HYDRAULIC EXCAVATOR

MAINTENANCE SPECIFICATIONS
SHOP
MANUAL model SK350LC-9E

INDEX
1 SPECIFICATIONS SECTION

SYSTEM
2 MAINTENANCE SECTION
3 SYSTEM SECTION
4 DISASSEMBLY SECTION

DISASSEMBLING
5 TROUBLESHOOTING
6 ENGINE SECTION

E / G TROUBLESHOOTING
7 PROCEDURE OF INSTALLING
OPTIONS SECTION
OPT.

Book Code No.S5LC0033E04

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Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
GENERAL SAFETY INFORMATION 3) CAUTION- Indicates a potentially hazardous
situation which, if not avoided, may result in mi-
nor or moderate injury. It may also be used to
alert against possible damage to the machine
Do not operate or perform any maintenance on this and its components and is represented as fol-
machine until all instructions found in the OPERA- lows:
TOR’S MANUAL and this MANUAL have been thor-
oughly read and understood.
Improper operation or maintenance of this machine (4) It is very difficult to forecast every danger that may
may cause accidents and could result in serious in- occur during operation. However, safety can be en-
jury or death. sured by fully understanding proper operating pro-
Always keep the manual in storage. cedures for this machine according to methods
If it is missing or damaged, place an order with an recommended by Manufacturer.
authorized our Distributor for a replacement.
(5) While operating the machine, be sure to perform
If you have any questions, please consult an autho-
work with great care, so as not to damage the ma-
rized our Distributor.
chine, or allow accidents to occur.
(1) Most accidents, which occur during operation, are (6) Continue studying the manual until all Safety, Oper-
due to neglect of precautionary measures and safe- ation and Maintenance procedures are completely
ty rules. Sufficient care should be taken to avoid understood by all persons working with the ma-
these accidents. Erroneous operation, lubrication chine.
or maintenance services are very dangerous and
may cause injury or death of personnel. Therefore
all precautionary measures, NOTES, DANGERS,
WARNINGS and CAUTIONS contained in the man-
ual and on the machine should be read and under-
stood by all personnel before starting any work with
or on the machine.
(2) Operation, inspection, and maintenance should be
carefully carried out, and safety must be given the
first priority. Messages of safety are indicated with
marks. The safety information contained in the
manual is intended only to supplement safety
codes, insurance requirements, local laws, rules
and regulations.
(3) Messages of safety appear in the manual and on
the machine : All messages of safety are identified
by either word of "DANGER", "WARNING" and
"CAUTION".
1) DANGER- Indicates an imminently hazardous
situation which, if not avoided, will result in
death or serious injury and is represented as
follows:

2) WARNING- Indicates a potentially hazardous

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

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Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
SAFETY PRECAUTIONS stands, capable of supporting the machine, before
performing any disassembly.

The proper and safe lubrication and maintenance

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

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Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
(13)Always use the proper tools that are in good condi- (19)Loose or damaged fuel, lubricant and hydraulic
tion and that are suited for the job at hand. Be sure lines, tubes and hoses can cause fires. Do not bend
you understand how to use them before performing or strike high pressure lines or install ones which
any service work. have been bent or damaged. Inspect lines, tubes
(14)Reinstall all fasteners with the same part number. and hoses carefully. Do not check for leaks with
Do not use a lesser quality fastener if replacements your hands. Very small (pinhole) leaks can result in
are necessary. a high velocity oil stream that will be invisible close
to the hose. This oil can penetrate the skin and
(15)Repairs which require welding should be per-
cause personal injury. Use card-board or paper to
formed only with the benefit of the appropriate ref-
locate pinhole leaks.
erence information and by personnel adequately
trained and knowledgeable in welding procedures. (20)Tighten connections to the correct torque. Make
Determine type of metal being welded and select sure that all heat shields, clamps and guards are in-
correct welding procedure and electrodes, rods or stalled correctly to avoid excessive heat, vibration
wire to provide a weld metal strength equivalent at or rubbing against other parts during operation.
least to that of the parent metal. Make sure to dis- Shields that protect against oil spray onto hot ex-
connect battery before any welding procedures are haust components in event of a line, tube or seal
attempted. failure must be installed correctly.
(16)Do not damage wiring during removal operations. (21)Do not operate a machine if any rotating part is
Reinstall the wiring so it is not damaged nor will be damaged or contacts any other part during opera-
damaged in operation of the machine by contacting tion. Any high speed rotating component that has
sharp corners, or by rubbing against some object or been damaged or altered should be checked for
hot surface. Do not connect wiring to a line contain- balance before reusing.
ing fluid. (22)Be careful when servicing or separating the tracks
(17)Be sure all protective devices including guards and (crawlers). Chips can fly when removing or install-
shields are properly installed and functioning cor- ing a track (crawlers) pin. Wear safety glasses and
rectly before starting a repair. If a guard or shield long sleeve protective clothing. Tracks (crawlers)
must be removed to perform the repair work, use can unroll very quickly when separated. Keep away
extra caution and replace the guard or shield after from front and rear of machine. The machine can
repair is completed. move unexpectedly when both tracks (crawlers)
are disengaged from the sprockets. Block the ma-
(18)The maintenance and repair work while holding the
chine to prevent it from moving.
bucket raised is dangerous due to the possibility of
a falling attachment. Don’t fail to lower the attach-
ment and place the bucket to the ground before
starting the work.

The copyright of this manual belongs to KOBELCO CONSTRUCTION MACHINERY CO., LTD.
Copy, reproduction, distribution, and delivery (including these actions on the Internet) of all or part of this
manual are prohibited without permission of KOBELCO CONSTRUCTION MACHINERY CO., LTD.

This manual is intended to provide instructions for repair, maintenance, and adjustment of the machine, sold
directly or indirectly by KOBELCO CONSTRUCTION MACHINERY CO., LTD. or Kobelco Construction
Machinery U.S.A Inc. and any use other than that purpose will not be allowed.
Also, all or part of this manual cannot be transferred, sold, or lent to a third person without permission of
KOBELCO CONSTRUCTION MACHINERY CO., LTD.

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Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
NA INDEX SK350LC-9E
Book Code No. Index
Title 1
Distribution Year–Month No. 33 25

MAINTENANCE SPECIFICATIONS
S5YN0129E01
OUTLINE 1
2014-07
S5LC0233E01
SPECIFICATIONS 2
2014-07
S5LC0332E01
ATTACHMENT DIMENSIONS 3
2014-07 34 2
S5LC1133E01
TOOLS 11
2014-07
S5LC1233E01 STANDARD MAINTENANCE
TIME SCHEDULE
12
2014-07
S5LC1333E03 MAINTENANCE STANDARD
AND TEST PROCEDURE 13 3
2016-04
51 11
S5LC2133E01 MECHATRO CONTROL
SYSTEM
21
2014-07
S5LC2233E01
HYDRAULIC SYSTEM 22
2014-07
S5LC2333E01
SYSTEM
ELECTRIC SYSTEM 23
2014-07 12
S5LC2433E01
COMPONENTS SYSTEM 24
2014-07
S5LC2525E01
AIR-CONDITIONER SYSTEM 25
2014-07
_

S5YN3129E01 DISASSEMBLING 21 13
DISASSEMBLING

2014-07 & ASSEMBLING 31

S5LC3226E01
ATTACHMENT 32
2014-07
S5LC3333E02
UPPER STRUCTURE 33
2014-11
S5LC3432E03
TRAVEL SYSTEM 34 46 22
2014-07
E / G TROUBLESHOOTING

S5LQ4636E01
BY ERROR CODES 46
2014-07
S5LC4732E02
BY TROUBLE 47
2014-07
_ 23
47 31
_

S5LC5133E02
ENGINE 51
2016-04
_
32 24
_

YC13-13001~ APPLICABLE MACHINES

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Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
NOTE:
This Manual is prepared as a technical material in This Manual may be properly revised due to the im-
which the information necessary for the maintenance provement of products, modification of specifications,
and repairing services of our hydraulic excavators are etc. And there are cases where the system on actual
collected, and is categorized into 7 Chapters, Specifica- machine and a part of the contents of this manual may
tion, Maintenance, System, Disassembly, Trouble- differ due to the variations of specification by countries.
shooting, Engine, and Installation Procedures for For the section in which the description is hardly under-
Optional Attachment. stood, contact our distributor.

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

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Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
 㨇1. OUTLINE㨉

Ძ
1. OUTLINE
TABLE OF CONTENTS

1.1 GENERAL PRECAUTIONS FOR MAKING REPAIRS ȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤ1-3

1.1.1 PREPARATION BEFORE DISASSEMBLING ȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤ1-3
1.1.2 SAFETY WHEN DISASSEMBLING AND ASSEMBLING ȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤ1-3
1.1.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT ȤȤȤȤȤȤȤȤȤȤȤȤ1-4
1.1.4 ELECTRICAL EQUIPMENT ȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤ1-6
1.1.5 HYDRAULIC PARTS ȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤ1-7
1.1.6 WELD REPAIR ȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤ1-7
1.1.7 ENVIRONMENTAL ISSUES ȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤ1-7
1.2 INTERNATIONAL UNIT SYSTEM ȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤȤ1-8

Book Code No. S5YN0129E01

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㨇1. OUTLINE㨉

Issue Date of Issue Applicable Machines Remarks

SK200-8 : YN12-56001~ S5YN0129E01
First Edition December, 2008
SK210LC-8 : YQ12-08001~ (SE Asia & Oceania)

June, 2013 SK210LC-9 : YQ13-10001~

(NA)

SK260LC-9 : LL14-08001~
(NA)
SK330-9 : LC12-15001~
SK350LC-9 : YC12-10001~ (NA)

July, 2013 SK500LC-9 : YS12-03501~

(NA)

August, 2013 ED160-3 : LH02-01501~

(EUR)

ED160-3 : LH02-01501~
(NA)

SK75SR-3E : YT08-30001~
(NA)

SK85CS-3E : LF08-05501~
(NA)

SK130HDL-8B : LX08-T0101~
(TKCM)

SK140SRLC-3 : YH07-09001~
(NA)

September, 2013 SK230SRLC : LA07-03001~

(NA)

SK260SRLC : YU07-04028~
(NA)

October, 2013 SK75SR-3E : YT08-30001~

(EUR)

SK210LC-9 : YQ13-10001~
(North America / Europe)

SK85MSR-3E : LF08-05501~
(EUR)

November, 2013 SK140SRLC-3 : YH07-09001~

(EUR)

SK230SRLC-3 : LA07-03001~
(EUR)

SK260CSR(N)LC-3 : YU07-04001~
(EUR)
SK260LC-9 : LL14-08003~
SK260NLC-9 : LL14-08003~ (North America / Europe)
SK330-9 : LC12-15001~
December, 2013
SK350(N)LC-9 : YC12-10002~ (NA / EUR)

January, 2014 SK500LC-9 : YS12-03501~

(North America / Europe)
SK135SR-3 : YY07-25001~
July, 2014
SK135SRLC-3 : YH07-09001~ (OCE)

SK350LC-9E : YC13-13001~
(NA)

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 㨇1. OUTLINE㨉

1.1 GENERAL PRECAUTIONS FOR MAKING REPAIRS

Ძ
1.1.1 PREPARATION BEFORE DISASSEMBLING

(1) Knowledge of operating procedure

Read Operator's Manual carefully to understand the operating procedure.

(2) Cleaning machines

Clean machines of soil, mud, and dust before carrying into the service shop. Carrying a soiled
machine into the service shop, causes making less efficient work and damage of parts.

(3) Inspecting machines

Confirm the disassembling section before starting work, determine the disassembly procedure taking the
conditions in work shop into account, and request to procure necessary parts in advance.

(4) Recording
Record the following items to keep contact and prevent malfunction from recurring.

1. Inspecting date, place

2. Model name, Serial number and Record on hour meter
3. Trouble condition, place, cause
4. Visible oil leak, water leak and damage
5. Clogging of filters, oil level, oil quality, oil contamination and looseness.
6. Examine the problems on the basis of monthly operation rate with the last inspection date and
records on hour meter.

(5) Arrangement and cleaning in service shop

1. Tools required for repair work.
2. Prepare the places to put the disassembled parts.
3. Prepare oil pans for leaking oil, etc.

1.1.2 SAFETY WHEN DISASSEMBLING AND ASSEMBLING

(1) Safety
1. Wear appropriate clothing, safety shoes, safety helmet, goggles, and clothes with long sleeves.
2. Attach "Don't operate" tag to control lever, and begin a meeting before starting the work.
3. Before starting inspection and maintenance stop the engine.
4. Confirm the position of first-aid kit and fire extinguisher, and also where to make contact for
emergency measure and ambulance to prepare for accidents and fire.
5. Choose a hard, level and safe place, and put attachment on the ground without fail.
6. Use hoist, etc. to remove parts of heavy weight (23kg [50 lb] or more).
7. Use proper tools, and change or repair defective tools.
8. Machine and attachment required to work in the lifting condition should be supported with
supports or blocks securely.

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㨇1. OUTLINE㨉

1.1.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT

(1) Removing hydraulic equipment assy

1. Before removing pipes, release the pressure of hydraulic oil tank, or open the cover on the return
side to tank, and take out the filter.
2. Drain the oil in the removed pipes into pan to prevent the oil from spilling on the ground.
3. Pipes with plugs or caps to prevent oil leaking, entry of dust, etc.
4. Clean the outside surface of equipment, etc. before disassembling, and drain hydraulic oil and gear
oil before putting them on working bench.

(2) Disassembling hydraulic equipment

1. Since performance and function of hydraulic equipment after disassembly and assembly results in
immunity from responsibility on the manufacture's side, disassembly, assembly and modification
without permission are strictly prohibited.
2. If it is unavoidably necessary to disassemble and modify, it should be carried out by experts or
personnel qualified through service training.
3. Make match mark on parts for reassembling.
4. Before disassembling, read Disassembling Instruction in advance, and determine if the
disassembly and assembly are permitted or not.
5. For parts which are required to use jig and tools, don't fail to use the specified jig and tools.
6. For parts which can not be removed in the specified procedure, never force removal. First check
for the cause.
7. The removed parts should be put in order and tagged so as to install on proper places without
confusion.
8. For common parts, pay attention to the quantity and places.

(3) Inspecting parts

1. Check that the disassembled parts are free from adherence, interference and uneven working face.
2. Measure the wear of parts and clearance, and record the measured values.
3. If an abnormality is detected, repair or replace the parts.

(4) Reassembling hydraulic equipment

1. During the parts cleaning, ventilate the room.
2. Before assembly, clean parts roughly first, and then completely.
3. Remove adhering oil by compressed air, and apply hydraulic oil or gear oil, and then assemble
them.
4. Replace the removed O-ring, back-up rings and oil seal with new ones, and apply grease oil on
them before assembling.
5. Removes dirt and water on the surface on which liquid sealant are applied, decrease them, and
apply liquid sealant on them.
6. Before assembling, remove rust preventives on new parts.
7. Use special tools to fit bearings, bushing and oil seal.
8. Assemble parts matching to the marks.
9. After completion, check that there is no omission of parts.

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 㨇1. OUTLINE㨉

(5) Installing hydraulic equipment

1. Confirm hydraulic oil and lubrication oil.

Ძ
2. Air release is required in the following cases ;
a. Change of hydraulic oil
b. Replacement of parts on suction pipe side
c. Removing and attaching hydraulic pump
d. Removing and attaching swing motor
e. Removing and attaching travel motor
f. Removing and attaching hydraulic cylinder
3. For air bleed of hydraulic pump and swing motor, loosen drain plug on the upper part, start
engine, and run in low idling, then bleed air until hydraulic oil is comes out. After completion of
comes, tighten plug securely.
4. For air bleed of travel motor and hydraulic cylinder, starts engine and operate it for 10 minutes
or more at no-load and low speed.
5. Air in pilot circuit can be bleed out by only operating digging, swing and traveling motions
thoroughly.
6. Check hydraulic oil level.
Move attachments to hydraulic oil check position, and check hydraulic oil level of tank. Refill oil if
the oil level is lower than the specified level.
How to check oil level of hydraulic oil tank

If hydraulic oil and lubricating oil are not filled and also air bleed is not performed, the hydraulic
equipment may be damaged.

For cylinder, don't move it to the stroke end at beginning.

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Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
㨇1. OUTLINE㨉

1.1.4 ELECTRICAL EQUIPMENT

(1) The disassembly of electrical equipment is not allowed.

(2) Handle equipment with care so as not to drop it or bump it.
(3) Connector should be removed by unlocking while holding the connector.
Never stress in tension to the caulked section by pulling wire.
(4) Check that connector is connected and locked completely.
(5) Engine key off before removing and connecting connector.
(6) Engine key off before touching terminals of starter and alternator.
(7) Remove battery grounding terminal before beginning work close to battery and battery relay with
tools.
(8) Wash machine with care so as not to splash water on electrical equipment and connector.
(9) When water has entered in the waterproofed connector, the removing of water is not easy. So
check the removed waterproofed connector with care to protect it from entry of water. If moisture
adheres on it, dry it completely before connecting.

Battery fluid is dangerous.

The battery fluid is dilute sulfuric acid, and causes scald and loss of eyesight by adhering on eyes,
skin and clothes. When the fluid has adhered on them, take an emergency measure immediately and
see a doctor for medical advice.
-When it has adhered on skin; Wash with soap and water.
-When it has got in eyes; Wash in water for 10 minutes or more immediately.
-When it has spilled out in large quantity; Use sodium bicarbonate to neutralize, or wash away with
water.
-When it was swallowed; Drink milk or water.
-When it has adhered on clothes; Wash it immediately.

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 㨇1. OUTLINE㨉

1.1.5 HYDRAULIC PARTS

Ძ
(1) O-ring
࡮ Check that O-ring is free from flaw and has elasticity before fitting.
࡮ Even if the size of O-ring is equal, the usage differs, for example in dynamic and static sections,
the rubber hardness also differs according to the pressure force, and also the quality differs
depending on the materials to be seated. So, choose proper O-ring.
࡮ Fit O-ring so as to be free from distortion and bend.
࡮ Floating seal should be put in pairs.

(2) Flexible hose (F hose)

࡮ Even if the connector and length of hose are the same, the parts differ according to the
withstanding pressure. Use proper parts.
࡮ Tighten it to the specified torque, and check that it is free from twist, over tension, interference,
and oil leak.

1.1.6 WELD REPAIR

(1) The weld repair should be carried out by qualified personnel in the specified procedure after
disconnecting the grounding cable of battery. If the grounding cable is not disconnected, the
electrical equipment may be damaged.
(2) Remove parts which may cause fire due to the entry of spark beforehand.
(3) Repair attachments which are damaged, giving particular attention to the plated section of piston
rod to protect it from sparks, and don't fail to cover the section with flame-proof clothes.

1.1.7 ENVIRONMENTAL ISSUES

(1) Engine should be started and operated in the place where air can be sufficiently ventilated.
(2) Waste disposal
The following parts follows the regulation.
Waste oil, waste container and battery
(3) Precautions for handling hydraulic oil
Hydraulic oil may cause inflammation of eyes.
Wear goggles to protect eyes on handling it.
-When it has got in eyes ;
Wash eyes with water until the stimulus is gone.
-When it was swallowed ;
Don't force him to vomit it, but immediately receive medical treatment.
-When it has adhered on skin ;
Wash with soap and water.
(4) Others
For spare parts, grease and oil, use KOBELCO genuine ones.

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㨇1. OUTLINE㨉

1.2 INTERNATIONAL UNIT SYSTEM

Introduction
Although this manual uses the SI units system.
Outline of SI units system is described here.
Given hereinunder are an excerpt of the units
that are related to this manual :
1. Etymology of SI Units
English : International System of units
2. Construction of SI Unit System

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 㨇1. OUTLINE㨉

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㨇1. OUTLINE㨉

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 㨇2. SPECIFICATIONS㨉

Წ
2. SPECIFICATIONS
TABLE OF CONTENTS

2.1 NAME OF COMPONENTS ääääääääääääääääääääääääääääääää2-3

2.2 GENERAL DIMENSIONS äääääääääääääääääääääääääääääääää2-4
2.2.1 SK350LC-9E [6.50m (21ft-4in) Boom + 3.30m (10ft-10in) Standard Arm + 1.40m3 (1.83cu-yd)
Bucket] äääääääääääääääääääääääääääääääääääääääääää2-4
2.3 WEIGHT OF COMPONENTS äääääääääääääääääääääääääääääää2-5
2.4 TRANSPORTATIONääääääääääääääääääääääääääääääääääää2-7
2.4.1 OVERALL DIMENSIONS OF MACHINE ON A TRAILER ääääääääääääääää2-7
2.4.2 DIMENSIONS OF ATTACHMENT äääääääääääääääääääääääääää2-8
2.5 SPECIFICATIONS AND PERFORMANCE ääääääääääääääääääääääääää2-10
2.5.1 SPEED AND CLIMBING CAPABILITY äääääääääääääääääääääääää2-10
2.5.2 ENGINE äääääääääääääääääääääääääääääääääääääää2-10
2.5.3 HYDRAULIC COMPONENTS äääääääääääääääääääääääääääää2-10
2.5.4 WEIGHT äääääääääääääääääääääääääääääääääääääää2-11
2.6 TYPE OF CRAWLER äääääääääääääääääääääääääääääääääää2-12
2.6.1 SK350LC-9E äääääääääääääääääääääääääääääääääääää2-12
2.7 TYPE OF BUCKET ääääääääääääääääääääääääääääääääääää2-13
2.8 COMBINATIONS OF ATTACHMENT ääääääääääääääääääääääääääää2-14
2.9 ENGINE SPECIFICATION äääääääääääääääääääääääääääääääää2-15
2.9.1 SPECIFICATIONS ääääääääääääääääääääääääääääääääää2-15
2.9.2 ENGINE CHARACTERISTIC CURVE (HINO J08E-VV) ääääääääääääääääää2-16

Book Code No. 6/&(

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㨇2. SPECIFICATIONS㨉

Issue Date of Issue Applicable Machines Remarks

S5LC0233E01
First Edition July, 2014 SK350LC-9E : YC13-13001~
(NA)

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 㨇2. SPECIFICATIONS㨉

2.1 NAME OF COMPONENTS

Წ
No. NAME No. NAME No. NAME
1 Engine 15 Fuel Cooler 29 Track Guide
2 Hydraulic Pump 16 Engine Radiator 30 Upper Roller
3 Diesel Particulate Filter (DPF) 17 Inter Cooler 31 Travel Motor
4 SCR 18 Operator Cab 32 Boom Cylinder
5 Main Control Valve 19 Left Side Door 33 Boom
6 DEF Supply Module 20 Right Side Door 34 Arm Cylinder
7 Hydraulic Oil Tank 21 Engine Hood 35 Arm
8 Fuel Tank 22 Counterweight 36 Bucket Cylinder
9 DEF Tank 23 Slewing Bearing 37 Idler Link
10 Slewing Motor 24 Swing Flasher 38 Bucket Link
11 Swivel Joint 25 Track Shoe Assembly 39 Bucket
Rotary Multi-Control Valve
12 Engine Air Cleaner 26 Track Idler 40
(Option)

13 Battery 27 Idler Adjust

14 Oil Cooler 28 Lower Roller

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㨇2. SPECIFICATIONS㨉

2.2 GENERAL DIMENSIONS

2.2.1 SK350LC-9E [6.50m (21ft-4in) Boom + 3.30m (10ft-10in) Standard Arm +

1.40m3 (1.83cu-yd) Bucket]

Dimensions marked * do not include the height of the shoe lug.

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 㨇2. SPECIFICATIONS㨉

2.3 WEIGHT OF COMPONENTS

Item / Model SK350LC-9E

Machine complete: kg (lb) 37,300 (82,200)
1. Upper frame assy (Assembly of following :) 16,700 (36,800)
1.1 Upper frame 3,100 (6,840)
1.2 Counterweight

Წ
Counterweight (Semi-weighted) 8,800 (19,400)
1.3 Cab 480 (1,060)
1.4 Engine *750 (1,650)
1.5 Hydraulic oil tank *205 (450)
1.6 Fuel tank *220 (490)
1.7 Slewing motor (including reduction unit) *445 (980)
1.8 Control valve *240 (530)
1.9 Boom cylinder *315 (690) X 2
1.10 Pin (for mounting boom) 80 (180)
1.11 Pump *140 (310)
1.12 Radiator (including intercooler) *180 (400)
1.13 Urea tank *15 (30)
2. Lower frame assy (Assembly of following :) 13,100 (28,890)
2.1 Lower frame 4,200 (9,260)
2.2 Slewing bearing 555 (1,220)
2.3 Travel motor (including reduction unit) 400 (880) X 2
2.4 Upper roller 30 (70) X 4
2.5 Lower roller 60 (130) X 18
2.6 Front idler 180 (400) X 2
2.7 Idler adjuster 190 (420) X 2
2.8 Sprocket 75 (165) X 2
2.9 Swivel joint *25 (50)
2.10 Track guide 39 (86) X 6
2.11 Track link with 600mm (23.6in) shoes assy 2,050 (4,520) X 2
2.11 Track link with 800mm (31.5in) shoes assy 2,610 (5,760) X 2
2.11.1 Track link assy 900 (1,990) X 2
3. Attachment (Assembly of following / STD :) 6,700 (14,770)
{6.50m(21ft-4in)Boom+3.30m(10ft-10in)Arm+1.40m3(1.83cu-yd)Bucket}
3.1 Bucket assy (STD) 1,075 (2,370)
3.2 STD Arm assy (Assembly of following :) 2,000 (4,410)
3.2.1 STD Arm 1,270 (2,800)
3.2.2 Bucket cylinder *265 (580)
3.2.3 Idler link 30 (70) X 2
3.2.4 Bucket link 140 (310)
3.2.5 Pin (2pcs.for mounting bucket cylinder / 2pcs. for mounting bucket) 115 (250)
3.3 Boom assy (Assembly of following :) 3,600 (7,940)
3.3.1 Boom 2,650 (5,840)
3.3.2 Arm cylinder *505 (1,110)
3.3.3 Pin (Mounting arm Mounting arm cylinder) 70 (150)

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㨇2. SPECIFICATIONS㨉

Item / Model SK350LC-9E

4. Lubricant and water (Assembly of following :) 755 (1,660)
4.1 Hydraulic oil 215 (470)
4.2 Engine oil 25 (55)
4.3 Fuel 485 (1,070)
4.4 Water 30 (66)
4.5 DEF 55 (120)

Marks * show dry weight.

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 㨇2. SPECIFICATIONS㨉

2.4 TRANSPORTATION

2.4.1 OVERALL DIMENSIONS OF MACHINE ON A TRAILER

(1) 6.50m (21ft-4in) Boom+3.30m (10ft-10in) Arm+1.40m3 (1.83cu-yd) Bucket
Weight
Machine
600 mm (23.6") 700 mm (27.6") 800 mm (31.5") 900 mm (35.4")

Წ
Model
Shoe Shoe Shoe Shoe
36,100 kg 36,800 kg 37,300 kg 37,600 kg
SK350LC-9E
(79,500 lb) (81,100 lb) (82,200 lb) (82,900 lb)

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㨇2. SPECIFICATIONS㨉

2.4.2 DIMENSIONS OF ATTACHMENT

(1) BOOM
Item / Type 6.50m (21ft-4in) Boom
Length X Height X Width 6.75 X 1.84 X 0.83
L X H X W: m (ft-in) (22'2" X 6'0" X 2'9")
Weight: kg (lbs) 3,290 (7,250)

(2) ARM AND BUCKET

2.6m(8ft-6in) Arm + 3.30m(10ft-10in) Arm + 4.15m(13ft-7in) Arm +
Item / Type 3
1.6m (2.09cu-yd) Bucket 1.40m3(1.83cu-yd) Bucket 1.20m3(1.57cu-yd) Bucket
Length X Height X Width 5.41 X 1.13 X 1.57 6.07 X 1.12 X 1.42 6.94 X 1.10 X 1.24
L X H X W: m (ft-in) (17'9" X 3'8" X 5'2") (19'11" X 3'8" X 4'8") (22'9" x 3'7" x 4'1")
Weight: kg (lbs) 2,870 (6,330) 2,960 (6,530)

(3) Arm
Item / Type 2.6 m (8ft-6in) Arm 3.30 m (10ft-10in) Arm 4.15 m (13ft-7in) Arm
Length X Height X Width 3.82 X 1.09 x 0.62 4.48 X 0.97 x 0.62 5.35 X 0.99 X 0.63
L X H X W: m (ft-in) (12'6" X 3'7" X 2'2") (14'8" X 3'2" X 2'2") (17'7" X 3'3" X 2'1")
Weight: kg (lbs) 1,660 (3,660) 1,830 (4,040)

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 㨇2. SPECIFICATIONS㨉

(4) Bucket
Type Hoe bucket
Length X Height X Width 1.64 X 1.46 X 1.24 1.62 X 1.47 X 1.42 1.62 X 1.42 X 1.57
L X H X W: m (ft-in) (5'5" X 4'9" X 4'1") (5'4" X 4'10" x 4'8") (5'4" X 4'8" X 5'2")
Weight: kg (lbs) 930 (2,050) 1080 (2,380) 1140 (2,510)
Bucket capacity:
1.2 (1.57) 1.40 (1.83) 1.60 (2.09)
m3(cu-yd)

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㨇2. SPECIFICATIONS㨉

2.5 SPECIFICATIONS AND PERFORMANCE

2.5.1 SPEED AND CLIMBING CAPABILITY

Item / Area & Model SK350LC-9E

Swing speed 10.0 min-1 {10.0 rpm}
Travel speed (1-speed/2-speed) 3.3 / 5.6 km/h (2.05 / 3.5 mile/h)
Gradeability 70 % (35 degree)

2.5.2 ENGINE

Engine model HINO J08E-VV

Water-cooled, 4-cycle 6 cylinder direct injection type engine
Type
with intercooler turbo charger
Number of cylinders-BoreXStroke 6 -112 dia. mm X 130 mm(4.41 in X 5.12 in)
Total displacement 7.684 L (468.9 cu-in)
Rated output / Engine speed (ISO 14396) 213 kW (286 hp) / 2,100 min-1 (rpm)
Rated output / Engine speed (ISO 9249) 201 kW (270 hp) / 2,100 min-1 (rpm)
Maximum torque / Engine speed (ISO14396) 1,017 N-m (750 lbf-ft)/ 1,600 min-1 (rpm)
Maximum torque / Engine speed (ISO9249) 988 N-m (736 lbf-ft)/ 1,600 min-1 (rpm)
Starter 24 V / 5.0kW
Alternator 24 V / 60A

2.5.3 HYDRAULIC COMPONENTS

Hydraulic pump Variable displacement axial piston pump X 2 + gear pump X 1

Hydraulic motor (swing) Axial piston motor X 1
Variable displacement axial piston motor X 2
Hydraulic motor (travel)
(with counterbalance valve)
Control valve 8-spool control valve X 1
Cylinder
Double action cylinder
(Boom, Arm, Bucket)
Oil cooler Air-cooled type

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 㨇2. SPECIFICATIONS㨉

2.5.4 WEIGHT

Item / Model SK350LC-9E

Fully equipped weight 37,300 (82,200)
Upper structure 16,700 (36,800)
Lower machinery
(600mm grouser shoe : Europe) 13,100 (28,890)
(800mm grouser shoe : North America)

Წ
Attachment
6.50m(21ft-4in) Boom+3.30m(10ft-10in) Arm 6,700 (14,770)
+1.40m3 (1.83cu-yd) Bucket

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㨇2. SPECIFICATIONS㨉

2.6 TYPE OF CRAWLER

2.6.1 SK350LC-9E

Use 800mm (31.5in) grouser shoes on rough ground (areas covered with rocks and gravel). If you
drive or excavate with other shoes, this may cause shoe bending, shoe bolt looseness, and track
assembly (link, roller, etc.)

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2.7 TYPE OF BUCKET

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㨇2. SPECIFICATIONS㨉

2.8 COMBINATIONS OF ATTACHMENT

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

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 㨇2. SPECIFICATIONS㨉

2.9 ENGINE SPECIFICATION

2.9.1 SPECIFICATIONS

Applicable machine SK350LC-9E

Engine model HINO J08E-VV
Water-cooled, 4 cycle 6 cylinder direct injection type diesel engine

Წ
Type
with intercooler turbo-charger
Number of cylinder-Bore X Stroke 6 X 112mm (4.41 in) X 130mm (5.12 in)
Total displacement 7,684cc (469 cu-in)
Compression ratio 17.0
Rated out put (without fan NET) 213 kW (286 HP) at 2,100 min-1 (rpm)
Maximum torque (without fan NET) 1,017 N-m (750 lbf-ft) at 1,600 min-1 (rpm)
High idling 2,100 min-1
Low idling 1,000 min-1
Injection starting pressure 3.2 MPa (464 psi)
Thermostat action Start 350 K (170F degrees)/Full open 363 K (194F degrees)
Firing order 1 - 4 - 2 - 6 - 3 - 5
Compression pressure 3.4 MPa (493 psi) to 3.7 MPa (537 psi) at 280 min-1
Fuel injection timing Electron type
Valve clearance Open Close
14 deg. before top 30 deg. after bottom
Intake valve 0.3 mm at cool
Valve clearance dead point dead point
54 deg. before top 13 deg. after top
Exhaust valve 0.45 mm at cool
dead point dead point
Starter capacity 24 V X 5.0 kW
Generator capacity (Alternator) 24 V X 60 A
850 dia. (33.5 in) X suction type 6 fans, V-belt drive,
Cooling fan drive method
pulley ratio Crank / Fan= 0.80
Full level 26.0 L (6.87 gal)
Engine oil quantity Low level 20.0 L (5.28 gal)
Total 28.5 L (7.53 gal)
Dry weight 733 kg (1620 lbs)
Fuel consumption ratio 212 g / kw-h (156 g / PS-h)
Allowable inclination Front / Rear and Right / Left : 35 degrees
1,314 mm X 941 mm X 1,087 mm
Dimension (L X W X H)
(4 ft 3.73 in X 37.1 in X 3 ft 6.8 in)
Rotating direction Counterclockwise seeing from flywheel side

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㨇2. SPECIFICATIONS㨉

2.9.2 ENGINE CHARACTERISTIC CURVE (HINO J08E-VV)

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 㨇3. ATTACHMENT DIMENSIONS㨉

3. ATTACHMENT DIMENSIONS
TABLE OF CONTENTS

Ჭ
3.1 BOOM ääääääääääääääääääääääääääääääääääääääääää3-3
3.1.1 BOOM DIMENSIONAL DRAWING äääääääääääääääääääääääääää3-3
3.1.2 BOOM MAINTENANCE STANDARD ääääääääääääääääääääääääää3-4
3.2 ARM ääääääääääääääääääääääääääääääääääääääääää3-6
3.2.1 ARM DIMENSIONAL DRAWING ääääääääääääääääääääääääääää3-6
3.2.2 ARM MAINTENANCE STANDARD äääääääääääääääääääääääääää3-7
3.3 BUCKETäääääääääääääääääääääääääääääääääääääääää3-10
3.3.1 BUCKET DIMENSIONAL DRAWING ääääääääääääääääääääääääää3-10
3.3.2 LUG SECTION DIMENSIONAL DRAWING äääääääääääääääääääääää3-11
3.3.3 BOSS SECTION DIMENSIONAL DRAWING ääääääääääääääääääääää3-12

Book Code No. S5LC0332E01

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㨇3. ATTACHMENT DIMENSIONS㨉

Issue Date of Issue Applicable Machines Remarks

SK330-9 : LC12-15001~ S5LC0332E01
First Edition June, 2013
SK350LC-9 : YC12-10001~ (NA)
SK330-9 : LC12-15001~
December, 2013
SK350(N)LC-9 : YC12-10002~ (NA / EUR)

July, 2014 SK350LC-9E : YC13-13001~

(NA)

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 㨇3. ATTACHMENT DIMENSIONS㨉

3.1 BOOM

3.1.1 BOOM DIMENSIONAL DRAWING

Ჭ
Boom dimensional drawing

STD
6.50M (21ft-4in) BOOM
LC02B00373F1
No. NAME DIMENSIONS: mm (ft-in)
A Boom length 6,500 (21'4")
B Boom foot width 826 (32.5")
C Boom end inner width 405.8 (16.0")
D Boom end outer width 577 (22.7")
E Height of boom cylinder rod pin 1,115 (3'8")
F Height of arm cylinder (head side) pin 1,460.8 (4'9.5")
G Distance between pins of boss R2,955 (9'8")
H Distance between pins of bracket R3,390.5 (11'1.5")
I Arm cylinder (head side) inner width 146 (5.75")
J Outer width of bracket on the boom cylinder (rod side) mounting 564 (22.2")
d1 Boom foot pin dia. 125 dia. (4.92")
d2 Boom cylinder (rod side) pin dia. 110 dia. (4.33")
d3 Pin dia. of boom end. 110 dia. (4.33")
d4 Arm cylinder (head side) pin dia. 110 dia. (4.33")

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3.1.2 BOOM MAINTENANCE STANDARD

(1) Clearance of pin and bushing on boom section

Clearance of pin and bushing on boom section

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

Ჭ
Clearance in thrust direction on the boom cylinder installation section

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3.2 ARM

3.2.1 ARM DIMENSIONAL DRAWING

ARM DIMENSIONAL DRAWING

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3.2.2 ARM MAINTENANCE STANDARD

(1) Clearance of pin and bushing

Ჭ
Clearance of pin and bushing on arm section

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

Clearance of arm and cylinder installing sections in thrust direction

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3.3 BUCKET

3.3.1 BUCKET DIMENSIONAL DRAWING

(1) Hoe bucket

Bucket dimensional drawing

No. NAME No. NAME

A Distance between pin and bracket G Outer width of bucket bottom
B Distance between bucket pin and tooth end H Bucket outer width of front side
C Inner width of bucket top end I Pitch between teeth
D Inner width of lug Io Pitch between teeth
E Inner width of bracket d1 Outer dia. of bushing
F Outer width of side cutter d2 Pin dia.

(2) BUCKET DIMENSIONAL TABLE

Type GD bucket(General Duty) [mm(ft-in)]
3
1.40 m 1.20 m3 1.60 m3
Capacity
(1.83 cu-yd) (1.57 cu-yd) (2.09 cu-yd)
Part No. LC61B00115F1 LC61B00052F1 LC61B00118F1
A R517 (20.4") <-- <--
B R1,690 (5'7") <-- <--
C 1,238 (4'1") 1,060 (3'6") 1,388 (4'7")
D 444 (17.5") <-- <--
E 382 (15.0") <-- <--
F 1,415 (4'8") 1,240 (4'1") 1,565 (5'2")
G 1,122 (3'8") 936 (36.9") 1,272 (4'2")
H 1,238 (4'1") 1,060 (3'6") 1,388 (4'7")
I 280.5 (11") 316 (12'4") 318 (12.5")
IO 280.5 (11") 315 (12'4") 318 (12.5")
d1 㱢105 (4.13") <-- <--
d2 㱢90 (3.54") <-- <--

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 㨇3. ATTACHMENT DIMENSIONS㨉

3.3.2 LUG SECTION DIMENSIONAL DRAWING

Ჭ
Dimension of lug section

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㨇3. ATTACHMENT DIMENSIONS㨉

3.3.3 BOSS SECTION DIMENSIONAL DRAWING

Dimension of boss section

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 㨇11. TOOLS㨉

11. TOOLS
TABLE OF CONTENTS

11.1 TIGHTENING TORQUES FOR CAPSCREWS AND NUTS ääääääääääääääääää11-3
11.2 SCREW SIZE ääääääääääääääääääääääääääääääääääääää11-5
11.2.1 CAPSCREW (BOLT) äääääääääääääääääääääääääääääääää11-5
11.2.2 CAPSCREW (SOCKET BOLT) ääääääääääääääääääääääääääää11-5
11.2.3 SOCKET SET SCREW äääääääääääääääääääääääääääääää11-5
11.3 TIGHTENING TORQUE FOR HOSE AND FITTING äääääääääääääääääääää11-6
11.3.1 JOINT (O-RING TYPE) äääääääääääääääääääääääääääääää11-6
11.3.2 HYDRAULIC HOSE (30 DEG. FLARE TYPE) äääääääääääääääääääää11-6
11.3.3 JOINT (ORS TYPE) äääääääääääääääääääääääääääääääää11-6
11.3.4 SPLIT FLANGE äääääääääääääääääääääääääääääääääää11-6
11.4 TIGHTENING TORQUES FOR NUTS AND SLEEVESääääääääääääääääääää11-7
11.5 PLUGS äääääääääääääääääääääääääääääääääääääääää11-8
11.5.1 PLUG FOR HYDRAULIC PIPE JOINT ääääääääääääääääääääääää11-8
11.5.2 PLUG FOR HYDRAULIC EQUIPMENT ääääääääääääääääääääääää11-9
11.6 SPECIAL SPANNER FOR TUBE äääääääääääääääääääääääääääää11-11
11.7 SPECIAL TOOLS ääääääääääääääääääääääääääääääääääää11-12
11.8 APPLICATION OF SCREW LOCKING COMPOUND AND SEALING COMPOUNDäääääää11-14
11.9 SUCTION STOPPERäääääääääääääääääääääääääääääääääää11-15
11.9.1 COMPONENTS äääääääääääääääääääääääääääääääääää11-15
11.9.2 DIMENSIONäääääääääääääääääääääääääääääääääääää11-15
11.9.3 APPLICABLE MODEL ääääääääääääääääääääääääääääääää11-15
11.10 UPPER FRAME LIFTING JIG ääääääääääääääääääääääääääääää11-16
11.11 ENGINE MOUNTING PEDESTAL ääääääääääääääääääääääääääää11-17
11.12 MUFFLER ASSY LIFTING JIG äääääääääääääääääääääääääääää11-18
11.13 WHIRL-STOP JIG OF DEF TANK FIXING BAND äääääääääääääääääääää11-19

Book Code No. S5LC113E01

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㨇11. TOOLS㨉

Issue Date of Issue Applicable Machines Remarks

S5LC1133E01
First Edition July, 2014 SK350LC-9E : YC13-13001~
(NA)

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 㨇11. TOOLS㨉

11.1 TIGHTENING TORQUES FOR CAPSCREWS AND NUTS

Table "Metric coarse thread (Not plated)" and Table "Metric fine thread (Not plated)" indicate
tightening torques applicable to cases where no special note is given.
Overtightening of bolts may result in a twist-off and a fracture under load.
Insufficient tightening may lead to a loosening or loss of bolts. Always tighten bolts to proper torques.



Tightening torque for metric coarse threads (not plated)

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Tightening torques for metric fine threads (not plated)

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 㨇11. TOOLS㨉

11.2 SCREW SIZE

11.2.1 CAPSCREW (BOLT)



11.2.2 CAPSCREW (SOCKET BOLT)

11.2.3 SOCKET SET SCREW

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11.3 TIGHTENING TORQUE FOR HOSE AND FITTING

11.3.1 JOINT (O-RING TYPE)

11.3.2 HYDRAULIC HOSE (30 DEG. FLARE TYPE)

11.3.3 JOINT (ORS TYPE)

11.3.4 SPLIT FLANGE

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11.4 TIGHTENING TORQUES FOR NUTS AND SLEEVES

Table below indicates standard tightening torques applicable to cases where no particular note is given.
Overtightening or undertightening of nuts and sleeves in FLARELESS JOINT may develop oil leaks
through pipe connections.
Always tighten nuts and sleeves to proper torques.



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11.5 PLUGS

11.5.1 PLUG FOR HYDRAULIC PIPE JOINT

(1) Cap nut (Joint plug)

(2) Plug (Tube plug)

(3) Nut

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11.5.2 PLUG FOR HYDRAULIC EQUIPMENT

(1) PF screw

(2) PT screw



(3) Plug for(F)flare hose

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(4) Plug for ORS joints

Male

Female

(5) Plug for half clamp

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11.6 SPECIAL SPANNER FOR TUBE



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11.7 SPECIAL TOOLS

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11.8 APPLICATION OF SCREW LOCKING COMPOUND AND

SEALING COMPOUND
(1) For general use
Manufacturer
Service Features
Loctite Three-Bond
#242 1360K Low strength
Screw locking
#262 1374 Middle strength
compound
#271 1305 High strength
Sealing compound #515 1215 Sealing

(2) For specific location

No. Use Manufacturer Name Equivalent Applicable
(Manufacturer ; Loctite)
# 1901 Anti-seizure Cylinder
Three-Bond # 1215 gray # 5699 Swing motor
# 1211 white # 5301J Swing motor
# 1303B # 211 Main pump
(Manufacturer ; Three-Bond)
Sealing
Loctite # 222 # 1344N Main pump
compound
1 # 277 # 1307N Pilot valve
&
adhesive (Manufacturer ; Three-Bond)
Loctite Parmatex 98D # 1121 Hydraulic oil tank :
Sumitomo
Chemical Co., Cyano Bond PO-1 Hose
Ltd.
Shell
petroleum Shell Alvania EP2 New Molyknock Grease 2 Swing bearing grease bath

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11.9 SUCTION STOPPER

11.9.1 COMPONENTS



Components of suction stopper

11.9.2 DIMENSION

Dimension of suction stopper

11.9.3 APPLICABLE MODEL

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11.10 UPPER FRAME LIFTING JIG

Upper frame lifting jig

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11.11 ENGINE MOUNTING PEDESTAL



Engine stand

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11.12 MUFFLER ASSY LIFTING JIG

Muffler assy lifting jig

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11.13 WHIRL-STOP JIG OF DEF TANK FIXING BAND



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 㨇12. STANDARD MAINTENANCE TIME TABLE㨉

12. STANDARD MAINTENANCE

TIME TABLE
TABLE OF CONTENTS

12.1 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR ääääää12-4
12.2 ENGINE MAINTENANCE SERVICE STANDARD TIME LISTäääääääääääääääää12-17
12.2.1 MEASURING METHOD äääääääääääääääääääääääääääääää12-17
12.2.2 WORKING CONDITION äääääääääääääääääääääääääääääää12-17
12.2.3 STANDARD TIME CONSTITUENT ääääääääääääääääääääääääää12-18
12.2.4 MEANING OF WORDS IN USE äääääääääääääääääääääääääää12-19


Book Code No. 6/&(

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㨇12. STANDARD MAINTENANCE TIME TABLE㨉

Issue Date of Issue Applicable Machines Remarks

S5LC1233E01
First Edition July, 2014 SK350LC-9E : YC13-13001~
(NA)

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 㨇12. STANDARD MAINTENANCE TIME TABLE㨉

PREFACE
(1) Working Conditions
1. Workers:
More than one worker shall be 1st class service technician (having five years or more of field
experience and having received training in the operation).
2. Equipment:
Jigs, tools, apparatuses and testers used in field service work shall be available commercially.
The maintenance plant shall be equipped with a service shop, a crane and inspection
apparatuses necessary for specific self inspection activities.
3. Place:
A flat land where work may be performed and to which a service car or a truck crane is
accessible.

(2) Range of standard maintenance time

1. Standard maintenance time=Direct maintenance time X Preparation time
2. Direct maintenance time: Net time actually spent for maintenance
3. Spare time:
Time needed to move machines for service, prepare safety operations, discuss work, and process
the needs of the body.


(3) Extra time (not included in the standard service time)
1. Repair time:
Machining, sheet metal, welding, melt cutting, folding and extracting bolts, servicing parts, and
painting.
2. tems excluded from service time because of uncertainty in time:
Receiving a vehicle into shop, transfer, delivery, inspection on completion, investigation of causes
of faults, diagnosis, and inspection.
3. Indirect time:
Time for; field work, preparation of necessary parts before leaving for work, return for field work,
waiting time because of user's convenience in the field, paper work after returning to shop, and
preparation of bills.
4. Special time: Work at early morning, at midnight and on holidays are to be calculated separately.
5. Separate calculation: The operating time for service cars, trucks with a crane and crane trucks.

(4) Applicable machine for estimation of standard maintenance time

1. Standard machine
2. A well maintained and controlled machine with a standard combination of attachments which is
used in a general environment.

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㨇12. STANDARD MAINTENANCE TIME TABLE㨉

12.1 STANDARD WORKING TIME TABLE FOR THE

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

A/C : Air conditioner C/V : Control valve O/H : Over haul

ASSY : Assembly Cyl : Cylinder SOL : Solenoid
ATT : Attachment E/G : Engine SW : Switch
BRG : Bearing F hose : Flexible hose V : Valve

(2) Classification of work code

No. GROUP REMARKS
01 Attachment Indicates installing, removing, replacement and overhaul.
02 Cab & Guard
03 Swing frame
04 Travel system
Electric Indicates the installing, removing and replacement of single items.
06
equipments
09 E/G relation Indicates overhaul of the single engine.
(Materials prepared by manufacturer)

(3) Conditions for standard service time of the engine

1. Tools designated by E/G maker are used
2. Genuine parts are changed
3. Correct working procedures are observed.

࡮ The time required for works specified in this Chapter shows the total time for maintenance.

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 㨇12. STANDARD MAINTENANCE TIME TABLE㨉

01 Attachment
Work to be Unit:
Group Location Unit Remarks
done Hour
00 Bucket relation See 32.1.2
01 Bucket ASSY Detach/attach 1 pc. Include adjustment 0.9
02 -Bucket attaching and detaching Preparation 1 pc. 0.1
position
03 -Bucket attaching pin Detach/attach 1 Include stopper pin. 0.2
04 -Bucket drive pin Detach/attach 1 0.2
05 -Bucket sling and movement Preparation 1 pc. 0.3
06 Bucket (single) O/H 1 pc. Not include attaching and 3.6
detaching
07 -Tooth Replace 1 pc. 0.9
08 -Side cutter Replace 1 pc. 1.8
09 -Bushing Replace 1 pc. 0.9
10 Arm relation See 32.1.3
11 Arm ASSY Detach/attach 1 pc. 1.9
12 -Bucket cylinder attaching and Preparation 1 pc. 0.6
detaching position and piping
13 -Bucket cylinder rod pin Detach/attach 1 pc. Include stopper pin. 0.2
14 -Bucket cylinder head pin Detach/attach 1 pc. Include stopper pin. 0.2 
15 -Bucket cylinder assy Detach/attach 1 pc. 0.2
16 -Arm cylinder rod pin Detach/attach 1 pc. Include stopper pin. 0.2
17 -Boom top pin Detach/attach 1 pc. Include wire stop pin 0.2
18 -Arm sling and movement Detach/attach 1 pc. 0.3
30 Boom portion See 32.1.4
31 Boom ASSY Detach/attach 1 pc. 2.1
32 -Boom attaching and detaching position Preparation 1 pc. 0.1
33 -Boom cylinder temporary slinging Preparation 2 pcs. 0.3
34 -Boom cylinder rod pin Detach/attach 2 Include two stopper pins. 0.3
35 -Boom cylinder piping Detach/attach 2 pc. 0.3
36 -Arm & bucket piping Detach/attach 1 pc. 0.3
37 -Boom assy temporary slinging Detach/attach 1 pc. 0.1
38 -Boom foot pin Detach/attach 1 Include stopper pin. 0.3
39 -Boom assy slinging Detach/attach 1 pc. 0.2
40 Arm cylinder attaching and detaching Detach/attach 1 pc. 0.7
41 -Arm cylinder piping Detach/attach 1 pc. 0.3
42 -Arm cylinder head pin Detach/attach 1 pc. Include stopper pin. 0.2
43 -Arm cylinder slinging Detach/attach 1 pc. 0.2
50 Boom cylinder attaching and detaching Detach/attach 2 pcs. 1.0
51 -Boom cylinder piping Detach/attach 2 0.4
52 -Boom cylinder head pin Detach/attach 2 pcs. 0.3
53 -Boom cylinder slinging Detach/attach 2 0.3
60 Bucket cylinder O/H 1 4.0
61 -Pin bushing Replace 1 Include seal. 1.5
70 Arm cylinder O/H 1 4.0
71 -Pin bushing Replace 1 set Include seal. 1.5
80 Boom cylinder O/H 2 8.0
81 -Pin bushing Replace 1 set Include seal. 1.5

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02 Cab & Guard (1/2)

Work to be Unit:
Group Location Unit Remarks
done Hour
10 Cab relation See 33.1.2
11 Cab ASSY Detach/attach 1 pc. 1.6
12 -Front lower glass, floor mat Detach/attach 1 pc. each 0.1
13 -Seat rear cover top, bottom Detach/attach 1 pc. each 0.3
14 -Right side panel (include A/C duct) Detach/attach 3 0.3
15 -Cable and harness (electric) Detach/attach 6 0.2
16 -Controller (KPSS) Detach/attach 1 pc. 0.2
17 -Cab mounting bolt Detach/attach 8 pcs. 0.2
18 -Cab slinging Detach/attach 3 places 0.3
20 Guard relation See 33.1.4
21 Plate (A16) Detach/attach 1 pc. 0.2
22 Stay (G13) Detach/attach 1 pc. 0.2
23 Bonnet assy (G1) Detach/attach 1 pc. 0.3
24 Bonnet assy (G2) Detach/attach 1 pc. 0.3
25 Stay (H1) Detach/attach 1 pc. 0.2
26 Stay (H2) Detach/attach 1 pc. 0.2
27 Stay (H3) Detach/attach 1 pc. 0.2
28 Panel assy (B1) Detach/attach 1 pc. 0.2
29 Panel assy (B2) Detach/attach 1 pc. 0.2
30 Panel assy (B3) Detach/attach 1 pc. 0.2
31 Guard (C1) Detach/attach 1 pc. 0.2
32 Guard (A14) Detach/attach 1 pc. 0.2
33 Guard (A15) Detach/attach 1 pc. 0.2
34 Cover (C4) Detach/attach 1 pc. 0.2
35 Guard assy (C3) Detach/attach 1 pc. 0.2
36 Cover assy (C5) Detach/attach 1 pc. 0.2
37 Guard assy (C2) Detach/attach 1 pc. 0.2
38 Pillar (A16) Detach/attach 1 pc. 0.2
39 Beam (A38) Detach/attach 1 pc. 0.2
40 Beam (A40) Detach/attach 1 pc. 0.2
41 Beam (A41) Detach/attach 1 pc. 0.2
42 Panel (A22) Detach/attach 1 pc. 0.2
43 Pillar (A18) Detach/attach 1 pc. 0.2
44 Guard (A19) Detach/attach 1 pc. 0.2
45 Pillar (A17) Detach/attach 1 pc. 0.2
46 Duct (D4) Detach/attach 1 pc. 0.2
47 Duct (D3) Detach/attach 1 pc. 0.2
48 Plate (D5) Detach/attach 1 pc. 0.2
49 Guard (D1) Detach/attach 1 pc. 0.2

Note: The numbers in the parenthesis like guard (A22) match the guard numbers on the upper
structure.

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 㨇12. STANDARD MAINTENANCE TIME TABLE㨉

02 Cab & Guard (2/2)

Work to be Unit:
Group Location Unit Remarks
done Hour
50 Guard (D2) Detach/attach 1 pc. 0.2
51 Bracket assy (A11) Detach/attach 1 pc. 0.2
52 Guard (A12) Detach/attach 1 pc. 0.2
53 Beam (A5) Detach/attach 1 pc. 0.2
54 Beam (A10) Detach/attach 1 pc. 0.2
55 Bracket (A8) Detach/attach 1 pc. 0.2
56 Pillar (A1) Detach/attach 1 pc. 0.2
57 Pillar (A2) Detach/attach 1 pc. 0.2
58 Pillar (A3) Detach/attach 1 pc. 0.2
59 Pillar (A9) Detach/attach 1 pc. 0.2
60 Pillar (A20) Detach/attach 1 pc. 0.2
61 Cover assy (E1) Detach/attach 1 pc. 0.2
62 Cover assy (E2) Detach/attach 1 pc. 0.2
63 Cover assy (E3) Detach/attach 1 pc. 0.2
64 Cover assy (E6) Detach/attach 1 pc. 0.2
65 Guard (E5) Detach/attach 1 pc. 0.2
66 Stay (F1) Detach/attach 1 pc. 0.2


70 Under cover relation See 33.1.5
71 Cover (1) Detach/attach 1 pc. 0.1
72 Cover (2) Detach/attach 1 pc. 0.1
73 Cover (3) Detach/attach 1 pc. 0.1
74 Cover (4) Detach/attach 1 pc. 0.1
75 Cover (5) Detach/attach 1 pc. 0.1
76 Cover (6) Detach/attach 1 pc. 0.1
77 Cover (7) Detach/attach 1 pc. 0.1
78 Cover (10) Detach/attach 1 pc. 0.1
79 Cover (11) Detach/attach 1 pc. 0.1
80 Cover (12) Detach/attach 1 pc. 0.1
90 Counterweight relation See 33.1.12
91 Counterweight ASSY Detach/attach 1 pc. 0.9
92 -Counterweight temporary slinging Preparation 1 pc. 0.3
93 -Counterweight mounting bolt Detach/attach 1 pc. 0.3
94 -Counterweight slinging Detach/attach 1 pc. 0.2

Note: The numbers in the parenthesis like cover (2) match the cover numbers on the upper structure.

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㨇12. STANDARD MAINTENANCE TIME TABLE㨉

03 Swing frame (1/3)

Work to be Unit:
Group Location Unit Remarks
done Hour
10 Intake relation See 33.1.10
11 Air cleaner ASSY Detach/attach 1 pc. 0.4
12 -Hose (3) Detach/attach 1 0.1
13 -Air cleaner mounting bolt Detach/attach 1 set 0.2
14 -Element Replace 1 0.1
20 Exhaust relation See 33.1.11
21 SCR and DPF Detach/attach 1 set
22 -Filter Detach/attach 1 pc.
23 -Harness connector Detach/attach 1 pc.
24 -Hose Detach/attach 1 pc.
25 -Bracket Detach/attach 1 pc.
26 -Rubber mount Detach/attach 1 pc.
30 Radiator relation See 33.1.13
31 Radiator ASSY Detach/attach 1 pc. 5.0
32 -Coolant (LLC) Replace 1 pc. 0.3
33 --Concentration of coolant Measuring 1 pc. 0.2
34 -A/C condenser Moving 1 pc. 0.3
35 -Fuel cooler Moving 1 pc. 0.3
36 -Stay Detach/attach 1 pc. 0.1
37 -Bracket Detach/attach 1 0.3
38 -Fan rubber Detach/attach 1 pc. 0.3
39 -Sub tank hose Detach/attach 1 pc. 0.1
40 -Fan guard Detach/attach 3 pc. 0.4
41 -Water hose (radiator ~ E/G) Detach/attach 2 0.6
42 -Radiator mounting bolts removing Detach/attach 1 set 0.2
43 -Under cover Detach/attach 1 pc. 0.1
44 -Hydraulic oil tank suction stopper Detach/attach 1 pc. 0.2
45 -Hydraulic oil piping Detach/attach 1 pc. 0.6
-Inter cooler hose & tube Detach/attach 2 pcs. 0.5
46 (E/G to inter cooler)
47 -Radiator lifting or hoisting Detach/attach 1 pc. 0.2
48 -Radiator inter cooler core & oil cooler Cleaning 1 pc. 1.0
50 Fuel relation See 33.1.6
51 Fuel tank ASSY Detach/attach 1 pc. 1.8
52 -Fuel Replace 1 pc. 0.4
53 -Hose (water separator side) Detach/attach 2 0.1
54 -Tube (tank side) Detach/attach 1 0.1
55 -Fuel tank installing bolts Detach/attach 1 pc. 0.3
56 -Tank slinging Detach/attach 1 pc. 0.3
Other necessary works Detach/attach 1 pc. Removing and installing 0.4
guard

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 㨇12. STANDARD MAINTENANCE TIME TABLE㨉

03 Swing frame (2/3)

Work to be Unit:
Group Location Unit Remarks
done Hour
60 Hydraulic oil tank relation See 33.1.7
61 Hydraulic oil tank ASSY Detach/attach 1 pc. 3.0
65 -Cover Detach/attach 1 pc. 0.2
66 -Hydraulic oil Replace 1 pc. 0.6
68 -Pilot drain hose Detach/attach 1 pc. 0.2
69 -Pump suction hose Detach/attach 1 pc. 0.5
70 -Mounting bolt Detach/attach 1 pc. 0.2
71 -Hydraulic oil tank slinging Detach/attach 1 pc. 0.3
72 -Return filter Replace 1 0.2
73 -Suction filter Cleaning 1 0.2
80 Pump relation See 33.1.8
81 Pump ASSY Detach/attach 1 pc. 3.2
82 -Hydraulic oil tank cover Detach/attach 1 pc. 0.3
83 -Strainer & stopper Detach/attach 1 pc. 0.3
84 -Piping Detach/attach 1 set 1.0
85 -Guard Detach/attach 5 pcs. 1.0
86 -Pump slinging Detach/attach 1 pc. 0.5
87 -Cleaning Cleaning 1 pc. 0.1 
88 -Vent air Adjust 1 pc. 0.1
89 Pump ASSY O/H 1 pc. 4.0
90 Swing motor unit relation See 33.1.20
91 Swing motor ASSY Detach/attach 1 pc. 2.4
92 -Piping Detach/attach 1 set 1.0
93 -Mounting bolt Detach/attach 1 pc. 0.7
94 -Unit slinging Detach/attach 1 pc. 0.5
95 -Cleaning and sealant Cleaning 1 set 0.2
96 Swing motor O/H 1 pc. 4.0
97 Swing reduction gear O/H 1 pc. 5.0
100 Swivel joint relation See 33.1.21
101 Swivel joint ASSY Detach/attach 1 2.6
102 -Piping (Top part only) Detach/attach 1 set 0.5
103 -Whirl stop bolt Detach/attach 1 0.2
104 -Cover Detach/attach 1 0.4
105 -Joint & elbow Detach/attach 1 set 0.4
106 -Mounting bolt Detach/attach 1 set 0.4
107 -Swivel joint slinging Detach/attach 1 0.4
108 -Cleaning Cleaning 1 set 0.3
109 Swivel joint O/H 1 set Removing and installing 3.6
guard
Other necessary works Detach/attach 1 set Lower piping 0.6
120 Main control valve See 33.1.16
121 Main control valve ASSY Detach/attach 1 pc. 2.5
122 -Attach tag to port name of pipe Preparation 1 pc. 0.6
123 -Piping Detach/attach 1 set 1.7
124 -Bracket mounting bolt Detach/attach 1 pc. 0.1
125 -Valve slinging Detach/attach 1 pc. 0.1
126 Main control valve ASSY Detach/attach 1 set 6.0
Other necessary works Detach/attach 1 set Guard 0.4

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㨇12. STANDARD MAINTENANCE TIME TABLE㨉

03 Swing frame (3/3)

Work to be Unit:
Group Location Unit Remarks
done Hour
130 Valve relation
131 Solenoid valve ASSY Detach/attach 1 1.0
132 -Attach tag to port name of pipe Preparation 1 0.2
133 -Piping Detach/attach 1 set 0.5
134 -Mounting bolt Detach/attach 1 0.3
140 Engine (E/G) mounting relation See 33.1.14
141 Engine ASSY Detach/attach 1 pc. After removing pump & 2.0
radiator
142 -Harness connector & grounding & Detach/attach 1 pc. 0.3
cable connection
143 -Fuel hose Detach/attach 1 pc. 0.1
144 -Others Detach/attach 1 set 0.5
145 -Mounting bolt Detach/attach 1 pc. 0.5
146 -Engine slinging Detach/attach 1 set 0.3
147 -Cleaning Cleaning 1 pc. 0.5
148 Engine O/H 1 set Reference for engine
(Chapter 51)
149 -Fan ring Detach/attach 1 pc. 0.2
Other necessary works Detach/attach 1 set Removing and installing 0.6
guard
Detach/attach 1 set Removing and installing 0.9
Counterweight
Detach/attach 1 set Removing and installing 3.2
pump
Detach/attach 1 set Removing and installing air 0.4
cleaner
Detach/attach 1 set Removing and installing 0.4
muffler
Detach/attach 1 set Removing and installing 4.0
radiator
150 Upper frame See 33.1.22
151 Upper frame ASSY Detach/attach 1 pc. After removing swivel joint 1.3
152 -Mounting bolt Detach/attach 1 set 0.4
153 -Upper frame slinging Detach/attach 1 pc. 0.4
154 -Cleaning Cleaning 1 pc. 0.3
155 -Sealant Apply 1 pc. 0.2
Other necessary works Detach/attach 1 set Cab 1.4
Detach/attach 1 set Guard 0.4
Detach/attach 1 set Counterweight 0.9
Detach/attach 1 set Boom 2.1

12-10
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 㨇12. STANDARD MAINTENANCE TIME TABLE㨉

04 Travel system
Work to be Unit:
Group Location Unit Remarks
done Hour
00 Travel relation See 34.1.2
01 Track link ASSY Detach/attach One side Include adjustment of 2.0
tension
02 -Track link attaching and detaching Preparation One side 0.1
position
03 -Master pin Detach/attach One side 0.7
04 -Track link extending and winding Detach/attach One side 0.7
05 Shoe plate Replace 1 pc. 0.4
10 Upper roller relation See 34.1.3
11 Lower roller ASSY Detach/attach 1 After removing track link 0.3
12 Lower roller O/H 1 1.0
20 Lower roller relation See 34.1.4
21 Lower roller ASSY Detach/attach 1 0.3
22 Lower roller O/H 1 1.5
30 Front idler relation See 34.1.5
31 Front idler ASSY Detach/attach One side After removing track link 0.8
32 Front idler ASSY slinging Detach/attach One side 0.3 
33 Front idler ASSY Detaching One side 0.5
34 Idler ASSY O/H One side 1.5
40 Sprocket See 34.1.6
41 Sprocket Replace One side After removing track link 0.9
50 Travel motor relation See 34.1.7
51 Travel motor ASSY Detach/attach One side After removing track link 2.4
52 -Motor cover Detach/attach One side 0.1
53 -Hydraulic piping Detach/attach One side 1.3
54 -Motor mounting bolt Detach/attach One side 0.6
55 -Motor slinging Detach/attach One side 0.2
56 Motor cleaning Cleaning One side 0.2
57 Travel motor O/H One side 4.0
58 Travel reduction gear O/H One side 4.0
60 Swivel joint relation
61 Pipe on swivel joint travel side Detach/attach 1 pc. Include bonnet assy 0.6
removing and installing.
62 Swivel joint O/H 1 pc. See 33.2.6 3.6
70 Swing bearing See 34.1.8
71 Swing bearing ASSY Detach/attach 1 pc. After removing upper frame 0.8
72 Swing bearing mounting bolt Detach/attach 1 pc. 0.6
73 Swing bearing slinging Detach/attach 1 pc. 0.4

12-11
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㨇12. STANDARD MAINTENANCE TIME TABLE㨉

06 Electric equipments (1/4)

Work to be Unit:
Group Location Unit Remarks
done Hour
Controller
C-1 Controller (KPSS) Replace 1 0.5
C-2 Gauge cluster Replace 1 1.0
C-4 Air conditioner Amplifier Replace 1 2.0
C-5 Engine coolant level controller Replace 1 1.0
C-8 Engine controller Replace 1 1.0
C-12 Dosing controller Replace 1 1.0
Diode
D-4 Diode Replace 1 0.3
D-5 Diode Replace 1 0.3
D-6 Diode Replace 1 0.3
D-9 Diode Replace 1 0.3
D-10 Diode Replace 1 0.3
D-12 Diode Replace 1 0.3
D-13 Diode Replace 1 0.3
D-14 Diode Replace 1 0.3
D-16 Diode Replace 1 0.3
D-17 Diode Replace 1 0.3
D-20 Diode Replace 1 0.3
D-21 Diode Replace 1 0.3
D-22 Diode Replace 1 0.3
D-23 Diode Replace 1 0.3
D-25 Diode Replace 1 0.3
D-66 Diode Replace 1 0.3
D-67 Diode Replace 1 0.3
Electric equipments
E-1 Fuse & relay box Replace 1 0.3
E-2 Alternator Replace 1 1.0
E-3 Hour meter Replace 1 0.3
E-5 Horn (High) Replace 1 0.3
E-6 Horn (Low) Replace 1 0.3
E-7 Tuner AM & FM Replace 1 0.3
E-8 Speaker left Replace 1 0.3
E-9 Speaker right Replace 1 0.3
E-10 Receiver dryer Replace 1 Include gas sealing. 1.0
E-11 Air compressor Replace 1 Include Counterweight 1.0
removing and installing.
E-12 Battery Replace 2 0.4
E-13 Travel alarm Replace 1 0.3
E-22 DC-DC converter Replace 1 0.3
E-23 12V socket Replace 1 0.3
E-27 Accel emergency mode volume Replace 1 0.5
E-46 Rear camera Replace 1 0.3
E-49 DC-DC converter (proportional) Replace 1 0.3
E-63 DC-DC converter (for camera) Replace 1 0.3
E-76 Fusible link Replace 1 0.3
E-77 Supply module Replace 1 1.0
E-78 Resistor Replace 1 1.0
E-79 Dosing module Replace 1 1.0

12-12
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 㨇12. STANDARD MAINTENANCE TIME TABLE㨉

06 Electric equipments (2/4)

Work to be Unit:
Group Location Unit Remarks
done Hour
E-84 DCU fuse Replace 1 0.3
E-89 Sensor fuse Replace 1 0.3
E-99 ECU fuse Replace 1 0.3
E-100 Varistor Replace 1 0.3
Light
L-1 Boom work light left Replace 1 Bulb 0.2
L-2 Frame working light right Replace 1 0.2
L-3 Swing flasher left Replace 1 0.2
L-4 Swing flasher right Replace 1 0.2
L-5 Room light Replace 1 0.2
L-6 Boom work light right Replace 1 0.2
L-7 Cab working light front 1 (OPT.) Replace 1 0.2
L-8 Cab working light front 2 (OPT.) Replace 1 0.2
Motor
M-1 Starter motor Replace 1 Include Counterweight 1.2
removing and installing.
M-3 Wiper motor Replace 1 0.5
M-4 Washer motor Replace 1 0.5 
Proportional valve
PSV-A Arm 2 speed inverse proportional valve Replace 1 0.5
PSV-B P2 unload proportional valve Replace 1 Include proportional valve 0.5
block removing and
installing.
PSV-C Travel straight proportional valve Replace 1 0.5
PSV-D P1 unload proportional valve Replace 1 0.5
PSV-R Controll proportional valve Replace 1 0.5
PSV-P1 P1 pump proportional valve Replace 1 0.5
PSV-P2 P2 pump proportional valve Replace 1 0.5
Relay
R-1 Battery relay Replace 1 0.3
R-2 Starter relay Replace 1 0.3
R-3 Glow relay Replace 1 0.3
R-4 Safety relay Replace 1 0.1
R-5 Horn relay Replace 1 0.1
R-6 Work light relay Replace 1 0.1
R-8 Travel alarm relay Replace 1 0.1
R-9 Cab working light relay 1 Replace 1 0.1
R-11 Cab working light relay 2 Replace 1 0.1
R-19 Flasher relay Replace 1 0.1
R-23 Auto idle stop relay 1 Replace 1 0.1
R-24 Auto idle stop relay 2 Replace 1 0.1
R-25 E/G emergency stop relay Replace 1 0.1
R-26 Safety lock lever relay Replace 1 0.1
R-28 Alternator relay Replace 1 0.1
R-29 Wiper motor relay (Normal rotation) Replace 1 0.1
R-30 Wiper motor relay (Reverse rotation) Replace 1 0.1
R-31 Wiper motor relay arc prevention relay Replace 1 0.1
R-32 Washer motor relay Replace 1 0.1
R-94 Neutral stop relay Replace 1 0.1

12-13
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㨇12. STANDARD MAINTENANCE TIME TABLE㨉

06 Electric equipments (3/4)

Work to be Unit:
Group Location Unit Remarks
done Hour
Sensor OPT
SE-1 Pressure sensor : Bucket digging Replace 1 0.3
SE-2 Pressure sensor : Bucket dump Replace 1 0.3
SE-3 Pressure sensor : Boom up Replace 1 0.3
SE-4 Pressure sensor : Boom down Replace 1 0.3
SE-5 Pressure sensor : Swing Replace 1 0.3
SE-7 Pressure sensor : Arm in Replace 1 0.3
SE-8 Pressure sensor : Arm out Replace 1 0.3
SE-9 Pressure sensor : Travel right Replace 1 Include under cover 0.5
removing and installing
SE-10 Pressure sensor : Travel left Replace 1 Include under cover 0.5
removing and installing
SE-11 Pressure sensor : P2 side OPT. Replace 1 Include under cover 0.5
removing and installing
SE-13 Engine speed sensor Replace 1 Include under cover 0.5
removing and installing
SE-15 Fuel sensor Replace 1 Include guard removing 0.5
and installing
SE-16 Accel potentiometer Replace 1 0.5
SE-20 Pressure sensor : P1 side : P1 side Replace 1 Include under cover 0.5
(OPT.) removing and installing
SE-22 Pressure sensor : P1 pump Replace 1 0.5
SE-23 Pressure sensor : P2 pump Replace 1 0.5
SE-61 DPR differential pressure sensor Replace 1 0.5
SE-62 Suction temperature sensor/Air flow meter Replace 1 0.5
SE-87 Nox sensor 1 Replace 1 0.3
SE-88 Nox sensor 2 Replace 1 0.3
SE-89 UREA sensor Replace 1 0.3
SE-90 AMB temp. sensor Replace 1 0.3
SE-91 SCR FR temp. sensor Replace 1 0.3
SE-92 Exhaust temp. sensor 3 Replace 1 0.3
SE-93 Exhaust temp. sensor 4 Replace 1 0.3
SE-94 Exhaust temp. sensor 5 Replace 1 0.3
Solenoid
SV-1 Swing parking SOL Replace 1 Include proportional valve 0.5
block removing and
installing.
SV-2 Attachment boost pressure SOL Replace 1 Include proportional valve 0.5
block removing and
installing.
SV-3 2-speed travel SOL Replace 1 Include proportional valve 0.5
block removing and
installing.
SV-4 Safety lever lock SOL Replace 1 Include proportional valve 0.5
block removing and
installing.
SV-68 Valve assy water Replace 1 0.5

12-14
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 㨇12. STANDARD MAINTENANCE TIME TABLE㨉

06 Electric equipments (4/4)

Work to be Unit:
Group Location Unit Remarks
done Hour
Switch
SW-1 Key switch Replace 1 0.3
SW-4 Swing parking release switch Replace 1 0.3
SW-7 Engine oil pressure switch Replace 1 0.3
SW-8 Clogged air filter switch Replace 1 0.3
SW-10 Horn switch (left) Replace 1 0.3
SW-11 Safety lever lock switch Replace 1 0.3
SW-19 Wiper interlock switch Replace 1 0.3
SW-20 Attachment power boost switch (right) Replace 1 0.3
SW-26 Cab working light switch Replace 1 0.3
SW-27 Engine cooling coolant level switch Replace 1 0.3
SW-35 Heavy lift switch Replace 1 0.3
SW-37 Independent travel switch Replace 1 0.3
SW-55 Boom work light switch Replace 1 0.3
SW-96 Drain pressure switch Replace 1 0.3
SW-131 Manual reproduction switch Replace 1 0.3



12-15
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This page is blank for editing convenience.

12-16
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 㨇12. STANDARD MAINTENANCE TIME TABLE㨉

12.2 ENGINE MAINTENANCE SERVICE STANDARD TIME LIST

(Provisional version)
Preface
This standard working time is based on the work time required for service of engine like disassembly,
check, adjustment and assembly and so on under a following condition.
This standard working time is provided under the following conditions.

12.2.1 MEASURING METHOD

(1) The time from the worker beginning working at the regular position of machine to the returning to
the regular position after completion of the work is counted as working time.
(2) The measuring unit is in 0.1 minute, and then round up the fractions.
(3) The work is carried out by a couple of workmen as a general rule, and the man-hour of two
workers is counted as the working time. But light work which can be carried out easily by a
person and the efficient is higher is counted as a workman.

12.2.2 WORKING CONDITION

12.2.2.1 TOOLS, INSTRUMENT 
(1) Hand tool;
Tools which are commercially available and each workman usually carries
(2) Common tool;
Tools which are commercially available and each workman do not usually carry but the storing
place is specified
(3) Special tool;
Tools especially prepared by HINO Motor's Ltd. and the storing place is specified
(4) Machine tool;
When measuring equipment and instrument are used, the time required to move parts to the
specified place is included but the time waiting for tool is not included as a general rule

12.2.2.2 WORKING PROCEDURE

The disassembly and assembly should be carried out according to working procedure prepared by
HINO Motor's Ltd. Service Technical Dept. Training Group.

12.2.2.3 STANDARD WORKMAN QUALIFICATION

Workmen shall basically acquire 2 to 3 years of maintenance experience of HINO

12-17
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㨇12. STANDARD MAINTENANCE TIME TABLE㨉

12.2.3 STANDARD TIME CONSTITUENT

12.2.3.1 STANDARD WORKING TIME = NET WORKING TIME + STANDARD TIME + STANDARD
ALLOWANCE TIME
(1) Net working time
The time workman works actually and the time required for measurement, cleaning, and so on is
included, but the time required for troubleshooting is not included
(2) Standard time
Time required for preparation to the beginning of work, preparation of special tool, measuring
equipment, parts and so on, and for the work site clean-up.
(3) Standard allowance time
Calculate the allowance time directly required for workmen from the following equation.
Net standard time X HINO allowance rate
Allowance rate varies within the range of 0.15 tp 0.75 according to the work difficulty, contents,
working position and so on.

12.2.3.2 ALLOWANCE RATE, STANDARD PREPARATION TIME

12.2.3.2.1 HINO allowance rate (0.15 to 0.75)
(1) Basic rate: 0.10
(2) Working posture allowance (Fatigue coefficient): Take any one of the followings according to the
work contents.
Standing work: 0.05
Work in bent posture: 0.10
Work while lying: 0.15
(3) Difficult work allowance: 0.30
(4) Seized rusted section (For new vehicle): 0.50
Take any one of above (3) and (4).
Min. allowance rate = Basic allowance + standing work allowance = 0.1 + 0.05 = 0.15
Max. allowance rate = Basic allowance + work allowance in lying + seized rusted section = 0.1 +
0.15 + 0.5=0.75

12.2.3.2.2 STANDARD WORKING TIME

(1) Working standard time: 3 minutes (One time for a set of works)
(2) Special tool standard time: 3 minutes (One time for a set of works)
(3) Standard time of non-portable machine: 3 minutes (For single work)
(4) Part standard time: 6 minutes (up to 10 items), 10 minutes (10 items or more)
(One time for a set of works)
(5) est:15 minutes (One time for a set of works)
(6) Preparation time for chain block, measuring instrument, piston, heater and so on: 3 minutes
(One time for a set of works)
(7) General cleaning: 2 minutes (One time for a set of works)
(8) Safety treatment like wheel stopper, and so on: 3 minutes
(9) Visual checks: 2 minutes
The preparation time is classified into as described above, and only items required for the every
work are selected, calculated and counted as preparation time of the work.

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 㨇12. STANDARD MAINTENANCE TIME TABLE㨉

12.2.4 MEANING OF WORDS IN USE

࡮ Completed machine:
When detaching, replacing and adjusting the specified parts, it means the time which is determined
by addition of the preparation time, net working time and standard allowance time of the work.
࡮ Single unit:
When detaching, replacing and adjusting the specified parts, it means the time in which the
preparation time of the work is omitted and which is determined by addition and subtraction
to/from the work for "Completed machine".
࡮ Removal and installation:
The work to remove specified parts from machine and to attach the parts, and then to perform
necessary adjustment
࡮ Simultaneous replacement:
The work to remove specified parts in 2 types or more from machine and to attach the spare
parts, and then to perform necessary adjustment
࡮ Adjustment:
The work to carry out necessary adjustment with the specified parts removed or attached:
࡮ Overhaul:
The work to remove specified assembled parts from machine, disassemble and check them, and
then to attach the spare parts to machine and to perform necessary adjustment

࡮ Include:
Explains the contents of work to make the specified work range clear
࡮ Exclude:
Shows the work which is not included in the specified primary work
࡮ Unit:
Time is shown by hour.

