FOREWORD

This manual, which is written for engineers who service the machine, describes procedures for disassembly and as-
sembly, inspection and maintenance, and troubleshooting, as well as maintenance reference values and an outline of
the specifications. Refer to this manual during daily work to improve your services. Note that the information is subject
to change without notice due to design modifications made to the machine from time to time by the manufacturer.

Directional terms: front, rear, left, right

In this manual, the “front” refers to the end of the machine where the dozer blade is mounted, while the “rear” refers to
the other end where the travel motor is mounted. The “right” or “left” refers to the side viewed by a person sitting in the
operator’s seat.

Machine serial number

The machine serial number is stamped on the identification plate. Be sure to include this number when sending a report
or inquiry or when ordering parts.

Control of manual
Appoint a person in charge of keeping the manuals up to date in your company and inform us of the person’s name
for our records. Any revisions or additions to this manual will be sent to the person.

Symbols used in this manual

The symbols used in this manual have the following meanings.

Indicates the machine serial number.

Means “Refer to the section quoted.”
Indicates the mass of the equipment or machine.
Means “Tighten to the torque specified here.”
Indicates the use of thread-locking compound.
Indicates the use of grease.

Manual structure
This manual consists of the following parts.
1. Safety
2. Service data
3. Function
4. Disassembly and assembly
5. Troubleshooting
6. Other
 SAFETY 1
Safety alert symbol ..................................................... 1-2
Safety precautions ...................................................... 1-3
Cautions when working............................................... 1-9

1-1
 SAFETY
SAFETY ALERT SYMBOL 1
SAFETY ALERT SYMBOL
This symbol represents the safety
alert.
The message that follows the symbol
contains important information re-
garding human safety.
Read and understand the message to
avoid personal injury or death.

Safety label
Safety labels are used to alert operators or other people
exposed to the risks of injury or damage. There are the
following three types of labels.
Read the labels carefully as they are important for your
safety.

DANGER
The word “DANGER” indicates an imminently hazardous
situation which, if not avoided, is likely to result in serious
injury or death.

WARNING
The word “WARNING” indicates a potentially hazardous
situation which, if not avoided, could result in serious inju-
ry or death.

CAUTION
The word “CAUTION” indicates a potentially hazardous
situation which, if not avoided, may result in minor or
moderate injury.

IMPORTANT: The word “IMPORTANT” is used to alert

operators and maintenance personnel about situations
which could result in damage to the machine and its com-
ponents.

This manual is intended for trained and qualified person-

nel only. Warnings or cautions described in this manual
do not necessarily cover all safety measures. It is also im-
possible to cover all hazards and risks which may be as-
sociated with the maintenance of the machine in every
environment. For maintenance work, each person must
take adequate safety precautions against possible haz-
ards in the respective working environment.

1-2
 SAFETY
SAFETY PRECAUTIONS 1
SAFETY PRECAUTIONS Install an extinguisher and a first aid kit

Observe all safety rules

• Operation, inspection and maintenance of this ma-
chine must be performed only by a trained and quali-
fied person.
• All rules, regulations, precautions and safety proce-
dures must be understood and followed when per-
forming operation, inspection and maintenance of this
machine.
• Do not perform any operation, inspection or mainte-
nance of this machine when under the influence of al-
cohol, drugs, medication, fatigue or insufficient sleep.
1BAA02Z

Wear safe clothing and protective gear • Install an extinguisher to fight a fire, and learn how to
use it.
• Prepare a first aid kit and keep it at a designated
place.
• Decide on the procedures to be used in case of fire or
other hazards.
• Decide on and take note of the contact(s) in case of
emergency.

Place a “Do not operate” alert sign

Serious injury or death may result if an unauthorized per-
son starts the engine or touches the controls during in-
spection or maintenance.
1BAA01Z • Before performing maintenance, stop the engine, re-
• Do not wear loose clothing or any accessory that can move the key and store it in a safe place.
catch on the controls or the moving parts of the ma- • Prominently display a “Do not operate” alert sign on
chine. places such as the starter switch and the control lever.
• Do not wear clothing stained with oil or grease that can Place another sign outside of the machine as neces-
easily catch fire. sary.
• Wear protective gear such as helmet, safety shoes,
protective goggles, respirator, gloves and earmuffs, Use the correct tools
as appropriate, depending on the work involved. Es-
pecially make sure to wear protective eye-wear and
mask when working with a grinding/polishing/sanding
machine, hammer or compressed air, as metal frag-
ments or other objects could scatter in such an envi-
ronment.
• Wear hearing protectors when operating the machine.
Loud and prolonged noise can damage or destroy
your hearing.

1BAA03Z

Do not use damaged or weakened tools or tools de-

signed for other purposes. Use only the correct tools for
the work involved.

1-3
 SAFETY
SAFETY PRECAUTIONS 1
Regularly replace the safety-critical parts When the canopy is tilted up
• Regularly replace fuel hoses to prevent a fire hazard. • If the canopy is raised or lowered while the engine is
Hoses wear out over time, even if they do not show any moving, the machine may accidentally start moving,
symptom of wear. resulting in severe injury to the maintenance person-
• Regardless of the replacement schedule, replace im- nel. Make sure that the working equipment has been
mediately if a symptom of wear is found. lowered to the ground and the engine has been turned
off before raising/lowering the canopy.
Explosionproof lighting • When the canopy is tilted up, firmly secure the canopy
with a stopper to prevent it from falling.

Keep the machine clean

1BAA04Z

To prevent an ignition or explosion, use explosion-proof

lights when inspecting fuel, oil, coolant or battery fluid.
1BAA06Z

Prohibit access by unauthorized persons • Clean the machine before performing maintenance
and try to keep it clean.
• Before washing, cover the electrical parts with vinyl to
prevent water from entering, as this could cause a
short-circuit or malfunction. Do not use water or steam
to wash the battery, sensors, connectors or the opera-
tor’s seat area.

Stop the engine before performing maintenance

Make sure the engine is stopped before starting inspec-
tion or maintenance. If maintenance must be performed
with the engine running, always work as a 2-person team,
communicating with each other.
1BAA05Z
• One of them must sit at the operator’s seat and stop
Do not allow unauthorized personnel in the work area the engine whenever necessary. He/she must take
while working. care not to touch the lever or pedal unless necessary.
Take particular care that no unauthorized person is • The one who performs maintenance must make sure to
present when grinding, welding or using a hammer. keep his/her body or clothing away from the moving
part of the machine.

Prepare the work area

• Select a level and firm ground on which to perform
maintenance work. Make sure that the work area is
light enough and well ventilated.
• Straighten any obstacle or dangerous object, remove
any spill of oil or grease and clean the work area.

1-4
 SAFETY
SAFETY PRECAUTIONS 1
Keep clear of the moving fan and belt When working on the machine

1BAA07Z 1BAA09Z

• Any object that can be easily caught in moving parts • To prevent slipping/falling from machine, clear the
must be kept away. footing and observe the following:
• If a hand or tool becomes trapped in the fan or fan belt, a. Do not spill oil or grease on the machine.
you could lose your finger. Do not touch the fan or belt b. Keep the machine tidy and clean.
while they are moving. c. Be careful when walking around the machine.
• Never jump down from the machine. Climb up/down
When working under the machine the ladder (steps) holding the handrail to support your
weight in a three point secure stance (hand and feet).
• Wear protective gear according to the work involved.

Securing the working equipment

When replacing/repairing the bucket teeth or side cutter,
secure the relevant equipment to prevent any accidental
movement.

Secure the engine hood and guard when they are

open
Firmly secure the machine when the engine hood or
1BAA08Z
guard is left open. Do not keep the hood or guard open
• Before performing maintenance or repairs under the on a windy day or if the machine is parked on a slope.
machine, set all movable equipment against the
ground or in the lowermost position. Place heavy components in a stable position
• Place chocks under the crawler tracks to secure the
machine.
• If it is unavoidably necessary to work under the raised
machine or working equipment, be sure to firmly sup-
port it by using an arm stopper, wooden block, stand
or safety brace. Never go under the raised machine or
working equipment without such protection measures.

1BAA10Z

When it is necessary to temporally place a heavy compo-

nent, such as the hoe attachment, on the ground during
removal or installation, be sure to place it in a stable po-
sition.

1-5
 SAFETY
SAFETY PRECAUTIONS 1
Caution when filling with fuel or oil Be careful with hot and pressurized components

1BAA11Z 1BAA12Z

• Keep away from heat, sparks and flame while filling Before performing inspection and maintenance, stop the
with fuel or oil. engine and allow the machine to cool down.
• Never remove the fuel cap or try to fuel when the en- • The engine, muffler, radiator, hydraulic lines, sliding
gine is running or still hot. parts and many other parts of the machine are hot im-
• Maintain control of the fuel filler nozzle when filling the mediately after the engine is stopped. Wait until it
tank. cools before making any inspection or adjustments.
• Refill with fuel or oil outdoors or in a well ventilated • The engine coolant, hydraulic oil and other oils are
place, with the engine turned off. also hot and under high pressure. Touching these liq-
• Clean up spilled fuel or oil immediately. uids will cause burns.
• Do not overfill the tank.
• Firmly tighten the fuel cap or oil cap. If the fuel cap is Handling of radiator
lost, replace it only with the original manufacturer’s ap-
proved cap. Use of a non-approved cap without prop-
er venting may result in pressurization of the tank.
• Never use fuel for cleaning.
• Use the correct grade of fuel for the operating season.

Handling of hoses
Oil leak or fuel leak can cause a fire.
• Do not twist, bend or hit the hoses.
• Never use twisted, bent or cracked pipes, tubes or
hoses; otherwise, they may burst.
• Retighten loose connections.
1BAA13Z

Do not remove the radiator cap when the coolant is hot.

Wait until it cools down, and then remove the radiator cap
by loosening it slowly to release the internal pressure.

1-6
 SAFETY
SAFETY PRECAUTIONS 1
Be careful with oils under pressure Be careful with grease under pressure

1BAA14Z 1BAA15Z

Pressure is maintained in the hydraulic circuit long after In the track adjuster, the grease has been injected under
the engine has been shut down. high pressure. If the tension is adjusted without following
• Do not fill with, dispose of fuel/oil, or perform the in- the prescribed procedure, the grease discharge valve
spection and maintenance until the internal pressure is may fly off, resulting in injury.
completely released. • Loosen the grease discharge valve slowly.
• The hydraulic oil escaping from a small hole can be • Do not put your face, arms, legs or body in front of the
hazardous if contacted. It is under high enough pres- grease discharge valve.
sure to penetrate the skin or eyes and cause serious
injury. If leak is suspected, protect your eyes and skin Handling of the accumulator
by wearing protective glasses and thick gloves to
search for a leak. Also use a paperboard or plywood
to keep your skin from oil spurting. If oil penetrates the
skin, it must be surgically removed within a few hours
by a doctor familiar with this type of injury.

Release internal pressure before working on the

hydraulic system
Oil may spurt out if caps or filters are removed or pipes
are disconnected before releasing the pressure in the
hydraulic system.
• Gradually loosen the vent plug to release the internal
pressure of the hydraulic oil tank. 1BAA16Z

• Move all the control levers and pedals several times in Be sure to handle the high-pressure nitrogen gas en-
all directions to release the pressure from the circuit of closed in the accumulator with care according to proce-
the working equipment (for link type controls). dure. If handled incorrectly, it could explode and cause
• When removing plugs or screws, or when disconnect- serious injury. Strictly observe the following precautions:
ing hoses, stand to the side and loosen them slowly to • Do not disassemble.
gradually release the internal pressure before remov- • Do not allow flame near it or throw it into a fire.
ing. • Do not drill, weld or fuse.
• Do not subject it to physical shock such as hitting, roll-
ing or dropping.
• Before disposing of the unit, the sealed gas must be
drained. Contact your sales or service dealer for help
with this.

Disconnect the battery

Disconnect the wiring from the both terminals (+ and -)
on the battery before working on the electrical system or
doing electric welding. Otherwise, short-circuit and ex-
plosion of the battery can result.

1-7
 SAFETY
SAFETY PRECAUTIONS 1
Use caution when handling batteries Have a service agent repair welding cracks or
other damage
Ask a service agent to make any repairs that require
welding. If the agent is unavailable, make sure the weld-
ing is done by a qualified person in a properly equipped
workplace.

Checks after maintenance

• Gradually raise the engine speed from low idle to max-
imum and check that no oil or water is leaking from the
parts serviced.
• Move the controls and check that the machine is oper-
1BAA17Z
ating properly.
• Batteries contain sulfuric acid which will damage eyes
or skin if contacted. Disposing of wastes
• If eye contact occurs, flush immediately with clean
water and get prompt medical attention.
• If accidentally swallowed, drink large quantities of
water or milk and call a physician immediately.
• If acid contacts skin or clothing, wash off immedi-
ately with a lot of water.
• Wear protective glasses and gloves when working with
batteries.
• Batteries generate flammable hydrogen gas which
may explode. Keep away from flame and sparks.
• Do not use or charge the battery when the electrolyte
level is lower than the lower limit: otherwise, it could
cause an explosion.
1BAA18Z
• Be sure to stop the engine by turning off the starter
• Always collect oil that is drained from the machine in
switch before inspecting or handling the battery.
containers. Improperly disposed waste oil can cause
• Be careful not to let metal tools (or any metal objects)
environmental harm.
such as a hammer or spanner come into contact with
• Follow appropriate laws and regulations when dispos-
the battery terminals.
ing of harmful objects such as oil, fuel, coolant, sol-
• When disconnecting the battery wiring, always discon-
vent, filters and batteries.
nect it from the earth side (-). When connecting, con-
nect the earth side last.
• Loose battery terminals may result in sparks. Be sure
to fasten terminals tightly.
• Make sure the battery caps are tightened securely.
• Do not charge a battery or jump-start the engine if the
battery is frozen; otherwise it may explode.
Warm the frozen battery to 15°C (59°F) before use.

1-8
 SAFETY
CAUTIONS WHEN WORKING 1
CAUTIONS WHEN WORKING When removing/installing the hydraulic unit
• Make sure that the temperature of the hydraulic oil has
When disassembling or assembling dropped and is cool enough to work with.
• Clean the machine before disassembly. • To prevent the hydraulic oil from escaping under pres-
• Check the following items and record the results: sure, release the residual pressure in the piping.
a. Model, machine serial number, hour meter. • Be sure to install caps or plugs on all openings in the
b. Reason for repair, repair history. hydraulic unit to prevent dirt from getting into the unit
c. Are the filters dirty? through them.
d. The conditions of the fuel and oil.
e. Any damage or looseness to any part?
• Where necessary, draw alignment indicators to avoid
assembly errors. To avoid misconnection, place indi-
cators such as reference tags on pipes.
• Clean all disassembled parts and new parts, arrange
them neatly, and place indicators as necessary.
• Be sure to replace all seals and cotter pins with new
ones.
• Keep those parts that should not come in contact with
water or oil away from those with oil on the surface.
• When installing bearings, bushings and oil seals, a
press tool should be used. If a hammer is used, use a
cushioning material to avoid damage. • The hydraulic oil adhering to the unit is often mistaken
• Wipe all joining surfaces clean until there is no dirt or for an oil leak, so wipe off the unit thoroughly.
dust adhering to them. • Be sure that no damage is caused to the plating on the
• Wrap the thread tight with seal tape starting 1 or 2 rod in the hydraulic cylinder.
threads away from the thread end. The tape should be • Removal and installation of the hydraulic cylinder
overlapped by about 10 mm (0.39 in). should be done with the rod fully retracted.
• Be sure to bleed the air after installing the hydraulic
cylinder. ( “4. Disassembly and assembly: Cylin-
der”)
• Always bleed the air when hydraulic oil is changed or
a hydraulic device is replaced.( “4. Disassembly
and assembly: Drive system”)

1-9
 SAFETY
CAUTIONS WHEN WORKING 1
When connecting/disconnecting the hoses or Handling of seals
pipes • Clean the grooves for O-rings and remove any burrs.
• When hydraulic hoses or pipes are connected, tighten
them once to the prescribed torque, then loosen them
slightly and retighten them to the prescribed torque.
a. Tighten the fittings after the installation surfaces fit
snugly together.
b. The above procedures do not apply to fittings with
seal tape.
• Use two spanners, one to tighten/loosen and the other
to secure the mating hose/pipe to ensure that the hose
is not twisted.

• Be careful not to twist the O-rings. If twisted, remove it

with your fingertips.
• When inserting, be careful not to damage the seal.
• Handling of the floating seal
a. After removal, wipe all oil off the O-ring and housing
of the floating seal.
b. When assembling, apply a thin coating of gear oil to
the contact surface of the housing,
c. After assembly, turn the seal two or three times to
1CAA03Z
get it to fit snugly.
• After connecting the hydraulic hoses or pipes, apply • Apply grease to the lip of the oil seal.
the maximum working pressure five or six times to a. This is to prevent wear from occurring upon first
check for leakage. start up after assembly.
• If high pressure, vibration or shock is applied to a twist-
ed hose, oil leak, hose breakage or damage to the
hose fitting can result.
• Be sure that the hydraulic hoses are not contacting
sharp objects or each other. This could cause surface
flaws on the hoses, resulting in breakage.

1CAA04Z

1-10
SERVICE DATA 2
Dimensional drawing
Specification tables
Table of masses
Lubricant and fuel chart
Performance criteria
Tightening torque
Hydraulic circuit diagram
Electrical circuit diagram
Wire harness diagram
 SERVICE DATA
DIMENSIONAL DRAWING 2
DIMENSIONAL DRAWING
Machine dimensions

Unit: mm (in.)
Standard arm Middle arm Long arm
Rubber crawler Steel crawler Rubber crawler Steel crawler Rubber crawler Steel crawler
A 7725 (304.1) I 7780 (306.2) I 7815 (307.6) I
B 2460 (96.9) I I I I I
C 2815 (110.9) 2805 (110.4) 2815 (110.9) 2805 (110.4) 2815 (110.9) 2805 (110.4)
D 2000 (78.8) I I I I I
E 930 (36.6) 895 (35.3) 930 (36.6) 895 (35.3) 930 (36.6) 895 (35.3)
F 2900 (114.2) 2890 (113.9) 2900 (114.2) 2890 (113.9) 2900 (114.2) 2890 (113.9)
G 3615 (142.4) 3600 (141.7) 3615 (142.4) 3600 (141.7) 3615 (142.4) 3600 (141.7)
H 2490 (98.0) I I I I I
J 500 (19.7) I I I I I
K 475 (18.6) 440 (17.4) 475 (18.6) 440 (17.4) 475 (18.6) 440 (17.4)
L 2885 (113.5) I 2965 (116.8) I 3015 (118.6) I
M 2285 (90.0) I 2360 (93.0) I 2405 (94.6) I
P 625 (24.7) I I I I I
Q 910 (35.9) I I I I I
R 2490 (98.0) I I I I I
S 550 (21.7) I I I I I
T 5725 (225.3) I 5780 (227.5) I 5815 (228.9) I
U 2410 (95.0) I I I I I
V 77° I I I I I
W 53° I I I I I

1
DIMENSIONAL DRAWING 2A0AS00
 SERVICE DATA
DIMENSIONAL DRAWING 2
Operating range

2A0AS02

Unit: mm (in.)
Standard arm Middle arm Long arm
Rubber crawler Steel crawler Rubber crawler Steel crawler Rubber crawler Steel crawler
A 8280 (326.1) I 8520 (335.4) I 8755 (344.8) I
B 8080 (318.1) 8090 (318.4) 8325 (327.7) I 8570 (337.3) I
C 4985 (196.3) 5020 (197.6) 5235 (206.2) 5270 (207.5) 5485 (216.0) 5520 (217.3)
D 4135 (162.9) 4170 (164.2) 4375 (172.3) 4410 (173.6) 4620 (181.8) 4650 (183.1)
E 8315 (327.3) 8280 (326.0) 8495 (334.4) 8460 (333.1) 8670 (341.4) 8640 (340.2)
F 5860 (230.8) 5830 (229.5) 6045 (237.9) 6010 (236.7) 6220 (245.0) 6190 (243.7)
G 2340 (92.2) 2310 (90.9) 2105 (82.8) 2070 (81.5) 1855 (73.1) 1825 (71.9)
H 5240 (206.3) I 5305 (208.8) I 5365 (211.2) I
J 540 (21.3) 505 (20.0) 540 (21.3) 505 (20.0) 540 (21.3) 505 (20.0)
K 510 (20.2) 545 (21.5) 510 (20.2) 545 (21.5) 510 (20.2) 545 (21.5)

2
DIMENSIONAL DRAWING 2A0AS00
 2
SERVICE DATA
SPECIFICATION TABLES

SPECIFICATION TABLES
Rubber C a n op y kg ( l b ) –
crawler Cab kg (lb) 14850 (32740)
Operating mass
Steel C a n op y kg ( l b ) –
crawler Cab kg (lb) 14850 (32740)
Net (ISO 14396) kW/min (hp/rpm)
-1
77/2000(103.3/2000)
Rated output
Net (ISO 9249/SAEJ1349) kW/min (hp/rpm) -1
71.8/2000(96.3/2000)
3
Heaped capacity m (ft. 3) 0.45 ( 15.89)
Bucket capacity 3 3
Struck capacity m (ft. ) 0.34 ( 12.01)

Performance
Sta nd a rd l oa d i ng ma ss kg ( l b ) 610 ( 1345)
Sl e w sp e e d mi n-1 (rpm) 13.8 (13.8)
Rubber 1s t km/h ( mp h) 3.0 ( 1.9)
crawler 2n d km/h ( mp h) 5.3 ( 3.3)
Travel speed
Steel 1st km/h (mph) 2.8 (1.76)
crawler 2nd km/h (mph) 5.0 (3.08)
Ma xi mum tra c ti v e forc e kN ( l b f) 72.4 ( 16280)
% 70
Gradeability
deg . 35
Rubber C a n op y kPa ( p si ) –
crawler Ca b kPa ( p si ) 45.3 ( 6.57)
Ground pressure
Steel C a n op y kPa ( p si ) –
crawler Ca b kPa ( p si ) 46.9 ( 6.8)
Sound -p owe r l e v e l dB ( A) 101
Noise level Sound-pressure
dB ( A) –
level*

*: At the operator location as stipulated by ISO 6396: 2008.

Dimensions of completed machine
Standard arm mm (in.) 7725 (304.1)
Overall length Middle arm mm (in.) 7780 (306.2)
Long arm mm (in.) 7815 (307.6)
During normal operation mm ( i n .) 2490 ( 98.0)
Overall width
Tra c k re tra c te d mm ( i n .) –
Rubber C a n op y mm ( i n .) –
crawler Cab mm (in.) 2815 (110.9)
Overall height
Steel C a n op y mm ( i n .) –
crawler Cab mm (in.) 2805 (110.4)

Dimensions of base machine

Overall length of base machine mm (in.) 4140 (163.0)
Overall width of base ma- During normal operation mm ( i n .) 2490 ( 98.0)
chine Tra c k re tra c te d mm ( i n .) –
U p p e r struc ture ov e ra l l wi d th mm ( i n .) 2460 ( 96.9)
Upper structure overall Le ft mm ( i n .) 1245 ( 49.0)
width Ri g h t mm ( i n .) 1215 ( 47.8)
Ca b ov e ra l l wi d th mm ( i n.) 1090 ( 42.9)

1
SPECIFICATION TABLES 2B0AS001
 SERVICE DATA
SPECIFICATION TABLES 2
Rubber Canopy mm (in.) –
Overall height of base ma- crawler Cab mm (in.) 2815 (110.9)
chine Steel Canopy mm (in.) –
crawler Cab mm (in.) 2805 (110.4)
Swing radius mm (in.) 2000 (78.8)
Upper structure rearmost distance from axis of rotation mm (in.) 2000 (78.7)
Clearance height under up- Rubber crawler mm (in.) 930 (36.6)
per structure Steel crawler mm (in.) 895 (35.3)
Rubber crawler mm (in.) 2890 (113.7)
Crawler base
Steel crawler mm (in.) 2880 (113.4)
Rubber crawler mm (in.) 3605 (141.9)
Crawler overall length
Steel crawler mm (in.) 3585 (141.2)
Undercarriage overall During normal operation mm (in.) 2490 (98.0)
width Track retracted mm (in.) –
During normal operation mm (in.) 1990 (78.3)
Track gauge
Track retracted mm (in.) –
Track shoe width mm (in.) 500 (19.7)
Ground clearance of un- Rubber crawler mm (in.) 475 (18.6)
dercarriage Steel crawler mm (in.) 440 (17.4)
Engine
Model Isuzu 4JJ1X
4-cycle, inline water-cooled overhead cam shaft,
Type
direct-injection, supercharged exhaust turbo
Number of cylinders Quantity 4
Cylinders Bore mm (in.) 95.4 (3.8)
Stroke mm (in.) 104.9 (4.1)
Total displacement mL (cu. in.) 2999 (183)
N·m (ft.-lb.) 385 (284)
Maximum torque
min-1 (rpm) 1600 (1600)
g/(kW·h)
Specific fuel consumption (at rated output) 213 (0.350)
(lb./hp-hr.)
Fuel/air cleaner Filter paper-type
Fan Feed supply system
Cooling system
Radiator Pressurized
Voltage V 24
Starting system
Output kW 4.0
Voltage V 24
Generator
Output kW 1.2
Voltage V 12
Battery Capacity A·h 80
Quantity 2

2
SPECIFICATION TABLES 2B0AS00
 SERVICE DATA
SPECIFICATION TABLES 2
Hydraulic system
Hydraulic pump drive system Engine-linked
Type Double variable piston pump and 2 gear pumps
Quantity 1
L/min.
112 (29.6)
(US gal./min.)
L/min.
112 (29.6)
Hydraulic pump (US gal./min.)
Delivery
L/min.
54.8 (14.5)
(US gal./min.)
L/min.
20 (5.3)
(US gal./min.)
Hydraulic pump control system Total horsepower control
MPa (psi) 34.3 (4970)
MPa (psi) –
Main relief valve pressure setting
MPa (psi) –
MPa (psi) –
Hydraulic tank pressure Pressure tank
Type Directional control valve with 12 valves in series
Control valve
Operation type –
Type Glass fiber filter type
Hydraulic oil filter Filter precision BETA 10 = 6.0
Installation position Return circuit (inside tank)
Cooling system Air-cooled
Hydraulic oil cooler
Radiation surface area m2 (ft.2) –

Operating device
Position Left side
Cab
Construction Suspension seat, adjustable
Steel-enclosed cab
Cab or canopy Construction
with fully reinforced glass windows
Variable travel speed switch
Shifting operation
(handle grip of operating lever)
Travel operation Hydraulic pilot operated, 2 levers
Slew operation Hydraulic pilot-operated
Control levers and pedals Arm operation Hydraulic pilot-operated
Bucket operation Hydraulic pilot-operated
Boom operation Hydraulic pilot-operated
Boom swing operation Hydraulic pilot-operated pedal system
Other Auxiliary line piping operation: Switch operated
Water temperature gauge, fuel gauge, engine emer-
gency warning light, third hydraulic line, charge warn-
Instruments, switches Cluster gauges
ing light, hydraulic pressure warning light, water tem-
perature warning light, variable-speed travel indicator
Headlight V-W 24-70 H3 halogen
Lighting device
Boom light V-W 24-70 H3 halogen
Warning, safety devices 24 V, 113 dB (A)
With AUX IN AM/FM radio, air conditioner, wipers,
Others
and defroster

3
SPECIFICATION TABLES 2B0AS00
 2
SERVICE DATA
SPECIFICATION TABLES

Slew equipment
Slew bearing Type Ball bearing-type
Type Constant-volume, swash plate piston motor
Slew motor
Quantity 1
Reduction gears Type Epicyclic gearing (2-stage)
Type Counterbalance valveless type, with make-up valve
Slew brake
Quantity 1
Slew parking brake Type W et, friction plate type
Slew lock Type –

Lower machinery
Power transmission device
Variable displacement (2-speed) piston motor, with
Type
Travel motor counterbalance valve
Quantity 2
Reduction gears Type Epicyclic gearing (2-stage)
Travel brake Type Brake valve with shockless relief
Parking brake Type W et, friction plate type
Undercarriage
Type Rubber crawler
Number of shoes
Quantity –
(on one side)
Shoe width mm (in.) 500 (19.7)
Lug height mm (in.) 35 (1.3)
Track shoe
Type Steel crawler with triple grouser
Number of shoes
Quantity 44
(on one side)
Shoe width mm (in.) 500 (19.7)
Grouser height mm (in.) 20 (0.8)
Carrier roller
Quantity 1
(on one side)
Roller
Track roller
Quantity 7
(on one side)
Track adjuster Type Hydraulic cylinder type (with cushion spring)
Track gauge extension mechanism –

Working equipment
Backhoe attachment
Heaped capacity m 3 (ft.3) 0.45 (15.89)
Bucket capacity 3 3
Struck capacity m (ft. ) 0.34 (12.01)
Standard mm (in.) 850 (33.5)
Bucket width
With side cutter mm (in.) 970 (38.2)
Bucket mass kg (lb) 305 (672)
Boom length mm (in.) 4060 (159.8)
Standard mm (in.) 2070 (81.5)
Arm length Middle mm (in.) 2320 (91.3)
Long mm (in.) 2570 (101.2)
Bucket wrist radius mm (in.) 1230 (48.2)
Bucket wrist angle deg. 180

4
SPECIFICATION TABLES 2B0AS00
 SERVICE DATA
SPECIFICATION TABLES 2
Left deg. 75
Boom swing angle
Right deg. 55
Eccentricity of boom swing pivot mm (in.) 150 (5.9)
Working dimensions (Standard arm)
Maximum reach mm (in.) 8280 (326.1)
Maximum reach at ground reference plane mm (in.) 8080 (318.1)
Minimum radius of ground level finishing mm (in.) 8565 (337.2)
Maximum digging depth mm (in.) 4985 (196.3)
Reach at maximum digging depth mm (in.) 3350 (131.8)
Maximum vertical digging depth mm (in.) 4135 (162.9)
Maximum height of cutting edge mm (in.) 8315 (327.3)
Reach at maximum height mm (in.) 3760 (148.0)
Maximum dumping height mm (in.) 5860 (230.8)
Reach at maximum dumping height mm (in.) 3760 (148.0)
Minimum dumping height mm (in.) 2340 (92.2)
Minimum radius of equipment and attachment mm (in.) 2885 (113.5)
Minimum radius of equipment at maximum front offset mm (in.) 2285 (90.0)
Overall height at minimum radius of equipment and attachment mm (in.) 6260 (246.5)
Overall height of equipment at maximum front offset mm (in.) 6260 (246.5)
Left mm (in.) 625 (24.7)
Max. bucket offset distance
Right mm (in.) 910 (35.9)

Main structure
Integrated hydraulic cylinder,
Boom
drive swing type
Arm –
Type –
Bucket
Number of teeth Quantity 5

Hydraulic cylinder
Number of cylinders Quantity 2
Boom cylinder Bore mm (in.) 100 (3.9)
Stroke mm (in.) 995 (39.2)
Number of cylinders Quantity 1
Arm cylinder Bore mm (in.) 110 (4.3)
Stroke mm (in.) 1105 (43.5)
Number of cylinders Quantity 1
Bucket cylinder Bore mm (in.) 100 (3.9)
Stroke mm (in.) 875 (34.5)
Number of cylinders Quantity 1
Swing cylinder Bore mm (in.) 140 (5.5)
Stroke mm (in.) 835 (32.9)

Digging force
Bucket cylinder kN (lbf) 98.7 (22190)
Maximum digging force
Arm cylinder kN (lbf) 64.9 (14590)
Maximum lifting force Boom cylinder kN (lbf) 59.8 (13440)
Attachment (optional) Long arm, middle arm

5
SPECIFICATION TABLES 2B0AS00
 SERVICE DATA
SPECIFICATION TABLES 2
Dozer blade
Type Straight type
Operation type Hydraulic hoisting type
Number of cylinders Quantity 2
Dozer blade cylinder Bore mm (in.) 115 (4.5)
Stroke mm (in.) 235 (9.3)
Dimensions
Width mm (in.) 2490 (98.0)
Dozer blade dimensions
Height mm (in.) 550 (21.7)
Cutting angle deg. 60
Distance between the front end of the dozer blade and the axis
mm (in.) 2395 (94.4)
of rotation
Dozer blade maximum lifting mm (in.) 540 (21.3)
Dozer blade maximum lowering mm (in.) 510 (20.2)
Dozer blade approach angle deg. 30

6
SPECIFICATION TABLES 2B0AS00
 SERVICE DATA
TABLE OF MASSES 2
TABLE OF MASSES
Upper structure kg (lb)
Engine 333 (734)
Radiator assembly 81 (179)
Main pump 87 (192)
Gear pump 5 (12)
Hydraulic tank assembly 110 (243)
Fuel tank assembly 82 (180)
Control valve assembly 204 (450)
Pilot valve 2 (5)
Slew motor 170 (375)
Cab 370 (816)
Canopy –
Counterweight 2250 (4960)
Counterweight (with added weight) 2750 (6063)
Swing bracket 497 (1096)
Swing cylinder 188 (414)

Lower structure kg (lb)

Swivel joint 24 (53)
Slew bearing 200 (441)
Rubber crawler 752 (1658)
Steel crawler (500-mm-wide model) 750 (1654)
Steel crawler (600-mm-wide model) 895 (1974)
Steel crawler (700-mm-wide model) 992 (2187)
Segmented rubber crawler 812 (1790)
Travel motor 145 (320)
Carrier roller 16 (34)
Track roller 24 (53)
Front idler assembly 103 (226)
Track adjuster 97 (213)
Blade (500-mm-wide model) 567 (1250)
Blade (600-mm-wide model) 578 (1274)
Blade (700-mm-wide model) 590 (1300)
Dozer blade cylinder 61 (134)

Hoe attachment kg (lb)

Boom 669 (1474)
Arm (standard model) 273 (602)
Arm (middle model) 312 (688)
Arm (long model) 343 (756)
Bucket (Standard model) 305 (672)
Boom cylinder 110 (243)
Arm cylinder 137 (302)
Bucket cylinder 94 (207)

1
TABLE OF MASSES 2B1AS00
 SERVICE DATA
LUBRICANT AND FUEL CHART 2
LUBRICANT AND FUEL CHART
Select the appropriate fuel, lubricant, and grease according to temperature by referring to the table below.
• Regardless of the specified time, change the oil if it becomes too dirty or degraded.
• When refilling, never mix oils of different brands. If a brand is to be changed, replace all of the fuel/oil.
Selection by air temperature
When to change/
Part Type -4 14 32 50 68 86 104°F Capacity
replenish
-20 -10 0 10 20 30 40°C

Upper limit:
Diesel engine oil Every 500 hrs. af- 17 L (18.0 US qt.)
Engine oil pan SAE 10W-30
API: CJ-4 ter the first 50 hrs. Lower limit:
13 L (13.7 US qt.)

Takeuchi genuine
ISO VG46 Every 4000 hrs.***
hydraulic oil 46
Total amount of oil:
215 L (56.8 US gal.)
Hydraulic tank
ISO VG32 Tank capacity:
Anti-wear hydrau-
ISO VG46 Every 2000 hrs.*** 95 L (25.1 US gal.)
lic oil
ISO VG68

Cooling water
(water + coolant)**
SAE-J814C,
Engine cooling Mixture of 50% coolant
J1941, J1034, or Every 1000 hrs. 18.5 L (19.5 US qt.)
system Mixture of 30% coolant
J2036
ASTM-D6210 or
D4985 (USA)
Every 1000 hrs.
Slew reduction Gear oil
SAE 90 after the first 250 5.3 L (5.6 US qt.)
gear API: GL-4
hrs.*
Every 1000 hrs.
Travel reduction Gear oil
SAE 90 after the first 250 2.1 L (2.2 US qt.)
gear API: GL-4
hrs.*
Engine oil
Carrier roller SAE 30 – 0.05 L (1.7 fl. oz.)
API: CD class
Gear oil
Track roller ISO VG 220 – 0.29 L (9.8 fl. oz.)
API: GL-3
Engine oil
Idler SAE 10W-30 – 0.20 L (6.8 fl. oz.)
API: CD class
Slew bearing Every 500 hrs.
Lithium grease
Working equip- Daily or every 10
EP-2 – As required
ment hrs.
NLGI No. 2
Levers When required

* If the ratio of traveling time to total operating time is high, replace the gear oil earlier than the specified time.
** For water, use tap water (soft). Do not use well or river water.
When the ambient temperature drops below 0°C (32°F), add coolant (antifreeze). Follow the coolant manufactur-
er’s instructions to determine the mixture ratio.
*** The replacement interval for hydraulic oil depends on the type of oil being used. New machines are shipped from
the factory with the Takeuchi genuine hydraulic oil 46. This manual describes when to replace the hydraulic oil
assuming that this Takeuchi oil is used. When a conventional anti-wear hydraulic oil is used, replace it every 2000
hours.

1
LUBRICANT AND FUEL CHART 2C0AS00
 SERVICE DATA
LUBRICANT AND FUEL CHART 2
Diesel fuel standards
Use a diesel fuel that is compliant with any of the stan-
dards listed below. The table below shows standards
from various countries/regions.
Diesel fuel standards Country/Region
ASTM D975
USA
No. 1-D, S15, S500
Canada
No. 2-D, S15, S500
EN590:96 EU
ISO 8217 DMX International standard
BS 2869-A1 (or A2) UK
JIS K2204 Grade, 2-go Japan
KSM-2610 Korea
GB252 China

Part Type Capacity

To maintain the performance and service life of the engine,
always use clean and high-quality fuel.
• To avoid freezing in cold climates, use a light oil that still
functions when the temperature is at least 12°C (54°F) be-
low the lowest expected ambient temperature.
• Use a light oil with a cetane number of 45 or higher. When
operating at a very low temperature or at a high altitude, a
higher cetane number fuel will be required.
• Use fuel with an overall sulfur content below 0.05% to
Fuel tank Diesel fuel 0.0015%. Be sure to use fuel with an ultra-low sulfur con- 250 L (66.0 US gal.)
tent for applications in the U.S. or Canada, in particular.
• The use of fuel containing a high sulfur content may cause
sulfuric acid corrosion to occur inside the cylinder.
• Do not mix fuel with any kerosene, used engine oil, or left-
over fuel.
• Poor quality fuel can degrade engine performance. It can
also damage the engine.
• Refrain from adding additives to the fuel. Some fuel addi-
tives can degrade engine performance.

2
LUBRICANT AND FUEL CHART 2C0AS00
 2
SERVICE DATA
PERFORMANCE CRITERIA

PERFORMANCE CRITERIA
Standard values table
Item Standard value Allowable value
min-1
Idling -20 ( 1000 -20 )
1000 +20 +20
(rpm)
Engine speed
min-1
Maximum R.P.M. -20 ( 2000 -20 )
2000 +20 +20
(rpm)
Boom MPa (psi) -0.5 ( 4975 -73 )
34.3 +1.4 +203

Arm MPa (psi) 34.3 -0.5 ( 4975 +203

+1.4
-73 )
Hydraulic oil pres-
Dozer blade MPa (psi) -0.5 ( 3408 -73 )
23.5 +1.8 +261
sure
Slew MPa (psi) 32.4 +2.8
-0 ( 4699 +406
-0 )
Pilot pressure MPa (psi) 3.9 -0.1 ( 566 -15 )
+0.5 +73

Retracted s 3.2 +0.5

-0.5 4.0
+0.5
Extended s 2.8 -0.5 3.6
Boom cylinder
Retracted s
Extended s
Retracted s 2.8 +0.5
-0.5 3.6
Arm cylinder +0.5
Extended s 3.0 -0.5 3.8
+0.4
Bucket cylin- Retracted s 2.1 -0.4 2.7
der Extended s 3.1 +0.4
-0.4 3.8
Cylinder speed +1.2
Retracted s 9.2 -1.2 11.3
+1.2
Extended s 9.3 -1.2 11.4
Swing cylinder
Retracted s
Extended s
Retracted s 3.5 +0.4
-0.4 4.3
+0.5
Dozer blade Extended s 4.2 -0.5 5.1
cylinder Retracted s
Extended s
Normal speed s 9.2 +0.8
-0.8 10.9
Slew time
Low speed s
Overrun when slewing stops mm (in.) -150 ( 19.7 -5.9
500 +150 +5.9
) 865 (34.1)
Natural travel drop mm (in.) 0 ( 0 )
Slew bearing mm (in.) 0 ( 0 )
Natural slew drop
Swing cylinder mm (in.) 10 +0
-10 ( 0.4 +0.0
-0.4 ) 20 (0.8)
+1.4
Rubber s 11.4 -1.4 13.9
1st
Travel speed 10 m Steel s 12.0 +1.7
-1.7 14.9
(32.8 ft.) Rubber s 6.6 +1.2
-1.2 8.7
2nd +1.4
Steel s 6.9 -1.4 9.3
+3.0
Rubber s 44.3 -3.0 51.7
1st
Travel speed Steel s 47.5 +3.0
-3.0 55.3
(5 revs.) Rubber s 25.9 +2.5
-2.5 32.0
2nd +2.5
Steel s 27.8 -2.5 34.2
Straight-ahead traveling mm (in.) 100 +0
-100 ( 19.7 +0
-3.9 ) 400 (15.7)
Bucket
Straight travel func- Arm To be moved forward using simultaneous
tion check Boom operation
Dozer blade

1
PERFORMANCE CRITERIA 2D0AS00
 2
SERVICE DATA
PERFORMANCE CRITERIA

Bucket cylinder speed Retracted s 4.3 +1.1

-1.1 5.8
Boom cylinder mm (in.) 4 +0
-4 ( 0.2 +0.0
-0.2 ) 8 (0.3)
Arm cylinder mm (in.) 4 +0
-4 ( 0.2 +0.0
-0.2 ) 8 (0.3)
Arm cylinder
mm (in.) ( )
(with emergency shut-off valve)
Natural cylinder
Bucket cylinder mm (in.) 4 +0
-4 ( -0.2 )
0.2 +0.0 8 (0.3)
drop
Dozer blade cylinder mm (in.) 4 +0
-4 ( 0.2 -0.2 )
+0.0
8 (0.3)
Bucket tip mm (in.) 10 +0
-10 ( 0.4 +0.0
-0.4 ) 20 (0.8)
Bucket tip
mm (in.) ( )
(with emergency shut-off valve)
Backlash mm (in.) 10 +0
-10 ( -0.4 )
0.4 +0.0 20 (0.8)
Right control lever mm (in.) 4 -4 (
+0
0.2 +0.0
-0.2 ) 8 (0.3)
Left control lever mm (in.) 4 +0
-4 ( 0.2 +0.0
-0.2 ) 8 (0.3)
Lever play
Travel lever mm (in.) 4 +0
-4 ( 0.2 +0.0
-0.2 ) 8 (0.3)
Dozer blade lever mm (in.) 4 +0
-4 ( 0.2 +0.0
-0.2 ) 8 (0.3)
Swing lever N (lbf)
Lever control force
Dozer blade lever N (lbf)

Slew bearing play mm (in.) -0.4 ( 0.02 -0.02 )

0.5 +0.4 3 (0.1)
+0.02

Rubber mm (in.) 155 to 165 (6.1 to 6.5)

Track tension Rubber pads mm (in.) 235 to 265 (9.3 to 10.4)
Steel mm (in.) 250 to 280 (9.8 to 11.0)

2
PERFORMANCE CRITERIA 2D0AS00
 2
SERVICE DATA
PERFORMANCE CRITERIA

Hydraulic pump assignment table

P1 Right travel, slew, boom, arm, 1st auxiliary line piping 112.0 L/min. (29.6 US gal./min.)
Left travel, bucket, boom, arm, boom swing, 1st aux-
P2 112.0 L/min. (29.6 US gal./min.)
iliary line piping*
P3 Pilot pressure, travel speed switching 20.0 L/min. (5.3 US gal./min.)
Pr Dozer blade, 2nd auxiliary line piping 54.8 L/min. (14.5 US gal./min.)

Pump P1
Right travel Pressure: 34.3 MPa (4974 PSI) Test port P1
Slew Pressure: 31.4 MPa (4553 PSI) Test port P1
Boom Pressure: 34.3 MPa (4974 PSI) Test port P1
Arm Pressure: 34.3 MPa (4974 PSI) Test port P1
1st auxiliary line piping Pressure: 24.5 MPa (3553 PSI) Test port P1

Pump P2
Left travel Pressure: 34.3 MPa (4974 PSI) Test port P2
Bucket Pressure: 34.3 MPa (4974 PSI) Test port P2
Boom Pressure: 34.3 MPa (4974 PSI) Test port P2
Arm Pressure: 34.3 MPa (4974 PSI) Test port P2
1st auxiliary line piping* Pressure: 24.5 MPa (3553 PSI) Test port P2

Pump P3
Pilot pressure Pressure: 3.9 MPa (566 PSI) Test port P3
Travel speed switching Pressure: 3.9 MPa (566 PSI) Test port P3

Pump Pr
Dozer blade Pressure: 23.6 MPa (3422 PSI) Test port Pr
2nd auxiliary line piping Pressure: 23.6 MPa (3422 PSI) Test port Pr

* The first auxiliary line piping is also used for the P2 flow rate in high-flow applications.

3
PERFORMANCE CRITERIA 2D0AS001
 SERVICE DATA
PERFORMANCE CRITERIA 2
Methods for inspecting performance
Hydraulic oil pressure (Boom, arm)
Measurement method
• Engine: Maximum R.P.M.
• Hydraulic oil temp.: 50°C to 60°C (122°F to 140°F)
• Install a pressure gauge on the pressure detection
port. Operate the hydraulic circuit to be tested, and
measure the relief pressure.
Pressure detection port
Circuit Relief valve
Port Size
Boom
R1 P1, P2 G1/4
Arm

Adjustment method
1. Loosen the locknut (2), and turn the setscrew (1) to
adjust the set pressure.
• Turn the setscrew clockwise to increase the set
pressure.
• Turn the setscrew counterclockwise to decrease
the set pressure.
2. In order to keep the setscrew (1) from turning after
the pressure has been adjusted, tighten the locknut
(2) while holding the setscrew (1) firmly in place.
Lock nut: 30 ± 2 N·m (22.1±1.5 ft.-lb)
3. Operate the relief valve once more to confirm that the
pressure that has been set is stabilized.

4
PERFORMANCE CRITERIA 2D0AS00
 SERVICE DATA
PERFORMANCE CRITERIA 2
Hydraulic oil pressure (Dozer blade)
Measurement method
• Engine: Maximum R.P.M.
• Hydraulic oil temp.: 50°C to 60°C (122°F to 140°F)
• Install a pressure gauge on the pressure detection
port. Operate the hydraulic circuit to be tested, and
measure the relief pressure.
Pressure detection port
Circuit Relief valve
Port Size
Dozer
RPr Pr G1/4
blade

Adjustment method
1. Loosen the locknut (2), and turn the setscrew (1) to
adjust the set pressure.
• Turn the setscrew clockwise to increase the set
pressure.
• Turn the setscrew counterclockwise to decrease
the set pressure.
2. In order to keep the setscrew (1) from turning after
the pressure has been adjusted, tighten the locknut
(2) while holding the setscrew (1) firmly in place.
Lock nut: 30 ± 2 N·m (22.1±1.5 ft.-lb)
3. Operate the relief valve once more to confirm that the
pressure that has been set is stabilized.

5
PERFORMANCE CRITERIA 2D0AS00
 SERVICE DATA
PERFORMANCE CRITERIA 2
Hydraulic oil pressure (Slew)
Measurement method
• Engine: Maximum R.P.M.
• Hydraulic oil temp.: 50°C to 60°C (122°F to 140°F)
• Install a pressure gauge on the pressure detection
port. Operate the hydraulic circuit to be tested, and
measure the relief pressure. (Secure the upper struc-
ture so that it cannot slew in the direction to be mea-
sured.)
Pressure detection port
Circuit Relief valve
Port Size
Right slew SR1
P1 G1/4
Left slew SR2

Adjustment method
1. Loosen the locknut (2), and turn the setscrew (1) to
adjust the set pressure.
• Turn the setscrew clockwise to increase the set
pressure.
• Turn the setscrew counterclockwise to decrease
the set pressure.
2. In order to keep the setscrew (1) from turning after
the pressure has been adjusted, tighten the locknut
(2) while holding the setscrew (1) firmly in place.
Locknut: 49 N·m (36.1 ft.-lb)
3. Operate the relief valve once more to confirm that the
pressure that has been set is stabilized.

6
PERFORMANCE CRITERIA 2D0AS00
 SERVICE DATA
PERFORMANCE CRITERIA 2
Hydraulic oil pressure (Pilot pressure)
Measurement method
• Engine: Maximum R.P.M.
• Hydraulic oil temp.: 50°C to 60°C (122°F to 140°F)
• Install a pressure gauge on the pressure detection
port to measure the relief pressure.
Pressure detection port
Relief valve
Port Size
R3 P3 G1/4

Adjustment method
1. Loosen the locknut (2), and turn the setscrew (1) to
adjust the set pressure.
• Turn the setscrew clockwise to increase the set
pressure.
• Turn the setscrew counterclockwise to decrease
the set pressure.
2. In order to keep the setscrew (1) from turning after
the pressure has been adjusted, tighten the locknut
(2) while holding the setscrew (1) firmly in place.
Locknut: 29 N·m (21.4 ft.-lb)
3. Operate the relief valve once more to confirm that the
pressure that has been set is stabilized.

7
PERFORMANCE CRITERIA 2D0AS00
 SERVICE DATA
PERFORMANCE CRITERIA 2
Travel speed (5 revs.)
• Engine: Maximum R.P.M.
• Hydraulic oil temp.: 50°C to 60°C (122°F to 140°F)
• Measuring attitude: Excavator body to be raised using
both the hoe attachment and the dozer blade
• Set crawler belts in motion. Starting after one full revo-
lution, measure the time required for five revolutions.
(To measure speed after it has stabilized.)

Travel speed (10 m)

• Engine: Maximum R.P.M.
• Hydraulic oil temp.: 50°C to 60°C (122°F to 140°F)
• Measuring attitude: Traveling
• Drive 5 meters (16.4 ft.) first and then start measuring
the time required for the machine to travel another 10
meters (32.8 ft.). Do this on level ground.

„ Traveling attitude
With the bucket in a no-load state and the boom raised,
fully extend the arm and bucket cylinders and adjust the
hoe attachment so that its lowest part is even with the ex-
cavator’s minimum ground clearance level. The dozer
blade should not be touching the ground.

Straight-ahead traveling
• Engine: Maximum R.P.M.
• Hydraulic oil temp.: 50°C to 60°C (122°F to 140°F)
• Measuring attitude: Traveling
• Starting from an approach of 5 meters (16.4 ft.), drive
the excavator in a turn for 10 meters (32.8 ft.), and then
measure the distance, X (from the 5-m point). Do this
on level ground.

8
PERFORMANCE CRITERIA 2D0AS00
 SERVICE DATA
PERFORMANCE CRITERIA 2
Natural travel drop
• Engine: Stopped
• Hydraulic oil temp.: 50°C to 60°C (122°F to 140°F)
• Inclination angle: 15°
• Measuring attitude: Fully extend the boom, arm, and
bucket cylinders. Completely retract the dozer blade
cylinder.
• Leave the excavator parked at an angle for 5 minutes
and then measure the amount of natural drop.

Slew time
• Engine: Maximum R.P.M.
• Hydraulic oil temp.: 50°C to 60°C (122°F to 140°F)
• Measuring attitude: With the bucket in a no-load state,
completely retract the arm cylinders, and then fully ex-
tend the bucket cylinder and make adjustments so that
the boom foot pin and bucket pin are at the same
height.
• Set the upper structure in motion, wait 1 rotation, and
then measure the time required for the next 2 rotations.

Overrun when slewing stops

• Engine: Maximum R.P.M.
• Hydraulic oil temp.: 50°C to 60°C (122°F to 140°F)
• Measuring attitude: Same as that for measuring slew
time
• Draw matching marks on the outer race of the slew
bearing and the lower frame at points rotated exactly
180° from the starting point. With the hoe attachment
in a no-load state, slew another 180 degrees, at which
point the operation lever should return back to neutral.
Measure the difference between the position marks
and the point at which the hoe attachment was
stopped.

Natural slew drop

• Engine: Stopped
• Hydraulic oil temp.: 50°C to 60°C (122°F to 140°F)
• Inclination angle: 15°
• Measuring attitude: Same as that for measuring slew
time
• Rotate the upper structure so that it is directly abeam
of the grade. Next, draw positional marks on the outer
race of the slew bearing and on the lower frame. Mea-
sure the amount of distance that opens up between
the marks after 5 minutes have passed.

9
PERFORMANCE CRITERIA 2D0AS00
 SERVICE DATA
PERFORMANCE CRITERIA 2
Boom cylinder speed
• Engine: Maximum R.P.M.
• Hydraulic oil temp.: 50°C to 60°C (122°F to 140°F)
• Measuring attitude: Completely retract the arm cylin-
der, and fully extend the bucket cylinder.
• Next, measure the time required for the bucket to
reach its highest elevation point (lowest point) from its
lowest point (highest point) at rest on the ground. (ex-
clusive of cushion operating time).

Arm cylinder speed

• Engine: Maximum R.P.M.
• Hydraulic oil temp.: 50°C to 60°C (122°F to 140°F)
• Measuring attitude: With the bucket in a no-load state,
completely retract the arm cylinder, fully extend the
bucket cylinder, position the arm horizontally, and rest
the dozer blade on the ground.
• Measure the time required for the arm cylinder to move
from the fully retracted position to the fully extended
position, and vice versa.

Bucket cylinder speed

• Engine: Maximum R.P.M.
• Hydraulic oil temp.: 50°C to 60°C (122°F to 140°F)
• Measuring attitude: With the bucket in a no-load state,
completely retract the arm cylinder, position the arm
horizontally, and rest the dozer blade on the ground.
• Measure the time required for the bucket cylinder to
move from the fully retracted position to the fully ex-
tended position, and vice versa.

Dozer blade cylinder speed

• Engine: Maximum R.P.M.
• Hydraulic oil temp.: 50°C to 60°C (122°F to 140°F)
• Measuring attitude: Using the hoe attachment, lift up
the dozer blade end of the excavator.
• After raising and lowering the dozer blade one full
stroke each, measure the time required per stroke in
each direction.

10
PERFORMANCE CRITERIA 2D0AS00
 SERVICE DATA
PERFORMANCE CRITERIA 2
Swing cylinder speed
• Engine: Maximum R.P.M.
• Hydraulic oil temp.: 50°C to 60°C (122°F to 140°F)
• Measuring attitude: Same as that for measuring slew
time
• While swinging the boom from left (right) to right (left),
measure the time required for a full stroke in each di-
rection. (exclusive of cushion operating time).

Natural cylinder drop

Boom, arm bucket, dozer blade, bucket tip
• Engine: Stopped
• Hydraulic oil temp.: 50°C to 60°C (122°F to 140°F)
• Measuring attitude: With the bucket in a no-load state,
completely retract the dozer blade and arm cylinders,
and then fully extend the bucket cylinder and make
adjustments so that the boom foot pin and bucket pin
are at the same height.
• Maintain this attitude for 5 minutes and then measure
the change in rod length and the distance that the
bucket tip moved.

Swing
• Engine: Stopped
• Hydraulic oil temp.: 50°C to 60°C (122°F to 140°F)
• Inclination angle: 15°
• Measuring attitude: Same as that for measuring slew
time
• Rotate the upper structure so that it is directly abeam
of the grade, and then measure the change in rod
length after 5 minutes has passed.

Lever operating force

• With the engine turned off, place a push-pull scale on
the handle grip center or the pedal edge to measure
the force. Record the readings at the point at which the
lever/pedal reaches a full stroke.

11
PERFORMANCE CRITERIA 2D0AS001
 SERVICE DATA
PERFORMANCE CRITERIA 2
Lever play
• Measure any discernible play at the tip of the lever or
pedal.

Backlash
• Measuring attitude: Completely retract the arm cylin-
der, and fully extend the bucket cylinder.
• Move the tips of the bucket teeth from side to side (left
and right), and measure the amount of play.

Slew bearing play

1. With the bucket in a no-load state, completely retract
the arm cylinder, fully extend the bucket cylinder,
move the dozer blade back, and make adjustments
so that the boom foot pin and bucket pin are at the
same height.
2. Attach a dial gauge to the bottom face of the slew
bearing’s outer race located near the front of the ex-
cavator, and set the dial gauge to 0.
3. Lower the boom, raise the crawler to the height, H,
and then read the dial gauge to get the measure-
ment.

Track tension
• Measuring attitude: Excavator body to be raised using
both the hoe attachment and the dozer blade. For
models with rubber crawlers, line up the crawler seam
joint (marked with an M or symbol) with the upper cen-
ter of the upper structure.
• Measure the width of the gap between the bottom sur-
face of the frame and the top surface of the track shoe
at the center of the crawler frame.

12
PERFORMANCE CRITERIA 2D0AS00
 SERVICE DATA
TIGHTENING TORQUE 2
TIGHTENING TORQUE
Hydraulic hose
UNION NUT
Tightening torque ÜBERWURFMUTTER
ECROU D'UNION
Hose fitting size Union nut (G) Taper thread (R)
N·m ft.-lb N·m ft.-lb
1/8 9.8 +4.9
0 7.3 +3.5
0 11.8 ± 1.2 8.7 ± 0.8 TAPER THREAD
KEGELWINDUNG
1/4 24.5 +4.9
0 18.1 +3.5
0 29.4 ± 2.9 21.7 ± 2.1 FILETAGE CONIQUE

3/8 49.0 +4.9

0 36.2 +3.5
0 53.9 ± 5.4 39.8 ± 3.9
1/2 58.8 +4.9
0 43.4 +3.5
0 88.3 ± 8.8 65.1 ± 6.4
3/4 117.7 +4.9
0 86.8 +3.5
0 147.1 ± 14.7 108.5 ± 10.7 2EAA01Z

1 137.3 +4.9
0 101.3 +3.5
0 196.1 ± 19.6 144.7 ± 14.3

Bite-type pipe fitting for steel pipe

Outer diameter of pipe Tightening torque

(mm) N·m ft.-lb
8 34.3 ± 4.9 23.5 ± 3.5
10 41.7 ± 2.5 30.7 ± 1.7
12 58.8 ± 4.9 43.4 ± 3.5
15 88.3 ± 4.9 65.1 ± 3.5
16 93.2 ± 4.9 68.7 ± 3.5
18 132.4 ± 4.9 97.6 ± 3.5 2EAA02Z

22 205.9 ± 9.8 151.8 ± 7.2

27.2 245.2 ± 9.8 181.0 ± 7.2
28 313.8 ± 19.6 231.4 ± 14.3
32 313.8 ± 19.6 231.4 ± 14.3
35 411.9 ± 19.6 303.7 ± 14.3

1
TIGHTENING TORQUE 2E0AS00
 SERVICE DATA
TIGHTENING TORQUE 2
Joint for piping

Tightening torque
Nominal thread
Steel Cast steel
diameter (R)
N·m ft.-lb N·m ft.-lb
1/8 11.8 ± 1.2 8.7 ± 0.8 10.8 ± 1.1 8.0 ± 0.7
1/4 29.4 ± 2.9 21.7 ± 2.1 24.5 ± 2.5 18.1 ± 1.7
3/8 53.9 ± 5.4 39.8 ± 3.9 49.0 ± 4.9 36.2 ± 3.5
1/2 88.3 ± 8.8 65.1 ± 6.4 73.5 ± 7.4 54.3 ± 5.3
3/4 147.1 ± 14.7 108.5 ± 10.7 127.5 ± 12.7 94.1 ± 9.3 2EAA03Z

1 196.1 ± 19.2 144.7 ± 14.3 171.6 ± 17.2 126.6 ± 12.5

Joint for piping (O-ring seal type)

O-RING
Nominal thread diameter Tightening torque O-RING
JOINT TORIQUE
(G) N·m ft.-lb
1/8 19.6 ± 2.0 14.5 ± 1.4
1/4 34.3 ± 4.9 25.3 ± 3.5
3/8 53.9 ± 4.9 39.8 ± 3.5
1/2 63.7 ± 4.9 47.0 ± 3.5
3/4 93.2 ± 4.9 68.7 ± 3.5
1 107.9 ± 9.8 79.5 ± 7.2
1–1/4 117.7 ± 9.8 86.8 ± 7.2
2EAA04Z
1–1/2 137.3 ± 9.8 101.2 ± 7.2

Nominal thread diameter Tightening torque

(UNF) N·m ft.-lb
7/19–20 16.7 ± 2.0 12.3 ± 1.4
1/2–20 22.6 ± 2.0 16.6 ± 1.4
9/16–18 31.4 ± 2.9 23.1 ± 2.1
3/4–16 59.8 ± 4.9 44.1 ± 3.5
1–1/16–12 102.0 ± 5.9 75.2 ± 4.4
1–5/16–12 135.3 ± 7.8 99.8 ± 5.8
1–5/8–20 181.4 ± 9.8 133.8 ± 7.2

2
TIGHTENING TORQUE 2E0AS00
 SERVICE DATA
TIGHTENING TORQUE 2
Bolts and nuts (JIS strength category 10.9)
Tightening torque
Thread Size × pitch General tightening points Special tightening points
N·m ft.-lb N·m ft.-lb
M6 × 1.0 9.8 ± 0.5 7.2 ± 0.4 11.8 ± 1.1 8.7± 0.4

M8 × 1.25 22.6 ± 1.1 16.6 ± 0.8 26.5 ± 2.5 19.5 ± 0.9

M10 × 1.5 47.1 ± 2.4 34.7 ± 1.7 54.9 ± 4.9 40.5 ± 2.0

Coarse M12 × 1.75 83.4 ± 4.1 61.5 ± 3.0 97.1 ± 7.4 71.6 ± 3.5

M14 × 2.0 134.4 ± 6.7 99.1 ± 4.9 155.9 ± 12.7 115.0 ± 5.7

M16 × 2.0 207.9 ± 10.4 153.3 ± 7.7 241.2 ± 17.2 177.9 ± 8.9

M20 × 2.5 410.9 ± 20.5 303.1 ± 15.1 475.6 ± 23.7 350.8 ± 17.5

M8 × 1.0 24.5 ± 1.2 18.1 ± 0.9 28.4 ± 1.4 21.0 ± 1.0

M10 × 1.25 50.0 ± 2.5 36.9 ± 1.8 58.8 ± 2.9 43.4 ± 2.2

M12 × 1.5 87.3 ± 4.3 64.4 ± 3.2 102.0 ± 5.1 75.2 ± 3.8
Fine
M14 × 1.5 135.3 ± 6.8 99.9 ± 5.0 157.9 ± 7.8 116.5 ± 5.8

M16 × 1.5 220.6 ± 11.0 162.7 ± 8.1 256.0 ± 12.7 188.8 ± 9.4

M20 × 1.5 452.1 ± 22.6 333.4 ± 16.6 524.7 ± 26.1 387.0 ± 19.2

1. General tightening points (non-lubricated)

All securing points that have no special tightening
torque specified in this manual and that are not spe-
cial tightening points.
2. Special tightening points (grease with molybdenum
disulfide applied)
Points where a specific tightening torque is specified
in this manual.
3. Points where thread-locking compound should be
applied (ThreeBond #1324).
4. If a tightening torque value is specified in this manual
for a point not listed in the table above, follow the
specification listed in the manual.
5. To tighten multiple bolts and nuts evenly, tighten op-
posite bolts/nuts alternately as a pair.

