharp tool like
screwdriver is put into the mating surface, the mat-
ing surface is scored, causing an oil leakage ; do
not use sharp tools.

3. Remove parallel pins (242) from rear flange

(201).

242 201

4. Remove bearing (150) from rear flange (201).

150

201

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 34. TRAVEL SYSTEM

10) Removing the shockless relief valve (SRV) from

the rear flange.
1. Remove two plugs (282) of rear flange (201).
2. Remove O-ring (238) from plug (282).

• Do not reuse removed O-ring (238).

282 201

3. Remove piston (286) from rear flange (201).

286 201

4. Remove two plugs (289) from rear flange (201).

5. Remove O-ring (238) from plug (289).

• Do not reuse removed O-ring (238).

289 238

6. Remove spring (290), valve (287) and sleeve

(288) from rear flange (201) in that order.

287, 288, 290 201

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34. TRAVEL SYSTEM

7. Remove O-ring (292), backup ring (294) from

sleeve (288).

• Do not reuse removed O-ring (292) and backup ring

(294).

294 288

8. Remove piston seal (293) from valve (287).

PISTON SEAL (293)

• Do not reuse removed piston seal (293).

VALVE (287)

9. Remove plug (285) and steel ball (296) from rear

flange (201).

• Do not disassemble plug (285) except in case nec-

essary.
• Be careful to fall the steel ball (296).

285, 296 201

11) Removing the brake valve parts from the rear

flange.
1. Remove two plugs (224) of rear flange (201).
2. Remove O-ring (236) from plug (224).

• Do not reuse removed O-ring (236).

236, 224 201

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 34. TRAVEL SYSTEM

3. Remove two spring retainer (225) and two

springs (228) from rear flange (201).
4. Remove spool (223) from rear flange (201).

• To remove spool (223), place your hand on one part

of the plug port of rear flange (201) and tilt it down.
Then spool (223) falls down. Hold the tip and re-
move it.

223, 225, 228 201

5. Remove two plugs (282) from rear flange (201).

6. Remove O-ring (238) from plug (282).

• Do not reuse removed O-ring (238).

238 282

7. Remove two springs (230) and two valve (227)

from rear flange (201).

227, 230 201

12) Removing the pilot valve parts from the rear

flange.
1. Remove plug (221), spool (271) and spring (281)
from the rear flange (201).
2. Remove O-ring (292) from plug (221).
221
271
281
• Do not reuse removed O-ring (292).

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34. TRAVEL SYSTEM

13) Removing the parking brake 112

The sudden blowing of compressed air may cause pis-

ton (112) to jump out of the spindle (2) incurring the
danger of injury. Cover piston (112) for protection.

1. Blow jet air into the passage hole for the paring
brake of the spindle (2) and take out the piston
(112) from the spindle (2).

2. Remove O-ring (135), (141) from piston (112). 112

• Do not reuse removed O-ring (135), (141).

135, 141

14) Removing the hydraulic motor section

• When placing the travel motor on its side, oil spills ;

place a container under the travel motor. 115
115
116
116
1. Incline travel motor 90 degrees. (Lay it down.)
2. Drain out the oil of the travel motor.
3. Remove two friction plate (115) and two separa-
tor plate (116).

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 34. TRAVEL SYSTEM

4. Hold cylinder block (104) by hand, remove shoe 106

(106) adhered on swash plate (103) turning 2 or
3 times alternately.

• If the cylinder block is pulled out without separating

shoe, the shoe (106) remained on swash plate
(103) (piston, shoe) may drop in spindle (2).

5. Remove cylinder block (104) from shaft (102).

6. Remove piston assy [piston (105) and shoe
(106)] and retainer plate (107) from cylinder
block (104). 104 102 2

• When removing the cylinder block, hold the retainer

plate (107) by both hands and remove it with the
piston assy.
106
• The piston (105) and the shoe (106) are made in
107
one piece as they are caulked by the spherical sur-
105
face of the piston. It is not possible to remove the
piston from the shoe without damaging the shoe. 104
When replacement is required, replace 9 sets of
piston (105) and shoe (106). (Hereafter called pis-
ton assy.)

7. Remove the piston assy (105), (106) from retain-

er plate (107). [Nine pistons]

107 105, 106

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34. TRAVEL SYSTEM

8. Remove thrust ball (108) from cylinder block 108

(104).

104

9. Remove three rollers (151) from cylinder block 151

(104).

104

15) Remove spring (114) from inside of cylinder

block.
1. Place cylinder block (104) on the press bench.

PRESS

• Do not remove the spring except when replaced.

• When removing the spring, align the Jig (I) with the Plastic sheet
washer in order to prevent the cylinder block from RETAINER METAL (I)
being damaged by contact.
• Put a plastic sheet over the cylinder block so as not
to score the surface of the cylinder block. JIG 104

34-62
 34. TRAVEL SYSTEM

2. Apply Jig (I) on washer (110), remove snap ring RETAINER METAL (I)
(146) from the groove with snap ring plier press- PRESS
JIG (I)
ing the metal with a press. 146

114
110 104
Release press slowly. Sudden releasing may cause
spring to fly out incurring the danger of injury.

3. Remove the snap ring (146), washer (110),

110
spring (114), and washer (110) from inside the
cylinder block (104).

110

114

104
16) Removing out swash plate (103).
1. Removing swash plate (103) from shaft (102).

• When removing it, check that pivot (176) is not ad-

hered on swash plate (103).

102 103

2. Pull shaft (102) out of spindle (2). Then bearing

(149) is removed together.

• The shaft comes off easily if the tip of the shaft on

the reduction gear side is tapped lightly, using a
plastic mallet. If it is struck forcibly, shaft may be
projected. Strike it with care.

3. Remove two pivots (176) and two parallel pins

(177) from the spindle (2).
149 102 176, 177 2

34-63
34. TRAVEL SYSTEM

161, 162

The blowing of compressed air may cause two speed

piston assy projecting incurring the danger of injury.
Cover projection section for protection.

4. Blow compressed air through passage of spin-

dle, and remove two speed switching piston assy
(piston, shoe) and spring (185) from spindle (2).
Piston assy
• Piston (161)
• Shoe (162)

PRESS
• Compressed air
149
Pressure : 0.29~0.49 MPa (43~71 psi)
RETAINER METAL (II)
17) Removing bearing.
1. Place the retainer metal (II) on a press bench.

102

• Remove it only when replacing the ball bearing.

2. Put the shaft (102) in it. Hold down the tip of the
shaft by press and remove the bearing (149)
from the shaft.

• Do not reuse the bearing.

18) Remove hold flange (3) FIXING METAL

1. Turn over the travel motor.
2. Fix hub (1) and spindle (2) with fixed metal. Then,
the fixed metals should be tightened on symmet-
rical positions each other.

• If the hold flange (3) is removed without attaching

the fixing metal, the hub (1) separates from the
spindle (2), causing the spindle (2) to fall from the
work bench.
1 2

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 34. TRAVEL SYSTEM

3. Turn over the travel motor.

When the snap ring is removed, the tip of the pliers slips
from the snap ring hole and the snap ring jumps up in
some cases. Be careful not to slip the pliers.

4. Remove three snap rings (20) from the hold

flange (3).

20 1 3

5. Put matching mark on snap ring (20) and hold

flange (3) with an oil paint marker.

• This is to place them in the same positions as at in-

stallation.

3 20

6. Incline travel motor 90 degrees.

7. Loosen three reamer bolts (19).

• The threaded portion of reamer bolt (19) is provided

with adhesive agent and may cause the seizure on
the reamer portion where the adhesive agent is ap-
plied, leading to the difficulty of disassembling.
Therefore loosen reamer bolt 19) slowly. If it turns
tightly in the middle way, tighten it one more time,
then loosen it again.
19
• The tightening torque is 794 ± 49 N•m (590 ± 36
lbf•ft). A torque more than it is needed to loosen the
bolt because of adhesive.

8. Tilt the travel motor to 90 degrees once again to

bring it back where it was.
9. Remove holding flange (3) from spindle (2).

34-65
34. TRAVEL SYSTEM

10. Put match marks on hold flange (3) and spindle

(2) with paint marker.

• This is intended to install the hold flange (3) in the

same position as the spindle (2).
• The three mounting holes for reamer bolts (19) in
the spindle (2) are machined together. In case they
must be replaced, replace the spindle 2) and the
hold flange (3) together as a set assy). [Hereafter
called spindle assy]
3

19) Removing fixing metal. FIXING METAL

1. Turn over the travel motor.
2. Remove three fixing metal.

20) Removing spindle.

1. Place a clean container under the travel motor.
2. Tighten two eye bolts into the tapped holes of
spindle (2) so they are located in diagonally op-
posite positions.
3. Hook sling to eye bolt, lift spindle (2) up and re-
move it from hub (1). Then, floating seal (31),
outer race of bearing (22), and oil seal (132) are
also removed together.

1 2, 31, 22, 132

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 34. TRAVEL SYSTEM

21) Removing bearing, RV gear assy and pin

1. Remove floating seal (31) from hub (1).
2. Remove bearing (21) from hub (1) striking
pin(17) end face with punch and mallet. Then,
RV gear assy [RV gear A (4), RV gear B (5),
crankshaft (9), bearing (22) bearing (23), spacer
(12)] and pin (17) are also removed together.

• Remove bearing (21) striking 3 or 4 points of perim-

eter evenly taking care for bearing not to be in-
31
clined.
• When the fit section of outer race of bearing (21) is MALLET 1
separated, bearing (21), RV gear assy and pin (17) ALUMINUM ROD 21
drop from hub (1). So spread rubber mat under the
working bench to protect them from damage.

22 4
17
23
5
12

21
9

3. Separate RV gear A (4) and RV gear B (5) from

crankshaft (9).

21
• Never remove bearing (22), bearing (23) and spac-
er (12) from crankshaft (9) except for replacement.

4. Turn over the travel motor.

5. Remove bearing (21)

21

• Remove bearing (21) striking 3 or 4 points of perim-

eter evenly taking care for bearing not to be in-
clined.

34-67
34. TRAVEL SYSTEM

22) Removing the spindle fittings.

OIL SEAL (132)
1. Remove oil seal (132) from spindle (2).

SPINDLE (2)

• Never reuse removed oil seal (132).

2. Remove floating seal (31) from spindle (2).

31

3. Remove the outer races (3 pcs.) of bearing (22)

from spindle (2).

• It is sometimes hard to remove the outer race of the

bearing (22) as the outer race of the taper roller
bearing comes in close contact with the mating sur-
face of the spindle by oil films of lubricating oil. In
that case, tap the center of the spindle (2) with alu-
minum rod. Then the outer race is removed easily.

2 22

23) Disassembling holding flange

1. Remove outer race of bearing (22) from hold
flange (3).

3 22

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 34. TRAVEL SYSTEM

24) Rough washing of parts.

1. Classify the parts as four groups ; hub (1), spin-
dle (2), cover (8), and rear flange (201) and other
parts (hereafter called built-in parts).
2. Put the hub, spindle, cover and rear flange in a
cleaning bath and clean them.

• Soil and sand are adhered to the outer surface of

parts in some cases ; clean them and remove soil
and sand from the parts.
1

Wash oil is flammable. Be careful not to catch fire.

3. Put the built-in parts in a rough cleaning bath and

clean the parts.

• Before cleaning stained parts, immerse them in

wash oil until dust and stain become soft and are
floated to protect them from damaging when clean-
ing.

25) Finish cleaning

1. Put parts in a finish cleaning container and clean
them well, turning them slowly.
2. Wipe off the light oil adhered to the parts, using a
clean rag.

• Blow compressed air in the inner surface of hub (1),

spindle (2) and hold flange (3) to dry in the dust free
and dry conditions. After drying, apply hydraulic oil
to every part.
3
• Inner surface of rear flange (1), hydraulic motor
parts, and RV gear assy are to be dried naturally in
the dust free and dry conditions. After drying every
part, apply hydraulic oil to every part.
• Use care not to damage the surface of twenty eight
pins (17) or lose them while handling.

34-69
34. TRAVEL SYSTEM

34.2.1.6 ASSEMBLY
(1) Assemble it by reversing the procedure of disassembly.
(2) General precautions for assembly
1) Assemble it in clean air condition.
2) Do not use cloth gloves during assembly.
3) Replace or repair the damaged parts during disassembly according to the instructions in the "Maintenance
standard". Replace O-ring, oil seal, etc. with new one.
4) Clean every part sufficiently, and blow them with compressed air do not use rag.
5) Prior to assembling, apply clean hydraulic oil to moving and sliding portions of hydraulic motor valve.
6) Tighten bolt and plug to the specified torque using torque wrench.
7) Replace reamer bolt with new ones. If it is unavoidably reused, remove completely the adhesive agent on
reamer bolt, repair flaws on bolt seat surface with oilstone, and degrease it.
8) Prior to assembling, apply grease to lip portions of O-ring, oil seal, and floating seal to protect it from being
damaged, and to moving section and sliding section.
9) After assembly, plug every port to prevent the entry of dust, etc.
(3) Preparatory arrangement for assembly
After replacing parts with new ones, adjust the pre-load of bearing and thickness of snap ring without fail.
1. When the following parts are replaced, the preload adjustment of bearing is required.
Hub (1)
Spindle (2)
Hold flange (3)
Bearing (21)
2. When the following parts are replaced, the snap ring thickness adjustment is required.
Spindle kit (2)
Hold flange (3)
Crankshaft (9)
Spacer (12)
Bearing (22)
The assembling procedure varies according to the procedure of the above described parts.

• Where replacing the above parts, the previously adjusted parts should be used. If unadjusted parts are used,
the travel motor moves abnormally, causing early breakage.

34-70
 34. TRAVEL SYSTEM

1) Installing hub (1).

1. Install two eye bolts into the tapped holes of hub
(1) so they are located in diagonally opposite po-
sitions.
2. Hook eye bolt of hub (1), and lift up and place it
on working bench.
• Align hub (1) to the mounting holes of the work
bench, while matching the holes in hub (1) with
those in the work bench.

3. Install hub (1) to the work bench and fasten sock-

et bolts so they are located in diagonal positions.

Fasten the socket bolts securely. If the bolts are not

tightened sufficiently, the travel motor may fall when
turned over, which is dangerous.

4. Insert bearing (21) in hub (1).

• Place a pin punch against the outer race of bearing

(21), hammer it lightly all around and press in the
bearing little by little.

21

5. Assemble floating seal (31) to hub (1), using the

assembling jigs (I), (II).

31 FLOATING SEAL INSERT JIG (I) (II)

34-71
34. TRAVEL SYSTEM

2) Assembling spindle section.

1. Coat the O-ring of floating seal (31) with hydrau-
lic oil and install the floating seal into the groove
of the floating seal groove in spindle (2), using
assembling jigs (II), (III).

• Remove O-ring from floating seal and apply grease

on its outside lightly.
• Fit floating seal so that spindle groove is in parallel
with floating seal surface after fitting O-ring in spin- FLOATING SEAL
31 2 INSERT JIG (II) (III)
dle groove rightly.

2. Insert three outer races of bearing (22) in holes

of spindle (2) respectively.

22 2

3. Tighten two eye bots in the threaded holes on

spindle (2) in symmetric situations.
4. Tighten eye bolt, and lift up spindle (2) and place
it in hub (1).

1 2

5. Fix hub (1) and spindle (2) with fixing metal in

symmetrical position.
6. Turn over the travel motor.

• If the motor is turned over without attaching the fix-

ing metal, the hub (1) separates from the spindle
(2), causing the spindle (2) to fall from the work
bench.

FIXING METAL 1 2

34-72
 34. TRAVEL SYSTEM

3) Install RV gear assy.

1. Insert RV gear A (4) to hub (1).

1 4

2. Fit three crankshafts (9) in holes for bearing (22)

inside of spindle (2).

• Then, bearing (22), bearing (23) and spacer (12)

are already fitted in crankshaft.

9, 12, 22, 23

3. Insert RV gear B (5) to hub (1)

• Since teeth of RV gear A (4) and RV gear B (5) are

engaged in phase, match punched point on the
end, and fit it.

1 5

4. Insert twenty eight pins (17) between pin groove

of hub (1) and tooth groove of gear.

• Prior to inserting, apply lube oil to pin (17).

17

34-73
34. TRAVEL SYSTEM

5. Insert bearing (21) to hub (1) 21

• Apply pin punch on outer race of bearing (21), and

strike it in all around with mallet to press fit.

4) Installing hold flange

1. Check that hub (1), spindle (2), hold flange (3),
two bearings (21) are not replaced with new
ones.

1
• If they are not replaced, proceed the next process.
• Even if one of them is replaced, adjust hold flange
(3) referring to Item " procedure of the Pre-load to
bearing (20)" in this section, and proceed to next
process.

2. Fit hold flange (3) to inner race of bearing (21) in

hub (1).

• Install hold flange (3) to bearing (21) on the same

position as it was, put matchmarks on spindle (2)
21 1 9 3
and crankshaft (9).
• If it is difficult to insert hold flange (3) in inner race
of bearing (21), strike hold flange (3) lightly and
equally with plastic mallet to insert in bearing (21).

5) Tightening reamer bolt (19).

1. Coat the reamer part of reamer bolt (19) with an-
tiseize lubricant and coat the threaded part of the
reamer bolt with adhesive.

• In case oily matter is stuck to the reamer bolt, de-

grease it and after cleaning, dry them in natural
condition. Coat the reamer bolts with adhesive.
• Fasten three reamer bolts (19) equally little by little.
If you fasten one or two bolts first, hold flange (3)
19 3
tilts, making bearing (21) unable to be pressed into
hold flange (3). This causes reamer bolts (19) to
seize themselves. Therefore, tighten them evenly
all round.

2. Tighten three reamer bolts (19) until hold flange

(3) is fitted into bearing (21) evenly.
3. Tighten three reamer bolts (19) to the specified
torque.
Tightening torque : 794 N•m (586 lbf•ft)

34-74
 34. TRAVEL SYSTEM

4. Turn over the travel motor. 22

5. Remove (two) fixing metal.
6. Turn over the travel motor.
7. Fit the outer race of bearing (22) to hold flange
(3).

6) Fixing snap ring.

1. Check that spindle (2), hold flange (3), crankshaft
(9), bearing (22) and spacer (12) are not re-
placed.

• Go to next process if nothing is replaced.