12-19
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㨇12. STANDARD MAINTENANCE TIME TABLE㨉

SK200-8 SK330-8
Q'ty
Work Adding Adding
Work Work unit Works
No. hour hour
1 1
by 1 by 1
each each
Engine adjustment A Completed Timing adjustment
1 00101 2.3 2.5
set machine Valve clearance adjustment
Engine adjustment B Completed
2 00103 A set and nozzle adjustment - -
set machine
Include; Engine warm-up,
valve clearance adjustment,
Compression Completed
3 00111 removing air cleaner element 3.4 4.3
measuring machine
and battery specific gravity
measurement
Replacing cylinder,
block, piston, ring From engine is removed
8 99012 Single unit 27.4 31.6
and liner condition
simultaneously
Replacing crank
From engine is removed
9 99013 shaft, piston, ring and Single unit 20.8 25.8
condition
liner simultaneously
From engine is removed
condition
Replacing cylinder Include; Valve clearance
Single unit 24.4 30
block adjustment
Exclude; Installing expansion
plug knock pin
From engine is removed
11 00126 Replacing crank shaft Single unit 18.4 22.8
condition
Replacing crank From engine is removed
12 00127 Single unit 18.4 22.8
shaft main bearing condition
From engine is removed
condition
Include; Adjustment of water
pump, oil pump, valve
clearance, valve lapping and
15 00151 Engine overhaul Single unit measurement/cleaning 38.5 44.3
Exclude; Replacing of
injection pump, electrical
equipment, water pressure
test, clutch overhaul and
valve guide
Compression
16 00152 Single unit 2.3 3.1
measuring
From piston & connecting rod
17 00153 Replacing piston Single unit 0.5 0.5 0.5 0.5
are removed conditions
From piston & connecting rod
18 00154 Replacing piston ring Single unit 0.2 0.2 0.2 0.2
are removed conditions
Replacing cylinder From piston & connecting rod
19 00155 Single unit 0.4 0.4 0.4 0.4
liner are removed conditions

12-20
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
 㨇12. STANDARD MAINTENANCE TIME TABLE㨉

SK200-8 SK330-8
Q'ty
Work Adding Adding
Work Work unit Works
No. hour hour
1 1
by 1 by 1
each each
Replacing connecting From piston & connecting rod
20 00157 Single unit 0.3 0.3 0.3 0.3
rod are removed conditions
From connecting rod is a
Replacing piston pin
21 00158 Single unit single unit condition 0.4 0.4 0.4 0.4
bushing
Include; Reaming
Replacing expansion
26 00165 Single unit 0.4 0.4 0.4 0.4
plug
Valve clearance Completed
41 00302 1.7 2
adjustment machine
Replacing rocker
42 00305 One set 1.3 1.4
chamber cover upper
Replacing rocker Include; Removal and
43 00306 One set - 4.3
chamber cover lower installing upper

44 00304
Replacing rocker
One set 1.3 1.4

chamber cover gasket
Removal and
Completed
45 00312 installing rocker arm 2.6 3.3
machine
and support
Completed
46 00313 Replacing rocker arm 2.6 3.4
machine
Replacing rocker arm Completed
47 00314 2.6 3.4
support machine
Replacing rocker arm Completed
48 00315 2.6 3.4
shaft machine
Excluding; Removal and
Removal and
Completed installing of nozzle holder or
50 00322 installing cylinder 8.2 10.4
machine injector and injector sub
head
harness
Include; Valve lapping
Replacing cylinder Completed
51 00323 Exclude; Replacing of valve 11.5 16.9
head machine
guide
Include; Valve lapping
Overhaul of cylinder Completed Exclude; Replacing of valve
52 00324 13.3 18.8
head machine guide, water pressure test
and replacing valve seat
Replacing cylinder Completed
53 00325 8.2 10.4
head gasket machine
Completed
54 00326 Replacing valve Include; Valve lapping 10.2 15.6
machine
Completed Exclude; Removal and
55 00327 Replacing valve spring 4.9 8.8
machine installing of cylinder head
Replacing valve stem Completed Exclude; Removal and
57 00328 5.3 9.4
seal machine installing of cylinder head

12-21
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
㨇12. STANDARD MAINTENANCE TIME TABLE㨉

SK200-8 SK330-8
Q'ty
Work Adding Adding
Work Work unit Works
No. hour hour
1 1
by 1 by 1
each each
Removal and
61 00376 installing camshaft One set 1.2 0.2 1.6 0.2
housing plug
Removal and
Completed
62 00377 installing camshaft 2.6 3.4
machine
(with camshaft gear)
With manifold and nozzle
holder
Replacing cylinder
Include; Valve lapping
head
Excluding; Removal and
63 00352 (one piece and one Single unit 6.1 6.5
installing of cylinder head,
set require same
replacing valve guide, water
hour)
pressure test and replacing
valve seat
Unit of 1
66 00355 Replacing valve guide 1 0.8 1 0.8
cylinder
Replacing expansion
72 00361 Single unit 0.4 0.4 0.4 0.4
plug
Replacing rocker arm
(one piece and one Unit of 1
73 00371 0.1 0.1
set require same cylinder
hour)
Replacing rocker arm
support
Unit of 1
74 00372 (one piece and one 0.1 0.1
cylinder
set require same
hour)
Replacing rocker arm Unit of 1
75 00373 0.3 0.1 0.3 0.1
bushing cylinder
From cylinder head is
Unit of 1
76 00374 Replacing valve removed condition 0.5 0.5 0.5 0.5
cylinder
Include; Valve lapping
Unit of 1 From cylinder head is
77 00375 Replacing valve spring 0.2 0.2 0.2 0.2
cylinder removed condition
Replacing valve stem Unit of 1 From cylinder head is
78 00330 0.3 0.3 0.3 0.3
seal cylinder removed condition
Removal and
81 00406 One set Include; Function check 2.3 2.3
installing supply pump
From engine is removed
84 00411 Tightening oil pan Single unit 0.5 0.5
condition
Removal and From engine is removed
85 00412 Single unit 0.5 0.5
installing oil pan condition
From engine is removed
86 00413 Replacing oil pan Single unit 0.7 0.7
condition

12-22
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 㨇12. STANDARD MAINTENANCE TIME TABLE㨉

SK200-8 SK330-8
Q'ty
Work Adding Adding
Work Work unit Works
No. hour hour
1 1
by 1 by 1
each each
Replacing oil pan From engine is removed
87 00414 Single unit 0.7 0.7
gasket condition
Replacing oil pan From engine is removed
88 00421 Single unit 0.5 0.5 0.8
drain cock condition
Replacing oil pan From engine is removed
89 00422 Single unit 0.5 0.5 0.4
drain cock gasket condition
Replacing breather From engine is removed
92 00443 Single unit 0.3 0.2 0.3
hose condition
Replacing oil level From engine is removed
93 00444 Single unit 0.1 0.1
gauge condition
Replacing oil level From engine is removed
94 00445 Single unit 0.2 0.2 0.1
gauge guide condition
Replacing oil level From engine is removed
95 00446
gauge bracket
Single unit
condition
0.2 0.2 0.5

Replacing fly wheel From engine is removed
102 00512 Single unit 3.4 3.4 0.2
housing condition
Replacing fly wheel From engine is removed
103 00541 Single unit 5.4 5.4 0.3
housing gasket condition
Replacing rear end From engine is removed
104 00542 Single unit 5.4 5.4
plate condition
Replacing rear end From engine is removed
105 00543 Single unit 5.4 5.4
plate gasket condition
Replacing crank From engine is removed
106 00515 Single unit 5.4 5.4
shaft rear oil seal condition
Replacing crank From fly wheel is removed
119 00552 Single unit 0.2 0.2
shaft rear oil seal condition
Replacing intake
131 00613 One set Include; Applying liquid gasket 2 2.3
manifold
Replacing intake
132 00614 One set Include; Applying liquid gasket 2 2.3
manifold gasket
Removal and
133 00636 installing intake pipe One set 1.3 1.6
(manifold side)
Replacing intake
134 00637 One set 1.3 1.6
pipe (manifold side)
Replacing air intake
135 00622 One set 0.4 0.2 0.4 0.2
hose
Replacing air intake
136 00623 One set 0.4 0.2 0.4 0.2
pipe
Replacing air intake
137 00626 One set Turbo charger to inter cooler 0.4 0.4
pipe
Replacing air intake
138 00627 One set Air cleaner to turbo charger 0.4 0.2 0.4 0.2
pipe

12-23
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㨇12. STANDARD MAINTENANCE TIME TABLE㨉

SK200-8 SK330-8
Q'ty
Work Adding Adding
Work Work unit Works
No. hour hour
1 1
by 1 by 1
each each
Replacing silencer Completed
139 00675 0.3 0.2 0.3 0.2
body machine
Tightening exhaust Completed
142 00641 0.9 1.3
manifold machine
Removal and
Completed
143 00643 installing exhaust With insulator and stud bolt 2.8 3.2
machine
manifold
Include; Replacing stud bolt
Replacing exhaust Completed
144 00644 with new one and insulator 3.0 3.4
manifold machine
(TI system)
Replacing exhaust Completed
145 00645 2.8 3.2
manifold gasket machine
One side
Replacing exhaust of Removal and installing of
146 00646 2.4 2.6
heat insulator completed turbo charger
machine
Replacing exhaust
147 00651 One set 0.8 0.8
pipe
Replacing exhaust
148 00653 One set 0.6 0.6
pipe gasket
Removal and
164 00686 One set 2.9 2.5
installing turbo charger
Replacing turbo
165 00687 One set Include; Replacing stud bolt 2.6 2.5
charger
Replacing turbo Include; Removal and
167 00689 One set 0.9 0.9
charger oil return pipe installing of lower insulator
Replacing air intake
174 00624 pipe upper (cooler to One set 0.4 0.4
manifold)
Removal and
From engine is removed
installing engine and
188 00701 Single unit condition Include; Removal 5.4 5.4
timing gear cover
and installing of cylinder head
(fly wheel housing)
Replacing timing gear From engine is removed
189 00711 cover (fly wheel Single unit condition Include; Removal 5.4 5.4
housing) and installing of cylinder head
Replacing timing gear
From timing gear cover is
190 00712 cover gasket Single unit 0.7 0.7
removed condition
(fly wheel housing)
Replacing timing gear
From timing gear cover is
191 00713 cover plate Single unit 1.0 1.0
removed condition
(rear end plate)

12-24
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 㨇12. STANDARD MAINTENANCE TIME TABLE㨉

SK200-8 SK330-8
Q'ty
Work Adding Adding
Work Work unit Works
No. hour hour
1 1
by 1 by 1
each each
Replacing timing gear
cover plate gasket From timing gear cover is
192 00714 Single unit 1.0 1.0
(rear end plate removed condition
gasket)
Replacing idler gear From timing gear cover is
193 00725 Single unit 0.2 0.2 0.2
(main) removed condition
Replacing idler gear From timing gear cover is
194 00736 Single unit 0.1 0.1 0.2
(sub) removed condition
Replacing idler gear From timing gear cover is
195 00726 Single unit 0.2 0.2
shaft (main) removed condition
Replacing idler gear From timing gear cover is
196 00737 Single unit 0.1 0.1
shaft (sub) removed condition
Replacing crank
197 00724 Single unit 0.4 0.4
shaft gear rear 
Replacing cam idle From timing gear cover is
201 00738 Single unit 0.4 0.4
gear removed condition
Replacing cam idle From timing gear cover is
202 00739 Single unit 0.4 0.4
gear shaft removed condition
From timing gear cover is
203 00731 Replacing camshaft Single unit 0.8 0.8
removed condition
Replacing camshaft From timing gear cover is
204 00732 Single unit 0.8 0.8
gear removed condition
205 00751 Replacing crank pulley One set 1.9 1.9
Replacing crank
206 00754 One set 2.8 2.8
dumper
Replacing crank
207 00755 One set 2.2 2.2
shaft front oil seal
Replacing crank
208 00757 shaft front oil seal One set 2.8 2.8
retainer
Replacing crank
209 00758 shaft front oil seal One set 2.8 2.8
retainer gasket
Checking injection Completed
211 00801 0.3 0.3
timing machine
Replacing priming
226 00834 One set 0.4 0.4
pump
Cleaning fuel feed
227 00835 One set 0.4 0.4
pump strainer
Replacing through
228 00836 One set 0.4 0.4
feed valve
Replacing fuel
230 00838 One set 2.5 0.1 2.5 0.1
injection pipe

12-25
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㨇12. STANDARD MAINTENANCE TIME TABLE㨉

SK200-8 SK330-8
Q'ty
Work Adding Adding
Work Work unit Works
No. hour hour
1 1
by 1 by 1
each each
Replacing fuel filter
236 00851 One set 0.5 0.5 0.2
assembly
Replacing fuel filter
237 00857 One set 0.3 0.3
cartridge
253 00875 Replacing fuel hose One set 0.8 0.8
Replacing fuel
254 00876 One set 0.8 0.8
leakage pipe
Replacing oil filter
276 00912 One set 0.4 0.4
cartridge
Replacing oil filter
277 00907 relief valve (oil filter One set 0.3 0.3
regulator valve)
Replacing oil filter
relief valve spring
278 00908 One set 0.3 0.3
(oil filter regulator
valve)
Replacing oil filter
279 00909 One set 0.3 0.3
safety valve
Replacing oil filter
280 00910 One set 0.3 0.3
safety valve spring
00961
Removal and
(timin
installing fly wheel From engine is removed
294 g Single unit 6.1 6.1
housing condition
gear
(timing gear cover)
cover)
From engine is removed
295 00942 Replacing oil pump Single unit 6.3 6.3
condition
Replacing oil pump From engine is removed
296 00944 Single unit 6.5 6.5
gear condition
From engine is removed
297 00943 Overhaul of oil pump Single unit 6.5 6.5
condition
Replacing suction
298 00946 One set 0.1 0.1
strainer
Replacing suction
299 00947 One set 0.1 0.1
strainer O-ring
301 00951 Replacing oil pipe One set 0.4 0.4 0.4 0.4
302 00954 Replacing oil hose One set 0.4 0.4 0.4 0.4
Replacing cooling oil
303 00971 1 0.2 0.2 0.2 0.2
jet
Removal and Include; Filling engine coolant
327 01028 One set 4.0 4.0
installing water pump up
Include; Filling engine coolant
328 01029 Replacing water pump One set 4.0 4.0
up

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 㨇12. STANDARD MAINTENANCE TIME TABLE㨉

SK200-8 SK330-8
Q'ty
Work Adding Adding
Work Work unit Works
No. hour hour
1 1
by 1 by 1
each each
Overhaul of water
329 01030 Single unit 0.8 0.8
pump
Replacing water
330 01031 Single unit 0.6 0.6
pump pulley
Replacing water
331 01032 One set Liquid gasket 4.0 4.0
pump casing gasket
332 01036 Replacing cooling fan One set 0.9 0.9
Replacing fluid fan
333 01037 One set 0.9 0.9
coupling
Replacing thermostat Include; Filling engine coolant
334 01044 One set 1.3 1.3
casing up
Replacing thermostat Include; Filling engine coolant
336 01046 One set 1.0 1.0
casing cover up
Replacing thermostat Include; Filling engine coolant

337 01047 One set 1.0 1.0
casing cover gasket up
Include; Checking for
338 01048 Replacing thermostat One set temperature at valve start 1.0 1.0
opening
Include; Checking for
339 01049 Checking thermostat One set temperature at valve start 1.0 1.0
opening
Replacing coolant
341 01053 One set 0.3 0.2 0.3 0.2
hose
Replacing radiator
342 01054 One set 0.3 0.2 0.3 0.2
hose
Replacing fluid fan
343 01071 1 0.3 0.3
coupling
344 01072 Replacing cooling fan 1 0.3 0.3
From cooling fan is removed
345 01073 Replacing water pump 1 1.7 1.7
condition
Overhaul of water
346 01074 1 0.8 0.8
pump
Removal and
402 01401 One set 0.8 0.8
installing alternator
403 01402 Replacing alternator One set 0.9 0.9
Replacing alternator
404 01406 One set 1.0 1.0
support bracket
405 01408 Replacing V-belt One set 0.3 0.3
Removal and
438 01801 installing supply pump One set Include; Function check 3.0 3.0

Replacing supply
439 01802 One set Include; Function check 3.0 3.0
pump

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㨇12. STANDARD MAINTENANCE TIME TABLE㨉

SK200-8 SK330-8
Q'ty
Work Adding Adding
Work Work unit Works
No. hour hour
1 1
by 1 by 1
each each
Removal and
installing common
440 01830 rail assembly (with One set Include; Function check 3.8 3.8
pressure sensor,
pressure limiter)
Replacing common
rail assembly (with
441 01804 One set Include; Function check 3.8 3.8
pressure sensor,
pressure limiter)
Removal and
Completed
442 01805 installing injector Include; Function check 2.9 3.5
machine
assembly
Replacing injector Completed Include; Function check and
443 01806 3.4 4.0
assembly machine reprogramming
Removal and
444 01807 installing injector One set Include; Function check 1.9 0.2 1.9 0.2
assembly
Replacing injector Include; Function check and
445 01808 One set 2.4 0.2 2.4 0.2
assembly reprogramming
Removal and
446 01809 installing injector sub One set Include; Function check 1.9 1.9
harness assembly
Replace injector sub
447 01810 One set Include; Function check 1.9 1.9
harness assembly
Removal and
448 01811 One set Include; Function check 1.2 0.3 1.2 0.3
installing flow dumper
Replacing flow
449 01812 One set Include; Function check 1.2 0.3 1.2 0.3
dumper
Removal and
450 01813 installing pressure One set Include; Function check 1.2 1.2
limiter
Replacing pressure
451 01814 One set Include; Function check 1.2 1.2
limiter
Replacing common
452 01815 One set Include; Function check 1.2 1.2
rail pressure sensor
Replacing main
453 01816 One set Include; Function check 1.2 1.2
engine speed sensor
Replacing sub engine
454 01817 One set Include; Function check 1.2 1.2
speed sensor
Replacing coolant
455 01818 One set Include; Function check 1.2 1.2
temperature sensor
Replacing fuel
456 01819 One set Include; Function check 1.2 1.2
temperature sensor

12-28
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 㨇12. STANDARD MAINTENANCE TIME TABLE㨉

SK200-8 SK330-8
Q'ty
Work Adding Adding
Work Work unit Works
No. hour hour
1 1
by 1 by 1
each each
Replacing accel
457 01820 One set Include; Function check 1.5 1.5
sensor
Removal and
460 01823 installing pressure 1 Include; Function check 0.3 0.3
sensor
Removal and
461 01824 installing pressure 1 Include; Function check 0.3 0.3
limiter
Replacing injection
463 01826 One set Include; Function check 1.2 0.1 1.2 0.1
pipe
Replacing fuel pipe
464 01827 (common rail to One set Include; Function check 1.2 0.1 1.2 0.1
supply pump)

465 01828
Replacing fuel
One set Include; Function check 1.7 1.7 
leakage pipe
Checking leakage of
469 01840 One set Include; Function check 1.2 1.2
pressurized fuel
Replacing main
471 01901 One set Include; Function check 1.2 1.2
engine speed sensor
Replacing sub engine
472 01902 One set Include; Function check 1.2 1.2
speed sensor
Replacing coolant
473 01903 One set Include; Function check 1.2 1.2
temperature sensor
Replacing accel
474 01904 One set Include; Function check 1.5 1.5
sensor
Removal and
475 01908 One set Include; Function check 2.1 2.5
installing EGR valve
476 01909 Replacing EGR valve One set Include; Function check 2.1 2.5
Removal and
479 01916 One set 1.8 1.8
installing EGR cooler
480 01917 Replacing EGR cooler One set 1.8 1.8
Removal and
481 01918 installing closed One set 0.3 0.3
ventilator
Replacing closed
482 01919 One set 0.3 0.3
ventilator

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㨇12. STANDARD MAINTENANCE TIME TABLE㨉

12-30
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 㨇13. MAINTENANCE STANDARD AND TEST PROCEDURE㨉

13. MAINTENANCE STANDARD AND

TEST PROCEDURE
TABLE OF CONTENTS

13.1 HOW TO USE MAINTENANCE STANDARDS AND PRECAUTIONS äääääääääääää13-3

13.2 PERFORMANCE INSPECTION STANDARD TABLE ääääääääääääääääääää13-5
13.3 MEASUREMENT OF ENGINE SPEED äääääääääääääääääääääääääää13-7
13.4 MEASUREMENT OF HYDRAULIC PRESSUREäääääääääääääääääääääää13-8
13.5 MEASURING TRAVEL PERFORMANCES äääääääääääääääääääääääää13-13
13.6 MEASURING SWING PERFORMANCES ääääääääääääääääääääääääää13-16
13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES ääääääääääääääää13-19
13.8 MEASURING PERFORMANCES OF SWING BEARING äääääääääääääääääää13-21
13.9 MECHATRO CONTROLLER äääääääääääääääääääääääääääääää13-23
13.10
DIESEL
PARTICULATE
FILTER
(DPF) äääääääääääääääääääääääää13-31
13.11
DEF
SCR
SYSTEM äääääääääääääääääääääääääääääääääää13-36 

Book Code No. 6/&(

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㨇13. MAINTENANCE STANDARD AND TEST PROCEDURE㨉

Issue Date of Issue Applicable Machines Remarks

S5LC1333E01
First Edition July, 2014 SK350LC-9E : YC13-13001~
(NA)
S5LC1333E02
Revision September, 2014 SK350LC-9E : YC13-13001~
(NA)
S5LC1333E03
April, 2016 SK350LC-9E : YC13-13001~
(NA)

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 㨇13. MAINTENANCE STANDARD AND TEST PROCEDURE㨉

13.1 HOW TO USE MAINTENANCE STANDARDS AND

PRECAUTIONS
(1) Application
1. When the machine is new;
Confirm that the performances are in accordance with standard specifications as compared to the
performance standards.
2. At specific self inspection; (Rule by country)
Use the data for the criterion, for the purpose of correction, adjustment and replacement.
3. When performances are deteriorated;
Determine whether it is caused by a fault or end of service life after long hours of operation, to
be used for safety and economical considerations.
4. When main components are replaced;
For example, use data to restore performances of pumps and others.

(2) Terminology
1. Standard values;
Values to be used to condition or assemble a new machine. Where special notes are not given,
these values represent standard specifications (machine with standard attachments and standard
shoes).
2. Reference values for remedy;
Values at which readjustment is required. In order to ensure performance and safety it is strictly
prohibited to use the machine over the specified values.
3. Service limit;
This is the limit value at which reconditioning is impossible without replacement of parts. If the
value is expected to exceed the service limit before next inspection and correction are performed, 
replace the parts immediately. The operation over the specified values causes increase of
damage and requires the down time of machine, and also causes safety problems.

(3) Cautions to be Exercised at Judgment

1. Evaluation of measured data;
Disagreement of measuring conditions, variations of data peculiar to a new machine, and
measuring errors are to be evaluated. Determine generally at what levels measured values are
located, instead of determining whether or not values fall within or run out of the reference values.
2. Determining correction, adjustment or replacement;
Machine performances deteriorate with time as parts wear and some deteriorated performances
may be restored to new levels. Therefore, determine correction, adjustment or replacement,
depending upon the operating hours, kind of work and circumstances in which the machine is
placed, and condition the machine performances to its most desirable levels.

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㨇13. MAINTENANCE STANDARD AND TEST PROCEDURE㨉

(4) Other Cautions to be Exercised

1. Parts liable to degrade;
Rubber products, such as, hydraulic hoses,
O rings, and oil seals deteriorate with time ; replace them at regular intervals or at overhauls.
2. Parts requiring regular replacement;
Out of critical hoses that are necessary to secure safety, we designate Very Important Parts
(V.I.P) and recommend that they should be replaced regularly.
3. Inspection and replacement of oils and greases;
In performing maintenance, it is necessary for the user to familiarize himself with how to handle
the machine safely, cautions to be exercised and inspection/lubrication procedures. Refer to the
operators manuals as well.

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 㨇13. MAINTENANCE STANDARD AND TEST PROCEDURE㨉

13.2 PERFORMANCE INSPECTION STANDARD TABLE

Unless otherwise specified, measure it on "H" mode.



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㨇13. MAINTENANCE STANDARD AND TEST PROCEDURE㨉

13-6
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 㨇13. MAINTENANCE STANDARD AND TEST PROCEDURE㨉

13.3 MEASUREMENT OF ENGINE SPEED

13.3.1 MEASUREMENT OF ENGINE SPEED

(1) Warming up of engine
Start engine to raise the coolant temperature of engine to 60 to 90C degrees (140 to 194F degrees)
at surface of radiator upper tank.
The E/G coolant tem-perature gauge is used to measure. The range in white color shows the
temperature of approx. 65 to 105 C degrees (149 to 221F degrees), so confirm that the pointer
indicates the temperature within the white range.

(2) Engine speed measured value through service diagnosis (See below Fig.)
1. Turn "ON" the starter switch with the buzzer stop switch pressed.
2. A program No. and an actual engine revolution are displayed as the No.2 Item.
3. The screen advances like No.2, No.3....each time the "Up arrow switch" on the gauge cluster is
pushed. 
4. The screen returns like No.45, No.44....each time the "Down arrow switch" is pushed.
5. The display does not disappear unless the starter switch is turned to"OFF".

Service diagnosis for E/G speed measuring

(Example)

Switch for E/G speed indication

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㨇13. MAINTENANCE STANDARD AND TEST PROCEDURE㨉

13.4 MEASUREMENT OF HYDRAULIC PRESSURE

13.4.1 PREPARING TO MEASURE HYDRAULIC PRESSURE

(1) Hydraulic equipment
6.9 MPa (1000psi) pressure gauge: 1unit
49 MPa (7100psi) pressure gauge: 2 units
Pressure measuring equipment and
instrument for analysis: 1 set
(2) Measuring cleanliness of hydraulic oil

Gauge port on main pump

After releasing air in the hydraulic oil tank, open the cover and sample oil in the hydraulic tank, and
measure with the instrument for analysis. If the measured value is higher than the standard value,
replace the return filter or change the hydraulic oil.

13.4.2 PLACE TO INSTALL PRESSURE GAUGE

(1) Main circuit
After releasing the pressure in hydraulic oil tank and system, replace plugs PF1/4 of main pump
gauge ports (a1) (a2) with plugs for pressure measurement, and attach pressure gauge 49 MPa
(7100 psi).
(2) Pilot circuit
Replace pilot gauge plug (a5) with plug PF1/4 for pressure measurement, and attach pressure
gauge 6.9 MPa (1000 psi).

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 㨇13. MAINTENANCE STANDARD AND TEST PROCEDURE㨉

13.4.3 PRESSURE ADJUSTMENT POSITION

(1) Main control valve



Relief valve position on main control valve

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㨇13. MAINTENANCE STANDARD AND TEST PROCEDURE㨉

(2) Pilot relief valve

The pilot relief valve PR1 is located on the gear pump that is attached to the main pump.

Pilot relief valve position

(3) Swing over load relief

The swing motor is equipped with plugs PA,PB for pressure measurement, but the measurement is
carried out using gauge ports (a1) and (a2). (See "Gauge port on main pump" Fig.)

Swing over load relief position

13-10
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 㨇13. MAINTENANCE STANDARD AND TEST PROCEDURE㨉

13.4.4 PROCEDURE FOR ADJUSTING RELIEF VALVE

(1) Pilot relief valve
Adjust it with adjust screw (311).
Tools: Spanner: 24 mm,
Tightening torque : 29.4 N-m (22 lbf-ft)
Tools: Allen wrench: 6 mm

Pilot relief valve

(2) 2-stage main relief valve

(Commom for travel and ATT sections)
Start from the boosting side, first. Loosen nut (1), adjust the pressure with adjusting screw (2)
and tighten nut (1) after completion of the adjustment on the boosting side.
Then, loosen nut (3), adjust the pressure on the standard side with adjusting screw (4) and tighten
nut (3) after completion of the adjustment.
Tools: Spanner: 32 mm, 
Tightening torque : 27.4 to 31.4 N-m (20 to 23 lbf-ft)
Tools: Spanner: 22 mm,
Tightening torque : 27.4 to 31.4 N-m (20 to 23 lbf-ft)
Tools: Spanner: 19 mm, Adjust screw
Tools: Allen wrench: 6 mm

Main relief valve (Travel section, ATT

common section)

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㨇13. MAINTENANCE STANDARD AND TEST PROCEDURE㨉

(3) Over load relief valve

(Boom, bucket, arm sections)
Loosen lock nut (1) and adjust it with adjust screw (2).
Tools: Spanner: 22 mm,
Tightening torque : 27.4 to 31.4 N-m (20 to 23 lbf-ft)
Tools: Allen wrench: 6 mm

Over load relief valve (Boom, bucket, arm

sections)

(4) Over load relief valve (Swing)

When the adjustment of pressure is required, loosen lock nut (1) and adjust the pressure with cap
(2).
Tools: Spanner: 30, 38 mm,
Tightening torque: 118 N-m (87 lbf-ft)
Tools: Allen wrench: 12 mm

Swing over load relief valve

(5) Travel over load relief valve

This valve was adjusted by valve maker.
Do not replace any inner parts except for
O-ring.
Travel over load relief valve

13-12
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 㨇13. MAINTENANCE STANDARD AND TEST PROCEDURE㨉

13.5 MEASURING TRAVEL PERFORMANCES

13.5.1 TRAVEL SPEED

(1) Purposes
Measure the travel sprocket revolution and
confirm the performances between the
hydraulic pump and the travel motor of the
travel drive system.
(2) Conditions
Hydraulic oil temperature;
45 to 55C degrees (113 to 131F degrees)
Crawler on the right and left sides are
tensioned evenly. One side lifted position

(3) Preparation
Attach the reflection panel with a magnet to
the travel motor cover.
Swing the swing frame through 90°as
shown in above Fig. and make the crawler
on one side take off the ground, using the
attachment.

Adhering position of reflection panel


(4) Measurement
Engine revolution; Hi idle
2-speed travel switch; 1st speed and 2nd
speed
Measuring points; Right and left
Method, example 1;
Measure revolution with a stroboscope
Method, example 2;
Measure the revolutions per minute visually.

13.5.2 DEVIATION OF TRAVEL

(1) Purpose
Measure the amount of deviation at 20 (66
t) travel and confirm the horizontal balance
between the hydraulic pump and the travel
motor of the travel drive system.
(2) Condition
Hydraulic oil temperature;
45 to 55C degrees (113 to 131F degrees)
Travel position
RH and LH crawler are tensioned evenly.
Firm, level ground
Engine revolution; Hi idle

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㨇13. MAINTENANCE STANDARD AND TEST PROCEDURE㨉

(3) Preparation
1.
Straight course more than 30 m (108 ft)
2.
Travel position in which the bottom of the
bucket is lifted by about 30 cm (1 ft).
Measuring method

(4) Measurement
1.
Measure the max. deviation distance of
the circular arc in the 20 m (66 ft) length,
excluding the preliminary run of 3 to 5 m
(10 to 16 ft).
2.
Operate the travel lever at the same time.

13.5.3 PERFORMANCES OF PARKING BRAKE

(1) Purpose
Confirm that the parking brake holds a
stopped condition of the machine in a
no-load travel position and on a 15 degree
slope.
(2) Condition
A slope with (Approx. 15 deg) gradient
and a stopped condition in a no-load travel
position.
(3) Preparation
Place an angle meter on the shoe plate Parking brake operating position
and confirm that it makes an angle more
than 15 degree.
Hang a perpendicular in parallel with the
guide frame rib on the track frame and
put a mark (matching mark) on the shoe
plate.

(4) Measurement
Five minutes after the engine stops,
measure the movement distance of the
matching mark.

Method of measurement

13-14
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 㨇13. MAINTENANCE STANDARD AND TEST PROCEDURE㨉

13.5.4 DRAIN RATE OF TRAVEL MOTOR

(1) Purpose
To measure the drain rate of the travel
motor and to confirm the performances of
the travel motor.
(2) Conditions
Hydraulic oil temperature;
45 to 55C degrees (113 to 131F degrees)
Engine revolution; Hi idle
Location of stopper applied to travel sprocket

(3) Preparation
1.
Place a stopper under the RH and LH
travel sprockets.
2.
Stop the engine and release pressure from
the hydraulic circuit.
3.
Connect a hose with the drain port of the
travel motor and take drain in a container.

Method of measuring the drain rate of travel

motor

(4) Measurement ; at Travel Lock
1.
Start the engine and relieve pressure at the
full stroke of the travel lever.
2.
Measure the drain rate for 30 seconds of
relieving.

Unless you observe the rotary force direction at travel lock, rib "A" may be broken by stopper "B" in
some cases. (See Upper right Fig.)

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13.6 MEASURING SWING PERFORMANCES

13.6.1 SWING SPEED

(1) Purpose
Measure the swing time and confirm the
performances between the hydraulic pump
and the swing motor of the swing drive
system.
(2) Conditions
Hydraulic oil temperature;
45 to 55C degrees (113 to 131F degrees)
Firm, level ground
Engine revolution; Hi idle
(3) Preparation
Swing speed measuring position (at the min.
Put the bucket empty and extend the
reach)
boom, arm and bucket cylinder fully.
And the machine becomes a position of
minimum reach.

(4) Measurement
Swing the machine by bringing the swing lever to its full stroke. Measure the time required to
make two turns after one turn of preliminary run and calculate the time required for one turn.

13.6.2 PERFORMANCE OF SWING BRAKE

(1) Purpose
Confirm the braking torque performances by
the swing relief valve.
(2) Conditions
Hydraulic oil temperature;
45 to 55C degrees (113 to 131F degrees)
Firm, level ground
Engine revolution; Hi idle

(3) Preparation
1.
Put the bucket empty, retract the arm
cylinder fully and extend the bucket
cylinders fully. And move the boom so
that the arm top pin is positioned at same
Swing brake performance measuring position
height with boom foot pin.
2.
Put a matching mark on the outer
circumference of the swing bearing of the
upper frame side and of the track frame
side. Place two poles (flags) on the front
and back of the extended line of the
matching mark.

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

13.6.3 PERFORMANCE OF SWING PARKING BRAKE

(1) Purpose
To confirm the mechanical performances
of the swing parking brake that is fitted to
the inside of the swing motor.
(2) Conditions
On a slope of 15 degree incline.
Stop the machine at right angles with the 
slope. Put the bucket empty, retract the
arm cylinder fully and extend the bucket Swing parking brake performance measuring
cylinder fully. And move the boom so that position
the arm top pin is positioned at same
height with boom foot pin.

(3) Preparation
Put the angle meter on the shoe plate
and make sure that the angle is more
than 15 degree.
Put a matching mark on the outer race
side and on the inner race side.

Measuring position of swing parking brake

performances

(4) Measurement
When five minutes has passed after the
engine stops, measure the length of the
movement of the matching marks.

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13.6.4 DRAIN RATE OF SWING MOTOR

(1) Purpose
Measure the drain rate of the swing motor
and confirm the performances of the swing
motor.
(2) Conditions
Hydraulic oil temperature; 45 to 55C
degrees (113 to 131F degrees)
Firm, level ground
Engine revolution; Hi idle
(3) Preparation
1.
Stop the engine.
2.
Release pressure from inside the hydraulic
circuit.
3.
Disconnect the swing motor drain hose
from its end returning to the hydraulic oil
tank and take oil in a container.
4.
Put a plug to the tank side.

(4) Measurement; at Swing Lock

1.
Start the engine and put the side faces of
bucket against the inside of the right or
left shoe plates.
2.
Relieve the swing motor at full stroke of
the swing motion.
3.
Collect the amount of drained oil in a
container for 30 seconds.

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13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES

13.7.1 OPERATING TIME OF CYLINDERS

(1) Purpose
Measure the operating time of the boom,
arm and bucket and confirm the
performances between the hydraulic pump
and the cylinder of the attachment drive
system.
Measuring position for bucket digging and
dump

(2) Condition
Hydraulic oil temperature; 45 to 55C
degrees (113 to 131F degrees)
Engine revolution; Hi idle
Operating time excluding the cushion stroke

Measuring position for boom up and down

motions

(3) Preparation
Firm level ground with the bucket empty 
(4) Measurement1; Boom up and down
With the boom operating lever at full stroke,
measure the required operating time of the
bucket between the ground surface and its
highest position. Measuring position for arm in and out
motions

Measurement 2; Arm in and out, bucket

digging and dump
In a position in which the tooth of the bucket
rises to a level of about 30 cm (1ft) above
ground, measure the full stroke operating time
required with the arm and bucket operating
levers at full stroke.

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

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13.7.2 OIL TIGHTNESS OF CYLINDERS

(1) Purpose
Confirm that the cylinder oil tight by checking the moving length of the cylinder rods.
(2) Condition
Hydraulic oil temperature; 45 to 55C degrees (113 to 131F degrees)
Firm, level ground
After cylinders are replaced, bleed off air from the cylinders, before checking for oil tightness.
Retract the arm cylinder rod 50 mm (2 in) from stroke end so that the piston does not match a
same range of the cushioning mechanism.
(3) Preparation
Put the bucket empty. Retract the arm cylinder rod 50mm (2in) from the most retracted position.
And extend the bucket cylinders fully. Then hold the boom so that the arm top pin is positioned at
same height with boom foot pin.
(4) Measurement
Measure the items five minutes after the engine is turned off.

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13.8 MEASURING PERFORMANCES OF SWING BEARING

(1) Purpose
Measure the gap between the lower frame
and the bottom face of the swing bearing
and estimate the degree of wear of the
swing bearing.
(2) Condition
Firm, level ground
The swing bearing mounting bolts are not
loosened.
The swing bearing is lubricated well, not How to measure the axial play of swing
making abnormal sound during turning. bearing

(3) Preparation
1.
Install a dial indicator to the magnetic
base and fix it to the lower frame.
2.
Direct the upper swing body and the lower
frame toward the travel direction, bring the
Measuring position 1
probe of the dial indicator in contact with
the bottom surface of the outer race on the
swing body side and set the reading at
zero. 
(4) Measurement 1 (Measuring position 1 and
2)
1.
Measure the displacement of the outer race
in the axial direction in position 1 [The
arm at 90 degrees to 110 degrees and
Measuring position 2
the crawler front is lifted by attachment
about 30cm (1ft)] and in position 2, using a
dial indicator.

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(5) Measurement 2 (Measuring position 3)

1.
Retract the arm cylinder fully and extend
the bucket cylinder fully. And move the
boom so that the arm top pin is
positioned at same height with boom foot
Measuring position 2
pin. Then swing the bucket right and left by
man power. But in this case, the gap of
the attachment is included.

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13.9 MECHATRO CONTROLLER

13.9.1 ENGINE CONTROL INPUT / OUTPUT

INPUT / OUTPUT

13.9.2 ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT (B-C
ADJUSTMENT)
13.9.2.1 PURPOSE OF THE ADJUSTMENT
There are 2 kinds of adjustment of mechatro controller as shown below; every adjustment is an
essential function to ensure performance of machine.

(1) Adjustment of pump ("B" adjustment)

This adjustment is performed to correct the output variation by coordinating the output hydraulic
pressure with engine rated output.
(2) Adjustment of unloading valve ("C" adjustment)
This adjustment is performed to correct the open variation of unloading valve to improve the
operability further.

13.9.2.2 IN CASES WHERE THE ADJUSTMENT OF MECHATRO CONTROLLER IS REQUIRED;

When the following parts are replaced or repaired, carry out the adjustment without fail.

(1) Mechatro controller

(2) Engine or engine controller
(3) Hydraulic pump or hydraulic pump proportional valve
(4) Unloading proportional valve, spool of unloading valve

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13.9.2.3 PREPARATION
(1) Raise the oil temperature to about 50C degrees (122F degrees) to warm up the engine.
(2) Turn the air-con OFF.
(3) Turn the starter key switch OFF to stop the engine.
When the mechatro controller was replaced, the following error code is displayed because the
adjustment data is not entered.
A215, A225, A015, A025, A035
As the error codes other than those shown above may suggest failures of machine, repair the
machine into the ordinary operating condition according to Error Code List.

For machines equipped with lifting magnet, turn the generator OFF.

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13.9.2.4 ADJUSTING PROCEDURE

Gauge cluster

(1) Adjustment of pump ("B" adjustment)

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

2. Keep buzzer stop switch on gauge cluster

pressed for 5 seconds and release it and
the screen for selecting adjustment is
displayed. When adjustment data is not
entered in mechatro controller, "READY" is
indicated. If the adjustment operation is
once performed, "FIN" is indicated.
And the lever lock solenoid is
automatically released, disabling all
operations.

3. Press menu switch on gauge cluster to

display "START ENGINE".
"Engine SPEED", P1, P2 "PUMP
PRESSURE" and "STEP" (acceleration
command voltage) are indicated.

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4. After engine starting, press the menu switch

on gauge cluster, and "MEMORY PUMP"
displayed. And the adjustment shifts to
pump adjustment automatically. Then the
speed shifts from LOW idling to HIGH
idling. And "MEMORY PUMP" is displayed.
And the unloading proportional valve and
pump proportional valve actuate, accordingly
the loading of pump is increased.
The "ENGINE SPEED", P1, P2 "PUMP
PRESSURE" and P1, P2 pump
"PROPO-VALVE" current (command value)
are indicated.

5. After detection of the engine rated speed,

the adjustment of pump is automatically
completed. And "FINISH PUMP" is
displayed.
(Press the buzzer stop switch on gauge
cluster while this display is appeared and
the adjustment is completed. The
unloading adjustment required later is not
performed, and default value is written.)

(2) Adjustment of unloading valve ("C" adjustment)

Procedure
1. The adjustment shifts from pump to
unloading, and the unloading valve
actuates, accordingly the pump pressure is
detected. And "MEMORY UNLOAD" is
displayed.
The "ENGINE SPEED", P1, P2 "PUMP
PRESSURE" and P1, P2 "PROPO-VALVE"
voltage (command value) are indicated.

2. When the unloading valve operates to the

specified value, the adjustment of
unloading proportional valve is
automatically terminated. And "FINISH
UNLOAD" is displayed.
The speed is shifted to the speed
corresponding to acceleration potentiometer.
The adjusting current value is indicated on
the display of current of P1, P2 unloading
proportional valves. The adjusting range is
usually 520 to 635 mA.

Stop the engine. (The adjusted data is

automatically stored.)

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(3) Corrective actions taken when the adjustment can not be performed;

1. In cases where the adjustment of pump

can not be performed; And "ERROR
PUMP" is displayed.
Judging condition 1:
P1 and P2 average pump pressure at the
time when the adjustment is completed is
25MPa or less.
Judging condition 2:
The adjustment does not complete
although the pump proportional valve
current reaches to the specified value.

The P1 and P2 pump pressures usually

increase to 33~38MPa.
When the pressure does not increase;

a. Identify the reason why the pressure does not increase,

-Check that the relief valve operates normally.
-Check that the hydraulic circuit is free from leak of pressure.
-Check that the pressure sensor functions normally.
And so on.
b. Identify the reason why the actual flow rate does not increase,
-Check that the pump proportional valve operates normally.
-Check that the pump regulator operates normally. 
And so on.

2. In cases where unloading valve can not

be performed; And "ERROR UNLOAD" is
displayed.
Judging condition 1:
The pump pressure does not increase up
to the pressure in the range of the
specified adjustment. Or the increased
pressure is held as it is.
Judging condition 2:
Pressure sensor of either P1 pump or P2
pump is failed.

Normally the pump pressures of P1 and

p2 pumps gradually increase to 10 to 25
MPa.
(It may be affected by operating oil
temperature.)

When the pump pressure does not increase;

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a. Identify the reason why the pressure does not increase,

-Check that the relief valve operates normally.
-Check that the hydraulic circuit is free from leak of pressure.
-Check that the pressure sensor functions normally.
And so on.

(4) Other precautions:

1. In the event of a failure, there is case where the adjustment may not be performed normally.
First serve the machine, and perform the adjustment work.
2. In the condition where large load is constantly applied to engine, the adjustment could not be
performed normally.

For machines equipped with lifting magnet, turn the generator OFF.

(5) When the adjustment of unloading valve only is performed; ("C" adjustment)
In the event where only unloading valve and unloading proportional valve are replaced, perform the
adjustment of unloading valve only.

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

2. Keep buzzer stop switch on gauge cluster

pressed for 5 seconds and release it and
the screen for selection of adjustment type
is displayed. And "ADJUST" is displayed.
When adjustment data is not entered in
mechatro controller, "READY" is indicated. If
the adjustment operation is once performed,
"FIN" is indicated.
And the lever lock solenoid is
automatically released, disabling all
operations.

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3. Change the adjusting items with up arrow

switch (ً) and down arrow switch (ٕ),
and select "ADJUST UNLOAD". (See Fig.
"Gauge cluster")
Like the output adjustment, when
adjustment data is not entered in mechatro
controller, "READY" is indicated. If the
adjustment operation is once performed,
"FIN" is indicated.

4. Press menu switch on gauge cluster to

display "START ENG".
"ENGINE SPEED", P1, P2 "PUMP
PRESSURE" and "STEP" (acceleration
command voltage) are indicated.

5. After starting engine, press menu switch

on gauge cluster and "MEMORY
UNLOAD" is indicated, the engine speed
is automatically increased and the
adjustment of unloading valve is performed.
"ENGINE SPEED", P1, P2 "PUMP 
PRESSURE" and "PROPO-VALVE"
(acceleration command current) are
indicated.

6. When the unloading proportional valve

operates to the specified value, the
adjustment of unloading proportional valve
automatically completes. "FINISH
UNLOAD" is indicated.
The speed is shifted to the speed
corresponding to acceleration potentiometer.
The value of adjusting current is indicated
on the display of current of P1 and P2
unloading proportional valves. The
adjusting range is usually 520 to 635 mA.

Stop the engine. (The adjusted data is

automatically stored.)

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13.9.3 OPERATIONS IN THE EVENT OF A FAILURE OF EQUIPMENT OF

MECHATRO CONTROLLER
(1) Engine emergency mode
When the trouble occurs and the control of engine is impossible, the engine speed can be
controlled by operating emergency acceleration (E-27) provided on the seat rear side.

Operating procedure:
1. Set the emergency acceleration to NORMAL position.
2. Start engine.
3. Turn the emergency acceleration to HI side and control the engine speed.
4. When stopping the engine, set the emergency acceleration to NORMAL position before stopping.

Never increase the engine speed immediately after starting engine. It is dangerous.
To avoid this danger, repeat the above procedure, or the engine speed does not increase.
When the machine does not operate, set the emergency acceleration to NORMAL position.
(2) Pump emergency mode
In the event where a failure of P1 or P2 pump proportional valve represented in items of self
diagnosis is indicated on multi display provided on the gauge cluster, the full power control of
pump and positive control through mechatro controller are unavailable. Then the P1 and P2 pumps
are automatically switched to emergency mode, making the operation with the power shift control
of pump and the constant power control by means of self-pressure possible. But be careful that, at
emergency mode, the accuracy of inching becomes poor, the frequency of engine down is
increased, and the engine stalls in LOW speed condition.

The emergency mode should be used in only case of emergency. We recommend that the defective
section is repaired by troubleshooting as early as possible.

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13.10 DIESEL PARTICULATE FILTER (DPF)

13.10.1 HANDLING OF DPF

DPF is a device which traps soot emitted from the engine using the filter to clean up the exhaust gas.
When the certain quantity of soot is deposited on the filter (about after 10 hrs. of operating time), DPF
is changed to a mode of the soot combustion. At this mode, restoring the filter function by the soot
combustion is called "regeneration".
To avoid malfunction of DPF, observe the following points. (According to operating condition, the
deposition time varies.)
During the soot combustion, the exhaust sound is changed but this is not malfunction.

When the certain quantity of soot is deposited on the filter, DPF automatically carries out the
combustion of deposited soot in accordance with operating condition of the machine. See "ABOUT
AUTOMATIC REGENERATION" for details.
In some cases, according to operating condition, the soot combustion is not automatically finished.
When this occurs, the request for operating the DPF manual regeneration switch will be displayed on
the gauge cluster.
At that time, pull up the safety lock lever to the "LOCKED" position and push the DPF manual
regeneration switch. This operation prevents the deposition of extraordinary quantity of soot and keeps
the cleaning ability of DPF always in good condition. The soot combustion is carried out by the
high-performance catalyst and the common rail fuel injection system. 

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13.10.2 ABOUT AUTOMATIC REGENERATION

The automatic regeneration will start when a
certain amount of soot is deposited and the
exhaust gas is at a high temperature.
During the automatic regeneration, the indicator
meaning "automatic regeneration" is displayed
on the multi-display, but normal operation is
possible.

Immediately after the machine operation or during the regeneration, the exhaust pipe, the area around
the muffler, and the exhaust gas are extremely high temperature. If the flammables are brought to near
them, it may cause a fire and also cause burns by the high temperature exhaust gas.

If the exhaust temperature is decreased, or the engine is stopped during the automatic regeneration,
the automatic regeneration is interrupted. When soot does not combust completely because these
things are repeated, the request for operating the DPF manual regeneration switch will be displayed on
the gauge cluster. At that time, pull up the safety lock lever to the "LOCKED" position and then push
the DPF manual regeneration switch to carry out the manual regeneration.

As for the manual regeneration, see "13.10.3 ABOUT MANUAL REGENERATION".

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13.10.3 ABOUT MANUAL REGENERATION

When this indication is displayed on the multi-display, immediately pull up the safety lock lever and
push the DPF manual regeneration switch to carry out the combustion of soot deposited in DPF. The
request for operating the DPF manual regeneration switch tends to be displayed when performing low
load operation continuously.

-When the certain quantity of soot is deposited on the filter, DPF carries out the automatic
regeneration in accordance with operating condition of the machine. In some cases, according to
operating condition, the automatic regeneration is not finished. When this occurs, the above-mentioned
indication is displayed on the multi-display, so pull up the safety lock lever to the "LOCKED" position
and then push the DPF manual regeneration switch to carry out the manual regeneration. During the
manual regeneration, the engine speed is fixed. This is not a failure but to make the exhaust
temperature rise to help the soot combustion.
-When the regeneration is not carried out immediately, it may cause a limited engine speed due to too
much amount of deposited soot. To recover from that condition, remove DPF and bring it to our
authorized service shop near you.


-The soot combustion is finished in about 10 to 20 minutes.
-The soot combustion makes the temperature inside the muffler rise, so the more the temperature
inside the muffler rises, the shorter the time of soot combustion becomes.
-The soot combustion soon after the machine operation is finished faster than the soot combustion at
the time of that the engine is still cold. If the engine is cold, the soot combustion may take 20
minutes or more because the warming-up operation is carried out before the soot combustion.

A. Operation procedures
1. Move the machine to the safe place.

-Immediately after the machine operation or during the regeneration, the exhaust pipe, the area
around the muffler, and the exhaust gas are extremely high temperature. If the flammables are brought
to near them, it may cause a fire and also cause burns by the high temperature exhaust gas.
-If the wall is faced to the exhaust outlet of muffler, the wall may be discolored.

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2. Operate the machine to place the attachment in the position of parking and pull up the safety lock
lever.
3. Push the DPF manual regeneration switch. The display for the DPF manual regeneration switch
in the multi-display may be changed to "REGENERATION". The idling engine speed is fixed and
the pump relief operation starts.
4. When the indication of "REGENERATION" in the screen of multi-display goes out, the soot
combustion is finished. Usual machine operation becomes possible. (If the original engine speed
is set to low speed, it keeps low speed. If the original engine speed is set to high speed, it
keeps low speed until the machine is operated. When the machine is operated, the engine speed
returns to its originally set speed. )

-If the safety lock lever is pulled down to the "UNLOCKED" position during the regeneration, the
regeneration is stopped and the indication of "1. LIFT UP LOCK LEVER 2. PUSH REGENERATION
SW" is displayed on the multi-display but machine operation is possible.
-If the regeneration is stopped due to the engine stop or pulling down the safety lock, the indication
of "1. LIFT UP LOCK LEVER 2. PUSH REGENERATION SW" is displayed again on the multi-display.
Perform the manual regeneration procedures again.

If operation is continued without "manual

regeneration" and soot becomes deposited too
much, the warning "EXHAUST GAS AFTER
TREATMENT EQUIPMENT WILL BE
DAMAGED" appears on the multi-display and
the engine speed is fixed at low speed.
In that case, contact our authorized service
shop near you.
Inspection and maintenance on DPF are
required.

13.10.4 INSPECTION
Inspection interval: Every 1,000 hrs. (Or every 1 year)

Inspection for damage of the body of DPF and the sensor wiring and hoses attached to the body of
DPF is required. If damage (cracking etc.) on the surface of sensor hose is found at the time of
inspection, replace the hose immediately. Please contact us or our authorized dealer/distributor for
inspection and replacement.

To inspect DPF, diagnosis by the special tool is required.

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13.10.5 MAINTENANCE STANDARD

࡮ Inspection and maintenance on the body of DPF and the sensor wiring and hoses attached to
the body of DPF are required in every 2 years. Please contact us or our authorized
dealer/distributor for inspection and replacement.
࡮ Clean or replace DPF in every 4,500 hrs.

If inspection and maintenance are not performed, it may cause malfunction of the engine and DPF.

Replace the hose for DPF differential pressure sensor with new one in every 2 years.
Replace the DPF installation mount with new one in every 2 years.

13.10.6 PRECAUTION FOR USE OF DPF

A. Do not use the fuel other than the specified fuel

Use the low-sulfur diesel fuel (S50: Sulfur content 50 ppm or less). In cold areas, use appropriate
low-sulfur diesel fuel. If you use the unspecified fuel, it adversely affects the engine and DPF and 
causes white smoke or malfunction.

B. Use the recommended brand engine oil

To keep the DPF function in good condition for long periods, use the recommended brand engine oil.

C. Do not modify the tail pipe

If the direction or length of the tail pipe is modified, it will adversely affect DPF. Do not modify the tail
pipe.

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㨇13. MAINTENANCE STANDARD AND TEST PROCEDURE㨉

13.11 DEF SCR SYSTEM

This machine is equipped with SCR (Selective Catalytic Reduction) system for reduction of NOx
(nitrogen oxide) emission.

13.11.1 WHAT IS SCR?

SCR is an addreviation for "Selective Catalytic Reduction", a general term for after treatment system
which promotes a chemical reaction by using a catalyst for eliminating or detoxifying particular chemical
ingredients. By mixing the NOx with the ammonia contained in DEF, NOx will be separated into water
andnitrogen.

13.11.2 WHAT IS DEF?

DEF serves as a carrying agent for the ammonia needed to reduce nitrogen oxide (NOx) emissions
from diesel engines. When DEF is injected into the engine exhaust gas upstream of the SCR
catalyst, it will be rapidly hydrolyzed producing the oxidizing ammonia needed by the SCR system to
lower the level of NOx emissions.

࡮ DEF is crystallized as white powder when it is dried. If you find the crystallized DEF on the
surface of the DEF tank, wipe it off with clean cloth.
࡮ Keep your face away from DEF and do not sniff the DEF when you open the filter cap of the
DEF tank. DEF may produce an odor when it is warmed up.
࡮ If you dispose of the DEF follow your local regulations.
࡮ The DEF in the DEF tank freezes at -11°C (12°F). If the DEF in the DEF tank is frozen, do not
warm the DEF tank by using the burner and heater. The machine is equipped with the defrost
device, and frozen DEF will be defrosted during operation.

Use of DEF

Use the DEF specified by ISO 22241-1.

API certifies the DEF complying with this standard. Use the DEF with the following label.

After turning "OFF" the starter switch, operation sound from the DEF supply module is heard, but this
is not a failure of the machine.
Even though the engine is stopped and the starter switch is turned "OFF", a control called after run
is carried out for a few minutes. The after run is a control which sends DEF remained in the DEF
lines back to the DEF tank to prevent them from freezing or being crystalized when they are dried.

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13.11.3 DEF QUALITY WARNING AND OUTPUT LIMITATION

When the warnings in the following list appear, poor DEF quality is detected. Immediately replace
DPF with specified new DEF.


If you mix DEF with liquid containing oil or liquid other than DEF by mistake and run the engine, the
DEF supply module, DEF lines, and DEF sensor unit should be replaced with new ones and also
cleaning of the DEF tank is required. Please contact KOBELCO authorized service shop.

If the machine is left without proper treatment with these warnings displayed, the output is limited
step by step and finally, the machine becomes inoperable.

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Replacing procedure after DEF quality warning

Replace DEF with the starter switch left at the "ON" position.

1. Prepare a container for drained DEF.

2. Loosen 2 bolts of cover (1) under the
DEF tank and remove cover (1).
3. Remove drain plug (2) and O-ring (3) at
the bottom of the DEF tank and drain the
DEF in the DEF tank completely.
4. After draining DEF, reinstall drain plug (2)
and O-ring (3) to the original position and
tighten them.
5. Refill DEF by seeing "Checking of DEF
Level and Refilling" in Chapter 3.
Add 35 liters {9.3 gal} or more of new DEF
into the empty tank.
6. After refilling DEF, check that no warning
appears on the multi-display.

When DEF is replaced with the starter switch at the "OFF" position, turn the starter switch to the "ON"
position after DEF replacement is completed and wait for 6 minutes. Then check that no warning
appears on the multi-display.

When poor DEF quality is detected again

If poor DEF quality is detected again during 40 hours after returning from the poor DEF quality
warning, the output limitation of the third stage, which is the third from the first detection stage, is
applied on the machine.
And also, if 30 minutes have passed after the time of detection, the machine becomes inoperable.

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13.11.4 DEF LEVEL WARNING AND OUTPUT LIMITATION

If the DEF level becomes close to the levels that cause the following warnings appear, refill DEF
immediately.
When the warnings appear, refill DEF according to the procedure below.


Display of DEF level meter
1 (First stage): Level 2 (yellow)
2 (Second stage): Level 1 (red)
3 (Third stage): Level 0 (no indicator)

If the machine is left without proper treatment with these warnings displayed, the output is limited
step by step and finally, the machine becomes inoperable.

Refilling procedure after fuel level warning

1. Refill DEF by seeing "Checking of DEF Level and Refilling" in Chapter 3.
Refill 20 liters or more of new DEF (until the DEF level meter indicates the level 5 or more) after
the warnings above appear. If DEF is not refilled to the level 5 or more, the warnings are not
cancelled.
2. After that, turn the starter switch to the "ON" position, wait for 1 minute, and then check the DEF
level from the DEF level meter.

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13.11.5 FAILURE WARNING OF DEF SCR SYSTEM COMPONENT AND OUTPUT

LIMITATION
When the warnings in the following list appear, the machine may be used improperly or exhaust
emission is deteriorated because of system failure.
If the following warnings are displayed, please contact KOBELCO authorized service shop.

If the machine is left without proper treatment with these warnings displayed, the output is limited
step by step and finally, the machine becomes inoperable.

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When failure of DEF SCR system component is detected again

If failure of the DEF SCR system component is detected again during 40 hours after returning from
the failure warning of DEF SCR system component, the output limitation of the third stage, which is
the third from the first detection stage, is applied on the machine.
And also, if 30 minutes have passed after the time of detection, the machine becomes inoperable.

If "1. LIFT UP LOCK LEVER 2. PUSH REGENERATION SW." appears with "POWER LIMITATION IN
PROGRESS" or "EXTREME POWER LIMITATION IN PROGRESS", return the DEF SCR system to
normal condition first, and then press the DPF manual regeneration switch to carry out regeneration.

13.11.6 EMERGENCY EVACUATION MODE

If the machine should be moved to somewhere emergently even though the machine is in a state of
the third level of warning and under engine restriction due to DEF/AdBlue shortage, abnormal quality,
or a failure of the exhaust gas cleaning device, keep pressing switch (1) for 5 seconds to enter the
emergency evacuation mode.
After entering the emergency evacuation mode, only a travel operation becomes possible as usual.
But operations other than the travel operation remain under restriction.

- The emergency evacuation mode can be used for only total 30 minutes or up to 3 times. Use this 
mode only in a case of emergency and if the warnings are displayed, take proper measures
immediately.
- Keep pressing switch (1) for 5 seconds securely to enter the emergency evacuation mode. If not
keeping pressing switch (1) for 5 seconds securely, the machine will not enter the emergency
evacuation mode.

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 㨇21. MECHATRO CONTROLLER㨉

21. MECHATRO CONTROLLER

TABLE OF CONTENTS

21.1 SUMMARY OF MECHATRO CONTROL SYSTEM äääääääääääääääääääää21-4

21.1.1 MECHATRO CONTROL SYSTEM IN GENERAL ääääääääääääääääääää21-4
21.1.2 UNLOAD VALVE CONTROL äääääääääääääääääääääääääääää21-6
21.1.3 POSITIVE CONTROL & P-Q CONTROL äääääääääääääääääääääää21-7
21.1.4 BOOM UP CONFLUX CONTROL äääääääääääääääääääääääääää21-9
21.1.5 ARM IN RECIRCULATION & CONFLUX CONTROL ääääääääääääääääää21-11
21.1.6 ARM-IN ANTI-CAVITATION CONTROL ääääääääääääääääääääääää21-13
21.1.7 ARM-OUT CONFLUX CONTROL äääääääääääääääääääääääääää21-14
21.1.8 BUCKET DIGGING ANTI-CAVITATION CONTROL äääääääääääääääääää21-16
21.1.9 SWING PRIORITY CONTROL ääääääääääääääääääääääääääää21-18
21.1.10 TRAVEL STRAIGHT CONTROL äääääääääääääääääääääääääää21-20

21.1.11 PRESSURE RELEASE CONTROL ääääääääääääääääääääääääää21-22
21.1.12 N&B SWITCH CONTROL (OPTION) äääääääääääääääääääääääää21-24
21.1.13 OPTION CONFLUX CONTROL (OPTION) ääääääääääääääääääääää21-26
21.2 MECHATRO CONTROLLER äääääääääääääääääääääääääääääää21-28
21.2.1 SUMMARY OF MULTI DISPLAY äääääääääääääääääääääääääää21-28
21.2.2 SELF DIAGNOSIS DISPLAY äääääääääääääääääääääääääääää21-43
21.2.3 SERVICE DIAGNOSIS DISPLAY FUNCTION äääääääääääääääääääää21-44
21.2.4 TROUBLE HISTORY DIAGNOSISäääääääääääääääääääääääääää21-54
21.2.5 SET PROCEDURE OF MAINTENANCE SCHEDULE ääääääääääääääääää21-55
21.2.6 ADJUSTING PROCEDURE OF DISPLAY äääääääääääääääääääääää21-57
21.2.7 MECHATRO CONTROL EQUIPMENT äääääääääääääääääääääääää21-63

Book Code No. S5L&213E01

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Issue Date of Issue Applicable Machines Remarks

S5LC2133E01
First Edition July, 2014 SK350LC-9E : YC13-13001~
(NA)

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 㨇21. MECHATRO CONTROLLER㨉

PREFACE
This manual explains only those related to the electro hydraulic conversion as mechatro control. This
manual summarizes the mechatro system and the function of the mechatro controller related
apparatuses. Regarding the conditions before and after each conversion, refer to the hydraulic system
and the electric system.



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21.1 SUMMARY OF MECHATRO CONTROL SYSTEM

21.1.1 MECHATRO CONTROL SYSTEM IN GENERAL

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21.1.2 UNLOAD VALVE CONTROL

(1) On starting any one of operations, the control pilot secondary pressure switches spools and
enters in respective low pressure sensors.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro
controller processes pilot signal and outputs command according to the input voltage to each
unload pressure proportional valve.
(3) Each unload pressure proportional valves output pilot secondary pressure according to the
command output by mechatro controller and switches each unload spools.
(4) With this operation, the bleed opening according to lever manipulated movement is obtained,
consequently the pump pressure which is used to actuate each actuators are delivered and
makes each actuator start operating.

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21.1.3 POSITIVE CONTROL & P-Q CONTROL



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(1) Positive control

1. On starting any one of operations, pilot secondary pressure switches each spool and is input to
each low pressure sensor.
2. The output voltage of low pressure sensor is input to mechatro controller and the mechatro
controller processes pilot signal and outputs command according to the input voltage to each
unload pressure proportional valve.
3. Each pump proportional valve outputs pilot secondary pressure according to the command output
by mechatro controller and changes the tilting angle of each pump and controls the delivery rate.
4. With this operation, the delivery rate according to lever manipulated movement is fed to the
actuator, and consequently the working speed according to the lever manipulated movement will be
obtained.

(2) P-Q control

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

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21.1.4 BOOM UP CONFLUX CONTROL



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(1) On starting boom up operation, boom up operating pilot pressure switches boom spool and boom
up conflux spool and is input to low pressure sensor.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro
controller processes pilot signal and outputs command according to the input voltage to P1 and P2
proportional valves and P1 and P2 unload proportional valves.
(3) Each proportional valve outputs pilot proportional valve secondary pressure according to the
command output by mechatro controller and changes P1 and P2 pump delivery rate and switches
P1 and P2 unload pressure control valve.
(4) With original hydraulic pressure command, boom main spool and boom up conflux spool are
switched, and also with the command by mechatro controller, P1 and P2 pumps and P1 and P2
unload valves are switched and consequently the delivery oil on P1 pump side confluxes delivery
oil on P2 pump side during boom up operation.

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21.1.5 ARM IN RECIRCULATION & CONFLUX CONTROL



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(1) Recirculation and conflux (Low loading)

1. On starting arm-in operation, arm-in operating pilot secondary pressure is input to arm 1 spool,
arm 2 spool and low pressure sensor.
2. The output voltage of low pressure sensor is input to mechatro controller and the mechatro
controller processes pilot signal and outputs command according to the input voltage to P1 and P2
proportional valves, P1 and P2 unload proportional valves and reverse proportional valve for arm-in
2 spool.
In case of combined operation, the pilot pressure other than arm-in operation is input to low
pressure sensor and the output voltage is input to mechatro controller. And the mechatro
controller processes pilot signal according to the combined operation and outputs command, which
is different from the arm-in independent operation, to P1 pump proportional valve, P1 unload
proportional valve and reverse proportional valve for arm-in 2 spool.
3. Primary pressure of reverse proportional valve for arm-in 2 spool is arm-in pilot secondary pressure
and it switches arm 2 spool by proportional secondary pressure according to command. (Arm 2
spool controls recirculation rate and conflux rate.)
The other proportional valves output proportional secondary pressure according to command from
mechatro controller. These proportional valves change the delivery rate of P1, P2 pump, and
switch P1, P2 unload valve.
4. The arm 1 spool is switched according to original oil pressure command, and P1, P2 pumps, P1,
P2 unload spools and arm 2 spool are switched according to the command output by mechatro
controller, and consequently the return oil from the arm cylinder rod side is recirculated in P1 and
P2 pumps delivery oil during arm operation.

(2) Recirculation cut

The voltage output by high pressure sensor on P2 side is input to mechatro controller, and when the
load is raised during arm operation the mechatro controller processes pilot signal processing according
to the pressure detected by high pressure sensor and outputs command to cut recirculation into
reverse proportional valve for arm-in 2 spool.
The reverse proportional valve for arm-in 2 spool outputs pilot secondary pressure according to the
command output by mechatro controller and switches arm 2 spool to recirculation cut position, and
consequently recirculation passage is blocked.

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21.1.6 ARM-IN ANTI-CAVITATION CONTROL



(1) On starting arm-in operation, arm-in operating pilot secondary pressure switches arm 1 spool and
is input to low pressure sensor.
(2) The engine speed command output by accel potentiometer is input to mechatro controller.
(3) Low pressure sensor output voltage is input to mechatro controller, and the mechatro controller
processes pilot signal processing and outputs command according to the input voltage to P2 pump
proportional valve and P2 unload proportional valve.
(4) And also outputs command according to input pressure output by potentiometer to reverse
proportional valve for arm 2 spool.
(5) Each proportional valves output pilot secondary pressure according to each command output by
mechatro controller, and consequently since the reverse proportional valve for arm 2 spool is
controlled to spool stroke according to engine speed and changes recirculation rate to prevent the
cavitation from occurring even if pump delivery rate is low due to low engine speed.

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21.1.7 ARM-OUT CONFLUX CONTROL

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(1) On starting arm-out operation, arm-out operating pilot pressure switches arm 1 spool and arm 2
spool and is input to low pressure sensor.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro
controller processes pilot signal and outputs command according to the input voltage to P1 and P2
proportional valves and P1 and P2 unload proportional valves.
(3) Each proportional valve outputs pilot proportional valve secondary pressure according to the
command output by mechatro controller and changes P1 and P2 pump delivery rate and switches
P1 and P2 unload pressure control valves.
(4) With original hydraulic pressure command, arm 1 spool and arm 2 spool are switched and also
with the command output by mechatro controller, P1 and P2 pumps and P1 and P2 unload valves
are switched, and consequently the delivery oil on P2 pump side confluxes delivery oil on P1
pump side during arm-out operation.



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21.1.8 BUCKET DIGGING ANTI-CAVITATION CONTROL

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(1) On starting bucket digging (dump) operation, bucket digging operating pilot pressure switches
bucket spool and is input to low pressure sensor.
(2) The engine speed command output by accel potentiometer is input to mechatro controller.
(3) The output voltage of low pressure sensor is input to mechatro controller and the mechatro
controller processes pilot signal and outputs command according to the input voltage to P1 and P2
pump proportional valves, P1 and P2 unload proportional valves and travel straight proportional
valve.
(4) Each proportional valve outputs pilot proportional valve secondary pressure according to the
command output by mechatro controller and changes P1 and P2 pump delivery rate and switches
P1 and P2 unload valves and travel straight valve of control valve.
(5) The tandem passage is connected to P2 port because of the travel straight valve switched and P1
pump delivery oil confluxes P2 pump delivery oil because of P2 unload valve switched.
(6) ATT boost solenoid valve turns the solenoid valve on according to the engine speed, and outputs
secondary pressure, and actuate stroke limiter and then controls the stroke of bucket spool.
The control of spool stroke makes the prevention of cavitation possible even if engine speed is
low and pump delivery rate is low.
(7) When P1 pump pressure was raised at cylinder stroke end, etc. the solenoid valve is closed
according to the pump pressure, and when the pump pressure is high, the boost solenoid valve
does not work to control the stroke limit of bucket spool.



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21.1.9 SWING PRIORITY CONTROL

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(1) During arm-in operation, arm operating pilot secondary pressure switches arm spool and is input
to low pressure sensor on starting swing operation (or arm-in operation during swing operation),
and swing operation pilot secondary pressure switches swing spool and is input to low pressure
sensor.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro
controller processes pilot signal and outputs command according to the input voltage to P1 and P2
proportional valves, P1 and P2 unload pressure proportional valves, travel straight valve and
reverse proportional valve for arm 2 spool.
(3) Each proportional valve outputs pilot proportional valve secondary pressure according to the
command output by mechatro controller and changes P1 and P2 pump delivery rate and switches
P1 and P2 unload spool, travel straight spool, arm 2 spool.
(4) With original hydraulic pressure command, arm 1 spool and swing spool are switched and also
with the command by mechatro controller, P1 and P2 unload spools, travel straight spool and
arm 2 spool are switched enabling for two pump flow rates to be supplied to the arm cylinder
head side, and consequently the return oil on arm cylinder rod side is recirculated into arm
cylinder head side.
(5) ion by priority, and operated by the recirculated oil, making the operation with minimum speed
drop possible.



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21.1.10 TRAVEL STRAIGHT CONTROL

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(1) Judgment travel straight

1. During travel operation (right and left), pilot pressure switches each spool and is input to low
pressure sensor on carrying out attachment system operation.
2. Mechatro controller decides as travel straight on receiving the input according to the combination
shown in the table from the low pressure sensor and turns travel straight signal on.
3. On turning travel straight signal on, the following commands are output to each proportional valve.

(2) Operation of each proportional valve

(Basically attachment operation is actuated by P1 pump and travel operation is actuated by P2 pump
in travel straight condition.)

1. Travel straight proportional valve

Outputs switching pressure according to the high priority select pressure in the attachment system
operating (Boom, arm, bucket, swing, option) pilot pressure during operation.
2. P1 unload proportional valve
Outputs switching pressure according to the high priority select pressure in the attachment system
operating pilot pressure during operation.
3. P2 unload proportional valve
Outputs switching pressure according to the high priority select in the travel operating pilot
pressure during operation.
4. P1 pump proportional valve
Outputs switching pressure according to the high priority select pressure in the attachment system
operating pilot pressure during operation.
5. P2 pump proportional valve
Outputs switching pressure according to the high priority select in the travel operating pilot
pressure during operation. 

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21.1.11 PRESSURE RELEASE CONTROL

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(1) Change mechatro controller to "PRESSURE DRAINING MODE" by operating switch on gauge
cluster.
For detail of changing mode method, refer to "How to switch to "Pressure release mode"" on item
22.11.1.
(2) Once mechatro controller decides it as pressure release control, regardless of each input signal
(operating pilot, accel potentiometer, etc.) the mechatro controller;
1.
Outputs minimum tilt angle command to P1, P2 pump proportional valves and fixes P1, P2 pump
to minimum tilt angle.
2.
Outputs command of pressure release and outputs command of pressure release control to ECU
and fixes engine speed to pressure release control speed.
3.
Outputs maximum command to P1 and P2 unload valves and each pilot secondary pressure fixes
P1 and P2 unload valves to the maximum opening.
(3) Mechatro controller senses output voltage from the main pump high pressure sensor, decides the
pump pressure and displays "DRAINING HYD. PRESS" or "FAIL DRAIN HYD. PRESS" on gauge
cluster.
(4) Each pump delivery oil is unloaded to tank passage enabling for the remained pressure (trapped
pressure) to be released by operating each control lever and switching spool with the unload valve
opened.



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21.1.12 N&B SWITCH CONTROL (OPTION)

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(1) Nibbler circuit

1. Select nibbler mode through select switch.
2. Nibbler display appears on gauge cluster.
3. The return oil from the nibbler passes through selector valve and option spool and led to tank
line of main control valve.
4. When selecting nibbler mode through select switch, the breaker pressure sensor has not function
to output.
It is in normal when there is no output from sensor in nibbler mode, and in cases of other than
above, error display is output to gauge cluster.

(2) Breaker circuit

1. Select breaker mode through select switch.
2. Breaker display appears on gauge cluster.
3. The return oil from the breaker passes through selector valve and directly returns into hydraulic oil
tank.
4. When selecting breaker mode through select switch, the breaker pressure sensor outputs signal.
It is in normal when there is an output from sensor in breaker mode, and in cases of other than
above, error display is output to gauge cluster.



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21.1.13 OPTION CONFLUX CONTROL (OPTION)

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(1) Using "OPTION SETTING" display located on "USER MENU" screen, the flow rate is adjusted. At
this time, if the setting flow rate is larger than one pump flow rate, the flow becomes automatically
confluent flow.
(2) On starting option operation, option operating pilot pressure switches option spool and is input to
low pressure sensor.
(3) The output voltage of low pressure sensor is input to mechatro controller and the mechatro
controller processes pilot signal and outputs command according to the input voltage to P1 and P2
pump proportional valves, P1 and P2 unload pressure proportional valves and travel straight
proportional valve.
(4) Each proportional valves output pilot proportional valve secondary pressure according to the
command output by mechatro controller and changes P1 and P2 pump delivery rate and switches
P1 and P2 unload valves and travel straight valve of the control valve.
(5) The parallel passage on P2 side is connected to P1 port because of the travel straight valve
switched and P1 pump delivery oil confluxes P2 pump delivery oil because of the P2 unload valve
switched.



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21.2 MECHATRO CONTROLLER

21.2.1 SUMMARY OF MULTI DISPLAY

Electro-hydraulic conversion information is displayed on the multi display of the gauge cluster.

(1) Controls

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(2) Gauge cluster

The gauge cluster is made up of meters (fuel
level, engine coolant temperature), switch panel
with various switches and multi-display.

A. METERS
1: Engine Coolant Temperature Meter
2: Fuel Level Meter
3: DEF Level Meter

B. SWITCH PANEL
4: Screen Change Switch
5: Buzzer Stop Switch
6: Work Mode Select Switch
7: Washer Switch
8: Wiper Switch
9: Travel Speed Select Switch
10: Auto Acceleration Switch
11: Menu Switch
12: Digging Switch
13: Nibbler Switch
14: Breaker Switch
15: Arrow Switch
DETAIL OF ALLOW SWITCH
a: Up Arrow Switch
b: Down Arrow Switch
c: Right Arrow Switch 
d: Left Arrow Switch

C. DISPLAY
16: Multi Display (LCD)

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(3) Screen selection by work mode select switch

The mode after the engine starting is always the start from "H" mode. The work mode is switched in
order of "H" to "S" to "E" to "H" each time the work mode select switch is pressed.
Select proper work mode shown below according to the work condition and the purpose. For the
selected work mode, refer to the upper left corner of display.

࡮ S mode: For standard excavating work

࡮ ECO mode: For low fuel consumption
excavating work
࡮ H mode: For heavy duty excavating work

S mode
"S mode" is suitable for standard digging and
loading works and is in saving fuel consumption
and is in good balance to the workload.

ECO mode
"Eco mode" is the mode focusing on better
fuel economy, allowing for normal digging
operation with lower fuel consumption than S
mode.

H mode
"H mode" is suitable for heavy duty digging
work which gives priority to the workload at
the high speed.

(4) Condition for turning the green mark on

The logic is, when the fuel consumption value
is 90 % or less of the fuel consumption value
of relief operation at H mode, the green mark
turns on (common logic in each mode).

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(5) Screen selection by attachment mode switich

This switch is used for switching the attachment
mode.
Attachment mode display
Press Digging mode switch (1) to select Digging
mode from attachment modes. And selected
Digging mode is indicated.Press Nibbler mode
switch (2) to select Nibbler mode from
attachment modes. And selected Nibbler mode
is indicated.Press Breaker mode switch (3) to
select Breaker mode from attachment modes.
And selected Breaker mode is indicated.
Depending on the attachment employed, select
the applicable mode from "Digging", "Nibbler"
and "Breaker".
Before the working, confirm whether
appropriate attachment had been selected.

1. Digging mode switch

2. Nibbler mode switch
3. Breaker mode switch



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(6) Procedure of setting a flow rate and a option relief pressure at Nibbler/Breaker mode
1: Buzzer Stop Switch
2: Menu Switch
3: Nibbler Mode Switch
4: Breaker Mode Switch
5: Up Arrow Switch
6: Down Arrow Switch
7: Next Arrow Switch
8: Back Arrow Switch

According to some kind of attachment, it is required to change the flow rate and relief pressure for
service circuit.
Regarding the adjustment of flow rate and relief pressure for Nibbler and Breaker, the settings of 10
patterns are available.

Both Nibbler are set in conditions "SET 6" as factory default in the above table at shipping.
Both Breaker are set in conditions "SET 1" as factory default in the above table at shipping.
* The meaning of "Not set yet" shows that 50MPa as pressure is temporary value.

Set the flow rate and relief pressure in accordance with next procedure.
And these setting values in above adjustment are selectable by using after-mentioned "Flow rate and
Relief pressure Selection".

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1) When using Nibbler

1. Turn starter switch ON. After pressing Nibbler mode switch (3) to select Nibbler mode, turn
starter switch OFF.
2. Hold down buzzer stop switch (1) and turn starter switch ON. The service diagnosis screen (a) is 
displayed.
3. Start the engine.
4. Hold down buzzer stop switch (1) and press menu switch (2) 3 times. "SERVICE MENU" screen
(b) is displayed.
5. Using switch "UP ARROW SWITCH" (5) or "DOWN ARROW SWITCH" (6), point the cursor to
"SERVICE ADJUST 1" display (b). Press "NEXT ARROW SWITCH" (7), and SERVICE ADJUST
1-1 is displayed. Then press "UP ARROW SWITCH" (5) and SERVICE ADJUST 1-2 (C) is
displayed.
6. Using switch "UP ARROW SWITCH" (5) or "DOWN ARROW SWITCH" (6), point the cursor to
"NIBBLER SETTING" display (c). Press NEXT ARROW switch (7), and NIBBLER SETTING (d) is
displayed.
7. There are 10 steps from "SET 1" to "SET 10". Using switch "UP ARROW SWITCH" (5) or
"DOWN ARROW SWITCH" (6), and select desired set number. To set desired set number, press
"NEXT ARROW SWITCH" (7).
8. Using switch "UP ARROW SWITCH" (5) or "DOWN ARROW SWITCH" (6), set the desired flow
rate. Then press menu switch (2) and the cursor is pointed to pressure display (f).
9. During pressing rear (heel side) of optional right pedal (P2 pump optional operation), use switch
"UP ARROW SWITCH" (5) or "DOWN ARROW SWITCH" (6), and adjust pump pressure.When the
value of pressure reaches the desired pressure, press menu switch (2) to set. (If you fail to
press rear (heel side) of optional right pedal, 0MPa is displayed.)
10. Then, the cursor is pointed to pressure (see display (g)). Use switch "UP ARROW SWITCH" (5) or
"DOWN ARROW SWITCH" (6), and adjust pump pressure.When the value of pressure reaches the
desired pressure, press menu switch (2) to set. (If you fail to press front (toe side) of optional
right pedal, 0MPa is displayed.)
11. Then, the display returns to "SERVICE ADJUST 1-2" screen (c).

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2) When using Breaker

1. Turn starter switch ON. After pressing Breaker mode switch (4) to select Breaker mode, turn
starter switch OFF.
2. Hold down buzzer stop switch (1) and turn starter switch ON. The service diagnosis screen (a) is
displayed.
3. Start the engine.
4. Hold down buzzer stop switch (1) and press menu switch (2) 3 times. "SERVICE MENU" screen
(b) is displayed.
5. Using switch "UP ARROW SWITCH" (5) or "DOWN ARROW SWITCH" (6), point the cursor to
"SERVICE ADJUST 1" display (b). Press "NEXT ARROW SWITCH" (7), and SERVICE ADJUST
1-1 is displayed. Then press "UP ARROW SWITCH" (5) and SERVICE ADJUST 1-2 (C) is
displayed.
6. Using switch "UP ARROW SWITCH" (5) or "DOWN ARROW SWITCH" (6), point the cursor to
"BREAKER SETTING" display (c). Press "NEXT ARROW SWITCH" (7), and BREAKER SETTING
(d) is displayed.
7. There are 10 steps from "SET 1" to "SET 10". Using switch "UP ARROW SWITCH" (5) or
"DOWN ARROW SWITCH" (6), and select desired set number. To set desired set number, press
"NEXT ARROW SWITCH" (7).
8. Using switch "UP ARROW SWITCH" (5) or "DOWN ARROW SWITCH" (6), set the desired flow
rate. Then press menu switch (2) and the cursor is pointed to pressure display (f).
9. During pressing front (toe side) of optional right pedal (P2 pump optional operation), use switch
"UP ARROW SWITCH" (5) or "DOWN ARROW SWITCH" (6), and adjust pump pressure. When
you reach the desired pressure, press menu switch (2) to set. (If you fail to press front (toe side)
of optional right pedal, 0MPa is displayed.)
10. Then, the display returns to "SERVICE ADJUST 1-2" screen (c).

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(7) Pump flow rate adjustment (Nibbler mode / Breaker mode) (Option)
1: Screen Change Switch
2: Buzzer Stop Switch
3: Work Mode Select Switch
4: Washer Switch
5: Wiper Switch
6: Travel Speed Select Switch
7: Auto Accel Switch
8: Menu Switch
9: Attachment Mode Select Switch
10: Arrow Switch



1. After turning starter key switch ON, the main screen (a) is appeared.
2. When the display is main screen (a), change the attachment mode from "DIGGING MODE" to
"NIBBLER MODE" or "BREAKER MODE". The flow rate indication screen (b) appears.
3. When the display is flow rate indication screen (b), press "Menu Switch" to enter into "USER
MENU" display (c).
4. Move cursor to "OPTION SETTING", and press "NEXT" to enter into "OPTION SETTING" display
(e).
5. When the display is "OPTION SETTING" display (e), move cursor to desired flow rate. And press
the menu switch to set target flow rate.

If there is no switch operation for 20 seconds, this display returns to main display.

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(8) Maintenance screen displays

This screen displays the remaining time to the
end of recommended replacement/change
interval specified for filter/oil.

After turning starter key switch ON or starting

engine, Then, the display returns to "SERVICE
ADJUST 1-2" screen (c).
This display shows the recommended
replacement time of engine oil, time for next
engine oil change and date of previous engine
oil change.

For the initial set value of recommenced replacement/change time, see the following table.

Replacement interval
Item Default
Engine oil 500 Hr
Fuel filter 500 Hr
Hydraulic oil filter 1,000 Hr
Hydraulic oil 5,000 Hr

This menu is available for confirmation of the following items.

The maintenance screen changes each time the screen change switch is pressed.

1.
Remaining time display to the engine oil change
This display shows the remaining time of
"INTERVAL, REMAINING TIME, EXCHANGE
DAY".

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2.
Remaining time display to the coming fuel filter
replacement
This display shows the remaining time of
"INTERVAL, REMAINING TIME, EXCHANGE
DAY".

3.
Remaining time display to the coming hydraulic
oil filter replacement
This display shows the remaining time of
"INTERVAL, REMAINING TIME, EXCHANGE
DAY".

4.
Remaining time display to the coming hydraulic
oil change
This display shows the remaining time of
"INTERVAL, REMAINING TIME, EXCHANGE
DAY".

-For the setting procedure of maintenance time to be performed to the coming oil change in each
type and filter replacement, see the 21.2.6 SET PROCEDURE OF MAINTENANCE SCHEDULE. 

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(9) Consumption
1: Screen Change Switch
2: Buzzer Stop Switch
3: Work Mode Select Switch
4: Washer Switch
5: Wiper Switch
6: Travel Speed Select Switch
7: Auto Accel Switch
8: Menu Switch
9: Arrow Switch

1. Turn on the starter key switch "ON" and the main screen (a) is appeared. And press "Menu
Switch" (8) to enter into "USER MENU" display (b).
2. Using "UP" or "DOWN" arrow switch, move the cursor to "CONSUMPTION" as display (c), and
press "RIGHT" arrow switch. And "Fuel Efficiency Graph" display (d) appears.
3. The graph indicates the fuel consumption from 12 hours ago to now in a 2 hour intervals. And the
values of "Operating Time" "Fuel Consumption" and "Average Fuel Efficiency" are indicated.
4. To reset these values, press "Menu Switch" (8).
5. Press "Screen Change Switch" (1) and the display returns to main screen (a).

Use the indicated "Average Fuel Efficiency" for reference.

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(10) Gauge cluster display

After key is switched on and logo mark display disappears, screen for operator is displayed on multi
screen. The display functions of multi display are explained below.

1. Display function for operator:

Screen usually displayed during operation
1.1 Clock display function:
Current time is displayed.
1.2 Self-diagnosis display :
When abnormality is detected on mechatro system like sensor, proportional valve, etc., this displays
error code.
1.3 Warning display:
When machine was thrown into dangerous state, or was failed, displays warning contents with the
symbol and statement.



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Error codes were stored as trouble history, and displayed on the monitor by the trouble history display
function.

1.4 Machine condition display :

Displays machine operating condition.

2. Display function for maintenance:

Displays remaining time up to replacement/change of following items.
(1) Engine oil (2) Fuel filter (3) Hydraulic oil filter (4) Hydraulic oil

3. Failure history display function:

Stores abnormality occurred on mechatro system in the past and displays in order of recent occurrence.

4. Mechatro adjustment display:

Displays procedure for adjustment of mechatro system like output adjustment and unload adjustment,
etc.

5. Service diagnosis display :

Displays information like pressure sensor sensed value, proportional valve command, etc. output by
mechatro controller

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(11) Rearview camera

1) Setting of display picture of rearview camera
1: Buzzer Stop Switch
2: Menu Switch
3: Up Arrow Switch
4: Down Arrow Switch
5: Next Arrow Switch
6: Back Arrow Switch

1. Hold down buzzer stop switch (1) and turn starter switch ON. The service diagnosis screen (a) is 
displayed.
2. Hold down buzzer stop switch (1) and press menu switch (2) 3 times. "SERVICE MENU" screen
(b) is displayed.
3. Using "UP" switch (3) or "DOWN" switch (4), point the cursor to "SERVICE ADJUST 1" display
(b). Press "NEXT" switch (5), and SERVICE ADJUST 1-2 (c) is displayed.
4. Using "UP" switch (3) or "DOWN" switch (4), point the cursor to "CAMERA 1 SETTING" display
(c).
5. Press "NEXT" switch (5), and the cursor is pointed to "OFF" on display (d).
6. Press "UP" switch (3), and it points "ON" of display (e).
7. Press menu switch (2), and rearview camera is set.
8. After that screen returns to "SERVICE ADJUST 1-2" (c).
9. Turn off starter key switch.

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2) Troubleshooting
1. Gauge cluster is powered on but picture does not appear and it shows blue screen.

No. Parts Parts/Normal condition Corrective action

Make sure that connector between
Power-supply box to Cab
1 power-supply box and cab harness is Check connections.
harness
connected.
Make sure that connector between cable
2 Cable to Cab harness Check connections.
and cab harness is connected.
Make sure that connector between cable
3 Cable to Camera cable Check connections.
and camera cable should is connected.
Make sure that No. 30 fuse (5A) did not
4 Fuse & Relay box Replace fuse.
melt down.
Make sure that CAMERA 1 SETTING in
SERVICE ADJUSTMENT1-2 screen is ON,
5 Setting of camera Check the setting.
and CAMERA 2 and CAMERA 3
SETTING are OFF.

2. Gauge cluster is powered on but picture does not appear and it shows fuel consumption graph or
logo.

No. Parts Parts/Normal condition Corrective action

Make sure that CAMERA 1 SETTING in
SERVICE ADJUSTMENT1-2 screen is ON,
1 Setting of camera Check the setting.
and CAMERA 2 and CAMERA 3
SETTING are OFF.

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21.2.2 SELF DIAGNOSIS DISPLAY

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

(2) I/O configuration

(3) Self diagnosis display items

As-displayed clock (Usually main screen). When error occurred, specifies failed section and the failure
type with the aid of error code.



࡮ ECU failure code list

For detail of engine error code refer to "section 51 engine chapter".

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21.2.3 SERVICE DIAGNOSIS DISPLAY FUNCTION

The current service diagnosis is displayed on multi display based on the data received from mechatro
controller. This section explains the operating procedure and examples of each screen. The values in
display changes according to the conditions like engine speed, attachment position, etc.

(1) Service diagnosis display screen operating procedure

1. Turn starter switch ON keeping buzzer stop switch pressed.

Buzzer stop switch

2. After logo mark is displayed, the screen changes in service diagnosis mode.
The service diagnosis screen "Mode No.1", "Screen No.1" is displayed first.
The service diagnosis is classified into three modes, 1, 2, and 3, and the present mode is displayed in
"Screen No.1".
The screen number each mode can display differs. The screen number displayed by each mode is as
follows.

࡮ Mode No.1 : Screen No.1 to No.22

࡮ Mode No.2 : Screen No.1, Screen No.23 to No.27
࡮ Mode No.3 : Screen No.1, Screen No.27 to No.31

3. The screen changes each time each switch is pressed from now on.

Up arrow switch
Screen gains by 1 in order.
(No.2-->No.3-->No.4-->...)

Down arrow switch

Screen loses by 1 in order.
(No.24-->No.23-->No.22-->...)

Next arrow switch

Service diagnosis number advances from No.1
to No.3, and then returns to No.1.
(No.1 No.2 No.3 No.1 ...)

Back arrow switch

Service diagnosis number advances from No.3
to No.1, and then returns to No.3.
(No.3-->No.2-->No.1-->No.3-->...)

4. Turn key switch OFF and the display of service diagnosis mode is closed.

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(2) Service diagnosis display screen (Example)

The service diagnosis display screen list is shown below. The conditions for display are H mode,
engine low speed and lever to neutral position.)

1) Service diagnosis mode No.1



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2) Service diagnosis mode No.2

3) Service diagnosis mode No.3

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(3) Service diagnosis data list

Preface and precaution
The following is the data decided as normal status after service diagnosis for every operation. Use
these data to decide normal/abnormal status.

࡮ The values in following display are reference values with standard attachment attached machine.
࡮ The value of pressure sensor is calculated taking variation into accounts. When compared to
performance check reference criteria, measure it with the aid of calibrated measuring instrument.
࡮ The current of proportional valve is not the measured value, but command value. The measured
value should be confirmed by the value in the displayed value for each proportional valve.
࡮ The current value of pump proportional valve is reference value because it varies according to
pump pressure and adjusted torque value.
࡮ The value in display during operation shows the value in steady state, rather than, at start of
operation.
࡮ Check on machine after sufficiently warming up machine.
࡮ The value in display may differ according to software version. Contact our dealer/distributor.

Operation No.1: No operation Operation No.2: No operation

H mode Hi idle S mode Hi idle
No.24 ARM, SWING No.24 ARM, SWING
C-1 P1-PRES 0.2 to 2.0 M C-1 P1-PRES 0.2 to 2.0 M
C-2 P2-PRES 0.2 to 2.0 M C-2 P2-PRES 0.2 to 2.0 M
E-1 P1-PSV 350 mA E-1 P1-PSV 350 mA
E-2 P2-PSV 350 mA E-2 P2-PSV 350 mA
D-1 P1-UL(BPC) 750 mA D-1 P1-UL(BPC) 750 mA
D-2 P2-UL(BPC) 750 mA D-2 P2-UL(BPC) 750 mA 
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
D-6 ARM-IN-2 750 mA D-6 ARM-IN-2 750 mA
B-3 ARM OUT 0.0 M B-3 ARM OUT 0.0 M
B-4 ARM IN 0.0 M B-4 ARM IN 0.0 M
B-1 BOOM RAISE 0.0 M B-1 BOOM RAISE 0.0 M
B-7 SWING 0.0 M B-7 SWING 0.0 M
G-3 ENG SPEED 1970 to 2030 G-3 ENG SPEED 1870 to 1930
POWER SHIFT 0 mA POWER SHIFT 0 mA

Operation No.3: Operation No.4:

Boom up in full lever operation & relief Boom up in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.23 BOOM No.23 BOOM
C-1 P1-PRES 33.0 to 35.8 M C-1 P1-PRES 13.0 to 18.0 M
C-2 P2-PRES 33.0 to 35.8 M C-2 P2-PRES 13.0 to 18.0 M
E-1 P1-PSV 470 to 585 mA E-1 P1-PSV 630 to 770 mA
E-2 P2-PSV 470 to 585 mA E-2 P2-PSV 630 to 770 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 360 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
B-1 BOOM RAISE 3.0 M B-1 BOOM RAISE 3.0 M
B-2 BOOM LOWER 0.0 M B-2 BOOM LOWER 0.0 M
G-3 ENG SPEED 1970 to 2030 G-3 ENG SPEED 1970 to 2030
POWER SHIFT 0 mA POWER SHIFT 0 mA

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Operation No.5:
Boom down in full lever operation & in operation
H mode Hi idle
No.23 BOOM
C-1 P1-PRES 5.0 to 9.0 M
C-2 P2-PRES 0.2 to 2.0 M
E-1 P1-PSV 600 to 620 mA
E-2 P2-PSV 350 mA
D-1 P1-UL(BPC) 427 to 477 mA
D-2 P2-UL(BPC) 750 mA
B-1 BOOM RAISE 0.0 M
B-2 BOOM LOWER 3.0 M
G-3 ENG SPEED 1970 to 2030
POWER SHIFT 0 mA

Operation No.6: Operation No.7:

Arm-in in full lever operation & relief Arm-in in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.24 ARM, SWING No.24 ARM, SWING
C-1 P1-PRES 33.0 to 35.8 M C-1 P1-PRES 9.0 to 13.0 M
C-2 P2-PRES 33.0 to 35.8 M C-2 P2-PRES 9.0 to 13.0 M
E-1 P1-PSV 470 to 585 mA E-1 P1-PSV 750 to 770 mA
E-2 P2-PSV 470 to 585 mA E-2 P2-PSV 750 to 770 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 360 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
D-6 ARM-IN-2 200 mA D-6 ARM-IN-2 395 mA
B-3 ARM OUT 0.0 M B-3 ARM OUT 0.0 M
B-4 ARM IN 3.0 M B-4 ARM IN 3.0 M
B-1 BOOM RAISE 0.0 M B-1 BOOM RAISE 0.0 M
B-7 SWING 0.0 M B-7 SWING 0.0 M
G-3 ENG SPEED 1970 to 2030 G-3 ENG SPEED 1970 to 2030
POWER SHIFT 0 mA POWER SHIFT 0 mA

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Operation No.8: Operation No.9:

Arm-out in full lever operation & relief Arm-out in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.24 ARM, SWING No.24 ARM, SWING
C-1 P1-PRES 33.0 to 35.8 M C-1 P1-PRES 15.0 to 22.0 M
C-2 P2-PRES 33.0 to 35.8 M C-2 P2-PRES 15.0 to 22.0 M
E-1 P1-PSV 470 to 585 mA E-1 P1-PSV 570 to 680 mA
E-2 P2-PSV 470 to 585 mA E-2 P2-PSV 570 to 680 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 360 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
D-6 ARM-IN-2 750 mA D-6 ARM-IN-2 750 mA
B-3 ARM OUT 3.0 M B-3 ARM OUT 3.0 M
B-4 ARM IN 0.0 M B-4 ARM IN 0.0 M
B-1 BOOM RAISE 0.0 M B-1 BOOM RAISE 0.0 M
B-7 SWING 0.0 M B-7 SWING 0.0 M
G-3 ENG SPEED 1970 to 2030 G-3 ENG SPEED 1970 to 2030
POWER SHIFT 0 mA POWER SHIFT 0 mA

* Measure the values after a lapse of 5 minutes or after release of low temperature mode

Operation No.10: Operation No.11:

Swing in full lever operation & relief Swing in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.24 ARM, SWING No.24 ARM, SWING
C-1 P1-PRES 0.2 to 2.0 M C-1 P1-PRES 0.2 to 2.0 M
C-2 P2-PRES 28.0 to 35.8 M C-2 P2-PRES 10.0 to 15.0 M 
E-1 P1-PSV 350 mA E-1 P1-PSV 350 mA
E-2 P2-PSV 615 to 770 mA E-2 P2-PSV 770 mA
D-1 P1-UL(BPC) 750 mA D-1 P1-UL(BPC) 750 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
D-6 ARM-IN-2 750 mA D-6 ARM-IN-2 750 mA
B-3 ARM OUT 0.0 M B-3 ARM OUT 0.0 M
B-4 ARM IN 0.0 M B-4 ARM IN 0.0 M
B-1 BOOM RAISE 0.0 M B-1 BOOM RAISE 0.0 M
B-7 SWING 3.0 M B-7 SWING 3.0 M
G-3 ENG SPEED 1970 to 2030 G-3 ENG SPEED 1970 to 2030
POWER SHIFT 0 mA POWER SHIFT 0 mA

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Operation No.12: Operation No.13:

Bucket digging in full lever operation & relief Bucket digging in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.25 BUCKET No.25 BUCKET
C-1 P1-PRES 33.0 to 35.8 M C-1 P1-PRES 7.0 to 11.0 M
C-2 P2-PRES 33.0 to 35.8 M C-2 P2-PRES 7.0 to 11.0 M
E-1 P1-PSV 470 to 585 mA E-1 P1-PSV 670 to 770 mA
E-2 P2-PSV 470 to 585 mA E-2 P2-PSV 600 to 620 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 360 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 720 mA D-3 S-TRAVEL 720 mA
B-5 BUCKET DIG 3.0 M B-5 BUCKET DIG 3.0 M
B-6 BUCKET DUMP 0.0 M B-6 BUCKET DUMP 0.0 M
G-3 ENG SPEED 1970 to 2030 G-3 ENG SPEED 1970 to 2030
POWER SHIFT 0 mA POWER SHIFT 0 mA

Operation No.14: Operation No.15:

Bucket dump in full lever operation & relief Bucket dump in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.25 BUCKET No.25 BUCKET
C-1 P1-PRES 33.0 to 35.8 M C-1 P1-PRES 15.0 to 24.0 M
C-2 P2-PRES 33.0 to 35.8 M C-2 P2-PRES 15.0 to 24.0 M
E-1 P1-PSV 470 to 585 mA E-1 P1-PSV 550 to 770 mA
E-2 P2-PSV 470 to 585 mA E-2 P2-PSV 550 to 770 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 360 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 720 mA D-3 S-TRAVEL 720 mA
B-5 BUCKET DIG 0.0 M B-5 BUCKET DIG 0.0 M
B-6 BUCKET DUMP 3.0 M B-6 BUCKET DUMP 3.0 M
G-3 ENG SPEED 1970 to 2030 G-3 ENG SPEED 1970 to 2030
POWER SHIFT 0 mA POWER SHIFT 0 mA

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Operation No.16: Operation No.17:

P2 side option in full lever operation & relief P2 side option in full lever operation & relief
NIBBLER mode Hi idle BREAKER mode Hi idle
No.27 OPT No.27 OPT
C-1 P1-PRES 22.5 to 26.0 M C-1 P1-PRES 0.2 to 1.5 M
C-2 P2-PRES 22.5 to 26.0 M C-2 P2-PRES 22.5 to 26.0 M
E-1 P1-PSV 530 to 665 mA E-1 P1-PSV 350 mA
E-2 P2-PSV 530 to 665 mA E-2 P2-PSV 770 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 750 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 720 mA D-3 S-TRAVEL 350 mA
E-3 OPT RELIEF 0 mA E-3 OPT RELIEF 0 mA
B-16 P1 OPT 0.0 M B-16 P1 OPT 0.0 M
B-17 P2 OPT 2.0 to 2.6 M B-17 P2 OPT 2.0 to 2.6 M
F-4 OPT SELECT NIB F-4 OPT SELECT BRK
DOUBLE FLOW SW. --- DOUBLE FLOW SW. ---
G-3 ENG SPEED 1970 to 2030 G-3 ENG SPEED 1970 to 2030
POWER SHIFT 0 mA POWER SHIFT 0 mA

* Conflux switch is ON. Relief set pressure is * Conflux switch is OFF. Relief set pressure is
value of shipping. value of shipping.