3
TIGHTENING TORQUE 2E0AS00
 SERVICE DATA
TIGHTENING TORQUE 2
Hose clips
For the hydraulic hoses

Tightening
Part no. Tightening range
torque
15337-***** mm (in.) N·m ft.-lb
-00013 9.5 to 12 (0.37 to 0.47)
-00016 11 to 16 (0.43 to 0.63) 3.4 2.5
-00019 13 to 20 (0.51 to 0.79)
-00022 14 to 22 (0.55 to 0.87)
-00025 17 to 25 (0.67 to 0.98)
-00028 22 to 30 (0.87 to 1.18) 4.8 3.6
-00035 25 to 35 (0.98 to 1.38)
-00041 30 to 40 (1.18 to 1.57)
-00048 35 to 50 (1.38 to 1.97) 1 7 mm (0.28 in.)
2 Tightening range
-00054 40 to 55 (1.57 to 2.17)
5.8 4.3
-00060 45 to 60 (1.77 to 2.36)
-00070 55 to 70 (2.17 to 2.76)
-00080 60 to 80 (2.36 to 3.15)
-00090 70 to 90 (2.76 to 3.54)
6.7 5.0
-00102 80 to 100 (3.15 to 3.94)
-00115 90 to 120 (3.54 to 4.72)

4
TIGHTENING TORQUE 2E0AS00
 SERVICE DATA
TIGHTENING TORQUE 2
For hoses other than the hydraulic hoses

Tightening
Part no. Tightening range
torque
15337-
mm (in.) N·m ft.-lb
*****
-00015 8 to 15 (0.31 to 0.59)
2.5 to 1.8 to
-00017 11 to 17 (0.43 to 0.67)
3.4 2.5
-00021 13 to 22 (0.51 to 0.87)
-00024 15 to 25 (0.59 to 0.98)
-00029 19 to 29 (0.75 to 1.14)
3.9 to 2.9 to
-00031 19 to 31 (0.75 to 1.22)
4.9 3.6
-00033 22 to 33 (0.87 to 1.30)
-00039 26 to 39 (1.02 to 1.54) 1 7 mm (0.28 in.)
-00045 32 to 45 (1.26 to 1.77) 2 Tightening range
-00051 32 to 51 (1.26 to 2.01)
-00052 38 to 51 (1.50 to 2.01)
-00057 44 to 57 (1.73 to 2.24)
-00061 40 to 61 (1.57 to 2.40)
-00066 50 to 66 (1.97 to 2.60)
-00069 50 to 69 (1.97 to 2.72)
-00071 50 to 71 (1.97 to 2.80)
-00076 58 to 76 (2.28 to 2.99)
-00081 60 to 81 (2.36 to 3.19)
-00086 68 to 86 (2.68 to 3.39)
-00091 70 to 91 (2.76 to 3.58)
4.9 to 3.6 to
-00096 77 to 96 (3.03 to 3.78)
5.9 4.3
-00101 80 to 101 (3.15 to 3.98)
-00113 87 to 113 (3.43 to 4.45)
-00121 100 to 121 (3.94 to 4.76)
-00131 110 to 131 (4.33 to 5.16)
-00139 104 to 138 (4.09 to 5.43)
-00166 130 to 166 (5.12 to 6.54)
-00181 150 to 181 (5.91 to 7.13)
-00206 175 to 206 (6.89 to 8.11)
-00232 200 to 232 (7.87 to 9.13)
-00257 226 to 257 (8.90 to 10.12)
-00283 251 to 283 (9.88 to 11.14)
-00308 277 to 307 (10.91 to 12.09)

5
TIGHTENING TORQUE 2E0AS00
 SERVICE DATA
HYDRAULIC CIRCUIT DIAGRAM 2
HYDRAULIC CIRCUIT DIAGRAM
ＳＬＥＷ ＭＯＴＯＲ BRADE BOOM
１００Ｍｅｓｈ ｉ＝１３／８８ ＲＥＬＩＥＦ ＳＥＴ ＰＲＥＳＳＵＲＥ：３１．４ＭＰａ ARM ５ ５
ＤＩＳＰＬＡＣＥＭＥＮＴ：７２．７ｃｍ３／ｒｅｖ φ１１５×φ７０−２３５ｓｔ×２ φ１００×φ７０−９９５ｓｔ
ＢＬＰ １００Ｍｅｓｈ ＢＳＰ １００Ｍｅｓｈ ＥＱＵＩＶＡＬＥＮＴ ＤＩＳＰ.：１２３６ｃｍ３／ｒｅｖ φ１１０×φ８０−１１０５ｓｔ R L
ＴＲＰ ＲＥＤＵＣＴＩＯＮ ＧＥＡＲ ＲＡＴＩＯ：１７．０００ ２ｎｄ ＡＵＸ． ４ｔｈ ＡＵＸ． Ｌ Ｒ
１２ ＩＮＰＵＴ Ａ（ＢＥＲＯＷ）
：ＲＥＶＥＲＳＥ ＲＥＤ ＲＥＤ ＩＮＰＵＴ Ａ（ＵＰＰＥＲ）：ＦＯＲＷＡＲＤ １１ １０ SWING BUCKET
ＴＲＴ１６ ＢＬＴ ＢＳＴ
ＩＮＰＵＴ Ｂ（ＵＰＰＥＲ）：ＦＯＲＷＡＲＤ ＩＮＰＵＴ Ｂ（ＢＥＬＯＷ）：ＲＥＶＥＲＳＥ ５４．８Ｌ／ｍｉｎ ５４．８Ｌ／ｍｉｎ φ１４０×φ９０−８３５ｓｔ ９ ８
７ φ１００×φ７０−８７５ｓｔ
Ｌ Ｒ Ｌ Ｒ
ＢＬ ＢＳ ＳＨ
ＴＲ ３５ １３
２１ ２０ Ｄ Ｄ
１７ ＰＧ
Ｐ Ｐ
５０ Ｃ１ Ｃ４ Ｃ２
Ｃ３
４ Ｔ
２ １ ２ １
１ ２ ３ ４ Ｐ１ Ｐ２

１００Ｍｅｓｈ ３ｒｄ ＡＵＸ． Ｌ Ｒ

４７
２ [Ｈｉｇｈ Ｐｒｅｓｓｕｒｅ Ｔｙｐｅ] Ａ Ｂ φ１．８ ３３
７ ３ ３Ａ ２Ａ ３Ｂ
１４ ＬＰ ＲＰ １００Ｍｅｓｈ
４ ６
Ａ Ｂ Ａ Ｂ Ｇ ５１
５ ＡＭ Ｂ Ｄｒ ３６
ＬＴ ＲＴ Ｃ２ Ｃ２ Ｃ２
ＩＮＰＵＴ Ａ：ＲＩＧＨＴ ＳＬＥＷ Ｍ φ０.８ φ０.８
Ｌ Ｒ ＧＣＡＦ
３７．８ＭＰａ ＤＰｉ
ＴＲＡＶＥＬ ＭＯＴＯＲ
ＭＴ１ ＭＰ１ ＩＮＰＵＴ Ｂ：ＬＥＦＴ ＳＬＥＷ Ｅ ＲＥＬＩＥＦ ＳＥＴ ＰＲＥＳＳＵＲＥ：３４．３ＭＰａ
Ｍ
Ｍ１ Ｍ１
Ｍ

１５ １ｓｔ ＡＵＸ． Ｂ １ｓｔ ＤＩＳＰ.：７５．５ｃｍ３／ｒｅｖ ３Ｐ ２Ｐ Ｔ

３７ ２ｎｄ ＤＩＳＰ.：４２．７ｃｍ３／ｒｅｖ
 １１２Ｌ／ｍｉｎ ＥＱＵＩＶＡＬＥＮＴ ＤＩＳＰ.(１ｓｔ)：４０７７ｃｍ３／ｒｅｖ
４０
３４ ＥＱＵＩＶＡＬＥＮＴ ＤＩＳＰ.(２ｎｄ)：２３０６ｃｍ３／ｒｅｖ ５３
Ｈｉｇｈ−Ｆｌｏｗ ６ Ｐｉｌ Ｐｉｌ
Ｖ２ Ｔ Ｐｉｌ ＲＥＤＵＣＴＩＯＮ ＧＥＡＲ ＲＡＴＩＯ：５４．０００
Ｔ
 ２２４Ｌ／ｍｉｎ ＢＤ ３７．８ＭＰａ
Ｔ
３７．８ＭＰａ
１ ３ ２ ４ １ ３ ２ ４ ＰｉＧＣＡＦＥ Ｖ２ Ｖ２
ＬＥＦＴ ＲＩＧＨＴ ＤＵＭＰ ＣＲＯＷＤ
ＣＤＢＡ
ＢＭＨ
ＢＭＲ

１００Ｍｅｓｈ ３１

ＳＳ２Ｐ
２ｎｄ ＡＵＸ. １８
ＳＳ２Ｔ Ｔｒ４
ＢＲ３
ＳＳ２ ＡＲ３
ＭＡＩＮ ＲＥＬＩＥＦ ＰＲＥＳＳＵＲＥ ２ｎｄ ＳＥＲＶＩＣＥ
ＤＣＢＡ Ｂ Ａ ｐｒｂ３
１ ２ Ｇ Ａ Ｐ１、Ｐ２：３４．３ＭＰａ
４３２１ Ｐ３(Ｐｒ)：２３．６ＭＰａ ｐｒａ３
４６ ＯＶＥＲＬＯＡＤ ＲＥＬＩＥＦ ＰＲＥＳＳＵＲＥ ＢＲ２
１００Ｍｅｓｈ
Ａ５、Ｂ５、Ａ７、Ｂ７、Ａ８、Ｂ８、ＡＲ１、ＢＲ１ ＡＲ２ ４２
 ：３７．８ＭＰａ ＢＬＡＤＥ
ＳＳ１Ｐ Ａ２、Ｂ２、ＡＲ３、ＢＲ３：２４．５ＭＰａ ＤＯＷＮ ＵＰ ｐｒｂ２
１ｓｔ ＡＵＸ.
１８ ＡＲ２、ＢＲ２：２７．１ＭＰａ
ｐｒａ２
ＳＳ１Ｔ Ｔｒ６
Ｐｒ
ｐｒａ１
ＳＳ１ ＢＯＯＭ ＳＷＩＮＧ
Ｔ１ＤＲ ｐｂｕ Ｔ２ ＬＥＦＴ ＲＩＧＨＴ
１ ２ ｐｓ１ ｐｒｂ１
ＡＲ１
φ０.５ ＢＲ１
φ０.５
５４ ＡＤＡＰＴＥＲ ｐｓ２
３ｒｄ ＡＵＸ. ＷＩＴＨ ＯＲＩＦＩＣＥ
Ｔ
ｐｃ１
Ａ
４０ Ｐ ｐｃｃ
３９ Ａ５ ＡＤＡＰＴＥＲ
Ｇ ＡＢ ＷＩＴＨ ＯＲＩＦＩＣＥ
Ｂ５
ＡＲＭ Ｎｏ.２
Ｆｒｏｍ ＳＯＬ.Ｖ. ＣＲＯＷＤ ＤＵＭＰ
３８ ｐｂ５
(＃１９)"Ｃ３" Ｐ １．４ＭＰａ
０．３２Ｌ ＡＲＭ Ｎｏ.１ ｐｂ９
Ｔｏ Ｈｙｄ.ＴａｎｋＴ ＤＵＭＰ ＣＲＯＷＤ ｐａ９
"Ｔ４" １９ ｐａ５
ＰＡＣ ２０
ｐｃ２
Ｂ１ ｐｃ３ Ａ８
（ＬＥＶＥＲ ＬＯＣＫ）
Ｂ８
ＢＯＯＭ Ｎｏ.２ ＢＯＯＭ Ｎｏ.１
Ａ Ｄ ＵＰ ＤＯＷＮ ＤＯＷＮ ＵＰ ｐｂ８
ｐｂ４
(ＳＰＥＥＤ ＳＨＩＦＴ ｐａ４ ｐａ８
      ＴＲＡＶＥＬ) Ｂ３ Ｂ７
Ｔ Ａ３ Ａ７
ＳＬＥＷ ｐｂ３ ｐｂ７ ＢＵＣＫＥＴ
２５
ＬＥＦＴ ＲＩＧＨＴ ＣＲＯＷＤ ＤＵＭＰ
Ｐ Ｃ１ Ｂ２
ｐａ３ ｐａ７
Ｃ３ Ｂ６
Ｃ２ Ａ２
１ｓｔ ＳＥＲＶＩＣＥ ｐｂ２ Ａ６
Ａ Ｂ Ｐ４ ｐｂ６ ＬＥＦＴ ＴＲＡＶＥＬ
ＦＯＲＷＡＲＤ ＲＥＶＥＲＳＥ ４３
ｐａ２ ｐａ６
２９ １０μ Ａ１ Ａ２ Ｂ１
０．１５ＭＰａ ａ１ ＰＨ１ ＰＨ２
（ＦＲＯＮＴ） × × × ×ａ２ （ＲＥＡＲ）
Ａ１
２８ ＲＩＧＨＴ ＴＲＡＶＥＬ ｐｂ１
０．１ＭＰａ ＲＥＶＥＲＳＥ ＦＯＲＷＡＲＤ ｐａ１ Ａ Ｂ

Ｔｓ３
Ｔｓ５
Ｐｉ２ Ｐ１ ＰＴ ＰＡ Ｐ３
２２ φ０.５ ＰＰ Ｐ２
φ０.５ ４０ ４５
Ｐｉ１
ＥＮＧＩＮＥ ×
３２ Ｐ１ Ｐ２ Ｐ３ ａ４
ＡＭ−４ＪＪ１Ｘ Ｐ１
β１０＝６（ＭＩＮＩＭＵＭ） ７１．８ｋＷ／２０００ｍｉｎ
−１ Ｄｒ１
２３ ２４ ０．３５ＭＰａ （９７．６ＰＳ／２０００ｒｐｍ） ａ３× Ａ３１００Ｍｅｓｈ
Ｂ１ Ｂ３
Ａ４
Ｐ４
６７１０ ９５８３４２ １ ３．９ ＭＰａ
ＬＥＶＥＬ ＣＡＰＡＣＩＴＹ：９５Ｌ １
ＡＩＲ ＢＲＥＡＴＨＥＲ ＡＬＬ ＣＡＰＡＣＩＴＹ：１６０Ｌ Ｄｒ２× Ｂ４ ４８
ＩＮＴＡＫＥ:０．００５ＭＰａ ５５
ＯＵＴＬＥＴ:０．０３ＭＰａ
０．１ＭＰａ ＦＩＬＴＲＡＴＩＯＮ ＲＡＴＩＮＧ ３
：１０μ
２７ １５０Ｍｅｓｈ ２ Ｐ２：２７．４ｃｃ／ｒｅｖ ＴＢ１１４０ ＨＹＤＲＡＵＬＩＣ ＣＩＲＣＵＩＴ ＤＩＡＧＲＡＭ Drawing No. 1
Ｉｎ Ｃｏｍｐｌｉａｎｃｅ ｗｉｔｈ ＥＣ（ＮＲＭＭ）ＥＰＡ Ｔｉｅｒ４
Ｐ１+Ｐ２、Ｐ３ 05701-00820 2
 ５６×２＋１０ｃｃ／ｒｅｖ 2F0AS01

1
HYDRAULIC CIRCUIT DIAGRAM 2F0AS00
 SERVICE DATA
HYDRAULIC CIRCUIT DIAGRAM 2

３０
６０ ２９１５４０１−４０８１０ ＣＨＥＣＫ ＶＡＬＶＥ
５９ ２８１５５１２−００６００ ＰＩＬＯＴ ＬＩＮＥ ＦＩＬＴＥＲ
５８ ２７１５５０１−００１１０ ＳＵＣＴＩＯＮ ＦＩＬＴＥＲ
５７ ２６
５６ ２５１９１１３−００７９０ ＯＩＬ ＣＯＯＬＥＲ
５５１９０１７ー５９５００ ＳＯＬＥＮＯＩＤ ＶＡＬＶＥ Ｈｉｇｈ−Ｆｌｏｗ (ＯＰＴ) ２４１５５１１−０３５００ ＲＥＬＩＥＦ ＶＡＬＶＥ
５４１９０１７ー５２９００ ＳＯＬＥＮＯＩＤ ＶＡＬＶＥ ２３１５５１１−０３４００ ＲＥＴＵＲＮ ＦＩＬＴＥＲ
５３１９０１７−４９４００ ＳＯＬＥＮＯＩＤ ＶＡＬＶＥ ３ｒｄ ＡＵＸ(Ｈ.Ｐ.) (ＯＰＴ) ２２１５４０１−４１２３５ ＣＨＥＣＫ ＶＡＬＶＥ
５２ ２１１９０１７−３５０００ ＲＥＭＯＴＥ Ｃ．Ｖ． ＳＷＩＮＧ
５１１９０１７−４７７００ ＥＭＥＲＧＥＮＣＹ ＳＨＵＴ-ＯＦＦ ＶＡＬＶＥ ＢＯＯＭ Ｌ，Ｈ ２０１９０１７−５４１００ ＳＨＵＴＴＬＥ ＶＡＬＶＥ
５０１９０１７−４８３００ ＳＯＬＥＮＯＩＤ ＶＡＬＶＥ ４ｔｈ ＡＵＸ. (ＯＰＴ) １９１９０１７−４４６００ ＳＯＬＥＮＯＩＤ ＶＡＬＶＥ
４９ １８１９０１７−５２２００ ＳＯＬＥＮＯＩＤ ＶＡＬＶＥ １ｓｔ,２ｎｄ ＡＵＸ
４８１７００１ー００１２６ ＰＲＥＳＳＵＲＥ ＳＥＮＳＯＲ １７１９０１７−４５４００ ＲＥＭＯＴＥ Ｃ．Ｖ． ＢＬＡＤＥ
４７０５７７１−０１０２１ ＭＡＮＩＦＯＬＤ １６１９０１７−４３８００ ＲＥＭＯＴＥ Ｃ．Ｖ． ＴＲＡＶＥＬ
４６１９０１７ー３０５００ ＳＥＬＥＣＴＯＲ ＶＡＬＶＥ (ＯＰＴ) １５１９０１７−６０２００ ＲＥＭＯＴＥ Ｃ．Ｖ． Ｒ，Ｈ（ＯＰＴ）
４５１７００１ー０００６９ ＰＲＥＳＳＵＲＥ ＳＷＩＴＣＨ １．４７ＭＰａ（ＮＯ） １５１９０１７−６４０００ ＲＥＭＯＴＥ Ｃ．Ｖ． Ｒ，Ｈ
４４ １４１９０１７−６３９００ ＲＥＭＯＴＥ Ｃ．Ｖ． Ｌ，Ｈ
４３１９０１７ー４４７００ ＳＨＯＣＫＬＥＳＳ ＶＡＬＶＥ １３１９０００−９８５００ ＳＷＩＮＧ ＣＹＬＩＮＤＥＲ
４２１７００１ー０００１５ ＰＲＥＳＳＵＲＥ ＳＷＩＴＣＨ ０．５９ＭＰａ（ＮＯ） １２１９０００−９８３００ ＡＲＭ ＣＹＬＩＮＤＥＲ
４１ １１１９０００−９８７００ ＢＬＡＤＥ ＣＹＬＩＮＤＥＲ(Ｌ)
４０１７００１ー０００６５ ＰＲＥＳＳＵＲＥ ＳＷＩＴＣＨ ２．６０ＭＰａ（ＮＯ） １０１９０００−９８６００ ＢＬＡＤＥ ＣＹＬＩＮＤＥＲ(Ｒ)
３９１９０１７ー４７２００ ＳＯＬＥＮＯＩＤ ＶＡＬＶＥ ３ｒｄ ＡＵＸ. (ＯＰＴ) ９ １９０００−９８２００ ＢＯＯＭ ＣＹＬＩＮＤＥＲ(Ｌ)
３８１５５２２−０００２０ ＡＣＣＵＭＵＬＡＴＯＲ (ＯＰＴ) ８ １９０００−９８１００ ＢＯＯＭ ＣＹＬＩＮＤＥＲ(Ｒ)
３７１９０１７−４４４００ ＥＭＥＲＧＥＮＣＹ ＳＨＵＴ-ＯＦＦ ＶＡＬＶＥ ＡＲＭ(ＯＰＴ) ７ １９０００−９８４００ ＢＵＣＫＥＴ ＣＹＬＩＮＤＥＲ
３６１９０１７−４７６００ ＥＭＥＲＧＥＮＣＹ ＳＨＵＴ-ＯＦＦ ＶＡＬＶＥ ＢＯＯＭ Ｒ，Ｈ ６ １９０４０−０９４００ ＳＷＩＶＥＬ ＪＯＩＮＴ
３５１９０１７−１９８００ ＳＴＯＰ ＶＡＬＶＥ ５ １９０３１−２６０００ ＴＲＡＶＥＬ ＭＯＴＯＲ Ｗｉｔｈ Ｐ．Ｂ
３４１９０１７−４４２００ ＳＴＯＰ ＶＡＬＶＥ ４ １９０３１−２７７００ ＳＬＥＷ ＭＯＴＯＲ Ｗｉｔｈ Ｐ．Ｂ
３３１７００１−００１２６ ＰＲＥＳＳＵＲＥ ＳＥＮＳＯＲ ３ １９０２０−２９０００ ＳＵＢ ＰＵＭＰ
３２１５５２０−００９００ ＡＩＲ ＢＲＥＡＴＨＥＲ ２ １９０２０−２７６００ ＭＡＩＮ ＰＵＭＰ
３１０５６５０−２９６１０ ＢＯＯＭ ＭＡＮＩＦＯＬＤ １ １９０１０−４６８００ ＣＯＮＴＯＲＯＬ ＶＡＬＶＥ
Ｎｏ ＰＡＲＴ Ｎｏ． ＮＡＭＥ ＯＦ ＰＡＲＴ ＲＥＭＡＲＫＳ Ｎｏ ＰＡＲＴ Ｎｏ． ＮＡＭＥ ＯＦ ＰＡＲＴ ＲＥＭＡＲＫＳ
Drawing No. 2
05701-00820 2
2F0AS021

2
HYDRAULIC CIRCUIT DIAGRAM 2F0AS00
 SERVICE DATA
HYDRAULIC CIRCUIT DIAGRAM 2
Control valve Travel motor
Part number 19010-46800 Part number 19031-26000
Type KVMM-160-TA Type GM21VA
MPa at L/min. 34.3 at 77 1st cm3/rev (cu. in./rev) 4077 (248.79)
P1, P2 Total displacement
(psi at US gal./min.) (5032 at 20.3) 2nd cm3/rev (cu. in./rev) 2306 (140.72)
Set main relief valve pressure
MPa at L/min. 23.6 at 50 1st cm3/rev (cu. in./rev) 75.5 (4.61)
Pr Motor displacement
(psi at US gal./min.) (3422 at 13.2)
2nd cm3/rev (cu. in./rev) 42.7 (2.61)
A5, B5, A7, B7,
MPa at L/min. 37.8 at 20 Reduction gear ratio 54.0
A8, B8, AR1,
(psi at US gal./min.) (5481 at 5.3) 2nd-speed switching speed MPa (psi) 3.9 (566)
BR1
Parking brake torque N·m (ft.-lb.) 13400 (9883.3)
Set overload relief valve pressure A2, B2, AR3, MPa at L/min. 24.5 at 20
BR3 (psi at US gal./min.) (3553 at 5.3) Parking brake release pressure MPa (psi) 0.76 (110)
MPa at L/min. 27.1 at 20 Amount of reduction gear lubricant used L (US gal.) 2.1 (0.6)
AR2, BR2
(psi at US gal./min.) (3930 at 5.3)
Swivel joint
Main pump Part number 19040-09400
Part number 19020-27600 Type RCJ-080A-8G-2031
Type K7V63DTP155R-9N38-VD
P1, P2 cm 3/rev (cu. in./rev) 56 (3.23) Bucket cylinder
Displacement
P3 cm3/rev (cu. in./rev) 10 (0.61) Part number 19000-98400
P1, P2 L/min. (US gal./min.) 112 (29.6) Type 81U170-A
Delivery*
P3 L/min. (US gal./min.) 20 (5.3) Bore diameter × rod diameter mm (in.) 100×70 (3.9×2.8)
Stroke mm (in.) 875 (34.4)
* Rotation speed to be set to 2000/min.
Maximum retraction length** mm (in.) 1350 (53.1)
Sub pump
** Length from the center of the pinhole on the tube side to the center of the pinhole on the rod side
Part number 19020-27500
Type SGP2A27F1H1-R277 Boom cylinder
Displacement cm3/rev (cu. in./rev) 27.4 (1.67) 19000-98100
Part number
Delivery* L/min. (US gal./min.) 54.8 (14.5) 19000-98200
81B185-A
* Rotation speed to be set to 2000/min. Type
81B186-A
Slew motor
Bore diameter × rod diameter mm (in.) 100×70 (3.9×2.8)
Part number 19031-27700 Stroke mm (in.) 995 (39.2)
Type MSG-85P-17TR Maximum retraction length** mm (in.) 1503 (59.2)
Total displacement cm3/rev (cu. in./rev) 1236 (75.43)
** Length from the center of the pinhole on the tube side to the center of the pinhole on the rod side
Motor displacement cm3/rev (cu. in./rev) 72.7 (4.41)
Reduction gear ratio 17 Dozer blade cylinder
Set relief valve pressure MPa (psi) 31.4 (4553) 19000-98600
Part number
Parking brake torque N·m (ft.-lb.) 8041 (5930) 19000-98700
Parking brake release pressure MPa (psi) 1.5 (218) 81D131-ARH
Type
Parking brake switching pressure MPa (psi) 0.4 (58.0) 81D132-ALH
Amount of reduction gear lubricant used L (US gal.) 5.3 (1.4) Bore diameter × rod diameter mm (in.) 115×70 (4.5×2.8)
Stroke mm (in.) 235 (9.4)
Maximum retraction length** mm (in.) 675 (26.6)

** Length from the center of the pinhole on the tube side to the center of the pinhole on the rod side

3
HYDRAULIC CIRCUIT DIAGRAM 2F0AS00
 SERVICE DATA
HYDRAULIC CIRCUIT DIAGRAM 2
Arm cylinder Solenoid valve (1st and 2nd auxiliary lines)
Part number 19000-98300 Part number 19017-52200
Type H10140701 Type 2KWE5A-30/G24R-270
Bore diameter × rod diameter mm (in.) 110×80 (4.3×3.1) Power supply voltage V 24
Stroke mm (in.) 1105 (43.5)
Maximum retraction length** mm (in.) 1601 (63.0) Solenoid valve (Lever lock and travel speed switching)
Part number 19017-44600
** Length from the center of the pinhole on the tube side to the center of the pinhole on the rod side
Type 16251-0000C
Swing cylinder
Power supply voltage V 24
Part number 19000-98500
Type 81S137-A Solenoid valve (3rd auxiliary line)
Bore diameter × rod diameter mm (in.) 140×90 (5.5×3.5) Part number 19017-47200
Stroke mm (in.) 835(32.9) Type GA-2344
Maximum retraction length** mm (in.) 1440(56.7) Power supply voltage V 24
** Length from the center of the pinhole on the tube side to the center of the pinhole on the rod side
Solenoid valve (4th auxiliary line)
Pilot valve (L)
Part number 19017-48300
Part number 19017-63900
Type L745L136DEAC070
Type PV48K
Power supply voltage V 27
Port 1, Port 3 MPa (psi) 0.54 to 2.4 (78 to 348)
Secondary pressure (proportional range)
Port 2, Port 4 MPa (psi) 0.74 to 2.4 (107 to 348) Solenoid valve (3rd high-pressure auxiliary line)
Port 1, Port 3 Degrees (°) 19°
Angle for independent operation Part number 19017-49400
Port 2, Port 4 Degrees (°) 25°
Type GA-2800

Pilot valve (R) Power supply voltage V 24

19017-64000 Solenoid valve

Part number
19017-60200
Part number 19017-52900
PV48K
Type Type 16682-00000
PV48K1406
Power supply voltage V 24
Port 1, Port 3 MPa (psi) 0.54 to 2.4 (78 to 348)
Secondary pressure (proportional range)
Port 2, Port 4 MPa (psi) 0.74 to 2.4 (107 to 348) Solenoid valve (High-flow)
Port 1, Port 3 Degrees (°) 19°
Angle for independent operation Part number 19017-59500
Port 2, Port 4 Degrees (°) 25°
Type GA3262B
Power supply voltage V 24
Pilot valve (Travel)
Part number 19017-43800
Type RCVD8C4137
Secondary pressure (proportional range) MPa (psi) 0.54 to 2.4 (78 to 348)

Pilot valve (Blade)

Part number 19017-45400
Type PV6P1050A
Secondary pressure (proportional range) MPa (psi) 0.49 to 2.06 (71 to 299)

Pilot valve (Swing)

Part number 19017-35000
Type PV6P1013B
Secondary pressure (proportional range) MPa (psi) 0.49 to 2.06 (71 to 299)

4
HYDRAULIC CIRCUIT DIAGRAM 2F0AS00
 SERVICE DATA
ELECTRICAL CIRCUIT DIAGRAM 2
ELECTRICAL CIRCUIT DIAGRAM
Wire/cable color symbols
Wiring/cable Colors
Symbol Color Symbol Color Symbol Color
B Black W White V Violet
G Green Y Yellow Dg Dark green
L Blue P Pink Ch Chocolate
R Red O Orange

1 Cross-sectional area (mm2)

2 Base color
3 Stripe color*
* There may be wires of solid color with no stripe.

Types of wire to use

• Use AVSS wire for cross-sectional areas of 2 mm2 or less.
• Use AV or AVS wire for cross-sectional areas exceeding 2 mm2. (AVX wire can be used for wires of solid color.)

Temperature
Symbol Overview Characteristics
limit

AV Low-voltage cables for automobiles • Wire used in low-voltage circuits. 80°C (176°F)

• A wire with dramatically improved heat resistance over that of

Heat-resistant, cross-linked, vinyl-insulated low-
AVX AV wire, enabling it to provide high reliability while responding 100°C (212°F)
voltage cables
to rises in temperature in automotive wiring environments.
• A thinner wire than the AV wire with equivalent electrical charac-
AVS Thin-insulation low-voltage cables for automobiles 80°C (176°F)
teristics.
• A wire with an even thinner insulator than AVS wire that has
AVSS Thin-insulation low-voltage cables for automobiles 80°C (176°F)
equivalent electrical characteristics.

1 Conductor: Annealed copper

2 Insulator: Vinyl

1
ELECTRICAL CIRCUIT DIAGRAM 2G0AS00
 SERVICE DATA
ELECTRICAL CIRCUIT DIAGRAM 2
Electrical Schematic Diagram

2
ELECTRICAL CIRCUIT DIAGRAM 2G0AS00
 SERVICE DATA
ELECTRICAL CIRCUIT DIAGRAM 2

3
ELECTRICAL CIRCUIT DIAGRAM 2G0AS00
 SERVICE DATA
WIRE HARNESS DIAGRAM 2
WIRE HARNESS DIAGRAM 1 To maintenance socket
2 To 1st auxiliary line solenoid
3 To 2nd auxiliary line solenoid
4 To side light
5 To cab interior
6 To air cleaner clogging detector sen-
sor
7 To battery relay
8 To heater relay
9 To slow blow fuse
0 To engine
a To pressure switch (Refer to “r Con-
trol valve details” for more informa-
tion)
b To 3rd auxiliary line solenoid
c To double solenoid
d To 4th auxiliary line solenoid
e To boom light
f To horn
g To work light
h To automatic supply pump
i To side light
j To fuel sender
k To ECM
l To extension module
m To atmospheric pressure sensor
n To feed pump
o To water separator
p To fuel filter
q Earth ground point
r Control valve details
s Pressure switch B1
t Pressure switch B2
u Pressure switch PA
v Pressure switch PT
w To fuel filter
x To feed pump
y Water separator
z To cluster gauge
A To starter switch
B To switches
C To controller
D To grip
E Wiring diagram for area around oper-
ator
F To 3rd auxiliary line footswitch
G To body harness
H Details on inside of left control box
I Details on inside of right control box
J Operating pattern switch connector

1. Main harness (05742-07730)

2. Body harness (05742-07740)
3. Wire harness (05742-07760)
4. Unit assembly
5. Atmospheric pressure sensor as-
sembly

1
WIRE HARNESS DIAGRAM 2H0AS00
 SERVICE DATA
WIRE HARNESS DIAGRAM 2

1 Starter B terminal
2 To pump proportional valve
3 To pressure sensor
4 To left, right connectors

1. Engine harness (05742-07750)

2
WIRE HARNESS DIAGRAM 2H0AS00
 SERVICE DATA
WIRE HARNESS DIAGRAM 2
Main harness

Location Name Location Name

2A AC1-1 2B CN71
2A AC1-2 3A CN75
1A AC2-1 1C CN76
1A AC2-2 2B CN78
1A AC2-3 2A CN79
3A AC3 1A CN92
1A AC4 1B CN94
1A AC-C 1A CN96
2C AC-T 1A CN97
2A A-SUS 2B CNB
1C BL 2C CR12
1C BL GND 2C CR13
2B CAN 2C CR14
2C CN21 3B CT1
1C CN29 3B CT3
1C CN30 3B D2
1B CN31 1B D5
1B CN32 3B FBOX
1C CN33 3B J31
1B CN34 3B J41
2B CN35 2A J44
3B CN42 4A J46
4A CN44 2A J47
1C CN60 3B J53
4A CN61 2B OPT1
4A CN62 2A OPT2
4A CN63 3B R1
4A CN64 2C R4
1B CN66 3C R-BOX
1B CN68 3A S-HEAT
4A CN70 2A Earth

3
WIRE HARNESS DIAGRAM 2H0AS00
 SERVICE DATA
WIRE HARNESS DIAGRAM 2
Initial Connector type of Pin End con- Connector type of Pin Line di- Initial Connector type of Pin End con- Connector type of Pin Line di-
No. Color Line type Remarks1 Remarks2 No. Color Line type Remarks1 Remarks2
connector initial connector no. nector end connector no. ameter connector initial connector no. nector end connector no. ameter

1 A-SUS 1809070 1 F-BOX 18 O AVSS 0.75f F6 OPT1 54 CN32 VC2 3 CT1 DRC26-50S-01 39 GW AVSS 0.5f

2 A-SUS 1809070 2 JG3 B AVSS 0.75f 55 CN32 VC2 7 CN32 VC2 9 B AVSS 0.5f

3 AC-T 12162197 1 AC1-1 776164-1 10 Y AVSS 0.85f 56 CN32 VC2 8 CN32 VC2 10 R AVSS 0.5f

4 AC-T 12162197 2 AC1-1 776164-1 17 L AVSS 0.85f 57 CN32 VC2 8 J48 R AVSS 0.5f

5 AC1-1 776164-1 7 AC2-1 DT04-04P-CE03 1 V AVSS 1.25f 58 CN32 VC2 9 CN33 VC2 7 B AVSS 0.5f

6 AC1-1 776164-1 8 AC2-3 DT06-04S-CE05 3 O AVSS 1.25f 59 CN32 VC2 10 CN33 VC2 8 R AVSS 0.5f

7 AC1-1 776164-1 9 AC4 DT06-04S-CE05 3 L AVSS 1.25f 60 CN33 VC2 3 CT1 DRC26-50S-01 49 V AVSS 0.5f

8 AC1-1 776164-1 11 AC2-1 DT04-04P-CE03 3 Br. AVSS 1.25f 61 CN33 VC2 7 CN34 VC2 7 B AVSS 0.5f

9 AC1-1 776164-1 13 J44 RG AVSS 1.25f F9 AC MOTOR 62 CN33 VC2 8 CN34 VC2 8 R AVSS 0.5f

10 AC1-1 776164-1 15 AC4 DT06-04S-CE05 2 G AVSS 1.25f 63 CN34 VC2 2 CN79 7323-2800 7 RY AVSS 1.25f

11 AC1-1 776164-1 16 AC2-1 DT04-04P-CE03 4 L AVSS 1.25f 64 CN34 VC2 3 F-BOX 17 RY AVSS 1.25f

12 AC1-1 776164-1 18 CN94 7123-7564-40 7 B AVSS 1.25f F14 STARTER

65 CN35 7123-2845 1 F-BOX 28 WY AVSS 0.75f
SWITCH
13 AC1-1 776164-1 19 AC2-1 DT04-04P-CE03 2 L AVSS 1.25f
66 CN35 7123-2845 2 CT1 DRC26-50S-01 44 RG AVSS 0.5f STARTER ACC
14 AC1-1 776164-1 20 AC-C 12162193 2 B AVSS 0.85f
67 CN35 7123-2845 3 CN61 7123-2845 1 BW AVSS 0.5f STARTER C
15 AC1-1 776164-1 21 AC3 DT06-06S-CE05 5 W AVSS 1.25f
68 CN35 7123-2845 4 D5 7123-2228 1 BY AVSS 0.75f STARTER ACC
16 AC1-1 776164-1 22 AC3 DT06-06S-CE05 4 L AVSS 1.25f
69 CN44 7123-2228 1 F-BOX 15 RL AVSS 1.25f F3 LEVER LOCK
17 AC1-1 776164-1 23 J81 W AVSS 1.25f CAN 0 H
70 CN44 7123-2228 2 CN61 7123-2845 3 R AVSS 1.25f
18 AC1-1 776164-1 24 CN94 7123-7564-40 10 G AVSS 1.25f
71 CN60 7123-6030 1 J49 B AVSS 0.5f Sensor GND-1
19 AC1-1 776164-1 26 J82 B AVSS 1.25f CAN 0 L
72 CN60 7123-6030 2 CT1 DRC26-50S-01 21 W MVVS 0.5
20 AC1-1 776164-1 27 AC-C 12162193 1 L AVSS 0.85f
73 CN60 7123-6030 3 J55 R MVVS 0.5 Sensor 5V-1
21 AC1-1 776164-1 28 CN94 7123-7564-40 8 W AVSS 1.25f
74 CN61 7123-2845 2 CN94 7123-7564-40 15 G AVSS 0.5f IS-START
22 AC1-1 776164-1 30 CN94 7123-7564-40 9 V AVSS 1.25f
75 CN61 7123-2845 4 J52 RW AVSS 1.25f F3 Limit SW
23 AC1-1 776164-1 33 AC2-3 DT06-04S-CE05 2 V AVSS 1.25f
76 CN62 7123-2865 1 F-BOX 30 V AVSS 0.75f F15 ANTI-THRIFF
24 AC1-2 12033769 A AC2-2 DT04-2P 2 W AVSS 2f
77 CN62 7123-2865 2 F-BOX 22 YB AVSS 0.5f F10 ANTI-THRIFF
25 AC1-2 12033769 B JG3 B AVSS 0.75f
78 CN62 7123-2865 3 F-BOX 16 WY AVSS 1.25f F4 controller
26 AC2-2 DT04-2P 1 J44 RG AVSS 2f F9 AC MOTOR
79 CN62 7123-2865 3 R-BOX 30 WY AVSS 1.25f F4 controller
27 AC2-3 DT06-04S-CE05 1 J44 RG AVSS 1.25f F9 AC MOTOR
80 CN62 7123-2865 4 R-BOX 31 WR AVSS 0.5f
28 AC2-3 DT06-04S-CE05 4 JG3 B AVSS 0.75f
81 CN62 7123-2865 5 CN62 7123-2865 6 B AVSS 0.75f
29 AC3 DT06-6S-CE05 1 J46 LW AVSS 0.5f F8 AC SWITCH
82 CN62 7123-2865 6 JG3 B AVSS 0.75f
30 AC3 DT06-6S-CE05 2 J46 LW AVSS 0.5f F8 AC SWITCH
83 CN63 7323-2228 1 J53 RL AVSS 0.75f F3 LEVER LOCK
31 AC3 DT06-6S-CE05 3 JG3 B AVSS 0.75f
84 CN63 7323-2228 2 JG3 B AVSS 0.75f
32 AC4 DT06-04S-CE05 1 J44 RG AVSS 1.25f F9 AC MOTOR
85 CN64 7323-2228 1 J52 RW AVSS 0.5f F3 Limit SW
33 AC4 DT06-04S-CE05 4 JG3 B AVSS 0.75f
86 CN64 7323-2228 2 CT3 DTM06-12SB 2 BrW AVSS 0.5f
34 BL CB104 1 CR14 7123-8307-30 1 Y AVSS 0.75f
87 CN66 7123-1330 1 J68 WY AVSS 0.75f F4 controller
35 BL GND CB104 1 JG3 B AVSS 0.75f
88 CN66 7123-1330 2 JG4 B AVSS 0.75f
36 CN21 VC2 2 F-BOX 24 RY AVSS 0.75f F12 ECU ACC
89 CN66 7123-1330 3 R-BOX 18 L AVSS 1.25f LIGHT Relay2 C
37 CN21 VC2 3 CN92 1743062-2 4 G AVSS 0.75f ENGINE STOP
90 CN66 7123-1330 4 JG3 B AVSS 0.75f
38 CN29 VC2 2 CT1 DRC26-50S-01 32 YR AVSS 0.5f
91 CN66 7123-1330 5 CN92 1743062-2 6 BrW AVSS 0.5f
39 CN29 VC2 2 R-BOX 17 YR AVSS 0.75f
92 CN66 7123-1330 7 J81 W MVVS 0.5 CAN 0 H
40 CN29 VC2 3 JG3 B AVSS 0.5f
93 CN66 7123-1330 8 J82 B MVVS 0.5 CAN 0 L
41 CN29 VC2 7 CN30 VC2 2 B AVSS 0.5f
94 CN66 7123-1330 9 J83 Br. MVVS-S 0.5
42 CN29 VC2 7 JG3 B AVSS 0.5f
95 CN66 7123-1330 10 CN78 174045-2 12 W MVVS 0.5
43 CN29 VC2 8 CN30 VC2 8 R AVSS 0.5f
96 CN66 7123-1330 11 CN78 174045-2 11 B MVVS 0.5
44 CN29 VC2 8 J48 R AVSS 0.5f
97 CN66 7123-1330 12 JG4 Gr. MVSS-S 0.5
45 CN30 VC2 2 CN30 VC2 7 B AVSS 0.5f
98 CN68 7122-1330 1 CT1 DRC26-50S-01 26 Y AVSS 0.5f
46 CN30 VC2 3 CT1 DRC26-50S-01 43 O AVSS 0.5f
99 CN68 7122-1330 2 CT1 DRC26-50S-01 25 O AVSS 0.5f
47 CN31 VC2 2 CN31 VC2 7 B AVSS 0.5f
100 CN68 7122-1330 3 J48 R AVSS 0.5f
48 CN31 VC2 2 JG3 B AVSS 0.5f
101 CN68 7122-1330 4 CT1 DRC26-50S-01 28 G AVSS 0.5f
49 CN31 VC2 3 CT1 DRC26-50S-01 34 Lg. AVSS 0.5f
102 CN68 7122-1330 6 CT1 DRC26-50S-01 29 GW AVSS 0.5f
50 CN31 VC2 8 J48 R AVSS 0.5f
103 CN68 7122-1330 7 R-BOX 10 W AVSS 0.75f F2 WIPER
51 CN32 VC2 1 CT1 DRC26-50S-01 31 WY AVSS 0.5f
52 CN32 VC2 2 CN32 VC2 7 B AVSS 0.5f Drawing No. 2
53 CN32 VC2 2 JG3 B AVSS 0.5f 05742-07730-2 4
2H0AS03

4
WIRE HARNESS DIAGRAM 2H0AS00
 SERVICE DATA
WIRE HARNESS DIAGRAM 2
Initial Connector type of Pin End con- Connector type of Pin Line di- Initial Connector type of Pin End con- Connector type of Pin Line di-
No. Color Line type Remarks1 Remarks2 No. Color Line type Remarks1 Remarks2
connector initial connector no. nector end connector no. ameter connector initial connector no. nector end connector no. ameter
104 CN68 7122-1330 8 CN92 1743062-2 14 RL AVSS 0.75f 156 CN92 1743062-2 13 CR12 7123-2262 3 YR AVSS 0.75f
105 CN68 7122-1330 9 CT1 DRC26-50S-01 47 YG AVSS 0.5f 157 CN92 1743062-2 15 J57 B AVSS 1.25f Sensor GND-1
106 CN68 7122-1330 10 CT1 DRC26-50S-01 48 GR AVSS 0.5f 158 CN92 1743062-2 16 J55 R MVVS 0.5 Sensor 5V-1
107 CN68 7122-1330 11 CT1 DRC26-50S-01 24 P AVSS 0.5f 159 CN92 1743062-2 17 CT1 DRC26-50S-01 46 W MVVS 0.5
108 CN68 7122-1330 12 CT1 DRC26-50S-01 23 Br. AVSS 0.5f 160 CN92 1743062-2 18 R-BOX 27 Gr. AVSS 0.75f
109 CN68 7122-1330 13 CT1 DRC26-50S-01 41 Sb AVSS 0.5f 161 CN92 1743062-2 19 J68 WY AVSS 0.5f F4 controller
110 CN70 7322-2228 1 CN92 1743062-2 21 RW AVSS 0.5f F3 Limit SW 162 CN92 1743062-2 20 CT1 DRC26-50S-01 19 WG AVSS 0.5f
111 CN70 7322-2228 2 CN92 1743062-2 22 BrW AVSS 1.25f 163 CN92 1743062-2 23 CT2 DTM06-12SA 6 G AVSS 0.5f
112 CN71 7123-2228 1 CT1 DRC26-50S-01 40 RY AVSS 0.5f 164 CN92 1743062-2 24 CT2 DTM06-12SA 9 YW AVSS 0.5f
113 CN71 7123-2228 2 JG3 B AVSS 0.75f 165 CN92 1743062-2 25 CT2 DTM06-12SA 10 G AVSS 0.5f
114 CN75 DT06-08SA-CE05 1 CNA 174045-2 7 R MVVS 0.5 Sensor 5V-1 166 CN92 1743062-2 26 CT3 DTM06-12SB 3 LY AVSS 0.5f
115 CN75 DT06-08SA-CE05 2 J51 B AVSS 0.5f Sensor GND-1 167 CN92 1743062-2 27 CT2 DTM06-12SA 7 Br. AVSS 0.5f
116 CN75 DT06-08SA-CE05 3 CNA 174045-2 8 W MVVS 0.5 168 CN92 1743062-2 28 CT2 DTM06-12SA 11 P AVSS 0.5f
117 CN75 DT06-08SA-CE05 4 CNA 174045-2 11 RB AVSS 0.5f 169 CN92 1743062-2 29 CR13 7123-2262 3 WR AVSS 1.25f
118 CN75 DT06-08SA-CE05 5 CNA 174045-2 10 GB AVSS 0.5f 170 CN92 1743062-2 30 CT3 DTM06-12SB 1 LW AVSS 0.5f
119 CN75 DT06-08SA-CE05 6 JG3 B AVSS 0.5f 171 CN92 1743062-2 31 CT3 DTM06-12SB 5 W AVSS 0.5f
120 CN75 DT06-08SA-CE05 7 CR13 7123-2262 4 Gr. AVSS 0.5f 172 CN92 1743062-2 32 CT3 DTM06-12SB 6 Gr. AVSS 0.5f
121 CN75 DT06-08SA-CE05 8 CNA 174045-2 12 LG AVSS 0.5f 173 CN92 1743062-2 33 CT3 DTM06-12SB 7 L AVSS 0.5f
122 CN76 DT06-08SA-CE05 1 CNA 174045-2 1 R MVVS 0.5 Sensor 5V-1 174 CN92 1743062-2 34 CT3 DTM06-12SB 8 P AVSS 0.5f
123 CN76 DT06-08SA-CE05 2 J50 B AVSS 0.5f Sensor GND-1 175 CN92 1743062-2 35 CT3 DTM06-12SB 9 Y AVSS 0.5f
124 CN76 DT06-08SA-CE05 3 CNA 174045-2 2 W MVVS 0.5 176 CN92 1743062-2 36 R-BOX 13 Y AVSS 1.25f LIGHT Relay C
125 CN76 DT06-08SA-CE05 4 CNA 174045-2 5 Gr. AVSS 0.5f 177 CN94 7123-7564-40 1 J63 Br. MVVS-S 0.5
126 CN76 DT06-08SA-CE05 5 CNA 174045-2 4 W AVSS 0.5f 178 CN94 7123-7564-40 2 J61 W MVVS 0.5 CAN 0 H
127 CN76 DT06-08SA-CE05 6 JG3 B AVSS 0.5f 179 CN94 7123-7564-40 3 J62 B MVVS 0.5 CAN 0 L
128 CN76 DT06-08SA-CE05 7 CT1 DRC26-50S-01 38 YB AVSS 0.5f 180 CN94 7123-7564-40 4 CT1 DRC26-50S-01 13 Br. MVVS-S 0.5
129 CN76 DT06-08SA-CE05 8 CNA 174045-2 6 LG AVSS 0.5f 181 CN94 7123-7564-40 5 J64 W MVVS 0.5
130 CN78 174045-2 1 CN92 1743062-2 12 W AVSS 0.5f 182 CN94 7123-7564-40 6 J65 B MVVS 0.5f
131 CN78 174045-2 2 JG4 B AVSS 0.5f 183 CN94 7123-7564-40 13 CT1 DRC26-50S-01 27 L AVSS 0.5f
CC-ISOCAN H 184 CN94 7123-7564-40 14 CT3 DTM06-12SB 4 Sb AVSS 0.5f
132 CN78 174045-2 3 CN94 7123-7564-40 11 Sb AVSS 0.5f
twisted 185 CN96 7222-4220-30 1 F-BOX 1 R AVS 5
CC-ISOCAN L 186 CN96 7222-4220-30 2 J31 R AVSS 3f
133 CN78 174045-2 4 CN94 7123-7564-40 12 L AVSS 0.5f
twisted
187 CN97 7123-4220-40 1 JG4 B AVS 3f SG
134 CN78 174045-2 5 CN92 1743062-2 11 G AVSS 0.5f CC-KW2000
188 CN97 7123-4220-40 2 JG3 B AVS 5
135 CN78 174045-2 6 J68 WY AVSS 0.5f F4 controller
189 CNA 174045-2 3 J92 B AVSS 0.5f Sensor GND-1
136 CN78 174045-2 7 J61 W AVSS 0.5f CAN 0 H
190 CNA 174045-2 9 J94 B AVSS 0.5f Sensor GND-1
137 CN78 174045-2 8 J62 B AVSS 0.5f CAN 0 L
191 CNB 174058-2 1 J55 R MVVS 0.5 Sensor 5V-1
138 CN78 174045-2 9 J64 W AVSS 0.5f CN78-10 twisted
192 CNB 174058-2 2 CT1 DRC26-50S-01 22 W MVVS 0.5
139 CN78 174045-2 10 J65 B AVSS 0.5f CN78-9 twisted
193 CNB 174058-2 3 J91 B AVSS 0.5f Sensor GND-1
140 CN79 7323-2800 2 F-BOX 14 W AVSS 0.75f F2 WIPER
194 CNB 174058-2 4 CT1 DRC26-50S-01 42 W AVSS 0.5f
141 CN79 7323-2800 3 F-BOX 26 G AVSS 0.75f F13 HORN
195 CNB 174058-2 5 R-BOX 22 Gr. AVSS 0.5f
142 CN79 7323-2800 4 J47 RY AVSS 1.25f
196 CNB 174058-2 6 CT1 DRC26-50S-01 45 LG AVSS 0.5f
143 CN79 7323-2800 5 JG3 B AVSS 0.75f
197 CNB 174058-2 7 J55 R MVVS 0.5 Sensor 5V-1
144 CN79 7323-2800 6 R-BOX 18 L AVSS 1.25f LIGHT Relay2 C
198 CNB 174058-2 8 CT1 DRC26-50S-01 37 W MVVS 0.5
145 CN79 7323-2800 8 R-BOX 9 WY AVSS 0.75f WIPER Rrkay NC
199 CNB 174058-2 9 J93 B AVSS 0.5f Sensor GND-1
146 CN79 7323-2800 9 R-BOX 8 YW AVSS 0.75f WIPER Rrkay C
200 CNB 174058-2 10 CT1 DRC26-50S-01 36 GB AVSS 0.5f
147 CN79 7323-2800 10 J47 RY AVSS 1.25f
201 CNB 174058-2 11 CT1 DRC26-50S-01 35 RB AVSS 0.5f
148 CN92 1743062-2 1 F-BOX 19 YG AVSS 1.25f F7 OPT2
202 CR12 7123-2262 1 CR14 7123-8307-30 6 WR AVSS 0.5f
149 CN92 1743062-2 2 R4 7123-1424-40 2 L AVSS 0.75f
203 CR12 7123-2262 2 J52 RW AVSS 0.5
150 CN92 1743062-2 3 R4 7123-1424-40 1 LR AVSS 0.75f
204 CR12 7123-2262 3 CT1 DRC26-50S-01 15 YW AVSS 0.5f
151 CN92 1743062-2 5 F-BOX 30 V AVSS 0.75f F15 ANTI-THRIFF
205 CR12 7123-2262 4 CR14 7123-8307-30 7 LW AVSS 0.5f
152 CN92 1743062-2 7 D5 2 YB AVSS 0.75f
206 CR13 7123-2262 1 CT1 DRC26-50S-01 18 YW AVSS 0.5f
153 CN92 1743062-2 8 R-BOX 28 BY AVSS 1.25f
154 CN92 1743062-2 9 CN35 7123-2845 2 RY AVSS 0.75f STARTER ACC Drawing No. 3
155 CN92 1743062-2 10 R-BOX 23 BW AVSS 0.75f 05742-07730-2 4
2H0AS03

5
WIRE HARNESS DIAGRAM 2H0AS00
 SERVICE DATA
WIRE HARNESS DIAGRAM 2
Initial Connector type of Pin End con- Connector type of Pin Line di- Initial Connector type of Pin End con- Connector type of Pin Line di-
No. Color Line type Remarks1 Remarks2 No. Color Line type Remarks1 Remarks2
connector initial connector no. nector end connector no. ameter connector initial connector no. nector end connector no. ameter
207 CR13 7123-2262 1 FOOT SW CA104 1 YW AVSS 0.5f 271 J54 J57 B MVVS 0.5 Sensor GND-1
208 CR13 7123-2262 2 J52 RW AVSS 0.5f F3 Limit SW 272 J54 J57 Gr MVVS-S 0.5
209 CR13 7123-2262 3 CT1 DRC26-50S-01 17 WR AVSS 0.5f 273 J54 J91 B MVVS 0.5 Sensor GND-1
210 CR14 7123-8307-30 2 JG3 B AVSS 0.75f 274 J54 J91 Gr MVVS-S 0.5
211 CR14 7123-8307-30 5 R-BOX 26 WY AVSS 0.75f F4 controller 275 J54 J93 Gr MVVS-S 0.5
212 CT1 DRC26-50S-01 1 JG4 B AVSS 0.5f 276 J54 J93 B MVVS 0.5 Sensor GND-1
213 CT1 DRC26-50S-01 2 J68 WY AVSS 0.5f F4 controller 277 J61 J61 W MVVS 0.5 CAN 0 H
214 CT1 DRC26-50S-01 3 J61 W MVVS 0.5f CAN 0 H 278 J61 J81 W MVVS 0.5 CAN 0 H
215 CT1 DRC26-50S-01 4 J62 B MVVS 0.5f CAN 0 L 279 J62 J62 B MVVS 0.5 CAN 0 L
216 CT1 DRC26-50S-01 5 J63 Br. AVSS 0.5f 280 J62 J82 B MVVS 0.5 CAN 0 L
217 CT1 DRC26-50S-01 6 J64 W MVVS 0.5f 281 J63 J83 Br. MVVS-S 0.5
218 CT1 DRC26-50S-01 7 J65 B MVVS 0.5f 282 J64 J64 W AVSS 0.5
219 CT1 DRC26-50S-01 8 J55 R AVSS 0.5f Sensor 5V-1 283 J64 J64 W AVSS 0.5
220 CT1 DRC26-50S-01 9 J54 B AVSS 0.5f Sensor GND-1 284 J65 J65 B AVSS 0.5f
221 CT1 DRC26-50S-01 16 J52 RW AVSS 0.5f F3 Limit SW 285 J65 J65 B AVSS 0.5f
222 CT1 DRC26-50S-01 20 F-BOX 22 YB AVSS 0.5f F10 ANTI-THRIFF 286
223 CT1 DRC26-50S-01 30 R-BOX 1 RB AVSS 0.5f 287
224 CT1 DRC26-50S-01 33 R-BOX 27 Gr. AVSS 0.5f 288 OPT1- CB104 1 JG3 B AVSS 1.25f
225 CT1 DRC26-50S-01 50 D2 7123-2228 1 WY AVSS 0.5f 289 OPT2+ CB104 1 J47 RY AVSS 1.25f
226 CT2 DTM06-12SA 1 JG4 B AVSS 0.5f 290 OPT2- CB104 1 JG3 B AVSS 0.75f
227 CT2 DTM06-12SA 2 J68 WY AVSS 0.5f F4 controller 291 R-BOX 2 JG3 B AVSS 0.75f
228 CT2 DTM06-12SA 3 J64 W AVSS 0.5f F14 STARTER
292 R-BOX 3 F-BOX 28 WY AVSS 0.75f
229 CT2 DTM06-12SA 4 J65 B AVSS 0.5f SWITCH

230 CT2 DTM06-12SA 5 JG4 Br. AVSS 0.5f 293 R-BOX 5 D5 2 YB AVSS 0.75f

231 CT2 DTM06-12SA 8 R-BOX 6 W AVSS 0.5f 294 R-BOX 7 JG3 B AVSS 0.5f

232 CT2 DTM06-12SA 12 J48 R AVSS 0.5f 295 R-BOX 11 J41 RY AVSS 1.25f F1 LIGHT RELAY

233 CT3 DTM06-12SB 10 J53 RL AVSS 0.5f F3 LEVER LOCK 296 R-BOX 12 R-BOX 17 YR AVSS 0.75f

234 CT3 DTM06-12SB 11 J53 RL AVSS 0.5f F3 LEVER LOCK 297 R-BOX 15 J41 RY AVSS 1.25f F1 LIGHT RELAY

235 CT3 DTM06-12SB 12 J53 RL AVSS 0.5f F3 LEVER LOCK 298 R-BOX 16 J41 RY AVSS 1.25f F1 LIGHT RELAY

236 D2 7123-2228 2 R-BOX 31 WR AVSS 0.5f 299 R-BOX 20 J41 RY AVSS 1.25f F1 LIGHT RELAY

248 F-BOX 13 J41 RY AVSS 2 F1 LIGHT RELAY 300 R-BOX 21 R-BOX 25 G AVSS 0.75f F13 HORN

249 F-BOX 14 R-BOX 10 W AVSS 0.75f F2 WIPER 301 R-BOX 21 R-BOX 33 G AVSS 0.75f F13 HORN

250 F-BOX 15 J53 RL AVSS 1.25f F3 LEVER LOCK 302 R-BOX 23 R-BOX 35 BW AVSS 0.75f

251 F-BOX 16 J68 WY AVSS 1.25f F4 controller 303 R-BOX 26 R-BOX 30 WY AVSS 0.75f F4 controller

252 F-BOX 17 J47 RY AVSS 1.25f 304 R-BOX 32 JG3 B AVSS 0.75f

253 F-BOX 18 OPT1+ CB104 1 O AVSS 1.25f F6 OPT1 305 R1 776522-1 1 J64 W AVSS 0.5

254 F-BOX 19 S-HEAT 1809070 1 YG AVSS 0.75f F7 OPT2 306 R1 776522-1 2 J65 B AVSS 0.5f

255 F-BOX 20 J46 LW AVSS 0.5f F8 AC SWITCH 307 S-HEAT 1809070 2 JG3 B AVSS 0.75f

256 F-BOX 21 J44 RG AVSS 1.25f F9 AC MOTOR 308 Earth JG3 B AVS 5

257 F-BOX 25 J31 R AVSS 2f 309 CN34 VC2 7 CN33 VC2 2 B AVSS 0.5f

258 F-BOX 26 R-BOX 25 G AVSS 0.75f F13 HORN

259 F-BOX 27 J31 R AVSS 2f
260
261 F-BOX 29 J31 R AVSS 2f
262 FOOT SW CB104 1 J52 RW AVSS 0.5f F3 Limit SW
263
264 J49 J54 Gr MVVS-S 0.5
265 J49 J54 B MVVS 0.5 Sensor GND-1
266 J50 J92 Gr MVVS-S 0.5
267 J50 J92 B MVSS 0.5 Sensor GND-1
268 J51 J94 Gr MVVS-S 0.5
269 J51 J94 B MVSS 0.5f Sensor GND-1
Drawing No. 4
270 J53 J53 RL AVSS 0.75f F3 LEVER LOCK 05742-07730-2 4
2H0AS03

6
WIRE HARNESS DIAGRAM 2H0AS00
 SERVICE DATA
WIRE HARNESS DIAGRAM 2
Body harness

Location Name Location Name Location Name

2C +/- 3B CN59 2B F18
1B AC-D 2A CN6 4B FUEL
3A C8 1B CN72 2B GP
3A CASE 1C CN73 2C IN
2A CN1 3B CN74 2B IN/OUT
1A CN10 2A CN8 3B L1
2A CN11 2C CN80 4B L2
2A CN12 2B CN82 1A L3
2A CN13 2B CN84 4B L9
3A CN14 1A CN9 2B MAIN
2A CN2 1A CN91 4B MC
2A CN3 1A CN93 1B MT
1B CN36 1A CN95 2C OPT3
3B CN37 1A CN98 2C OUT
2B CN38 1B CR11 3B R2
2A CN39 4A CT 3B R5
3A CN4 3B CT4 1C SBF-1
2A CN40 3A CTG 1C SBF-2
2A CN41 1C D1 1B SBF-3
2A CN43 2C D3 1B STARTER CUT
2A CN5 2C D4 1C TM1
4B CN51 2A D7 4B TM13
2A CN52 3A D8 1C TM2
3A CN56 3A D9 1C TM3
2C CN57 2B F17 1C TM4
3A CN58

7
WIRE HARNESS DIAGRAM 2H0AS00
 SERVICE DATA
WIRE HARNESS DIAGRAM 2
Initial Connector type of Pin End con- Connector type of Pin Line di- Initial Connector type of Pin End con- Connector type of Pin Line di-
No. Color Line type Remarks1 Remarks2 No. Color Line type Remarks1 Remarks2
connector initial connector no. nector end connector no. ameter connector initial connector no. nector end connector no. ameter

1 +/- 7323-1424-40 1 D3 7323-2228 2 G AVSS 0.5f IS-START 54 CN52 DT06-04S-CE05 1 J25 B AVSS 0.5f Sensor GND-1

2 +/- 7323-2228 1 D4 7323-2228 1 BR AVSS 0.5f GLOW RERAY - 55 CN52 DT06-04S-CE05 2 CN91 1743059-2 16 R MVVS 0.5 Sensor 5V-1

3 +/- 7323-2228 2 CT 3-1355136-3 74 RY AVSS 0.75f F12 ECU ACC 56 CN52 DT06-04S-CE05 4 CN91 1743059-2 17 W MVVS 0.5

4 +/- 7323-1424-40 2 D3 7323-2228 1 BY AVSS 0.5f Au on 6189-

57 CN57 6189-1046 1 CT 3-1355136-3 57 RL AVSS 0.5f SP-12V
1046 side
5 +/- 7323-2228 2 D4 7323-2228 2 RY AVSS 0.75f F12 ECU ACC
Au on
6 AC-P 12065287 1 CN93 7222-7564-40 7 B AVSS 1.25f
58 CN57 6189-1046 2 CT 3-1355136-3 53 BL AVSS 0.5f SG-12VRT 6189-1046
7 AC-P 12065287 2 CN93 7222-7564-40 8 W AVSS 1.25f side
8 AC-P 12065287 3 CN93 7222-7564-40 9 V AVSS 1.25f Au on 6189-
59 CN57 6189-1046 3 CT 3-1355136-3 22 P AVSS 0.5f IA-MAF
9 CASE LA106 1 CT 3-1355136-3 77 B AVSS 0.75f 1046 side

10 CN1 7123-1424-40 1 CN91 1743059-2 21 RW AVSS 0.5f F3 Limit SW Au on 6189-

60 CN57 6189-1046 4 CT 3-1355136-3 21 V AVSS 0.5f IA-IAT
1046 side
11 CN1 7123-1424-40 2 CN91 1743059-2 22 BrW AVSS 0.5f
Au on 6189-
12 D9 7123-2228 2 CN91 1743059-2 23 G AVSS 0.5f 61 CN57 6189-1046 5 CTG 6195-0054 8 W AVSS 0.5f
1046 side
13 D9 7123-2228 1 JG2 B AVSS 0.5f 62 CN58 174357-2 a J22 RY AVSS 0.5f SP-5V2
14 CN3 7123-1424-40 1 CN91 1743059-2 24 YW AVSS 0.5f 63 CN58 174357-2 b J17 BY AVSS 0.5f SG-5VRT2
15 CN3 7123-1424-40 2 JG2 B AVSS 0.5f Au on
64 CN58 174357-2 c CT 3-1355136-3 27 WY AVSS 0.5f IA-BARO
16 CN4 DT06-02S-CE05 1 CN91 1743059-2 25 G AVSS 0.5f 174357-2 side
17 CN4 DT06-02S-CE05 2 JG2 B AVSS 0.5f Au on
65 CN59 12065287 A J17 BW AVSS 0.75f SG-5VRT2
12065287 side
18 CN5 DT06-02S-CE05 1 CN91 1743059-2 26 LY AVSS 0.5f
Au on
19 CN5 DT06-02S-CE05 2 JG2 B AVSS 0.5f 66 CN59 12065287 B J22 RY AVSS 0.75f SP-5V2
12065287 side
20 CN6 7123-1424-40 1 CN91 1743059-2 27 Br. AVSS 0.5f
Au on
21 CN6 7123-1424-40 2 JG2 B AVSS 0.5f 67 CN59 12065287 C CT 3-1355136-3 23 L AVSS 0.75f
12065287 side
22 CN7 DT06-02S-CE05 1 CN91 1743059-2 28 P AVSS 0.5f 68 CN65 7123-6030 1 CT 3-1355136-3 30 RY AVSS 0.5f SG-5VRT1
23 CN7 DT06-02S-CE05 2 JG2 B AVSS 0.5f 69 CN65 7123-6030 2 J18 YG AVSS 0.5f IA-ACCEL1,2
24 CN8 DT06-02S-CE05 1 CN91 1743059-2 29 WR AVSS 0.5f 70 CN65 7123-6030 3 CT 3-1355136-3 8 GR AVSS 0.5f SP-5V1
25 CN8 DT06-02S-CE05 2 CN91 30 LW AVSS 0.5f 71 CN73 7123-2228 1 CN91 1743059-2 14 RL AVSS 0.75f
26 CN9 DT06-02S-CE05 1 CN91 1743059-2 31 W AVSS 0.5f 72 CN73 7123-2228 2 JG2 B AVSS 0.75f
27 CN9 DT06-02S-CE05 2 JG2 B AVSS 0.5f 73 CN74 7223-1824-40 1 CR11 6020-6161 2 RY AVSS 0.75f
28 CN10 DT06-02S-CE05 1 CN91 1743059-2 32 Gr. AVSS 0.5f 74 CN74 7223-1824-40 2 JG2 B AVSS 0.75f
29 CN10 DT06-02S-CE05 2 JG2 B AVSS 0.5f 75 CN80 7322-2228 1 L4 7323-2228 1 Y AVSS 1.25f LIGHT Relay C
30 CN11 DT06-02S-CE05 1 CN91 1743059-2 33 L AVSS 0.5f 76 CN80 7322-2228 2 L4 7323-2228 2 B AVSS 1.25f
31 CN11 DT06-02S-CE05 2 JG2 B AVSS 0.5f 77 CN82 7123-7564-40 1 J21 RY AVSS 0.75f F12 ECU ACC
32 CN12 DT06-02S-CE05 1 CN91 1743059-2 34 P AVSS 0.5f 78 CN82 7123-7564-40 2 CN93 7222-7564-40 13 L AVSS 0.5f
33 CN12 DT06-02S-CE05 2 JG2 B AVSS 0.5f 79 CN82 7123-7564-40 3 CT 3-1355136-3 55 Gr. PEXBS-S 0.5f Shielded
34 D7 7123-2228 2 J24 YR AVSS 0.75f 80 CN82 7123-7564-40 4 CT 3-1355136-3 20 Y AVSS 0.75f IA-THE2
35 D9 7123-2228 1 JG2 B AVSS 0.75f 81 CN82 7123-7564-40 5 CT 3-1355136-3 19 G AVSS 0.75f IA-THE1
36 D8 7123-2228 2 J24 YR AVSS 0.75f 82 CN82 7123-7564-40 6 CT 3-1355136-3 10 B PEXBS 0.5f SP-5V3
37 D9 7123-2228 1 JG2 B AVSS 0.75f 83 CN82 7123-7564-40 7 CT 3-1355136-3 24 W PEXBS 0.5f IA-EXHP
38 CN36 963040-3 1 CT4 DTM06-12SA 10 RW AVSS 0.5f 84 CN82 7123-7564-40 8 CT 3-1355136-3 52 R PEXBS 0.5f
39 CN36 963040-3 2 JG2 B AVSS 0.5f 85 CN82 7123-7564-40 9 J17 BW AVSS 0.75f SG-5VRT2
40 CN37 + CB104 1 CT4 DTM06-12SA 9 WG AVSS 0.5f 86 CN82 7123-7564-40 10 CN91 1743059-2 35 Y AVSS 0.5f
41 CN37 - CA104 1 JG2 B AVSS 0.5f 87 CN82 7123-7564-40 11 JG2 B AVSS 0.5f
42 CN38 6180-2321 1 J26 WY AVSS 0.5f 88 CN82 7123-7564-40 12 J56 B MVVS 0.5f Sensor GND-2
43 CN38 6180-2321 2 JG2 B AVSS 0.5f 89 CN82 7123-7564-40 13 J76 MVVS 0.5 Sensor 5V-2
44 CN39 6180-2321 1 CN91 1743059-2 18 Gr. AVSS 0.75f 90 CN82 7123-7564-40 14 CT4 DTM06-12SA 11 W MVVS 0.5
45 CN39 6180-2321 2 JG2 B AVSS 0.75f 91 CN82 7123-7564-40 15 CN93 7222-7564-40 10 G AVSS 1.25f Compressor
46 CN40 6180-2321 1 J26 WY AVSS 0.5f 92 CN84 7222-4220-30 1 IN/OUT 7123-4220-30 2 W AVS 5
47 CN40 6180-2321 2 JG2 B AVSS 0.5f 93 CN84 7222-4220-30 2 JG2 B AVS 5
48 CN41 6180-2321 1 J26 WY AVSS 0.5f 94 CN91 1743059-2 1 MT+ 7316-2095 1 YG AVSS 1.25f
49 CN41 6180-2321 2 JG2 B AVSS 0.5f 95 CN91 1743059-2 2 CT 3-1355136-3 79 L AVSS 0.75f
50 CN43 6180-2321 1 CN91 1743059-2 20 WG AVSS 0.5f 96 CN91 1743059-2 3 J19 LR AVSS 0.75f MAIN RERAY C
51 CN43 6180-2321 2 JG2 B AVSS 0.5f
52 CN51 6180-3241 1 J77 W AVSS 0.5f Drawing No. 2
53 CN51 6180-3241 2 J56 B AVSS 0.5f Sensor GND-2 05742-07740 4
2H0AS06

8
WIRE HARNESS DIAGRAM 2H0AS00
 SERVICE DATA
WIRE HARNESS DIAGRAM 2
Initial Connector type of Pin End con- Connector type of Pin Line di- Initial Connector type of Pin End con- Connector type of Pin Line di-
No. Color Line type Remarks1 Remarks2 No. Color Line type Remarks1 Remarks2
connector initial connector no. nector end connector no. ameter connector initial connector no. nector end connector no. ameter
97 CN91 1743059-2 4 CT 3-1355136-3 61 G AVSS 0.75f ENGINE STOP 147 CT 3-1355136-3 82 MC CB104 1 P AVSS 0.5f
98 CN91 1743059-2 5 CR11 6020-6161 3 V AVSS 0.75f F15 ANTI-THRIFF STARTER
148 CT 3-1355136-3 92 6098-1493 2 YB AVSS 0.75f Starter Cut Reray -
99 CN91 1743059-2 6 CT 3-1355136-3 70 BrW AVSS 0.5f CUT

100 CN91 1743059-2 7 D1 7123-2228 2 YB AVSS 0.75f 149 CT 3-1355136-3 93 D4 7323-2228 1 BR AVSS 0.5f GLOW RERAY -

101 CN91 1743059-2 8 T-ARAM+ CB104 1 BY AVSS 1.25f 150 CT4 DTM06-12SA 1 JG1 B AVSS 0.5f

102 CN91 1743059-2 9 J21 RY AVSS 0.75f F12 ECU ACC 151 CT4 DTM06-12SA 2 J69 WY AVSS 0.5f F4 controller

103 CN91 1743059-2 10 TM13 7116-5110 1 BW AVSS 0.75f 152 CT4 DTM06-12SA 3 J66 W AVSS 0.5f

104 CN91 1743059-2 11 CT 3-1355136-3 12 G AVSS 0.5f CC-KW2000 153 CT4 DTM06-12SA 4 J67 B AVSS 0.5f

105 CN91 1743059-2 12 CT 3-1355136-3 81 W AVSS 0.5f 154 CT4 DTM06-12SA 5 J69 WY AVSS 0.5f F4 controller

106 CN91 1743059-2 13 J24 YR AVSS 0.75f 155 CT4 DTM06-12SA 7 J56 B AVSS 0.5f Sensor GND-2

107 CN91 1743059-2 15 J58 B AVSS 0.5f Sensor GND-1 156 CT4 DTM06-12SA 8 J26 WY AVSS 0.5f

108 CN91 1743059-2 19 J69 WY AVSS 0.5f F4 controller 157 CTG 6195-0054 7 J19 LR AVSS 0.75f MAIN RERAY C

109 CN91 1743059-2 36 J23 Y AVSS 1.25f LIGHT Relay C 158 D1 7123-2228 1 JG2 B AVSS 0.75f

110 CN93 7222-7564-40 1 OPEN Br. MVVS-S 0.5 159 D1 7123-2228 1 TM4 LA104 1 B AVSS 0.75f

111 CN93 7222-7564-40 2 CT 3-1355136-3 94 W MVVS 0.5 CAN 0 H 160 D1 7123-2228 2 TM3 LA104 1 YB AVSS 0.75f

112 CN93 7222-7564-40 3 CT 3-1355136-3 72 B MVVS 0.5 CAN 0 L STARTER

161 D3 7323-2228 1 6098-1493 3 BY AVSS 0.5f
CUT
113 CN93 7222-7564-40 4 OPEN Br. MVVS 0.5
162 D3 7323-2228 2 J20 G AVSS 0.5f IS-START
114 CN93 7222-7564-40 5 J66 W MVVS 0.5
163 D4 7323-2228 2 J21 RY AVSS 0.75f F12 ECU ACC
115 CN93 7222-7564-40 6 J67 B MVVS 0.5
164 F17 7124-9681 1 J32 R AVSS 2f
CC-ISOCAN H
116 CN93 7222-7564-40 11 CT 3-1355136-3 50 Sb AVSS 0.5f 165 F17 7124-9681 2 MAIN 6098-1493 5 RB AVS 2f F17 ECU B
twisted
CC-ISOCAN L 166 F18 7124-9681 1 J32 R AVSS 2f
117 CN93 7222-7564-40 12 CT 3-1355136-3 28 L AVSS 0.5f
twisted 167 F18 7124-9681 2 FUEL + CB104 1 Br AVSS 2f F18 FUEL PUMP
118 CN93 7222-7564-40 14 CT 3-1355136-3 62 Sb AVSS 0.5f 168 FUEL - CA104 1 JG2 B AVSS 2f
119 CN93 7222-7564-40 15 J20 G AVSS 0.5f IS-START 169 IN 7323-3010 1 SBF2 LA306 OUT G AVS 5
120 CN95 7123-4220-30 1 SBF1 LA406 OUT R AVS 5 170 IN/OUT 7123-4220-30 1 SBF1 LA406 OUT R AVS 5
121 CN95 7123-4220-30 2 SBF3 7122-4125-50 OUT R AVSS 2f 171
122 CN98 7222-4220-40 1 JG1 B AVS 3f SG 172 CN82 7123-7564-40 16 J56 Gr MVVS-S 0.5
123 CN98 7222-4220-40 2 JG2 B AVS 5 173
124 CR11 6020-6161 1 J19 LR AVSS 0.75f MAIN RERAY C 174
125 CR11 6020-6161 4 JG2 B AVSS 0.75f 175 J25 J58 B MVVS 0.5 Sensor GND-1
126 CT 3-1355136-3 1 JG1 B AVSS 1.25f SG 176 J25 J58 Gr MVVS-S 0.5
127 CT 3-1355136-3 2 JG1 B AVSS 1.25f SG 177
128 CT 3-1355136-3 3 JG1 B AVSS 1.25f SG 178
129 CT 3-1355136-3 4 JG1 B AVSS 1.25f SG 179 L1+ CB104 1 J23 Y AVSS 1.25f LIGHT Relay C
130 CT 3-1355136-3 5 JG1 B AVSS 1.25f SG 180 L1- CB104 1 JG2 B AVSS 1.25f
131 CT 3-1355136-3 6 JG1 B AVSS 1.25f SG 181 L2 7323-2228 1 J23 Y AVSS 1.25f LIGHT Relay C
132 CT 3-1355136-3 7 J19 LR AVSS 1.25f MAIN RERAY C 182 L2 7323-2228 1 L3 7323-2228 1 LgR AVSS 1.25f LIGHT Relay C
133 CT 3-1355136-3 9 J22 RY AVSS 0.75f SP-5V2 183 L2 7323-2228 2 JG2 B AVSS 1.25f
134 CT 3-1355136-3 25 J18 YG AVSS 0.5f IA-ACCEL1 184 L2 7323-2228 2 L3 7323-2228 2 B AVSS 1.25f
135 CT 3-1355136-3 26 J18 YG AVSS 0.5f IA-ACCEL2 185 L4 7323-2228 1 J23 Y AVSS 1.25f LIGHT Relay C
136 CT 3-1355136-3 29 J19 LR AVSS 1.25f MAIN RERAY C 186 L4 7323-2228 2 JG2 B AVSS 0.75f
137 CT 3-1355136-3 37 JG1 B AVSS 0.75f PG-SIGN MAIN RERAY
187 MAIN 6098-1493 1 J15 Y AVSS 0.75f
138 CT 3-1355136-3 40 J20 G AVSS 0.5f IS-START COIL+