• Even if one of them is replaced, adjust clearance in
shaft direction of bearing (22) and proceed to next
process.
(Refer to Item 21) "Procedure of axial clearance ad-
3 20
justment of bearing (22)" in this section.)
• When replacement of snap ring (20) only is re-
quired, use the same snap ring as the removed
snap ring (20) or select one equivalent to the re-
moved one from 15 types.

2. Fix snap ring (20) to the snap ring groove in hold

flange (3).

• Install three snap rings (20) meeting to match mark

on hold flange (3).
When required to use new snap ring (20), use snap
ring selected according to the specified thickness in
the previous process.

34-75
34. TRAVEL SYSTEM

3. Put three snap rings (25) to crankshaft (9).

9 25

7) Installing spur gear (7).

1. Install three spur gears (7) to crankshaft (9).

• Put the matching marks (punched) of three spur

gears (7) as shown below and fix them to crank-
shaft (9).

Position the matching marks

(punched) on the spur gears and
install them.
7

HOLD FLANGE

2. Fix three snap rings (25) into the snap ring

grooves of crankshaft (9).

25

8) Install oil seal (132).

1. Turn over travel motor.
2. Coat the lip of the oil seal with lithium grease and
fix oil seal (132) into the oil seal hole in spindle
(2), using retainer metal and a hammer.

RETAINER METAL (III) 2 132

34-76
 34. TRAVEL SYSTEM

9) Fixing shaft (102).

1. Put bearing (149) in a heating bath and heat it at
100 ±10°C (212 ±18°F) for ten minutes and in-
sert it into shaft (102).

Carry out the insertion work with leather gloves. Use

care so as not to get burns.

102 149
• Insert bearing (149) into shaft (102) so it comes in
close contact with the flange of the shaft.

2. Fix two parallel pins (177) into the pin holes of

spindle (2).
3. Coat two pivots (176) with lithium grease and fix
it into parallel pins (177) of spindle (2).
4. Install spring (185) and piston assy [piston shoe
(161), shoe (162)] on spindle (2).
5. Incline travel motor 90 degrees. (Lay it down)

2 176, 177

6. Install shaft (102) into spindle (2).

• Install shaft (102) to spindle (2) taking care so as

not to score the lip of oil seal (132) placed in spindle
(2). Scoring of the lip causes oil leakage which
leads to early damage of the travel motor.

2 102

34-77
34. TRAVEL SYSTEM

7. Coat the spline of shaft (102) with lithium grease. 103

8. Install swash plate (103) to spindle (2).

• Apply grease on contact surface of swash plate

(103) with spindle (2).
• Meet two pivots (176) with pivot attaching holes of
swash plate and install swash plate (103) in spindle
(2).

10) Installing cylinder block

1. Place washer (110), spring (114), washer (110) 110
110
and snap ring (146), in that order into cylinder
block (104).
2. Place cylinder block (104) on the press bench. 114
114

104

3. Put retainer metal (I) on washer (110) and fit snap

ring (146) in the groove of cylinder block (104).

PRESS
• Put a plastic sheet over cylinder block (104) so the
contact surface of cylinder block is not scored in
contact with timing plate (109). Plastic sheet

RETAINER METAL (I) 104

11) Installing hydraulic motor parts.

1. Put three rollers (151) into the holes cylinder
151
block (104).
2. Put thrust ball (108) on cylinder block (104).
3. Fit nine piston assy to retainer plate (107). 108

104
• After fixing it, immerse the whole unit in hydraulic
oil.

34-78
 34. TRAVEL SYSTEM

4. Fit nine piston assy to cylinder block (104).

• Match retainer plate (107) with the spherical part of

thrust ball (108) and install them.

107 105

5. Install cylinder block (104) into shaft (102). 104

• Insert cylinder block (104) into the spline of shaft

(102) by aligning the spline hole with the spline of
the shaft.
• After installing the cylinder block, turn it by hand
and make sure that it does not loosen.

12) Installing parking brake.

• Immerse friction plate (115) in hydraulic oil before

fitting it.

1. Incline work bench 90 degrees. (Lay it down.)

2. Install friction plate (115) and separator plate
(116) on groove outside of cylinder block alter-
nately. Then install friction plate first, and then
separator plate.
3. Fit O-rings (135),(141) to the O-ring grooves of 116
piston (112). In that case, coat O-rings (135),
(141) with a thin film of grease.
4. Incline the travel motor 90 degrees. (Lay it down)
5. Install piston (112) into spindle (2).

• If it is hard to fit the piston (112) into the spindle (2)

due to the resistance of O-rings (135),(141), lightly
tap the end face of the piston (112), using a plastic
mallet.
• Take care so as not to score the O-rings when in-
stalling the piston (112). 141 112

34-79
34. TRAVEL SYSTEM

13) Installing the brake valve parts into rear flange 238
1. Fit two O-rings (238) to two plugs (282).

• Coat O-ring (238) with grease.

2. Install valve (227) and spring (230) on rear flange

(201). Apply grease on valve and spring in order
to adhere them to rear flange (201).
3. Install the plug (282) in rear flange (201).

282

• Place on the work bench by directing rear flange

(201) with its plug attaching face up. Align the cen-
ter of threaded hole with the plug 282) center.
• Prevent spring (230) from falling from valve 227).
Note that if spring (230) falls from valve 227), the
valve does not contact with the seat surface of rear
flange (201) properly, causing oil leaks.

4. After installing two plugs (282), temporarily fas-

ten rear flange (201) by means of allen wrench.
5. Install spool (223) into rear flange (201).

227 201

• Coat the spool with hydraulic oil and insert the

spool into the rear flange.
• Attach the spool by aligning the hole of the rear
flange with the spool and prevent the inner surface
of the rear flange and the outer surface of the spool
from being damaged by mutual interference.
• In case damage resulting from inter-ference should
occur to the holes in the rear flange and the outer
surface of the spool, internal leaks will occur after
assembly, ultimately deteriorating the performanc-
es of the travel motor.
282

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 34. TRAVEL SYSTEM

6. Fit O-ring (236) to plug (224). 236

• Coat O-ring (236) with grease.

7. Fit spring retainer (225) and spring (228) to plug

(224).

224

8. Tighten two plugs (224) into rear flange (201). 224

• When tighten the plugs into the rear flange, use

care so as not to deform the spring.

9. Temporarily tighten two plugs (224) to rear flange

(201) by means of a spanner.

201

14) Into rear flange assembling shockless relief

valve (SRV).
1. Fit O-ring (291), O-ring (292) and backup ring
(294),(295) to sleeve (288).
2. Fit O-rings (238) to plug (289).

• Coat O-ring (291),(292),(238) with grease.

294, 295 288

3. Install piston seal (293) to valve (287).

PISTON SEAL (293)

• Piston seal (293) is made up of O-ring and teflon
ring, and apply grease on both rings and fit O-ring
first, then teflon ring.

VALVE (287)

34-81
34. TRAVEL SYSTEM

4. Insert sleeve (288), valve (287) and spring (290) 288

to rear flange (201).

• Apply hydraulic oil on valve (287) and insert it in

sleeve (288).
• Parts inside of sleeve are fitted in the factory as a
sleeve kit, so take care not to make a wrong combi-
nation.

201

5. Temporarily tighten two plugs (289) to rear flange 289

(201) by means of a spanner.

• When tighten the plugs into the rear flange, use

care so as not to deform the spring.

201

6. Fit O-ring (238) to plug (282). 282

• Coat O-ring (238) with grease.

7. Insert piston (286) to rear flange (201).

• Piston (286) and rear flange (201) are factory fitted

for assembly. Do not mistake the combination.

8. Temporarily tighten two plugs (282) to rear flange

(201) by means of a spanner.

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 34. TRAVEL SYSTEM

9. Install steel ball (296) to rear flange (201).

• Assemble the steel balls into the rear flange by

caulking.

10. Tighten plug (284) to rear flange (201) and tight-

en it to specified torque.
Tightening torque : 12.3 N•m (9.0 lbf•ft)

296 201

15) Installing fittings to rear flange. 271

1. Installing pilot valve into rear flange.
1) Place rear flange directing the contact surface
with spindle (2) upward.
2) Insert spring (281), spool (271) into rear flange
(201).

• When tighten the plugs into the rear flange, use

care so as not to deform the spring.

3) Fit O-ring (292) to plug (221). 201

221

• Coat O-ring (292) with grease.

4) Tighten plug (221) to rear flange (201) and tight-

en it to specified torque.
Tightening torque : 58.8 N•m (43 lbf•ft)

2. Apply hydraulic oil to bearing (150), and install it

in rear flange (201).

150

201

34-83
34. TRAVEL SYSTEM

3. Drive two parallel pins (242) in pin holes of rear

flange (201).

242 201

4. Apply grease to the surface of timing plate (109)

in contact with rear flange (201).
5. Install timing plate (109) on rear flange (201) tak-
ing parallel pin (242) as a guide.

• Install timing plate (109) until it is completely con-

tacted with rear flange (201). Grease film is used to
protect them from dropping.

109 201

16) Connecting rear flange with spindle.

1. Fix O-ring (28),(30) into the O-ring groove of
spindle (2).

• Fit O-ring (30) without application of grease. Appli-

cation of grease may cause taking the oozed
grease out of contact face of rear flange and spin-
dle for the leaking oil. So never apply grease on O-
ring (30).

2 30

2. Fix two parallel pins (43) to spindle (2). 43

3. Fill hydraulic oil 0.5 (0.13 gal) into spindle (2).

34-84
 34. TRAVEL SYSTEM

4. Align two parallel pins (43) set in spindle (2) with 201
the pin holes of the rear flange and install rear
flange (201) to spindle (2).

• At the time when rear flange (201) is installed on

spindle (2), fit eight springs (113) on the rear flange
side. Apply grease on spring (113) to prevent them
from dropping.

5. Install six socket bolts (245) to spindle (2) and

tighten them up.
Tightening torque : 102 N•m (75 lbf•ft)

245 2

6. Tighten plug (282). 282

Tightening torque : 98.1 N•m (72 lbf•ft)

7. Tighten plug (224). 224

Tightening torque : 353 N•m (260 lbf•ft)

34-85
34. TRAVEL SYSTEM

8. Tighten plug (282). 282

Tightening torque : 98.1 N•m (72 lbf•ft)

9. Tighten plug (289). 289

Tightening torque : 98.1 N•m (72 lbf•ft)

17) Installing input gear.

1. Turn over travel motor.
2. Fit shaft (15) to shaft (102).
3. Fit input gear (6) to shaft (15).

• Fix input gear (6) to shaft (15) by matching the teeth

of three spur gears (7). When gear is not engaged,
check it for possible error.

15

4. Fix snap ring (24) into the snap ring groove of the
shaft (15).
16, (15), (26)
5. Coat steel ball (36) with grease and put it on the
concave part of input gear (6). 24
7

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 34. TRAVEL SYSTEM

18) Installing cover

1. Fill lubricating oil in hub (1).
Oil volume : 1.3 (0.34 gal)
2. Fit O-ring (29) into the O-ring groove of cover (8).

• Apply grease to O-ing (29).

3. Install hub (1) to cover (8).

• Align the matching marks on cover (8) and hub (1)

and install them.
• Install cover (8) in hub (1), tapping the outer circum-
ference of cover (8) lightly by means of a plastic
mallet. Use care that if the cover is fixed jerkily by
striking it hard, the O-ring is scored and brings
about an oil leakage.

4. Fix ring (18) into the ring groove of hub (1).

18 1

5. Fit the O-ring (35) to flange plug (33). 33

Tighten with flange plug (33) into the cover (8).
Tightening torque : 58.8 N•m (43 lbf•ft)
6. Fit the O-ring (35) to flange plug (34).
Tighten with flange plug (34) into the cover (8).
Tightening torque : 58.8 N•m (43 lbf•ft)

8 34

34-87
34. TRAVEL SYSTEM

19) Removing travel motor

1. Remove the travel motor attaching bolts from the
work bench.

20) The specified pre-load must be applied to bear-

ing (21) to ensure the proper life.

• Therefore, when the parts exerting influences on

the pre-load are replaced, assemble it temporarily
in the following procedure and check the pre-load.
If it is assembled without checking the pre-load, the
malfunction of hydraulic motor may be caused and
the life may be shortened.
• Parts exerting influences on the pre-load. Hub (1),
spindle (2), hold flange (3), bearing (21). BEARING PRELOAD ADJUSTING JIG

• When the above parts are not replaced, omit this

procedure, and proceed to the procedure shown in
Item 4) " 1 " in this section.
• Pre-load checking and pre-load adjusting proce-
dure are described below.

1. Procedure of the pre-load to bearing.

1) Attach the bearing pre-load adjusting jig to spin-
dle (2) tighten the special nut, and press bearing
(21) into hub (1).
A specified tightening
Torque of special nut : 39.2 N•m (29 lbf•ft)
Depth micrometer
2) Determine the depth "A" through the measuring
BEARING (21) Bearing pre-load
hole of the bearing pre-load adjusting jig, using a adjusting JIG
depth micrometer. B

3) Since the dimension "B" of the bearing pre-load A

adjusting jig is known, determine the clearance
C
"C" by the following formula :
HUB (1)
"C"="A"-"B"
A : Actual value SPINDLE (2)

B : Dimensions of jig body

C : Specified dimension

34-88
 34. TRAVEL SYSTEM

4) Then determine dimension "D" of hold flange (3).

D
5) After measurement steps 2)~4), adjust hold
E
flange (3) as follows :
Dimension "C" is the specified dimension of the
hold flange.
I. When actual dimension "D" of hold flange (3) is
0.02 mm (0.0008 in) smaller than a specified val- 3
ue "C";
Remove surface E of hold flange (3) to a speci-
fied value by lathe.
II. Where the actual dimension of the hold flange
falls within ± 0.02 mm (0.0008 in) of the specified
clearance "D" ;
Use the hold flange (3) as it is.
III. When actual dimension "D" of the hold flange (3)
is 0.02 mm (0.0008 in) larger than a specified
value "C" ;
Replace the flange with a new spindle assy.
The adjustment allowance for new hold flange
(3) is specified without fail.

• Since hold flange and spindle are drilled at the

same time, they are integrated in an assembly unit.
Therefore they can not be replaced separately. Re- BEARING PRELOAD ADJUSTING JIG
place them as an assembly unit, that is, together
with spindle.
This assy is called as spindle assy.
• To replace the spindle assy, disassembling and as-
sembling works should be performed again.

6) Remove bearing pre-load adjustment jig from

spindle (2).
7) After completion of hold flange adjustment in the
procedure shown in Sections I, II, and III, pro-
ceed to the procedure shown in Item 34.2.1.6 (3)
6) " 2 " in this section.

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34. TRAVEL SYSTEM

21) Procedure of axial clearance adjustment of

bearing (22)

• When the following parts have been replaced, it is

necessary to adjust the axial clearance of taper roll-
er bearing (22) to a specified value by adjusting the
thickness of snap ring (20). If it is installed without
adjustment, malfunction of hydraulic motor may be
caused and the life may be shortened.

Spindle (2), hold flange (3),

crankshaft (9), spacer (12),
bearing (22).

• When the above parts are not replaced, the adjust-

ment of thickness of snap ring is unnecessary. Pro-
ceed to the regular assembly shown in Item 6) " 1 "
in this section.
• The clearance adjustment is described below.

1. Lightly tap the outer race with mallet and jig (IV)
of bearing (22) attached to crankshaft (9).

• Put the RV gear assy in spindle (2) securely.

RETAINER METAL (IV)

2. Fix the thinnest snap ring (20) into the snap ring
groove in hold flange (3).

20 3

34-90
 34. TRAVEL SYSTEM

3. Lightly tap the outer periphery of snap ring (20)

via jig (IV).

• Confirm that the RV gear assy is securely set in

spindle (2).

RETAINER METAL (IV)

4. Insert a thickness gauge between snap ring (20)

and bearing (22) and measure the clearance.
5. Thickness measurement of snap rings
• Set thickness of snap ring (max.)
MAX. = Thickness of thickness gauge + Thick-
ness of presently set snap ring
• Set thickness of snap ring (min.)
THICKNESS
MIN. = Thickness of thickness gauge + Thick-
GAUGE
ness of presently set snap ring - 0.05 mm
(0.002 in)
6. When the thickness of the snap ring has been
determined, select one out of fifteen kinds A
through Z (refer to 34.2.1.7) and fit it to the hold
flange.
7. Install snap ring satisfying the set thickness, and
proceed to the procedure Item 34.2.1.6 (3) 6) "2"
in this section.

34-91
34. TRAVEL SYSTEM

34.2.1.7 DIMENSIONS OF SNAP RING

Item Dimension
Snap ring (20) Class Dimension t mm (in)
A over 1.90 to 1.95 (0.075 to 0.077) incl.
B over 1.95 to 2.00 (0.077 to 0.078) incl.
C over 2.00 to 2.05 (0.078 to 0.081) incl.
D over 2.05 to 2.10 (0.081 to 0.083) incl.
E over 2.10 to 2.15 (0.083 to 0.085) incl.
F over 2.15 to 2.20 (0.085 to 0.087) incl.
G over 2.20 to 2.25 (0.087 to 0.089) incl.
H over 2.25 to 2.30 (0.089 to 0.091) incl.
I over 2.30 to 2.35 (0.091 to 0.093) incl.
J over 2.35 to 2.40 (0.093 to 0.094) incl.
K over 2.40 to 2.45 (0.094 to 0.096) incl.
L over 2.45 to 2.50 (0.096 to 0.098) incl.
X over 1.75 to 1.80 (0.069 to 0.071) incl.
Y over 1.80 to 1.85 (0.071 to 0.073) incl.
t MARKING STAMP
(CLASS) Z over 1.85 to 1.90 (0.073 to 0.075) incl.

34-92
 34. TRAVEL SYSTEM

34.2.1.8 PERFORMANCE INSPECTION

• After completing the maintenance, carry out the performance inspection in the following procedure

34-93
34. TRAVEL SYSTEM

34.2.1.9 SERVICE STANDARDS

Disassemble and inspect the motors according to this standard. Handle each component carefully, exercising par-
ticular care so the moving parts and the sliding parts are not scored.
(1) Seals
Replace all seals (O-ring, oil seal, floating seal) once used even if no damage is seen.
(2) Wear parts maintenance standard
1) Replace any part that shows damage on appearance.
2) Replace such parts that show the following abnormalities, as well.