Operation No.18: Operation No.19 :

Travel right in full lever operation & travel idling Travel left in full lever operation & travel idling
H mode Hi idle H mode Hi idle
No.26 TRAVEL No.26 TRAVEL
C-1 P1-PRES 7.0 to 13.0 M C-1 P1-PRES 0.2 to 1.5 M 
C-2 P2-PRES 0.2 to 2.0 M C-2 P2-PRES 7.0 to 13.0 M
E-1 P1-PSV 770 mA E-1 P1-PSV 350 mA
E-2 P2-PSV 350 mA E-2 P2-PSV 770 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 750 mA
D-2 P2-UL(BPC) 750 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
B-9 TRAVEL(R) 2.0 to 2.5 M B-9 TRAVEL(R) 0.0 M
B-10 TRAVEL(L) 0.0 M B-10 TRAVEL(L) 2.0 to 2.5 M
Pi-P1 0.0 M Pi-P1 0.0 M
Pi-P2 0.0 M Pi-P2 0.0 M
G-3 ENG SPEED 1970 to 2030 G-3 ENG SPEED 1970 to 2030
POWER SHIFT 0 mA POWER SHIFT 0 mA

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21.2.4 TROUBLE HISTORY DIAGNOSIS

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

(1) How to display

1. Turn the starter key switch ON while
pressing buzzer stop switch (1). The
service diagnosis screen (a) appears.
2. During pressing buzzer stop switch (1),
press menu switch (2) three times.
"TROUBLE HISTORY" appears on
SERVICE MENU screen (b).
3. Using "UP" arrow switch (3) or "DOWN"
arrow switch (4), move the cursor to
"TROUBLE HISTORY" in screen (b). Press
"NEXT" arrow switch (5) to display trouble
history screen (c).
4. Transmit the data of trouble history (one
or many) and hour meter to the gauge
cluster.
-The data of hour meter and 10 failures are
displayed on the screen.
-In case there are more than 10 failures
data, go to the next page to check the
next data.
5. Paging (up and down)
-Press "UP" arrow switch to move the item
up.
-Press "DOWN" arrow switch to move the
item down.
6. Turn the starter key switch OFF, and the
display is disappeared.

(2) How to delete contents of trouble history

1. Display trouble history screen.
2. Press work mode change switch and buzzer stop switch simultaneously for 5 seconds or more.
3. When "NO ERROR" is displayed, the deletion is completed.
4. Turn starter switch off.

All the stored items are erased. It is impossible to erase data partially.

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21.2.5 SET PROCEDURE OF MAINTENANCE SCHEDULE

This machine is equipped with multi-display
which makes confirmation of remaining time to
the coming replacement/change time of engine
oil, fuel filter, hydraulic oil filter and hydraulic
oil. When the remaining time reaches to Zero
(0), replace or change them and perform the
initial setting in the following order.

Interval of replacement of parts is mentioned below.

-Engine oil: 500 Hr
-Fuel filter: 500 Hr
-Hydraulic filter: 1,000 Hr
-Hydraulic oil: 5,000 Hr


1. The engine oil change time is displayed on the multi-display by 500 hours as a warning, but the
buzzer does not sound.
2. The fuel filter change time is displayed on the multi-display by 500 hours as a warning, but the
buzzer does not sound.
3. The hydraulic oil filter change time is displayed on the multi-display by 1000 hours as a warning,
but the buzzer does not sound.
4. The hydraulic oil change time is displayed on the multi-display by 5000 hours as a warning, but the
buzzer does not sound.

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21.2.6 ADJUSTING PROCEDURE OF DISPLAY

(1) For operator
1) Auto Idle Stop
1: Screen Change Switch
2: Buzzer Stop Switch
3: Work Mode Select Switch
4: Washer Switch
5: Wiper Switch
6: Travel Speed Select Switch
7: Auto Acceleration Switch
8: Menu Switch
9: Arrow Switch



1. After turning the starter key switch "ON", main screen (a) is appeared. And press "Menu Switch"
(8) to enter into "USER MENU" display (b).
2. Using "UP" or "DOWN" arrow switch, move the cursor to "SWITCH STATUS". Press "RIGHT"
arrow switch to enter into "SWITCH STATUS" display (d).
3. Using "UP" or "DOWN" arrow switch, move the cursor to "AUTO IDLE STOP" as display (e).
4. Press "RIGHT" arrow switch to enter into display (f), and the background color of "OFF" turns to
be blue.
5. Using "UP" or "DOWN" arrow switch, move the cursor from "OFF" to "ON".
6. Press "Menu Switch" (8) to set the status. At this time, the background color of "ON" turns to be
black.
7. Turn "OFF" the starter key switch once to store the status of "AUTO IDLE STOP".

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2) Clock Adjustment Switches

1: Screen Change Switch
2: Buzzer Stop Switch
3: Work Mode Select Switch
4: Washer Switch
5: Wiper Switch
6: Travel Speed Select Switch
7: Auto Accel Switch
8: Menu Switch
9: Arrow Switch

1. After turning the starter key switch "ON", main screen (a) is appeared. And press "MENU
SWITCH" (8) to enter into "USER MENU" display (b).
2. Using "UP" or "DOWN" arrow switch, move the cursor to "CLOCK SETTING" as display (c).
Press "RIGHT" arrow switch to enter into "CLOCK SETTING" display (d).
3. Using "UP" or "DOWN" arrow switch, select any of "YEAR/MONTH/DAY/HOUR/MINUTE" as display
(d).
4. Press "RIGHT" arrow switch to enter into display (e). The background color of "value" turns to be
blue.
5. Using "UP" or "DOWN" arrow switch, select the desired value.
6. After adjustment, press "Menu Switch" (8) to store the desired value as memory and at this time,
the background color of "value" turns to be black.
7. Press "Screen Change Switch" (1), and the display returns to main screen (a).

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3) Contrast Adjustment Switches

1: Screen Change Switch
2: Buzzer Stop Switch
3: Work Mode Select Switch
4: Washer Switch
5: Wiper Switch
6: Travel Speed Select Switch
7: Auto Accel Switch
8: Menu Switch
9: Arrow Switch



1. After turning the starter key switch "ON", main screen (a) is appeared. And press "Menu Switch"
(8) to enter into "USER MENU" display (b).
2. Using "UP" or "DOWN" arrow switch, move the cursor to "SCREEN SETTING" as display (c).
Press "RIGHT" arrow switch to enter into "SCREEN SETTING" display (d).
3. Using "UP" or "DOWN" arrow switch, move the cursor to "CONTRAST" as display (d).
4. Press "RIGHT" arrow switch to enter into display (e). The background color of "value" turns to be
blue.
5. Using "UP" or "DOWN" arrow switch, select the desired values.
The adjustable range is from 1 (Faint) to 10 (Clear).
* The default value is 5.
6. After adjustment, press "Menu Switch" (8) to store the desired value as memory and at this time,
the background color of "value" turns to be black.
7. Press "Screen Change Switch" (1), and the display returns to main screen (a).

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4) Brightness (Day) Adjustment

1: Screen Change Switch
2: Buzzer Stop Switch
3: Work Mode Select Switch
4: Washer Switch
5: Wiper Switch
6: Travel Speed Select Switch
7: Auto Acceleration Switch
8: Menu Switch
9: Arrow Switch

1. After turning the starter key switch "ON", the main screen (a) is appeared. And press "Menu
Switch" (8) to enter into "USER MENU" display (b).
2. Using "UP" or "DOWN" arrow switch, move the cursor to "SCREEN SETTING" as display (c).
Press "RIGHT" arrow switch to enter into "SCREEN SETTING" display (d).
3. Using "UP" or "DOWN" arrow switch, move the cursor to "Brightness (day)" as display (e).
4. Press "RIGHT" arrow switch and the display becomes as display (f). The background color of the
"value" turns to be blue.
5. Using "UP" or "DOWN" arrow switch, select the desired value.
The adjustable range is from 1 (Dark) to 100(Bright).
* The default value is 100.
6. After adjustment, press "Menu Switch" (8) to store the desired value as memory and at this time,
the background color of "value" turns to be black.
7. Press "Screen Change Switch" (1), and the display returns to main screen (a).

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5) Brightness (Night) Adjustment

1: Screen Change Switch
2: Buzzer Stop Switch
3: Work Mode Select Switch
4: Washer Switch
5: Wiper Switch
6: Travel Speed Select Switch
7: Auto Acceleration Switch
8: Menu Switch
9: Arrow Switch



1. After turning the starter key switch "ON", the main screen (a) is appeared. And press "Menu
Switch" (8) to enter into "USER MENU" display (b).
2. Using "UP" or "DOWN" arrow switch, move the cursor to "SCREEN SETTING" as display (c).
Press "RIGHT" arrow switch to enter into "SCREEN SETTING" display (d).
3. Using "UP" or "DOWN" arrow switch, move the cursor to "Brightness (night)" as display (e).
4. Press "RIGHT" arrow switch and the display becomes as display (f). The background color of the
"value" turns to be blue.
5. Using "UP" or "DOWN" arrow switch, select the desired values.
The adjustable range is from 1 (Dark) to 100 (Bright).
* The default value is 5.
6. After adjustment, press "Menu Switch" (8) to store the desired value as memory and at this time,
the background color of "value" turns to be black.
7. Press "Screen Change Switch" (1), and the display returns to main screen (a).

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(2) Function for service

Following items are provided for adjustment of service function.

Item CONTENTS
Language Language selection
Rise-up wiper Wiper control change (When cab is changed)
Idle stop ON/OFF of auto idle stop (ON/OFF of adjustment for user) and time adjust
P1 option pressure sensor ON/OFF of self diagnosis for P1 option pressure sensor
P2 option pressure sensor ON/OFF of self diagnosis for P2 option pressure sensor
Swing alarm ON/OFF of swing alarm (ON/OFF of adjustment for user)
Left pedal for rotation of Does left rotation pedal use?
option attachment (Unload valve does not actuate because P4 pump is equipped in EU.)
Setting of optional Optional flow rate limitation, relief pressure limitation, combination of return selector
equipment adjustment.
Engine speed ON/OFF of engine rpm display
Auto acceleration Adjustment the type of the engine speed of auto deceleration runs up abruptly.
Change of starter mode Change of start mode
Low temperature mode Low temperature mode release
forcible release
Pressure release For pressure release
Camera 1 setting ON/OFF of rearview camera 1 display
Camera 2 setting ON/OFF of rearview camera 2 display
Camera 3 setting ON/OFF of rearview camera 3 display
Fuel efficiency graph ON/OFF of fuel efficiency graph display
Logo setting ON/OFF of company logo display

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21.2.7 MECHATRO CONTROL EQUIPMENT

(1) C-1 Mechatro controller
1) Outside view

2) List of connectors



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(2) Gauge cluster (symbol C-2)

1) General view

2) Connector CN-600 (Harness side)

No. Item name Wire color No. Item name Wire color
1 Reserved - 5 Source (+24V) White
2 Reserved - 6 GND Black
3 Reserved - 7 Source (+24V) White
4 Reserved - 8 Reserved -

3) Connector CN-601 (Harness side)

No. Item name Wire color No. Item name Wire color
1 Reserved - 7 Reserved -
2 Reserved - 8 Reserved -
3 Reserved - 9 Reserved -
4 Rearview camera video signal White 10 GND Black
5 Reserved - 11 Reserved -
Mechatro-controller --> Gauge cluster -->
6 Gauge cluster (CAN Red 12 Mechatro-controller (CAN White
communication) communication)

4) Function
a. It processes signals by communication between the gauge cluster and the mechatro controller,
displays them in lamps, displays them in LCDs and actuates the buzzer.
b. It outputs coolant temperature signals, fuel level signals and panel switch signals to the mechatro
controller through the communication port.

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5) Summary of display and drive item

No. Item Remarks
1 Monitar display LCD dot 120X168
2 -
3 -
4 Buzzer Piezo-electricity type
5 Screen change switch
6 Buzzer stop switch
7 Work mode select switch
8 Digging mode switch
9 Nibbler mode switch
10 Breaker mode switch
11 Up arrow switch
12 Down arrow switch
13 Next arrow switch
14 Back arrow switch
15 Back light LED



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(3) Relay & fuse box (symbol E-1)

1) General view

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2) Circuit diagram



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(4) High pressure sensor: LS52S00015P1

(5) Low pressure sensor: LC52S00019P1

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 㨇22. HYDRAULIC SYSTEM㨉

22. HYDRAULIC SYSTEM

TABLE OF CONTENTS

22.1 SUMMARY äääääääääääääääääääääääääääääääääääääää22-3

22.2 HYDRAULIC CIRCUITS AND COMPONENTS äääääääääääääääääääääää22-4
22.3 COLOR CODING STANDARD FOR HYDRAULIC CIRCUITS ääääääääääääääää22-6
22.4 NEUTRAL CIRCUIT äääääääääääääääääääääääääääääääääää22-6
22.5 TRAVEL CIRCUIT ääääääääääääääääääääääääääääääääääää22-8
22.6 BUCKET CIRCUIT ääääääääääääääääääääääääääääääääääää22-10
22.7 BOOM CIRCUIT äääääääääääääääääääääääääääääääääääää22-12
22.8 SWING CIRCUIT ääääääääääääääääääääääääääääääääääää22-16
22.9 ARM CIRCUIT äääääääääääääääääääääääääääääääääääää22-18
22.10 COMBINED CIRCUIT ääääääääääääääääääääääääääääääääää22-24
22.11 PRESSURE DRAINING äääääääääääääääääääääääääääääääää22-28



Book Code No. 6/&(

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Issue Date of Issue Applicable Machines Remarks

S5LC2233E01
First Edition July, 2014 SK350LC-9E : YC13-13001~
(NA)

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22.1 SUMMARY

22.1.1 FUNCTION AND FEATURES OF HYDRAULIC CIRCUIT

The hydraulic circuits are built up with the following functions and features in order to achieve easy
operability, safety, mass volume handling and low fuel consumption.



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22.2 HYDRAULIC CIRCUITS AND COMPONENTS

STD. SCHEMATIC HYD. LINES LC01Z00099P1

Item Component name Part No. Model No.
1 Hyd. pump assy LC10V00029F4 K5V140DTP (without PTO.)
2 Control valve (main) LC30V00039F2 KMX15YE
3 Swing motor unit LC15V00022F2 M5X180-CHB
4 Travel motor unit LC15V00023F2 M4V290/170F-RG6.5F
5 Boom cylinder (RH & LH) LC01V00044F1 100 dia. X 140 dia. X 1550
6 Arm cylinder LC01V00054F1 120 dia. X 170 dia. X 1788
7 Bucket cylinder LC01V00055F4 100 dia. X 150 dia. X 1193
8 Swivel joint YN55V00053F1
9 Pilot valve (ATT) LQ30V00033F2 PV48K2075
10 Pilot valve (travel) YN30V00105F2 6TH6 NRZ
11 Inline filter YN50V00020F1 Y-457400
12 Suction strainer LC50V00006F2 SB281J0A023A
13 Solenoid valve assy YN35V00047F3 8KWE5A-30
14 Return filter LC52V01002F3 FZ1F183S040A
15 Air breather YN57V00010F1
16 Restrictor YN21V00005F4 07745-00000
Multi control valve (lever less) YF30V00020F1 STD
17
Multi control valve (with lever) YF30V00013F2 OPT.

The part numbers may be changed due to modification, so use only the numbers for references.

22-4
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
 [22. HYDRAULIC SYSTEM]

22.2.1 STANDARD

SE22 SE23 P MB MB P
a1 P P
MAIN PUMP PSV1 A1 A2 a2 PSV2
PH1 PH2

PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8 35.8~37.8 SWING
MPa VB VB MPa 3
PG
VA VA

REG REG

1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT

a3
8
a4
Dr

5.0MPa
M A B
a5
203kw B1
/2100min-1 B3 Dr3 A3

11 2
MAIN CONTROL VALVE P2 P1 T1 T2
SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
ARM OUT
15 CMR1
CT1 ARM IN
PL
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
14 BL P P P P P P
12 CT2 CP2
BOOM T3 BHL MULTI 1 2 3 4 5 6 7 8
TRAVEL RIGHT P2UNLOAD CONFLUX
PAr PB1

BR CP1
AR PCa
HYD.TANK NOTES 1 1 2 3 4 5 6 7 8
PBr CCb
PAs 17
Dr SE5 NOTE 1
BOOM LCb LCs Pss
SWING P
PBb PBs

As
37.8MPa Bs
(ROD)Bb PAa1
9
CRb
LCa RH LH
(HEAD)Ab
ARM 1
SOL/V BLOCK PBa1
PAb BUCKET 22
P1 LEVER CYLINDER
A1 LOCK XAb 39.7MPa 37.8MPa
SV-4
BUCKET LCc Aa (HEAD)
PCc 7 P T P T
SWING PBc BOOM ARM
A2 P/B & BUCKET & SWING
SV-1 37.8MPa ARM
CRar CYLINDER
(ROD)Bc PLc2 6
TRAVEL
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2 OPTION
LCo 5 10
PAo
BOOM
A5 P2UNLOAD CYLINDER 3 6 4 1 5 2
PSV-B
16 Ao RIGHT TRAVEL FORWARD
Bo P SE9 P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL LEFT TRAVEL REVERSE
A6 PRIORITY
PSV-C

A7 P1UNLOAD
PSV-D (P3) (P4)

A8 ARM2
PSV-A 16

T2 P2
LC01Z00099P1 01
13

22-5
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
[22. HYDRAULIC SYSTEM]

22.3 COLOR CODING STANDARD 22.4 NEUTRAL CIRCUIT 22.4.3 PUMP POSITIVE FLOW CONTROL 22.4.4 PUMP P-Q CURVE CONTROL
FOR HYDRAULIC CIRCUITS (1) Type: OPERATION
This section describes the following. Electric flow controlled variable displacement (1) Type:
pump. Electrical flow control type variable pump
(1) Bypass cut valve and unload valve control (2) Principle: (2) Principle:
Blue (2) Safety lock lever and pilot circuit The current command I to the pump's solenoid Perform an operation of the value from pump high
Feed, drain circuit (3) Pump positive flow control proportional valve controls the delivery rate of the pressure sensor to P-Q curve control value, and
(4) Pump P-Q (Pressure-Quantity) curve control pump. send a command to the pump solenoid proportional
less than 0.44 MPa (64 psi)
(3) Operation: valve.
Green
1. Flow rate rise operation (Eg. P1 pump) (3) Operation:
Return, make up circuit, 22.4.1 OPERATION OF UNLOADING By operating any of control levers, the operating The pump high pressure sensor converts the
0.44~0.59 MPa (64~86 psi) VALVE AND BY-PASS CUT VALVE secondary pressure of pilot valve rises, and the pressure to the output voltage corresponding to the
HOUSED IN CONTROL VALVE rising pressure is transformed to the rise of output pump delivery pressure.
Purple
voltage corresponding to the pressure input by the The mechatro controller converts the voltage output
Secondary pilot pressure, (1) Unloading valve
low pressure sensor. Mechatro controller signal- by the high pressure sensor to the P-Q curve
On starting engine, like by-pass cut valve, the
(including proportional vlave) processes this change of voltage, resulting in rise control value. On the other hand, select the pump
secondary pressures output by P1 and P2
0.59~5 MPa (86~725 psi) of command current value I to the pump positive control command current value from the
unloading proportional valves (PSV-D, PSV-B)
proportional solenoid valve and consequently the low pressure sensor in lower order, and the values
Red exert on PCb and PCa ports, consequently the P1
pump flow rate rises. This is called "Positive are output to respective pump proportional valve as
Primary pilot pressure, and P2 unloading valves are switched to OPEN
Control System". a command current.
side.
(including proportional vlave) As the pump command current value rises, the With this operation, the pump power is controlled
(2) By-pass cut valve
secondary pressure of proportional solenoid valve so as not to be exceed the engine power, therefore
5 MPa (725 psi) When machine is under normal conditions, by-pass
also rises. On the regulator attached on the pump, engine dose not stall.
Orange cut valve is closed normally. If pilot pressure sensor
the spool (652) through piston (643) is pushed
or unloading proportional valve is disconnected or
Main pump drive pressure, leftward, and stops at the position where being in
malfunctioned, the unloading valve closes
5~34.3 MPa (725~4970 psi) proportion to the force of pilot spring (646).
completely. Even if control valve is in neutral
The tank port connected to the large bore of servo
Blue tone position, hydraulic oil is trapped. As a result, the
piston (532) opens, and the piston moves leftward
pump relieves due to pressure increase.
At valve operation by delivery pressure P1 of the small bore resulting
In such the case, before the machine is repaired,
Red valve in the increase of tilt angle (Į).
open the by-pass cut valve manually. And the
The servo piston and spool (652) are connected to
When solenoid proportional valve (reducing) is machine is operable by draining excess oil to
operating feedback lever (611). Therefore when servo piston
hydraulic tank.
moves leftward, the spool (652) also moves
Red solenoid
rightward by means of feedback lever. With this
In active and exciting movement, the opening of spool sleeve closes
Displaying the flow circuit and standby circuit when
22.4.2 SAFETY LOCK LEVER AND PILOT gradually, and the servo piston stops at the position
operating. CIRCUIT the opening closed completely.
Regarding the electrical symbols in this manual, refer (1) Purpose: 2. Flow rate reduction operation
to the electric circuit diagram. To protect attachment from unexpected movement As the current value I of mechtro controller
for safety. reduces, the secondary pressure of solenoid
(2) Principle: proportional valve reduces, and spool (652) is
Cut pressure source of pilot valve for operation. moved rightward by the force of pilot spring (646).
(3) Operation: With the movement of spool, the delivery pressure
If the safety lock lever (red) is pushed forward after P1 usually flows into the large bore of piston
the engine starts, the limit switch (SW-11) is turned through the spool.
on. The timer relay is actuated one second later The delivery pressure P1 flows in the small bore of
which causes the solenoid (SV-4) of the solenoid servo piston, but the servo piston moves rightward
valve block (13) to be energized and makes the due to the difference of area, resulting in the
pilot operating circuit to stand by. reduction of tilt angle. Similarly, when the servo
piston moves rightward, the spool (652) is moved
leftward by the feedback lever.
The operation is maintained until the opening of
spool sleeve is closed.

22-6
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
 [22. HYDRAULIC SYSTEM]

SE22 SE23 P MB MB P
a1 P P
MAIN PUMP PSV1 A1 A2 a2 PSV2
PH1 PH2

PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8 35.8~37.8 SWING
MPa VB VB MPa 3
PG
VA VA DB

REG REG
651
652 M

1 29.0MPa
611 D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT

643 532 8
a3 646 a4
Dr

5.0MPa
M A B
a5
203kw B1
/2100min-1 B3 Dr3 A3

11 2
MAIN CONTROL VALVE P2 P1 T1 T2
SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
ARM OUT
CMR1
CT1 ARM IN
PL
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
14 BL P P P P P P
12 CT2 CP2
BOOM T3 BHL MULTI 1 2 3 4 5 6 7 8
TRAVEL RIGHT P2UNLOAD CONFLUX
PAr PB1

BR CP1
AR PCa
HYD.TANK NOTES 1 1 2 3 4 5 6 7 8
PBr CCb
PAs 17
Dr SE5 NOTE 1
BOOM LCb LCs Pss
SWING P
PBb PBs

As
37.8MPa Bs
(ROD)Bb PAa1
9
CRb
LCa RH LH
(HEAD)Ab
ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER 22
A1 LOCK XAb 39.7MPa 37.8MPa
SV-4
BUCKET LCc Aa (HEAD)
PCc 7 P T P T
SWING PBc BOOM ARM
A2 P/B & BUCKET & SWING
SV-1 37.8MPa ARM
CRar CYLINDER
(ROD)Bc PLc2 6
TRAVEL
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2 OPTION
LCo 5 10
PAo
BOOM
A5 P2UNLOAD CYLINDER 3 6 4 1 5 2
16 Ao RIGHT TRAVEL FORWARD (OCEANIA)
PSV-B Bo P SE9 P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL LEFT TRAVEL REVERSE
A6 PRIORITY
PSV-C

A7 P1UNLOAD
PSV-D (P3) (P4)

A8 ARM2
PSV-A 16

T2 P2
LC01Z00099P1 01
13
NEUTRAL CIRCUIT : Positive control function at safety lock lever down (unlocked position)

22-7
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
[22. HYDRAULIC SYSTEM]

22.5 TRAVEL CIRCUIT 22.5.2 2-SPEED TRAVEL SOLENOID

COMMAND CIRCUIT AND AUTO
This section describes the following.
1st SPEED RETURN FUNCTION
(1) Purpose:
(1) Travel forward pilot simultaneous operation circuit Change travel motor speed with switch.
(2) 2 speed travel solenoid command circuit and auto (2) Principle:
1-speed return function If the switch is turned, an electric signal is issued. It
(3) Travel main circuit excites the 2-speed travel solenoid which in turn
(4) Travel motor function converts the primary pilot pressure and the self
pressure to a tilting angle of the variable
displacement motor.
22.5.1 TRAVEL FORWARD PILOT (3) Operation:
SIMULTANEOUS OPERATION If the rabbit marked switch on the gauge cluster is
CIRCUIT pressed, the solenoid (SV-3) of the proportional
valve block (13) is excited and changes the
(1) Purpose:
proportional valve. Then the solenoid command
Light operating force and shockless operation
pressure is issued from port A3, enters the P port of
(2) Mechatronics:
the travel motor (4), opens the oil passage to the
1. If the travel lever with damping mechanism is
2nd speed select piston, and causes the motor to
operated for travel right, left and forward motions,
run in the 2nd speed tilting mode by its self
the secondary pilot proportional pressure comes
pressure. However, when the main circuit pressure
out of the 3, 1 ports of P/V (10). The higher of the
rises above 28 MPa (4060 psi), the motor's self
pressures is selected, comes out of the 6, 5 ports
pressure pushes the 2nd speed select piston back
and acts upon the low pressure sensors (SE9) (SE-
to the 1st speed.
10).
2. The pilot secondary pressure flows to PAr and PAL
ports of the control valve (2), moves the travel
spool, and switches the main circuit. 22.5.3 TRAVEL MAIN CIRCUIT
3. The low pressure sensor output voltage is input into (1) Operation:
mechatro controller. The mechatro controller The delivery oil from Pump A1 and A2 ports by
performs signal processing and outputs current changing the travel spool with the operation of
corresponding to the increase of flow rate to P1 travel pilot flows in each VA port on the left side of
pump proportional valve (PSV-P1) and P2 pump travel motor (4) through C,D ports of swivel joint (8)
proportional valve (PSV-P2), and at the same time from AL, AR ports of C/V, and rotates the travel
the command current is output to P1 unloading motor.
valve (PSV-D) and P2 unloading valve (PSV-B).
4. The secondary pressures output by P1 pump
proportional valve (PSV-P1) and P2 pump 22.5.4 TRAVEL MOTOR FUNCTION
proportional valve (PSV-P2) exert on pump
(1) Function:
regulator, actuating the pump on the delivery flow
1. Prevents the motor from over running on a slope.
rate increase side.
2. Check valve that prevents cavitation of the
5. The secondary pressure delivered in P1 unloading
hydraulic motor.
valve (PSV-D) and P2 unloading valve (PSV-B) is
3. Shockless relief valve and anti cavitation valve
fed to Pcb and PCa ports provided in control valve
when inertia force stops.
(2).
4. High/Low 2 step speed change mechanism and
The secondary pressure from proportional valve
auto 1st speed return at high load.
which has exerted on PCb and PCa ports switches
5. Travel parking brake.
the unloading spool in CLOSE side.

22-8
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
 [22. HYDRAULIC SYSTEM]

SE22 SE23 P MB MB P
a1 P P
MAIN PUMP PSV1 A1 A2 a2 PSV2
PH1 PH2

PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8 35.8~37.8 SWING
MPa VB VB MPa 3
PG
VA VA DB

REG REG

1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT

a3
8
a4
Dr

5.0MPa
M A B
a5
203kw B1
/2100min-1 B3 Dr3 A3

11 2
MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
ARM OUT
CMR1
CT1 ARM IN
PL
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
14 BL P P P P P P
12 CT2 CP2
BOOM T3 BHL MULTI 1 2 3 4 5 6 7 8
TRAVEL RIGHT P2UNLOAD CONFLUX
PAr PB1

BR CP1
AR PCa
HYD.TANK NOTES 1 1 2 3 4 5 6 7 8
PBr CCb
PAs 17
Dr SE5 NOTE 1
BOOM LCb LCs Pss
SWING P
PBb PBs

As
37.8MPa Bs
(ROD)Bb PAa1
9
CRb
LCa RH LH
(HEAD)Ab
ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER 22
A1 LOCK XAb 39.7MPa 37.8MPa
SV-4
BUCKET LCc Aa (HEAD)
PCc 7 P T P T
SWING PBc BOOM ARM
A2 P/B & BUCKET & SWING
SV-1 37.8MPa ARM
CRar CYLINDER
(ROD)Bc PLc2 6
TRAVEL
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2 OPTION
LCo 5 10
PAo
BOOM
A5 P2UNLOAD CYLINDER 3 6 4 1 5 2
PSV-B
16 Ao RIGHT TRAVEL FORWARD
Bo P SE9 P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL LEFT TRAVEL REVERSE
A6 PRIORITY
PSV-C

A7 P1UNLOAD
PSV-D (P3) (P4)

A8 ARM2
PSV-A 16

T2 P2
LC01Z00099P1 01
13
TRAVEL CIRCUIT : Travel 2nd speed, RH & LH simultaneous operation.

22-9
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
[22. HYDRAULIC SYSTEM]

22.6 BUCKET CIRCUIT 22.6.2 AUTO ACCELERATION side is throttled by bucket spool and returns to tank
OPERATION circuit from BC port of C/V (2).
References:
This section describes the following. (1) Principle:
• In bucket dumping operation, the travel straight
Auto acceleration actuates according to signals
valve also switches like digging operation, resulting
(1) Bucket digging pilot circuit from low pressure sensor.
in confluence with travel straight.
(2) Auto accel operation (2) Operation:
• When the bucket operation and other operation are
(3) Flow control in the work mode <When lever is set to neutral position>
simultaneously performed, the travel straight valve
(4) Bucket digging travel straight main circuit In the event where the sensor does not receive
does not actuate, resulting in single flow of bucket
(5) Bucket spool stroke limiter signal for 4 seconds or more even though the
circuit.
acceleration dial is set to MAX position, the engine
speed should be raised to 1000 rpm.
22.6.1 PILOT CIRCUIT FOR BUCKET <When lever is operated>
When the pressure 0.6 MPa (87 psi) is input to low 22.6.5 BUCKET SPOOL STROKE
DIGGING
pressure sensor in STD specification (travel, LIMITER
(1) Mechatronics:
bucket, swing, arm), proportional voltage from low (1) Purpose :
1. When the operation for bucket digging is
pressure sensor inputs in mechatro controller, and To secure simultaneous operability of boom and
performed, the pilot proportional secondary
then the engine speed returns to the dial set arm on boosting up attachment pressure (Pump
pressure is delivered through port 1 of the right pilot
position corresponding to the lever operation. flow rate decreases.) and to prevent cavitations at
V (9), flows to PAc port, and acts on the low
low engine speed
pressure sensor (SE-1), and at the same time the
(2) Operation:
bucket spool is switched.
22.6.3 STAND-BY CURRENT CONSTANT On boosting up attachment pressure, pilot primary
2. The voltage output by low pressure sensor inputs in
CONTROL pressure exerts on PCc port of C/V(2) through
mechatro controller. The mechatro controller
attachment booster solenoid valve, operates stroke
performs signal processing and outputs current (1) Principle:
limiter of bucket spool, and throttle oil path of spool.
corresponding to the increase of pump flow rate to When the engine speed is intermediate speed or
As a result, P1 pump pressure increases, making
pump proportional valves (PSV-P1) and (PSV-P2) lower, command current value to have the pump
the simultaneous operation of boom up and bucket
on the P1 and P2 pump sides, and at the same delivery rate constant is output.
digging possible.
time the command current is output to P1 unloading (2) Operation:
Even though the engine speed is low, similarly the
valve (PSV-D), P2 unloading valve (PSV-B) and Even if the engine speed specified by acceleration
cavitations can be prevented by actuating the
travel straight proportional valve (PSV-C). potentiometer is low speed, as the delivery rate
stroke limiter.
In the following pages, the relation of operation of corresponds to the intermediate speed, the
low pressure sensor to both the increase of pump actuator moves earlier than the movement
flow rate and unloading proportional valve is the equivalent to the control lever angle rate in light
same. Therefore the explanation is omitted. load operation.
3. The secondary pressure output by P1 pump
proportional valve (PSV-P1) and P2 pump
proportional valve (PSV-P2) exerts on pump 22.6.4 BUCKET DIGGING AND TRAVEL
regulator, actuating the pump onto the delivery flow STRAIGHT CONFLUENCE
increase side. (CONFLUX) MAIN CIRCUIT
4. The secondary pressure delivered in P1 unloading
(1) Operation:
valve (PSV-D) and P2 unloading valve (PSV-B) is
1. The oil delivered through A1 port of P1 pump goes
led to PCb and PCa ports provided in control valve
into P1 port of C/V (2), opens load check valve LCc
(2).
through parallel circuit and enters in bucket spool.
The secondary pressure from proportional valve
2. On the other hand, the oil delivered through P2 port
which has exerted on PCb and PCa ports switches
of P2 pump goes into P2 port of C/V (2),
the unloading spool in CLOSE side.
confluences with oil from P1 pump through travel
5. The secondary pressure delivered in travel straight
straight valve, and goes into bucket spool.
proportional valve (PSV-C) is led to PTb port
(Confluence of oil from 2 pumps)
provided in control valve (2) and shifts the travel
3. With the function of pilot circuit, the oil flow is
straight valve.
switched from bucket spool, and is fed into bucket
cylinder head side through AC port of C/V (2). On
the other hand, the return oil from cylinder rod (R)

22-10
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
 [22. HYDRAULIC SYSTEM]

SE22 SE23 P MB MB P
a1 P P
MAIN PUMP PSV1 A1 A2 a2 PSV2
PH1 PH2

PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8 35.8~37.8 SWING
MPa VB VB MPa 3
PG
VA VA DB

REG REG

1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT

a3
8
a4
Dr

5.0MPa
M A B
a5
203kw B1
/2100min-1 B3 Dr3 A3

11 2
MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
ARM OUT
CMR1
CT1 ARM IN
PL
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
14 BL P P P P P P
12 CT2 CP2
BOOM T3 BHL MULTI 1 2 3 4 5 6 7 8
TRAVEL RIGHT P2UNLOAD CONFLUX
PAr PB1

BR CP1
AR PCa
HYD.TANK NOTES 1 1 2 3 4 5 6 7 8
PBr CCb
PAs 17
Dr SE5 NOTE 1
BOOM LCb LCs Pss
SWING P
PBb PBs

As
37.8MPa Bs
(ROD)Bb PAa1
9
CRb
LCa RH LH
(HEAD)Ab
ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER 22
A1 LOCK B XAb 39.7MPa 37.8MPa
SV-4
BUCKET LCc Aa (HEAD)
PCc 7 P T P T
SWING PBc BOOM ARM
A2 P/B & BUCKET & SWING
SV-1 37.8MPa ARM
CRar CYLINDER
(ROD)Bc PLc2 6
TRAVEL
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2 OPTION
LCo 5 10
PAo
BOOM
A5 P2UNLOAD CYLINDER 3 6 4 1 5 2
PSV-B
16 Ao RIGHT TRAVEL FORWARD
Bo P SE9 P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL LEFT TRAVEL REVERSE
A6 PRIORITY
PSV-C

A7 P1UNLOAD
PSV-D (P3) (P4)

A8 ARM2
PSV-A 16

T2 P2
LC01Z00099P1 01
13
BUCKET CIRCUIT : Bucket digging (Travel straight conflux), Auto-accelation and Standby flow rate constant control

22-11
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
[22. HYDRAULIC SYSTEM]

22.7 BOOM CIRCUIT

(1) Boom up pilot circuit

(2) Boom up 2 pumps conflux main circuit in C/V

22.7.1 BOOM RAISE PILOT CIRCUIT

(1) Operation:
1. If boom up operation is performed, the secondary
pilot proportional pressure from the right pilot valve
(10) gets out of port 3 and acts upon the low
pressure sensor (SE3). At the same time, the
pressure acts upon the PAb and PB1 ports.
2. The secondary pressure which enters the PAb port
of C/V (2) shifts the boom spool. The secondary
pressure which enters the PB1 port shifts the boom
conflux spool.

22.7.2 BOOM UP 2 PUMPS CONFLUX

MAIN CIRCUIT IN C/V
(1) Purpose:
Boom up speed up
(2) Principle:
Confluxing oil from 2 pumps
(3) Operation:
1. The oil delivered through A1 port of P1 pump flows
into C/V (2) P1 port, and branches into bypass
circuit and parallel circuit. Since P1 unloading valve
is closed, the boom spool is moved and bypass
circuit is closed, the oil opens load check valve LCb
through parallel circuit and flows into boom spool.
2. Then the oil passes through boom spool, opens
lock valve of boom lock valve CRb, and is led into H
side of boom cylinder through C/V (2) Ab port.
3. Meanwhile, the oil delivered from the A2 port of the
P2 pump enters the P2 port of C/V (2) and due to
shut off the P2 unloading valve, the oil then passes
through the parallel circuit and via the restrictor on
the circumference of the boom conflux spool,
pushes the load check valve CCb open from the
boom conflux circuit, and combines the oil
delivered by the P1 pump internally.
4. The return oil from boom cylinder R side flows into
tank circuit through boom spool from C/V (2) Bb
port.

22-12
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
 [22. HYDRAULIC SYSTEM]

SE22 SE23 P MB MB P
a1 P P
MAIN PUMP PSV1 A1 A2 a2 PSV2
PH1 PH2

PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8 35.8~37.8 SWING
MPa VB VB MPa 3
PG
VA VA DB

REG REG

1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT

a3
8
a4
Dr

5.0MPa
M A B
a5
203kw B1
/2100min-1 B3 Dr3 A3

11 2
MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
ARM OUT
CMR1
CT1 ARM IN
PL
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
14 BL P P P P P P
12 CT2 CP2
BOOM T3 BHL MULTI 1 2 3 4 5 6 7 8
TRAVEL RIGHT P2UNLOAD CONFLUX
PAr PB1

BR CP1
AR PCa
HYD.TANK NOTES 1 1 2 3 4 5 6 7 8
PBr CCb
PAs 17
Dr SE5 NOTE 1
BOOM LCb LCs Pss
SWING P
PBb PBs

As
37.8MPa Bs
(ROD)Bb PAa1
9
LCa RH LH
(HEAD)Ab CRb
ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 LEVER CYLINDER
A1 LOCK XAb 39.7MPa 37.8MPa
22
SV-4
BUCKET LCc Aa (HEAD)
PCc 7 P T P T
SWING PBc BOOM ARM
A2 P/B & BUCKET & SWING
SV-1 37.8MPa ARM
CRar CYLINDER
(ROD)Bc PLc2 6
TRAVEL
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2 OPTION
LCo 5 10
PAo
BOOM
A5 P2UNLOAD CYLINDER 3 6 4 1 5 2
PSV-B
16 Ao RIGHT TRAVEL FORWARD
Bo P SE9 P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL LEFT TRAVEL REVERSE
A6 PRIORITY
PSV-C

A7 P1UNLOAD
PSV-D (P3) (P4)

A8 ARM2
PSV-A 16

T2 P2
LC01Z00099P1 01
13
BOOM CIRCUIT : Boom up operation, Confluence function.

22-13
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
[22. HYDRAULIC SYSTEM]

22.7.5 CONSTANT RECIRCULATION

This section describes boom lower operation. FUNCTION OF BOOM DOWN MAIN
CIRCUIT
(1) Boom down pilot circuit
(2) Prevention of natural fall by lock valve and (1) Purpose:
actuation at lowering Prevention of cavitation during boom lowering
(3) Constant recirculation function of boom down main motion.
circuit (2) Principle:
The oil returning from the boom cylinder head (H) is
recirculated to the rod (R).
(3) Operation:
22.7.3 BOOM DOWN PILOT CIRCUIT
When the oil is supplied to the boom cylinder rod
(1) Operation: (R) side during boom down operation, the boom
1. If the boom down operation is performed, the moves faster than it should do in some cases by
secondary pilot proportional pressure comes out of the self weight of the attachment.
portaC of the right pilot valve (9) and acts upon the On that occasion, the circuit pressure on the rod
low pressure sensor (SE-4). (R) side is on the negative side.
At the same time, the pressure acts upon the PBb The oil supplied to the boom cylinder rod (R) flows
port of C/V (2). into the A1 port of the P1 pump and the P1 port of
2. The voltage output of the low pressure sensor (SE- C/V. The oil then passes through the boom spool
4) enters the mechatro controller and processed in and goes out of the Bb port.
it. On that occasion, the oil returning from the head
3. Then, the proportionl secondary pressure fed into (H) goes through the recirculation path in the boom
C/V (2) PBb port and branches off in two lines and spool, pushes the check valve in the spool open, is
switches boom spool and releases boom lock recirculated to the Bb port and is supplied to the rod
valve. (R). When the (R) pressure is larger than the head
(H) pressure, the check valve in spool closes.
Thereupon, the recirculation is stopped.
22.7.4 PREVENTION OF NATURAL FALL
BY LOCK VALVE AND ACTUATION
AT LOWERING
(1) Purpose:
Prevention of natural fall when the lever is neutral.
(2) Principle:
The oil is prevented from returning to the boom
spool by the poppet seat of the boom lock valve.
(3) Operation:
In the boom down action, the selector valve is
changed over by the secondary proportional
pressure of PBb port. Then the poppet spring
chamber of the lock valve CRb gets through the
drain line (Dr) and makes the lock valve poppet
open.
When the boom lever is at neutral, the drain line on
the lock valve CRb poppet spring chamber is
closed which causes the poppet closed.
The result is that the oil returning from the boom
cylinder head (H) to the boom spool is held and
makes the leak from the boom spool zero.
Thus the boom cylinder is prevented from making a
natural fall.

22-14
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
 [22. HYDRAULIC SYSTEM]

SE22 SE23 P MB MB P
a1 P P
MAIN PUMP PSV1 A1 A2 a2 PSV2
PH1 PH2

PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8 35.8~37.8 SWING
MPa VB VB MPa 3
PG
VA VA DB

REG REG

1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT

a3
8
a4
Dr

5.0MPa
M A B
a5
203kw B1
/2100min-1 B3 Dr3 A3

11 2
MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
ARM OUT
CMR1
CT1 ARM IN
PL
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
14 BL P P P P P P
12 CT2 CP2
BOOM T3 BHL MULTI 1 2 3 4 5 6 7 8
TRAVEL RIGHT P2UNLOAD CONFLUX
PAr PB1

BR CP1
AR PCa
HYD.TANK NOTES 1 1 2 3 4 5 6 7 8
PBr CCb
PAs 17
Dr SE5 NOTE 1
BOOM LCb LCs Pss
SWING P
PBb PBs

As
37.8MPa Bs
(ROD)Bb PAa1
9
CRb
LCa RH LH
(HEAD)Ab
ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 LEVER CYLINDER
A1 LOCK XAb 39.7MPa 37.8MPa
22
SV-4
BUCKET LCc Aa (HEAD)
PCc 7 P T P T
SWING PBc BOOM ARM
A2 P/B & BUCKET & SWING
SV-1 37.8MPa ARM
CRar CYLINDER
(ROD)Bc PLc2 6
TRAVEL
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2 OPTION
LCo 5 10
PAo
BOOM
A5 P2UNLOAD CYLINDER 3 6 4 1 5 2
PSV-B
16 Ao RIGHT TRAVEL FORWARD
Bo P SE9 P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL LEFT TRAVEL REVERSE
A6 PRIORITY
PSV-C

A7 P1UNLOAD
PSV-D (P3) (P4)

A8 ARM2
PSV-A 16

T2 P2
LC01Z00099P1 01
13
BOOM CIRCUIT : Boom down operation & Prevention of natural boom falling.

22-15
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
[22. HYDRAULIC SYSTEM]

22.8 SWING CIRCUIT 22.8.3 SWING MAIN CIRCUIT

(1) Operation:
This section describes the following operations. The oil delivered from the A2 port of the P2 pump
enters the P2 port of C/V (2) and is branched off
(1) Swing left pilot circuit into the bypass line and the parallel circuit.
(2) Swing auto parking brake However, since the bypass line is closed as the
(3) Swing main circuit swing spool is shifted, the oil pushes the load check
(4) Swing motor circuit valve LCs open through the parallel circuit, enters
the B port of the swing motor via the Bs port of C/V
(2), and rotates the swing motor counterclockwise.
22.8.1 PILOT CIRCUIT FOR LEFT SWING
(1) Operation:
1. When the left swing operation is performed, the 22.8.4 SWING MOTOR CIRCUIT
pilot proportional secondary pressure is delivered (1) Anti cavitation circuit at swing deceleration
through port (5) of left pilot V (9), and the secondary (2) Shockless relief valve that prevents the swing
pressure acts on PBs port of C/V (2), and motor from being reversed.
simultaneously flows out from Pss port of C/V and
acts on low pressure sensor (SE-5).
2. The voltage output by the low pressure sensor is
input in the mechatro controller, and is signal-
processed.
3. Then, the secondary pressure led into PBs port of
C/V (2) switches the swing spool.

22.8.2 SWING AUTO PARKING BRAKE

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

22-16
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
 [22. HYDRAULIC SYSTEM]

SE22 SE23 P MB MB P
a1 P P
MAIN PUMP PSV1 A1 A2 a2 PSV2
PH1 PH2

PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8 35.8~37.8 SWING
MPa VB VB MPa 3
PG
VA VA DB

REG REG

1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT

a3
8
a4
Dr

5.0MPa
M A B
a5
203kw B1
/2100min-1 B3 Dr3 A3

11 2
MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
ARM OUT
CMR1
CT1 ARM IN
PL
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
14 BL P P P P P P
12 CT2 CP2
BOOM T3 BHL MULTI 1 2 3 4 5 6 7 8
TRAVEL RIGHT P2UNLOAD CONFLUX
PAr PB1

BR CP1
AR PCa
HYD.TANK NOTES 1 1 2 3 4 5 6 7 8
PBr CCb
PAs 17
Dr SE5 NOTE 1
BOOM LCb LCs Pss
SWING P
PBb PBs

As
37.8MPa Bs
(ROD)Bb PAa1
9
CRb
LCa RH LH
(HEAD)Ab
ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 LEVER CYLINDER 22
A1 LOCK XAb 39.7MPa 37.8MPa
SV-4
BUCKET LCc Aa (HEAD)
PCc 7 P T P T
SWING PBc BOOM ARM
A2 P/B & BUCKET & SWING
SV-1 37.8MPa ARM
CRar CYLINDER
(ROD)Bc PLc2 6
TRAVEL
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2 OPTION
LCo 5 10
PAo
BOOM
A5 P2UNLOAD CYLINDER 3 6 4 1 5 2
PSV-B
16 Ao RIGHT TRAVEL FORWARD
Bo P SE9 P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL LEFT TRAVEL REVERSE
A6 PRIORITY
PSV-C

A7 P1UNLOAD
PSV-D (P3) (P4)

A8 ARM2
PSV-A 16

T2 P2
LC01Z00099P1 01
13
SWING CIRCUIT : Swing operation (LH)

22-17
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
[22. HYDRAULIC SYSTEM]

22.9 ARM CIRCUIT load check valve LCAT2, goes through arm 2 spool,
and confluences with P2 pump delivery oil in the
valve section, and then is flowed into arm cylinder
This section describes the following operations.
head (H) side through Aa port of C/V (2).
(1) Arm in, light-load operating pilot circuit 3. The return oil from arm cylinder (R) side flows in Ba
(2) Arm in, light-load variable normal recirculation main port of C/V (2) and passes through the Ba port
because the arm lock valve CRar is open, and is
circuit / internal conflux main circuit
flowed into arm 2 spool through arm 1 spool.
4. Because arm 2 spool is switched to normal
recirculation position, causing restriction of
22.9.1 ARM IN, LIGHT-LOAD OPERATING passage to tank, the return oil from arm cylinder (R)
PILOT CIRCUIT side flows into arm cylinder (H) side.
(1) Purpose: -Because, at light load, the pressure in cylinder rod
Speed-up and Anticavitation when the arm is at (R) side is higher than that in the head (H) side, it
light loaded. opens the check valve housed-in arm 2 spool and
(2) Principle: is recirculated in the head (H) side, resulting in the
The oil returning from the arm cylinder rod (R) is speed up of arm-in operation at light load.
recirculated variably to the head (H) at arm 2 spool 5. Cavitations prevention control in arm-in operation
in C/V. Command current is output to arm 2 solenoid
(3) Operation: proportional valve by signal processing of E/G
1. When the arm in operation is performed, the speed and arm-in pilot pressure, accordingly the
secondary pilot proportional pressure gets out of arm 2 spool is switched to neutral (cavitations
port 7 of the left pilot valve (9) and acts upon the prevention) position, resulting in cavitations
low pressure sensor (SE-7). prevention.
At the same time, the pressure is branched off in
two flows, acts upon the Paa1 port and the PLc2 Position of arm 2 spool
port, changes over the arm spool and the arm lock
Neutral position
valve CRar. releases. (Anticavitation position)
Normal recirculation position
2. The output voltage by the low pressure sensor is
input into mechatro controller, and is pilot signal- Recirculation

processed, and is output to P1, P2 pump

proportional valve (PSV-P1), (PSV-P2) and arm 2 From arm out
inverse proportional valve (PSV-A). P/V
3. The secondary pressure from pilot proportional From arm 2 inverse
proportional valve
valve, which is reduced by arm 2 inverse
proportional valve (PSV-A) switches arm 2 spool. Reference:
In light-load arm-in operation (normal recirculation,
conflux), when the attachment to which the circuit in P1
pump side is applied is operated, the meter-in path of
22.9.2 ARM-IN, LIGHT-LOAD VARIABLE
arm 2 spool is closed, resulting in single flow operation.
NORMAL RECIRCULATION,
INTERNAL CONFLUX MAIN Spool position at arm in,
light load and combined operation
CIRCUIT (This position is not shown in hydraulic diagram)
(1) Operation: Neutral position Meter-in passage
1. The P2 pump delivery oil flows in travel left section (Close)

through P2 port of C/V (2) and is branched off in by-

pass circuit and parallel circuit, but because arm 1
spool is switched, the delivery oil which goes
Normal recirculation opsition
through parallel circuit opens load check valve LCa Arm 2 spool
and is flowed into arm 1 spool.
2. On the other hand, P1 pump delivery oil flows in P1
port of C/V (2), and the flows in travel straight
section and travel right tandem path. Then because
arm 2 spool was switched, the delivery oil opens

22-18
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
 [22. HYDRAULIC SYSTEM]

SE22 SE23 P MB MB P
a1 P P
MAIN PUMP PSV1 A1 A2 a2 PSV2
PH1 PH2

PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8 35.8~37.8 SWING
MPa VB VB MPa 3
PG
VA VA DB

REG REG

1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT

a3
8
a4
Dr

5.0MPa
M A B
a5
203kw B1
/2100min-1 B3 Dr3 A3

11 2
MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
ARM OUT
CMR1
CT1 ARM IN
PL
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
14 BL P P P P P P
12 CT2 CP2
BOOM T3 BHL MULTI 1 2 3 4 5 6 7 8
TRAVEL RIGHT P2UNLOAD CONFLUX
PAr PB1

BR CP1
AR PCa
HYD.TANK NOTES 1 1 2 3 4 5 6 7 8
PBr CCb
PAs 17
Dr SE5 NOTE 1
BOOM LCb LCs Pss
SWING P
PBb PBs

As
37.8MPa Bs
(ROD)Bb PAa1
9
CRb
LCa RH LH
(HEAD)Ab
ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 LEVER CYLINDER
A1 LOCK XAb 39.7MPa 37.8MPa
22
SV-4
BUCKET LCc Aa (HEAD)
PCc 7 P T P T
SWING PBc BOOM ARM
A2 P/B & BUCKET & SWING
SV-1 37.8MPa ARM
CRar CYLINDER
(ROD)Bc PLc2 6
TRAVEL
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2 OPTION
LCo 5 10
PAo
BOOM
A5 P2UNLOAD CYLINDER 3 6 4 1 5 2
PSV-B
16 Ao RIGHT TRAVEL FORWARD
Bo P SE9 P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL LEFT TRAVEL REVERSE
A6 PRIORITY
PSV-C

A7 P1UNLOAD
PSV-D (P3) (P4)

A8 ARM2
PSV-A 16

T2 P2
LC01Z00099P1 01
13
ARM CIRCUIT : Arm in (Light load) operation, Arm variable recirculation & Anti cavitation function

22-19
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
[22. HYDRAULIC SYSTEM]

return oil goes through arm lock valve CRar and

This section describes the following operations. flows in arm 2 spool.
4. The return oil returns directly into tank circuit
(3) Arm in, heavy load operating pilot circuit because arm 2 spool is switched to recirculation cut
(recirculation cut) position.
(4) Arm in, heavy load operating sequence confluxed
main circuit
Position of arm 2 spool

Neutral position Recirculation cut position

22.9.3 ARM IN, HEAVY LOAD

OPERATING PILOT CIRCUIT From arm out
P/V
(1) Operation:
From arm 2 inverse
1. Left pilot valve actuation due to arm-in operation is proportional valve
equivalent to that at light load operation.
2. In arm-in operation, when the heavy loading is
applied to arm and the P2 pump pressure
increases to the set pressure, the voltage output by
P2 pump pressure sensor (SE-23) is converted to
signal (signal processing) by mechatro controller,
consequently the current of arm 2 solenoid
proportional valve is controlled according to the
load pressure and the arm variable recirculation is
cut.
When the recirculation is cut, internal confluence is
held similarly to that in light load operation.

22.9.4 ARM IN, HEAVY LOAD

OPERATING RECIRCULATION
CUT MAIN CIRCUIT
(1) Purpose:
Speed up for arm in operation
(2) Principle:
Cut the recirculation and reduce rod pressure.
(3) Operation:
1. P2 pump delivery oil flows in the travel left section
through P2 port of C/V (2) and branched off in by-
pass circuit and parallel circuit. Consequently the
arm spool is switched and pushes and opens load
check valve LCa through parallel circuit, and flows
in the arm spool.
2. On the other hand, P1 pump delivery oil flows in P1
port of C/V (2), and flow in travel right tandem
passage through travel straight section. Then
because arm 2 spool was switched, the delivery oil
opens load check valve LCAT2, and confluences
with P2 pump delivery oil in the valve section, and
is flowed into arm cylinder head (H) side through
Aa port of C/V(2).
3. The return oil from arm cylinder (R) side flows in Ba
port of C/V(2) and is flowed to arm lock valve CRar,
but because the arm lock valve CRar is open, the

22-20
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
 [22. HYDRAULIC SYSTEM]

SE22 SE23 P MB MB P
a1 P P
MAIN PUMP PSV1 A1 A2 a2 PSV2
PH1 PH2

PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8 35.8~37.8 SWING
MPa VB VB MPa 3
PG
VA VA DB

REG REG

1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT

a3
8
a4
Dr

5.0MPa
M A B
a5
203kw B1
/2100min-1 B3 Dr3 A3

11 2
MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
ARM OUT
CMR1
CT1 ARM IN
PL
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
14 BL P P P P P P
12 CT2 CP2
BOOM T3 BHL MULTI 1 2 3 4 5 6 7 8
TRAVEL RIGHT P2UNLOAD CONFLUX
PAr PB1

BR CP1
AR PCa
HYD.TANK NOTES 1 1 2 3 4 5 6 7 8
PBr CCb
PAs 17
Dr SE5 NOTE 1
BOOM LCb LCs Pss
SWING P
PBb PBs

As
37.8MPa Bs
(ROD)Bb PAa1
9
CRb
LCa RH LH
(HEAD)Ab
ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 LEVER CYLINDER
A1 LOCK XAb 39.7MPa 37.8MPa
22
SV-4
BUCKET LCc Aa (HEAD)
PCc 7 P T P T
SWING PBc BOOM ARM
A2 P/B & BUCKET & SWING
SV-1 37.8MPa ARM
CRar CYLINDER
(ROD)Bc PLc2 6
TRAVEL
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2 OPTION
LCo 5 10
PAo
BOOM
A5 P2UNLOAD CYLINDER 3 6 4 1 5 2
PSV-B
16 Ao RIGHT TRAVEL FORWARD
Bo P SE9 P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL LEFT TRAVEL REVERSE
A6 PRIORITY
PSV-C

A7 P1UNLOAD
PSV-D (P3) (P4)

A8 ARM2
PSV-A 16

T2 P2
LC01Z00099P1 01
13
ARM CIRCUIT : Arm in (Heavy load) operation, Arm confluence & recirculation cut function

22-21
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
[22. HYDRAULIC SYSTEM]

22.9.7 NATURAL FALL PROTECTION

This section describes the following operations. WITH ARM LOCK VALVE
(5) Arm out pilot circuit (1) Purpose:
(6) Arm out 2 pumps conflux main circuit To prevent the arm from falling naturally by the
(7) Natural fall protection with arm lock valve weight of the arm and bucket.
(2) Principle:
Complete seat of the return circuit against the arm
spool of the arm cylinder (R) side circuit.
22.9.5 ARM OUT PILOT CIRCUIT
(3) Operation:
(1) Operation: 1. When the secondary pressure for arm operation
1. When the arm out operation is performed, the disappears and the arm cylinder stops, the
secondary pilot proportional pressure gets out of pressure on the rod (R) side passes through the
port 8 of the left pilot valve (9), and acts upon the selector of the lock valve from the Ba port of C/V,
low pressure sensor (SE-8). At the same time, the acts the back pressure on the lock valve CRar and
oil is branched off in two flows and act upon the seats the lock valve.
PBa1 and Pba2 ports of C/V (2). 2. Since the oil flow into the arm spool from the lock
2. The operating proportional secondary pressure valve is shut off completely, natural fall of the arm
flowed in Pba1 port of C/V (2) switches the arm 1 due to oil leaks through the arm spool is prevented.
spool.
3. Then, the operating secondary pressure flowed in
PBa2 port of C/V (2) switches the arm 2 spool
valve.

22.9.6 ARM OUT 2 PUMPS CONFLUX

MAIN CIRCUIT
(1) Purpose:
Arm out operation speed up.
(2) Principle:
The oil delivered by the P1 pump is confluxed with
that delivered by the P2 pump in C/V (2).
(3) Operation:
1. P1 pump delivery oil opens load check valve
(LCAT2) by switching arm 2 spool and confluxes
with P2 pump delivery oil just short of the arm lock
valve.
2. And, P2 pump delivery oil flows through arm 1
spool and confluences with P1 delivery oil, opens
lock valve of arm lock valve CRar with free flow and
is flowed into arm cylinder rod (R) side through Ba
port of C/V(2).
3. On the other hand, the return oil from arm cylinder
(H) side flows in Aa port, and returns into tank
circuit through arm 1 spool and arm 2 spool.
The return line which does not pass through boost
check valve is used for this return circuit to reduce
the pressure loss.

22-22
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
 [22. HYDRAULIC SYSTEM]

SE22 SE23 P MB MB P
a1 P P
MAIN PUMP PSV1 A1 A2 a2 PSV2
PH1 PH2

PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8 35.8~37.8 SWING
MPa VB VB MPa 3
PG
VA VA DB

REG REG

1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT

a3
8
a4
Dr

5.0MPa
M A B
a5
203kw B1
/2100min-1 B3 Dr3 A3

11 2
MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
BOOST
CHECK ARM OUT
CMR1
CT1 ARM IN
PL
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
14 BL P P P P P P
12 CT2 CP2
BOOM T3 BHL MULTI 1 2 3 4 5 6 7 8
TRAVEL RIGHT P2UNLOAD CONFLUX
PAr PB1

BR CP1
AR PCa
HYD.TANK NOTES 1 1 2 3 4 5 6 7 8
PBr CCb
PAs 17
Dr SE5 NOTE 1
BOOM LCb LCs Pss
SWING P
PBb PBs

As
37.8MPa Bs
(ROD)Bb PAa1
9
CRb
LCa RH LH
(HEAD)Ab
ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 LEVER CYLINDER
A1 LOCK XAb 39.7MPa 37.8MPa
22
SV-4
BUCKET LCc Aa (HEAD)
PCc 7 P T P T
SWING PBc BOOM ARM
A2 P/B & BUCKET & SWING
SV-1 37.8MPa ARM
CRar CYLINDER
(ROD)Bc PLc2 6
TRAVEL
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2 OPTION
LCo 5 10
PAo
BOOM
A5 P2UNLOAD CYLINDER 3 6 4 1 5 2
PSV-B
16 Ao RIGHT TRAVEL FORWARD
Bo P SE9 P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL LEFT TRAVEL REVERSE
A6 PRIORITY
PSV-C

A7 P1UNLOAD
PSV-D (P3) (P4)

A8 ARM2
PSV-A 16

T2 P2
LC01Z00099P1 01
13
ARM CIRCUIT : Arm out operation, Confluence function

22-23
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
[22. HYDRAULIC SYSTEM]

22.10 COMBINED CIRCUIT travel straight spool is shifted and exerts on the
right travel operation.
(In travel straight operation, P2 pump delivery oil
This section describes only the difference in combined
operation. exerts on travel operation.)
4. However, a portion of the flow is led to the travel
(1) Boom up / travel, pilot circuit straight spool notch restriction. The speed of
(2) Boom up / travel, main circit attachments like travel, boom, etc. is adjusted by
the circuit of restriction.

22.10.1 BOOM UP / TRAVEL, PILOT

CIRCUIT
(1) Operation:
<Operation: Different point of pilot circuit from
independent operation >
1. The mechatro controller outputs command current
to travel straight solenoid proportional valve after
signal processing, and the solenoid valve outputs
secondary pressure and acts on PTb port of C/V
(2).
2. Then the pressure of PTb port switches the travel
straight valve.

22.10.2 BOOM UP / TRAVEL, MAIN

CIRCUIT
(1) Purpose:
To insure straight travel movement during travel
operation even if the attachment is operated.
(2) Principle:
The travel action and the attachment action are
actuated by separate pumps.
(3) Operation:
1. P1 pump delivery oil flows through P1 port of C/
V(2) and branches off in P1 parallel circuit and
travel straight spool.
P2 pump delivery oil flows through P2 port of C/
V(2) and branches off in P2 tandem circuit and
travel straight spool.
2. The delivery oil flowed into P1 parallel circuit of P1
pump opens check valve CT1 and LCb and flows in
boom spool, which exerts on boom up operation.
The delivery oil flowed into travel straight spool of
P1 pump opens check valve CT2 because the
travel straight spool is shifted, and flows in boom
conflux spool and exerts on boom up operation with
the internal oil conflux.
(In travel straight operation, P1 pump delivery oil
exerts on swing operation of attachment.)
3. The delivery oil flowed into P2 tandem circuit of P2
pump flows in left travel spool to travel leftward.
The delivery oil flowed into travel straight spool of
P2 pump flows in right travel spool because the

22-24
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
 [22. HYDRAULIC SYSTEM]

SE22 SE23 P MB MB P
a1 P P
MAIN PUMP PSV1 A1 A2 a2 PSV2
PH1 PH2

PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8 35.8~37.8 SWING
MPa VB VB MPa 3
PG
VA VA DB

REG REG

1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT

a3
8
a4
Dr

5.0MPa
M A B
a5
203kw B1
/2100min-1 B3 Dr3 A3

11 2
MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
ARM OUT
CMR1
CT1 ARM IN
PL
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
14 BL P P P P P P
12 CT2 CP2
BOOM T3 BHL MULTI 1 2 3 4 5 6 7 8
TRAVEL RIGHT P2UNLOAD CONFLUX
PAr PB1

BR CP1
AR PCa
HYD.TANK NOTES 1 1 2 3 4 5 6 7 8
PBr CCb
PAs 17
Dr SE5 NOTE 1
BOOM LCb LCs Pss
SWING P
PBb PBs

As
37.8MPa Bs
(ROD)Bb PAa1
9
CRb
LCa RH LH
(HEAD)Ab
ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER 22
A1 LOCK XAb 39.7MPa 37.8MPa
SV-4
BUCKET LCc Aa (HEAD)
PCc 7 P T P T
SWING PBc BOOM ARM
A2 P/B & BUCKET & SWING
SV-1 37.8MPa ARM
CRar CYLINDER
(ROD)Bc PLc2 6
TRAVEL
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2 OPTION
LCo 5 10
PAo
BOOM
A5 P2UNLOAD CYLINDER 3 6 4 1 5 2
PSV-B
16 Ao RIGHT TRAVEL FORWARD
Bo P SE9 P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL LEFT TRAVEL REVERSE
A6 PRIORITY
PSV-C

A7 P1UNLOAD
PSV-D (P3) (P4)

A8 ARM2
PSV-A 16

T2 P2
LC01Z00099P1 01
13
COMBINED CIRCUIT : Boom up & Travel forward 1st speed operation, Travel straight function.

22-25
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
[22. HYDRAULIC SYSTEM]

Position of arm 2 spool

In this section, the independent operation is omitted
and describes difference in combined operation.
Position of forced recirculation

Neutral position Meter-in passage

(3) Swing / Arm in light load, pilot circuit (Close)
(4) Swing / Arm in, swing priority main circuit
From From arm 2
arm out inverse
P/V proportional valve
Normal recirculation opsition
22.10.3 SWING / ARM IN LIGHT LOAD, Arm 2 spool
PILOT CIRCUIT
(1) Operation:
1. On operating swing (left) and arm in motions
simultaneously, mechatro controller outputs
command current to travel straight solenoid
proportional valve (PSV-C) and arm 2 solenoid
inverse proportional valve according to signal
processing, and this proportional valve outputs
secondary pressure, which acts on PTb port and
PAa2 port of C/V(2).
2. PTb port pressure switches the travel straight spool
2 steps, and the PAa2 port pressure switches the
arm 2 spool to the forced recirculation position.

22.10.4 SWING / ARM IN, SWING

PRIORITY MAIN CIRCUIT
(1) Purpose:
Stable swing speed.
(2) Principle:
Raise the oil pressure flowing to arm cylinder, and
give a priority of the delivery of P2 pump to swing
operation.
(3) Operation:
1. The swing main circuit operates with P2 pump flow.
But on P2 pump circuit side, the flow goes to the
swing circuit and arm circuit simultaneously
because the swing circuit and arm circuit are
parallel. Then since the return oil from arm cylinder
rod (R) side is restricted in the arm 2 spool because
the arm 2 spool is switched to forced recirculation
position, the pressure of return oil is raised, causing
the rise of circuit pressure on the arm cylinder head
(H) side.
2. At the same time meter-in of arm 2 spool closes
and arm in conflux is therefore cancelled, and
delivery oil from P2 pump and P1 pump are
combined in the parallel circuit on P2 pump side
because the travel straight spool was switched.
The conflux oil of P1 and P2 delivery oil in high
pressure flows in swing side taking priority over all
others.
This operation is called "Swing Priority Circuit".

22-26
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
 [22. HYDRAULIC SYSTEM]

SE22 SE23 P MB MB P
a1 P P
MAIN PUMP PSV1 A1 A2 a2 PSV2
PH1 PH2

PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8 35.8~37.8 SWING
MPa VB VB MPa 3
PG
VA VA DB

REG REG

1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT

a3
8
a4
Dr

5.0MPa
M A B
a5
203kw B1
/2100min-1 B3 Dr3 A3

11 2
MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
ARM OUT
CMR1
CT1 ARM IN
PL
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
14 BL P P P P P P
12 CT2 CP2
BOOM T3 BHL MULTI 1 2 3 4 5 6 7 8
TRAVEL RIGHT P2UNLOAD CONFLUX
PAr PB1

BR CP1
AR PCa
HYD.TANK NOTES 1 1 2 3 4 5 6 7 8
PBr CCb
PAs 17
Dr SE5 NOTE 1
BOOM LCb LCs Pss
SWING P
PBb PBs

As
37.8MPa Bs
(ROD)Bb PAa1
9
CRb
LCa RH LH
(HEAD)Ab
ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 LEVER CYLINDER
A1 LOCK XAb 39.7MPa 37.8MPa
22
SV-4
BUCKET LCc Aa (HEAD)
PCc 7 P T P T
SWING PBc BOOM ARM
A2 P/B & BUCKET & SWING
SV-1 37.8MPa ARM
CRar CYLINDER
(ROD)Bc PLc2 6
TRAVEL
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
A5 P2UNLOAD CYLINDER 3 6 4 1 5 2
PSV-B
16 Ao RIGHT TRAVEL FORWARD
Bo P SE9 P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL LEFT TRAVEL REVERSE
A6 PRIORITY
PSV-C

A7 P1UNLOAD
PSV-D (P3) (P4)

A8 ARM2
PSV-A 16

T2 P2
LC01Z00099P1 01
13
COMBINED CIRCUIT : Swing / Arm in operation, swing priority function

22-27
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
[22. HYDRAULIC SYSTEM]

22.11 PRESSURE DRAINING 22.11.2 PRESSURE RELEASE MAIN

CIRCUIT
This section describes the following operations.

(1) Pressure drain (releasing) pilot circuit

When the hydraulic pressure releasing is performed,
(2) Pressure drain (releasing) main circuit
make sure to place bucket on the ground.

(1) Operation:
22.11.1 PRESSURE RELIEVING PILOT
When the operating lever is shifted to neutral during
CIRCUIT
engine running, "DRAINING HYD. PRESS." is
(1) Purpose: displayed on the gauge cluster while the mode
To release the pressure in main circuit for piping switch is changed to pressure relieving mode. In
repair works. this time the intermittent buzzer sounds
(2) Principle: continuously. When right and left operating levers
After the mode is switched to "Pressure Relief are operated 4 or 5 times to their full stroke,
Mode" with switch on gauge cluster, mechatro pressure is relieved.
controller outputs the following commands. After draining pressure is completed, turn off the
1. Minimum tilting command value to pump starter key and buzzer sound stops. If the pump
proportional valve (PSV-P1, PSV-P2). pressure is determined to be more than 1 MPa (145
2. Output "Pressure relief control speed command psi) by the output value of the high pressure sensor
value" at ECU. (Electric system) or the high pressure sensors (SE-22,23) are
3. Stand-by command value to P1, P2 unloading broken, "FAIL DRAIN HYD. PRESS." is displayed
proportional valves and the buzzer sounds continuously. In that case,
How to switch to "Pressure release mode" also the buzzer is not stopped unless the engine
1. Select the service diagnosis mode. key is turned to OFF. Repeat the pressure releasing
(Hold down the "BUZZER STOP SWITCH" on procedure once again.
gauge cluster, turn the starter key switch on.) (2) Hydraulics:
2. Select the service adjustment mode 1. If the travel straight valve is turned to the pressure
(Under the condition that "Screen No.1" of "Service release position, the oil delivered by each pump is
diagnosis mode 1" is indicated, hold down the unloaded to the tank passage. If the spools are
"BUZZER STOP SWITCH", press the "MENU switched by pilot operation, the remaining pressure
SWITCH" 3 times. When "SERVICE MENU" is from the actuators may be relieved to the tank
displayed, using "UP" switch or "DOWN" switch, circuit, i.e. the main circuit pressure may be
select "SERVICE ADJUST 1". Press "NEXT" released.
switch, to select "SERVICE ADJUST 1-2".)
3. Using "UP" switch or "DOWN" switch, and select
"PRESS DRAIN".
Then press "NEXT" switch, and cursor points to
"OFF".
4. Press "UP" switch to display "ON", and press
"MENU" switch.
5. Screen of gauge cluster changes to ordinary
display, and "DRAINING HYD. PRESS." is
appeared.
(3)?Operation:
1. Pump proportional valve reduces the pump flow
rate to the minimum.
2. Unloading proportional valves (PSV-D, PSV-B)
output secondary pressure and the secondary
pressure flows in PCb, PCa ports of C/V(2) and
switches the P1, P2 unloading valves to OPEN
position.

22-28
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
 [22. HYDRAULIC SYSTEM]

SE22 SE23 P MB MB P
a1 P P
MAIN PUMP PSV1 A1 A2 a2 PSV2
PH1 PH2

PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8 35.8~37.8 SWING
MPa VB VB MPa 3
PG
VA VA DB

REG REG

1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT

a3
8
a4
Dr

5.0MPa
M A B
a5
203kw B1
/2100min-1 B3 Dr3 A3

11 2
MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
ARM OUT
CMR1
CT1 ARM IN
PL
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
14 BL P P P P P P
12 CT2 CP2
BOOM T3 BHL MULTI 1 2 3 4 5 6 7 8
TRAVEL RIGHT P2UNLOAD CONFLUX
PAr PB1

BR CP1
AR PCa
HYD.TANK NOTES 1 1 2 3 4 5 6 7 8
PBr CCb
PAs 17
Dr SE5 NOTE 1
BOOM LCb LCs Pss
SWING P
PBb PBs

As
37.8MPa Bs
(ROD)Bb PAa1
9
CRb
LCa RH LH
(HEAD)Ab
ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 LEVER CYLINDER
A1 LOCK XAb 39.7MPa 37.8MPa
22
SV-4
BUCKET LCc Aa (HEAD)
PCc 7 P T P T
SWING PBc BOOM ARM
A2 P/B & BUCKET & SWING
SV-1 37.8MPa ARM
CRar CYLINDER
(ROD)Bc PLc2 6
TRAVEL
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2 OPTION
LCo 5 10
PAo
BOOM
A5 P2UNLOAD CYLINDER 3 6 4 1 5 2
PSV-B
16 Ao RIGHT TRAVEL FORWARD
Bo P SE9 P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL LEFT TRAVEL REVERSE
A6 PRIORITY
PSV-C

A7 P1UNLOAD
PSV-D (P3) (P4)

A8 ARM2
PSV-A 16

T2 P2
LC01Z00099P1 01
13
PRESSURE DRAIN (RELEASE) CIRCUIT : At pressure release mode.

22-29
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
[22. HYDRAULIC SYSTEM]

22-30
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
 㨇23. ELECTRICAL SYSTEM㨉

23. ELECTRICAL SYSTEM

TABLE OF CONTENTS

23.1 ELECTRIC CIRCUIT DIAGRAM ääääääääääääääääääääääääääääää23-3

23.2 ELECTRICAL EQUIPMENT LIST äääääääääääääääääääääääääääää23-13
23.3 HARNESS äääääääääääääääääääääääääääääääääääääää23-15
23.3.1 HARNESS LIST äääääääääääääääääääääääääääääääääää23-15
23.3.2 INSTRUMENT PANEL ASSY äääääääääääääääääääääääääääää23-16
23.3.3 CONTROLLER INSTALL ääääääääääääääääääääääääääääää23-17
23.3.4 OPERATORS CONTROLS äääääääääääääääääääääääääääää23-21
23.3.5 UPPER ELECTRIC ASSY ääääääääääääääääääääääääääääää23-23
23.3.6 UPPER HARNESS ASSY ääääääääääääääääääääääääääääää23-24
23.3.7 UPPER HARNESS ASSY (FLOOR PLATE) äääääääääääääääääääää23-45
23.3.8 ENGINE HARNESS ASSY ääääääääääääääääääääääääääääää23-54
23.3.9 HARNESS ASSY (REAR CAMERA) äääääääääääääääääääääääää23-57
23.3.10 CAB HARNESS ASSY ääääääääääääääääääääääääääääää23-60
23.3.11 BOOM HARNESS ASSY ääääääääääääääääääääääääääääää23-67
23.3.12 BOOM LIGHT INSTALL äääääääääääääääääääääääääääääää23-68
23.3.13 UPPER LIGHT INSTALL ääääääääääääääääääääääääääääää23-68
23.3.14 FLASHER LAMP INSTALL äääääääääääääääääääääääääääää23-69
23.3.15 TRAVEL ALARM ASSY äääääääääääääääääääääääääääääää23-69
23.3.16 CAMERA INSTAL äääääääääääääääääääääääääääääääää23-70



Book Code No. S5/&(

23-1
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
㨇23. ELECTRICAL SYSTEM㨉

Issue Date of Issue Applicable Machines Remarks

S5LC2333E01
First Edition July, 2014 SK350LC-9E : YC13-13001~
(NA)

23-2
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
 [23. ELECTRICAL SYSTEM]

23.1 ELECTRIC CIRCUIT DIAGRAM

23

(1/12)
LC03Z00050P1 01

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[23. ELECTRICAL SYSTEM]

(2/12)
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 [23. ELECTRICAL SYSTEM]

23

(3/12)
LC03Z00050P1 01

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[23. ELECTRICAL SYSTEM]

(4/12)
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 [23. ELECTRICAL SYSTEM]

23

(5/12)
LC03Z00050P1 01

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[23. ELECTRICAL SYSTEM]

(6/12)
LC03Z00050P1 01

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 [23. ELECTRICAL SYSTEM]

23

(7/12)
LC03Z00050P1 01

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[23. ELECTRICAL SYSTEM]

(8/12)
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 [23. ELECTRICAL SYSTEM]

23

(9/12)
LC03Z00050P1 01

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[23. ELECTRICAL SYSTEM]

(10/12)
LC03Z00050P1 01

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 㨇23. ELECTRICAL SYSTEM㨉

23.2 ELECTRICAL EQUIPMENT

LIST



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㨇23. ELECTRICAL SYSTEM㨉

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23.3 HARNESS

23.3.1 HARNESS LIST



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23.3.2 INSTRUMENT PANEL ASSY

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23.3.3 CONTROLLER INSTALL (1/3)



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23.3.3 CONTROLLER INSTALL (2/3)

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23.3.3 CONTROLLER INSTALL (3/3)



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23.3.3.7-2 IT CONTROLLER HARNESS :

YY11E01202P1

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23.3.4 OPERATORS CONTROLS (1/2)



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23.3.4 OPERATORS CONTROLS (2/2)

23.3.4.7 RADIO INSTALL

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23.3.5 UPPER ELECTRIC ASSY



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23.3.6 UPPER HARNESS ASSY (1/7)

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23.3.6 UPPER HARNESS ASSY (2/7)



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23.3.6 UPPER HARNESS ASSY (3/7)

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23.3.6 UPPER HARNESS ASSY (4/7)



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23.3.6 UPPER HARNESS ASSY (5/7)

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23.3.6 UPPER HARNESS ASSY (6/7)



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23.3.6 UPPER HARNESS ASSY (7/7)

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23.3.6-1 UPPER HARNESS (1/12) : LC13E01515P3



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23.3.6-1 UPPER HARNESS (2/12) : LC13E01515P3

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23.3.6-1 UPPER HARNESS (3/12) : LC13E01515P3



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23.3.6-1 UPPER HARNESS (4/12) : LC13E01515P3

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23.3.6-1 UPPER HARNESS (5/12) : LC13E01515P3



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23.3.6-1 UPPER HARNESS (6/12) : LC13E01515P3

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23.3.6-1 UPPER HARNESS (7/12) : LC13E01515P3



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23.3.6-1 UPPER HARNESS (8/12) : LC13E01515P3

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 㨇23. ELECTRICAL SYSTEM㨉

23.3.6-1 UPPER HARNESS (9/12) : LC13E01515P3



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㨇23. ELECTRICAL SYSTEM㨉

23.3.6-1 UPPER HARNESS (10/12) : LC13E01515P3

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 㨇23. ELECTRICAL SYSTEM㨉

23.3.6-1 UPPER HARNESS (11/12) : LC13E01515P3



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㨇23. ELECTRICAL SYSTEM㨉

23.3.6-1 UPPER HARNESS (12/12) : LC13E01515P3

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 㨇23. ELECTRICAL SYSTEM㨉

23.3.6-2 BATTERY CABLE : LQ13E01278P1

23.3.6-3 BATTERY RELAY CABLE : LC13E01407P1
23.3.6-4 BATTERY GROUNDING CABLE :
LC13E01408P1
23.3.6-5 STARTER CABLE : LC13E01410P1
23.3.6-6 ENGINE GROUNDING CABLE :
LC13E01413P1



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㨇23. ELECTRICAL SYSTEM㨉

23.3.6-7 FLOOR GROUNDING CABLE :

LE13E01006P1
23.3.6-8 RELAY CABLE : LC13E01180P2
23.3.6-10 AIR CLEANER HARNESS : LC13E01193P1

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23.3.7 UPPER HARNESS ASSY (FLOOR

PLATE) (1/3)



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23.3.7 UPPER HARNESS ASSY (FLOOR PLATE) (2/3)

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23.3.7 UPPER HARNESS ASSY (FLOOR PLATE) (3/3)



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23.3.7-1 FLOOR HARNESS (1/5) : LC13E01518P2

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23.3.7-1 FLOOR HARNESS (2/5) : LC13E01518P2



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23.3.7-1 FLOOR HARNESS (3/5) : LC13E01518P2

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23.3.7-1 FLOOR HARNESS (4/5) : LC13E01518P2



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23.3.7-1 FLOOR HARNESS (5/5) : LC13E01518P2

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 㨇23. ELECTRICAL SYSTEM㨉

23.3.7-10 FLOOR GROUNDING CABLE :

LE13E01005P1
23.3.7-11 CAB SUB-HARNESS : LC13E01566P1



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23.3.8 ENGINE HARNESS ASSY

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23.3.8-1 ENGINE HARNESS (1/2) : LC16E01074P2



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23.3.8-1 ENGINE HARNESS (2/2) : LC16E01074P2

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23.3.9 HARNESS ASSY (REAR CAMERA)

(1/3)



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23.3.9 HARNESS ASSY (REAR CAMERA) (2/3)

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23.3.9 HARNESS ASSY (REAR CAMERA) (3/3)

23.3.9.1 CABLE : LS55E01004D2



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23.3.10 CAB HARNESS ASSY (1/2)

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23.3.10 CAB HARNESS ASSY (2/2)



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23.3.10.1 CAB HARNESS (1/4) : LC14E01065P1

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23.3.10.1 CAB HARNESS (2/4) : LC14E01065P1



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23.3.10.1 CAB HARNESS (3/4) : LC14E01065P1

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23.3.10.1 CAB HARNESS (4/4) : LC14E01065P1



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23.3.10.6 HOUR METER HARNESS : YN11E01205P1

23.3.10.7 POWER SUPPLY SOCKET HARNESS :
YN13E01580P1

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23.3.11 BOOM HARNESS ASSY

23.3.11-1 BOOM HARNESS : LC15E01053P1



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23.3.12 BOOM LIGHT INSTALL

23.3.13 UPPER LIGHT INSTALL

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23.3.14 FLASHER LAMP INSTALL

23.3.15 TRAVEL ALARM ASSY



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23.3.16 CAMERA INSTAL

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 㨇24. COMPONENTS SYSTEM㨉

24. COMPONENTS SYSTEM

TABLE OF CONTENTS

24. COMPONENTS SYSTEM

24.1 HYDRAULIC COMPONENTS äääääääääääääääääääääääääääääää24-3
24.1.1 HYDRAULIC PUMP - REGULATORääääääääääääääääääääääääää24-3
24.1.2 CONTROL VALVE ääääääääääääääääääääääääääääääääää24-24
24.1.3 PILOT VALVE (ATT)äääääääääääääääääääääääääääääääää24-62
24.1.4 PILOT VALVE (TRAVEL)äääääääääääääääääääääääääääääää24-66
24.1.5 SWING MOTOR UNIT ääääääääääääääääääääääääääääääää24-68
24.1.6 TRAVEL MOTOR ääääääääääääääääääääääääääääääääää24-79
24.1.7 SWIVEL JOINT äääääääääääääääääääääääääääääääääää24-93
24.1.8 CYLINDER äääääääääääääääääääääääääääääääääääää24-95
24.2 ELECTRICAL EQUIPMENT ääääääääääääääääääääääääääääääää24-101
24.2.1 ELECTRICAL EQUIPMENT LIST äääääääääääääääääääääääääää24-101
24.2.2 SPECIFICATIONS ELECTRICAL EQUIPMENT äääääääääääääääääääää24-105



Book Code No. S5LC24E0

24-1
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㨇24. COMPONENTS SYSTEM㨉

Issue Date of Issue Applicable Machines Remarks

S5LC2433E01
First Edition July, 2014 SK350LC-9E : YC13-13001~
(NA)

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 㨇24. COMPONENTS SYSTEM㨉

24.1 HYDRAULIC COMPONENTS

24.1.1 HYDRAULIC PUMP - REGULATOR

24.1.1.1 SUMMARY
(1) Outside view and Hydraulic port



Hydraulic pump - regulator

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㨇24. COMPONENTS SYSTEM㨉

(2) Hydraulic circuit diagram

Hydraulic circuit diagram of pump

(3) Specifications

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 㨇24. COMPONENTS SYSTEM㨉

24.1.1.2 HYDRAULIC PUMP

24.1.1.2.1 CONSTRUCTION
(1) Main pump



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㨇24. COMPONENTS SYSTEM㨉

(2) Gear pump (For pilot)

No. Parts Q'TY No. Parts Q'TY

307 Poppet 1 361 Front case 1
308 Seat 1 433 Flange socket; M8X40 2
309 Ring 1 434 Flange socket; M8X55 2
310 Spring 1 435 Flange socket; M8X20 4
311 Adjust screw 1 466 VP plug; PF1/4 1
312 Lock nut; M14X1.5 1 700 Ring 1
351 Gear case 1 710 O-ring; 1B G95 1
353 Drive gear 1 725 O-ring; 1B P11 1
354 Driven gear 1 732 O-ring; 1B P16 1
355 Filter 1 850 Locking ring 1

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(3) PTO gear case (OPT.)

No. Parts Q'TY No. Parts Q'TY

115 Idle shaft 1 435 Flange socket; M10X20 4
117 2nd gear 1 468 VP plug; PF3/4 1
118 3rd gear 1 710 O-ring; 1B G80 1
125 Ball bearing 2 711 O-ring; 1B G85 1
126 Roller bearing 1 728 O-ring; 1B P24 1
128 Bearing spacer 2 825 Snap ring 1
262 Cover 2 826 Snap ring 1
326 Gear case 1 885 Spring pin 1
414 Capscrew; M10X20 4 886 Pin 2



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㨇24. COMPONENTS SYSTEM㨉

24.1.1.2.2 OPERATION
The pump assy is equipped with two pumps
arranged on the same axis that are connected
with gear (116) and distribute the rotating power
to the gear trains on a different axis. Thus the
engine rotation is transmitted to front shaft (111)
that drives the two pumps and, at the same
time, drives the auxiliary pump (OPT) arranged
on another shaft.
The pump assy consists largely of the rotary
group, the main part of the pump that makes
rotary on; the swash plate group that changes
the delivery rate; the valve block group that
selects between oil suction and delivery and the
PTO group (OPT) that transmits the drive power
to the auxiliary pump.