139 CT 3-1355136-3 51 J19 LR AVSS 1.25f MAIN RERAY C 188 MAIN 6098-1493 2 JG2 B AVSS 0.75f

MAIN RERAY 189 MAIN 6098-1493 3 J19 LR AVSS 2f MAIN RERAY C

140 CT 3-1355136-3 54 J15 Y AVSS 0.75f
COIL+ 190 MC CA104 1 JG2 B AVSS 0.5f
141 CT 3-1355136-3 56 CTG 6195-0054 2 LW AVSS 0.75f IA-EVRV 191 MT- 7316-2095 1 JG2 B AVSS 1.25f
142 CT 3-1355136-3 59 JG1 B AVSS 0.75f PG-SIGN 192 OPT3+ CB104 1 J23 Y AVSS 1.25f LIGHT Relay C
143 CT 3-1355136-3 73 J19 LR AVSS 1.25f MAIN RERAY C 193 OPT3- CB104 1 JG2 B AVSS 1.25f
144 CT 3-1355136-3 75 J17 BW AVSS 0.75f SG-5VRT2 194 R2 776522-1 1 J66 W AVSS 0.5
MAIN RERAY
145 CT 3-1355136-3 76 J15 Y AVSS 0.75f
COIL+
Drawing No. 3
146 CT 3-1355136-3 78 CTG 6195-0054 1 GR AVSS 0.75f
05742-07740 4
2H0AS06

9
WIRE HARNESS DIAGRAM 2H0AS00
 SERVICE DATA
WIRE HARNESS DIAGRAM 2
Initial Connector type of Pin End con- Connector type of Pin Line di-
No. Color Line type Remarks1 Remarks2
connector initial connector no. nector end connector no. ameter
195 R2 776522-1 2 J67 B AVSS 0.5f
196 SBF1 LA406 IN TM2 LA308 1 Y AV 8
197 SBF2 LA306 IN TM1 LA308 1 RW AVS 5
198 SBF3 7122-4125-50 IN TM1 LA308 1 RW AVS 5
199 SBF3 7122-4125-50 OUT J32 R AVSS 2f
200 SG LA210 1 JG1 B AVS 3f SG
STARTER
201 6098-1493 1 J19 LR AVSS 0.75f MAIN RERAY C
CUT
STARTER
202 6098-1493 4 JG2 B AVSS 0.5f
CUT
203 T-ARAM- LA106 1 JG2 B AVSS 1.25f
204 TM14 7116-5110 1 JG2 B AVSS 0.75f
205 GP 7222-4210-40 1 OUT 7323-3010 1 Y AVS 5
Body
206 LA310 1 JG2 B AVS 5
earth 1
Body
207 LA310 1 JG2 B AVS 5
earth 2
208 D7 7123-2228 2 CN13 963040-3 1 YR AVSS 0.75f
209 D7 7123-2228 1 CN13 963040-3 2 B AVSS 0.75f
210 D8 7123-2228 2 CN14 963040-3 1 YR AVSS 0.75f
211 D8 7123-2228 1 CN14 963040-3 2 B AVSS 0.75f
212 D9 7123-2228 2 CN2 963040-3 1 G AVSS 0.5f
213 D9 7123-2228 1 CN2 963040-3 2 B AVSS 0.5f
214 R5 776522-1 1 J76 G AVSS 0.5f
215 R5 776522-1 2 J77 WG AVSS 0.5f
216 J76 CT4 DTM06-12SA 6 R MVVS 0.5f
217 J77 CT4 DTM06-12SA 12 W AVSS 0.5f

Drawing No. 4
05742-07740 4
2H0AS06

10
WIRE HARNESS DIAGRAM 2H0AS00
 SERVICE DATA
WIRE HARNESS DIAGRAM 2
Wire harness

From To
No. Nominal Color Remarks
Model Position Model Position
Water temperature
25 CT-25 2-C CN-A3 8-A 0.75 RB
sensor OUT
Boost pressure
26 CT-26 2-C J5 6-C 0.75 LR
sensor GND
27
28 CT-28 2-C CN-A14 8-A 0.75 Br NE pulse SLD
29
30 CT-30 1-C J2 4-C 0.75 BR SCV-LOW
31 CT-31 3-C CN-D1 8-B 1.25 L OS-INJ1(#1)
32
33 CT-33 3-C CN-D9 8-C 1.25 BR OS-INJ4(#2)
34
35 CT-35 3-C CN-B5 8-D 0.75 WR EGR motor A (U)
36
37
38
39
Hydraulic sensor
40 CT-40 2-C CN-A20 8-B 0.75 BY
GND
41 CT-41 2-C J6 5-C 0.5 B NE (GND)
Boost temperature
42 CT-42 2-C J8 6-C 0.75 B
sensor (-)
43 CT-43 2-C CN-D15 8-C 0.75 Br G pulse SLD
44
45 CT-45 2-C J9 4-C 0.75 RL SCV-H1
46 CT-46 3-B CN-D2 8-B 1.25 WB OS-INJ3(#4)
47
48 CT-48 3-B CN-D4 8-B 1.25 WL OS-INJ2(#3)
Intake valve motor
49 CT-49 3-B CN-C12 8-E 0.75 RW
close +
Intake valve motor
50 CT-50 3-B CN-C13 8-E 0.75 G
close -
51
52 CT-52 3-B CN-B1 8-C 0.75 GB EGR sensor A (U)
53 CT-53 2-B CN-B2 8-C 0.75 GW EGR sensor A (V)
54 CT-54 2-B CN-B3 8-C 0.75 GY EGR sensor A (W)
55
56 CT-56 2-B CN-D18 8-C 0.5 W G pulse OUT
57 CT-57 2-B CN-A6 8-A 0.5 W NE pulse OUT
Common rail
From To 58 CT-58 2-B CN-A14 8-A 0.75 Br pressure sensor
No. Nominal Color Remarks SLD
Model Position Model Position
59
1 CT-1 3-C CN-D5 8-B 1.25 BW INJ-COM1A
60 CT-60 1-B J9 4-C 0.75 RW SCV-HI
2 CT-2 3-C CN-D6 8-B 1.25 R INJ-COM1B
61 J3 6-C CN-A5 8-A 0.5 R RAIL-VCC
3
62 J3 6-C CN-A1 8-A 0.5 R NE(VCC)
4
63 J8 6-C CN-A13 8-A 0.75 RL
5 CT- 5 3-C CN-B7 8-D 0.75 WL EGR motor A (W)
64 J8 6-C CN-D19 8-C 0.5 OrB
Boost pressure
6 CT- 6 3-C J1 7-C 0.75 RL 65 J8 6-C CN-C9 8-E 0.75 B
sensor Vcc
7 66 J7 6-C CN-A17 8-A 0.5 B
8 67 J7 6-C CN-A15 8-A 0.5 B
Fuel temperature 68 J5 6-C CN-A19 8-A 0.75 RL
9 CT-9 2-C CN-A31 8-B 0.75 YG 69 J5 6-C CN-B8 8-D 0.75 LW
sensor OUT
Boost temperature 70 J1 7-C CN-A29 8-B 0.75 RW
10 CT-10 2-C CN-A9 8-A 0.75 BR 71 J1 7-C CN-B4 8-C 0.75 L
sensor (+)
Common rail 72 J9 4-C CN-D16 8-C 0.75 RW
11 CT-11 2-C CN-A10 8-A 0.5 W pressure sensor 73 J2 4-C CN-D20 8-C 0.75 RB
OUT 74 J4 7-C CN-D17 8-C 0.5 R
Hydraulic sensor 75 J4 7-C CN-C8 8-E 0.75 R
12 CT-12 2-C CN-A25 8-B 0.75 LY
OUT 76 J6 5-C J7 6-C 0.5 B
Boost pressure 77
13 CT-13 2-C CN-A24 8-B 0.75 L
sensor 78
Intake valve 79
14 CT-14 2-C CN-C11 8-E 0.5 VW
position sensor
80 CT-G5 3-B CN-A4 8-A 0.75 G To O/H LAMP (+)
15 CT-15 1-C J2 4-C 0.75 BR SCV-LOW
To water
16 CT-16 3-C CN-D8 8-B 1.25 B INJ-COM2A 81 CT-G6 3-B CN-A8 8-A 0.75 R temperature meter
17 CT-17 3-C CN-D13 8-C 1.25 LR INJ-COM2B (+)
18 82 CT-G7 3-B CN-C3 8-D 0.75 LR TURBO (+)
19 83 J6 5-C CN-G8 4-B 0.5 B
20 CT-20 3-C CN-B6 8-D 0.75 WR EGR motor A (V) 84 CT-G1 3-A CN-C1 8-D 0.75 GR TURBO (-)
21 CT-21 3-C J3 6-C 0.5 R 85 CT-G2 3-A CN-C5 8-D 0.75 LW VACUUM OUT
22 CT-22 3-C J4 7-C 0.5 R G-VCC
Hydraulic sensor
23 CT-23 2-C CN-A30 8-B 0.75 WB
Vcc
24

11
WIRE HARNESS DIAGRAM 2H0AS00
 SERVICE DATA
WIRE HARNESS DIAGRAM 2
Engine harness

Initial
Connector type of Pin Type of initial End con- Connector type of Pin Type of initial Line di-
No. connec- Color Line type Remarks1 Remarks2
initial connector no. pin nector end connector no. pin ameter
tor
1 AC5 12065172 B CN83 7222-7564-40 15 G AEX 1.25f Compressor
2 ALT E LA306 1 J12 B AEX 5
3 CN85 7123-4220-30 1 J11 W AEX 5
4 CN85 7123-4220-30 2 J12 B AEX 5
5 D6 776427-1 1 J12 B AEX 1.25f
6 D6 776427-1 2 J11 W AEX 1.25f
7 STMS LA304 1 J11 W AEX 5
8 ALT R,L 7323-1424-40 2 CN83 7222-7564-40 1 RY AEX 0.75f F12 ECU ACC
9 ALT R,L 7323-1424-40 1 CN83 7222-7564-40 2 L AEX 0.75f
10 CN27 DT06-04S-CE05 1 1062-16-0622 CN83 7222-7564-40 12 G AESSXCS 0.5f Sensor GND-2
11 CN27 DT06-04S-CE05 2 1062-16-0622 CN83 7222-7564-40 13 R AESSXCS 0.5f Sencor 5V-2
12 CN27 DT06-04S-CE05 4 1062-16-0622 CN83 7222-7564-40 14 W AESSXCS 0.5f
13 CN54 7282-7023-10 1 7114-4029-08 CN83 7222-7564-40 4 Y AEX 0.75f IA-THE2 Au on 7282-7023-10 side
14 CN54 7282-7023-10 2 7114-4029-08 J13 BW AEX 0.75f SG-5VRT2 Au on 7282-7023-10 side
15 CN55 7282-7026-40 1 7114-4029-08 CN83 7222-7564-40 5 G AEX 0.75f IA-THE1 Au on 7282-7026-10 side
16 CN55 7282-7026-40 2 7114-4029-08 J13 BW AEX 0.75f SG-5VRT2 Au on 7282-7026-10 side
17 CN56 6189-0099 1 CN83 7222-7564-40 8 R AESSXCS 0.75f Au on 6189-0099 side
18 CN56 6189-0099 2 CN83 7222-7564-40 7 W AESSXCS 0.75f IA-EXHP Au on 6189-0099 side
19 CN56 6189-0099 3 CN83 7222-7564-40 6 G AESSXCS 0.75f SP-5V3 Au on 6189-0099 side
20 CN83 7222-7564-40 3 OPEN Gr AESSX 0.5f Shielded
21 CN83 7222-7564-40 9 J13 BW AEX 0.75f SG-5VRT2
22 CN83 7222-7564-40 10 HYD 174352-2 1 Y AEX 0.5f
23 CN83 7222-7564-40 11 HYD 174352-2 2 B AEX 0.5f
24 ALTB LA406 1 STMB LA408 1 R AEX 8
25 CN83 7222-7564-40 16 OPEN Gr AESSX 0.5f Shielded

12
WIRE HARNESS DIAGRAM 2H0AS00
 FUNCTION 3
Hydraulic pump (Main)
Hydraulic pump (Sub)
Control valve
Pilot valve (control lever)
Pilot valve (swing)
Pilot valve (blade)
Pilot valve (travel)
Proportional control solenoid valve
Emergency shut-off valve
Solenoid valve
Shockless valve
Cylinders
Travel motor
Slew motor
Swivel joint
 FUNCTION
HYDRAULIC PUMP (MAIN) 3
HYDRAULIC PUMP (MAIN)
This pump is formed of two variable displacement piston
pumps (1) and (2) and a gear pump (3). The two variable
displacement piston pumps operate over the same shaft.
However, the gear pump (3) operates on a different shaft
than the variable displacement piston pumps.
Roughly speaking, this pump is formed of a cylinder
block (4) that produces rotating motion, a regulator (5)
that changes the discharge flow rate, and a PTO group
(6) that is used to transmit the gear pump motion to the
driving shaft.

Cylinder block
The cylinder block (4) is formed of pistons (7), and at its
end surface, it is in contact with the valve plate (10) that
contains the intake port (8) and the discharge port (9).
The cylinder block (4) rotates freely and is connected to
the shaft (11) via the spline. The swash plate (12), on the
other hand, is fixed at an angle to the housing, and the
pistons (7) are designed to rotate along with the swash
plate (12).
Here, the cylinder block (4) rotates as the shaft (11) is ro-
tated, and the pistons (7) mounted in the cylinder block
(4) follow and move back and forth with the motion of the
swash plate (12), which activates the suction and dis-
charge pumps.
In this way, the nine pistons (7) complete one stroke of in-
take and exhaust for every stroke of the cylinder block
(4). Thus, continuous operation of intake and exhaust
can be obtained by continuous rotation of the shaft (11).
The displacement of the pistons (7) can be varied
through modification of the angle of inclination of the
swash plate (12) as the degree of displacement depends
on the inclination of the swash plate (12).

Regulator
This regulator is equipped with three control functions, a
flow rate control function for discharging only the neces-
sary amount according to the pilot pressure Pi from the
control valve, a function for controlling horsepower to
prevent excessive load on the motor using the discharge
pressures P1 and P2, and a power shift control function
for controlling the set pump horsepower setting using the
power shift pressure Pf from the Pr pump (2nd service
and blade). If these control functions are used together,
low-inclination operation commands (low flow rate com-
mands) are given priority based on mechanical calcula-
tions.

1
HYDRAULIC PUMP (MAIN) 3I0AS00
 FUNCTION
HYDRAULIC PUMP (MAIN) 3
1. Flow rate control
The angle of inclination (discharge rate) of the swash
plate of the pump is controlled by the pilot pressure Pi
from the control valve.
This regulator uses a load flow rate control (negative con-
trol) method through which the discharge rate Q is low-
ered as the pilot pressure Pi is increased, such that when
a command is issued for the pilot pressure Pi according
to the amount of flow required for operation, the pump
discharges only the necessary amount so that no power
is wasted unnecessarily.

Decrease in flow rate

When the pilot pressure Pi from port Ps2 in the control
valve is increased, the piston (1) moves to the right side
and stopped at a position at which the force of the spring
(2) is balanced with the hydraulic pressure.
The pin (4) attached to the lever (3) is inserted into the
groove (A) on the piston (1), and when the piston (1)
moves, the lever (3) turns clockwise around the securing
pin (5) of the pivot point (B).
The pin (7) attached to the lever (6) is inserted into the
hole (C) on the lever (3), and the pin (7) moves right when
the lever (3) rotates clockwise. The pin (10) secured to
the inclined pin (9) used to tilt the swash plate (8) is at-
tached to the second surface (D) of the lever (6), and the
lever (6) turns counter-clockwise around the second sur-
face (D) when the pin (7) moves. The spool (11) is linked
to the lever (6) via the pin (12) and moves to the right.
When the spool (11) moves, the discharge pressure P1
is transmitted to the port Cl through the spool (11) and
flows to the large-diameter section of the servo piston
(13). The discharge pressure P1 normally flows to the
small-diameter section of the servo piston (13), but the
servo piston (13) moves to the right due to the differential
area, causing the angle of inclination to decrease, which
results in the discharge pressure P1 flowing into the
large-diameter section.
When the servo piston (13) moves to the right, the sec-
ond surface (D) also moves to the right. The spring (14)
is attached to the spool (11) that normally exerts a pulling
force on the spool (11) that pulls it to the left, which caus-
es the pin (7) to be pushed into the hole (C) of the lever
(3). As can be inferred from the above, the lever (6) turns
counter-clockwise around the hole (C) when the second
surface (D) moves, resulting in the spool (11) moving to
the left. The movement of these parts causes the opening
between the sleeve (15) and the spool (11) to gradually
close, and the servo piston (13) stops at the position at
which the opening is completely closed.

2
HYDRAULIC PUMP (MAIN) 3I0AS00
 FUNCTION
HYDRAULIC PUMP (MAIN) 3
Increase in flow rate
When the pilot pressure Pi decreases, the piston (1)
moves to the left due to the force of the spring (2), and
the lever (3) turns clockwise around section B. The pin
(7) is pushed into the hole (C) on the lever (3) via the
spool (11), pin (12), and lever (6), which causes the lever
(6) to move counter-clockwise around the second width
(D) when the lever (3) moves clockwise, which results in
the spool (11) moving to the left.
When the spool (11) moves, port CI is connected to port
T, the pressure on the large-diameter section of the servo
piston (13) is released, and the servo piston (13) is
moved to the left by the discharge pressure P1 in the
small-diameter section, which causes the flow rate to in-
crease.
The second surface (D) moves to the left, causing the le-
ver (6) to turn clockwise around the hole (C), when the
servo piston (13) moves, resulting in the spool (11) mov-
ing to the right. The spool (11) continues to move until the
opening between the sleeve (15) and the spool (11) clos-
es and stops at the position at which the opening is
closed.

2. Horsepower control
As the discharge pressure P1 of the self-operating pump
and the discharge pressure P2 of the other pump in-
crease, the angle of inclination of the pump (discharge
rate) drops automatically such that the input torque is
controlled so as to be maintained below a set value. (The
input horsepower is constant when the rotation speed is
constant.)
With a tandem double pump, a simultaneous full-horse-
power method is used for operation according to the total
load pressure of the two pumps such that the regulators
in the two pumps are controlled and maintained at the
same angle of inclination (discharge rate) when horse-
power control is in effect. For this reason, when horse-
power control is in effect, engine overloading is prevent-
ed automatically independent of the load on the two
pumps.

3
HYDRAULIC PUMP (MAIN) 3I0AS00
 FUNCTION
HYDRAULIC PUMP (MAIN) 3
Prevention of excessive load
When the discharge pressure P1 of the self-operating
pump or the discharge pressure P2 of the other pump in-
creases, P1 and P2 are exerted on the step section of the
piston (16), which causes the rod (17) to be pushed to
the right to the position at which the spring force and oil
pressure of the spring (18) and spring (19) are balanced.
The movement of the rod (17) is transmitted to the lever
(20) via the pin (4), which causes the lever (20) to move
counter-clockwise around the pivot point (E). The pin (7)
attached to the lever (6) is thrust into the hole (F) on the
lever (20), which causes the lever (6) to move clockwise
around the second surface (D) when the lever (20)
moves counter-clockwise, resulting in the spool (11)
moving to the right.
When the spool (11) moves, the discharge pressure P1
causes the discharge rate in the large-diameter section
of the piston (13) to drop via port Cl, which works to pre-
vent excess load on the motor.
The movement of the servo piston (13) is transmitted to
the lever (6) via the second surface (D), which causes
the lever (6) to move counter-clockwise around the hole
(F), resulting in the spool (11) moving until the opening
between the spool (11) and the sleeve (15) and stopping
at the position at which the opening is closed.

Restoration of flow rate

When the discharge pressure P1 of the self-operating
pump or the discharge pressure P2 of the other pump
decreases, the rod (17) is pushed back by the spring
(18) and spring (19), and the lever (20) rotates clockwise
around the pivot point (E). The lever (6) turns counter-
clockwise around the second surface (D) when the lever
(20) turns clockwise, resulting in the spool (11) moving to
the left. As can be inferred from the above, port Cl opens
into the tank port, causing the pressure in the large-diam-
eter section of the servo piston (13) to be released, re-
sulting in the servo piston (13) moving to the left and the
pump discharge rate increasing.
The movement of the servo piston (13) is transmitted to
the spool (11) via the mechanism in the lever (6), and the
spool (11) continues to move until the opening between
the spool (11) and the sleeve (15) is closed.

4
HYDRAULIC PUMP (MAIN) 3I0AS00
 FUNCTION
HYDRAULIC PUMP (MAIN) 3
3. Power shift (Lowered horsepower control)
The pressure from the Pr pump (2nd service and blade)
controls the set pump horsepower as a power shift pres-
sure Pf.
When the power shift pressure Pf is increased, the rod
(17) moves to the right via the pin (21) and piston (16),
which causes the angle of inclination of the pump to
drop and the set horsepower to decrease, as was de-
scribed in the explanation for operation to prevent ex-
cessive load for control of horsepower. Conversely, if
the power shift pressure Pf is decreased, the set
horsepower will increase.

4. Command override system for low-inclination (low flow

rate) operation
As described above, the inclination command for flow
rate and horsepower control is transmitted to the lever (6)
and spool (11) via the holes (C) and (F) in the lever (3)
and lever (20). In the diagram shown at right, the lever (3)
is being affected by a command that causes its angle of
inclination to be greater than that of the lever (20) such
that the pin (7) makes contact with only the hole (F) in the
lever (20), which has the smaller angle of inclination. As
a result, the hole (C) of the lever (3) remains open and
free of contact with the pin (7).
With this kind of mechanical selection system, low-incli-
nation commands for flow rate control and horsepower
control are given priority over other commands.

5
HYDRAULIC PUMP (MAIN) 3I0AS00
 FUNCTION
HYDRAULIC PUMP (MAIN) 3
PTO group
The PTO group is formed of a 1st gear (1), 2nd gear (2),
and 3rd gear (3), and the 2nd gear (2) and 3rd gear (3)
are supported by a bearing (4) and a bearing (5), re-
spectively.
When the driving shaft rotates, the rotation of the driving
shaft is conveyed to the 1st gear (1) and transmitted to
the 3rd gear (3) via the 2nd gear (2) to drive the gear
pump connected to the 3rd gear (3).

6
HYDRAULIC PUMP (MAIN) 3I0AS00
 FUNCTION
HYDRAULIC PUMP (SUB) 3
HYDRAULIC PUMP (SUB)
The hydraulic pump (sub) (1) is a gear pump that is a
constant-volume pump that discharges a constant vol-
ume of discharge material over a constant speed.
The hydraulic pump (sub) (1) is connected to the PTO
group (2) of the hydraulic pump (main) through gears
that transmit the rotation of the engine from the PTO
group.
Hydraulic pump, PTO group

The gear pump is composed of two mutually engaging 6

gears (drive gear (6) and driven gear (7)) that are con-
tained in a gear case. When the drive gear (6) is rotated,
the space between the case and the gears is filled with
the oil that flows from the inlet to the outlet.

7 3I1AQ02Z

1
HYDRAULIC PUMP (SUB) 3I1AS00
 1 Arm 1
2 Boom 2

CONTROL VALVE
3 Slew
4 1st auxiliary line
5 Travel (R)
CONTROL VALVE

6 Outlet
7 2nd auxiliary line
8 Blade
9 Inlet
0 Swing
a Arm 2
b Boom 1
c Bucket
d Travel (L)

1
e Straight travel
CONTROL VALVE
FUNCTION
3

3J0AS00
 1 Arm 1
2 Boom 2

CONTROL VALVE
3 Slew
4 1st auxiliary line
5 Travel (R)
6 Outlet
7 2nd auxiliary line
8 Blade
0 Swing
a Arm 2
b Boom 1
c Bucket
d Travel (L)
e Travel forward

2
CONTROL VALVE
FUNCTION
3

3J0AS00
 FUNCTION
CONTROL VALVE 3
When all spools are in the neutral position
Neutral passage (Fig. 1), (Fig. 2)
Fig. 2
The oil supplied from the port P1 is sent from the neutral passage (L1) to the neutral passage (L2) and through the
opening (Lc1) in the low-pressure relief valve into the tank passage (Ta) to be returned to ports T1 and T2.
The oil supplied from the port P2 is sent from the neutral passage (R1) to the oil passage (R2) via the neutral cut spool
and through the opening (Rc1) in the low-pressure relief into the tank passage (Ta) to be returned to ports T1 and T2.
The pressure in the pressure chambers (L2) and (R2) of the upstream flow section of the low-pressure relief vale flows
into the pumps from ports ps1 and ps2 to control the discharge rates of pumps P1 and P2.
If an excessive amount of oil flows into the neutral passages, the low-pressure relief valve operates to prevent the pres-
sure in ports ps1 and ps2 from rising to an abnormal level.

Fig. 1
In addition, the oil supplied from the port P1 flows from the passage (2) into the parallel passage (L3) via the bridge (4)
and straight travel valve and through the passage (1). The auxiliary, slew, boom 2, and arm 1 sections are connected
together via each check valve, and the flow is stopped by the spool in each section.

Fig. 2
The parallel passage (L3) is connected to the neutral passage (L1) via the passage (S1-2) and the check valve (S1-1)
such that the oil flows from port P1 to the parallel passage (L3) without going through the straight travel valve when the
travel section (Section 1) is not operating.

Fig. 1
The oil (3rd pump) supplied from port Pr flows from the passage (13) in the inlet section into the neutral passage (Pg).
The oil that flows into the blade section flows from the passage (Tg) into the inlet section via the outlet section (cover)
and flows into the oil in the machine body tank passage (Ta).

Fig.2
In addition, the flow of the oil supplied from the port Pr is connected to the blade section via the parallel passage (G3)
and check valve and is stopped by the spool.

Signal passage (Fig. 1)

The oil supplied from the port PP flows to port PT via the opening (Lc3). At the same time, it also flows from the land
(Rc3) through the land (Lc4) and passage (6) and into the drain passage (DR).
Part of the oil supplied from the port PP flows to port PA from the opening (Lc5). In addition, it also flows from the bucket
spool land (Rc4) and into the drain passage (DR) via the passages (L4), (9), and (R4).
The oil that passes through the opening (Lc6) flows into the tank passage (Ta) from the land (Lc7). The oil also flows
from the travel spool land (Rc5) and into the tank passage (Ta) through the passage (5).
At this time, the oil that flows through the passage (5) flows into the switching pressure chamber (Pts) from the spool
cycle passage of the straight travel valve.
The chamber (Tts) on the opposite side from the straight travel valve spool is connected to the tank passage (Ta) via
a notch opening in the outer circumference of the spool and used to decrease the impact of shocks during switching.

3
CONTROL VALVE 3J0AS00
 FUNCTION
CONTROL VALVE 3
Independent operation
Travel spool switching (Fig. 3), (Fig. 4)

5 Travel (R) f Neutral

d Travel (L) g Switching
e Straight travel

When the pressure from the pilot port pb1 (pa1) of the travel (R) section (section 1) increases causing the travel spool
to be switched, the oil supplied from the port P1 flows from the neutral passage (L1) through the spool neck and into
the port B1 (A1). The oil that returns back returns to the tank passage (Ta) from port A1 (B1) through the spool neck.
When the pressure from the pilot port pb6 (pa6) of the travel (L) section (section 6) increases causing the travel spool
to be switched, the oil supplied from the port P2 flows from the neutral passage (R1) through the spool neck or the
passage (S6-1) and into the port B6 (A6).
At this time, the poppet (S6-2) does not open as the pressure in the parallel passage (R3) is the same as that in the
passage (S6-1).
The oil that returns back returns to the tank passage (Ta) from port A6 (B6) through the spool neck.
Either the land (Lc4) or the land (Rc3) closes when the spool in either travel section (Section 1 or Section 6) switches.
The flow of the oil supplied from the port PP into the tank passage is blocked, which causes the pressure in the port
PT to increase.

4
CONTROL VALVE 3J0AS00
 FUNCTION
CONTROL VALVE 3
1st auxiliary line spool switching (Fig. 5)

4 1st auxiliary line

d Travel (L)

The neutral passage (L1) closes when the pressure from the pilot port pb2 (pa2) of the 1st auxiliary line (Section 2) is
increased causing the spool to switch. The oil supplied from the port P1 flows from the parallel passage (L3) and into
port B2 (A2) through the load check valve (S2-1), passage (S2-2), and spool neck.
The oil that returns back returns to the tank passage (Ta) from port A2 (B2) through the spool neck.
A load check is used in this section that allows external oil to flow from port P4.

5
CONTROL VALVE 3J0AS00
 FUNCTION
CONTROL VALVE 3

3 Slew
c Bucket

Slew spool switching (Fig. 6)

The neutral passage (L1) closes when the pressure in the pilot port Pb3 (Pa3) in the slew section (Section 3) increases
and causes the slew spool to switch. The oil supplied from the port P1 flows from the parallel passage (L3) through the
load check valve (S3-1), passage (S3-2), and spool neck and into the passage B3 (A3).
The oil that returns back returns from port A3 (B3) through the spool neck to the tank passage (Ta).

Bucket spool switching (Fig. 6)

The neutral passage (R1) closes when the pressure in the pilot port pb7 (pa7) in the bucket section (Section 7) increas-
es and causes the bucket spool to switch. The oil supplied from port P2 flows from the parallel passage (R3) and into
port B7 (A7) through the load check valve (S7-1), passage (S7-2), and spool neck.
The oil that returns back returns from port A7 (B7) through the spool neck to the tank passage (Ta).

6
CONTROL VALVE 3J0AS00
 FUNCTION
CONTROL VALVE 3
Boom spool switching
Neutral position (Fig. 7)

2 Boom 2
b Boom 1

This valve is installed in the anti-drift valve on the cylinder bottom side of the boom 1.
When in the neutral position, the poppet (AD1) is firmly seated by the pressure of the port (A8) flowing from the spring
chamber (AD5) through the passage (AD2), poppet (AD3), and passage (AD4).

7
CONTROL VALVE 3J0AS00
 FUNCTION
CONTROL VALVE 3
Raising (2nd-speed flow) (Fig. 8)

2 Boom 2
b Boom 1

The neutral passage (R1) closes when the pressure in the pilot port pa8 in the boom 1 section (Section 8) increases
and causes the boom 1 spool to switch. The oil supplied from the port P2 flows through the parallel passage (R3), load
check valve (S8-1), and spool neck to the port A8.
The neutral passage (L1) closes when the pressure in the pilot port pa4 in the boom 2 section (Section 4) increases
and causes the boom 2 spool to switch. The oil supplied from the port P1 flows through the parallel passage (L3), load
check valve (S4-1), spool neck, and passage (7) to the port A8. The oil that returns back returns from port B8 through
the spool neck to the tank passage (Ta).

8
CONTROL VALVE 3J0AS00
 FUNCTION
CONTROL VALVE 3
Lowering (Reclaiming) (Fig. 9)

2 Boom 2
b Boom 1

The neutral passage (R1) closes when the pressure in the pilot port pb8 in the boom 1 section (Section 8) increases
and causes the boom 1 spool to switch. The oil supplied from the port P2 flows through the parallel passage (R3), load
check valve (S8-1), and spool neck to the port B8. Simultaneously, when the pressure in the port pc2 increases causing
the poppet (AD3) of the anti-drift valve to switch and the pressure in the spring chamber (AD5) to drop, the poppet
(AD1) opens, and oil returning from the port A8 flows into the tank passage (Ta). Part of the oil returning back pushes
on and opens the poppet (S8-3) inside the boom 1 spool, and flows through the passage (S8-2) into the port B8 to
prevent cavitation from forming on the cylinder load side.

9
CONTROL VALVE 3J0AS00
 FUNCTION
CONTROL VALVE 3
Arm spool switching
Dumping (2nd-speed flow) (Fig. 10)

1 Arm 1
a Arm 2

When the pressure in the pilot port pb5 of the arm 1 section (Section 5) increases causing the arm 1 spool to switch,
the oil supplied from the port P1 flows from the neutral passage (L1) through the load check valve (S5-1), passage (S5-
2), and spool neck and into the port A5.
When the pressure in the pilot port pa9 of the arm 2 section (Section 9) increases causing the arm 2 spool to switch,
the oil supplied from the port P2 flows from the neutral passage (R1) through the load check valve (S9-1), passage (S9-
2), spool neck, and passage (10) and into the port A5. Simultaneously, part of the oil supplied from the port P2 flows
from the opening (S9-3) in the passage (R3) through the check valve (S9-4), passage (S9-2), and passage (10) and
into the port A5. The oil that returns back returns from the port B5 through the arm 1 spool neck back into the tank
passage (Ta), and the oil from the passage (11) returns through the arm 2 spool neck back into the tank passage (Ta).

10
CONTROL VALVE 3J0AS00
 FUNCTION
CONTROL VALVE 3
Crowding (2nd-speed flow) (Fig. 11), (Fig. 12)

1 Arm 1
a Arm 2

When the pressure in the pilot port pb5 of the arm 1 section (Section 5) increases causing the arm 1 spool to switch,
the oil supplied from the port P1 flows from the neutral passage (L1) through the load check valve (S5-1), passage (S5-
2), and spool neck and into the port B5.
When the pressure in the pilot port pb9 of the arm 2 section (Section 9) increases causing the arm 2 spool to switch,
the oil supplied from the port P2 flows from the neutral passage (R1) through the load check valve (S9-1), passage (S9-
2), spool neck, and passage (11) and into the port B5. Simultaneously, part of the oil supplied from the port P2 flows
from the opening (S9-3) in the passage (R3) through the check valve (S9-4), passage (S9-2), and passage (11) and
into the port B5.
When the pressure in the port pc1 increases causing the poppet (AD3) of the anti-drift valve to switch and the pressure
in the spring chamber (AD5) to drop, the poppet (AD1) opens, and oil returning from the port A5 flows through the
spool neck, passage (S5-3), and arm variable reclaiming opening (Lc8) back into the tank passage (Ta). Part of the oil
returning back pushes on and opens the poppet (S5-4) inside the arm 1 spool, and flows through the passage (S5-2)
into the port B5 to increase the speed of the cylinder. This also works to prevent cavitation from forming on the bottom
side.

Variable reclaiming (during crowding) (Fig. 11), (Fig. 12)

During crowding of the arm, the spool (S5-6) moves in response to the pressure in the passage (S5-2) flowing from the
passage (S5-5), causing the degree to which the arm variable reclaiming opening (Lc8) is opened to change. If the
pressure in the passage (S5-2) is high, the amount that the spool (S5-6) moves increases causing the degree to which
the opening (Lc8) is opened to drop. This causes the reclaiming flow rate to change in response to the pressure at the
bottom of the am cylinder.

11
CONTROL VALVE 3J0AS00
 FUNCTION
CONTROL VALVE 3
Parallel opening for the arm (Fig. 10), (Fig. 11), (Fig. 12,) (Fig. 13), (Fig. 14)

Fig. 10, Fig. 11

There are openings formed in both the arm 1 section (Section 5) and arm 2 section (Section 9) in the parallel circuit for
the arm for this valve that are used to control the flow rate so that the arm speed is at a proper speed even during
composite operation.
After the parallel circuit of the arm 2 section (Section 2) closes the opening (RC6) of the sleeve (S9-3) from the parallel
passage (R3), it is connected to the passage (S9-2) through the poppet (S9-4).

Fig. 13, Fig. 14

After the parallel circuit of the arm 1 section (Section 5) pushes open the poppet (S5-8) from the parallel passage (L3)
and the opening (Lc9) of the parallel variable opening spool closes, the passages (S5-2) and (12) are connected to-
gether.
The degree to which the opening (Lc9) is opened can be changed using increases in pressure in the pilot port (pbu)
(pc3).

12
CONTROL VALVE 3J0AS00
 FUNCTION
CONTROL VALVE 3
Add-on spool switching (Fig. 16)

The 2nd auxiliary line will be presented here as a typical example of this kind of switching.
The neutral passage (Pg) closes when the pressure from the pilot port prb3 (pra3) of the 2nd auxiliary line (Section 12)
is increased causing the spool to switch. The oil supplied from the port Pr flows from the parallel passage (G3) through
the load check valve (S12-1), passage (S12-2), and spool neck and into port BR3 (AR3).
The oil that returns back returns from port AR3 (BR3) through the spool neck to the tank passage (Ta).

13
CONTROL VALVE 3J0AS00
 FUNCTION
CONTROL VALVE 3
Relief valve
Main relief valve for the machine body (Fig. 17)

The oil supplied from the port P1 flows through the poppet (LP), or the oil supplied from the port P2 flows through the
poppet (RP) and passage (3), and into the main relief valve. When the main relief valve operates, the maximum pres-
sure of the pumps on the P1 and P2 sides is restricted to a set value.

Relief valve for the add-on Pr (Fig. 18)

The oil supplied from the port Pr flows into the main relief valve. The maximum pressure of the Pr pump is limited to a
set value through operation of the main relief valve.

Overload relief valve

An overload relief valve is provided in each of the cylinder ports in each section that prevents the pressure in the ac-
tuator from rising to an abnormal level due to an external force.
This relief valve is also equipped with a function designed to prevent suction of oil from the tank and cavitation from
occurring when the pressure in the cylinder port becomes a negative pressure.

14
CONTROL VALVE 3J0AS00
 FUNCTION
CONTROL VALVE 3
Composite operation
Composite travel operation (Fig. 19), (Fig. 20)

During simultaneous left-and-right travel operation (during forward travel, reverse travel, or spin turns), when opera-
tions other than travel operations are run simultaneously, or when simultaneous left-and-right travel operations are run
while other operations other than travel operations are being run, the oil supplied from the port PP is blocked from flow-
ing to the tank passage (Ta) by signal land sections other than travel sections switched with the lands (Lc4), (Lc7),
(Rc3), and (Rc5), which causes the pressure in the signal passage to increase to the relief pressure setting for the hy-
draulic generator for signals.
The straight travel spool is switched by the increase in the signal pressure. The pressure in the ports PT and PA also
increases.
When the straight travel spool switches, the oil supplied from the port P1 flows from the neutral passage (L1) and into
the travel (R) section (Section 1), and at the same time, through the passage (2), straight travel spool neck, and neutral
passage (R1) and into the travel (L) section (Section 6).
The oil supplied from the port P2 flows through the straight travel spool neck and passage (1) and into the parallel pas-
sage (L3).
The travel sections (Section 1 and Section 6) are moved by the oil supplied from the port P1 and devices in other op-
erating sections are moved by the oil supplied from the port P2, which works to prevent veering in travel during com-
posite operations involving simultaneous left-and-right travel operation and operation of other devices.
If the load pressure in other sections is higher than the load pressure in the travel section (Section 6), part of the oil
supplied from the port P2 pushes on and opens the poppet (S6-2) and flows through the opening at the end of the
poppet and into the passage (S6-1). This works to alleviate the impact from shocks from deceleration with travel during
switching of the straight travel valve.

15
CONTROL VALVE 3J0AS00
 FUNCTION
CONTROL VALVE 3
Anti-drift valve
The anti-drift valve is used to prevent spontaneous drop
of the arm (boom) cylinder and is mounted in the cylinder
port on the arm rod (boom bottom) side.
In neutral, the cylinder port pressure flows into the spring
chamber (AD5) from the passage (AD2) through the hol-
low hole in the poppet (AD3) and the passage (AD4).
The poppet (AD1) is firmly seated by the pressure differ-
ential produced by the spring force and differential area
of the poppet.

When the arm is in the dump position (the boom is

raised), the oil supplied from the pump pushes the pop-
pet (AD1) open and flows into the cylinder port.

When the arm is in the crowd position (the arm is low-

ered), the pc1 (pc2) pressure increases causing the
poppet (AD3) to switch, which leads to the oil in the
spring chamber (AD5) to flow through the hollow hole in
the poppet (AD3) and hollow hole in the spool (AD6) and
into the drain passage (DR). This causes the poppet
(AD1) to open, and the oil that returned from the cylinder
port flows into the tank passage (Ta) through the spool.

16
CONTROL VALVE 3J0AS00
 FUNCTION
CONTROL VALVE 3
Main relief valve
The main relief valve is mounted between the pump cir-
cuit and tank circuit of each inlet housing and serves to
maintain the circuit pressure at the set value.

Machine body main relief valve

B
This relief valve is installed between the neutral passage "LP"
“HP” and low-pressure passage “LP,” and oil flows
through the opening hole in the main poppet into the in-
ternal cavity (C) to fill the internal cavity (C).

A
In addition, the opening in the sleeve (2) and the main "HP"
poppet (1) are firmly seated using the different areas of
“A” and “B.”
1 C 2

3J0AS20

When the pressure in the neutral passage “HP” reaches

the set pilot spring force, the pilot poppet (3) opens. E D
"LP"
The oil flows around the pilot poppet (3) from the hole (D)
and through the gap (E) into the tank passage “LP.”

"HP"

3J0AS21

When the pilot poppet (3) is opened, the pressure in the

internal cavity (C) drops causing the main poppet (1) to C
"LP"
open, which results in the oil in “HP” flowing into the con-
necting passage “LP.”

"HP"

1 3

3J0AS22

17
CONTROL VALVE 3J0AS00
 FUNCTION
CONTROL VALVE 3
Add-on main relief valve
This relief valve is installed between the neutral passage 2

B
“HP” and low-pressure passage “HP,” and oil flows "LP"
through the opening hole in the main poppet into the in-
ternal cavity (C) to fill the internal cavity (C).
In addition, the opening in the sleeve (2) and the main

A
poppet (1) are firmly seated using the different areas of "HP"
“A” and “B.”

1 C
3J0AS23

When the pressure in the neutral passage “HP” reaches

the set pilot spring force, the pilot poppet (3) opens. E D
The oil flows around the pilot poppet (3) from the hole (D)
"LP"
and through the gap (E) into the tank passage “LP.”

"HP"

3
3J0AS24

When the pilot poppet (3) is opened, the pressure in the

internal cavity (C) drops causing the main poppet (1) to
open, which results in the oil in “HP” flowing into the con-
necting passage “LP.”

18
CONTROL VALVE 3J0AS00
 FUNCTION
CONTROL VALVE 3
Port relief valve
The port relief valve is located between the actuator and
the tank circuit. It protects the actuator from pressure
shock caused by the sudden blocking of the actuator
port or by overloading, or absorbs abnormal pressure
caused by an external force. In addition, it also prevents
the oil from forming suction cavitation in the tank when
the actuator port experiences a negative pressure.

This relief valve is installed between the cylinder port

“HP” and low-pressure passage “LP,” and oil flows
through the opening hole in the piston (C) to fill the inter-
nal cavity (G).
In addition, the sleeve (K) and the main poppet (D) are
firmly seated using the different areas of “A” and “B.”

When the pressure in the cylinder port “HP” reaches the

set spring force of the pilot poppet, the pilot poppet (E)
opens. "LP" E H
The oil flows around the circumference of the poppet and
through the hole (H) into the low-pressure passage “LP.”

"HP"

3J0AS27

When the pilot poppet (E) is opened, oil flows through the
opening (I) in the piston (C), which produces a pressure
differential with the passage “HP” on the back of the pis-
ton (C), causing the piston (C) to move and set the pop-
pet (E).

19
CONTROL VALVE 3J0AS00
 FUNCTION
CONTROL VALVE 3
The oil flowing from the passage “HP” to the back of the
poppet (D) flows only through the gap between the pop-
pet (D) and piston (C) and the opening (F), which causes
the pressure differential to increase. This causes the
poppet (D) to open, resulting in oil flowing into the direct
passage “LP.”

An anti-boiled unit that supplies oil when cavitation forms

is mounted in the cylinder port “HP” in this relief valve.
The sleeve (K) opens due to the differential area between
“A” and “B” when the pressure of the cylinder port “HP”
from the low-pressure side “LP” is low.
The oil from the low-pressure side “LP” flows into the low-
pressure side of the cylinder port “HP,” which prevents
cavitation from forming.

20
CONTROL VALVE 3J0AS00
 FUNCTION
CONTROL VALVE 3
Negative control valve
This valve supplies negative control signals to the vari-
able displacement hydraulic pumps.
The negative control signals maintain the angle of incli-
nation of the swashplate so that the discharge rate of the
pump is kept at the minimum rate when the engine is
stopped.

Generation of signal pressure

The oil supplied from the pump port (P1) flows through
the neutral passage (L1) and from the neutral down-
stream passage (A) through the negative control open-
ing (D) into the tank passage.
At this time, a pressure is generated in the passage (B)
by the negative control opening (D) that flows into the
negative control signal port (Ps1) from the passage (E).
When the main spool for upstream flow through the neu-
tral downstream passage (A) is operated, the oil flowing
through the neutral downstream passage (A) decreases
in volume, causing the negative control signal pressure
to become low.

Relief operation
If an excessive amount of oil flows into the neutral down-
stream passage (A), the pressure generated in the pas-
sage (B) by the negative control opening (D) travels into
the chamber (C) in back of the poppet, which causes the
poppet to move due to the difference in the size of the
area on which pressure is exerted between the passage
(B) and the chamber (C). When the poppet moves, the oil
flows from the passage (B) through the hole passage (F)
in the plug and into the tank passage (Ta). This works to
prevent excessive amounts of pressure from being pro-
duced in the negative control signal pressure port.

21
CONTROL VALVE 3J0AS00
 FUNCTION
PILOT VALVE (CONTROL LEVER) 3
PILOT VALVE (CONTROL LEVER)
The pilot valve is a remote-controlled valve with a reduc-
ing valve system used to operate the spool in the control
valve. The pilot valve comes with right and left control le-
vers.
The pilot valve casing contains a vertical shaft hole that
incorporates a reducing valve. When the lever is tilted,
the push rod and spring seat are pushed down, chang-
ing the spring force of the secondary pressure.
The casing contains the oil inlet port P (the primary pres-
sure) and the tank port T. The secondary pressure corre-
sponding to the changes in operating angle performed
by the lever (1) can be provided through the output ports
A and B located below the vertical shaft hole. The sec-
ondary pressure functions as the pilot pressure to actu-
ate the spool of the control valve (2).

When the lever (1) is in the neutral position:

The force of the spring (3) that determines the output
pressure (secondary pressure) of the pilot valve is not
conveyed to the spool (4). This causes the spool (4) to be
pushed up by the return spring (5), and the output ports
A and B are connected to the tank port T. This causes the
pressures in the ports A and B to be equal to the pres-
sure in the tank port T.

When the lever (1) is tilted:

When the lever (1) is tilted and the push rod (6) is
pushed, the spool (4) moves downward and the input
port P is connected with the output port A. Then, the oil
from the pilot pump flows into the output port A, generat-
ing a pressure.

1
PILOT VALVE (CONTROL LEVER) 3K2AS00
 FUNCTION
PILOT VALVE (CONTROL LEVER) 3
When the lever (1) is kept at a certain position:
When the pressure in the output port A increases to the
level equivalent to the force of the spring (3) set by the
inclination of the lever (1), the hydraulic pressure is bal-
anced with the spring force. When the pressure in the
output port A becomes higher than the set spring force,
the output port A is disconnected from the input port P
while it is now connected with the tank port T. When the
pressure in the output port A becomes lower than the set
spring force, the output port A is connected with the input
port P, while it is now disconnected from the tank port T.
Thus, the secondary pressure is always kept constant.

2
PILOT VALVE (CONTROL LEVER) 3K2AS00
 FUNCTION
PILOT VALVE (SWING) 3
PILOT VALVE (SWING)
The pilot valve is a remote-controlled valve with a reduc-
3
ing valve system used to operate the spool in the control
valve. The pilot valve (swing) is located on the left side of 4
the driver’s seat on the floor.
The pilot valve casing (1) contains a vertical shaft hole
that incorporates a reducing valve (2). When the cam (3) 5
T
is tilted, the push rod (4) and spring seat (5) are pushed
down, which changes the pressure of the secondary 2
6
pressure spring (6).
The casing (1) contains the oil inlet port P (primary pres- 2
sure) and the tank port T. The secondary pressure which
corresponds to changes in operating angle produced 1
using the cam (3) can be provided through the output P A B 3K3AQ01Z

ports A and B located below the vertical shaft hole. The

secondary pressure functions as the pilot pressure to ac-
tivate the spool of the control valve.

When the cam (3) is in the neutral position:

The force of the spring (6) that determines the output
pressure (secondary pressure) of the pilot valve is not
conveyed to the spool (7). This causes the spool (7) to be
pushed up by the return spring (8) and spring sheet (5),
and the output ports A and B are connected to the tank
port T, which makes the pressures in the ports A and B
be equal to the pressure in the tank port T.

When the cam (3) is tilted: 3

When the cam (3) is tilted and the push rod (4) is pushed,
4
the spring sheet (5) and spool (7) move downward, and
the input port P is connected to the output port A. The oil
from the pilot pump then flows into the output port A to 5
generate a pressure.

7
P

A B 3K3AQ03Z

1
PILOT VALVE (SWING) 3K3AQ00
 FUNCTION
PILOT VALVE (SWING) 3
When the cam (3) is kept at a certain position: 3
When the pressure in the output port A increases to a lev-
el equivalent to the force of the spring (6) set by the incli-
nation of the cam (3), the hydraulic pressure is balanced
with the spring force. When the pressure in the output
port A becomes higher than the set spring force, the out- T
put port A is disconnected from the input port P and then
becomes connected to the tank port T. When the pres-
sure in the output port A drops below than the set spring 6
force, the output port A becomes connected to the input
port P and it is then disconnected from the tank port T. P
The secondary pressure is thus always kept constant.
A B 3K3AQ04Z

2
PILOT VALVE (SWING) 3K3AQ00
 FUNCTION
PILOT VALVE (BLADE) 3
PILOT VALVE (BLADE)
The pilot valve is a remote-controlled valve with a reduc-
3
ing valve system used to operate the spool in the control
valve. The pilot valve (blade) is located on the right side 4
of the driver’s seat on the floor.
The pilot valve casing (1) contains vertical shaft holes
that incorporatea reducing valves (2). When the cam (3) 5
T
is tilted, the push rod (4) and spring seat (5) are pushed
down, which changes the pressure of the secondary 2
6
pressure spring (6).
The casing (1) contains the oil inlet port P (primary pres- 2
sure) and the tank port T. The secondary pressure which
corresponds to changes in operating angle produced 1
using the cam (3) can be provided through the output P A B 3K3AQ01Z

ports A and B located below the vertical shaft hole. The

secondary pressure functions as the pilot pressure to ac-
tivate the spool of the control valve.

When the cam (3) is in the neutral position:

The force of the spring (6) that determines the output
pressure (secondary pressure) of the pilot valve is not
conveyed to the spool (7). This causes the spool (7) to be
pushed up by the return spring (8) and spring sheet (5),
and the output ports A and B are connected to the tank
port T, which makes the pressures in the ports A and B
be equal to the pressure in the tank port T.

When the cam (3) is tilted: 3

When the cam (3) is tilted and the push rod (4) is pushed,
4
the spring sheet (5) and spool (7) move downward, and
the input port P is connected to the output port A. The oil
from the pilot pump then flows into the output port A to 5
generate a pressure.

7
P

A B 3K3AQ03Z

1
PILOT VALVE (BLADE) 3K3AQ01
 FUNCTION
PILOT VALVE (BLADE) 3
When the cam (3) is kept at a certain position: 3
When the pressure in the output port A increases to a lev-
el equivalent to the force of the spring (6) set by the incli-
nation of the cam (3), the hydraulic pressure is balanced
with the spring force. When the pressure in the output
port A becomes higher than the set spring force, the out- T
put port A is disconnected from the input port P and then
becomes connected to the tank port T. When the pres-
sure in the output port A drops below than the set spring 6
force, the output port A becomes connected to the input
port P and it is then disconnected from the tank port T. P
The secondary pressure is thus always kept constant.
A B 3K3AQ04Z

2
PILOT VALVE (BLADE) 3K3AQ01
 FUNCTION
PILOT VALVE (TRAVEL) 3
PILOT VALVE (TRAVEL)
The pilot valve is a remote-controlled valve with a reduc-
ing valve system used to operate the spool in the control
valve. The pilot valve (travel) is located the below the 3
4
travel lever near the driver’s seat.
The pilot valve casing (1) contains vertical shaft holes
5
that incorporate reducing valves (2). When the cam (3) is
tilted, the push rod (4) and spring seat (5) are pushed
6 T
down, which changes the pressure of the secondary
pressure spring (6).
The casing (1) contains the oil inlet port P (primary pres- 2 2
sure) and the tank port T. The secondary pressure which
corresponds to changes in operating angle produced 1 P
using the cam (3) can be provided through the output A B 3K3AQ05Z

ports A and B located below the vertical shaft hole. The

secondary pressure functions as the pilot pressure to ac-
tivate the spool of the control valve.
This pilot valve also comes equipped with a damping
function to prevent hunting oscillation resulting from the
supply of oil lagging behind from occurring during sud-
den operation.

When the cam (3) is in the neutral position:

The force of the spring (6) that determines the output
pressure (secondary pressure) of the pilot valve is not
conveyed to the spool (7). This causes the spool (7) to be
pushed up by the return spring (8) and spring sheet (5),
and the output ports A and B are connected to the tank
port T, which makes the pressures in the ports A and B
be equal to the pressure in the tank port T.

When the cam (3) is tilted:

When the cam (3) is tilted and the push rod (4) is pushed, 3
the spring sheet (5) and spool (7) move downward, and
the input port P is connected to the output port A. The oil 4
from the pilot pump then flows into the output port A to
5
generate a pressure.
T

P
7
1
A B 3K3AQ07Z

1
PILOT VALVE (TRAVEL) 3K3AQ02
 FUNCTION
PILOT VALVE (TRAVEL) 3
When the cam (3) is kept at a certain position:
When the pressure in the output port A increases to a lev- 3
el equivalent to the force of the spring (6) set by the incli-
nation of the cam (3), the hydraulic pressure is balanced
with the spring force. When the pressure in the output
port A becomes higher than the set spring force, the out-
put port A is disconnected from the input port P and then T
becomes connected to the tank port T. When the pres-
sure in the output port A drops below than the set spring 6
force, the output port A becomes connected to the input
port P and it is then disconnected from the tank port T.
The secondary pressure is thus always kept constant. P
A B 3K3AQ08Z

Damping function
The damping function prevents hunting oscillation from
occurring due to the supply of oil lagging behind during
sudden operation of the pilot valve.
When the cam (3) is tilted, which pushes the push rod (4) 3
on the port A side, the spool (7) and piston (9) move 4-1
downward. At this time, the oil in the piston chamber (10)
is discharged from the orifice (11) in the piston (9), which
4 12
generates a pressure. This damping pressure prevents
the push rod (4) from moving suddenly.
Meanwhile, the push rods (4-1) on the port B side are
moved upward by the spring (12) via the piston (13). 11
The ball (14) is pushed up, causing the oil in the tank 13
chamber to flow into the piston chamber (15), which pre- 9
vents the piston chamber (15) from experiencing a neg-
15
ative pressure. The oil outside of the piston chamber re-
10
turns to the tank through the tank channel in the top of the 14
casing.

A B
3K3AQ09Z

2
PILOT VALVE (TRAVEL) 3K3AQ02
 FUNCTION
PILOT VALVE (TRAVEL) 3
If the cam (3) is tilted all the way down and then tilted in
the opposite direction, the push rods (4-1) on the port B
side are pushed down, and the piston (13) is moved
downward.
At this time, the oil in the piston chamber (15) is dis- 3
charged from the orifice (16) in the piston, which gener-
ates a pressure. 4-1
Meanwhile, the push rod (4) on the port A side is moved
upward by the spring (17) via the piston (9). 4 16
The ball (14) is pushed up, causing the oil in the tank
channel to flow into the piston chamber (10), which pre-
vents the piston chamber (10) from experiencing a neg- 15
ative pressure. The oil outside of the piston chamber re- 17
13
turns to the tank from the tank channel connected to the 9
tank in the top of the casing.
The pilot valve is formed in this way so that the damping 10
function works to prevent hunting oscillation no matter
the position from which the handle is operated. 14

A B
3K3AQ10Z

3
PILOT VALVE (TRAVEL) 3K3AQ02
 FUNCTION
PROPORTIONAL CONTROL SOLENOID VALVE 3
PROPORTIONAL CONTROL SOLENOID VALVE
The proportional lever (2) and proportional amplifier (3)
of the pilot valve (1) control the driving current that flows
to the proportional control solenoid valve (4), which con-
trols the pilot pressure of the control valve (5) (auxiliary 2
section) whereby the flow rate of the auxiliary line piping 1
changes.
The proportional control solenoid valve controls the sec- 3
ondary pressure using the built-in proportional pressure- 5
educing valve. The secondary pressure generated cor-
responds to the changes in current because of the force
used to generate the secondary pressure being applied
to the solenoid in accordance with the amount of current 4
flowing through the coil. 3K4AQ01Z

When current flows through the solenoid, a thrust force

proportional to the current is generated and moves the S 6
spool (6) so that the oil supplied from the port P is intro- 7 8
duced into the port A on the secondary pressure side, S=A1-B1
which increases the pressure Pa of the port A.
The pressure Pa acts on the differential area S between B1 A1
the cross section A1 and cross section B1 of the spool
Fk
(6), and the spool (6) is pushed to the solenoid side by Fs Fks
the oil pressure, Pa × s. The spool (6) stops at the posi- Paxs
tion where the sum of the oil pressure, Pa × s, and the
force, Fk, exerted by the springs (7) is balanced with the
thrust force, Fs, generated by the solenoid. The weight, P A T
Fks, of the spring (8) used for fine adjustment of the sec-
ondary pressure acts in the direction (left) of assistance Paxs Fk Fs Fks
3K4AQ02Z

of the thrust force from the solenoid.

When the thrust force is greater than a set value, the

spool (6) is moved to the left, which connects the port P 9 6
(supply side) and the port A (secondary side) together
through the notch (9).

P A T

3K4AQ03Z

When the thrust force is lower than a set value, the spool
(6) is moved to the right, which connects the port A (sec- 6 10
ondary side) and the port T (tank side) together through
the notch (10).
The opening areas of the notch (9) on the supply side
and the notch (10) on the discharge side are thus con-
trolled by the movement of the spool (6), and a second-
ary (pilot) pressure can be provided that corresponds to
the thrust force generated by the solenoid.

P A T

3K4AQ04Z

1
PROPORTIONAL CONTROL SOLENOID VALVE 3K4AQ00
 FUNCTION
EMERGENCY SHUT-OFF VALVE 3
EMERGENCY SHUT-OFF VALVE
The emergency shut-off valve is used to keep the boom
or arm from falling to maintain safety by blocking and
shutting off the oil from the cylinder head side even if the
hydraulic hose should become damaged while the boom
or arm is being raised.
The pressure oil of the hydraulic pump pushes up the
check valve (1) from the port V2 while the boom or arm is
being raised and flows from the port C2 to the boom or
arm cylinder.
PIL

3K5AQ01Z

The pilot pressure is introduced into the port PIL from the
pilot valve (2) while the boom or arm is being lowered.
The pilot pressure moves the spool (3) to the left side
from the port PIL. The return oil from the cylinder flows
from the port C2 through the channels in the spool (3)
and check valve (1) to the tank channel from the port V2.

PIL

3K5AQ02Z

The channels in the check valve (1) and spool (3) are
blocked if the hydraulic hose becomes damaged, which
shuts off the oil on the cylinder head side to prevent the
boom and arm from falling even if either tries to go down.

PIL

3K5AQ03Z

1
EMERGENCY SHUT-OFF VALVE 3K5AQ00
 FUNCTION
SOLENOID VALVE 3
SOLENOID VALVE
This valve switches circuit connections by moving the
spool using magnets and supplies the pilot pressure to
the pilot valve and 2nd-speed travel switch.
The pilot pressure is kept constant with the relief valve.

Solenoid valve
When the solenoid is not energized:
The oil in the port P (pump side) is blocked by the spool
(1).
The oil flows through the port A (on the pilot circuit side
of the pilot valve or 2nd-speed travel switch) and port T
(on the tank side), which results in the pressure of the
downstream pilot circuit being the same as the tank pres-
sure.

When the solenoid is energized:

A magnetic field is generated around the coil that causes
the push rod to be pulled downward and the spool (1) to
be pushed down. This causes the oil in the port P to flow
to the port A, and the pressure is transmitted to the lower
pilot circuit.

Check valve
The IN port is connected to the pump and the OUT port
to the accumulator.
This works to prevent a backward flow of oil from the OUT
port to the IN port side should the pressure in the IN port
become a negative pressure.

1 IN
2 OUT

1
SOLENOID VALVE 3K6AS00
 FUNCTION
SHOCKLESS VALVE 3
SHOCKLESS VALVE
This valve controls the flow rate used to operate the con-
trol valve spool from the pilot valve and keeps it at a con-
stant rate when the boom is lowered and works to pre-
vent the machine from vibrating so that the boom does
not drop suddenly.

Port A side Port B side

The hydraulic oil supplied from port A passes through the
orifice (1) and flows into the port B through a side hole in
the plunger (2).
The pressure P1 flows into chamber C on the left side of
the plunger (2) before closing and the pressure P2 flows
into chamber D on the right side after closing. Because
the areas a and b of the plunger (2) affected by pressure
are the same size, the pressure differential PC between
P1 and P2 is determined by the force of the spring (3).
When the pressure in port A increases causing the flow
rate through the orifice (1) to increase, the pressure dif-
ferential between P1 and P2 rises, and the plunger (2)
moves to the right and pushes on the spring (3). When
this occurs, the opening e through which pressure flows
from outside of the valve decreases in size, which acts to
decrease the flow rate for flow from the outside of the
valve.
The opening e is closed and becomes balanced so that
the plunger (2) becomes static until the pressure differ-
ential between P1 and P2 becomes equal to the pressure
differential PC set initially.
In addition, should the reverse occur and the pressure in
the port A decrease causing the flow rate through the or-
ifice (1) to decrease, the pressure differential between P1
and P2 drops, and the plunger (2) moves to the left of the
spring (3), and the opening e becomes bigger, which en-
ables the hydraulic oil to flow from port A more easily. The
plunger (2) then moves and becomes static until the
pressure differential between P1 and P2 becomes equal
to the pressure differential PC set initially.
That is, if the pressure differential for the port A side and
port B side of the valve is changed, the pressure before
and after the orifice (1) inside the valve becomes con-
stant.

Port B side Port A side

When hydraulic oil is supplied to port B, the hydraulic oil
passes through the orifice (1) and flows into port A. At this
time, due to resistance with regard to allowing passage in
the orifice (1), the relationship in pressure between P1 and
P2 becomes such that P1 < P2, and the plunger (2) moves
to the left side. When this occurs, the circuit for section f
opens, and the hydraulic oil from port B flows through the
side hole in the plunger (2), and the entire volume flows into
port A.
If the hydraulic oil is cut off, the plunger (2) returns to the
center position using the force of the spring.

1
SHOCKLESS VALVE 3K9AS00
 FUNCTION
CYLINDERS 3
CYLINDERS
The pressure oil flowing alternately in through the outlet
and inlet on both sides (head and rod sides) of the piston
acts on the piston and the force produced causes the
piston to move back and forth.
For those cylinders with a cushion mechanism, the shock
resulting from the piston colliding with the cover at the
stroke end is dampened by the mechanism.

Cushion mechanism

When the piston (1) approaches the stroke end and ap-
pears likely to bump into the cover (2), the cushion bear-
ing (3) that is moving ahead of the piston enters the cush-
ion seal (4). As this shuts off the return passage for the
hydraulic oil on the back of the piston, the oil is expelled
only from the throttle hole or the groove provided in the
cushion bearing (3). This causes the piston (1) backpres-
sure to increase, slowing the piston speed.

1
CYLINDERS 3L0AS00
 FUNCTION
TRAVEL MOTOR 3
TRAVEL MOTOR
This section includes descriptions of the hydraulic motor,
which is driven by hydraulics, the brake valve, the relief
valve, the 2nd-speed switching mechanism, the parking
brake, and the reduction gears.

Hydraulic motor
The hydraulic motor is an axial piston motor with a
swashplate design. It converts the force of the pressure
oil transmitted from the pump into rotational movement.
The cylinder block (104) of the hydraulic motor is formed
of pistons (105), and its end surface comes in contact
with the valve plate (109), which contains the two cres-
cent-shaped ports B and C. The cylinder block (104) can
be rotated and is connected to the shaft (102) via the
spline.
The pressure oil supplied from the pressure oil pump is
injected into the cylinder block (104) through the valve
plate (109). At this time, the pressure oil is injected only
into one side (the port B side) connected to the bottom
dead center during a stroke of the pistons (105).
The pressure oil pushes on each piston (105) to generate
a force, F (=P×A), which acts on the angled surface of
the swashplate (103). The force F is split into two force
components F2 and F3 through the angle θ of the angled
surface, and the radial component F3 of these force
components produces a torque (=F3×ri). The total
torque T (=∑(F3×ri)) of each piston (105) is used as the
rotational force that turns the hydraulic motor. This rota-
tional force turns the cylinder block (104) and the shaft
(102) via the pistons (105).

1
TRAVEL MOTOR 3M0AS00
 FUNCTION
TRAVEL MOTOR 3
Brake valve
During normal operation
When pressure oil is supplied from port (A), the pressure
oil opens the valve (327), causing the oil to flow into port
(C) on the hydraulic motor inlet side, which works to turn
the hydraulic motor.
Simultaneously, the pressure oil enters the chamber (a)
from the orifice (329) and operates on the end surface of
the spool (323) to generate a force that causes the spool
(323), which is in a neutral position, to slide to the left by
the force of the spring (328).
Once the spool (323) has been slid, a gap (passage) is
formed between the spool (323) and the rear flange by
the groove in the spool.
This passage enables the return oil to return to the tank
side through the port (D) in the passage on the return
side of the hydraulic motor and through the port (B),
which enables the hydraulic motor to turn.
In addition, the pressure oil enters the port (E) due to the
sliding of the spool (323). The pressure oil that entered
the port (E) moves the piston of the parking brake and re-
leases the parking break.
For pressure oil supplied from the port (B), the spool and
valve move horizontally in reverse and rotate in reverse.

2
TRAVEL MOTOR 3M0AS00
 FUNCTION
TRAVEL MOTOR 3
Stop operation (Braking operation)
When the supply of oil from the port (A) stops during trav-
el operation, the oil pressure pushing against the spool
(323) is eliminated, and the spool (323) that was slid to
the left attempts to return to the neutral position through
the washer (325) using the force from the spring (328).
At this time, the oil in the chamber (a) attempts to flow to
the port (A) side through the orifice (329), but a back
pressure is generated due to effects of the opening cre-
ated in the orifice (329), which works to control the return
speed of the spool (323).
Simultaneously, the hydraulic motor attempts to continue
rotating due to the influence of inertia, even after the sup-
ply of oil has stopped, which causes the return oil for the
hydraulic motor to attempt to return to the port (B) side
from the port (D) and through the gap (passage) be-
tween the spool groove and the rear flange.
Once the spool (323) returns all the way to the neutral po-
sition, the passage on the hydraulic motor return side is
completely shut off by the spool (323), causing the hy-
draulic motor to stop.
During operation, this brake valve controls the sliding
speed of the spool (323) and shape of the spool groove
used to close the passage on the hydraulic motor return
side, which enables the hydraulic motor to be smoothly
brought to a stop while it tries to rotate due to the inertial
force produced by the generated backpressure.
Meanwhile, when the hydraulic motor attempts to stop
due to braking, inertia causes the pump to continue ro-
tating and operating to attempt to absorb oil even after
the supply of pressure oil is shut off.
However, the passage on the suction side is blocked off
by the spool (323) so that the oil cannot be refilled, which
causes cavitation to begin to form.
At this time, the valve (327) operates under a slight neg-
ative pressure to open the oil pressure circuit between
the circuit on the port (A) side and the port (C) of the mo-
tor suction vent, which prevents cavitation from forming
in the hydraulic motor.
If the pressure oil is supplied from the port (B), the move-
ment of each of the aforementioned parts becomes sym-
metrical, which causes the motor to stop.

3
TRAVEL MOTOR 3M0AS00
 FUNCTION
TRAVEL MOTOR 3
Function to prevent out-of-control operation
If the hydraulic motor begins rotating due to an external
force, the machine may begin operating uncontrollably
(run out of control) during operation at normal tempera-
ture. This could occur when the driver is trying to go
down a steep incline, for example.
An explanation of the mechanism used to prevent uncon-
trollable operation (out-of-control operation) is provided
here.
The hydraulic motor begins rotating due to an external
force during operation at normal temperature. The pres-
sure in the port (A) or port (B) supplying operating oil
drops.
When the pressure rises toward the level at which the
machine operates uncontrollably, the spool (323) begins
moving toward the neutral position.
Tthe size of the area of the passage for the oil from the
port (D) on the hydraulic motor outlet port side to the port
(B) decreases along with the travel distance of the spool
(323).
This limits the flow rate for the operating oil discharged
from the port (D) to the port (B).
The pressure (backpressure) in the port (D) increases at
the same time.
This controls the flow rate and pressure of the hydraulic
motor outlet port, which works to prevent uncontrolled
machine operation.

4
TRAVEL MOTOR 3M0AS00
 FUNCTION
TRAVEL MOTOR 3
Explanation of relief valve operation
At startup
The pressure oil supplied from the pump flows from port
(A) to port (C).
Port (C) is connected to the hydraulic motor, and the
pressure oil that flows into port (C) exerts a rotational
force on the hydraulic motor.
At this time, in the relief valve (A), the valve (202a) does
not open through operation with the pressure oil.
In the relief valve (B), the valve (202b) is opened by the
pressure oil from port (C) when a pressure exceeding a
given level is exerted, and the pressure oil flows into port
(D).
The pressure oil from port (C) flows through the opening
(e) in the valve (202b), the opening (f) in the sleeve
(203b), and the orifice (384) into the chamber (y).
This pressure oil that flowed into the chamber (y) causes
the piston (381) to move to the stroke end in the direction
of the arrow.
When the piston (381) reaches the stroke end, the pres-
sure between the opening (e) in the valve (202b) and the
opening (f) in the sleeve (203b) increases.
The release pressure in the relief valve (B) increases to a
value about the system pressure of the shovel due to the
increase in pressure of the pressure oil, which causes
the valve (202b) to become closed.
The pressure of the port (C) increases and exerts a rota-
tional force on the motor due to the operation of the relief 1 Relief valve A
valve (A) and relief valve (B). 2 Relief valve B

5
TRAVEL MOTOR 3M0AS00
 FUNCTION
TRAVEL MOTOR 3
Pressure conditions in port (C) during the operation de-
scribed above

However, depending on the condition of the machine im-

mediately before it stops, the valve (202b) of the relief
valve (B) may not open if the piston (381) has reached
the stroke end.
The resultant pressure acting on the port (C) in this case
is described below.