Item
Parts Trouble Reference value Allowable value
No.
Spindle kit
(2) Spindle
• Severe damage to appearance
(3) Hold flange
(19) Reamer bolt • Abnormal wear such as scoring is
present.
RV gear assy
(4) RV gear (A) • The RV gear tooth surface shows
(5) RV gear (B) uneven wear.
(9) Crankshaft • Crankshaft-related parts do not
(22) Conical roller bearing move smoothly when crankshaft
(23) Needle roller bearing (9) is turned.

• The end face of the circumference

20 Snap ring
is abnormally worn.
• Dent is present.
21 Bearing • Flaking is seen.
• Uneven wear is present.
Rear flange kit
(201) Rear flange • Part in contact with spool (223) is
scratched.
• Clearance with spool is large.
• Surface in contact with valve (227) Clearance on
Clearance on diameter
is scratched. diameter
35 µ
• Depth to the contact surface with 9~15 µ
(0.0014 in)
valve (227) is large. (0.0003~0.0006 in)
(223) Spool • Outer circumference is scored.
• Outer circumference is worn un-
evenly.
Clearance on
• Outer circumference is scored. Clearance on diameter
diameter
(286) Piston • Outer circumference is worn un- 40 µ
12~20 µ
evenly. (0.0016 in)
(0.0005~0.0008 in)
• Contact surface with oil seal (132)
(102) Shaft is worn.
• Spline is worn.

34-94
 34. TRAVEL SYSTEM

Item
Parts Trouble Reference value Allowable value
No.
• Spline is worn.
• Bore surface is worn badly.
(104) Cylinder block
• Sliding surface with timing plate
(109) is scored or worn unevenly.
Piston Assy
(105) Piston • Clearance is present in the axial
(106) Shoe direction between piston (105) and Clearance Clearance
shoe (106). 0.04 mm 0.14 mm
• Shoe is worn abnormally. (0.0016 in) (0.0055 in)
• Shoe is worn unevenly.
• The end face of the circumference
(107) Retainer plate
is worn unevenly.
• Spherical sliding part with retainer
(108) Thrust ball
plate (107) is worn unevenly.
• Sliding surface is seized or worn
(109) Timing plate
unevenly.
(115) Friction plate • Both end faces are worn unevenly. Braking torque
Braking torque
• Specified torque can not be 97 N•m
97 N•m
(116) Separator plate reached. (72 lbf•ft)
(72 lbf•ft)
• Seizure is seen. or over
(227) Valve • Seat surface is scored.
(149) Bearing • Dent is present.
• Flaking is seen.
(150) Bearing
• Uneven wear is present.
(287) Valve • Outer circumference is scored.
(288) Sleeve • Outer circumference is scored.

34-95
34. TRAVEL SYSTEM

[MEMO]

34-96
 41. TROUBLESHOOTING
(MECHATRO CONTROL)
TABLE OF CONTENTS

41.1 OUTLINE ............................................................................................................................ 41-3

41.1.1 JUDGMENT OF ACTUAL THING AT SITE ............................................................... 41-3
41.2 TABLE OF ACTUATOR FOR TROUBLESHOOTING : MECHATRO CONTROL .............. 41-5
41.3 TROUBLESHOOTING SUMMARIZED : MECHATRO CONTROL .................................... 41-8
41.4 CHECK POINT FOR MECHATRO SYSTEM ...................................................................... 41-10

41

41-1
41. TROUBLESHOOTING (MECHATRO CONTROL)

41-2
 41. TROUBLESHOOTING (MECHATRO CONTROL)

41.1 OUTLINE
Troubleshooting provides process locating for the
cause of trouble in the order that trouble occurred.
This manual describes how to solve the specific phe-
nomenon systematically as possible. For troubleshoot-
ing concerning the inside of equipment, refer to
troubleshooting for each manual of equipment.

41.1.1 JUDGMENT OF ACTUAL THING AT SITE

(1) Get to the site as quickly as possible.
Verify model, serial number, situation of trouble and
field, and notify person of arrival time.
(2) Verify background of trouble occurred.
1) Model name and serial number.
2) Kind of attachment.
Check that the combination of attachment is
proper or that the operating method is not unrea-
sonable.
3) Operating time on the hour-meter.
4) History of trouble occurred and additional works.
5) Recurrence of past trouble, or problems on the
Verifying background of trouble occurred.
additional works.
(3) How to diagnose trouble
1) Verify defective part.
2) Make the condition of trouble again.
3) Where defective part can not be verified, surmise
causes systematically.
4) Verify reasons for surmise.
5) Report methods, procedure, and period for re-
pairing to user.
(4) Explanation of the cause of trouble
1) Explain the cause of trouble to clients. For exam-
ple, oil leak through piston is caused by flaws on
Confirm the symptoms of the trouble.
the piston rod. And the method of using the ma-
chines should be explained so that the same
kind of trouble not reoccur.
2) Treatment of damaged parts
The damaged parts to be claimed and returned
are evidence, so they should be handled with
care. Protect them from entry of water, soil, etc.
into port of hydraulic unit, etc. and return them.
And also use care not to flaw and damage those Diagnosing fail by means of troubleshooting
surfaces.

41-3
41. TROUBLESHOOTING (MECHATRO CONTROL)

This page is blank for editing convenience.

41-4
 41. TROUBLESHOOTING (MECHATRO CONTROL)

41.2 TABLE OF ACTUATOR FOR TROUBLESHOOTING : MECHATRO CONTROL

Electric Hydraulic

Low pressure sensor or

Conflux / single change

solenoid valve (OPT.)

Swing / extra change
proportional valve

proportional valve

Safety lock lever

Travel 1-2speed

Travel boost-up
solenoid valve

solenoid valve

solenoid valve

solenoid valve

solenoid valve

solenoid valve
bypass cut

bypass cut
straight

Slewing P / B
Operating
Actuator
condition

PSV-C Travel
SW.
PSV-B P2

PSV-D P1

P1 pump

P2 pump
SV-1

SV-2

SV-3

SV-4

SV-5

SV-8
Boom up slow operation

Boom up full lever operation

Boom down operation

Arm out slow operation

Arm out full lever operation

Independent operation

Arm in slow operation

Arm in full lever operation

Bucket digging

Bucket dump

Boom swing left operation

Boom swing right operation

Slewing operation

Nibbler & Breaker

Travel LH / RH operation
(1st. speed)
Travel LH / RH operation
(2nd speed)
Travel right operation
+ Boom operation
Travel right operation
+ Bucket operation
Travel right operation
Combined operation

+ Arm operation
Travel right operation
+ Slewing operation
Travel left operation
+ Boom operation
Travel left operation
+ Bucket operation
Travel left operation
+ Arm operation
Travel left operation
+ Slewing operation
Travel LH / RH operation
+ Boom up operation

41-5
41. TROUBLESHOOTING (MECHATRO CONTROL)

Hydraulic
Control valve

Conflux/single change valve

Boom up conflux valve
Operating

P1 bypass cut valve

P2 bypass cut valve

Actuator
condition

Nibbler & breaker

Travel straight
Boom swing

Travel right

Travel left
Slewing
Bucket
Boom

Arm

Boom up slow operation

Boom up full lever operation

Boom down operation

Arm out slow operation

Arm out full lever operation

Independent operation

Arm in slow operation

Arm in full lever operation

Bucket digging

Bucket dump

Boom swing left operation

Boom swing right operation

Slewing operation

Nibbler & Breaker

Travel LH / RH operation
(1st. speed)
Travel LH / RH operation
(2nd speed)
Travel right operation
+ Boom operation
Travel right operation
+ Bucket operation
Travel right operation
Combined operation

+ Arm operation
Travel right operation
+ Slewing operation
Travel left operation
+ Boom operation
Travel left operation
+ Bucket operation
Travel left operation
+ Arm operation
Travel left operation
+ Slewing operation
Travel LH / RH operation
+ Boom up operation

41-6
 41. TROUBLESHOOTING (MECHATRO CONTROL)

Hydraulic
Motor Cylinder Lock valve

Slewing priority lock valve

Boom swing lock valve

Operating
Actuator
condition

Nibbler & Breaker

Travel right motor

Boom lock valve

Travel left motor

Arm lock valve

Slewing motor

Bucket

Swing
Boom

Arm
Boom up slow operation

Boom up full lever operation

Boom down operation

Arm out slow operation

Arm out full lever operation

Independent operation

Arm in slow operation

Arm in full lever operation

Bucket digging

Bucket dump

Boom swing left operation

Boom swing right operation

Slewing operation

Nibbler & Breaker

Travel LH / RH operation
(1st. speed)
Travel LH / RH operation
(2nd speed)
Travel right operation
+ Boom operation
Travel right operation
+ Bucket operation
Travel right operation
Combined operation

+ Arm operation
Travel right operation
+ Slewing operation
Travel left operation
+ Boom operation
Travel left operation
+ Bucket operation
Travel left operation
+ Arm operation
Travel left operation
+ Slewing operation
Travel LH / RH operation
+ Boom up operation

41-7
41. TROUBLESHOOTING (MECHATRO CONTROL)

41.3 TROUBLESHOOTING SUMMARIZED : MECHATRO CONTROL

Electric or hydraulic cause Hydrau- Normal criterion
Operating
No. Trouble lic or
condition
Cause Check point electric 1 2 3

1-1 No Safety lock Safety lock lever SOL (SV-4) 24V at SV-4 connector. 24V at SW-11. 24V at fuse box
operation lever down solenoid (SV-4) does connector connector
works at full not change over and (CN-14M)
Electric
stroke there is no hydraulic white & black
source for pilot valve.

1-2 Moves Lever at P1 bypass cut P1 bypass cut Current for P1 bypass cut Arm in sensor and arm
unexpectedly neutral proportional valve proportional Electric proportional valve : 315mA. out sensor values :
moves unexpectedly valve (PSV-D) less than 1.3V.
and the P1 circuit connector Secondary pilot pressure for Secondary pilot
pressure rises. Hydrau-
P1 bypass cut valve : pressure :
lic
0.54MPa (78psi). 0.59MPa (85psi).
Lever at P2 bypass cut P2 bypass cut Current for P2 bypass cut Boom raise sensor and
neutral proportional valve proportional Electric proportional valve : 315mA. slewing sensor values
moves unexpectedly valve (PSV-B) : less than 1.3V.
and P2 circuit connector Secondary pilot pressure for Secondary pilot
pressure rises. Hydrau-
P2 bypass cut proportional pressure :
lic
valve : 0.54MPa (78psi). 0.59MPa (85psi).
2-2 Only bucket Bucket P2 bypass cut P2 bypass cut Current for P2 bypass cut Boom raise sensor and
is slow lever and proportional valve proportional Electric proportional valve : 315mA. slewing sensor values
other levers moves unexpectedly, valve (PSV-B) : less than 1.3V.
at full P2 circuit pressure connector Secondary pilot pressure for Lever at neutral Secondary pilot
stroke rises, and P1 circuit Hydrau-
P2 bypass cut valve : Secondary pilot pressure with pressure for bucket :
flow decreases. lic
0.54MPa (78psi). lever neutral : 0.59MPa (85psi). 3.43MPa (500psi)
2-3 Only boom Boom lever P2 bypass cut P2 bypass cut Feedback current for P2 Command current for P2 Boom raise sensor
raise speed at full proportional valve proportional Electric bypass cut proportional bypass cut proportional : more than 4.0V
is low stroke does not move and valve (PSV-B) valve : 709mA. valve : 709mA.
the boom conflux feedback current Secondary pilot pressure for Secondary pilot
flow is not created. Hydrau-
P2 bypass cut valve : pressure for travel :
lic
2.55MPa (370psi) 2.35MPa (340psi)
Travel lever Travel straight valve Travel straight Command current for P2 Travel right and left
at neutral moves unexpectedly proportional Electric bypass cut proportional sensors: less than
and is actuated by P1 valve (PSV-C) valve : 315mA. 1.3V.
pump flow. command current Secondary pilot pressure for Secondary pilot
Hydrau-
P2 bypass cut valve : pressure for travel :
lic
0.54MPa (78psi). 0.59MPa (85psi).
Only speeds Travel lever Travel straight valve Travel straight Command current for travel Travel right and left
other than at neutral moves unexpectedly proportional Electric straight proportional valve : sensor value : less
boom raise, and P2 pump flow to valve (PSV-C) 315mA. than 1.3V.
arm in and tank. command current Secondary pilot pressure for Secondary pilot
out are low Hydrau-
PO port travel straight valve : pressure for travel :
lic
0.54MPa (78psi). 0.59MPa (85psi).
2-4 Only arm in Arm lever Arm conflux flow is P1 bypass cut Command current for P1 Arm in sensor :
speed is at full not created. proportional Electric bypass cut proportional valve : more than 4.0V
low stroke valve (PSV-D) 709mA.
command current Secondary pilot pressure for Secondary pilot
Hydrau-
P1 bypass cut valve : pressure for arm in :
lic
2.55MPa (370psi). 3.43MPa (500psi)
2-5 Only arm Arm lever Arm conflux flow is P1 bypass cut Command current for P1 Arm out sensor :
out speed is at full not created. proportional Electric bypass cut proportional valve : more than 4.0V.
low stroke valve (PSV-D) 709mA
command current Secondary pilot pressure for Secondary pilot
Hydrau-
P1 bypass cut valve : pressure for arm out :
lic
2.55MPa (370psi). 3.43MPa (500psi)
4-1 Fine bucket Fine bucket P1 bypass cut P1 bypass cut Command current for P1 Arm in and arm out
digging and operation proportional valve proportional Electric bypass cut proportional valve : sensor values :
dump moves unexpectedly valve (PSV-D) 315mA less than 1.3V.
operations and the P1 circuit connector Secondary pilot pressure for Secondary pilot Unload pressure for
can not be pressure rises Hydrau-
P1 bypass cut valve : pressure for arm in and P1 pump : approx.
done lic
0.54MPa (78psi). out : 0.59MPa (85psi) 1.96MPa (280psi)
4-2 Fine boom Fine boom P1 bypass cut P1 bypass cut Command current for P2 Arm in and arm out
raise and raise and proportional valve proportional Electric bypass cut proportional valve : sensor values :
lower lower moves unexpectedly valve (PSV-D) 315mA. more than 1.3V.
operations operations and the P1 circuit connector Secondary pilot pressure for Secondary pilot Unload pressure for
can not be pressure rises. Hydrau-
P2 bypass cut valve : pressure for arm in and P1 pump : approx.
done lic
0.54MPa (78psi). out : 0.59MPa (85psi). 1.96MPa (280psi)
4-3 Fine slewing Fine slewing P2 bypass cut P2 bypass cut Command current for P2 Swing sensor and
right and right and proportional valve proportional Electric bypass cut proportional valve : boom raise sensor
left left moves unexpectedly valve (PSV-D) 315mA. values : less than 1.3V.
operations operations and the P2 circuit connector Secondary pilot pressure for Unload pressure for P2 Secondary pressure for
can not be pressure rises. Hydrau-
P2 bypass cut valve : pump : approx. 1.96MPa slewing and boom raise :
done lic
0.54MPa (78psi). (280psi) or less. 0.59MPa (85psi)
Fine slewing Slewing left or Slewing parking Slewing parking Command voltage for slewing Slewing sensor
right and left right lever to solenoid is not solenoid (SV-1) Electric parking solenoid : 0V values :
operations full stroke deenergized. connector more than 4.0V
impossible. Secondary pilot pressure for Secondary pilot pressure
Hydrau-
slewing parking solenoid : for slewing :
lic
3.43MPa (500psi) 3.43MPa (500psi)

41-8
 41. TROUBLESHOOTING (MECHATRO CONTROL)

Note : The below table shows items to be highlighted in the electrical and hydraulic troubleshooting.
"Normal criterion" is a list of figures which come up in the electrical and hydraulic troubleshooting.
Regarding the inspecting procedures, refer to each troubleshooting.
Electric or hydraulic cause Hydrau- Normal criterion
Operating
No. Trouble lic or
condition
Cause Check point electric 1 2 3