Construction of hydraulic pump

(1) Rotary group

The rotary group consists of shaft(111), cylinder block (141), piston (151), shoe (152), plate (153),
spherical bushing (156), and cylinder spring (157).
The shaft is supported by bearings (123) and (124) at its both ends. The shoe, which is caulked to
the piston, forms a spherical joint and relieves it of thrust force that is generated by load pressure.
Further, the piston is provided with a pocket so it moves lightly on shoe plate (211), taking hydraulic
balance.
The sub group of the piston-shoe is pressed against the shoe plate by the cylinder spring, via the
retainer plate and the spherical bushing, so that it moves smoothly over the shoe plate. The cylinder
block (141) is also pressed against valve plate (313) by the action of cylinder spring (157).

Rotary group

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 㨇24. COMPONENTS SYSTEM㨉

(2) Swash plate group

The swash plate group consists of swash plate
(212), shoe plate (211), swash plate support
(251), tilting bushing (214), tilting pin (531),
and servo piston (532). The swash plate is the
cylindrical part that is formed on the opposite
side of the shoe sliding surface and is
supported by the swash plate support.
The hydraulic force controlled by the regulator
flows into the hydraulic chamber that is
provided on both sides of the servo piston. This
moves the servo piston to the right and left.
The result is that the swash plate swings on
the swash plate support via the spherical part Swash plate group
of the tilting pin and changes the tilting angle
(a).

(3) Valve block group

The valve block group consists of valve block
(312), valve plates (313 or 314), and valve
plate pin (885). The valve plates having two
crescent-shaped ports are installed to valve
block (312) to feed oil and recycle it from
cylinder block (141). The oil switched over by
the valve plate is connected with the external
pipe by way of the valve block.

Valve block group



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㨇24. COMPONENTS SYSTEM㨉

(4) PTO group (Option)

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

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 㨇24. COMPONENTS SYSTEM㨉

24.1.1.3 REGULATOR
24.1.1.3.1 CONSTRUCTION



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24.1.1.3.2 OPERATION
(1) Control function
Control function ...... Electric flow control.
-Positive flow control.
-Total horsepower control.
Emergency mode control.
-Hydraulic positive control.
-Hydraulic total horsepower control.

(2) Summary
The regulator KR3S-YT0K for the in-line type axial piston pump K5V series is composed of the
control mechanism as mentioned below:

1. Electric flow control and positive flow control

The tilting angle of the pump (delivery rate) is controlled by controlling the current command
value of the solenoid proportional reducing valve attached to the regulator. The regulator makes
positive flow control (positive control) that increases the delivery rate as the secondary pressure
of the solenoid proportional reducing valve rises. Since this function permits the output power of
the pump to be varied, it is possible to attain optimum power according to the operating
condition. Also, since the pump delivers only the necessary oil flow, the machine does not
consume excessive power.
2. Constant power control at emergency mode
When the electromagnetic proportional pressure-reducing valve cannot output the secondary
pressure due to the trouble, the spool for emergency mode is switched automatically, and the
control is switched from electric control to hydraulic control (emergency mode).
In emergency mode, the power shift command pressure Pf shifts the power set value. The power
shift pressure (secondary pressure of electromagnetic proportional pressure-reducing valve) is led to
power control section of regulator on each pump through pump inside passage and shifts
respective control to the same power set value.
In the power shifted condition, as self pump delivery pressure Pd1 rises, the pump tilt angle
(delivery rate) is automatically reduced; consequently the input torque is controlled to the constant
value or less. (When the speed is constant, the input power is also constant.)
This pump is controlled by Pd1 only regardless of another delivery pressure. Condition where the
power is controlled, the regulator of each pump is controlled to the different tilt angle (delivery
rate). Consequently in the condition where the power is controlled, the overloading of engine is
automatically prevented regardless of the loading of pump 2. And in normal condition, because
the power shift pressure is 0MPa, the power control is not worked.
With this mechanism, it is possible to obtain proper power for the working condition.
This regulator is made up of the above two kinds of control system, but when both controls are
actuated together, the low tilt angle (low delivery rate) command precede on mechanical operation
described later.



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㨇24. COMPONENTS SYSTEM㨉

(3) Explanation of operation

1. Flow rate electrical control
The pump delivery rate is controlled
according to the command current value
corresponding to the movement of control
devices. This relation is shown in right
figure.

a. Flow rate increase (See right Fig.)

As the command current value I rises, the
secondary pressure P2 of electromagnetic
proportional pressure-reducing valve rises,
and by pressing pilot piston (643) in (A)
direction it stops at the position the
secondary pressure P2 balances the pilot
spring force (646). The movement of pilot
piston is transferred to lever 2 (613)
through pin (875), and rotates at (B)
fulcrum in arrow direction. Furthermore the
lever 2 movement is transferred to feedback
lever (611) through pin (897) and rotates at
(C) fulcrum in the same arrow direction as
(B). Consequently the spool (652)
connected to feedback lever moves towards
(D). When the spool moves towards (D),
the port CL connected to tank port is
open and the pressure in servo piston large
bore diameter chamber is released,
consequently the servo piston (532) moves
towards (E) according to delivery pressure
Pd1 in small bore diameter piston chamber,
resulting in the rise of flow rate. Since the
feed back lever is connected to the servo
piston and spool, the feed back lever
rotates at (F) fulcrums with the movement
of the servo piston towards (E),
consequently the spool is returned to the
original position. With this movement, the
opening of spool sleeve gradually closes,
and the servo piston stops at the position
the opening closes completely.

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b. Flow rate decrease (See right Fig.)

As the command current value I is
reduced, the secondary pressure P2 of
electromagnetic proportional
pressure-reducing valve is reduced, and by
pressing pilot piston (643) in (G) direction it
stops at the position the pilot spring force
(646) balances the secondary pressure P2.
The movement of pilot piston is transferred
to lever 2 (613) through pin (875), and
rotates at (H) fulcrum in arrow direction.
Furthermore the lever 2 movement is
transferred to feedback lever (611) through
pin (897) and rotates at (I) fulcrum in the
same arrow direction as (H). Consequently
the spool (652) connected to the feedback
lever moves towards (J). When the spool
moves towards (J), the delivery pressure
Pd1 is led in servo piston large bore
diameter chamber through spool and port
CL. The servo piston small bore diameter
chamber constantly receives delivery the
pressure Pd1, consequently the servo
piston moves towards (K) according to the
difference of area resulting in the reduction
of tilt angle, and finally the flow rate is
reduced. Since the feed back lever is
connected to servo piston and spool, the
feed back lever rotates at (L) fulcrum with
the movement of servo piston towards (K),
consequently the spool is returned to the
original position. With this movement, the
opening of spool sleeve gradually closes,
and the servo piston stops at the position
the opening closes completely.

2. Power control (In emergency mode)

When the load pressure rises, the pump
tilt angle is reduced preventing the
overloading of engine as shown in right Fig.
The operation of power control is the
same as the flow rate control, and is
explained below. 

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a. Overload prevention operation (See right

Fig.)
Because the delivery pressure Pd1 acts
on the compensating rod stepped section
with the rise of self pump delivery
pressure Pd1 the compensating rod (623) is
pushed towards (M), and moves to the
position the delivery pressure Pd1
balances the spring force of outer spring
(625) and inner spring (626). The
movement of compensating rod is
transferred to lever 1 (612) through pin
(875), and rotates at (N) fulcrum in arrow
direction. Furthermore the lever 1 (612)
movement is transferred to feedback lever
(611) through pin (897) and rotates at (O)
fulcrum in the same arrow direction as
(N). Consequently the spool (652)
connected with feedback lever moves
towards (P). When the spool moves
towards (P), the delivery pressure Pd1 is
led in servo piston large bore diameter
chamber through spool and CL port. Since
the delivery pressure Pd1 is constantly led
to servo piston large bore diameter
chamber, the servo piston moves towards
(Q) according to the difference of area,
resulting in the reduction of tilt angle,
consequently the flow rate is also reduced.
Since the feed back lever is connected with
servo piston and spool, the feed back
lever rotates at (R) fulcrum with the
movement of the servo piston towards (Q),
consequently the spool is returned to the
original position. With this movement, the
opening of spool sleeve gradually closes,
and the servo piston stops at the position
the opening closes completely.

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b. Flow rate recovery operation (See right Fig.)

Because the compensating rod (623) is
pushed towards (S) with the force of outer
spring (625) and inner spring (626) with
reduction of self pump delivery pressure
Pd1, and moves to the position the spring
force of outer spring (625) and inner
spring (626) balances the delivery pressure
Pd1. The movement of compensating rod is
transferred to lever 1 (612) through pin
(875), and rotates at (T) fulcrum in arrow
direction.
Furthermore the lever 1 (612) movement is
transferred to feedback lever (611) through
pin (897) and rotates at (T) fulcrum in the
same arrow direction as (N). Consequently
the spool (652) connected to feedback lever
moves towards (V).
As the spool moves towards (V), CL port is
open and connected to tank port, the
pressure of servo piston large bore
diameter chamber is released and the servo
piston (532) moves towards (W) with
delivery pressure Pd1 in small bore
diameter chamber, and consequently the
flow rate is raised. Since the feed back
lever is connected to servo piston and
spool, the feed back lever rotates at (X)
fulcrum with the movement of the servo
piston towards (W), consequently the spool
is returned to the original position.
With this movement, the opening of spool
sleeve gradually closes, and the servo
piston stops at the position the opening
closes completely.

3. Priority mechanism of low tilt angle (low flow rate) command

As the said explanation, the tilting commands of flow rate control and power control are transferred
to feedback lever (611) and spool (652) through the large bore section of lever 1 (612) and lever
2 (613), but because the pin (dia 5) is extruded in large bore (dia 9), pin (897) on the side where
making tilt angle smaller contacts with it, consequently the bore (dia 9) of lever on the side
where larger tilt angle command is given is free without contact with pin (897). In this mechanical
selecting manner, the command on the side of low tilt angle of the flow rate control and power 
control has a priority.

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4. Power shift control

As shown in right Fig., the pump set power
is controlled according to the movement of
control by power shift pressure Pf.
As power pressure Pf rises, the
compensating rod (623) moves rightward
through pin (898) and compensating piston
(621). Consequently like the overloading
prevention operation of power control, the
pump tilt angle becomes smaller and the
power setting value is reduced.
Conversely, if the power shift pressure Pf is
reduced, the power set value is raised.
The power shift pressure Pf of this pump is
ordinary set to 0MPa, but in emergency
mode, the power shift pressure Pf is
raised to 4.9 MPa.

24.1.1.3.3 ADJUSTING THE REGULATOR

The regulator may be adjusted in terms of maximum flow, minimum flow, horsepower (at emergency
mode control) control characteristics, flow control characteristics using the adjust screw.

(1) Adjusting the maximum flow (See construction Fig.)

Adjust the maximum flow by loosening nut (808) and by tightening set screw (954) (or loosening
it). Tightening set screw (954) decreases the delivery rate, as indicated in right Fig..
Only the maximum flow varies, but other control characteristics remain unchanged.

Adjusting the max. delivery flow

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(2) Adjusting the minimum flow (See construction Fig.)

Adjust the minimum flow by loosening nut (806) and by tightening socket screw (953) (or
loosening it). Tightening socket screw increases the delivery rate, as indicated in right Fig..
Other control characteristics remain unchanged in the same way as maximum flow adjustment,
care should be used of the fact that overtightening may increase a required power at the
maximum delivery pressure (at relieving action).

Adjusting the min. delivery flow

(3) Adjusting the input horsepower

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

1. Adjusting the Outer Spring (See constuction Fig.)

(At emergency mode)
Adjust it by loosening lock nut (630) and by tightening adjust screw (628) (or loosening it).
Tightening the adjust screw shifts the control chart to the right and increases the input
horsepower, as indicated in right Fig..
Since turning the adjust screw C (628) by N turns changes the setting of the inner spring (626),
return the adjust screw C (627) by NX1.48 turns at first.



Adjusting the input horsepower (1)

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2. Adjusting the Inner Spring (See construction Fig.)

(At emergency mode)
Adjust it by loosening nut (802) and by adjust screw (C) (627) (or loosening it). Tightening the
adjust screw increases the flow and then the input horsepower, as indicated in right Fig.. And the
input torque raises.

Adjusting the input horsepower (2)

(4) Adjusting the flow control characteristics (See construction Fig.)

Adjust them by loosening nut (801) and socket bolt (924) (or loosening it). Socket bolt causes the
control chart to move to the right as shown in right Fig..

Adjusting the flow control characteristics

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24.1.1.3.4 CAUSES OF FAULT RESULTING FROM REGULATOR

When trouble due to this regulator occurs, disassemble and inspect it referring to "Chapter LC33-II"

(1) When the engine is overloaded,

Load every unit of pump, and check on pumps on the right and left sides for possible damages. When
pumps on both sides are failed, check on them for the following failures 1), 2). When pump on the
one side is failed, start checking from para. 3).

1. Check that the power shift command current I is normal

2. The power shift pressure is low.
-Check the dither of amp.
-Replace solenoid proportional reducing valve.
3. Stick of compensating piston (621) and compensating rod (623)
-Disassemble and clean it.
4. Stick of pin (898)
-Disassemble and clean it.

(2) The max. flow rate is not delivered.

1. Check that pilot differential pressure Pi is normal.
2. Stick of pilot piston (643)
-Disassemble and clean it.
3. Stick of spool (652)
-Disassemble and clean it.
4. Stick of pin (898)
-Disassemble and clean it.

Note: When the damage of part is severe, replace the part with new one.



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24.1.1.4 CONTROL CURVE OF PUMP

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24.1.2 CONTROL VALVE

24.1.2.1 SPECIFICATIONS
24.1.2.1.1 OUTSIDE VIEW

Outside view

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24.1.2.1.2 PORTS
Port size Tightening torque Ports Description
PF3/4 150 to 180 N-m (111 to 133 lbf-ft) MU
(T3) Pluged
(P5) Pluged
(P6) Pluged
PF3/8 69 to 78 N-m (51 to 58 lbf-ft) PAa1 Arm 1 (in) pilot port
PBa1 Arm 1 (out) pilot port
PAb Boom (up) pilot port
PBb Boom (down) pilot port
PAc Bucket (digging) pilot port
PBc Bucket (dump) pilot port
PBL Travel left (reverse) pilot port
PBr Travel right (reverse) pilot port
PAs Swing (right) pilot port
PBs Swing (left) pilot port
PAa2 Arm 2 (in) pilot port
PBa2 Arm 2 (out) pilot port
PAo Option pilot port
PBo Option pilot port
DR Drain port
PF1/4 34 to 39 N-m (25 to 29 lbf-ft) Pss Swing pilot high pressure select port
PLc2 Lock valve select pilot port
PAL Travel left (forward) pilot port
PAr Travel right (forward) pilot port
PL Attachment boost port
PB1 Boom (up) conflux pilot port
PTb Travel straight pilot port
PCa Unload valve (P2 side) pilot port
PCb Unload valve (P1 side) pilot port
PCc Bucket (digging) stroke limiter pilot port
M12 83 to 110 N-m (61 to 81 lbf-ft) P1 Pump port (P1 side)
P2 Pump port (P2 side)
T1 Tank port 1
T2 Tank port 2
M10 49 to 65 N-m (36 to 48 lbf-ft) Ar Right travel motor port (forward)
Br Right travel motor port (reverse)
AL Left travel motor port (forward)
BL Left travel motor port (reverse)
As Swing motor port (right)
Bs Swing motor port (left)
Ab Boom cylinder head side port (up)
Bb Boom cylinder rod side port (down)
Aa Arm cylinder head side port (in)
Ba Arm cylinder rod side port (out)
Ac Bucket cylinder head side port (digging) 
Bc Bucket cylinder rod side port (dump)
Ao Optional pilot port
Bo Optional pilot port

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24.1.2.1.3 SPECIFICATIONS
Item Specifications
Model KMX15YD/B44131A
Maximum flow rate [L/min (gal/min)] 294 (74)X2
Maximum set pressure [MPa (psi)] 37.8 (5480) (Pump port)/ 39.7 (5760) (Actuator port)
Main relief valve set pressure Std 34.3 (4970) [at 135X2L/min (36X2gal/min)]
[MPa (psi)] When power boost pressure 37.8 (5480) [at 125X2L/min (33X2gal/min)]
Overload relief valve set pressure
39.7 (5760) [at 30L/min (8gal/min)]
(Boom head, Bucket head, Arm rod) [MPa (psi)]
Overload relief valve set pressure
37.8 (5480) [at 30L/min (8gal/min)]
(Boom rod, Bucket rod, Arm head) [MPa (psi)]

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24.1.2.2 CONSTRUCTION AND OPERATION

24.1.2.2.1 CONSTRUCTION
(1) Control valve



Section (1/6)

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Section (2/6)

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Section (3/6)

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Section (4/6)

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Section (5/6)

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Section (6/6)

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Tightening torque Tightening torque

No. NAME Q'TY No. NAME Q'TY
N-m (lbf-ft) N-m (lbf-ft)

101 Casing A 1 322 Spring 4

102 Casing B 1 323 Spring 3

220~250(162~184) 154 Plug PF3/4 3 324 Spring 3

20~24(15~18) 159 Plug PT1/4 MEC (Pre-coat bolt) 1 325 Spring 1

7.8~9.8(5.8~7.2) 160 Plug PT1/16 MEC (Pre-coat bolt) 5 326 Spring 1

161 O-ring 7 327 Spring 3

162 O-ring 15 328 Spring 1

163 O-ring 11 329 Spring 3

164 O-ring 19 331 Spring seat 24

201 Cover 3 16~18(11.8~13.3)

333 Spacer bolt 12
202 Cover 6 Loctite #262

203 Cover 1 336 Stopper 10

204 Sub cover 1 339 Stopper 1

205 Cover 5 340 Stopper 1

206 Cover 1 511 Poppet 11

207 Back pressure check valve cover 1 512 Poppet 2

209 Cover 2 514 Poppet 2

210 Cover 2 515 Poppet 1

9.8~14(7.2-10.3) 211 Lock valve selector sub 2 517 Poppet 1

212 Plate 1 518 Poppet 1

213 Plate 1 521 Spring 11

25~34(18~25) 216 Piston 1 522 Spring 2

261 O-ring 12 523 Spring 1

264 O-ring 10 524 Spring 2

266 O-ring 4 527 Spring 1

273 Socket bolt 40 528 Spring 1

98~120(72~89) 274 Socket bolt 4 230~260(170~192) 551 Plug 13

98~120(72~89) 275 Socket bolt 4 130~150(96~111) 552 Plug 2

25~34(18~25) 278 Socket bolt 5 230~260(170~192) 556 Plug 3

301 Boom spool sub 1 562 O-ring 2

302 Arm 1 spool 1 13~17(9.59~12.5) 563 Plug 2

303 Swing spool 1 564 O-ring 2

304 Bucket spool 1 69~78(51~58) 601 Main relief valve 1

305 Boom conflux spool 1 69~78(51~58) 602 Port relief valve 3

306 Travel spool 2 69~78(51~58) 603 Port relief valve 3

307 Travel straight spool 1 69~78(51~58) 604 Relief valve plug assy 2

308 Arm 2 spool sub 1 98~120(72~89) 606 Bypass cut valve 2

309 P1 unload spool 1 140~180(103~133) 973 Socket bolt 8

310 P2 unload spool 1 140~180(103~133) 974 Socket bolt 2

311 Option spool 1 977 Name plate 1

321 Spring 5 978 Rivet 2

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(2) Main relief valve (Two step relief) (601)

Main relief valve (Two step relief)

Tightening torque Tightening torque

No. NAME Q'TY No. NAME Q'TY
N-m (lbf-ft) N-m (lbf-ft)
69 to 78 (51 to 58) 103 Plug; M27 1 562 Back up ring 1
104 Adjust screw 1 611 Poppet 1
121 C-ring 1 613 Stopper 1
122 Spacer 1 614 Piston 1
123 C-ring 1 621 Spring 1
124 Filter stopper 1 652 Adjust screw 1
125 Filter 1 661 O-ring 1
163 O-ring 1 663 O-ring 1
512 Plunger 1 664 O-ring 1
521 Spring 1 28 to 31 (21 to 23) 671 Lock nut; M14 1
541 Seat 1 46 to 52 (34 to 38) 673 Lock nut; M24 1
561 O-ring 1

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(3) Over load relief valve (602,603)

Over load relief valve

Tightening torque Tightening torque

No. NAME Q'TY No. NAME Q'TY
N-m (lbf-ft) N-m (lbf-ft)
69 to 78 (51 to 58) 101 Body; M27 1 541 Seat 1
69 to 78 (51 to 58) 102 Plug; M27 1 561 O-ring 1
161 O-ring 1 562 Backup ring 1
162 O-ring 1 563 O-ring 1
123 C-ring 1 564 Backup ring 1
124 Filter stopper 1 611 Poppet 1
125 Filter 1 612 Spring seat 1
301 Piston 1 621 Spring 1
511 Plunger 1 651 Adjust screw 1
521 Spring 1 661 O-ring 1
522 Spring 1 28 to 31 (21 to 23) 671 Lock nut; M14 1



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(4) Arm 2 spool (308)

Arm 2 spool

Tightening
Tightening torque
torque No. NAME Q'TY No. NAME Q'TY
N-m (lbf-ft)
N-m (lbf-ft)
308 Spool 1 33 to 35 (24 to 26) Loctite #638 351 Plug 1
318 Plunger 1 362 O-ring 1
341 Spring 1 372 Backup ring 1

(5) Boom spool (301)

Boom spool

Tightening
Tightening torque
torque No. NAME Q'TY No. NAME Q'TY
N-m (lbf-ft)
N-m (lbf-ft)
301 Spool 1 16 to 18 (12 to 13) Loctite #638 350 Plug 1
317 Plunger 1 361 O-ring 1
340 Spring 1 371 Backup ring 1

(6) Travel straight spool (307)

Travel straight spool

Tightening
Tightening torque
No. NAME Q'TY torque No. NAME Q'TY
N-m (lbf-ft)
N-m (lbf-ft)
307 Spool 1 361 O-ring 1
16 to 18 (12 to 13) Loctite #638 350 Plug 1 371 Backup ring 1

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(7) Lock valve selector (211)

Lock valve selector

Tightening torque Tightening torque

No. NAME Q'TY No. NAME Q'TY
N-m (lbf-ft) N-m (lbf-ft)
101 Casing 1 10 to 14 (7.4 to 10.3) 171 Socket bolt 3
161 O-ring 4 49 to 59 (36 to 44) 201 Plug 1
164 O-ring 1 321 Spring 1
166 O-ring 1 511 Spool 1
167 O-ring 1 541 Sleeve 1



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(8) Bypass cut valve (606)

Bypass cut valve

Tightening torque Tightening torque

No. NAME Q'TY No. NAME Q'TY
N-m (lbf-ft) N-m (lbf-ft)
98 to 120 (72 to 89) 101 Plug 1 202 O-ring 1
102 O-ring 1 25 to 29 (18 to 21) 301 Lock nut 1
25 to 29 (18 to 21) 201 Adjusting screw 1

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(9) Swing shuttle valve cover (204)

Swing shuttle valve cover

Tightening torque Tightening torque

No. NAME Q'TY No. NAME Q'TY
N-m (lbf-ft) N-m (lbf-ft)
166 O-ring 1 542 Seat 1
202 Cover 1 25 to 29 (18 to 21) 554 Plug 1
541 Steel ball 1 7.9 to 9.8 (5.9 to 7.2) 555 Plug 1



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(10) Boost check valve (517)

Boost check valve

Tightening
Tightening torque
torque No. NAME Q'TY No. NAME Q'TY
N-m (lbf-ft)
N-m (lbf-ft)
101 Poppet 1 20 to 29 (15 to 21) Loctite #262 104 Plug 1
102 Poppet 1 107 Spring 1

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24.1.2.2.2 HYDRAULIC CIRCUIT DIAGRAM

Hydraulic circuit diagram



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24.1.2.2.3 OPERATION
(1) In neutral position
The hydraulic oil delivered by hydraulic pump P1 enters port P1 of control valve, and passes through
unloading valve P1 (309), low pressure circuit (D) and boost check valve (517), and returns to the
hydraulic tank through tank port T1. And when the operation of unloading valve is impossible due to
failure of electric control system, because the by-pass cut valve (606) located on the downstream of
center by-pass passage (52) opens, the hydraulic oil through hydraulic pump P1 port passes through
travel straight spool (306), and then flows though the center by-pass passage (52) which passes
through travel right, boom, bucket and arm 2 and the by-pass cut valve (606) on P1 side, and flows
into low pressure circuit (D) and boost check valve (517), and then returns to the hydraulic tank
through tank port T1.
The hydraulic oil delivered by hydraulic pump P2 passes through unloading valve P2 (310), low
pressure circuit (D) and boost check valve (517) and returns to the hydraulic tank through tank port T1
similarly to the hydraulic oil from hydraulic pump P1. And when the operation of unloading valve is
impossible, because the by-pass cut valve (606) located on the downstream of center by-pass passage
(55) opens, the hydraulic oil through hydraulic pump P2 port passes through main passage, and then
flows though the center by-pass passage (55) which passes through travel left, swing, arm 1 and
option and the by-pass cut valve (606) on P2 side, and flows into low pressure circuit (D) and boost
check valve (517), and then returns to the hydraulic tank through tank port T1.

In neutral position

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 㨇24. COMPONENTS SYSTEM㨉

(2) Actuation in travel operation

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

In left reverse travel (at PBL is pressurized)



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㨇24. COMPONENTS SYSTEM㨉

2. In travel straight operation

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

Movement of travel straight spool

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 㨇24. COMPONENTS SYSTEM㨉

(3) Actuation in bucket operation

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

In bucket digging operation (Stroke limiter ON)



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㨇24. COMPONENTS SYSTEM㨉

2. In bucket dumping operation

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

In bucket dumping operation

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 㨇24. COMPONENTS SYSTEM㨉

(4) Boom
1. In boom up operation
On starting boom up operation, the pilot pressure enters port PAb and boom spool (301) moves
rightward against the force of springs (321) (322), and simultaneously the secondary pressure of
solenoid proportional valve [XI] acts on port PCa and switches unloading spool (309).
And the pilot pressure enters port PB1 and boom conflux spool (305) is switched against the force
of springs (325) (326) and the secondary pressure of solenoid proportional valve [X2] acts on port
PCa and switches unloading spools (310).
The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), pushes and
opens load check valve LCb (511), and flows through between the perimeter of boom spool (301)
and casing through U-shaped passage, and supplied to bucket cylinder head side (H) through port
(Ab).
In the meantime, the return oil from boom cylinder rod side (R) passes through between the
perimeter of boom spool (301) and casing, flows through low pressure circuit (D) and boost check
valve (517), and returns to the hydraulic tank through tank port T1.

In boom up operation (Boom spool)



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㨇24. COMPONENTS SYSTEM㨉

2. In boom up conflux operation

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

In boom up conflux operation (Boom conflux spool)

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 㨇24. COMPONENTS SYSTEM㨉

3. In boom down operation

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



In boom down operation

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㨇24. COMPONENTS SYSTEM㨉

(5) Arm operation

1. In arm out operation
On starting arm out operation, the pilot pressure enters ports PBa1 and PBa2, and arm 1 spool
(302) moves rightward against the force of springs (321) (322), and simultaneously the secondary
pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310).
And the pilot pressure also enters PBa2, and arm 2 spool (308) is switched against the force of
springs (321) (328) and the secondary pressure of solenoid proportional valve [X1] acts on port
PCb and switches unloading spools (309).
The hydraulic oil delivered by hydraulic pump P2 flows into parallel passage (56), pushes and
opens load check valve LCa (511), and flows into AR chamber through between the perimeter of
arm 1 spool (302) and casing through U-shaped passage.
In the meantime, the hydraulic oil delivered by hydraulic pump P1 flows through center by-pass
passage (52) and pushes and opens load check valve LCAT2 (511) and enters U-shaped
passage, and pushes and opens load check valve LCAP2 (515) provided with orifice, and flows
into U-shaped passage. And then the hydraulic oil flows through between the perimeter of arm 2
spool (308) and casing, and enters AR chamber through casing inside passage (RR) and
confluences the hydraulic oil from hydraulic pump P2 side.
The conflux hydraulic oil opens lock valve poppet CRar (514) and is supplied to arm cylinder rod
side (R).
In the meantime, the return oil from arm cylinder head side (H) flows through between the
perimeter of arm 1 spool (302) and casing and passes though low pressure circuit (D') and
casing inside passage (HH) and then flows into low pressure circuit (D') through between the
perimeter of arm 2 spool (308) and casing.
The return oil in low pressure circuit (D') returns to hydraulic tank through tank port T1 without
passing through boost check valve (517).

In arm out operation

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 㨇24. COMPONENTS SYSTEM㨉

2. In arm in operation (At light load: arm recirculation function)

On starting arm in operation, the pilot pressure enters ports PAa1 and PLc2, and arm 1 spool
(302) moves leftward against the force of springs (321) (322), and simultaneously the secondary
pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310).
At the same time, since the spool of lock valve selector (211) is switched, the spring chamber of
lock valve poppet CRar (514) is connected to the drain circuit and the retention of poppet (514) is
released.
And the pilot pressure enters PAa2 through solenoid proportional valve [XR], and arm2 spool (308)
moves leftward against the force of springs (321) (328) and the secondary pressure of solenoid
proportional valve [X1] acts on port PCb and switches unloading spools (309). But in light load
operation, because the solenoid proportional valve [XR] actuates and arm 2 spool (308) stays in
the position of circuit (I).
The hydraulic oil delivered by hydraulic pump P2 flows into parallel passage (56), pushes and
opens load check valve LCa (511), and flows into port (Aa) through between the perimeter of
arm 1 spool (302) and casing through U-shaped passage. In the meantime, the hydraulic oil
delivered by hydraulic pump P1 flows through center by-pass passage (52) and pushes and
opens load check valve LCAT2 (511) and enters U-shaped passage, and also the oil from
parallel passage (53) pushes and opens load check valve LCAP2 (515) provided with orifice and
flows into U-shaped passage. And then the hydraulic oil flows through between the perimeter of
arm 2 spool (308) and casing from U-shaped passage and enters port (Aa) through casing inside
passage (HH) and confluences the hydraulic oil from hydraulic pump P2 side.
The conflux hydraulic oil is supplied to arm cylinder head side (H) through port (Aa).
In the meantime, the return oil from arm cylinder rod side (R) enters the control valve through port
(Ba).
Because the retention of lock valve poppet CRar (514) which is located on this side of arm 1
spool (302) is released, the return oil pushes and opens lock valve poppet CRar (514) and
enters AR chamber. The return oil in AR chamber is led to arm 2 spool (308) through arm 1
spool (302) and casing inside passage (RR), but because arm 2 spool (308) does not connect to
low pressure passage (D) at circuit (I), the entire flow rate flows into arm 1 spool (302).
The return oil from chamber AR passes through the perimeter of arm 1 spool (302) and casing,
and flows through casing inside passage (RH) and is led to the inside of arm 2 spool (308)
through circular notch (a) of arm 2 spool (308). In light load operation, since the return oil
contains higher pressure than that of arm cylinder head side (H) with the self weight of arm, etc.
the hydraulic oil inside of arm 2 spool (308) passes through check valve (317) and flows into
casing inside passage (HH) and the supplied to arm cylinder head side (H) again. (Arm
recirculation function)
And a part of the return oil which was led to arm 2 spool (308) passes through check valve
(319), and flows through boost check valve (517) through load pressure circuit (D) and returns to
the hydraulic tank through tank port T1.



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In arm in operation (At light load: arm recirculation function)

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 㨇24. COMPONENTS SYSTEM㨉

3. In arm in operation (In heavy load operation)

The arm recirculation function is effective in actuating arm cylinder quickly in light load operation,
but in heavy load operation (work required large power); the function causes the power loss. This
control valve selects the presence of recirculation function in light and heavy load operation with
solenoid proportional valve [XR]. (Variable recirculation function)
The flow path of hydraulic oil in heavy load operation, the path on the supply side to arm
cylinder is the same as that in light load operation, differs from that of return oil. In heavy load
operation, solenoid proportional valve [XR] actuates and arm 2 spool (308) is positioned to circuit
(II). The return oil from arm cylinder rod side (R) enters the control valve through port (Ba).
Because the retention of lock valve poppet CRar (514) which is located on this side of arm 1
spool (302) is released, the return oil pushes and opens lock valve poppet CRar (514) and
enters AR chamber. The return oil in AR chamber is led to arm 2 spool (308) through arm 1
spool (302) and casing inside passage (RR). But because arm 2 spool (308) is connected to low
pressure passage (D) at circuit (aU), almost all the return oil passes through between the
perimeter of arm 2 spool (308) and casing and flows through boost check valve (517) through
low pressure (D) and returns to the hydraulic tank through tank port T1.
The return oil from AR chamber passes through between the perimeter of arm 1 spool (302) and
casing and flows through casing inside passage (RH) and then is led to the inside of arm 2
spool (308) through circular notch (a) of arm 2 spool (308). In heavy load operation, since the
pressure on arm cylinder head side (H) is higher than the rod side, the hydraulic oil in arm 2
spool (308) does not flow into casing inside passage (HH), but flows through check valve (319)
and passes through boost check valve (517) through low pressure (D) and returns to the
hydraulic tank through port T1.



In arm in operation (In heavy load operation)

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㨇24. COMPONENTS SYSTEM㨉

(6) Swing operation

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

Swing operation

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 㨇24. COMPONENTS SYSTEM㨉

(7) Spool actuation for operation in option

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

Spool actuation for operation in option



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㨇24. COMPONENTS SYSTEM㨉

(8) Lock valve operation

The lock valve is housed in between each port of the control valve connected to arm cylinder rod side
(R) and arm cylinder head side (H) and the arm spool and boom spool, and reduces the leaking due
to holding pressure caused by each cylinder.

1. At boom spool neutral position (Arm spool makes the same operation.)
When boom spool (301) is set to neutral position, spool (511) of lock valve selector is held on the
left side as shown in the figure. At this position, passages Sa and Sb are connected each other
at the inside of bushing (541) and on the perimeter of spool (511). Therefore in spring chamber
(RH) of lock valve poppet, the holding pressure receiving from boom cylinder head side (H)
passes from passage Sa to bushing (541) spool (511) and is connected through passage Sb,
consequently the lock valve poppet (514) is kept pressed the lower side as shown in the below
Fig. and restricts the leaking to the minimum.

Lock valve operation (At boom spool neutral position)

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2. In boom down operation (In arm in operation)

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


Lock valve selector operation (At boom down operation)

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㨇24. COMPONENTS SYSTEM㨉

(9) By-pass cut valve

This by-pass cut valve is located on the most downstream of P1 side center by-pass passage (52)
and P2 side center by-pass passage (55). And this by-pass cut valve controls the flow of hydraulic oil
from each center by-pass passage to low pressure passage (D).

1. In normal operation
Adjusting screw (201) is tightened up to end in normal operation. Tapered end of adjusting screw
(202) is seated on the seat of casing, and flow between center by-pass passage (52) and low
pressure passage (D) is blocked.
Consequently, in normal operation, center by-pass passage (52) is always blocked from low
pressure passage (D). And the hydraulic oil delivered by pump P1 does not flow through center
by-pass passage (52), but returns to hydraulic tank through P1 unload spool (309).

By-pass cut valve (In normal operation)

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2. At the time when failure occurred

When the electric system is failed, P1 unload spool (309) stops at neutral position. Hydraulic oil
entered from P1 pump is blocked with P1 unload spool (309). And pump pressure rises to set
pressure of main relief valve because oil flows through center by-pass passage (52) and it is
blocked with by-pass cut valve (606).
Meanwhile, the hydraulic oil flows from center by-pass passage (52) flows low pressure passage
(D) through by-pas cut valve (606).
Therefore when the electric system is failed, P1 unloading spool (309) is shifted to the neutral
position. And passage to low pressure passage (D) is blocked, but because center by-pass
passage (52) is connected to low pressure passage (D) through by-pass cut valve (606), the
abnormal rise of the pump pressure is prevented.

By-pass cut valve (In condition of failure)



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(10) Boost check valve, By-pass check valve

1. Boost check valve
The boost check valve is located between low pressure passage (D) and tank port T1 and
generates boost pressure necessary for the low pressure passage.

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

Boost check valve operation

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2. By-pass check valve

Even if the pressure at tank port T1 goes up due to the sudden change of return flow rate, the
by-pass check valve actuates and prevents the pressure at tank port T1 from going up higher than
the specified pressure, and consequently the oil cooler and filter located between tank port T1 and
the hydraulic tank are protected from possible damage.
When the pressure at tank port T1 goes up to the pressure added by spring (528), by-pass check
valve (518) is pushed and opens against the force of spring (528), and the hydraulic oil in tank
port T1 directly returns to the hydraulic tank through tank port T2.

By-pass check valve operation



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㨇24. COMPONENTS SYSTEM㨉

24.1.3 PILOT VALVE (ATT)

24.1.3.1 OUTLINE
(1) Outside view

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24.1.2.2 CONSTRUCTION

Pilot valve (ATT)

Tightening torque Tightening torque

No. NAME Q'TY No. NAME Q'TY
N-m (lbf-ft) N-m (lbf-ft)
101 Casing 1 *218 Seat 4
151 Plate 1 221 Spring 4
201-1 Spool 2 241-1 Spring 2
201-2 Spool 2 241-2 Spring 2
211 Plug 4 *246-1 Spring 2
212 Push rod 4 *246-2 Spring 2
213 Seal 4 47.1 (34.7) 301 Joint: M14 1
214 O-ring: 1B P20 4 302 Circular plate 1
216-1 Spring seat 2 68.6 (50.6) 312 Adjust nut: M14 1
216-2 Spring seat 2 501 Boots 1
217 Washer 2 (Shim) 4

Note) The parts marked * may not be equipped depending on valve type. 

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24.1.3.3 OPERATION
(1) Lever in neutral (See right Fig.)
The action of spring (509) (for secondary
pressure setting) that determines the
output pressure of the pilot valve does not
act upon spool (201). Therefore, spool
(201) (for return) is pushed up by spring
(221) [spring seat (216)]. The output ports
(2,4) connect with the T port. The result is
that the output pressure is equal to the
tank pressure.

Lever in neutral

(2) When the pilot lever is tilted (See right Fig.)

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

When the lever is tilted

(3) Lever held (See right Fig.)

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

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(4) Operation in the area where the tilting angle of the lever is large.
(varies with the model)
If the lever is inclined beyond a certain angle on certain models, the top end of the spool contacts
the bottom of the bore of the push rod. This keeps the output pressure connected with the P port
pressure.
Furthermore, on a model in which a spring seat and a spring are built in the push rod, the bottom
of the bore of the push rod contacts the spring if the lever is turned beyond a certain angle.
This causes the secondary pressure gradient to change by the spring action. Thereafter, the
bottom of the bore of the push rod contacts the top end of the spring seat, keeping the output
pressure connected with the P port.



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24.1.4 PILOT VALVE (TRAVEL)

24.1.4.1 OUTLINE
(1) Outside view

(2) Specifications

(3) Performance characteristics

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24.1.4.2 Construction and operation

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



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24.1.5 SWING MOTOR UNIT

24.1.5.1 SPECIFICATION
(1) General view

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(2) Specifications
Swing motor unit part No. LC15V00027F2
Type M5X180CHB-10A-60D/295
Part No. LC15V00022F2
3 3
Displacement cm (in ) 180.1 (11.0)
Working pressure MPa (psi) 32.4 (4700)
Hydraulic motor Max. flow L/min (gal/min) 294 (77.7)
Braking torque N-m (lbf-ft) 860-1120 (634-827)
Release pressure MPa (psi) 2.4~5.0 (348~725)
Relief set pressure MPa (psi) 29 (4205)
Weight kg (lbs) 72.5 (160)
Type 2KAR6P72/240-712
Anti-reaction valve block
Weight kg (lbs) 2.5 (5.5)
Hydraulic motor assy weight kg (lbs) 75 (165)
Part No. LC32W00011F1
Speed reduction type Planetary 2-stage
Reduction ratio 27.143
Lubicate oil Gear oil SAE90 (API class GL-4 grade)
Reduction unit
Lubicate oil volume L (gal) 7.4 (1.96)
Grease Extreme pressure lithium base #2 grease
Grease volume kg (lbs) Approx. 1.7 (3.7)
Weight kg (lbs) 371 (818)
Total weight kg (lbs) 446 (983)



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24.1.5.2 CONSTRUCTION
(1) Swing motor

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Tightening Tightening
torque No. NAME Q'TY torque No. NAME Q'TY
N-m (lbf-ft) N-m (lbf-ft)
177 (130) 051 Relief valve; M33-P1.5 2 69 (51) 400 Anti-reaction valve; 2
M22-P1.5
051-1 O-ring; 1B G30 2 400-1 O-ring; 1B P20 2
052 Anti-reaction valve sub 1 400-2 Backup ring 2
100 Casing for anti-reaction 1 431 (318) 401 Socket bolt; M20X45 4
valve
101 Drive shaft 1 443 Roller bearing 1
111 Cylinder 1 444 Roller bearing 1
114 Spring plate 1 451 Pin 2
121 Piston 9 539 (398) 469 ROMH plug; M36-P1.5 2
122 Shoe 9 472 O-ring; W1516,WG44 1
123 Set plate 1 488 O-ring; 1B P34 2
124 Shoe plate 1 491 Oil seal 1
131 Valve plate 1 702 Brake piston 1
36 (27) 151 Plug; PF1/4 2 706 O-ring; W1516,WG42 1
161 O-ring; 1B P11 2 707 O-ring; W1516,WG45 1
162 O-ring; 1B P12 2 712 Brake spring 14
163 O-ring; 1B P6 2 742 Friction plate 3
29 (21) 171 Socket bolt; M8X55 4 743 Separator plate 4
301 Casing 1 2.7 (2.0) 984 Plug; PF1/2 1
303 Valve casing 1 5.6 (4.1) 985 Plug; PF1 1
351 Plunger 2 0.9 (0.66) 986 Plug; PF1/4 1
355 Spring 2 98 (72) 994 Plug; PT3/4 1
390 Name plate 1
391 Rivet 2



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(2) Swing reduction unit

Tightening torque Tightening torque

No. Parts Q'TY No. Parts Q'TY
N-m (lbf-ft) N-m (lbf-ft)
1 Pinion 1 20 Plate 1
2 Shaft 1 21 Ring 1
3 #1 Sungear 1 22 Thrust washer 6
4 #1 Planetary pinion 3 23 Thrust washer 8
5 #1 Spider assy 1 24 Snapring 1
6 #2 Sungear 1 25 Snapring 3
7 #2 Planetary pinion 4 26 Spring pin 4
8 Ring gear 1 539±54 (398±40)*1 27 Capscrew ; M20X200 12
9 #2 Spider assy 1 28 Grease fitting 1
10 Shaft 4 29 Relief fitting 1
11 Needle bearing 11 69.1±4.4 (51±3)*2 30 Tube 1
12 Roller bearing 1 69.1±4.4 (51±3)*2 31 Elbow 1
13 Roller bearing 1 69.1±4.4 (51±3)*2 32 Plug 1
14 Oil seal 1 33 Cap 2
15 Housing 1 279±30 (206±22)*1 34 Capscrew 3
16 Oil seal 1 35 Shim ; t=0.1 1
17 Sleeve 1 36 Shim ; t=0.2 1
18 Sleeve 1 37 Shim ; t=0.3 1
19 Plate 1 38 Shim ; t=0.5 1

*1 : Apply Three Bond #1360K.

*2 : Apply seal tape or Loctite #577.
*3 : Apply Loctite #515.

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24.1.5.3 OPERATION
24.1.5.3.1 OPERATION OF HYDRAULIC MOTOR
If the high pressure oil flows into the cylinder
through the inlet port (a) of valve plate (131),
as shown on the figure on the right, the
hydraulic pressure acts upon piston (121) and
creates force F in the axial direction.
The force F may be divided into force F1
vertical to shoe plate (124) via shoe (122) and
force F2 at right angles with the shaft.
The force F2 is transmitted to cylinder block
(111) via pistons (121) and causes drive shaft
to turn so as to produce a rotating moment.
The cylinder block (111) has nine pistons
equally arranged. Rotating torque is transmitted
to drive shaft by turns by pistons connected to
inlet port of high pressure oil.
If the oil supply and discharge directions are
reversed, the drive shaft rotates in the opposite
direction.
Theoretical output torque T can be given by the
following equation.

Operation of hydraulic motor



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24.1.5.3.2 VALVE CASING SECTION

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

Operation of anti-cavitation check plunger

(2) Operation of relief valve

1. Consider where the relief valve is pressurized.
The pressure at the P, R ports is equal to the tank pressure at the beginning, as shown in below
Fig..
The relief valve begins to operates when the hydraulic pressure that is determined by the product
of the pressure-receiving area A1 of plunger(301) and the pressure P balances the hydraulic
pressure that is determined by the product of the pressure-receiving area A2 of the plunger(301)
and the pressure Pg of chamber g.
Thereafter, the pressure of chamber g rises and the piston 1 (302) begins to stroke. The load to
spring (321) increases by this movement of the piston.
As the result, the relief pressure P is raised and controlled in the pressure boost time t1 from P1
till Ps.
This process is explained in the following in the relationships between the movements of the
components shown in (2) to (4) of below Fig. and the relief pressure :

Functional explanation of relief valve (1) Functional explanation of relief valve (2)

a. Condition shown in above Fig..

If the P port of the relief valve is pressurized, pressure is built up in chamber g via the restrictor
m of plunger (301).
The hydraulic pressure acting on plunger (301) increases and when it balances the load Fsp of
spring (321), the relief valve performs relieving action by the pressure P1.
This relationship is expressed as :
P1XA1=FSP1+Pg1XA2
where FSP1 :
primary set load value of spring (321)

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b. Condition shown in below Fig..

The pressure of chamber g acts upon the pressure-receiving area A3-A4 of piston 1 (302). When
the hydraulic pressure rises above the load of spring (321), the piston 1 begins to move to the
left.
On that occasion, since the machine turns to the left while discharging the oil of chamber h
arranged between piston 1 and adjust plug (401) into chamber g via orifice n provided in piston
1 (302), chamber h serves as a dumping chamber.
The load of the spring increases slowly till piston 1 reaches the end of the adjust plug. The relief
pressure P rises smoothly.

Functional explanation of relief valve (3) Functional explanation of relief valve (4)

c. Condition shown in above Fig..

The machine does not travel to the left further when piston 1 (302) arrives at the end of adjust
plug (401). Therefore, the relief valve keeps its normal relieving action whereby the relief pressure
is held at P2. In the processes 1 to 3 above, the relief pressure changes as shown in above Fig..

Condition

2. Function when the relief valve pressure is reduced

Let us consider the pressure of the P port is reduced.
When the pressure at port P is reduced to zero, the pressure of chamber g falls to the tank
pressure level. The result is that the plunger (301) which is now open moves to the left and is
seated on seat (341). At the same time, the piston 1 (302) moves to the right by the action of
spring (321) and returns to the condition of above Fig..



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(3) Operation of anti-reaction valve

Hydraulic circuit diagram for anti-reaction valve.

1. Neutral condition:
Above Fig. illustrates the relationship
between the neutral condition of the
anti-reaction valve and the hydraulic circuits.
Now, let us consider a braking condition in
which brake pressure generates on the
AM port side.
Neutral condition

2. When brake pressure occurs:

If pressure (P) generates at the AM port,
it passes through the passage L, the hole
on the shaft of seat (313) and the
passage m of plunger (311) and is led to
the n chamber.
When the pressure P rises above a value
(Ps) set by spring (321), plunger (311) When brake pressure occurs
compresses spring (321) and shifts it to the
left.
Seat (313) compresses weak spring (322)
as pushed by plunger (311) and moves to
the left.

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3. At anti-reaction action
When inertia load stops moving (point Y below Fig.), brake pressure (P) tries to fall.
When P<Ps, plunger (311) moves toward the right return side by the action of spring (321). Seat
(313) tries to move to the right by the action of spring (322), but since chamber p provides
damping action by orifice g, the return of the seat makes a time delay with regard to the return of
the plunger.
Consequently, seat t opens. This makes a passage connecting the AM port and BM ports or both
ports of the hydraulic motor by way of L--> t--> r--> k. The result is that the pressures at the AM
and BM ports become equal (Pb), falling into the condition at point Z in below Fig..
This prevents the hydraulic motor from swing shock by the closing pressure of the AM port.

Pressure change diagram of anti-reaction

operation
At anti-reaction action

24.1.5.3.3 OPERATION OF BRAKE SECTION

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



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24.1.5.3.4 SWING REDUCTION UNIT

The swing reduction unit is used to reduce the
rotating speed which is transmitted by the
hydraulic motor and to convert it to the strong
turning force (torque).
This swing speed reduction unit is equipped
with planetary speed reducing mechanism.
The planetary mechanism is made up of sun
gear, planetary pinion, planetary shaft, spider
and ring gear, as shown in right Fig..

Planetary mechanism

For the operation of the 1st stage planetary, the

hydraulic motor rotates #1 sun gear (3). Sun
gear (3) is engaged with planetary pinion (4)
and rotates, but since ring gear (8) is fixed,
planetary pinion (4) revolves about sun gear
(3) with the planetary shaft and spider (5).

The role of spider is to hold the planetary

pinion and planetary shaft and transmits the
power from the planetary pinion to the spider
through the planetary shaft.
The #1 spider (5) is linked with #2 sun gear
(6) by the involute spline, and transmits the
power to the 2nd stage planetary mechanism.
For the operation of the 2nd stage planetary,
the power is transmitted to #2 sun gear (6)
#2 planetary pinion (7) #2 spider (9) similarly
Function of reduction unit
to the 1st stage. The #2 spider (9) is linked
with pinion shaft (2) by the involute spline, and
pinion (1) is engaged with the swing gear
fixed on the undercarriage (lower frame) and
rotates.

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24.1.6 TRAVEL MOTOR

24.1.6.1 SPECIFICATION
(1) Appearance

Travel motor

Rotation direction
Oil inlet Oil outlet Rotation direction
port port (Viewed from valve port side)
VA VB Right (Clockwise)
VB VA Left (counter clockwise)


Tightening torque
Port name Port size Function
N-m (lbf-ft)
P PF1/4 36 (26.6) Pilot (2 speed changeover) port
D1, D2 PF1/2 98.1 (72.4) Drain port
VA, VB PF1 255 (188) Motor drive port
MA, MB PF1/4 29.4 (21.7) Pressure measurement

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(2) SPECIFICATIONS

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24.1.6.2 CONSTRUCTION
24.1.6.2.1TRAVEL MOTOR

Travel motor

No. NAME No. NAME No. NAME

1 Casing 21 Brake piston 41 Restrictor spring(brake valve)
2 NPT 1/16 plug 22 D-ring (small dia.) 42 G1/8 plug
3 Oil seal 23 D-ring (big dia.) 43 O-ring 1B P8
4 Retaining ring IRTW68 24 Rear cover 44 Check valve

Expander plug 25 NPT 1/16 plug (MEC) 45 Check valve spring

5
MB800-040 26 Spool assy (M4V RBV) 46 M6 restrictor (0.6)
6 Shifter piston 27 Spring holder (M4V RBV) 47 O-ring 1B P12.5
7 Piston seal 28 Spring (M4V150RBV) 48 M8 restrictor (0.8)
8 Steel ball 25 29 M42 plug (4V RBV) 49 O-ring 1B P15
9 Shaft 30 O-ring 1B G40 50 O-ring 215.57X2.62
10 Bearing HR32209J Pilot valve spool 51 Bearing HR32207C
31
11 Pivot 10dia.(M4V290) 52 Shim
12 Swash plate 32 Pin (MRC03) 53 Parallel pin M68X12
13 Cylinder block 33 Spring holder (MRC03) 54 Valve plate
14 Cylinder spring 34 Spring (MRC03) 55 Brake spring
15 Spring holder 35 G3/8 pilot valve plug 56 HEX. socket head bolt M18X50
16 Ball joint 36 O-ring 1B P14 57 Overload relief valve ORV-240L

17 Shoe retainer 37 Connector (MRC03) 58 Coupling
18 Piston assy 38 G1/4 plug 59 Retaining ring C-type 40
19 Separating plate 39 O-ring 1B P11 60 G1/2 plug
20 Friction plate 40 Restrictor (brake valve) 61 O-ring 1B P18

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24.1.6.2.2 REDUCTION UNIT

Reduction unit

No. NAME No. NAME No. NAME

1 Housing 10 Planetary gear 2 19 Needle bearing FBNP-406040
2 Bearing 245BA35S1GS 11 Thrust washer 2 20 Carrier pin 1
3 Ring gear 12 Needle bearing FBNP-608660 21 Spring pin 6X36
4 HEX.socket head bolt M18X110 13 Carrier pin 2 22 Sun gear 1
5 Floating seal 368 14 Spring pin 10X50 23 Thrust plate
6 Shim 15 Sun gear 2 24 Cover
7 Lock washer 16 Carrier 1 25 HEX.socket head bolt M10X30
8 Support ring 17 Planetary gear 1 26 Plug G3/4
9 Carrier 2 18 Thrust washer 1 27 O-ring 1B P24

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24.1.6.3 MAKEUP OF TRAVEL MOTOR

The travel motor consists mainly of the rotary group that generates rotating power, the parking brake
that prevents the machine from moving by itself while it is parked, the variable displacement
mechanism that switches over the motor capacity to the large or small mode, the overload relief valve
that is built in the rear cover, and the brake valve (counterbalance valve) that controls the hydraulic
circuits.

(1) Rotary group

Cylinder block (13) is inserted in the gear tooth grooves of the spline of shaft (9) that is supported
by bearings (10, 51) at it both ends. The cylinder block (13) is pressed against rear cover (24)
with valve plate (54) by the action of spring (14).
9 piston assy (18) slide over shoe plate (12), while stroking in cylinder block (13).
A bearing retainer is arranged at the end face of piston assy (18) to reduce the sliding resistance.
The action of spring (14) is transmitted to spring retainer (15), ball joint (16), and shoe retainer
(17) and presses the end face of piston assy (18) against shoe plate (12) so the piston assy
moves close to the surface of shoe plate (12).
(2) Parking brake
Seven separator plates (19) and six friction plates (20) are inserted by turns in the spline grooves
in the outer surface of cylinder block (13) and are pressed against casing (1) by the action of 14
springs (55) via brake piston (21).
(3) Variable displacement mechanism
The variable displacement mechanism consists of pivot (11) supporting shoe plate (12) that is put
in two semispherical concaves provided in shoe plate tilting piston (6) that tilts shoe plate on
pivot (11) tilting stopper (H) supporting the piston at a certain position; the pilot valve that admits
the pressurised oil to the tilting piston (6) by an external command; and three check valves (44)
that take out the highest of the external command activated pilot pressure, the motor inlet pressure
and the motor outlet pressure and that sends it to the pilot valve.
(4) Overload relief valve
The overload relief valve consists of socket (57-1) that has valve seat (57-3) metallically seating
rear cover (24) of the motor and screwed up in rear cover (24) valve (57-2) engaged with socket
(57-1) that is tangential in contact with valve seat (57-3) by the action of adjust spring (57-9)
connecting piston (57-4) that is inserted in valve (57-2) and serves also as an oil path to pilot
body (57-6) piston (57-7) that is put in pilot body (57-6) and pressed against plug (57-5) and
shim (57-8).


Construction of overload relief valve

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(5) Brake valve portion

1. Spool
By shifting the spool (26), the discharged oil from hydraulic motor is automatically shut off or
restricted according to the condition and give the effect of holding, accelerating, stopping and
counterbalance operations.
2. Check valve (built in the spool)
This valve is located in the oil supplying passage to hydraulic motor, and at the same time
functions to lock oil displacement. Therefore, this valve serves as not only a suction valve but also
a holding valve for hydraulic motor.

Brake valve portion

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24.1.6.4 FUNCTION OF TRAVEL MOTOR

(1) Motor
High pressure oil delivered from hydraulic pump is led to inlet port that is provided in the brake
valve portion and, through the rear cover (24) and valve plate (54), led to cylinder block (13).
As shown in below Fig. (a), high pressure oil is supplied to the pistons which are on one side of
the line Y-Y that connects upper and lower dead points and produces force F1.
F1=PXA (P : pressure, A : area of piston section)
The swash plate (12) with inclined angle of divides this force F1 into thrust force F2 and radial
force F31-F34 (or F35). [below Fig. (b)] This radial force is applied to axis Y-Y as turning force
and generate drive torque of T.
T=r1 F31+r2 F32+r3 F33+r4 F34
(In case high pressure oil is applied to five pieces of pistons, r5 F35 should be added.)
This drive torque is transmitted via cylinder block (13) to driving shaft (9).

(2) Parking Brake

Parking brake is released when high pressure oil, selected by the brake valve portion that is
connected directly to the rear cover (24), is applied to the brake piston (21). Otherwise the braking
torque is always applied.
This braking torque is generated by the friction between the separating plates (19), inserted into
the casing (1), and friction plates (20), coupled to cylinder block (13) by the outer splines.
When no pressure is activated on the brake piston (21), it is pushed by the brake springs (55)
and it pushes friction plates (20) and separating plates (19) towards casing (1) and generates the
friction force which brakes the rotation of cylinder block (13) and hence the shaft (9).



Parking brake portion

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(3) Capacity Control Mechanism

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

Capacity control Mechanism

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(4) Function of overload relief valve

Two pieces of overload valves are located at cross-over position in the counterbalance circuit of
brake valve and have the following functions:

1. When hydraulic motor starts, keep the driving pressure below predetermined value and while
accelerating, bypasses surplus oil to return line.
2. When stopping the motor, keep the brake pressure, that develops on the outlet side of motor,
under the predetermined value to stop the inertial force.
3. To accelerate sharply while starting, and to mitigate the braking shock while stopping. For these
purposes, the developed pressure is kept comparatively low for a short period, then keep the line
pressure as normal value. While the pressure is low, meshing of reduction gears, crawler and
sprocket etc. can be smoothly done and the shock are absorbed.

When starting, "A" port pressure of overload valve increases, this pressure is applied to the
effective diameter of valve (57-2) which seats on the valve seat (57-3) and, at the same time, is
delivered, via small hole, to the connecting piston (57-4) located inside the valve (57-2) and the
piston bore pressure increases up to "A" port pressure. The valve (57-2) opposes to adjusting
spring (57-9) by the force of the pressure exerted on the area difference between valve seat's
effective diameter and piston bore and keep the predetermined pressure.
When hydraulically braking, the piston (57-7) is at the left position by the driving pressure, and
when "A" port pressure increases, the pressure is applied also to the piston (57-7) through the
small hole in the valve (57-2) and piston (57-7) moves rightward until it touches the cap (57-5).
In this while, the valve (57-2) maintains "A" port pressure at comparatively low against the
adjusting spring (57-9) force and exhaust oil to "B" port side. After the piston reached to the
plug, the valve acts the same as at starting.

Function of overload relief valve



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(5) Function of brake valve

1. Holding operation (see below Figure)

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

Holding Operation

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2. Accelerating operation (see below Figure)

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

Accelerating Operation



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3. Stopping operation (see below Figure)

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

Stopping operation

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4. Counterbalance operation (see below Figure)

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

Counterbalance operation



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24.1.6.5 FUNCTION OF REDUCTION GEAR

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

Planetary gear mechanism

See Fig. on the right.

When the sun gear S1 is driven by input
shaft, planetary action occurs among gears S1,
a and b and revolution of gear b transfers the
rotation of carrier K1 to second sun gear S2,
and also evokes planetary action between gear
S2, a and d.
This time, because carrier K2 is fixed to
frame, gear d drives ring gear a and then ring
gear a rotates to drive sprocket. Two stages reduction gear

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24.1.7 SWIVEL JOINT

24.1.7.1 GENERAL VIEW

General view of swivel joint

24.1.7.2 SPECIFICATIONS
Item Specifications
Assy parts No. YN55V00053F1
Working pressure 34.3 MPa (4970 psi)
High pressure ports
Max. impact pressure 51.5 MPa (7470 psi)
A, B, C, D
Rated flow 255 L/min (67 gal/min)
Low pressure ports Working pressure 0.5 MPa (73 psi)
E Rated flow 50 L/min (13 gal/min)
Low pressure ports Working pressure 5 MPa (725 psi)
F Rated flow 30 L/min (8 gal/min)
Revolution speed 15 min-1 (15 rpm)

A, B, C, D (Body) PF1
A, B, C, D (Stem) PF3/4
Ports size
E PF1/2
F PF1/4
Length: L 368 mm (14.5")
Weight 25 kg (245 lbs)

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24.1.7.3 CONSTRUCTION

Construction

No. NAME Q'TY No. NAME Q'TY

1 Body 1 7 O-ring(G95 1A) 1
2 Stem 1 8 Capscrew (M8X20) 2
3 Thrust plate 1 9 Capscrew (M8X30) 3
4 Cover 1 12 Plug 1
5 Seal 5 13 O-ring 1
6 Seal 1

24.1.7.4 FUNCTION
The swivel joint consists mainly of body (1) and stem (2) that rotate mutually, thrust plate (3)
preventing both components from falling off, cover (4) closing one side of body (1), seal (5) that
partitions off the circuits and seal assy (6) and O-ring (7) that prevent external leaks. Four ports for
the travel main circuits are provided on body (1) and stem (2). Further, four oil passing grooves are
arranged in the inner surface of body (1), with seal (5) fixed above and below the circumferential
groove. The body (1) and the stem (2) rotate mutually. The oil flowing in from body (1) or stem (2)
keeps on flowing to stem (2) or body (1) past the circumferential groove between body (1) and stem
(2) ; the oil flow is never shut off because of rotation. Further, an oil groove for lubrication that
connects with the drain port is provided, in order to prevent the body (1) from seizure with the stem
(2). This construction keeps on connecting the circuits between the swing bodies by means of a swivel
joint.

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24.1.8 CYLINDER
24.1.8.1 SPECIFICATIONS
(1) General View

General view of cylinder

(2) Specifications
Center distance of
Cylinder bore/Rod Stroke
Part No. of pins Full extend B Dry weight
Use Dia. mm Cushion
cylinder assy / Full retract A kg (lbs)
mm (ft-in) (ft-in)
mm (ft-in)
140 dia./100 dia. 1,550 3,651 / 2,101 With cushion 269
Boom LC01V00044F1
(5.51"/3.94") (5'1") (11'12" / 6'11") on rod side (593)
With cushion
170 dia./120 dia. 1,788 4,281 / 2,493 504
Arm LC01V00054F1 on both
(6.69"/4.72") (5'10") (14'1" / 8'2") (1,111)
sides
150 dia./100 dia. 1,193 3,005 / 1,812 With cushion 265
Bucket LC01V00055F4
(5.91"/3.94") (3'11") (9'10" / 5'11") on rod side (584)



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24.1.8.2 CONSTRUCTION AND FUNCTION

24.1.8.2.1 Construction
(1) Boom cylinder

Construction of boom cylinder

P/No: LC01V00044F1
No. NAME Q'TY No. NAME Q'TY No. NAME Q'TY
1 Cylinder tube 1 10 O-ring 1 19 Slide ring 2
2 Piston rod 1 11 Backup ring 1 20 Set screw; M14 1
3 Rod cover 1 12 Socket bolt; M18X80 12 21 Steel ball 1
4 Bushing 1 13 Cushion bearing 1 22 Pin bushing 1
5 Snap ring 1 14 Cushion seal 1 23 Wiper ring 2
6 Buffer ring 1 15 Piston 1 24 Pin bushing 1
7 U-ring 1 16 Seal ring 1 25 Wiper ring 2
8 Backup ring 1 17 Backup ring 2
9 Wiper ring 1 18 Slide ring 2

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(2) Arm cylinder

Construction of arm cylinder

P/No: LC01V00054F1
No. NAME Q'TY No. NAME Q'TY No. NAME Q'TY
1 Cylinder tube 1 11 Backup ring 1 21 Piston nut 1
2 Piston rod 1 12 Socket bolt; M22X95 12 22 Set screw; M16 1
3 Rod cover 1 13 Cushion bearing 1 23 Steel ball 1
4 Bushing 1 14 Cushion seal 1 24 Cushion bearing 1
5 Snap ring 1 15 Piston 1 25 Cushion seal 1
6 Buffer ring 1 16 Seal ring 1 26 Stopper 2
7 U-ring 1 17 Backup ring 2 27 Snap ring 1
8 Backup ring 1 18 Slide ring 2 28 Pin bushing 2
9 Wiper ring 1 19 Slide ring 2 29 Wiper ring 4
10 O-ring 1 20 Shim 1



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(3) Bucket cylinder

Construction of bucket cylinder

P/No: LC01V00055F4
No. NAME Q'TY No. NAME Q'TY No. NAME Q'TY
1 Cylinder tube 1 9 Wiper ring 1 17 Slide ring 2
2 Piston rod 1 10 O-ring 1 18 Slide ring 2
3 Rod cover 1 11 Backup ring 1 19 Shim 1
4 Bushing 1 12 Socket bolt; M20X95 12 20 Piston nut 1
5 Snap ring 1 13 Cushion bearing 1 21 Set screw; M14 1
6 Buffer ring 1 14 Piston 1 22 Steel ball 1
7 U-ring 1 15 Seal ring 1 23 Pin bushing 4
8 Backup ring 1 16 Backup ring 2 24 Wiper ring 4

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HYDRAULIC CYLINDER CONSTRUCTION (See structure Fig.)

By construction the hydraulic cylinder consists mainly of cylinder tube assy (1), piston rod assy (2) that
takes out the motion of pistons reciprocating in the cylinder tube assy, and cylinder head (3) that
serves as both a lid and a guide. Cylinder tube assy (1) is equipped with a pin mount (clevis) that
connects piston rod assy (2) with other parts. In addition to these main components, seal ring (16) and
back-up ring (17) are located between cylinder tube assy (1) and piston rod assy (2); buffer ring (6),
U-ring (7) back-up ring (8) and wiper ring (9) are located between piston rod assy (2) and cylinder
head (3); and an O-ring (10) and a back-up ring (11) are placed between cylinder tube assy (1) and
cylinder head (3)

24.1.9.2.2 OPERATION
If pressurized oil is fed alternatively to the oil
inlet and outlet provided in the cylinder, force
acts on the piston which in turn causes the
piston rod (2) to extend and retract.

Cushion mechanism on the rod side

(1) Operation of cylinder with cushion

1. Cushion on rod side
The cushion mechanism is provided to
prevent the generation of shock when the
moving speed of piston (15) is not
reduced and strikes cylinder head (3). An
oil in chamber "A" returns to the tank by
passing through passage "B" at a fixed flow
rate in a intermediate stroke state (Right
Fig.) of pressing head side. Next, in a state Cushioning action on the rod side
of just before stroke end (Right Fig.),
cushion ring (13) plunges into passage
"B". At this time, an oil in chamber "A"
passes clearance "D" and mouth gap "C",
an oil flow volume returning to tank
suddenly drops and the piston part
movement slows down.



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2. Cushion on head side (See right Fig.)

This construction is similar to the one of
cushion on rod side. In a state of
intermediate stroke pressing rod side, an oil
in chamber "A" returns to tank by passing
through passage "B" at a fixed flow rate.
Next, in a state of just before stroke end,
cushion bearing (24) plunges into passage
"B". At this time, the oil in chamber "A"
flows only through clearance "D" and mouth
gap "C" of cushion seal (25). So the
returning oil volume drops suddenly and the
piston movement slows down.

Cushion mechanism on the head side

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24.2 ELECTRICAL EQUIPMENT

24.2.1 ELECTRICAL EQUIPMENT LIST

Group Code Part Name Part No.

C-1 Mechatro controller (HARD) YN22E00425F1
C-2 Cluster gauge YN59S00028F6
C-4 Air-con controler LQ20M01328P1
(C) Controller C-5 Engine coolant level controller VHS834701230
C-7 IT controller -
C-8 Engine controller VH89661E0064
C-12 Dosing controller VH89550E0160
D-4 Diode YN02D01001P1(4P)
D-5 Diode Accessory of relay box
D-6 Diode
D-9 Diode
D-10 Diode
D-12 Diode
D-13 Diode
D-14 Diode
(D) Diode D-16 Diode
D-17 Diode
D-20 Diode
D-21 Diode Accessory of relay box
D-22 Diode
D-23 Diode
D-25 Diode YN02D01001P1(4P)
D-66 Diode
D-67 Diode
E-1 Fuse and Relay box YN24E00016F3
E-2 Alternator VH27060E0040
E-3 Hour meter LQ58S00002P1
E-5 Horn high LC53S00001D1
(E) Electric fittings E-6 Horn low LC53S00001D2
E-7 Tuner AM / FM YN54S00045P2
E-8 Speaker left LQ54S00003S002
E-9 Speaker right

E-10 Receiver drier LQ54S00005P1

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Group Code Part Name Part No.

E-11 Air-con compressor YX91V00001F1
E-12 Battery YN72S00014P1
E-13 Travel alarm YN53S00004F1
E-15 Fusible link LE73E00001S001
E-22 DC-DC Converter YN77S00069P1
E-23 12V socket YN81S01002P1
E-24 GPS antenna YN11E01235F1
E-25 Orbcomm antenna YN11E01248F1
E-27 Accel redundant volume YN52S00052P1
E-46 Rear camera YN55S00009F1
(E) Electric fittings E-49 DC-DC converter (Proportional) YN77S00069P1
E-63 DC-DC converter (For rear camera) YN77S00040P1
E-76 Fusible link LE73E00001S002
Engine accessory
E-77 Supply module
parts
E-78 Resistor
E-79 Dosing module VHS17J0E0030
E-84 DCU fuse YN24E00016S007
E-89 Sensor fuse YN24E00016S008
E-99 ECU fuse YN24E00016S005
E-100 Varistor LC01E01018P1
L-1 Boom working light left YW80S00001F1
L-2 Frame working light right YT80S00002F2
L-3 Swing flasher (LH) & rear work light YM80S00001F1
L-4 Swing flasher (RH) & rear work light YM80S00001F2
(L) Light
L-5 Room light LQ02C00031S020
L-6 Boom working light right YW80S00001F1
L-7 Cab working light front 1 YT80S00002F2
L-8 Cab working light front 2
M-1 Starter motor VH28100E0080
(M) Motor M-3 Wiper motor LQ53C00003S001
M-4 Washer motor YT54C00003F1
PSV-A Arm 2 speed inverse propo. valve YN35V00049F1
PSV-B P2 unload propo. valve YN35V00047F3 YN35V00048F2
PSV-C Travel straight propo. valve Solenoid valve assy

PSV-D P1 unload propo. valve

(P) Proportional LC30V00035F1
solenoid valve PSV-R Control propo. valve YN35V00048F1
Control valve
LC10V00029F4
PSV-P1 P1 pump propo. Valve YN35V00054F1
(North America) Pump
LC10V00030F4
PSV-P2 P2 pump propo. Valve
(Europe) Pump

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Group Code Part Name Part No.

R-1 Battery relay YN24S00008F1
R-2 Starter relay VHS283001271
R-3 Glow relay VHS286201420
R-4 Safety relay YN24S00010P1
R-5 Horn relay
R-6 Working light relay
R-8 Travel alarm relay
R-9 Cab working light relay 1
R-11 Cab working light relay 2
R-19 Flasher relay YY24S00001P2
(R) Reray
R-23 Auto idle stop relay 1 YN24S00010P1
R-24 Auto idle stop relay 2
R-25 E/G emergency stop relay
R-26 Lever lock relay
R-28 Alternator relay
R-29 Wiper motor relay YN24S00012P2
R-30 Wiper motor reversing relay
R-31 Prevent spark relay
R-32 Window Washer motor relay
R-94 Neutral stop relay YN24S00010P1
SE-1 Pressure sensor:Bucket digging LC52S00019P1
SE-2 Pressure sensor:Bucket dump
SE-3 Pressure sensor:Boom up
SE-4 Pressure sensor:Boom down
SE-5 Pressure sensor:Swing
SE-7 Pressure sensor:Arm in
SE-8 Pressure sensor:Arm out
SE-9 Pressure sensor:Travel RH
SE-10 Pressure sensor:Travel LH
(SE) Sensor
SE-11 Pressure sensor : P2 OPT.
SE-13 E/G speed sensor VHS894101290
SE-15 Fuel sensor YN52S00045F1
SE-16 Accel potentiometer LQ52S00025P1
SE-20 Pressure sensor : P1 OPT. LC52S00019P1
SE-22 Pressure sensor: Pump P1 LS52S00015P1
SE-23 Pressure sensor: Pump P2
SE-61 DPR differential pressure sensor Engine accessory parts 
SE-62 Suction temperature sensor/Air flow meter VH22204E0010

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Group Code Part Name Part No.

Engine accessory
SE-87 Nox sensor 1
parts
SE-88 Nox sensor 2
SE-89 UREA sensor

(SE) Sensor SE-90 AMB temp. sensor

SE-91 SCR FR temp. sensor
SE-92 Exhaust temp. sensor 3
SE-93 Exhaust temp. sensor 4
SE-94 Exhaust temp. sensor 5
SV-1 Swing parking brake SOL. YN35V00047F3 YN35V00051F1
SV-2 Power boost SOL. Solenoid valve assy YN35V00050F1
SV-3 Two speed select SOL
(SV) Solenoid
SV-4 Safety lock lever SOL YN35V00061F1
Engine accessory
SV-68 Valve assy water
parts
SW-1 Key switch YN50S00026F1
SW-4 Swing parking brake release switch YN50S00047P1
SW-7 E/G oil pressure switch VH83530E0220
SW-8 Air filter clogging switch YY11P01002F1
SW-10 Horn switch (LH) YN50E00017P1
SW-11 Safety lock lever switch YN50S00055F1
SW-19 Wiper interlock switch LQ50C00001S012
(SW) Switch SW-20 Power boost switch (RH) YN50E00017P1
SW-26 Cab work light switch YN50S00040D4
SW-27 Coolant level switch VHS834601510
SW-35 Heavy lift switch YN50S00040D5
SW-37 Independent travel switch YN50S00040DB
SW-55 Boom work light switch YN50S00040D1
SW-96 Drain pressure switch LV50S00003D5
SW-131 Manual reproduction switch LV50S00003D9

- The part number may be changed owing to modification, use them only for reference.

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24.2.2 SPECIFICATIONS ELECTRICAL EQUIPMENT



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 㨇25. AIR-CONDITIONER SYSTEM㨉



25. AIR-CONDITIONER SYSTEM

TABLE OF CONTENTS

25.1 BASIC SYSTEM OF AIR CONDITIONER (HVAC AIR CONDITIONER) ääääääääääää25-3

25.1.1 AIR CYCLE äääääääääääääääääääääääääääääääääääää25-3
25.1.2 AUTO AIR CONDITIONER SYSTEM OUTLINE ääääääääääääääääääää25-4
25.2 COMPONENTS AND CONSTRUCTION ääääääääääääääääääääääääää25-6
25.3 FUNCTION äääääääääääääääääääääääääääääääääääääää25-8
25.3.1 MECHANISM OF COOLING CIRCUIT äääääääääääääääääääääääää25-8
25.3.2 COOLING CIRCUIT äääääääääääääääääääääääääääääääää25-10
25.3.3 COMPONENT PARTS ääääääääääääääääääääääääääääääää25-11
25.4 DISASSEMBLY AND ASSEMBLYäääääääääääääääääääääääääääää25-15
25.4.1 PRECAUTIONS TO BE EXERCISED IN OPERATION äääääääääääääääää25-15
25.4.2 DISASSEMBLY AND ASSEMBLY OF UNIT ääääääääääääääääääääää25-17
25.5 CHARGING REFRIGERANT äääääääääääääääääääääääääääääää25-22
25.5.1 PRECAUTIONS TO BE EXERCISED IN OPERATION äääääääääääääääää25-22
25.5.2 OPERATING PROCEDURE äääääääääääääääääääääääääääää25-24
25.5.3 CHARGING PROCEDURE ääääääääääääääääääääääääääääää25-25
25.6 ELECTRIC CIRCUIT äääääääääääääääääääääääääääääääääää25-30
25.6.1 WIRING DIAGRAM AND CONNECTORS äääääääääääääääääääääää25-30
25.6.2 STRUCTURE AND OPERATION OF EACH PARTS ääääääääääääääääää25-32
25.7 TROUBLESHOOTING ääääääääääääääääääääääääääääääääää25-36
25.8 SELF-DIAGNOSIS ääääääääääääääääääääääääääääääääääää25-43

Book Code No. S5LC2525E01

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Issue Date of Issue Applicable Machines Remarks

S5LC2525E01
First Edition September, 2010 E385CLC : YC
NHK

SK350LC-9 : YC
NA
SK200-8 : YN12-58781~
December, 2010
SK210LC-8 : YQ12-08501~ (ANZ)
SK330-9 : LC12-15001~
June, 2013
SK350LC-9 : YC12-10001~ (NA)
SK330-9 : LC12-15001~
December, 2013
SK350(N)LC-9 : YC12-10002~ (NA / EUR)

July, 2014 SK350LC-9E : YC13-13001~

(NA)

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 㨇25. AIR-CONDITIONER SYSTEM㨉

25.1 BASIC SYSTEM OF AIR CONDITIONER (HVAC AIR

CONDITIONER)

Air-conditioner is the unit which places evaporator and heater core parallel, and unifies a blower fan
and internal / external air switching unit. And this unit changes hot air to cool air.

25.1.1 AIR CYCLE

࡮ Heater
Internal air or external air is taken in through inlet and the air is passing through filter and heat
exchange is performed with hot air (heating) at the heater core of air-con unit, and then the
heated air blows off from grille through duct.
࡮ Cooler
Internal air or external air is taken in through inlet and the air is passing through filter and heat
exchange is performed with cold air (dehumidifying and cooling) at the evaporator of air-con unit,
and then the cooled air blows off from grille through duct.
࡮ Heater system
The heater recycles (circulates) the cooling water in the engine, and the hot water delivered by
the engine flows in the heater core of air-con unit and then heat exchange is performed.
The internal air is heated and the heated air blows off from the grille provided on the inside of
cab.
The blow off air temperature is controlled by the temperature control switch on the control panel,
and the operation is controlled by air mixing damper on the air-con unit.

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25.1.2 AUTO AIR CONDITIONER SYSTEM OUTLINE

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25.2 COMPONENTS AND CONSTRUCTION

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AIR-CONDITIONER UNIT
No. Parts Q'ty No. Parts Q'ty
1 HEATER CORE GEN ASM 1 27 JOINT FOOT 1 
2 CASE INTAKE 1 28 JOINT DEF 1
3 LINER FILTER 1 29 ROD COMMON 2
4 PACKING INTAKE 1 30 LEVER MODE MAL 1
5 LINER INTAKE MAL 1 31 LEVER AM MAIN 1
6 LEVER INTAKE 1 32 LEVER AM SUB 1
7 DAMPER INTAKE ASSY 1 33 LINK MODE 1
8 INCAR SENSOR 1 34 MAIN ROD 1
9 DUCT JOINT ASM 1 35 DAMPER MODE ASSY A 3
10 CASE HEATER R 1 36 DAMPER MODE ASSY B 2
11 CASE HEATER L 1 37 DAMPER AIR MIX ASSY 1
12 CASE DRAIN 1 38 RELAY 24Ყ4PE 2
13 CLIP PS HARNESS 1 39 FAN DRIVER 1
14 COVER LINK 1 40 EVAPORATOR ASM 1
15 FILTER REC ASM 1 41 TXV(EXPANSION VALVE) 1
16 PACKING DUCT OUTLET A 2 42 EVA SENSOR 1
17 PACKING DUCT OUTLET B 1 43 SOCKET BOLT M5X40 2
18 COOLING HOSE 1 44 HERNESS HOLDER 1
19 BLOWER MOTOR ASM 1 45 THERMISTOR HOLDER 1
20 MOTER ACTUATOR 3 46 TAPPING SCREW 5X14(T1) 3
21 HARNESS ASM 1 47 TAPPING SCREW 4X16(T1) 36
22 LEVER VENT 1 48 BUSH D3PIN 4
23 LEVER FACE 1 49 ROD HOLDER 2
24 LEVER FOOT 1 50 TAPPING SCREW 4X16 1
25 LEVER DEF 1 51 INSULATION 2
26 JOINT VENT 1

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25.3 FUNCTION

25.3.1 MECHANISM OF COOLING CIRCUIT

(1) Mechanism of Cooling
In the cooling process, the refrigerant that
flows through the cooling circuit changes its
phases from liquid to gas and vice versa while
which process heat is transferred from the low
temperature part (compartment) to the high
temperature part (outside of the vehicle).

1. Kind of Refrigerant
Many kinds of refrigerants that change in that
way are available, but the following
requirements are needed for use in such
applications :

࡮ Latent heat of vaporization (heat of vaporization) is large.

࡮ It is easy to liquefy (condense). (It dose not require very high pressure for condensation.)
࡮ It is easy to gasify (evaporate). (It evaporates sufficiently at not too low pressure, i.e. cools down
an object.)
࡮ It has small specific heat. (Since the refrigerant itself is cooled by the expansion valve, the loss
resulting from it must be held down to a minimum.)
࡮ It has a high critical temperature and a low solidification point.
࡮ It is stable chemically and does not corrode and permeate into the circuit parts.
࡮ It is free from toxicity, objectionable odor, flammability and explosiveness and excels in thermal
conductivity and electric insulation.
࡮ It has small specific volume.
࡮ It is easy to find out leakage.
Out of refrigerants meeting the above-mentioned requirements, ones having characteristics that
suit the intended cooling unit are chosen and used. If a refrigerant other that those designated is
used, sufficient refrigeration will not be performed or the equipment in which the refrigerant is used
may be broken. Therefore, always use a designated refrigerant for the cooling unit.
Table shows the principal characteristics of the R134a refrigerant that is used in this machine.

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(2) Characteristics of Refrigerant (Right Fig.)

In general, the fluid (general term of gas and
liquid) has the following qualities:

1.
As a gas under certain pressure is cooled
down, it begins to condensate at a certain
temperature to take a liquid state. The
temperature at which condensation begins is
unique to each substance (fluid) at a given
pressure. The temperature determined by a
given pressure is called saturation temperature.
Pressure-temperature characteristics of R134a

2.
Inversely to 1) above, the pressure at which a gas condenses for a temperature is determined. This
pressure is called saturation pressure.
Right Fig. illustrates the relationships between the saturation temperature and the saturation pressure in
the case of refrigerant R134a used in the air-conditioner. At the temperature and the pressure on the
lower righthand side of the curve in above Fig. the refrigerant take a gaseous state, while at the
temperature and the pressure on the upper lefthand side of the curve, the refrigerant takes a liquid
state.
Let us think of a case where an air-conditioner is operated in the midst of summer. As the refrigerant
evaporates, it absorbs evaporation heat from the air of the compartment. In order to cool the inside of
the compartment down to 25C degrees (77F degrees), the refrigerant must transform (evaporate) from
a liquid to a gaseous state at a lower temperature. It can be seen from above Fig. that R134a under
a pressure above the atmospheric pressure is capable of cooling the inside of the compartment
sufficiently. (If a refrigerant that requires a pressure below the atmospheric pressure to cool it to a
required temperature is used, air is mixed into the circuits, thereby deteriorating the performance of the
cooling unit.) In the process in which gaseous refrigerant is brought back to a liquid state, the
refrigerant is cooled and condensed by the outer air exceeding 35C degrees (95F degrees).
Accordingly the refrigerant is capable of condensing at a pressure exceeding 1 MPa (145psi), as seen
from above Fig.

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25.3.2 COOLING CIRCUIT

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

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25.3.3 COMPONENT PARTS

(1) Evaporator (See right Fig.) 
The evaporator is an important heat exchanger
that absorbs the heat of the compartment air
(object) by the utilization of the latent
vaporization heat of the low-temperature,
low-pressure liquid-state refrigerant. Therefore,
it is necessary that satisfactory heat transfer
between the object and the refrigerant take
place in the evaporator.
To that end, the evaporator is equipped with
fins on the air side in order to increase the
heat transfer area of the air side and thereby
perform excellent thermal transfer between the
refrigerant and the air.
The humidity in the air condenses as the air
cools down and adheres to the outside of the
evaporator as water drops. The cooling effect
deteriorates if the water drops freeze. Therefore,
how to discharge water is an important point.
The amount of refrigerant supplied to the
evaporator is controlled by the expansion valve
which is described in the following. In order to
attain proper control, it is necessary to reduce
the pressure drop of the refrigerant of the
evaporator. Accordingly, reducing the pressure
drop is one constituent factor that makes the
evaporator attain its full performances.

(2) Expansion Valve

In order for the evaporator to fulfill its performances, a proper amount of low-pressure low-temperature
liquid refrigerant must be fed to the evaporator.
If the feed rate is too low, the refrigerant completes vaporization early in the evaporator which results
in deterioration of the cooling effect. If the feed rate is too high, unvaporized liquid refrigerant returns
to the compressor (liquid back). This not only deteriorates the cooling effect, but also damages the
compressor valves.
The expansion valve feeds the flowing high-pressure high-temperature liquid refrigerant to the
evaporator as low-pressure low-temperature liquid refrigerant (damp vapor of low dryness). The
expansion valve controls the feed rate of the refrigerant at the same time.

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Right Fig. shows how the block type

expansion valve is constructed. The temperature
sensing part is provided in the shaft of the
expansion valve to directly detect the
refrigerant temperature at the outlet of the
evaporator.
The diaphragm contains R134a in saturated
state. The pressure in the diaphragm changes
according to the temperature detected by the
sensor. The change in the pressure causes
the force acting upon the diaphragm to vary
accordingly.
The high-pressure high-temperature liquid
refrigerant that is fed from the receiver side
reduces the pressure abruptly as it passes
through the valve (throttling action). On that Block type expansion valve
occasion, part of the refrigerant evaporates by
the own heat of the refrigerant and cooled off.
The result is that low-pressure low-temperature
damp refrigerant vapor is fed to the evaporator.
The opening of the valve is determined by the
balance between the pressure (low) of the
evaporator side, the action of the adjust spring
and the pressing force of the diaphragm (the
temperature of the refrigerant at the outlet of
the evaporator to be sensed by the temperature
sensor). The feed rate is controlled
automatically so that under the pressure in the
evaporator, the refrigerant is properly overheated
(3 to 8C degrees ) and goes out of the
evaporator. This action is carried out by sensing
the refrigerant temperature at the outlet of the
evaporator as against the inlet pressure of the
evaporator and consequently controlling the feed
rate of the refrigerant.

This means that if the refrigerant pressure

drop in the evaporator is excessive, it is difficult
to control the overheating or the feed rate of
the refrigerant. For this reason, the smaller the
pressure drop of the evaporator, the better.
The expansion valve senses the pressure and
the temperature at the outlet of the evaporator
and controls the overheating of the refrigerant
Expansion valve outside view
and the refrigerant supply to the evaporator
more securely. The air-conditioner of this
machine adopts a block type expansion valve.

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(3) Compressor (See right Fig.)

The compressor performs the following three
functions in the cooling circuit:

1) Suction
2) Pumping
3) Compression

Compressor

1. The suction action, as combined with the throttling action, works to decrease the refrigerant
pressure in the evaporator. This permits the refrigerant to vaporize at low temperature in order to
perform cooling effect.
2. The pumping action serves to cause all the refrigerant to circulate in the cooling circuit. This
enables enables continuous cooling.
3. The compressive action, as combined with the action of the condenser which is mentioned
hereunder, transforms vaporized refrigerant back to a liquid state again.
The saturation temperature gets higher as the pressure increases. For instance, it becomes
possible to cool down the refrigerant by the use of an external air of 35C degrees (77F degrees)
and liquefy it. The compressive action of the compressor works to turn low pressure vaporized
refrigerant to high pressure vapor refrigerant. The condenser then serves to cool down the
refrigerant. However, since the compressive action takes place only for a short period, the
refrigerant hardly exchanges heat with external air. That is to say, it takes a near form of
thermally insulated compression, so that the refrigerant discharged by the compressor turns into
high-temperature high-pressure vapor and is delivered to the condenser.

(4) Condenser (See right Fig.)

This is a heat exchanger that cools the
vaporized refrigerant at high temperature and
high pressure by the use of external air and
condenses the refrigerant. The direction in
which heat moves is from the refrigerant to air,
the opposite to the case of the evaporator. Fins
are equipped on the external air side to
improve thermal transfer. If the refrigerant is not
cooled well by the condenser, the air in the
compartment can not be cooled sufficiently by
the evaporator. For that purpose, it is necessary
to secure ventilation required for the cooling of
the refrigerant. Condenser

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(5) Receiver dryer (See right Fig.)