1 Pressure
2 Release of relief valve B
3 Time

As described above, the pressure of the port (C) at start

up varies depending on the position of the piston (381).

The following is an example substituting the relief valve

(B) for the relief valve (A) in the above description of op-
erating principles for when the pressure oil supplied from
1
the pump flows from the port (B) to the port (D).

3M0AS07

1 Pressure
3 Time

6
TRAVEL MOTOR 3M0AS00
 FUNCTION
TRAVEL MOTOR 3
During shutdown
When the supply of oil to the port (A) for the hydraulic mo-
tor, which rotates from the supply of pressure oil from the
port (A) to the port (C), is depleted, the counterbalance
valve returns to the neutral position.
When the counterbalance valve returns to neutral, the
port (D) on the outlet port side is shut off, causing the
pressure within the port (D) to increase due to the rota-
tion of the hydraulic motor according to the amount of in-
ertia.
The pressure oil inside the port (D) flows through the
opening (c) in the valve (202a), the sleeve (203a), and
the orifice (384) and into the chamber (x) in the relief
valve (A).
The pressure oil that flowed into the chamber (x) causes
the piston (381) to move to the stroke end in the direction
of the arrow.
The pressure in the chamber (x) does not increase while
the piston (381) is being moved.
This causes the valve (202a) of the relief valve (A) to be
pushed open by the pressure oil in the port (D), resulting
in the pressure oil from the port (D) flowing into the port
(C) on the low-pressure side.
The relief valve (A) operates to control the pressure in the
port (D) and supply oil to the port (C), which works to pre-
vent cavitation.
When the piston (381) reaches the stroke end, the pres-
sure between the chamber (x) and the opening (b) in the
valve (202a) and opening (c) in the sleeve (203a) in- 1 Relief valve A
creases, causing the valve (202a) to close. 3 Relief valve B
In this case, the relief valve (A) works to relieve the sys-
tem pressure and stop the hydraulic motor.

7
TRAVEL MOTOR 3M0AS00
 FUNCTION
TRAVEL MOTOR 3
Pressure conditions in the hydraulic motor (port (D))
when the pressure oil supply described above is
stopped

The pressure while the piston (381) is moving is referred

to as the primary relief pressure (low pressure).
The pressure after the piston (381) has stopped moving
is referred to as the secondary relief pressure (high pres-
sure).

1 Pressure
2 Release of relief valve B
3 Time
4 While piston “d” is moved

8
TRAVEL MOTOR 3M0AS00
 FUNCTION
TRAVEL MOTOR 3
Automatic 2-speed switching mechanism
At low speed

If there is no pilot pressure supplied from the port (P), the

valve (363) is pushed upward by the force of the spring
(366) and the pressure oil from the port (A) or port (B).
The pressure oil from (C) is blocked, and the oil from the
chamber (W) is released into the drain (motor case) via
the valve (363).
As a result, the angle of inclination of the swashplate
(103) increases to the maximum angle θ1, which causes
the displacement of the hydraulic motor to be maximized
and rotation to proceed at low speed.

9
TRAVEL MOTOR 3M0AS00
 FUNCTION
TRAVEL MOTOR 3
At high speed

If there is a pilot pressure supplied from the port (P), the

pilot pressure overcomes the force of the spring (366)
and the pressure oil from the port (A) or port (B) and
pushes the valve (363) downward, which causes the
pressure oil from the port (C) to flow into the chamber (W)
via the valve (363).
The piston (161) pushes the swashplate (103) downward
until it makes contact with the surface (X) and held at that
position.
At this time, the swashplate (103) is positioned at the
minimum angle of inclination θ 2, which causes the dis-
placement of the hydraulic motor to be minimized and ro-
tation to proceed at high speed.

10
TRAVEL MOTOR 3M0AS00
 FUNCTION
TRAVEL MOTOR 3
Automatic switching to low speed during high-speed op-
eration

If the size of the load increases during high-speed oper-

ation, the pressure of the pressure oil in port (A) or port
(B) also increases, and when the pressure reaches a
specified value, the pressure overcomes the pilot pres-
sure of the port (P) and pushes the valve (363) upward.
The oil in the chamber (W) is released to the drain (motor
case) via the valve (363).
At this time, the swash plate (103) is pressed against the
surface (Y) and maintains a maximum angle of inclination
of θ1 in low-speed rotation.

11
TRAVEL MOTOR 3M0AS00
 FUNCTION
TRAVEL MOTOR 3
Parking brake
The parking brake works to prevent the hydraulic motor
from rotating due to an external force exerted while the
hydraulic motor is stopped. The parking brake uses a
friction disc braking mechanism and is formed together
with the hydraulic motor as one piece.
The friction disc (115) and the disc (116) of the hydraulic
motor are connected through the spline. The friction disc
(115) and the disc (116) are pressed against the spindle
by the springs (113) via the brake piston (112). The fric-
tion force between these discs generates a braking
torque that prevents the cylinder block (104) from rotat-
ing.

When the pressure oil is introduced into the motor, the

pressure oil flows from the parking brake release port (E)
into the brake piston chamber (F). The oil pressure over-
powers the spring force and moves the brake piston
(112) to the left. This creates a clearance between the
friction disc (115) and the disc (116), which releases the
parking brake function.
When the motor is stopped, the pressure oil from the
parking break release port is blocked, which causes the
springs (113) to generate a parking brake force.

12
TRAVEL MOTOR 3M0AS00
 FUNCTION
TRAVEL MOTOR 3
Reduction gears
The reduction gears are formed of a 2-stage planetary
gear system that works to slow down the high-speed ro-
tational movement from the hydraulic motor and converts
it to a low-speed, high torque.

The reduction gears of the hydraulic motor are formed of

a 2-stage planetary gear system that works to convert the
high-speed rotational movement from the hydraulic mo-
tor into a low-speed, high torque and use the torque to ro-
tate the hub (1).
The rotational movement of the hydraulic motor axis is
transmitted to the 1st-stage sun gear (3) connected to
the spline in the shaft (2). At this stage, the 1st-stage
planetary gear (4) is meshed with the sun gear (3) and
meshes with the hub (1) to move in orbital motion while
rotating.
The orbital motion rotates the gear (5) affixed to the plan-
etary gears (4) as well as the 2nd-stage sun gear (6) con-
nected to the gear (5). 1 Input
This rotation is transmitted to the hub (1) (ring gear) via 2 Output
the 2nd-stage planetary gears (8) affixed to the support
column of the spindle (7) and produces the output rota-
tion of the reduction gears. The rotation is transmitted
from the 1st-stage planetary gears (4).

13
TRAVEL MOTOR 3M0AS00
 FUNCTION
SLEW MOTOR 3
SLEW MOTOR
This section includes descriptions of the hydraulic motor
driven by hydraulics, the relief valve, the make-up valve,
the parking brake, the timer valve, and the reduction
gears.

Hydraulic motor
3 2 1
The cylinder block (1) is formed of pistons (2), and its end
surface comes in contact with the valve plate (3), which
contains two half-moon-shaped ports B and C. The cylin-
der block (1) rotates freely and is connected to the shaft
(4) via the spline. Meanwhile, the swashplate (5) is se-
cured to the housing.
When the high-pressure oil is made to flow into port B, the
A
pistons (2) push the swashplate (5) with a force F per pis-
ton (2).
F = P x A, P: Pressure, A: Cross-sectional area of piston
The force F used to push the swashplate (5) by the pis-
tons (2) is divided into two components: a force F1 that
pushes against the plate and a force F2 that rotates the F1
cylinder block (1). The total sum of the components in the F2 5 4
direction of rotation of the high-pressure side piston F
works to generate a rotational force in the cylinder block
(1), and the torque is transmitted via the spline to the F
shaft (4) to turn it. Conversely, if high-pressure oil is intro-
duced into the port C, the rotation occurs in the direction F2
opposite that of the above.

F
F2
B C
3N0AQ01Z

Relief valve
The relief valves are used to set the driving force and
braking force during slew operation of the machine, with
each having main port A, B lines and each being formed
of a circuit in which the relief valve return oil returns to the 6
main low-pressure line on the opposite side through the
make-up valves. The relief valves also come equipped 7
with shockless functions that reduce the impact of
shocks generated at the start of acceleration.
The inertial load at motor startup is fairly significant and
causes the oil pressure used for rotation to actually in-
B T A
crease. When this pressure reaches the set relief valve
3N0AQ02Z
pressure, the relief valve (6) turns on, and the oil opens
the make-up valve (7) and flows into the port B.
This type of motor starts rotating while activating the relief
valve (6), with the amount of relief oil decreasing to zero
as the number of rotations increases.
This allows shocks to be absorbed during startup.

1
SLEW MOTOR 3N0AS00
 FUNCTION
SLEW MOTOR 3
When the motor stops, the return circuit closes. However,
the motor continues trying to rotate using the inertial en-
ergy, which causes the port B pressure to increase and 6
the port A to experience a negative pressure in contrast.
When the port B pressure reaches the set value for the
relief valve, the oil acts on the relief valve (6), which caus-
es the make-up valve (7) to open and the oil to flow into
7
port A.
With the oil flowing into the port A in this way, shocks from
stopping are absorbed while the formation of cavitation
is prevented.
B T A
3N0AQ03Z

Structure of the relief valve

Use of a shockless relief valve has the effect of reducing
the impact of shocks, reducing the amount of stress gen- 1
erated in strengthening support parts, and the like.

2
3N0AQ04Z

1 Direct-acting differential area relief valve

2 Shockless piston
There are two stages in relief valve operation as listed
below.
1st-stage 10 9
At the beginning of operation, the shockless piston (8) is
moved, and a low pressure is maintained within the
spring chamber (9). For this reason, the area of the pop-
pet (10) affected by pressure is the poppet sheet area
(S1). The area affected by pressure is fairly large com-
pared to the area affected by pressure (S1-S2) during
regular relief setting. This allows the relief hydraulic pres-
S1 S2
sure to be maintained at a low value until the shockless 8
piston (8) finishes being moved.
3N0AQ05Z

2
SLEW MOTOR 3N0AS00
 FUNCTION
SLEW MOTOR 3
2nd-stage
Once the shockless piston (8) has stopped being
moved, the pressure inside the spring chamber (9) in- 10 9
creases and becomes equal to the pressure in front of
and behind the poppet (10). The relief valve is thus acti-
vated by the regular set pressure.

3N0AQ06Z

The diagram shows pressure waveforms for equipment

without shockless pistons and equipment with shockless
pistons.

3 3

4 4
5
1 2
3N0AQ07Z

1 Without shockless piston

2 With shockless piston
3 Pressure
4 Time
5 Region of shockless piston operation
Make-up valve
The make-up valve (7) has two different functions. 7 7
One of the functions is preventing cavitation occurring
due to the piston motor being overrun, which prevents
the slew body from running uncontrolled.

3N0AQ08Z

When the motor is turned using the inertial force of the

slew both to create a pumping action and the motor
speed in RPMs exceeds the speed in RPMs suitable for
the amount of oil supplied to the motor. Extra oil is sup-
plied from external to the main circuit of the motor via the
make-up valve (7) to make up for any lack of oil and to 6
prevent a vacuum from forming within the circuit.
7

B T A
3N0AQ02Z

3
SLEW MOTOR 3N0AS00
 FUNCTION
SLEW MOTOR 3
The other function is to prevent a vacuum from forming
inside the circuit through the supply of extra oil from the
make-up valve (7) to compensate for motor drain and 6
valve leaks to enable a braking function to be obtained
under normal circuit conditions when the circuit between
control valve and motor is closed off, as with the brake.
7

B T A
3N0AQ03Z

Parking brake
With the parking brake ON
The parking park has a hydraulic-release, multiple-disc
structure and a locking mechanism with a switching axis
that operates to turn the brake ON and OFF using exter-
nal signal pressure.
With the hydraulics for releasing the break shut off, the
disc (11) coupled with the spline in the outer periphery of
the cylinder block (1) pushes against the brake piston
(12) (which is stopped to prevent it from rotating) with the
spring force, causing the cylinder block (1) and case to
be immobilized together by a frictional force. This causes 12 11 1
3N0AQ09Z
the shaft to be locked in place.

When the brake-release pressure is supplied to the

brake cylinder chamber (13) through the port PB, the
brake piston uses the release pressure to overcome the
spring force, which cancels out the frictional force acting
on the disc and enables the shaft to rotate freely.

13
3N0AQ10Z

4
SLEW MOTOR 3N0AS00
 FUNCTION
SLEW MOTOR 3
Timer valve
The timer valve is used to prevent the parking brake from
being pulled during slew parking. While the inertial slew
force is being absorbed by the dynamic hydraulic brake,
the timer valve has the role of working to secure a delay
time period during which the parking brake does not op-
erate, with the delay time being set by the opening in the
orifice from which the discharge oil discharges from the
brake cylinder chamber and by the flow rate.
While the parking brake is activated, the pilot pressure
continuously flows into the port PG, and the spool (14) is
shifted to the left position by the spring (15) force, which 14
causes the port PG to close. dr

SH

PG

15

3N0AQ11Z

When the slew pilot pressure or arm pulling (CROWD) pi-

lot pressure is introduced into the port SH, the pilot pres-
sure overcomes the spring (15) force and moves the 14
spool to the right, causing the port PG to open. PB dr
The pressure oil in the port PG flows into the port PB for
releasing the parking brake through the center hole on SH
the spool (14), which releases the parking brake func-
tion.

PG

15

3N0AQ12Z

If the pilot pressure in the port SH decreases to zero, the

spool (14) is moved to the left by the spring (15) force,
the port PG closes, and the oil in the brake cylinder 16 14
chamber is also shut off. The oil that is shut off slowly dr
flows into the drain port dr from the orifice (16) in the pe-
riphery of the spool (14). This works as a timer that acti-
vates the parking brake after a certain amount of time so SH
as to prevent sudden operation of the parking brake.

PG

15

3N0AQ13Z

5
SLEW MOTOR 3N0AS00
 FUNCTION
SLEW MOTOR 3
Reduction gears
The motor shaft (1) connects the drive gear (2) and the
spline. The driving force of the hydraulic motor is trans-
mitted to the planetary gears (3) that are meshed with the
drive gear (2). The planetary gears (3) are meshed with
the ring gear in the reduction gear housing (4). This al-
lows the planetary gears to move in orbital motion along
the ring gear while rotating.
The planetary gears (3) are held in position via the bear-
ings in the holder (5), and the holder (5) transmits the or-
bital motion of the planetary gears (3) to the sun gear (6)
connected to the spline. The sun gear (6) meshes with
the planetary gears (7) and transmits the rotating motion
to the planetary gears (7) as in the first stage. The plane-
tary gears (7) mesh with the ring gear in the housing,
which allows them to move in orbital motion while rotat-
ing. The planetary gears (7) mesh with the ring gear in
the housing, which allows them to move in orbital motion
while rotating. The planetary gears (7) are held in posi-
tion via the bearings in the holder (8), and the holder (8)
transmits the orbital motion of the planetary gears (7) to
the pinion shaft connected to the spline.

6
SLEW MOTOR 3N0AS00
 FUNCTION
SWIVEL JOINT 3
SWIVEL JOINT
The swivel joint is located at the slew center of the ma-
chine and has the role of maintaining the connection to
the oil circuit regardless of the slew angle of the upper
frame.
A number of ports (3) equal to the number of fluid circuits
is provided on a hub (1) and shaft (2) that are mutually
rotatable. Grooves used as oil passages are processed
into the inner periphery of the hub (1) and the outer pe-
riphery of the shaft (2). A seal is applied to the top and
bottom of the peripheral grooves. The oil flowing from the
port (3) continues to flow through the oil pressure pas-
sage (5) between the hub (1) and shaft (2) to enable con-
tinued connection of the circuit located between the slew
assemblies without it being blocked due to rotation.

1
SWIVEL JOINT 3O0AS00
DISASSEMBLY AND ASSEMBLY 4
Service standards
Drive system
Travel system
Slew equipment
Upper frame
Operating device
Attachments
Hydraulic tank
Hydraulic pump (main)
Hydraulic pump (sub)
Control valve
Pilot valve
Pilot valve (swing, blade)
Pilot valve (travel)
Proportional control solenoid valve
Solenoid valve (dual-section)
Shockless valve
Cylinders
Travel motor
Slew motor
Swivel joint
 DISASSEMBLY AND ASSEMBLY
SERVICE STANDARDS 4
SERVICE STANDARDS
Carrier roller
Loctite #262
Unit: mm (in.)
Criteria
Code
Standard dimension Allowable value
A 120 (4.7) –
B 40 (1.6) –

Track roller
Unit: mm (in.)
Criteria
Code
Standard dimension Allowable value
A 130 (5.1) 124 (4.9)
B 50 (2.0) –

Sprocket B

Unit: mm (in.)
Criteria
Code
Standard dimension Allowable value
A 530.6 (20.9) 524.6 (20.7)
B 61 (2.4) 55 (2.5) A

4A0AF03Z

Idler
Unit: mm (in.)
Criteria
Code
Standard dimension Allowable value
A 454 (17.9) 448 (2.8)
B 65 (2.6) – A B

4A0AF04Z

1
SERVICE STANDARDS 4A0AS00
 DISASSEMBLY AND ASSEMBLY
SERVICE STANDARDS 4
Clearance for pin and bushing

2
SERVICE STANDARDS 4A0AS00
 DISASSEMBLY AND ASSEMBLY
SERVICE STANDARDS 4
Unit: mm (in.)
Criteria
Code Item Standard Allowable value Standard Allowable Action
dimension Axis Hole clearance clearance
-0.02 +0.19
0.16 to 0.24
65 (-0.0008) (+0.0075) 1
A Bucket and arm (0.0063 to
(2.5591) -0.05 +0.14 (0.04)
0.0095)
(-0.0020) (+0.0055)
-0.02 +0.19
0.16 to 0.24
65 (-0.0008) (+0.0075) 1
B Bucket and link (0.0063 to
(2.5591) -0.05 +0.14 (0.04)
0.0095)
(-0.0020) (+0.0055)
-0.02 +0.19
0.16 to 0.24
65 (-0.0008) (+0.0075) 1
C Arm and link (0.0063 to
(2.5591) -0.05 +0.14 (0.04)
0.0095)
(-0.0020) (+0.0055)
Link side
+0.19
0.16 to 0.24 1
(+0.0075)
(0.0063 to (0.04)
+0.14
-0.02 0.0095)
65 (+0.0055)
D Bucket cylinder and link (-0.0008)
(2.5591) Cylinder side
-0.05
(-0.0020) +0.25
0.07 to 0.30 1
(+0.0098)
(0.0028 to (0.04)
+0.05
0.0118)
(+0.0020)
-0.02 +0.25 Replace
0.07 to 0.30
65 (-0.0008) (+0.0098) 1
E Bucket cylinder and arm (0.0028 to
(2.5591) -0.05 +0.05 (0.04)
0.0118)
(-0.0020) (+0.0020)
-0.02 +0.19
0.16 to 0.24
75 (-0.0008) (+0.0075) 1
F Arm and boom (0.0063 to
(2.9528) -0.05 +0.14 (0.04)
0.0095)
(-0.0020) (+0.0055)
-0.02 +0.25
0.07 to 0.30
80 (-0.0008) (+0.0098) 1
G Arm cylinder and arm (0.0028 to
(3.1496) -0.05 +0.05 (0.04)
0.0118)
(-0.0020) (+0.0020)
-0.02 +0.25
0.07 to 0.30
80 (-0.0008) (+0.0098)
H Arm cylinder and boom (0.0028 to 1 (0.04)
(3.1496) -0.05 +0.05
0.0118)
(-0.0020) (+0.0020)
-0.02 +0.31
0.08 to 0.36
75 (-0.0008) (+0.0122)
I Boom and swing bracket (0.0031 to 1 (0.04)
(2.9528) -0.05 +0.26
0.0142)
(-0.0020) (+0.0102)
-0.02 +0.25
0.07 to 0.30
75 (-0.0008) (+0.0098)
J Boom cylinder and boom (0.0028 to 1 (0.04)
(2.9528) -0.05 +0.05
0.0118)
(-0.0020) (+0.0020)

3
SERVICE STANDARDS 4A0AS00
 DISASSEMBLY AND ASSEMBLY
SERVICE STANDARDS 4
-0.02 +0.25
0.07 to 0.30
75 (-0.0008) (+0.0098)
K Boom cylinder and swing bracket (0.0028 to 1 (0.04)
(2.9528) -0.05 +0.05
0.0118)
(-0.0020) (+0.0020)
-0.02 +0.17
0.17 to 0.22
140 (-0.0008) (+0.0067)
L Swing bracket and turntable (0.0067 to 1 (0.04)
(5.5118) -0.05 +0.15
0.0087)
(-0.0020) (+0.0059)
-0.02 +0.25
0.07 to 0.30
100 (-0.0008) (+0.0098)
M Swing cylinder and swing bracket (0.0028 to 1 (0.04)
(3.9370) -0.05 +0.05
0.0118)
(-0.0020) (+0.0020)
-0.02 +0.25
0.07 to 0.30
100 (-0.0008) (+0.0098)
N Swing cylinder and turntable (0.0028 to 1 (0.04)
(3.9370) -0.05 +0.05
0.0118)
(-0.0020) (+0.0020)
-0.02 +0.25
0.07 to 0.30
70 (-0.0008) (+0.0098) Replace
O Blade cylinder and blade (0.0028 to 1 (0.04)
(2.7559) -0.05 +0.05
0.0118)
(-0.0020) (+0.0020)
-0.02 +0.25
0.07 to 0.30
70 (-0.0008) (+0.0098)
P Blade cylinder and lower frame (0.0028 to 1 (0.04)
(2.7559) -0.05 +0.05
0.0118)
(-0.0020) (+0.0020)
-0.02 +0.19
0.16 to 0.24
70 (-0.0008) (+0.0075)
Q Blade and lower frame (0.0063 to 1 (0.04)
(2.7559) -0.05 +0.14
0.0095)
(-0.0020) (+0.0055)
-0.02 +0.17
0.17 to 0.22
140 (-0.0008) (+0.0067)
R Swing bracket and turntable (0.0067 to 1 (0.04)
(5.5118) -0.05 +0.15
0.0087)
(-0.0020) (+0.0059)
S Angle cylinder and blade arm – – – – –
T Angle cylinder and blade – – – – –
U Blade arm and blade – – – – –

4
SERVICE STANDARDS 4A0AS00
 DISASSEMBLY AND ASSEMBLY
DRIVE SYSTEM 4
DRIVE SYSTEM
Engine
Construction

OUT
IN
X
Z

ThreeBond #1324
1 Affix in the order of part A, part B, 1. Engine hood 9. Hose 17. Cushion rubber
and then part C. 2. Bracket 10. Hose 18. Cushion rubber
2 “A” die stamp
3. Bracket 11. Engine 19. Hose
4. Hose 12. DPD assembly 20. Earth ground cable
5. Hose 13. Air cleaner 21. Pipe
6. Hose 14. Oil filter 22. Gasket
7. Pipe 15. Gasket 23. Adapter
8. Pipe 16. Gasket 24. Air flow sensor

1
DRIVE SYSTEM 4B0AS00
 DISASSEMBLY AND ASSEMBLY
DRIVE SYSTEM 4
Removing the engine
1. Remove the battery ground cable (34) from the bat-
tery terminal.
2. Remove the engine hood, the side covers Right and
Left, and the engine cover (Front).
“Removing the covers”
3. Remove the counterweight.
“Removing the upper structure”
4. Disconnect the electrical wiring to the air cleaner
(13), and remove the air cleaner (13).
Bolt: 15 N·m (11.1 ft.-lb)
Band: 5.9 N·m (4.4 ft.-lb)
5. Remove the radiator assembly.
“Removing the radiator"
6. Remove the compressor (A).
• Do not loosen the hoses (B) as refrigerant gas
may be released from the hoses if they are loos-
ened.
a. Loosen the nut (C).
b. Loosen the bolt (D), and release the tension in the
V belt (E).
• Apply a force of 98 N (22 lbf) to the midpoint
between the pulley (F) and compressor (A) dur-
ing assembly to make the belt slacken by 8 mm
(0.3 in.). Alternatively, tighten the belt to a ten-
sion of 529 N (119 lbf) measured using a ten-
sion gauge.
• Use the bolt (D) to make adjustments.
c. Take out all bolts used to secure the compressor
in place, and remove the compressor.
• When removing the engine, place it in a loca-
tion where it is out of the way.

2
DRIVE SYSTEM 4B0AS00
 DISASSEMBLY AND ASSEMBLY
DRIVE SYSTEM 4
7. Disconnect the battery cable and the engine electri-
cal wiring on the engine side.
• Attach identification labels to each of the wires.
8. Disconnect the engine ground cable (20).
9. Disconnect the hoses (9) and (10).
10. Remove the DPD assembly (12).
a. Disconnect the electrical wiring to the DPD on the
DPD side.
• Attach identification labels to each of the wires.
b. Take out the part A, part B, and part C nuts, and
remove the DPD assembly (12).
• Disassembly, assembly, and inspection of the
DPD assembly
“Engine Workshop Manual”
• During assembly, take out the gasket (16), and
replace it with a new one.
• During assembly, affix the parts in the order of
part A, part B, and then part C.
Nut: 26.4 N·m (19.5 ft.-lb)
11. Remove the hydraulic pump.
“Removing the hydraulic pump”
12. Take out the nuts, and suspend the engine.
Nut top: 241 N·m (177.8 ft.-lb)
Nut bottom: 193 N·m (142.4 ft.-lb)
: 333 kg (737.4 lb)

Installing the engine

To install the engine, follow the same procedures as for
removal but in the reverse order.

3
DRIVE SYSTEM 4B0AS00
 DISASSEMBLY AND ASSEMBLY
DRIVE SYSTEM 4
Radiator
Construction

X
a

ThreeBond #1324

1. Bracket 9. Hose
2. Hose 10. Radiator assembly
3. Hose 11. Sub-tank
4. Hose 12. Drain valve
5. Hose 13. Hose
6. Pipe 14. Hose
7. Pipe 15. Nut
8. Hose

4
DRIVE SYSTEM 4B0AS00
 DISASSEMBLY AND ASSEMBLY
DRIVE SYSTEM 4
Removing the radiator
1. Remove the engine hood, the side covers Right and
Left, and the engine cover (Front).
“Removing the covers”
2. Drain the hydraulic oil from the tank.
“Removing the hydraulic tank”
3. Remove the counterweight.
“Removing the upper structure”
4. Place a receptacle under the drain valve (12), and
drain the coolant out into this receptacle.
• Total coolant volume: 18.5 L (19.5 US qt.)

5. Disconnect the hoses (A) and (B).

6. Remove the hoses (3), (4), (8), and (9).

4B0AS08

7. Disconnect the hoses (C) and (D).

• Place caps on the ends of the disconnected hos-
es.

WARNING
• Drain out the coolant when disconnecting the hoses.
• Read the repair manual for the air conditioner and fol-
low the instructions contained therein when working on
the air conditioner.

5
DRIVE SYSTEM 4B0AS00
 DISASSEMBLY AND ASSEMBLY
DRIVE SYSTEM 4
8. Disconnect the hoses (E) and (F).

9. Disconnect the hoses (G) and (H).

10. Take out the nut (15), and remove the radiator as-
sembly.
• Slowly raise the radiator assembly using a hoist
being careful not to bump it on the fan.
Radiator assembly: 81 kg (180 lb)

Installing the radiator

To install the radiator, follow the same procedures as for
removal but in the reverse order.
The radiator must be mounted at a right angle to the
frame and parallel to the cooling fan.
Adjust the position to ensure that there is a clearance of
17.5 mm (0.689 in.) for the fan and shroud.
1 To be mounted parallel thereto
2 To be mounted at a right angle thereto

6
DRIVE SYSTEM 4B0AS00
 DISASSEMBLY AND ASSEMBLY
DRIVE SYSTEM 4
Hydraulic pump
Construction

Apply molybdenum disulfide grease to the spline.

• Applying a large amount of grease on the spline
hole in the coupling assembly may cause the
grease to drip down onto rubber parts, which could
cause the rubber to deteriorate.

1 The bolts have already been coated with a special coat- 1. Engine housing 6. Stay
ing to prevent them from becoming loose. Do not use 2. Coupling assembly 7. Suction hose
bolts other than the ones that came with the machine.
3. Suction pipe 8. Main pump
Do not reuse bolts that have been loosened.
4. Flange pipe 9. Gear pump
2 Air vent port
5. Flange nipple 10. Pressure transmitter

7
DRIVE SYSTEM 4B0AS00
 DISASSEMBLY AND ASSEMBLY
DRIVE SYSTEM 4
Removing the hydraulic pump
1. Remove the battery ground cable from the battery
terminal.
2. Remove the engine hood, the side covers Right and
Left, and the engine cover (Front).
“Removing the covers”
3. Remove the DPD.
a. Disconnect the electrical wiring to the DPD on the
DPD side.
• Attach identification labels to each of the wires.
b. Take out the part A, part B, and part C nuts, and
remove the DPD assembly (D).
• Disassembly, assembly, and inspection of the
DPD assembly
“Engine Workshop Manual”
• During assembly, take out the gasket (E), and
replace it with a new one.
• During assembly, affix the parts in the order of
part A, part B, and then part C.
Nut: 26.4 N·m (19.5 ft.-lb)
4. Drain the hydraulic oil from the tank.
“Removing the hydraulic tank”
5. Disconnect the electrical wiring from the hydraulic
pump.
6. Disconnect the suction hoses from the hydraulic
pump.
7. Disconnect the discharge hoses from the hydraulic
pump.
8. Remove the filters.
9. Take out the bolts, and remove the hydraulic pump
assembly.
Apply molybdenum disulfide grease to the
spline.
Bolt: 256 N·m (189 ft.-lb)
Main pump: 87 kg (192 lb)
Gear pump: 5.4 kg (11.9 lb)

8
DRIVE SYSTEM 4B0AS00
 DISASSEMBLY AND ASSEMBLY
DRIVE SYSTEM 4
Installing the hydraulic pump
To install, follow the same procedures as for removal but
in the reverse order.

Cautions on starting the hydraulic pump

a. Fill the pump housing with hydraulic oil before start-
ing.
• Fill the pump housing with hydraulic oil from the
air vent port “2.”
b. Start the engine, let it run at a low idling speed for
ten minutes, and then extend and retract each cyl-
inder 4 or 5 times, without letting any reach the
stroke end.
c. Run the engine at high speed and then extend and
retract each cylinder 4 or 5 times, without letting
any reach the stroke end.
d. Return the engine speed to low idle and then ex-
tend and retract each cylinder 4 or 5 times, without
letting any reach the stroke end.

9
DRIVE SYSTEM 4B0AS00
 DISASSEMBLY AND ASSEMBLY
DRIVE SYSTEM 4
Fuel tank
Construction

1 To engine 1. Fuel tank 10. uel hose

2. Cap 11. Fuel hose
3. Strainer 12. Fuel hose
4. Fuel sender 13. Fuel hose
5. Sedimenter 14. Fuel hose
6. Fuel pump 15. Fuel filter
7. Fuel hose 16. Fuel filter
8. Fuel hose 17. Fuel cooler
9. Fuel hose 18. Bolt

10
DRIVE SYSTEM 4B0AS00
 DISASSEMBLY AND ASSEMBLY
DRIVE SYSTEM 4
Removing the fuel tank
1. Remove the covers from the perimeter around the
tank.
“Removing the covers”
2. Loosen the drain valve (A), and let the fuel drain out.
• Fuel tank capacity: 250 L (66.0 US gal.)
3. Disconnect the fuel hoses (7) and (14).

4. Take out the nut, and remove the sensor and bracket
from the fuel tank.

5. Disconnect the electrical wiring (E) from the fuel

sender (4).
6. Take out the bolts (18) holding the fuel tank (1) in
place, and suspend the fuel tank (1) and remove it.
: 78 kg (170 lb)

Installing the fuel tank

To install, follow the same procedures as for removal but
in the reverse order.

11
DRIVE SYSTEM 4B0AS00
 DISASSEMBLY AND ASSEMBLY
DRIVE SYSTEM 4
Fuel filler pump
Construction

1. Cover assembly for electronic parts 5. Pump

2. Harness 6. Fuel trailer
3. Hose 7. Plug
4. Hose 8. Level switch

12
DRIVE SYSTEM 4B0AS00
 DISASSEMBLY AND ASSEMBLY
DRIVE SYSTEM 4
Battery

1. Clamp 9. Rubber seat

2. Cover 10. Hook bolt
3. Seat 11. Bracket
4. Battery 12. Battery relay
5. Relay cable (+) 13. Glow lamp relay
6. Starter cable 14. Starter relay
7. Serial cable 15. Main relay
8. Earth ground cable 16. 24-V diode for the CA relay

13
DRIVE SYSTEM 4B0AS00
 DISASSEMBLY AND ASSEMBLY
DRIVE SYSTEM 4
Removing the battery

WARNING
• Wear protective glasses and gloves when working with
batteries.
• Batteries generate flammable hydrogen gas which may
explode. Keep away from flames and sparks.
• Be sure to stop the engine by turning off the starter
switch before inspecting or handling the battery.
• Be careful not to let metal tools (or any metal objects)
such as a hammer or wrench come into contact with the
battery terminals.
• When disconnecting the battery wiring, always discon-
nect it from the earth side (-). When connecting, con-
nect the earth side last.
• Loose battery terminals may cause sparks. Be sure to
fasten terminals tightly.

1. Disconnect the battery ground cable (8) from the

battery terminal.
2. Remove the relay cable (5).
3. Remove the serial cable (7).
4. Remove the nuts.
Nut top: 12.3 N·m (9.1 ft.-lb)
Nut bottom: 9.8 N·m (7.2 ft.-lb)
5. Remove the battery (4).

Installing the battery

To install, follow the same procedures as for removal but
in the reverse order.

14
DRIVE SYSTEM 4B0AS00
 DISASSEMBLY AND ASSEMBLY
TRAVEL SYSTEM 4
TRAVEL SYSTEM
Removing the crawler

WARNING
When working under the machine while it is raised up, be
sure to use a stand to support the machine.

Important: When replacing crawlers, replace both the

right and left ones at the same time.
1. Lift up the machine.
• Use the blade and hoe attachment to raise the
machine.
4C0AQ01Z
2. Loosen the crawler tension for the crawler (1).
• When loosening the check valve (2), do it slowly.
Stop loosening the check valve once grease 1
starts to come out.
If no grease comes out, slightly move the machine 4
forward and backward.
Check valve: 177 N·m (130 ft.-lb)
3. Insert the iron pipe (3) into the crawler and then ro-
2
tate the sprocket in the reverse direction.
4. Stop rotating the sprocket once the pipe reaches the
side of the idler.
5. Slide the crawler over to the side and remove it.
Crawler: 752 kg (1658 lb) 4C0AF01Z

Installing the crawler

1. Lift up the machine, and insert the crawler into the
frame.
• Set the crawler so that it is engaged with the
sprocket.
2. Insert the iron pipe (3) into the crawler and then ro-
tate the sprocket in the reverse direction.
3. Stop rotating the sprocket once the pipe (3) reaches
the side of the sprocket.
4. Slide the crawler into a position where it can be prop-
erly fitted to engage with the idler.
5. Position the crawler so as to ensure that it is securely
engaged with the sprocket and idler and then adjust
the crawler tension.
“2. Service data, Performance criteria”

1
TRAVEL SYSTEM 4C0AS00
 DISASSEMBLY AND ASSEMBLY
TRAVEL SYSTEM 4
Removing a steel crawler or segmented rubber crawler
1. Stop the machine at a position at which the master
pin is located at the front of the idler.
2. Loosen the crawler tension of the crawler (1).
• Proceed slowly when loosening the check valve
(2) and stop once grease starts to come out. If no
grease comes out, slightly move the machine for-
ward and backward. 2
Check valve: 177 N·m (130 ft.-lb)
3. Take out the master pin (3), and disconnect the
crawler (1). 3
4. Use the blade and hoe attachment to raise the ma-
1 4C0AF02Z
chine and then let the travel motor run at slow speed
in the reverse direction to unwind the crawler.
Steel crawler (500-mm-wide model): 750 kg
(1654 lb)
Segmented rubber crawler: 812kg (1790 lb)

Installing a steel crawler or segmented rubber

crawler
1. Use the blade and hoe attachment to lift up the ma-
chine and then position the crawler onto the bottom
of the frame.
• Be careful not to install the crawler in the wrong di-
rection.
4C0AF03Z
2. Fit the links into the sprockets and then let the travel
motor run at slow speed in the forward direction to
wind the crawler onto the sprockets.
3. Lower the machine and insert the master pin to se-
cure the crawler in place.
• Line up the pin holes, and insert a temporary pin.
4. Lift up the machine, and adjust the crawler tension.
• Check the crawler tension.
“2. Service data, Performance criteria”

4C0AF04Z

4C0AF05Z

2
TRAVEL SYSTEM 4C0AS00
 DISASSEMBLY AND ASSEMBLY
TRAVEL SYSTEM 4
Attaching/removing a segmented rubber crawler
The link assembly (1) is to be installed and removed in
the same way as for the steel crawler.
Insert the rubber pad (2) at the torque listed below.
Nut: 412 N·m (304 ft.-lb)

Replacing the crawler

Attach the shoe guide if replacing a rubber crawler with
a steel crawler.
Bolt: 256 N·m (189 ft.-lb)
ThreeBond #1324 or its equivalent

Removing the carrier roller

1. Loosen the crawler belt tension.
2. Use the hydraulic jack (1) to push up the crawler belt.
• Insert the stopper (2) to prevent the crawler belt
from popping out from the hydraulic jack (1) and
falling.
3. Loosen the nut (3), take out the bolt, and remove the
roller (4).

Installing the carrier roller

To install, follow the same procedures as for removal but
in the reverse order.
Bolt: ThreeBond #1324
Bolt: 256 N·m (189 ft.-lb)

3
TRAVEL SYSTEM 4C0AS00
 DISASSEMBLY AND ASSEMBLY
TRAVEL SYSTEM 4
Removing the track roller
1. Loosen the crawler tension.
2. Loosen the roller bolt (1) slightly (about one turn).
2
3. Lift up the machine, take out the bolt (1), and remove
1
the roller (2).

Installing the track roller

1. Temporarily secure the roller (2) in place by tighten-
ing down the bolt (1).
2. Lower the machine to the ground and then further
tighten down the bolt. 4C0AH03Z

Bolt: ThreeBond #1324

Bolt: 299 N·m (221 ft.-lb)
3. Lift up the machine, and adjust the crawler tension.

Removing the idler and track adjuster

1. Remove the crawler.
“Removing the crawler"
2. Pull out the idler and the track adjuster.
Idler: 103 kg (227 lb)
Track adjuster: 97 kg (214 lb)

Installing the idler and track adjuster 4C0AF09Z

To install, follow the same procedures as for removal but

in the reverse order.
2 1 182N·m
Apply on the sliding surfaces of the track adjuster
piston and cylinder.

Removing the travel motor

1. Remove the crawler.
“Removing the crawler"
2. Take out the bolts (1), and remove the sprocket (2).
Bolt: ThreeBond #1324
Bolt: 281 N·m (207 ft.-lb)
3. Remove the cover, and disconnect the hydraulic 3
hoses (4). 4C0AQ07Z

4. Suspend the travel motor (3) temporarily, and re-

move the bolts (5). 4
Bolt: ThreeBond #1324
Bolt: 281 N·m (207 ft.-lb)
5. Raise the travel motor (3), and remove it.
Travel motor: 145 kg (320 lb)

Installing the travel motor

To install, follow the same procedures as for removal but
in the reverse order.
5 4
282N·m
4C0AQ08Z

4
TRAVEL SYSTEM 4C0AS00
 DISASSEMBLY AND ASSEMBLY
SLEW EQUIPMENT 4
SLEW EQUIPMENT
Slew motor
Construction

1. Slew motor
2. Oil feed port
3. Pipe
4. Oil gauge
5. Parallel pin

1
SLEW EQUIPMENT 4D0AS00
 DISASSEMBLY AND ASSEMBLY
SLEW EQUIPMENT 4
Removing the slew motor
1. Disconnect the hydraulic hoses from the slew motor
(1).
2. Remove the bolts from the slew motor.
Bolt: ThreeBond #1324
Bolt: 476 N·m (351 ft.-lb)
3. Raise the slew motor (1), and remove it.
Slew motor: 170 kg (375 lb)

Installing the slew motor

To install, follow the same procedures as for removal but
in the reverse order.

2
SLEW EQUIPMENT 4D0AS00
 DISASSEMBLY AND ASSEMBLY
SLEW EQUIPMENT 4
Slew bearing
Construction

ThreeBond #1324
Grease the tooth surfaces and grease bus with lithium grease EP-2.
Approx. 12 L (12.7 US qt.)

1 Supply port hole 1. Reamer bolt

2 Use a reamer bolt at this position only 2. Slew bearing
3 "S" die stamp
3. Seal
4. Seal

3
SLEW EQUIPMENT 4D0AS00
 DISASSEMBLY AND ASSEMBLY
SLEW EQUIPMENT 4
Removing the slew bearing
1. Remove the hoe attachment.
“Removing the hoe attachment”
2. Remove the upper frame.
3. Remove the fixing bolts for the inner race.
Bolt: ThreeBond #1324
Bolt: 339 N·m (250 ft.-lb)
4. Raise the slew bearing (2), and remove it.
Slew bearing: 200 kg (441 lb)

Installing the slew bearing

To install, follow the same procedures as for removal but
in the reverse order.
• Refer to the construction diagram for the positions of
the reamer bolts and the grease supply port.
• Grease the tooth surfaces and grease bus with lithium
grease EP-2.

4
SLEW EQUIPMENT 4D0AS00
 DISASSEMBLY AND ASSEMBLY
SLEW EQUIPMENT 4
Swivel joint
Construction

ThreeBond #1324

1. Swivel joint
2. Stopper

5
SLEW EQUIPMENT 4D0AS00
 DISASSEMBLY AND ASSEMBLY
SLEW EQUIPMENT 4
Removing the swivel joint
1. Remove the upper frame.
“Removing the upper frame”
2. Disconnect the hydraulic hoses from the swivel joint
(1).
3. Take out the bolts holding the swivel joint (1) in place,
and remove the swivel joint (1).
Bolt: ThreeBond #1324
Bolt: 158 N·m (117 ft.-lb)
4. Raise the swivel joint (1), and remove it.
Swivel joint: 24 kg (53 lb)

Installing the swivel joint

For installation, follow the same procedures as for remov-
al but in the reverse order.
• When installing the swivel joint, secure it in place tem-
porarily using bolts, and position the center using a
dial gauge.
• Adjust the position so that the center offset is 1 mm
(0.0394 in.) or less.

6
SLEW EQUIPMENT 4D0AS00
 DISASSEMBLY AND ASSEMBLY
UPPER FRAME 4
UPPER FRAME
Upper frame
Construction

1 Adjust the shim so that dimension “A” on the top surface of the hydraulic tank and top surface of the counterweight
is 425 mm (16.7 in.).
Apply molybdenum disulfide grease.
ThreeBond #1324

1. Upper frame
2. Counterweight
3. Bushing
4. Shim (Selected usage)
5. Shim (Selected usage)

1
UPPER FRAME 4E0AS00
 DISASSEMBLY AND ASSEMBLY
UPPER FRAME 4

6. Elbow
7. Connector
8. Elbow
9. Grease fitting
10. Tube
11. Tube

2
UPPER FRAME 4E0AS00
 DISASSEMBLY AND ASSEMBLY
UPPER FRAME 4
Removing the upper frame
1. Remove the hoe attachment.
“Removing the hoe attachment”
2. Take out the cab.
“Removing the cab”
3. Remove the covers.
“Removing the covers”
4. Remove the hydraulic hoses from the swivel joint.
“Removing the swivel joint”
5. Take out the bolts holding the swivel joint stopper in
place, and remove the stopper.
“Removing the swivel joint”
Bolt: 339 N·m (250 ft.-lb)
ThreeBond #1324
6. Disconnect the elbow (6) from the slew bearing.
7. Remove all of the fixing bolts for the outer race of the
slew bearing except for two at the front of the ma-
chine and two at the rear.
• When installing the slew bearing, be sure to align
it with the positions of the grease supply port and
the reamer bolt.
“Removing the slew bearing”
Bolt: ThreeBond #1324
Bolt: 339 N·m (250 ft.-lb)
8. Raise the upper frame (1) temporarily, and remove
the remaining bolts while balancing the upper frame
(1).
9. Raise the upper frame, and remove it.

Installing the upper frame

To install, follow the same procedures as for removal but
in the reverse order.

3
UPPER FRAME 4E0AS00
 DISASSEMBLY AND ASSEMBLY
UPPER FRAME 4
Covers
Construction

4
UPPER FRAME 4E0AS00
 DISASSEMBLY AND ASSEMBLY
UPPER FRAME 4

ThreeBond #1324

1. Engine cover (Front) 9. Undercover 17. Hook 25. Hinge

2. Engine hood 10. Undercover assembly 18. Bracket 26. Bracket
3. Side cover R 11. Bracket 19. Wire 27. Cover
4. Side cover L 12. Handrail 20. Undercover 28. Gas Spring
5. Front cover 13. Toolbox 21. Plate 29. Cover
6. Center cover T 14. Partition plate 22. Gas Spring 30. Plate
7. Center cover F 15. Stay 23. Handrail 31. Shim
8. Center cover F 16. Bracket 24. Undercover 32. Toolbox

5
UPPER FRAME 4E0AS00
 DISASSEMBLY AND ASSEMBLY
UPPER FRAME 4
Removing the covers
1. Remove the battery ground cable from the battery
terminal.
2. Remove the engine hood (2).
a. Open the engine hood, and raise it up temporari-
ly.
b. Disconnect the electrical wires connected to the
engine hood.
c. Remove the gas spring (28).
d. Remove the fixing bolts for the hinge part.
Bolt: ThreeBond #1324
Bolt: 54.9 N·m (40.5 ft.-lb)
Engine hood: 34 kg (75 lb)
3. Remove the side cover R (3) and side cover L (4).
a. Open the side cover, and suspend it temporarily.
b. Remove the gas spring (22).
c. Remove the fixing bolts for the hinge part.
Bolt: ThreeBond #1324
Bolt: 54.9 N·m (40.5 ft.-lb)
4. Remove the center covers F (7) and (8).
5. Remove the center cover T (6) and the plate (14).
6. Remove the front cover (5).
• Disconnect the electrical wiring from the front
cover before attempting to remove the front cover
itself.
7. Remove the front engine cover (1).
• Take out the equipment fixing bolts screwed into
the cover to remove the device from the cover in
advance.
: 63 kg (140 lb)

Installing the covers

To install, follow the same procedures as for removal but
in the reverse order.

6
UPPER FRAME 4E0AS00
 DISASSEMBLY AND ASSEMBLY
UPPER FRAME 4
Cab
Construction

If the width of the clearance between the machine body

and the cab is not kept constant (9 mm (0.35 in.) or be-
low), adjust the width using the washers (7) and (8).
Bolt: ThreeBond #1324

1. Floor plate 5. Cover assembly

2. Cover 6. Pipe
3. Cab mount 7. Washer
4. Holder 8. Washer

7
UPPER FRAME 4E0AS00
 DISASSEMBLY AND ASSEMBLY
UPPER FRAME 4

9. Box 15. Cover R

10. Cover 16. Bracket
11. Cover R 17. Radio
12. Cover C 18. Speaker
13. Cover L 19. Wire harness
14. Cover L

8
UPPER FRAME 4E0AS00
 DISASSEMBLY AND ASSEMBLY
UPPER FRAME 4

20. Cab

9
UPPER FRAME 4E0AS00
 DISASSEMBLY AND ASSEMBLY
UPPER FRAME 4
Removing the cab
1. Remove the battery ground cable from the battery
terminal.
2. Remove the operator's seat from the bracket.
3. Remove the cover R (11), cover C (12), and cover L
(13).
4. Remove the cover L (14) and cover R (15).
5. Disconnect the electrical wiring and air conditioner
ducts from the cab.
6. Disconnect the window washer hose from the cab.
7. Remove the seat bracket.
8. Take out the nuts and bolts holding the cab in place,
and suspend the cab and remove it.
Cab: 370 kg (815 lb)

Installing the cab

To install, follow the same procedures as for removal but
in the reverse order.
• Suspend the cab horizontally, and secure it in place
with nuts while it is suspended.

10
UPPER FRAME 4E0AS00
 DISASSEMBLY AND ASSEMBLY
OPERATING DEVICE 4
OPERATING DEVICE
Control levers
Construction
Travel, swing levers

ThreeBond #1324
1. Bracket 6. Bracket
2. Travel lever R 7. Bracket
3. Travel lever L 8. Swing pedal
4. Travel pedal R 9. Pilot valve (Travel)
5. Travel pedal L 10. Pilot valve (Swing)

1
OPERATING DEVICE 4F0AS00
 DISASSEMBLY AND ASSEMBLY
OPERATING DEVICE 4
Hydraulic pilot unit
Type A (ISO)

RP
R4
R3
R1
R2
RT Pa7
Pa5
Pa4
Pa3

Pb5
Pb8
Pb3
Pb7

LP
L4
L3
L1
a L2
LT
MP6
MT6
MP7
MT7

J1
J3
J5
J7

J2
J4
J6
J8

Pra3

Pra2

Prb3 Pa8
Pa9
Pra1
Prb2 Pa5
Pa4
Pc2
Prb1

Pc3
Pa6 Pb8 Pa3
Pa2
Pb9
Pc1
Pc3
Pa1
Pb6
Pb3
Pb1 Pb9
Pb5
BLT Pb2

BLP

BL2

BL1

SS22 SS2P
SS2T
BST
SS21

BSP SS1P
SS12
SS1T
SS11
BS1

TR4
BS2 TRT MP2
TR3 MP3
MP4
MP5
TRP

TR1 MT2
MT3
MT4
TR2 MT5

2
OPERATING DEVICE 4F0AS00
 DISASSEMBLY AND ASSEMBLY
OPERATING DEVICE 4
Table of connections
1 R1 ↔ J2 8 1. Pilot valve (Right)
1 R2 ↔ J4 8 2. Pilot valve (Left)
1 R3 ↔ J1 8 3. Pilot valve (Travel)
1 R4 ↔ J3 8 4. Pilot valve (Swing)
1 RP ↔ MP6 11 5. Pilot valve (Blade)
1 RT ↔ MT6 11 6. Solenoid valve (1st auxiliary line piping)
2 L1 ↔ J7 8 7. Solenoid valve (2nd auxiliary line piping)
2 L2 ↔ J5 8 8. Joint
2 L3 ↔ J8 8 9. Shockless valve
2 L4 ↔ J6 8 10. Control valve
2 LP ↔ MP7 11 11. Manifold
2 LT ↔ MT7 11
3 TR1 ↔ pa6 10
3 TR2 ↔ pb6 10
3 TR3 ↔ pa1 10
3 TR4 ↔ pb1 10
3 TRP ↔ MP2 11
3 TRT ↔ MT2 11
4 BS1 ↔ pra1 10
4 BS2 ↔ prb1 10
4 BSP ↔ TRP 3
4 BST ↔ TRT 3
5 BL1 ↔ prb2 10
5 BL2 ↔ pra2 10
5 BLP ↔ MP3 11
5 BLT ↔ MT3 11
6 SS11 ↔ pa2 10
6 SS12 ↔ pb2 10
6 SS1P ↔ MP5 11
6 SS1T ↔ MT5 11
7 SS21 ↔ pra3 10
7 SS22 ↔ prb3 10
7 SS2P ↔ MP4 11
7 SS2T ↔ MT4 11
8 J1 ↔ pa7 10
8 J2 ↔ pb7 10
8 J3 ↔ pa4 10
9 BSA ↔ pb8 10
8 J5 ↔ pa5 10
8 J6 ↔ pb5 10
8 J7 ↔ pa3 10
8 J8 ↔ pb3 10
10 pa4 ↔ pa8 10
10 pa5 ↔ pa9 10
10 pb5 ↔ pb9 10
10 pc1 ↔ pb9 10
10 Pc2 ↔ pb8 10
10 Pc3 ↔ pa3 10
10 Pc3 ↔ pb3 10

3
OPERATING DEVICE 4F0AS00
 DISASSEMBLY AND ASSEMBLY
OPERATING DEVICE 4
Type A (ISO) – Type G (JCB)

RP
R4
R3 Pa7
R1 Pa5
R2
RT Pa4
Pa3

Pb5
Pb8
Pb3
Pb7

LP
L4
L3
a L1
L2
MP6 LT
MT6
MP7
MT7

J1
J3
J5
J7

J2 S1
J4
J6
J8 S4
SC
b
S2 SD

SB S3
SA

4
OPERATING DEVICE 4F0AS00
 DISASSEMBLY AND ASSEMBLY
OPERATING DEVICE 4
Pra3

Pra2

Prb3 Pa8
Pa9
Pra1
Prb2 Pa5
Pa4
Pc2
Prb1

Pc3
Pa6 Pb8 Pa3
Pa2
Pb9
Pc1
Pc3
Pa1
Pb6
Pb3
Pb1 Pb9
Pb5
BLT Pb2

BLP

BL2

BL1

SS22 SS2P
SS2T
BST
SS21

BSP SS1P
SS12
SS1T
SS11
BS1

TR4
BS2 TRT MP2
TR3 MP3
MP4
MP5
TRP

TR1 MT2
MT3
MT4
TR2 MT5

5
OPERATING DEVICE 4F0AS00
 DISASSEMBLY AND ASSEMBLY
OPERATING DEVICE 4
Table of connections
1 R1 ↔ J2 8 1. Pilot valve (Right)
1 R2 ↔ SA 12 2. Pilot valve (Left)
1 R3 ↔ J1 8 3. Pilot valve (Travel)
1 R4 ↔ SB 12 4. Pilot valve (Swing)
1 RP ↔ MP6 11 5. Pilot valve (Blade)
1 RT ↔ MT6 11 6. Solenoid valve (1st auxiliary line piping)
2 L1 ↔ J7 8 7. Solenoid valve (2nd auxiliary line piping)
2 L2 ↔ SC 12 8. Joint
2 L3 ↔ J8 8 9. Shockless valve
2 L4 ↔ SD 12 10. Control valve
2 LP ↔ MP7 11 11. Manifold
2 LT ↔ MT7 11 12. Selector valve
3 TR1 ↔ pa6 10
3 TR2 ↔ pb6 10
3 TR3 ↔ pa1 10
3 TR4 ↔ pb1 10
3 TRP ↔ MP2 11
3 TRT ↔ MT2 11
4 BS1 ↔ pra1 10
4 BS2 ↔ prb1 10
4 BSP ↔ TRP 3
4 BST ↔ TRT 3
5 BL1 ↔ prb2 10
5 BL2 ↔ pra2 10
5 BLP ↔ MP3 11
5 BLT ↔ MT3 11
6 SS11 ↔ pa2 10
6 SS12 ↔ pb2 10
6 SS1P ↔ MP5 11
6 SS1T ↔ MT5 11
7 SS21 ↔ pra3 10
7 SS22 ↔ prb3 10
7 SS2P ↔ MP4 11
7 SS2T ↔ MT4 11
12 S1 ↔ J4 8
12 S2 ↔ J3 8
12 S3 ↔ J5 8
12 S4 ↔ J6 8
8 J1 ↔ pa7 10
8 J2 ↔ pb7 10
8 J3 ↔ pa4 10
9 BSA ↔ pb8 10
8 J5 ↔ pa5 10
8 J6 ↔ pb5 10
8 J7 ↔ pa3 10
8 J8 ↔ pb3 10
10 pa4 ↔ pa8 10
10 pa5 ↔ pa9 10
10 pb5 ↔ pb9 10
10 pc1 ↔ pb9 10
10 pc2 ↔ pb8 10
10 pc3 ↔ pa3 10
10 pc3 ↔ pb3 10

6
OPERATING DEVICE 4F0AS00
 DISASSEMBLY AND ASSEMBLY
OPERATING DEVICE 4
Dozer blade lever

1. Blade lever
2. Plate
3. Pilot valve (Blade)

7
OPERATING DEVICE 4F0AS00
 DISASSEMBLY AND ASSEMBLY
OPERATING DEVICE 4
Lever stand
Pilot valve (Left)

1 Adjusting the limit switch: When the limit switch is in

the ON position, the tip of the switch should be visi-
ble from the boot.
Apply rubber grease #9106 (for natural rubber).

1. Panel (Main) 9. Elbow rest

2. Panel (Side) 10. Plate
3. Base 11. Pilot valve (Left)
4. Lever 12. Gas spring
5. Plate 13. Limit switch
6. Plate 14. Snatch lock
7. Bracket 15. Stopper
8. Shaft 16. Spring

8
OPERATING DEVICE 4F0AS00
 DISASSEMBLY AND ASSEMBLY
OPERATING DEVICE 4
Pilot valve (Right)

1. Panel (Main)
2. Base
3. Elbow rest
4. Pilot valve (Right)

Control box R

1. Starter switch
2. Knob
3. Variable resistor
4. Switch
5. Switch
6. Switch
7. Switch
8. Switch
9. Ornament

9
OPERATING DEVICE 4F0AS00
 DISASSEMBLY AND ASSEMBLY
ATTACHMENTS 4
ATTACHMENTS
Hoe attachment
Construction

1. Arm 11. O-ring

2. Link arm 12. Bucket cylinder
3. Guide link R 13. Shim
4. Guide link L 14. Shim
5. Pin 15. Pipe
6. Pin 16. Pipe
7. Pin 17. O-ring
8. Pin 18. O-ring
9. Pin 19. Shim (Selected usage)

1
ATTACHMENTS 4G0AS00
 DISASSEMBLY AND ASSEMBLY
ATTACHMENTS 4

A: Apply NEVER-SEEZ lubricant to the pin insertion hole

and then insert the pin into the hole.

20. Boom 27. Pin

21. Boom cylinder R 28. Shim (Selected usage)
21-1. Boom cylinder L 29. Shim (Selected usage)
22. Arm cylinder 30. Shim (Selected usage)
23. Pin 31. O-ring
24. Pin 32. O-ring
25. Pin 33. Shim (Selected usage)
26. Pin 34. Castle nut

2
ATTACHMENTS 4G0AS00
 DISASSEMBLY AND ASSEMBLY
ATTACHMENTS 4

PIL
T
X

35. Bucket pipe R

36. Bucket pipe L
37. Arm pipe
38. Wire harness
39. Working lamp
40. O-ring
41. O-ring

3
ATTACHMENTS 4G0AS00
 DISASSEMBLY AND ASSEMBLY
ATTACHMENTS 4

A: Apply NEVER-SEEZ lubricant to the pin insertion hole

and then insert the pin into the hole.
B: Attach the washer with the side with the grease
groove facing upward (toward the bracket side).

42. Boom bracket

43. Pin
44. Pin
45. Pin
46. Pin
47. Swing cylinder
48. Shim (Selected usage)
49. Washer (Selected usage)

4
ATTACHMENTS 4G0AS00
 DISASSEMBLY AND ASSEMBLY
ATTACHMENTS 4

X
Y

50. Blade
51. Blade cylinder R
52. Blade cylinder L
53. Pin

5
ATTACHMENTS 4G0AS00
 DISASSEMBLY AND ASSEMBLY
ATTACHMENTS 4
Removing the hoe attachment

WARNING
• Be sure to release any residual pressure in the piping
before disconnecting the hydraulic hose.
• Do not attempt to insert any fingers into the hole when
adjusting the pin hole position.

Important:
• When tightening the lock bolt with a double nut, allow a
clearance of 0.5 mm to 1.0 mm (0.0197 in. to 0.0394
in.) between the nut and the lock collar.
• Adjust the clearance for the pin connector to a width of
between 0.2 mm to 0.5 mm (0.0079 in. to 0.0197 in.)
using a shim.
• Be sure to bleed the air from the cylinder before starting
operation for the first time after reassembling hydraulic
devices such as the hydraulic cylinder or hydraulic pip-
ing.

The numbers in parentheses, ( ), listed after the names of

parts throughout this document are used to refer to the
same parts as the numbers listed in the construction di-
agram and parts lists.

Removing the bucket

1. Orient the back of the bucket downward, and lower
the bucket all the way down to the ground.
2. Take out the bolts, and remove the pins.
3. Remove the bucket.
Bucket: 305 kg (670 lb)

Installing the bucket

To install, follow the same procedures as for removal but
in the reverse order.
Before beginning attachment of the bucket, place the O-
ring in the temporary placement position “A” in the outer
circumference of the bucket bushing, and move it to the
specified position “B” after completing attachment.

6
ATTACHMENTS 4G0AS00
 DISASSEMBLY AND ASSEMBLY
ATTACHMENTS 4
Removing the link
• Completely retract the bucket cylinder, and lower the
tip of the arm to the ground.
1. Take out the pin (6), and remove the link arm (2).
a. Guide links R (3) and L (4) .... Exercise caution as
they may drop
b. Cylinder (12).......................... Place on the skid
c. Link arm (2) .............................. Suspend temporarily
2. Take out the pin (7), and remove the guide links R (3)
and L (4).

Installing the link

To install, follow the same procedures as for removal but
in the reverse order.

Removing the arm

1. Disconnect the hydraulic hoses from the bucket cyl-
inder (12).
Next, disconnect the hydraulic hoses from the auxil-
iary line ports.
2. Suspend the bucket cylinder (12) temporarily and
then pull out the pin (8) and remove the bucket cylin-
der.
Bucket cylinder: 94 kg (205 lb)
3. Place the skid under the arm cylinder (22), and re-
move the pin (9).
4. Take out the cotter pin, and remove the castle nut
(34).
5. Suspend the arm (1) temporarily and then pull out the
pin (24) and remove the arm.
Arm: 273 kg (600 lb)

Installing the lift arm

To install, follow the same procedures as for removal but
in the reverse order.

Important:
When securing the arm with the fixing pin (24) and castle
nut (34), make sure not to tighten the castle nut (34) too
much.
After tightening down the castle nut (34) with a hand, firm-
ly tighten it down until the tightening hole positions for the
fixing pin (24) and cotter pin for the castle nut (34) line up
properly.

7
ATTACHMENTS 4G0AS00
 DISASSEMBLY AND ASSEMBLY
ATTACHMENTS 4
Removing the boom
Lower the tip of the boom all the way to the ground.
1. Disconnect the hydraulic hoses from the arm cylin-
der (22).
2. Suspend the arm cylinder (22) temporarily and then
pull out the pin (23) and remove the arm cylinder.
Arm cylinder: 147 kg (325 lb)
3. Remove the boom cylinders.
a. Disconnect the hydraulic pipings from the boom
cylinders R (21) and L (21-1).
b. Remove the covers and plates from the boom cyl-
inders R and L.
c. Suspend the boom cylinder R (21) temporarily.
d. Push in the pin (27), and disconnect the rod side
of the cylinder and lower the cylinder to the
ground.
• Push in the pin (27) only until the rod becomes
disconnected.
e. Suspend the boom cylinder L (21-1) temporarily
and then remove the pin (27) and lower the rod
side of the cylinder all the way to the ground.
f. Suspend the boom cylinder R (21) temporarily,
disconnect the head side from the head pin (26),
and raise the cylinder.
Boom cylinder: 110 kg (245 lb)
g. Suspend the boom cylinder L (21-1) temporarily,
take out the head pin (26), and raise the cylinder
as in the above step.
4. Disconnect the electrical wiring (38) to the boom light
from the wiring on the machine body side.
5. Disconnect the hydraulic hoses connected from the
machine body side from the pipes.
6. Suspend the boom (20) temporarily and then pull out
the pin (25) and remove the boom.
Boom: 669 kg (1475 lb)

Installing the boom

To install, follow the same procedures as for removal but
in the reverse order.

8
ATTACHMENTS 4G0AS00
 DISASSEMBLY AND ASSEMBLY
ATTACHMENTS 4
Removing the swing bracket
1. Remove the cover and clamp from the boom bracket
(42).
2. Remove the plate, take out the pin (46), and discon-
nect the swing cylinder (47) from the swing bracket.
3. Suspend the boom bracket (42) temporarily and then
pull out the pins (43) and (44) and remove the swing
bracket.
• Be careful not to damage the hoses when working
with them.
Pin insertion bolt: 102 N·m (75.2 ft.-lb)
Boom bracket: 497 kg (1095 lb)

Installing the swing bracket

To install, follow the same procedures as for removal but
in the reverse order.
• During assembly, apply NEVER-SEEZ NS lubricant (an
anti-seizing lubricant) to the fixing pin holes on the
swing bracket and then insert the pins (46) and (45)
into the appropriate holes.
• Attach the washer (49) with the side with the grease
groove facing upward (toward the boom bracket side).

9
ATTACHMENTS 4G0AS00
 DISASSEMBLY AND ASSEMBLY
ATTACHMENTS 4
Removing the blade
Lower the blade all the way down to the ground.
1. Disconnect the hydraulic hoses from the blade cylin-
ders R (51) and L (52).
2. Suspend the blade cylinder R (51) temporarily and
then take out the pins (53) and remove the blade cyl-
inder.
Next, remove the blade cylinder L in the same way as
for the blade cylinder R.
Blade cylinder R: 61 kg (135 lb)
3. Suspend the blade (50) temporarily and then take
out the pins (53) and remove the blade (50).
Blade: 567 kg (1250 lb)

Installing the blade

To install, follow the same procedures as for removal but
in the reverse order.

10
ATTACHMENTS 4G0AS00
 DISASSEMBLY AND ASSEMBLY
ATTACHMENTS 4
Adjusting the clearance between the bucket and arm (Equipment)

WARNING
• Set all movable equipment against the ground or in the
lowermost position possible before performing mainte-
nance or repairs under the machine.
• When adjusting clearances, secure all relevant equip-
ment to prevent any accidental movement.

1. Lower the bucket all the way to the ground in a stable

position as shown in the above diagram.
2. Slew the upper structure slightly to the left, and lightly
push the arm toward the leftside of the bucket. (To-
ward the side without an adjuster.)
3. Set the safety lock lever in the locked position, and
stop the engine.
4. Loosen the three bolts (2) slightly using a wrench,
and remove the shim from the clearance C between
the blade (3) and the bucket. The shim is split into
two parts. Insert a screwdriver into the seam be-
tween the left and right shims and loosen the bolt
slightly to make it easier to remove the shims.
5. Move the O-ring (5) over, and measure the width of
the clearance (a).
6. To eliminate the clearance (a), push down on the
head of the bolt (2) with a finger. Pushing down on
the head of the bolt causes the clearance (b) to be-
come wider. Insert enough of the shims removed in
the above step into the clearance (b) as will go in
comfortably.
7. Insert the rest of the shims into the clearance (c) and
then tighten down the bolt to secure everything in
place.
Bolt: 83 N·m (61.5 ft.-lb)
This completes the clearance adjusting procedure.

Supplementary notes: The number of shims used for the

T clearances (b) and (c) is two sets of six or twelve total.
If the shim to be inserted into clearance (c) in 7. above is
omitted and forgotten, the end of the bolt (2) may jut past
the boss (6). If this occurs, the boss on the end of the arm
may be damaged or the bolt may break in two. If the end
surface of the boss (6) becomes worn and the width of
the groove for the O-ring exceeds 5 mm (0.2 in.), replace
the existing boss with a new one.

11
ATTACHMENTS 4G0AS00
 DISASSEMBLY AND ASSEMBLY
HYDRAULIC TANK 4
HYDRAULIC TANK

ThreeBond #1324

1. Hydraulic tank 9. Check valve 16. Elbow

2. Suction pipe 10. Sight gauge 17. Elbow
3. Cover 11. O-ring 18. Cover
4. Suction filter 12. Plug 19. Bracket
5. Return filter 13. Adapter 20. Plate
6. Relief valve 14. Elbow 21. Check valve
7. Spring 15. Adapter 22. Spacer (Selected usage)
8. Air breather

1
HYDRAULIC TANK 4H0AS00
 DISASSEMBLY AND ASSEMBLY
HYDRAULIC TANK 4
Removing the hydraulic tank
The numbers in parentheses ( ), listed after the names of
parts throughout this document are used to refer to the
same parts as the numbers listed in the construction di-
agram and parts lists.

1. Remove the covers from the perimeter around the

hydraulic tank.
“Removing the covers”
2. Drain the hydraulic oil from the hydraulic tank (1).
a. Push the button on the air breather (8) to release
the internal pressure in the hydraulic tank.
b. Loosen the drain plug (12), and drain out the oil.
• Tank level capacity: 95 L (25.1 US gal.)
3. Disconnect the low-pressure hoses from the hydrau-
lic tank.
4. Disconnect the high-pressure hoses from the hy-
draulic tank.
• Attach an identification tag on each hoses to avoid
mixing them up during reassembly.
5. Take out the bolts holding the hydraulic tank in place,
and suspend the hydraulic tank and remove it.
• During assembly, if any clearance exists between
the attachment surfaces of the machine body and
the hydraulic tank, insert a spacer (22) to get rid
of the clearance.
Bolt: ThreeBond #1324
Bolt: 102 N·m (75.2 ft.-lb)
Hydraulic tank: 94 kg (205 lb)

Installing the hydraulic tank

For installation of the hydraulic tank, follow the same pro-
cedures as for removal but in the reverse order.

2
HYDRAULIC TANK 4H0AS00
 DISASSEMBLY AND ASSEMBLY
HYDRAULIC TANK 4
Inspecting and refilling the oil in the hydraulic tank

WARNING
• Oil may spurt out if caps or filters are removed or pipes
are disconnected before the pressure in the hydraulic
system is released.
• Push the button on the air breather (8) to release the in-
ternal pressure in the hydraulic tank.

Inspection
The oil level changes with the oil temperature. Inspect
the oil while maintaining the machine at the attitude
shown in the figure.

Machine attitude for inspecting the hydraulic oil level

1. Start the engine, and run it at low speed.
2. Fully retract the arm cylinder and the bucket cylinder,
and then lower the bucket to the ground.
3. Stop the engine.
4. Inspect the oil level using the sight gauge (10).
When the oil temperature is about 20°C (68°F): The
level should be halfway between the upper limit (H)
and the lower limit (L). If it is below the lower limit (L),
replenish.
When the oil temperature is about 50 to 80°C (122 to
176°F): The level should be near the upper limit (H).

Refilling the oil

Important: Do not refill to above the (H) mark. Doing so
may cause damage to the hydraulic circuit or cause oil to
spurt out. If the oil level is accidentally filled to above the
(H) mark, stop the engine and allow the hydraulic oil to
cool down before draining off the excess oil from the drain
plug (12).
Important: Failure to pressurize the hydraulic tank may
cause the pump to suck in air, which will adversely affect
the hydraulic units.