4-4 Fine arm in Fine arm in or P2 bypass cut Connector of P2 Command current for P2 bypass Slewing sensor and
and out out operation proportional valve bypass cut Electric cut proportional valve : 315mA boom raise sensor
motions moves unexpectedly proportional valve values : less than 1.3V
impossible. and the P2 circuit (PSV-B) Secondary pilot pressure for Secondary pressure for Unload pressure for
pressure rises. Hydrau-
P2 bypass cut valve : slewing and boom P2 pump : approx.
lic
0.54MPa (78psi) raise actions : 0.59MPa (85psi) 1.96MPa (280psi)
5 Travel 1-2 Travel 1-2 Travel 1-2 speed Connector for travel 24V across power supply for 100th is indicated as 1 in
travel 1-2 speed solenoid and controller service diagnosis
speed change speed select solenoid (SV-3) does 1-2 speed solenoid
Electric ground. 23 and travel pressure sensor
impossible. switch is on. not change over. values: less than 1.3V lever
in neutral.
Secondary pilot pressure
Hydrau-
for command travel 1-2 speed
lic
select : 3.43MPa (500psi)
6 Travel speed Travel lever at Travel straight valve Command current of Command current of travel 8 sensor values for
is low. full stroke. moves unexpectedly travel straight Electric straight proportional valve : bucket, boom, slewing
(single (Other levers and the machine proportional valve 315mA and arm : less than 1.3V
operation) in neutral) travels only by the (PSV-C) Secondary pilot pressure of PO 8 sensor values for Secondary pilot
delivery rate of P1 Hydrau-
port travel straight valve : bucket, boom, slewing pressure for travel :
pump. lic
0.54MPa (78psi) and arm : 0.59MPa (85psi) 2.35MPa (340psi)
8 Machine can Levers at full stroke Travel straight valve Command current of Command current for travel Swing sensor and
not travel in combined does not change over travel straight Electric straight proportional valve : arm in/out sensor :
straight. operations of and the travel action proportional valve 315mA more than 4.0V
slewing/travel or is affected by the (PSV-C) Secondary pilot pressure for PO Secondary pilot pressure
arm/travel actions. delivery rate of P1 Hydrau-
port travel straight valve : for swing and arm
pump. lic
2.55MPa (370psi) in/out : 3.43MPa (500psi)
Levers at full stroke Travel straight valve Command current of Command current for travel Boom raise/lower sensor
in combined does not change over travel straight Electric straight proportional valve : and bucket close/open
operations of and the travel action proportional valve 315mA sensor : more than 4.0V
boom/travel or is affected by the (PSV-C) Secondary pilot pressure for PO Secondary pilot pressure for
bucket/travel. delivery rate of P1 Hydrau-
port travel straight valve : boom raise/lower and bucket
pump. lic
2.55MPa (370psi) close/open : 3.43MPa (500psi)
10 Slewing power Slewing lever Slewing parking Connector for slewing 0V across power supply of Slewing sensor :
is not available. at full stroke. solenoid does not parking solenoid Electric slewing parking solenoid and more than 4.0V
demagnetize. (SV-1) ground
Secondary pilot pressure for Secondary pilot pressure
Hydrau-
slewing parking solenoid for slewing :
lic
: 3.43MPa (500psi) 3.43MPa (500psi)
11 Slewing speed Slewing lever at P2 bypass cut Feedback current of Feedback current for P2 bypass Command current for P2 Slewing sensor :
is low. full stroke. proportional valve P2 bypass cut Electric cut proportional valve : 709mA bypass cut proportional more than 4.0V
does not change over proportional valve valve : 709mA
and part of the (PSV-B) Secondary pilot pressure for P2 Secondary pilot pressure
delivery of P2 pump Hydrau-
bypass cut valve : 2.55MPa for slewing :
flows to tank. lic
(370psi) 3.43MPa (500psi)
12 Slewing power Slewing lever P2 bypass cut Feedback current of Command current for P2 bypass Command current for P2 Slewing sensor :
is poor. at full stroke. proportional valve P2 bypass cut Electric cut proportional valve : 709mA bypass cut proportional more than 4.0V
does not change over proportional valve valve : 709mA
and the P2 circuit (PSV-B) Secondary pilot pressure for P2 Secondary pilot pressure
pressure does not Hydrau-
bypass cut valve : 2.55MPa for slewing :
rise. lic
(370psi) 3.43MPa (500psi)
13 Slewing motion Slewing lever Swing parking brake Connector for slewing 24V across power supply of Slewing sensor and
can not be at neutral. is released. parking solenoid Electric slewing parking solenoid and arm in sensor
held on a ground. values : more than 1.3V
slope. Secondary pilot pressure of Secondary pressure for
Hydrau-
slewing parking solenoid : slewing and arm
lic
3.43MPa (500psi) in : 0.59MPa (85psi)
14 Travel boost Travel lever at Travel pilot pressure Check value of Value of travel
doesn't work at full stroke. sensors (SE9) and pressure sensor. Electric pressure sensor
travel single (SE10) are failure. is 4V or more.
operation Travel boost-up Check movement of If apply 24V to travel boost-up When solenoid is
solenoid (SV8) is solenoid or replace Hydrau-
solenoid, the solenoid is disassembled, does
failure. solenoid. lic
switched. spool move smoothly?
15 When travel Travel and P3 pump pressure Check value of Value of travel
and dozing are dozer levers sensor (SE17) pressure sensor. Electric pressure sensor
operated are fully is failure. is 4V or more.
simultaneously, stroked at Travel boost-up Check movement of If apply 24V to travel boost-up When solenoid is
engine is same time. solenoid (SV8) is solenoid or replace Hydrau-
solenoid, the solenoid is disassembled, does
stalled failure. solenoid. lic
switched. spool move smoothly?

41-9
41. TROUBLESHOOTING (MECHATRO CONTROL)

41.4 CHECK POINT FOR MECHATRO SYSTEM

(1) Mounting position of connectors for solenoids (solenoid valves) : SV-1, SV-3, SV-4, SV-8, (SV-2 OPT)
(2) Mounting position of connectors for solenoid proportional valves : PSV-B, PSV-C, PSV-D
(3) Detail sensor connector : SE-1~SE-10

TRAVEL BOOST-UP SOL (SV-8)

CONFLUX-SINGLE SELECT SOL (SV-2) SLEWING PARLING P2 BYPASS CUT PROPORTIONAL VALVE (PSV-B)
Normal spec. does not need connection. SOL (SV-1)
UNDER FLOOR HARNESS
TRAVEL 1,2-SPEED SOL (SV-3)

SAFETY LOCK LEVER SOL (SV-4) TO INSTRUMENT PANEL HARNESS

TRAVEL STRAIGHT PROPORTIONAL

PRESSURE SENSOR (TRAVEL LEFT) (SE-10) VALVE (PSV-C)
P1 BYPASS CUT PROPORTIONAL
PRESSURE SENSOR (TRAVEL RIGHT) (SE-9) VALVE (PSV-D)
OPT PEDAL PRESSURE SWITCH HYD. FLUID TEMP. SW
(KCMA OPT.)

TRAVEL 1,2-SPEED SWITCH

4, P, T PORT : PF 3/8 GROUND
1, 2, 3, 8, B, C, D PORT : PF1/4 GROUND CABLE CONNECTOR
TRAVEL BOOST-UP
SV-8

4, P, T PORT : PF 3/8
1, 2, 3, A, B, C, D PORT : PF1/4

Fig. 41-1 Solenoid valve, solenoid proportional valve connector / Detail sensor connector

41-10
 42. TROUBLESHOOTING
(HYDRAULIC SYSTEM)
TABLE OF CONTENTS

42.1 TROUBLE DIAGNOSIS : HYDRAULIC ............................................................................. 42-3

42.2 TROUBLESHOOTING ....................................................................................................... 42-6

42

42-1
42. TROUBLESHOOTING (HYDRAULIC SYSTEM)

42-2
 42. TROUBLESHOOTING (HYDRAULIC SYSTEM)

42.1 TROUBLE DIAGNOSIS : HYDRAULIC

Component Oil pressure

Pump Control valve

Pump regulator (for P1,P2)

Flow conflux change spool

Check valve for relief
P2 bypass cut valve
P1 bypass cut valve
Travel straight spool

Boom swing spool

Load check valve

Pilot relief valve
E/G revolution

Slewing spool

Conflux spool
Bucket spool

Shuttle valve
Boom spool
Travel spool

N&B spool

Lock valve
Arm spool
Classification

P1 pump
P2 pump

P3 pump
Group No.

Operating
condition Device No. 1 2
No operation is possible.
1 Machine operates unexpectedly
even though lever is in neutral.
All actions
Bucket digging and dump
Lower
Speed is slow

Boom raise conflux

Raise
2 Arm in conflux
Arm out conflux
Boom swing
N&B
Attachment operation

All motions
Bucket digging and dump
Power lacks

Lower
Boom
3 Raise
Arm in and out
Hydraulic systems

Boom swing
N&B
Fine operation impossible

Bucket digging
Lower
Boom
Raise
4 Slewing left, right
Arm in and out
Boom swing
N&B
5 Travel 1,2 speed change impossible
Travel operation

6 Travel speed is low

7 Travel power is low
8 Machine cannot travel straight or
deviates in one direction or zigzags
9 Machine drifts on a dwonhill and
does not stop still on a slope
10 Slewing motion does not work
Slewing operation

11 Slewing speed is low

Slewing power is poor
12
Slewing motion drifts very large
Machine is not held still on a slope
13 An usual sound is heard during
slewing motion speed is low

42-3
42. TROUBLESHOOTING (HYDRAULIC SYSTEM)

Component Oil pressure

Slewing Travel motor Cylinder Other valve Proportional
motor valve block

Counter balance check valve

Pilot valve (1-2 speed select)

Travel 1-2 speed sol. valve

Safety lock lever sol. valve
Slewing parking sol. valve
Counter balance valve

Flow conflux sol. valve

Boom swing cylinder

Pilot valve (travel)

Multi select valve
Pilot valve (ATT)
Reduction parts

Bucket cylinder
Boom cylinder
Parking brake

Parking brake
Bypass valve

Arm cylinder

Swivel joint
Classification

Group No.

Motor
Operating
condition Device No. 4 5 6 7 8 9 11 12 13 14 15
No operation is possible.
1 Machine operates unexpectedly
even though lever is in neutral.
All actions
Bucket digging and dump
Lower
Speed is slow

Boom raise conflux

Raise
2 Arm in conflux
Arm out conflux
Boom swing
N&B
Attachment operation

All motions
Bucket digging and dump
Power lacks

Lower
Boom
3 Raise
Arm in and out
Hydraulic systems

Boom swing
N&B
Fine operation impossible

Bucket digging
Lower
Boom
Raise
4 Slewing left, right
Arm in and out
Boom swing
N&B
5 Travel 1,2 speed change impossible
Travel operation

6 Travel speed is low

7 Travel power is low
8 Machine cannot travel straight or
deviates in one direction or zigzags
9 Machine drifts on a dwonhill and
does not stop still on a slope
10 Slewing motion does not work
Slewing operation

11 Slewing speed is low

Slewing power is poor
12
Slewing motion drifts very large
Machine is not held still on a slope
13 An usual sound is heard during
slewing motion speed is low

42-4
 42. TROUBLESHOOTING (HYDRAULIC SYSTEM)

Component Oil pressure

Proportional Filter Main control valve Travel Slewing
valve block

P2 bypass cut proportional valve

P1 bypass cut proportional valve

Travel straight proportional valve

Travel boost-up sol. valve

Boom swing LH or RH
N&B close or open
Main relief valve

Right shockless

Right shockless
Suction strainer

Bucket digging

Left shockless

Left shockless
Bypass check

Bucket dump

Boom down
Return filter
Inline filter
Classification

Boom up
Breather

Arm out
Group No.

Arm in
Operating
condition Device No. 15 16 17 18 19 20
No operation is possible.
1 Machine operates unexpectedly
even though lever is in neutral.
All actions
Bucket digging and dump
Lower
Speed is slow

Boom raise conflux

Raise
2 Arm in conflux
Arm out conflux
Boom swing
N&B
Attachment operation

All motions
Bucket digging and dump
Power lacks

Lower
Boom
3 Raise
Arm in and out
Hydraulic systems

Boom swing
N&B
Fine operation impossible

Bucket digging
Lower
Boom
Raise
4 Slewing left, right
Arm in and out
Boom swing
N&B
5 Travel 1,2 speed change impossible
Travel operation

6 Travel speed is low

7 Travel power is low
8 Machine cannot travel straight or
deviates in one direction or zigzags
9 Machine drifts on a dwonhill and
does not stop still on a slope
10 Slewing motion does not work
Slewing operation

11 Slewing speed is low

Slewing power is poor
12
Slewing motion drifts very large
Machine is not held still on a slope
13 An usual sound is heard during
slewing motion speed is low

42-5
42. TROUBLESHOOTING (HYDRAULIC SYSTEM)

42.2 TROUBLESHOOTING
(1)-1
No operation is possible.

24V is alive across orange/white and black terminals of connector NO To electric

(CN-256F) of lever lock solenoid (SV-4). troubleshooting
YES Is the main relief valve
Only the hydraulic pilot system NO pressure within a standard NO Pilot relief valve NO
(ATT and travel motion) not value? pressure is about Replace relief valve.
operative? [P1,P2 : 29.4MPa (4270psi)] 3.43MPa (500psi).
[P3 : 19.6MPa (2840psi)] Inspect or replace pump.
YES YES
YES Also inspect pump
coupling.

Inspect if there is any other cause.

NO
The primary pressure of pilot pump is about 3.43MPa (500psi). Inspect or replace pilot pump and pilot relief valve.

YES
NO
The pilot valve P port inlet pressure is approx. 3.43MPa (500psi). Inspect or replace safety lock lever solenoid valve.

YES
NO
The secondary pressure of pilot valve is approx. 3.43MPa (500psi). Inspect or replace pilot valve.

(1)-2
Machine moves unexpectedly with levers in neutral.

Machine stops moving unexpectedly if the connector (CN-253F) for YES To electrical
proportional valve P1 bypass cut is disconnected. troubleshooting
NO
Pump NO The secondary pilot pressure of the system that is YES
Inspect or replace pilot
delivery moving unexpectedly is generated when the lever is
valve.
pressure in in neutral.
unloaded NO
condition is YES
approx. The spool returning spring of the circuit that is Inspect or replace spool
1.96MPa moving unexpectedly is broken. assy and pilot cover.
(280psi). NO
NO The outer YES
The spool of the system that is operating unexpectedly
YES moves smoothly by hand. (Remove pilot cover.)
circumference of Replace spool assy.
spool is scratched.
NG
NO
YES Replace control valve

Pilot pressure at ports Pb4, Pd4 (P1, P2 bypass YES Inspect or replace the proportional valve for bypass
cut valve) is approx. 0.54MPa (78psi). cut valve that is defective.
NO NG
Inspect or replace proportional valve block.

YES Inspect or replace bypass cut valve spool assy and

Return spring of bypass cut valve spool is broken.
pilot cover.
NO
Bypass cut valve spool moves smoothly by hand. NO Spool is scored YES Replace bypass cut valve
(together with P1 and P2 bypass cut valves) on inspection. spool assy.
YES NO NG
Replace control valve.

Replace control valve.

Boom or YES Inspect or replace overload relief valve. Inspect lock

arm? valve parts and replace if faulty.
NO
YES
Spool of the circuit that operates unexpectedly is scored on. Replace spool assy.

NO Inspect or replace Inspect the cylinder of the circuit that Inspect or replace control
overload relief valve. operates unexpectedly and replace if faulty. valve.
(Inside leak)

42-6
 42. TROUBLESHOOTING (HYDRAULIC SYSTEM)

(2)-1
All attachment motions are slow.

Do motions get normal if the coupler for YES

tralve straight proportional valve is To electric troubleshooting.
disconnected?
NO
NO Inspect or replace pilot
Primary pilot pressure is 3.43MPa (500psi).
pump and pilot relief valve.
YES
Secondary pilot pressure at PO port (travel YES Inspect or replace travel
straight) is approx. 0.54MPa (78psi). straight proportional valve.
NO NG
Inspect or replace
proportional valve block.

NO Inspect or replace travel

Return spring of travel straight spool is
straight spool assy and pilot
broken.
cover.
YES
NO Outer circumference of YES
Travel straight spool moves smoothly by Replace travel straight spool
travel straight spool is
hand. (Remove the pilot cover.) assy.
scored.
YES NG
NO
Replace control valve.

Main relief pressure is approx. 29.4MPa NO Inspect or replace main NG Replace control valve or
(4270psi) relief valve. pump.
YES

(2)-2
Only the bucket motion is slow.

Is the motion normal if connector (CN-254F) YES

To electrical troubleshooting.
for proportional P2 bypass cut is disconnected?
NO
Secondary pilot pressure at Pa3, Pb3 ports (bucket NO Inspect or replace pilot
close and open ports) is 3.43MPa (500psi). valve.
YES
Inspect overload relief valve
Relief pressure that selects bucket is approx. NO Relief pressures for both YES on the faulty pressure side
29.4MPa (4270psi). Check the pressure for bucket close and open are
and replace valve if
bucket close and open as well. not at 29.4MPa (4270psi).
defective.
YES NO Confirm the check valve
before relief valve for NG
Replace control valve.
control valve. Check the
seat of it as well.
YES
Return spring for bucket spool is broken. Replace bucket spool assy.

NO
Bucket spool moves smoothly by hand. NO Outer circumference of YES
Replace bucket spool assy.
(Remove pilot cover.) bucket spool is scored.
NO NG
YES
Replace control valve.

Is the motion slow if coupler for travel NO To electric troubleshooting.

straight proportional valve is disconnected? (to "All motions are slow.")
YES
Pilot pressure at port PO (travel straight) is NO Inspect or replace travel
approx. 0.54MPa (78psi). straight proportional valve.
YES NG
Inspect or replace
Return spring for travel straight spool is
proportional valve block.
broken.
NO YES
Inspect travel straight spool
assy and pilot cover and
Continued to next page.
replace them if faulty.

42-7
42. TROUBLESHOOTING (HYDRAULIC SYSTEM)

Continued from previous page.

NO
NO Outer circumference of YES
Travel straight spool moves smoothly by Replace travel straight spool
travel straight spool is
hand. assy.
scored.
YES NG
NO
Replace control valve.

Is the motion slow if pump delivery ports P1 NO

Inspect or replace pump.
and P2 are exchanged.
YES
Replace control valve.

Inspect bucket cylinder for

oil tightness and replace it.

(2)-3 Diagnosis 29 ; mechatronic (C-1) controller service diagnosis 29

Only the boom raise motion is slow.
(Diagnosis 29)
Control current of P2 bypass cut proportional NO
valve is approx. 700mA when full lever To electric troubleshooting.
operation is performed for boom raise motion.
YES
Secondary pilot pressure at port Pc4 (P2 NO Inspect or replace P2 bypass NG Inspect or replace
bypass cut valve) is approx. 2.55MPa (370psi). cut proportionate valve. proportional valve block.
YES
Pilot pressure at Pa2, Pd4 ports (boom raise NO Inspect or replace ATT pilot
and boom conflux) is approx. 3.43MPa
valve.
(500psi).
YES
Relief pressure is approx. 29.4MPa (4270psi) NO NG
Check boom port relief Replace overload relief valve
when full lever operation is performed for
pressure. at port A2 (boom head side).
boom up motion.
YES
YES Inspect or replace P2 bypass
Return spring for P2 bypass cut valve spool is
cut spool assy and pilot
broken.
cover.
NO
NO Outer circumference of P2 YES
P2 bypass cut valve spool moves smoothly by Replace P2 bypass cut spool
bypass cut valve spool is
hand. (Remove pilot cover.) assy.
scored.
YES NG
NO
Replace control valve.

Return spring of boom spool is broken. YES Inspect or replace boom

(Remove pilot cover.) spool assy and pilot cover.
NO
Boom spool moves smoothly by hand. NO Outer circumference of YES
Replace boom spool assy.
(Remove pilot cover.) boom spool is scored.
YES NO NG
Replace control valve.

Return spring for boom conflux spool is YES Inspect or replace boom
broken. spool assy and Pilot cover.
NO
NO Outer circumference of YES Replace boom conflux spool
Boom conflux spool moves smoothly by hand.
boom conflux spool is scored. assy.
YES NG
NO
Replace control valve.

Replace control valve.

42-8
 42. TROUBLESHOOTING (HYDRAULIC SYSTEM)

(2)-4
Motions other than boom up, arm in and out are slow.
(Diagnosis 30)
Control current for travel straight
proportional valve is approx. 315mA. NO
To electric troubleshooting
(Are the motions slow if coupler for travel
straight proportional valve is disconnected?)
YES
Pilot pressure at port PO (travel straight) is YES Inspect or replace travel NG Inspect or replace
approx. 0.54MPa (78psi). straight proportional valve. proportional valve block.