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

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25.4 DISASSEMBLY AND ASSEMBLY


25.4.1 PRECAUTIONS TO BE EXERCISED IN OPERATION
(1) Special Refrigerator Oil
This air-conditioner uses special refrigerator oil
SP20 for use with new refrigerant R134a. Oils
other than SP20 may not be used. Since
SP20 tends to absorb moisture and may
corrode paint and resin, the following points
must be noted:
1.
Do not keep open all pipe connections on a
new compressor and the component parts of
the installed refrigeration circuit
(Remove valves and caps at the pipe openings
of the compressor, just before connecting pipes.
If you have removed a pipe joint for repair,
put a cap to both ports immediately.)
2.
Use care so SP20 does not adhere to the
painted surface and resin parts. In case SP20
has adhered to such surfaces, wipe it off
immediately.

(2)
The receiver dryer is filled with desiccant to
absorb moisture in the circuit. Therefore,
remove the valve at the pipe port immediately
before connecting pipes.

(3)
Tightening Torque
1. Pipe Joints
When connecting pipe joints, coat the O-ring
with special oil (SP20) and fasten to the
tightening torque indicated in the table, using a
double spanner.
2. Screws and Bolts
Fasten to the tightening torque indicated in the
table

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(4)
Amount of Oil for Compressor
The compressor SD7H (HD type) is filled with
135cc (8.2cu-in) of oil. If the oil volume is
small, seizure at high revolution and shortening
of service life will occur. If the oil volume is
large, the cooling ability will be deteriorated.
Once the air-conditioner is operated, part of
the oil is dispersed in the refrigeration circuit.
Therefore, when replacing the parts in right
Table, adjust the oil level to that of table.

(5)
Before performing operation, stop the engine
and turn off all power supplies to the equipment
related to the air-conditioner.

(6)
After the operation is over, confirm that all
faults have been repaired completely, by
operating the air-conditioner.

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25.4.2 DISASSEMBLY AND ASSEMBLY OF UNIT

(1) Disassembly and assembly of blower motor 
1. Disassembly
- Disconnect cooler hose from A/C unit.
- Loosen 3 tapping screws.
- Remove blower motor as shown.
- Disconnect cooler hose from blower motor.
2. Assembly
Assemble the A/C unit in the reverse
order of disassembly.

(2) Disassembly and assembly of internal/external actuator

1. Disassembly
- Loosen 3 tapping screws.
- Remove actuator as shown.
2. Assembly
Assemble the actuator in the reverse order
of disassembly.

Insert lever pin of actuator into groove of damper lever.

(3) Disassembly and assembly of relay

1. Disassembly
- Loosen tapping screws.
- Remove relay as shown.
2. Assembly
Assemble the relay in the reverse order of
disassembly.

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㨇25. AIR-CONDITIONER SYSTEM㨉

(4) Disassembly and assembly of inner air sensor

1. Disassembly
- Pressing lock of connector 1 remove the
connecter from inner air sensor.
- Pressing lock of sensor remove inner air
sensor as shown.
- Remove cord sandwiched between
components of unit slowly.
- Lift inner air filter upwards and remove it.
- Pressing lock of connector 2 inwards
and remove the connecter.
2. Assembly
Assemble the inner air sensor in the
reverse order of disassembly.

(5) Disassembly and assembly of fan driver

1. Disassembly
- Disconnect connector from fan driver.
- Loosen 2 tapping screws.
- Remove fan driver as shown.
2. Assembly
Assemble the fan driver in the reverse
order of disassembly.

(6) Disassembly and assembly of link cover

1. Disassembly
- Loosen 4 tapping screws.
- Remove link cover as shown.
2. Assembly
Assemble the link cover in the reverse
order of disassembly.

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(7) Disassembly and assembly of mode actuator and air mix actuator
1. Disassembly
- Remove link cover. (See item 25.4.6)

- Disconnect connector from 2 actuators.
- Turn rod latch of mode actuator in the
direction of arrow as shown. And release
link rod.
- Twist link bar of air mix actuator in the
direction of arrow as shown. And remove
the link rod from damper lever.
- Loosen 3 tapping screws fixing each
actuator.
- Remove each actuator as shown.
2. Assembly
Assemble the actuators in the reverse order
of disassembly.

(8) Disassembly and assembly of heater core

1. Disassembly
- Remove link cover. [See item 25.4.2 (6)]
- Disconnect connector from air mix
actuator.
- Remove heater core as shown.
2. Assembly
Assemble the heater core in the reverse
order of disassembly.

Do not exert excessive load on piping.

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(9) Disassembly and assembly of evaporator

1. Disassembly
- Turn HVAC unit upside down.
- Loosen 5 tapping screws.
- Disconnect connector of evaporator sensor.
- Pull out evaporator as shown.
2. Assembly
Assemble the inner air sensor in the
reverse order of disassembly.

To avoid damage, pull out evaporator sensor cord from groove of HVAC unit carefully.

(10) Disassembly and assembly of expansion valve

1. Disassembly
- Loosen 2 socket bolts.
- Remove expansion valve as shown.

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 㨇25. AIR-CONDITIONER SYSTEM㨉


Do not exert excessive load on piping.

2. Assembly
- Assemble the expansion valve in the reverse order of disassembly.
- Prior to assembly, apply PAG oil to O-ring.

Breakage of O-ring causes gas leak.

(11) Disassembly and assembly of evaporator sensor

1. Disassembly
- Remove harness holder and thermistor holder from evaporator.

To avoid trouble, do not pull cord forcibly.

2. Assembly
- Assemble the evaporator sensor in the reverse order of disassembly.
- Install the harness holder and thermistor holder as shown.
- Install the tip of sensor and thermistor holder as shown.

When the sensor cord is loose-fitted, the cord is caught by door.

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㨇25. AIR-CONDITIONER SYSTEM㨉

25.5 CHARGING REFRIGERANT

25.5.1 PRECAUTIONS TO BE EXERCISED IN OPERATION

(1) Assign a person in charge of handling refrigerant.
Refrigerant charge operation involves dangers as it handles high pressure gas. Assign a person
familiar with how work is done for handling refrigerant.

- Wear protective goggles. (You may lose your sight if the refrigerant gets in your eyes.)
- The refrigerant in liquid state is at very low temperature [approx. -26C degrees (-15F degrees)].
Therefore, handle it with care. (You may get a frostbite if the refrigerant is sprayed over your skin.)

(2) Storage and Transportation

1. Keep the service can (hereinafter called can) less than 40C degrees (104F degrees). Since high
pressure gas of R134a is filled in the can in a saturated liguefied state, the pressure in the can
increases sharply as temperature rises. The can may explode as the result.
It is for this reason why the can temperature must be kept below 40C degrees (104F degrees).
2. For storage, choose dark cold place not exposed to direct sunlight.
3. If the can is placed near a fire, it is exposed to radiation heat and gets hot. This causes the
inside pressure to rise and may cause the can to blow out. Do not bring the can close to a fire.
4. The inside of the closed compartment gets very hot as the radiation heat of the sunlight enters
the compartment. The areas of the compartment which are exposed to direct sunlight may rise to
a dangerous temperature level. Do not bring the can into the compartment.
5. Note that if the can has scratches, dents and distortion, the strength of the can will deteriorate.
a. Do not drop or knock on the can.
b. When transporting, loading or unloading cans and packages containing cans, do not throw or
drop them.
6. Keep can out of reach of children.

(3) Charging
1. When warming the can in which refrigerant is charged, do not fail to open the service can valve
and the low pressure valve of the gauge manifold and warm the can in warm water of 40C
degrees (104F degrees) or below. If the can is put in hot water or heated by a direct fire, the
pressure of the can may rise sharply, thereby the can explodes.
2. When charging refrigerant while running the engine, to avoid explosion, do not open the high
pressure valve (HI) of the gauge manifold.

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(4) Others
Reuse of service cans is prohibited by regulation, do not reuse them. Do not allow foreign matter to
enter the air-conditioner circuit. Air, water and dust are detrimental to the refrigeration cycle. Install the

components of the air-conditioner correctly and speedily. Pay full attention to the entry of water and
dust.

- Be careful about overcharge of gas.

- Fasten pipes to the specified torque.

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㨇25. AIR-CONDITIONER SYSTEM㨉

25.5.2 OPERATING PROCEDURE

(1)
Refrigerant charge into the air-conditioner consists mainly of "vacuum making operation", and "gas
charge operation".

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

(2) Operation Chart

(3) Tools

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 㨇25. AIR-CONDITIONER SYSTEM㨉

25.5.3 CHARGING PROCEDURE

25.5.3.1 VACUUM MAKING OPERATION 
(1) Connecting gauge manifold (See right Fig.)
1.
Close the high pressure valve (HI) and the low
pressure valve (LO) of the gauge manifold.
2.
Connect the charging hoses (red and blue)
with the service valves of the compressor.
Red hose :
High pressure side (HI) of the gauge manifold
--> high pressure side (DIS) of compressor
Blue hose :
Low pressure side (LO) of gauge manifold -->
low pressure side (SUC) of compressor

Do not mistake the high pressure hose for the low pressure hose in any circumstances when
connecting them. Put the hose in firmly till a clicking sound is heard.

3.
Connect the center valve of the gauge
manifold with the charging hose of the vacuum
pump.

Connecting gauge manifold

Some kinds of gauge manifolds are not equipped with an open/close valve in the center.

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㨇25. AIR-CONDITIONER SYSTEM㨉

(2) Vacuum making (See right Fig.)

1.
Open the high pressure valve (HI) and the low
pressure valve (LO) of the gauge manifold.
2.
Turn on the switch of the vacuum pump and
make vacuum for more than 30 minutes.
3.
When vacuum making for a specified duration
is over (degree of vacuum : less than - 750
mmHg), close the high pressure valve and the
low pressure valve of the gauge manifold.
4.
Then turn off the vacuum pump.

Vacuum making operation

(3) Air-tightness Check

Close the high pressure valve and the low pressure valve of the gauge manifold, leave it as it is for
more than five minutes and make sure that the gauge indication does not return toward 0.

If the gauge indication goes toward 0, there is somewhere that is leaking. Retighten pipe joints, make
vacuum again and make sure of no leakage.

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25.5.3.2 GAS CHARGING OPERATION

(1) Charging from high pressure side (See right Fig.)
1.

After making vacuum repeatedly, change the
charging hose (yellow) of the gauge manifold
from the vacuum pump to the service can.

2.
Air purge
Open the service can valve. (However, close
the high and low pressure valves of the gauge
manifold.) Then push the gas valve of the side
Gas charging operation
service port on the low pressure side of the
gauge manifold, using a screw driver, in order
to let out the air in the charging hose by the
pressure of the refrigerant. (See right Fig.)
(The operation ends when a hissing sound is
heard.)

3.
Open the high pressure valve of the gauge
manifold and charge in refrigerant. [Charge in
gaseous refrigerant to a gauge pressure of
0.1MPa (14psi).]
After charging, close the high pressure valve
of the gauge manifold and the service and
valve. (See right Fig.)

Gas charging operation (High pressure side)

Do not run the compressor during this work, (Otherwise the refrigerant flow in reverse direction which
causes the service can and the hoses to explode. This is very dangerous.)

(2) Checking for gas leak

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

Use the leak tester for R134a. (Do not use one for flon gas service as it provides poor sensitivity.)

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(3) Charging from low pressure side (See right Fig.)

1.
Make sure that the high-pressure and
low-pressure valves of the gauge manifold and
the service can valve are closed.
2.
Start the engine and run the revolution from
1400 to 1600rpm and close the cab door and
the windows.
3.
Turn on the air-conditioner switch, set the fan
switch to Max and the temperature control
switch to cool Max.
4.
When charging gas, set the discharge pressure
Gas charging operation (Low pressure side)
of the compressor from 1.4 to 1.6 MPa (200 to
230psi).

5.
Open the low pressure valve of the gauge
manifold and the service can valve and fill in
refrigerant till air bubbles of the sight glass of
the receiver disappear. (See Fig. "Gas charging
operation")
[Total amount of gas to be charged:
850g to 950g (1.89 to 2.11 lbs)]
6.
When refrigerant charge is completed, close
the low pressure valve of the gauge manifold
and the service can valve. Receiver dryer

- Do not open the high pressure valve of the gauge manifold.

- Do not turn over the service can. (The compressor valve may be damaged because the refrigerant is
sucked in a liquid state.)

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(4) Criterion for checking the amount of refrigerant filled in



- If the air-conditioner is run with poor refrigerant R134a, it has adverse effect on the compressor.
- If the refrigerant is charged too much (overcharged), the cooling performance is deteriorated.
Moreover, the circuit pressure gets abnormally high: Always keep a proper level.

(5) Removing Gauge Manifold

When the refrigerant level has been checked, disconnect the charging hoses from the compressor as
follows.

1. Press the "L" shape metal fitting of the charging hose (blue) on the low pressure side against the
service valve of the compressor to avoid leakage of the refrigerant. As soon as the nut has been
removed, disconnect the charging hose from the service valve.
2. Leave the high pressure side as it is till the high pressure gauge reading falls. [below 1MPa
(140psi)].
3. Disconnect the charge hose (red) on the high pressure side the same way as on the low pressure
side.

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25.6 ELECTRIC CIRCUIT

25.6.1 WIRING DIAGRAM AND CONNECTORS

Electric diagram (1/2)

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Electric diagram (2/2)

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25.6.2 STRUCTURE AND OPERATION OF EACH PARTS

(1) Control panel
The control unit is integrated into control
panel, and processes the signal input by
each sensor, etc. and the signal input by Control panel
each switch through control panel with the
function of the built-in micro computer, and
comprehensively controls each actuator
(Air inlet / outlet mode select, air mix),
blower motor and compressor on the output
side.
And the self-diagnosis performance is
provided to facilitate the trouble shooting.

(2) Fan driver

The power transistor shifts the blower motor
into variable speed with base current from
the control unit.

<Check for fan driver>

Check over the continuities between
terminals of fan driver.

Blower controller

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(3) Relay
Four-electrode relay is used for the blower OFF relay and compressor relay.


1. Blower OFF relay
The blower OFF relay turns on after
receiving the signal from the control
amplifier.
When the blower OFF relay turns on, the
source voltage is supplied to the blower
motor and the blower motor starts running.
2. Compressor relay
The relay ON-OFF is switched by the
control amplifier and electronic thermostat
control.
3. Relay specification and inspection
a. Coil resistance: 320 ohms
b. Specified voltage: DC20V to 30 V
c. Be careful about the coil polarity of relay.
d. Inspection:
Inspect the continuity between terminals 3
and 4 as follows.
20 to 30 V applied between terminals 1-2:
Continued
20 to 30 V not applied between terminals
1-2: Not continued

(4) Motor actuator

Air mix actuator is located in at the center
of air-con unit, and opens and closes air
mix damper through the link motion.
The air mix actuator incorporates
potentiometer which is switched by linked
shaft with actuator.
When the target air mix door position is
determined through the temperature control
switch, the control unit reads the level of Both motor actuators
potentiometer of the actuator. And it
determines the rotating direction of motor in
either normal rotation or reverse rotation.
And the motor rotates, the contact point is
moved, and when the contact point is
detached or the output signal of control unit
turns OFF, the motor stops.

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(5) Mode actuator

Mode actuator is located in outlet of air
conditioner unit. And it opens or closes
mode door through link motion.
The mode actuator incorporates
potentiometer which is switched by linked
shaft with actuator.
When the target air mix door position is
determined through the temperature control
switch, the control unit reads the level of
potentiometer of the actuator. And it
determines the rotating direction of motor in
either normal or reverse rotation. And the
motor rotates, the contact point is
detached or the output signal of control unit
turns OFF, the motor stops.

(6) The actuator for air inlet / outlet (12V)

The actuator for inlet and outlet air mode
select is installed on the blower intake
unit, and opens and closes inlet or outlet
air damper through the link motion. The
actuator for inlet and outlet air mode
select incorporates position detection
switch which is switched with the movement
of shaft of the actuator. When the inlet or
outlet damper position is set by the inlet
and outlet switch on the control panel, the
control unit reads the signal of the position
detection switch in the actuator and
determines the rotation direction of motor in
either normal rotation or reverse rotation.
And the motor rotates, the position
detection switch also rotates and makes it
stop at the set position of the inlet or outlet
air damper.

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 㨇25. AIR-CONDITIONER SYSTEM㨉

(7) Evaporator sensor - air inlet sensor

This sensor is used to control the
evaporator outlet temperature with the

compressor ON-OFF to protect the
evaporator from freezing, and this
evaporator sensor functions as a sensor of
this control.
- Evaporator sensor and air inlet sensor
Evaporator sensor - air inlet sensor
specifications
Terminal resistance:
at 0 degree C: 7.2 kilo-ohms
at 25 degree C: 2.2 kilo-ohms

(8) Solar sensor

This solar sensor, which is used to correct
the solar radiation to the auto air
conditioner detects the strength and solar
orientation of sunbeam after transforming Solar sensor
them into current by means of photo diode.
<Check for solar sensor>
Disconnect solar sensor connecter from
harness. Using voltmeter measure the
voltage between connector terminals.
The measured voltage should be varied by
intensity of sunshine. (When there is no
sunshine, measured voltage is almost 0
volt.)

- Measure the voltage in the voltage measurement mode (V mode).

- Measurement in resistance mode (Ohm mode) causes the damage of devices.

(9) Dual pressure switch

This dual pressure switch is attached on L-hose and is used to turn OFF the compressor, and
employs dual type (for high and low pressure control) to protect the cooler cycle from possible
failure at the time when abnormal pressure was generated on the high pressure side.

Dual pressure switch

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25.7 TROUBLESHOOTING

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 㨇25. AIR-CONDITIONER SYSTEM㨉



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㨇25. AIR-CONDITIONER SYSTEM㨉

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 㨇25. AIR-CONDITIONER SYSTEM㨉

25.8 SELF-DIAGNOSIS


1. When error occurs in input circuit of motor actuator drive line, the error can be displayed on
the monitor of LCD display.

2. When error occurs in evaporator sensor and intake air sensor, the error can be displayed on
the monitor of LCD display.

3. Detection of each sensor error by monitor mode function (Detection of failure control of
control panel)
࡮ When the air conditioner is in operating condition, press the internal and external air selector
switch (6) and main power switch (1) for one second or more simultaneously. And the display of
monitor mode begins. To return the display to previous display, operate 2 switches according to
above mentioned same operation.
࡮ Normal condition, disconnection and short circuit of intake air sensor, evaporator sensor and solar
sensor are indicated in segment of display.
࡮ Normal condition and short circuit of solar sensor is indicated in segment of display.
(* Detection of disconnection is not indicated.)

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 㨇31. DISASSEMBLING AND ASSEMBLING㨉

31. DISASSEMBLING AND ASSEMBLING

TABLE OF CONTENTS

31.1 EXPLAINING CHAPTER OF WHOLE DISASSEMBLY & ASSEMBLY ̖̖̖̖̖̖̖̖̖̖̖̖31-3

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



Book Code No. S5YN3129E01

31-1
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㨇31. DISASSEMBLING AND ASSEMBLING㨉

Issue Date of Issue Applicable Machines Remarks

SK200-8 : YN12-56001~ S5YN3129E01
First Edition December, 2008
SK210LC-8 : YQ12-08001~ (SE Asia & Oceania)

June, 2013 SK210LC-9 : YQ13-10001~

(NA)

SK260LC-9 : LL14-08001~
(NA)
SK330-9 : LC12-15001~
SK350LC-9 : YC12-10001~ (NA)

July, 2013 SK500LC-9 : YS12-03501~

(NA)

August, 2013 ED160-3 : LH02-01501~

(EUR)

ED160-3 : LH02-01501~
(NA)

SK75SR-3E : YT08-30001~
(NA)

SK85CS-3E : LF08-05501~
(NA)

SK130HDL-8B : LX08-T0101~
(TKCM)

SK140SRLC-3 : YH07-09001~
(NA)

September, 2013 SK230SRLC : LA07-03001~

(NA)

SK260SRLC : YU07-04028~
(NA)

October, 2013 SK75SR-3E : YT08-30001~

(EUR)

SK210LC-9 : YQ13-10001~
(North America / Europe)

SK85MSR-3E : LF08-05501~
(EUR)

November, 2013 SK140SRLC-3 : YH07-09001~

(EUR)

SK230SRLC-3 : LA07-03001~
(EUR)

SK260CSR(N)LC-3 : YU07-04001~
(EUR)
SK260LC-9 : LL14-08003~
SK260NLC-9 : LL14-08003~ (North America / Europe)
SK330-9 : LC12-15001~
December, 2013
SK350(N)LC-9 : YC12-10002~ (NA / EUR)

January, 2014 SK500LC-9 : YS12-03501~

(North America / Europe)
SK135SR-3 : YY07-25001~
July, 2014
SK135SRLC-3 : YH07-09001~ (OCE)

SK350LC-9E : YC13-13001~
(NA)

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 㨇31. DISASSEMBLING AND ASSEMBLING㨉

31.1 EXPLAINING CHAPTER OF WHOLE DISASSEMBLY &

ASSEMBLY

31.1.1 FORM FOR CHAPTER OF DISASSEMBLY & ASSEMBLY

This chapter is consist of 3-Section as follows.

(1) ATTACHMENTS : Chapter 32

1) Removing and Installing
2) Disassembling and Assembling
a. Cylinder
(2) UPPER STRUCTURE : Chapter 33
1) Removing and Installing
2) Disassembling and Assembling
a. Hydraulic pump
b. Control Valve
c. Pilot Valve (ATT)
d. Pilot Valve (Travel)
e. Slewing Motor
f. Swivel Joint
(3) TRAVEL SYSTEM : Chapter 34
1) Removing and Installing
2) Disassembling and Assembling
a. Travel Motor

31.1.2 INDICATION OF TIGHTENING TORQUE

Tightening torque is indicated as follows, for example ;
T=98N-m(72 lbf-ft)
Tolerance is to 10% unless otherwise specified.

࡮ Refer to "Chapter 11 TOOLS" for standard tightening torque.



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 㨇32. ATTACHMENTS㨉

32. ATTACHMENTS
TABLE OF CONTENTS

32.1 REMOVING AND INSTALLING ääääääääääääääääääääääääääääää32-3

32.1.1 ATTACHMENT ASSY ääääääääääääääääääääääääääääääää32-3
32.1.2 BUCKET ääääääääääääääääääääääääääääääääääääää32-3
32.1.3 ARM ääääääääääääääääääääääääääääääääääääääää32-6
32.1.4 BOOM äääääääääääääääääääääääääääääääääääääää32-9
32.2 DISASSEMBLING AND ASSEMBLING ääääääääääääääääääääääääää32-14
32.2.1 CYLINDER äääääääääääääääääääääääääääääääääääää32-14



Book Code No. S5LC3226E01

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㨇32. ATTACHMENTS㨉

Issue Date of Issue Applicable Machines Remarks

S5LC3226E01
First Edition September, 2010 SK350LC-9 : YC
NA
SK330-9 : LC12-15001~
June, 2013
SK350LC-9 : YC12-10001~ (NA)
SK330-9 : LC12-15001~
December, 2013
SK350(N)LC-9 : YC12-10002~ (NA / EUR)

July, 2014 SK350LC-9E : YC13-13001~

(NA)

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

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32.1 REMOVING AND INSTALLING

32.1.1 ATTACHMENT ASSY

Front attachment and position

32.1.2 BUCKET
32.1.2.1 REMOVING BUCKET
(1) Put the machine in position to remove
bucket.

Position to remove bucket

(2) Removing capscrew (1)

Loosen the double nut (2) and pull out the capscrew (1).



Removing capscrew (1)

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(3) Removing bucket attaching pin (K)

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

Removing bucket attaching pin

(4) Removing bucket drive pin (J)

Put bucket on the ground, position it so
that the bucket drive pin (J) is not loaded,
adjust bucket link, and pull out pin (J).
Store the removed pin (J) in original
position again.

Removing bucket drive pin

32.1.2.2 ATTACHING BUCKET

(1) Attaching bucket drive pin (J)
Attach bucket drive pin (J) first, then
continue in the reverse procedure of
removing.

Attaching bucket

-When aligning the pin holes, do not put your finger in the pin holes, but align them visually.
-Check the seals for damaged and replace as necessary.
-When inserting the pin, coat the shaft with grease.

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32.1.2.3 PROCEDURE FOR ADJUSTING CLEARANCE

Adjustment of clearance between bucket and arm

(1) Shift O-ring (3) toward the bucket boss,

using a spatula. (a-->b)
(2) When adjusting clearance (B), bring the
non-adjusting side of the bucket in contact
with the arm.
(3) Measure clearance (B) and check that it is
within 1.0 mm (0.04 in).
(4) Adjust clearance (B) where it is more than
1.0 mm (0.04 in).
(5) An average of 5 shims (10) of 1mm
(0.04in) thickness are set in the plate (13)
fixed by the three capscrews (7). The
clearance can be decreased by 1mm
(0.04in) if one shim is removed.
Tools: Socket: 30mm, Adjusting clearance between bucket and arm
Tightening torque : 314 N-m (232 lbf-ft)
(6) After adjustment, tighten the capscrews
evenly.
-The gap exceeding the specified dimension
causes early wear.
(7) Operate the bucket and confirm that the
total sum of both clearance is within 1.0
mm (0.04 in).
(8) Replace O-ring (3) on its original position.

-When shifting O-ring (3) by means of a spatula, use care so as not to damage O-ring (3).
-Remove shims (10), push out bushing (12) rightwards by means of three capscrews (7) and adjust
clearance (B) so it settles within the standard value evenly all round.



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32.1.3 ARM
32.1.3.1 REMOVING ARM
(1) Put the machine in position to remove arm.
Extend the arm cylinder, retract the bucket
cylinder and bring the arm down on the
ground.

Position to remove arm

(2) Disconnecting piping of bucket cylinder

Release pressure of hydraulic tank, place
oil pan to prepare for oil leaking, and
disconnect pipes.
When the removal of bucket cylinder is
not required, skip to procedure (6).

Disconnecting piping of bucket cylinder

Plug both end of disconnected pipes.

Plug:
Tools section 11.5.2-(4)
Tools section 11.5.2-(5)

(3) Removing bucket cylinder rod pin (H)

1. Loosen nut (10), remove capscrew

M20X160 (9), and push out pin (H).

Tools: Spanner: 30mm

Detail of bucket cylinder rod pin (H)

2. Retract cylinder rod.

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(4) Removing cylinder head pin (G)

Loosen nut (3), remove capscrew
M20X165 (2), and push out pin (G).

Tools: Spanner: 30mm

Detail of bucket cylinder head pin (G)

(5) Removing bucket cylinder

Sling tube of bucket cylinder with nylon
sling, and remove it.
Bucket cylinder weight: 260 kg (573 lbs)

Slinging bucket cylinder

(6) Removing arm cylinder rod pin (E)

Put a wooden block between the arm cylinder and the boom.
Loosen nut (3), remove capscrew M20X180 (2), and push out arm cylinder rod pin (E).

Tools: Spanner: 30mm

Retract arm cylinder rod, and return pin (E) to the original position (hole).

Detail of arm cylinder rod pin (E)



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(7) Removing boom top pin (F)

Loosen capscrew M16X35 (2), plate (1) and
pull out boom top pin (F).

Tools: Spanner: 24mm

Insert pin (F) into the original hole.

Detail of boom top pin (F)

(8) Slinging arm assy

Sling arm with nylon sling and remove it.

Arm weight: 1,275 kg (2,811 lbs)

Slinging arm assy

32.1.3.2 ATTACHING ARM

Instal the arm in the reverse order of removing, paying attention to the following:

1. When aligning the pin holes, do not put

your finger in the pin holes, but align them
visually.
2. Check the seals for damage and replace
as necessary.
3. When inserting the pin, coat the shaft with
grease.
4. Pin lock nut handling procedure
Tools: Spanner: 30mm

5. When installing the arm and the cylinder, inspect the clearance in the thrust direction of the pins
and decide the thickness of shims by referring to the Maintenance Standard.
6. When attaching the shims, attach resin shim first and then fill gap with iron shim.
7. Tightening torque

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32.1.4 BOOM
32.1.4.1 PREPARATION FOR REMOVING AND ATTACHING BOOM
When removing and attaching boom in the position shown in below Fig. to remove and attach boom
foot pin (A), removing and attaching of cab and guard are required.

32.1.4.2 REMOVING BOOM

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

(2) Lifting up boom cylinder temporarily

Remove the right and left boom cylinders
one side by one side according to the
following procedure:
Lift up boom cylinder temporarily to
prevent it from dropping.

Lifting up boom cylinder temporarily

(3) Press the boom cylinder rod pin (C)

At the one side of pin (C), loosen nut (5),
remove capscrew (4) (M20X190), and
remove collar (3). And push pin (C) to the
end of boom boss.

Tools: Spanner: 30mm

Detail of boom cylinder rod pin (C)


(4) Preparing for disconnecting cylinder pipes
Retract the above mentioned cylinder rod,
and place one side of cylinder on stand. (See right Fig.)

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(5) Disconnecting the arm cylinder and bucket

cylinder pipings
Release pressure from arm and bucket
circuit and bleed air in hydraulic tank, and
then disconnect pipe at (A1), (A2), (A3),
(A4) and hose (5), (6), (8), (10).

Tools: Spanner: 41mm

Tools: Allen wrench: 12mm

After disconnection of pipe, plug every pipe.

ORS Plug: See Tools 11.5.2-(4).
Half clamp: See Tools 11.5.2-(5).

Boom piping disconnection

(6) Lifting up boom assy temporarily

Lift up boom cylinder with nylon sling so that boom foot pin (A) is not loaded.

Weight of single boom: 2,670 kg (5,890 lbs)

Boom assy temporary lift up procedure

(7) Removing boom foot pin (A)

1. Remove capscrew (3) M20X60, and plate

(2).

Tools: Spanner: 30mm

2. Draw out pin (A).

Details of boom foot pin (A) section

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(8) Hoisting boom assy

Hoist and remove boom assy.

Weight of single boom: 2,670 kg (5,890 lbs)

Boom assy hoisting procedure

(9) Completion of removal of front attachments

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

1. Disconnect hose (F1) and (F2) at position

A. After disconnection of hose, plug both
ends of hose.

Plug: TOOLS
11.5.2-(4) Plugs for ORS fitting
11.5.2-(5) Plugs for half clamp
Tools: Spanner: 41mm
Tools: Allen wrench: 12mm

2. Removing arm cylinder head pin (D)

Loosen nut (3), remove capscrew
M20X180 (2) and pull out pin (D).

Tools: Spanner: 30mm

3. Removing arm cylinder

Weight of arm cylinder: 504 kg (1,110 lbs) 
Removing arm cylinder

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(11) Removing and installing boom cylinder

1. Disconnect hose (C2) at the position B.

And plug their both ends.
Plug: Tools 11.5.2-(4) Plugs for ORS fitting
: Tools 11.5.2-(5) Plugs for half clamp
Tools: Spanner: 41mm

Removing and installing boom cylinder

2. Removing boom cylinder foot pin (B)

(See right Fig., below Fig.)
Loosen nut (5), remove capscrews
M20X190 (4) and pull out pin (B).
Tools: Spanner: 30mm
3. Remove boom cylinder (2).
Weight of boom cylinder: 269 kg (590 lbs)
4. Remove another boom cylinder the same
way.
Removing and installing boom cylinder head
pin (B)

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32.1.4.3 ATTACHING BOOM

(1) Attaching boom foot pin (A)
First of all, insert boom foot pin (A) and install the boom assy.
Attach it in the reverse procedure of removing, paying attention to the following points.

1. When aligning the pin holes, do not put

your finger in the pin holes, but align them
visually.
2. Check that the dust seals is not damaged
and replace as necessary.
3. When inserting the pin, coat the shaft with
grease.
4. Refer to paragraph 32.1.3.2 about installing
of jam nut.
5. When installing boom and cylinder, check Boom foot pin (A)
the clearance of mounting section in thrust
direction, and decide the thickness of shim
according to the maintenance standard.
6. When attaching the shims, attach resin
shim first and then fill gap with iron shim.
7. Tightening torque



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32.2 DISASSEMBLING AND ASSEMBLING

32.2.1 CYLINDER
32.2.1.1 PREPARATION BEFORE DISASSEMBLY
Before assembly, secure a dustfree workshop and necessary equipment and facilities.

32.2.1.1.1 WORK AREA

The following working area is required for disassembly:
(1) Ample space
For the disassembly of the hydraulic cylinder, the cylinder tube and the piston rod must be drawn
out. For this reason, the first condition is that the working area is long enough for the work. In
terms of width, it is also necessary to keep sufficient space to disassembly, cleaning and
measuring equipment are placed and the work can be performed.
(2) Suitable working environment
The hydraulic cylinder is a precision-machined product that uses seals and packings made of
rubber and plastic materials. For this reason full care should be exercised so the hydraulic cylinder
is free from dust, dirt, and in particular, such hard particles as sand, metal chips, and weld slag
(spatter). If the hydraulic cylinder is assembled with hard particles adhered on such components
as the cylinder tube and the piston rod, the tube inner surface and the rod surface are scratched
as the cylinder operates, consequently disabling it in worst cases. Damage to the piston seals
and the rod seals will result in oil leaks. For this reason, grinding and welding operation should
not be performed in the neighborhood of the working area to keep it clean.

32.2.1.1.2 APPARATUS
The following equipment are required for disassembly:
(1) Hoist or crane
The hoist or crane must be capable of carrying the cylinder in an assembled condition. It must
also be capable of making level and liner movement under load for retracting and extending the
piston rod and the tube.
(2) Work bench
The work bench must have strength and rigi-dity capable of accommodating the total length of
the cylinder in its most retracted condition and of withstanding the repulsive force of the
tightening torques of the cylinder head and the piston nut. Since a vise is attached to the bench,
the width of the work bench must be sufficiently large.
(3) Support stand
If the piston rod is fully extended in a free condition, the bushing and the seals may be
damaged as the rod bushing and the piston are twisted due to the weight of the rod. A stand is
required to support the rod to prevent damage of seals.
(4) Hydraulic source
A Hydraulic source is required for disassembly and assembly of the cylinder head and piston nut
and for oil leak tests after completion of assembly.
(5) Jet air source
It is used for drying after oil draining and cleaning of the cylinder.
(6) Cleaning bath, cleaning oil and detergent
(7) Oil pan and oil reservoir
An oil pan is necessary to contain oil drained from the cylinder and oil spilt during work.
An oil reservoir is required to collect oil spilt on the floor and waste oil.

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(8) Others
Oil extracting hoses, wooden blocks, clean cloths and sawdust in which oil soaked are also
necessary.

32.2.1.1.3 NECESSARY TOOLS

List of Tools and Jigs
Tool/Jig Remarks Tool/Jig Remarks
Hammer 1. Steel hammer Spatula Metallic one with smooth corners.
2. Wooden or plastic mallet
Screwdriver A few types of large and small sizes Gimlet A sharp-point tool may be used in
place of a gimlet.
Chisel Flat chisel Special jig 1. For removing and press-fitting bushing.
(A), (D), (C)
2. For press-fitting wiper ring. (D)
3. For inserting and reforming seal ring.
(E),(F),(G),(H)
(See para 32.2.1.9 for detail)
Vise One having an operation wide enough to Rust
hold cylinder head O.D. and tube remover
mounting pins (clevis)
Wrench 1. Eye wrench Measuring 1. Slide caliper
2. Allen wrench instruments 2. Micrometer
3. Extension pipe for wrenches 3. Cylinder gauge (Fig. "Cylinder gauge")
4. V-block

࡮ For the details of special tools and jigs, refer to the back pages of this manual.

32.2.1.1.4 EXTERNAL CLEANING

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

32.2.1.1.5 DISCHARGING OIL

Place a wooden-block on the work bench and
place the cylinder on it to prevent it from
rotating. Charge air into ports A and B 
alternately to actuate the piston rod till the
hydraulic oil in the cylinder is drained out. At
this time, connect a suitable hose to each port
so that the hydraulic oil may not gush out.

Preparation

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32.2.1.2 CONSTRUCTION OF CYLINDER (GENERAL EXAMPLE OF CYLINDER)

Construction of general cylinder

No. NAME Q'TY No. NAME Q'TY No. NAME Q'TY

1 Cylinder tube 1 10 O-ring 1 19 Slide ring 2
2 Piston rod 1 11 Back-up ring 1 20 Shim *1
3 Rod cover 1 12 Socket bolt 12 21 Piston nut *1
4 Bushing 1 13 Cushion bearing 1 22 Setscrew; M12 1
5 Snap ring 1 14 Cushion seal 1 23 Steel ball 1
6 Buffer ring 1 15 Piston 1 24 Pin bushing 2
7 U-ring 1 16 Seal ring 1 25 Wiper ring 4
8 Back-up ring 1 17 Back-up ring 2
9 Wiper ring 1 18 Slide ring 2

Note: In case of piston with piston nut type, the parts with * are not used.

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32.2.1.3 DISASSEMBLY
࡮ When disassembling and servicing the cylinder, check the construction and the availability of
service parts as well as necessary tools and jigs on separate Parts Manual.
࡮ The figures in parentheses after part names correspond to those in Fig. "construction of general
cylinder"
࡮ The following explanation and quantities are for a general use cylinder which has separated
piston and piston nut.
In case that piston and piston nut are combined, the construction differs from separated type, refer
to the sentence in parenthesis.

32.2.1.3.1 REMOVING ROD COVER AND PISTON ROD

(1) Hold the clevis section of the tube in a
vise.
(2) Pull out piston rod (2) about 200 mm
(8in). Because the piston rod is heavy,
finish extending it with air pressure after the
above-mentioned oil draining operation.

Use mouth pieces so as not to damage the machined surface of the cylinder tube. Do not make use
of the outside piping as a locking means.

(3) Loosen and remove socket bolts (12) of the

rod cover in sequence.
(4) Strike the corner of the rod cover flange by
means of a plastic mallet till rod cover (3)
comes off.

Cover the extended piston rod (2) with cloths to prevent it from being accidentally damaged during
operation.

࡮ At this time, the weight of piston rod (2)

is loaded on rod cover (3). Therefore, lift 
the top end of the piston rod with a hoist
to the extent that only the rod weight may
be held.

Drawing out piston rod assy (2).

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(5) Draw out the piston rod assy from cylinder

tube (1).

Method of drawing out the piston rod assy

Since the piston rod assy is heavy in this case, lift the tip of the piston rod (2) with a hoist and
draw it out. However, when piston rod (2) has been drawing out to approximately two thirds of its
length, lift it in its center to draw it completely. However, since the plated surface of piston rod (2) is
lifted, do not use a wire rope which may score the surface, but use a strong cloth belt or a rope.

(6) Place the removed piston rod on a

horaizontal wooden V-block.

-Cover a V-block with cloths.

Method of placing the piston rod

(7) Remove slide ring (18) and (19) from piston

(15).

Remove slide ring (18) and (19)

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32.2.1.3.2 REMOVING PISTON ASSY

(1) Fix piston rod (2) by holding its clevis
section in a vise. Fix the piston rod (2)
securely as piston nut (21) is tightened to
a high torque.

How to loosen piston nut (21)

-Note that the tightening torque differs with the type, the working pressure and the mounting method of
the piston (15), though the rod diameter remains the same.
-It is also necessary to place a suitable supporting block near the piston (15). In case a V-block is
used, put cloths or something over the rod to prevent it from damage.

(2) Scrape off the caulked part of setscrew

(22) of piston nut (21) by means of a hand
drill and loosen setscrew (22) and remove
ball (23).

Tools: Allen wrench: 6mm

Removing setscrew (22) and ball (23)

(3) Loosen and remove piston nut (21) or

[piston (15)].

How to loosen piston nut (21)



-Since piston nut (21) is tightened to a high torque, use a eye wrench suitable for the outside
diameter of piston nut (21).
-In case that piston and piston nut are combined, apply the eye wrench to hexagonal part of piston
and loosen the piston directly.

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(4) Remove piston (15) by tapping with plastic

mallet, supporting weight of piston (15) with
hoist.

Removing piston (15)

In case that piston and piston nut are combined, the shim (20) is not used.

(5) After removing cushion bearing (13) and

cushion seal (14), separate rod cover (3)
from piston rod (2). If it is too hard to slide
it, knock the flanged part of rod cover (3)
with a plastic mallet. But when drawing it
out, lift rod cover (3) by hoist and pull it
straight horizontally.

Removing rod cover (3)

Take care so rod bushing (4) and the lip of packings (6,7,8,9) may not be damaged by thread of the
piston rod (2).

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32.2.1.3.3 DISASSEMBLING PISTON ASSY

(1) Remove seal ring (16) and back-up ring
(17).

Removing seal ring (16) and back-up ring (17)

Cut the seal ring (16) by tapping it with a screwdriver or a chisel. Take care not to strike it too hard,
otherwise the groove may be damaged.

32.2.1.3.4 DISASSEMBLING ROD COVER ASSY

(1) Remove O-ring (10) and back-up ring (11).
Remove back-up ring (11) and O-ring (10)
in that order. Remove back-up ring (11)
and O-ring (10) by pulling and stretching
them with an spatula like earpick.

Removing the outer circumferential seal of

rod cover (3)

(2) Remove buffer ring (6), U-ring (7) and

back-up ring (8). Each seal is fixed in the
groove on the bore and removing in
flawless is impossible.
Stab each seal with a gimlet and pull it out
of the groove.

Removing the inner circumferential seal of


rod cover (3)

Take care in this operation not to damage the grooves.

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(3) Remove wiper ring (9). When taking out

wiper ring (9), fix rod cover (3) in a vise.

Removing wiper ring (9)

(4) Remove snap ring (5) and bushing (4).

Remove snap ring (5) first, and remove
bushing (4). But the bushing (4) is press
fitted in rod cover (3), so push it out by
press with jig as shown in the figure.
See para 32.2.1.9.3 (1) for removing.

Removing rod bushing (4)

32.2.1.3.5 REMOVING PIN BUSHING

(1) Apply driver to wiper ring (25) of cylinder
tube (1) and piston rod (2), and strike it
by hammer lightly.
(2) Push out pin bushing (24) press fitted in
cylinder tube (1) and piston rod (2) with
press.

Drawing out pin bushing (24)

32.2.1.4 CLEANING
(1) After disassembly the cylinder, wash all parts with commercial detergent.
(2) Do not use the used oil seal, O-ring, back-up ring, etc. even if they are not damaged after
inspection.
(3) After cleaning, dry all parts by compressed air, and put them on the working bench taking care
not to damage them.

Never use benzene(gasoline, thinner, etc.) because it may be damage the rubber, etc.

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32.2.1.5 ASSEMBLING PIN BUSHING

Start assembling the following sub assy
-Cylinder tube assy
-Piston assy
-Rod cover assy

32.2.1.5.1 ASSEMBLING PIN BUSHING

(1) Press fit pin bushing (24) in cylinder tube
(1) and piston rod (2) respectively with
press.
(2) Press fit wiper ring (25) in the upper and
lower sides of cylinder tube (1) and piston
rod (2) respectively with press.

Press fitting of pin bushing (24)

-Before press fitting, apply grease on wiper ring and boss hole.
-Before press fitting the pin bushing, align the position of oil hole.

32.2.1.5.2 ASSEMBLING OF PISTON ASSY

(1) The fitting of seal ring (16) requires
special tool as shown in right Fig. Seal ring
(16) is pushed in by press, etc. with
pushing in tool as shown in the figure.
(The O-ring of seal ring (16) and back-up
ring (17) on one side should be installed
beforehand.)

How to fit seal ring (16)

Heat them, and they may be soften. But never heat them over 100C degrees (212.0F degrees) or
more. 

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(2) Fit back-up ring (17) on the other side.

After fitting, correct it immediately to prevent
from expansion of seal ring (16) with
correcting jig (H) as shown in right Fig.

Installing seal ring (16)

-For piston, stop it once tentatively (for 3 to 5 seconds), and then push it in fully.
-After fitting, wind tape around seal ring (16) 2 or 3 times, and remove it immediately before piston
(15) is inserted in cylinder tube (1).
-Fit slide rings (18) (19) at the same time when piston (15) is inserted in cylinder tube (1).

32.2.1.5.3 ASSEMBLING ROD COVER ASSY

(1) Press fit bushing (4) in rod cover (3) with
bushing press-fitting jig (A). Then, fit snap
ring (5) in the groove. Apply hydraulic oil
on internal surface of rod cover (3).

The snap ring (5) can not be fitted when the bushing (4) is not press-fitted fully to the stop end.

(2) Apply grease to wiper ring (9), and fit wiper

ring (9), directing the lip side toward the
groove of retainer tool (D). And set
retainer tool (D) on rod cover (3) and press
fit wiper ring (9) with press.

Press fitting of bushing (4)

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(3) Fit buffer ring (6), back-up ring (8) and U-ring (7) in their grooves in that order. Before setting
packings, coat them with hydraulic oil (or vaseline if not available). If you forget the coating, the
packings may be scored. When attaching seals, deform them in a heart shape as illustrated.

Inserting a seal into the inner circumference

of rod cover.

How to fit U-ring (7)

-U-ring (7) is harder than other packing and it would be difficult to deform them in a heart shape. In
such a case, put a U-ring in the groove obliquely by hand as deep as possible and push in the last
part with a push bar till it is set with a click.
-Buffer ring (6) should be fitted taking care of the fitting direction. The reverse fitting may cause
deformation, damage, etc. of the piston due to high pressure generated between the buffer ring and
U-ring.
-If U-ring (7) is set upside down, the lip may be damaged. Check that it is positioned correctly.
-Attach back-up ring (11) on the open air side of O-ring (10). (See above Fig.).



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32.2.1.5.4 INSERTING ROD COVER ASSY TO PISTON ROD

Inserting rod cover (3) to piston rod assy by the following procedure.

(1) Fix piston rod assy on working bench.

(2) Install rod cover (3) on piston rod (2) with
inserting guide jig (I) as shown in right
Fig. paying attention for the lip section of
U-ring not to be caught on the stepped
section.
Inserting rod cover (3)

-For the rod the outer diameter of piston installing section is small, insert spacer on the faucet
section of rod first, and attach inserting guide jig.
-Apply hydraulic oil on the inserting guide jig and outer surface of piston rod lightly to make the
insertion smooth.

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32.2.1.5.5 ASSEMBLING PISTON ASSY ONTO PISTON ROD

(1) Install cushion on the extraction side, cushion bearing (13) and cushion seal (14) by the following
procedure.

1. Put cushion seal (14) on it, directing the

slit machined side toward the piston side.
2. Fit cushion bearing (13) on it directing the
flattening side as shown in right Fig.

Cushion mechanism on extension side

(2) When cushion is installed on the retraction side, fit cushion bearing (13) and cushion seal (14) by
the following procedure.

1. Fit cushion bearing before fitting piston

nut. The nut attached obstructs the fitting of
cushion bearing.
2. Put cushion seal on it, directing the slit
machined side toward the piston side.
3. Fit cushion bearing on it directing the
flattening side as shown in right Fig.
4. Put stopper in the groove. Push cushion
bearing to stopper fully, and drive snap
ring. Use plastic mallet in order not to
damage the rod, cushion bearing. Cushion mechanism on retraction side

Cushion seal and cushion bearing should be fitted taking care of the fitting direction. If they are fitted
in reverse directions, the cushion does not effective.
After installing cushion, be sure that the cushion bearing moves up and down, and right and left.



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(3) Insert shim (20), and tighten piston nut (21)

or [piston (15)] till it gets tight.
Always tighten the piston nut (21) or [piston
(15)] of each piston to specified torque
(Refer to 32.2.1.7.3).

Tightening piston nut (21)

-In case that piston and piston nut are combined, the shim (20) is not used. Apply the eye wrench to
hexagonal part of piston and loosen the piston directly.
-Always correct the threads in piston nut (21) or [piston (15)] before fixing piston nut, using a tapping.
-Insufficient tightening torque causes an inner leak and a damage of thread. And over tightening torque
causes a bulge of cushion bearing and a deformation of piston contacted surface.
-Clean and decrease (with solvent) the parts of piston assembly, and dry it, then tighten this piston
assembly.

(4) Put steel ball (23) into hole and tighten

setscrew (22).
Tools: Allen wrench: 6mm

After tightening the setscrew to a specified

torque, caulk the two places of the thread
of the piston nut side to secure the
setscrew.
See para 32.2.1.7.3 for torque.
Attaching setscrew (22)

(5) Attach two slide rings (18) and (19). Take

off vinyl tape wound around the perimeter
of piston (15), apply high-quality grease (or
vaseline) to slide ring (18), (19) and attach
the slide rings in a manner that they may
be coiled around the groove. Set the slide
rings about 180 degrees apart with each
other so that the slits may not point to the
same direction. Attaching slide ring (18), (19)

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32.2.1.5.6 OVERALL ASSEMBLY

(1) Place a V-block on a work bench (A wooden V-block is preferable.). Place the cylinder tube assy
(1) on it and fix the assy by passing a wooden bar through the clevis pin hole to lock the assy.
(2) Insert the piston rod assy into the cylinder tube assy, while lifting and moving the piston rod assy
with a hoist. In this operation, apply hydraulic oil (or vaseline) to the inner surface of the tube
mouth and the circumference of the piston. Align the center of the piston rod assy with the
center of the cylinder tube assy and put it in straight forward. When inserting, make sure that
slide rings (18), (19) on the perimeter of the piston is not out of the groove.
(3) Tighten socket bolt (12). Match the bolt holes of the rod cover flange to the threaded holes in
the cylinder assy, and screw in socket bolts (12) one by one. Tighten the bolts to a specified
torque, taking care so the bolts may not be tightened unevenly. See para. 32.2.1.7.3 for torque.

Tools: Allen wrench: 14mm

Inserting piston rod assy

Tightening socket bolts (12)

Take care so as not to damage the rod surface by accidentally slip a wrench. Covering the rod
surface with cloth is recommended to prevent damage to it.



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32.2.1.6 INSPECTION AFTER ASSEMBLY

(1) No-load functional test
Place the cylinder level at no load,
operate the piston rod 5 to 6 strokes by
the directional valve and make sure that it
operates without failure.

External leak test

-Do not raise the hydraulic pressure above the maximum pressure of 37.8MPa (5480psi) for the
cylinder of the machine.
-Grease coated on the O-rings and the seals of the rod cover may come out. Wipe it off and retest
the cylinder in such a case.

(2) Leak test

1. Apply a test pressure to the retracting and extending sides of the cylinder for three minutes
independently, and check that the rod section and the welds have external leaks and permanent
deformation. For an internal leak test, connect the cylinder with a test unit as shown in below Fig.
2. After completing the test, apply a plug to each port and store the cylinder. (Below Fig.)

࡮ For storage, place the cylinder on wooden V-blocks and bring the cylinder to the most retracted
condition.

How to store the cylinder

Internal leak test

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32.2.1.7 MAINTENANCE STANDARDS

32.2.1.7.1 INSPECTION AFTER DISASSEMBLY
Visually inspect all parts after cleaning to see that excessive wear, crack and other damage that are
detrimental to use are not present.

(1) Inspection Item

Parts Name Inspecting Portion Inspection Item Remedy
1. Neck of rod pin Presence of crack Replace
2. Weld on rod hub Presence of crack Replace
3. Stepped part to which
Presence of crack Replace.
piston is attached
4. Threads Presence of seizure Recondition or replace
Measure degree of bend (See Refer to Table "Example of
5. Bend
Fig. "Measuring method") measurement"
6. Plated surface Check that:
Piston rod
1) Plating is not worn off to 1) Replace or replate
base metal
2) Rust is not present on 2) Replace or replate
plating.
3) Scratches are not present. 3) Recondition, replate or
replace.
Recondition, replate or
7. Rod Wear of O. D.
replace.
8. Bushing at mounting part Wear of I. D. Replace
1. Weld on bottom Presence of crack Replace
2. Weld on head Presence of crack Replace
Cylinder tube 3. Weld on hub Presence of crack Replace.
4. Tube interior Presence of damage Replace if oil leak is seen.
5. Bushing at mounting part Wear on inner surface Replace
1. Bushing 1) Wear on inner surface 1) See para. 32.2.1.7.2
Rod cover 2) Flaw on inner surface 2) Replace if score is
deeper than coating.

(2) Repair method

Check all seals and parts to see that they do not show excessive damage and wear. For correction of
scores on the piston rod, observe the following procedure:

1. Correct very fine longitudinal scratches with an oilstone. Replace the piston rod if the scratch is so
deep as may be caught by your nail.
2. In case of a smooth indention, recondition by removing the sharp area around the indention with
an oilstone. If the score or the indention is excessive, replace or replate the damaged part.

࡮ Always regrind after replating. The thickness of the plating must be maximum 0.1 mm (0.004 in).
࡮ In case plating is removed to the base metal during reconditioning with an oilstone, do not fail to
replate the surface.

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32.2.1.7.2 LIMIT OF SERVICEABILITY

Serviceability limits represent the limits of wear on the sliding surfaces of the cylinder tube and the rod
that have no such damage as may degrade the sealing effect.

(1) Clearance between piston rod and rod bushing

Replace the bushing if the clearance between the piston rod and the rod bushing exceeds 0.25mm
(0.01in).
(2) Bend of piston rod
The allowable bend of the rod is maximum 1mm / 1m (0.04"/3'3"). For measurement, support
both ends of the parallel section of the piston rod with V-blocks, set a dial indicator in the center
between the two V-block turn the piston rod, and read the difference between the maximum and
minimum deflection on the dial indicator.
Table shows an example of measurement.

Measuring Method

Even if the bend is within the above limit, the cylinder may not operate smoothly because of localized
bend. Beware of it during function test after assembly. Replace the rod if the cylinder makes a
squeaking noise or dose not operate smoothly.

32.2.1.7.3 TIGHTENING TORQUE

32.2.1.7.4 VOLUME OF OIL LEAK

The oil leak rates as mentioned in 1.6 (2) of Inspection after Assembly are as shown in INSPECTION
AFTER ASSEMBLY 32.2.1.6 (2).

Cylinder Volume of Internal Oil Leak

Boom 1.0 cc (0.06 cu-in) or below / 3 min
Arm 1.0 cc (0.06 cu-in) or below / 3 min
Bucket 1.0 cc (0.06 cu-in) or below / 3 min

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32.2.1.8 TROUBLESHOOTING



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32.2.1.9 JIGS LIST

32.2.1.9.1 SPECIAL JIG LIST (POSSIBLE TO SUPPLY)
When assembling, the following jigs are required.

For above jigs, contact our dealer.

(The Jig No. List provided by cylinder maker is shown in the following page.)

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Special Jig No. List

(1) For jigs for rod cover, select jig corresponding to respective rod diameter.
(2) For jigs for piston, select jig corresponding to the cylinder bore.

Application rod diameter [mm (in)] Kit No. of maker

65 (2.56") 3006J-56001
70 (2.76") 3007J-06001
75 (2.95") 3007J-56001
80 (3.15") 3008J-06001
85 (3.35") 3008J-56001
Jig for rod cover
90 (3.54") 3009J-06001
removing & installing
95 (3.74") 3009J-56001
100 (3.94") 3010J-06001
105 (4.13") 3010J-56001
110 (4.33") 3011J-06001
115 (4.53") 3011J-56001
120 (4.72") 3012J-06001
Application cylinder bore [mm (in)] Kit No. of maker
95 (3.74") 3009J-51001
100 (3.94") 3010J-01001
105 (4.13") 3010J-51001
110 (4.33") 3011J-01001
115 (4.53") 3011J-51001
120 (4.72") 3012J-01001
Jig for seal ring
125 (4.92") 3012J-51001
inserting & correcting
130 (5.12") 3013J-01001
135 (5.32") 3013J-51001
140 (5.51") 3014J-01001
145 (5.71") 3014J-51001
150 (5.91") 3015J-01001
160 (6.30") 3016J-01001
170 (6.69") 3017J-01001



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32.2.1.9.2 OTHER SPECIAL JIGS (PREPARED BY SERVICE SHOP)

(1) Bushing removing jig (Symbol J)

Bushing removing jig

(2) Wrench for piston nut or [piston]

Wrench for piston nut or [piston]

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32.2.1.9.3 SPECIAL JIG HANDLING PROCEDURE

(1) How to remove bushing from rod cover.
1. Attaching chuck assy tool
Insert tool in rod cover slowly until the edge top end of chuck assy reaches to the end of bushing
(4).

࡮ Special attention must be paid so that the inner surface of rod cover is not damaged by the
edge of tool.
࡮ Attach top on the position 5mm (0.2 in) from the bushing end face so that the edge does not
protrude from the end face.

2. Tightening chuck assy tool temporarily

a. Fit allen wrench to the head of adjuster bolt on the top end of tool, and insert lever in the round
hole on the rear end of tool.
b. Fix it with allen wrench and lever to the position where the tool does not drop even if the rod
cover is raised, inclining it forward and rearward.

࡮ Move rod cover onto the working bench holding tool attached.
࡮ Be careful not to drop it on foots, etc.



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3. Attaching tools for retainer

Put retainer on the press bench directing
the wiper ring fitting section of rod cover
upward, then put retainer tool (D) on the
rod cover.
-Fit retainer tool as shown in the right
figure directing large diameter section
(flange section) upward.
-Clean the surface of press bench, and
take care for the tool bottom face not to be
damaged by foreign matter like dust, chip,
etc.

4. Cutting into of the edge of chuck

Press the upper section of retainer tool
gradually so that the edge of chuck tool (A)
cuts into the bushing surface.
Set the pressing force to 2 to 3 tons (4410
to 6615 lbs).

After completion of pressing, tighten

adjuster bolt again by hand.

-Press it with retainer tool (D).

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5. Setting of tools for block

Prepare block (C), and put rod cover (3) on it aligning them.
Select corresponding block (C) in shape, dimensions, etc. from the table shown below.

6. Removing of bushing

a. Move block (C) and rod cover (3) with tool

under the press.
b. Press the upper part of retainer tool (D)
slowly until bushing (4) is take out from rod
cover (3) (until there is a sound that the
chuck tool (A) drops on the work bench)
-The force of 3 tons (6615 lbs or less) is
necessary to press it out.
The stroke of press ram is about 32 to 52
mm (1.26 in to 2.04 in). (But it varies
according to the difference of dimension of
cylinder head.)

-Press it with retainer tool (D).

When the block and rod cover assy are not 

aligned, interrupt the work and align the
block and rod cover assy.

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7. Removing of rod cover

a. Remove block (C) with rod cover (3) near side, remove retainer tool (D) from rod cover (3), and
then move rod cover (3) to other place.
b. Take out the chuck tool (A) with bushing from block (C).

Do not work under the press because it is very dangerous.

8. Removing of bushing

a. Place chuck tool (A) with bushing (4) sideways, and loosen adjuster bolt with allen wrench and
lever.
b. Place the chuck tool (A) vertically and turn the adjuster by hand until the wedge is raised about
5mm (0.2 in).
c. Remove the wedge from the edge of chuck

࡮ Clean the surface of work bench, and be careful for the tool not to be damaged by foreign
matters like dust, chips, etc.

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9. Tightening of adjuster bolt

Tighten the chuck tool (A) the bushing (4)
is removed to the extent that there is no
gap between the chuck and the wedge
upper face, turning the adjuster bolt by
hand.

-This special tool differs according to the

corresponding piston rod diameter.
-The chuck edge is an important portion.
Take care of handling and storage.



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(2) Rod cover bushing press-fitting procedure

1. Temporary setting of head bushing
Put rod cover (3) on the press-working bench directing the tube connection upward.

Set bushing (4) on the inner surface of rod cover (3) temporarily.

࡮ Make sure that the inner and outer surfaces of bushing (4) are free from foreign matter.

2. Setting chuck assy tool (A)

Insert the chuck assy tool (A) in temporary-set bushing (4) directing the flange downward, and set
it on rod cover (3).

࡮ Be sure that the adjuster bolt is tightened to the extent that there is no gap between adjuster of
chuck assy (A) and wedge.

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3. Attaching retainer tool

Put retainer tool (D) on the wedge
stepped section of chuck assy tool (A)
slowly directing the flange upward.

-Align chuck assy (A) and the wedge.

4. Preparation for press-fitting

Move the rod cover on which chuck tool
(A) and retainer tools are attached under
the press.

-Adjust it so that the press ram is

centered to the tool.



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5. Press-fitting of bushing
Push the head of retainer (D) with press,
and press fit bushing (4) to the specified
position of rod cover (3) slowly.

-The pressing force should be held 5 tons

(11025 lbs) or less, keeping the required
force for the press-fitting.
-Raise the pressure gradually adjusting the
force by means of pressure adjusting valve
of press unit.
-Be sure that the end face of bushing is
located on the interior of the groove for
snap ring. When it is located on near
place, press fit and adjust the location
again.

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 㨇33. UPPER SLEWING STRUCTURE㨉



33. UPPER SLEWING STRUCTURE

TABLE OF CONTENTS

33.1 REMOVING AND INSTALLING ääääääääääääääääääääääääääääää33-3

33.1.1 OPERATOR SEATääääääääääääääääääääääääääääääääää33-3
33.1.2 CAB ääääääääääääääääääääääääääääääääääääääää33-5
33.1.3 BATTERY ääääääääääääääääääääääääääääääääääääää33-8
33.1.4 GUARD äääääääääääääääääääääääääääääääääääääää33-10
33.1.5 UNDER COVER äääääääääääääääääääääääääääääääääää33-19
33.1.6 FUEL TANKäääääääääääääääääääääääääääääääääääää33-20
33.1.7 HYDRAULIC TANK äääääääääääääääääääääääääääääääää33-22
33.1.8 DEF TANK äääääääääääääääääääääääääääääääääääää33-26
33.1.9 HYDRAULIC PUMP äääääääääääääääääääääääääääääääää33-27
33.1.10 AIR CLEANER äääääääääääääääääääääääääääääääääää33-33
33.1.11 MUFFLER äääääääääääääääääääääääääääääääääääää33-35
33.1.12 COUNTERWEIGHT äääääääääääääääääääääääääääääääää33-36
33.1.13 RADIATOR & OIL COOLERäääääääääääääääääääääääääääää33-37
33.1.14 ENGINE ääääääääääääääääääääääääääääääääääääää33-44
33.1.15 CONSOLE COVER äääääääääääääääääääääääääääääääää33-48
33.1.16 MULTI CONTROL VALVEääääääääääääääääääääääääääääää33-49
33.1.17 CONTROL VALVE äääääääääääääääääääääääääääääääää33-51
33.1.18 PILOT VALVE (FOR ATT) äääääääääääääääääääääääääääää33-54
33.1.19 PILOT VALVE (FOR TRAVEL) äääääääääääääääääääääääääää33-56
33.1.20 SWING MOTOR UNIT äääääääääääääääääääääääääääääää33-57
33.1.21 SWIVEL JOINTäääääääääääääääääääääääääääääääääää33-59
33.1.22 UPPER FRAME ääääääääääääääääääääääääääääääääää33-62
33.2 DISASSEMBLING AND ASSEMBLING ääääääääääääääääääääääääää33-64
33.2.1 HYDRAULIC PUMP - REGULATORääääääääääääääääääääääääää33-64
33.2.2 CONTROL VALVE ääääääääääääääääääääääääääääääääää33-90
33.2.3 PILOT VALVE (ATT)äääääääääääääääääääääääääääääääää33-124
33.2.4 PILOT VALVE (FOR TRAVEL) ääääääääääääääääääääääääääää33-137
33.2.5 SWING MOTOR UNIT ääääääääääääääääääääääääääääääää33-147
33.2.6 SWIVEL JOINT äääääääääääääääääääääääääääääääääää33-176

Book Code No. S5/&E0

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Issue Date of Issue Applicable Machines Remarks

S5LC3333E01
First Edition July, 2014 SK350LC-9E : YC13-13001~
(NA)
S5LC3333E02
Revision November, 2014 SK350LC-9E : YC13-13001~
(NA)

PREFACE
(1) This Manual describes all the procedures from removing to installing, arranging them by item.
(2) This Manual consists [Removing and installing], and [Disassembling and assembling].
(3) The removing and installing can be performed in the procedure specified in Table of Contents,
but in view of actual repairing or time saving some process can be omitted.
(4) The removing and installing procedure does not completely cover all possible situations because of
differences of field condition and defective section.
(5) Recognize well that the service man must decide a work procedure before proceeding to repair.
When deciding the work procedure, choose an item that is needed, familiarize yourself with the
contents of the work and itemize the work procedure, before starting work.
(6) Disconnect the negative terminal of battery first, when the removing and the installing of the
electric component and wiring are performed.
(7) The explanatory note and figure of this manual may differ from the actual machine by the
difference in specification.

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33.1 REMOVING AND INSTALLING


33.1.1 OPERATOR SEAT
33.1.1.1 REMOVAL
(1) Preparation for removal
1. Remove the head rest (A1-1) of the operator's seat (A1) to ease handling.
2. Move the whole control stand to its foremost position.
3. Move the operator's seat to its forward end.
4. Incline the reclining seat as forward as possible.

(2) Remove operator's seat. (Include upper rail.)

1. With the above-mentioned condition, remove
two cap screws (B2) M8X20 from the upper
rail. Then move the control stand to its
rearmost end and remove two capscrews
(B2) M8X20.
Tools: Allen wrench: 6 mm
2. Remove the operator's seat. [about 28 kg
(62 lbs).]
Carry out the following operations as
required.
3. Remove seat belt (C1), bracket (C2).
4. Remove armrest (A3)(A4).
5. Remove bracket assy (1), rail (7).

Disassembling and Assembling seat

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33.1.1.2 INSTALLATION
Install it in reverse procedure of removing according to the tightening torque table.

Disassembling and Assembling armrest

Reference : Movement on rail

Upper rail.....Fixed on lower surface of seat
[Forward 80mm (0.26in), backward 80mm (0.26in)]
Lower rail.....Fixed on seat stand.
[Forward 60mm (0.19in), backward 60mm (0.19in)]
Amount of adjustment of seat height
[Up; 23mm (0.07in), down; 37mm (0.16in)]
Suspension stroke
[Up; 37.5mm (1.48in), down; 37.5mm (1.48in)]

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33.1.2 CAB
33.1.2.1 REMOVAL 
(1) Remove floor mat.
(2) Remove cover assy (A8).
1.
Remove cover (A9) and loosen 4
sems-bolts (A38) M6X20.
Tools: Phillips screwdrive
2.
Disconnect harness connector of power
socket and remove cover assy (A8).
(3) Removal of cover assy (A10).
1.
Remove cover (A11) and loosen 3
sems-bolts (A38) M6X20.
Tools: Phillips screwdriver
2.
Remove cover assy (A10).
(4) Removal of harness connector.
(See Chapter 23 "Electric System")
1.
Disconnect connectors of cab harness at
rear right of cab.
2.
Disconnect antenna cable for tuner located
at rear left of cab.
3.
Disconnect harness for cab light located at Disassembly and assembly of right panels
rear left of cab. (A1), (A8) and (A10)
(5) Removal of cover assy (A1).
1.
Loosen 2 sems-bolts (A38) M6X20.
Tools: Phillips screwdriver
2.
Disconnect harness connector of hour-meter
and remove cover assy (A1).
(6) Remove plastic tube for window washer
located at right front of cab.

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(7) Removal of mechatro-controller

1.
Loosen 4 sems-bolts (B11) M6X25.
2.
With harnesses are connected condition,
remove mechatro-controller, and place it in
front of it temporally.

Removal of mechatro-controller

(8) Removal of cab attaching bolts

1.
Loosen 4 capscrews (C1) M12X35.
2.
Loosen a nut (C6) M20 and remove a
washer (C5).
3.
Loosen a pin (C3) M30.
4.
Loosen 4 nut (D4) M16.

Removing and installing cab mounting bolts

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(9) Slinging cab

1.
Remove 2 plastic plugs at the front of the

ceiling of the cab, and attach 2 eyebolts.
Then hook slinging wires to eyebolts as
shown in figure.
2.
Then lift up cab slowly avoiding interference
with surroundings.
Wire with hook;
Length 1.5m (4ft 11in) X Dia. 12mm
(0.4in) X 4pcs.
Weight of cab; Approx. 480kg (1060 lbs)

Slinging cab

33.1.2.2 Installation
Install it in reverse order of removing according to the Tightening Torque Table.

Allen wrench Tightening torque

Tightening position
HEX(mm) N-m (lbf-ft)
Capscrew (C1) 19 80 (66)
Nut (C6) M20 30 191 (141)
Pin (C3) M30 36 191 (141)
Sems bolt M6 (A38) (B11) Plus driver 5.0 (3.7)
Nut (D4) M16 20 191 (141)

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33.1.3 BATTERY
33.1.3.1 REMOVING
(1) Open left panel assy (B1), (B2).
1.
Open it with starter key.
2.
Open left panel assy (B1).
3.
Fix it with stay.
(2) Remove battery cover (A3).
Loosen nut (A7) M10 and remove battery
cover (A3).
Tools: Spanner: 17 mm

(3) Remove battery cable

1.
Remove cable (C4) [between the earth
and battery (-)].
(Always remove (-) terminal first and install
it at last.)
2.
Cable (C2) [between battery (+) and (-)]
3.
Cable (C3) [between battery (+) and battery
relay]
Tools: Spanner: 13 mm Removing and installing battery cable

(4) Remove battery (B1)

1.
Loosen 2 capscrews (A5) M10X235.
Tools: Socket 17 mm
2.
Remove plate (A4).
3.
Remove battery (B1).

Removing and installing battery

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Follow the battery removal order.
Start removing battery from grounding side, and finish attaching to grounding side. If this order is
missed, short-circuits may occur.

33.1.3.2 INSTALL
(1) Install the battery in the reverse order of removing.
Hold down plate (A4) against battery (B1), and tighten capscrew (A5).
Tools: Socket: 17 mm,
Tightening torque : 10.8 N-m (8.0 lbf-ft)
(2) Installing grounding cable
Install grounding cable (C4) last. Especially care must be taken that the grounding face is free
from painting, rust, etc.
Tools: Socket: 13 mm

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33.1.4 GUARD
33.1.4.1 PREPARATION FOR REMOVAL
(1) All the locked cover, open them using
starter key.

Arrangement of guard assy

33.1.4.2 REMOVE GUARD

(1) Remove bonnet assy (G1), (G2).
1.
Unlock and open bonnet assy (G1).
2.
Loosen 2 sems bolts (A37) M10X40 and
remove plate (A16).
3.
Loosen a sems bolts (G15) M10X25 and
remove stay (G13).
4.
Loosen 4 nuts (G10) M12 and remove
bonnet assy (G1).
Weight: 31 kg (68 lbs)
5.
Loosen 2 sems bolts (G9) M12X45. Removing bonnet assy (G1),(G2)
6.
Loosen 4 nuts (G10) M12 and remove
bonnet assy (G2).
Weight: 21 kg (46 lbs)
Tools: Socket: 17 mm, 19 mm

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*Open and close bonnets

(1) Open bonnets (G1 and G2)
1.

Unlock and open bonnet (G1).
2.
Loosen 2 sems bolts (G9) M12X45.
3.
Close and lock bonnet (G1).
4.
Open bonnets (G1 and G2) by holding them up together.
(2) Close bonnets (G1 and G2)
1.
Hold up bonnets (G1 and G2) to remove the stay.
2.
Close bonnets (G1 and G2).
3.
Unlock and open bonnet (G1).
4.
Install two sems bolts (G9) M12X45.
5.
Close and lock bonnet (G1).

When opening bonnet (G2) during work, be sure to open and close bonnets (G1 and G2) together as
mentioned in the procedures above.

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(2) Remove stay (H1),(H2),(H3).

1.
Loosen 2 sems bolts (H10) M12X35 , 2
sems bolts (H11) M12X40 and remove stay
(H2).
2.
Loosen 4 sems bolts (H10) M12X35 and
remove stay (H3).
3.
Loosen 4 sems bolts (H12) M12X55 and
remove stay (H1).
Tools: Socket: 19 mm

Removing stay (H1),(H2) and (H3)

(3) Remove panel assy (B1),(B2),(B3).

1.
Unlock panel assy (B1).
2.
Loosen 4 nuts (B4) M12 and remove
panel assy (B1).
3.
Loosen 4 nuts (B4) M12 and remove
panel assy (B2).
4.
Unlock panel assy (B3).
5.
Loosen 4 nuts (B4) M12 and remove
panel assy (B3).
Tools: Socket: 19 mm
Weight:
panel assy (B1) : 13 kg (29 lbs)
panel assy (B2) : 13 kg (29 lbs)
panel assy (B3) : 12 kg (26 lbs)

Removing panel assy (B1),(B2) and (B3)

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(4) Remove guard (C1).

1.
Loosen 12 sems bolts (C8) M12X25 and

remove guard (C1).
Tools: Socket: 19 mm
Weight:
guard (C1) : 22 kg (49 lbs)

Removing guard (C1)

(5) Remove guard (A14),(A15).

1.
Loosen 4 sems bolts (A23) M12X25 and
remove guard (A14).
2.
Loosen 5 sems bolts (A23) M12X25 and
remove guard (A18).
Tools: Socket: 19 mm
(6) Remove guard assy (C2),(C3) , cover (C4)
and cover assy (C5).
1.
Loosen 3 sems bolts (C8) M12X25 and
remove cover (C4).
2.
Loosen 6 sems bolts (C8) M12X25 and
remove guard assy (C3).
3.
Loosen 4 sems bolts (C8) M12X25 and
remove cover assy (C5).
4.
Loosen 3 sems bolts (C8) M12X25 and
remove guard assy (C2).
Tools: Socket: 19 mm
Weight:
guard assy (C2) : 10 kg (22 lbs)

Removing guard, guard assy, cover and cover

assy

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(7) Remove pillar (A16) , beam (A38).

1.
Loosen 4 sems bolts (A23) M12X25 and
remove pillar (A16).
2.
Loosen 2 sems bolts (A23) M12X25 and
remove beam (A38).
Tools: Socket: 19 mm
(8) Remove beam (A40),(A41).
1.
Loosen 3 sems bolts (A23) M12X25 and
remove beam (A40).
2.
Loosen 3 sems bolts (A23) M12X25 and
remove beam (A41).
Tools: Socket: 19 mm
(9) Remove pillar (A21) and panel (A22).
1.
Loosen 2 sems bolts (A24) M12X25 and
remove pillar (A21).
2.
Loosen 3 sems bolts (A23) M12X25 and
remove panel (A22).
Tools: Socket: 19 mm
(10) Remove pillar (A18).
1.
Loosen 2 sems bolts (A37) M12X35 and
remove pillar (A18).
Tools: Socket: 19 mm
(11) Remove guard (A19) , pillar (A17).
1.
Loosen 2 sems bolts (A23) M12X25 and
remove guard (A19).
2.
Loosen 2 sems bolts (A23) M12X25 and
remove pillar (A17).
Tools: Socket: 19 mm

Removing pillar, panel, guard and beam

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(12) Remove duct (D3),(D4).

1.
Loosen 3 sems bolts (D6) M12X25 and

remove duct (D4).
2.
Loosen 3 sems bolts (D6) M12X25 and
remove duct (D3).
Tools: Socket: 19 mm
(13) Remove guard (D1),(D2), plate (D5).
1.
Loosen 2 sems bolts (D6) M12X25 and
remove plate (D5).
2.
Loosen 13 sems bolts (D6) M12X25 and
remove guard (D1).
3.
Loosen 3 sems bolts (D6) M12X25 , a
sems bolt (D9) M12X30 and remove guard
(D2).
Tools: Socket: 19 mm
Weight:
guard (D1) : 17 kg (38 lbs)

Removing duct, guard and plate

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(14) Remove bracket assy (A11) and guard

(A12).
1.
Loosen 3 sems bolts (A23) M12X25 and
remove bracket assy (A11).
2.
Loosen a sems bolt (A23) M12X25 , 2
sems bolts (A24) M12X30 and remove
guard (A12).
Tools: Socket: 19 mm
Weight:
guard (A14) : 11 kg (24 lbs)
(15) Remove beam (A5),(A10) and bracket (A8).
1.
Loosen 6 sems bolts (A23) M12X25 and
remove beam (A5).
2.
Loosen 4 sems bolts (A23) M12X25 and
remove beam (A10).
3.
Loosen 3 sems bolts (A23) M12X25 and
remove bracket (A8).
Tools: Socket: 19 mm
(16) Remove pillar (A1),(A2),(A3),(A9) and (A23).
1.
Loosen a sems bolt (A33) M12X25 and
remove pillar (A1).
2.
Loosen 2 sems bolts (A33) M12X25 and
remove pillar (A2).
3.
Loosen a sems bolt (A33) M12X25 and
remove pillar (A3).
Removing bracket assy, guard, beam,
4.
bracket and pillar
Loosen 2 sems bolts (A24) M12X30 and
remove pillar (A9).
5.
Loosen 2 sems bolts (A33) M12X25 and
remove pillar (A23).
Tools: Socket: 19 mm

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(17) Remove cover (E4), cover assy (E1), (E2),

(E3), (E6) and guard (E5).
1.

Loosen 2 sems bolts (E8) M12X25 and
remove cover assy (E3).
2.
Loosen 2 sems bolts (E8) M12X25 and
remove cover assy (E2).
3.
Loosen 6 sems bolts (E8) M12X25 and
remove cover (E4).
4.
Loosen 2 sems bolts (E8) M12X25 and
remove cover assy (E6).
5.
Loosen 2 sems bolts (E8) M12X25 and
remove guard (E5).
6.
Open cover (E1-1), loosen 4 sems bolts
(E7) M12X30, and remove cover assy (E1).
Tools: Socket: 19 mm
Weight:
cover assy (E1) : 33 kg (73 lbs)

Removing cover (E4) and cover assy

(E1),(E2),(E3),(E6), and guard(E5)

(18) Remove stay (F1).

1.
Loosen a capscrew (F5) M10X55 , 2
capscrews (F7) M16X70 and remove clamp
(F3).
2.
Loosen a capscrew (F5) M10X55 , a
capscrew (F6) M12X60 and remove clamp
(F4) , stay (F1).
Tools: Socket: 17 mm, 19 mm, 24 mm

Removing stay (F1)

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(19) Remove other brackets, as required.

33.1.4.3 INSTALLATION
(1) Installing is done in the reverse order of removing.
(2) Tightening torque

Unit:N-m (lbf-ft)
Size Capscrew Sems bolt Nut
M10 46.5 (34.3) 46.5 (34.3) -
M12 80 (59.0) 80 (59.0) 80 (59.0)
M16 191 (140.9) - -

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33.1.5 UNDER COVER

33.1.5.1 REMOVAL 
(1) Remove under cover (1,2,3,4,5,6,7,10,11,12)
1. Remove attaching sems bolts (8) M12X30 and sems bolts (9) M12X40 and sems bolts (13)
M12X25.
2. Remove covers.
Tools: Socket: 19 mm

Under cover assy

33.1.5.2 INSTALLATION
(1) Install under cover (1,2,3,4,5,6,7,10,11,12)
Tools: Socket: 19 mm
Tightening torque: 80 N-m (59 lbf-ft)

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33.1.6 FUEL TANK

33.1.6.1 PREPARATION FOR REMOVAL
(1) Draining fuel. (See below Fig.)
1.
Unlock cap (B2) with a starter key and
open it.
2.
Loosen valve (A7) under the tank.
3.
Draining fuel
Capacity of tank: 580 L (153 gal)
(2) Remove stay (E1),(H10), guard (A17) and
cover (H4).
(See 33.1.4 GUARD)
(3) Remove the connector for level sensor
(A4).
(See below Fig.)
(4) Remove fuel hose
1.
Loosen clip (21) and draw out hoses (8)
and (12).
2.
Put in plugs that match the hose bore.

Removing fuel hose (8), (12)

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33.1.6.2 REMOVAL
(1) Remove 6 capscrews (A1) M20X50.
Tools: Socket: 30 mm

Tank capacity: 580 liters (153 gal)
(2) Hook the wire to the lifting eye on the
fuel tank assy (B1) and remove the fuel
tank.
Weight: 191 kg (421 lbs)
(3) Remove shim (A3).

Removing fuel tank

Record the shim locations.

33.1.6.3 INSTALLATION
(1) Installing is done in the reverse order of removing.
Tank attaching bolt (A1) M20X50
Tools: Socket: 30 mm, Apply Loctite #262
Tightening torque: 370 N-m (273 lbf-ft)

If the gap (looseness) between tank mount and frame exceeds 1 mm (0.04 inch), adjust the gap with
shim (A3) and tighten capscrew (A1) to install the tank.

(2) Tightening torque

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33.1.7 HYDRAULIC TANK

33.1.7.1 PREPARATION FOR REMOVAL
(1) Remove bonnet assy (G1), (G2) panel assy
(B3), guard (A14), (A15), (C1) and other
guards necessary to remove the hydraulic
oil tank.
(See 33.1.4 GUARD.)

Remove guard

(2) Release internal pressure of tank

Remove cap on air breather and push
valve (head of bolt) by your finger.

Bleeding internal pressure of tank

Keep pressing until the hissing stops.

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(3) Remove cover (B3).

1. Remove 6 sems bolts (B9) M10X25.
Tools: Socket: 17 mm

2. Remove cover (B3).
3. Remove suction strainer (B4).
(4) Remove cover (B2).
1. Remove 6 capscrews (B9) M10X25.
Tools: Socket: 17 mm
2. Remove cover (B2).
3. Remove filter element (B7).
(5) Turn the handle of element assy (B), and
disassemble the removed filter element (B7).
Disassemble parts: (B), (C), (D), (E), (J)X3
(6) Draining hydraulic oil
Place pump in tank and draw up hydraulic
oil.
Capacity of tank: 245 L (65 gal)

Remove cover (B2), (B3)

33.1.7.2 REMOVAL
(1) Draw out the suction hose (A1)
Remove 2 clips (A2) of the tank side and
pull out hose (A1).
Tools: 2: Flat-blade screwdriver

Removing and installing the suction hose

(2) Disconnecting the main pipe return hose

1.
Remove 2 sems bolts (B11) M12X35 and
remove return hose (B1).
Tools: Spanner: 19 mm
2.
Remove 2 sems bolts (B11) M12X35 and
remove return hose (B2).
3.
Remove drain hose (B3) of pump.
Tools: Spanner: 36 mm
Removing main piping return hose
4.
Remove drain hose (B4) of swing motor.
Tools: Spanner: 36 mm

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(3) Disconnecting pilot return hose

1. Remove pilot hose (C1).
Tools: Spanner: 22 mm

2. Remove pilot hose (C2).

Tools: Spanner: 22 mm

3. Remove pilot hose (C3).

Tools: Spanner: 22 mm

Remove pilot return hose

(4) Remove drain hose (D1) of pilot pump

Tools: Spanner: 22 mm

Removing pump drain hose

(5) Remove hydraulic tank attaching bolt

Remove 4 capscrews (A1) M20X45.
Tools: Socket: 30 mm
(6) Slinging hydraulic oil tank
Place a wire sling, using the lifting plate on
top of the tank.
Tank weight: Approx : 207 kg (456 lbs)
(7) Remove shim (A3).

Removing hydraulic tank

Record the shim locations.

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33.1.7.3 INSTALLATION
(1) Cleaning hydraulic oil tank
(2) Cleaning suction hose

(3) Cleaning mount of tank.
Installing is done in the reverse order of removing.
(4) Install 4 mounting capscrews (A1) M20X45 with Loctite #262. (See Fig. "Removing hydraulic tank".)
Tools: Socket: 30 mm, Apply Loctite # 262
Tightening torque: 370 N-m (273 lbf-ft)

If the gap (looseness) between tank mount and frame exceeds 1mm (0.04 inch), adjust the gap with
shim (A3) and tighten capscrew (A1) to install the tank.

(5) Connection of suction hose (A3)(See

Fig."Removing and installing the suction".)
1. Apply PERMATEX on pipe side of hose
connection and insert it.
2. Put the hose with clip (A2).
Tightening torque: 5.39 N-m (4.0 lbf-ft)
(6) Assembling return element
Assemble filter element by the use of
element kit (B-110). (See Fig."Remove
cover", Right Fig.)
(7) Install return element (B7). (See Fig.
"Remove cover")
(8) Installing suction strainer (B4)
(9) Tighten sems bolts (B9) M10X25 that
attach tank covers (B2), (B3).
Element & suction strainer
M10 Tightening torque : 46.5 N-m (34 lbf-ft)

1. Three elements (J) are used as one set.

2. Replace O-ring (D) and packing (E) with new ones respectively.

Replace O-ring fitted on the back side of tank cover with new one.

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33.1.8 DEF TANK

33.1.8.1 PREPARATION FOR REMOVAL
(1) Remove cover (E4), cover assy (E1), (E2),
(E3), (E6) and guard (E5).
(See 33.1.4 GUARD)
(2) Remove the piping and harnesses.
(See Chapter 51. ENGINE)

Remove guard

33.1.8.2 REMOVAL
(1) Remove nut (6) M10.
Tools: Wrench: 17 mm
Tools: Whirl-stop jig (See 11.13)
(2) Remove capscrew (3) M10X65 and band
assy (1), (2).
Tools: Allen wrench: 8 mm
Tools: Whirl-stop jig (See 11.13)
(3) Remove the DEF tank assy.
Weight: 14 kg (31 lbs)

33.1.8.3 INSTALLATION
Install the DEF tank in the reverse procedures of removal.

(1) Install band assy (1), (2).

Tools: Allen wrench: 8 mm
Tools: Socket: 17 mm
Tools: Whirl-stop jig (See 11.13)

(2) Tightening torque

(3) Install the piping and harnesses.

(See Chapter 51. ENGINE)

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33.1.9 HYDRAULIC PUMP

33.1.9.1 PREPARATION FOR REMOVAL 
(1) Release pressure in hydraulic oil tank.
(See 33.1.7 HYDRAULIC TANK)
(2) Remove six capscrews (B9) M10X25.
(3) Remove cover (B3)
Tools: Socket: 17 mm
(4) Take out suction strainer.
(5) Install suction stopper.
For suction stopper, see chapter 11. Tools.

Suction stopper installing

(6) Remove guards

1.
Remove bonnet assy (G1), (G2).
2.
Remove stay (H2), panel assy (B3) and guard (A19), (A24), (A37), (A40), (A41).
3.
Remove those parts that are required to remove the hydraulic pump such as the fuel filter assy.

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(7) Removing muffler assy

1. Remove the piping and harnesses. (Refer to 33.1.11 MUFFLER)

2. Remove 4 capscrews (59) M12X40.
3. Remove 2 sems bolts (33) M12X40.
4. Install the eyebolts to the "a" portions (3 locations) of bracket (31).
5. Install the dedicated lifting jig to the eyebolts and remove the muffler assy
(11.12 MUFFLER ASSY LIFTING JIG)

Removal of muffler assy

Example of lifting muffler assy

Lift the muffler assy so as not to allow the chains, etc. of the lifting jig to interfere with the muffler
body, piping, and harnesses and cause damage to them.

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33.1.9.2 REMOVAL
(1) Loosen 8 capscrews (A15) M12X90 and
remove half clamp (A4). And disconnect 2

hoses (A1), (A2) from the delivery side.
Tools: Allen wrench: 10 mm
(2) Remove pilot pump suction hose (E1)
(See below Fig.)
Tools: Spanner: 36 mm
(3) Remove suction hose (A3) and drain hose
(C4)
1.
Remove 4 capscrews (B2) M12X30.
Tools: Allen wrench: 10 mm Removing hoses
2.
Remove elbow (B1) of suction hose (A3)
from pump.
3.
Remove drain hose (C4).

(4) Removing other hoses

1. Disconnect hoses of the following ports.
2. Attach tags to hoses to identify.
3. Put a plug in the hoses and the pump.

Removing other hoses

Remove the parts marked * only if necessary.

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(5) Remove connector

Remove 4 connectors of all pressure
sensors and proportional valves.

Removing connector

(6) Remove main pump

1. Put a wire sling on the hydraulic pump and

tension the wire sling a little. Loosen 8
capscrews (4) M10X35.
Tools: Socket: 17 mm
2. Draw out the power take-off assy from the
flywheel housing slowly, adjusting the
tension of the wire rope.
On that occasion, the assembly is drawn
out with the insert NA (2-3) remaining on
the flywheel side.
3. Remove element (2-1) from the tip of the
spline shaft.
4. Remove 4 capscrews (2-6) M20X50 that
fasten insert R (2-4) and remove insert R
(2-4).
Tools: Allen wrench: 17 mm
5. Remove hub (2-2)
If you loosen 2 set screws (2-7) M20X25,
hub comes off from the spline shaft of the
pump.
Tools: Allen wrench: 17 mm
6. Remove 4 capscrews (2-5) M20X60 that
fasten the insert NA (2-3) with the engine Removing pump
side flywheel, as necessary. Then remove
and spring pin (2-8) from insert NA (2-3).
Tools: Allen wrench: 17 mm
7. Removing bracket (1)
Loosen 4 capscrews (3) M20X55, and
remove bracket (1) from pump (0).

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33.1.9.3 INSTALLATION
Installing is done in the reverse order of removing.
(1) Installing bracket (1)

Tighten bracket (1) with capscrew (3) and install bracket temporarily.
Tools: Allen wrench: 17 mm
Tightening torque: 431 N-m (318 lbf-ft)
Apply Loctite #262
(2) Installing hub (2-2)
Put hub (2-2) into the pump spline till it enters 3mm (0.12 in) from the end face of the spline
(See below Fig. Detail aa). Then install two set screws (2-7) and fix them together.
Tools: Allen wrench: 17 mm
Tightening torque: 210 N-m (155 lbf-ft)
(3) Install spring pin (2-9)
Put spring pin (2-9) into hub (2-2).
(4) Installing insert (2-4)
Install insert (2-4) into hub (2-2) by means of capscrews (2-6) coated with Loctite #262.
Tools: Allen wrench: 14 mm
Tightening torque : 465 N-m (343 lbf-ft)
(5) Installing element (2-1)
Put element (2-1) into hub (2-2) and insert (2-4).
(6) Installing insert NA (2-3)
Put spring pin (2-8) into insert NA (2-3) and install it to the engine flywheel by means of
capscrews (2-5).
Tools: Allen wrench: 17 mm
Tightening torque: 465 N-m (343 lbf-ft)
(See Fig."Removing pump" about above mentioned (1) to (5).)