1. Push the button on the air breather to release the in-

ternal pressure in the hydraulic tank, and remove the
tank.
2. Add oil to the tank up to the halfway point on the side
gauge (10).

Bleeding off the air

Important: After replacing the hydraulic oil, bleed the air
from the hydraulic circuits and hydraulic devices. Failure
to do so may damage the hydraulic devices.

3
HYDRAULIC TANK 4H0AS00
 DISASSEMBLY AND ASSEMBLY
HYDRAULIC TANK 4
Hydraulic pump
1. Loosen the plug (1) used for bleeding air from the hy-
draulic pump.
2. Tighten the plug (1) once the hydraulic oil overflows
from the plug hole.

If the boom and arm are not operating normally, there

may be air trapped in the lines or parts listed below.

4
HYDRAULIC TANK 4H0AS00
 DISASSEMBLY AND ASSEMBLY
HYDRAULIC TANK 4
Emergency shut-off valve
1. Place a receptacle under hose (A) or hose (B) to
catch waste oil that is drained out.
2. Start the engine, and let it run at a low-idling speed.
3. Move the safety lock lever to the full-release position.

a. Boom
4. Secure the hose fitting (A) in place with a wrench to
keep it from moving and then slowly loosen the hose
nut (1).
5. Slowly move the boom downward little by little until
air bubbles no longer escape from the hose nut (1)
connector.
6. Secure the hose fitting (A) in place with a wrench to
keep it from moving and then tighten the hose nut (1).
: 50 N·m (36.9 ft.-lb)

b. Arm
7. Slowly loosen the hose (B).
8. Slowly pull the arm outward little by little until air bub-
bles no longer escape from the hose (B) connector.
9. Screw the hose (B) back on.
: 50 N·m (36.9 ft.-lb)

Slew motor and cylinder

1. Start the engine, and let it run at a low-idling speed
for 10 minutes.
2. With the engine left idling, extend and retract each
cylinder 4 or 5 times without letting any reach the
stroke end.
3. Slowly slew the machine to the left and right several
times.
4. Run the engine at high speed and then extend and
retract each cylinder 4 or 5 times without letting any
reach the stroke end.
5. Slew the machine to the left and right several times.
6. Return the engine speed to low idle and then extend
and retract each cylinder 4 or 5 times without letting
any reach the stroke end.

5
HYDRAULIC TANK 4H0AS00
 DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP (MAIN) 4
HYDRAULIC PUMP (MAIN)
Construction

04. Gear pump 156. Bushing 314. Valve plate L 535. Stopper S 774. Oil seal
05. PTO unit 157. Spring 401. Cap screw 548. Pin 789. Backup ring
111. Shaft 211. Shoe plate 402. Cap screw 702. O-ring 792. Backup ring
113. Shaft 212. Swash plate 406. Cap screw 710. O-ring 806. Nut
116. First gear 214. Bushing 466. Plug 711. O-ring 808. Nut
123. Bearing 251. Support 467. Plug 717. O-ring 824. Ring
124. Needle bearing 255. Pin 468. Plug 723. O-ring 886. Spring pin
127. Spacer 261. Cover 490. Plug 724. O-ring 901. Screw
141. Cylinder block 271. Casing F 531. Pin 727. O-ring 953. Adjusting screw
151. Piston 272. Casing R 532. Servo piston 728. O-ring 954. Adjusting screw
152. Seal 312. Block 533. Plug 732. O-ring 983. Pin
153. Plate 313. Valve plate R 534. Stopper L 733. O-ring

1
HYDRAULIC PUMP (MAIN) 4I0AS00
 DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP (MAIN) 4
Disassembly and assembly
The numbers in parentheses, ( ), listed after the names of
parts throughout this document are used to refer to the
same parts as the numbers listed in the construction di-
agram and parts lists.
General precautions
• Perform disassembly and assembly work in a clean
place. Provide clean containers to hold parts during
disassembly.
• Clean around the ports before disassembly. Remove
paint around connectors with a wire brush.
• Clean the disassembled parts with wash oil.
• Put alignment marks on all parts to ensure that they are
reassembled in the same positions.
• After each disassembly, replace all seals and apply a
thin layer of grease to each.
• Check each part for abnormal wear or seizing. Re-
move any burrs with sandpaper.
• Remove adhesive from screw holes that use adhesive
through the tap. Do not reuse mounting bolts or
screws.
• Do not use cloth gloves during assembly. Fibers from
the gloves could fall off and clog valves, etc., which
could cause parts to become faulty.
• During assembly, be sure to apply clean hydraulic oil
to all moving parts in and sliding parts that come into
contact with the hydraulic motor and valve parts be-
fore installing or attaching the part.
• Plug all ports once assembly has been completed in
order to prevent dust and dirt from entering.
• Do not attempt to adjust the adjusting screws at times
other than when necessary.

2
HYDRAULIC PUMP (MAIN) 4I0AS00
 DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP (MAIN) 4
Disassembly
1. Remove the plug (468), and all the oil to drain out
from the casings (271) and (272).
2. Take out the cap screws, and remove the regulator.

3. Take out the cap screws, and remove the PTO unit
(05).

4. Take out the cap screws, and remove the gear pump
(04).

3
HYDRAULIC PUMP (MAIN) 4I0AS00
 DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP (MAIN) 4
5. Take out the cap screws, and disassemble the cas-
ings (271) and (272) and the valve block (274).
6. Remove the first gear (116) from the valve block
(274).

7. Remove the cylinder block (141), the piston (151),

the shoe (152), the plate (153), the bushing (156),
and the spring (157) from the casings (271) and
(272).

8. Take out the cap screws, and remove the cover

(261).
• Insert a flat-bladed screwdriver into the notched
groove on the cover and use it to pry open the
cover to remove.
• Be careful not to damage the oil seal (774) for the
cover.

4
HYDRAULIC PUMP (MAIN) 4I0AS00
 DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP (MAIN) 4
9. Lightly tap on the rear ends of the shafts (111) and
(113) to remove the shafts from the casings (271)
and (272).

10. Remove the shoe plate (211) and swash plate (212)
from the casings (271) and (272).

11. Remove the pin (255) from the support (251).

• Push it out using a piece of wire or other object.
• When pushing the wire into the hole, make sure
not to confuse the pin insertion hole with the oil
supply line for the support.
• If the O-ring (728) has hardened, making it diffi-
cult to remove the pin, lightly tap the O-ring with a
hammer or other tool to loosen it.

12. Remove the valve plates (313) and (314) from the
block (312).

5
HYDRAULIC PUMP (MAIN) 4I0AS00
 DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP (MAIN) 4
Assembly
1. Attach the support (251) to the casings (271) and
(272).
2. Adjust the position of the pin groove on the support
(251).
3. Insert the pin (255).
• If the O-ring has hardened, making it difficult to in-
sert the pin, lightly tap the O-ring with a hammer
or other tool to loosen it.

4. Attach the swash plate (212) and the shoe plate

(211) to the support (251).
a. Attach the shoe plate (211) to the swash plate
(212).
b. Attach the bushing of the swash plate to the pin
(531).
• Using your fingers on both hands, check to en-
sure that the swash plate slides smoothly.
• Take care not to damage the sliding surfaces of
the shoe plate.
• Apply grease to sliding surfaces of the swash
plate (212), support (251), and shoe plate
(211).

5. Insert the shafts (111) and (127) into the casings

(271) and (272).

6
HYDRAULIC PUMP (MAIN) 4I0AS00
 DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP (MAIN) 4
6. Attach the cover (261) to the casing (271).
• The cover can be attached as is without grease
applied as there is grease on the oil seal (774) in-
side the cover.
• Take care not to damage the inner oil seal when
attaching the cover.
Cap screw: 21 N·m

7. Insert the piston (151), shoe (152), plate (153), bush-

ing (156), and spring (157) into the cylinder block
(141). (Cylinder block assembly.)
8. Slide the cylinder block assembly and guide (156)
onto the shaft (111), and insert the resultant assem-
bly into the casing.

9. Line up the valve plates (313) and (314) with the

spring pin (886) and insert them into the block (312).
• Take care not to confuse the intake and exhaust
directions on the valve plates.

7
HYDRAULIC PUMP (MAIN) 4I0AS00
 DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP (MAIN) 4
10. Position the pump parallel under the attachment sur-
face for the regulator.
11. Attach the first gear (116) to the block (312).
12. Affix the casings (271) and (272) and the block (312)
in place using cap screws.
• Attach the block so that the regulator is on top and
the intake flange is to the right as viewed from the
front.
Cap screw: 240 N·m

13. Install the gear pump (04).

Cap screw: 17 N·m

14. Insert the PTO unit (05) into the block (312).
• Be sure to insert the PTO unit in the proper direc-
tion.
Cap screw: 33 N·m

8
HYDRAULIC PUMP (MAIN) 4I0AS00
 DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP (MAIN) 4
15. Line up the pin (531) so that it fits into the feedback
lever on the regulator, and attach the regulator.
• Take care not to confuse the front and rear regu-
lators.
Cap screw: 29 N·m
16. Insert the plug (468).
Plug: 110 N·m

9
HYDRAULIC PUMP (MAIN) 4I0AS00
 DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP (MAIN) 4
Inspection and adjustment
Checking the parts

Item Criteria Action

Piston and cylinder block When the width of the clearance (S) between Replace
the piston and cylinder block assembly is above
0.056 mm (0.0022 in.)

D
d
When there is damage, scratches, abnormal
wear, or other problems present on the surfaces
S = D-d
of sliding parts
4I0AF22Z

Amount of looseness be- When the amount of looseness (S) between the Replace
tween the piston and piston and shoe is above 0.3 mm (0.011 in.)
shoe
Shoe thickness When the thickness (t) of the shoe is below Replace
3.7 mm (0.15 in.)

Spring When the free height of the spring is below Replace

40.3 mm (1.59 in.)

Plate and bushing as- When the height (H-h) of the assembled plate Replace
sembly and bushing is below 15. 8 mm (0.62 in.)

Seals, O-rings — During reassembly after parts disassembled Replace

Shafts and oil seals — When there is abnormal damage, wear, or sei- Replace
zure on relevant surfaces
Valve plate
Plate

10
HYDRAULIC PUMP (MAIN) 4I0AS00
 DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP (SUB) 4
HYDRAULIC PUMP (SUB)
Construction

1. Flange 9. Bushing
2. Rear cover 10. Bushing
3. Housing 11. Bushing
4. Drive gear 12. Gasket
5. Drive gear 13. Gasket
6. Driven gear 14. Oil seal
7. Driven gear 15. Snap ring
8. Bushing

1
HYDRAULIC PUMP (SUB) 4I1AS00
 DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP (SUB) 4
Disassembly and assembly
The numbers in parentheses, ( ), listed after the names of
parts throughout this document do not necessarily match
the numbers of the same parts listed in the construction
diagrams and parts lists. The numbers listed are for part
numbers used in illustrations.
General precautions
• Perform disassembly and assembly work in a clean
place. Provide clean containers to hold parts during
disassembly.
• Clean around the ports before disassembly. Remove
paint around connectors with a wire brush.
• Clean the disassembled parts with wash oil.
• Put alignment marks on all parts to ensure that they are
reassembled in the same positions.
• After each disassembly, replace all seals and apply a
thin layer of grease to each.
• Check each part for abnormal wear or seizing. Re-
move any burrs with sandpaper.
• Remove adhesive from screw holes that use adhesive
through the tap. Do not reuse mounting bolts or
screws.
• Do not use cloth gloves during assembly. Fibers from
the gloves could fall off and clog valves, etc., which
could cause parts to become faulty.
• During assembly, be sure to apply clean hydraulic oil
to all moving parts in and sliding parts that come into
contact with the hydraulic motor and valve parts be-
fore installing or attaching the part.
• Plug all ports once assembly has been completed in
order to prevent dust and dirt from entering.
• Do not attempt to adjust the adjusting screws at times
other than when necessary.

2
HYDRAULIC PUMP (SUB) 4I1AS00
 DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP (SUB) 4
Disassembly
1. Remove the cap screws
Cap screw: 88.2 N·m to 93.1 N·m

4IAB02Z

2. Remove the flange (1).

3. Remove the gasket (2) from the flange (1).
4. Remove the snap ring (3) and the oil seal (4) from the
flange (1).
• Be careful not to scratch or otherwise damage the
flange.
• When assembling, install the oil seal using the jigs
“A” and “B”.

4 1

4IAB04Z

3
HYDRAULIC PUMP (SUB) 4I1AS00
 DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP (SUB) 4
5. Remove the rear cover (5).
6. Remove the gasket (6) from the rear cover (5).

7. Disassemble the front pump.

a. Remove the bushing “A” (7), the bushing “B” (8),
the drive gear (9), and the driven gear (10) from
the housing.
• Be careful not to mix up the bushings.
• Be careful not to scratch or otherwise damage
the inner part of the housing.
8. Remove the gaskets (11) and (12) from the bushing
“A” (7) and the bushing “B” (8).

9. Disassemble the rear pump using the same proce-

dure as for the front pump.

Assembly
For assembly, refer to the construction diagram and re-
verse the disassembly procedure.

4
HYDRAULIC PUMP (SUB) 4I1AS00
 DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP (SUB) 4
Inspection and adjustment
Checking the parts
After checking the disassembled parts for dirt or discol-
oration, clean them with diesel fuel. However, do not let
diesel fuel get on rubber parts. Check each part for the
following points and if there is any trouble, repair or re-
place the part.

Housing
The gear pump is made so that the crests of the gear
teeth make light contact with the housing walls as a
means of increasing its efficiency. Therefore, contact
marks can be seen near the suction port in any pump that
has been operated. It is normal if the depth of the contact
marks is within 0.1 mm. If the depth exceeds the usage
limit in the above figure, replace the pump assembly.
SUCTION SIDE
ANSAUGSEITE
CÔTÉ D'ASPIRATION
A

DISCHARGE SIDE
CONTACT MARKS ABGABESEITE
KONTAKTMARKIERUNGEN COTE DECHARGE
MARQUES DE CONTACT 4IAB08Z 4IAB09Z

5
HYDRAULIC PUMP (SUB) 4I1AS00
 DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP (SUB) 4
Bushing
The ideal situation is for the sliding surfaces to have no
roughness and for the suction side half to be lustrous. Al-
so, it is satisfactory if strong contact marks can be seen
on the side surface on the suction side and minute con-
tact marks can be seen on the discharge side.
Replace the bushing if it is in the following condition.
• Contact marks can be seen on the sliding surface of
the entire bearing inner diameter and it is rough with
scratches that easily catch a fingernail.
• There are many scratches around the circumference
of the side surface and it is rough with scratches that
easily catch a fingernail.
• There are marks due to trapping of foreign matter on
the sliding surface of the bearing inner diameter and
the side surface.
Dirty hydraulic oil is one likely cause of such wear. In
such a case, replace the hydraulic oil and flush out the
affected hydraulic circuit completely.
Other likely causes are as follows.
• There is excessive load caused by damage to the re-
lief valve.
• There is cavitation or aeration.
• The hydraulic oil temperature is too high.
• The hydraulic oil is deteriorated.
• The viscosity of the hydraulic oil is too low.
If it becomes necessary to replace the bushings, it
means that the gear shaft and gear side surfaces are
also rough or worn severely, and the gears will thus also
need to be replaced at the same time as the bushings.
The dimensions for the bushing use limit are shown in the
figure on the right.

Gear
Replace any gear that is found to be in any of the below
conditions.
1. The shaft or gear side surfaces are rough with
scratches that can become easily caught on a finger-
nail.
2. There are cracks in the tooth roots or extremely ab-
normal wear to the tooth surfaces.
The shaft size for the gear use limit is shown in the figure
above.

6
HYDRAULIC PUMP (SUB) 4I1AS00
 DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP (SUB) 4
Seals
• Check oil seals for scratches in the seal surface, wear,
deformation, or deterioration of the rubber’s elasticity.
If any such problems are found, replace the faulty part.
• Replace the seals whenever the hydraulic pump is dis-
assembled.
• Check the backup ring for scaling and cutting. If any
such problems are found, replace the faulty part.

Test operation
The best method for testing pump operation is to mount
the pump under test onto a test stand. However, if it is not
possible to do so, use an actual machine in which the
pump to be tested is mounted.
If any abnormal wear is discovered during disassembly,
be sure to replace the hydraulic oil and return filter.
1. Insert a pressure gauge into the high-pressure pip-
ing near the pump.
2. Run the engine at 500 min-1 to 1000 min-1, and set
the control valve to the neutral position.
3. Run the pump for 10 minutes under the conditions
listed in 2 above, and increase the engine speed to
1500 min-1 to 2000 min-1 and then let the engine run
for another 10 minutes.
4. Next, run the pump for 5 minutes at a time for each
additional 1.96 MPa to 2.94 MPa of pressure until it
reaches the rated pressure.
After operating each circuit for about 5 minutes, replace
the return filter or clean it.
During the process of raising the pressure, pay careful
attention to the oil temperature, the pump surface tem-
perature, and the operating noise. If the oil temperature
or the pump surface temperature becomes abnormally
high, eliminate the load from the pump and let the tem-
perature drop before resuming the test.

Measuring the discharge volume

After completing the test operation, measure the dis-
charge volume.
1. Connect a tester (1) to the discharge side of the
pump (2). 2 1
• Be sure to connect the tester to the proper side.
2. Open the loading valve on the tester, and start the
engine.
3. Run the engine at the rated speed.
4. Gradually close the loading valve and apply the rat-
ed pressure to the pump (2).
5. Measure the discharge volume and the pump engine 4IAB10Z

speed in rpm.

7
HYDRAULIC PUMP (SUB) 4I1AS00
 DISASSEMBLY AND ASSEMBLY
CONTROL VALVE 4
CONTROL VALVE
Construction

1
CONTROL VALVE 4J0AS00
 DISASSEMBLY AND ASSEMBLY
CONTROL VALVE 4

2
CONTROL VALVE 4J0AS00
 DISASSEMBLY AND ASSEMBLY
CONTROL VALVE 4

3
CONTROL VALVE 4J0AS00
 DISASSEMBLY AND ASSEMBLY
CONTROL VALVE 4

4
CONTROL VALVE 4J0AS00
 DISASSEMBLY AND ASSEMBLY
CONTROL VALVE 4
1 Arm 1
2 Boom 2
3 Slew
4 1st auxiliary line
5 Travel (R)
6 2nd auxiliary line
7 Blade
8 Swing
9 Arm 2
0 Boom 1
a Bucket
b Travel (L)
c Travel forward

1. O-ring 19. Plug 37. Spool end 53. Cap screw

2. O-ring 20. Plug 38. Cap 54. Cap screw
3. O-ring 21. Poppet 39. Cap 55. Cap screw
4. O-ring 22. Spring 40. Plug 56. Plug
5. O-ring 23. Poppet 41. Orifice 57. Plug assembly
6. O-ring 24. Poppet 42. Cap 58. Bolt
7. Backup ring 25. Spring 43. Relief valve 59. Nut
8. O-ring 26. Spacer (Negative control) 60. Bolt
9. O-ring 27. Anti-drift valve 44. Orifice 61. Nut
10. O-ring 28. Plug assembly 45. Poppet 62. Swing section
11. Cap 29. Sleeve 46. Spring 63. Inlet housing
12. Cap 30. Poppet 47. Outlet housing 64. Main relief valve (Pr)
13. Cap 31. Spring 48. Main relief valves 65. 2nd auxiliary line section
14. Poppet 32. Poppet (P1, P2) 66. Plug assembly
15. Spring 33. Spring 49. Port relief valve 67. Blade section
16. Plug 34. Flange 50. Port relief valve
17. Plug assembly 35. Spring holder 51. Port relief valve
18. Plug assembly 36. Spring 52. Cap screw

5
CONTROL VALVE 4J0AS00
 DISASSEMBLY AND ASSEMBLY
CONTROL VALVE 4
Swing section

1. Spool
2. Cap
3. O-ring
4. Cap
5. Poppet
6. Spring
7. O-ring
8. Plug
9. O-ring
10. O-ring

Blade section

1. Spool
2. Cap
3. O-ring
4. Cap
5. Poppet
6. Spring
7. O-ring
8. Plug
9. O-ring
10. O-ring

2nd auxiliary line section

1. Spool
2. Cap
3. O-ring
4. Cap
5. Poppet
6. Spring
7. O-ring
8. Plug
9. O-ring
10. O-ring

6
CONTROL VALVE 4J0AS00
 DISASSEMBLY AND ASSEMBLY
CONTROL VALVE 4
Main relief valves (P1, P2)

2 3 7 4 5 6 10 1 11 13 14

1. Plug 8. O-ring
2. Sleeve 9. Backup ring
3. Main poppet 10. O-ring
4. Piston 11. O-ring
5. Needle valve 12. Set screw
6. Spring 13. Washer
8 9 12
N0D207 7. Spring 14. Nut

Main relief valve (Pr)

1. Plug 8. O-ring
2. Sleeve 9. Backup ring
3. Main poppet 10. O-ring
4. Piston 11. O-ring
5. Needle valve 12. Set screw
6. Spring 13. Washer
7. Spring 14. Nut

Port relief valve

5 3 7 16 6 1 8 9 13 12 10
1. Housing 10. Set screw
2. Plug 11. Washer
3. Poppet 12. Nut
4. Poppet 13. O-ring
5. Piston 14. O-ring
6. Needle valve 15. Backup ring
7. Spring 16. O-ring
8. Spring 17. O-ring
4 18 17 14 15 2 11
N0D208 9. Spring 18. Backup ring

7
CONTROL VALVE 4J0AS00
 DISASSEMBLY AND ASSEMBLY
CONTROL VALVE 4
Relief valve (Negative control)

2 4 3 1

1. Plug
2. Sleeve
3. O-ring
N0D209 4. O-ring

Anti-drift valve

14 3 4 5 7 13 11 10 9 12 6 1

15
1. Body 9. O-ring
8
2. Poppet 10. O-ring
3. Plug 11. Backup ring
2
4. Piston 12. Backup ring
5. Spool 13. O-ring
6. Sleeve 14. Plug
7. Spring 15. Spring seat
N0D210
8. Spring

8
CONTROL VALVE 4J0AS00
 DISASSEMBLY AND ASSEMBLY
CONTROL VALVE 4
Disassembly and assembly

WARNING
• Be careful as the springs and spring seat may pop out
when the caps are removed.
• Oil may spurt out if caps or filters are removed or pipes
are disconnected before the pressure in the hydraulic
system is released.

The numbers in parentheses, (), listed after the names of

parts throughout this document do not necessarily match
the numbers of the same parts listed in the construction
diagrams and parts lists. The numbers listed are for part
numbers used in illustrations.
General precautions
• Perform disassembly and assembly work in a clean
place. Provide clean containers to hold parts during
disassembly.
• Clean around the ports before disassembly. Remove
paint around connectors with a wire brush.
• Clean the disassembled parts with wash oil.
• Put alignment marks on all parts to ensure that they are
reassembled in the same positions.
• After each disassembly, replace all seals and apply a
thin layer of grease to each.
• Check each part for abnormal wear or seizing. Re-
move any burrs with sandpaper.
• Remove adhesive from screw holes that use adhesive
through the tap. Do not reuse mounting bolts or
screws.
• Do not use cloth gloves during assembly. Fibers from
the gloves could fall off and clog valves, etc., which
could cause parts to become faulty.
• During assembly, be sure to apply clean hydraulic oil
to all moving parts in and sliding parts that come into
contact with the hydraulic motor and valve parts be-
fore installing or attaching the part.
• Plug all ports once assembly has been completed in
order to prevent dust and dirt from entering.
• Do not attempt to adjust the adjusting screws at times
other than when necessary.

9
CONTROL VALVE 4J0AS00
 DISASSEMBLY AND ASSEMBLY
CONTROL VALVE 4
Disassembly
1. Remove the main relief valves P1, P2 (1) and the
main relief valve Pr (2) and then remove the O-rings
from the valves.
Valve (1): 78 N·m to 88 N·m
Valve (2): 49 N·m to 59 N·m
2
2. Remove the relief valves [Negative control] (3) and 3
then remove the O-rings from the valves.
Valve: 103 N·m to 113 N·m
3. Remove the port relief valves (4) and then remove
the O-rings from the valves.
• Do not disassemble the relief valves unless abso-
4
lutely necessary. 1 N0D230

Valve (1): 78 N·m to 88 N·m

4. Take out the plug (6), and remove the spring (7) and 8 7 6
poppet (8).
Plug: 103 N·m to 113 N·m

8 7 6
N0D231

5. Disassemble the travel section and travel forward 8 7 6

section.
a. Take out the plug (6), and remove the spring (7)
and poppet (8).
Plug: 103 N·m to 113 N·m

N0D232

10
CONTROL VALVE 4J0AS00
 DISASSEMBLY AND ASSEMBLY
CONTROL VALVE 4
b. Take out the cap screws, and remove the covers
(11) and (12).
11
Cap screws: 20 N·m to 25 N·m 13 9
c. Remove the O-rings from the housing.
d. Remove the spool assemblies (11) and (12).
e. Take out the cap screws, and remove the covers
(13) and (14).
Cap screws: 20 N·m to 25 N·m
f. Remove the O-rings from the housing.

14 10
12 N0D233

g. Take out the cap screws (44), and remove the

spool. 44
• In order to keep the spool from becoming dam-
aged, secure it in place between two plates. 45
• Loctite compound has been applied to the
screw threads. Heat the screws to about 200°C 46
(392°F) to loosen the compound in order to re-
move the screws. 45
Cap screws: 9.8 N·m to 11.8 N·m
h. Remove the spring holder (45), and take out the
spring (46) and spring holder (45).

N0D245

6. Disassemble the 1st auxiliary line section and travel 17 16 15

section.
a. Take out the plug (15), and remove the spring (16)
and poppet (17).
Plug: 103 N·m to 113 N·m
b. Take out the plug (6), and remove the spring (7)
and poppet (18).
Plug: 103 N·m to 113 N·m

18 7 6
N0D234

c. Remove the covers (9) and (13), and take out the
spools (19) and (20).
19
“Disassembling the travel and forward travel
9
sections” 13

20 N0D235

11
CONTROL VALVE 4J0AS00
 DISASSEMBLY AND ASSEMBLY
CONTROL VALVE 4
7. Disassemble the slew and bucket sections. 8 7 6
a. Take out the plug (6), and remove the spring (7)
and poppet (8).
Plug: 103 N·m to 113 N·m

8 7 6
N0D236

b. Remove the covers (9) and (13), and take out the
spools (21) and (22).
21
“Disassembling the travel and forward travel 13 9
sections”

22 N0D237

8. Disassemble the boom 1 and boom 2 sections. 8 7 6

a. Take out the cap screws, and remove the anti-drift
valve (23).
Cap screws: 20 N·m to 25 N·m
b. Take out the spacer (24), and remove the O-ring
and backup ring from the spacer (24).
• Insert a bolt (M6×1.0) into the screw hole on the
spacer and tighten it all the way down as far as
it will go and then grip the bolt with fingers and
remove it. 23
c. Remove the spring (25) and the poppet (26). 8 7 6
d. Take out the plug (6), and remove the spring (7) 26 25 24
N0D238
and poppet (8).
Plug: 103 N·m to 113 N·m
e. Remove the covers (9) and (13), and take out the
spools (27) and (28).
27
“Disassembling the travel and forward travel 9
13
sections”

28 N0D239

12
CONTROL VALVE 4J0AS00
 DISASSEMBLY AND ASSEMBLY
CONTROL VALVE 4
9. Disassemble the arm 1 and arm 2 sections.
26 25 24
a. Remove the anti-drift valve (23), and take out the 23
spacer (24), spring (25), and poppet (26).
“Disassembling the boom 1 and boom 2 sec-
tions”

N0D240

b. Take out the plug (6), and remove the spring (7)
and poppet (8).
8 7 6
Plug: 103 N·m to 113 N·m
c. Take out the cap screws, and remove the flange
(29).
Cap screws: 39 N·m to 44 N·m
d. Remove the O-rings from the housing.
e. Take out the sleeve (30), and remove the springs
(31) and (32).
f. Remove the poppets (33) and (34).

30
33 32 34 31 29 N0D241

g. Remove the covers (9) and (13), and take out the
spools (35) and (36). 35
“Disassembling the travel and forward travel 13 9
sections”

36 N0D242

10. Take out the plug (37), and remove the O-ring from
41 40 39 38
the plug.
Plug: 103 N·m to 113 N·m 37
11. Remove the spring (38) and spool (39).
12. Remove the sleeve (40) and the piston (41).
13. Remove the O-rings and backup rings from the
sleeve (40).

N0D243

13
CONTROL VALVE 4J0AS00
 DISASSEMBLY AND ASSEMBLY
CONTROL VALVE 4
14. Take out the cap screws, and remove the cover.
15. Remove the O-rings from the housing.
16. Remove the spool assembly (43).

42 43

N0D244

17. Disassemble the spool. 47

• In order to keep the spool from becoming dam-
aged, secure it in place between two plates. 48
• Loctite compound has been applied to the screw
threads. Heat the screws to about 200°C (392°F)
to loosen the compound in order to remove the 49
screws.
a. Remove the screws (47), and take out the spool. 48
b. Remove the spring holder (48), and take out the
spring (49) and spring holder (48).

N0D246

18. Take out the cap screws, and remove the cover (20).
Cap screws: 8.8 N·m to 10.8 N·m
19. Remove the O-rings from the housing. 50
20. Remove the spool assembly (51).
21. Disassemble the spool.
“17. Disassemble the spool.”

51
N0D247

22. Take out the plug (52), and remove the spring (53)
and poppet (54).
Plug: 73 N·m to 79 N·m 52
53

54

N0D248

14
CONTROL VALVE 4J0AS00
 DISASSEMBLY AND ASSEMBLY
CONTROL VALVE 4
Add-on sections (Swing, blade, auxiliary lines)
1. Take out the nuts (1) and (2), and remove the speci-
fied sections.
1 2
Nut (1): 145 N·m to 159 N·m
Nut (1): 89 N·m to 97 N·m

N0D249

2. Take out the plug (3), and remove the spring (4) and
poppet (5). 3
Plug: 103 N·m to 113 N·m

N0D250

3. Take out the cap screws, and remove the cover (6).
Cap screws: 20 N·m to 25 N·m
4. Remove the O-rings from the housing. 7
5. Remove the spool assembly. 6

N0D251

6. Take out the cap screws, and remove the cover (8).
Cap screws: 20 N·m to 25 N·m

N0D252

15
CONTROL VALVE 4J0AS00
 DISASSEMBLY AND ASSEMBLY
CONTROL VALVE 4
Anti-drift valve
1. Take out the plug (1), and remove the O-ring.
Plug: 147 N·m to 157 N·m
2. Remove the piston (2), spool (3), and spring (4).
4
3
2
1

N0D254

3. Take out the plug, and remove the O-ring.

Plug: 147 N·m to 157 N·m
13
4. Take out the sleeve (6), and remove the O-rings (8) 12
and (9) and backup rings (10) and (11) from the 7
11
sleeve (6).
10 89
• Make sure to attach the O-rings and backup rings
in the proper places during assembly. Failure to
6
do so may cause the boom to drop. 5
5. Remove the poppet (7), spring seat (12), and spring
(13).

N0D255

16
CONTROL VALVE 4J0AS00
 DISASSEMBLY AND ASSEMBLY
CONTROL VALVE 4
Main relief valves
1. Remove the plug assembly (1), sleeve (2), spring (3),
and main poppet (4).
• The pilot seating is caulked to the end of the plug
and thus cannot be disassembled.
2. Take out the lock nut (5), and remove the washer (6)
and set screw (7) from the plug assembly.
• During assembly, after adjusting the set screw,
tighten the lock nut all the way down as far as it
can be.
3. Remove the spring (8) and valve (9) from the plug as-
sembly (1).
4. Remove the O-ring (10), backup ring (11), and O-
ring (12) from the plug assembly (1).

Assembly
For assembly, refer to the construction diagram and re-
verse the disassembly procedure.

17
CONTROL VALVE 4J0AS00
 DISASSEMBLY AND ASSEMBLY
CONTROL VALVE 4
Inspection and adjustments
Inspection

Part Criteria Action

Housing, • If there are scratches, rust, or corrosion present on the parts that • Replace
Valve body make sliding contact with the spool
• If there are scratches, rust, or corrosion present on the seal pockets • Replace
of sections into which the spool enters
• If there are scratches, rust, or corrosion of the seal part of the port in • Replace
contact with the O-ring
• If there are scratches, rust, or corrosion in the seal part of the relief • Replace
valve, etc.
• If there is other damage present that is thought to impair normal op- • Replace
eration of the machine
Spool • If there is scratching on the outer sliding surfaces that are rough • Replace
enough to be caught on a fingernail
• If there is scratching on sliding surfaces on the end seals • Replace
• If the spool does not move smoothly enough • Repair or replace
Load check • If the sealing is faulty due to breakdown of the valve or spring • Repair or replace
valve • If insertion and movement within the housing moves smoothly without • Normal
any parts becoming caught
Spring and re- • If there is noticeable rust, corrosion, deformation, or breakage of the • Replace
lated parts, springs, holder, or cover
sections
Spool seals and • If there is leakage to external • Repair or replace
related parts, • If there is rust, corrosion, or deformation in the seal holder • Repair or replace
sections
Main relief • If there is rust or damage on the external surfaces of the parts • Replace
valves, port re- • If there is damage on surfaces that make contact with the valve • Replace
lief valves, anti- seating
cavitation valve • If there is damage on surfaces that make contact with the poppet • Replace
• If the spring is damaged or otherwise abnormal • Replace
• For O-rings, backup rings, and seals • Replace after disassem-
bly as a general rule

Adjustment
Adjusting the main relief valve pressure
“2. Service data, Performance criteria”

18
CONTROL VALVE 4J0AS00
 DISASSEMBLY AND ASSEMBLY
PILOT VALVE 4
PILOT VALVE
Construction

1. Washer 10. Plug 19. Nut

2. O-ring 11. Rod 20. Lever
3. Seal 12. Holder 21. Handle
4. O-ring 13. Washer 22. Spring pin
5. Plate 14. Spring 23. Boot
6. Cap screw 15. Spring 24. Casing
7. Spring pin 16. Joint 25. Spool
8. Bushing 17. Plate
9. Plate 18. Nut

1
PILOT VALVE 4K2AS00
 DISASSEMBLY AND ASSEMBLY
PILOT VALVE 4
Special tools
Figures in diagrams are given in mm.

Installation jig A
Quantity: 1
Material A: S45C
Material B: SCM415N (Carburizing hardening)

Installation jig B
Quantity: 2
Material B: SCM415N (Carburizing hardening)

Disassembly and assembly

The numbers in parentheses, (), listed after the names of
parts throughout this document are used to refer to the
same parts as the numbers listed in the construction di-
agram and parts lists.
General precautions
• Perform disassembly and assembly work in a clean
place. Provide clean containers to hold parts during
disassembly.
• Clean around the ports before disassembly. Remove
paint around connectors with a wire brush.
• Clean the disassembled parts with wash oil.
• Put alignment marks on all parts to ensure that they are
reassembled in the same positions.
• After each disassembly, replace all seals and apply a
thin layer of grease to each.
• Check each part for abnormal wear or seizing. Re-
move any burrs with sandpaper.
• Remove adhesive from screw holes that use adhesive
through the tap. Do not reuse mounting bolts or
screws.
• Do not use cloth gloves during assembly. Fibers from
the gloves could fall off and clog valves, etc., which
could cause parts to become faulty.
• During assembly, be sure to apply clean hydraulic oil
to all moving parts in and sliding parts that come into
contact with the hydraulic motor and valve parts be-
fore installing or attaching the part.
• Plug all ports once assembly has been completed in
order to prevent dust and dirt from entering.
• Do not attempt to adjust the adjusting screws at times
other than when necessary.

2
PILOT VALVE 4K2AS00
 DISASSEMBLY AND ASSEMBLY
PILOT VALVE 4
Disassembly
1. Disconnect the electrical wiring from the handle (21).
2. Remove the boot (23) and the handle (21).
3. Take out the nut (18), and remove the plate (17).
• Place the valve in a vice and secure it using a
copper or lead plate.

4. Take out the joint (16), and remove the plate (9).
• Use the installation jigs A and B.

• Take care as the plugs (10) may start to come out.

5. Remove the plugs (10) from the casing (24), and re-
move the rods (11) from the plugs (10).
• Use a flat-bladed screwdriver to remove the plugs
if they cannot be pried out by hand.
• Take care as the plugs may pop out due to spring
pressure.

3
PILOT VALVE 4K2AS00
 DISASSEMBLY AND ASSEMBLY
PILOT VALVE 4
6. Remove the seals (3) and O-rings (4) from the plugs
(10).

7. Remove the reducing valves and the springs (14)

from the casing (24).
• Keep a record to indicate which hole on the cas-
ing (24) that the reducing valves came out of to
ensure that each valve can be returned to its
same hole during reassembly.

8. Disassemble the reducing valve.

a. Push in the holder (12) to compress the spring
(15) in order to move the spool (25) from the small
hole side to the large hole side of the holder (12).
• The holder is not to be pushed down by more
than 6 mm (0.24 in.).

b. Remove the holder (12), spring (15), and washer

(13) from the spool (25).

4
PILOT VALVE 4K2AS00
 DISASSEMBLY AND ASSEMBLY
PILOT VALVE 4
9. Take out the cap screws (6), and remove the plate
(5) from the casing (24).
• Replace any washers as they cannot be reused.

10. Remove the O-ring (2) and bushing (8) from the cas-
ing (24).

5
PILOT VALVE 4K2AS00
 DISASSEMBLY AND ASSEMBLY
PILOT VALVE 4
Assembly
1. Attach the bushing (8) and O-ring to the casing (24).

2. Use the cap screws (6) and washers (1) to attach the
plate (5) to the casing (24).
• Make sure to replace the old washers with new
ones as they cannot be reused.
Cap screw: 20.6 N·m ± 1.5 N·m

3. Assemble the reducing valve.

a. Attach the washer (13), spring (15), and holder
(12) to the spool (25).

b. Push in the holder (12) to compress the spring

(15) in order to move the spool (25) from the large
hole side to the small hole side of the holder (12).
• The holder is not to be pushed down by more
than 6 mm (0.24 in.).

6
PILOT VALVE 4K2AS00
 DISASSEMBLY AND ASSEMBLY
PILOT VALVE 4
4. Insert each of the springs (16) and reducing valves
back into the same holes on the casing from which
they were removed before disassembly.

5. Attach the O-ring (4) and seal (3) to the plug (10).

6. Attach the rods (11) to the plugs (10).

• Apply lubricating oil to the rods.

7. After inserting the plugs (10) and attaching the plate

(17), attach the joint (16).
• Use the installation jigs A and B to attach the joint.
Joint: 47.1 N·m ± 2.9 N·m

7
PILOT VALVE 4K2AS00
 DISASSEMBLY AND ASSEMBLY
PILOT VALVE 4
8. Use the nut (18) to affix the plate (17).
• Tighten the nut (18) to the point where plate con-
tacts all four rods uniformly.
• Do not allow the plate to move when tightening the
nut.
Nut: 68.6 N·m ± 4.9 N·m

9. Apply grease to the rotating parts on the joint (16)

and to the contact surfaces of the plate (17) and rods
(11).
10. Attach the handle (24) to the boot (23) and then at-
tach the boot (23).

8
PILOT VALVE 4K2AS00
 DISASSEMBLY AND ASSEMBLY
PILOT VALVE 4
Inspection and adjustments
Inspection

Part Criteria Action

O-rings — • Replace
Seals — • Replace
Spool • When the wear on the sliding portions is 10 μm (0.0004 in.) or greater • Replace
compared to non-sliding portions
• When there are scratches present on the sliding portions • Replace
• If the spool does not move smoothly enough • Replace
Rods • If the front end is worn by 1 mm (0.04 in.) or more • Replace
• When there are scratches present on the sliding portions • Replace
Plugs • If the seal has become imperfect due to damage • Repair or replace
Controls • If the pin, shaft, or joint of the controls exhibits looseness of 2 mm • Tighten to the specified
(0.08 in.) or more torque
• If the pin, shaft, or joint of the controls exhibits looseness of 2 mm • Replace
(0.08 in.) or greater due to wear, etc.
Casing, plate • If there are scratches, rust, or corrosion present on the parts that • Replace
make sliding contact with the spool
• If there are scratches, rust, or corrosion on any parts of the seal that • Repair or replace
make contact with the O-ring

9
PILOT VALVE 4K2AS00
 DISASSEMBLY AND ASSEMBLY
PILOT VALVE (SWING, BLADE) 4
PILOT VALVE (SWING, BLADE)
Construction

16 13 15 14

12
11

10

4K4AF01Z

1. Casing 7. Shim 13. Shaft

2. Cover 8. Spool 14. Bushing
3. Plug 9. Spring seat 15. Cam
4. Seal 10. Washer 16. Ball
5. O-ring 11. Spring
6. Push rod 12. Spring

1
PILOT VALVE (SWING, BLADE) 4K3AQ00
 DISASSEMBLY AND ASSEMBLY
PILOT VALVE (SWING, BLADE) 4
Special Jigs
(for bushing removal)

Disassembly and Assembly

General Precautions
• Perform disassembly and assembly work in a clean

Ø8 -0.2
-0.3
-0.3
-0.4
place. Provide clean containers to hold parts during 30
°

Ø10
disassembly.
• Clean around the ports before disassembly. Remove 20 2
paint around connectors with a wire brush.
• Clean the disassembled parts with wash oil. 30
• Put alignment marks on all parts to reassemble them in
the same positions. 4K5AF02Z

• After each disassembly, replace all seals and apply a

thin layer of grease to them.
• Check each part for abnormal wear or seizing. Re-
move any burrs with sandpaper.
• Do not move adjusting screws, unless absolutely nec-
essary.

Disassembly

WARNING
The spring may fly out during disassembly. Refer to the
construction diagram and take precautions.

1. Insert a cushion plate between the pilot valve and the

vise, and fasten the pilot valve.
• Pull the bellows upward to remove it from the cov-
er.

4K4AF02Z

2. Remove the cap screw with an Allen key.

• Be aware that a high torque is required to loosen
this screw.

4K4AF03Z

2
PILOT VALVE (SWING, BLADE) 4K3AQ00
 DISASSEMBLY AND ASSEMBLY
PILOT VALVE (SWING, BLADE) 4
3. Place a steel bar (7 mm dia. max.) against the cam
shaft and tap it lightly with a hammer.

4K4AF04Z

4. Remove the cam.

• Treat the cam and ball as an integral assembly
(that cannot be taken apart).
• Record the positional relationship between the
cam and the cover.

4K4AF05Z

5. Remove the cap screws with an Allen key.

4K4AF06Z

6. Remove the cover.

• Record the positional relationship between the
cam and the casing.

4K4AF07Z

3
PILOT VALVE (SWING, BLADE) 4K3AQ00
 DISASSEMBLY AND ASSEMBLY
PILOT VALVE (SWING, BLADE) 4
7. Remove each plugs with the push rod, packing and
O-ring.
• Record the positional relationship between the
plugs and the casing.

4K4AF08Z

8. Remove the pressure reducing valve assemblies

and the return springs from the casing.
• Record their positional relationships with the cas-
ing holes.

4K4AF09Z

4K4AF10Z

9. Lay the cover sideways on a flat surface. Place the

special jig against the bushing and tap it lightly with
a hammer to remove the bushing.

4K4AF11Z

4
PILOT VALVE (SWING, BLADE) 4K3AQ00
 DISASSEMBLY AND ASSEMBLY
PILOT VALVE (SWING, BLADE) 4
10. To disassemble the pressure reducing valve, push
down the spring seat to compress the secondary
pressure spring. At the same time, move the spring
seat sideways and pull out the spool through the
larger hole.
• Take care not to scratch the spool surface.
• Do not push down the spring seat more than 4
mm.
• During re-assembly, assemble the parts above as
a set.

4K4AF12Z

11. Separate the spool, secondary pressure spring,

shim and washer.
• During re-assembly, assemble the parts above as
a set.
• The washer adjusts the preset value of the sec-
ondary pressure spring. The washer thickness
differs for each spool assembly. In some cases
this washer is omitted.

4K4AF13Z

12. Remove the push rod from the plug.

4K4AF14Z

13. Remove the packing from the plug.

• Use a small flat head screwdriver to remove the
packing.
• Take care not to scratch the inner surface of the
plug.

4K4AF15Z

5
PILOT VALVE (SWING, BLADE) 4K3AQ00
 DISASSEMBLY AND ASSEMBLY
PILOT VALVE (SWING, BLADE) 4
14. Remove the O-ring from the plug.

4K4AF16Z

6
PILOT VALVE (SWING, BLADE) 4K3AQ00
 DISASSEMBLY AND ASSEMBLY
PILOT VALVE (SWING, BLADE) 4
Assembly
1. In sequence, install the washer, shim, secondary
pressure spring and spring seat onto the spool.
• The washer adjusts the preset value of the sec-
ondary pressure spring. The washer thickness
differs for each spool assembly. In some cases
this washer is omitted.

4K4AF17Z

2. Insert the spool through the larger hole of the spring

seat. Push down the spring seat to compress the
secondary pressure spring and move the spring seat
sideways to install it.
• Take care not to scratch the spool surface.
• Do not push down the spring seat more than 4
mm.

4K4AF18Z

3. Fasten the casing in a vice.

• Install the return springs in the casing.
• Install them in the positions they were in before
disassembly.

4K4AF19Z

4. Install the pressure reducing valve sub-assemblies

in the casing.
• Install them in the positions they were in before
disassembly.
• When installing the pressure reducing valve sub-
assemblies, do not allow the lower end of the
spools to hit hard against the corners of the cas-
ing.

4K4AF20Z

7
PILOT VALVE (SWING, BLADE) 4K3AQ00
 DISASSEMBLY AND ASSEMBLY
PILOT VALVE (SWING, BLADE) 4
5. Attach the O-ring to the plug.

4K4AF21Z

6. Insert the packing in the plug.

• Insert the packing in the correct orientation.
• Apply a thin layer of grease to the packing before
inserting it.

4K5AF36Z

4K4AF22Z

7. Insert the push rod into the plug.

• Apply hydraulic oil to the push rod before installa-
tion.
• Do not force in the push rod hard enough to dam-
age the packing lip.

4K4AF23Z

8. Install the push rod sub-assemblies assembled at

step 7 above into the casing.

4K4AF24Z

8
PILOT VALVE (SWING, BLADE) 4K3AQ00
 DISASSEMBLY AND ASSEMBLY
PILOT VALVE (SWING, BLADE) 4
9. Lay the cover sideways on a flat surface. Place the
special jig against the bushing and tap it lightly with
a hammer to press-fit the bushing into the cover.
• Ensure that the end of the bushing does not pro-
trude into the inside of the cover.

4K4AF11Z

10. Attach the cover to the casing.

• Install it in the same position as before disassem-
bly.
• Make sure that the cover is not lifted by the return
springs.

4K4AF25Z

11. Tighten the cap screws to the specified torque.

• Ensure that the cover is level.
Cap screw: 8.8 ± 0.1 N·m

4K4AF26Z

12. Attach the cam to the cover.

• Install it in the same position as before disassem-
bly.

4K4AF27Z

9
PILOT VALVE (SWING, BLADE) 4K3AQ00
 DISASSEMBLY AND ASSEMBLY
PILOT VALVE (SWING, BLADE) 4
13. Insert the cam shaft while holding down the cam.
Apply grease to the sliding surfaces of the cam
shaft bearing.

4K4AF28Z

14. Apply Loctite to the cap screw.

Cap screw: Loctite #241, or equivalent.

4K4AF29Z

15. Tighten the cap screw to the specified torque.

Cap screw: 6.9 ± 1.0 N·m

4K4AF30Z

16. Tilt the cam and apply grease to the top of the push
rods.
Apply the grease with a soft spatula to avoid
scratching the surfaces of the push rods or
plugs.

4K4AF31Z

10
PILOT VALVE (SWING, BLADE) 4K3AQ00
 DISASSEMBLY AND ASSEMBLY
PILOT VALVE (SWING, BLADE) 4
17. Engage the top of the bellows with the cam, and in-
sert the bottom of the bellows into the groove in the
cover.
• Before inserting the bottom of the bellows into the
groove in the cover, spray the inside of the bel-
lows with rust-inhibiting oil.
• Be sure to attach the bellows correctly. The dust-
proof and waterproof properties will be compro-
mised if the bellows is not firmly inserted into the
groove or is twisted in the groove.

4K4AF32Z

4K4AF33Z

11
PILOT VALVE (SWING, BLADE) 4K3AQ00
 DISASSEMBLY AND ASSEMBLY
PILOT VALVE (SWING, BLADE) 4
Inspection and adjustment
Checking the parts

Part Criteria Action

O-ring — • Replace
Seal — • Replace
Spool • Wear on the sliding surfaces is 10 μm or more than the non-sliding • Replace
surfaces.
• Scratches on the sliding surfaces • Replace
• Spool does not move smoothly. • Replace
Push rod • Tip is worn 1 mm or more • Replace
• Scratches on the sliding surfaces • Replace
Plug • Imperfect sealing due to damage • Repair or replace
Controls • Looseness in the pin, shaft or joint of the controls results in 2 mm • Tighten to the specified
play, or more. torque
• Wear of the pin, shaft or joint of the controls results in 2 mm play, or • Replace
more.
Casing, port • Scratches, rust, or corrosion at the parts in sliding contact with the • Replace
plate spool.
• Scratches, rust, or corrosion of the seal area in contact with the O- • Repair or replace
ring

12
PILOT VALVE (SWING, BLADE) 4K3AQ00
 DISASSEMBLY AND ASSEMBLY
PILOT VALVE (TRAVEL) 4
PILOT VALVE (TRAVEL)
Construction

Loctite #241

1. Casing 9. O-ring 17. Cap screw 25. Bushing

2. Casing 10. Push rod 18. Spool 26. Shaft
3. Cover 11. Washer 1 19. Spring seat 27. Cam
4. Plug 12. Washer 2 20. Washer 3 28. Cap screw
5. Grease cup 13. Spring seat 21. Spring 29. Screw
6. Seal 14. Cap screw 22. Spring 30. Nut
7. O-ring 15. Piston 23. Spring 31. Boot
8. O-ring 16. Ball 24. Spring

1
PILOT VALVE (TRAVEL) 4K3AQ01
 DISASSEMBLY AND ASSEMBLY
PILOT VALVE (TRAVEL) 4
Disassembly and Assembly
The numbers in parentheses () listed after the names of
parts in this document match the numbers used in the
construction diagrams and parts lists.
General Precautions
• Perform disassembly and assembly work in a clean
place. Provide clean containers to hold parts during
disassembly.
• Clean around the ports before disassembly. Remove
paint around connectors with a wire brush.
• Clean the disassembled parts with wash oil.
• Put alignment marks on all parts to reassemble them in
the same positions.
• After each disassembly, replace all seals and apply a
thin layer of grease to them.
• Check each part for abnormal wear or seizing. Re-
move any burrs with sandpaper.
• Do not move adjusting screws, unless absolutely nec-
essary.

Special Jigs
(for bushing removal)

Disassembly

WARNING
The spring may fly out during disassembly. Refer to the
construction diagram and take precautions.

1. Remove the boot (31) from the cover (3).

2
PILOT VALVE (TRAVEL) 4K3AQ01
 DISASSEMBLY AND ASSEMBLY
PILOT VALVE (TRAVEL) 4
2. Loosen the cap screws (28).

3. Remove the shaft (26).

• Use a rod (8 mm dia. max.) and tap it with a ham-
mer.

4. Remove the cam (27) with the screws (29) and nuts
(30) attached.
• Take care to prevent the push rod (10) flying out.
• Neutral adjustment is required for the screws (29)
and nuts (30). Do not remove them, unless abso-
lutely necessary.

5. Remove the cap screws (17) and remove the cover

(3).

3
PILOT VALVE (TRAVEL) 4K3AQ01
 DISASSEMBLY AND ASSEMBLY
PILOT VALVE (TRAVEL) 4
6. Remove the push rod (10) from the plug (4).
• Take care not to scratch the push rod (10) surfac-
es.

7. Remove the plug (4) from the casing (2), with the
grease cup (5) and seal (6) attached.

8. Remove the piston (15) and the springs (23) (24)

from the casing (2).

9. Remove the spring seat (13) from the casing (2).

4
PILOT VALVE (TRAVEL) 4K3AQ01
 DISASSEMBLY AND ASSEMBLY
PILOT VALVE (TRAVEL) 4
10. Remove the balls (16) from the casing (2).
• Use a magnet.

11. Remove the cap screws (14) and remove the casing
(2).

12. Remove the O-rings (7) (9) from the casing (1).

13. Remove the pressure reducing valves and springs

(22).

5
PILOT VALVE (TRAVEL) 4K3AQ01
 DISASSEMBLY AND ASSEMBLY
PILOT VALVE (TRAVEL) 4
14. Remove the bushings (25) from the cover (3).
• Use the jig.

15. Disassemble the pressure reducing valve.

a. Remove washer 1 (11).
• Stand the spool (18) on a flat surface. Push down
the spring seat (19).
• Do not push down the spring seat (19) more than
4 mm.

b. Remove the spring seat (19), spring (21), washer

2 (12), and washer 3 (20) from the spool (18).
• Washer 2 is used for adjustment. In some cases
this washer is omitted.

16. Remove the grease cup (5) from the plug (4).

6
PILOT VALVE (TRAVEL) 4K3AQ01
 DISASSEMBLY AND ASSEMBLY
PILOT VALVE (TRAVEL) 4
17. Remove the seal (6) and the O-ring (8) from the plug
(4).

7
PILOT VALVE (TRAVEL) 4K3AQ01
 DISASSEMBLY AND ASSEMBLY
PILOT VALVE (TRAVEL) 4
Assembly
1. Assemble the pressure reducing valve.
a. Install washer 2 (12), washer 3 (20), spring (21),
and the spring seat (19) onto the spool (18).

b. Attach washer 1 (11) to the spool (18).

• Stand the spool (18) on a flat surface. Push down
the spring seat (19).
• Do not push down the spring seat (19) more than
4 mm.
• Engage the sharp edge of washer 1 (11) onto the
head of the spool (18).

2. Install the springs (22) and the pressure reducing

valves in the casing.

3. Fit the O-rings (7) (9) to the casing (1).

8
PILOT VALVE (TRAVEL) 4K3AQ01
 DISASSEMBLY AND ASSEMBLY
PILOT VALVE (TRAVEL) 4
4. Use the cap screws (14) to attach the casing (2).
Cap screw: 8.8 ± 1 N·m

5. Insert the balls (16) in the casing (2).

6. Insert the spring seat (13) in the casing (2).

7. Install the piston (15) and the springs (23) (24) in the
casing (2).

9
PILOT VALVE (TRAVEL) 4K3AQ01
 DISASSEMBLY AND ASSEMBLY
PILOT VALVE (TRAVEL) 4
8. Attach the seal (6) and O-ring (8) to each plug (4).
• Insert the seal (6) in the correct orientation.

9. Attach the grease cup (5) to the plug (4).

10. Insert the push rod (10) into the plug (4).
• Apply hydraulic oil to the push rod (10) before in-
stallation.

11. Install the plugs (4) and push rods (10) assembled at
step 10 above into the casing.

10
PILOT VALVE (TRAVEL) 4K3AQ01
 DISASSEMBLY AND ASSEMBLY
PILOT VALVE (TRAVEL) 4
12. Install the bushings (25) in the cover (3).
• Use the jig.

13. Attach the cover (3) to the casing (2) using the cap
screws (17).
• Ensure that the cover (3) is level.
Cap screw: 55 ± 9.8 N·m

14. Attach the cam (27) to the cover (3).

• If the screw (29) and nut (30) have been removed,
reattach them temporarily.

15. Insert the shaft (26).

11
PILOT VALVE (TRAVEL) 4K3AQ01
 DISASSEMBLY AND ASSEMBLY
PILOT VALVE (TRAVEL) 4
16. Attach the cap screws (28).
Cap screw: 6.9 ± 1 N·m
Loctite #241

17. Adjust the cam (27) and cover (3) level.

a. Turn the screws to adjust the cams (27) and cover
(3) level.
• Ensure that the screws are not loose.
b. Tighten to the specified torque.
Nut: 33 ± 3.4 N·m

18. Apply grease to the top of the push rods and fill the
grease cups with grease.

19. Install the boot (31).

• Spray the inside of the boot with rust-inhibiting oil.

12
PILOT VALVE (TRAVEL) 4K3AQ01
 DISASSEMBLY AND ASSEMBLY
PILOT VALVE (TRAVEL) 4
Inspection and adjustment
Checking the parts

Part Criteria Action

O-ring — • Replace
Seal — • Replace
Spool • Wear on the sliding surfaces is 10 μm or more than the non-sliding • Replace
surfaces.
• Scratches on the sliding surfaces • Replace
• Spool does not move smoothly. • Replace
Push rod • Tip is worn 1 mm or more • Replace
• Scratches on the sliding surfaces • Replace
Plug • Imperfect sealing due to damage • Repair or replace
Controls • Looseness in the pin, shaft or joint of the controls results in 2 mm • Tighten to the specified
play, or more. torque
• Wear of the pin, shaft or joint of the controls results in 2 mm play, or • Replace
more.
Casing, port • Scratches, rust, or corrosion at the parts in sliding contact with the • Replace
plate spool.
• Scratches, rust, or corrosion of the seal part in contact with the O-ring • Repair or replace

13
PILOT VALVE (TRAVEL) 4K3AQ01
 DISASSEMBLY AND ASSEMBLY
PROPORTIONAL CONTROL SOLENOID VALVE 4
PROPORTIONAL CONTROL SOLENOID VALVE
Construction

1. Proportional control solenoid

2. Bolt
3. Spool

1
PROPORTIONAL CONTROL SOLENOID VALVE 4K4AS00
 DISASSEMBLY AND ASSEMBLY
PROPORTIONAL CONTROL SOLENOID VALVE 4
Disassembly and assembly
The numbers in parentheses, ( ), listed after the names of
parts throughout this document do not necessarily match
the numbers of the same parts listed in the construction
diagrams and parts lists. The numbers listed are for part
numbers used in illustrations.
General precautions
• Perform disassembly and assembly work in a clean
place. Provide clean containers to hold parts during
disassembly.
• Clean around the ports before disassembly. Remove
paint around connectors with a wire brush.
• Clean the disassembled parts with wash oil.
• Put alignment marks on all parts to ensure that they are
reassembled in the same positions.
• After each disassembly, replace all seals and apply a
thin layer of grease to each.
• Check each part for abnormal wear or seizing. Re-
move any burrs with sandpaper.
• Remove adhesive from screw holes that use adhesive
through the tap. Do not reuse mounting bolts or
screws.
• Do not use cloth gloves during assembly. Fibers from
the gloves could fall off and clog valves, etc., which
could cause parts to become faulty.
• During assembly, be sure to apply clean hydraulic oil
to all moving parts in and sliding parts that come into
contact with the hydraulic motor and valve parts be-
fore installing or attaching the part.
• Plug all ports once assembly has been completed in
order to prevent dust and dirt from entering.
• Do not attempt to adjust the adjusting screws at times
other than when necessary.

Disassembly
1. Take out the bolts, and remove the proportional con-
trol solenoid valve (1).
Bolt: 7 N·m ± 0.5 N·m 1

T9H204

2
PROPORTIONAL CONTROL SOLENOID VALVE 4K4AS00
 DISASSEMBLY AND ASSEMBLY
PROPORTIONAL CONTROL SOLENOID VALVE 4
2. Remove the O-ring from the proportional control so-
lenoid valve (1).
• Do not attempt to remove the sleeve (2) that is
united to the solenoid (4) by the retaining ring (3)
as the parts are swaged together.
• Make sure that the spool (5) moves back and forth
a little if pushed from the sleeve (2) end.
4
Assembly 3
For assembly, refer to the construction diagram and re- 2
verse the disassembly procedure.
5 T9H205

Inspection and adjustments

Inspection

Part Criteria Action

Coil • If the solenoid is burned out, shorted out, or suffering from wiring dis- • Replace
connects
• If the wiring is shorted out or broken • Replace
Body • If there are scratches, rust, or corrosion present on the parts that • Replace
make sliding contact with the spool
• If there are scratches, rust, or corrosion on the seal part in contact • Replace
with the O-ring
• If there is other damage present that could possibly impair normal • Replace
operation of the machine
• If there are scratches on the outer circumference that could easily • Replace
Spool get caught on by a fingernail
• If the spool does not move smoothly enough • Repair or replace
Spring • If there is rust, corrosion, deformation, or breakage present • Replace
O-rings — • Replace

3
PROPORTIONAL CONTROL SOLENOID VALVE 4K4AS00
 DISASSEMBLY AND ASSEMBLY
SOLENOID VALVE (DUAL-SECTION) 4
SOLENOID VALVE (DUAL-SECTION)
Construction

1. Cover 9. Plug
2. Plunger 10. Plug
3. Spring 11. O-ring
4. Plug 12. O-ring
5. Spring 13. O-ring
6. Spool 14. O-ring
7. Solenoid 15. O-ring
8. Body

1
SOLENOID VALVE (DUAL-SECTION) 4K6AS00
 DISASSEMBLY AND ASSEMBLY
SOLENOID VALVE (DUAL-SECTION) 4
Disassembly and assembly
The numbers in parentheses, ( ), listed after the names of
parts throughout this document do not necessarily match
the numbers of the same parts listed in the construction
diagrams and parts lists. The numbers listed are for part
numbers used in illustrations.
General precautions
• Perform disassembly and assembly work in a clean
place. Provide clean containers to hold parts during
disassembly.
• Clean around the ports before disassembly. Remove
paint around connectors with a wire brush.
• Clean the disassembled parts with wash oil.
• Put alignment marks on all parts to ensure that they are
reassembled in the same positions.
• After each disassembly, replace all seals and apply a
thin layer of grease to each.
• Check each part for abnormal wear or seizing. Re-
move any burrs with sandpaper.
• Remove adhesive from screw holes that use adhesive
through the tap. Do not reuse mounting bolts or
screws.
• Do not use cloth gloves during assembly. Fibers from
the gloves could fall off and clog valves, etc., which
could cause parts to become faulty.
• During assembly, be sure to apply clean hydraulic oil
to all moving parts in and sliding parts that come into
contact with the hydraulic motor and valve parts be-
fore installing or attaching the part.
• Plug all ports once assembly has been completed in
order to prevent dust and dirt from entering.
• Do not attempt to adjust the adjusting screws at times
other than when necessary.

Disassembly
1. Take out the plug (1), and remove the spring (2) and
plunger (3).
Plug: 21.6 N·m ± 2.0 N·m
2. Remove the O-ring from the plug (1).
3. Take out the cap screws, and remove the cover (4)
and O-ring.
Cap screw: 3.9 N·m ± 1.0 N·m

3 2 1
N0H102

2
SOLENOID VALVE (DUAL-SECTION) 4K6AS00
 DISASSEMBLY AND ASSEMBLY
SOLENOID VALVE (DUAL-SECTION) 4
4. Take out the plug (5), and remove the O-ring.
Plug: 9.8 N·m ± 1.0 N·m
4

N0H103

5. Take out the cap screws, and remove the solenoid

coil (6).
• Mark the body and coil with alignment indicators
to ensure that parts are put back in the proper 6
places during reassembly.
• Take care not to lose the push rod.
6. Remove the O-ring from the solenoid coil (6).

N0H104

7. Take out the plug (7), and remove the O-ring.

Plug: 26.5 N·m ± 2.9 N·m

7 7

N0H105

8. Remove the spool (8) and spring (9) from the body.
• Mark the spool and spring with alignment indica-
tors to ensure that parts are put back in the proper
places during reassembly.

Assembly
For assembly, refer to the construction diagram and re-
8 8
verse the disassembly procedure.

9 9
N0H106

3
SOLENOID VALVE (DUAL-SECTION) 4K6AS00
 DISASSEMBLY AND ASSEMBLY
SOLENOID VALVE (DUAL-SECTION) 4
Inspection and adjustments
Inspection

Part Criteria Action

Coil • If the solenoid is burned out, shorted out, or suffering from wiring dis- • Replace
connects
• If the wiring is shorted out or broken • Replace
Body • If there are scratches, rust, or corrosion present on the parts that • Replace
make sliding contact with the spool
• If there are scratches, rust, or corrosion on the seal part in contact • Replace
with the O-ring
• If there is other damage present that could possibly impair normal • Replace
operation of the machine
Spool • If there are scratches on the outer circumference that could easily • Replace
get caught on by a fingernail
• If the spool does not move smoothly enough • Repair or replace
Spring • If there is rust, corrosion, deformation, or breakage present • Replace
O-rings — • Replace

4
SOLENOID VALVE (DUAL-SECTION) 4K6AS00
 DISASSEMBLY AND ASSEMBLY
SHOCKLESS VALVE 4
SHOCKLESS VALVE
Construction

6 12 4 3 2 8 10 1 3 5 10 9 11 7

4K9AK01Z

1. Plunger 7. Connector
2. Ring 8. Orifice
3. Spring 9. Snap ring
4. Body 10. O-ring
5. Sleeve 11. O-ring
6. Connector 12. O-ring

1
SHOCKLESS VALVE 4K9AS00
 DISASSEMBLY AND ASSEMBLY
SHOCKLESS VALVE 4
Disassembly and assembly
The numbers in parentheses, ( ), listed after the names of
parts throughout this document do not necessarily match
the numbers of the same parts listed in the construction
diagrams and parts lists. The numbers listed are for part
numbers used in illustrations.
General precautions
• Perform disassembly and assembly work in a clean
place. Provide clean containers to hold parts during
disassembly.
• Clean around the ports before disassembly. Remove
paint around connectors with a wire brush.
• Clean the disassembled parts with wash oil.
• Put alignment marks on all parts to ensure that they are
reassembled in the same positions.
• After each disassembly, replace all seals and apply a
thin layer of grease to each.
• Check each part for abnormal wear or seizing. Re-
move any burrs with sandpaper.
• Remove adhesive from screw holes that use adhesive
through the tap. Do not reuse mounting bolts or
screws.
• Do not use cloth gloves during assembly. Fibers from
the gloves could fall off and clog valves, etc., which
could cause parts to become faulty.
• During assembly, be sure to apply clean hydraulic oil
to all moving parts in and sliding parts that come into
contact with the hydraulic motor and valve parts be-
fore installing or attaching the part.
• Plug all ports once assembly has been completed in
order to prevent dust and dirt from entering.
• Do not attempt to adjust the adjusting screws at times
other than when necessary.

Disassembly
1. Remove the connector (7) from the body (4), and re-
move the O-ring (11).
Connector: 34.3 N·m ± 4.9 N·m

2
SHOCKLESS VALVE 4K9AS00
 DISASSEMBLY AND ASSEMBLY
SHOCKLESS VALVE 4
2. Remove the snap ring (9), and remove the sleeve.
3. Take out the connector (6), and remove the O-ring 9
6 4 5
(12).
Connector: 48.5 N·m ± 4.9 N·m

4K9AK03Z

4. Remove the spring (3) and plunger (1) from the body
(4).
3 1 3 4
Assembly
For assembly, refer to the construction diagram and re-
verse the disassembly procedure.