NO
YES Inspect or replace travel
Return spring for travel straight spool is broken. straight spool assy and pilot
cover.
NO
NO Outer circumference of YES Replace travel straight spool
Travel straight spool moves smoothly by
travel straight spool is assy.
hand. (Remove pilot cover.)
scored.
YES
NO Replace control vlave.

Replace control valve.

(2)-5
Only arm digging action is slow.

(Diagnosis 26)
Command current for P1 bypass cut NO
proportional valve is approx. 700mA when To electric troubleshooting.
boom raise lever is shifted to the full.
YES
Secondary pressure of P1 bypass cut
proportional valve at port Pb4 (P1 bypass
NO Inspect or replace P1 bypass NG Inspect or replace
cut proportional valve. proportional valve block.
cut) is approx. 2.55MPa (370psi).
YES
Secondary pilot pressure at Pc3, Pc3' ports NO Inspect or replace pilot
(arm in, lock valve release) is approx.
valve.
3.43MPa (500psi).
YES
NO Inspect or replace overload
Relief pressure is approx. 29.4MPa (4270psi)
relief valve at port C3 (arm
when arm in lever is shifted to the full.
head side).
YES
YES Inspect or replace arm spool
Arm spool return spring is broken.
assy and pilot cover.
NO
Arm spool moves smoothly by hand. NO Outer circumference of arm YES
Replace arm spool assy.
(Remove pilot cover.) spool is scored.
NO NG
YES
Replace control valve.

Replace control valve.

(2)-6
only arm out operation is slow.

(Diagnosis 26)
Command current for P1 bypass cut proportional NO
valve is approx. 700mA when arm out lever is To electrical troubleshooting.
shifted to the full.
YES
Secondary pilot pressure at port Pb4 (P1 NO Inspect or replace P1 bypass NG Inspect or replace
bypass cut valve) is approx. 2.55MPa (370psi). cut proportional valve. proportional valve block
YES
Secondary pilot pressure at port Pd3 (arm out) NO
Inspect or replace pilot valve.
is approx. 3.43MPa (500psi) or over.
YES
Continued to next page.

42-9
42. TROUBLESHOOTING (HYDRAULIC SYSTEM)

Continued from previous page.

YES
Relief pressure is approx. 29.4MPa (4270psi) NO Inspect or replace overload relief
when arm out lever is shifted to the full. valve at port D3 (arm rod side).
YES
YES Inspect or replace arm spool
Arm spool return spring is broken. assy and pilot cover.
NO
Arm spool moves smoothly by hand. NO Outer circumference of arm YES
Replace arm spool assy.
(Remove pilot cover.) spool is scored.
YES NO NG
Replace control valve.

Replace control valve.

(2)-7
Only boom swing action is slow.
YES
Secondary pilot pressure at Pa5, Pb5, Pb5´ NO
Inspect or replace pilot valve.
ports is approx.3.43MPa (500psi)
YES
NO Inspect or replace overload
Relief pressure is approx.29.4MPa n(4270psi) relief valve at port A5
when boom swing lever is shifted to the full. (boom swing head side).
YES
Boom swing spool return spring is broken. YES Inspect or replace boom swing
spool assy and pilot cover.
NO
Boom swing spool moves smoothly by hand. NO Outer circumference of arm YES Replace boom swing spool
(Remove pilot cover) spool is scored. assy.
YES NO NG
Replace control valve.

Replace control valve.

(3)-1
All ATT operating power is poor.

Each independent operating speed is within a NO Refer to "All motions are

standard value. slow.".
YES
Relief pressures of P1, P2 pumps are approx. NO Check main relief pressure NG Replace the relief valve of
29.4MPa (4270psi). of control valve. main control valve.
YES
Primary pilot pressure is approx. 3.43MPa NO Replace pilot pump and
Check pilot relief pressure.
(500psi). relief valve.
YES
Inspect or replace travel
Travel straight spool return spring is broken. YES straight spool assy and pilot
cover.
NO
NO Outer circumference of YES
Travel straight spool moves smoothly by Replace travel straight spool
travel straight spool is
hand. (Remove pilot cover.) assy.
scored.
YES NG
NO
Replace control valve.

Inspect or replace control

valve or pump.

42-10
 42. TROUBLESHOOTING (HYDRAULIC SYSTEM)

(3)-2
Bucket close (digging) power is poor.

No-load independent operating speed is within NO Refer to "Only bucket

a standard value. motion is slow."
YES
NO NG Replace overload relief valve
Relief pressure is approx. 29.4MPa (4270psi) Check overload relief valve
at port A3 (bucket head
when bucket close lever is shifted to the full. on bucket close side.
side).
YES
Secondary pilot pressureat port Pa3 (bucket NO Inspect or replace pilot
close) is approx. 3.43MPa (500psi). valve.
YES
YES Inspect or replace bucket
Bucket spool return spring is broken. spool assy and pilot cover.
NO
Bucket spool moves smoothly by hand. NO Outer circumference of YES
Replace bucket spool assy.
(Remove pilot cover.) bucket spool is scored.
YES NO NG
Replace control valve.

Replace control valve or

pump.

(3)-3
Boom up (raise) operating power is poor.

No-load independent operating speed is within NO Refer to "Only boom raise

a standard value. motion is slow."
YES
Relief pressure of both P1 and P2 pumps is NO Inspect or replace overload
approx. 29.4MPa (4270psi) when boom raise relief valve at port A2
lever is shifted to the full. (boom head side).
YES
Secondary pilot pressure at port Pa2 (boom NO Inspect or replace pilot
raise) is approx. 3.43MPa (500psi). valve.
YES
YES Inspect or replace boom
Boom spool return spring is broken. spool assy and pilot cover.
NO
Boom spool moves smoothly by hand. NO Outer circumference of YES
Replace boom spool assy.
(Remove pilot cover) boom spool is scored.
YES NO NG
Replace control valve.

Inspect or replace control

valve or pump.

42-11
42. TROUBLESHOOTING (HYDRAULIC SYSTEM)

(3)-4
Arm in power is poor.

No-load independent operating speed is within NO Refer to "Only arm in is

a standard value. slow.".
YES
Relief pressure of both P1 and P2 pumps is NO NG Replace overload relief valve
Check overload relief
approx. 29.4MPa (4270psi) when arm in at port C2 (on arm head
pressure on arm head side.
lever is shifted to the full. side).
YES
Secondary pilot pressure at ports Pc3 and
PC3' (arm in and lock valve release) is
NO Inspect or replace pilot
approx. 3.43MPa (500psi). valve.

YES
Arm spool return spring is broken.
YES Inspect or replace arm spool
assy and pilot cover.
NO
Arm spool moves smoothly by hand. NO Outer circumference of arm YES
(Remove pilot cover.) Replace arm spool assy.
spool is scored.
YES NO NG
Replace control valve.

Replace control valve or

pump.

(3)-5
Boom swing power is poor.

No-load independent operating speed is within NO Refer to "Only arm in is

a standard value. slow."
YES
Relief pressure of P1 pump is approx. 29.4MPa NO Replace overload relief valve
Check overload relief
(4270psi) when boom swing lever is shifted to at port A5
pressure.
the full. (On boom swing side).
YES
Primary pilot pressure is approx. NO Replace pilot pump and relief
Check pilot relief pressure.
3.43MPa (500psi). valve.
YES
YES Inspect or replace boom swing
Boom swing spool return spring is broken. spool assy and pilot cover.
NO
Boom swing spool moves smoothly by hand. NO Outer circumference of YES Replace boom swing spool
(Remove pilot cover) boom spool is scored. assy.
YES NO NG
Replace control valve.

Replace control valve or

pump.

42-12
 42. TROUBLESHOOTING (HYDRAULIC SYSTEM)

(4)-1
Machine can not perform fine operation of bucket close and open.

Machine returns normal if connector of P1 bypass cut YES

To electric troubleshooting.
proportional valve (PSV-D) is disconnected.
NO
Unload pressure of P1 NO No-load independent operating NO Refer to "Only bucket
pump is less than speed is within a standard
motion is slow.".
1.96MPa (280psi) when value.
bucket close lever is at
neutral. YES
Secondary pilot pressure at
YES Inspect or replace P1 NG
port Pb4 (P1 bypass cut valve) YES Inspect or replace
bypass cut
is approx. 0.54MPa (78psi) proportional valve block.
proportional valve.
when lever is at neutral.
NO
YES Inspect or replace P1 bypass
P1 bypass cut spool return cut spool assy and pilot
spring is broken. cover.
NO
P1 bypass cut spool moves NO Outer circumference of YES Replace P1 bypass cut spool
smoothly by hand. (remove P1 bypass cut spool is
assy.
pilot cover.) scored.
NG
YES NO
Replace control valve.
Secondary pressure of pilot
valve is approx. 0.54MPa Replace control valve.
(78psi) when bucket close
lever is just shifted a YES Inspect or replace pilot
little. valve.
NO
Pilot spool return spring is YES Inspect or replace bucket
broken. spool assy or pilot cover.
NO
Bucket spool moves NO Outer circumference of bucket YES
Replace bucket spool assy.
smoothly by hand. spool is scored.
(Remove pilot cover.) NG
NO
YES Replace control valve.

Replace control valve.

42-13
42. TROUBLESHOOTING (HYDRAULIC SYSTEM)

(4)-2
Machine can not perform fine operation of boom raise and lower motions.

Machine gets normal if connector of P1 bypass cut proportional YES To electrical

valve (PSV-D) is disconnected. troubleshooting.
NO
Unload pressure of P1
pump is less than NO Secondary pilot pressure at YES Inspect or replace NG Inspect or replace
port Pb4 (P1 bypass cut valve) proportional valve for
1.96MPa (280psi) when proportional valve block.
is approx. 0.54MPa (78psi). P1 bypass cut valve.
boom lever is at neutral.

YES NO
YES Inspect or replace P1 bypass
Return spring or P1 bypass
cut spool assy and pilot
cut spool is broken.
cover.
NO Outer circumference of Replace P1 bypass cut spool
P1 bypass cut spool moves NO P1 bypass cut spool is YES assy.
smoothly by hand. scored.
NG
YES NO
Replace control valve.

Replace control valve.

Secondary boom pilot pressure is approx. YES Inspect or replace pilot

0.54MPa (78psi) when lever is just shifted. valve.
NO
YES Inspect or replace boom
Return spring of boom spool is broken.
spool assy and pilot cover.
NO
Boom spool moves NO Outer circumference of boom YES
Replace boom spool assy.
smoothly by hand. spool is scored.
YES NO NG
Replace control valve.

Does boom lock valve NO Inspect or replace lock

move smoothly by hand? valve.
YES Replace control valve.

(4)-3
Machine can not perform fine slewing operation.

Machine gets normal if connector of P2 bypass cut proportional YES To electrical

valve (PSV-B) is disconnected. troubleshooting.
NO
Machine gets normal if connector for slewing parking brake YES
To electrical troubleshooting.
solenoid (SV-1) is disconnected.
NO
Secondary pressure of slewing pilot valve is approx. 0.59MPa YES Inspect or replace NG Inspect or replace
(85psi), while pilot pressure of parking brake soleonid valve is swing parking solenoid
proportional valve block.
0MPa (0psi). valve.
NO
Unload pressure of P2 Pilot pressure of port Pd4 (P2
pump is approx. 1.96MPa NO bypass cut valve) is approx. YES Inspect or replace NG Inspect or replace
proportional valve for
(280psi) or less when 0.54MPa (78psi) when slewing proportional valve block.
P2 bypass cut valve.
slewing lever is at neutral. lever is at neutral.
YES NO
Return spring for P2 bypass YES Inspect or replace P2 bypass
cut spool is broken. cut spool and pilot cover.
NO
P2 bypass cut spool moves NO Outer circumference of YES
Replace P2 bypass cut spool
smoothly by hand. (Remove P2 bypass cut spool is
assy.
pilot cover.) scored.
NG
YES NO
Replace control valve.

Continued to next page. Replace control valve.

42-14
 42. TROUBLESHOOTING (HYDRAULIC SYSTEM)

Continued from previous page.

Secondary pilot pressure of parking brake solenoid valve is NO Inspect or replace slewing
0MPa (0psi) when secondary pressure of pilot valve is
parking solenoid valve.
approx. 0.59MPa (85psi).
NG
YES
Inspect or replace
proportional valve block.
Secondary pressure of pilot
valve at start up is approx. NO Inspect or replace pilot
0.54MPa (78psi). valve.
YES
NO Inspect or replace slewing
Fine operation is possible
pilot shuttle valve of control
if Pd2´ port is plugged.
valve.
YES
Return spring for slewing YES
Replace slewing spool assy.
spool is broken.
NO
Slewing spool moves NO Outer circumference of slewing YES
Replace slewing spool assy.
smoothly by hand. spool is scored.
YES NO NG
Replace control valve.

Replace control valve.

(4)-4
Machine can not perform fine operation of arm in and out.

Machine gets normal if connector of P2 bypass cut proportional YES

To electrical troubleshooting
valve (PSV-B) is disconnected.
NO
P2 pump unload pressure NO Secondary pilot pressure at YES Inspect or replace NG Inspect or replace
is less than 1.96MPa port Pd4 (P2 bypass cut valve) proportional valve for
proportional valve block.
(280psi) when arm lever is is approx. 0.54MPa (78psi). P2 bypass cut valve.
at neutral.
NO
YES YES Inspect or replace P2 bypass
Return spring of P2 bypass
cut spool assy and pilot
cut spool is broken.
cover.
NO
P2 bypass cut spool moves NO Outer circumference of YES
Replace P2 bypass cut spool
smoothly by hand. P2 bypass cut spool is
assy.
(Remove pilot cover.) scored.
NG
YES NO
Replace control valve.

Secondary pressure is Replace control valve.

approx. 0.54MPa (78psi)
when arm lever is shifted YES Inspect or replace pilot
a little. valve.
NO
Return spring of arm spool YES
Replace arm spool assy.
is broken.
NO
Arm spool moves smoothly NO Outer circumference of arm YES
Replace arm spool assy.
by hand. spool is scored.
YES NO NG
Replace control valve.

Arm lock valve moves NO Inspect or replace lock

smoothly by hand. valve.
YES
Piston in slewing Confirm piston movement by disconnecting NO Inspect or replace slewing
priority block connector at port Pc3' and pushing piston
priority block parts.
moves smoothly. through the port hole, using a rod.
YES
Replace control valve.

42-15
42. TROUBLESHOOTING (HYDRAULIC SYSTEM)

(5)
Travel 1st and 2nd speeds can not be changed over.

24V is alive across light green/black and NO

black of connector for travel 1-2 speed To electrical troubleshooting
soleonid (SV-3).
YES
Pilot pressure of travel 1-2 speed select NO Inspect or replace travel 1-2 NG Inspect or replace
solenoid (SV-3) is approx. 3.43MPa (500psi). speed select solenoid valve. proportional valve block.
YES
Travel 1-2 speed select can not be done in NO Inspect travel motor (orifice in passage to 1-2 select valve, inclusion
heavy duty condition on a slope or on a muddy
of foreign matter in shuttle valve, etc.) or replace it.
land.
Since the delivery rate of pump is small at heavy duty, the difference
YES between 1 and 2 speeds gets smaller. This makes you feel sometimes
that speed is not changed. But this is normal.

(6)
Travel independent speed is low.

Are both travel speeds low? NO

(H-mode, Hi idle, 1-speed, sprocket Refer to "Travel deviates."
revolution ; 33rpm)
YES (Diagnosis 30)
Command current of proportional
valve is approx. 315mA. (Is the speed NO To electrical
low if coupler of travel straight troubleshooting.
proportional valve is disconnected?)
YES
Secondary pressure for NO Inspect or replace travel
travel remote control is
remote control valve.
approx. 2.35MPa (340psi).
YES
NO Secondary pilot pressure at YES Inspect or replace NG Inspect or replace
Is the pivot turn possible?
port PO (travel straight valve) travel straight
(in both directions) proportional valve block.
is approx. 2.55MPa (370psi). proportional valve.
YES
NO
YES Inspect or replace travel
Return spring of travel
straight spool assy and pilot
straight spool is broken.
cover.
NO
Travel straight spool moves NO Outer circumference of YES Replace travel straight spool
travel straight spool is
smoothly by hand. assy.
scored.
YES NG
NO
Replace control valve.

Replace control valve.

Return spring of travel YES Inspect or replace travel

spool is broken. spool assy and pilot cover.
NO
Travel spool moves NO Outer circumference of travel YES
Replace travel spool assy.
smoothly. spool is scored.
YES NO NG
Replace control valve.
Relief pressure in all NO
travel motions is approx. Inspect or replace travel
29.4MPa (4270psi). motor relief valve.

YES Inspect or replace travel

motor.

42-16
 42. TROUBLESHOOTING (HYDRAULIC SYSTEM)

(7)
Travel power is poor.

(Diagnosis 30)
Command current for travel straight NO To electrical
proportional valve is approx. 315mA. troubleshooting.
YES
Power lack is felt on a slope YES Inspect or replace travel
or in muddy fields. power boost SOL.
NO NG
NG Since the delivery rate of pump is small and travel
Replace pump power boost
speed is low in heavy duty condition, power lack
regulator inspect or replace it.
is felt in some cases, but it is normal.

The value of travle RH/LH NO Abnormality removed after YES Travel RH/LH pressure
pressure sensor (SE9 or replacing travel RH/LH pressure
sensor error.
SE10) is 4.0V or more at sensor (SE9 or SE10).
full lever condition. NO
YES The value of travle RH/LH pilot YES Inspect harness between
pressure is 2.35MPa (340psi) or travel RH/LH pressure
more at full lever condition. sensor and C1 controller.
NO
Inspect travel pilot valve.

Is the secondary pilot NO Inspect or replace travel

pressure for travel approx.
pilot valve.
2.35MPa (340psi)?
YES
Is a pivot turn possible? NO Pilot pressure at port PO NO Inspect or replace NG Inspect or replace travel
(travel straight valve) is travel straight
(in both directions) pilot valve.
approx. 0.54MPa (78psi). proportional valve.
YES
YES
YES Inspect or replace travel
Return spring of travel
straight spool assy and pilot
straight spool is broken.
cover.
NO
Travel straight spool moves NO Outer circumference of YES Replace travel straight spool
travel straight spool is
smoothly by hand. assy.
scored.
YES NG
NO
Replace control valve.

Replace control valve.