(7) Installing the pump (See Fig."Removing

pump",Right Fig.)
Lift the pump with bracket (1). Place
coupling (2) in the groove of element (2-1)
so as to receive insert NA (2-3).
(8) Coat 8 capscrews (4) M10X35 with Loctite
#262 and put them in place.
Tools: Socket: 17 mm
Tightening torque : 64.7N-m (48 lbf-ft)
(9) Fasten hoses (A1), (A2) on the delivery
side with half clamp (A11) and capscrews
(A19) M12X40.
(See Fig."Removing hoses")
Tools: Allen wrench: 10 mm
Tightening torque: 62.2 N-m (46 lbf-ft)
(10) Install suction hose (A3) with 4 capscrews
(B2) M12X30. (See Fig."Removing hoses")
Tools: Allen wrench: 10 mm
Tightening torque : 66.7 N-m (49 lbf-ft)
(11) Install the hydraulic piping by referring to
"HYDRAULIC SYSTEM".
Installing hydraulic pump

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(12) Installing the hose (See Fig."Removing other hoses")

(13) Installing pressure sensor connector and proportional valve connector.

(14) Remove suction stopper
(15) Install suction strainer

When the pump is replaced, replenish more than 1L (0.26 gal) of hydraulic oil from the drain port (Dr).

(16) Bleed air in pump

Bleed air by loosening the drain port (Dr).
(17) Check hydraulic oil level.
(18) Start engine and check it for oil leak and
noise.
(19) Attach drain down pipe under engine
muffler.

Bleed air port (Dr) in pump

(20) Installation of muffler assy

(See the figure of 33.1.9.1 "Removal of muffler assy")

(21) Install guards

(See Fig."Removing guard assy (16) and guard (14),(15),(17). Fig."Removing guards")

Lift the muffler assy so as not to allow the chains, etc. of the lifting jig to interfere with the muffler
body, piping, and harnesses and cause damage to them.

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33.1.10 AIR CLEANER

33.1.10.1 PREPARATION FOR REMOVAL 
(1) Open bonnet assemblies (G1) and (G2)
and remove guards (C1) and (C6).
(See 33.1.4 GUARD)
(2) Open bonnet assy (G1), (G2).
(See 33.1.4 GUARD)
(3) Remove guard (A14), (A15).
(4) Unplug terminals on indicator (1-8) wiring.
(See below Fig.)

Preparation for removal

33.1.10.2 REMOVAL
(1) Pulling out hose (3).
1. Loosen clips (5), (6) on both sides of hose (3).
2. Pulling out hose (3)
Tools: Flat-blade screw driver
(2) Remove air cleaner assy (1)
1. Remove 4 sems bolts (7) M10X25
Tools: Socket: 17 mm
2. Remove air cleaner assy (1) from bracket (4).

Removing air cleaner

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33.1.10.3 INSTALLATION
(1) Installing is the reverse order of removing with attention paid to the following items:
1. Put in air hoses (2), (3) to the end as shown in Fig."Preparatiom for removal".
2. Tightening torque:

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33.1.11 MUFFLER
33.1.11.1 PREPARATION FOR REMOVAL 
(1) Remove bonnet assy (G1), (G2), guard
(C1), and panel assy (B3).
(2) Remove guard (A19), beam (A40), (A41),
and pillar (A18), (A21).
(See 33.1.4 GUARD)

Preparation for removal

33.1.11.2 REMOVAL
(See Chapter 51. ENGINE.)

33.1.11.3 INSTALLATION
Install the muffler in the reverse procedures of removal with referring the item below.

(1) Installation of muffler (1).

(See Chapter 51. ENGINE.)

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33.1.12 COUNTERWEIGHT
33.1.12.1 PREPARATION FOR REMOVAL
(1) Remove bonnet assy (G1), (G2).
(See 33.1.4 GUARD)

Lifting up counterweight

33.1.12.2 REMOVAL
(1) Lifting up counterweight temporarily
Hook wire rope to slinging jig, and lift it
and stretch wire rope to the degree where
it is providing no slack temporarily.
Weight of counterweight; (Semi-weighted)
Approx. 8,800kg (19,400 lb)
(2) Removing counterweight (C1)
1. Remove 4 capscrews (A1) M36X420.
Tools: Socket: 55 mm
2. Remove shim (A3), (A4), (A5). (Select)
3) Remove counterweight (C1).

Removing counterweight

33.1.12.3 INSTALLATION
(1) Install counterweight in the reverse order of
removing.
(2) Install shim (A3), (A4), (A5) as it was.
(select)
(3) Slinging counterweight
Check that the attaching bolts can be
screwed in by hand.
(4) Apply Loctite #262 on capscrews (A1),
and tighten them with washers (A2).
Tools: Socket: 55 mm
Fastening the counterweight attaching
Tightening torque : 2940 N-m (2170 lbf-ft)
capscrew
(5) Remove slinging tools, and install bonnet
assy (G1), (G2).

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33.1.13 RADIATOR & OIL COOLER

33.1.13.1 PREPARATION FOR REMOVAL 
(1) Bleed air from the hydraulic tank and install
the suction stopper.(See 33.1.7 and 33.1.9)
(2) Remove bonnet assy (G1), (G2) (See
33.1.4 GUARD)
(3) Remove battery (See 33.1.3 BATTERY)
(4) Remove guard (D1). (See 33.1.4 GUARD)
(5) Remove beam (A7). (See 33.1.4 GUARD)
(6) Open panel assy (B1), (B2). (See 33.1.4
GUARD) Removing under cover (4), (10)

(7) Removing under cover installed on lower

side of radiator.
1. Remove 8 sems bolts (9) M12X30.
2. Remove cover (4), (10).
Tools: Socket: 19 mm
(8) Drain down of radiator
Put container 18L (4.8 gal) under drain
valve for draining water.
[Water capacity of radiator : 11L (2.9 gal)]
(9) Remove hose from radiator sub tank (1)
Remove clip of radiator cap side and
disconnect hose (9).
(10) Disconnect hose (7).

Removing hose of sub tank (1)

Do not loosen the joints of the hoses related to the air-conditioner. Otherwise the refrigerant leaks.

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(11) Move air-conditioner condenser and receiver

tank and fuel cooler.
1. Loosen 4 sems bolts (23) M8X25 and
2 sems bolts (8) M8X20.
Tools: Socket: 13 mm
2. Move a set of air-conditioner condenser
and receiver tank and fuel cooler.
(12) Disconnect of coolant level switch (B5).
(See Fig."Removing radiator assy")

Moving condensers and receiver tank and

fuel cooler

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33.1.13.2 REMOVAL
(1) Remove radiator stay (A1).
1.

Remove 4 sems bolts (A2) M12X35.
Tools: Spanner: 19 mm
2.
Remove 2 stays (A1), (A6).
(2) Remove water hose (2),(3)
1.
Loosen the hose bands (23) for water hose
(2).
Tools: Flat-blade screwdriver
2.
Remove hose (2).
3. Removing radiator assy
Loosen hose band (23) on water hose (3).
Tools: Flat-blade screwdriver
4.Remove hose (3).

(3) Remove hoses (4)(6) for inter-cooler

1.
Loosen 4 sems bolts (28) M8X20 from tube
(10).
Tools: Spanner: 13 mm
2.
Loosen 2 sems bolts (29) M8X25.
Tools: Spanner: 13 mm
3.
Loosen hose bands (24), (25) and remove
hose (4).
Tools: Flat-blade screwdriver
4.
Loosen hose bands (24) and remove hose
(5).
Tools: Flat-blade screwdriver
5.
Loosen hose bands (24) and remove hose
(6).
Tools: Flat-blade screwdriver

Removing hose for radiator/inter-cooler

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(4) Remove guard (13), (14), (15) (See

Fig."Removimg hose of sub tank")
1. Remove 2 sems bolts (27) M8X16 from
clip (26).
2. Remove 7 sems bolts (30) M10X20
3. Remove guard (13), (14), (15).
Tools: Spanner: 13, 17 mm

Remove guard (13), (14), (15)

(5) Disconnecting hydraulic oil hose (1), (2)

1.
Place an oil pan under the hose joint.
Loosen 4 sems bolts (13) M12X40, and
remove hoses (1) and (2).
(6) Remove radiator assy. (See Fig."Removing
radiator assy")
1.
Remove 4 sems bolts (A4) M20X45.
Tools: Spanner: 30 mm
Tools: Socket: 30 mm
2.
When lifting the engine fan, shift the
radiator so it does not interfere with the
engine fan.
3.
Plug up pipe ends with clean cloth, etc.
Removing hydraulic oil hose (1), (2)
4.
Removing radiator
Place a wire sling in the lifting eyes of the
radiator assy and remove the assy by
crane.
Weight: 176 kg (390 lbs)

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33.1.13.3 INSTALLATION
(1) Installing is done in the reverse order of removing. And removed clips of hose should be
clamped at original position.

(2) Install radiator assy
Place a wire sling in the lifting eyes of the radiator and move it to original position temporally.
And install hydraulic hose, radiator hose and hose of inter-cooler. Regarding Inserting width of
hose. (See Fig."Inserting width of hose")
(3) Radiator attaching bolt
Apply Loctite #262 on 4 semsbolts (A4) M20X45.
Tools: Socket: 30 mm
Tightening torque : 500 N-m (369 lbf-ft)
(4) Adjust the clearance between the fan and the radiator shroud all around the circumference, as
below :
Back and forth:
82 to 92mm (3.2 in to 3.6 in)
(5) Clean the plastering area of the insulation thoroughly before plastering it.
(6) Making up hydraulic oil and LLC (Long Life Coolant)
After completion of other installation, make up hydraulic oil and water.
Coolant volume of engine body : 16 L (3.5 gal)
Coolant capacity of radiator : 13.4 L (3.5 gal)
Hydraulic oil capacity of oil cooler : 9.6 L (2.5 gal)

Inserting width of hose

Back-and-forth adjusting position of radiator

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33.1.13.4 PROCEDURE OF DISASSEMBLING AND ASSEMBLING THE RADIATOR/INTER COOLER

CORE
(1) Preparation for disassembly and assembly
1.
Remove one under cover at the bottom of
the radiator.
2.
Wait till the engine coolant cools down so
you do not get burned. Then remove the
cap of the radiator, discharge the coolant
by opening the drain valve located at the
back bottom and receive it in a container.
* In case of removing inter cooler only,
the above mentioned work is not necessary.
(2) Disassembly
1.
Loosen each 2 bolts (6-5) at head and
bottom of shroud, remove upper plate
(6-2) and lower plate (6-3).
2.
Disconnect wiring connector of radiator
coolant level switch.
3.
Loosen 6 sems bolts (6-5) M10X20
attaching plate assy (6-4), remove plate
assy (18).
4.
Loosen 2 capscrews (15) M10X50 attaching
radiator core.
5.
After confirming that the coolant has been
drained out completely, loosen and remove
only the radiator side of hose bands (23) at
the top and bottom of the radiator. (See
Fig."Removing hose for rafiator/inter-cooler")
6.
Lift and remove radiator core using lifting
eyes and hoist on the radiator core.
Weight: 25 kg (55 lbs)
Confirm the missing of rubber bushing (14)
under the radiator core.
7.
Loosen 2 capscrews (15) M10X50 attaching
the top of the inter-cooler core.
Removing radiator and inter-cooler
8.
Loosen and remove only the inter-cooler
side of hose bands (24) at the top and
bottom of the inter-cooler. (See
Fig."Removing hose for radiator/inter-cooler")

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9.
Lift and remove inter-cooler using lifting eyes and hoist on the inter-cooler.
Confirm the missing of rubber bushing (14) under the inter-cooler.

10.
Disconnection of oil cooler hose
Disconnect hose (1), (2) from upper and lower of cooler, and drain hydraulic oil. (See Fig."Removing
hydraulic oil hose (1), (2)")
11.
Lift cooler temporally using cooler head flange for slinging.
12.
Loosen 4 bolts (3) M10 attaching oil cooler.
13.
Lift the oil cooler.

There is no predetermined sequential order in removing radiator core, inter-cooler core and oil cooler.
Removing these components can be done as necessary.

(3) Installing
Installing is done in the reverse order of removing.

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33.1.14 ENGINE
33.1.14.1 PREPARATION FOR REMOVING
(1) Remove battery ground (See 33.1.3 BATTERY)
(2) Remove bonnet and guard (See 33.1.4 GUARD ) Remove under cover (See 33.1.5 UNDER
COVER)
(3) Remove air cleaner hose (See 33.1.10 AIR CLEANER)
(4) Remove counterweight (See 33.1.12 COUNTERWEIGHT)
(5) Remove radiator hose and inter-cooler hose (See 33.1.13 RADIATOR & OIL COOLER)
(6) Remove fuel hose and heater hose, and if necessary disconnect air-con hose.
(7) If necessary, remove pump, muffler and radiator.
(8) Remove harness connector (Refer to ELECTRIC SYSTEM)
1. Remove E/G ground cable
2. Starter cable-Starter B terminal
3. Remove the connector that connects the upper harness with the engine and ECU harness.
4. Upper harness

Prepare a stand, which withstands the weight of the engine assy and can place the removed engine
firmly. (Refer to Tools)

Outside view of engine

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33.1.14.2 REMOVAL



Dismounting and mounting engine (1/2)

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Dismounting and mounting engine (2/2)

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(1) Remove hose of engine oil filter

Place oil pan under the connection of filter (1), and disconnect hoses (27), (28), (29) at * positions.
Tools: Spanner: 19 mm, 41 mm

(2) Plug connector of filter side and hose.
(3) Loosen engine mounting bolt of frame
1. Loosen 4 nuts (53) M18.
Tools: Socket: 27 mm
2. Loosen 4 capscrews (46) M18X130.
3. Remove 4 plates (35).
4. Remove upper rubber mounts (34) and (35) 2 each.
(4) Slinging engine body
1. Sling engine hooking wire to lifting lugs on the front and rear sides.
Weight: Approx. 739 kg (1,630 lbs)
Wire: 6 dia. (0.236")X1 m (3 ft 3 in) - 2 pcs.

Prepare a stand, which withstands the weight of the engine assy and can place the removed engine
firmly. (Refer to "Tool".)

(5) Position engine on the stand stably.

(6) Remove 4 rubber mounts (19), (20).

33.1.14.3 INSTALLATION
Installing is done in the reverse order of removing.
(1) Tightening torque

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33.1.15 CONSOLE COVER

33.1.15.1 REMOVAL
(1) Removing right-hand console cover
1. Press into the "A" part of rubber boot
which is tucked into console, and remove
right rubber boot (3-4) from console.
2. Loosen 3 sems bolts (1-18) M6X16 and
remove lower console (1-3).
Tools: Plus screw driver

Removing boot (4)

(2) Removing left-hand console cover

1. Remove left boot (3-4) same way as right
console cover. (See above Fig.)
Tools: Flat-blade screwdriver
2. Loosen 2 sems bolts (1-18) M6X16.
Tools: Plus screw driver
3. Remove the left upper console cover (1-4)
in the same way as right-hand console
cover.
4. Loosen 2 sems bolts (1-18) M6X16 while
lifting left under console cover (1-5) up, and
remove left lower console cover.

Removing console covers

33.1.15.2 INSTALLATION
Install it in reverse order of removing according to the tightening torque table.

Removing left armrest

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33.1.16 MULTI CONTROL VALVE

33.1.16.1 PREPARATION FOR REMOVAL 
(1) Bleed pressure air in hydraulic oil tank
(See 33.1.7 HYDRAULIC TANK)
(2) Remove under cover (3). (See 33.1.5
UNDER COVER)
(3) Open the left panel assy (B2) located at
rear of cab.
(See 33.1.4 GUARD)

Removing multi control valve

33.1.16.2 REMOVAL
(1) Attach tag on which hose name is entered to the remote control hoses between multi control valve
and pilot V, and write numbers P1 to P8 on it.
See Tools 11.5 PLUG (3)
Tools: Spanner: 19 mm, 22 mm
(2) Attach tag on which hose name is entered to the remote control hoses between multi control valve
and main control valve, and write numbers C1 to C8 on it.
See Tools 11.5 PLUG (3)
Tools: Spanner: 19 mm, 22 mm
(3) Remove 4 sems bolts (B11) M8X20, and remove multi control valve (0) with bracket (B5) from
machine.

Connection between multi control valve and

P/V

Removing hoses between main C/V and multi

C/V

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33.1.16.3 INSTALLATION
(1) Installing is done in the reverse order of removing
(2) Relations between pilot valve and multi control valve hose

(3) Tightening torque

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33.1.17 CONTROL VALVE

33.1.17.1 PREPARATION FOR REMOVING 
(1) Remove guard (A17), (A18).
(See 33.1.4 GUARD)
(2) Remove under cover (5).
(See 33.1.5 UNDER COVER)
(3) Install the suction stopper to the hydraulic
oil tank.
(4) Remove the hoses in Fig. "Control valve
ports (1/2)" and Fig. "Control valve ports
(2/2)".

Removing the standard main control valve

Mark each hose with a port name before removing it.

33.1.17.2 REMOVAL
(1) Remove 4 capscrews (3) M16X45, and remove control valve (5) by hoist.
Tools: Spanner: 24 mm
Weight: Approx. 252 kg (556 lbs)

33.1.17.3 INSTALLATION
(1) Installing is done in the reverse order of remove.
1. Install control valve by tightening 4 capscrews (3) M16X45.
Tools: Spanner: 24 mm
Tightening torque: 284 N-m (209 lbf-ft)
2.

(2) Check for oil leak and operation.

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Control valve ports (1/2)

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Control valve ports (2/2)

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33.1.18 PILOT VALVE (FOR ATT)

33.1.18.1 PREPARATION FOR REMOVING
The removing procedure for right and left is the same, so the preparation for left side is described
here.

(1) Put attachment on ground, stop engine

and release pressure in tank.
(2) Remove left console cover (1-4), (1-5)
assy referring to Section 33.1.15CONSOLE
COVER.
(3) Disconnect harness connector for horn at *
position.
(4) Attach a tag to the hose to make assembly
work easier.
Installing and removing boot and lever part

33.1.18.2 REMOVAL
(1) Remove hoses from your side to far side in
order.
Tools: Spanner: 19 mm, 22 mm
(2) Move the boot (3-4) up and loosen nut
(3-3).
(See above Fig.)
Tools: Spanner: 22 mm
(3) Turn and loosen lever (3-1-6) tightened in
pilot valve, and remove lever assy in a set.
(See above Fig.)
(4) Remove 4 capscrews (A16) M6X25. (See
right Fig.)
Tools: Allen wrench: 5 mm
(5) Remove pilot valve.
(6) Plug hose ends.
Plug PF1/4, PF3/8 Pilot valve connector

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33.1.18.3 INSTALLATION
Install it in the reverse order of removal and
tighten it.

Tools: Allen wrench: 5 mm
Tightening torque: 11.8 N-m (11 lbf-ft):
capscrew (A16)

Pilot valve port position

Make sure the tightening torque for capscrews, because pilot valve is made of aluminum.

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33.1.19 PILOT VALVE (FOR TRAVEL)

33.1.19.1 PREPARATION FOR REMOVING
(1) Release pressure in hydraulic oil tank
(See 33.1.7 HYDRAULIC TANK)
(2) Remove under cover (1) (See 33.1.5
UNDER COVER)
(3) Remove floor mat (B1).

Removing floor mat, pedal and and lever

33.1.19.2 REMOVAL
(1) Separate the two pressure sensors SE-9
(A9) and SE-10 (A9) at the connector.
Tools: Spanner: 24mm
(2) Attach tag, and discount connectors and
hoses (A2), (A3), (A4), (A5)
Tools: Spanner: 19mm (P port)
Tools: Spanner: 22 mm (T port, 1 to 4 port)
(3) Plug hose ends
Plug PF1/4, PF3/8
(4) Remove 4 sems-bolts (A8) M8X25, and
remove right and left pedals (A5), (A6).
Tools: Spanner: 13mm
(5) Remove 4 sems-bolts (A7) M10X20 and
remove right and left lever (A1), (A2).
Tools: Socket: 17mm
(6) Remove 4 sems-bolts (A11) M10X30.
Tools: Spanner: 17mm
(7) Remove pilot valve lifting it upward.
(8) Stop up holes with plugs PF1/4.

Installing and Removing pilot valve

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33.1.20 SWING MOTOR UNIT

33.1.20.1 PREPARATION FOR REMOVING 
(1) Park machine on firm level ground and place attachment on ground.
(2) Remove the guard (8). (See 33.1.4 GUARD)
(3) Operate the switch on gauge cluster and select the pressure release mode, and then release the
inner pressure in circuit by operating control lever. (See 22.11 HYDRAULIC SYSTEM PRESSURE
DRAINING(RELEASING) CIRCUIT)
(4) Bleed air from the hydraulic oil tank and attach to each hose a tag showing port name and other
information.

33.1.20.2 REMOVAL
(1) Remove hose.
1. Remove hose (8) from the connector in the makeup port M.
Tools: Spanner: 41 mm
2. Remove 2 hoses (2), (3) from the Tee in the drain port Dr.
Tools: Spanner: 36 mm
3. Remove hose (A4) from the elbow of the PG port (For swing parking brake) (See below Fig.)
Tools: Spanner: 19 mm
4. Loosen 8 capscrews (A24) M10X30 and remove half clamp (A30). And disconnected A,B port
hoses (A7), (A4) from the motor.
Tools: Allen wrench: 8 mm
Put in plugs half clamp, PF1, PF3/4, PF1/2, and PF1/4 into the removed ports.

Removing swing unit piping

Removing swing unit

(2) Removing the swing unit

Remove 14 capscrews (5) M24X70.
Tools: Socket: 36 mm
1. Remove two plastic caps (2) M10 at the top of the swing motor and install eye bolts.
Tools: Flat-blade screwdriver
2. Put a wire sling in the eye bolts and remove the swing motor unit.
Weight of swing motor unit; Approx. 446kg (983 lbs) (Include reduction assy)

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33.1.20.3 PREPARATION FOR INSTALL

(1) Clean mating surfaces of swing motor unit and upper frame.
Tools : spatula, wash oil
(2) Apply Loctite #515 on entire mounting surface of swing motor unit.

33.1.20.4 INSTALLATION
Install the swing motor unit in the reverse order of disassembly, confirming the orientation of the
swing motor unit.

(1) Tighten 14 capscrews (5) M24X70.

Tools: Socket: 36 mm
Tightening torque : 932 N-m (687 lbf-ft)
Apply Loctite #262
(2) Fill inside from motor drain port to casing with hydraulic oil before piping for drain
(3) Piping tightening torque

Installing swing motor unit

33.1.20.5 PREPARATION FOR DRIVE

(1) Before starting operation, check that gear oil #90 (API grade GL-4) level of swing reduction is
sufficient.
Amount of oil : 7.4 L (2.0 gal)
(2) When starting operation, operate motor in low idling and at low speed for several minutes, and
check it for possible oil leak and noise.

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33.1.21 SWIVEL JOINT

33.1.21.1 PREPARATION FOR REMOVING 
Remove boom piping hose

33.1.21.2 REMOVAL
(1) Remove travel motor hose and tube
1. Remove 2 hoses (A9). (E port : PF1/2)
Tools: Spanner: 27 mm, Tightening torque : 78.5 N-m (58 lbf-ft)
2. Remove tubes (A1), (A2). (C, Dport : PF1)
Tools: Spanner: 41 mm, Tightening torque : 255 N-m (188 lbf-ft)
3. Remove tubes (A3), (A4). (A, B port : PF1)
Tools: Spanner: 41 mm, Tightening torque : 255 N-m (188 lbf-ft)
4. Remove 2 hoses (A10). (F port : PF1/4)
Tools: Spanner: 19 mm, Tightening torque : 29.4 N-m (22 lbf-f)

Removing piping (lower side)

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(2) Disconnecting the hoses on the top part of

swivel joint
1. Remove drain hose (2). (E port: PF3/4)
Tools: Spanner: 36 mm
Tightening torque: 118 N-m (87 lbf-ft)
2. Remove hoses (A6), (A8).
(A, C port : 1-3/16-12UN)
Tools: Spanner: 36 mm
Tightening torque: 177 N-m (130 lbf-ft)
3. Remove hoses (A9), (A16).
(B, D port : 1-3/16-12UN)
Tools: Spanner: 36 mm
Tightening torque: 177 N-m (130 lbf-ft)
4. Remove hose (A7).
(F port : Travel 2-speed change over port :
PF1/4)
Tools: Spanner: 19 mm
Tightening torque: 29 N-m (21 lbf-ft)

Disconnecting the hoses on the top part of

swivel joint

(3) Remove whirl-stop of swivel joint.

1. Loosen the nut (10) M24.
2. Remove a capscrew (9)M24X130.
Tools: Spanner: 36 mm

Removing whirl-stop nut & the capscrew

(4) Remove joint for piping (See

Fig."Removing piping (lower side)", and
sbove Fig.)
1. Remove 2 connectors (B2). (F port)
2. Remove connector (A15) (F port) for
travel 2-speed change over. (PF1/4)
Tools: Spanner: 19 mm
(5) Remove seal (B1)
1. Remove 6 sems bolts (B4) M10X25.
Tools: Socket: 17 mm Removing seal (B1)
2. Remove clip (B3).
Tools: Flat-blade screwdriver
3. Remove plate (B2), seal (B1).

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(6) Remove capscrew for installation

Attach eye bolt, lift it up temporarily, and
remove 3 capscrews (C2) M12X25.

Tools: Socket: 19 mm
(See 11.7 SPECIAL TOOLS No.9 Plug)

Removing capscrew for installation

(7) Slinging the swivel joint

Weight: Approx. 24 kg (53 lbs)

33.1.21.3 INSTALLATION
(1) Installing is done in the reverse order of
removing.
Piping tightening torque
(2) Check for oil leak and the hydraulic oil
level.
(3) Check for operating.

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33.1.22 UPPER FRAME

33.1.22.1 PREPARATION FOR REMOVING
(1) Remove attachment
(See chapter 32)
(2) Remove cab (See 33.1.2 CAB)
(3) Remove guard (See 33.1.4 GUARD)
(4) Remove counterweight
(See 33.1.11 COUNTERWEIGHT)
(5) Remove swivel joint
(See 33.1.19 SWIVEL JOINT)

Temporarily lift upper frame

33.1.22.2 REMOVAL
(1) Lifting up upper frame temporarily
Temporarily lift the unit at three points ; the
upper frame lifting jig (Refer to Tool
"chapter 11"), the 2 lifting holes near the
boom foot pin and the angle steel at the
back of the upper frame.
(2) Marking match marks on swing bearing
Put match marks on upper frame and
swing bearing. Matching mark on swing bearing and upper
frame

(3) Removing upper frame attaching bolts

Remove 34 capscrews (10) M24X135 and
a reamer bolt (11) used to install swing
bearing and upper frame.
Tools: Socket: 36 mm
(4) Slinging upper frame
Sling according to above Fig, and remove
upper frame and put it on a stand.
Weight: Approx. 5 ton (11,000 lbs)

Removing upper frame attaching bolts

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33.1.22.3 INSTALLATION
(1) Installing is done in the reverse order of removing.
(2) Cleaning mating surfaces of upper frame and swing bearing.

(3) Apply Loctite #515 to the inside of the capscrews on the contact surface.
(4) Slinging upper frame
Match marks and install it with a reamer bolt (8) temporarily.
Tools: Socket: 36 mm Apply Loctite #262
(5) Install swing bearing
Install 34 capscrews (7) M24X135.
Tools: Socket: 36 mm Apply Loctite #262
Tightening torque : 932 N-m (687 lbf-ft)
Install a reamer bolt (8).
Tools: Socket: 36 mm
Tightening torque : 932 N-m (687 lbf-ft)

Bearing mount

Reamer bolt position (*) Apply Loctite to

shaded area

Confirm the reamer bolt positions referring to above Fig.

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33.2 DISASSEMBLING AND ASSEMBLING

33.2.1 HYDRAULIC PUMP - REGULATOR

33.2.1.1 HYDRAULIC PUMP
33.2.1.1.1 Structural exploded view
(1) Main pump

Structural exploded view of main pump

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Marks (W), (X), (Y), (Z) in Fig."Structural exploded view of regulator" show the position where
regulator is installed.

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(2) Gear pump (For pilot)

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

307 Poppet 1 361 Front case 1
308 Seat 1 433 Flange socket; M8X40 2
309 Ring 1 434 Flange socket; M8X55 2
310 Spring 1 435 Flange socket; M8X20 4
311 Adjust screw 1 466 VP plug; PF1/4 1
312 Lock nut; M14X1.5 1 700 Ring 1
351 Gear case 1 710 O-ring; 1B G95 1
353 Drive gear 1 725 O-ring; 1B P11 1
354 Driven gear 1 732 O-ring; 1B P16 1
355 Filter 1 850 Locking ring 1

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33.2.1.1.2 Disassembly and assembly of main pump

(1) Tools
The right list shows the tools required for remove and install.

(2) Disassembling procedure
1. Selecting a place for disassembly.
-Choose a clean place.
-Spread rubber sheet or cloth on work
bench to protect parts from damaging.
2. Cleaning
Remove dust and rust, etc. on pump
surface with wash oil.

3. Drain oil
Drain out the oil in the pump casing by
removing drain port plug (466), (468).
Tools: Spanner: 19 mm, 36 mm

-Drain out oil from the plug of the front

pump and the rear pump.
4. Removing regulator and PTO gear casing
Remove the socket bolts [412, 413, 414
(See Fig."Structural exploded view of main
pump", Fig."Structural exploded view of
regulator")]. Then remove the regulator and
the PTO cover (326).
Tools: Allen wrench: 6 mm, 8 mm
-Regarding the disassembly of the regulator,
refer to article of Regulator.

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5. Remove gear pump

Remove the socket bolts (435). Then
remove the gear pump (04).
Tools: Allen wrench: 6 mm
6. Remove socket bolt (401)
Loosen socket bolts (401) that fasten
swash plate support (251), pump casing
(271) and valve block (312).
Tools: Allen wrench: 17 mm

Remove socket bolt (401)

7. Disassembling the pump casing and the

valve block
Place the pump level on a work bench with
its mounting surface of the regulator facing
down. Then separate pump casing (271)
and valve block (312).

-When facing the mounting surface of the

regulator down, place a rubber sheet on a
work bench so as not to score the Disassembling the pump casing (271) and the
mounting surface. valve block (312)
-When the pump casing has been
separated from the valve block, draw out
the 1st gear (116) at the same time.

8. Drawing out the cylinder assy

Draw out cylinder (141) out of pump casing
(271) in parallel to shaft (111). At the same
time draw out piston (151), plate (153),
spherical bushing (156) and cylinder spring
(157).

-Use care so as not to score the sliding

surface of the cylinder, spherical bushing,
shoe and the swash plate.

Drawing out the cylinder assy

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9. Remove seal cover (F)

Remove socket bolt (406) M8 and seal
cover F (261).

Tools: Allen wrench: 6 mm

-The seal cover (F) may be drawn out

with ease if it is taken out by tightening
bolts in the tapped holes (M6 tap) of the
seal cover (F).
-An oil seal is fitted to seal cover (F).
Therefore, use care so as not to score
the oil seal. Removing seal cover F (261)

10. Separating the swash plate support and the

pump casing
Knock lightly on the mounting flange of
swash plate support (251) from the pump
casing (271) side and separate the swash
plate support from the pump casing.

Separating the swash plate (251) support

and the pump casing (271)

11. Remove shoe plate and swash plate

Draw out shoe plate (211) and swash
plate (212) from pump casing (271).

Removing shoe (211) and swash plate (212)

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12. Drawing out the shaft

Tap lightly the shaft end (111, 113) by
means of a plastic hammer and draw out
the shaft from the swash plate support.

Drawing out the shaft (111), (113)

13. Remove valve plate

Remove valve plate (313, 314) from valve
block (312).

-The valve plate may come off during the

operation under 6).

Removing valve plates (313), (314)

14. Remove other parts

If necessary, remove stopper (L) (534),
stopper (S) (535), servo piston (532) and
tilting pin (531) from pump casing (271),
and remove needle bearing (124) from
valve block (312).

-When removing the tilting pin, use care

so as not to score the head of the tilting
pin, using a jig.
-It is hard to separate the tilting pin from
the servo piston in some cases as Loctite
is coated on the mating part between them.
Use care so as not to score the servo
piston by applying undue force.
-Do not draw out needle bearings except
when their service life has ended.
-Do not loosen hex nuts (806),(808) of
valve block (312) and swash plate support Removing other parts
(251). A set flow rate changes.

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(3) Installing procedure

1. Precautions to be exercised in installation
Assembly is a reverse order of disassembly, but notice the following.

a. Repair scored parts at disassembly. Get replacements ready beforehand.
b. Wash parts sufficiently in cleaning oil and dry them with jet air.
c. Do not forget to coat the sliding areas and bearings with clean hydraulic oil.
d. In principle, replace sealing parts such as O-rings and oil seals.
e. Tighten socket bolts and plugs to specified torques in this manual, using a torque wrench.
f. Do not mix up front pump parts with rear pump parts.

2. Installing swash plate support

Attach swash plate support (251) to pump
casing (271) by tapping the swash plate
support lightly with a plastic hammer.

-When the servo piston, the tilting pin, the

stopper (L) and the stopper (S) have been
removed, install them to the pump casing
beforehand.
-When tightening servo piston and tilting
pin, use a jig so as not to damage the
head of the tilting pin and feedback pin.
Coat the screwed part with Loctite #262. Installing swash plate support (251)

3. Installing swash plate

Place the pump casing with its mounting
surface of the regulator facing down, insert
the tilting bushing of the swash plate into
tilting pin (531), and fit swash plate (212)
to swash plate support (251) properly.

-Confirm by the fingers of your both hands

that swash plate moves smoothly.
-The shaft be installed easily if grease is
applied to the sliding parts of swash plate
and swash plate support.
-Do not damage the sliding surface of shoe
Installing swash plate (212)
plate.

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4. Installing shaft
Install shaft (111) fitted with bearing (123),
bearing spacer (127) and snap ring (824),
to swash plate support (251).

-Do not knock on the shaft with a hammer

or something.
-Fix the bearing by lightly tapping the
outer race of it by means of a plastic
hammer and set it exactly to the end by
using a steel rod and others.

Installing shaft (111)

5. Installing seal cover

Assemble seal cover (F) (261) to pump
casing (271) and fix it with socket bolts
(406).
Tools: Allen wrench: 6 mm
Tightening torque: 29 N-m (22 lbf-ft)

-Coat the oil seal in seal cover (F) with a

thin film of grease.
-Handle the oil seal with sufficient care so
it is not scored.
Installing seal cover F (261)

6. Inserting piston cylinder sub

Assemble the piston cylinder sub [cylinder
block (141), piston (151), shoe (152), plate
(153), spherical bushing (156) and cylinder
spring (157)].
Align the spherical bushing with the cylinder
spline and insert them into the pump
casing.

Inserting piston cylinder sub

7. Installing valve plate

Install valve plate (313), (314) to valve
block (312) by aligning pin.

-Do not mistake the suction and delivery

sides of the valve plate.

Installing valve plates (313), (314)

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8. Installing valve block

Install valve block (312) to pump casing
(271) and fasten them together with socket

bolts (401).
Tools: Allen wrench: 17 mm
Tightening torque ; 430 N-m (320 lbf-ft)

-Work will be promoted if assembly is

started from the rear pump.
-Exercise care so as not to mistake the
direction of the valve block (312). (Install it Installing valve block (312)
so the regulator comes up as seen from
the front side and the suction flange comes
on the right.)
-Insert the 1st gear into the valve block
beforehand and connect it with the spline
of the shaft.
9. Installing gear pump
Install gear pump (04) and fasten them
together with socket bolts (435).
Tools: Allen wrench: 6 mm,
Tightening torque; 17 N-m (12.5 lbf-ft)

10. Installing regulator and PTO cover

Pinch feedback pin of tilting pin in feedback
lever of the regulator and PTO cover (326),
install the regulator and fasten socket bolt.
(412)(413) (See Fig."Structural exploded
view of regulator"]
Socket bolt (412)(413): For regulator
Tools: Allen wrench: 6 mm,
Tightening torque; 29 N-m (21 lbf-ft)
Socket bolt (414): PTO Cover (326)
Installing regulator and PTO cover
Tools: Allen wrench: 8 mm,
Tightening torque; 57 N-m (42 lbf-ft)

-Do not mistake the front regulator for the

rear regulator.

11. Installing drain port plug

The work is complete when drain port VP plugs (466), (468) have been set.
Tools: Allen wrench: 19 mm, 36 mm
Tightening torque; 36 N-m (27 lbf-ft)
Tightening torque; 170 N-m (125 lbf-ft)

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33.2.1.1.3 Maintenance standards

(1) Replacement standards for abrasive parts
Replace or readjust parts that exceed the following standards of wear.
However, always replace such parts that show excessive damage on appearance.

Recommended
Standard
Part name and inspection item value Remedy
dimension
forreplacement
0.039 0.067
Clearance between piston and cylinder bore (D-d) Replace piston or cylinder.
(0.0015 ) (0.0026 )
Gap between piston and caulked part of 0 - 0.1 0.3
(㱐 ) Replace piston shoe assy.
shoe (0.004 ) (0.012 )
4.9 4.7
Thickness of shoe (t) Replace piston shoe assy.
(0.193 ) (0.185 )
41.1 40.3
Free height of cylinder spring (L) Replace cylinder spring.
(1.618 ) (1.587 )
Combined height of retainer plate and 23.0 22.0 Replace a set of spherical
(H-h)
spherical bushing (0.906 ) (0.866 ) bushing or retainer plate.

(2) Repair standards for cylinder, valve plate and swash plate (shoe plate face)

Valve plate (sliding section) Surface roughness requiring correction 3 - Z

Swash plate (shoe plate face)
Standard surface roughness
Cylinder (sliding section) Less than 0.4Z (lapping)
(correction value)
Roughness of each surface

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33.2.1.1.4 Troubleshooting
(1) Locating causes of troubles
The pump is usually fitted with a regulator, auxiliary valves and auxiliary pumps, and this makes fault

location extremely difficult. However, faults would be found out easily if the following check items were
attended to.

1. Inspecting the filter and drain oil

Inspect the filter element to check for abnormal contaminations. Some metallic particles will be
deposited on it as the shoe and the cylinder wear off. In case metallic particles are found in
large quantity, the elements may be damaged. In that case check the drain oil in the pump casing
as well.
2. Checking for abnormal vibration and sound
Check that the pump does not vibrate and make an abnormal sound.
Check that the hunting of the regulator and the attached valve's relief valve are of regular
frequency. In case vibration and sound are abnormal, the pump may be making a cavitation or
internally broken.
3. When two pumps are used
In case two single pumps or motors are used or when a double pump is used. change pump
pipelines. This will make clear that the pumps are faulty or the circuit after the pumps is faulty.
4. Pressure measurements
If the problem is related to control functions, avoid disassembling the pumps carelessly, but look
for causes by measuring pressures.

(2) Troubleshooting
1. Overloading to engine

Cause Remedy Remarks

1. 1)
Revolution and pressure are Set pressure to specified value.
higher than set values.
2. 2) 2)
Regulator torque is set higher than Readjust regulator. Refer to Regulator Manual.
normal.
3. 3) 3)
Pump's internal parts are seized or Replace damaged parts. Check filter and drain oil to see if
broken. abnormal wear particles are present.
4. 4)
Regulator is piped incorrectly. Pipe regulator correctly.

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2. Pump's oil flow rate is extremely low and delivery pressure is not available.

Cause Remedy Remarks

1. 1) 1)
Regulator is out of order Repair regulator. Refer to Regulator Manual.
2. 2) 2)
Pump's internal parts are seized or Replace damaged parts. Check filter and drain oil.
broken.
3. 3) 3)
Attached pump is out of order Replace damaged parts. Remove attached pump and check
shaft joint.
4. 4) 4)
Attached valve is out of order. Check attached valve. Particularly Refer to Manual for Attached Valve.
poppet, seat and spring.
5. 5)
Regulator is piped incorrectly. Pipe correctly.

3. Abnormal Sound and Vibration

Cause Remedy Remarks

1. 1) 1-1)
Cavitation Prevent cavitation. The boost pressure is low.
Check that hydraulic oil is not 1-2)
clouded. The attached pump is in trouble.
1-3)
The suction pipe is inhaling air.
1-4)
The suction resistance is high.
2. 2)
Caulked part of shoe is broken. Replace piston shoe and shoe
plate.
3. 3)
Cylinder is cracked Replace cylinder.
4. 4)
Pump is installed improperly. Correct installation.
5. 5) 5)
Regulator is hunting. Repair regulator, See Regulator Manual.
6. 6) 6)
Relief valve in attached valve is Repair attached valve. See the Manual for Attached Valve.
hunting.

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33.2.1.2 REGULATOR
33.2.1.2.1 Structural exploded view


Structural exploded view of regulator

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Marks (W), (X), (Y), (Z) in Fig."Structural exploded view of main pump"how the position where regulator
is installed.

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33.2.1.2.2 Disassembly and assembly

(1) Tools
The right list shows the tools required for remove and install.

(2) Disassembling procedure
1. Selecting a place for disassembly.

-Choose a clean place.

-Spread rubber sheet or cloth on work
bench to protect parts from damaging.
2. Cleaning
Remove dust and rust, etc. on regulator
surface with wash oil.

3. Remove regulator (See Fig."Structural

exploded view of regulator")
Remove socket bolts (412, 413) and
separate the regulator from the pump body.
Tools: Allen wrench: 6 mm
4. Remove port plate (See Fig."Structural
exploded view of regulator")
Remove socket bolt (438) and separate
the port plate (656).
Tools: Allen wrench: 5 mm
Removing regulator

5. Remove cover (See Fig."Structural exploded

view of regulator")
Remove socket bolts (438) and remove
cover (C) (629).
Tools: Allen wrench: 5 mm

-The cover is equipped with adjust screws

(628), adjust stem (627), lock nut (630),
hex nut (801) and set screw (924). Do not
loosen those screws and nuts. If they are
loosened, preadjusted set pressure and flow
values change.
Removing cover (C) (629)

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6. Remove compensating parts

(See Fig."Structural exploded view of
regulator" (D) section, See Fig."Removing
cover(C) (629), Fig."Removing compensating
parts")
After removing the cover (C) (629) sub
assy, take out outer spring (625), inner
spring (626) and spring seat (624) from
the compensating part. Then take out
adjust stem (645), pilot spring (646) and
spring seat (644) from the pilot part. Removing compensating parts
-Adjust stem (645) comes out easily if an
M4 bolt is used.

7. Remove pilot cover and the set spring

Remove socket bolt (439) and pilot cover
(641).
Once the pilot cover comes off, separate
set spring (655) from the pilot section.
(Fig."Structural exploded view of regulator"
(A) and (B) section)
Tools: Allen wrench: 5 mm

Removing pilot cover (641) and set spring

(655)

8. Remove spring seat, return spring and

sleeve
(Fig."Structural exploded view of regulator"
(A) section)
Remove snap ring (814). Then remove
spring seat (653), return spring (654) and
sleeve (651).

-Sleeve (651) is equipped with snap ring

(836).
-When removing snap ring (814), return
Removing spring seat (653), return spring
spring (654) comes out : Use care so as
(654) and sleeve (651)
not to lose it.

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9. Remove adjust plug

(Fig."Structural exploded view of regulator"(F),(G) section) emove snap ring (858) and take out
fulcrum plug (614) and adjust plug (615).

-Fulcrum plug (614) and adjust plug (615) come off easily if a M6 bolt is used.

Removing fulcrum plug (614)

Removing adjust plug (615)

10. Remove lever (Fig."Structural exploded

view of regulator"(G) section)
Remove lever 2 (613).
Do not draw out pin (875).

-The work is eased if tweezers is used.

Removing lever 2 (613)

11. Remove feedback lever

Draw out pin (874) and remove feedback lever (611).

-Push out pin (874) [pin dia : o4mm (0.157in)] from above with a slender steel rod so as not to
interfere with lever 1 (612).

Removing feedback lever (611) [1]

Removing feedback lever (611) [2]

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12. Remove lever (Fig."Structural exploded

view of regulator"(F) section)
Remove lever 1 (612).
Do not draw out pin (875).
13. Remove pilot piston and spool
(Fig."Structural exploded view of
regulator"(C),(A) section)
Draw out pilot piston (643) and spool (652).

14. Remove piston casing, compensating

piston and compensating rod (Fig."Structural
exploded view of regulator"(B) section)
Draw out piston casing (622), compensating
piston (621) and compensating rod (623).

-Piston casing (622) comes out from the

opposite side of the piston casing if
compensating rod (623) is pushed out.

Part of exploded view of regulator

15. Remove spool (642) and spring (662)

Remove VP plug (466) from pilot cover
(641), and draw out spool (642) and spring
(662).

This completes disassembly.

Part of exploded view of regulator

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(3) Installing procedure :

Assembly is the reverse order of disassembly. Do the work paying attention to the following :


࡮ Repair those parts that were damaged during disassembly and prepare replacement parts
beforehand.
࡮ If foreign matter enters, it causes malfunction; clean parts thoroughly in cleaning oil, blow them
with jet air and assemble parts in a clean place.
࡮ Always tighten bolts and plugs to the specified torque. The tolerance of torque should be within
10%.
࡮ Do not fail to coat the moving parts with clean hydraulic oil, before assembly.
࡮ In principle, replace seals such as O-ring.

1. Installing compensating rod (Fig."Structural

exploded view of regulator"(B) section)
Assemble compensating rod (623) into the
compensating hole of casing (601).
2. Assembling lever
Put the pin pressed in lever 1 (612) into
the groove of the compensating rod (623).
Then assemble the lever to the pin (875)
that is pressed in the casing.
Part of exploded view of regulator

3. Assembling spool and sleeve (See

Fig."Structural exploded view of regulator"(A)
section)
Assemble spool (652) and sleeve (651) into
the spool hole of the casing.

Direction of the spool (652)

-Make sure that the spool and the sleeve
move smoothly in the casing.
-Beware of the direction of the spool.

4. Assembling feedback lever

Assemble feedback lever (611). Then put
pin (874) into the pin hole of the feedback
lever.

-The work is eased if the pin is put in the

feedback lever a little, beforehand.
-Take care so as not to mistake the
direction of the feedback lever.
Assembling feedback lever (611)

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5. Assembling pilot piston (See Fig."Structural

exploded view of regulator"(C) section)
Assemble pilot piston (643) into the positive
control hole of the casing.

-Make sure that the pilot piston moves

smoothly.
6. Assembling lever (See Fig.."Structural
exploded view of regulator"(G) section)
Place pin (875) pressed in lever 2 (613)
into the groove of the pilot piston and Assembling lever 2 (613)
assemble lever 2 (613).

7. Installing fulcrum plug (See Fig."Structural

exploded view of regulator"(F) section)
Assemble fulcrum plug (614) so pin (875)
pressed in the fulcrum comes in the pin
hole of lever 2 (613). Then fit snap ring
(858).

Installing fulcrum plug (614)

8. Installing adjust plug (See Fig. 33-111 (G)

section)
Insert adjust plug (615) and fit a snap ring
(858).

-Use care so as not to mistake the holes

into which the fulcrum and adjust plug are
inserted.
-At this point, operate the feedback lever
and make sure that the gap is not large
and that the lever moves smoothly.
Installing adjust plug (615)

9. Installing return spring and the spring seat

(See Fig."Structural exploded view of
regulator"(A) section)
Assemble return spring (654) and spring
seat (653) into the spool hole and fit snap
ring (814).

Installing return spring (654) and spring seat

(653)

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10. Assembling compensating parts (See

Fig."Structural exploded view of
regulator"(A),(B) section)

Assemble set spring (655) into the spool
hole. Place compensating piston (621) and
piston casing (622) into the compensating
hole and attach pilot cover (641). Then
fasten them together with socket bolts
(438), (439).
Assembling compensating parts
Tools: Allen wrench: 5 mm
Tightening torque; 12 N-m (8.7 lbf-ft)

11. Installing spool and spring

Assemble spool (642) and spring (662)
into pilot cover (641), and tighten VP plugs
(466).

Assembling spool (642)

12. Assembling into the pilot hole and the

compensating hole
(See Fig."Structural exploded view of
regulator"(E),(D) section)
Put spring seat (644), pilot spring (646) and
adjust stem (645) into the pilot hole. Then
assemble spring seat (624), inner spring
(626) and outer spring (625) into the
compensating hole.
-Do not mistake the direction of the spring Assembling into the pilot hole and
seat. compensating hole

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13. Installing cover

Attach cover (C) (629) fitted with adjust
screws (628), (925), adjust stem (627),
lock nut (630), nut (801) and socket bolt
(924). Then fasten them with socket bolts
(438).
Tools: Allen wrench: 5 mm
Tightening torque; 12 N-m (8.7 lbf-ft)
14. Installing block cover (See Fig."Removing
regulator" )
Attach block cover (656).
Tools: Allen wrench: 5 mm
Tightening torque; 12 N-m (8.7 lbf-ft) Installing cover (C) (629)
This completes assembly.

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33.2.1.3 PTO GEAR CASING (OPT.)

33.2.1.3.1 Structural exploded view


Tightening torque Tightening torque

No. Parts Q'ty No. Parts Q'ty
N-m (lbf-ft) N-m (lbf-ft)
115 Idle shaft 1 33 (25) 435 Flange socket; M10X20 4
117 2nd gear 1 74 (54) 468 VP plug; PF3/4 1
118 3rd gear 1 710 O-ring; 1B G80 1
125 Ball bearing 2 711 O-ring; 1B G85 1
126 Roller bearing 1 728 O-ring; 1B P24 1
128 Bearing spacer 2 825 Snap ring 1
262 Cover 2 826 Snap ring 1
326 Gear casing 1 885 Spring pin 1
33 (25) 414 Socket bolt; M10X20 4 886 Pin 2

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33.2.1.3.2 Disassembly and assembly

(1) Tools
The right list shows the tools required for
remove and install.

(2) Disassembling procedure

1. Selecting a place for disassembly.
-Choose a clean place.
-Spread rubber sheet or cloth on work bench to protect parts from damaging.
2. Cleaning
Remove dust and rust, etc. on pump surface with wash oil.
3. Drain oil
Drain out the oil in the pump casing by removing drain port plug (468).
Tools: Spanner: 27 mm
-Drain out the oil from the plugs of the front pump and the rear pump.
4. Remove cover
Remove the socket bolts (414). Then remove the cover (262).
Tools: Allen wrench: 8 mm
5. Remove PTO gear casing
Remove flange socket (435) and PTO gear casing.
Tools: Allen wrench: 8 mm

Removing PTO gear casing

Removing gear pump

6. Removing the 2nd gear, the roller bearing

and the bearing spacer
Draw out the spring pin (885) and remove
idle shaft (115). Then draw out 2nd gear
(117), roller bearing (126) and bearing
spacer (128).
-Roller bearing (126) can not be separated
from 2nd gear (117).

Removing 2nd gear (117)

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7. Removing the 3rd gear and the ball bearing

Remove snap ring (825) and draw out 3rd
gear (118) and ball bearing (125).

-Ball bearing (125) can not be separated
from 3rd gear (118).

Removing 3rd gear (118) and ball bearing

(125)

(3) Installing procedure

Assembly is a reverse order of disassembly, but notice the following.

1. Repair scored parts at disassembly. Get replacements ready beforehand.

2. Wash parts sufficiently in cleaning oil and dry them with jet air.
3. Do not forget to coat the sliding areas and bearings with clean hydraulic oil.
4. In principle. replace sealing parts such as O rings and oil seals.
5. Tighten socket bolts and plugs to specified torques in Service Standard, using a torque wrench.
6. Do not mix up front pump parts with rear pump parts.

33.2.1.3.3 Maintenance standards

In case a pitching (1 pit is more than 1mm (0.039in), while the area ratio is more than 5%.) is seen
on the gear tooth surface of 2nd gear (117) and 3rd gear (118), replace the gears. Replace the
gears also in case they show excessive damage.

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33.2.2 CONTROL VALVE

33.2.2.1 SECTIONAL VIEW
1. Outside view

Section (1/6)

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Section (2/6)

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Section (3/6)

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Section (4/6)

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Section (5/6)

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Section (6/6)

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Tightening torque Tightening torque

No. NAME Q'TY No. NAME Q'TY
N-m (lbf-ft) N-m (lbf-ft)

101 Casing A 1 322 Spring 4

102 Casing B 1 323 Spring 3

220~250(162~184) 154 Plug PF3/4 3 324 Spring 3

20~24(15~18) 159 Plug PT1/4 MEC (Pre-coat bolt) 1 325 Spring 1

7.8~9.8(5.8~7.2) 160 Plug PT1/16 MEC (Pre-coat bolt) 5 326 Spring 1

161 O-ring 7 327 Spring 3

162 O-ring 15 328 Spring 1

163 O-ring 11 329 Spring 3

164 O-ring 19 331 Spring seat 24

201 Cover 3 16~18(11.8~13.3)

333 Spacer bolt 12
202 Cover 6 Loctite #262

203 Cover 1 336 Stopper 10

204 Sub cover 1 339 Stopper 1

205 Cover 5 340 Stopper 1

206 Cover 1 511 Poppet 11

207 Back pressure check valve cover 1 512 Poppet 2

209 Cover 2 514 Poppet 2

210 Cover 2 515 Poppet 1

9.8~14(7.2-10.3) 211 Lock valve selector sub 2 517 Poppet 1

212 Plate 1 518 Poppet 1

213 Plate 1 521 Spring 11

25~34(18~25) 216 Piston 1 522 Spring 2

261 O-ring 12 523 Spring 1

264 O-ring 10 524 Spring 2

266 O-ring 4 527 Spring 1

273 Socket bolt 40 528 Spring 1

98~120(72~89) 274 Socket bolt 4 230~260(170~192) 551 Plug 13

98~120(72~89) 275 Socket bolt 4 130~150(96~111) 552 Plug 2

25~34(18~25) 278 Socket bolt 5 230~260(170~192) 556 Plug 3

301 Boom spool sub 1 562 O-ring 2

302 Arm 1 spool 1 13~17(9.59~12.5) 563 Plug 2

303 Swing spool 1 564 O-ring 2

304 Bucket spool 1 69~78(51~58) 601 Main relief valve 1

305 Boom conflux spool 1 69~78(51~58) 602 Port relief valve 3

306 Travel spool 2 69~78(51~58) 603 Port relief valve 3

307 Travel straight spool 1 69~78(51~58) 604 Relief valve plug assy 2

308 Arm 2 spool sub 1 98~120(72~89) 606 Bypass cut valve 2

309 P1 unload spool 1 140~180(103~133) 973 Socket bolt 8

310 P2 unload spool 1 140~180(103~133) 974 Socket bolt 2

311 Option spool 1 977 Name plate 1

321 Spring 5 978 Rivet 2

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33.2.2.2 PREPARATION FOR DISASSEMBLY

(1) General precautions
1. As all the hydraulic components are precisely machined, it is essential to carry out disassembly

and reassembly in an especially clean location.
2. When handling the control valve, take special care to prevent the entry of foreign matter, such as
dust or sand.
3. Cap each port of the control valve before removing the valve from the machine. Before
disassembly, confirm that each cap is in place and then clean the exterior of the assembly.
Use a workbench. Lay a clean sheet of paper or rubber mat over the workbench.
4. When carrying or moving the control valve, hold the body, and never put pressure on a lever, an
exposed spool, or the end cover. Handle the valve with care.
5. Tests(for relief characteristics, leaks, overload valve setting, flow resistance, etc.) that are desired
after disassembly and reassembly require hydraulic testing apparatus.
For this reason, do not disassemble hydraulic units that you are capable of disassembling but
cannot test or adjust.
Prepare beforehand washing fluid, hydraulic oil, grease, etc. .

(2) Tools
Prepare the following tools before disassembling the control valve.

No. Tools Q'TY Remarks

a Vise 1
b Box end wrench 1 of each size 24mm, 27mm, 32mm
c Allen wrench 1 of each size 5mm, 6mm, 10mm, 12mm, 14mm, 22mm
d Spanner 1 32 mm
e Loctite #262 1
f Spatula 1
g Pincers 1
h Adjustable wrench 1

33.2.2.3 DISASSEMBLY
The figures in parentheses after part names in this manual represent those item numbers in the
structural sectional drawing under Fig."Section(1/6)"to Fig."Section(6/6)"

(1) Place the control valve on a work bench so

as to locate back pressure check valve
upwards.

Preparation for disassembly

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Disassemble the valve in a clean place, and be careful not to damage flange surfaces or plate
mounting surfaces.

33.2.2.3.1 Disassembling P1 unload spool

(1) Loosen the socket bolts (273) and remove
the spring cover (202) and the O-ring
(261) for P1 unload spool.

Removing spring cover (202) for P1 unload

spring cover

(2) Draw out, from casing B (102), as a assy

of P1 unload spool (309), spring seat (331),
springs (327), (329), stopper (336) and bolt
(333).

Drawing out P1 unload spool assy (309)

When drawing out the spool assy, use care so as not to score casing B (102).

(3) Fix the P1 unload spool assy with vise via

a protective plate (aluminum plate, etc.) and
remove bolt (333). Then separate spring
seat (331), springs (327), (329) and stopper
(336) from P1 unload spool (309).

Disassembling P1 unload spool assy (309)

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33.2.2.3.2 Disassembling the travel spool (left travel and right travel)
(1) Loosen the socket bolts (273) and remove
the spring cover (201) and the O-ring

(261) for travel.

Removing spring cover (201)

(2) Draw out the assy of travel spool (306),

spring seat (331), springs (323), (324),
stopper (336) and bolt (333) from casing
A (101) or casing B (102).

Drawing out travel spool (306) assy

When drawing out the spool assy, take care so as not to score the casing A (101) or the casing B
(102).

(3) Fix the travel spool assy with vise via a protective plate (aluminum plate, etc.). Remove bolt
(333) and separate spring seat (331), springs (323), (324) and stopper (336) from travel spool
(306).

Removing right travel spring cover (201) Disassembling travel spool (306) assy

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33.2.2.3.3 Disassembling the boom conflux spool

(1) Loosen socket bolts (273) and remove
spring cover (201) for boom conflux and
O-ring (261).
(2) Draw out the assy of boom conflux spool
(305), spring seat (331), springs (325),
(326), stopper (339) and bolt (333) from
casing A (101).

Removing spring cover (202)

When drawing out the spool assy, use care so as not to score casing A (101).

(3) Fix the boom conflux spool with vise via a

protective plate (aluminum plate, etc.) and
remove bolt (333). Then separate spring
seat (331), springs (325), (326) and stopper
(339) from boom conflux spool (305).

Drawing out boom conflux spool (305) assy

33.2.2.3.4 Disassembling the boom spool

(1) Loosen socket bolts (273) and remove
spring cover (203) for boom spool and
O-ring (261), (266).
(2) Draw out the assy of boom spool (301),
spring seat (331), springs (321), (322),
stopper (336) and bolt (333) from casing B
(102).

Removing spring cover (203)

When drawing out the spool assy, take care so as not to score casing B (102).

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(3) Fix the boom spool assy with vise via a

protective plate (aluminum plate, etc.) and
remove bolt (333). Then separate spring

seat (331), springs (321), (322) and stopper
(336) from boom spool (301). Do not
disassemble boom spool (301) further
unless there is special reason.

Drawing out boom spool (301) assy

33.2.2.3.5 Disassembling the swing spool

(1) Loosen the socket bolts (273) and remove
the spring cover sub (204) and the O-ring
(261), (266) for swing. Do not disassemble
spring cover sub (204) further unless there
is special reason.
(2) Draw out the assy of swing spool (303),
spring seat (331), springs (321), (322),
stopper (336) and bolt (333) from casing A
(101).

Removing spring cover sub (204)

When drawing out the spool assy, use care so as not to score casing A (101).

(3) Fix the swing spool assy with vise via a

protective plate (aluminum plate, etc.) and
remove bolt (333). Then separate spring
seat (331), springs (321), (322) and stopper
(336) from swing spool (303).

Drawing out swing spool (303) assy

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33.2.2.3.6 Disassembling bucket spool

(1) Loosen socket bolts (273) and remove
bucket spring cover (209) and O-ring (261).

Removing spring cover (209)

(2) Draw out the assy of bucket spool (304),

spring seat (331), springs (321), (322),
stopper (336) and bolt (333) from casing B
(102).

Drawing out bucket spool (304) assy

When drawing out the spool assy, use care so as not to score casing B (102).

(3) Fix the bucket spool assy with vise via a

protective plate (aluminum plate, etc.) and
remove bolt (333). Then separate spring
seat (331), springs (321), (322) and stopper
(336) from bucket spool (304).
(4) When needed to disassemble the spring
cover of bucket spool, loosen plug (551)
with casing B (102) installed. After
removed cover (209) from casing B (102),
remove plug (551) and then take out piston
(216).
Disassembling bucket spring cover (209)

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33.2.2.3.7 Disassembling arm 1 spool

(1) Loosen socket bolts (273), and remove
spring cover (201) and O-ring (261) of arm

1 spool.
(2) Draw out the assembly which is consist of
arm 1 spool (302), spring seat (331), spring
(321, 322), stopper (336) and bolt (333)
from casing A (101).

Removing arm 1 spring cover (201)

When drawing out the spool assy, use care so as not to score casing A (101).

(3) Fix the arm 1 spool assy with vise via a

protective plate (aluminum plate etc.) and
remove bolt (333). Then remove spring seat
(331), spring (321, 322) and stopper (336)
from arm 1 spool (302).

Disassembling arm 1 spool (302) assy

33.2.2.3.8 Disassembling arm 2 spool

(1) Loosen socket bolts (273), and remove
spring cover (201) and O-ring (261) of arm
2 spool.
(2) Draw out the assembly which is consist of
arm 2 spool (308), spring seat (331), spring
(321, 328), stopper (340) and bolt (333)
from casing B (102).

Removing arm 2 spring cover (201)

When drawing out the spool assy, use care so as not to score casing B (102).

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(3) Fix the arm 2 spool assy with vise via a

protective plate (aluminum plate etc.) and
remove bolt (333). Then remove spring seat
(331), spring (321, 328) and stopper (340)
from arm 2 spool (308). Do not
disassemble arm 2 spool (308) further
unless there is special reason.

Disassembling arm 2 spool (308) assy

33.2.2.3.9 Disassembling option spool

(1) Loosen socket bolts (273), and remove
spring cover (201) and O-ring (261) of
option spool.
(2) Draw out the assembly which is consist of
option spool (311), spring seat (331), spring
(323, 324), stopper (336) and bolt (333)
from casing A (101).

Removing option spring cover (201)

When drawing out the spool assy, use care so as not to score casing A (101).

(3) Fix the option spool assy with vise via a

protective plate (aluminum plate etc.) and
remove bolt (333). Then remove spring seat
(331), spring (323, 324) and stopper (336)
from option spool (311).

Drawing out option spool assy (311)

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33.2.2.3.10 Disassembling travel straight spool

(1) Loosen the socket bolts (273) and remove
the spring cover (202) and the O-ring

(261) for travel straight.
(2) Draw out the assy of travel straight spool
(307), spring seat (331), springs (327),
(329), stopper (336) and bolt (333) from
casing B (102).

Drawing out travel straight spool (307) assy

When drawing out the spool assy, take care so as not to score the casing B (102).

(3) Fix the travel straight spool assy with vise via a protective plate (aluminum plate, etc.). Remove
bolt (333) and separate spring seat (331), springs (327, 329) and stopper (336) from travel straight
spool (307).

33.2.2.3.11 Disassembling P2 unload spool

(1) Loosen socket bolts (273), and remove
spring cover (202) of P2 unload spool and
O-ring (261).
(2) Draw out the assembly which is consist of
P2 unload spool (310), spring seat (331),
spring (327, 329), stopper (336) and bolt
(333) from casing A (101).

Removing P2 unload spring cover (202)

When drawing out the spool assy, use care so as not to score casing A (101).

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(3) Fix the P2 unload spool assy with vise via

a protective plate (aluminum plate etc.)
and remove bolt (333). Then remove
spring seat (331), spring (327, 329) and
stopper (336) from P2 unload spool (310).

Drawing out P2 unload spool assy (310)

33.2.2.3.12 Removing spool covers

(1) Travel, bucket, arm 1, arm 2 and option
Loosen socket bolts (273) and remove
spool cover (205) and O-ring (264).
(2) Swing
Loosen socket bolts (273) and remove
spool cover (206) and O-ring (264), (266).
Do not disassemble spool cover (206)
further unless there is special reason.
(3) Boom
Loosen socket bolts (273) and remove
spool cover (206) and O-ring (264). Do
Removing spool cover (205),(206),(208)
not disassemble spool cover (208) further
unless there is special reason.

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33.2.2.3.13 Removing relief valve and plug assy for relief valve hole
(1) Remove the main relief valve (601) and
overload relief valve (602) and (603) from

the casing.

Removing main relief valve (601)

-Distinguish overload relief valve between (602) and (603) with a tag to prevent them from being
confused during reassembly, as they are the same in appearance and shape but differ in pressure
setting.
-Regarding the disassembly of the relief valves themselves, do not disassemble it.

Removing overload relief valve (602) and (603)

Removing plug assy (604) for relief valve hole

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33.2.2.3.14 Removing by-pass cut valve

(1) Remove by-pass cut valve (606) from the
casing.

Removing by-pass cut valve (606)

33.2.2.3.15 Removing lock valve selector sub

(1) Loosen socket bolts (211-171), (279) and
remove lock valve selector sub (211) and
emergency cab manual lowering device
(215) from the casing.
Further disassembly of the lock valve
selector sub (211) and emergency boom
manual lowering device (215) is not allowed.

Removing lock valve selector sub (211)

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33.2.2.3.16 Removing back pressure check valve

(1) Loosen socket bolt (278) and remove back
pressure check valve (207) from the casing.


Removing back pressure check valve cover

(207)

(2) Remove springs (527), (528), boost check

valve poppet sub (517) and by-pass check
valve poppet (518) from the casing. The
further disassembly of boost check valve
poppet sub (517) is not allowed.

Replace control valve so that the spool

cover face directs downward.

Removing boost check valve sub (517) and

by-pass check valve poppet (518)

When replacing, take care so as not to score the spool cover.

33.2.2.3.17 Removing plate

(1) Loosen socket bolts (274), (275) and
remove plates (212), (213).
(2) After removing plates, remove all O-rings
(162), (163) remained on the casing side.

Removing plate (212),(213)

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33.2.2.3.18 Removing check valve

(1) Remove plugs of load check valve, conflux
check valve, etc. and then remove poppet
(511) and spring (521).
(2) Load check valve on the swing section
Remove plug (556) and then remove
poppet (511) and spring (523).
(3) Load check valve on arm 2 section
Remove plug (551) and then remove
poppet (515) and spring (521).

Removing plug (551),(556),(552)

-The plug and spring in use differ from the above (1). Do not mix the parts when assembling parts
again.
-The poppet in use differs from the above (1). Do not mix the parts when assembling parts again.

(4) Lock valve

Remove plug (556) and then remove
poppet (514) and spring (524).
(5) Main relief valve
Remove plug (552) and then remove
poppet (512) and spring (522).

Removing poppet (511),(512),(514),(515)

-The plug, poppet and spring in use differ from the above (4). Do not mix the parts when assembling
parts again.
-The plug, poppet and spring in use differ from the above (5). Do not mix the parts when assembling
parts again.

The plugs in which the procedure for disassembly is not included in the above procedure are usually
used to block auxiliary holes and holes caused by casting. Do not disassemble further if unnecessary.

33.2.2.3.19 Disassembling casing

Further disassembly of the casing is not allowed.

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33.2.2.3.20 Inspection after disassembly

Thoroughly clean all disassembled parts with wash oil, and dry them with jet air. Place each part on a
clean sheet of paper or cloth for inspection.

(1) Control valve
1. Inspect the entire surface of each part for burrs, scratches, cuts, and other defects.
2. Confirm that the O-ring groove surface of the casing or the block is free from foreign matter, dents
or rust.
3. If the check valve seat of the casing or the block has dents or damage on its surface, smooth it
by lapping.
4. Confirm that O-ring or the outer circumference of the sliding part of a manual spool is free from
scratches, dents, and the like. Remove any small defects with an oil stone or lapping compound.
5. Manually confirm that all sliding and fitted parts move smoothly. Confirm that all grooves and
passages are free from foreign matter.
6. Replace any broken or deformed spring with new one.
7. Of a relief valve malfunctions, repair it by following the relief valve disassembly and reassembly
procedures.
8. Replace all O-ring with new ones.

Take care not leave lapping compound behind in the casing or block.

(2) Relief valve

1. Make sure that the poppet and the seat surface at the tip of the seat are without fault and that
the contact surface is even all over.
2. Manually confirm that the main poppet slides smoothly onto and off the seat.
3. Confirm that the outer circumference of the main poppet and the inner circumference of its seat
are free from defects such as scratches.
4. Confirm that each spring is free from breakage, deformation, and excessive wear.
5. Confirm that the orifices of the main poppet and its seat are not clogged.
6. Replace all O-rings with new ones. (Between casing and seal)

33.2.2.4 REASSEMBLY
(1) Here, only the reassembly procedures are described. Regarding drawings, refer to the disassembly
procedures.
(2) Figures in parentheses after part names in this instruction represent those item numbers in the
structural sectional drawing. (Fig."Section(1/6)" to Fig."Section(6/6)")
(3) Precautions on reassembling O-ring

1. Confirm that O-rings are free from defects caused by poor handling.
2. Apply thin coat of grease or hydraulic oil to O-rings and their mating parts.
3. Do not stretch O-rings to the extent that they become permanently set.
4. When installing O-rings, do not roll them into place. Twisted O-rings do not easily untwist by
themselves after installation, and can cause oil leaks.
5. Use a torque wrench to tighten each attaching bolt. Tighten to the specified torque in
"Maintenance Standards."

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33.2.2.4.1 Installing check valve

(1) Load check valve, conflux check valve, and so on
Attach poppet (511) and spring (521) in place, place O-ring (164) in plug (551) and tighten them
to the specified torque. (9 places)
(2) Load check valve of swing section
Attach poppet (511) and spring (523) in place, place O-ring (164) in plug (556) and tighten them
to the specified torque. (1 place)
(3) Load check valve of arm 2 section
Attach poppet (515) and spring (521) in place, place O-ring (164) in plug (551) and tighten them
to the specified torque. (1 place)
(4) Lock valve section
Attach poppet (514) and spring (524) in place, place O-ring (164) in plug (556) and tighten them
to the specified torque. (2 places)
(5) Main relief valve section
Attach poppet (512) and spring (522) in place, place O-ring (562) in plug (552) and tighten them
to the specified torque. (2 places)

Take care to prevent misassembling of parts and assembling position error because the parts in (1)
to (5) are similar in shape.

33.2.2.4.2 Assembling plate

(1) Place O-rings (162), (163) in casing.
(2) Attach plates (212), (213) and tighten socket bolts (274), (275) to the specified torque.

Replace control valve so that this plate face directs downward.

33.2.2.4.3 Assembling back pressure check valve

(1) Attach boost check valve poppet sub (517), by-pass check valve poppet (518) and springs (527),
(528).
(2) Attach O-rings (264), (266) in back pressure check valve cover, attach it to casing A (101) and
tighten socket bolt (278) to the specified torque.

33.2.2.4.4 Assembling lock valve selector sub

(1) Attach lock valve selector sub (211) to the casing and tighten socket bolt (211-171) to the
specified torque.

33.2.2.4.5 Assembling by-pass cut valve

(1) Attach by-pass cut valve (606) to casing and tighten it to the specified torque.

Take care to prevent drop of poppet (606-201) and spring (606-202) when attaching by-pass cut valve.

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33.2.2.4.6 Assembling relief valve and relief valve hole plug assembly
(1) Tighten main relief valve (601), port relief valves (602), (603) and relief valve hole plug assembly
(604) in respective place to the specified torque.


Assemble it giving attention to the label attached when disassembling to prevent mistake because the
port relief valves (602), (603) are similar in shape.

33.2.2.4.7 Assembling p2 unload spool

(1) Hold the mid section of P2 unload spool (310) with vise provided with protection plate (aluminum
plate, etc.), fit spring seat (331), springs (327), (329) and stopper (336) and tighten bolt (333) to
the specified torque.

-Apply Loctite #262 when tightening bolt (333).

-Take care not to deform P2 unload spool (310) because of careless over clamping.

(2) Place P2 unload spool assembly in item (1) in casing A (101).

Place P2 unload spool assembly in casing A (101) carefully. Do not squeeze it into place.

(3) Attach spring cover (202) with O-ring (261) attached to the spring side of P2 unload spool
assembly and tighten socket bolt (273) to the specified torque.

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33.2.2.4.8 Assembling travel straight spool

(1) Hold the mid section of travel straight spool (307) with vise provided with protection plate
(aluminum plate, etc.), fit spring seat (331), springs (327), (329) and stopper (336) and tighten
bolt (333) to the specified torque.

-Apply Loctite #262 when tightening bolt (333).

-Take care not to deform travel straight spool (307) because of careless over clamping.

(2) Place travel straight spool assembly in item (1) in casing B (102).

Place travel straight spool assembly in casing B (102) carefully. Do not squeeze it into place.

(3) Attach spring cover (202) with O-ring (261) attached to the spring side of travel straight spool
assembly, and tighten socket bolt (273) to the specified torque.

33.2.2.4.9 Assembling spool in option

(1) Hold the mid section of spool in option (311) with vise provided with protection plate (aluminum
plate, etc.), fit spring seat (331), springs (323), (324) and stopper (336) and tighten bolt (333) to
the specified torque.

-Apply Loctite #262 when tightening bolt (333).

-Take care not to deform option spool (311) because of careless over clamping.

(2) Place spool assembly in option in item (1) in casing A (101).

Place option spool assembly in casing A (101) carefully. Do not squeeze it into place.

(3) Attach spring cover (201) with O-ring (261) attached to the spring side of spool assembly in option
and tighten socket bolt (273) to the specified torque.

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33.2.2.4.10 Assembling arm 2 spool

(1) Hold the mid section of arm 2 spool (308) with vise provided with protection plate (aluminum plate,
etc.), fit spring seat (331), springs (321), (328) and stopper (340) and tighten bolt (333) to the

specified torque.

-Apply Loctite #262 when tightening bolt (333).

-Take care not to deform arm 2 spool (308) because of careless over clamping.

(2) Place arm 2 spool assembly in option in item (1) in casing B (102).

Place arm 2 spool assembly in casing B (102) carefully. Do not squeeze it into place.

(3) Attach spring cover (201) with O-ring (261) attached to the spring side of arm 2 spool assembly
and tighten socket bolt (273) to the specified torque.

33.2.2.4.11 Assembling arm 1 spool

(1) Hold the mid section of arm 1 spool (302) with vise provided with protection plate (aluminum plate,
etc.) and fit spring seat (331), springs (321), (322) and stopper (336) and tighten bolt (333) to the
specified torque.

-Apply Loctite #262 when tightening bolt (333).

-Take care not to deform arm 1 spool (302) because of careless over clamping.

(2) Place arm 1 spool assembly in item (1) in casing A (101).

Place arm 1 spool assembly in casing A (101) carefully. Do not squeeze it into place.

(3) Attach spring cover (201) with O-ring (261) attached to the spring side of arm 1 spool assembly,
and tighten socket bolt (273) to the specified torque.

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33.2.2.4.12 Assembling bucket spool

(1) Hold the mid section of bucket spool (304) with vise provided with protection plate (aluminum
plate, etc.), fit spring seat (331), springs (321), (322) and stopper (336) and tighten bolt (333) to
the specified torque.

-Apply Loctite #262 when tightening bolt (333).

-Take care not to deform bucket spool (304) because of careless over clamping.

(2) Place bucket spool assembly in item (1) in casing B (102).

Place bucket spool assembly in casing B (102) carefully. Do not squeeze it into place.

(3) Attach spring cover (209) with O-ring (261) attached to the spring side of bucket spool assembly
and tighten socket bolt (273) to the specified torque.
(4) Attach piston (216) to spring cover (209), place O-ring (164) in plug (551) and tighten to the
specified torque.

33.2.2.4.13 Assembling swing spool

(1) Hold the mid section of swing spool (303) with vise provided with protection plate (aluminum
plate, etc.), fit spring seat (331), springs (321), (322) and stopper (336) and tighten bolt (333) to
the specified torque.

-Apply Loctite #262 when tightening bolt (333).

-Take care not to deform swing spool (303) because of careless over clamping.

(2) Place swing spool assembly in item (1) in casing A (101).

Place swing spool assembly in casing A (101) carefully. Do not squeeze it into place.

(3) Attach spring cover sub (204) with O-rings (261), (266) attached to the spring side of swing spool
assembly and tighten socket bolt (273) to the specified torque.

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33.2.2.4.14 Assembling boom spool

(1) Hold the mid section of boom spool (301) with vise provided with protection plate (aluminum
plate, etc.), fit spring seat (331), springs (321), (322) and stopper (336) and tighten bolt (333) to

the specified torque.

-Apply Loctite #262 when tightening bolt (333).

-Take care not to deform boom spool (301) because of careless over clamping.

(2) Place boom spool assembly in item (1) in casing B (102).

Place boom spool assembly in casing B (102) carefully. Do not squeeze it into place.

(3) Attach spring cover (203) with O-rings (261), (266) attached to the spring side of boom spool
assembly and tighten socket bolt (273) to the specified torque.

33.2.2.4.15 Assembling boom conflux spool

(1) Hold the mid section of boom conflux spool (305) with vise provided with protection plate
(aluminum plate, etc.), fit spring seat (331), springs (325)(326) and stopper (339) and tighten bolt
(333) to the specified torque.

-Apply Loctite #262 when tightening bolt (333).

-Take care not to deform boom conflux spool (305) because of careless over clamping.

(2) Place boom conflux spool assembly in item (1) in casing A (101).

Place boom conflux spool assembly in casing A (101) carefully. Do not squeeze it into place.

(3) Attach spring cover (202) with O-ring (261) attached to the spring side of boom conflux spool
assembly and tighten socket bolt (273) to the specified torque.

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33.2.2.4.16 Assembling travel spool (travel right and left)

(1) Hold the mid section of travel spool (306) with vise provided with protection plate (aluminum
plate, etc.), fit spring seat (331), springs (323), (324) and stopper (336) and tighten bolt (333) to
the specified torque.

-Apply Loctite #262 when tightening bolt (333).

-Take care not to deform travel spool (306) because of careless over clamping.

(2) Place travel spool assembly in item (1) in casing A (101) or casing B (102).

Place travel spool assembly in casing A (101) or casing B (102) carefully. Do not squeeze it into
place.

(3) Attach spring cover (201) with O-ring (261) attached to the spring side of travel spool assembly
and tighten socket bolt (273) to the specified torque.

33.2.2.4.17 Assembling P1 unload spool

(1) Hold the mid section of P1 unload spool (309) with vise provided with protection plate (aluminum
plate, etc.), fit spring seat (331), springs (327), (329) and stopper (336) and tighten bolt (333) to
the specified torque.

-Apply Loctite #262 when tightening bolt (333).

-Take care not to deform P1 unload spool (309) because of careless over clamping.

(2) Place P1 unload spool assembly in item (1) in casing A (101).

Place P1 unload spool assembly in casing A (101) carefully. Do not squeeze it into place.

(3) Attach spring cover (202) with O-ring (261) attached to the spring side of P1 unload spool
assembly and tighten socket bolt (273) to the specified torque.

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33.2.2.4.18 Assembling spool cover, and so on

(1) Travel, bucket, arm 1, arm 2, option
Place O-ring (264) in spool cover (205) and tighten socket bolt (273) to the specified torque.

(2) Swing
Place O-rings (264), (266) in spool cover (206) and tighten socket bolt (273) to the specified
torque.
(3) Boom
Place O-ring (264) in spool cover (208) and tighten socket bolt (273) to the specified torque.

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33.2.2.5 MAINTENANCE STANDARDS

33.2.2.5.1 Inspection of components
Parts name Inspection item Criterion and remedy
Casing 1. 1.
Look for scratches, rusting and corrosion. If any of the following parts are damaged,
replace the casing.
-Sliding part of casing hole and spool,
particularly the land, to which holding
pressure is applied.
-Area of sealing part that is in contact with
O-ring.
-Sealing and seating part of main or
overload relief valve.
-Area of seating part or sliding part of
poppet.
-Sealing part of plug.
-Defects of other parts that seem to
prevent normal function.
Spool 1. 1.
Look for scratches, galling, rusting and If a detectable defect with your fingernail is
corrosion. found on the sliding part of the outer
circumference, replace the spool.
2. 2.
Insert the spool in the casing bore, and If the spool damages the O-ring or does
move it while turning it. not move smoothly, repair or replace the
spool.
Poppet If spring is damaged, replace it.
1. 1.
Look for damage on the poppet and the If the seat of poppet or spring are
spring. damaged, correct or replace it.
2. 2.
Insert the poppet in the casing, and move If the poppet moves lightly without catching,
it. it is normal.
Spring and related 1. 1.
parts Look for rust, corrosion, deformation, and If damaged heavily, replace.
breakage of the spring, spring seat,
stopper, spacer bolt and cover.
Main relief valve 1. 1.
Port relief valve Look for rust and damage on outer surface. Replace.
By-pass cut valve 2. 2.
Inspect the contact face of the valve seat. If damaged, replace.
3. 3.
Inspect the O-ring, backup ring, and seal. As a general rule, replace all parts with
new ones. (Between casing and seal)

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33.2.2.6 TROUBLESHOOTING
(1) If an abnormal condition is noticed, check to see if the problem is with the control valve itself, one
of the main pumps, the gear pump, or a circuit. To this end, you will need to measure pilot

pressure, pump delivery pressure, load pressure, etc. If any part of the system is to be
disassembled for inspection, follow the disassembly and reassembly procedures in this manual.
(2) Dust is the enemy of hydraulic components. Pay strict attention to protection from dust. If any
part of the system is to be disassembled, take dust protection measures beforehand.
(3) Moving parts must be handled with care. If they are damaged, smooth the damage using an oil
stone or the like.
(4) Take care not to damage the contact face of O-rings. A damaged contact face will certainly
cause oil leaks.

33.2.2.6.1 Control valve

Trouble Cause Remedy
1. 1) 1)
Travel does not Malfunctioning main relief valve. Check travel relief valve pressure
occur. -Foreign matter between main poppet and -Disassemble and clean. If damaged
Slow to start up seat. heavily, replace the assy as a unit.
(or poor power). -Foreign matter between poppet and seat. -Same as above.
Slow response. -Sticking main poppet. -Correct sticking part with oil stone.
-Broken or deformed spring. -Replace spring.
-Clogged main poppet throttle. -Remove foreign matter.
-Loosened adjusting screw -Readjust, and tighten lock nut to specified
torque.
2. 1) 1)
Machine does not Malfunctioning travel straight valve. Check pilot pressure.
move straight -Sticking spool. -Correct sticking part with oil stone.
during simultaneous -Broken or deformed spring. -Replace spring.
operation of travel -Clogged small hole in spool. -Remove foreign matter.
and attachment. 2) 2)
Malfunctioning main relief valve. Remove main relief valve.
3. 1) 1)
Excessive natural Excessive clearance between casing and Replace spool.
falls of attachment spool.
under its own 2) 2)
weight when spool Spool is not completely in neutral position. Check secondary pilot pressure.
is in neutral. -Foreign matter between casing and spool, -Disassemble, clean and smooth sticking
or sticking spool. part with oil stone.
-Broken or deformed spring. -Replace spring.
-Clogged pilot circuit. -Remove foreign matter.
3) 3)
Malfunctioning overload relief valve. Refer Check overload relief valve pressure.
to item 1. 1) above. (See 33.2.2.3.20 (2)) (See 33.2.2.3.20 (2))
-Foreign matter between valve seat and -Clean and check damage on seat surface.
casing.
4) 4)
Lock valve function is faulty. (Arm, boom) Replace
-Foreign matter between poppet seat and -Disassemble, clean.
casing. -Correct stuck part with oil stone or replace.
-Poppet is stuck. -Replace spring.
-Broken or deformed spring. -Replace lock valve selector assy.
-Selector spool is stuck.

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Trouble Cause Remedy

4. 1) 1)
When raising Malfunctioning load check valve.
attachment, at first it -Foreign matter between poppet and casing. -Disassemble and clean. If heavily
drops. -Sticking poppet. damaged, replace control valve.
-Broken or deformed spring. -Correct sticking part with oil stone.
-Replace spring.
5. 1) 1)
Bucket, boom, arm Malfunctioning main spool. Check secondary pilot pressure.
or swing does not -Excessive clearance between casing and -Replace spool.
operate. spool. -Disassemble and clean.
Slow to start up -Foreign matter between casing and spool. -Correct stuck part with oil stone.
(or poor power).Slow -Sticking spool. -Replace spring.
response. -Broken or deformed return spring. -Remove foreign matter.
-Clogged pilot circuit.
2) 2)
Malfunctioning main relief valve. Refer to Check main relief valve pressure. Refer to
item 1. 1) above. item 1. 1) above.
(See 33.2.2.3.20 (2)) (See 33.2.2.3.20 (2))
3) 3)
Malfunctioning overload relief valve. Refer Check overload relief valve pressure.
to item 1. 1) above. (See 33.2.2.3.20 (2))
(See 33.2.2.3.20 (2))
6. 1) 1)
Boom conflux does Malfunctioning conflux valve. Measure pilot pressure.
not operate. -Excessive clearance between casing and -Replace spool.
spool. -Disassemble and clean.
-Foreign matter between casing and spool. -Correct stuck part with oil stone.
-Sticking spool. -Replace spring.
-Broken or deformed return spring. -Remove foreign matter.
-Clogged pilot circuit.

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33.2.2.6.2 Relief valve

Trouble Cause Remedy
1. Main or pilot poppet of relief valve is Check for foreign matter on each poppet. 
No pressure rise. sticking and valve is open, or there is Confirm that each component slides
foreign matter on valve seat. smoothly.
If failure is found, replace it in an
assembly.
2. Main or pilot poppet of relief valve seat is If failure is found, replace it an assembly.
Unstable relief damaged.
pressure.
3. 1) 1)
Incorrect relief Wear due to foreign matter. Replace damaged assembly
pressure setting. 2) 2)
Loosened locknut or adjusting screw. Adjust pressure.
4. Confirm that each component operates
Oil leak. smoothly. Replace damaged or worn
1) component.
Damaged seat. 1)
Damaged O-ring. If failure is found, replace it an assembly.
2) 2)
Sticking component due to foreign matter. Confirm that there are no scratches,
scores, or foreign matter present before
reassembling.
If failure is found, replace it an assembly.

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33.2.3 PILOT VALVE (ATT)

33.2.3.1 CROSS-SECTIONAL VIEW

Pilot valve (For ATT)

Tightening torque Tightening torque

No. NAME Q'TY No. NAME Q'TY
N-m (lbf-ft) N-m (lbf-ft)
101 Casing 1 *218 Seat 4
151 Plate 1 221 Spring 4
201-1 Spool 2 241-1 Spring 2
201-2 Spool 2 241-2 Spring 2
211 Plug 4 *246-1 Spring 2
212 Push rod 4 *246-2 Spring 2
213 Seal 4 47.1 (34.7) 301 Joint: M14 1
214 O-ring: 1B P20 4 302 Circular plate 1
216-1 Spring seat 2 68.6 (50.6) 312 Adjust nut: M14 1
216-2 Spring seat 2 501 Boots 1
217 Washer 2 (Shim) 4

Note) The parts marked * might not be equipped depending on valve type.

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33.2.3.2 DISASSEMBLY
(1) Plug each port of pilot valve, and clean it
with kerosine.

P port: PF1/4
1 to 4 and T port: PF3/8
(2) Fix pilot valve with vise via a protective
plate (Alminum plate etc.), and remove
boots (501).

Removing boot (501)

(3) Remove adjusting nut (312) applying

spanners to adjusting nut (312) and
circular plate (302).
Tools: Spanner: 22 mm, 32 mm

Removing adjusting nut (312)

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(4) Remove circular plate (302)

Tools: Spanner: 32 mm

Removing circular plate (302)

Circular plate is removed

Installing Jig A

(5) Turn joint (301) in counterclockwise with Jig

A to remove.
Jig A: See page 33.2.3.7(1).
Tools: Spanner: 24 mm

Removing joint (301)

When the force of return springs (221) is strong, never loosen joint (301). If loosened, it might result in
jumping out of plate (151), plug (211) and push rod (212).
Remove joint (301) pressing plate (151) downward with two fingers.

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(6) Remove plate (151)

-When the force of return springs (221)
are strong, press plate to let it come up

slowly.

Removing plate (151)

-When the force of return springs (221) are

weak, plug is left in casing (101) due to
sliding resistance of O-ring (214).
Tools: Pull plug (211) out with a driver.