4K9AK04Z

Inspection and adjustments

Inspection

Part Criteria Action

Body • If there are scratches, rust, or corrosion present on the parts that • Replace
make sliding contact with the spool
• If there are scratches, rust, or corrosion on the seal part in contact • Replace
with the O-ring
• If there is other damage present that could possibly impair normal • Replace
operation of the machine
Plunger • If there are scratches on the outer circumference that could easily • Replace
get caught on by a fingernail
• If the spool does not move smoothly enough • Repair or replace
Spring • If there is rust, corrosion, deformation, or breakage present • Replace
O-rings — • Replace

3
SHOCKLESS VALVE 4K9AS00
 DISASSEMBLY AND ASSEMBLY
CYLINDERS 4
CYLINDERS
Construction
Boom cylinder

1. Buffer ring 8. Piston packing 15. Rod cover 22. Dust ring
2. Rod packing 9. O-ring 16. Bushing 23. Nut
3. Backup ring 10. Backup ring 17. Snap ring 24. Set screw
4. Dust seal 11. Tube 18. Snap ring 25. Cap screw
5. O-ring 12. Bushing 19. Cushion bearing 26. Dust seal
6. Backup ring 13. Piston rod 20. Piston 27. Grease nipple
7. O-ring 14. Bushing 21. Wear ring 28. Grease nipple

Arm cylinder

1. Buffer ring 9. O-ring 17. Snap ring 25. Stop ring

2. Rod packing 10. Backup ring 18. Cushion bearing 26. Cap screw
3. Backup ring 11. Tube 19. Piston 27. Check valve
4. Dust seal 12. Bushing 20. Wear ring 28. Dust seal
5. O-ring 13. Piston rod 21. Dust ring 29. Grease nipple
6. Backup ring 14. Rod cover 22. Nut
7. O-ring 15. Bushing 23. Set screw
8. Piston packing 16. Snap ring 24. Plunger

1
CYLINDERS 4L0AS00
 DISASSEMBLY AND ASSEMBLY
CYLINDERS 4
Bucket cylinder

1. Buffer ring 8. Piston packing 15. Rod cover 22. Nut

2. Rod packing 9. O-ring 16. Bushing 23. Set screw
3. Backup ring 10. Backup ring 17. Snap ring 24. Cap screw
4. Dust seal 11. Tube 18. Snap ring 25. Dust seal
5. O-ring 12. Bushing 19. Piston 26. Grease nipple
6. Backup ring 13. Piston rod 20. Wear ring
7. O-ring 14. Bushing 21. Dust ring

Swing cylinder

1. Buffer ring 8. Piston packing 15. Rod cover 22. Dust ring
2. Rod packing 9. O-ring 16. Bushing 23. Nut
3. Backup ring 10. Backup ring 17. Snap ring 24. Set screw
4. Dust seal 11. Tube 18. Snap ring 25. Cap screw
5. O-ring 12. Bushing 19. Cushion bearing 26. Dust seal
6. Backup ring 13. Piston rod 20. Piston 27. Grease nipple
7. O-ring 14. Bushing 21. Wear ring 28. Grease nipple

2
CYLINDERS 4L0AS00
 DISASSEMBLY AND ASSEMBLY
CYLINDERS 4
Dozer blade cylinder

1. Buffer ring 10. Tube 18. Wear ring

2. Rod packing 11. Bushing 19. Dust ring
3. Dust seal 12. Piston rod 20. Nut
4. O-ring 13. Rod cover 21. Set screw
5. Backup ring 14. Bushing 22. Dust seal
6. O-ring 15. Snap ring 23. Grease nipple
7. Piston packing 16. Snap ring 24. Grease nipple
8. O-ring 17. Piston

3
CYLINDERS 4L0AS00
 DISASSEMBLY AND ASSEMBLY
CYLINDERS 4
Special tools
Special wrench (For the piston nut)

Unit: mm
Cylinders A B C D E F G T
Arm 90 150 80 11 300 70 40 12 to 15
Boom
80 130 70 11 300 70 40 12 to 15
Bucket
Swing 99 159 89 11 300 70 40 12 to 15
Dozer blade 85 140 75 11 300 70 40 12 to 15

Special wrench (For the piston)

Unit: mm
Cylinders A B C D E F G T Combined bolts
Arm 65 115 85 10 300 70 40 12 to 15 M8×20 (Qty. 2)
Boom
55 105 75 11 300 70 40 12 to 15 M10×20 (Qty. 2)
Bucket
Swing 80 150 110 14 300 70 40 12 to 15 M12×20 (Qty. 2)
Dozer blade 60 110 80 12 300 70 40 12 to 15 M10×20 (Qty. 2)

4
CYLINDERS 4L0AS00
 DISASSEMBLY AND ASSEMBLY
CYLINDERS 4
Installation jig (For the piston seals)

Unit: mm
Cylinders A B C D E F G
Arm 109.5 ± 0.1 111 ± 0.1 100 90 22.0 63 90
Boom
99.5 ± 0.1 101 ± 0.1 90 80 23.0 63 90
Bucket
Swing 139.5 ± 0.1 141 ± 0.1 130 120 26.0 63 94
Dozer blade 114.5 ± 0.1 116 ± 0.1 105 95 28.0 63 96

Corrective jig (For the piston seals)

Unit: mm
Cylinders A B C D E F G
Arm 120 128 112 ± 0.1
Boom
110 118 102 ± 0.1
Bucket 46 75 10 to 15 100
Swing 150 158 142 ± 0.1
Dozer blade 125 133 117 ± 0.1

5
CYLINDERS 4L0AS00
 DISASSEMBLY AND ASSEMBLY
CYLINDERS 4
Press-fitting jig (For the pin bushing)

Unit: mm
Cylinders A B C D E F G H I
Arm 79.5 0
-0.1 94.5 ± 0.1 115 95 6.5 ± 0.1 90 20 10 120
Boom 74.5 0-0.1 89.5 ± 0.1 110 90 5.5 ± 0.1 95 20 10 125
Rod side 5.0 ± 0.1 90 20 10 120
Bucket 64.5 0-0.1 79.5 ± 0.1 100 80
Head side 4.5 ± 0.1 85 20 10 115
Swing 99.5 0
-0.1 114.5 ± 0.1 135 115 4.5 ± 0.1 115 20 10 145
Dozer blade 69.5 0
-0.1 84.5 ± 0.1 105 85 6.0 ± 0.1 75 20 10 105

Press-fitting jig (For the dust seals)

Unit: mm
Cylinders A B C D E F G H I J
Arm 85 88 93 108 80 5 5.5 15 5 25.5
Boom
Bucket 75 78 83 98
80 5 5.0 15 5 25
Dozer blade
Swing 95 98 103 118

6
CYLINDERS 4L0AS00
 DISASSEMBLY AND ASSEMBLY
CYLINDERS 4
Installation jig (For the rod cover)

Unit: mm
Cylinders A B C D E F G
Arm 70.5 75 75.3 ± 0.1 80 0
-0.1 32 28.5 155
Boom 60.5 65 65.3 ± 0.1 70 0-0.1 22 28.5 145
Bucket 60.5 65 — 70 0-0.1 — 28.5 110
Swing 80.5 85 85.3 ± 0.1 90 0-0.1 32 28.5 180
Dozer blade 65.5 67 — 70 0
-0.1 — 17 105

7
CYLINDERS 4L0AS00
 DISASSEMBLY AND ASSEMBLY
CYLINDERS 4
Disassembly and assembly
This section provides a description of procedures mainly
for standard cylinders. Complete actual work proce-
dures while studying the construction of the parts provid-
ed in this section.
The numbers in parentheses, ( ), listed after the names of
parts throughout this document do not necessarily match
the numbers of the same parts listed in the construction
diagrams and parts lists. The numbers listed are for part
numbers used in illustrations.
General precautions
• Perform disassembly and assembly work in a clean
place. Provide clean containers to hold parts during
disassembly.
• Clean around the ports before disassembly. Remove
paint around connectors with a wire brush.
• Clean the disassembled parts with wash oil.
• Put alignment marks on all parts to ensure that they are
reassembled in the same positions.
• After each disassembly, replace all seals and apply a
thin layer of grease to each.
• Check each part for abnormal wear or seizing. Re-
move any burrs with sandpaper.
• Remove adhesive from screw holes that use adhesive
through the tap. Do not reuse mounting bolts or
screws.
• Do not use cloth gloves during assembly. Fibers from
the gloves could fall off and clog valves, etc., which
could cause parts to become faulty.
• During assembly, be sure to apply clean hydraulic oil
to all moving parts in and sliding parts that come into
contact with the hydraulic motor and valve parts be-
fore installing or attaching the part.
• Plug all ports once assembly has been completed in
order to prevent dust and dirt from entering.
• Do not attempt to adjust the adjusting screws at times
other than when necessary.

Disassembly
Cylinder assembly
1. Secure the cylinder horizontally by securing the cle-
vis of the tube in a vice and placing a wooden sup-
port under the other end.
2. Drain out any hydraulic oil left remaining in the cylin-
der.
• Move the piston rod slowly to prevent the hydrau-
lic oil from spraying out.

4LAA07Z

8
CYLINDERS 4L0AS00
 DISASSEMBLY AND ASSEMBLY
CYLINDERS 4
3. Loosen the cap screw (1), and remove the pipe (2).

4. Take out the cap screw (3) in the rod cover.

• Cover the piston rod to prevent it from becoming
damaged.

5. Remove the piston rod assembly (4) from the tube

(5).
a. Raise and temporarily suspend the rod with a
crane such that the rod and tube are straight.
b. Tap the end corner of the pipe port flange to cre-
ate a clearance.
c. Insert the end of a flat-bladed screwdriver into the
clearance to widen the clearance further.
d. Remove the piston rod assembly from the tube.
• Pull it straight out so as not to damage sliding
surfaces.

9
CYLINDERS 4L0AS00
 DISASSEMBLY AND ASSEMBLY
CYLINDERS 4
Cylinder assembly (Blade cylinder)
1. Secure the cylinder horizontally by securing the cle-
vis of the tube in a vice and placing a wooden sup-
port under the other end.
2. Drain out any hydraulic oil left remaining in the cylin-
der.
• Move the piston rod slowly to prevent the hydrau-
lic oil from spraying out.

4LAA07Z

3. Loosen the cap screw (1), and remove the pipe (2).

4. Disengage the anti-rotation lock for the rod cover.

• As the anti-rotation lock is built directly into the
cylinder tube, take care not to damage the tube
when releasing the lock.

4LAA08Z

5. Loosen the rod cover.

• Pull the piston rod outward about 200 mm (7.9 in.)
in advance.
• Cover the piston rod to prevent it from becoming
damaged.
6. Remove the piston rod assembly from the tube.
• Pull it straight out so as not to damage sliding sur-
faces.

4LAA09Z

10
CYLINDERS 4L0AS00
 DISASSEMBLY AND ASSEMBLY
CYLINDERS 4
Piston rod assembly
1. Secure the piston rod assembly horizontally.

4LAA10Z

2. Remove the piston section.

a. Take out the set screw (8).
• The set screw (8) is swaged with a punch in two
places. Apply oil while gently loosening it.

b. Remove the piston nut (9) using the special

wrench (for the piston nut).

c. Remove the piston (10) using the special wrench

(for the piston).

11
CYLINDERS 4L0AS00
 DISASSEMBLY AND ASSEMBLY
CYLINDERS 4
3. Remove the rod cover assembly (12) from the rod.

Piston
1. Remove the wear ring (13) and dust ring (14) from
the piston (10).
2. Remove the piston seals.
a. Remove the backup ring (15).

b. Remove the seal ring (16) and backup ring (17).

• Secure the piston so that it does not move, and
remove the seal ring and backup ring using a
flat-bladed screwdriver and a hammer.

3. Remove the O-ring (18) and backup ring (19) from

the inside of the piston.
• Use a spatula to scrape away the rings.

12
CYLINDERS 4L0AS00
 DISASSEMBLY AND ASSEMBLY
CYLINDERS 4
Rod cover
1. Remove the O-rings (20) and (21) and backup ring
(22) from the rod cover.
2. Remove the buffer seal (23) and rod packing (24).

3. Remove the retaining ring (26).

4. Remove the dust seal (27).

a. Place the rod cover in a vice.
b. Insert the blade of a flat-bladed screwdriver into
the groove on the dust seal, and tap the screw-
driver with a hammer to remove the seal.
5. Scrape away the bushing to remove it.
• Do not remove the bushing unless it is badly dam-
aged by wear or seizing.

13
CYLINDERS 4L0AS00
 DISASSEMBLY AND ASSEMBLY
CYLINDERS 4
Clevises
1. Remove the dust seals from the clevises of the tube
and piston rod.

4LAA22Z

2. Remove the bushing from the piston rod.

• Pull out the bushing using a press with a support-
ing metal plate.

Assembly
Clevises
1. Press-fit the bushing into the piston rod and tube.
• Complete using the press-fitting jig (28) (for the
bushing).

2. Attach the dust seal using a press with a supporting

metal plate.

14
CYLINDERS 4L0AS00
 DISASSEMBLY AND ASSEMBLY
CYLINDERS 4
Rod cover
1. Attach the dust seal (27).
• Use the press-fitting jig (29) (for the dust seal) to
press-fit the dust seal into the cover to ensure that
an equal amount of pressure is applied around
the circumference of the dust seal.
• Apply grease to the inner sides of the dust seal.

2. Attach the buffer ring (23), rod packing (24), and

backup ring (25).
• Shape the seal into a heart, and insert it from the
direction of the arrow side.

• Position the R part on the backup ring (30) for the

buffer ring (23) as shown in the diagram.
3. Attach the O-ring (20).
4. Attach the O-ring (21) and backup ring (22).

15
CYLINDERS 4L0AS00
 DISASSEMBLY AND ASSEMBLY
CYLINDERS 4
Piston

WARNING
Wear gloves when completing this procedure to keep
from getting burned on the heated seal ring.

1. Insert the back ring (17) into the piston.

2. Place the special jig (for the piston seal) (31) onto the
piston, and use it to attach the seal ring (16).
• Heat the hydraulic oil to a temperature of around
150°C to 180°C (302°F to 356°F) using an electri-
cal heater, and dip the seal ring into the heated oil
for five minutes and then attach it to the back ring
while it is still warm.

3. Correct the shape and length of the seal ring using

the corrective jig (for the piston seal) (32) as the seal
ring may become stretched during attachment.

4. Attach the backup ring (15) to both sides of the seal

ring (16).
• Position the R part on the backup ring as shown in
the diagram.
5. Attach the O-ring (18) and backup ring (19).

16
CYLINDERS 4L0AS00
 DISASSEMBLY AND ASSEMBLY
CYLINDERS 4
Piston rod assembly
1. Attach the rod cover assembly to the piston rod.
• Secure the piston rod assembly horizontally.
• Use the installation jig (33) (for the rod cover) to
attach the rod cover assembly.
• Apply hydraulic oil to the surfaces of the installa-
tion jig and rod.

2. Attach the piston to the piston rod.

• Attach the piston together with the cushion ring if
using a cushion ring.
• Use the special wrench (for the piston) to attach
the piston.
• Gently tighten the piston taking care not to tighten
it too far.
Piston (Blade cylinder): 735 N·m ± 69 N·m
Piston (Other cylinders): 981 N·m ± 98 N·m

3. Fasten on the piston nut (9).

• Use the special wrench (for the piston nut) to
screw on the piston nut.
• Gently tighten the piston nut taking care not to
tighten it too far.
• If using a cushion ring, after fastening on the pis-
ton nut, do not tighten down the cushion ring but
instead leave a clearance of around 0.5 mm (0.02
in.) in the direction of the shaft, and check to en-
sure that the cushion ring moves freely.
Piston nuts (For the arm, boom, and bucket cyl-
inders): 1274 N·m ± 127 N·m
Piston nut (For the swing cylinder): 1860 N·m ±
186 N·m
Piston nut (For the blade cylinder): 1274 N·m ±
130 N·m
4. Fasten on the set screw (8) and swage it into place
in two places using a punch.
Set screw: Apply Loctite #242.
Set screw: 15 N·m ± 1.5 N·m

17
CYLINDERS 4L0AS00
 DISASSEMBLY AND ASSEMBLY
CYLINDERS 4
Cylinder assembly
1. Secure the tube horizontally, and insert the piston
rod assembly into the tube.
• Insert the tube straight into the piston rod, lining
up the center of the tube with the center of the pis-
ton rod shaft.

2. Attach the rod cover, and fasten it in place with the

cap screw (3).
• Make sure that the pipe flange of the rod cover is
oriented properly when attaching the rod cover.
Cap screws (Arm, boom, and bucket cylinders):
211 N·m ± 5 N·m
Cap screw (Swing cylinder): 353 N·m ± 10 N·m
3. Insert the check valves (for the arm cylinder, swing
cylinder).
• Attach parts in order of valve, spring, spring re-
tainer, and then plug with attached O-ring.
Plug: 49.0 N·m ± 4.9 N·m

Cylinder assembly (Blade cylinder)

1. Secure the tube horizontally, and insert the piston
rod assembly into the tube.
• Insert the tube straight into the piston rod, lining
up the center of the tube with the center of the pis-
ton rod shaft.

2. Attach the rod cover and tighten it down with screws.

• Make sure that the pipe flange of the rod cover is
oriented properly when attaching the rod cover.
Rod cover: 588 N·m ± 98 N·m
3. Bend the lock rib on the tube and lock it into place.

4LAA36Z

18
CYLINDERS 4L0AS00
 DISASSEMBLY AND ASSEMBLY
CYLINDERS 4
Inspection and adjustments
Inspection after disassembly
Clean each part thoroughly with cleaning oil, then carry
out the following checks. When a cylinder has been dis-
assembled, replace all the seals with new ones.

1. Piston rod
• Replace the rod if it has any cracks.
• Repair any damaged threads, or replace the rod
entirely if there are damaged threads.
• Replace the rod if the plating layer of the plated
portion is broken, rusted, or scratched.
• Replace the rod if it is bent by more than the limit
of 1 mm in 1 m. (For the measurement method, re-
fer to the figure on the right.)
• Replace the bushing if the inner diameter of the
clevis bushing is worn.

Measuring the bend

a. Place the portion of the rod with the same diame-
ter at both ends on V-blocks to support it.
b. Place a dial gauge at the center point between the
two blocks.
c. Rotate the rod, and record the readings for maxi-
mum and minimum run-out shown on the dial
gauge.
If the amount of bending in the rod is within the
above limit but is great across a short distance so 1/2
that the rod does not move smoothly, replace the
rod if it makes a squeaking sound during the op-
eration test after reassembly or if it catches during 4LAA37Z

movement.

2. Tube
• Replace the tube if there are cracks in the welded
portion.
• Replace the tube if the inside surface is scratched
or if it leaks hydraulic oil.
• Replace the bushing if the inner diameter of the
clevis bushing is worn.

3. Rod cover
• Replace the bushing if the bushing inner diameter
is worn and the clearance with the piston rod is
greater than 0.25 mm (0.0098 in.).
• Replace the bushing if the inside surface of the
bushing is scratched and the scratches penetrate
beyond the coating layer.

19
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 DISASSEMBLY AND ASSEMBLY
CYLINDERS 4
Inspection after assembly
No load operation test
1. Place the cylinder in a horizontal position with no
load.
2. Apply gentle pressure alternately to the ports at the
ends, and operate the piston rod 5 or 6 times.
3. Make sure that there are no errors or abnormal oper-
ating conditions.

4LAA38Z

Leak test
• External leak
1. Apply a test pressure to the retraction side and to the
extension side for 3 minutes each.
2. Make sure that there are no abnormalities such as
external leakage or permanent deformation, etc. in
the rod seal or rod cover mount or in any welded por-
tion.

• Internal leak
1. Disconnect the hose on the extension side.
4LAA39Z
2. Apply the test pressure to the retraction side for 3
minutes.
3. Measure the amount of oil that has leaked from the
extension side.
• The amount of leakage should be 1 mL/3 min. or
less.

Bleeding air from the hydraulic cylinder

Bleed air out of the cylinder when the cylinder is removed
or when the hydraulic piping or other parts are discon-
nected.
1. Start the engine, and let it idle for approximately 5
minutes.
2. With the engine running at slow speed, extend and
retract the cylinder 4 or 5 times.
• Move the piston rod to a position 100 mm (3.94
in.) before the end of the stroke, being careful not
to relieve air.
3. With the engine running at top speed, repeat the op-
eration outlined in (2), and then, with the engine run-
ning at slow speed, move the piston rod to the stroke
end to bleed off the air in the cylinder.

20
CYLINDERS 4L0AS00
 DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR 4
TRAVEL MOTOR
Construction

1
TRAVEL MOTOR 4M0AS00
 DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR 4
1. Gear case 102. Driving shaft 205. Plug 376. Orifice
2. Motor housing 103. Swash plate 206. Spring 377. Filter
3. Carrier 104. Cylinder block 207. O-ring 378. Steel ball
4. Sun gear 105. Piston 208. Backup ring 379. Plug
5. Planet gear 106. Shoe 209. O-ring 380. Plug
6. Pin 107. Shoe holder 210. Backup ring 381. Piston
7. Carrier 108. Guide 211. O-ring 383. O-ring
8. Sun gear 109. Valve plate 212. O-ring 384. Orifice
9. Planet gear 110. Washer 213. Shim 396. Plug
10. Pin 112. Break piston 301. Valve body 398. Plug
11. Thrust washer 113. Spring 323. Spool 399. Plate
12. Thrust washer 114. Spring 324. Plug
13. Thrust plate 115. Friction disc 325. Washer
14. Cover 116. Center disc 326. Plug
15. Coupling 132. Oil seal 327. Valve
16. Pin 135. O-ring 328. Spring
17. Pin 139. O-ring 329. Orifice
22. Lock washer 145. Retaining ring 330. Spring
23. Shim 149. Bearing 331. O-ring
24. Angular bearing 150. Bearing 336. O-ring
27. Bearing 151. Pin 341. Pin
28. Bearing 161. Piston 343. Cap screw
29. Floating seal 162. Shoe 352. Plug
30. Plug 167. Pivot 353. Ball
31. O-ring 171. Pin 354. Plug
32. O-ring 185. Spring 357. Plug
33. O-ring 201. Valve seat 358. O-ring
34. Pin 202. Valve 359. O-ring
35. Cap screw 203. Sleeve 363. Spool
36. Retaining ring 204. Collar 366. Spring

2
TRAVEL MOTOR 4M0AS00
 DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR 4
Brake valve, Hydraulic motor

3
TRAVEL MOTOR 4M0AS00
 DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR 4
Reduction gears

4
TRAVEL MOTOR 4M0AS00
 DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR 4
Special tools
Unit: mm
Press-fitting jig (A)

Inserting jig (B)

Inserting jig (C)

5
TRAVEL MOTOR 4M0AS00
 DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR 4
Unit: mm
Inserting jig (D)

Inserting jig (E)

Inserting jig (F)

6
TRAVEL MOTOR 4M0AS00
 DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR 4
Unit: mm
Press-fitting jig (G)

Press-fitting jig (H)

7
TRAVEL MOTOR 4M0AS00
 DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR 4
Disassembly and assembly
General precautions
• Perform disassembly and assembly work in a clean
place. Provide clean containers to hold parts during
disassembly.
• Clean around the ports before disassembly. Remove
paint around connectors with a wire brush.
• Clean the disassembled parts with wash oil.
• Put alignment marks on all parts to ensure that they are
reassembled in the same positions.
• After each disassembly, replace all seals and apply a
thin layer of grease to each.
• Check each part for abnormal wear or seizing. Re-
move any burrs with sandpaper.
• Remove adhesive from screw holes that use adhesive
through the tap. Do not reuse mounting bolts or
screws.
• Do not use cloth gloves during assembly. Fibers from
the gloves could fall off and clog valves, etc., which
could cause parts to become faulty.
• During assembly, be sure to apply clean hydraulic oil
to all moving parts in and sliding parts that come into
contact with the hydraulic motor and valve parts be-
fore installing or attaching the part.
• Plug all ports once assembly has been completed in
order to prevent dust and dirt from entering.
• Do not attempt to adjust the adjusting screws at times
other than when necessary.

Disassembly
1. Remove the cover.
a. Take out the cap screws.
b. Place a supporting metal plate over the protrusion
on the cover, and tap the plate with a hammer.

8
TRAVEL MOTOR 4M0AS00
 DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR 4
c. Install the i bolt and remove the cover.

2. Remove the thrust plate.

3. Remove the sun gear.

4. Remove the planet gear assembly.

9
TRAVEL MOTOR 4M0AS00
 DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR 4
5. Remove the coupling.

6. Remove the planet gear assembly.

Remove the sun gear.

7. Remove the lock washers.

8. Remove the gear case.

10
TRAVEL MOTOR 4M0AS00
 DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR 4
9. Remove the floating seal.

10. Remove the angular bearing.

11. Remove the relief valve assemblies.

12. Remove the plugs.

Remove the springs and washers.

11
TRAVEL MOTOR 4M0AS00
 DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR 4
13. Remove the spools.

14. Remove the plugs.

15. Remove the spools and springs.

16. Remove the plugs.

12
TRAVEL MOTOR 4M0AS00
 DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR 4
17. Remove the pistons.

18. Remove the plugs.

19. Remove the steel balls.

20. Take out the cap screws.

21. Remove the valve body.

13
TRAVEL MOTOR 4M0AS00
 DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR 4
22. Remove the valve plate.

23. Remove the bearing.

24. Remove the pin from the valve body.

25. Remove the pin from the motor housing.

14
TRAVEL MOTOR 4M0AS00
 DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR 4
26. Remove the brake piston.
• Insert compressed air through the passage hole
on the brake piston and then remove the brake
piston.

27. Remove the four center discs and three friction

discs.

28. Remove the cylinder block.

29. Remove the piston assembly and shoe holder.

15
TRAVEL MOTOR 4M0AS00
 DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR 4
30. Remove the guide.

31. Remove the three pins.

32. Remove the swash plate.

33. Remove the shaft.

Remove the two pivots and two pins.

16
TRAVEL MOTOR 4M0AS00
 DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR 4
34. Remove the piston assembly and spring.

35. Remove the shim.

36. Remove the floating seal.

37. Remove the oil seal.

17
TRAVEL MOTOR 4M0AS00
 DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR 4
Assembly
1. Press-fit the angular bearings into the gear case.
• Use the bearing press-fitting jig (A).
• Make sure to orient the bearings in the proper as-
sembly direction before completing this step.

2. Attach the floating seal to the gear case.

a. Grease the O-ring on the floating seal.
b. Place the jigs and seal in the order of inserting jig
B, floating seal, and then inserting jig C.
c. Push down on the inserting jig B until it reaches
the inserting jig C.
d. Remove the inserting jigs, and check to ensure
that the end surface of the gear case and surface
of the floating seal are parallel to each other and
separated by less than 1 mm.

3. Attach the floating seal to the motor housing.

a. Grease the O-ring on the floating seal.
b. Place the jigs and seal in the order of inserting jig
D, floating seal, and then inserting jig C.
c. Push down on the inserting jig B until it reaches
the inserting jig D.
d. Remove the inserting jigs, and check to ensure
that the end surface of the Motor housing and sur-
face of the floating seal are parallel to each other
and separated by less than 1 mm.

18
TRAVEL MOTOR 4M0AS00
 DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR 4
4. Perform precompression adjustment of the angular
bearing.
• Perform whenever the gear case, angular bear-
ing, or spindle is replaced. The angular bearing
may become damaged or fail in a short amount of
time if the precompression is not set appropriate-
ly.
a. Place the lock washer in the motor housing tem-
porarily, and measure the dimension C.

b. Measure the assembly thickness D of the angular

bearing.
c. Subtract dimension D from dimension C. Select a
shim that will introduce a clearance of between
0.13 mm and 0.17 mm according to the resultant
rank listed in the below table.

Code T (mm) Code T (mm)

A 0.9 G 1.5
B 1.0 H 1.6
C 1.1 I 1.7
D 1.2 J 1.8
E 1.3 K 1.9
F 1.4 L 2.0

5. Attach the shim selected in step 4. above to the mo-

tor housing.

6. Attach the gear case to the motor housing.

19
TRAVEL MOTOR 4M0AS00
 DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR 4
7. Line up the lock washer with the groove on the motor
housing.

8. Use the inserting jig E to attach the lock washer to the

groove on the motor housing.

9. Attach the oil seal to the motor housing.

• Use the inserting jig F.
• Apply lithium grease to the lip on the oil seal.
• Make sure to orient the oil seal in the proper as-
sembly direction before completing this step.
10. Insert the two pins into the pin holes on the motor
housing.
11. Attach the two pivots to the pins that were attached
to the motor housing.
• Apply lithium grease to one hemispherical sur-
face of each pivot.

12. Insert the spring into the piston assembly.

• Grease the spring.
13. Apply hydraulic oil to the sliding surfaces of the pis-
ton assembly and then insert the piston into the pis-
ton hole on the motor housing.
14. Attach the two pins to the motor housing.

20
TRAVEL MOTOR 4M0AS00
 DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR 4
WARNING
Wear gloves when completing this procedure to keep
from getting burned on the heated bearing.

15. Attach the bearing to the shaft.

a. Place the bearing in the heating tank and heat it
at 100°C ± 10°C for ten minutes.
b. Use the press-fitting jig G to press-fit the bearing
into the shaft.

16. Attach the shaft to the motor housing.

• Take care not to damage the oil seal.

17. Insert the swash plate into the motor housing.

a. Grease the surfaces of the swash plate and motor
housing that make contact with each other.
b. Line up the holes on the swash plate with the piv-
ots inserted into the motor housing when inserting
the swash plate.

18. Insert the parts into the cylinder block in the order of
washer, spring, second washer, and then snap ring.
• Insert with the sharp corner of the snap ring ori-
ented toward the inlet port side.
• Insert with the sharp corner of the washer that
make contact with the snap ring oriented toward
the snap ring.

21
TRAVEL MOTOR 4M0AS00
 DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR 4
19. Insert the snap ring into the groove on the cylinder
block.
• Place the press-fitting jig H onto the washer, and
press the press-fitting jig H down onto the washer
using the press machine.
• Use pliers to insall the snap ring.

20. Attach the three pins to the cylinder block, and place
the guide on top of the pins.

21. Insert the nine piston assemblies into the shoe holder
and then insert the shoe holder with piston assem-
blies into the cylinder block.
• Dip the shoe holder with inserted piston assem-
blies into hydraulic oil before inserting into the cyl-
inder block.

22. Attach the cylinder block to the shaft.

• After placing the cylinder block onto the shaft,
turn the cylinder block with a hand to check for
looseness.
Inspect the cylinder block closely if there is any
looseness found.

22
TRAVEL MOTOR 4M0AS00
 DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR 4
23. Place the four center discs and three friction discs on
the cylinder block in an alternating fashion, as in cen-
ter disc then friction disc and then center disc and so
on.
• Dip the friction discs in hydraulic oil before plac-
ing them on the cylinder block.

24. Grease the O-rings, and place them on the brake

piston.
25. Insert the brake piston into the motor housing.

26. Insert the spring and spool into the valve.

27. Grease the O-ring, and attach it to the plug.

28. Insert the plug into the valve body.
Plug: 98.1 N·m ± 19.6 N·m

23
TRAVEL MOTOR 4M0AS00
 DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR 4
29. Insert the steel balls into the valve body.

30. Grease the O-ring, and attach it to the plug.

31. Insert the plug into the valve body.
Plug: 12.3 N·m ± 2.45 N·m

32. Attach the piston to the valve body.

33. Grease the O-ring, and attach it to the plug.

34. Insert the plug into the valve body.
Plug: 58.8 N·m ± 9.81 N·m

24
TRAVEL MOTOR 4M0AS00
 DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR 4
35. Grease the spool, and attach it to the valve body.

36. Grease the O-ring, and attach it to the plug.

37. Attach the washer and spring to the O-ring.

38. Insert the plug into the valve body.

Plug: 441 N·m ± 39.2 N·m

39. Insert the bearing into the valve body.

• Grease the bearing with hydraulic oil before in-
serting it.
40. Insert the pin into the pin hole on the valve body.

25
TRAVEL MOTOR 4M0AS00
 DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR 4
41. Attach the valve plate to the valve body.
• Grease the surfaces of the valve plate and valve
body that make contact with each other.
• Insert the pin into the guide, and attach the valve
plate.

42. Insert the ten springs into the valve body.

• Thoroughly grease the springs to prevent them
from falling out of the valve body.

43. Insert the large O-ring and two small O-rings into the
motor housing.
44. Pour 1 L of hydraulic oil into the motor housing.

45. Insert the valve body into the motor housing.

• Line up the pin holes on the valve body with the
two pins to insert the valve body.
46. Screw in the ten cap screws.
Cap screw: 102 N·m ± 15.7 N·m

26
TRAVEL MOTOR 4M0AS00
 DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR 4
47. Insert the two relief valve assemblies.
Relief valve assembly: 98.1 N·m to 19.6 N·m

48. Attach the sun gear to the planet gear.

49. Insert the planet gear assembly into the gear case.

• Attach with the planet gear and valve body ports

oriented as shown in the diagram at left.

50. Attach the coupling to the drive shaft.

27
TRAVEL MOTOR 4M0AS00
 DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR 4
51. Insert the planet gear assembly into the gear case.

52. Attach the sun gear to the coupling.

• Attach the sun gear so that it lines up with the po-
sition of the spline.

53. Attach the thrust plate to the planet gear assembly.

54. Apply sealant to the surface that is to contact the

cover on the gear case.
• Apply the sealant evenly so as not to leave seams
or openings.
Sealant: Loctite #515

28
TRAVEL MOTOR 4M0AS00
 DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR 4
55. Attach the cover to the gear case.

56. Screw in the cap screws.

Cap screw: 66.7 N·m ± 3.92 N·m
Cap screw: Loctite #242

57. Pour 2.1 L of gear oil into the gear case to fill it.

58. Insert the plug into the cover.

Plug: 98.1 N·m ± 19.6 N·m

29
TRAVEL MOTOR 4M0AS00
 DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR 4
Inspection and adjustments
Checking the parts
• Seal parts (O-rings, oil seals, floating seals) are to be
replaced with entirely new parts if removed during as-
sembly even if no damage is seen.
• All should be replaced if there is any notable damage
to the part exterior.
• Replace parts if any of the abnormalities (problem) list-
ed in the table below can be seen.

Standard value
Allowable value
Part name Problem seen (Standard di-
(Criteria)
mension)
Hub • Severe damage to the exterior. — —
• Pitting occurring on the surface of the ring gear teeth.
• Abnormal wear occurring such as seizure, etc.
Spindle • Severe damage to the exterior. — —
• Abnormal wear occurring such as seizure, etc.
Carrier assembly • Abnormal wear occurring such as seizure, etc. — —
Sun gear • Pitting occurring on the surface of the teeth. — —
Planetary gear • Flaking occurring on the rolling surfaces of the bearings.
Thrust washers • Discoloration or abnormal wear occurring on the sliding sur- — —
faces.
Main bearings • Indentations seen. — —
• Flaking occurring.
• Extreme amounts of abnormal wear observed.
Needle bearings • Pitting occurring in the rolling surfaces. — —
• Abnormal wear occurring on the retainer end surfaces.
Inner rings • Flaking occurring on the rolling surfaces of the bearings. — —
Rear flange • Damage occurring on the sliding surfaces with the spool. — —
Shaft • Wear occurring on the surface that make contact with the oil — —
seal.
• Wear occurring in the spline.
Swash plate • Seizure occurring. — —
Cylinder block • Wear occurring in the spline. — —
• High level of wear occurring on the inner surface of the bore.
• Damage and wear occurring on the sliding surfaces with the
valve plate.
Piston assembly • A clearance observed between the piston and shoe in the ax- Clearance Clearance
Shoe ial direction. 0.05 mm 0.15 mm
• Abnormal wear and extreme wear occurring in the shoe.
Retainer plate • Extreme wear occurring on the sliding surfaces with the shoe. — —
• Damage and extreme wear occurring on the sliding surfaces
with the guide.

30
TRAVEL MOTOR 4M0AS00
 DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR 4
Standard value
Allowable value
Part name Problem seen (Standard di-
(Criteria)
mension)
Thrust ball • Extreme wear occurring on the hemispherical sliding surfac- — —
es with the retainer plate.
Valve plate • Seizure and extreme wear occurring on the rolling surfaces. — —
Friction disc • Extreme wear occurring on each end. Damping Damping
Other discs • Specified torque not met. torque, torque,
• Seizure occurring. 206 N·m or 206 N·m or
above above
Piston • Scratches observed in the outer circumference. — —
Bearings • Indentations seen. — —
• Flaking occurring.
• Wear occurring.
2nd-speed piston • Abnormal wear occurring in the outer circumference. — —
Shoe • Abnormal wear and extreme wear occurring in the shoe.
Spool • Abnormal wear occurring in the outer circumference. — —
• Scratches observed in the outer circumference.

31
TRAVEL MOTOR 4M0AS00
 DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR 4
Performance Verification Testing
After completing travel motor installation, conduct performance verification testing using the procedures listed below.
1. Required measurement equipment

1 Pressure gauges (3.43 MPa readings) Qty. 2

2 Graduated cylinder (Up to 5 L) Qty. 1
3 Stopwatch Qty. 1

2. Test procedures

1 Motor installation and piping work Insert the travel motor into the machine and connect the piping.
Do not attach the crawler.

Notes)
1) When making piping connections, connect the piping so that the pressure gauges (main circuit) can be installed
and the drain volume from the hydraulic motor can be measured.
2) When installing the travel motor, do not tap it with a hammer or other part; instead, install using the bolt holes.

2 Idling of the Switching Travel motor rotation Pressure Direction of ro- Operating time
travel motor speed tation
Low-speed rotation 10 min-1 Without load Left/right At least 1 min.
High-speed rotation 20 min-1 per type

3 Travel mo- 1 Pre-test prepara- Run the travel motor to warm it up until the temperature ranges listed be-
tor perfor- tions low have been reached.
mance veri- • Hydraulic oil temp.: 45°C to 55°C
fication • External reduction gear hub temp.: 40°C to 80°C
testing 2 Verification test The travel motor unit is considered to have passed if the criteria for pass-
ing listed below are met for low-speed operation.
Criteria for passing
• Pressure differential for travel motor driving: 1.57 MPa or less/10 min-1
• Hydraulic motor drain volume: 1.2 L/min-1 or less/10 min-1

If the unit does not satisfy the requirements to pass the test, disassemble and make adjustments, and then test again.

32
TRAVEL MOTOR 4M0AS00
 DISASSEMBLY AND ASSEMBLY
SLEW MOTOR 4
SLEW MOTOR
Construction
Hydraulic motor

1. Motor housing 10. Cylinder block 19. O-ring

2. Oil seal 11. Washer 20. Break piston
3. Bearing 12. Spring 21. Spring
4. Shaft 13. Snap ring 22. Spring
5. Swash plate 14. Friction disc 23. O-ring
6. Piston assembly 15. Center disc 24. Valve plate
7. Shoe holder 16. O-ring 25. Bearing
8. Guide 17. O-ring 26. Pin
9. Pin 18. Collar 27. Snap ring

1
SLEW MOTOR 4N0AS00
 DISASSEMBLY AND ASSEMBLY
SLEW MOTOR 4
Reduction gears

1. Pinion shaft 8. Bearing 15. Ring gear

2. Collar 9. Nut 16. O-ring
3. Seal 10. O-ring 17. Planet gear
4. Cover 11. Ring gear 18. Sun gear
5. Bearing 12. O-ring 19. Valve
6. Case 13. Planet gear 20. Plug
7. Oil seal 14. Sun gear 21. Screw

2
SLEW MOTOR 4N0AS00
 DISASSEMBLY AND ASSEMBLY
SLEW MOTOR 4
Brake valve

1. Valve body 13. O-ring 25. Orifice

2. Poppet 14. Backup ring 26. O-ring
3. O-ring 15. Guide 27. Filter
4. Spring 16. O-ring 28. Washer
5. Housing 17. O-ring 29. Orifice
6. Poppet 18. Backup ring 30. O-ring
7. Seat 19. O-ring 31. Valve body
8. Seat 20. Backup ring 32. Spool
9. Spring 21. Valve body 33. Spring
10. Plug 22. Check valve assembly 34. O-ring
11. O-ring 23. Spring
12. Piston 24. Sleeve

3
SLEW MOTOR 4N0AS00
 DISASSEMBLY AND ASSEMBLY
SLEW MOTOR 4
Special tools
Press-fitting jigs (A) to (H)

Dimensions (mm)
Items A (Inner B (Outer L
diameter) diameter) (Length)
Press-fitting jig (A) 47 90 170
Press-fitting jig (B) 160 ± 1 168.3 160
Press-fitting jig (C) 74 ± 1 82 ± 0.5 80
Press-fitting jig (D) 85 ± 1 94 ± 0.5 40
Press-fitting jig (E) 41 60 80
Press-fitting jig (F) 68 79 140
Press-fitting jig (G) 101.7 ± 1 114.3 ± 1 250
Press-fitting jig (H) 77 ± 0.5 128 ± 1 75

Stopper jig (I)

1 STUD BOLT M20×50 UNI 5911

2 ø9.5, m6, L = 20 mm
No. 4 pins at 90°
MATERIAL: 40CrMo4
HARDENED-TEMPERED
90/100 daN/mm2 CASE STRENGTH

4
SLEW MOTOR 4N0AS00
 DISASSEMBLY AND ASSEMBLY
SLEW MOTOR 4
Socket jig (J)

Press-fitting jig (K)

Press-fitting jig (L)

5
SLEW MOTOR 4N0AS00
 DISASSEMBLY AND ASSEMBLY
SLEW MOTOR 4
Disassembly and assembly
General precautions
• Perform disassembly and assembly work in a clean
place. Provide clean containers to hold parts during
disassembly.
• Clean around the ports before disassembly. Remove
paint around connectors with a wire brush.
• Clean the disassembled parts with wash oil.
• Put alignment marks on all parts to ensure that they are
reassembled in the same positions.
• After each disassembly, replace all seals and apply a
thin layer of grease to each.
• Check each part for abnormal wear or seizing. Re-
move any burrs with sandpaper.
• Remove adhesive from screw holes that use adhesive
through the tap. Do not reuse mounting bolts or
screws.
• Do not use cloth gloves during assembly. Fibers from
the gloves could fall off and clog valves, etc., which
could cause parts to become faulty.
• During assembly, be sure to apply clean hydraulic oil
to all moving parts in and sliding parts that come into
contact with the hydraulic motor and valve parts be-
fore installing or attaching the part.
• Plug all ports once assembly has been completed in
order to prevent dust and dirt from entering.
• Do not attempt to adjust the adjusting screws at times
other than when necessary.

Disassembly
Slew motor
1. Remove the cap screws, and remove the reversal
prevention valve.

K3D626

2. Take out the cap screws, and disassemble the hy-

draulic motor (1) and reduction gears (2).
• Secure the hydraulic motor in place with a vice. 1
• Draw alignment marks on the hydraulic motor and
reduction gears to ensure that they are reassem-
bled in the same positions. 2

K3D627

6
SLEW MOTOR 4N0AS00
 DISASSEMBLY AND ASSEMBLY
SLEW MOTOR 4
Brake valve and hydraulic motor
1. Take out the cap screws, and remove the timer valve
(1).
• Be careful not to lose the O-ring.

L3D613

2. Take out the cap screws, and remove the valve body
(2). 2
• Secure the hydraulic motor in place with a vice.
• Be careful not to allow the valve plate to fall.

K3D629

3. Remove the valve plate (3) from the valve body.

L3D614

4. Remove the bearing (4).

• Do not remove unless it needs to be replaced.

L3D615

7
SLEW MOTOR 4N0AS00
 DISASSEMBLY AND ASSEMBLY
SLEW MOTOR 4
5. Remove the check valve. 9
a. Remove the plug (9). 10
b. Remove the spring (10) and the check valve (11). 11

11
10
9

L3D617

6. Remove the relief valve.

• Do not loosen the set screw or the nut (13).
• Do not disassemble the relief valve.

13

12
L3D618

7. Remove the brake piston (15).

WARNING
Metal fragments and other objects may scatter into the air
in work areas in which compressed air is used. Wear pro-
tective gear such as goggles and a protective face mask.

• Take precautions against the brake piston flying

out of the brake release port PB by increasing the
air pressure.

8. Remove the collar (17).

8
SLEW MOTOR 4N0AS00
 DISASSEMBLY AND ASSEMBLY
SLEW MOTOR 4
9. Remove the cylinder block (18), the friction discs
(19), and the center discs (20).

10. Remove the shoe holder (14) and piston assembly 14 21 22 23

(21) from the cylinder block.
11. Remove the guide (22) and pins (23) from the cylin-
der block.

L3D622

12. Remove the snap ring (24), washer (25), spring (26), 24
25
and washer (27) from the cylinder block (18).
26
• Do not disassemble unless repair is needed.
• If repair is needed, replace the entire cylinder 27
block assembly. 18

A
E5D622

13. Remove the swash plate (28).

9
SLEW MOTOR 4N0AS00
 DISASSEMBLY AND ASSEMBLY
SLEW MOTOR 4
14. Remove the pinion shaft (29).
• If unable to remove the shaft easily, tap it lightly
29
with a plastic hammer.

L3D624

15. Remove the bearing (30) from the pinion shaft (29)
29
using the press-fitting jig (A).
• Do not disassemble unless repair is needed.
• Bearings that have been removed cannot be re-
used and must be replaced.

30

K3D643

16. Remove the timer valve. 31

• Be careful not to damage attachment surfaces. 32
a. Remove the plug (31). 33
b. Remove the spring (32) and spool (33).
• Use a tweezers to remove the parts.

K3D644

10
SLEW MOTOR 4N0AS00
 DISASSEMBLY AND ASSEMBLY
SLEW MOTOR 4
Reduction gears
1. Place alignment marks on the ring gear and case be-
fore disassembling to ensure that the parts are as-
sembled back in their original positions.

2. Remove the sun gear.

3. Remove the 1st stage planet gear assembly.

4. Remove the ring gear.

11
SLEW MOTOR 4N0AS00
 DISASSEMBLY AND ASSEMBLY
SLEW MOTOR 4
5. Remove the O-ring.

6. Remove the sun gear.

7. Remove the 2nd stage planet gear assembly.

8. Remove the ring gear.

12
SLEW MOTOR 4N0AS00
 DISASSEMBLY AND ASSEMBLY
SLEW MOTOR 4
9. Remove the ring gear from the case.

10. Remove the crimping on the ring nut.

11. Attach the stopper jig (I) and socket jig (J) to the ring
nut.

12. Use a torque multiplier wrench to loosen the ring nut.

13
SLEW MOTOR 4N0AS00
 DISASSEMBLY AND ASSEMBLY
SLEW MOTOR 4
13. Remove the ring nut.

14. Take out the cap screws.

15. Use a puller tool to remove the pinion shaft, bearing,

and cover unit from the case.

16. Remove the bearing and cover unit from the pinion
shaft using the press-fitting jig (D).

14
SLEW MOTOR 4N0AS00
 DISASSEMBLY AND ASSEMBLY
SLEW MOTOR 4
17. Remove the cover.

18. Remove the seal from the cover.

19. Remove the bearing from the case using the press-
fitting jig (E).

20. Remove the oil seal from the case using the press-fit-
ting jig (F).

15
SLEW MOTOR 4N0AS00
 DISASSEMBLY AND ASSEMBLY
SLEW MOTOR 4
Reversal prevention valve
1. Remove the plug (1) and spring (2). 1
2. Remove the check valve assembly (3). 2
3
3. Remove the sleeve (4).

4
3
2
1 G4D613

4. Remove the plug (5) and orifice (6). 5

G4D614

5. Remove the orifice (7), washer (8), and filter (9). 7

8
• Replace the filter whenever the reversal preven-
9
tion valve is disassembled.

G4D615

16
SLEW MOTOR 4N0AS00
 DISASSEMBLY AND ASSEMBLY
SLEW MOTOR 4
Assembly
Reversal prevention valve
1. Insert the filter (9), washer (8), and orifice (7). 7
Orifice: 4.9 N·m ± 1 N·m 8
9

G4D615

2. Insert the orifice (6). 5

Orifice: 2.45 N·m ± 0.49 N·m
6
3. Insert the plug (5) with attached O-ring.
Orifice: 61.8 N·m ± 2.9 N·m

G4D614

4. Insert the sleeve (4). 1

2
5. Insert the check valve assembly (3) and the spring 3
(2).
6. Insert the plug (1) with attached O-ring.
Plug: 61.8 N·m ± 2.9 N·m

4
3
2
1 G4D613

17
SLEW MOTOR 4N0AS00
 DISASSEMBLY AND ASSEMBLY
SLEW MOTOR 4
Brake valve and hydraulic motor
1. Assemble the timer valve. 31
• Be careful not to damage attachment surfaces. 32
a. Insert the spool (33) and the spring (32).
33
b. Insert the plug (31) with attached O-ring.
Plug: 39.2 N·m ± 2.0 N·m

K3D644

2. Insert the washer (27), spring (26), washer (25), and 24

25
snap ring (24) into the cylinder block.
26
• Attach the washer (27) with the surface (A) on the
cylinder block side. 27
18

A
E5D622

3. Insert the pin (23) into the cylinder block. 14 21 22 23

• Grease the pin.
4. Insert the guide (22).
5. Insert the shoe holder (14) into the piston assembly
(21), and insert the shoe holder (14) and piston as-
sembly (21) into the cylinder block.
• Apply enough hydraulic oil to the parts before in-
serting them.

L3D622

6. Insert the bearing (30) into the shaft (29).

29
• Press-fit the bearing into the shaft using the press-
fitting jig (E).

30

K3D643

18
SLEW MOTOR 4N0AS00
 DISASSEMBLY AND ASSEMBLY
SLEW MOTOR 4
7. Insert the oil seal into the case.
• Grease the oil seal.
• Use the press-fitting jig (K) to push the oil seal all
the way into the case.

8. Insert the pinion shaft (29) into the motor housing.

29
• Press-fit the pinion shaft into the motor housing
using the press-fitting jig (F).

L3D633

9. Attach the swash plate (28) to the motor housing.

• Grease side A.

10. Attach the cylinder block (6) to the housing.

• When attaching, be careful not to allow the pins
and shoe holder to come loose from the cylinder
block.
11. Insert the center discs (20) and the friction discs
(19).
• Line up the positions of the gaps in the spline
teeth.

19
SLEW MOTOR 4N0AS00
 DISASSEMBLY AND ASSEMBLY
SLEW MOTOR 4
12. Insert the collar (17) with attached O-rings.

13. Insert the brake pistons (15) with attached O-rings

into the motor housing.
• Insert the brake pistons so that position (A) for the
6.4-mm-diameter pin hole is at the position in the
diagram at right.
• Press-fit the brake piston using the press ma-
chine.

14. Insert the sixteen large springs (34), the eight small
springs (35), and the O-rings.
• Insert the eight small springs (35) into the loca-
tions indicated in the diagram at right.

15. Attach the O-ring and backup ring to the relief valve
(12).
16. Insert the relief valve into the cover.
• Do not loosen the set screw (13).
Plug: 373 N·m ± 20 N·m
13

12
L3D618

20
SLEW MOTOR 4N0AS00
 DISASSEMBLY AND ASSEMBLY
SLEW MOTOR 4
17. Insert the check valve into the valve body. 9
a. Insert the spring (10) and the poppet (11). 10
b. Insert the plug (9) with attached O-ring into the 11
cover.
Plug: 157 N·m ± 10 N·m

11
10
9

L3D617

18. Insert the bearing (4) into the valve body.

L3D615

19. Insert the pin and the valve plate (3).

• Grease the backside of the valve plate to prevent
the pin from falling out.
• After inserting the pin, tap location (A) with a
punch to swage the valve plate into place.

20. Attach the valve body (2), and secure it using the
cap screws. 2
• Be careful not to allow the valve plate to fall.
Cap screw: 294 N·m ± 20 N·m

K3D629

21
SLEW MOTOR 4N0AS00
 DISASSEMBLY AND ASSEMBLY
SLEW MOTOR 4
21. Insert the timer valve (1).
a. Insert the O-rings into the motor housing.
b. Affix the timer valve in place using the cap
screws.
9.2 N·m ± 1.0 N·m
1

L3D613

22
SLEW MOTOR 4N0AS00
 DISASSEMBLY AND ASSEMBLY
SLEW MOTOR 4
Reduction gears
1. Attach the oil seal to the case.
• Grease the oil seal.
• Use the press-fitting jig (L).

2. Apply grease to the bearing attachment section in

the case.
SHELL RETINAX HD-2 or an equivalent

3. Attach the collar to the pinion shaft.

• Grease the inner circumference of the collar.
• Press-fit the collar onto the pinion shaft using the
press-fitting jig (G).

23
SLEW MOTOR 4N0AS00
 DISASSEMBLY AND ASSEMBLY
SLEW MOTOR 4
4. Attach the cover to the pinion shaft.
• Attach the seal ring to the cover.

5. Insert the bearing into the pinion shaft.

• Press-fit the bearing into the pinion shaft using the
press-fitting jig (G).
• Grease the bearing with SHELL RETINAX HD-2
grease or an equivalent.

6. Insert the pinion shaft into the case.

• Press-fit the pinion shaft into the case using the
press-fitting jig (B).

7. Attach the cover, and affix it in place using the cap

screws.
Cap screw: Loctite #242
Cap screw: 24.5 N·m ± 4.9 N·m

24
SLEW MOTOR 4N0AS00
 DISASSEMBLY AND ASSEMBLY
SLEW MOTOR 4
8. Insert the bearing into the pinion shaft.
• Grease the inner surfaces of the inner race on the
bearing.
• Press-fit the inner race into the pinion shaft using
the press-fitting jig (H).

9. Attach the ring nut to the pinion shaft.

10. Attach the stopper tool (I) and socket tool (J) to the
ring nut.

11. Use a torque multiplier wrench to tighten the ring nut.

Ring nut: 44 N·m to 48 N·m (Using a torque mul-
tiplier wrench)
Ring nut: 1100 N·m to 1200 N·m (Using a stan-
dard torque wrench)

25
SLEW MOTOR 4N0AS00
 DISASSEMBLY AND ASSEMBLY
SLEW MOTOR 4
12. Swage the ring nut in three places (at intervals of
120°).

13. Insert the O-rings into the case.

• Grease the O-rings.

14. Insert the 2nd stage planet gear assembly.

15. Attach the sun gear.

26
SLEW MOTOR 4N0AS00
 DISASSEMBLY AND ASSEMBLY
SLEW MOTOR 4
16. Attach the ring gear.
• Line up the assembly marks placed on the parts
before disassembly.

17. Attach the O-ring to the ring gear.

• Grease the O-ring.

18. Attach the ring gear.

• Line up the assembly marks placed on the parts
before disassembly.

19. Attach the 1st stage ring gear.

27
SLEW MOTOR 4N0AS00
 DISASSEMBLY AND ASSEMBLY
SLEW MOTOR 4
20. Attach the sun gear.
• Check to ensure that the part is at the below di-
mensions before attachment to the motor assem-
bly.

Slew motor
1. Attach the hydraulic motor (1) to the reduction gears
(2), and secure it in place using the cap screws.
Cap screw: 85 N·m ± 4.3 N·m 1

K3D627

2. Attach the O-ring to the valve body.

3. Insert the reversal prevention valve into the valve
body, and secure it in place using the cap screws.
Cap screw: 32.4 N·m ± 2.0 N·m

K3D626

28
SLEW MOTOR 4N0AS00
 DISASSEMBLY AND ASSEMBLY
SLEW MOTOR 4
Inspection and adjustments
Use limit for parts
Brake valve
Part Criteria Action
Check valve, • If there is severe damage to sliding parts or excessive surface rough- • Replace
piston ness
• If there is a great amount of looseness occurring between the body • Replace
and the check valve, piston
• If there is severe damage to the seat or seating is not uniform • Replace
Housing • If there is severe damage to sliding parts or excessive surface rough- • Replace
ness
• If there is damage, etc. that allows oil leakages to occur • Replace
Relief valve as- • If there are abnormal drops in the set pressure • Replace
sembly • If there is vibration due to the set pressure being unstable • Replace
• If there is increased leakage due to faulty seating • Replace
Spring • If there is a high degree of breakage or deformation • Replace

Hydraulic motor
Standard When replacement
Part Action
dimension recommended
Clearance (S) be- 0.02 mm 0.04 mm (0.0016 in.) Replace the cylinder block
tween the piston (0.0008 in.) and swash plate assembly
and cylinder bore
D
d

S = D-d
4I0AF22Z

Amount of loose- 0.15 mm 0.4 mm (0.016 in.) Replace the cylinder block
ness (S) between (0.006 in.) and swash plate assembly
the piston and
shoe

4I0AF23Z

Bearings If there is flaking or Replace

pitching on the rolling
surface
Sliding surface (1) If there is roughness Repair with a lapping tool
of the cylinder on the sliding surfac- (Powder #1000) or replace
1
block es
Sliding surface (2) Replace
of the port block
2
4N0AF30Z

29
SLEW MOTOR 4N0AS00
 DISASSEMBLY AND ASSEMBLY
SLEW MOTOR 4
Reduction gears
Part Criteria Action
Drive gear, • If there is pitting, abrasion, etc. occurring on the surface of the gear • Replace
housing, inter- teeth
nal gear • If the amount of looseness between the housing, gears and the motor • Replace
joints has increased due to spline wear
Planetary gear • If there is pitting, abrasion, etc. occurring on the surface of the gear • Replace
teeth
• If there is flaking, abrasion, etc. occurring on rolling surfaces of the • Replace
needle bearings
Needle bear- • If there is flaking, abrasion, etc. occurring on rolling surfaces of the • Replace
ing, planetary needle bearings and shafts
shaft • If there are indentations, etc. occurring on rolling surfaces of the nee- • Replace
dle bearings and shafts
• If there are abnormalities occurring in the rotation of the bearings • Replace
(abnormal noise generated, rotation not smooth, etc.)
Carrier, shaft • If there is a great amount of looseness occurring between the carri- • Replace
ers, shafts and the planetary shafts
Shaft • If the amount of looseness between the shaft and the pinion has in- • Replace
creased due to spline wear
Thrust washers • If there is an excessive amount of wear occurring • Replace
Ball bearing, • If there are abnormalities occurring in rotation (abnormal noise gen- • Replace
roller bearing erated, rotation not smooth, etc.)
• If there is flaking, abrasion, etc. occurring on rolling surfaces • Replace
• If there are indentations, etc. occurring on rolling surfaces • Replace
Collar, oil seals, • If there is damage, etc. that allows oil leakages to occur • Replace
O-rings

Reversal prevention valve

Part Criteria Action
Check valve • If there is severe damage to sliding parts or excessive surface rough- • Replace
ness
• If there is a great amount of looseness occurring between the body • Replace
and the check valve
• If there is severe damage to the seat or the seating is not uniform • Replace
Body • If there is severe damage to sliding parts or excessive surface rough- • Replace
ness
• If there is damage, etc. that allows oil leakages to occur • Replace
Spring, sleeve • If there is a high degree of breakage or deformation • Replace

30
SLEW MOTOR 4N0AS00
 DISASSEMBLY AND ASSEMBLY
SWIVEL JOINT 4
SWIVEL JOINT
Construction

1. Seal 6. Dust seal 11. Pin

2. O-ring 7. Shaft 12. Snap ring
3. O-ring 8. Hub 13. Bolt
4. Backup ring 9. Flange 14. Plug
5. Dust seal 10. Spacer 15. Spring washer

1
SWIVEL JOINT 4O0AQ00
 DISASSEMBLY AND ASSEMBLY
SWIVEL JOINT 4
Disassembly and Assembly
The numbers in parentheses () listed after the names of
parts in this document do not match the numbers used in
the construction diagrams and parts lists.
General Precautions
• Perform disassembly and assembly work in a clean
place. Provide clean containers to hold parts during
disassembly.
• Clean around the ports before disassembly. Remove
paint around connectors with a wire brush.
• Clean the disassembled parts with wash oil.
• Put alignment marks on all parts to reassemble them in
the same positions.
• After each disassembly, replace all seals and apply a
thin layer of grease to them.
• Check each part for abnormal wear or seizing. Re-
move any burrs with sandpaper.

Disassembly
1. Take out the bolts and remove the hub from the
flange (1).
• Hold the hub in a vise.
• During assembly, use a pipe on the stopper pin of 1
the shaft to check that the shaft rotates smoothly.
Bolt: 24.5 to 39.2 N·m

4O0AF03Z

2. Remove the O-ring (2), snap ring (3) and thrust ring
4
(4).
• During assembly, ensure that the snap ring is
firmly engaged in the groove.

3 4O0AF04Z

2
SWIVEL JOINT 4O0AQ00
 DISASSEMBLY AND ASSEMBLY
SWIVEL JOINT 4
3. Remove the shaft (5) from the hub.
• Place a knock pin (6) against the end of the shaft
and tap it with a hammer.
• Select a knock pin made of a material such as
copper or plastic.
• During assembly, apply a thin coating of hydrau-
lic oil to the outer circumference of the shaft.
6

4O0AF05Z

4. Remove the dust seals from the shaft.

4O0AF06Z

5. Remove the seals from the inside diameter of the

hub.
• Check the positions of the seals in the construc-
tion diagram.
• Remove the O-ring with an awl or similar pointed
tool.
• Do not strongly deform or bend localized portions
of the slipper seal.
• During assembly, make sure that the O-ring is not
twisted.

4O0AF07Z

Assembly
For assembly, refer to the construction diagram and re-
verse the disassembly procedure.

3
SWIVEL JOINT 4O0AQ00
 DISASSEMBLY AND ASSEMBLY
SWIVEL JOINT 4
Inspection and adjustment
Inspection procedures and remedial actions
Inspection interval Inspection point Inspection procedure Action
2000 hours Seals preventing ex- Check if oil is leaking externally. If a leak is found, replace the
ternal leakage of oil O-rings.
4000 hours All seals –– Replace all seal parts.
Disassemble and in- All sliding surfaces Check for abnormal wear, scratch- Remedy in accordance with
spect regardless of ing, or corrosion due to seizing or the use limit of parts.
leaks trapped foreign matter.
Disassembly due to All parts Check for abnormal wear, scratch- Remedy in accordance with
malfunction ing, or corrosion due to seizing or the limit of use of parts.
trapped foreign matter. Replace the seal kit.

Use limit for parts

Hub, shaft
Part Criteria Action
Areas in sliding contact • High-frequency induction-hardened surfaces worn • Replace
with seals away; peeling due to seizing or trapping of foreign
matter
Sliding surfaces of hub • Abnormal wear or scratches 0.1 mm deep or more • Replace
and shaft (excepting due to seizing or trapping of foreign matter
seals) • Scratches 0.1 mm deep or more • Repair with a grindstone
Sliding surfaces of • Wear exceeding 0.5 mm or abnormal wear • Replace
thrust ring • Wear not exceeding 0.5 mm • Repair to make surfaces smooth
• Repairable scratches due to seizing or trapping of • Repair to make surfaces smooth
foreign matter that do not exceed the 0.5 mm wear
limit

Flange
Part Criteria Action
Areas in sliding contact • Wear exceeding 0.5 mm or abnormal wear • Replace
with shaft • Wear not exceeding 0.5 mm • Repair to make surfaces smooth
• Repairable scratches due to seizing or trapping of • Repair to make surfaces smooth
foreign matter that do not exceed the 0.5 mm wear
limit

Thrust ring
Criteria Action
Wear exceeding 0.5 mm or abnormal wear Replace
Wear not exceeding 0.5 mm Repair to make surfaces smooth
Repairable scratches due to seizing or trapping of foreign matter that do not ex- Repair to make surfaces smooth
ceed the 0.5 mm wear limit

4
SWIVEL JOINT 4O0AQ00
 DISASSEMBLY AND ASSEMBLY
SWIVEL JOINT 4
Inspection after assembly
After assembly, perform an oil leak test on each circuit
using the apparatus shown in the figure.

3
1

6
4

4O0AF08Z

1. Connect the pipe (3) from the hydraulic pump (2) to

the shaft (1) side port.
2. Connect the pressure gauge (5) to the hub (4) side.
• Increase the pressure gradually to 20.6 MPa while
adjusting the relief valve (6). Perform the leak test
for one minute.
• Open the neighboring ports on both sides and vi-
sually check for leaks from the ports.
• Perform a color check to detect external leaks.

5
SWIVEL JOINT 4O0AQ00
TROUBLESHOOTING 5
Overall machine
Traveling
Slewing
Boom
Arm
Bucket
Boom swing
Blade
Auxiliary hydraulics
Piston pump
Gear pump
Control valve
Pilot valve
Solenoid valve
Cylinders
Travel motor
Slew motor
 TROUBLESHOOTING
5
This “Troubleshooting” section describes the fault diagnosis and corrective actions mainly for hydraulic systems. The
cause of the problem can be investigated by following the steps in the chart shown at the beginning of each item.

Notes on troubleshooting and servicing

1. Do not disassemble the faulty part without first investigating the following.
a. Ask the user the following questions.
• The situation when the fault occurred.
• Any abnormalities or changes before the fault occurred.
• Any faulty parts other than the part in question.
• Any identical failure in the past
b. Drive the machine yourself and confirm the faulty condition.
• Determine if it is really faulty by referring to the performance criteria. Note that such determination may differ
depending on the person.

Important
By operating the user’s machine, you could make a bad situation worse. Therefore, before driving the machine, always
ask the user’s permission to do so.
c. Determine the cause of trouble based on the information obtained from the user and by driving the machine
yourself. Also remember that once the machine has been disassembled, it is almost impossible to reproduce
the conditions of the trouble, and so there will be no second chance to find out the true cause. Therefore be
sure to find the true cause of the trouble before attempting disassembly.
2. When multiple causes are suspected, start with the simplest one.
3. Think why the trouble occurred and try to correct the root cause of the problem.

1
5A0AQ00
 TROUBLESHOOTING
OVERALL MACHINE 5
OVERALL MACHINE
No operation is possible.

Check the hydraulic oil Insufficient

1 Add hydraulic oil.
level.

Sufficient

Faulty • Repair or replace the hy-

Check the hydraulic
2 draulic pump.
pump.
• Replace the coupling.

1. Check the hydraulic oil level.

Check the hydraulic oil tank level.
“4. Disassembly and assembly, Hydraulic oil
tank”
When adding, use the same brand of oil currently be-
ing used.
“2. Service data, Fuel and lubricant table”
2. Check the hydraulic pump.
• Check the discharge pressure of the main hy-
draulic pump and sub hydraulic pump.
“2. Service data, Performance criteria.”
• Refer to the hydraulic pump assignment table for
details.

Right travel, slew, 1st auxiliary line pip-

P1
ing, boom [2], arm [1]

Main Left travel, bucket, boom [1], arm [2],

P2
swing

P4 2nd auxiliary line, blade

Lever lock, 2nd speed travel, slew PB

Sub P3
opened

1
OVERALL MACHINE 5B0AS00
 TROUBLESHOOTING
OVERALL MACHINE 5
All systems working, but power insufficient.

Check the hydraulic oil Insufficient

1 Add hydraulic oil.
level.

Sufficient

The hydraulic pump is Noise Replace the seal tape, O-ring

2 emitting an abnormal Suction line faulty
and hose.
noise.

No noise

Action appropriate to the

Frothing in the tank
cause of the frothing.

Check the main relief Faulty

3 Repair or replace.
valve.

Normal

The hydraulic pump is

4 Repair or replace.
faulty.

1. Check the hydraulic oil level.

Check the hydraulic oil tank level.
“4. Disassembly and assembly, Hydraulic oil
tank”
When adding, use the same brand of oil currently be-
ing used.
“2. Service data, Fuel and lubricant table”
2. The hydraulic pump is emitting an abnormal noise.
The noise is likely to be caused by cavitation in the
pump, due to a faulty suction line. Check the follow-
ing.
a. The lines for sucking the hydraulic oil.
• Apply grease or oil on the suspected faulty sec-
tions and check for a change. (check if air is
being sucked)
b. Clogging in the suction filter.
c. Apply pressure to the hydraulic oil tank.
“4. Disassembly and assembly, Hydraulic oil
tank”
3. Check the main relief valve.
Measure the relief pressure of the main relief valve.
• If the measured value is within the specifications,
the main relief valve is normal.
“2. Service data, Performance criteria”

2
OVERALL MACHINE 5B0AS00
 TROUBLESHOOTING
OVERALL MACHINE 5
4. The hydraulic pump is faulty.
If the inside of the pump is excessively worn or dam-
aged, it is likely that metal pieces are in the hydraulic
oil. If this is the case, do the following.
• Replace the elements of the line filter and the re-
turn filter.
• Replace the hydraulic oil or perform flushing.
• When replacing the hydraulic oil, clean the tank
and the suction strainer.
If the pump seal is damaged, replace it.

3
OVERALL MACHINE 5B0AS00
 TROUBLESHOOTING
OVERALL MACHINE 5
Boom, bucket, slew and arm fail to move or are too slow.

Faulty • Repair or replace the gear

Check the hydraulic
1 pump.
pump.
• Replace the coupling.

Normal
Faulty
2 Check the fuse. Replace the fuse.

Normal

Faulty Adjust or replace the limit

3 Check the limit switch.
switch.

Normal

Check the lever lock sole- Faulty Repair or replace the lever
4
noid valve. lock solenoid valve.

Normal

Check the pilot relief Faulty Repair or replace the pilot re-
5
valve. lief valve.

Normal
Faulty Repair or replace the pilot
6 Check the pilot valve.
valve.

1. Check the hydraulic pump.

Check the pump (P3) that supplies hydraulic pres-
sure for the pilot valve.
“2. Service data, Performance criteria”
Also, check the line filter for possible clogging, and
clean it if necessary.
2. Check the fuse.
Check the fuse in the power supply circuit used to
run the solenoid valve.

4
OVERALL MACHINE 5B0AS00
 TROUBLESHOOTING
OVERALL MACHINE 5
3. Check the limit switch.
The limit switch can be switched ON by moving the
lever stand to the driving position.
Then, use a tester to check if there is voltage up to
the lever lock solenoid valve.
• The switch is working normally if there is a voltage
present.
“2. Service data, Electrical circuit diagram”

4. Check the lever lock solenoid valve.

Check according to the guidelines below.
a. Turn ON the starter switch.
b. Lightly press down the protruding part on the so-
lenoid end.
c. The limit switch changes from OFF to ON using
the lever stand.
d. If you feel vibration under your fingers when the
spool is moved and the circuit is switched, the le-
ver lock solenoid valve is normal.
5. Check the pilot relief valve.
Measure the relief pressure of the pilot relief valve.
• If the measured value is within the specifications,
the pilot relief valve is normal.
“2. Service data, Performance criteria”
6. Check the pilot valve.
“4. Disassembly and assembly, Pilot valve”

5
OVERALL MACHINE 5B0AS00
 TROUBLESHOOTING
TRAVELING 5
TRAVELING
No right or left travel

Check the operation of Abnormal Check the main relief valve

1 actuators other than the
and pump.
travel motor.
Normal

Check the pilot valve Faulty Repair or replace the pilot

2
(travel). valve (travel).

Normal

Faulty Repair or replace the housing

3 Check the control valve.
block.

Normal

Faulty Repair or replace the swivel

4 Check the swivel joint.
joint.

Normal

Faulty Repair or replace the travel

5 Check the travel motor.
motor.

1. Check the operation of actuators other than the travel

motor.
• Check whether only the travel operation is faulty.
If the operation of other actuators is also defective,
see Overall machine.
2. Check the pilot valve (Travel).
• Disconnect the hose connecting the pilot valve
and control valve (Pa1, Pb1, Pa6, Pb6) from the
control valve, and attach a pressure gauge to the
disconnected hose.
• Operate the travel lever, and measure the pres-
sure.
• The pilot valve is working normally if the pressure
varies between 0 MPa and 3.9 MPa (0 and 566
psi), according to the lever angle.
• If the measured pressure is found to be abnormal,
check the pilot valve.

1
TRAVELING 5C0AS00
 TROUBLESHOOTING
TRAVELING 5
3. Check the control valve.
Disconnect the hose connecting the control valve
(A1, B1, A6, B6) and swivel joint from the control
valve, and attach a pressure gauge to the port of the
control valve.
• Operate the travel lever, and measure the pres-
sure.
Supply pressure: 34.3 MPa (4975 psi)
• If the measured pressure is found to be abnormal,
check the control valve.

4. Check the swivel joint.

Disconnect the hose connecting the swivel joint and
travel motor from the travel motor, and attach a pres-
sure gauge to the disconnected hose.
• Fit the pressure gauge to the section indicated by
the arrow.
• Operate the travel lever, and measure the pres-
sure.
• The valve is normal if the measured value stated
below is achieved.
Supply pressure: 34.3 MPa (4975 psi)
• If the measured pressure is found to be abnormal,
check the swivel joint.

5. Check the travel motor.

• If both forward travel and reverse travel are dis-
abled, the counterbalance valve spool (1) of the
travel motor may be stuck in the neutral position.
• If either forward or reverse travel is enabled but
the other is disabled, the counterbalance valve
spool (1) may be stuck in a position other than
neutral.
• Remove the plug (2) of the counterbalance valve,
and trying pushing on the spool (1) with a finger.
The spool (1) is working normally if it smoothly
moves by about 6 mm (0.24 in.).
For issues other than those listed above, check the
hydraulic motor and reduction gears of the travel mo-
tor.

2
TRAVELING 5C0AS00
 TROUBLESHOOTING
TRAVELING 5
Right or left travel speed decelerates and the machine veers to one side.

Is the veering value dur- Within spec Problem caused by the

1 Normal
ing travel within spec? combination of devices

Out-of-spec

Check the crawler belt Faulty Adjust to the specified crawl-

tension. Check for foreign
2 er tension and remove the for-
matter caught in the
eign matter.
crawler belt.

Normal

Check the pilot valve Faulty Repair or replace the pilot

3
(travel). valve (travel).