Return spring of travel YES Inspect or replace travel

spool is broken. straight spool and pilot
cover.
NO
Travel spool moves NO Outer circumference of travel YES
Replace travel spool assy.
smoothly by hand. spool is scored.
YES NO NG
Relief pressure is approx. Replace control valve.
29.4MPa (4270psi) when
travel lever is turned to NO Inspect or replace travel
the full. motor relief valve.
YES Inspect or replace travel
motor.

42-17
42. TROUBLESHOOTING (HYDRAULIC SYSTEM)

(8)-1
Machine does not travel straight.

Feed current for travel NO

straight proportional To electrical troubleshooting
valve (PSV-C) is 700mA.
YES
Secondary pilot pressure
at port PO (travel straight NO Secondary pressure of travel YES Inspect or replace travel
pilot valve is approx.
valve) is approx. 2.55MPa pilot valve.
2.35MPa (340psi).
(370psi).
NO Inspect or replace NG Inspect or replace
YES travel straight
proportional valve block.
proportional valve.
YES Inspect or replace travel
Return spring of travel
straight spool assy and pilot
straight spool is broken.
cover.
NO
Travel straight spool NO Outer circumference of travel YES Replace travel straight spool
moves smoothly by hand. straight spool is scored. assy.
YES NO NG
Replace control valve.

Replace control valve.

(8)-2
Machine deviates in single travel independent motion.

Does the travel deviates

In idle run, machine runs to the right and the NO in opposite direction if NO Inspect or replace control
left at different speeds. (H-mode, Hi idle, delivery ports are
valve.
1-speed, and sprocket rotation : 33rpm) exchanged?
YES YES
Inspect or replace pump.
Is the secondary pilot pressure for travel NO Inspect or replace travel
motions normal in both the right and the left
remote control valve.
directions? It is approx. 2.35MPa (340psi).
YES
Does the machine deviates if the right and NO Relief pressure in right and NO Inspect or replace travel
left pipes between control valve and motor are left travel motions is
motor rilief valve.
exchanged? approx. 29.4MPa (4270psi).
YES YES Inspect or replace travel
motor.
YES Inspect or replace travel
Return spring of travel spool is broken.
spool assy and pilot cover.
NO
NO Outer circumference of NO
Travel spool moves smoothly by hand. Replace travel spool assy.
travel spool is scored.
YES YES Replace control valve.

Confirm check valve and seat located before NO

Replace control valve.
the relief valve of control valve.
YES
Replace control valve.

42-18
 42. TROUBLESHOOTING (HYDRAULIC SYSTEM)

(9)
Machine drifts on a slope. (Machine can not be held on a slope.)

Machine can not be held on a slope when YES Inspect or replace travel
engine is off. motor.
NO
Secondary pilot pressure for travel is 0MPa NO Inspect or replace remote
(0psi). control valve.
YES
YES Inspect or replace travel
Return spring of travel spool is broken.
spool assy and pilot cover.
NO
NO Outer circumference of NO
Travel spool moves smoothly by hand. Replace travel spool.
travel spool is scored.
YES YES NG
Replace control valve.

Replace control valve.

42-19
42. TROUBLESHOOTING (HYDRAULIC SYSTEM)

(11)
Slewing speed is low.

Feedback current of P2 bypass cut NO

proportional valve (PSV-B) is 700mA when To electrical troubleshooting
slewing lever is turned to the full.
YES
Secondary pilot pressure at Pd4 port (P2 NO Inspect or replace P2 bypass NG Inspect or replace
bypass cut valve) is approx. 2.55MPa (370psi)
cut proportional valve. proportional valve block.
when slewing lever is shifted to the full.
YES
YES Inspect or replace P2 bypass
Return spring of P2 bypass cut spool is
cut spool assy and pilot
broken.
cover.
NO
NO Outer circumference of P2 YES Replace P2 bypass cut spool
P2 bypass cut spool moves smoothly by hand.
bypass cut spool is scored. assy.
YES NO NG
Replace control valve.

In case of a machine with a

multi control valve, check if the
condition returns normal by
moving back and forth with
slewing lever.

Secondary pilot pressure for slewing motion is NO Inspect or replace pilot

approx. 3.43MPa (500psi) when lever is
valve.
turned to the full in either direction.
YES Inspect or replace slewing
pilot shuttle valve of control
valve.

Slewing relief pressure is approx. 24.5MPa NO Inspect or replace slewing

(3560psi). motor relief.
YES NG

Machine drifts very much when slewing YES Inspect or replace slewing
parking is released (arm in action) on a slope. motor.
NO
YES Inspect or replace slewing
Return spring of slewing spool is broken.
spool assy and pilot cover.
NO
NO Outer circumference of YES
Slewing spool moves smoothly. Replace slewing spool assy.
swing spool is scored.
YES NO NG
Replace control valve.

Replace control valve.

42-20
 43. TROUBLESHOOTING
(ELECTRIC)
TABLE OF CONTENTS

43.1 TROUBLE DIAGNOSIS TABLE : ELECTRIC .................................................................... 43-3

43.2 CONTROLLER ERROR CODE DISPLAY .......................................................................... 43-7
43.3 SERVICE DIAGNOSIS ....................................................................................................... 43-8

43

43-1
43. TROUBLESHOOTING (ELECTRIC)

43-2
 43. TROUBLESHOOTING (ELECTRIC)

43.1 TROUBLE DIAGNOSIS TABLE : ELECTRIC

43-3
43. TROUBLESHOOTING (ELECTRIC)

43-4
 43. TROUBLESHOOTING (ELECTRIC)

43-5
43. TROUBLESHOOTING (ELECTRIC)

43-6
 43. TROUBLESHOOTING (ELECTRIC)

43.2 CONTROLLER ERROR CODE DISPLAY

When the hard check switch of the controller is set to "00" (The machine is tuned to "00" at shipment.), faults of de-
vices and harnesses connected to them are listed as below. When an error code is displayed, the CPU lamp on the
gauge cluster flickers and the buzzer blows intermittently. In some cases, the CPU lamp on the gauge cluster lights
continuously and the buzzer sounds continuously. This is to indicate a fault on the controller itself.

1. Trouble diagnosis
Error Error
Trouble diagnosis item Corrective action Trouble diagnosis item Corrective action
code code
E01 EEPROM data faulty Readjust engine speed or E16 Battery relay faulty Replace battery relay or
E02 Mechatronic adjustment faulty replace controller inspect harness between
E03 Fault on boom raise pressure sensor battery relay and controller.
E04 Fault on boom lower pressure sensor E17 Fault on P1 by-pass cut proportional valve Replace proportional valve
E05 Fault on arm in pressure sensor E18 Fault on P2 by-pass cut proportional valve or inspect harness between
E06 Fault on arm out pressure sensor E19 Fault on travel straight proportional valve proportional valve and controller.
E07 Fault on bucket digging pressure sensor Replace sensor or inspect E20 Fault on governor motor current Replace governor motor or
E08 Fault on bucket dump pressure sensor harness between sensor E21 Fault on governor motor inspect harness between
E09 Fault on slewing pressure sensor and controller. starting point governor motor and controller.
E10 Fault on P3 pump pressure sensor E22 Reverse rotation of engine Replace engine hydraulic
switch or inspect harness
E11 Fault on travel right pressure sensor
between engine oil switch
E12 Fault on travel left pressure sensor and controller.
E13 Accel dial faulty pressure sensor
E14 Fault on travel boost-up solenoid valve Replace selector valve or
inspect harness between
E15 Fault on slewing parking selector valve and
selector valve controller.

SERVICE DIAGNOSIS DISPLAY

HARDWARE CHECK SW A
Remove grommet,
and the right Hardware check SW (The left shows the
switches are "0.0" setting condition.)
appear. Turn the arrow at the center of switch
and set it to numeric value.
Insert precision driver (-) in to convex
indicated by arrow and turn the arrow to
set to numeric values.
INTERNAL ADJUSTMENT JP SW
HARDWARE CHECK SW B

43-7
43. TROUBLESHOOTING (ELECTRIC)

43.3 SERVICE DIAGNOSIS

The following items are displayed if the hard ware check switch located in the controller is changed over. Since the
hard ware check switch is tuned to "00" at shipment, error codes are displayed.

Hardware
check SW Service diagnosis item Contents of display Normal value
A B
0 0 Normal (no service diagnosis) Trouble diagnosis (error code)
0 1 A set value of engine rpm Displayed in 3 digits by 10 rpm. [230] at 2300 rpm. 1020~2250
0 2 An actual engine rpm Displayed in 3 digits by 10 rpm. [230] at 2300 rpm. Approx. 1020 to
approx. 2250
0 3 Key switch input / battery relay out put Statuses of key switch on 10th digit (ON [1] / OFF [0] ), and
battery relay on the 1st digit (ON [1] / OFF [0] ) are displayed.
0 4 Mode switch / option switch input Mode switch on the 10th digit ( [H] [S] [FC] ). Status of option switch on
the 1st digit (ON [0] / OFF [1] ) is displayed.
0 5 Wiper switch / washer switch / work light The following statuses are displayed ; wiper SW on the 100th digit
swich (push [1] / [OFF] [0] ), washer SW on the 10th digit (push [1] /
[OFF] [0] ), work lamp SW on the 1st digit (push [1] / OFF [0] ).
0 6 Voltage of accel dial Displayed in whole numbers to the 2nd decimal points. 0.4~4.6
0 7 Accel dial position Governor motor position converted from accel dial voltage is displayed in per cents. 0~100
0 8 Step number of governor motor Present step number of governor motor is displayed in three whole numbers. 0~630
0 9 Governor motor position What percent in position the present step number is between low 0~100
idle and high idle is displayed.
1 0 A-phase current of governor motor Displayed in whole numbers to the 2nd decimal points. 2.34A is Approx. 150
1 1 B-phase current of governor motor displayed in [234] .
1 2 Governor motor limit switch Status of governor motor limit switch on the 1st digit (ON [1] /
OFF [0] ) is displayed.
1 3 Boom raise pressure sensor Displayed in whole numbers to the 2nd decimal points. 2.34V is 0.4~5.0
1 4 Boom down pressure sensor displayed in [234] .
1 5 Arm out pressure sensor
1 6 Arm in pressure sensor
1 7 Bucket digging pressure sensor
1 8 Bucket dump pressure sensor
1 9 Slewing pressure sensor
2 0 P3 pump pressure sensor
2 1 Travel right pressure sensor
2 2 Travel left pressure sensor
2 3 Travel boost-up selector valve Statuses of travel 1-2 speed SW. in the 100th digit (push [1] / OFF
output command / feedback [0] ), output command in the 10th digit (ON [1] / OFF [0] ), and
feedback in the 1st digit (ON [1] / OFF [0] ) are displayed.
2 4 Output command of slewing parking Statuses of output command on the 10th digit (ON [1] / OFF [0] ),
selector valve / feedback and feedback on the 1st digit (ON [1] / OFF [0] ) are displayed.
2 5 Battery relay output command / feedback
2 6 Command current for P1 bypass cut proportional valve Current is displayed in mA. 280~760
2 7 Feedback current of P1 bypass cut proportional valve
2 8 Command current of P2 bypass cut proportional valve
2 9 Feedback current of P2 bypass cut proportional valve
3 0 Command current of travel straight proportional valve
3 1 Feedback current of tralve straight valve
3 2 Buzzer stop sw. / slewing flasher select SW. Statuses of buzzer stop (ON [1] / OFF [0] ), slewing flasher select
SW. on the 1st digit (ON [1] / OFF [0] ) are displayed.
Travel alarm relay / wiper motor relay / Status of on the 100th digit (OFF [0] ), on the 10th digit
3 3 slewing flasher relay command (OFF [0] ), and on the 1st digit (OFF [0] ) are displayed.

CPU trouble lamp command Statuses of washer motor relay command on the 100th digit (ON [1]
/ OFF [0] ), work light relay command on the 10th digit (ON [1] /
3 4
OFF [0] ), CPU trouble lamp command on the 1st digit (ON [1] /
OFF [0] ) are displayed.
3 5 Slewing flasher relay / lever lock SW. Statuses of slewing flasher relay on the 10th digit (ON [1] /
operating input OFF [0] ), and lever lock SW. input command on the 1st
digit (ON [1] / OFF [0] ) are displayed
Status of internal adjust switch on the 1st digit (TEST [1] / RUN
3 6 Internal adjust switch
[0] ) is displayed.

43-8
 43. TROUBLESHOOTING (ELECTRIC)

(1)-1
No motions operate.

Lever stand down

(Unlocked position)
24V is alive across
orange/white and black YES To hydraulic
of connector (CN-256F) troubleshooting
for lever lock solenoid.
NO

24V is alive across Harness between lever

orange/white of connector YES lock switch (SW-11) and YES
Inspect harness.
(CN-66F) for lever lock lever lock solenoid (SV-4)
switch (SW-11). is disconnected.
NO

Lever lock switch (SW-11) YES

Replace switch (SW-11).
is faulty.

24V is alive across white/

black of connector YES
(CN-66F) for lever lock
switch (SW-11).
NO Lever lock switch (SW-11) YES
Adjust and mount.
is attached improperly.

24V is alive across white/ YES Harness between fuse YES

black of connector box and lever lock switch Inspect harness.
(CN-14M) on fuse box. (SW-11) is disconnected.
NO

YES YES Inspect the shorted point

Fuse No.15 is blown. Harness shorted to frame.
of harness.
NO

Inspect if there is no
disconnection in fuse box.

43-9
43. TROUBLESHOOTING (ELECTRIC)

(1)-2
Machine moves unexpectedly when lever is at neutral.

(Hard check SW00) ; Error code E17 is indicated at this time.

Machine moves not unexpectedly when NO To hydraulic
connector (CN-253F) for P1 bypass cut
troubleshooting
proportional valve is disconnected.
YES
(Hard check SW15)
Arm out sensor (SE-8) shows more than YES Trouble disappears if arm out operation YES Arm out operation sensor
1.3V even when lever is at neutral. sensor (SE-8) is replaced. (SE-8) is faulty.
NO NO
Arm out pilot pressure is 0.59MPa NO
Replace C-1 controller.
(85psi) when lever is at neutral.
YES
Inspect ATT pilot valve.
(Hard check SW16)
Arm in sensor (SE-7) shows more than NO
ReplaceC-1 controller.
1.3V when lever is at neutral.
YES
Trouble disappears if arm in sensor (SE-7) YES Arm in sensor (SE-7) is
is replaced. faulty.
NO
Arm in pilot pressure is more than NO
Replace C-1 controller.
0.59MPa (85psi) when lever is at neutral.
YES
Inspect ATT pilot valve.

(Hard check SW00) ; Error code E18 comes out at this time.
Machine stops moving unexpectedly NO To hydraulic
when connector (CN-254F) for P2 bypass
troubleshooting
cut proportional valve is disconnected.
YES
(Hard check SW13)
Boom raise sensor (SE-3) shows more YES Trouble disappears when boom raise YES Boom raise sensor (SE-3)
than 1.3V when lever is at neutral. sensor (SE-3) is replaced. is faulty.
NO NO
Boom raise pilot pressure is more than NO
Replace C-1 controller.
0.59MPa (85psi) when lever is at neutral.
YES
Inspect ATT pilot valve.

(Hard check SW19)

Swing sensor (SE-5) shows more 1.3V YES Trouble disappears when slewing sensor YES Slewing sensor (SE-5)
when lever is at neutral. (SE-5) is replaced. is faulty.
NO NO
Slewing pilot pressure is more than NO
Replace C-1 controller.
0.59MPa (85psi) when lever is at neutral.
YES
Inspect ATT pilot valve.

43-10
 43. TROUBLESHOOTING (ELECTRIC)

(2)-1
Only bucket motion is slow

(Hard check SW00) ; Error code E18 comes out on that occasion.
Is the motion normal after
connector (CN-254F) of P2 NO To hydraulic
bypass cut proportional troubleshooting
valve is disconnected.
YES (Hard check SW13)
Boom raise sensor (SE-3) YES Trouble disappears if boom YES Boom raise sensor (SE-3)
shows 1.3V when lever is raise sensor (SE-3) is
is faulty.
at neutral. replaced.
Boom raise pilot pressure
NO NO is more than 0.59MPa NO
Replace C-1 controller.
(85psi) when lever is at
neutral.
YES
Inspect ATT pilot valve.
(Hard check SW19)
Slewing sensor (SE-5) YES Trouble disappears if slewing YES Slewing sensor (SE-5)
shows 1.3V when lever is
sensor (SE-5) is replaced. is faulty.
at neutral.
NO NO Slewing pilot pressure is NO
more than 0.59MPa (85psi) Replace C-1 controller.
when lever is at neutral.
YES
Inspect ATT pilot valve.

Replace C-1 controller.

(2)-2
Only boom raise speed motion is slow.

(Hard check SW29)

Feedback current for P2 bypass
cut proportional valve (PSV-B) YES To hydraulic
is approx. 709mA when boom troubleshooting
raise lever is shifted to the full.

NO (Hard check SW28) (Hard check SW13)

Command current for P2 bypass Boom raise sensor (SE-3)
cut proportionl valve (PSV-B) NO shows more than approx. 4.0V YES
Replace C-1 controller.
is approx. 709mA when boom when boom raise lever is
raise lever is shifted to the full. shifted to the full.
YES NO
Trouble disappears when boom YES Boom raise operating
raise sensor (SE-3) is replaced. sensor (SE-3) is faulty.
NO
Boom raise pilot pressure is
more than approx. 3.43MPa NO
(500psi) when boom raise lever Inspect ATT pilot valve.
is shifted to the full.
YES Harness between
Error code E03 is displayed on YES C-1 controller and YES
Inspect harness.
C-1 controller. boom raise sensor
(SE-3) is shorted.
NO
Contact between C-1 controller YES
Continued on next page. and boom raise sensor (SE-3) Inspect harness.
is poor.

43-11
43. TROUBLESHOOTING (ELECTRIC)

Continued from previous page.

YES Harness between C-1 controller Inspect harness between

Error code E18 is shown on C-1 YES and P2 bypass cut proportional YES C-1 controller and P2
controller. valve (PSV-B) is disconnected or bypass cut proportional
(Hard check SW30) shorted. valve (PSV-B).
NO
Command current for travel
straight proportional valve NO To hydraulic
(PSV-C) is more than approx.
troubleshooting
350mA only when boom raise
lever is shifted to the full.
YES
Travel right sensor (SE-9) shows NO
approx. 1.3V when travel right C-1 controller is faulty.
lever is at neutral.
YES
Trouble disappears if travel right YES Travel right sensor (SE-3)
sensor (SE-9) is replaced. is faulty.
NO
Travel right pilot pressure is NO Inspect harness between
more than 0.59MPa (85psi) when travel right sensor (SE-9)
lever is at neutral. and C-1 controller.
YES

Inspect travel pilot valve.