Removing plug (211)

To prevent personal injury, plug (211) must be removed slowly and evenly until the return spring
(221) force is completely released.

(7) Remove push rod (212), plug (211),

pressure reducing valve assy (spool),
return springs (221) from casing (101).

Removing push rod, plug, pressure reducing

valve and spring

Record combination of port holes on casing and the pulled out parts. The stroke differs according to
direction.

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(8) Push springs (241-1), (241-2) in the range

of 7 mm (0.276 in) that the movement of
spring seats (216-1), (216-2) and shift the
seats (216) in a side direction, and
remove spools (201-1), (201-2) through the
larger hole of seat.

Removing spool (201)

Never push down spring seat (216-1) in 7 mm (0.276 in) or more. (For port 1,3)
Never push down spring seat (216-2) in 9.4 mm (0.370 in) or more. (For port 2,4)

(9) Remove spool (201-1), (201-2), spring seats

(216-1), (216-2), spring (241-1), (241-2)
and washer (217).

Disassembling pressure reducing valve

(10) Remove spring (*246-1), (*246-2), spring

seat (*218), from push rod (212).

Disassembling push rod

The parts marked * might not be equipped depending on valve type.

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(11) Pull out push rod (212) from plug (211).

(12) Remove O-ring (214) from plug (211).



Removing push rod (212)

(13) Remove inside seal (213) from plug (211)

with small driver.

Removing seal (213)

33.2.3.3 CLEANING PARTS

(1) Clean parts with wash oil roughly.
(2) Clean parts with wash oil completely.
(3) Dry parts by swabbing clean rag.
(4) Apply rust preventives on parts.

33.2.3.4 ASSEMBLING
(1) Fit washer 2 (217), springs (241-1), (241-2),
spring seats (216-1), (216-2) to spool
(201-1), (201-2).

Assembling pressure reducing valve

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(2) Push spring (241-1), (241-2) in the range of

that the movement of spring seats (216-1),
(216-2) in a side direction, and install
spools (201-1) through the larger hole of
spring seat. (See Fig."Removing spool(201)")

Installing spools (201-1), (201-2)

Never push down spring seat (216-1) in 7 mm (0.276 in) or more. (For port 1,3)
Never push down spring seat (216-2) in 9.4 mm (0.370 in) or more. (For port 2,4)

(3) Place spring (221) into ports 1,3 of casing

(101), and then install pressure reducing
valve assy in it.
Place springs (221) into ports 2,4 and
install it.

Installing pressure reducing valve assy

Install the removed respective assy into respective holes.

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(4) Fit O-ring (214) and seal (213) into plug (211).
-Apply hydraulic oil on surface of push rod.



Installing O-ring (214) and seal (213)

(5) Insert push rod (212) in plug (211) and

install spring (*246-1) and spring seat
(*218) to push rod (212) on port 1,3 side.
Insert push rod (212) in plug (211) and
install spring (*246-2) and spring seat
(*218) to push rod (212) on port 2, 4 side.

Assembling push rod, spring (*246-1),(*246-2)

and seat (*218)

The parts marked * might not be equipped depending on valve type.

(6) Fit plug (211) assy to casing (101).

1.
When the force of spring (211) is weak, it
stops at the position where it is pushed in
by the sliding resistance of O-ring (214).

Installing plug assy

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2.
When the force of spring (221) is strong, attach
plate (151) and press 4 push rods by hand at
the same time, and tighten joint (301)
temporarily.
-Install spool (201) straight and evenly into the
hole of casing (101).
-Take care so that plug (211) and plate (151)
do not jump out of casing (101).

Installing plug assy and plate (151)

(7) Install joint (301) on casing (101) with jig A

securely.
Jig A : See 33.2.3.7 JIG.
Tightening torque : 47.1 N-m (32.8 to 37.2
lbf-ft)

Installing joint (301)

(8) Install circular plate (302) to joint (301)

(9) Screw adjusting nut (312) in until it touches
circular plate (302), and tighten it applying
spanner to stop circular plate returning.
Tools: Spanner: 32 mm
Tools: Socket: 22 mm
-Apply Loctite #277 to threads of joint.
Tightening torque: 68.6 N-m (51 lbf-ft)

Installing circular plate (302)

-Screw it in until it comes in contact with 4 push rods (212) equally.

-The exceeding of screw in may cause malfunction of machine.

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(10) Apply heat-resisting grease to joint (301)

rotating section and the top of push rod
(212).

(11) Cover it with boots.
(12) Spray rust preventives through each port
and attach plug respectively.

Applying grease to joint section and push rod

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33.2.3.5 MAINTENANCE STANDARDS

Check item Standard Remarks
When leakage quantity reaches to 1000 cc/
min. or more where handle is set in neutral
Conditions
position, or to 2000 cc/min. or more in
Leakage Primary pressure 2.94 MPa (426 psi)
operation, replace spool with new one.
Hydraulic oil viscosity 23 cSt
If leaked, even if the spool is replaced,
replace pilot valve assy with new one.
When the wear of sliding section is 10 㱘m
This condition may be the same as the
Spool more than the that of non sliding section,
above.
replace it with new one.
Push rod When the wear of top is 1 mm (0.04 in) or more, replace it with new one.
When looseness of 2 mm (0.08 in) or more
Looseness of control on circular plate (302) on control section and In case of the looseness due to the
section joint section (301) due to wear is pro- duced, loosening on tightening section, adjust it.
replace them with new ones.
When trouble such as noise, hunting, drop of
primary pressure, etc. has occurred in op-
eration, and it does not restore after taking
Stability of operation
corrective action according to below 33.2.3.6
(TROUBLESHOOTING), replace pilot valve
assy with new one.

-O-ring, etc. should be replaced with new one at every disassembling.

-If socket bolt (125) was loosened, seal washer (121) should be replaced.

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33.2.3.6 TROUBLESHOOTING
It is very difficult to find defective section. The following table explains the several estimated causes.
For repair, refer to the estimated causes and corrective actions.

The following table explains general phenomenon, estimated causes and corrective actions. However,
most machine problems are not caused by the failure of only one part, but involve relations with
other parts. Therefore corrective action other than those described in this table is often required. The
following table does not cover causes and corrective actions for all the troubles. So it may be
necessary to perform further investigation of troubles and causes.

Phenomenon Possible Cause Corrective action

1. 1.
Primary pressure is insufficient. Secure primary pressure.
2. 2.
Secondary pressure springs (241) are Replace with new ones.
broken or fatigued.
Secondary pressure
3. 3.
does not rise.
Clearance between spool (201) and cas-ing Replace spool (201).
(101) is abnormally large.
4. 4.
Handle has a looseness. Disassembly and reassembly or replace
handle section.
1. 1.
Sliding parts are caught. Repair the unsmoothed section.
Secondary pressure 2. 2.
is unstable. Tank line pressure varies. Bring pressure directly to oil tank.
3. 3.
Air has mixed into pipeline. Bleed air by operating it several times.
1. 1.
Secondary pressure Tank line pressure is high. Bring pressure directly to oil tank.
is high. 2. 2.
Sliding parts are caught. Correct.

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33.2.3.7 JIG
(1) Jig for removing and installing joint (301)

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33.2.4 PILOT VALVE (FOR TRAVEL)

33.2.4.1 CONSTRUCTION 

Exploded view of pilot valve

No. Parts Q'TY No. Parts Q'TY

5 Rubber boots 2 12-x Seal 14dia.X20dia.X3dia. 6
6 Foot pedal (Switch plate) (2) 12-y Wiper ring 6
6-d Switch plate 2 13 Damper spring 4
6-f Regulation screw M8X28 4 14 Check valve kit (2)
6-g Set screw M5X8 4
7 Retaining plate kit (1) 14-q Plug M8 2
7-h Plate 1 14-r Ball M6, 35 2
7-i Capscrew M10X20 2 15 Orifice (4)
7-j Shaft 2 15-u Plug M6 4
7-k Set screw M4X10 2 15-t Orifice M6, 0.6dia. 4
8 Flange kit 4 17 Shuttle valve kit (2)
10 Control spool 4 17-w' Shuttle valve & orifice 2
11 Return spring 4 17-r Ball M6, 35 2
12 Damper flange kit (4) 17-z Orifice M5, 0.8dia. 2
12-o Damper plunger 14 dia. 4 21 Plug 4

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33.2.4.2 DISASSEMBLY AND ASSEMBLY

(1) Boot replacement

The pilot control unit does not need to be removed from the machine to perform this operation.

1. Remove both faulty boots.

(using a flat screw driver if necessary)
2. Replace both boots with a new one.
* Reassembly:
-First fit the lower part of the rubber boot
on the retaining plate between the 2 switch
plates
-Then put the lower part in the external
groove of the retaining plate
-Finish by fitting the upper part of the
rubber boot on the switch plate.

(2) Switch plate removal

1. Remove:
-The pilot control unit from the machine.
-Both rubber boots (See 33.2.4.2 (1))
2. Remove the screw locking the axis using
a 2 mm socket wrench. (See right Fig.
No.1)
* Reassembly:
-Apply a droplet of Loctite #262 on the
locking screw thread.
-Torque :1.2 N-m (0.89 lbf-ft)
3. Fit a M3 screw on the switch plate axis in
order to remove it
(Using pliers if necessary). (See right Fig.
No.2)
* Reassembly:
-Position the axis so that the hole is
aligned with the locking screw as shown on
the picture (See right Fig. No.3)
4. Mark out the position of the switch plate
before removing it.
5. Repeat the operation for the second switch
plate.
6. Reassemble parts in reverse order.

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(3) Switch plate adjustment


If the switch plate is replaced, it is necessary to adjust the regulation screws.

1. Unscrew the 2 locking screws using a 2,5

mm socket wrench (See right Fig.)
* Reassembly:
-Apply a droplet of Loctite #262 on the
locking screw thread.
-Torque :3N-m 2.2 (lbf-ft)
2. Set the switch plate horizontally.
3. Screw on simultaneously both regulation
screws using a flat screw driver (5,5X150)
until feeling some resistance.

Do not misadjust the two damping screws. (See below Fig.)

4. Tighten the locking screws to hold the

regulation screws in position.
5. Repeat the operation for the second
switch plate making sure both switch
plates are parallel. (See above Fig.)

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(4) Retaining plate removal

1. Remove
-The pilot control unit from the machine.
-Both rubber boots (See 33.2.4.2 (1))
-Both switch plates (See 33.2.4.2 (2))
2. Unscrew simultaneously both screws holding
the retaining plate using a 8 mm socket
wrench.
(See right Fig.)
* Reassembly:
-Apply a droplet of Loctite #262 on the
screw thread.
-Torque :30N-m (22 lbf-ft)

3. Lift the retaining plate to remove it.

(See right Fig.)
* Reassembly:
-Use the retaining plate to insert the 4
guides into the body simultaneously and
perpendicularly.
(See right Fig. left side)
4. Reassemble parts in reverse order.
5. Drain the pilot control unit (See 33.2.4.3).

(5) Damping plunger seals replacement

1. Remove
-The pilot control unit from the machine.
-Both rubber boots. (See 33.2.4.2 (1))
-Both switch plates (See 33.2.4.2 (2))
-The retaining plate (See 33.2.4.2 (4))

2. Remove the wiper ring of the damping

plunger (1).
(See right Fig. No.1)
* Reassembly:
-Replace with a new wiper ring.
3. Remove the damping plunger (2).
(Rihgt Fig. No.2)

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Always place the damping plunger prior to the wiper ring, and make sure the wiper ring is correctly
positionned.

4. Using a needle, remove the seal placed

inside the body (See right Fig. No.3, 4)
* Reassembly :
-Replace with a new seal and grease it.

-Squeeze the seal between your fingers to

obtain a 8-shape.
(See right Fig. No.5)
-Insert the seal within the groove with your
fingers (lip in bottom position).
(See right Fig. No.6, 7)
-Push the seal against the side using the round
head of a small socket wrench. (Right Fig.
No.8)

5. Repeat the operation for the other 3 assemblies.

6. Extract the damping springs from the body (using flat nose pliers).
7. Inspect the damping springs. If defects are detected, replace the 4 springs.
8. Reassemble parts in reverse order.

During the reassembly, make sure the seal is correctly positionned, and pay attention not to damage
nor twist it.

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(6) Guide/plunger and regulation unit replacement

1. Remove
-The pilot control unit from the machine.
-Both rubber boots (See 33.2.4.2 (1))
-Both switch plates (See 33.2.4.2 (2))
-The retaining plate (See 33.2.4.2 (4))
2. Guide/plunger replacement:
-Insert the end of a thin screwdriver
between the guide and the body, carefully
lift the guide to remove it from the body.
3. Remove the guide / plunger assembly.
4. Repeat the operation for the other 3
sub-assemblies.
5. Visually check that the guides / plungers
are in good condition. If defects are
present, replace the 4 sub-assemblies.

Hold the guides with the other hand during the extraction operation to limit the effect of the return
spring.

6. Guide/plunger and relulation unit

replacement
-Extract the regulation units from the body
(using flat nose pliers).
-Inspect the regulation units. If defects are
detected on the parts, replace the 4 units.
7. Return spring replacement :
-Extract the return springs from the body
(using flat nose pliers).

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-Inspect the return springs. If defects are detected, replace the 4 springs.

8. Reassemble parts in reverse order.



(7) Throttle kit replacement

1. Remove
-The pilot control unit from the machine
-Both rubber boots (See 33.2.4.2 (1))
-Both switch plates (See 33.2.4.2 (2))
-The retaining plate (See 33.2.4.2 (4))
-The damping plungers and springs (See
33.2.4.2 (5))

2. Unscrew the screw using a 3mm socket

wrench.
(See right Fig.)
* Reassembly:
-Apply a droplet of Loctite #262 on the
screw thread
-Screw on until it sets just above the body.
(See right Fig.)
3. Unscrew the throttle using a 3 mm socket
wrench.
* Reassembly:
-Torque:4N-m (3 lbf-ft)
4. Repeat the operation for the other 3
assemblies.
5. Replace with new screws and new throttles.
6. Reassemble parts in reverse order.

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(8) Shuttle valve kit removal

1. Remove the pilot control unit from the
machine

The pilot control unit does not need to be disassembled to perform this operation.

2. Unscrew the shuttle valve using a 4 mm

socket wrench. (See right Fig.)
* Reassembly:
-Thoroughly clean the body to remove any
trace of loctite.
-Apply a droplet of Loctite #242 on the
shuttle valve thread.
-Torque :4N-m (3 lbf-ft)

Wait for 8 hours before using the machine to let the Loctite #242 dry completely.

3. Put the body up-side-down to remove the

shuttle valve and the ball. (See below Fig.)
4. Unscrew the throttle using a 2,5 mm socket
wrench.
* Reassembly:
-Hand tighten.
5. Repeat the operation for the other
subassemblies.
6. Inspect the shuttle valves, balls and
throttles. If defects are detected, replace
all the assemblies.

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7. Reassemble parts in reverse order.



(9) Check valve kit removal

1. Remove the pilot control unit from the machine

The pilot control unit does not need to be disassembled to perform this operation.

2. Unscrew the check valve plug using a 4

mm socket wrench.
(See right Fig.)
* Reassembly:
-Drain the pilot control unit
(See 33.2.4.3)
-Torque: 5N-m (3.7 lbf-ft)
3. Put the body up-side-down to remove the
ball.
4. Repeat the operation for the second check
valve kit.

5. Inspect the check valve plugs, O-rings and

balls. If defects are detected, replace all
the assemblies. (See right Fig.)
6. Reassemble parts in reverse order.

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33.2.4.3 DRAIN OF HYDRAULIC PILOT CONTROL UNIT

(1) When removing the retaining plate, the
throttle kit or the shuttle valve kit, it is
necessary to drain the pilot unit.
(2) Reassemble the pilot unit control completely.
(3) Install the pilot unit control in the machine.
(4) Slightly unscrew the check valve plug
using a 4mm socket wrench. (See right
Fig.)
(5) Switch on the machine.
(6) Operate gently the pedal until the bubbles
disappear.
(7) Tighten the check valve plug.
-Torque: 5 N-m (3.7 lbf-ft)
(8) Repeat the operation for the other check
valve plug.

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33.2.5 SWING MOTOR UNIT

33.2.5.1 CONSTRUCTION 
(1) Swing motor

Swing motor

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Tightening Tightening
torque No. NAME Q'TY torque No. NAME Q'TY
N-m (lbf-ft) N-m (lbf-ft)
177 (130) 051 Relief valve; M33-P1.5 2 69 (51) 400 Anti-reaction valve; 2
M22-P1.5
051-1 O-ring; 1B G30 2 400-1 O-ring; 1B P20 2
052 Anti-reaction valve sub 1 400-2 Backup ring 2
100 Casing for anti-reaction 1 431 (318) 401 Socket bolt; M20X45 4
valve
101 Drive shaft 1 443 Roller bearing 1
111 Cylinder 1 444 Roller bearing 1
114 Spring plate 1 451 Pin 2
121 Piston 9 539 (398) 469 ROMH plug; M36-P1.5 2
122 Shoe 9 472 O-ring; W1516,WG44 1
123 Set plate 1 488 O-ring; 1B P34 2
124 Shoe plate 1 491 Oil seal 1
131 Valve plate 1 702 Brake piston 1
36 (27) 151 Plug; PF1/4 2 706 O-ring; W1516,WG42 1
161 O-ring; 1B P11 2 707 O-ring; W1516,WG45 1
162 O-ring; 1B P12 2 712 Brake spring 14
163 O-ring; 1B P6 2 742 Friction plate 3
29 (21) 171 Socket bolt; M8X55 4 743 Separator plate 4
301 Casing 1 2.7 (2.0) 984 Plug; PF1/2 1
303 Valve casing 1 5.6 (4.1) 985 Plug; PF1 1
351 Plunger 2 0.9 (0.66) 986 Plug; PF1/4 1
355 Spring 2 98 (72) 994 Plug; PT3/4 1
390 Name plate 1
391 Rivet 2

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(2) Swing reduction unit



Sectional view of swing reduction unit

Tightening torque Tightening torque

No. Parts Q'TY No. Parts Q'TY
N-m (lbf-ft) N-m (lbf-ft)
1 Pinion 1 20 Plate 1
2 Shaft 1 21 Ring 1
3 #1 Sungear 1 22 Thrust washer 6
4 #1 Planetary pinion 3 23 Thrust washer 8
5 #1 Spider assy 1 24 Snapring 1
6 #2 Sungear 1 25 Snapring 3
7 #2 Planetary pinion 4 26 Spring pin 4
8 Ring gear 1 539±54 (398±40)*1 27 Capscrew ; M20X200 12
9 #2 Spider assy 1 28 Grease fitting 1
10 Shaft 4 29 Relief fitting 1
11 Needle bearing 11 69.1±4.4 (51±3)*2 30 Tube 1
12 Roller bearing 1 69.1±4.4 (51±3)*2 31 Elbow 1
13 Roller bearing 1 69.1±4.4 (51±3)*2 32 Plug 1
14 Oil seal 1 33 Cap 2
15 Housing 1 279±30 (206±22)*1 34 Capscrew 3
16 Oil seal 1 35 Shim ; t=0.1 1
17 Sleeve 1 36 Shim ; t=0.2 1
18 Sleeve 1 37 Shim ; t=0.3 1
19 Plate 1 38 Shim ; t=0.5 1

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33.2.5.2 DISASSEMBLY AND ASSEMBLY OF SWING MOTOR

33.2.5.2.1 Tools

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33.2.5.2.2 Disassembly
(1) General cautions
1. Hydraulic components are precision products and have small clearance. Therefore, assemble and

disassemble in a less dusty clean place. Use clean tools and cleaning oil and handle
components with full care.
2. If a component is removed from the main body, clean the area around the ports thoroughly and
plug them up so no dust and water do not enter. When fitting them back to the body, do not
remove the plugs till piping is completed.
3. Study the structural drawing before the work begins and prepare necessary parts according to your
purpose and the scope of work. Seals and O-rings once removed can not be used again.
Some parts can not be supplied as single parts and available only in sub assy. Prepare such
parts according to the parts manual.
4. The piston and the cylinder block are shop fitted when new. If you intend to reuse them, put a
matching mark on the piston and the cylinder block.

(2) Disassembly procedure

The figures in parentheses after part names in this manual represent those item numbers in Fig."Swing
motor".

1. Draining oil
Remove the drain plug and drain hydraulic
oil from casing (301).
2. Preparation for removing the valve casing
Fix the motor on a work bench so the
drive shaft (101) end comes down. On
that occasion, put a matching mark on the
mating parts of casing (301) and valve
casing (303).
-Choose a clean place, and lay with a
rubber sheet or a cloth on a work bench.
Handle the valve casing with care so parts
do not have dents.

Removing valve casing (303)

3. Loosen relief valve (051) and separate it

from valve casing (303).
Tools: Spanner: 41 mm
4. Loosen anti-reaction valve sub assy (052)
and remove from valve casing (303). (See
above Fig.)
Tools: Allen wrench: 6 mm
5. Separate ROMH plug (469) from valve
casing (303) and draw out spring (355) and
plunger (351).
Tools: Allen wrench: 17 mm

Removing relief valve (051), anti-reactionvalve

(052), anti-cavitation plunger (351) and valve
casing (303)

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6. Loosen socket bolt (401) and separate

valve casing (303) from casing (301). If
the socket bolt (401) are loosened, the
valve casing floats off casing (301) by the
force of brake spring (712).
Then separate valve plate (131) from valve
casing (303).
Tools: Allen wrench: 17 mm
7. Draw out brake spring (712) from brake
piston (702).
Removing brake piston (702)

8. Put the claw of the brake piston removing

jig in the concaved part of brake piston
(702).
Tighten 2 bolts of jig simultaneously, and
draw out the brake piston (702) with the
jig, from the casing.
9. Lay the motor on its side again and draw
out cylinder block (111) from drive shaft
(101). Then draw out piston (121), set plate
(123), spring (114) and shoe plate (124).

Drawing cylider block (111), piston sub assy,

friction plate (742) and separator plate

Handle the parts with care so as not to score the sliding surfaces of cylinder block (111) and shoe
(122).

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10. Draw out friction plate (742) and separator

plate (743) from casing (301).
11. Draw out drive shaft (101) from casing

(301), while lightly tapping the side face of
valve casing (303) in drive shaft (101),
using a plastic mallet.

-Do the following work as required.

Removing drive shaft (101)

a. Drawing the inner race of roller bearing

(443) from drive shaft (101), using a press.

-Do not reuse the removed bearing.

b. Drawing out the outer race of roller
bearing (443) from casing (301), by lightly
tapping the steel rod from the oil seal (491)
housing side.
(Do not reuse the bearing.)
c. Separate the outer race of roller bearing
(444) from valve casing (303), using a slide
hammer bearing puller. Removing inner race of roller bearing (443)

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33.2.5.2.3 Assembly
(1) General precautions
1. Repair those parts damaged after disassembly and prepare replacement parts beforehands.
2. Clean all parts thoroughly in cleaning oil and dry them with jet air.
3. Always coat the moving parts with clean hydraulic oil, before assembly.
4. Replace such seals as O-ring and oil seal in principle.
5. Tighten socket bolts and plugs to specified torques, using a torque wrench.

(2) Assembly procedure

The figures in parentheses after part names in
this manual represent those item numbers in
the Fig."Swing motor".

1. Preparation for assembly

Place casing (301) on a proper bench so
its valve casing (303) faces upward.

-This operation is necessary only when the

roller bearing is removed.
2. Shrinkage fit the inner race of roller bearing
(443) into drive shaft (101).

Assembling the inner race of bearings (443),

(444)

3. Shrinkage fit the inner race of roller bearing

(444) to drive shaft (101).

-This operation is necessary only when the

oil seal is removed.
Fit oil seal (491) to casing (301). On that
occasion, coat the lip of the oil seal with
grease and check the direction of it,
before fixing it.
4. Assemble the outer race of roller bearing
(443) into casing (301), by lightly tapping
the steel rod.
5. Attach drive shaft (101) to casing (301).
Fitting oil seal (491), outer race of roller
bearing (443), and drive shaft (101)

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6. Place casing (301) as shown in Right Fig.

and insert shoe plate (124).
On that occasion, the shoe plate does not

come off if it is coated with grease.

Inserting shoe plate (124)

7. Set the set plate (123) and spring (114),

then set piston sub (121, 122) assy.
8. Assemble piston sub assy (121, 122) fixed
in retainer plate (123) into cylinder (111).
Match it to the spline of drive shaft (101)
and insert it in place.

Inserting cylinder assy

9. Replace casing (301) with oil seal (491)

facing downward and assemble separator
plate (743) and friction plate (742) into
casing (301), in that order.
Assemble four separator plates and three
friction plates.

Installing of separator plate (743), friction

plate (742).

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Assemble the same phases of four slits in the gears of friction plate (742).
Assemble four slits in the four claws of separator plate (743) in the position of Fig."Installing of
separator plate (743),friction plate (742)".

10. Fit O-rings (706), (707) to casing (301). In

that case, if the O-rings are coated with
grease, they are hard to tear off when
brake piston (702) is inserted.
11. Assemble brake piston (702) into casing
(301).
12. Assemble brake spring (712) into brake
piston (702). In that case, make sure that a
spring is placed securely in the spot faced
part of the brake piston.
-This operation is necessary only where
roller bearing (444) is removed. Assembling brake piston

13. Insert the outer race of roller bearing (444) into valve casing (303), while lightly tapping the steel
rod placed on the outer race, using a hammer.
14. Assemble valve plate (131) into valve casing (303) and fit O-ring (472) in it.
15. Install valve casing (303) to casing (301) and fasten them with socket bolts (401).
Tools: Allen wrench: 17 mm,
Tightening torque: 431 N-m (320 lbf-ft)
16. Fit plunger (351) and spring (355) to valve casing (303). Then tighten ROMH plug (469) fitted
with O-ring (488) against valve casing (303).
Tools: Allen wrench: 17 mm,
Tightening torque: 539 N-m (398 lbf-ft)
17. Fit relief valve (051) to valve casing (303).
Tools: Spanner: 41 mm,
Tightening torque: 177 N-m (130 lbf-ft)
18. Fit anti-reaction sub assy (052) to valve casing (303).
Tools: Allen wrench: 6 mm,
Tightening torque: 29 N-m (22 lbf-ft)

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33.2.5.3 DISASSEMBLY AND ASSEMBLY OF SWING REDUCTION UNIT

33.2.5.3.1 Tools


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Code Tool name Remarks

i Snap ring plier For shaft
j Torque wrench 140 N-m (100 lbf-ft) class
k Plastic hammer (Wooden mallet)
m Press 30 ton (66150 lb) class
n Flat-bladed screw driver
p General tools Allen wrench, Steel bar
Thread sealant Three Bond #1360K
q
Sealant Loctite #515

33.2.5.3.2 Disassembly
The numbers in parentheses correspond to the ones in construction drawings Fig."Swing motor".

(1) Preparation
1. Before disassembly, clean the outside of the reduction unit thoroughly and check for no damage
and scoring.
2. Drain gear oil from the reduction unit.
3. Disconnect the drain tube.
4. Matching Mark
To facilitate the reassembly of the unit, put matching mark on the joining parts of the housing
before disassembly.

(2) Disassembling swing motor from reduction unit

1. Preparation for disassembly
Place the reduction unit assy on a stable
work bench as shown in Right Fig.
remove plug (32), drain out oil and put a
matching mark on the matching surface of
the figure on the right.
2. Removing swing motor assy
Loosen all socket bolt (27) (M20). Attach
eye bolts (M12) in the lifting bolt holes in
the top surface of the swing motor and lift
the assy by crane.
If it is hard to remove the swing motor
assy from the reduction unit, float it by Removing swing motor assy
inserting a flat-blade screwdriver in the
groove of the flange.
Tools: Allen wrench: 17 mm

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(3) Disassembling reduction unit

1. Remove #1 sun gear (3).
2. Removing #1 spider assy (5).

The spider assy (5) [consisting of thrust
washer (22), #1 pinion (4), needle bearing
(11) and snap ring (25)] can be removed
from the spline easily if it is lifted up in
that condition.

Removing #1 sun gear and #1 spider assy

3. Removing ring gear (8)

Attach eye bolts (M16) to the top surface
of ring gear (8) and lift the ring gear
lightly by a wire sling.
Put a flat-blade screwdriver (n) into the
matching surface of ring gear (8) and
housing (15) and remove ring gear (8) by
lightly tapping the outer circumference of
the ring gear with a plastic mallet (k).

Removing ring gear (8)

4. Remove #2 sun gear and #2 spider assy.

Draw out #2 sun gear (6) and remove the
#2 spider assy.
Regarding the disassembly of the #2 assy,
refer to par. (4) which will come up later.

Removing #2 spider assy

-Particularly if no failure is found, the further

disassembly (under condition shown in Right
Fig.) is not allowed. Check on parts for possible
failure according to the inspection procedure
shown in item 33.2.5.4.2 separately in this
condition. And we recommend that the pinion
shaft and housing assy are replaced together
as one set. But if it is unavoidably necessary to
replace a part of them, follow the procedure
shown below.
-If no failure is found in this step, the
disassembly later is not required.

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5. Remove pinion (1)

Place housing (reduction) (15) upwards.
Loosen 3 capscrews (M16X40) and
remove plate (20). Attach eyebolt (M8) to
pinion (1) and hoist pinion (1).
Tools: Socket: 24mm

-When oil seal (16) is separated from

housing (15), oil seal (16) and is pinion
(1) are removed together.

6. Remove plate (19)

Remove ring (21) from groove of housing
(15) using flat blade driver (n).
And remove plate (19).

Removing plate (19)

7. Pulling out shaft

Pull shaft (2), sleeve (18) and spherical
bearing (lower) (13) out by means of
press while supporting housing (15) as
shown in the figure.

-Spherical bearing (upper) (12) and oil seal

(14) are left in the housing.

Pulling out shaft (2)

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8. Removing spherical bearing (lower) (13)

Pull sleeve (18) and spherical bearing
(lower) (13) out by means of jigs (b) while

supporting pinion shaft assy as shown in
the figure.
Press force : 30t
-Do not use the removed bearing.

Removing spherical bearing (lower) (11)

9. Removing spherical bearing (upper)

Set housing (15) as shown in the figure,
insert jig (c) between bearing (12) and oil
seal (14) and remove bearing (12) by
striking from the upper side.
10. Remove oil seal (14) from housing (15).

-Do not use the removed oil seal and

bearing.

Removing spherical bearing (upper) (12) and

oil seal (14)

(4) Disassembling spider assy

(1) Disassembling #1 spider assy

a. Remove retaining ring (25) with a plier (i).

b. Remove thrust washers (22), pinion (4)
needle bearing (11).

Disassembling #1 spider assy

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-The shaft attached to spider assy (5) is caulked. When replacing parts, replace the spider assy as a
set.
-Pinions (4) can not be replaced singly. Replace them it in a set of three.

(2) Disassembling #2 spider assy

a. Drive spring pin (26) into shaft (10) using

steel bar 8 to 9 in diameter.
b. Draw out shaft (10) from spider (9) and
remove thrust washer (23), pinion (7) and
needle bearing (11).

Disassembling #2 spider assy

Pinions (7) can not be replaced singly. Replace them it in a set of four.

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33.2.5.3.3 Assembly
(1) Preparation
1. Sufficiently clean every part with wash oil and dry it with compressed air.

2. Check on every part for failure.

(2) Assembling pinion (1), shaft (2)

1. Attach oil seal (16) to pinion (1) by means
of jig (d).

Attaching oil seal (16)

2. Applying gear oil

Apply gear oil to the perimeter of axis of shaft (2)
lightly to prevent seizure.

3. Fitting spherical bearing (lower)

Seal sufficient grease in spherical bearing
(lower) (13) and after inserting sleeve (18),
press fit it in shaft (2) by means of jig (e).
Press force : 4~5t

-Since the bearing is formed with a partition

at the center section, seal grease in it from
both sides.

Fitting spherical bearing (lower)

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4. Apply sufficient grease to the pinion shaft

assy.
Grease : Lithium extreme-pressure grease
(SHELL Albania EP2 or equivalent)
: 1.7kg (3.75 lbf)

Apply grease

(3) Placing shaft assy in

1. Place housing (15) on level bench.
2. Attach eye bolt to screw (M10) at the axis
end of shaft assy, and perpendicularly hang
up pinion shaft assy and place it in the
housing.

-Horizontally orient the outer race of

spherical bearing and insert it in by striking
lightly.
If the outer race is tilted, it is hard to insert
even if striking. Then do not force to
insert it in, but take it away once and
horizontally orient the outer race twice and
insert it in again.

Placing pinion shaft assy in

3. Assembling plate (19)

Place plate (19) and attach ring into groove
of housing, and fix plate.

Assembling plate (19)

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4. Installing pinion (1)

Attach eyebolt (M18) to pinion (1), and
hoist it, then insert into shaft (2).

Install pinion (1) securely by hammering.
Attach plate (20) to shaft (2) by tightening
3 capscrews (34) (M16X40), and install it
on pinion (1).
Tools: Socket: 24mm
Tightening torque : 279N-m (206 lbf-ft)
(Apply Three Bond #1360K)

Installing pinion (1)

5. Set housing assy so that the pinion directs

downward.
6. Fit oil seal (14) in housing (15) by means
of jig (f).

-Apply Loctite #515 to the perimeter of oil

seal.
-Fill one third (1/3) of the space of the
groove-shaped section provided on the oil
seal (12) lip with grease.
-Insert it horizontally giving attention to the
lip of oil seal so as not be damaged.

7. Press fit spherical bearing (upper) (12) in

shaft (2) and housing (15) at the same
time by means of jig (g).
In this case insert sleeve (17) in advance.

Spherical bearing (upper) Press-fitting

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(4) Assembling spider assy

1. Assembling #1 spider assy

a. Coat the bore surface of pinion (4) with

grease. Put pinion (4) on thrust washer (22)
and assemble needle bearing (11) into the
bore surface

Assembling #1 spider assy

b. Fit thrust washers (22) and pinion (4) as in below Fig. and fit snap ring (25) by means of pliers
(i).

Fixing snap ring

Fix the snap ring with the sharp edge on the motor side (top side in the position of above Fig.).

2. Assembling #2 Spider assy

a. Coat the bore surface of pinion (7) with

grease. Put pinion (7) on thrust washer (23)
and fit needle bearing (11) to the bore
surface.
b. Fit thrust washer (23) and pinion (7) as in
Right Fig. insert shaft (10) into spider (9)
and drive spring pin (26).

Assembling #2 spider assy

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Insert shaft (10) into spider (9) so spring pin hole (26) is aligned.
Inthis case direct the oil hole of shaft (10) to outside of spider assembly.

(5) Installing #2 spider assy

Insert #2 spider assy in spline axis of shaft (2).

Assembling #2 spider assy

(6) Installing #2 sun gear (3)

Install #2 sun gear (3) directing the spline
upward.

Installing #2 sun gear (3)

(7) Installing ring gear (8)

Apply a thin film of sealant Loctite #515 to the
matching surface of housing (15) and ring gear
(8) and assemble them, aligning the gear teeth
and according to the matching marks given.

Installing ring gear (8)

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(8) Installing #1 spider assy

1. Mesh the #1 spider assy with ring gear
(8) and set them in place.
2. Mesh #1 sun gear (3) with #1 pinion (4)
and set them in place.

Installing #1 spider assy

(9) Fit drain tube (30) and plug (32).

Tools: Allen wrench: 10 mm

(10) Filling Lube Oil

Fill in 7.4L (2.0gal) of gear oil SAE90 (API Service Grade GL-4).

(11) Installing swing motor assy

Attach eye bolts (M12) in the tapped holes of
the swing motor and put a wire sling in them
Coat the matching surface of ring gear (8) with
sealant Loctite #515, insert the spline joint of
the swing motor and match the matching marks.
Coat socket bolts (27) with sealant Three-Bond
1360K and fasten them.
Tools: Allen wrench:17 mm,
Tightening torque: 539 N-m (398 lbf-ft)

Installing swing motor assy

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33.2.5.4 MAINTENANCE STANDARDS

33.2.5.4.1 Swing motor
(1) Replacement standards for parts

The following are the standards to determine whether or not parts may be reused from values taken at
disassembly. These are only general standards and in case the motor displays poor performance or
parts shows extreme damage and discoloration before disassembly, it is most important to determine
how many parts should be replaced, depending upon the purpose of disassembly and the remaining
service life of the motor that the user expects.

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(2) Standard for correcting sliding surfaces

If the surface roughness of the sliding surface of parts exceeds the following standard, correct it or
replace the parts.

Standard for correcting sliding surfaces

Surface roughness requiring
Name of parts Standard surface roughness
correction
Shoe 0.8-Z (Ra=0.2) (lapping) 3-Z (Ra=0.8)
Shoe plate 0.4-Z (Ra=0.1) (lapping) 3-Z (Ra=0.8)
Cylinder 1.6-Z (Ra=0.4) (lapping) 12.5-Z (Ra=3.2)
Valve plate 0.8-Z (Ra=0.2) (lapping) 6.3-Z (Ra=1.6)

࡮ Lap each sliding surface to a standard roughness level or finer.

࡮ If the spherical sliding surface of the spring (114) and cylinder (111) are roughened, replace parts
in pairs.

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33.2.5.4.2 Swing reduction gear

(1) Inspection at disassembly
1. Spacer and thrust washer

a. Inspect that the parts are not seized or worn abnormally or unevenly.
b. Inspect and measure the parts to see that the wear does not exceed the allowable values.
2. Gears
a. Inspect that the gear teeth do not show pitting and seizure.
b. Inspect by dye penetrant examination that the bottom of the teeth does not show cracks.

3. Bearing
Turn the bearing and check that it does not develop abnormal sound, catching and other faults.
Do not reuse spherical bearing
4. O-rings and oil seals
Do not reuse O-rings and oil seals; always replace them with new ones at reassembly.

(2) Inspection after assembly

1. Operation
Check to see that #1 sun gear (3) is not faulty when turned by hand.
2. Checking for oil leak and oil condition
Check for oil leak.
Check the oil level by level gauge and confirm that the oil is not dirty. If the oil is short, replenish
gear oil SAE90 (API Service Grade GL-4).

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(3) Maintenance standards

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33.2.5.5 TROUBLESHOOTING
33.2.5.5.1 Swing motor
(1) Hydraulic motor does not rotate. 
Trouble Cause Remedy
Pressure does 1. 1.
not rise. Relief valve pressure in circuit is not Set to correct value.
adjusted correctly.
2. 2.
Malfunction of relief valve.
2-1. 2-1.
Sticking plunger. Correct the stuck areas or replace the plunger.
2-2. 2-2.
Orifice on plunger is clogged. Disassemble and clean.
3. 3.
Plunger seat is faulty. Check the seat surface and replace the
plunger if scored.
4. 4.
Anti-reaction valve seat is faulty. Replace the anti-reaction valve cartridge or
block.
Pressure rises 1. 1.
Overload. Eliminate overload.
2. 2.
Moving parts are seized. Inspect and repair piston, shoe and cylinder
valve plate.
3. 3.
Brake release pressure is not working on Check circuit and correct it.
the motor
4. 4.
Brake piston is stuck. Disassemble and check.
5. 5.
Spool for releasing brake is stuck. Disassemble and check.
6. 6.
Friction plate is seized. Disassemble, check and repair.

(2) Rotating direction is reverse.

Trouble Cause Remedy
Rotating direction 1. Motor's assembling direction is reversed. 1. Assemble correctly.
is reverse. 2. Piping inlets and outlets are reversed. 2. Pipe correctly.

(3) Revolution does not rise to set value.

Trouble Cause Remedy
Revolution does 1. 1.
not rise to set Oil inflow is deficient. Check pump's delivery rate and circuits to
value motor.
2. 2.
Oil leaks are excessive due to high Lower oil temperature.
temperature.
3. 3.
Sliding surfaces are worn or damaged. Replace.

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(4) Brake torque is insufficient.

Trouble Cause Remedy
Brake torque 1. 1.
isinsufficient. Friction plate is worn. Disassemble and check. Replace if wear is
beyond standard value.
2. Brake piston is stuck. 2. Disassemble and check.
3. Brake release pressure is not released. 3. Check and correct circuit.
4. Break release spool is stuck. 4. Disassemble and check.
5. 5.
Spline of friction plate is damaged. Disassemble and check. Replace damaged
part.

(5) The swing motor drifts much.

Check the drain rate of the hydraulic motor. If it is less than 4 L/min (1.1 gal/min), you should think
that the motor is not faulty.

Trouble Cause Remedy

The swing 1. 1.
motor drifts Relief valve malfunctions. Replace.
much when it is Same as (1). Same as (1).
actuated by 2. 2.
external Plunger seat is faulty. Replace.
torques. (e.g. 3. 3.
Machine is on a Seat of the anti-reaction valve is no good. Replace the anti-reaction valve cartridge or
slope.) block.

(6) Oil leaks

1) Oil leak from oil seal
Trouble Cause Remedy
Oil leaks from oil 1. 1.
seal Lip of seal catches contaminant and Replace oil seal.
damaged.
2. 2.
Shaft is damaged or worn. Shift the lip and shaft positions or replace oil
seal.
3. 3.
Casing inner pressure has risen Repair drain piping if clogged up.
abnormally high, with the result that lip of
oil seal is flipped.
4. 4.
Shaft is rusted. Disassemble and correct.

2) Oil leak from matching surface

Trouble Cause Remedy
Oil leak from 1. O-ring is missing. 1. Set O-ring correctly and assemble it.
matching surface 2. O-ring has a scratch. 2. Replace.
3. Seal surface has a scratch. 3. Disassemble and correct.
4. Bolt is loose or damaged. 4. Tighten to specified torque or replace.

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33.2.5.5.2 Reduction unit



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33.2.6 SWIVEL JOINT

33.2.6.1 CONSTRUCTION VIEW

Construction of swivel joint

No. Part name Q'TY No. Part name Q'TY

1 Body 1 7 O-ring (G95 1A) 1
2 Stem 1 8 Socket bolt (M8X20) 2
3 Thrust plate 1 9 Socket bolt (M8X30) 3
4 Cover 1 12 Plug 1
5 Seal 5 13 O-ring (P80) 2
6 Seal assy 1

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33.2.6.2 DISASSEMBLY AND ASSEMBLY

33.2.6.2.1 Tools


33.2.6.2.2 Apparatus
(1) Hoist or crane
The lifting device should be capable of lifting the swivel joint assy.
(2) Work bench
The work bench should have an area of 1.2mX1.5m (4ftX5ft).
(3) Others
Also prepare cloth, wooden block and oil pan.

33.2.6.2.3 Cleaning outside

Clean the swivel joint to be free from dirt and dust, using steam and cleaning oil.

࡮ Keep all ports plugged up while cleaning.

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33.2.6.2.4 Disassembly
The part numbers used in this disassembly
procedure correspond to those of a
construction drawing in Fig."Construction of
swivel joint".

(1) Removing cover

1. Mark cover (4) and body (1) with matching
marks for convenient reassembly.
2. Place a V-block on a work bench, place a
swivel joint set on the side, fix it and
loosen socket bolt (9) by means of a pipe
and wrench. Alternately, the swivel joint
may be fixed by holding stem (2) in a vise.
Tools: Allen wrench:6 mm

Removing cover (4)

3. Remove cover (4) from body (1) and draw

out O-ring (7) from cover (4).

Removing O-ring (7)

(2) Removing thrust plate

Loosen socket bolt (8) fastening thrust plate (3),
in the same manner as the removing of the
above-mentioned cover.
Tools: Allen wrench:6 mm

Removing thrust plate (3)

When removing thrust plate (3) by fixing body (1), support stem (2) so it may not fall down.

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(3) Removing stem

Place body (1) on a V-block. Put a wooden
block against stem (2) via the body so about

half of the stem is covered by the wooden
block and knock it out using a mallet.
By hitting out the stem over about 1/2 from
the body, it can be easily pulled out by hand.
Stem weight: 10.5 kg (23 lbs)

Drawing out stem (2)

(4) Removing sealing parts

1. Remove rings (13) of seal assemblies (6)
and (5) with spatula (f).

Removing O-ring (13)

Pay attention to the body (1) not to be damaged by the top edge of spatula (f).

2. Pierce slipper ring of seal assemblies (6)

and (5) with pin (e) and remove them
from the seal groove. Right Fig. shows only
one pin, but use two pins to remove it
securely.

Removing out seal assy (5)(6)

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33.2.6.2.5 Assembly
Prior to assembly, clean each parts (excluding the O-ring and seal), and arrange in the sequence of
assembly.
Apply grease on the groove of seal to be installed on seal assembly (6) and O-ring (13).

(1) Assembling seals to body

1. Apply hydraulic oil to O-ring (13) thinly and insert it in O-ring groove.
Check the twist of O-ring

2. Slipper ring is assembled, after first

inserting the backup ring, by
slightly-distorting the shape as shown in
Right Fig. Also after inserting all of the
seals, be certain that these are installed in
the seal groove by use of the spatula.
3. Assemble seal (5) by the same procedure
above mentioned.
Inserting slipper ring (6)

Remove grease, hydraulic oil and vaseline from the groove of seal.
And insert seal (5).
Seals (5) have no back-up ring.

(2) Assembling stem

Lightly coat the outer circumference of stem
(2) and the inner surface of body (1) with
grease or vaseline and slowly insert stem (2)
into body (1).

Inserting stem (2)

-If stem (2) is pressed in too fast, the seal may be damaged. Do it slowly.
-The clearance between body (1) and stem (2) is about 0.1mm (0.004in). Push stem straight along
the shaft center.

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(3) Assembling thrust plate

1. While holding stem (2) and body (1), match
the hole of thrust plate (3) and the stem

(2) hole.
2. Next, after removing any oil from the thread
of socket bolt (8), coat it with Loctite #242
and tighten to stem (2).
Tools: Allen wrench:6 mm,
Tightening torque: 30.4 N-m (22 lbf-ft)
Tightening socket bolt (8)

(4) Assembling cover

After installing O-ring (7) to cover (4) and
aligning the matching marks of the cover (4)
and body (1), coat socket bolt (9) with Loctite
#242 and tighten it which will then complete
assembly.
Tools: Allen wrench:6 mm,
Tightening torque : 30.4 N-m (22 lbf-ft)

Tightening socket bolt (9)

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33.2.6.3 MAINTENANCE STANDARDS

33.2.6.3.1 Inspection procedure and remedy
Interval Check Item Checking Procedure Remedy
Seal for oil leakage Replace O-ring or dust seal , if any
2,000hr Check oil leakage outside
outside oil leakage can be found.
4,000hr In Replace all sealing parts such as
principle, All sealing parts slipper seal with back-up ring and
disassemble O-ring.
and check
Check abnormal wear, scoringor
regardless of Repair or replace referring to their
All sliding parts corrosion caused by
oil leakage or limit of service.
foreignmatters or seizure.
not.
When Check them for seizure, Repair or replace referring to their
disassembled All parts foreignmatters, abnormal wear, limit of service. O-rings and dust seal
for repair anddefect of seals. should be replaced.

33.2.6.3.2 Service limit of the parts

Parts Maintenance Standards Remedy
Sliding surface with Plating worn or peeled due to seizure or
Replace
sealing sections contamination.
1.
Worn abnormally or damaged more than 0.1
Sliding surface Replace
mm (0.004 in) in depth due to seizure or
between body and
contamination.
stem other than
sealing sections 2.
Smooth with oilstone.
Body, Stem Damaged less than 0.1 mm (0.004 in) in depth.

1.
Replace
Worn more than 0.5 mm (0.02 in) or abnormality.
2.
Sliding surface with Smooth
Worn less than 0.5 mm (0.02 in).
thrust plate
3.
Damage due to seizure or contamination Smooth
repairable within wear limit 0.5 mm (0.02 in).
1.
Replace
Worn more than 0.5 mm (0.02 in) or abnormality.
2.
Sliding surface with Smooth
Cover Worn less than 0.5 mm (0.02 in).
thrust plate
3.
Damage due to seizure or contamination Smooth
repairable within wear limit 0.5 mm (0.02 in).

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33.2.6.3.3 Inspection after assembly

After completion of assembly, inspection for oil
leakage, pressure resistance, etc., using a
device as shown in Right Fig.

(1) High pressure port (A,B,C,D and F port)

Install a directional valve and pressure
gauge to the stem side port and body
side port respectively, and while watching
the pressure gauge (for high pressure)
installed on the body side and also by
regulating high pressure relief valve (7),
gradually increase the pressure and when
the pressure has reached 1.5 times the
maximum working pressure, close stop
valve (3) and lock in the hydraulic oil in
the swivel. Keep stop valve (6) on the low
pressure relief valve side closed at this
time.
Check that it is free from looseness,
deformation, breakage, etc. under three
minutes pressurizing.
And, the oil leakage must be checked for
the first 1 minute, and if there be a
pressure drop for any reason, the pressure
drop should be in 10% of the trapped Hydraulic circuit for inspection equipment
pressure.
This checking must be carried out for every
circuit.

(2) Low pressure port (E port)

Similar to the high pressure port, install a
directional valve and pressure gauge on
each port of the stem side and body side.
Open stop valve (6) on the side of low
pressure relief valve (5) and while
watching the pressure gauge (for low
pressure) connected to the body side and
also by regulating low pressure relief valve
(5), gradually increase the pressure and
check for outside leakage with a color
check at a pressure of 0.49 MPa (71 psi).

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33.2.6.3.4 TROUBLESHOOTING
Trouble Cause Remedy
1. Defective O-ring & seal Replace all seals. 
External leakage of hydraulic oil
2. 1) 1)
Internal leakage of hydraulic oil Defective slipper seal Replace all seals.
2) 2)
Sliding face worn excessively Replace assy.
3. 1) 1)
Swivel stem seized Stem and body seized Grind and hone.
Replace assy, if stem and body are too
loose and causing oil leakage.
2) 2)
Inappropriate swivel stopper Reinstall
bracket Secure 2 to 3 mm (0.08 to 0.12 in)
allowance for bolt stopper.
4. Socket bolt tightened Retighten.
Loose swivel stem and cover insufficiently.

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 㨇34. TRAVEL SYSTEM㨉


34. TRAVEL SYSTEM
TABLE OF CONTENTS

34.1 REMOVING AND INSTALLING ääääääääääääääääääääääääääääää34-3

34.1.1 TRAVEL SYSTEM ääääääääääääääääääääääääääääääääää34-3
34.1.2 CRAWLER äääääääääääääääääääääääääääääääääääää34-3
34.1.3 UPPER ROLLER ääääääääääääääääääääääääääääääääää34-8
34.1.4 LOWER ROLLER ääääääääääääääääääääääääääääääääää34-15
34.1.5 FRONT IDLER (IDLER ADJUSTER ASSY) ääääääääääääääääääääää34-23
34.1.6 SPROCKET äääääääääääääääääääääääääääääääääääää34-29
34.1.7 TRAVEL MOTOR ääääääääääääääääääääääääääääääääää34-32
34.1.8 SWING BEARING ääääääääääääääääääääääääääääääääää34-35
34.2 DISASSEMBLING AND ASSEMBLING OF EQUIPMENT ääääääääääääääääää34-39
34.2.1 TRAVEL MOTOR ääääääääääääääääääääääääääääääääää34-39
34.2.2 CONSTRUCTION OF REDUCTION UNIT äääääääääääääääääääääää34-41
34.2.3 TRAVEL MOTOR ASSEMBLY ääääääääääääääääääääääääääää34-42
34.2.4 TRAVEL MOTOR ASSEMBLY ääääääääääääääääääääääääääää34-51
34.2.5 TRAVEL MOTOR ääääääääääääääääääääääääääääääääää34-56
34.2.6 TRAVEL MOTOR TROUBLESHOOTING ääääääääääääääääääääääää34-59
34.2.7 REDUCTION UNIT DISASSEMBLY ääääääääääääääääääääääääää34-62
34.2.8 ASSEMBLING ääääääääääääääääääääääääääääääääääää34-68
34.2.9 MAINTENANCE STANDARD äääääääääääääääääääääääääääää34-74

Book Code No. S5LC34E0

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Issue Date of Issue Applicable Machines Remarks

SK330-9 : LC12-15001~ S5LC3432E01
First Edition June, 2013
SK350LC-9 : YC12-10001~ (NA)
SK330-9 : LC12-15001~ S5LC3432E02
Revision December, 2013
SK350(N)LC-9 : YC12-10002~ (NA / EUR)
S5LC3432E03
July, 2014 SK350LC-9E : YC13-13001~
(NA)

PREFACE
(1) This Manual describes all the procedures from removing to attaching, arranging them by item.
(2) This Manual consists of first part. Removing and attaching, and sequel. Disassembling and
assembling.
(3) The removing and attaching can be performed in the procedure specified in Table of Contents, but
in view of actual repairing or time saving some process can be omitted.
(4) The removing and attaching procedure does not completely cover all possible situations because of
differences of field condition and defective section.
(5) Please be aware that the procedure to be followed must be determined according to the above
conditions.
When disassembly and assembly are required, select the necessary section, itemize the work
contents with good understanding, then starts working.

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 㨇34. TRAVEL SYSTEM㨉

34.1 REMOVING AND INSTALLING

34.1.1 TRAVEL SYSTEM



Designation and location of undercarriage

34.1.2 CRAWLER
34.1.2.1 REMOVING CRAWLER
(1) Position the machine to remove crawler.
(2) Pushing out master pin.
1.
Find the master pin and place it in its
removing/fixing position in right Fig..
2.
Loosen the grease nipple and slacken crawler.
Tools: Socket: 19 mm
Crawler removing position

-When loosening the grease nipple of the adjuster, do not loosen it more than one turn.
-Where grease does not come out well, move the machine back and forth. The over loosening of
grease nipple may cause it to jump out incurring danger of injury. So be careful not to over loosen
the grease nipple.

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3.
Pushing out master pin
Remove stopper pin at the end of the master
pin, hold a tool against the master pin, and hit
it with a hammer.
(Refer to Fig. "Press fitting of master pin")

Removing/fixing position of master pin

When using a big hammer, wear protective goggles and a long-sleeved uniform so you do not injure
yourself by flying objects.

(3) Removing crawler

Put attachment on ground so that weight is
not loaded to the lower frame, and remove
track link assy rotating sprocket.

Removing crawler

Crawler end section may fall on the ground just before extending it on the ground incurring danger of
injury.
Please keep well away from the equipment.

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34.1.2.2 INSTALLING
Installing is done in the reverse order of removing.

(1) Checking crawler installation direction.

Place the track links on the ground so they
converge, facing the front idler, as shown
in the figure on the right.



Installing direction of crawler

(2) Installing crawler

1. Preparation for installation
Treat paint flaking protection with care not
to damage lower flame.
2. Winding crawler
Insert a crowbar into the master pin hole,
lift the lower frame 1 to 2cm above the
ground level by holding it by hand so the
machine body weight is not exerted on the
shoe. Retract the sprocket to help push the
back winding of the crawler. Winding crawler
(3) Preparation for press fitting master pin
1. Preparing for installation
Put square wood under the shoe plate.
2. Aligning master pin holes
Aligning master pin holes through fine
adjustment turning sprocket.

-When using a big hammer, exercise care so you are not injured by flying objects the same way as
when pushing out the master pin.
-Coat the master pin with molybdenum disulfide grease, before pressing it in.

(4) Press fitting of master pin

Apply press fitting jig on master pin, and
strike it with a mallet to press fit.

Press fitting of master pin

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(5) Set the stopper pin.

(6) Adjusting crawler tension (See right Fig.)

After installing, adjust tension of crawler.
Tools: Socket: 19 mm

Adjusting crawler tension

34.1.2.3 CONSTRUCTION

Track link assy and shoe plate

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34.1.2.4 MAINTENANCE STANDARDS



34.1.2.5 TOOLS AND JIGS

(1) Tightening tools (2) Jig

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34.1.3 UPPER ROLLER

34.1.3.1 UPPER ROLLER ASSY
UPPER ROLLER ASSY No. LC64D00003F1
ITEM NAME Q'TY REMARKS
1 ROLLER ASSY 4 24100N7035F3
2 CAPSCREW 4 M20X150
3 WASHER 8
4 NUT 4

34.1.3.2 REMOVING
(1) Preparation for removal
Remove crawler (Above mentioned).
(2) Removing upper roller (1)
1.
Remove nuts on support tightening
section, and also remove capscrew (2)
M20X150.
Tools: Socket: 30 mm

Removing upper roller

34.1.3.3 INSTALLING
Installing is done in the reverse order of
removing.

(1) Inspection
Before reassembling, check it that it
rotates smooth manually and for leakage.
(2) Installing upper roller (1)
1.
To install the upper roller, turn up nut (4)
toward the center of machine.

2.
Insert it until collar comes in contact with
support.

3.
Apply Loctite #262 on capscrew M20X150,
and tighten it to the specified torque.
Tools: Socket: 30 mm
Tightening torque: 539 N-m (400 lbf-ft)

Installing upper roller

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34.1.3.4 CONSTRUCTION



Construction of upper roller

34.1.3.5 DISASSEMBLY AND ASSEMBLY

(1) Disassembly
1. Draining out oil
Remove plug (10) and drain out oil.
Tools: Allen wrench: 6 mm
2. Removing snap ring (11)
Mount the end face inside upper roller (1)
on stand jig (f) and separate snap ring
(11), using snap ring pliers.
3. Removing cover (5)
Take off cover (5) upwards, utilizing the
screwed hole for the plug.

Construction of upper roller

4. Removing O-ring (8)

Separate O-ring (8) from cover (5).
5. Removing plate (4)
Loosen 2 socket bolts (9) and draw out
plate (4) from roller (1).
Tools: Allen wrench: 10mm
6. Removing shaft (2)
Put the extrusion jig (h) against the end
face of shaft (2) and push shaft (2) with
collar (3) for floating seal (13), using a
press or hammer.

Extruding shaft

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7. Removing floating seal (13).

(Upper roller side)
Take out floating seal (13) from roller (1).

Taking out floating seal

8. Removing floating seal (13). (Shaft side)

Remove from collar (3), floating seal (13)
that is located on the side from which shaft
(2) was disassembled.

Removing floating seal and extruding bushing

Collar (3) is press fitted into shaft (2). Therefore do not disassemble it.

9. Removing bushing (6)

Since the bushing is thin, machine it on a
lathe or scrape it off, take care so as not
to damage the bore of roller (1).
If the bushing is not worn much, mount
upper roller (1) on jig (f), insert jig (g) into
the end face of bushing (6) and push it out
with a press.

Pushing in bushing

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(2) Assembly
Assembly of the upper roller is done in the reverse order of disassembly.

1. Place upper roller (1) on the top end face of jig (f), with its floating seal setting side facing down.

2. Confirm that the outer surface of bushing

(6) is not scuffed and coat the outer
surface of the inserting side of the bushing,
with molybdenum disulfide grease. 
3. Put jig (i) into bushing (6) and press it in,
using the bore of the bushing and the
bore of the roller as guides.

Fixing floating seal

If you fail in this operation by pressing the bushing unevenly, the bushing is distorted and gets
unserviceable. In that case, do not reuse the bushing as it may develop malfunctioning after assembly.

4. Installing floating seals (13)

Two floating seals (13) make a pair.
Attach one floating seal to retainer fixed in
shaft (2), and another to the inside of
upper roller (1).

-Prior to placing floating seal (13) in, apply

engine oil lightly to seal surface.
5. Inserting shaft (2)
Coat shaft (2) with a thin film of oil and
insert it into upper roller (1).
Inserting shaft

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6. Installing plate (4)

Mount upper roller (1) on the stand jig (f)
and attach plate (4) to the end face of the
shaft with bolt (9).
Tools: Allen wrench: 10 mm,
Tightening torque: 114.7 N-m (85 lbf-ft)
7. Installing O-ring (8)
Fit O-ring (8) to the groove of cover (5).

-Apply grease to O-ring.

8. Installing cover (5)
Attach cover (5) to upper roller (1). Use a
press in this operation as a press fit is
used.
9. Installing snap ring (11)
Fix snap ring (11) into upper roller (1),
using snap ring pliers. Installing cover

10. Filling oil

Fill in 100cc (6.1cu-in) of engine oil API
grade CD #30 through the plug hole in
cover (5).
11. Installing plug (10)
Wind seal tape around plug (10) and screw
it into the plug hole of cover (4).
Tools: Allen wrench: 6mm,
Tightening torque: 23 N-m (17 lbf-ft)

-After assembling the upper roller, confirm

that oil is not leaking from it and that it
rotates smoothly by hand.

Filling oil

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34.1.3.6 MAINTENANCE STANDARD



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34.1.3.7 TOOLS AND JIGS

(1) Tightening tools

(2) Jigs

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34.1.4 LOWER ROLLER

34.1.4.1 LOWER ROLLER ASSY


Lower roller assy and track guide

34.1.4.2 REMOVAL
(1) Preparation for removal
1.
Loosen the tension of the crawler, lift up
the lower frame by the front attachment
and stop the engine in that condition.

2.
Place a safety block (wood) at the front
Preparation for removal
and back of the lower frame.

(2) Removing track guide

Remove capscrews (5) M24X52 and remove track guide (2).
Tools: Socket: 36 mm,
Weight of track guide : Approx. 40 kg (88 lbs)

Installing track guide

(3) Remove lower roller

Remove capscrews (2) and remove lower
roller (1).
Tools: Socket: 32 mm,
Weight of lower roller: Approx. 57 kg
(126 lbs)

Installing lower roller

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34.1.4.3 INSTALLATION
(1) Installation of lower roller
Coat mounting capscrews (2) with Loctite #262 and fasten all 4 capscrews temporarily. Then
tighten them to a specified torque.
Tools: Socket: 32 mm,
Tightening torque: 731 N-m (540 lbf-ft)
(2) Installation of track guide
Capscrews (5) with Loctite #262 and fasten all 4 capscrews temporarily. Then tighten them to a
specified torque.
Tools: Socket: 36 mm,
Tightening torque: 932 N-m (690 lbf-ft)
(3) Adjusting tension of crawler
Tighten grease nipple and fill it with grease.
Tools: Socket: 19 mm,
Tightening torque: 59 N-m (43 lbf-ft)

34.1.4.4 CONSTRUCTION

Construction of lower roller

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34.1.4.5 DISASSEMBLY AND ASSEMBLY

(1) Disassembly
1. Remove plug (8) and drain out oil.
Tools: Allen wrench: 6mm
2. Removing pin (5)
Put both ends of lower roller assy on the
V-shaped blocks (K), apply push-out bar (L)
on upper end face of pin (5), and push
pin (5) out striking with mallet. 

Pushing out collar fixing pin (5)

3. Removing collar (2), O-ring (7)

Put lower roller on jig (M) for repair stand
so that the shaft (3) is perpendicularly
located, apply push-out jig (P) on shaft
end on upper side, and push shaft (3)
until the O-ring (7) separate from collar (2)
with press or mallet, and take out collar (2).
4. Removing shaft (3)
Reverse the top and bottom of the lower
roller, push shaft (3), and remove collar
(2) and O-ring (7) as one unit.

Removing shaft (3), collar (2)

The shaft (3) extrusion operation may cause the remaining lube oil to flow out. Prepare an oil
container beforehand.

5. Removing collar (2), O-ring (7)

Remove O-ring (7) from shaft (3) that was
drawn out in the previous paragraph.
6. Removing floating seal (6)
Remove floating seal (6) from collar (2).

Removing floating seal (6)

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7. Removing floating seal (6)

Remove floating seal (6) from roller (1).

Removing floating seal (6)

8. Removing bushing (4)

Since thickness of bushing (4) is thin
[thickness is 3.9mm (0.154in)], remove it
through lathe or strip it with care not
damage inner hole of roller. When the wear
of bushing is not large, place upper roller
(1) on jig (M) for repair stand and apply
the end of push-out jig (N) on the end face
of bushing (4) end, and push it out
striking it with mallet.

Extruding bushing (4)

Hammer the inside surface of roller lightly so as not to damage the surface. Put the extrusion jig (N)
uniformly over the circumference of bushing (4) and extrude it perpendicularly little by little.

(2) Installing
1. Attach O-ring (7) to one side
Install O-ring (7) to groove on shaft.

-Grease O-ring.
-Replace O-ring with new one without fail
Attach O-ring (7) to one side
at reassembling.

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2. Press fitting bushing (4)

Align inner hole of roller (1) and bushing
(4) and press fit it vertically in capacity of
press fit load, 5ton (11000 lbs), in the
condition that bushing push-in jig (Q) is
inserted into bushing (4).

-Apply molybdenum disulfide grease on

press-fit section of bushing, and press fit it 
in ordinary temperature.
-Bushing which fails to press-fit because of Press fitting bushing (4)
the one-side pressing should not be fitted.

3. Press fitting collar (2)

Fit O-ring (7) to the one side of shaft (3)
mating pin hole of collar (2) on which
floating seal (6) is fit with pin hole of shaft
(3) in advance. Use the press of capacity
17 ton (37500 lbs) or more.

-Care should be taken not to damage

O-ring (7) while press-fitting collar (2) to
shaft (3). Press fitting collar (2)

4. Inserting pin (5)

Press-fit pin (5) to pin hole on aligning pin
holes of shaft (3) and collar (2).

Inserting pin (5)

5. Attach floating seal (6) to roller side

Fit floating seal (6) to inner holes on both
ends of roller (1).

-Check that the seal surface is free from

flaws, rusts, etc. before reusing the floating
seal.
6. Inserting roller (1)
Insert roller (1) from the side where collar
(2) is not press-fitted to the shaft (3).
Inserting roller (1)

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7. Installing O-ring (7)

Install O-ring (7) to groove on shaft.

-Grease O-ring.
-Replace O-ring with new one without fail
at reassembling.
8. Press fitting collar (2)
Press-fit collar (2) to shaft (3).

-Press-fit collar (2) on aligning pin (5) hole.

9. Inserting pin (5)
Press-fit pin (5) in to the pin hole mating
pin hole of collar (2) with pin hole on the
end side of shaft (3).

Installing O-ring (7), collar (2)

10. Filling oil

Remove plug (8) and fill in 430cc
(26.14cu-in) of engine oil API grade CD
#30.
11. Check it for leakage
Before tightening plug (8), check it for
leakage in the condition of air pressure
0.2MPa (29psi).
12. Installing plug (8)
Apply oil resistant sealant on plug (8), and
tighten it in the plug hole on the collar (2)
end face. Installing filling oil plug (8)
Tools: Allen wrench: 6 mm,
Tightening torque:
21.6 to 24.5 N-m (15.9 to 18.1 lbf-ft)

After assembling the lower roller, confirm that oil is not leaking and that the roller rotates smoothly by
hand.

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34.1.4.6 MAINTENANCE STANDARD



Lower roller (Track roller)

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34.1.4.7 TOOLS AND JIGS

(1) Tightening tools

(2) Jig

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34.1.5 FRONT IDLER (IDLER ADJUSTER ASSY)

34.1.5.1 FRONT IDLER ASSY



Front idler assy

34.1.5.2 REMOVING
(1) Preparation for removal
Remove crawler. (Above mentioned)
(2) Removing idler assy
Sling idler assy, and push it forward with
bar.
Weight of front idler assy (one side): 361
kg (796 lbs)
(3) Installing
Installing is done in the reverse order of
removing.

Removing and installation the front idler

Keep away from the front side of front idler.

(4) Where idling assy (1) has to be separated

Loosen capscrew (3), and separate idler
assy (1) from idler adjuster assy (2).
Tools: Socket: 30 mm
Weight of idler assy : 175 kg (386 lbs)
Weight of idler adjuster assy : 185 kg (408
lbs)

-The separated idler assy (1) should be

placed on square timbers.

Separating idler assy (1) from idler adjuster

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34.1.5.3 IDLER ASSY

34.1.5.3.1 CONSTRUCTION

Idler assy

34.1.5.3.2 REMOVING AND INSTALLING

(1) Removing
1. Drain oil
Remove plug (8) on the side of collar (2)
to drain.
Tools: Allen wrench: 5 mm
2. Removing pin (5)
Apply pin push bar (jig R) to the top of
pin, and push out striking bar (jig R)
lightly by hammer. Removing pin (5)

3. Removing collar (2)

Put idler (1) on stand (U), apply push-out
jig (S) on shaft (3), push out shaft (3) with
collar (2), then remove collar (2).

Removing collar (2)

4. Removing collar (2) from shaft (3)

If removal of collar (2) on the opposite side
is required, turn over front idler and
proceed with the procedure described in
Par. 3.

Removing collar (2)

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5. Removing bushing (4)

With idler (1) mounted on the stand, tap
bushing (4) lightly by hammer, while placing
the bushing drawing rod (T) against the
end face of bushing (4) evenly all round, till
it comes out.
6. Removing floating seals (6)
Take out floating seals (6) from idler (1),
collar (2). If you intend to reuse floating 
seals (6), confirm that there is no scoring
Removing bushing (4)
and rusting on the contact surface and store
the floating seals in pairs by placing
card board between the sealing faces.
7. Removing O-ring (7)
Separate O-ring (7) from shaft (3).

(2) Assembly
1. Pressing in bushing (4)
Align inner hole of idler (1) and bushing (4)
and press fit it vertically with press so that
jig (V) for bushing press-fitting is inserted
into bushing (4).
2. Installing O-ring (7)
Fit O-ring (7) to O-ring groove on shaft (3).
Pressing in bushing (4)
-Apply grease to O-ring

3. Installing collar (2)

Press fit the O-ring (7) installed side of
shaft (3) into collar (2), and drive pin (5).
4. Installing floating seal (6)
Fit the half of floating seal (6) on each
side of collar (2) and idler (1).

Installing collar (2), shaft (3)

5. Inserting idler (1)

Insert floating seal (6) fitted side of idler (1)
into shaft (3).
6. Installing floating seal (6)
Fit floating seal (6) on the other side of
idler (1).

Inserting idler (1)

and installing floating seal (6)

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7. Installing collar (2)

Fit the half of floating seal (6) on the
other collar (2), press fit it in shaft (3),
and drive pin (5) in with hummer.
8. Filling oil-Inspection
Fill in 350cc (21.36 cu-in) of engine oil
API grade CD #30 through the plug hole of
collar (2), wind seal tape and tighten plug
(8). Installing collar (2) and filling oil
Tools: Allen wrench: 5 mm
Tightening torque : 17 N-m (12 lbf-ft)

-After installing the idler assy to the idler adjuster assy, make certain that no oil leaks from floating
seal and plug (8) and that idler (1) rotates smoothly.

34.1.5.3.3 MAINTENANCE STANDARD

Front idler

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34.1.5.3.4 TOOLS AND JIGS

(1) Tightening tools

(2) Jigs 

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34.1.5.4 IDLER ADJUSTER ASSY

34.1.5.4.1 CONSTRUCTION

Idler adjuster assy

34.1.5.4.2 MAINTENANCE STANDARD

No. ITEM STANDARD VALUE
A Installed length of spring 554mm (21.8in)
B Free length of spring About. 660mm (26.0in)
C Stroke 53mm (2.09in)
D Set length 797mm (31.4in)
E Outside view of piston Nor scoring and rusting
F Tightening torque of grease nipple 59N-m (43 lbf-ft)

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34.1.6 SPROCKET
34.1.6.1 REMOVING
(1) Preparation for removal
Remove crawler referring to "34.1.2
CRAWLER", lift up crawler frame with
attachment, and put it on square timbers
to float and stabilize.


Preparation for removal

(2) Removing sprocket

Loosen 26 capscrews (3) M20X55, for
the attaching of the sprocket by means of
a socket and remove the sprocket (1).

Weight of sprocket: 75 kg (165 lbs)

Tools: Socket: 30 mm

Removing sprocket

34.1.6.2 INSTALLING
(1) Check before installing
Check the mating portion of the travel
reduction unit and the sprocket, eliminate
burrs and contamination thoroughly and
install the sprocket.
(2) Installing sprocket temporarily
Coat the sprocket attaching capscrews (3)
with Loctite #262 and fasten the sprocket
temporarily.
(3) Installing sprocket completely
Remove the wooden blocks under the
truck frame, bring the machine down on the Installing sprocket completely
ground and tighten the sprocket.
Tools: Socket: 30 mm
Tightening torque: 539 N-m (400 lbf-ft)

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34.1.6.3 MAINTENANCE STANDARD (LC51D01008P1)

215.9 mm NUMBER OF
PITCH 21
(8.5 in) TEETH
SPECIFICATION
ø 68 mm ø 732.47 mm
ROLLER DIA. PITCH DIA.
(2.68 in) (28.8 in)

Sprocket

34.1.6.4 TOOLS AND JIGS

(1) Tools

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(2) Sprocket tooth profile gauge: W



Tooth profile gauge (Full scale)

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34.1.7 TRAVEL MOTOR

34.1.7.1 TRAVEL MOTOR

Installing travel motor

34.1.7.2 REMOVING
(1) Preparation for removal
Remove crawler, lift up crawler frame
using attachment, and put it on square
timbers to float and stabilize.
To release inner pressure from the
hydraulic circuit after stopping the engine.
Put the starter switch in the "ON" position
and, with the safety lock lever in operating
condition, operate the left / right travel lever
in full stroke several times and press the
travel 1-2 speed change switch several Removing and installing cover (1)
times to release the inner pressure from
the hydraulic circuit.
When you press the valve from above the
gum cap of the air breather on top of the
hydraulic tank, the internal pressure of the
hydraulic tank is released.
(2) Removing cover (1)
Remove sems bolt (6) M12X25 and also
remove covers (1).
Tools: Socket: 19 mm
(3) Preparation of oil pan

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(4) Removing hydraulic pipe

Release pressure from travel circuit, and
bleed air in hydraulic oil tank, then remove
all pipes connecting to travel motor. Then
plug up all pipes and joint section to
protect them from entry of dust.
Tools: Spanner: 19 mm, 27 mm, 32 mm,
41 mm
Refer to "Hydraulic pipe plug" 5.1 
(See Chapter 11. TOOLS)
Removing and installing hydraulic pipe
"Plug for flare hose" 5.2 (3) (See Chapter
11. TOOLS)

(5) Removing sprocket

Removing twenty two (one side)
capscrews (6-3) M20.
Tools: Socket: 30mm

Removing and installing sprocket

(6) Loosening travel motor attaching bolts (3)

Apply match marks on travel motor and
crawler frame, and remove eighteen (one
side) capscrews (3) M24.
Tools: Socket: 36mm

Removing and installing travel motor

attaching bolts

(7) Slinging travel motor assy

Sling travel motor with nylon sling applied
on the side close to sprocket installing
section and remove the motor.

Weight of motor: About. 400 kg (882 lbs)

Slinging travel motor

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34.1.7.3 INSTALLING
Installing of the travel motor piping is performed in the reverse order of removal.

1. Cleaning
Check that contact surface of travel motor
and crawler frame is free from burr and
stain.
2. Tightening torque
Tighten capscrew and hydraulic pipes to
the torque specified in "Tightening Torque".
3. Fill inside from motor drain port to casing
with hydraulic oil before piping for drain.
When starting operation, operate motor in
low idling and at low speed for several
minutes, and check it for possible oil
leakage and noise.

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34.1.8 SWING BEARING

34.1.8.1 SWING BEARING ASSY



Swing bearing assy

34.1.8.2 REMOVING
(1) Matchmarks
Remove upper structure, apply matchmarks
on inner race of swing bearing and lower
frame.
(2) Remove 36 capscrews (2) M24X80 for
installation inner race.
Tools: Socket: 36 mm
Matchmarks

(3) Removing grease

Remove grease in grease bath.
(4) Removing swing bearing
Attach eyebolt on swing bearing and sling it.

Weight of swing bearing: 540 kg (1190 lbs)

Removing and installing swing bearing

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34.1.8.3 INSTALLING
(1) Cleaning
Clean it completely so that installing
surfaces of swing bearing and lower frame
are free from dust and dirt.
(2) Installing
Install swing bearing on lower frame
meeting the matchmarks and positioning the
S mark on inner race as shown in the right
Fig..
(3) Temporary fastening of inner race
Coat the threads of the capscrews (2) with
Loctite #262 and tighten all the
capscrews (2) temporarily.
Tools: Socket: 36 mm
Location of S mark on swing bearing

(4) Regular tightening of inner race

Tighten the capscrews (2) at 180 degrees
intervals alternately to a specified torque.
Tools: Socket: 36 mm,
Tightening torque: 932 N-m (690 lbf-ft)
(5) Filling grease
Fill grease bath with 28.7 g (63 lbs) of
grease "NIPPON Grease NIGLUBE EP-2K"
or equivalent. Removing and installing capscrew (2)

34.1.8.4 CONSTRUCTION

Sectional view of swing bearing

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34.1.8.5 DISASSEMBLY AND ASSEMBLY

(1) Disassembly
1. Remove seal (5) fitted in the groove in the
outer circumference under inner race (2)
and seal (6) fitted in the groove in the
inner circumference on top of outer race (1)
and place them level on a square wooden
block or something.
2. Remove taper pin (7), using a hammer and 
an extrusion rod.
3. Remove plug (8), utilizing an pull bolt Disassembling swing bearing
inserted in the screwed hole (M10) in the
center of the plug and using a puller.

4. While rotating outer race (1) little by little,

take out ball (3) and retainer (4) through
plug hole, in that order.

Removing balls (3) and retainers (4)

(2) Installing
1. horoughly remove the grease from the
groove of the seal (6) located on the inner
surface of the outer race (1) and from the
groove of the seal (5) located on the
surface of the inner race (2).
And apply the adhesive (Cyano Bond
PX-3000 or equivalent) to the seal (5) and
stick the seal (5) into the groove
continuously.
Then place the inner race (2) on wood Fitting balls (3)
blocks flatly.

2. Lower outer race (1) to the position where

upper surface of inner race (2) and lower
portion of seal groove is mated, put
adjusting washer under outer race (1) so
that outer raceway surface of ball (3) aligns
with inner raceway, and support it.
3. Insert ball (3) and retainer (4), on which
grease is applied, through plug (8) hole on
outer race (1), alternately.
Fitting retainer (4)

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To insert ball (3) and retainer (4), use a push rod, etc., to protect persons from injury from inserting
fingers into plug hole.

4. Fit plug (8) to outer race (1) while checking it for direction and position of taper pin hole.
5. Apply adhesive (Cyano Bond PX-3000 or equivalent) to the seal (6) and stick the seal to the
groove of outer race (1) continuously. And join each joint of the seal (6) with adhesive (Cyano
Bond PX-3000 or equivalent).
6. After completion of assembly, caulk the edge of taper pin (7) by punching.
7. Check that grease nipple (9) is properly fitted, and fill it with grease. Then, check bearing for
smooth rotation and flaws on seal lip portion.
-Shell Albania EP#2; 240 cc (14.64 cu-in)

34.1.8.5 MAINTENANCE STANDARD

Maintenance standard concerning wear of swing bearing is described in the section 13.6 MEASURING
SWING PERFORMANCES of "Maintenance Standard and Test Procedure" in this manual.

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34.2 DISASSEMBLING AND ASSEMBLING OF EQUIPMENT

34.2.1 TRAVEL MOTOR



Travel motor

No. NAME No. NAME No. NAME

1 Casing 23 D-ring (big dia.) 44 Check valve
2 NPT 1/16 plug 24 Rear cover 45 Check valve spring
3 Oil seal 25 NPT 1/16 plug (MEC) 46 M6 restrictor (0.6)
4 Retaining ring IRTW68 26 Spool assy (M4V RBV) 47 O-ring 1B P12.5
5 Expander plug MB800-040 27 Spring holder (M4V RBV) 48 M8 restrictor (0.8)
6 Shifter piston 28 Spring (M4V150RBV) 49 O-ring 1B P15
7 Piston seal 29 M42 plug (4V RBV) 50 O-ring 215.57X2.62
8 Steel ball 25 30 O-ring 1B G40 51 Bearing HR32207C
9 Shaft 31 Pilot valve spool dia. 52 Shim
10 Bearing HR32209J 㱢10 (M4V290) 53 Parallel pin M6 8X12
11 Pivot 32 Pin (MRC03) 54 Valve plate
12 Swash plate 33 Spring holder (MRC03) 55 Brake spring
13 Cylinder block 34 Spring (MRC03) 56 HEX. socket head bolt M18X50
14 Cylinder spring 35 G3/8 pilot valve plug 57 Overload relief valve ORV-240L
15 spring holder 36 O-ring 1B P14 58 Coupling
16 Ball joint 37 Connector (MRC03) 59 Retaining ring C-type 40
17 Shoe retainer 38 G1/4 plug 60 G1/2 plug
18 Piston assy 39 O-ring 1B P11 61 O-ring 1B P18
19 Separating plate 40 Restrictor (brake valve)
20 Friction plate 41 Restrictor spring (brake valve)
21 Breake piston 42 G1/8 plug
22 D-ring (small dia.) 43 O-ring 1B P8

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࡮ Overload relief valve

Structure of overload relief valve

No. Name No. Name

57-1 Socket 57-8 Shim
57-2 Valve 57-9 Adjusting spring
57-3 Valve seat 57-10 O-ring 1B P7
57-4 Coupling piston 57-11 Backup ring T2 P7
57-5 Cap 57-12 O-ring 1B G25
57-6 Pilot body 57-13 Backup ring T2 G25
57-7 Piston

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34.2.2 CONSTRUCTION OF REDUCTION UNIT



Reduction unit

No. NAME No. NAME No. NAME

1 Housing 11 Thrust washer 2 20 Carrier pin 1
2 Bearing 245BA35S1GS Needle bearing 21 Spring pin 6X36
12
3 Ring gear FBNP-608660 22 Sun gear 1
4 HEX. socket head bolt M18X110 13 Carrier pin 2 23 Thrust plate
5 Floating seal 368 14 Spring pin 10X50 24 Cover
6 Shim 15 Sun gear 2 25 HEX. socket head bolt M10X30
7 Lock washer 16 Carrier 1 26 Plug G3/4
8 Support ring 17 Planetary gear 1 27 O-ring 1B P24
9 Carrier 2 18 Thrust washer 1
Needle bearing
10 Planetary gear 2 19
FBNP-406040

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34.2.3 TRAVEL MOTOR ASSEMBLY

34.2.3.1 TOOLS

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34.2.3.2 DISASSEMBLY
a. GENERAL INSTRUCTIONS
(1) Generally, hydraulic equipment is precisely manufactured and clearances between each parts are
very narrow.
Therefore, disassembling and assembling works should be performed on the clean place where
dusts hardly gather.
Tools and kerosene to wash parts should also be clean and handled with great care.
(2) When motor is removed from the host machine, wash around the ports sufficiently, and put the
plugs so that no dust and / or water may invade. 
Take off these plugs just before the piping works when re-attach it to the host machine.
(3) Before disassembling, review the sectional drawing and prepare the required parts, depending on
the purpose and the range of disassembling.
Seals, O-rings, etc., if once disassembled, are not reusable. There are some parts that should be
replaced as a sub-assembly.
Consult with the parts book in advance.
(4) The piston can be inserted to whichever cylinder block for the initial assembling.
However, their combination should not be changed if they are once used. To reuse them, put the
matching mark on both pistons and cylinder block before disassembling.
(5) Take great care not to pinch your hand between parts while disassembling nor let fall parts on
your foot while lifting them.

b. DISASSEMBLY PROCEDURES
(1) Removing accessory valves
Before disassembling motor, remove accessory valves.

According to disassembling purpose, select the valves to be removed.

However, you cannot disassemble the motor without removing overload relief valve (57).

There is dread of the burn, disassemble motor after cooling it to ambient temperature.

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1. Remove M42 plug (29) and O-ring (30).

2. Remove spring (28), spring holder (27) and spool assy (26).

Put the matching mark on both spool assy (26) and rear cover (24) so that spool assy (26) should not
be reversed on re-assembling.
It is impossible to disassemble this spool assy (26) further because spool assy (26) is fixed by
adhesive.

3. Remove plug (42), O-ring (43), check restrictor spring (41) and restrictor (40).
4. Remove overload relief valves (57).

When removing overload relief valve (57), valve seat (57-3) easily comes off, so take great care not to
fall into the rear cover (24) or lose.

5. Remove pilot valve plug (35) and then, remove O-ring (36), pilot valve spring (34), spring holder
(33), pilot valve spool (31) and pin (32).
6. Remove coupling (58).

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(2) Disassembling motor

1. Place the motor with the shaft horizontal,

remove Hex. socket head bolts M18X50
(56) of rear cover (24) leaving two on
diagonally upper and lower position.
Tools: Allen wrench㧦14mm
2. Install two guide pins diagonally into rear
cover (24). 
(Purpose: Prevention of falling rear cover)
3. Loosen slowly and simultaneously the
remaining two Hex. socket head bolts
M18X50 (56).
4. Remove rear cover (24) and brake springs
(55) taking care cylinder block (13) is not
coming out stuck with rear cover (24).

Removing rear cover

-Do not fall, at this moment, valve plate (54), brake springs (55), outer race of rear bearing (51) and/or
O-rings (50), (47), (49).
-There are shims (52) under the outer race of rear bearing (51). Take a great care not to lose.

5. Remove valve plate (54) without pulling out cylinder block (13).

Put the matching mark on both valve plate (54) and rear cover (24) so that valve plate (54) should
not be reversed on re-assembling.

6. Using removed Hex. socket head bolts M18

X50 (56), fasten two mount metals so as to
push in cylinder block (13) without
damaging it then inner race of rear
bearing (51) comes out. (See light Fig.)
7. Put two fingers of gear (bearing) puller
under the inner race of rear bearing (51)
and remove the race.

Removing rear bearing

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8. Attaching a hand on brake piston (21),

supply plant air through oil hole for
releasing brake and push out the piston
(21).

Enlargement figure of matching surface of

casing

Be aware of brake piston (21) popping out.

In case of using jig for pulling out brake piston (21), install jigs to M6 thread (2 places) of brake
piston (21) and pull out brake piston (21).

9. Put as a mark on a piston assy (18) such

as a paper pipe and put a matching mark
on cylinder block (13) so that they can be
re-assembled at the same position as
before.
10. Remove rotary group (cylinder block (13),
spring holder (15), nine piston assys (18),
shoe retainer (17), ball joint (16) and
cylinder spring (14)) as an assembly.
11. Remove separating plates (19) and friction
plates (20).
12. Remove nine piston assys (18), shoe
retainer (17) and ball joint (16) from rotary
group simultaneously.
13. Remove spring holder (15) and cylinder
springs (14).

Removing cylinder block

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-Put piston assys (18) into the cylinder block (13) matching the matching mark with shoe retainer (17)
as if assembled.
The purpose is to put piston assys (18) in the same bore of cylinder block (13) as before when
reassembled.
-Take care not to scratch sliding surfaces.
Do not reuse damaged ones. 
-It is impossible to disassemble piston and shoe because they are calked together.

Above disassembling is mentioned as a motor only and naturally can be applied to the motor with
reduction gears.
The situation is rather easier for with reduction gears because the shaft is rather restricted by a gear
to move.

14. Remove swash plate (12).

15. Do not detach shifter piston assy (6), (7),
(8).
If it needs to detach, attach a hand on
shifter piston and supply plant air through
the hole shown in Fig.19 and push it out.

Enlargement figure of matching surface of

casing

Be aware of shifter piston (6) popping out.

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16. Shaft (9) can comes out now.

17. If front bearing (10) happen to be
changed, remove inner races and outer
races using bearing puller if needed and
exchange to new ones as an assembly.

Remove swash plate

-When changing bearings (10), (51), shaft(9), casing(1) or rear cover (24), it affects the clearance of
the bearings.
Therefore, shim (52) should be adjusted.
-Shim (52) adjustment should be performed by measuring correctly the clearance for shim and change
shim that meets the clearance. (See Fig. "Deciding shim thickness")
Other jigs and tools are needed to measure and decide the thickness of the shim.
-Do not remove pivots (11). If it needs to disassemble them, put matching mark on pivots (11) with
swash plate (12).
-Never detach oil seal (3) only for the purpose of inspecting it. If disassembled, remove retaining ring
IRTW68 (4) first and remove oil seal (3).Never fail to replace oil seal (3) with new one.

18. Deciding shim (52) thickness for tapered

roller bearings.

Deciding shim thickness

This work should be done only when you have changed bearings (10), (51), shaft (9), casing (1) or
rear cover (24).

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1. Measure the assembling width "E" (See ).

Take care not to incline shaft (9).

2. Measure the depth "F" of rear cover (24)



Measure them at crossed 4 places on the circuit, then calculate their mean value.

3. When thickness of shim (52) to be used is placed as "S", the clearance "Y" can be calculated
as follows :
Y=F-(E+S)
4. Select one or two shim (52) so as the clearance "Y" to come to 0-0.1 mm (0~0.004") (clearance)
on this unit.

(3) Disassembling overload relief valve

As a rule, overload relief valve (57) should be handled as one service part. If there are any
trouble on overload relief valve (57) , replace as an assembly.

Disassembling overload relief valve

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Valve seat (57-3) is fitted in bore of socket (57-1) at clearance fit.

When removing overload relief valve (57), valve seat (57-3) easily comes off, so take great care not to
lose.
When assembling overload relief valve (57) to rear cover (24), apply grease sufficiently on
engagement part not to drop valve seat (57-3).

Engagement part

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34.2.4 TRAVEL MOTOR ASSEMBLY

34.2.4.1 GENERAL INSTRUCTIONS
(1) Wash each parts sufficiently with kerosene, and blow them by plant air.
(2) Assemble sliding parts after coating clean hydraulic oil on them.
(3) Take great care not to pinch your hand between parts or tools while assembling nor let fall parts
on your foot while lifting them.