Normal

Faulty Repair or replace the housing

4 Check the control valve.
block.

Normal

Faulty Repair or replace the swivel

5 Check the swivel joint.
joint.

Normal

Faulty Repair or replace the travel

6 Check the travel motor.
motor.

1. Is the veering value during travel within spec?

If the veering value falls within the specifications, the
machine is normal. The problem is caused by the
combination of devices.
“2. Service data, Performance criteria”
2. Adjust the crawler belt tension.
“2. Service data, Performance criteria”
3. Check the pilot valve (Travel).
“Traveling, No right or left travel”
4. Check the control valve.
“Traveling, No right or left travel”
5. Check the swivel joint.
“Traveling, No right or left travel”

3
TRAVELING 5C0AS00
 TROUBLESHOOTING
TRAVELING 5
6. Check the travel motor.
<Checking the counterbalance valve>
Check the movement of the counterbalance valve
spool of the travel motor to ensure that it moves
smoothly.
“Traveling, No right or left travel, Check the trav-
el motor”

<Checking the drain volume from the travel motor>

Raise the machine using the hoe attachment and
blade, and then run the travel motor under the condi-
tions listed below to obtain a measurement of drain
volume over one minute.
a. Push the button on the air breather of the hydrau-
lic tank to release the internal pressure in the hy-
draulic tank.
b. Disconnect the drain hose connected to the travel
motor, and attach a plug to the disconnected
hose.
c. Attach a drain-measurement hose to the drain
port on the travel motor.
d. Run the travel motor at 1st-speed, and measure
the resultant drain volume.
• Hydraulic oil temp.: 50°C to 60°C (122°F to
140°F)
• Engine: Maximum RPM
• Drain volume: 1.2 L/min. (0.32 US gal./min.) or
less
For issues other than those listed above, check the
hydraulic motor of the travel motor.

5C0AS02

4
TRAVELING 5C0AS00
 TROUBLESHOOTING
TRAVELING 5
2nd-speed travel is not possible.

Check the hydraulic Faulty

1 Repair or replace the pump.
pump.

Normal

Check the 2nd speed Faulty

2 Repair or replace.
travel switch.

Normal

Check the 2nd-speed so- Faulty Repair or replace the 2nd-

3
lenoid valve. speed solenoid valve.

Normal

Faulty Repair or replace the swivel

4 Check the swivel joint.
joint.

Normal

Faulty
5 The travel motor is faulty Repair or replace.

1. Checking the hydraulic pump.

Check the pump P3 that supplies hydraulic pressure
for the pilot valve.
“2. Service data, Performance criteria”
Also, check the line filter for possible clogging, and
clean it if necessary.
2. Check the 2nd speed travel switch.
a. Press the switch to turn it on. Use a tester to check
if there is a voltage present.
The switch is working normally if there is a voltage
present.
b. Check the harness continuity.
c. Check the switch.
d. Check the controller.

5
TRAVELING 5C0AS00
 TROUBLESHOOTING
TRAVELING 5
3. Check the 2nd-speed solenoid valve.
Check according to the guidelines below.
a. Turn ON the starter switch.
b. Lightly press down the protruding part on the so-
lenoid end.
c. The 2nd-speed travel switch changes from OFF to
ON.
d. If you feel vibration under your fingers when the
spool is moved and the circuit is switched, the
2nd-speed solenoid valve is normal.
• If the switching is abnormal, check the solenoid
valve.

4. Check the swivel joint.

Disconnect the travel motor end of the hose connect-
ing the swivel joint and travel motor. Attach a pres-
sure gauge to the disconnected hose. Turn on the
2nd-speed switch.
• Fit the pressure gauge to the section indicated by
the arrow.
• Supply pressure: 3.9 MPa (566 psi)
5. The travel motor is faulty.
Repair or replacve the 2nd speed control valve of the
travel motor.

6
TRAVELING 5C0AS00
 TROUBLESHOOTING
SLEWING 5
SLEWING
No slew movement.

Faulty Repair or replace the pilot

1 Check the pilot valve.
valve.

Normal

Faulty Repair or replace the housing

2 Check the control valve.
block.

Normal

Pressure too low Adjust the slew relief

3 Check the slew pressure. Adjust to the set pressure.
valve pressure.

Normal Pressure does not in-

crease
Repair or replace the slew re-
lief valve.

Faulty Repair or replace the slew

4 Check the slew motor.
motor.

Normal

Slew bearing is faulty. Replace

1. Check the pilot valve.

Disconnect the hose between the pilot valve and
control valve (Pa3, Pb3) from the control valve, and
attach a pressure gauge to the disconnected hose.
• Operate the lever (slew), and measure the pres-
sure.
• The pilot valve is working normally if the pressure
varies between 0 MPa and 3.9 MPa (0 and 566
psi), according to the lever angle.

1
SLEWING 5D0AS00
 TROUBLESHOOTING
SLEWING 5
2. Check the control valve.
Disconnect the hose connecting the control valve
(B3, A3) and slew motor from the control valve, and
attach a pressure gauge to the port of the control
valve.
• Operate the lever (slew), and measure the pres-
sure.
• The valve is normal if the measured value stated
below is achieved.
Supply pressure: 33.3 MPa (4830 psi)
3. Check the slew pressure.
Measure the pressure at the right and left slew relief
valves.
• If the measured value is within the specifications,
the slew pressure is normal.
“2. Service data, Performance criteria”
If the pressure can be adjusted, the slew relief valve
adjustment is incorrect. If the pressure cannot be ad-
justed, the slew relief valve is faulty.
4. Check the slew motor.
<Motor>
Separate the reduction gear (1) from the motor (2),
and try to rotate the motor (2).
• If it rotates.............. The reduction gear (1) or slew
bearing (3) is faulty.
• If it fails to rotate .... The slew motor (2) is faulty.

<Reduction gear>
Separate the reduction gear from the turntable (4),
and try to rotate the pinion by hand.
• If it rotates.............. The slew bearing (3) is faulty.
• If it fails to rotate .... The reduction gear is faulty.

2
SLEWING 5D0AS00
 TROUBLESHOOTING
SLEWING 5
No right or left slew movement.

Faulty Repair or replace the pilot

1 Check the pilot valve.
valve.

Normal
Faulty Repair or replace the housing
2 Check the control valve.
block.

Normal

Check the slew relief Faulty Repair or replace the slew re-
3
valve. lief valve.

Normal

Check the check valve in Faulty Repair or replace the brake

4
the slew brake valve. valve.

Normal

Repair or replace the slew

5 Slew motor is faulty.
motor.

1. Check the pilot valve.

The pilot valve spool may be faulty only on the side
where slew movement fails to occur.
“No slew movement, Check the pilot valve.”
2. Check the control valve.
Spool may fail to move only on the side where slew
movement fails to occur.
“No slew movement, Check the control valve.”
3. Check the slew relief valve.
Switch the left and right slew relief valves. If slewing
becomes possible, the relief valve is faulty.

3
SLEWING 5D0AS00
 TROUBLESHOOTING
SLEWING 5
4. Check the check valve in the slew brake valve.
No left or right slew movement occurs if foreign mat-
ter trapped in one of the check valves (1) or if the
valve is sticking.
• If foreign matter is trapped in either of the check
valves, the hydraulic oil returns from the check
valve into the tank.
5. Slew motor is faulty.
“4. Disassembly and assembly, Slew motor”

4
SLEWING 5D0AS00
 TROUBLESHOOTING
SLEWING 5
Slewing is slow or lacks force.

Is the slewing time within Within spec

1 Normal
spec?

Slow

Faulty Repair or replace the pilot

2 Check the pilot valve.
valve.

Normal

Faulty Repair or replace the housing

3 Check the control valve.
block.

Normal

Pressure too low Adjust the slew relief

4 Check the slew pressure. Adjust to the set pressure.
valve pressure.

Normal Pressure does not in-

crease.
Repair or replace the relief
valve.

Check the check valves Faulty Repair or replace the brake

5
in the slew brake valve. valve.

Normal

Faulty Repair or replace the slew

6 Check the slew motor.
motor.

Normal

Slew bearing is faulty. Replace

1. Is the slewing time within spec?

“2. Service data, Performance criteria”
2. Check the pilot valve.
“No slew movement, Check the pilot valve.”
3. Check the control valve.
“No slew movement, Check the control valve.”
4. Check the slew pressure.
“2. Service data, Performance criteria”
5. Check the check valve in the slew brake valve.
”No slew movement, Check the check valve in
the slew brake valve.”
6. Check the slew motor.
“No slew movement, Check the slew motor.”

5
SLEWING 5D0AS00
 TROUBLESHOOTING
SLEWING 5
Slewing occurs but overrun is large when slewing stops or slewing fails to stop.

Is the overrun when slew- Within spec

1 Normal
ing stops within spec?

Out-of-spec

Faulty Repair or replace the pilot

2 Check the pilot valve.
valve.

Normal

Faulty Repair or replace the housing

3 Check the control valve.
block.

Normal

Check the check valve in Faulty Repair or replace the brake

4
the slew brake valve. valve.

Normal

Pressure too low Adjust the slew relief

5 Check the slew pressure. Adjust to the set pressure.
valve pressure.

Pressure does not in-

crease.
Repair or replace the relief
valve.

1. Is the overrun when slewing stops within spec?

“2. Service data, Performance criteria”
2. Check the pilot valve.
Check to see if the pilot valve spool returns to the
neutral position when the operation lever (slew) is re-
leased after operation. Disconnect the hose con-
necting the pilot valve and control valve (Pa3, Pb3)
from the control valve, and attach a pressure gauge
to the disconnected hose.
• Read the pressure gauge when the lever (slew) is
released after operation.
• If the pressure is zero, the pilot valve is normal.

6
SLEWING 5D0AS00
 TROUBLESHOOTING
SLEWING 5
3. Check the control valve.
Check to see if the control valve (slew section) spool
returns to the neutral position when the operation le-
ver (slew) is returned to the neutral position. Discon-
nect the hose connecting the control valve (B3, A3)
and the slew motor from the control valve, and attach
a pressure gauge to the port of the valve.
• Read the pressure gauge when the lever (slew) is
released after operation.
• If the pressure is zero, the control valve is normal.
4. Check the check valve in the slew brake valve.
“No right or left slew movement, Check the
check valve in the slew brake valve.”
5. Check the slew pressure.
“2. Service data, Performance criteria”

7
SLEWING 5D0AS00
 TROUBLESHOOTING
SLEWING 5
When stopped on a slope, the upper-structure cannot maintain its posture.

Is the slew spontaneous Within spec

1 Normal
drop within spec?

Out-of-spec

Pressure too low Adjust the relief valve

2 Check the slew pressure. pressure for the slew Adjust to the set pressure.
brake valve.

Normal Pressure does not in-

crease.
Repair or replace the slew re-
lief valve.

Faulty Repair or replace the slew

3 Check the slew motor.
motor.

1. Is the slew spontaneous drop within spec?

“2. Service data, Performance criteria”
2. Check the slew pressure.
Measure the pressure at the right and left slew relief
valves.
• If the measured value is within the specifications,
the valve is normal.
“2. Service data, Performance criteria”
3. Check the slew motor.
“No slew movement, Check the slew motor.”

8
SLEWING 5D0AS00
 TROUBLESHOOTING
BOOM 5
BOOM
Boom cylinder does not move.

Check the operation of Abnormal

Check the main relief valve
1 actuators other than the
and pump.
boom cylinder.

Normal

Faulty Repair or replace the pilot

2 Check the pilot valve.
valve.

Normal

Faulty
3 Check the control valve. Repair or replace.

Normal

Test the port relief valve Problem solved The port relief valve is Repair or replace the port re-
4
with a replacement valve. faulty. lief valve.

No change

Check the emergency Faulty

5 Replace
shut-off valve.

Normal

Faulty Repair or replace the boom

6 Check the boom cylinder.
cylinder.

1. Check the operation of actuators other than the boom

cylinder.
• Check whether only the boom operation is faulty.
If the operation of other actuators is also defective,
see Overall machine.
2. Check the pilot valve.
Disconnect the hose between the pilot valve and
control valve (Pa4, Pb8) from the control valve, and
attach a pressure gauge to the disconnected hose.
• Operate the lever (boom), and measure the pres-
sure.
• The pilot valve is working normally if the pressure
varies between 0 MPa and 3.9 MPa (0 and 566
psi), according to the lever angle.
If the measured pressure is abnormal, replace the pi-
lot valve.

1
BOOM 5G0AS00
 TROUBLESHOOTING
BOOM 5
3. Check the control valve.
Disconnect the cylinder end of each of the hoses (A,
B, C, D) connecting the control valve and boom cyl-
inders, and attach a pressure gauge to each of the
disconnected hoses.
• Operate the lever (boom), and measure the pres-
sure.
Supply pressure: 34.3 MPa (4975 psi)
If the measured pressure is abnormal, replace the
control valve.

4. Test the port relief valve with a replacement valve.

If the boom cylinder is able to operate with a replace-
ment valve taken out from a normal port relief valve
of the arm, then the port relief valve on the boom side
is faulty.

5. Check the emergency shut-off valve.

Note: The emergency shut-off valve (1) allows pres-
sure to be supplied to the cylinder side from
the check valve (2) when the boom is raised,
which enables the boom to be prevented from
being lowered by the check valve (2) even if
some problem arises such as due to damage
in the hose on the downstream side on the low-
er part of the check valve.
When the boom is lowered, pilot pressure for
boom (lower) operation is supplied to the
emergency shut-off valve (1), and the emer-
gency shut-off valve (1) connects together the
cylinder head side and the return side on the
control valve.

2
BOOM 5G0AS00
 TROUBLESHOOTING
BOOM 5
a. Disconnect the hose from the emergency shut-off
valve (PIL port), and attach a pressure gauge to
the hose.
b. Operate the lever (boom), and measure the pres-
sure.
c. The emergency shut-off valve is faulty if the sup-
ply pressure is 3.9 MPa (566 psi).
6. Check the boom cylinder.
“4. Disassembly and assembly, Cylinders”

3
BOOM 5G0AS00
 TROUBLESHOOTING
BOOM 5
Boom cylinder is slow or lacks force.

Is the speed of the boom Within spec

1 Normal
cylinder within spec?

Out-of-spec

Faulty Repair or replace the pilot

2 Check the pilot valve.
valve.

Normal

Faulty Repair or replace the housing

3 Check the control valve.
block.

Normal

Test the port relief valve Problem solved The port relief valve is Repair or replace the port re-
4
with a replacement valve. faulty. lief valve.

No change

Faulty Repair or replace the boom

5 Check the boom cylinder.
cylinder.

1. Is the speed of the boom cylinder within spec?

“2. Service data, Performance criteria”
2. Check the pilot valve.
“Boom, Boom cylinder does not move.”
3. Check the control valve.
“Boom, Boom cylinder does not move.”
4. Test the port relief valve with a replacement valve.
“Boom, Boom cylinder does not move.”
5. Check the boom cylinder.
Check for leakage inside the boom cylinder (1).
a. With the bucket cylinder fully retracted and the
arm cylinder extended slightly from the fully re-
tracted position, lower the bucket tip to the
ground.

4
BOOM 5G0AS00
 TROUBLESHOOTING
BOOM 5
b. Disconnect the hose (A) from the rod end only,
and drain the oil from the piping. Insert a plug (1)
into the disconnected hose.
• Check the right and left cylinders separately,
one at a time. The two hoses should be discon-
nected from the cylinder that is not being
checked during the check of the other cylinder
and each hose fitted with a plug on the end that
was disconnected.

c. Retract the arm cylinder to lift the bucket off the

ground. If oil leaks from the cylinder piping from
which the hose was disconnected and the boom
cylinder rod retracts, the cylinder is leaking inter-
nally. If no oil leaks from the cylinder piping and
the boom cylinder rod retracts, the control valve is
leaking internally.

Check for leakage inside the boom cylinder (2).

a. Set the machine in the posture shown in the fig-
ure.

b. Disconnect the hose (B) from the head end, and

drain the oil from the cylinder piping. Insert a plug
(2) into the disconnected hose.
• Check the right and left cylinders separately,
one at a time. The two hoses should be discon-
nected from the cylinder that is not being
checked during the check of the other cylinder
and each hose fitted with a plug on the end that
was disconnected.

5
BOOM 5G0AS00
 TROUBLESHOOTING
BOOM 5
c. Operate the bucket to raise the machine body. If
oil leaks from the cylinder piping from which the
hose was disconnected and the boom cylinder
rod extends, the cylinder is leaking internally.
If no oil leaks from the cylinder piping and the
boom cylinder rod extends, the control valve is
leaking internally.
If the cylinder is damaged internally, the system
must be flushed out to remove any debris.

5G0AS03

6
BOOM 5G0AS00
 TROUBLESHOOTING
BOOM 5
Spontaneous drop of the boom cylinder is too large.

Is the spontaneous drop Within spec

1 of the boom cylinder with- Normal
in spec?

Out-of-spec

Check for leakage inside Faulty Repair or replace the boom

2
the boom cylinder. cylinder.

Normal

Test the port relief valve Problem solved The port relief valve is Repair or replace the port re-
3
with a replacement valve. faulty. lief valve.

Normal

4 Check the control valve. Replace the housing block.

1. Is the spontaneous drop of the boom cylinder within

spec?
“2. Service data, Performance criteria”
2. Check for leakage inside the boom cylinder.
“Boom, Boom cylinder is slow or lacks force.”
3. Test the port relief valve with a replacement valve.
“Boom, Boom cylinder does not move.”
4. Check the control valve.
“Boom, Boom cylinder does not move.”

7
BOOM 5G0AS00
 TROUBLESHOOTING
ARM 5
ARM
Arm cylinder does not move.

Check the operation of Abnormal

Check the main relief valve
1 actuators other than the
and pump.
arm cylinder.

Normal

Faulty Repair or replace the pilot

2 Check the pilot valve.
valve.

Normal

Faulty
3 Check the control valve. Repair or replace.

Normal

Test the port relief valve Problem solved The port relief valve is Repair or replace the port re-
4
with a replacement valve. faulty. lief valve.

No change

Check the emergency Faulty Replace the emergency shut-

5
shut-off valve. off valve.

Normal

Faulty Repair or replace the arm cyl-

6 Check the arm cylinder.
inder.

1. Check the operation of actuators other than the arm

cylinder.
• Check whether only the arm operation is faulty.
If the operation of other actuators is also defective,
see Overall machine.
2. Check the pilot valve.
Disconnect the hose between the pilot valve and
control valve (Pa5, Pb5) from the control valve, and
attach a pressure gauge to the disconnected hose.
• Operate the lever (arm), and measure the pres-
sure.
• The pilot valve is working normally if the pressure
varies between 0 MPa and 3.9 MPa (0 and 566
psi), according to the lever angle.
If the measured pressure is abnormal, replace the pi-
lot valve.

1
ARM 5G1AS00
 TROUBLESHOOTING
ARM 5
3. Check the control valve.
Disconnect the hose connecting the control valve
and arm cylinder from the pipe, and attach a pres-
sure gauge to the disconnected hose.
• Operate the lever (arm), and measure the pres-
sure.
Supply pressure: 34.3 MPa (4975 psi)
If the measured pressure is abnormal, replace the
control valve.

1 Arm
2 Bucket

4. Test the port relief valve with a replacement valve.

If the arm cylinder is able to operate with a replace-
ment valve taken out from a normal port relief valve
of the boom, then the port relief valve on the arm side
is faulty.

5. Check the emergency shut-off valve. M

• Check it in the cylinder extension direction.
C2
a. Disconnect the hose from the emergency shut-off E V2
valve (PIL port), and attach a pressure gauge to
the hose. Pil
T
b. Operate the lever (arm), and measure the pres-
sure.
c. The emergency shut-off valve is defective if the
pressure varies between 0 MPa and 3.9 MPa (0 C2 M
T
psi and 566 psi), according to the lever angle. V2

6. Check the arm cylinder. 1

2
“4. Disassembly and assembly, Cylinder” 5G0AQ04Z

2
ARM 5G1AS00
 TROUBLESHOOTING
ARM 5
Arm cylinder is slow or lacks force.

Is the speed of the arm Within spec

1 Normal
cylinder within spec?

Out-of-spec

Faulty Repair or replace the pilot

2 Check the pilot valve.
valve.

Normal

Faulty Repair or replace the housing

3 Check the control valve.
block.

Normal
Faulty Repair or replace the arm cyl-
4 Check the arm cylinder.
inder.

1. Is the speed of the arm cylinder within spec?

“2. Service data, Performance criteria”
2. Check the pilot valve.
“Arm, Arm cylinder does not move.”
3. Check the control valve.
“Arm, Arm cylinder does not move.”

3
ARM 5G1AS00
 TROUBLESHOOTING
ARM 5
4. Check the arm cylinder.
Check for leakage inside the arm cylinder.
a. Fully retract the arm cylinder and rest the bucket
on the ground.

b. Disconnect the two hoses from the cylinder. Insert

plugs (1) into the disconnected hoses and the cyl-
inder piping.

c. Raise the boom and lift the hoe attachment off the
ground. If the arm falls, the cylinder is faulty. If not,
internal leakage has is occurring inside the con-
trol valve.

4
ARM 5G1AS00
 TROUBLESHOOTING
ARM 5
Spontaneous drop of the arm is too large.

Is the spontaneous drop Within spec

1 of the arm cylinder within Normal
spec?

Out-of-spec

Faulty Repair or replace the arm cyl-

2 Check the arm cylinder.
inder.

Normal

3 Check the control valve. Replace the housing block.

1. Is the spontaneous drop of the arm cylinder within

spec?
“2. Service data, Performance criteria”
2. Check the arm cylinder.
“Arm, Arm cylinder is slow or lacks force.”
3. Check the control valve.
“Arm, Arm cylinder does not move.”

5
ARM 5G1AS00
 TROUBLESHOOTING
BUCKET 5
BUCKET
Bucket cylinder does not move or lacks force.

Check the operation of Abnormal

Check the main relief valve
1 actuators other than the
and pump.
bucket cylinders.

Normal

Faulty Repair or replace the pilot

2 Check the pilot valve.
valve.

Normal

Faulty
3 Check the control valve. Repair or replace.

Normal

Test the port relief valve Problem solved The port relief valve is Repair or replace the port re-
4
with a replacement valve. faulty. lief valve.

No change

Check the bucket cylin- Faulty Repair or replace the bucket

5
der. cylinder.

1. Check the operation of actuators other than the buck-

et cylinder.
• Check whether only the bucket operation is faulty.
If the operation of other actuators is also defective,
see Overall Machine.
2. Check the pilot valve.
Disconnect the hose between the pilot valve and
control valve (Pa7, Pb7) from one of the valves, and
attach a pressure gauge to the disconnected hose.
• Fit the pressure gauge to the section indicated by
the arrow.
• Operate the lever (bucket), and measure the
pressure.
• The pilot valve is working normally if the pressure
varies between 0 MPa and 3.9 MPa (0 and 566
psi), according to the lever angle.
If the measured pressure is abnormal, replace the pi-
5G2AS01
lot valve.
“Boom, Boom cylinder does not move.”

1
BUCKET 5G2AS00
 TROUBLESHOOTING
BUCKET 5
3. Check the control valve.
Disconnect the hose connecting the control valve
and bucket cylinder from the pipe, and attach a pres-
sure gauge to the disconnected hose.
• Operate the lever (bucket), and measure the
pressure.
Supply pressure: 34.3 MPa (4975 psi)
If the measured pressure is abnormal, replace the
control valve.

1 Arm
2 Bucket

4. Test the port relief valve with a replacement valve.

If the bucket cylinder is able to operate with a re-
placement valve taken out from a normal port relief
valve of the arm, then the port relief valve on the
bucket side is faulty.
5. Check the bucket cylinder.
“4. Disassembly and assembly, Cylinder”

2
BUCKET 5G2AS00
 TROUBLESHOOTING
BUCKET 5
Spontaneous drop of the bucket is too large.

Is the spontaneous drop Within spec

1 of the bucket cylinder Normal
within spec?

Out-of-spec

Check for leakage inside Faulty Repair or replace the bucket

2
the bucket cylinder. cylinder.

Normal

Oil leaking inside the control

Replace the housing block.
valve.

1. Is the spontaneous drop of the bucket cylinder within

spec?
“2. Service data, Performance criteria”
2. Check the bucket cylinder.
a. Fully extend the bucket cylinder, fully retract the
arm cylinder, and rest the bucket on the ground.

b. Disconnect the two hoses from the cylinder. Insert

plugs (1) into the disconnected hoses and the cyl-
inder piping.
c. Raise the boom and lift the hoe attachment off the
ground. If the bucket drops, the cylinder is faulty.
Otherwise, there is a leak inside the control valve.

3
BUCKET 5G2AS00
 TROUBLESHOOTING
BOOM SWING 5
BOOM SWING
Swing cylinder does not move.

Check the operation of

1 actuators other than the
swing cylinder.

Normal

Faulty Repair or replace the pilot

2 Check the pilot valve.
valve.

Normal

Faulty Repair or replace the housing

3 Check the control valve.
block.

Normal

Test the port relief valve Problem solved The port relief valve is Repair or replace the port re-
4
with a replacement valve. faulty. lief valve.

No change

Check the swing cylin- Faulty Repair or replace the swing

5
der. cylinder.

1. Use the table to check whether only the boom swing

cylinder operation is faulty. If the operation is faulty,
check the main relief valve and the hydraulic pump
(main).
“2. Service data, Performance criteria”
2. Check the pilot valve.
Disconnect the hose between the pilot valve and
control valve (Pra1, Prb1) from the control valve, and
attach a pressure gauge to the disconnected hose.
• Operate the pilot valve (boom swing), and mea-
sure the pressure.
• The pilot valve is working normally if the pressure
varies between 0 MPa and 3.9 MPa (0 and 566
psi), according to the lever angle.

1
BOOM SWING 5G3AS00
 5
TROUBLESHOOTING
BOOM SWING

3. Check the control valve.

Disconnect the hose connecting the control valve
(AR1, BR1) and swing cylinder (R, H) from the cylin-
der end, and attach a pressure gauge to the discon-
nected hose.
• Operate the lever (boom swing), and measure the
pressure.
Supply pressure: 17 MPa (2465psi)

4. Test the port relief valve with a replacement valve.

If the boom swing cylinder is able to operate with a
replacement valve taken out from a port relief valve
of the normal arm, then the port relief valve on the
boom swing side is faulty.
5. Check the swing cylinder
“4. Disassembly and assembly, Cylinders”

2
BOOM SWING 5G3AS001
 TROUBLESHOOTING
BLADE 5
BLADE
Blade cylinder does not move or lacks force.

Check the operation of

1 actuators other than the
blade cylinder.

Normal

Faulty Repair or replace the pilot

2 Check the pilot valve.
valve.

Normal

Faulty
3 Check the control valve. Repair or replace.

Normal

Test the port relief valve Problem solved The port relief valve is Repair or replace the port re-
4
with a replacement valve. faulty. lief valve.

No change

Faulty
5 Check the swivel joint. Repair or replace.

Normal

Faulty Repair or replace the blade

Check the blade cylinder.
cylinder.

1. Use the table to check whether only the blade cylin-

der operation is faulty. If the blade cylinder is faulty,
check the main relief valve and the hydraulic pump.
“2. Service data, Performance criteria”
Lever to operate Device to check
2nd auxiliary line Relief valve R3 Pump Pr

2. Check the pilot valve.

Disconnect the hose between the pilot valve (blade)
and control valve (Pra2, Prb2) from the control valve,
and attach a pressure gauge to the disconnected
hose.
• Operate the pilot valve (blade), and measure the
pressure.
• The pilot valve is working normally if the pressure
varies between 0 MPa and 3.9 MPa (0 and 566
psi), according to the lever angle.

1
BLADE 5G5AS00
 TROUBLESHOOTING
BLADE 5
3. Check the control valve.
Disconnect the hose connecting the control valve
(blade section) and swivel joint from the control valve
(AR2, BR2), and attach a pressure gauge to the port
of the control valve.
• Operate the pilot valve (blade), and measure the
pressure.
Supply pressure: 23.6 MPa (3423 psi)

4. Test the port relief valve with a replacement valve.

If the blade is able to operate with a replacement
valve taken out from a normal port relief valve of the
2nd auxiliary line, then the port relief valve on the
blade side is faulty.
After the above check is complete, return the port re-
lief valve to its prescribed position.

5. Check the swivel joint.

Disconnect the hose connecting the swivel joint and
blade cylinder from the cylinder. Attach a pressure
gauge to the disconnected hose.
• Fit the pressure gauge to the section indicated by
the arrow.
• Operate the pilot valve (blade), and measure the
pressure.
• The swivel joint is faulty if the measured value list-
ed below is not achieved.
Supply pressure: 23.6 MPa (3423 psi)

5G5AS01

2
BLADE 5G5AS00
 TROUBLESHOOTING
BLADE 5
The spontaneous drop of the blade is too large, or the blade cannot support the machine.

Is the spontaneous drop Within spec

1 Normal
of the blade within spec?

Out-of-spec

Check for leakage inside Faulty Repair or replace the housing

2
the blade cylinder. block.

Normal

Check the swivel joint Faulty Repair or replace the swivel

3
and control valve. joint or control valve.

1. Is the spontaneous drop of the blade within spec?

“2. Service data, Performance criteria”
2. Check for leakage inside the blade cylinder.
a. Raise the machine using the hoe attachment, and
fully lower the blade.

b. Disconnect the hose from the rod end of the blade

cylinder (right), and drain oil from the hose.
Insert a plug (1) into the disconnected hose.
• Remove the two hoses from the blade cylinder
(left) not being checked, and insert plugs (1) into
the disconnected ports and hoses.
• After checking the cylinder of the blade cylinder
(right), check the blade cylinder (left).

3
BLADE 5G5AS00
 TROUBLESHOOTING
BLADE 5

c. Raise the boom to apply a load to the blade.

• If the machine drops while the oil drains from
the cylinder piping, the cylinder is faulty.
If the machine drops even though no oil drains
out, the control valve or the swivel joint is faulty.
If the machine cannot be supported by the
blade, replace the port relief valve with a nor-
mal valve. If the blade can now support the ma-
chine, the port relief valve was faulty.

5G5AF05Z

3. Check the swivel joint and control valve.

Disconnect the control valve end of the hose con-
necting the swivel joint and control valve. Insert a
plug in the disconnected hose.
Follow the procedure in item 2 a to c above to apply
a load to the blade.
If the machine drops, the swivel joint is faulty.
If the machine does not drop, oil is leaking inside the
control valve.

4
BLADE 5G5AS00
 TROUBLESHOOTING
AUXILIARY HYDRAULICS 5
AUXILIARY HYDRAULICS
Prescribed pressure is not supplied to the 1st and 2nd auxiliary lines.

Check the operation of

1 actuators other than the
auxiliary line.

Normal

Check the voltage sup- Faulty

2 plied to the proportional Repair or replace.
control solenoid valve.

Normal

Check the proportional Faulty

3 Repair or replace.
control solenoid valve.

Normal

Faulty Repair or replace the housing

4 Check the control valve.
block.

1. Use the table to check whether only the auxiliary line

operation is faulty. If operation is faulty, check the
main relief valve and the hydraulic pump.
“2. Service data, Performance criteria”

1st auxiliary line

Lever to operate Device to check
Right travel Relief valve R1 Pump P1

2nd auxiliary line

Lever to operate Device to check
Dozer blade Relief valve R3 Pump P4

1
AUXILIARY HYDRAULICS 5G6AS00
 TROUBLESHOOTING
AUXILIARY HYDRAULICS 5
2. Check the voltage supplied to the proportional control
solenoid valve.
Operate the pilot valve proportional lever, and check
the voltage supplied to the proportional control sole-
noid valve from the proportional amplifier.
<1st auxiliary line>
• Terminals (1) and (2), Marking A
• Terminals (3) and (4), Marking B
24 V is normal.

<2nd auxiliary line>

• Terminals (5) and (6), Marking C
• Terminals (7) and (8), Marking D
24 V is normal.

5G6AS02

3. Check the proportional control solenoid valve.

<1st auxiliary line>
Disconnect the hose between the proportional con-
trol solenoid valve (1) and control valve (2), (Pa3,
Pb3) from the control valve, and attach a pressure
gauge to the disconnected hose.
• Operate the proportional lever for the pilot valve,
and measure the pressure.
• The pilot valve is working normally if the pressure
varies between 0 MPa and 3.9 MPa (0 and 566
psi), according to the lever angle.

<2nd auxiliary line>

Disconnect the hose between the proportional con-
trol solenoid valve (3) and control valve (Pra3, Prb3)
from the control valve, and attach a pressure gauge
to the disconnected hose.
• Operate the proportional lever for the pilot valve,
and measure the pressure.
• The pilot valve is working normally if the pressure
varies between 0 MPa and 3.9 MPa (0 and 566
psi), according to the lever angle.

2
AUXILIARY HYDRAULICS 5G6AS00
 TROUBLESHOOTING
AUXILIARY HYDRAULICS 5
4. Check the control valve. AR3

<1st auxiliary line>

BR3
Disconnect the auxiliary line hose from the control
valve (A2, B2), and attach a pressure gauge to the AR1

port on the control valve. A8

• Operate the proportional lever for the pilot valve, BR1
and measure the pressure. A7

• Supply pressure: 34.3 MPa (4975 psi) B8 B5 A5

B7

<2nd auxiliary line> A2

B2
Disconnect the auxiliary line hose from the control
valve, and attach a pressure gauge to the port on the
control valve (AR3, BR3).
• Operate the proportional lever for the pilot valve,
and measure the pressure.
• Supply pressure: 34.3 MPa (4975 psi)

3
AUXILIARY HYDRAULICS 5G6AS00
 TROUBLESHOOTING
PISTON PUMP 5
PISTON PUMP
Symptoms Major causes Remedies
Noise is too loud, unusual • Suction hose is crushed or suction filter • Remove the dirt and correct the crushing.
sound is heard is clogged.
• Joint in the suction side is loose and • Retighten each joint.
sucking air.
• Cavitation is being produced due to too • Replace with hydraulic oil of proper viscos-
high viscosity of the hydraulic oil. ity.
• Pump and engine are not center • Center them again.
aligned.
• Frothing of hydraulic oil. • Investigate the cause of frothing and cor-
rect it.
• Engine RPM is too high. • Run at the rated RPM.
• Mechanical damage to the parts (e.g., • Replace the damaged part(s) or the pump.
bearing).
• The regulator is experiencing hunting • Repair the regulator.
oscillation.
Discharge is insufficient • Engine RPM is too low. • Run at the rated RPM.
• Oil temperature is too high. • Stop running, and check the temperature
again after the oil cools down.
• Viscosity of hydraulic oil is too high. • Replace with hydraulic oil of proper viscos-
ity.
• Pump volume efficiency becomes low. • Replace the pump.
• Hydraulic oil tank level is too low. • Add oil to the specified level.
• Clogging in the suction piping or the • Clean the piping.
suction filter.
• Leak volume of hydraulic devices other • Repair or replace the leaking hydraulic de-
than the pump is increased. vice.
• The regulator is faulty. • Repair the regulator.
Pressure is not increased • Set pressure for the relief valve drops. • Set the relief valve pressure again.
• Leak volume of hydraulic devices other • Repair or replace the leaking hydraulic de-
than the pump is increased. vice.
• Pump volume efficiency becomes low. • Replace the pump.
Abnormal heat is generat- • Leak volume from the pump is in- • Replace the pump.
ed creased.
• Mechanical damage to the parts (e.g., • Replace the damaged part(s) or the pump.
bearing).
• Seizing on the sliding part. • Replace the damaged part(s) or the pump.
Oil leak • Seals are damaged. • Replace the seal(s).
• Sliding part between the shaft and the • Replace the shaft or the pump.
oil seal is worn out.
• Plugs and bolts are loosened. • Retighten the plugs and bolts, or replace
the seals.

1
PISTON PUMP 5I0AS00
 TROUBLESHOOTING
GEAR PUMP 5
GEAR PUMP
“4. Disassembly and assembly, Gear pump”

Symptoms Major causes Remedies

No discharging operation • Direction of rotation is incorrect. • Rotate in the rated direction.
• Hydraulic oil tank level is too low. • Add oil to the specified level.
• Clogging in the suction piping or the • Clean the piping.
suction filter.
• Viscosity of hydraulic oil is too high. • Replace with hydraulic oil of proper viscos-
ity.
• RPM is too low. • Run at the rated RPM.
Noise is too loud, unusual • Cavitation is being produced due to the • Remove the dirt and correct the crushing.
sound is heard crushed hose or clogged filter of the
suction side.
• Joint in the suction side is loose and • Retighten each joint.
sucking air.
• Cavitation is being produced due to too • Replace with hydraulic oil of proper viscos-
high viscosity of the hydraulic oil. ity.
• Pump and engine are not center • Center them again.
aligned.
• Frothing of hydraulic oil. • Investigate the cause of frothing and cor-
rect it.
• Oil seal is deformed, worn out or dam- • Replace the oil seal.
Oil leak from the oil seal
aged.
Oil leak from the mating • Body seal is damaged, or the sliding • Replace with a new one.
surface between the part is worn out.
housing and the flange or
housing and the cover
Discharge is insufficient • Bushing seal is damaged. • Replace the bushing seal.
• Cavitation is being produced. • Clean the suction filter and the suction pip-
ing.
• Aeration is being produced. • Check if piping is properly screwed in.
• Viscosity of hydraulic oil is too low. • Replace with hydraulic oil of proper viscos-
ity.

1
GEAR PUMP 5I1AQ00
 TROUBLESHOOTING
CONTROL VALVE 5
CONTROL VALVE
“4. Disassembly and assembly, Control valve”
The problems are listed individually in the table below, but in reality, many problems have multiple causes. Therefore,
try to check and eliminate each possible cause one at a time.

Symptoms Major causes Remedies

Oil leak from the spool • Flaw is on the sealing part or the seal lip • Replace with a new one.
seal is worn out due to prolonged use.
• Flaw (e.g., dents or scratches) on the • Repair or replace the spool.
sliding part of the spool seal is caused
by an external factor.
• The lid that is pushing the sealing parts • Correct the lid, and determine the partial
in place is installed improperly (lid is wear degree of the seal.
distorted)
• Old paint remains on the seal sliding • Remove it by using thinner or mechanical
part of the spool. force. When removing, take care not to
damage the spool surface or the seal lip.
• Tank pressure becomes too high for the • Remove the cause of the flow resistance.
performance of the sealing material.
Sliding part of the spool is • Foreign matter is caught in the sliding • Overhaul and repair or replace.
not smooth part of the spool.
• Oil film between the spool and the body • Try to decrease the oil temperature. If the
becomes too thin due to the increased relief valve is started often, find the cause
oil temperature. and correct it.
• Lubrication is disabled due to deterio- • Oil should be replaced. The circuit also
rated oil. should be overhauled in some cases.
• Spool is worn out because of prolonged • Replace the spool and the valve block as-
use or of the unbalanced force applied. sembly.
• Spool is bent by the external force. • Check for the straightness of the spool, and
repair or replace.
• Whole valve is distorted due to the dis- • Check the distortion, independent of the in-
tortion of the installation surface. stallation surface (loosening the bolts will
help).
• Valve is operated with the pressure or • For pressure, measure it with a pressure
the flow rate of out-of-spec. gauge. For flow rate, determine it by finding
out the movement speed and capacity of
the actuator.
• Fixing bolts are over-tightened. • Check if the fixing bolts are tightened with
the specified torque. If not, tighten them
again with the specified torque.
• Oil stays in the lid (spring or detent) op- • Oil may come out from the lid, if it is leaking
posite to the spool operation. in the seal of the spool. If that is the case,
replace the seal.
When the actuator is be- • Foreign matter is caught in the seat on • Disassemble the valve and overhaul or re-
ing raised, it drops once the load check valve, or the seat is place the faulty part(s).
damaged by large foreign matter.

1
CONTROL VALVE 5J0AQ00
 TROUBLESHOOTING
CONTROL VALVE 5
Symptoms Major causes Remedies
Spool’s neutral position • There are cases of a large oil leak in- • Check if the cylinder drops spontaneously
cannot be maintained side the cylinder. when it is held. If the cylinder is faulty, dis-
(cylinder drops) assemble and repair it.
• Since the clearance between the spool • Replace the spool and the valve block as-
and the body is too large, oil is leaking sembly.
from the clearance.
• Spool is not completely back in the neu- • Manual: Check if the link mechanism is in-
tral position. terfering with others.
Hydraulic operation: Check the pilot pres-
sure.
• Foreign matter is caught in the seat of • Disassemble, overhaul or replace.
the port relief valve or of the anti-cavita-
tion valve, and thus the oil is bypassing
the section. Or the seat is damaged.
Load cannot be moved • Foreign matter is caught in the seat of • Disassemble, overhaul or replace.
(pressure cannot be in- the port relief valve, and thus the oil is
creased) bypassing the section. Or the seat is
damaged.
• Adjuster screw on the relief valve is • Screw in the adjuster screw. If loose, set the
loose. adjustment again and fasten with a lock nut.
• Foreign matter is caught in the seat of • Disassemble, overhaul or replace.
the port relief valve or of the anti-cavita-
tion valve, and thus the oil is bypassing
the section. Or the seat is damaged.
• Spool stroke is out-of-spec. • Manual: Check if the link mechanism is in-
terfering with others. Check if the pin or pin
hole on the linking section is worn out.
• Oil supply from the pump is insufficient, • Hydraulic operation: Check the pilot pres-
because the pump is damaged. sure.
Check for any abnormality in the pump.
If the pump is faulty, replace it and find the
cause of the abnormality (e.g., faulty air
sucking or oil degradation).
Load cannot be moved • Overloading • Compare with a one with standard load.
(pressure is being in- • Mechanical resistance of related parts/ • Check and add oil, modify or repair the
creased) devices (unrelated to the hydraulic parts/devices.
pressure of the hydraulic oil) is large.
• Large resistance is generated, be- • Repair if the location of clogging or bent is
cause the circuit is clogged with large known.
foreign matter or the piping is bent.
• Spool stroke is out-of-spec. • Check if the link mechanism is interfering
with others and if the pin or pin hole on the
linking section is worn out.

2
CONTROL VALVE 5J0AQ00
 TROUBLESHOOTING
PILOT VALVE 5
PILOT VALVE
“4. Disassembly and assembly, Pilot valve”

Symptoms Major causes Remedies

The secondary pressure • Primary pressure is insufficient. • Keep the primary pressure.
is too low • The spring is broken or worn out. • Replace
• The clearance between the spool and • Replace the spool and the casing assem-
the casing is too large. bly.
• Too much play in the handle. • Disassemble and assemble or replace.
The secondary pressure • The sliding part is not smooth. • Repair or replace.
is unstable • The tank line pressure fluctuates. • Remove the faulty part(s) in the tank line.
• Air is present in the piping. • Bleed air by operating the valve several
times.
The secondary pressure • Pressure in the tank line is high. • Remove the faulty part(s) in the tank line.
is high • The sliding part is not smooth. • Repair or replace.

1
PILOT VALVE 5K2AQ00
 TROUBLESHOOTING
SOLENOID VALVE 5
SOLENOID VALVE
“4. Disassembly and assembly, solenoid valve”

Symptoms Major causes Remedies

Solenoid valve does not • Wiring short-circuit or wire break. • Replace
operate • Coil assembly short-circuit or wire • Replace
break.
• Foreign matter is caught in the spool. • Overhaul and repair or replace.
• Damage on the outer circumference of • Overhaul and repair or replace.
the spool.
• Proportional controller is faulty. • Repair or replace.
• Primary pressure is insufficient. • Keep the primary pressure.
Oil leakage from solenoid • O-ring is damaged. • Replace
valve • Seal nut is damaged. • Replace

1
SOLENOID VALVE 5K6AQ00
 TROUBLESHOOTING
CYLINDERS 5
CYLINDERS
“4. Disassembly and assembly, Cylinders”

Symptoms Major causes Remedies

Oil is leaking from the pis- • Foreign matter is trapped in the inside • Remove the foreign matter.
ton rod sliding surface (oil diameter of the rod packing or dust
forms a ring on the piston seal.
rod, which becomes larg- • Scratching or abnormality of the inter- • Replace the faulty part(s).
er and starts dripping) nal lip surface of the rod packing or
dust seal.
• Scratching on the sliding surface of the • Smooth the sliding surface with an oilstone
piston rod. (1.6 S or less).
• If the leak persists after smoothing the slid-
ing surface, replace the rod packing and
other seals.
• If the leak persists after replacing the seals,
replace the piston rod.
• Peeling of the hard chromium plated • Re-plate the hard chromium plating.
surface.
Oil leaking around the rod • O-ring is damaged. • Replace the faulty part(s).
cover. • Backup ring is damaged. • Replace the faulty part(s).
Oil leaking from welded • Tube welding is damaged. • Replace the faulty part(s).
joint.
Spontaneous cylinder • Foreign matter is trapped in the wear • Remove the foreign matter.
drop (“Spontaneous ring sliding surface.
drop” is defined as 0.5 • Scratching or abnormality of the wear • Replace the faulty part(s).
mm or greater piston ring sliding surface.
movement in 10 minutes
• Scratching on the piston packing slid- • Replace the faulty part(s).
when a static load is exert-
ing surface.
ed on the rod. The static
• O-ring is damaged. • Replace the faulty part(s).
load is determined by
multiplying the maximum
operating pressure by the
cylinder area.)

1
CYLINDERS 5L0AQ00
 TROUBLESHOOTING
TRAVEL MOTOR 5
TRAVEL MOTOR
“4. Disassembly and assembly, Travel motor”

Hydraulic motor
Symptoms Major causes Remedies
Motor fails to start • All the devices other than the motor and • Check whether the specified pressure is
the reduction gears are not working generated in the inlet port, and then check
correctly. and repair each device.
• Pressure oil is not flowing properly due • Replace the abnormally worn out part(s).
to abnormal wear of the motor’s sliding
part.
• Motor is faulty, as its main components • Replace the damaged part(s).
are damaged.
Rated speed cannot be • Specified volume of flow is not supplied • Check whether the specified pressure is
obtained to the motor due to the faulty oil pump. generated in the inlet port, and then check
and repair each device.
• Motor volume efficiency becomes low. • Check if there is abnormal wear on the slid-
ing part; if so, repair or replace it.
Rotational fluctuations are • High-pressure oil is leaking from the • Replace the abnormally worn part, if any.
large drain port, because the motor’s sliding
part is worn out.
• Bearing is worn out. • Replace the abnormally worn part, if any.
Oil leak • Oil leak due to O-ring breakage. • Replace the oil seal and O-ring.
• Oil seal is broken by the internal pres- • Repair the motor and replace the oil seal.
sure generated in the motor case due
to the abnormal wear of the sliding part
of the motor.
• Pressure increase in the drain piping • Clean the clogging in the drain piping and
caused by the clogging of foreign mat- replace the oil seal.
ter resulted in breakage of oil seal.

2nd-speed control
Symptoms Major causes Remedies
Straight-ahead traveling Spool cannot be switched.
level is low, switching to • Foreign matter is caught. • Remove foreign matter and correct or re-
2nd-speed travel is dis- place the faulty part(s).
abled
• Spring is missing. • Install the spring.
• Spring is damaged. • Replace the spring.
• Oil leak due to the abnormal wear of the • Replace the 2nd-speed control piston.
2nd-speed control piston.
• 2nd-speed control piston is missing. • Install the 2nd-speed control piston.
• Ball is abnormally worn out. • Replace the ball.

1
TRAVEL MOTOR 5M0AQ00
 TROUBLESHOOTING
TRAVEL MOTOR 5
Parking brake
Symptoms Major causes Remedies
Braking force is insuffi- • Disc surface is faulty. • Repair or replace
cient or not evenly applied • Spring is damaged. • Replace the spring.
• Bolt for manual releasing is being fitted. • Remove the bolt for manual release, and fit
the plug.
Abnormal heat generation • Release of braking is faulty.
due to brake drag • Oil leak due to O-ring breakage. • Replace the O-ring.
• Orifice is clogged. • Clean the orifice.
• Pilot pressure for the releasing is not • Check whether the specified pressure is
working. generated in the pilot port, and then check
and repair each device.

2
TRAVEL MOTOR 5M0AQ00
 TROUBLESHOOTING
SLEW MOTOR 5
SLEW MOTOR
Abnormal noise or heat indicates that a defect has occurred. If such a symptom occurs, immediately stop the machine
and locate the position of the fault.
The table below shows the causes of problems that can occur in the hydraulic circuits and the appropriate remedies.

Hydraulic motor, brake valve

Symptoms Description/location Major causes Remedies
Motor fails to start. • No pressure at the motor inlet • Relief valve set pressure is too
• Set correctly.
port. low.
• Faulty pump. • Repair or replace.
• Faulty control valve. • Repair or replace.
• Pressure is applied at the motor • Excessive load. • Reduce the load.
inlet port. • Faulty hydraulic motor. • Repair or replace.
• Faulty reduction gears. • Replace the reduc-
tion gears.
Motor speed does • Inadequate pump discharge vol- • Excessive pump drain volume. • Repair or replace
not increase. ume. the pump.
• Problem with motor function. • Poor hydraulic motor volumetric
• Replace the motor.
efficiency.
Oil leaks. • Leaking from oil seal. • Damage to the seal lip. • Replace the oil
seal.
• Leaking from mating surface. • Loose bolts. • Retighten the bolts.
• Defective O-ring. • Replace
• Scratches on mating surface. • Repair surface with
oilstone or sandpa-
per.
Abnormal noise • Noise from piping. • Pipes are inadequately support-
• Clamp the pipes.
from motor. ed.
Temperature in- • Lubricating oil. • Low oil level. • Add oil.
creases in the re- • Hydraulic oil in the casing. • Replace the reduc-
duction gear cas- tion gears.
ing.
• Gear unit. • Damaged bearing. • Replace the reduc-
tion gears.
• Damaged gear surfaces. • Replace the reduc-
tion gears.

1
SLEW MOTOR 5N0AQ00
 TROUBLESHOOTING
SLEW MOTOR 5
Parking brake
Symptoms Major causes Remedies
Brake cannot be re- • Release pressure PB and valve switch- • Set the release pressure PB and signal
leased. ing signal pressure SH are not generat- pressure SH to the prescribed pressure.
Low brake force. ed. Or, low supply pressure.
Brake slips, generating • Valve does not operate due to high • Check the drain circuit for clogging, and re-
noise and heat. drain pressure. pair if necessary. If drain from the motor is
excessive, check and repair the motor.
Timing valve does not switch.
• Scratched or worn sliding parts. • Repair or replace the sliding parts.
• Trapped foreign matter. • Remove foreign matter and repair or re-
place the faulty part(s).
• Damaged spring. • Replace
Brake piston does not operate.
• Damaged O-ring. • Replace
• Scratched or worn sliding parts. • Repair or replace the sliding parts.
• Trapped foreign matter. • Remove foreign matter and repair or re-
place the faulty part(s).
• Worn friction material. • Replace
• Damaged spring. • Replace

2
SLEW MOTOR 5N0AQ00
 OTHER 6
Maintenance software manual
Air conditioner
Lever switch pattern switching method
Hydraulic system schematic
 6
MAINTENANCE SOFTWARE MANUAL

MAINTENANCE SOFTWARE MANUAL

APPLICABLE MODELS: TB1140

APPLICABLE SERIAL NO.: 514400001~

1
6S1AS01
 6
MAINTENANCE SOFTWARE MANUAL
CONTENTS

CONTENTS
1. Outline
2. Connection methods
2-1. Items needed
2-2. Installation of the PLUS+1 GUIDE Service Tool
2-3. Installation of the Maintenance Tool driver
2-4. Connection to the machine and startup of the Maintenance Software
3. Description of functions
3-1. Main screen
3-2. Machine status
Inputs
Outputs
Feedback
CAN
Error Code1
Error Code HVAC
Status of other parts and sections
3-3. Engine status
Engine_Status
DPF_Status
3-4. AUX1 Settings
AUX1 status
Grip_Settings
Current_Settings
3-5. AUX2 Setting
3-6. Others
Option
Dev Control mode
Grip pattern
Misc
Liftalarm

2
CONTENTS 6S1AS01
 6
MAINTENANCE SOFTWARE MANUAL
1. OUTLINE

1. OUTLINE
This software program is designed for use in mainte-
nance procedures. You can perform the various types of
maintenance listed below using this software and a main-
tenance cable.

• Machine status
This function can be used to check the input/output con-
ditions for the controller, the actual current output by the
auxiliary line piping, the status of CAN communications,
the malfunction error codes displayed, and the status of
other machine parts and sections.

• Engine status
This function can be used to check the status conditions
of the engine and diesel particulate filter (DPF).

• AUX1 Settings
This function can be used to adjust the flow rates for the
flow select modes I, II, and III; adjust the operating sen-
sitivity of the sliding switches; and set the output current
setting value.

• AUX2 Settings
This function can be used to adjust the flow rates for the
2nd/4th auxiliary line piping, adjust the operating sensi-
tivity of the sliding switches, and set the output current
setting value.

• Other
This function can be used to set options, operate the die-
sel particulate defuser (DPD), set the lift alarm, change
the switch operation pattern, and perform other similar
tasks.

3
1. OUTLINE 6S1AS01
 6
MAINTENANCE SOFTWARE MANUAL
2. CONNECTION METHODS

2. CONNECTION METHODS
• To use the Maintenance Software program, complete
Steps 2-2 to 2-4 in sequential order.
• Screens shown and installation instructions may vary
depending on the operating system used due to differ-
ences in the language settings and OS used among
other factors. Refer to the instruction manual for the
computer you are using for additional information
should you have questions or need computer-specific
assistance.
• Note that the PLUS+1 GUIDE Service Tool installation
method may change without prior notice. Contact
Takeuchi Manufacturing should any questions arise
regarding installation.

2-1. Items needed

1. Computer

2. CD for installation (Product no.: 05701-00005)

3. Maintenance Tool (Product no. 17301-41810)

4. Cable assembly (Product no.: 17301-41820)

4
2. CONNECTION METHODS 6S1AS01
 6
MAINTENANCE SOFTWARE MANUAL
2. CONNECTION METHODS

2-2. Installation of the PLUS+1 GUIDE Service Tool

a. Start up the setup.exe file.（CD for installation）
• You must have administrator privileges to start
up the Setup Tool. Contact your system admin-
istrator for assistance if you are unable to exe-
cute the file.

b. Once you have executed the setup.exe file, the screen shown below will appear. Click the [Next] on the screen
to proceed.

5
2. CONNECTION METHODS 6S1AS01
 6
MAINTENANCE SOFTWARE MANUAL
2. CONNECTION METHODS

c. Click [Next] to proceed.

d. Click [Next] to proceed.

6
2. CONNECTION METHODS 6S1AS01
 6
MAINTENANCE SOFTWARE MANUAL
2. CONNECTION METHODS

e. Select “I accept the agreement” and then click [Next] to confirm and proceed.

f. Specify the folder for installation (continue as is unless wanting to use a folder other than the one selected) and
then click [Next] to proceed.

7
2. CONNECTION METHODS 6S1AS01
 6
MAINTENANCE SOFTWARE MANUAL
2. CONNECTION METHODS

g. Click [Next] to proceed.

• Uncheck the box if you do not wish to create a desktop icon.

h. Click [Install] to start the installation.

8
2. CONNECTION METHODS 6S1AS01
 6
MAINTENANCE SOFTWARE MANUAL
2. CONNECTION METHODS

i. The screen shown below will appear if the installation is successful.

Installation of the Maintenance Tool driver will start once the installation of the above file is completed. Proceed
to Step 2-3 to continue.

9
2. CONNECTION METHODS 6S1AS01
 6
MAINTENANCE SOFTWARE MANUAL
2. CONNECTION METHODS

2-3. Installation of the Maintenance Tool driver

1. Install the Maintenance Tool driver.
a. The window shown below will appear once Step 2-2 has finished. Click the [Next] in the window to proceed.

b. Select “I accept the agreement” and then click [Next] to confirm and proceed.

10
2. CONNECTION METHODS 6S1AS01
 6
MAINTENANCE SOFTWARE MANUAL
2. CONNECTION METHODS

c. Specify the folder for installation of the driver (continue as is unless wanting to use a folder other than the one
selected) and then click [Next] to proceed.

d. Click [Install] to start the installation.

11
2. CONNECTION METHODS 6S1AS01
 6
MAINTENANCE SOFTWARE MANUAL
2. CONNECTION METHODS

e. The screen shown below will appear if the installation is successful.

Click [Finish] to complete the installation and close the window.

12
2. CONNECTION METHODS 6S1AS01
 6
MAINTENANCE SOFTWARE MANUAL
2. CONNECTION METHODS

2-4. Connection to the machine and startup of the Maintenance Software

1. Connect the Maintenance Tool (product no. 17301-
41810) to the USB port on your computer.
a. The message shown at right will appear as soon
as you connect the Maintenance Tool to the USB
port on your computer and the device is recog-
nized.
Click on the message to start the Found New Hard-
ware Wizard.

6S1AT22

b. Select 2 “Yes, now and every time I connect a device” and then click 4 [Next] to proceed.

1 “Yes, this time only.”

2 “Yes, now and every time I
connect a device.”
3 “No, not this time.”
4 Next

13
2. CONNECTION METHODS 6S1AS01
 6
MAINTENANCE SOFTWARE MANUAL
2. CONNECTION METHODS

c. Select 1 “Install the software automatically.” Click 4 [Next] to start the Search wizard.

1 “Install the software auto-

matically.”
2 “Install from a list or specific
location.”
3 Next

d. A message such as the one shown below will appear to inform you that the installation has been completed.
Click 1 [Finish] to end the Wizard and close the window.

1 Finish

14
2. CONNECTION METHODS 6S1AS01
 6
MAINTENANCE SOFTWARE MANUAL
2. CONNECTION METHODS

2. Start up the PLUS+1 GUIDE Service Tool installed in Step 2-2.

a. Select [Program] from the Start menu and then click on [Sauer-Danfoss]. Click on PLUS+1 GUIDE 5.1, and se-
lect PLUS+1 GUIDE Service Tool.
• You can also start the program by clicking on the desktop icon if you chose to create one.

b. When the window shown below appears, confirm that [CG150] has been selected and then click [OK] to pro-
ceed.

15
2. CONNECTION METHODS 6S1AS01
 6
MAINTENANCE SOFTWARE MANUAL
2. CONNECTION METHODS

c. When the window shown below appears, confirm that [Sauer-Danfoss CG150 #0 (Channel 0)] has been select-
ed and then click [Set] to proceed.

3. Select [Communication]-[Gateway]-[CG150]-[Sauer-Danfoss CG150 #0 (Channel 0)].

• The Maintenance Tool may not be properly connected if the above is not available as a selection. Make sure
that the Maintenance Tool is firmly connected and then try again.

16
2. CONNECTION METHODS 6S1AS01
 6
MAINTENANCE SOFTWARE MANUAL
2. CONNECTION METHODS

4. Start up the Maintenance Software.

a. Select [File]-[Open].

b. Open the Maintenance Software file (File name: TB1140_***.P1D).

• The file should be located in the save location selected for the CD for installation (product no. 05701-
00005) that was selected in Step 2-1 above.

17
2. CONNECTION METHODS 6S1AS01
 6
MAINTENANCE SOFTWARE MANUAL
2. CONNECTION METHODS

5. Connect to the actual machine.

a. Remove the cover (B) on the floor space on the right side in back of the seat.
• Remove the two screws (C) and then remove the cover (B).
b. There is a connector (D) that is marked with a
“CAN_0” mark tube. Connect the cable assembly
(E) to this connector (D).

c. Connect the cable assembly (E) to the Mainte-

nance Tool (A).

1 To actual machine
2 To computer

18
2. CONNECTION METHODS 6S1AS01
 6
MAINTENANCE SOFTWARE MANUAL
3. DESCRIPTION OF FUNCTIONS

3. DESCRIPTION OF FUNCTIONS
3-1. Main screen
Click the different buttons to jump to the associated pages.

19
3. DESCRIPTION OF FUNCTIONS 6S1AS01
 6
MAINTENANCE SOFTWARE MANUAL
3. DESCRIPTION OF FUNCTIONS

3-2. Machine status

Inputs

1 Pin wiring diagram for the main controller: C1P**

2 Pin wiring diagram for the extension module (IX012):
C1P**

1. Input signal 5. Input signal to the main controller from the aux-
ON: Switch ON iliary line piping switches
OFF: Switch OFF Top: Voltage value
2. Input signal to the main controller from the Bottom: Stroke (-100% to +100%)
switches 6. Input signal to the extension module (IX012)
3. Input signal to the main controller by throttle from the switches
operation 7. Input signal to the extension module (IX012)
Top: Voltage value from the pressure sensor
Bottom: Degree of release for the accelerator 8. Input signal to the extension module (IX012)
pedal from the fuel sender
4. Input value to the controller from the pressure Top: Resistance value
sensor Bottom: Level of fuel remaining (0% to 100%)
9. Return to the Main screen

20
3. DESCRIPTION OF FUNCTIONS 6S1AS01
 6
MAINTENANCE SOFTWARE MANUAL
3. DESCRIPTION OF FUNCTIONS

Outputs

1 Pin wiring diagram for the IX012

2 A-key (Gray): C1P**
3 B-key (Black): C2P**

1. Output signal
ON: Switch ON
OFF: Switch OFF
2. Output signals to the devic-
es from the controller
3. Target output current to the
devices from the extension
module (IX012)
Feedback

1. Actual output current for the

devices
2. Power supply voltage (12 V)
Top: Main engine control
unit (ECU)
Middle: Extension module
(OX_024)
Bottom: Extension module
(IX_012)
3. Sensor voltage (5 V)
Top: Main controller
Bottom: Extension module
(IX_012)

21
3. DESCRIPTION OF FUNCTIONS 6S1AS01
 6
MAINTENANCE SOFTWARE MANUAL
3. DESCRIPTION OF FUNCTIONS

CAN

1. CAN communications state

Switching back and forth
between ON/OFF: Normal
Staying OFF: Abnormal

Error_Code

1. Current malfunction codes for the machine 4. Current malfunction codes for the engine
2. Past malfunction codes for the machine 5. Past malfunction codes for the engine
3. Current malfunction codes triggered on the ma- Read: Used to display a list of malfunction codes.
chine are read out.
Write: Current malfunction codes triggered on the
machine are read out in CSV format.
The P1A and CSV files for the extension modules
are created with the same content.
Delete: Used to delete the malfunction code log.

22
3. DESCRIPTION OF FUNCTIONS 6S1AS01
 6
MAINTENANCE SOFTWARE MANUAL
3. DESCRIPTION OF FUNCTIONS

Error_Code_HVAC

1. This function displays the

HVAC (air conditioner) error
codes.

Status of other parts and sections

1. Starter switch position 6. Travel speed

2. Engine status ON: 2nd-speed
ON: Engine running OFF: 1st-speed
OFF: Engine stopped 7. 3rd auxiliary line piping
3. Hour meter 8. 2nd/4th auxiliary line piping
4. Trip meter 9. Air conditioner status
5. Fuel gauge (0% to 100%)

23
3. DESCRIPTION OF FUNCTIONS 6S1AS01
 6
MAINTENANCE SOFTWARE MANUAL
3. DESCRIPTION OF FUNCTIONS

3-3. Engine status

Engine_Status

1. Engine status

DPF_Status

1. DPF status

24
3. DESCRIPTION OF FUNCTIONS 6S1AS01
 6
MAINTENANCE SOFTWARE MANUAL
3. DESCRIPTION OF FUNCTIONS

3-4. AUX1 Settings

AUX1 status

1. Current settings for the 1st

auxiliary line piping
2. Download: Used to down-
load the settings to the con-
troller.
3. Upload: Used to upload the
current settings from the
controller.
4. Flow rate for the flow select
mode

Making adjustments

DANGER
Make sure to exercise extreme caution after making adjustments as the machine could run in an unexpected way, which
could in certain cases cause severe injury or even death. Be extremely careful when operating the auxiliary line piping.

a. Click on (3) to pull up the current setting conditions (4).

b. Click above or below (4) to set the flow rate to any desired value.
c. Click on the box to the left of “Download” to check it.
d. Click on (2) to download the setting values set in b. to the controller.

25
3. DESCRIPTION OF FUNCTIONS 6S1AS01
 6
MAINTENANCE SOFTWARE MANUAL
3. DESCRIPTION OF FUNCTIONS

Grip_Settings

1. Set voltage
2. Voltage (mV)-Current (%)
characteristics graph
3. Download: Used to down-
load the settings to the con-
troller.
4. Upload: Used to upload the
current settings from the
controller.
5. Set Default: Used to return
the settings to the default
values.

Making adjustments

DANGER
Make sure to exercise extreme caution after making adjustments as the machine could run in an unexpected way, which
could in certain cases cause severe injury or even death. Be extremely careful when operating the auxiliary line piping.

The amount of voltage applied to the solenoid valve and the flow rate for the auxiliary line piping may vary depending
on the slide switch operation. Here, an explanation will be given for a method for adjusting the flow rate varying with
changes in voltage.
a. Click on (4) to pull up the current setting conditions (1) and (2).
b. Click above or below (1) to set the option setting to any desired value.
c. Click on (3) to download the setting values set in b. to the controller.

Example settings
For settings with Center: 2500 mV, Neutral Dead Band: 200 mV, Range: 1100 mV
There will be no operation within the 2500 mV ± 200 mV band.
There will be operation within the 1200 mV to 2300 mV and 2700 mV to 3800 mV bands.

26
3. DESCRIPTION OF FUNCTIONS 6S1AS01
 6
MAINTENANCE SOFTWARE MANUAL
3. DESCRIPTION OF FUNCTIONS

Current_Settings

1. Set current
2. Slide switch stroke (%)-Cur-
rent (×0.1 mA) characteris-
tics graph
3. Download: Used to down-
load the settings to the con-
troller.
4. Upload: Used to upload the
current settings from the
controller.

Making adjustments

DANGER
Make sure to exercise extreme caution after making adjustments as the machine could run in an unexpected way, which
could in certain cases cause severe injury or even death. Be extremely careful when operating the auxiliary line piping.

The amount of voltage applied to the solenoid valve and the flow rate for the auxiliary line piping may vary depending
on the slide switch operation. Here, an explanation will be given for a method for adjusting the current according to
slide switch operation.
a. Click on (4) to pull up the current setting conditions (1) and (2).
b. Click above or below (1) to set the option setting to any desired value.
c. Click on (3) to download the setting values set in b. to the controller.

27
3. DESCRIPTION OF FUNCTIONS 6S1AS01
 6
MAINTENANCE SOFTWARE MANUAL
3. DESCRIPTION OF FUNCTIONS

3-5. AUX2 Setting

This function can be used to set the 2nd/4th auxiliary line piping settings. The operation method is the same as for AUX1
Settings.
“3-4. AUX1 Settings”

28
3. DESCRIPTION OF FUNCTIONS 6S1AS01
 6
MAINTENANCE SOFTWARE MANUAL
3. DESCRIPTION OF FUNCTIONS

3-6. Others
Options

1. Option settings
2. Download: Used to down-
load the settings to the con-
troller.
3. Upload: Used to upload the
current settings from the
controller.

Setting the option settings

a. Click on (3) to pull up the current setting conditions (1).
b. After making settings for the different options, check the set items and then click (2).

29
3. DESCRIPTION OF FUNCTIONS 6S1AS01
 6
MAINTENANCE SOFTWARE MANUAL
3. DESCRIPTION OF FUNCTIONS

Dev Control mode

1. This function can be used to

forcibly set DPD regenera-
tion settings and activate
manual regeneration.

Operation method
a. In Step 1, select any option from 1 to 4.
“1”: Activate slow regeneration.
“2”: Forcibly activate manual regeneration.
“3”: Set automatic regeneration on.
“4”: Cancel automatic regeneration.
b. Click "Submit" to proceed.
c. In Step 2, click “Send Message” to execute the selection and proceed.

30
3. DESCRIPTION OF FUNCTIONS 6S1AS01
 6
MAINTENANCE SOFTWARE MANUAL
3. DESCRIPTION OF FUNCTIONS

Grip pattern

1. Download: Used to down-

load the settings to the con-
troller.
2. Upload: Used to upload the
current settings from the
controller.
3. Reverse the switch opera-
tion (A) and (B) for the 1st
auxiliary line piping.
4. Set the detent mode target
to switch operation (B).
5. Reverse the switch opera-
tion (C) and (D) for the 2nd/
4th auxiliary line piping.

Changing the switch pattern

DANGER
Make sure to read the instruction manual for the switch pattern switching kit before attempting the work.
After changing the switch pattern, make sure to affix the decal sticker for the switch pattern switching kit in the specified
location.

a. Click on (2) to pull up the current setting conditions.

b. Select the checkboxes for the items to be changed.
c. Click on (1) to download the items set in b. to the controller.

31
3. DESCRIPTION OF FUNCTIONS 6S1AS01
 6
MAINTENANCE SOFTWARE MANUAL
3. DESCRIPTION OF FUNCTIONS

Misc

1. Download: Used to down-

load the settings to the con-
troller.
2. Upload: Used to upload the
current settings from the
controller.
3. Change the wiper interval.
4. Return all settings other than
the hour meter settings back
to their initial values (factory
default settings).

Changing the interval

a. Click on (2) to pull up the current setting conditions.
b. Click above or below (3) to set the option setting to any desired value.
c. Click on (1) to download the value set in b. to the controller.

Initialization
Click on (4) to return controller settings except for the hour meter settings back to the factory default settings.

32
3. DESCRIPTION OF FUNCTIONS 6S1AS01
 6
MAINTENANCE SOFTWARE MANUAL
3. DESCRIPTION OF FUNCTIONS

Lift alarm

1. Download: Used to down-

load the settings to the con-
troller.
2. Upload: Used to upload the
current settings from the
controller.
3. Set pressure for the lift alarm

Changing the set pressure for the lift alarm

WARNING
Exercise adequate caution when changing the set pressure for the lift alarm. The machine could topple over when the
pressure is changed.

a. Click on (2) to pull up the current setting conditions.

b. Click above or below (3) to set the option setting to any desired value.
c. Click on (1) to download the value set in b. to the controller.