(2)-3
Only boom raise and arm in motions are slow.
YES (Hard check SW30) ; controller service diagnosis 30
Command current for
travel straight
proportional valve is NO To hydraulic
approx. 350mA or over at troubleshooting
boom raise or arm in
motions.
YES (Hard check SW21) (Hard check SW22)
Travel right sensor (SE-9) Travel left sensor (SE-10)
shows more than 1.3V NO shows approx. 1.3V or over NO
Replace C-1 controller.
when travel right lever is when travel left lever is at
at neutral. neutral.
YES YES
Trouble disappears if travel NO Travel left pilot pressure is NO Inspect harness between
left sensor (SE-10) is more than 0.59MPa (85psi) travel left sensor (SE-10)
replaced. when lever is at neutral. and C-1 controller.
YES YES

Inspect travel pilot valve.

Replace travel left sensor

(SE-10).

Travel right pilot pressure

Trouble disappears when NO NO Inspect harness between
is more than 0.59MPa
travel right sensor (SE-9) travel right sensor (SE-10)
(85psi) when lever is at
is replaced. and C-1 controller.
neutral.
YES
YES
Inspect travel pilot valve.

Replace travel right

sensor (SE-9).

43-12
 43. TROUBLESHOOTING (ELECTRIC)

(2)-4
Only arm in motion is slow.
(Hard check SW26)
Command current for
bypass cut proportional YES To hydraulic
valve (PSV-D) is approx.
troubleshooting
709mA when arm in lever is
shifted to the full.
NO (Diagnosis 16)
Arm in sensor (SE-7) shows (Hard check SW00)
approx. 4.0V or over when YES NO
Error code E17 is displayed. Replace C-1 controller.
arm in lever is shifted to
the full.
YES
NO Inspect harness between
P1 bypass cut
proportional valve (PSV-
D) and C-1 controller.

Trouble disappears if arm YES Arm in sensor (SE-7) is

in sensor (SE-7) is replaced. faulty.
NO
Arm in pilot pressure is
YES Inspect harness between
approx. 3.43MPa (500psi)
arm in sensor (SE-7) and
or over when arm in lever
C-1 controller.
is shifted to the full.
NO
Inspect ATT pilot valve.

(2)-5
Only arm out motion is slow.
(Hard check SW26)
Command current for P1
bypass cut proportional YES To hydraulic
valve (PSV-D) is approx.
troubleshooting
709mA when arm out lever
is shifted to the full.
NO (Hard check SW15)
Arm out sensor (SE-8) (Hard check SW00)
shows approx. 4.0V or over YES NO
Error code E17 is displayed. Replace C-1 controller.
when arm out lever is
shifted to the full.
YES
NO Inspect harness between
P1 bypass cut
proportional valve (PSV-
D) and C-1 controller.

Trouble disappears if arm YES Arm out sensor (SE-8) is

out sensor (SE-8) is
faulty.
replaced.
NO
Arm out pilot pressure is
YES Inspect harness between
approx. 3.43MPa (500psi)
arm in sensor (SE-8) and
or over when arm out lever
C-1 controller.
is shifted to the full.
NO
Inspect ATT pilot valve.

43-13
43. TROUBLESHOOTING (ELECTRIC)

(4)-1
Fine operation of bucket digging and dump motions can not be performed.

YES
Trouble gets normal if
connector on P1 bypass cut NO To hydraulic
proportional valve (PSV-D) troubleshooting.
is disconnected.
YES (Hard check SW16)
Arm in sensor (SE-7) shows NO Arm out sensor (SE-8) NO
approx. 1.3V or over when shows approx. 1.3V or over Replace C-1 controller.
lever is at neutral. when lever is at neutral.
YES YES
Trouble gets normal if arm YES Arm out sensor (SE-8) is
out sensor (SE-8) is
faulty.
replaced.
NO
Arm out pilot pressure is NO Inspect harness between
more than 0.59MPa (85psi) arm out sensor (SE-8) and
when lever is at neutral. C-1 controller.
YES
Inspect ATT pilot valve.

Trouble is corrected if arm YES Arm in sensor (SE-7) is

in sensor (SE-7) is replaced. faulty.
NO
Arm in pilot pressure is NO Inspect harness between
more than 0.59MPa (85psi) arm in sensor (SE-7) and
when lever is at neutral. C-1 controller.
YES
Inspect ATT pilot valve.

(4)-2

Fine operation of boom raise and lower motions can not be performed.

YES (Hard check SW00) ; Error code E17 is displayed at this time.
Trouble gets normal if
connector of P1 bypass cut NO To hydraulic
proportional valve (PSV-D) troubleshooting
is disconnected.
YES (Hard check SW16)
Arm in sensor (SE-7) shows YES Trouble disappears if arm YES Arm in sensor (SE-7) is
approx. 1.3V or over when
in sensor (SE-7) is replaced. faulty.
lever is at neutral.
NO NO
Arm in pilot pressure is NO Inspect harness between
0.59MPa (85psi) or over arm in sensor (SE-7) and
when lever is at neutral. C-1 controller.
YES

Inspect ATT pilot valve.

(Hard check SW15)
Arm out sensor (SE-8) NO
shows approx. 1.3V or over Replace C-1 controller.
when lever is at neutral.
YES
Trouble disappears if arm YES Arm out sensor (SE-8) is
out sensor (SE-8) is
faulty.
replaced.
NO
Arm out pilot pressure is NO Inspect harness between
more than 0.59MPa (85psi) arm out sensor (SE-8) and
when lever is at neutral. C-1 controller.
YES
Inspect ATT pilot valve.

43-14
 43. TROUBLESHOOTING (ELECTRIC)

(4)-3
Fine operation of slewing motion can not be performed.
(Hard check SW00) ;
Error code E18 is
indicated at this time.
(Hard check SW19)
Trouble gets normal if
connector of P2 bypass cut YES Slewing sensor (SE-5) YES Trouble is corrected if YES Slewing sensor (SE-5)
shows approx. 1.5V or over slewing sensor (SE-5) is
proportional valve (PSV-B) is faulty.
when lever is at neutral. replaced.
is disconnected.
NO NO
NO
Slewing pilot pressure is NO Inspect harness between
more than 0.59MPa (85psi) slewing sensor (SE-5)
when lever is at neutral. and C-1 controller.
YES
Inspect ATT pilot valve.

Boom raise sensor (SE-3) YES Trouble disappears if boom YES Boom raise sensor (SE-3)
shows approx. 1.3V or over raise sensor (SE-3) is
is faulty.
when lever is neutral. replaced.
NO NO
Boom raise pilot pressure
is more than 0.59MPa NO Inspect harness between
boom raise sensor (SE-3)
(85psi) when lever is at
and C-1 controller.
neutral.
YES
Inspect ATT pilot valve.

Replace C-1 controller.

Trouble gets normal if
connector of slewing NO To hydraulic
parking solenoid (SV-1) is troubleshooting
disconnected.
YES (Hard check SW19)
Slewing sensor (SE-5)
NO Trouble gets normal if YES
shows approx. 4.0V or over Slewing sensor (SE-5)
slewing sensor (SE-5) is
when lever is shifted to the is faulty.
replaced.
full.
NO
YES
Slewing pilot pressure is
YES Inspect harness between
approx. 3.43MPa (500psi)
slewing sensor (SE-5)
or over when lever is
and C-1 controller.
shifted to the full.
NO
Inspect ATT pilot valve.

Replace C-1 controller.

43-15
43. TROUBLESHOOTING (ELECTRIC)

(4)-4
Fine operation of arm in and out motions is not possible.
(Hard check SW00) ; Error code E18 is displayed at this time.
Trouble gets normal if
connector of P2 bypass cut NO To hydraulic
proportional valve (PSV-B) troubleshooting.
is disconnected.
YES
(Hard check SW19)
Slewing sensor (SE-5)
indicates approx. 1.3V or YES Trouble gets normal if YES Slewing sensor (SE-5)
slewing sensor (SE-5) is
over when lever is at is faulty.
replaced.
neutral.
NO
NO
Slewing pilot pressure is NO Inspect harness between
more than 0.59MPa (85psi) slewing sensor (SE-5)
when lever is at neutral. and C-1 controller.
YES
Inspect ATT pilot valve.

(Hard check SW13)

Boom raise sensor (SE-3)
indicates approx. 1.3V or NO
Replace C-1 controller.
over when lever is at
neutral.
YES
Trouble disappears if boom YES Boom raise sensor (SE-3)
raise sensor (SE-3) is
is faulty.
replaced.
NO
Boom raise pilot pressure is NO Inspect harness between
more than 0.59MPa (85psi) boom raise sensor (SE-3)
when lever is at neutral. and C-1 controller.
YES

Inspect ATT pilot valve.

43-16
 43. TROUBLESHOOTING (ELECTRIC)

(5)
Travel 1-2 speed can not be changed.

24V is alive across light green /

black harness and black harness of YES To hydraulic
connector for travel 1-2 speed troubleshooting
selecting solenoid (SV-3).
NO
YES
Fuse No. 15 is blown out. Replace fuse.
NO
There is continuity between pink / There is disconnection of harness (pink)
blue harness and ground in holding YES between travel 1-2 speed switch (SW-3) YES
Replace harness.
circuit, when travel 1-2 speed select and holding circuit unit (E-23), or
switch (SW-3) is pressed. disconnection of ground harness (black).
NO Replace travel 1-2 speed
NO switch.
There is 24V between light green /
blue harness of holding circuit unit NO Replace travel 1-2 speed
(E-23) and ground, when travel 1-2 relay.
spped switch (SW-3) is pressed.

YES
Replace holding circuit unit.

(6)
Travel independent speed is low.
(Hard check SW30)
Command current of travel
straight proportional (PSV-C) is NO To hydraulic
more than 350mA during troubleshooting
traveling.
YES (Hard check SW17)
Bucket digging sensor (SE-1) YES Trouble disappears if bucket digging YES Bucket digging sensor
indicates 1.3V when lever is at
sensor (SE-1) is replaced. (SE-1) is faulty.
neutral.
NO
NO
Bucket digging pilot pressure is NO
more than 0.59MPa (85psi) when Replace C-1 controller.
lever is at neutral.
YES
Inspect ATT pilot valve.
(Hard check SW18)
Bucket dump (SE-2) indicates more YES Trouble disappears if bucket dump YES Bucket dump sensor
than 1.3V when lever is at neutral. sensor (SE-2) is replaced. (SE-2) is faulty.
NO NO
Bucket dump pilot pressure is NO
more than 0.59MPa (85psi) when Replace C-1 controller.
lever is at neutral.
YES
Inspect ATT pilot valve.
(Hard check SW13)
Boom raise sensor (SE-3) indicates YES YES
Trouble disappears if boom raise Boom raise sensor (SE-3)
more than 1.3V when lever is at
sensor (SE-3) is replaced. is faulty.
neutral.
NO NO
Boom raise pilot pressure is more NO
than 0.59MPa (85psi) when lever is Replace C-1 controller.
at neutral.
YES
Continued on next page. Inspect ATT pilot valve.

43-17
43. TROUBLESHOOTING (ELECTRIC)

Continued from previous page.

NO (Hard check SW14)

Boom lower sensor (SE-4) indicates YES YES
Trouble disappears if boom lower Boom lower sensor (SE-4)
more than 1.3V when lever is at
sensor (SE-4) is replaced. is faulty.
neutral.
NO
NO
Boom lower pilot pressure is more NO
than 0.59MPa (85psi) when lever is Replace C-1 controller.
at neutral.
YES
Inspect ATT pilot valve.
(Hard check SW19)
Slewing sensor (SE-5) reads more YES Trouble disappears if slewing YES Slewing sensor (SE-5)
than 1.3V when lever is at neutral. sensor (SE-5) is replaced. is faulty.
NO NO
Slewing pilot pressure is more than NO
0.59MPa (85psi) when lever is at Replace C-1 controller.
neutral.
YES Inspect ATT pilot valve.
(Hard check SW16)
Arm in sensor (SE-7) reads more YES Trouble disappears when arm in YES Arm in sensor (SE-7) is
than 1.3V when lever is at neutral. sensor (SE-7) is replaced. faulty.
NO NO
Arm in pilot pressure is more than NO
0.59MPa (85psi) when lever is at Replace C-1 controller.
neutral.
YES
Inspect ATT pilot valve.
(Hard check SW15)
Arm out sensor (SE-8) reads more YES Trouble disappears if arm out YES Arm out sensor (SE-8) is
than 1.3V when lever is at neutral. sensor (SE-8) is replaced. faulty.
NO NO
Arm out pilot pressure is more than NO
than 0.59MPa (85psi) when lever is Replace C-1 controller.
at neutral.
YES Inspect ATT pilot valve.

Replace C-1 controller

43-18
 43. TROUBLESHOOTING (ELECTRIC)

(8)
Machine does not travel straight.

(Hard check SW31)

Feedback current of travel YES To hydraulic
straight proportional
troubleshooting
valve (PSV-C) is 700mA.
NO
Check harness (green/
(Hard check SW00) black and gray/black)
Error code E19 is YES between travel straight
indicated. proportional valve
(PSV-C) and C-1
NO controller.
(Hard check SW19)
Slewing sensor (SE-5)
Machine deviates to the YES reads more than 4.0V NO Trouble disappears if YES Slewing sensor (SE-5)
slewing sensor (SE-5) is
left. when lever is shifted to the is faulty.
replaced.
full.
NO
NO
YES
Slewing pilot pressure is
more than approx. YES Check harness between
slewing sensor (SE-5)
3.43MPa (500psi) when
and C-1 controller.
lever is shifted to the full.
NO
(Hard check SW15) Check ATT pilot valve.

Arm out sensor (SE-8)

indicates more than 4.0V NO Trouble disappears if arm YES Arm out sensor (SE-8) is
out sensor (SE-8) is
when lever is shifted to the faulty.
replaced.
full.
NO
YES
Arm out pilot pressure is
approx. 3.43MPa (500psi) YES Inspect harness between
arm out sensor (SE-8) and
or over when lever is
C-1 controller.
shifted to the full.
NO
Inspect ATT pilot valve.
(Hard check SW16)
Arm in sensor (SE-7) reads NO Trouble disappears if arm YES Arm in sensor (SE-7) is
more than 4.0V when lever in sensor (SE-7) is
faulty.
is shifted to the full. replaced.
YES NO
Replace controller. Arm in pilot pressure is
approx. 3.43MPa (500psi) YES Inspect harness between
arm in sensor (SE-7) and
or over when lever is
C-1 controller.
shifted to the full.
NO
(Hard check SW13) Inspect ATT pilot valve.
Boom raise sensor (SE-3)
NO Trouble disappears if boom YES Boom raise sensor (SE-3)
reads more than 4.0V
raise sensor (SE-3) is
when lever is shifted to the is faulty.
replaced.
full.
NO
YES
Boom raise pilot pressure
is approx. 3.43MPa YES Inspect harness between
boom raise sensor (SE-3)
(500psi) or over when lever
and C-1 controller.
is shifted to the full.
NO
Continued on next page. Inspect ATT pilot valve.

43-19
43. TROUBLESHOOTING (ELECTRIC)

Continued from previous page.

YES (Hard check SW14)

Boom lower sensor (SE-4)
NO Trouble disappears if boom YES
reads approx. 4.0V or over Boom lower sensor (SE-4)
lower sensor (SE-4) is
when lever is shifted to the is faulty.
replaced.
full.
NO
YES
Boom lower pilot pressure
YES Inspect harness between
is approx. 3.43MPa
boom lower sensor (SE-4)
(500psi) or over when lever
and C-1 controller.
is shifted to the full.
NO
(Hard check SW17) Inspect ATT pilot valve.
Bucket digging sensor
NO Trouble disappears if YES
(SE-1) reads approx. 4.0V Bucket digging sensor
bucket digging sensor
or over when lever is shifted (SE-1) is faulty.
(SE-1) is replaced.
to the full.
NO
YES
Bucket digging pilot
YES Inspect harness between
pressure is approx. 3.43MPa
bucket digging sensor
(500psi) or over when lever
(SE-1) and C-1 controller.
is shifted to the full.
NO
(Hard check SW18) Inspect ATT pilot valve.
Bucket dump sensor (SE-2)
NO Trouble disappears if YES
reads approx. 4.0V or over Bucket dump sensor
bucket dump sensor (SE-2)
when lever is shifted to the (SE-2) is faulty.
is replaced.
full.
NO
YES
Bucket dump pilot pressure
YES Inspect harness between
is approx. 3.43MPa
bucket dump sensor (SE-
(500psi) or over when lever
2) and C-1 controller.
is shifted to the full.
NO
Inspect ATT pilot valve.

Replace C-1 controller.

(10)
Slewing motion does not work.

Slewing motion works if NO To hydraulic

connector of slewing parking
troubleshooting
solenoid (SV-1) is disconnected.
YES (Hard check SW19)
Slewing sensor (SE-5) reads NO YES
Trouble disappears if slewing Slewing sensor (SE-5)
approx. 1.3V or over when
sensor (SE-5) is replaced. is faulty.
lever is shifted to the full.
YES NO
Slewing pilot pressure is
YES Inspect harness between
approx. 3.43MPa (500psi) or
slewing sensor (SE-5)
over when lever is shifted to
and C-1 controller.
the full.
NO
Inspect ATT pilot valve.

Replace C-1 controller.

43-20
 43. TROUBLESHOOTING (ELECTRIC)

(11)
Slewing speed is low.

(Hard check SW29)

Feedback current of P2 bypass
cut proportional valve (PSV-B) YES To hydraulic
is approx. 709mA when slewing troubleshooting
lever is shifted to the full.
NO (Hard check SW28) (Hard check SW19)
Command current of P2 bypass Slewing sensor (SE-5)
cut proportional valve (PSV-B) NO reads approx. 4.0V NO Trouble disappears if YES Slewing sensor (SE-5)
slewing sensor (SE-5) is
is approx. 709mA when slewing when lever is shifted is faulty.
replaced.
lever is shifted to the full. to the full.
YES NO
YES
Slewing pilot pressure is
approx. 3.43MPa (500psi) YES Inspect harness between
slewing sensor (SE-5)
or over when lever is
and C-1 controller.
shifted to the full.
NO
Inspect ATT pilot valve.