33
3. DESCRIPTION OF FUNCTIONS 6S1AS01
 MAINTENANCE SOFTWARE MANUAL
AIR CONDITIONER 6
AIR CONDITIONER
Compressor assembly

A: Create a clearance.
B: Adjust the fan belt until it yields approximately 8 mm
(0.3 in.) when a force of 98 N (22 lbf) is applied to a
middle point between the pulley and the compressor.
If a tension gauge is used: 529 N (118.9 lbf)
: Loctite #271 or its equivalent

1 Engine IN 1. Bracket 6. Compressor

2 Engine OUT 2. Bracket 7. Belt
3 To “D” condenser IN 3. Guard 8. Hose
4 From “S” air conditioner unit 4. Shaft 9. Hose
5. Shaft

1
AIR CONDITIONER 6S2AS00
 MAINTENANCE SOFTWARE MANUAL
AIR CONDITIONER 6
Condenser assembly

1. Dryer
2. Hose
3. Hose
4. Hose
5. Bracket
6. Transducer

2
AIR CONDITIONER 6S2AS00
 MAINTENANCE SOFTWARE MANUAL
AIR CONDITIONER 6
Air conditioner unit assembly 1

1 To transducer 1. Box 7. Hose 13. Control panel

2. Plate 8. Wire harness 14. Actuator
3. Hose 9. Bracket 15. Charge sensor
4. Accumulator 10. Controller 16. Thermosensor
5. Hose (Drain) 11. Hose
6. Hose 12. Hose

3
AIR CONDITIONER 6S2AS00
 MAINTENANCE SOFTWARE MANUAL
AIR CONDITIONER 6
Air conditioner unit assembly 2

1. Hose 5. Louver
2. Hose 6. Air conditioner unit
3. Louver 7. Bracket
4. Louver

4
AIR CONDITIONER 6S2AS00
 MAINTENANCE SOFTWARE MANUAL
AIR CONDITIONER 6
Air conditioner unit

1. Air conditioner unit 9. Filter 17. Core

2. Cover 10. Box 18. Wire harness
3. Cover 11. Thermostat 19. Panel
4. Evaporator 12. Motor 20. Bracket
5. Heater 13. Valve 21. PCB assembly
6. Housing assembly 14. Control panel 22. Plate
7. Knob 15. Box
8. Orifice 16. Plate

5
AIR CONDITIONER 6S2AS00
AIR CONDITIONER SYSTEM(RED DOT)
Overview of System Operation
• Truck and Heavy Equipment Systems
• Air Conditioner-System Operation
• Heater System Operation
• Environmental Effects on System Operation
• Chapter Review

Truck and Heavy Equipment Systems

A variety of HVAC systems are in use today, some old and some new. There are:
• Vehicle manufacturer installed systems
• Owner specified systems
• Add-on systems
• Retrofit systems
The system components come in different colors, shapes, and sizes. They may be
mounted in or on the cab in varied locations. Owners or fleet maintenance people can
modify systems by adding controls, auxiliary units or ducts. Major components are
sometimes replaced due to damage or failure. All systems were, at least originally,
designed and installed to meet the needs of an operator. Figure 2-1 includes illus-
trations of various AC and Heater systems. They illustrate system advantages and
disadvantages explained in the paragraphs that follow.
The HVAC system includes both heater and air conditioner components, usually
a common control, and air ducts. The system cools the cab by removing heat energy.
It removes moisture from damp air in the cab and adds fresh outside air to the cab. In
this way, the operator can work comfortably in all kinds of weather.
A sleeper unit, built in or added on, increases the air volumes in the cab. The air
conditioner or heater must circulate and cool or heat a larger amount of air. This is ac-
complished by routing ducts and controls to the sleeper compartment as part of system
design. Components may be increased in size to handle the larger cab air volume. A
bigger heater core, air conditioning evaporator coil, condenser, blower or fan may be
included. Often, on long haul trucks, auxiliary air conditioning and heater components
and controls are added. The objective remains the same, to move heat energy and
maintain occupant comfort.

1
System Operation

Air Conditioner—System Operation

We have described the movement of heat energy and basic HVAC system function in
Chapter 1. Now we will go into some detail on how an air conditioner operates. The
system is sealed to keep out air and moisture. To operate properly, the inside of the
system contains a measured amount of refrigerant and special refrigerant oil that keeps
the system lubricated. Figure 2-2 is an illustration of system components without the
cab outline, in-cab controls, component housing, and air ducts or vents. Please study
it for a moment. Note the information printed next to each component. Remember that
the components may be positioned and attached to the truck in various locations.

2
 Air Conditioner—System Operation

The following AC components are discussed in detail in this section:

1. Compressor/Clutch Assembly
2. Condenser
3. Receiver-Drier
4. Expansion Valve
5. Evaporator Coil

Figure 2-2
Air Conditioner components
are connected together to
illustrate system operation.
The components shown are
not to scale. The refrigerant
and refrigerant oil are clear
in color and not visible in
this drawing. The small ar-
rows inside the components
and connecting hoses show
the direction of refrigerant
flow (refrigerant circuit).

1. Compressor/Clutch Assembly
The compressor/clutch assembly is the heart of the system. When the clutch is engaged,
the compressor pumps refrigerant and oil around the system. It raises the temperature
and pressure of the refrigerant gas, and forces it to the condenser where it changes
state and becomes a liquid. The compressor also sucks the vaporized refrigerant out
of the evaporator and back inside itself in the form of gas. One way valves inside the
compressor separate the compressed gas (high pressure) side of the system from the
suction (low pressure) side. Figure 2-3 shows a cutaway view of a compressor with the
high and low pressure sides noted.

3
System Operation

Figure 2-3
The compressor inlet is
low pressure and the outlet
is high pressure. The reed
valves are one way. They
open to allow refrigerant gas
to enter the compressor on
the down stroke and exit on
the upstroke. Note the open
valves in the illustrations.

The clutch is mounted on the shaft of the compressor and is engaged by electromag-
netic action. Part of the clutch assembly is an electromagnetic wire coil. The coil is
energized through a thermostat that senses the temperature in the evaporator coil. If
the evaporator is too warm the electrical contacts close and allows power to flow to the
clutch. The compressor shaft is engaged and moves the refrigerant around inside the
system. Figure 2-4 is a cutaway view of the clutch mounted on the compressor.

Figure 2-4
The clutch shown here has
its electromagnetic coil
mounted on the compressor
body. When the coil is ener-
gized, magnetic force pulls
the clutch drive plate into
the pulley. This action locks
the pulley to the compressor
drive shaft and drives the
compressor.

2. Condenser
The refrigerant gas leaves the compressor and moves through a high pressure hose to
the condenser. Inside the condenser the gas “changes state” and becomes a liquid. It
is still hot and under pressure. Remember in Chapter 1 when we talked about water at
212 degrees Fahrenheit? Heat energy was involved in the “change of state,” but the
temperature did not change. The same kind of action happens inside the AC system.
The refrigerant gas gives up a lot of heat energy to the outside air as it “changes state”
in the condenser. Figure 2-5 illustrates a condenser. Air moving through the condenser
absorbs heat from the refrigerant. The amount of air flow through the condenser is the
major factor in how well the condenser functions.

4
 Air Conditioner—System Operation

Figure 2-5
As the refrigerant gas moves
through the tubing coil from
top to bottom, it condenses
(changes state) into a liquid.
For ease of installation,
condenser fittings are often
routed close together.

3. Receiver-Drier
The liquid refrigerant continues to move inside the system, out of the condenser
through a tube or hose to the receiver-drier. The receiver-drier serves as a small stor-
age tank and filter for the refrigerant. It is also a good location to mount pressure
switches and often contains a sight glass (small window) used to view activity inside
the system. The receiver-drier, Figure 2-6, also separates gas (bubbles) from the liquid
with a pick-up tube as shown in this illustration. Some receiver-driers have a spring to
preload the desiccant pack.

Figure 2-6
This cutaway view of a re-
ceiver-drier shows the filter
elements, inlet, outlet and
refrigerant path. The sight
glass is a small window into
the system used in diagnosis
and when adding refrigerant
(charging the system).

5
System Operation

4. Expansion Valve (Refrigerant Metering Device)

When refrigerant moves from the receiver-drier, it travels through another high pres-
sure hose to a metering device at the inlet of the evaporator coil. The metering device
can be an expansion valve, an expansion tube or a combination (multiple function)
valve. Between the compressor and this point inside the system, the pressure is high
and can range from 150 to 250 pounds per square inch. The expansion valve (TXV) is
closely connected to the evaporator. A diaphragm opens the valve by exerting pressure
on the spring. Pressure comes from gas inside the diaphragm housing on top of the
valve and in the sealed sensing bulb. The sensing tube is located in the outlet of the
evaporator and picks up heat from warm refrigerant leaving the evaporator. The gas in
the valve diaphragm housing and sensing tube expands when it gets warmer and forces
the expansion valve open at the metering orifice.

Figure 2-7
This block type expansion
valve cutaway view will
give you a better idea how
these valves work. Spring
pressure holds the valve
closed.

5. Evaporator Coil
The expansion valve or other type of metering device bleeds high pressure refrigerant
into the evaporator coil, where the pressure is low. The refrigerant expands rapidly in
this low pressure environment. When it expands it “changes state”. The sudden drop
in pressure brings the refrigerant temperature down quickly inside the evaporator coil.
Figure 2-8 shows an evaporator coil and thermostat. Refrigerant is sprayed into the
evaporator by the high side pressure when the expansion valve opens. The refrigerant
absorbs heat from the air when the blower forces the air through the fins. When the
thermostat probe senses the upper limit of the thermostat heat setting, a circuit closes.
The compressor clutch engages and the compressor operates and moves more refriger-
ant to the high side of the system.

6
 Air Conditioner—System Operation

Figure 2-8
The evaporator coil as
shown is of fin and tube
construction. The thermostat
probe is positioned in
between the evaporator fins
and senses the temperature.

Note: Moisture in the air (humidity) condenses on the fins of the evapo-
rator as water droplets which drain out of the evaporator through
a drain hose. This action dehumidifies the air in the cab as part of
system operation, and contributes to operator comfort.
Cab air forced across the evaporator coil gives up heat energy to the cold refrig-
erant inside the coil. The cooled air circulates in the cab for occupant comfort.
Refrigerant continues to expand and absorb heat energy in the evaporator coil.
Refrigerant changes from liquid to gas before it leaves the evaporator on the way
back to the compressor. The refrigerant gas moves to the compressor through a
low pressure (suction) hose. When the compressor is operating, it sucks the re-
frigerant gas back inside, compressing and raising its temperature and pressure.
Some of AC system operation is controlled by the operator, and some is automatic.
The operator can turn the system on and off, regulate the air velocity with the blower
control, and in some designs adjust the thermostat control. The system and component
operating range settings automatically cycle the clutch on and off. The operation of
the expansion valve or other refrigerant metering device at the inlet to the evaporator
is automatic.
Individual system features may differ, but the basic system function remains the
same. Variations in components and controls are described in Chapters 4 and 5. The
engine provides the power for both air conditioner and heater operation. It drives the
AC compressor and the cooling system water pump. Engine RPM affects the efficiency
of both the heater and air conditioner. The slower the engine RPM, the less capacity a
heater or AC system will have.

WARNING When an AC system is operating, the high pressure side com-

ponents, fittings and high pressure lines or hoses can be hot
enough to burn your skin if you touch them. This includes the
compressor, clutch, hoses, condenser, receiver-drier, and any
control devices or metal tubing. The low pressure side will be
cool to the touch. In operation the AC system is under load
and high side pressures normally range between 150 and 250
pounds per square inch for R-12 and higher for some other
refrigerants.

7
System Operation

Heater System Operation

Heater and air conditioner systems both have the same basic function of moving heat.
They take advantage of nature’s laws where heat energy always moves from a warmer
to a cooler area. In a heater system there is no “change of state” involved in system
operation. The system is sealed and operates under pressure, but the pressure is low
when compared to an air conditioner.
A heater system uses the engine coolant to carry excess heat energy to the cab air.
The heart of the system is the water pump. The water pump forces hot coolant through
a hose from the engine block and through the heater core. The coolant is returned to the
engine cooling system either at the suction side of the water pump or to the radiator.
The heater fan or blower forces cab air through the heater core where heat energy
moves from the engine coolant to the air in the cab. Figure 2-9 illustrates the main
heater system components. In-cab controls, component housing and air vents are not
shown.
The following heater components are discussed in detail in this section:
1. Heater Core
2. Water Valves
3. Defrosters and Ducts
4. Blowers and Fans

Figure 2-9
This view of a heater system
shows the main components
and how they are connected.

Additional heater controls, ducts, air vents, blend-air doors, temperature regulating
devices and auxiliary heaters may be installed as part of a heater system. These may be
air, vacuum, electrical or mechanically operated.

8
 Environmental Effects

1. Heater Core
Heater cores are like small radiators. The fin and tube construction is designed to
route coolant flow for the best possible heat energy transfer from coolant to cab
air. Hoses from and to the engine are connected to the core with clamps. The core
outlet may be larger or the same size as the inlet.

2. Water Valves
Water valves may be cable, vacuum or air controlled. The valve can be either
open, closed or set part way open. Some valves have a bypass design to return
coolant to the engine. Most are manually controlled although electronic systems
are now being installed.

3. Defrosters and Ducts

Defrosting is accomplished by directing heated dry air through ducts to the
windshield. The heater system serves the dual purpose of defrosting and heating.
Controls are used to route the air flow to the windshield and occupant areas by
opening and closing duct doors. Controls may be manual, air or vacuum.
Many vehicles use a “defrost interlock” system which utilizes the air condi-
tioner to dry the defrost air and clear the cab windows more quickly.

4. Blowers and Fans

Blowers or fans are used in the system to move cab air through the heater core
and evaporator. Air can be pushed or pulled through the core depending on sys-
tem design. Blower or fan speed is usually selected by the operator.

Environmental Effects on System Operation

The environment outside the cab involves more than the weather. It may be hot and
humid or cold and dry. That is only part of the condition the HVAC system must handle
to maintain an ideal comfort range. A truck can be at idle, in traffic or moving along
for hours on the Interstate at 65 M.P.H. The load condition on a trip can include going
out full, coming home empty, or driving across the Rockies or Kansas plains during
the day or night. The truck color and shape, the windows and angle of the sun are all
variables that can increase or decrease the “load” on the system. The following are a
few examples of environmental effect:
• A black cab-over (COE) with a dark color interior will be more dif-
ficult to cool than the same vehicle with white paint and a light colored
interior. The black cab picks up and holds the radiant heat from the sun
more easily than the white one.
• In Florida or Houston the humidity in mid summer can be very high
with the temperature in the high 90’s or low 100’s. The AC unit must
remove a lot of moisture from the air in the cab as the air moves through
the evaporator fins. The more moisture on the fins, the less effective the
transfer of heat is to the refrigerant inside the evaporator coil.

9
System Operation

• On a cold day the temperature can drop below zero. The engine may
run cooler so the engine coolant is cooler when it circulates through
the heater. The heat in the cab moves out of the cab faster (remember
heat always moves to a cooler area until both are the same tempera-
ture—nature’s law). To maintain cab comfort you have to increase the
flow of coolant through the heater, increase coolant temperature, and/or
move more air through the heater core.
• On a hot day, an off-road vehicle experiences cooling at a slower rate
than an on-road vehicle. This is a result of high sun-load, large window
area and often less insulation.
It is important for you to keep environmental effects in mind when you are servicing
or diagnosing heater or air conditioner systems. If you work in Denver the altitude will
affect system function and pressure. In Houston the heat and humidity may lower heat
transfer to the air at the condenser and increase system operating pressures.

Chapter Review
• HVAC systems range from simple cab heaters to multi-function com-
bination systems. The multi-function system can heat and cool the cab
and sleeper unit, and have separate auxiliary components and controls
for driver and passenger comfort.
• Both heater (engine) coolant and air conditioner refrigerant circulate
inside sealed, pressurized systems. The normal air conditioner operat-
ing pressure ranges from 150 to 250 pounds per square inch, sometimes
higher with a different refrigerant.
• Air conditioners have a high and a low pressure side within the system.
The compressor is the starting point of the high side. Pressure drops at
the expansion valve opening to the evaporator.
• The basic components of an AC system are the compressorclutch as-
sembly, high pressure lines, condenser, receiver-drier, expansion valve,
evaporator, thermostat, blower assembly, and suction lines. There may
be other controls installed for more complex systems.
• The basic components of a heater system are the inlet and outlet hoses,
a water valve and valve control, heater core and fan or blower assembly.
There may be other controls for more complex systems.
• An air conditioner system uses the “change of state” of refrigerant inside
the system to move heat from the cab air to the outside air. Refrigerant
changes from a gas to a liquid in the condenser, and back to a gas in the
evaporator.
• A heater system uses the heat from the engine, carried to the heater core
by the action of the water pump, to warm the air in the cab. There is no
change of state within the heater system.
• Environmental conditions affect how both heaters and air conditioners
work. Weather, driving conditions, color of the vehicle are factors. All
contribute to heat gain or loss inside a cab and how much heat energy
must be moved to maintain occupant comfort.

10
 Inspection and Maintenance-
without gauges
• Discussion of Inspection & Maintenance Survey Results
• Visual Inspection - System Off
• Electrical System Inspection
• Performance Inspection - Engine Running
• Heater System Inspection
• Preventive Maintenance Worksheet
• Chapter Review

Discussion of Inspection & Maintenance Survey Results

There are three reasons for regular inspection and maintenance procedures:
1. They save money in the long run by reducing down time and often
prevent more costly repairs.
2. They help to insure driver comfort and safety.
3. They add to your store of knowledge about these systems and main-
tain your level of efficiency.

About half of all heavy duty vehicles have air conditioners. Surveys of AC system
owners find that over 30% of the systems are serviced every six months or less, and
another 62% are serviced at least once a year.
The survey also covered how often the different components required maintenance.
Figure 7.1 below shows survey finding percentages. Failure of any of the AC compo-
nents listed in the survey could cause a system to malfunction or stop cooling.

Figure 7-1 INSPECTION & MAINTENANCE SURVEY

This chart shows mainte-
nance frequency, lists key
parts and how often they
require maintenance.

Note: The above survey results may not apply to your situation. Actual
operating conditions for the vehicles you service will determine
or influence maintenance frequency and requirements.
The following inspection procedures should take about 15 to 20 minutes, longer if
corrective steps, part replacement or adding refrigerant is necessary. There is a “Pre-
ventive Maintenance Worksheet” you may use at the end of this chapter, Figure 7-9

11
Inspection & Maintenance

Visual Inspection - System Off

Your observations and the corrective measures you take may be different depending
on circumstances. The following inspection procedures are explained in more detail
below:
1. Observe the System
2. Inspect Parts
3. Check Hoses and Fittings
4. Check for Refrigerant Leaks

Use the following procedures as a general rule in performing a visual inspection with
the AC system off:

1. Observe the System

Your first inspection step is to answer the following question if you can:
• Has the vehicle just come in off the road and has the HVAC system
been in use?
• Did the operator or work order explain or describe any problems
about the system?
• Did someone else work on the system yesterday, 700 miles down the
road? Your first inspection step is to answer these questions if you
can.

CAUTION Even when someone has told you what is wrong with an HVAC
system, you should perform a visual inspection. Always make
a visual inspection before you hook up the manifold gauge set.
Never add refrigerant to a system until you have made a com-
plete visual and performance inspection.

2. Inspect Parts
Look at the system for what might come loose, leak, wear out or become dirty
and not function the way it should. The main points for visual inspection of the
system are emphasized in Figure 7-2.

12
 Visual Inspection

Figure 7-2
This system illustration
notes the main points for
visual inspection.

A. Condenser – Is it free of leaves, bugs, bird feathers or mud? The condenser must
be relatively clean to work well as a heat exchanger. How you clean the condenser
depends on where it is mounted. The condenser fin comb, air hose and nozzle, or
soap and water may be used. Where possible, check condenser mounting bolts or
screws and tighten them if necessary.
Condenser failure often results from loose hoses. Hose movement will cause
fatigue failure of condenser tubing adjacent to the fittings. Make sure the hoses are
securely clamped.
While inspecting the condenser check the receiver-drier sight glass and connec-
tions. Look to see if the sight glass has a moisture indicator that is showing moisture
in the system.
B. Components Under the Hood – Tip the cab or raise the hood. Look at the
compressor mounting bracket, compressor clutch assembly, drive belt and pulley
alignment. The mounting bracket, compressor, clutch and drive pulley should be
fastened securely, and a clutch groove (there may be two groves) should be in line
with the drive pulley. Tighten all bolts shown in Figure 7-3, as you inspect.

Figure 7-3
Engine and compressor
vibration can work mount-
ing bolts loose. Tighten
all mounting bolts as you
inspect the system. Slots in
the mounting bracket are
used to move the compressor
clutch assembly in order to
adjust belt tension or align-
ment.

13
Inspection & Maintenance

C. Drive Belt – The drive belt should be tight and in good condition. Use a belt ten-
sion gauge to check tension (120 pounds maximum). With experience, you can feel
belt tension by twisting the belt. Try feeling belt tension after using the gauge, when
you know the tension is correct. Replace belts if they are frayed or look worn.
If the clutch pulley/belt alignment is obviously off, you need to loosen the com-
pressor or mounting bracket, or both—and use the alignment bar to line up the clutch
pulley with the drive pulley. Tighten compressor mounting bolts first, then the bolts
holding the bracket. The mounting bracket should have slots or other means of
adjustment to allow you to adjust the tension of the drive belt. When you use a pry
bar to apply tension, be sure you do not pry against the compressor. Pry against the
mounting bracket.

3. Check Hoses and Fittings

Check all hoses and fittings. Look for places where hoses flex when the cab is tilted.
Any places the hoses or fittings are fastened, clamped, connected, bent or secured are
potential wear points. This also applies to places where hoses are not clamped or sup-
ported but should be (often near the condenser). All of these spots are potential leak or
damage points. Tighten, re-fasten, add, or replace as indicated by your inspection.

4. Check for Refrigerant Leaks

System refrigerant leaks can be anywhere but there are obvious places. You can spot
some by looking for signs of refrigerant oil forced out with refrigerant leakage. One
location leaks frequently occur is the compressor shaft seal. The shaft and seal are
hidden behind the clutch assembly, but centrifugal force will throw the oil off the
shaft and against the engine, bracket or whatever is close. Check these points when
you examine the compressor clutch and mounting bracket. A solution of soap and
water applied around potential leak points works well for detecting leaks. A leak in the
evaporator may be indicated if you feel around the condensate drain hole and find oil
present.

Note: You can add inexpensive dry nitrogen gas to the system instead of
R-12 if system pressures are low. Dispense the gas at no more than
200-250 PSI as this is sufficient pressure to cause or indicate a leak
point in the AC system. AC service procedures for complete system
recovering of refrigerant, evacuating, and recharging are covered and
illustrated in Chapter 9.

Note: A leaking heater core could also result in coolant at the condensate
drain.

14
 Electrical System Inspection

You can feel for oil at the bottom of all connections (see Figure 7-4) if the system
is not too hot. Of course, a few minutes with an electronic leak detector is the
best way to check for leaks. Keep in mind that pressure is different in a system at
rest, so small leaks may be hard to find. Pressure in a system at rest, will equalize
at from 60 to 95 PSI, depending on outside air temperature. This means there is
more pressure in the low side of the system at rest than during normal system
operation. Just the opposite is true of the high side; at rest, high side pressure is
lower. You may want to use the detector to check for leaks in the high side when
the air conditioner is operating, if you suspect a leak and can’t find it when the
system is at rest.

Figure 7-4
This illustration shows a po-
tential refrigerant leak point
at the condenser fitting.

Electrical System Inspection

The two stages of an electrical inspection are explained in more detail below:
1. Inspect Electrical Connections
2. Check Electrical Current Flow and Device Functions
Use the following procedures to perform an electrical system inspection:

1. Inspect Electrical Connections

First, while you are making your visual inspection under the hood (cab) and/or at
the roof top condenser, take a moment and check all electrical connections visu-
ally and by feel. Look for any corrosion on leads or connectors and clean them.
Make sure all leads and wires are properly supported and securely connected.

2. Check Electrical Current Flow and Device Functions

Perform the following steps to check current flow and electrical device func-
tions:

A. Turn the Ignition On – To check current flow the ignition must be on.

15
Inspection & Maintenance

B. Turn the AC System On – This will power the thermostat and clutch.
If it does not come on, use the AC mode switch to check the leads to the
switch. You should be able to hear a “click” from the thermostat and hear
the clutch drive plate “snap” against the clutch pulley. You can not check
thermostat cycling on and off until you do the performance inspection. Fig-
ure 7-5 illustrates a typical AC electrical system and the places you should
inspect.

Figure 7-5
The electrical system inspec-
tion points are noted with
check marks (✔) on this
wiring diagram (electrical
schematic).

C. Check Fuses – If there is a failure and you have made sure all con-
nections are clean and tight, you need to check fuses—in-cab as well as
in-line.

D. Check Clutch Engagement – Since you can’t see and may not hear the
clutch engage, get out and look at the clutch. If it’s engaged, you will see
that the drive plate is against the pulley and not slightly spaced from it. If
you are not sure the clutch is engaged, look for the lead wire connector near
the clutch. Break and close that connection. The clutch will disengage and
engage again.

E. Test Blower Speed Operation – Some systems have a common switch

that turns on the air conditioner and powers the blower motor. Test blower
speed operation by adjusting this or the separate blower control switch.
Feeling the air flow from the ducts or note blower sound (speed) changes.

F. Inspect Roof Mounted Condensers – Don’t forget to inspect roof

mounted condensers and AC systems for dirt and debris. Be sure the con-
denser fan(s) are working properly and all parts and electrical connections
are securely fastened. The roof mounted condenser fans may come on when
the system is turned on. Like the thermostat and most clutches, the normal
on-off cycling action can not be observed until the engine is running with
the AC system on.

16
 Electrical System Inspection

Performance Inspection – Engine Running

The purpose of visual and electrical inspection is to detect obvious problems and assure
AC system function for an accurate performance inspection. If you do the performance
inspection first, you could be mislead. Problem areas discovered during the perfor-
mance inspection can give you false clues or symptoms, and result in repair errors and
come-backs. The following performance inspection procedures are explained in more
detail below:
1. Inspect System Component Cycling and
Cab Temperature Levels
2. Check Clutch Cycling Under Load
3. Check Sight Glass
The performance inspection does not cover pressure and temperature sensitive safety
devices (cutout switches, fan control, Trinary etc.). Testing these devices requires the
use of the manifold gauge set for observation of internal system pressures during tests.
These are explained in Chapter 8.
Use the following procedures as a general rule in a performance inspection:

1. Inspect System Component Cycling and Cab

Temperature Levels
A. Turn On the Engine and Air Conditioner – Inspect for system compo-
nent cycling and cab temperature levels.

Note: System performance testing will be much faster if all doors

and windows in the cab are closed.
The cab air must cool down to thermostat control setting lev-
els before system components will cycle on and off, indicating
correct function. This is called ‘stabilizing the system’ and takes
about five minutes of operation. In very hot weather the system
may not cycle.
B. Check Thermometer Readings – In the cab you can use your thermom-
eter to measure air temperature at the vents. When the evaporator is easy to
reach with a thermometer probe without removing some of the dash or duct
work, use the probe to measure evaporator temperature. When the AC unit
is on and working correctly, you can see the thermometer dial needle move
down to about 32 degrees, then rise six to ten degrees and move back down
again. The movement up and down indicates that the cycling clutch and
thermostat, or orifice tube and accumulator pressure switch (to the clutch)
are functioning correctly. In systems with a non-cycling clutch, this move-
ment indicates correct function of the refrigerant metering device.
The needle movement is called “temperature swing.” When you can ad-
just the thermostat setting, the range of swing should change. For example,
from full cooling (cold) to moderate (between cold and warm), the swing
may change from 32-38 to 32-42 degrees.

17
Inspection & Maintenance

These readings at the vents will be higher and temperature swing slower
and not as obvious. Also blower speed will cause the temperature, levels to
read higher (high air speed) or lower (low air speed) at the same thermostat
setting. When you measure air temperature, an electronic thermometer/py-
rometer is a great tool to have. You can easily measure cab air temperature
at several locations quickly.
Swing temperatures vary depending on where you measure temperature,
and on outside temperature, humidity and altitude. The chart in Figure 7-6,
shows some examples of typical temperature variables. Don’t forget that
cab and sleeper area temperatures can vary within the same vehicle. Also,
electronic controls used in newer HVAC systems often keep the tempera-
ture spread within a narrower range.

air temp. 70° 80° 90° 100°

Figure 7-6
degrees f. The chart of AC system and
air quality humid dry humid dry humid dry humid dry
cab temperature range shows
you typical variables.
center outlet 43° 40° 44° 40° 47° 40° 52° 41°
air temp. to to to to to to to to
degrees f. 47° 44° 48° 44° 51° 44° 56° 45°

left & right air outlet temperature will vary

left right left right left right left right

outlet air temp. 40° 41° 41° 43° 46° 47° 48° 50°
range degrees f. to to to to to to to to
41° 44° 45° 47° 52° 54° 55° 56°

2. Check Clutch Cycling Under Load

The following operating inspections, visual and by feel, are done outside the cab
while you wait for the system to stabilize.
A. Lift hood – With the hood up (or cab tilted) observe the clutch cycling
under load.

Note: If the condenser is hood mounted you may not have adequate air
flow through it.
B. Touch suction and discharge lines – Soon after system start up you can
safely feel the suction and discharge lines and note their change in tempera-
ture. The discharge line will get hot (after a while it may be to hot to touch)
and the suction line will get cooler.

3. Check Sight Glass

The sight glass is the only point where you can actually see inside the air condi-
tioner during operation. Check the sight glass through the window on the top of
the receiver-drier (or the separate in-line sight glass). If the system is functioning
properly and cooling the cab adequately, the sight glass should be clear (you will
not see anything in it). If it is not clear when the system is first turned on, wait a
few minutes for the system to stabilize, then look again. Figure 7-7 illustrates and
explains what you may observe in the sight glass. Roof mounted condenser fans
may run continuously or cycle on and off. If you can’t tell by sound you may have
to climb a ladder and observe the fan blades.

18
 Performance Inspection

Figure 7-7
These drawings illustrate
conditions you may observe
in the sight glass window.

Note: A roof mounted condenser or AC unit assembly often includes

a roof mounted receiver-drier (and sight glass) close to the con-
denser.

Heater System Inspection

A heater system inspection is really a combination engine cooling system and heater
inspection. All heater/cooling system rubber parts deteriorate due to the air (ozone),
heat, coolant and oils. They should be replaced at regular intervals to prevent break-
down on the road. Metal parts and gaskets are subject to malfunction or breakdown
due to fatigue and corrosion.
Coolant has a limited life and should be replaced regularly. If it is dirty, the cool-
ing system should be drained and flushed or back flushed (using special equipment)
before refilling with clean water and anti-freeze. Coolant must be hot when using the
hydrometer to check protection (freeze-up) level. The following inspection procedures
are explained in more detail below:
1. Check Heater Control Valve Function
2. Inspect Other Functions

1. Check Heater Control Valve Function

Many air conditioner/heater systems depend on the heater control valve for tem-
perature control and positive closure. You can easily check heater control valve
function as follows.
A. Cool engine – Start with the engine cool, set the temperature to cold and
leave the fan off. As the engine warms up, feel the heater return hose. If the
hose feels warm or hot, the heater control valve is leaking internally. This
type of leak can seriously reduce air conditioning performance.

19
Inspection & Maintenance

B. Warm up engine – Next, let the engine warm up to normal operating

temperature and set both fan and temperature on high. Feel both heater sup-
ply and return hoses. If there is a noticeable difference in their temperature,
it indicates a low flow of coolant through the heater core (a partially closed
or blocked heater control valve). This could result in poor heating perfor-
mance during cold weather conditions.

Figure 7-8
Heater/cooling system
potential problem areas and
checks are indicated in this
drawing.

2. Inspect Other Functions

There are some things you can’t see or feel when you inspect the thermostat,
heater core, radiator pressure cap, electrical switch and control valve functions.
Some of these can be checked with the pressure and thermostat testers as de-
scribed in Chapter 6. A hand pump pressure tester can also be used to check for
coolant leaks. This is done by using the pump to raise the pressure inside the
system above normal operating pressure to force small suspected leaks to show
up.
Heater/cooling electrical and valve component inspection is the same as air
conditioner inspection. The controls are operated to see if they function correctly
to maintain or vary cab temperature and air flow.

Preventive Maintenance Worksheet

Please feel free to modify or copy the worksheet in Figure 7-9. Actual vehicle use, mile-
age, operating conditions and maintenance budget may influence service frequency.

20
 Chapter Review

Chapter Review
The purpose of these brief inspection procedures is for vehicle system maintenance
and to determine if further, more detailed service is required. The uses of a manifold
gauge set, system troubleshooting, recovery, flushing, evacuating and charging are
explained in the next chapter.
High usage and operating condition variations are tough on air conditioning and
heater components. You should establish and follow regular inspection and mainte-
nance procedures to improve overall system function and component service life.
The typical inspection should not take more than 15 to 20 minutes unless com-
ponent replacement and/or complete system evacuation and recharging is warranted.
The survey results shown in Figure 7-1, indicate belts, compressor clutch assembly,
condenser and the refrigerant lines are the most frequent problem areas. However,
your own experience with service and maintenance may vary from survey results.
Inspection should first be visual and by feel. Some of your electrical system inspec-
tion will be done as you inspect other components (checking leads, connections and
for loose wires). When you check the electrical circuit, begin with the engine off but
ignition on. A system performance inspection with the engine running and system on
really combines electrical and AC or heater system function.

21
22
Troubleshooting
& Service Procedures
• Troubleshooting Overview
• Understanding System Function
• A Troubleshooting Example
• Manifold Gauge Set Installation
• Troubleshooting by Manifold Gauge Set Readings
• Review of Frequent Problem Areas
• Conclusion
Can you fix an air conditioner or heater system without finding and correcting the
cause of the problem? You bet you can! It happens every day and it’s not good for
business. Here is an example. A truck pulls in off the road and the operator asks to have
his rig serviced in a hurry. He tells you the air conditioner isn’t cooling like it should
and dashes into the restaurant for lunch.
You tip the hood, and check the sight glass on top of the receiver-drier. You see
bubbles, not a lot but a fairly constant stream of them. It is obvious the system is low
on refrigerant so you hook up the manifold gauge set, purge the gauge set hoses of
air, and add refrigerant until the sight glass clears. Then you check evaporator tem-
perature and it’s OK. The air conditioner is repaired right? Wrong! What you did is
add refrigerant and the problem went away. You did not find and fix the cause of the
problem.
Component failure in an air conditioning system may be the result of a problem
elsewhere in the system. For example, a belt or clutch failure might be caused by a
dirty condenser restricting air flow and increasing head pressures. High head pressures
commonly create problems with other system components. Take time to look beyond
the obvious for a potential hidden problem.

Troubleshooting Overview
Troubleshooting includes collecting enough information to locate the cause of the
problem, then correcting the problem and its cause by replacement, adjustment, and/or
repairing. You begin by gathering information from the most to the least important
sources.
Starting with the most important:
1. Your personal knowledge and experience with AC systems.
2. The vehicle operator's knowledge and experience—question him or her.
3. The work order.
4. Good test equipment and the HVAC system
The routine you follow when troubleshooting should proceed from the most to least
productive way of locating the problem and fixing the cause.

23
Troubleshooting & Service Procedures

Experienced troubleshooters talk to the operator if they can, then personally verify the
symptoms of the problem whenever possible. They attempt quick fixes on the basis
of their knowledge of common system problems and causes when appropriate. They
know where components are located, and make repairs when they have a good idea
of what the problem is. They fix the cause or causes as well as the problem. They are
confident of their knowledge and ability.

Note: The best troubleshooters all know who to call when they get
stuck. They know someone who knows more than they do and
are not too proud to ask for help or suggestions when needed. The
key—understanding system function

The Key–Understanding System Function

Your complete understanding of AC and heater systems and how they work, plus
what can go wrong, is the key to troubleshooting and repair. We have talked about
components and system function before. Now let’s take a little different approach in
describing what happens when the air conditioner is turned on. In Figure 8-1 we have
used numbers on the illustration to track normal air conditioner function.

Figure 8-1
An illustration of the typical
HVAC system. The numbers
follow the action when the
AC part of the system is
working properly (moving
heat out of the cab and into
the outside air).

24
 Understanding System Function

When you turn on the air conditioner at the control panel (1), the thermostat (2), is
supposed to sense a warm temperature at the evaporator. A circuit in the thermostat
should close, allowing current to flow through the thermostat to the compressor clutch
field coil (3). When this happens, the clutch field coil becomes an electromagnet and
pulls the clutch drive plate (4) tight against the clutch pulley (5).

Note: The same AC switch (1) may also turn on the fan or blower motor
(2a) to circulate air in the cab. The air feels warm at first but will
cool quickly.
A belt connects the clutch pulley to a drive pulley (6) on the engine. The engine pro-
vides the power to turn the clutch pulley and drive the compressor (7) when the clutch
is engaged. When operating, the compressor compresses and pushes refrigerant gas
to the condenser (8), through the receiver-drier (9), and to the expansion valve (10)
orifice. When it does, it puts a lot of pressure on the gas. The compressor raises the
temperature and pressure of the refrigerant inside the high side of the system.
At the same time, the compressor is also sucking in low pressure refrigerant gas
from the expansion valve orifice, evaporator and through the low side of the system.
The movement of the refrigerant inside the system transfers heat energy from the cab
to the outside air for occupant comfort.
The automatic functions of the thermostat (or the pressure valve on some accumu-
lators), and the expansion valve, help maintain pressures and temperatures inside the
system at safe and efficient operating levels. Pressure and temperature are constantly
changing due to compressor and expansion valve action, the amount of heat energy
being moved and the environment or weather conditions.
The engine cooling system fan and clutch (11), and the evaporator blower motor
(2a), move a sufficient amount of air through the condenser and evaporator. On the
road, vehicle speed provides most of the (ram) air required for the condenser to work
right. In a parked or slow moving vehicle the engine fan (or roof or remote mounted
condenser and fans) moves sufficient air through the condenser fins.

Note: Clean refrigerant and refrigeration oil should be inside the system
in the amount specified by the manufacturer. Moisture, sludge
(moisture combined with refrigerant oil or desiccant), or desic-
cant particles will prevent the correct performance of the system
and may cause component damage.

A Troubleshooting Example
Remember the story at the beginning of this chapter? The vehicle operator pulled in
off the road and asked you to repair the rig. He was in such a hurry he didn’t tell you
anything except that the air conditioner wasn’t cooling. Here is the best way to handle
that kind of situation.

25
Troubleshooting & Service Procedures

Use your knowledge and experience. Ask yourself what could have caused a lack of
cooling in that rig! Did the compressor drive belt break? Did a pressure switch or
relief valve cutout the compressor because of high or low system pressure? Does the
switch or valve in this type of system reset itself? Could there be a superheat switch
and thermal limiter with a melted fuse. Did someone else service the system recently
and put in too much refrigerant?
Could there be contaminants in the system blocking the expansion valve (expan-
sion tube)? If there is a leak, why and how did refrigerant get out of the system? You
know if refrigerant can get out, air and moisture may get inside as well, especially if
the leak is on the suction side of the system. Could there be a restriction to refrigerant
flow in one of the high pressure lines because of a kink? From your knowledge and
experience, you already know about these possibilities and others when you talk to the
operator (before he has the chance to leave).
The right kind of questions can speed up troubleshooting and your service work
by pinpointing the problem(s) that needs fixing. Your conversation with the operator
might be as follows:

• How long ago did the AC system stop cooling?

Answer: About an hour ago.

• What steps did you take when you noticed the lack of cooling?
Answer: I put it on maximum cool.

• Then what did you do?

Answer: When it wouldn’t cool, I opened the window and turned
the air conditioner off.

• Is this problem new or has it happened before, and when?

Answer: In the last few days I’ve had problems with cooling off
and on—this is the first time it’s happened when I was close to a
place that did AC service.

• Do you get any cooling at all?

Answer: Yes but it seems to quit after a while.

• Do you still get air flow at the vents from the blower?
Answer: Yes.

• When was your air conditioner checked thoroughly?

Answer: Before I bought the rig last May (a year ago).

• Has the heater been used recently and did it work OK?
Answer: Yes.

26
 A Troubleshooting Example

• Have you had other service problems in the last few months?
Answer: No.

• (If the answer was yes, you should ask—When? Where?

What was fixed or replaced?).

• Finally, ask the operator if he or she has a wiring diagram for the
system.

Now let’s look at the information you have gathered from the operator and what you
know from experience. He believes the problem is that the AC system quits cooling
after it has been on for a while! You know that the AC system has not been maintained
since the rig was purchased a year ago. Because of that, there could be several causes
for the problem (lack of cooling) and there may be other potential problems about to
develop.
It is possible that some refrigerant has leaked. Moisture and other contamination
may be inside the system. You have been told there are no heater problems, but that
doesn’t mean there are none that might affect AC system operation. The AC system
has quit cooling several times in the last few days. The problem may have become
more severe than when it quit cooling the first time.
If enough refrigerant or oil has leaked out, a low pressure cutout switch may have
cut the circuit to the clutch, protecting the compressor. Because the system has not
been maintained in a year, there may be other components that should be serviced. You
could fix the probable causes, and the system might work and then break down again
as the rig drives out of your place. From your knowledge and what the operator has just
told you, you know this may not be a quick fix problem.
It’s up to you to describe the service situation to the operator. Tell him you need to
do a complete system maintenance inspection to find and correct the problem or other
potential problems. He can give you the go ahead for full service and repair now, wait
till you have inspected the system to determine cause and cost, or delay repair until he
has some down time available.
Normally when the operator can tell you what the problem is, you would first oper-
ate the system to verify the problem. In this situation your troubleshooting (your own
knowledge added to what the operator told you), indicates the next step. You need to
do a complete maintenance inspection instead! Proceed as described in Chapter 7.
Correct any obvious problems and check carefully for leaks. Leak testing should be
visual, by feel and with a leak detector. Next, do your performance test with the engine
running and the AC system on.

Note: Don’t forget to check the heater system too! If the water valve
is not closed, then hot engine coolant flowing through the heater
core would warm the air at the same time the evaporator was
trying to cool it. The result would be the appearance of an AC
problem.

27
Troubleshooting & Service Procedures

If your AC and heater visual, electrical and leak inspections don’t turn up any problems,
save time by hooking up the manifold gauge set before you make the performance test.
If you find a leak and can correct it easily by tightening a connection, do so. But if too
much refrigerant leaked out, you may have to add some refrigerant to the system for an
effective performance test. We will get into detail on troubleshooting with gauges after
we explain manifold gauge set installation and adding refrigerant.

Manifold Gauge Set Installation

CAUTION Never hook up the gauge set when the engine and air con-
ditioner are running. Be sure all the valves on the manifold
are closed all the way (turn them clockwise). Check the hose
connections on the manifold for tightness.

Locate the low and high side system service fittings and remove their protective caps.
Position or hang the manifold gauge set in a convenient location. Figure 8-2 illustrates
a good example of manifold gauge set hookup in one service situation.

Figure 8-2
A typical manifold gauge
set hookup is shown in this
illustration. The center hose
on the gauge set is con-
nected to the vacuum pump.

The manifold gauge set is a necessary tool in troubleshooting AC system problems.

The following steps are performed during and after installing the manifold gauge set:
1. Purging Air from the Gauge Set Hoses
2. Adding Refrigerant to the System
3. Stabilizing the AC System.

28
 Manifold Gauge Set Installation

1. Purging Air From Gauge Set Hoses

Environmental regulations require that all service hoses have a shutoff valve
within 12 inches of the service end. These valves are required to ensure only a
minimal amount of refrigerant is lost to the atmosphere. R-12 gauge set hoses
have a valve near the end of all three hoses. R-134a gauge sets have a combina-
tion quick disconnect and shutoff valve on the high and low sides. The utility
(center) hose also requires a valve.
The initial purging is best accomplished when connected to recovery or re-
cycle equipment. Figure 8-3 illustrates the gauge set connections for purging and
refrigeration recovery.

Figure 8-3
The purging setup for
manifold gauge set and
compressor service valves
are shown here.

Note: The manifold gauges read system pressure when the hand valves
are closed if the hose end valves, and the stem type service valves
(if included) are open.

2. Adding Refrigerant to the System

Now that the gauges are connected, you may need to add some refrigerant to the
AC system before you can do an effective performance inspection. However, if
leaks are obvious they should be repaired prior to adding refrigerant.

Note: Loss of some refrigerant is not unusual over an extended period

of time. Adding refrigerant is a typical procedure when the AC
system is maintained on a regular basis.

When adding refrigerant to the system, connect the center hose from the mani-
fold gauge set to the refrigerant dispensing valve on the container. Figure 8-4
illustrates this connection.

29
Troubleshooting & Service Procedures

Figure 8-4
In this illustration we have
noted how refrigerant is
added to the air conditioner.

Before adding refrigerant to the system you should study the sight glass while the
engine is running and the air conditioner is on. Even if you found a leak during the
system inspection and corrected it, you have no way of knowing how much refriger-
ant has leaked. You will not be able to tell how much refrigerant is in there, but you
can see if bubbles are present.
Then check the gauges for unusually high or low readings, or a lack of pressure.
Following this procedure, and using your knowledge and experience, decide if it
is safe and makes sense to add refrigerant in order to make your full performance
inspection.
You are now ready to add refrigerant to the system. For your safety and to
prevent system damage use the following procedure.

1. Turn on the engine and set the idle at 1200 to 1500 RPM and then turn
on the air conditioner.

CAUTION Do not open the high pressure hand valve on the manifold
gauge set. The compressor could pump refrigerant into the
container and cause it to BURST. Be sure to keep the refriger-
ant container upright to prevent liquid refrigerant from enter-
ing the compressor.

2. Open the refrigerant dispensing valve on the container and then the
low pressure hand valve on the manifold. This allows refrigerant to
enter the system as a gas on the low pressure or suction side of the
compressor. The compressor will pull refrigerant into the system.

30
 Manifold Gauge Set Installation

3. Add refrigerant until the gauges read in the normal range and the sight
glass appears clear. The sight glass may not be clear for a moment just
before or after the clutch cycles on and off but should generally be
clear. Gauge readings will fluctuate as the compressor cycles on and
off.

Note:
Pressures within the air conditioning system vary with ambient
temperature. A normal pressure range is defined as follows:
Low side 15–30 PSIG
High side 150–280 PSIG
If R-134a is used in place of R-12 the high side readings will
be about 20 PSI higher. For this reason many OEMs are recom-
mending an increase in condenser capacity when retrofitting to
the new refrigerant, R-134a.

CAUTION If the gauges show any abnormally high or low pressures as

you are adding refrigerant, stop and investigate for probable
cause. Never add more than one pound of refrigerant. If the
system is low enough on refrigerant to require more than that
amount you should stop and check again for leaks. Then re-
cover all of the refrigerant, repair, evacuate and recharge the
air conditioner. (See Chapter 9). You may want to add dry
nitrogen gas to the AC system instead of R-12 if pressures are
below normal and a leak is suspected. Nitrogen gas is sold in
cylinders under high pressure, 1800 to 2000 PSI. Be sure the
cylinder has a pressure regulating valve to control the pressure
when dispensing nitrogen gas. Dispose the gas at no more than
200-250 psi, as this is sufficient pressure to cause or indicate a
leak point. See note under Troubleshooting by Manifold Gauge
Set Readings in this chapter.

4. When the gauges show normal, close the hand valve on the manifold,
the hose end shutoff valve, and the valve on the refrigerant container.
You can now proceed with the performance inspection.

3. Stabilizing The AC System

For reliable gauge readings as an aid in troubleshooting, the AC system must be
stabilized.

CAUTION Be sure your tools and test equipment are clear of all moving
parts of the engine and air conditioner.

31
Troubleshooting & Service Procedures

Start the engine and set to a fast idle of 1200 to 1500 RPM. Turn on the air con-
ditioner. After a quick in-cab performance test of control function, blower speeds
and air flow, set the AC system controls to maximum cooling and blower speed
on high. All windows must be closed. If cab temperature is hot (rig has been sit-
ting in the sun with the windows closed), open the windows for a minute or so to
let the hot air out. Run the engine and air conditioner about five minutes for the
system to stabilize. In hot humid weather or where the AC condenser can’t re-
ceive adequate air flow from the engine fan you may have to use a floor mounted
fan to force sufficient air flow through condenser fins. This helps to stabilize the
system by simulating ram air flow found under normal operating conditions.
When a vehicle has a tilt cab or hood and the condenser is part of the grill, you
must use the floor fan to get air to the condenser. You could tilt the cab or hood
back to normal position, carefully routing the manifold gauge set and hoses away
from moving parts. Then place the gauges so you can read system pressure.

Troubleshooting by Manifold Gauge Set Readings

The series of figures that follow (Figures 8-6 through 8-15) show gauges with typical
readings indicating AC system problems. Each figure is followed by troubleshooting
tips, probable causes for the gauge readings shown, and appropriate service and repair
procedures.

Low Refrigerant Charge in the System

Figure 8-5
Gauge reading, low refriger-
ant charge in the system.

Tip: You see bubbles in the sight glass. The air from vents in the
cab is only slightly cool.

Cause: Insufficient refrigerant (charge) in the system.

32
 Manifold Gauge Set Readings

Repair Procedure:
Check for leaks with your leak detector. If you find a leak
at a connection, tighten it then add refrigerant as necessary.
If a component or line is leaking (defective), recover all
refrigerant from the system. Replace the defective part and
then check the compressor oil level and replace missing
oil. Evacuate and recharge with refrigerant, then check AC
operation and performance.

Figure 8-6 Extremely Low Refrigerant Charge in the System

Gauge reading, extremely
low refrigerant charge in
system.

Tip: The sight glass is clear or shows oil streaks. The air from
vents in the cab seems warm. If there is a low pressure or
Trinary™ switch in the system it may have shut off the
compressor (clutch).

Cause: Extremely low or no refrigerant in the system. There is a

leak in the system.

Repair Procedure:
Add refrigerant to the system, at least half of the normal
full charge amount. Then perform your leak test. As an al-
ternative to a refrigerant, add dry nitrogen gas to the system
and then test for leaks.

Note: It may be necessary to use a jumper wire to bypass some

types of low pressure cutout switches to operate the com-
pressor (clutch) when you add refrigerant to the system.

33
Troubleshooting & Service Procedures

After finding a leak, recover all refrigerant from the system

and repair the leak. Check the compressor and replace any
refrigeration oil lost due to leakage. Evacuate and recharge
the system with refrigerant, then check AC operation and
performance.

Air and/or Moisture in the System

Figure 8-7
Gauge reading, air and/or
moisture in the system.

Tip: The sight glass may be clear or show some bubbles. The
air from vents in the cab is only slightly cool. In a cycling
clutch type system with a thermostatic switch, the switch
may not cycle the clutch on and off, so the low pressure
gauge will not fluctuate.

Cause: Air and/or moisture in the system.

RepairProcedure:
Test for leaks, especially around the compressor shaft seal
area. When the leak is found, recover refrigerant from the
system and repair the leak. Replace the receiver-drier or
accumulator because the desiccant may be saturated with
moisture (there is no way to tell). Check the compressor
and replace any refrigeration oil lost due to leakage. Evacu-
ate and recharge the system with refrigerant, then check AC
operation and performance.

34
 Manifold Gauge Set Readings

Figure 8-8 Excessive Air and/or Moisture in the System

Gauge reading, excessive
air and/or moisture in the
system.

Tip: There may be occasional bubbles in the sight glass. Air

from vents in the cab is only slightly cool.

Cause: System contains excessive air and/or moisture.

Repair Procedure:
Test for leaks, recover refrigerant from the system and re-
pair the leak. Depending on the type of system, replace the
receiver-drier or accumulator. The desiccant is saturated
with moisture. Check and replace any compressor oil lost
due to leakage. Evacuate and recharge the system, then
check AC operation and performance.

Figure 8-9 Expansion Valve (TXV) Stuck Closed or Plugged

Gauge reading, expansion
valve (TXV) stuck closed.

Tip: Air from vents in the cab is only slightly cool. The expan-
sion valve body is frosted or sweating.

35
Troubleshooting & Service Procedures

Cause: An expansion valve malfunction could mean the valve is

stuck in the closed position, the filter screen is clogged
(block type expansion valves do not have filter screens),
moisture in the system has frozen at the expansion valve
orifice, or the sensing bulb is not operating. In vehicles
where the TXV and sensing bulb are accessible, perform
the following test. If not accessible, then proceed to Repair
Procedure.

Test: 1. Warm diaphragm and valve body in your hand or care-

fully with a heat gun. Activate system and watch to see
if the low pressure gauge rises.

2. Next, carefully spray a little nitrogen, or any substance

below 32 degrees Fahrenheit, on the capillary coil
(bulb) or valve diaphragm. The low side gauge needle
should drop and read at a lower (suction) pressure on the
gauge. This indicates the valve was part way open and
that your action closed it. Repeat the test, but first warm
the valve diaphragm or capillary with your hand. If the
low side gauge drops again, the valve is not stuck.

3. Clean the surfaces of the evaporator outlet and the cap-

illary coil or bulb. Make sure the coil or bulb is securely
clamped to the evaporator outlet tube and the insulation
is in place. Next proceed with recovering refrigerant
from the system.

Repair Procedure:
Inspect the expansion valve screen (except block type
valves). To do this you must recover all refrigerant from the
system. Disconnect the inlet hose fitting from the expan-
sion valve. Remove, clean and replace the screen, then re-
connect the hose. Any signs of contamination will require
flushing the system. Next, replace the receiverdrier. Then
evacuate and recharge the system with refrigerant, and
check AC operation and performance.

36
 Manifold Gauge Set Readings

Note: If the expansion valve tests did not cause the low pressure
gauge needle to rise and drop, and if the other procedures
described did not correct the problem, the expansion
valve is defective. You must recover all refrigerant from
the system again, and replace the expansion valve and
receiver-drier. Evacuate and recharge the system with
refrigerant, then check AC operation and performance.

Expansion Valve (TXV) Stuck Open

Figure 8-10
Gauge reading, expansion
valve (TXV) stuck open.

Tip: Air from vents in the cab is warm or only slightly cool.

Cause: The expansion valve is stuck open and/or the capillary tube
(bulb) is not making proper contact with the evaporator
outlet tube. Liquid refrigerant may be flooding the evapora-
tor making it impossible for the refrigerant to vaporize and
absorb heat normally. In vehicles where the TXV and sens-
ing bulb are accessible, check the capillary tube for proper
mounting and contact with the evaporator outlet tube. Then
perform the following test. If the TXV is not accessible,
then proceed to Repair Procedure.

Test: 1. Operate the AC system on it’s coldest setting for a few

minutes. Carefully spray a little nitrogen or other cold
substance, on to the capillary tube coil (bulb) or head of
the valve.

2. The low pressure (suction) side gauge needle should

now drop on the gauge. This indicates the valve has
closed and is not stuck open. Repeat the test, but first
warm the valve diaphragm with your hand.

37
Troubleshooting & Service Procedures

3. If the low side gauge shows a drop again, the valve is

not stuck. Clean the surfaces of the evaporator outlet
and the capillary coil or bulb. Make sure the coil or bulb
is securely fastened to the evaporator outlet and covered
with insulation material. Operate the system and check
performance.

Repair Procedure:
If the test did not result in proper operation of the expansion
valve, the valve is defective and must be replaced. Recover
all refrigerant from the system and replace the expansion
valve and the receiver-drier. Evacuate and recharge the
system with refrigerant, then check AC operation and per-
formance.

System High Pressure Side Restriction

Figure 8-11
Gauge reading, system high
pressure side restriction.

Tip: Air from vents in the cab is only slightly cool. Look for
sweat or frost on high side hoses and tubing, and frost ap-
pearing right after the point of restriction. The hose or line
may be cool to the touch near the restriction.

Cause: There could be a kink in a line, or other restriction in the

high side of the system.

38
 Manifold Gauge Set Readings

Repair Procedure:
After you locate the defective component containing the
restriction, recover all of the refrigerant. Replace the de-
fective component and the receiver-drier. Evacuate and
recharge the system with refrigerant, then check AC opera-
tion and performance.

Compressor Malfunction
Figure 8-12
Gauge reading, compressor
malfunction.

Tip: The compressor may be noisy when it operates.

Cause: Defective reed valves or other compressor components. If

the compressor is not noisy, there may be a worn or loose
compressor clutch drive belt.

Repair Procedure:
If you find the belt worn or loose, replace or tighten it and
recheck system performance and gauge readings. To in-
spect and service the compressor, you must isolate (front
seat the stem type compressor service valves) and recover
refrigerant, or fully recover R-12 from systems containing
Schrader valves. Remove the compressor cylinder head
and check the appearance of the reed valve plate assembly.
If defective, replace the valve plate and install with new
gaskets, or replace the compressor assembly.

39
Troubleshooting & Service Procedures

If you find particles of desiccant in the compressor, remove

and replace it and the receiver-drier. Before doing so, back
flush other system components (except the expansion
valve) using a flushing kit. If there are stem type valves
and you isolate the compressor, the rest of the system must
be purged of refrigerant before you can disconnect and
flush system components (Chapter 9 describes the flush-
ing procedure). After flushing, reassemble the components.
Always check the oil level in the compressor, even if you
install a new or rebuilt unit. Tighten all connections and
evacuate the system. Recharge the air conditioner with re-
frigerant and check system operation and performance.

Note: Rotary compressors have a limited oil reservoir. Extra oil

must be added for all truck installations

Condenser Malfunction or System Overcharge

Figure 8-13
Gauge reading, condenser
malfunction or system
overcharge.

Tip: The air from vents in the cab may be warm. In R-12 systems
there can be bubbles in the sight glass. The high pressure
hoses and lines will be very hot. Don’t forget to check the
engine cooling system components—fan and drive belt, fan
clutch operation, and the radiator shutter.

40
 Manifold Gauge Set Readings

Cause: The condenser is not functioning correctly or there may

be an overcharge of refrigerant inside the system. Another
possibility is lack of (ram) air flow through the condenser
fins during testing. Engine cooling system component
malfunction can cause high pressure by blocking air flow
(radiator shutter) or not providing air flow (fan clutch) in
sufficient quantity.

Repair Procedure:
Inspect the condenser for dirt, bugs or other debris and clean
if necessary. Be sure the condenser is securely mounted and
there is adequate clearance (about 1-1/2 inches) between
it and the radiator. Check the radiator pressure cap and
cooling system, including the fan, fan clutch, drive belts
and radiator shutter assembly. Replace any defective parts
and then recheck AC system operation, gauge readings and
performance.

If the problem continues, the system may be over- charged

(have too much refrigerant inside). Recover the system
slowly until low and high pressure gauges read below nor-
mal, and bubbles appear in the sight glass. Then add refrig-
erant (charge the system) until pressures are normal and
the bubbles disappear. Add another quarter to half pound of
refrigerant and recheck AC system operation, gauge read-
ings and performance.

If the high gauge readings do not change, you should recover

all of the refrigerant and flush (it may be partially plugged)
or replace the condenser. Also replace the receiver-drier or
accumulator. Then connect the components and evacuate
the system. Recharge the air conditioner with refrigerant
and check system operation and performance.

41
Troubleshooting & Service Procedures

Thermostatic Switch Malfunction Figure 8-14

Gauge reading, thermostatic
switch malfunction.

Tip: The low side gauge needle may fluctuate in a very narrow
range compared to a normal range. The compressor clutch
may be cycling on and off more frequently than it should.

The low side gauge needle may fluctuate in an above nor-

mal range as the clutch cycles. This may be an indication
that the thermostat is set too high (someone may have at-
tempted to adjust the factory setting). A new thermostat may
have been installed incorrectly (capillary tube not inserted
between the evaporator fins in the proper position).

Cause: The thermostatic switch is not functioning properly or at

all.

Repair Procedure:
Replace the thermostatic switch. When you remove the
old thermostat, replace it with one of the same type. (They
operate in a factory preset temperature range.) Take care in
removing and handling the thermostat and thin capillary
tube attached to it. Don’t kink or break the tube.

Position the new thermostat capillary tube at or close to

the same location and seating depth between the evaporator
coil fins as the old one. Connect the electrical leads.

42
 Review of Frequent Problem Areas

Note: See the Thermostat section in Chapter 10. Fan clutch, ra-
diator shutter, condenser, compressor, and the newer air
and water valve control systems are covered in Chapter
10.

Review of Frequent Problem Areas

In HVAC systems a limited number of things can go wrong. Moving parts of the com-
pressor, clutch, and expansion valve or refrigerant metering device can malfunction or
break down from metal fatigue, contamination, abnormal pressure or lack of lubrica-
tion. Electrical connections may corrode, become disconnected or break. Fuses blow
from shorts or overload. Belts slip or break.
Vibration from the engine or road surface can work bolts and air or vacuum lines
loose, or rub and break or wear parts out. Motors may burn out. The inside of the
system can become contaminated from moisture, air or desiccant material breakdown.
Refrigerant may leak out of the system quickly or very slowly. Moisture in the system
can combine with refrigerant to form acid and attack (corrode) metal parts from the
inside. Moisture and refrigeration oil can combine to form sludge that may block re-
frigerant flow.
The following problems are discussed in more detail in this section:
1. Belts and Compressor Clutch
2. Condenser
3. Refrigerant Lines, Hoses, and Fittings
4. Refrigerant Metering Valves
5. Other Problems

1. Belts and Compressor Clutch

Let’s review problem areas listed at the beginning of Chapter 7. The most fre-
quent repairs are replacing belts and servicing or replacing the compressor or
clutch. Heavy duty vehicle operation puts a lot of stress on these parts. There are
several main reasons.
There is often continuous operation for long periods of time. There may be
frequent sudden RPM variations when shifting gears up or down. For this reason
the AC clutches used in heavy duty systems usually have double row ball bear-
ings. Vibration and road shock contribute to loose or broken mounting brackets,
electrical connections and fittings. Belts, bearings and compressor reed valves
wear out.
Various compressor clutch cutout switches are used because the AC designers
know about compressor operating conditions. System leaks, high operating pres-
sures, malfunctioning engine cooling system components—all cause compressor
problems and failures. When refrigerant and refrigeration oil leaks out of a sys-
tem or there is contamination blocking oil flow, the compressor will be starved
for oil and seize.

43
Troubleshooting & Service Procedures

2. Condenser
Condensers get dirty and the dirt reduces heat movement by insulating the con-
denser. The fittings come loose or break from stress if the condenser or connecting
hoses are not secured properly to keep the effects of vibration at a minimum.
Heat transfer efficiency and pressure in the condenser are affected by the
amount of outside air flowing through condenser fins. A lack of air flow can mean
the refrigerant doesn’t give up enough heat energy to the outside air (it doesn’t
change state). The refrigerant arrives at the evaporator as a gas and can’t pick up
any heat energy from cab air. In the cab, air from the vents is only slightly cool
or warm.
One possible cause of condenser malfunction could be the engine cooling sys-
tem. This is why fan clutches and radiator shutters are often controlled or over-
ridden by AC switch function. In fact, we can add fan clutch, radiator shutters and
also fan motors to condenser problems. If they don’t function to allow sufficient
air through the condenser, pressure inside the system may become dangerously
high. A lack of air through the condenser fins can raise high side pressure and
blow out the weakest point in a system, or damage the compressor.

3. Refrigerant Lines, Hoses and Fittings

Problems with these parts may be caused by normal deterioration, vibration dam-
age, lack of maintenance or human error (improper installation or replacement).
All rubber parts are attacked by ozone (oxygen) in the air. Rubber parts break
down slowly and become more vulnerable to the effects of vibration with the
passage of time.
Heavy duty vehicle vibration causes stress on all lines, fittings and connections.
Regular maintenance includes checking and tightening any suspect line, or hose
retainers, or grommet position where the grommet is protecting a line or hose
from abrasion. Any insulating material wrapped around hoses must be in place
and securely fastened.

4. Refrigerant Metering Valves

When you consider valve problems there are obvious differences in valve con-
struction and what can go wrong. If a valve is clogged with sludge or other
obstruction, the result is a valve problem but the cause is contamination in the
system. Valves get stuck open or closed, although most often closed when the
gas charge is lost from the diaphragm housing in a traditional TXV. The capillary
tube can vibrate loose from the evaporator outlet tube. The capillary can break
and the small quantity of temperature sensitive gas can escape. The diagnosis of
a valve as defective calls for replacement.

5. Other Problems—Leaks, Moisture, and Adding

Refrigerant
Before any refrigerant was put inside the AC system, someone used a vacuum
pump to evacuate any air and moisture. Vacuum is really a force pulling against
all hoses, fittings and components from the inside. When the system is charged
with refrigerant, the pressure goes from minus (a vacuum) to plus pressure inside
the hoses and all components. The refrigerant and refrigeration oil are trying to
escape from the system at all times.

44
 Conclusion

Technicians frequently add refrigerant to a system, replacing refrigerant seep-

age through system connections or fittings. If the system has been maintained
regularly (every three to six months), adding a small amount of refrigerant may
result in normal system function. However, the best procedure is to check all
connections and look for, find and repair any leaks before adding refrigerant.
When your leak detector indicates the presence of a leak, you can’t tell how
long the system has been leaking. Finding one leak doesn’t mean there are not
others. Until you have some AC system work experience, it will be hard to guess
how much refrigerant may have leaked. If you have to top a system off with a half
pound of refrigerant or more, adding refrigerant is not the answer.
Find the leak. Recover all of the refrigerant and repair the system. The mois-
ture absorbing capacity of any desiccant material is limited and cannot be mea-
sured. For that reason, replace the receiver-drier or accumulator. Then evacuate
the system for an hour and recharge with refrigerant.
When a compressor shaft seal has leaked oil and the refrigerant charge is a little
low, the shaft seal may have leaked because the air conditioner was not used. The
seal can get a little out of round from the weight of the crankshaft and leak above
the shaft. Running the compressor may cause the seal to swell and close up the
leak. The shaft rotation exerts force all around the seal and puts life back into it.
To prevent this from happening, manufacturers recommend regular AC system
operation a minimum of every couple of weeks even in cool weather.
Keep in mind that the compressor can cause a vacuum inside the system if there
is a restriction in the system. That means it can suck air and moisture inside under
some conditions. It will pull these contaminants in through the same space where
refrigerant and refrigerant oil has leaked out.

Conclusion
What could the air conditioning problem and it’s cause have been at the beginning of
this chapter? The operator was in a hurry, but you were able to start your troubleshoot-
ing with the answers he gave you. Problems your inspection may have turned up are
a very low refrigerant charge, a contaminated system or defective compressor. Those
are not quick fix jobs.
On the other hand, you might have found enough debris on the condenser fin sur-
face to boost high side pressures to an abnormal level during the hottest part of the day.
So the Trinary™ or high pressure switch would cut out from high pressure—but reset
itself. You cleaned the condenser, added a half pound of refrigerant and AC system
pressures and function returned to normal. Service and repair took a half hour. But
there was no way to tell without using your knowledge and experience. By now you
are pretty familiar with AC system problems, the reasons for some of them, trouble-
shooting and repair. In Chapter 9 we will describe complete system purging, evacua-
tion, flushing and recharging.

45
 MAINTENANCE SOFTWARE MANUAL
LEVER SWITCH PATTERN SWITCHING METHOD 6
LEVER SWITCH PATTERN SWITCHING METHOD
Standard pattern

1
LEVER SWITCH PATTERN SWITCHING METHOD 6S5AS00
 MAINTENANCE SOFTWARE MANUAL
LEVER SWITCH PATTERN SWITCHING METHOD 6
Case 1: Reversing the 1st auxiliary line piping and 2nd auxiliary line piping

2
LEVER SWITCH PATTERN SWITCHING METHOD 6S5AS00
 MAINTENANCE SOFTWARE MANUAL
LEVER SWITCH PATTERN SWITCHING METHOD 6
WARNING
1

• Make sure to change the decal sticker after changing

CN_B

CN_A
the switch pattern.
• Slowly run the machine to check to ensure that the new
A
decal sticker matches machine operation.

1. Disconnect the connector CAN and connector CNB

of the body harness on the back of the right control
box.
2. Attach the harness (A) between the disconnected
connector CAN and connector CNB.
• Harness (A) is included in the OPERATING LE-
I Details on inside of right control box
VER SWITCH KIT (Part No. 05701-00006).
J Operating pattern switch connector

3. Replace the decal sticker in the specified location

with the switch pattern written on it to reflect the
change.

Details of Change Location Part number 2 1

1 05693-66541
Harness (A) attached
2 05693-66542

• The part no. is printed on the lower right on the de-

cal.
• The decal is included in the OPERATING LEVER
SWITCH KIT (Part No. 05701-00006).
6S5AS07

3
LEVER SWITCH PATTERN SWITCHING METHOD 6S5AS00
 MAINTENANCE SOFTWARE MANUAL
LEVER SWITCH PATTERN SWITCHING METHOD 6
Case 2: Reversing A and B around or C and D around
Reversing A and B

Reversing C and D

Reversing both A and B around and C and D around

WARNING
• Make sure to change the decal sticker after changing
the switch pattern.
• Slowly run the machine to check to ensure that the new
decal sticker matches machine operation.

1. Connect the maintenance tool to the machine, and

run the TB1140 maintenance software.
Connecting the maintenance tool and starting up the
software
“6 Maintenance Software Manual”
2. Change the switch pattern.
“6 Maintenance Software Manual”

4
LEVER SWITCH PATTERN SWITCHING METHOD 6S5AS00
 MAINTENANCE SOFTWARE MANUAL
LEVER SWITCH PATTERN SWITCHING METHOD 6
3. Replace the decal sticker in the specified location
with the switch pattern written on it to reflect the
change.

Details of Change Location Part number 2 1

A and B reversed 1 05693-66547
C and D reversed 2 05693-66548

• The part no. is printed on the lower right on the de-

cal.
• The decal is included in the OPERATING LEVER
SWITCH KIT (Part No. 05701-00006).
6S5AS07

5
LEVER SWITCH PATTERN SWITCHING METHOD 6S5AS00
 MAINTENANCE SOFTWARE MANUAL
LEVER SWITCH PATTERN SWITCHING METHOD 6
Case 3: Reversing the 1st auxiliary line piping and 2nd auxiliary line piping and reversing either
A and B around or C and D around
Reversing A and B

Reversing C and D

Reversing both A and B around and C and D around

WARNING
• Make sure to change the decal sticker after changing
the switch pattern.
• Slowly run the machine to check to ensure that the new
decal sticker matches machine operation.

1. Reverse the 1st auxiliary line piping and 2nd auxiliary

line piping.
Reversing the lines
“Case 1”
2. Reverse A and B around or C and D around.
“Case 2”

6
LEVER SWITCH PATTERN SWITCHING METHOD 6S5AS00
 MAINTENANCE SOFTWARE MANUAL
LEVER SWITCH PATTERN SWITCHING METHOD 6
3. Replace the decal sticker in the specified location
with the switch pattern written on it to reflect the
change.

Details of Change Location Part number 2 1

A and B left as is 2 05693-66542
Harness (A) A and B reversed 2 05693-66544
attached C and D left as is 1 05693-66541
C and D reversed 1 05693-66543

• The part no. is printed on the lower right on the de-

cal.
6S5AS07
• The decal is included in the OPERATING LEVER
SWITCH KIT (Part No. 05701-00006).

7
LEVER SWITCH PATTERN SWITCHING METHOD 6S5AS00
 Anti-Drift Valve

Increase in flow rate

Increase in flow rate
 Anti-Drift Valve

Decrease in flow rate

Increase in flow rate

7
Increase in flow rate
Increase in flow rate
Increase in flow rate
Increase in flow rate Increase in flow rate
Increase in flow rate
Increase in flow rate
Decrease in flow rate Decrease in flow rate
Decrease in flow rate Increase in flow rate
Decrease in flow rate
Decrease in flow rate