Replace C-1 controller.

Error code E18 is YES Inspect harness between P2 bypass cut

indicated. proportional valve (PSV-B) and C-1 controller.
NO
Replace C-1 controller.

(12)
Slewing power is poor.

(Hard check SW29)

Feedback current of P2 bypass
cut proportional valve (PSV-B) YES To hydraulic
is approx. 709mA when slewing troubleshooting
lever is shifted to the full.
NO (Hard check SW28) (Hard check SW19)
Command current of P2 bypass Slewing sensor (SE-5)
cut proportional valve (PSV-B) NO reads approx. 4.0V NO Trouble disappears if YES Slewing sensor (SE-5)
slewing sensor (SE-5) is
is approx. 709mA when slewing when lever is shifted is faulty.
replaced.
lever is shifted to the full. to the full.
YES NO
YES
Slewing pilot pressure is
approx. 3.43MPa (500psi) YES Inspect harness between
slewing sensor (SE-5)
or over when lever is
and C-1 controller.
shifted to the full.
NO
Inspect ATT pilot valve.

YES
Replace C-1 controller.
Error code E18 is NO
Replace C-1 controller.
indicated.
YES Inspect harness between P2 bypass cut
proportional valve (PSV-B) and C-1 controller.

43-21
43. TROUBLESHOOTING (ELECTRIC)

(13)-1
Slewing motion can not be held on a slope.

YES
24V is alive across
pink/black and black wires YES To hydraulic
of connector for slewing troubleshooting
parking solenoid (SV-1).
NO
Slewing parking release NO
switch (SW-4) is at Turn to NORMAL.
NORMAL.
YES (Hard check SW19)
Slewing sensor (SE-5) YES Trouble gets normal if YES Slewing sensor (SE-5)
reads more than 1.3V slewing sensor (SE-5)
is faulty.
when lever is at neutral. is replaced.
NO NO
Slewing pilot pressure
NO Inspect harness between
is more than 0.59MPa
slewing sensor (SE-5)
(85psi) when lever is at
and C-1 controller.
neutral.
YES
Inspect ATT pilot valve.

Arm in sensor (SE-7) reads YES Trouble gets normal if arm YES Arm in sensor (SE-7) is
more than 1.3V when lever in sensor (SE-7) is
faulty.
is at neutral. replaced.
NO NO
Arm in pilot pressure is NO Inspect harness between
more than 0.59MPa (85psi) arm in sensor (SE-7) and
when lever is at neutral. C-1 controller.
YES
Inspect ATT pilot valve.

Inspect that harness (pink

If slewing right (or slewing
YES and black) between slewing
left, or arm in) lever is
parking brake solenoid
operated, error E15 is
(SV-1) and C-1 controller
indicated.
is not disconnected.
NO

Replace C-1 controller.

43-22
 43. TROUBLESHOOTING (ELECTRIC)

(14)
Auto idling stop (AIS) does not When overheating is
function. E/G does not stop after an NO Is E/G water temperature warning YES detected, AIS does not work
elapse of 30 seconds after the lock to protect E/G.
indicated?
lever was moved upward to locked Check on it in normal opera-
position.) NO tion condition.

YES When AIS selector SW is

Is AIS selector SW off? off, it does not work. Switch
AIS SW on and check on it.
NO

Check the line between AIS

24V is impressed on timer unit No.1 NO
selector SW and timer unit,
pin terminal.
and check fuse No.2
YES

Check the line between timer

24V is impressed on timer unit No.7 NO unit and alternator. The AIS
pin terminal during engine running. is not actuated if alternator
is not actuated.
YES

Is ATT operation possible even if the YES

Replace a limit switch of
lock lever is moved upward to locked
lock lever.
position?
NO
24 V is impressed on timer unit No.2 YES (24V) Check the line between
pin terminal during lock lever is moved locklever limit switch and
upward to locked position. controller.
NG
Replace a timer unit.

43-23
43. TROUBLESHOOTING (ELECTRIC)

43-24
 44. TROUBLESHOOTING
(ENGINE)
TABLE OF CONTENTS

44.1 TROUBLE DIAGNOSIS : ENGINE ..................................................................................... 44-3

44.2 TROUBLESHOOTING ....................................................................................................... 44-7

44

44-1
44. TROUBLESHOOTING (ENGINE)

44-2
 44. TROUBLESHOOTING (ENGINE)

44.1 TROUBLE DIAGNOSIS : ENGINE

Service man
Inspection Visual check
Filters Fluid Gas / Fluid

Poor quality fuel is used or heavy oil is used.

Fuel system trouble (Air or water entered.)

Viscosity of engine oil is not suited, engine oil is

Gas leaks from valve and gasket.

leaking, or the engine oil level not proper.
Fuel is of poor quality or leaking.
Specific gravity of battery fluid
Component

Fuel not filled up or leaking.

Oil cooler element clogged.

Engine oil is too much.

Gauze filter clogged.

Blowby gas is much.

Air cleaner clogged.

Breather hose bent.

Cooling water level
Fuel filter clogged.

Battery fluid level

Oil filter clogged.
Group No.

V-belt slips.
System

Trouble
Starting trouble

1 Starter does not run.

2 Starter runs but does ont start.

Idling unsmooth

Medium speed hunting

Rotation trouble

3 High speed unsmooth

Does not reach max revolution.

Max. revolution is too high.

Revolution does ont change if

4
work modes are changed.
Accel potentiometer does
5
Engine

not work properly.

E/G deficiency in output

Drop in output

6
Over heat

Knocking occurs after

7
warming-up E/G

Exhaust gas is black

8
Exhaust gas is white
(In cold state, white smoke does
not disappear after idling.)
Other trouble

9 Excessive oil consumption.

10 Excessive fuel consumption.

Engine does not stop when

11
key is turned off.
Power is off the moment the key
12 is turned to OFF, but engine does
not stop.

44-3
44. TROUBLESHOOTING (ENGINE)

Service man Engine dealer

Shovel side Engine side
Fuel system
Electrical fittings Electrical fittings

Component

Connector and electric wiring

Mechatoronic controller

Check injection timing

Mechatoro "A" adjust.

Auto idle stop relay 2

Accel potentiometer

Feed pump function

Stepping motor

Inspect nozzle.
Injection pump
Starter motor
Battery relay

Starter relay
Group No.

Safety relay
Starter key

Glow relay
Timer unit

Alternator
System

Glow
Fuse

Trouble
Starting trouble

1 Starter does not run.

2 Starter runs but does ont start.

Idling unsmooth

Medium speed hunting

Rotation trouble

3 High speed unsmooth

Does not reach max revolution.

Max. revolution is too high.

Revolution does ont change if

4
work modes are changed.
Accel potentiometer does
5
Engine

not work properly.

E/G deficiency in output

Drop in output

6
Over heat

Knocking occurs after

7
warming-up E/G

Exhaust gas is black

8
Exhaust gas is white
(In cold state, white smoke does
not disappear after idling.)
Other trouble

9 Excessive oil consumption.

10 Excessive fuel consumption.

Engine does not stop when

11
key is turned off.
Stop
Power is off the moment the key position
12 is turned to OFF, but engine does
not stop.

44-4
 44. TROUBLESHOOTING (ENGINE)

Engine dealer
Suction/ Lubrication
exhaust Cooling Main structure
system system

chamber through piston or through valve guide.

Control rack movement unsmooth.

Component

Check if engine oil goes into combustion

Oil cooler element damaged.

Crank shaft oil seal no good.

Compression pressure low.

Governor spring fatigued.

Flywheel gear damaged.

Valve spring is fatigued.

Valve spring fatigued.

Air cleaner & muffler

Oil strainer clogged.

Internal parts stuck.

Head gasket faulty.

Check thermostat.
Check relief valve.

Piston liner worn.

Piston ring worn.

Check fuel feed.

Valve clearance

Fuel is mixed.
Group No.
System

Trouble
Starting trouble

1 Starter does not run.

2 Starter runs but does ont start.

Idling unsmooth

Medium speed hunting

Rotation trouble

3 High speed unsmooth

Does not reach max revolution.

Max. revolution is too high.

Revolution does ont change if

4
work modes are changed.
Accel potentiometer does
5
Engine

not work properly.

E/G deficiency in output

Drop in output

6
Over heat

Knocking occurs after

7
warming-up E/G

Exhaust gas is black

8
Exhaust gas is white
(In cold state, white smoke does
not disappear after idling.)
Other trouble

9 Excessive oil consumption.

10 Excessive fuel consumption.

Engine does not stop when

11
key is turned off.
Power is off the moment the key
12 is turned to OFF, but engine does
not stop.

44-5
44. TROUBLESHOOTING (ENGINE)

This page is blank for editing convenience.

44-6
 44. TROUBLESHOOTING (ENGINE)

44.2 TROUBLESHOOTING
(1)
Starter does not run.

NO Check a battery fluid level and NO

Check a battery voltage. Charge or replace battery.
specific gravity.
OK
NO Battery relay’s B terminal of coil side YES Check a grounding of battery
Battery relay is turned on if starter
relay, and if necessary re-
key is turned on. is impressed 24V.
place battery relay.
YES NO
24V is impressed on output side NC YES Check the line between AIS
terminal of AIS relay No.1. relay No.1 and battery relay.
NO
24V is impressed on common terminal NO Check a key switch, fuse
of AIS relay No.1. and fusible link.
YES
If disconnect a connector of timer unit YES
Replace a timer unit.
for AIS, battery relay turns on.
NO
Replace an AIS relay No.1.

If 24V is impressed on ST terminal

of key switch, check this 24V at S NO 24V is impressed on NC terminal YES Check the line between AIS
terminal side of safety relay in engine output side of AIS relay No.2. relay No.2 and safety relay.
sub-harness assy.
NO
YES NO Check key switch, and check
24V is impressed on common
the line between ST terminal
terminal of AIS relay No.2.
and AIS relay No.2
YES

Replace an AIS relay No.2.

NO Check the cable between

24V is impressed on starter motor
battery relay and starter
B terminal.
motor.
YES
24V is impressed on starter motor YES
Replace a starter motor.
S terminal.
NO
YES Check the line between
24V is impressed on safety relay
safety relay C terminal and
C terminal.
starter motor S terminal.
NO

Replace a safety relay.

NOTES:
AIS means Auto Idling Stop.
Check key switch in START position.
Emergency stop knob (Engine stop) is returned to running position.

44-7
44. TROUBLESHOOTING (ENGINE)

(2)
Starter turns but engine is hard to start.

Check starter power is strong WEAK Check battery fluid level and
Charge or replace battery.
or weak. specific gravity.
OK
Check engine itself. Check compression
pressure and valve
clearance. Check that
Check that air filter clogged valve spring is not
Check air suction system. fatigued, that piston liner
lamp lights.
is not worn, that piston
OK OK ring is not worn, that
head gasket is not faulty
Check that air cleaner clogged
and that flywheel gear is
lamp and sensor.
not damaged. Also check
radiator and thermostat.

E/G side Check gauze filter.

Check feed pump
OK performance, injection
Check fuel feed system.
pump, injection nozzle
Check fuel gauge and water and injection timing.
Machine
separator. Check that poor
side
quality fuel is not used.

YES
Check electric system. E/G side 24V is alive on glow plug. Glow plug is faulty.

NO
24V is alive on wire No.66 YES Harness between glow
(5W) of CN-153F on glow relay relay and glow plug is
(R-3). faulty.
NO
NO Harness between glow
24V is alive on wire No.55 (5Y)
relay and battery relay is
of CN--154F on glow relay (R-3).
faulty.
OK
24V is alive across wire No.62 YES
of CN-155F on glow relay (R-3) Replace glow relay.
and earth.
NO
NO Harness between glow
Ground connection is poor. relay and battery relay is
faulty.

Check E/G oil of viscosity if it NO

Check viscosity of E/G oil. is suited to atmospheric Replace engine oil.
temperature.

Checking condition : E/G starter key is in ON position.

Internal connection

44-8
 44. TROUBLESHOOTING (ENGINE)

(3)
E/G revolution is faulty.

Check high pressure pipe

and injection nozzle.
Check that compression
Idling not smooth.
pressures in cylinder are
equal. Check injection
pump and thermostat.
Idling is faulty.

Idling revolution is too *Adjust

1
mechatro "A"
high.

Check control rack.

Medium revolution is Hunting occurs at
Change over governor
faulty. medium revolution.
spring.

Check that air is not YES

Bleed air.
mixed in fuel.
OK
Check that air cleaner is
Check air suction system.
not clogged.
OK
Check fuel gauge, water
separator and gauze filter.
Check fuel system.
Check also that poor
quality fuel is not used.
High idling is faulty. OK

Check injection nozzle,

injection pump and
injection timing.

E/G does ont reach max.

revolution.
*Adjust
1
mechatro "A"
Max revolution is too
high.

Checking condition ; E/G water temperature is more than 50 C (122 F).

*1 ; Refer to Electric Troubleshooting.

44-9
44. TROUBLESHOOTING (ENGINE)

Note ; (6) matches the group No. on page 1. The same is true on the following pages.
(6)
E/G output is insufficient.
Check that E/G water OK Check the contents of
Overheat temperature lamp is on and
excavating.
that buzzer sounds.
NO Check E/G water
temperature switch,
Inspect electric system.
gauge cluster, electric
wiring and connectores.
OK
Check coolant level.
Inspect cooling system. Check that fan belt does
not slip.
OK Check thermostat.
Also check that radiator.
Oil cooler is not clogged.

Check that poor quality

Check fuel system.
fuel is not used.
OK
Check E/G oil system. Check E/G oil filter.

Check air suction Check that air filter clogged OK Check that air cleaner is
system. lamp lights. not clogged.
OK
Check that air is not mixed
Check fuel system. Bleed air.
in fuel.
OK OK
Check feed pump, injection
Check water separator and
pump, injection nozzle and
gauze filter. Check also that
injection timing.
poor quality fuel is not used.

Check viscosity of E/G oil if

Check E/G oil. it is suited to atmospheric Replace engine oil.
temperature.
OK
Check that blowby gas is not Check compression
much, that gas does not leak pressure and valve
from gasket, and that engine clearance. Check that
Check engine body oil goes into combustion valve spring is not
chamber through piston or fatigued. Check that
through valve guide control rack moves
smoothly. Check that
piston ring is not worn.
Checking condition ; High idling Check also that head
gasket is net faulty.

(7)
Knocking occurs after warming-up E/G.

OK
Check that poor quality fuel
Check fuel system. Replace fuel.
is not used.

Check that engine oil goes into Judge it if oil is there on

Check E/G itself. combustion chamber through exhaust port.
piston.
OK
Check that blowby gas is not Check compression
much and that gas does not pressure, injection timing
leak from gasket. and injection nozzle.

Checking condition ; E/G water temperature is more than 50 C (122 F).

44-10
 44. TROUBLESHOOTING (ENGINE)

(8)
Exhaust is abnormal.

OK
Check that air cleaner is not
Exhaust gas is black. Replace air element.
clogged.
OK
Check engine oil viscosity.
Check that engine oil is not
too much.
Check injection nozzle,
OK injection timing, injection
Check that gas is not leaking pump and valve clearance.
from head gasket. Check that valve spring is
not fatigued and that piston
ring is not faulty.

Check that water is not

Exhaust gas is white. Check water separator.
mixed in fuel.
OK
Check that engine oil goes
into combustion chamber
through piston or through valve Check compression pressure
guide. Blowby gas is much. and injection timing.
A lot of gas leaks from gasket.

Checking condition ; Engine water temperature is more than 50 C (122 F).

(9)
Excessive oil consumption.

Check leakage by checking

Check that engine oil is not Retighten.
the ground under E/G or by
leaking. Replace packing and seal.
placing an oil pan under E/G.
(Check that engine oil is not
filled up too much.) OK
Check that breather hose is
Replace breather hose.
not bent or clogged.
OK
Check that poor quality fuel
Advise to replace fuel.
is not used.
OK
Check viscosity of engine oil. Advise to replace engine oil.

OK Check that ; CR shaft oil seal

Check that engine oil does is not faulty, piston liner is
not into combustion chamber not worn, or piston ring is
Checking condition ; No engine oil leaks. through piston or through valve not worn.
guide.

(10)
Excessive fuel consumption.

Check that poor quality fuel

Check fuel leakage. Advise to replace fuel.
is not used.
OK
Blowby gas is much.
Check that gas does not leak Check nozzle function.
from gasket.
OK
Check injection timing.

Check compression pressure.

Checking condition ; Use proper fuel.

44-11
44. TROUBLESHOOTING (ENGINE)

(11)
Check that
E/G does not stop Confirm governor Check if governor
governor motor link
when starter key is lever stop bolt motor is not faulty
connecting bolts are
turned off. position. mechanically.
not loose.
OK
Check that Wire number 60 Check resistance
NG Replace starter key
terminal M of of instrument panel across terminals M
if resistance across
starter key switch harness CN-43F and B on starter
M and B is 0‰.
shows 0V. shows 0V. key.
See Fig.3.
OK
Check that battery Does resistance
relay terminal L Wire No.857 of NG across C1 controller
Check C1
measures 0V four main harness CN- terminals 11-1 and
controller.
seconds after key is 150F measures 0V. 14-22 measure
turned off. 72‰?

(12) OK
When starter key is Replace C1
Does battery NG
turned off, power is Check that battery Replace battery controller if
terminals A and B
cut off but engine relay operates. relay. resistance measures
measure 0‰?
does not stop. 0‰.
See Fig.2.

Checking condition ; Starter key is off.

CN-152F
TERMINAL A1 LOCK

Flowing direction of main current

TERMINAL A1, A B, B1 TERMINAL TERMINAL B1

FLW FLW
TERMINAL A
VIEW I
2.0 sq 2.0 sq
FLW 2.0 sq
TERMINAL B
FLW 2.0 sq
G B2
W L P COIL
H COIL

BRACKET EARTH

Circuit diagram TERMINAL L

TERMINAL L
TERMINAL B2

AVS 1.25L TERMINAL B2

AVS 1.25G GROUND
GROUND CABLE TERMINAL
AVS 1.25B
CN-150M

Fig. 44-1 Battery relay

Fig. 44-2 Key SW. terminal

44-12
 51. ENGINE
TABLE OF CONTENTS

See the attached Engine manufacturer's SERVICE MANUAL

51

51-1
51. ENGINE

PREFACE
This manual explains the engine proper and is a faithful reproduction of Engine manufacturer's service manuals.

51-2