34.2.4.2 ASSEMBLING PROCEDURES 

(1) Coat outer surface of oil seal (3) and
inner face of casing (1) with grease. Using
jig, rightly and evenly press in the oil seal
(3) into casing (1).
(2) Fix oil seal (3) by retaining ring (4).
(3) Put the outer race of bearing (10) on
casing (1) (this fit is loose), and press the
inner race on shaft (9) (this fit is tight).

Inserting oil seal

It is easier to fit inner race if the inner race is heated or boiled under 100 degrees centigrade.
Never over heat!

(4) Insert shaft (9) into casing (1) after coating grease on the contact surface to oil seal (3) lip.
(5) Put shifter piston assy (6), (7), (8) into casing (1).

-Insert shifter piston assy not to incline

-When inserting shifter piston assy, apply grease sufficiently on piston seal (7) and take a great care
not to cut piston seal (7).

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(6) Insert pivots (11) into the casing (1).

-Take care to match the matching mark

with casing (1) and also to coincide the
direction of sliding trace on sphere surface
with those contact trace on swash plate
(12) if the motor was operated a certain
hours.
(7) Apply grease sufficiently on three spherical
recess of swash plate (12) and assemble
it in casing (1).

Assembling swash plate

(8) Insert piston assys (18), shoe retainer

(17), ball joint (16), spring holder (15),
cylinder spring (14) on to cylinder block
(13) as shown and then insert the whole
assembly to shaft (9).

Assembling rotary group

Piston assys (18) should be inserted into the same bore as before.

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(9) Rightly knock in the inner race of rear

bearing (51) to the rear end of shaft (9)
by using jig (A1) and plastic hammer (A2).
(10) Install all the separating plates (19) and
friction plates (20) alternately between
casing (1) and cylinder block (13)
adjusting on the notches and splines.
Separating plates (19) comes both first and
last. 
(11) Insert brake piston (21) into casing (1)
using inserting jig (B) after attaching D-rings
(22), (23) to brake piston (21).

Inserting brake piston

Apply grease sufficiently on D-rings (22), (23). Insert brake piston (21) by using inserting jig not to
incline.
Two kinds of D-rings are used on brake piston (21). The larger one (23) is first inserted into the
hole, then the smaller one (22) enters.
It is impossible to see how the smaller ring goes into the hole. Therefore, never push it forcibly into
the hole.
Otherwise, it may be scraped off by the edge of the hole of casing (1).

When changing bearings (10), (51), shaft (9), casing (1) or rear cover (24), it affects the clearance of
the bearings. Therefore, shim (52) should be adjusted. Refer to Chapter 34.2.3.2 b (2)-18) "Deciding
shim (52) thickness for tapered roller bearings" and decide shim (52) thickness.

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(12) Install two guide pins diagonally on casing

(1).
(Purpose: Guide for installing rear cover)
(13) Lay down rear cover (24) to mount valve
plate (54) coinciding matching mark made
prior to disassembling and also place
brake springs (55) with ample grease to
be attached to rear cover (24) while
assembling. Also set shim (52), outer race
of rear bearing (51) and O-rings (50), (47),
(49) on rear cover (24).
(14) Insert rear cover (24) to casing (1) along
the guide pin, and install two Hex. socket
head bolts M18X50 (56) diagonally upper
and lower position and tight them to
assemble rear cover (24) parallely. Inserting brake piston
Then, install the rest of Hex. socket head
bolts M18X50 (56) and remove guide pin
and install two the remainder.
Tools: Allen wrench㧦14mm,
Tightening torque :324N-m (239 lbf-ft)

When removing outer race of rear bearing (51), install shim (52) without fail.
Confirm that O-rings (47), (49), (50) are installed to rear cover (24).

(15) Assemble coupling (58).

(16) Assemble spring (34), spring holder (33),

pilot valve spool (31) and pin (32) to rear
cover (24), and then install pilot valve plug
(35) with O-ring (36).
Tightening torque : 49.0~58.8N-m
(36.1~43.4 lbf-ft)
(17) Assemble overload relief valves (57).
Tools: Spanner : 32 mm
Tightening torque : 98~117.6N-m (72.3~86.7
lbf-ft)

Assembling accessory valves

Valve seat (57-3) is fitted in bore of socket (57-1) at clearance fit. When assembling overload relief
valve (57) to rear cover (24), valve seat (57-3) easily comes off, so take great care not to lose and
apply grease sufficiently on engagement part not to drop valve seat (57-3).

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(18) Assemble restrictor (40) and restrictor spring (41) to rear cover (24), and then install G1/8 plug
(42) with O-ring (43).
Tightening torque : 14.7N-m (10.8 lbf-ft)

In case of assembling NEW restrictor (40), fit valve seat of restrictor (40) with rear cover (24).
(After inserting restrictor (40) to rear cover (24), knock restrictor (40) slightly by hammer.) 
(19) Inserting spool assy (26) to rear cover (24) coinciding matching mark made prior to
disassembling, and then assemble spring holder (27) and spring (28).

Spool assy (26) is unsymmetry. Insert spool assy (26) in an appropriate direction.

(20) Assemble M42 plug (29) with O-ring (30).

Tightening torque : 441~461N-m (325~329 lbf-ft)

34.2.4.3 INITIAL PRE-CONDITIONING OPERATION

(1) Drain charge
Fill up hydraulic oil in the motor casing after assembling.
M4V290/170F motor has two drain ports (G1/2). Bleed air in motor casing from un-piping port
(upper side).
(2) Initial Pre-conditioning operation
Operate motor 5 minutes at low speed mode and low-idle, check if there are abnormal noise or
leak of oil.

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34.2.5 TRAVEL MOTOR

34.2.5.1 MAINTENANCE STANDARD OF PARTS
The followings are the general maintenance standards. However, it is the most important to determine
which parts should be replaced, depending on the characteristics before disassembling, damages and
discoloration of exterior view, the purpose of disassembling, the expected remaining service life, etc..

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Method

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34.2.5.2 TIGHTENING TORQUE

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34.2.6 TRAVEL MOTOR TROUBLESHOOTING

CAUSE OF TROUBLE AND REMEDY
The followings are the general instructions to be followed when some troubles occur with hydraulic
motors.

34.2.6.1 GENERAL INSTRUCTIONS

(1) Judge the nature of abnormality before trouble shooting, and ascertain if the same symptom has
occurred before or not. 
Review if the motor itself is actually troubled.
(2) In many cases, the wear is caused by dusts.
Take great care to prevent dusts in disassembling and assembling.
(3) All the parts especially those of moving parts should be carefully handled, and be careful not to
score or scratch the sliding surfaces.
(4) Be careful not to score the seating surface for O-ring, etc..
We recommend you to replace O-rings with the new ones, if once disassembled.

34.2.6.2 CAUSE OF TROUBLE AND REMEDY

(1) Hydraulic motor never starts
Symptom Cause Remedy
Pressure never Malfunction of built-in relief valve. Repair or replace relief valve
increases
Pressure increases 1. 1.
Parking brake is not released After inspection of clogging, repair or replace
(Clogging of restrictor)
2. 2.
Parking brake is not released Re-install the spool in correct direction
(Spool is installed in wrong direction)
3. 3.
Stuck friction or separating plate of Replace friction and separating plate
parking brake portion
4. 4.
Stuck brake piston Repair outer dia. of brake piston or replace it.
5. 5.
Seizure of sliding portion Check, repair or replace piston shoe, swash
plate, cylinder block valve plate etc..
6. 6.
Malfunction of spool Repair or replace
(Stick between spool and body)
(Clogging of restrictor)

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(2) Hydraulic motor rotates weakly

Symptom Cause Remedy
Set pressure of Malfunction of spool Repair or replace
overloadvalve is (Stick between spool and body)
correct, but brake
is released belatedly
Parking brake is High oil viscosity. Raise oil temperature or change the hydraulic
released, but motor oil
is hard to start
Parking brake is 1. 1.
released, but motor Parking brake is not completely released. Check clogging of choke
starts weakly (Clogging of choke of pressure release
passage)
2. 2.
Relief valve catches small particles Wash relief valve, check or replace seat of it
3. 3.
Seizure of sliding portion Check, repair or replace sliding portion

(3) Drive shaft never rotate up to the set value

Symptom Cause ‫ݣ‬ ሊ
Rotation of drive 1. 1.
shaft never reaches Shortage of oil coming in Check oil flow or hydraulic circuit to motor.
the set value 2. 2.
Large wear or flaw made on shoe, Check, repair or replace the parts
cylinder block or valve plate

(4) Brake refuses to work

Symptom Ҿ ‫׆‬ ‫ݣ‬ ሊ
Brake refuses Malfunction of parking brake Check, repair or replace brake piston, friction
to work 1. plate, spring, etc.
Worn friction plate
2.
Broken spring
Brake works Malfunction of spool Repair or replace or clean up
on counter 1.
lever Stick between spool and body
operation 2.
Stick of check valve or that by small particle
3.
Clogging of restrictor

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(5) Oil leakage

Symptom Cause Remedy
Oil leakage 1. 1.
Loose Hex. socket head bolt or plug Fasten it with given torque
2. 2.
O-ring is torn off Replace O-ring
3. 3.
Oil leaks inside gear casing Replace oil seal

(6) Would not shift from high to low
Symptom Cause Remedy
Would not shift from Stick of spool of pilot valve Replace pilot valve assy.
high to low

(7) Abnormal noise

Symptom Cause Remedy
Abnormal noise Malfunction of spool Bleed air
appear together with Air is caught inside brake valve
big vibration when Stick between spool and body Repair or replace
brake is slowly
applied or oil is
supplied to other
circuits while motor
is running

(8) Hunting occurs while descending the slope

Symptom Cause Remedy
Severe hunting while Malfunction of spool Repair or replace
inching -Stick between spool and body
-Restrictor is not seated completely
Interference with parking brake Repair or replace
-Permanent set or broken spring

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34.2.7 REDUCTION UNIT DISASSEMBLY

34.2.7.1 TOOLS
Jigs and measuring instruments.

34.2.7.2 DISASSEMBLY
(1) Preparation before removal
1. The travel unit removed from the machine has dust and mud. Wash them with cleaning oil.
2. Loosen drain or oil filling plug (26) and drain the oil out of the reduction unit.

When oil is hot, pressure is built up inside. Take care as the oil gushes out in some cases.

3. Putting matching marks

Put a matching mark on the outside of each matching surface so it may be installed where it was.

-The numbers in the parentheses after part names correspond to those in the assembly drawing
on Fig. "Reduction unit".

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(2) Setting reduction unit (or whole propelling unit) on work stand
1. Remove Hex. socket head bolts M10X30
(25) at 3 places from cover (24) almost
equally apart each other, then install M10
eye bolts. Lift up the unit using them and
place it on work stand with cover (24)
upward.



Setting propelling unit on work stand

Take great care not to pinch your hand between parts while disassembling nor let fall parts on your
foot while lifting them.
Lift the parts up horizontally.

(3) Removing cover

1. Remove the rest of Hex. socket head
bolts M10X30 (25) that secure cover (24).
Tools: Allen wrench㧦8mm
2. As the cover (24) is adhered to ring gear
(3), remove cover (24) by lightly hammering
slantwise upward by wooden bar aiming at
projection of cover (24).

Removing bolts

Removing cover

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(4) Removing carrier 1 assy

1. Remove thrust plate (23).
2. Screw three M10 eye bolts in carrier 1 (16)
and lift up and remove carrier 1 as
sub-assy (16), (17), (18), (19), (20), (21).
3. Remove sun gear 1 (22).

Removing carrier 1 assy

(5) Removing carrier 2 assy

1. Remove sun gear 2 (15).
2. Screw three M10 eye bolts in carrier 2 (9)
and lift up and remove carrier 2 as
sub-assy (9), (10), (11), (12), (13), (14).

Removing carrier 2 assy

(6) Disassembling housing assy

1. Remove support ring (8).

Removing support ring

2. Take off lock washers (7) by tapping on

screw driver or on similar tool placed at
parting surface of them.

Removing lock washer

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3. Screw three M10 eye bolts in ring gear

(3) almost equally apart each other, then lift
it up horizontally and remove housing
ass'y including ring gear (3), housing (1),
angular bearing (2), a piece of floating
seal (5) and Hex. socket head bolts
M18X110 (4) together.



Removing housing assy

(7) Disassembling housing assy

1. Screw three M20 eye bolts in housing (1)
almost equally apart each other. Lift up
the housing assy and place it on work
stand with housing (1) upward.
Put a mating mark outside of housing (1)
and ring gear (3).
2. Remove floating seal (5) from housing (1).
3. Remove Hex. socket head bolts M18X110
(4), leaving two of them diagonally.
Tools: Allen wrench㧦14mm
4. Loosen the rest two Hex. socket head bolts
M18X110 (4) and tap lightly the head of
them then ring gear (3) can be easily
Disassembling housing assy
removed from housing (1).

-Take care not to damage the sliding surface of floating seal (5) or its O-ring.
-Bearings (2) have been tightly press fitted in housing (1). Don't remove the bearings (2) unless
otherwise their exchange is needed.
In case bearings (2) removed, don't re-use them.
New bearings (2) should be used and shim (6) adjusting be required.

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(8) Removing floating seal

1. Remove a piece of floating seal (5) of
motor side.

Removing floating seal (23)

(9) Disassembling carrier 1 assy

Disassembling carrier 1 assy

When carrier pins 1 (20) are to be re-used, mark each pin with its mated hole of carrier 1 (16) to
assure the same combination as before.

1. Knock spring pins 6X36 (21) fully into

carrier pins 1 (20).
2. Tap carrier pins 1 (20) out from carrier 1
(16).
3. Remove thrust washers 1 (18), planetary
gears 1 (17) and needle bearings (19).
4. Knock out spring pins 6X36 (21) from
carrier pins 1 (20) for re-assembling.

Disassembling carrier 1 assy

When carrier pin 1 (20) or planetary gear 1 (17) is needed to be exchanged, three pins or three gears
should be all exchanged.

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(10) Disassembling carrier 2 assy

When carrier pins 2 (13) are to be re-used, mark each pin with its mated hole of carrier 2 (9) to
assure the same combination as before.

1. Knock spring pins 10X50 (14) fully into

carrier pins 2 (13). 
2. Tap carrier pins 2 (13) out from carrier 2
(9).
3. Remove thrust washers 2 (11), planetary
gears 2 (10) and needle bearings (12).
4. Knock out spring pins 10X50 (14) from
carrier pins 2 (13) for re-assembling.

Disassembling carrier 2 assy

When carrier pin 2 (13) or planetary gear 2 (10) is needed to be exchanged, three pins or three gears
should be all exchanged.

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34.2.8 ASSEMBLING
(1) GENERAL INSTRUCTIONS
1. Clean every part by kerosene and dry them
by air blow. Surfaces to be applied by
Loctite must be degreased by solvent.
2. Check every parts for any abnormals.
3. Each Hex. socket head bolt should be used
with Loctite #242 applied on its threads.
4. Apply gear oil slightly on each part before
assembling.
5. Take great core not to pinch your hand
between parts while assembling nor let fall Assembling carrier assy
parts on your foot while lifting them.

(2) Assembling carrier 2 assy

1. Install planetary gears 2 (10), needle
bearings (12) and thrust washer 2 (11)
into carrier 2 (9).
2. Install carrier pins 2 (13) into carrier 2 (9)
where the holes for spring pins 10X50
(14) are to be in line with those of carrier
2 (9).
3. Install spring pins 10X50 (14) into carrier 2
(9) and at the same time into carrier pins 2
Drive spring pin
(13).
(Sink spring pins of 1 - 2 mm (0.04"~0.08")
from surface)
4. Calk carrier 2 (9) on diagonally position to
prevent spring pin 10X50 (14) from coming
out.

(3) Assembling carrier 1 assy

1. Install planetary gears 1 (17), needle
bearings (19) and thrust washers 1 (18)
into carrier 1 (16).
2. Install carrier pins 1 (20) into carrier 1
(16) where the holes for spring pins are to
be in line with those of carrier 1 (16).
3. Install spring pins 6X36 (21) into carrier 1
(16) and at the same time into carrier pins
1 (20).
(Sink spring pins of 1 - 2 mm Caulking the spring pin
(0.04"~0.08")from surface)
4. Calk carrier 1 (16) on diagonally position
to prevent spring pin 6X36 (21) from
coming out.

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(4) Installing main bearing and floating seal

1. Install main bearing (2) to inner surface of housing (1).
2. Install a piece of floating seal (5) on motor casing and also install another piece of floating seal
(5) on housing (1).



Install direction of floating seal (5)

Install floating seal (5)

(5) Assembling housing assy

1. Apply Loctite #515 on mating surfaces of
housing (1) and ring gear (3) without a gap.
2. Install three M20 eye bolts equally apart on
housing (1). Using the eye bolts, hang the
housing (1) by wire rope and place it on
ring gear (3), coinciding mating marks.
3. After applying Loctite #242 on the threads
of 25 pieces of Hex. socket head bolts
M18X110 (4), tighten them with torque
wrench.
Tools: Allen wrench㧦14mm,
Tightening torque : 377.3N-m (278 lbf-ft)

Assembling housing assy

How to apply Loctite #242

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-Clean the groove for floating seals (5) to eliminate oil, dust, paint or other foreign material.
-Apply gear oil slightly on sliding surfaces of floating seals (5) before assembling but strictly dry on
O-rings and on its grooves.
-Confirm that O-ring of floating seals (5) are not twisted and that floating seals are correctly installed.
i.e. parallel as shown each other between housing (1) and motor casing after assembled. (See Fig.
"Install direction of floating seal")
-It is recommended to use jig to install floating seal.

(6) Deciding shim thickness for angular bearings

This work should be done only when you have to change motor casing, housing (1), bearings (2) or
lock washers (7). Unless otherwise use the same shim (6) as before.

1. Fit in two bearings (2) on housing (1)

pressing their outer races.
2. Press inner races of two bearings (2) lightly
and evenly, measure the assembling width
"A" of inner races.
3. Measure the motor side assembling width
"B" for bearings (2).
4. Measure the groove width "C" of motor
casing.
5. Measure the thickness "D" of lock washers
(7).

Deciding shim thickness

Measure them at 4 places evenly apart on the circumferences then calculate and use those mean
values.
Measure them to the accuracy of 0.01 mm (0.0004").

6. When thickness of shim (6) to be used is placed as "S", the clearance "X" can be calculated as
follows :
X=(B+C)-(A+D+S)
7. Select a shim (6) so as the clearance X to come to -0.08 mm (interference)~ +0.02 mm
(clearance) (-0.0031"~0.0008") on this unit.

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(7) Installing housing assy

1. Place motor on work stand with the shaft
upward, and put the selected shim (6) on
the bearing mating surface of motor casing.
2. Install three M10 eye bolts on ring gear
(3) almost equally apart and lift it up.
Descend it concentric with motor and put
bearings (2) on housing (1) into motor
casing. Use press machine and press 
inner race of bearing (2) into full depth.

Pressing housing assy in

3. While pressing inner race of bearing (2),

install lock washers (7) into groove.

Installing lock washer

4. Install support ring (8) over outside of lock

washers (7).

Installing support ring

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(8) Assembling carrier 2 assy

1. Install three M10 eye bolts equally apart on
carrier 2 (9).
Using the eye bolts, hang the carrier 2
assy by wire rope and place three
planetary gears 2 (10) as shown on right
Fig., put carrier 2 assy into ring gear (3)
and mesh the splines to those of motor.
2. Insert and mesh sun gear 2 (15) on center.

Installing direction of carrier 2

Assembling carrier 2 assy

Positioning carrier 2 assy as Fig. "Installing direction of carrier 2" is important to obtain better
lubrication.

(9) Assembling carrier 1 assy

1. Install three M10 eye bolts equally apart on
carrier 1 (16). Using the eye bolts, hang
the carrier 1 assy by wire rope and place it
in ring gear (3), rotate planetary gears 1
(17) by hand and adjust carrier 1 (16) to
mesh with sun gear 2 (15).
2. Making sure that coupling is on the shaft
end, install sun gear 1 (22) on center.
3. Place thrust plate (23) on carrier 1 (16).

Assembling carrier 1 assy

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Face sharp edged side to cover (24). (See Fig. "Assembling carrier 1 assy")

(10) Installing cover

1. Apply Loctite#515 on mating surfaces of
cover (24) and ring gear (3) and install
cover (24) on ring gear (3). 
2. After applying Loctite #242 on the threads
of 18 pieces of Hex. socket head bolts
M10X30 (25), tighten them with torque
wrench.
Tools: Allen wrench㧦8mm, Installing cover (24)
Tightening torque : 68.6N-m (50.6 lbf-ft)

(11) Filling gear oil

1. Fill gear oil (SAE #90 API class GL-4 or GL-5, 9.5 litters (2.5 gal)) from two G3/4 ports.
2. Tighten taper screw plugs (26).
Tools: Allen wrench : 14mm
Tightening torque : 147.1N-m (108 lbf-ft)

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34.2.9 MAINTENANCE STANDARD

34.2.9.1 INSPECTION BEFORE ASSEMBLING
(1) Thrust washer
1. Check if there are seizure, abnormal wear or uneven wear.
2. Check if the wear is over the allowable limit.
(2) Gears
1. Check if there are pitting or seizure on the tooth surface.
2. Check if there are clacks on the root of tooth by die check.
(3) Bearings
Rotate by hand to see if there are something unusual such as noise or uneven rotation.
(4) Floating seal
Check flaw or score on sliding surfaces or on O-rings.

34.2.9.2 MAINTENANCE STANDARD OF PARTS

The followings are the general maintenance
standards. However, it is most important to
determine which parts should be replaced,
depending on the characteristics shown before
disassembling, damages or discoloration of
exterior view, the purpose of disassembling,
the expected remaining service life etc..

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34.2.9.3 TIGHTENING TORQUE

Use torque wrench when tightening the following Hex. socket head bolts and plugs.



34.2.9.4 INSPECTION AFTER ASSEMBLED

(1) Quantity of lubrication
After installed the propelling unit, position the drain port at lowest position and check if lubrication
oil comes out when loosen the level plug.
(2) Rotating inspection
Put the unit on the test stand and rotate with no load and check if there are abnormal noise or
leak of oil. Take care not to overspeed the motor. Rotate within specified flow rate.

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 㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

46. TROUBLE SHOOTING

(BY ERROR CODES)
TABLE OF CONTENTS

46.1 JUDGMENT OF ACTUAL THING AT SITE ääääääääääääääääääääääää46-3

46.2 CLASSIFICATION OF FAILURE AND TROUBLESHOOTING ääääääääääääääää46-4
46.3 THE BLOWN FUSE OF MECHATRO CONTROLLER ääääääääääääääääääää46-5
46.4 TROUBLESHOOTING BY ERROR CODE äääääääääääääääääääääääää46-6



Book Code No. S5/4(

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Issue Date of Issue Applicable Machines Remarks

S5LQ4636E01
First Edition June, 2013 SK260LC-9 : LL14-08001~
(NA)

SK210LC-9 : YQ13-10001~
(NA)
SK330-9 : LC12-15001~
SK350LC-9 : YC12-10001~ (NA)

October, 2013 SK210LC-9 : YQ13-10001~

(North America / Europe)
SK260LC-9 : LL14-08003~
November, 2013
SK260NLC-9 : LL14-08003~ (North America / Europe)
SK330-9 : LC12-15001~
December, 2013
SK350(N)LC-9 : YC12-10002~ (NA / EUR)

July, 2014 SK350LC-9E : YC13-13001~

(NA)

Preface
Troubleshooting provides process locating for
the cause of trouble in the order that trouble
occurred. This manual describes how to solve
the specific phenomenon systematically as
early as possible. For troubleshooting
concerning the inside of equipment, refer to
troubleshooting for each manual of equipment.
Attending the field to verify actual thing.

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46.1 JUDGMENT OF ACTUAL THING AT SITE

(1) Get to the site as quickly as possible.

Verify model, serial number, situation of trouble
and field, and notify person of arrival time.
(2) Verify background of trouble occurred
1. Model name and serial number
2.
Kind of attachment
Check that the combination of attachment is
proper or that the operating method is not
unreasonable.
3. Operating time by hour-meter
Verifying background of trouble occurred.
4.
History of trouble occurred and additional works.
5.
Recurrence of past trouble, or problems on the
additional works.

(3) How to diagnose trouble

1. Verify defective part
2. Make the condition of trouble again
3.
Where defective parts can not be verified,
surmise causes systematically.
4. Verify reasons for surmise
5.
Report methods, procedure, and period for
repairing to user.

Confirm the symptoms of the trouble. 

(4) Explanation of the cause of trouble

1.
Explain the cause of trouble to clients. For
example, oil leak through piston is caused by
flaws on the piston rod. And the method of
using the machines should be explained so that
the same kind of trouble does not reoccur. Diagnosing fail by means troubleshooting.
2.
Treatment of damaged parts
The damaged parts to be claimed and
returned are evidence so they should be
handled with care. Protect them from entry of
water, soils, etc. into port of hydraulic unit, etc.
and return them. And also use care not to
flaw and damage those surfaces.

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46.2 CLASSIFICATION OF FAILURE AND TROUBLESHOOTING

Classify failures into the following 3 types and carry out the troubleshooting.

No. Classes of failure Troubleshooting

A When error code after self-diagnosis is displayed Carry out troubleshooting according to the error code.
on gauge cluster
B When no failure is detected currently but error When it is hard to recreate the failure situation,
code after self diagnosis is remained in trouble cancel the data in the history and reproduce the
history failed situation or suppose the cause according to
the troubleshooting by error code, and then repair it.
C When error code after self diagnosis is not -Carry out troubleshooting according to instructions in
displayed or is not remained in the history Chapter 47 "TROUBLESHOOTING BY TROUBLE".
-Carry out troubleshooting according to instructions in
Chapter 48 "TROUBLE DIAGNOSIS MODE".

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46.3 THE BLOWN FUSE OF MECHATRO CONTROLLER

If the fuse of mechatro controller has blown, the following display appears on the gauge cluster.

(1) The blown fuse of mechatro controller

a. Blown fuse 5A of mechatro controller :

"DATA COMMUNICATION ERROR" is displayed on the gauge cluster in the condition where the
controller program is not executed.
b. Blown fuse 20A of mechatro controller
The controller functions normally but the power supply applied when the controller drives the
solenoid, etc. stops.
Many error codes are displayed on the gauge cluster.
D013, D023, D033, D063,
E013, E023, F021



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㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

46.4 TROUBLESHOOTING BY ERROR CODE

When error code was displayed on the gauge cluster with the aid of self-diagnosis display function,
carry out the troubleshooting referring to applicable page in the contents of error codes.

Described
Error Code Trouble
page
A015 Engine adjustment (A adjustment) is not adjusted yet or is failed. 46-9
A025 Not yet adjusted pump torque or failed adjustment of pump torque (B adjustment). 46-9
A035 Unload valve adjustment (C adjustment) is not adjusted yet or is failed. 46-10
A045 Not yet adjusted boom up or failed adjustment of boom up. 46-10
A055 Not yet adjusted arm in or failed adjustment of arm-in. 46-11
A065 Not yet adjusted arm-out or failed adjustment of arm out. 46-11
A215 Written data of ROM adjustment data is incorrect. 46-12
A225 Writing of ROM adjustment data is incorrect. 46-12
A235 Written data of ROM hour meter data is incorrect. 46-13
A245 Writing of ROM hour meter data is incorrect. 46-13
A255 Writing of proportional valve adjustment data is incorrect. 46-14
B012 Incorrect output of boom up pressure sensor 46-14
B013 Disconnection of boom up pressure sensor 46-15
B014 Short-circuit of boom up pressure sensor 46-15
B022 Incorrect output of boom down pressure sensor 46-16
B023 Disconnection of boom down pressure sensor 46-16
B024 Short-circuit of boom down pressure sensor 46-17
B032 Incorrect output of arm out pressure sensor 46-17
B033 Disconnection of arm out pressure sensor 46-18
B034 Short-circuit of arm out pressure sensor 46-18
B042 Incorrect output of arm in pressure sensor 46-19
B043 Disconnection of arm in pressure sensor 46-19
B044 Short-circuit of arm in pressure sensor 46-20
B052 Incorrect output of bucket digging pressure sensor 46-20
B053 Disconnection of bucket digging pressure sensor 46-21
B054 Short-circuit of bucket digging pressure sensor 46-21
B062 Incorrect output of bucket dump pressure sensor 46-22
B063 Disconnection of bucket dump pressure sensor 46-22
B064 Short-circuit of bucket dump pressure sensor 46-23
B072 Incorrect output of swing pressure sensor 46-23
B073 Disconnection of swing pressure sensor 46-24
B074 Short-circuit of swing pressure sensor 46-24
B092 Incorrect output of travel right pressure sensor 46-25
B093 Disconnection of travel right pressure sensor 46-25
B094 Short-circuit of travel right pressure sensor 46-26
B102 Incorrect output of travel left pressure sensor 46-26

46-6
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 㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Described
Error Code Trouble
page
B103 Disconnection of travel left pressure sensor 46-27
B104 Short-circuit of travel left pressure sensor 46-27
B113 Disconnection of pressure sensor of optional selector positioning 46-28
B114 Short-circuit of pressure sensor of optional selector positioning 46-28
B162 Incorrect output of P1 optional side pressure sensor 46-29
B163 Disconnection of P1 side optional pressure sensor 46-29
B164 Short-circuit of P1 side optional pressure sensor 46-30
B172 Incorrect output of P2 optional side pressure sensor 46-30
B173 Disconnection of P2 side optional pressure sensor 46-31
B174 Short-circuit of P2 side optional pressure sensor 46-31
C012 Incorrect output of P1 pump pressure sensor 46-32
C013 Disconnection of P1 pump pressure sensor 46-32
C014 Short-circuit of P1 pump pressure sensor 46-33
C022 Incorrect output of P2 pump pressure sensor 46-33
C023 Disconnection of P2 pump pressure sensor 46-34
C024 Short-circuit of P2 pump pressure sensor 46-34
C033 Disconnection of boom head pressure sensor 46-35
C034 Short-circuit of boom head pressure sensor 46-35
C043 Disconnection of boom rod pressure sensor 46-36
C044 Short-circuit of boom rod pressure sensor 46-36
D012 Failure of output transistor ON at P1 unload proportional valve 46-37
D013 Disconnection of P1 unload proportional valve 46-37
D022 Failure of output transistor ON at P2 unload proportional valve 46-38
D023 Disconnection of P2 unload proportional valve 46-38
D032 Failure of output transistor ON at travel straight proportional valve 46-39
D033 Disconnection of travel straight proportional valve 46-39 
D062 Failure of output transistor ON at arm in high speed proportional valve 46-40
D063 Disconnection of arm in high speed proportional valve 46-40
E012 P1 pump proportional valve Output transistor ON failure 46-41
E013 Disconnection of P1pump proportional valve 46-41
E022 P2 pump proportional valve Output transistor ON failure 46-42
E023 Disconnection of P2 pump proportional valve 46-42
E032 Option relief 1 proportional valve Output transistor ON failure 46-43
E033 Option relief 1 proportional valve's wiring is disconnected. 46-43
E042 Option relief 2 proportional valve Output transistor ON failure 46-44
E043 Option relief 2 proportional valve's wiring is disconnected. 46-44
F011 Failure of output transistor OFF and GND short of attachment boost SOL valve 46-45
F013 Failure of output transistor ON and disconnection of attachment boost SOL valve 46-45
F021 Failure of output transistor OFF and GND short of swing parking SOL valve 46-46
F023 Failure of output transistor ON and disconnection of swing parking SOL valve 46-47

46-7
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㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Described
Error Code Trouble
page
F031 Failure of output transistor OFF and GND short of travel 1-2 speed SOL valve 46-48
F033 Failure of output transistor ON and disconnection of travel 1-2 speed SOL valve 46-48
F041 Failure of output transistor OFF and GND short of optional selector SOL valve 46-49
F043 Option selector solenoid valve Output transistor ON failure and disconnection 46-49
G032 Overrun of speed sensor of direct input Mechatro-controller 46-50
G033 Disconnection of speed sensor of direct input Mechatro-controller 46-50
Overrun of speed sensor of direct input Mechatro-controller and received data from
G042 46-51
E/G controller.
Disconnection of speed sensor of direct input Mechatro-controller and received data
G043 46-52
from E/G controller.
H013 Disconnection of acceleration potentio 46-53
H014 Power short-circuit of acceleration potentio 46-53
H023 Disconnection of boom angle potentio 46-54
H024 Power short-circuit of boom angle potentio 46-54
H033 Disconnection of arm angle potentio 46-55
H034 Power short-circuit of arm angle potentio 46-55
H091 Failure of GND short-circuit of fuel sensor 46-56
H093 The input voltage from fuel sensor is less than 0.1V. 46-56
H101 Hydraulic oil temperature sensor grounding is short-circuited. 46-57
H103 Hydraulic oil temperature sensor's wiring is disconnected. 46-57
I111 Received error of CAN1 communication (passive error) 46-58
I113 Reception of CAN1 communication is abnormal. (Time-out error) 46-58
I121 Transmission of CAN1 communication is abnormal. (Busoff error) 46-59
I211 Reception of CAN2 communication is abnormal. (Busoff error) 46-59
I213 Reception of CAN2 communication is abnormal. (Time-out error) 46-60
I221 Transmission of CAN2 communication is abnormal. (Busoff error) 46-60
I313 Received error of cluster communication (time-out error) 46-61
K014 Adhesion of battery relay terminal 46-62
R014 Failure of arc prevention relay of wiper motor 46-63
R024 Failure of normal rotation relay of wiper motor 46-63
R034 Failure of reverse rotation relay of wiper motor 46-64
R044 Failure of washer motor relay 46-64
R054 Bucket limit relay error 46-65
R134 Failure of swing right flasher relay 46-65
R144 Failure of swing left flasher relay 46-66
R154 Failure of travel alarm relay 46-66
R164 Failure of auto idling stop relay 2 46-67
R174 Failure of engine forcible stop relay 46-67
R184 Failure of lever lock relay 46-68
R214 Failure of safety relay 46-68
Z010 Injector is broken. 46-69

46-8
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 㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code A015

Trouble Not yet adjusted engine or failed adjustment of engine (A adjustment).
Judging Engine adjustment is missed. Or it is impossible to set the adjusting value within the adjusting
condition range.
Symptom Deviated from the reqired value, but no problem in normal operations.
Control in the
Rotate with the default engine speed.
event of failure
Returned in
The engine adjustment is completed normally.
normal condition

Service Screen No. 2 G-3 SPEED SET

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Checking Carry out engine adjustment (A adjustment). When "ERROR ENG" was
displayed during adjustment, refer to the section "Adjustment procedure -
Measures to be taken with the adjustment failed"
2 -Mechatro controller Check that the error is corrected after replacement of controller.
3

Error code A025

Trouble Not yet adjusted pump torque or failed adjustment of pump torque (B adjustment).
Judging The adjustment of pump torque is missed. Or the adjusting value can not be set in the
condition adjusting range.
Symptom Deviated from the pump output, but no problem in normal operations.
Control in the
Work with the default data.
event of failure
Returned in
The pump proportional valve adjustment is completed normally.
normal condition

Service Screen No. 9 E-1 P1 PUMP 

diagnosis Screen No. 9 E-2 P2 PUMP
checking screen Screen No.
Checking object Checking contents and remedy
1 -Checking Carry out pump adjustment (B adjustment).
When"ERROR PUMP" was displayed during adjustment, refer to the
section "Adjustment procedure - Measures to be taken with the
adjustment failed"
2 -Mechatro controller Check that the error is corrected after replacement of controller.
3

46-9
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code A035

Trouble Not yet adjusted unload valve or failed adjustment of unload valve (C adjustment).
Judging The adjustment of unload valve is missed. Or the adjusting value can not be set in the
condition adjusting range.
Symptom Deviated from the unload valve output, but no problem in normal operations.
Control in the
Work with the default data.
event of failure
Returned in
The adjustment of unload valve is completed normally.
normal condition

Service Screen No. 8 D-1 P1 UN-LOAD (BP-CUT)

diagnosis Screen No. 8 D-2 P2 UN-LOAD (BP-CUT)
checking screen Screen No.
Checking object Checking contents and remedy
1 -Checking Carry out adjustment of unload valve (C adjustment).
When"ERROR PUMP" was displayed during adjustment, refer to the
section "Adjustment procedure - Measures to be taken with the
adjustment failed"
2 -Mechatro controller Check that the error is corrected after replacement of controller.
3

Error code A045

Trouble Not yet adjusted boom up or failed adjustment of boom up.
Judging The adjustment of boom up is missed. Or the adjusting value can not be set in the adjusting
condition range.
Symptom Deviated from the boom up movement, but no problem in normal operations.
Control in the
Work with the default data.
event of failure
Returned in
The adjustment of boom up is completed normally.
normal condition

Service Screen No.

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Checking Carry out adjustment of pump torque (B adjustment).
When"ERROR PUMP" was displayed during adjustment, refer to the
section "Adjustment procedure - Measures to be taken with the
adjustment failed".
2 -Mechatro controller Check that the error is corrected after replacement of controller.
3

46-10
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
 㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code A055

Trouble Not yet adjusted arm in or failed adjustment of arm-in.
Judging The adjustment of arm-in is missed. Or the adjusting value can not be set in the adjusting
condition range.
Symptom Deviated from the arm-in movement, but no problem in normal operations.
Control in the
Work with the default data.
event of failure
Returned in
The adjustment of arm-in is completed normally.
normal condition

Service Screen No.

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Checking Carry out adjustment of pump torque (B adjustment).
When"ERROR PUMP" was displayed during adjustment, refer to the
section "Adjustment procedure - Measures to be taken with the
adjustment failed".
2 -Mechatro controller Check that the error is corrected after replacement of controller.
3

Error code A065

Trouble Not yet adjusted arm-out or failed adjustment of arm out.
Judging The adjustment of arm-out is missed. Or the adjusting value can not be set in the adjusting
condition range.
Symptom Deviated from the arm-out movement, but no problem in normal operations.
Control in the
Work with the default data.
event of failure
Returned in

The adjustment of arm-out is completed normally.
normal condition

Service Screen No.

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Checking Carry out adjustment of pump torque (B adjustment).
When"ERROR PUMP" was displayed during adjustment, refer to the
section "Adjustment procedure - Measures to be taken with the
adjustment failed".
2 -Mechatro controller Check that the error is corrected after replacement of controller.
3

46-11
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code A215

Trouble The data of ROM adjustment is written incorrectly.
Judging Check adjustment data, and judge the content of memory is correct or not. (Trouble history
condition only)
Symptom It is not normal output, but no problem in normal operation.
Control in the
Controlled by the default value.
event of failure
Returned in
It does not regain. Replace controller.
normal condition

Service Screen No.

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3

Error code A225

Trouble The data of ROM adjustment is written incorrectly.
Judging
Check adjustment data, and judge the data is correct or not.
condition
Symptom No effect
Control in the
Controlled by the correct memory data.
event of failure
Returned in
It does not regain. Replace controller.
normal condition

Service Screen No.

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3

46-12
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
 㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code A235

Trouble The data of ROM hourmeter is written incorrectly.
Judging
Check backup, and judge the content of memory is correct or not.
condition
Symptom No effect
Control in the
Controlled by the correct memory data.
event of failure
Returned in
It does not regain. Replace controller.
normal condition

Service Screen No.

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3

Error code A245

Trouble The data of ROM hourmeter is written incorrectly.
Judging
Check adjustment data, and judge the content of memory is correct or not.
condition
Symptom It is not normal output, but no problem in normal operation.
Control in the
Controlled by the default value.
event of failure
Returned in
It does not regain. Replace controller.
normal condition

Service Screen No.

diagnosis Screen No.
checking screen Screen No.

Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3

46-13
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code A255

Trouble The data of proportional valve adjustment is written incorrectly.
Judging
Check adjustment data, and judge the content of memory is correct or not.
condition
Symptom It is not normal output, but no problem in normal operation
Control in the
Controlled by the default value.
event of failure
Returned in
It does not regain. Replace controller.
normal condition

Service Screen No.

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3

Error code B012

Trouble Boom up pressure sensor outputs error.
Judging After starter switch ON and engine does not start yet. And the input voltage from the sensor
condition after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The boom up operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on
normal condition it again.

Service Screen No. 5 B-1 BOOM RAISE

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Boom up pressure sensor When B012 is cancelled and other error occurs by turning the starter
SE-3 switch on after replacing the connector with that of other sensor, check
the sensor unit for possible failure and replace it if necessary.
2 -Wiring between boom up When B012 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other sensor, check the wiring for possible
CN-126F failure according to the wiring checking procedures and repair it if
CN-101F necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-14
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
 㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code B013

Trouble Boom up pressure sensor's wiring disconnects.
Judging
The input voltage from boom up pressure sensor is less than 0.1V.
condition
Symptom The boom up speed slows down.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency
event of failure mode)
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 5 B-1 BOOM RAISE

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Boom up pressure sensor When B013 is cancelled and other error occurs by turning the starter
SE-3 switch on after replacing the connector with that of other sensor, check
the sensor unit for possible failure and replace it if necessary.
2 -Wiring between boom up When B013 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other sensor, check the wiring for possible
CN-126F failure according to the wiring checking procedures and repair it if
CN-101F necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Error code B014

Trouble Boom up pressure sensor's power source is shortcut.
Judging
The input voltage from boom up pressure sensor is 4.7V or more.
condition
Symptom The boom up speed slows down.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode) 
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 5 B-1 BOOM RAISE

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Boom up pressure sensor When B014 is cancelled and other error occurs by turning the starter
SE-3 switch on after replacing the connector with that of other sensor, check
the sensor unit for possible failure and replace it if necessary.
2 -Wiring between boom up When B014 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other sensor, check the wiring for possible
CN-126F failure according to the wiring checking procedures and repair it if
CN-101F necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-15
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code B022

Trouble Boom down pressure sensor outputs error.
Judging After starter switch ON and engine does not start yet. And the input voltage from the sensor
condition after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The boom down operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on
normal condition it again.

Service Screen No. 5 B-2 BOOM LOWER

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Boom down pressure sensor When B022 is cancelled and other error occurs by turning the starter
SE-4 switch on after replacing the connector with that of other sensor, check
the sensor unit for possible failure and replace it if necessary.
2 -Wiring between boom down When B022 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other sensor, check the wiring for possible
CN-127F failure according to the wiring checking procedures and repair it if
CN-101F necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Error code B023

Trouble Boom down pressure sensor's wiring is disconnecting.
Judging
The input voltage from boom down pressure sensor is less than 0.1V.
condition
Symptom The boom down operability becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 5 B-2 BOOM LOWER

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Boom down pressure sensor When B023 is cancelled and other error occurs by turning the starter
SE-4 switch on after replacing the connector with that of other sensor, check
the sensor unit for possible failure and replace it if necessary.
2 -Wiring between boom down When B023 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other sensor, check the wiring for possible
CN-127F failure according to the wiring checking procedures and repair it if
CN-101F necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-16
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
 㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code B024

Trouble Boom down pressure sensor's power source is shortcut.
Judging
The input voltage from boom down pressure sensor is 4.7V or more.
condition
Symptom The boom down operability becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 5 B-2 BOOM LOWER

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Boom down pressure sensor When B024 is cancelled and other error occurs by turning the starter
SE-4 switch on after replacing the connector with that of other sensor, check
the sensor unit for possible failure and replace it if necessary.
2 -Wiring between boom down When B024 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other sensor, check the wiring for possible
CN-127F failure according to the wiring checking procedures and repair it if
CN-101F necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Error code B032

Trouble Arm-in pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the sensor
condition after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The arm-out operability becomes poor.
Control in the
Normal control
event of failure 
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on
normal condition it again.

Service Screen No. 5 B-3 ARM OUT

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Arm-out pressure sensor When B032 is cancelled and other error occurs by turning the starter
SE-8 switch on after replacing the connector with that of other sensor, check
the sensor unit for possible failure and replace it if necessary.
2 -Wiring between arm-out When B032 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other sensor, check the wiring for possible
CN-131F failure according to the wiring checking procedures and repair it if
CN-101F necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-17
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code B033

Trouble Arm-out pressure sensor's wiring is disconnecting.
Judging
The input voltage from arm-out pressure sensor is less than 0.1V.
condition
Symptom Shock at stopping of arm-out is great.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Set output of P1 and P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 5 B-3 ARM OUT

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Arm-out pressure sensor When B033 is cancelled and other error occurs by turning the starter
SE-8 switch on after replacing the connector with that of other sensor, check
the sensor unit for possible failure and replace it if necessary.
2 -Wiring between arm-out When B033 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other sensor, check the wiring for possible
CN-131F failure according to the wiring checking procedures and repair it if
CN-101F necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Error code B034

Trouble Arm-out pressure sensor's power source is shortcut.
Judging
The input voltage from arm-out pressure sensor is 4.7V or more.
condition
Symptom Shock at stopping of arm-out is great.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Set output of P1 unload proportional valves to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 5 B-3 ARM OUT

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Arm-out pressure sensor When B034 is cancelled and other error occurs by turning starter switch
SE-8 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between arm-out When B034 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-131F Check wiring for possible failure according to the wiring checking
CN-101F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-18
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
 㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code B042

Trouble Arm-in pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the arm-in
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The arm-in operability becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency
event of failure mode)
Set output of P1 and P2 unload proportional valve to 0mA. (Valve emergency mode)
Set output of arm 2 arm-in proportional valve to 200mA.
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on
normal condition it again.

Service Screen No. 5 B-4 ARM IN

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Arm-in pressure sensor When B042 is cancelled and other error occurs by turning the starter
SE-7 switch on after replacing the connector with that of other sensor, check
the sensor unit for possible failure and replace it if necessary.
2 -Wiring between arm-in When B042 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other sensor, check the wiring for possible
CN-130F failure according to the wiring checking procedures and repair it if
CN-101F necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Error code B043

Trouble Arm-in pressure sensor's wiring is disconnecting.
Judging
The input voltage from arm-in pressure sensor is less than 0.1V.
condition
Symptom Bucket can drag under the condition that the bucket bottom put on the ground.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency 
event of failure mode)
Set output of P1 and P2 unload proportional valve to 0mA. (Valve emergency mode)
Set output of arm 2 arm-in proportional valve to 200mA.
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 5 B-4 ARM IN

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Arm-in pressure sensor When B043 is cancelled and other error occurs by turning the starter
SE-7 switch on after replacing the connector with that of other sensor, check
the sensor unit for possible failure and replace it if necessary.
2 -Wiring between arm-in When B043 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other sensor, check the wiring for possible
CN-130F failure according to the wiring checking procedures and repair it if
CN-101F necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-19
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㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code B044

Trouble Arm-in pressure sensor's power source is shortcut.
Judging
The input voltage from arm-in pressure sensor is 4.7V or more.
condition
Symptom Bucket can drag under the condition that the bucket bottom put on the ground.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency
event of failure mode)
Set output of P1, P2 unload proportional valves to 0mA. (Valve emergency mode)
Set output of arm 2 arm-in proportional valve to 200mA.
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 5 B-4 ARM IN

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Arm-in pressure sensor When B044 is cancelled and other error occurs by turning the starter
SE-7 switch on after replacing the connector with that of other sensor, check
the sensor unit for possible failure and replace it if necessary.
2 -Wiring between arm-in When B044 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other sensor, check the wiring for possible
CN-130F failure according to the wiring checking procedures and repair it if
CN-101F necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Error code B052

Trouble Bucket digging pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the bucket
condition digging pressure sensor after starter switch ON is in the range of 1.4V or more to less than
4.7V.
Symptom The bucket digging operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on
normal condition it again.

Service Screen No. 5 B-5 BUCKET DIG

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Bucket digging pressure When B052 is cancelled and other error occurs by turning the starter
sensor switch on after replacing the connector with that of other sensor, check
SE-1 the sensor unit for possible failure and replace it if necessary.
2 -Wiring between bucket digging When B052 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other sensor, check the wiring for possible
CN-124F failure according to the wiring checking procedures and repair it if
CN-101F necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-20
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 㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code B053

Trouble Bucket digging pressure sensor's wiring is disconnected.
Judging
The input voltage from bucket digging pressure sensor is less than 0.1V.
condition
Symptom The bucket digging speed slows down a little.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 5 B-5 BUCKET DIG

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Bucket digging pressure When B053 is cancelled and other error occurs by turning the starter
sensor switch on after replacing the connector with that of other sensor, check
SE-1 the sensor unit for possible failure and replace it if necessary.
2 -Wiring between bucket digging When B053 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other sensor, check the wiring for possible
CN-124F failure according to the wiring checking procedures and repair it if
CN-101F necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Error code B054

Trouble Bucket digging pressure sensor's power source is shortcut.
Judging
The input voltage from bucket digging pressure sensor is 4.7V or more.
condition
Symptom The bucket digging speed slows down a little.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode) 
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 5 B-5 BUCKET DIG

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Bucket digging pressure When B054 is cancelled and other error occurs by turning the starter
sensor switch on after replacing the connector with that of other sensor, check
SE-1 the sensor unit for possible failure and replace it if necessary.
2 -Wiring between bucket digging When B054 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other sensor, check the wiring for possible
CN-124F failure according to the wiring checking procedures and repair it if
CN-101F necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-21
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㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code B062

Trouble Bucket dump pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the bucket
condition dump pressure sensor after starter switch ON is in the range of 1.4V or more to less than
4.7V.
Symptom The bucket dump operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on
normal condition it again.

Service Screen No. 5 B-6 BUCKET DUMP

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Bucket dump pressure sensor When B062 is cancelled and other error occurs by turning the starter
SE-2 switch on after replacing the connector with that of other sensor, check
the sensor unit for possible failure and replace it if necessary.
2 -Wiring between bucket dump When B062 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other sensor, check the wiring for possible
CN-125F failure according to the wiring checking procedures and repair it if
CN-101F necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Error code B063

Trouble Bucket dump pressure sensor's wiring is disconnected.
Judging
The input voltage from bucket dump pressure sensor is less than 0.1V.
condition
Symptom The bucket dump speed slows down a little.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 5 B-6 BUCKET DUMP

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Bucket dump pressure sensor When B063 is cancelled and other error occurs by turning the starter
SE-2 switch on after replacing the connector with that of other sensor, check
the sensor unit for possible failure and replace it if necessary.
2 -Wiring between bucket dump When B063 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other sensor, check the wiring for possible
CN-125F failure according to the wiring checking procedures and repair it if
CN-101F necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-22
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 㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code B064

Trouble Bucket dump pressure sensor's power source is shortcut.
Judging
The input voltage from bucket dump pressure sensor is 4.7V or more.
condition
Symptom The bucket dump speed slows down a little.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 5 B-6 BUCKET DUMP

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Bucket dump pressure sensor When B064 is cancelled and other error occurs by turning the starter
SE-2 switch on after replacing the connector with that of other sensor, check
the sensor unit for possible failure and replace it if necessary.
2 -Wiring between bucket dump When B064 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other sensor, check the wiring for possible
CN-125F failure according to the wiring checking procedures and repair it if
CN-101F necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Error code B072

Trouble Swing pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the swing
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The swing operability becomes poor.
Control in the
Normal control
event of failure 
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on
normal condition it again.

Service Screen No. 6 B-7 SWING

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Swing pressure sensor When B072 is cancelled and other error occurs by turning the starter
SE-5 switch on after replacing the connector with that of other sensor, check
the sensor unit for possible failure and replace it if necessary.
2 -Wiring between swing When B072 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other sensor, check the wiring for possible
CN-169F failure according to the wiring checking procedures and repair it if
CN-103F necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-23
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㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code B073

Trouble Swing pressure sensor's wiring is disconnected.
Judging
The input voltage from swing pressure sensor is less than 0.1V.
condition
Symptom The swing operability becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 6 B-7 SWING

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Swing pressure sensor When B073 is cancelled and other error occurs by turning the starter
SE-5 switch on after replacing the connector with that of other sensor, check
the sensor unit for possible failure and replace it if necessary.
2 -Wiring between swing When B073 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other sensor, check the wiring for possible
CN-169F failure according to the wiring checking procedures and repair it if
CN-103F necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Error code B074

Trouble Swing pressure sensor's power source is shortcut.
Judging
The input voltage from swing pressure sensor is 4.7V or more.
condition
Symptom The swing operability becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 6 B-7 SWING

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Swing pressure sensor When B074 is cancelled and other error occurs by turning the starter
SE-5 switch on after replacing the connector with that of other sensor, check
the sensor unit for possible failure and replace it if necessary.
2 -Wiring between swing When B074 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other sensor, check the wiring for possible
CN-169F failure according to the wiring checking procedures and repair it if
CN-103F necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-24
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 㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code B092

Trouble Travel right pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the travel
condition right pressure sensor after starter switch ON is in the range of 1.4V or more to less than
4.7V.
Symptom The travel right operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on
normal condition it again.

Service Screen No. 6 B-9 TRAVEL (R)

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Travel right pressure sensor When B092 is cancelled and other error occurs by turning the starter
SE-9 switch on after replacing the connector with that of other sensor, check
the sensor unit for possible failure and replace it if necessary.
2 -Wiring between travel right When B092 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other sensor, check the wiring for possible
CN-301F failure according to the wiring checking procedures and repair it if
CN-102F necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Error code B093

Trouble Travel right pressure sensor's wiring is disconnected.
Judging
The input voltage from Travel right pressure sensor is less than 0.1V.
condition
Symptom The Travel right operability becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode) 
P1, Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 6 B-9 TRAVEL (R)

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Travel right pressure sensor When B093 is cancelled and other error occurs by turning the starter
SE-9 switch on after replacing the connector with that of other sensor, check
the sensor unit for possible failure and replace it if necessary.
2 -Wiring between travel right When B093 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other sensor, check the wiring for possible
CN-301F failure according to the wiring checking procedures and repair it if
CN-102F necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-25
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㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code B094

Trouble Travel right pressure sensor's power source is shortcut.
Judging
The input voltage from Travel right pressure sensor is 4.7V or more.
condition
Symptom The Travel right operability becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
P1, Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 6 B-9 TRAVEL (R)

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Travel right pressure sensor When B094 is cancelled and other error occurs by turning the starter
SE-9 switch on after replacing the connector with that of other sensor, check
the sensor unit for possible failure and replace it if necessary.
2 -Wiring between travel right When B094 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other sensor, check the wiring for possible
CN-301F failure according to the wiring checking procedures and repair it if
CN-102F necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Error code B102

Trouble Travel left pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the travel
condition left pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The travel left operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on
normal condition it again.

Service Screen No. 6 B-10 TRAVEL (L)

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Travel left pressure sensor When B102 is cancelled and other error occurs by turning starter switch
SE-10 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between travel left When B102 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other sensor, check the wiring for possible
CN-302F failure according to the wiring checking procedures and repair it if
CN-102F necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-26
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 㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code B103

Trouble Travel left pressure sensor's wiring is disconnected.
Judging
The input voltage from Travel left pressure sensor is less than 0.1V.
condition
Symptom The Travel left operability becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
P1, Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 6 B-10 TRAVEL (L)

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Travel left pressure sensor When B103 is cancelled and other error occurs by turning the starter
SE-10 switch on after replacing the connector with that of other sensor, check
the sensor unit for possible failure and replace it if necessary.
2 -Wiring between travel left When B103 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other sensor, check the wiring for possible
CN-302F failure according to the wiring checking procedures and repair it if
CN-102F necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Error code B104

Trouble Travel left pressure sensor's power source is shortcut.
Judging
The input voltage from Travel left pressure sensor is 4.7V or more.
condition
Symptom The Travel left operability becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode) 
P1, Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 6 B-10 TRAVEL (L)

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Travel left pressure sensor When B104 is cancelled and other error occurs by turning the starter
SE-10 switch on after replacing the connector with that of other sensor, check
the sensor unit for possible failure and replace it if necessary.
2 -Wiring between travel left When B104 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other sensor, check the wiring for possible
CN-302F failure according to the wiring checking procedures and repair it if
CN-102F necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-27
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㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code B113

Trouble Option selector position detect pressure sensor's wiring is disconnected.
Judging
The input voltage from option selector position detect pressure sensor is less than 0.1V.
condition
Symptom When breaker mode is selected, option selector valve error is indicated.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 16 B-11

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Option selector position When B113 is cancelled and other error occurs by turning the starter
detect pressure sensor switch on after replacing the connector with that of other sensor, check
SE-29 the sensor unit for possible failure and replace it if necessary.
2 -Wiring between option When B113 is displayed by turning the starter switch on after replacing
selector position detect the connector with that of other sensor, check the wiring for possible
pressure sensor and controller failure according to the wiring checking procedures and repair it if
CN-162F necessary.
CN-104F
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Error code B114

Trouble Option selector position detect pressure sensor's wiring is disconnected.
Judging
The input voltage from selector position detect pressure sensor is 4.7V or more.
condition
Symptom When breaker mode is selected, option selector valve error is indicated.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 16 B-11

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Option selector position When B114 is cancelled and other error occurs by turning the starter
detect pressure sensor switch on after replacing the connector with that of other sensor, check
SE-29 the sensor unit for possible failure and replace it if necessary.
2 -Wiring between option When B114 is displayed by turning the starter switch on after replacing
selector position detect the connector with that of other sensor, check the wiring for possible
pressure sensor and controller failure according to the wiring checking procedures and repair it if
CN-162F necessary.
CN-104F
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-28
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 㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code B162

Trouble P1 side option pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the P1 side
condition option pressure sensor after starter switch ON is in the range of 1.4V or more to less than
4.7V.
Symptom The P1 side option operability becomes poor.
Control in the
Set the pressure sensor of P1 side to 0 MPa.
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on
normal condition it again.

Service Screen No. 6 B-16 P1 OPT.

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -P1 side option pressure When B162 is cancelled and other error occurs by turning the starter
sensor switch on after replacing the connector with that of other sensor, check
SE-20 the sensor unit for possible failure and replace it if necessary.
2 -Wiring between P1 side option When B162 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other sensor, check the wiring for possible
CN-304F failure according to the wiring checking procedures and repair it if
CN-102F necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Error code B163

Trouble P1 side option pressure sensor's wiring is disconnected.
Judging
The input voltage from P1 side option pressure sensor is less than 0.1V.
condition
Symptom The P1 side option does not work.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode) 
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
But normal control is done when the left control pedal selection is ON.
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 6 B-16 P1 OPT.

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -P1 side option pressure When B163 is cancelled and other error occurs by turning the starter
sensor switch on after replacing the connector with that of other sensor, check
SE-20 the sensor unit for possible failure and replace it if necessary.
2 -Wiring between P1 side option When B163 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other sensor, check the wiring for possible
CN-304F failure according to the wiring checking procedures and repair it if
CN-102F necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-29
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㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code B164

Trouble P1 side option pressure sensor's wiring is disconnected.
Judging
The input voltage from P1 side option pressure sensor is 4.7V or more.
condition
Symptom The P1 side option does not work.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
But normal control is done when the left control pedal selection is ON.
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 6 B-16 P1 OPT.

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -P1 side option pressure When B164 is cancelled and other error occurs by turning the starter
sensor switch on after replacing the connector with that of other sensor, check
SE-20 the sensor unit for possible failure and replace it if necessary.
2 -Wiring between P1 side option When B164 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other sensor, check the wiring for possible
CN-304F failure according to the wiring checking procedures and repair it if
CN-102F necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Error code B172

Trouble P2 side option pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the P2 side
condition option pressure sensor after starter switch ON is in the range of 1.4V or more to less than
4.7V.
Symptom The P2 side option operability becomes poor.
Control in the
Set the pressure sensor of P2 side to 0 MPa.
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on
normal condition it again.

Service Screen No. 6 B-17 P2 OPT.

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -P2 side option pressure When B172 is cancelled and other error occurs by turning the starter
sensor switch on after replacing the connector with that of other sensor, check
SE-11 the sensor unit for possible failure and replace it if necessary.
2 -Wiring between P2 side option When B172 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other sensor, check the wiring for possible
CN-303F failure according to the wiring checking procedures and repair it if
CN-102F necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-30
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 㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code B173

Trouble P2 side option pressure sensor's wiring is disconnected.
Judging
The input voltage from P2 side option pressure sensor is less than 0.1V.
condition
Symptom The P2 side option does not work.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 6 B-17 P2 OPT.

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -P2 side option pressure When B173 is cancelled and other error occurs by turning the starter
sensor switch on after replacing the connector with that of other sensor, check
SE-11 the sensor unit for possible failure and replace it if necessary.
2 -Wiring between P2 side option When B173 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other sensor, check the wiring for possible
CN-303F failure according to the wiring checking procedures and repair it if
CN-102F necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Error code B174

Trouble P2 side option pressure sensor's wiring is disconnected.
Judging
The input voltage from P2 side option pressure sensor is 4.7V or more.
condition
Symptom The P2 side option does not work.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode) 
Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
But normal control is done when the left control pedal selection is ON.
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 6 B-17 P2 OPT.

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -P2 side option pressure When B174 is cancelled and other error occurs by turning the starter
sensor switch on after replacing the connector with that of other sensor, check
SE-11 the sensor unit for possible failure and replace it if necessary.
2 -Wiring between P2 side option When B174 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other sensor, check the wiring for possible
CN-303F failure according to the wiring checking procedures and repair it if
CN-102F necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

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㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code C012

Trouble P1 pump pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the P1
condition pump pressure sensor after starter switch ON is in the range of 1.4V or more to less than
4.7V.
Symptom The P1 pump operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on
normal condition it again.

Service Screen No. 7 C-1 PUMP P1

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -P1 pump pressure sensor When C012 is cancelled and other error occurs by turning the starter
SE-22 switch on after replacing the connector with that of other sensor, check
the sensor unit for possible failure and replace it if necessary.
2 -Wiring between P1 pump When C012 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other sensor, check the wiring for possible
CN-139F failure according to the wiring checking procedures and repair it if
CN-103F necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Error code C013

Trouble P1 pump pressure sensor's wiring is disconnected.
Judging
The input voltage from P1 pump pressure sensor is less than 0.1V.
condition
Symptom The delicate operability of P1 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 7 C-1 PUMP P1

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -P1 pump pressure sensor When C013 is cancelled and other error occurs by turning the starter
SE-22 switch on after replacing the connector with that of other sensor, check
the sensor unit for possible failure and replace it if necessary.
2 -Wiring between P1 pump When C013 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other sensor, check the wiring for possible
CN-139F failure according to the wiring checking procedures and repair it if
CN-103F necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

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 㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code C014

Trouble P1 pump pressure sensor's power source is shortcut.
Judging
The input voltage from P1 pump pressure sensor is 4.7V or more.
condition
Symptom The delicate operability of P1 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 7 C-1 PUMP P1

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -P1 pump pressure sensor When C014 is cancelled and other error occurs by turning starter switch
SE-22 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between P1 pump When C014 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other sensor, check the wiring for possible
CN-139F failure according to the wiring checking procedures and repair it if
CN-103F necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Error code C022

Trouble P2 pump pressure sensor outputs error.
Judging After starter switch ON and engine does not start yet. And the input voltage from the P2
condition pump pressure sensor after starter switch ON is in the range of 1.4V or more to less than
4.7V.
Symptom The P2 pump operability becomes poor.
Control in the
Normal control
event of failure 
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on
normal condition it again.

Service Screen No. 7 C-2 PUMP P2

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -P2 pump pressure sensor When C022 is cancelled and other error occurs by turning the starter
SE-23 switch on after replacing the connector with that of other sensor, check
the sensor unit for possible failure and replace it if necessary.
2 -Wiring between P2 pump When C022 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other sensor, check the wiring for possible
CN-140F failure according to the wiring checking procedures and repair it if
CN-103F necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

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㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code C023

Trouble P2 pump pressure sensor's wiring is disconnected.
Judging
The input voltage from P2 pump pressure sensor is less than 0.1V.
condition
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 7 C-2 PUMP P2

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -P2 pump pressure sensor When C023 is cancelled and other error occurs by turning the starter
SE-23 switch on after replacing the connector with that of other sensor, check
the sensor unit for possible failure and replace it if necessary.
2 -Wiring between P2 pump When C023 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other sensor, check the wiring for possible
CN-140F failure according to the wiring checking procedures and repair it if
CN-103F necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Error code C024

Trouble P2 pump pressure sensor's power source is shortcut.
Judging
The input voltage from P2 pump pressure sensor is 4.7V or more.
condition
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 7 C-2 PUMP P2

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -P2 pump pressure sensor When C024 is cancelled and other error occurs by turning the starter
SE-23 switch on after replacing the connector with that of other sensor, check
the sensor unit for possible failure and replace it if necessary.
2 -Wiring between P2 pump When C024 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other sensor, check the wiring for possible
CN-140F failure according to the wiring checking procedures and repair it if
CN-103F necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

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 㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code C033

Trouble Boom head pressure sensor's wiring is disconnected.
Judging
The input voltage from boom head pressure sensor is less than 0.1V.
condition
Symptom Indication load value of High-reach crane becomes abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 7 C-3 BOOM-HEAD

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Boom head pressure sensor When C033 is cancelled and other error occurs by turning the starter
SE-24 switch on after replacing the connector with that of other sensor, check
the sensor unit for possible failure and replace it if necessary.
2 -Wiring between boom head When C033 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other sensor, check the wiring for possible
CN-706F failure according to the wiring checking procedures and repair it if
CN-104F necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Error code C034

Trouble Boom head pressure sensor's power source is shortcut.
Judging
The input voltage from boom head pressure sensor is 4.7V or more.
condition
Symptom Indication load value of High-reach crane becomes abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.

normal condition

Service Screen No. 7 C-3 BOOM-HEAD

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Boom head pressure sensor When C034 is cancelled and other error occurs by turning the starter
SE-24 switch on after replacing the connector with that of other sensor, check
the sensor unit for possible failure and replace it if necessary.
2 -Wiring between boom head When C034 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other sensor, check the wiring for possible
CN-706F failure according to the wiring checking procedures and repair it if
CN-104F necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

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㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code C043

Trouble Boom rod pressure sensor's wiring is disconnected.
Judging
The input voltage from boom rod pressure sensor is less than 0.1V.
condition
Symptom Indication load value of High-reach crane becomes abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 7 C-4 BOOM-ROD

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Boom rod pressure sensor When C043 is cancelled and other error occurs by turning the starter
SE-25 switch on after replacing the connector with that of other sensor, check
the sensor unit for possible failure and replace it if necessary.
2 -Wiring between boom rod When C043 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other sensor, check the wiring for possible
CN-705F failure according to the wiring checking procedures and repair it if
CN-104F necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Error code C044

Trouble Boom rod pressure sensor's power source is shortcut.
Judging
The input voltage from boom rod pressure sensor is 4.7V or more.
condition
Symptom Indication load value of High-reach crane becomes abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 7 C-4 BOOM-ROD

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Boom rod pressure sensor When C044 is cancelled and other error occurs by turning the starter
SE-25 switch on after replacing the connector with that of other sensor, check
the sensor unit for possible failure and replace it if necessary.
2 -Wiring between boom rod When C044 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other sensor, check the wiring for possible
CN-705F failure according to the wiring checking procedures and repair it if
CN-104F necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

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 㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code D012

Trouble P1 unload proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Option conflux can not be done.
Control in the
Set output of P1 unload proportional valve to 0mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 8 D-1 P1 UN-LOAD (BP-CUT)

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -P1 unload proportional valve When D012 is cancelled and other error occurs by turning the starter
PSV-D switch on after replacing the connector with that of other proportional
valve, check the proportional valve unit for possible failure and replace it
if necessary.
2 -Wiring between P1 unload When D012 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other proportional valve, check the wiring for
CN-120F possible failure according to the wiring checking procedures and repair it
CN-105F if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Error code D013

Trouble P1 unload proportional valve's wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 100mA or less, judging is not done.)
Symptom Option conflux can not be done.
Control in the The feed-back value from proportional valve is less than 100mA. (If output is less than
event of failure 100mA, judging is not done.) 
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 8 D-1 P1 UN-LOAD (BP-CUT)

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -P1 unload proportional valve When D013 is cancelled and other error occurs by turning the starter
PSV-D switch on after replacing the connector with that of other proportional
valve, check the proportional valve unit for possible failure and replace it
if necessary.
2 -Wiring between P1 unload When D013 is displayed by turning the starter switch on after replacing
pressure sensor and controller the connector with that of other proportional valve, check the wiring for
CN-120F possible failure according to the wiring checking procedures and repair it
CN-105F if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

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㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code D022

Trouble P2 unload proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Independent operations of boom up and of bucket digging/dump become slow.
Control in the
Set output of P2 unload proportional valve to 0mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 8 D-2 P2 UN-LOAD (BP-CUT)

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -P2 unload proportional valve When D022 is cancelled and other error occurs by turning the starter
PSV-B switch on after replacing the connector with that of other proportional
valve, check the proportional valve unit for possible failure and replace it
if necessary.
2 -Wiring between P2 unload When D022 is displayed by turning the starter switch on after replacing
proportional valve and controller the connector with that of other proportional valve, check the wiring for
CN-118F possible failure according to the wiring checking procedures and repair it
CN-105F if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Error code D023

Trouble P2 unload proportional valve's wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 100mA or less, judging is not done.)
Symptom Independent operations of boom up and of bucket digging/dump become slow.
Control in the
Set output of P2 unload proportional valve to 0mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 8 D-2 P2 UN-LOAD (BP-CUT)

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -P2 unload proportional valve When D023 is cancelled and other error occurs by turning the starter
PSV-B switch on after replacing the connector with that of other proportional
valve, check the proportional valve unit for possible failure and replace it
if necessary.
2 -Wiring between P2 unload When D023 is displayed by turning the starter switch on after replacing
proportional valve and controller the connector with that of other proportional valve, check the wiring for
CN-118F possible failure according to the wiring checking procedures and repair it
CN-105F if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

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 㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code D032

Trouble Travel straight proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Travel deviation occurs by combined operation of travel and attachment.
Control in the
Set Travel straight proportional valve output to 0mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 8 D-3 S-TRAVEL

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Travel straight proportional When D032 is cancelled and other error occurs by turning the starter
valve switch on after replacing the connector with that of other proportional
PSV-C valve, check the proportional valve unit for possible failure and replace it
if necessary.
2 -Wiring between Travel straight When D032 is displayed by turning the starter switch on after replacing
proportional valve and controller the connector with that of other proportional valve, check the wiring for
CN-119F possible failure according to the wiring checking procedures and repair it
CN-105F if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Error code D033

Trouble Travel straight proportional valve's wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 100mA or less, judging is not done.)
Symptom Travel deviation occurs by combined operation of travel and attachment.
Control in the The feed-back value from proportional valve is less than 100mA. (If output is less than
event of failure 100mA, judging is not done.) 
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 8 D-3 S-TRAVEL

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Travel straight proportional When D033 is cancelled and other error occurs by turning the starter
valve switch on after replacing the connector with that of other proportional
PSV-C valve, check the proportional valve unit for possible failure and replace it
if necessary.
2 -Wiring between Travel straight When D033 is displayed by turning the starter switch on after replacing
proportional valve and controller the connector with that of other proportional valve, check the wiring for
CN-119F possible failure according to the wiring checking procedures and repair it
CN-105F if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

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㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code D062

Trouble Arm-in spool 2 proportional valve and output transistor ON are failure.
Judging condition The feed-back value from proportional valve is 1000mA or more.
Symptom Operability of combined operation with arm-in becomes poor.
Control in the
Set Arm-in spool 2 proportional valve output to 0mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 8 D-6 ARM IN-2-SPEED
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 -Arm-in spool 2 proportional When D062 is cancelled and other error occurs by turning the starter
valve switch on after replacing the connector with that of other proportional
PSV-A valve, check the proportional valve unit for possible failure and replace
it if necessary.
2 -Wiring between Arm-in spool 2 When D062 is displayed by turning the starter switch on after replacing
proportional valve and controller the connector with that of other proportional valve, check the wiring for
CN-121F possible failure according to the wiring checking procedures and repair it
CN-105F if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Error code D063

Trouble Arm-in spool 2 proportional valve's wiring is disconnected.
Judging condition The feed-back value from proportional valve is 100mA or less.
(If output is 100mA or less, judging is not done.)
Symptom Operability of combined operation with arm-in becomes poor.
Control in the The feed-back value from proportional valve is less than 100mA. (If output is less than
event of failure 100mA, judging is not done.)
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 8 D-6 ARM IN-2-SPEED
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 -Arm-in spool 2 proportional When D063 is cancelled and other error occurs by turning the starter
valve switch on after replacing the connector with that of other proportional
PSV-A valve, check the proportional valve unit for possible failure and replace
it if necessary.
2 -Wiring between Arm-in spool 2 When D063 is displayed by turning the starter switch on after replacing
proportional valve and controller the connector with that of other proportional valve, check the wiring for
CN-121F possible failure according to the wiring checking procedures and repair it
CN-105F if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

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 㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code E012

Trouble P1 pump proportional valve Output transistor ON failure
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom The delicate operability of attachment becomes poor.
Control in the
Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 9 E-1 PUMP P1

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -P1 pump proportional valve When E012 is cancelled and other error occurs by turning the starter
PSV-P1 switch on after replacing the connector with that of other proportional
valve, check the proportional valve unit for possible failure and replace it
if necessary.
2 -Wiring between P1 pump When E012 is displayed by turning the starter switch on after replacing
proportional valve and controller the connector with that of other proportional valve, check the wiring for
CN-141F possible failure according to the wiring checking procedures and repair it
CN-105F if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Error code E013

Trouble P1 pump proportional valve's wiring is disconnected.
Judging The feed-back value from proportional valve is less than 100mA. (If output is less than
condition 100mA, judging is not done.)
Symptom The delicate operability of attachment becomes poor.
Control in the
Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure 
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 9 E-1 PUMP P1

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -P1 pump proportional valve When E013 is cancelled and other error occurs by turning the starter
PSV-P1 switch on after replacing the connector with that of other proportional
valve, check the proportional valve unit for possible failure and replace it
if necessary.
2 -Wiring between P1 pump When E013 is displayed by turning the starter switch on after replacing
proportional valve and controller the connector with that of other proportional valve, check the wiring for
CN-141F possible failure according to the wiring checking procedures and repair it
CN-105F if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

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㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code E022

Trouble P2 pump proportional valve Output transistor ON failure
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom The delicate operability of attachment becomes poor.
Control in the
Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 9 E-2 PUMP P2

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -P2 pump proportional valve When E022 is cancelled and other error occurs by turning the starter
PSV-P2 switch on after replacing the connector with that of other proportional
valve, check the proportional valve unit for possible failure and replace it
if necessary.
2 -Wiring between P2 pump When E022 is displayed by turning the starter switch on after replacing
proportional valve and controller the connector with that of other proportional valve, check the wiring for
CN-142F possible failure according to the wiring checking procedures and repair it
CN-105F if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Error code E023

Trouble P2 pump proportional valve's wiring is disconnected.
Judging The feed-back value from proportional valve is less than 100mA. (If output is less than
condition 100mA, judging is not done.)
Symptom The delicate operability of attachment becomes poor.
Control in the
Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 9 E-2 PUMP P2

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -P2 pump proportional valve When E023 is cancelled and other error occurs by turning the starter
PSV-P2 switch on after replacing the connector with that of other proportional
valve, check the proportional valve unit for possible failure and replace it
if necessary.
2 -Wiring between P2 pump When E023 is displayed by turning the starter switch on after replacing
proportional valve and controller the connector with that of other proportional valve, check the wiring for
CN-142F possible failure according to the wiring checking procedures and repair it
CN-105F if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

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 㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code E032

Trouble Option relief 1 proportional valve Output transistor ON failure
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Not relieved at the set pressure.
Control in the
Set output of option relief 1 proportional valve to 0mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 7 E-3 OPT RELIEF 1

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Option relief 1 proportional When E032 is cancelled and other error occurs by turning the starter
valve switch on after replacing the connector with that of other proportional
PSV-PE valve, check the proportional valve unit for possible failure and replace it
if necessary.
2 -Wiring between option relief When E032 is displayed by turning the starter switch on after replacing
1 proportional valve and the connector with that of other proportional valve, check the wiring for
controller possible failure according to the wiring checking procedures and repair it
CN-148F if necessary.
CN-105F
3 -Mechatronic controller Check that the error is corrected after replacement of controller.

Error code E033

Trouble Option relief 1 proportional valve's wiring is disconnected.
Judging The feed-back value from proportional valve is less than 100mA. (If output is 100mA or less,
condition judging is not done.)
Symptom Not relieved at the set pressure.
Control in the
Set output of option relief 1 proportional valve to 0mA.

event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 7 E-3 OPT RELIEF 1

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Option relief 1 proportional When E033 is cancelled and other error occurs by turning the starter
valve switch on after replacing the connector with that of other proportional
PSV-PE valve, check the proportional valve unit for possible failure and replace it
if necessary.
2 -Wiring between option relief When E033 is displayed by turning the starter switch on after replacing
1 proportional valve and the connector with that of other proportional valve, check the wiring for
controller possible failure according to the wiring checking procedures and repair it
CN-148F if necessary.
CN-105F
3 -Mechatronic controller Check that the error is corrected after replacement of controller.

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㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code E042

Trouble Option relief 2 proportional valve Output transistor ON failure
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Not relieved at the set pressure.
Control in the
Set output of option relief 2 proportional valve to 0mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 7 E-4 OPT RELIEF 2

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Option relief 2 proportional When E042 is cancelled and other error occurs by turning the starter
valve switch on after replacing the connector with that of other proportional
PSV-I valve, check the proportional valve unit for possible failure and replace it
if necessary.
2 -Wiring between option relief When E042 is displayed by turning the starter switch on after replacing
2 proportional valve and the connector with that of other proportional valve, check the wiring for
controller possible failure according to the wiring checking procedures and repair it
CN-132F if necessary.
CN-106F
3 -Mechatronic controller Check that the error is corrected after replacement of controller.

Error code E043

Trouble Option relief 2 proportional valve's wiring is disconnected.
Judging The feed-back value from proportional valve is less than 100mA. (If output is 100mA or less,
condition judging is not done.)
Symptom Not relieved at the set pressure.
Control in the
Set output of option relief 2 proportional valve to 0mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 7 E-4 OPT RELIEF 2

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Option relief 2 proportional When E043 is cancelled and other error occurs by turning the starter
valve switch on after replacing the connector with that of other proportional
PSV-I valve, check the proportional valve unit for possible failure and replace it
if necessary.
2 -Wiring between option relief When E043 is displayed by turning the starter switch on after replacing
2 proportional valve and the connector with that of other proportional valve, check the wiring for
controller possible failure according to the wiring checking procedures and repair it
CN-132F if necessary.
CN-106F
3 -Mechatronic controller Check that the error is corrected after replacement of controller.

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 㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code F011

Trouble ATT boost solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Judging
The feed-back signal is grounding level while exciting command is output.
condition
Symptom ATT boost does not change.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is 24V level while exciting command is output.
normal condition

Service Screen No. 3 F-1 POWER BOOST

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -ATT boost solenoid valve When F011 is cancelled and other error occurs by turning the starter
SV-2 switch on after replacing the connector with that of other solenoid valve,
check the solenoid valve unit for possible failure and replace it if
necessary.
2 -Wiring between ATT boost When F011 is displayed by turning the starter switch on after replacing
solenoid valve and controller the connector with that of other solenoid valve, check the wiring for
CN-117F possible failure according to the wiring checking procedures and repair it
CN-105F if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Error code F013

Trouble ATT boost solenoid valve and output transistor ON are failure, and disconnection.
Judging
The feed-back signal is 24V level while exciting command is not output.
condition
Symptom ATT boost does not change.
Control in the
Normal control
event of failure 
Returned in
The feed-back signal is grounding level while exciting command is not output.
normal condition

Service Screen No. 3 F-1 POWER BOOST

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -ATT boost solenoid valve When F013 is cancelled and other error occurs by turning the starter
SV-2 switch on after replacing the connector with that of other solenoid valve,
check the solenoid valve unit for possible failure and replace it if
necessary.
2 -Wiring between ATT boost When F013 is displayed by turning the starter switch on after replacing
solenoid valve and controller the connector with that of other solenoid valve, check the wiring for
CN-117F possible failure according to the wiring checking procedures and repair it
CN-105F if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

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㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code F021

Trouble Swing parking solenoid valve and output transistor OFF are failure, and grounding is
short-circuit.
Judging
The feed-back signal is grounding level while exciting command is output.
condition
Symptom Swing parking brake does not change.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is 24V level while exciting command is output.
normal condition

Service Screen No. 3 F-2 SWING-BRAKE

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Swing parking solenoid valve When F021 is cancelled and other error occurs by exchanging the
SV-1 connector for other solenoid valve. Check solenoid valve unit for
possible failure. If failure found, replace it.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 -Swing PB release switch Set swing PB release switch to the release side and check that
SW-4 connector (CN-63F) is switched. If failure is found, replace it.
3 -Wiring between swing When F021 is displayed by turning the starter switch on after replacing
parking solenoid valve, swing the connector with that of other solenoid valve, check the wiring for
PB release switch, and possible failure according to the wiring checking procedures and repair it
controller if necessary.
CN-123F
CN-63F
CN-108F
CN-105F
CN-158F
4 -Mechatro controller Check that the error is corrected after replacement of controller.

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 㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code F023

Trouble Swing parking solenoid valve and output transistor ON are failure, and disconnection.
Judging
The feed-back signal is 24V level while exciting command is not output.
condition
Symptom Swing parking brake does not change.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is grounding level while exciting command is output.
normal condition

Service Screen No. 3 F-2 SWING-BRAKE

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Swing parking solenoid valve When F023 is cancelled and other error occurs by exchanging the
SV-1 connector for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 -Swing PB release switch Set swing PB release switch to the release side and check that
SW-4 connector (CN-63F) is switched. If failure is found, replace it.
3 -Wiring between swing When F023 is displayed by turning the starter switch on after replacing
parking solenoid valve, swing the connector with that of other solenoid valve, check the wiring for
PB release switch, and possible failure according to the wiring checking procedures and repair it
controller if necessary.
CN-123F
CN-63F
CN-108F
CN-105F
CN-158F
4 -Mechatro controller Check that the error is corrected after replacement of controller.



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㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code F031

Trouble Travel 1, 2 speed solenoid valve and output transistor OFF are failure, and grounding is
short-circuit.
Judging condition The feed-back signal is grounding level while exciting command is output.
Symptom Travel 2 speed is not obtainable.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is 24V level while exciting command is output.
normal condition
Screen No. 3 F-3 1/2-TRAVEL
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 -Travel 1, 2speed solenoid valve When F031 is cancelled and other error occurs by turning the starter
SV-3 switch on after replacing the connector with that of other solenoid
valve, check the solenoid valve unit for possible failure and replace it
if necessary.
2 -Wiring between travel 1, 2speed When F031 is displayed by turning the starter switch on after replacing
solenoid valve and controller the connector with that of other solenoid valve, check the wiring for
CN-122F possible failure according to the wiring checking procedures and repair
CN-105F it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Error code F033

Trouble Travel 1, 2 speed solenoid valve and output transistor ON are failure, and disconnection.
Judging condition The feed-back signal is 24V level while exciting command is not output.
Symptom Travel 2 speed is not obtainable or is keeping 1 speed.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is grounding level while exciting command is not output.
normal condition
Screen No. 3 F-3 1/2-TRAVEL
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 -Travel 1, 2speed solenoid valve When F033 is cancelled and other error occurs by turning the starter
SV-3 switch on after replacing the connector with that of other solenoid
valve, check the solenoid valve unit for possible failure and replace it
if necessary.
2 -Wiring between travel 1, 2speed When F033 is displayed by turning the starter switch on after replacing
solenoid valve and controller the connector with that of other solenoid valve, check the wiring for
CN-122F possible failure according to the wiring checking procedures and repair
CN-105F it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

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 㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code F041

Trouble Option selector solenoid valve and output transistor OFF are failure, and grounding is
short-circuit.
Judging
The feed-back signal is grounding level while exciting command is output.
condition
Symptom Option selector valve does not change to breaker side.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is ground level while exciting command is output.
normal condition

Service Screen No. 9 F-4 OPT SELECT

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Option selector solenoid valve When F041 is cancelled and other error occurs by turning the starter
SV-13 switch on after replacing the connector with that of other solenoid valve,
check the solenoid valve unit for possible failure and replace it if
necessary.
2 -Wiring between option selector When F041 is displayed by turning the starter switch on after replacing
solenoid valve and controller the connector with that of other solenoid valve, check the wiring for
CN-251F possible failure according to the wiring checking procedures and repair it
CN-105F if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Error code F043

Trouble Option selector solenoid valve Output transistor ON failure and disconnection.
Judging
The feed-back signal is 24V level while exciting command is not output.
condition
Symptom Option selector solenoid valve does not change.
Control in the
Normal control

event of failure
Returned in
The feed-back signal is ground level while exciting command is not output.
normal condition

Service Screen No. 9 F-4 OPT SELECT

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Option selector solenoid valve When F043 is cancelled and other error occurs by turning the starter
SV-13 switch on after replacing the connector with that of other solenoid valve,
check the solenoid valve unit for possible failure and replace it if
necessary.
2 -Wiring between option selector When F043 is displayed by turning the starter switch on after replacing
solenoid valve and controller the connector with that of other solenoid valve, check the wiring for
CN-251F possible failure according to the wiring checking procedures and repair it
CN-105F if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

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㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code G032

Trouble Mechatro controller direct input speed sensor is overrun.
Judging
Engine rpm input is 3000rpm or more. (Only trouble history)
condition
Symptom Operate without problem.
Control in the
Receive rpm from engine controller and control the rpm.
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 2 G-3 MEAS 1 (for mechatro controller)

diagnosis Screen No. 2 G-3 MEAS 2 (receive from engine controller)
checking screen Screen No.
Checking object Checking contents and remedy
1 -Engine speed sensor Measure the resistance between terminals of speed sensor.
SE-13 Normal value: 1.6 to 2.0 kilo-ohms
2 -Wiring between engine Check wiring for possible failure according to the wiring checking
speed sensor and controller procedure and repair it if necessary.
CN-136F Especially check wiring for false disconnection and noise included.
CN-106F
3 -Mechatro controller Check that the error is corrected after replacement of controller.
(Controller is broken by only applying power to grounding of signal.)

Error code G033

Trouble Mechatro controller direct input speed sensor, Disconnection
Judging
Voltage of alternator is 12V or more, and speed sensor indicates excess low engine rpm.
condition
Symptom Operate without problem.
Control in the
Receive rpm from engine controller and control the rpm.
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 2 G-3 MEAS 1 (for mechatro controller)

diagnosis Screen No. 2 G-3 MEAS 2 (receive from engine controller)
checking screen Screen No.
Checking object Checking contents and remedy
1 -Engine speed sensor Measure the resistance between terminals of speed sensor.
SE-13 Normal value: 1.6 to 2.0 kilo-ohms
2 -Wiring between engine Check wiring for possible failure according to the wiring checking
speed sensor and controller procedure and repair it if necessary.
CN-136F
CN-106F
3 -Mechatro controller Check that the error is corrected after replacement of controller.
(Controller is broken by only applying power to grounding of signal.)

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 㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code G042

Trouble Mechatro controller direct input speed sensor and received data from engine controller are
overrun.
Judging
Engine rpm input is 3000rpm or more. (Only trouble history)
condition
Symptom Operate without problem.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 2 G-3 MEAS 1 (for mechatro controller)

diagnosis Screen No. 2 G-3 MEAS 2 (receive from engine controller)
checking screen Screen No.
Checking object Checking contents and remedy
1 -Engine speed sensor Measure the resistance between terminals of speed sensor.
SE-13 Normal value: 1.6 to 2.0 kilo-ohms
2 - Wiring between engine Check wiring for possible failure according to the wiring checking
speed sensor and controller procedure and repair it if necessary.
CN-136F Especially check wiring for false disconnection and noise included.
CN-106F
3 -Wiring between ECU engine Check wiring for possible failure according to the wiring checking
speed sensor and controller procedure and repair it if necessary.
pressure sensor and controller Especially check wiring for false disconnection and noise included.
4 -Mechatro controller Check that the error is corrected after replacement of controller.
(Controller is broken by only applying power to grounding of signal.)
5 -Engine controller Check that the error is corrected after replacement of controller.



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㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code G043

When cranking is executed for five seconds or more, this error code might be displayed. In
case that the engine does not start, check by the table of "Section 47.3 Engine related
Troubleshooting". Execute the following check when the error code G043 is displayed after
starting the engine.
Trouble Mechatro controller direct input speed sensor and received data from engine controller are
disconnected.
Judging Voltage of alternator is 12V or more, and speed sensor and receipt data from engine
condition controller is less than extreme low engine rpm.
Symptom Engine speed down may cause extension by abrupt loading.
Control in the
Enter 0 rpm for engine speed. Enter 0 for ESS power shift command.
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 2 G-3 MEAS 1 (for mechatro controller)

diagnosis Screen No. 2 G-3 MEAS 2 (receive from engine controller)
checking screen Screen No.
Checking object Checking contents and remedy
1 -Engine speed sensor Measure the resistance between terminals of speed sensor.
SE-13 Normal value: 1.6 to 2.0 kilo-ohms
2 -Wiring between engine Check wiring for possible failure according to the wiring checking
speed sensor and controller procedure and repair it if necessary.
CN-136F
CN-106F
3 -Wiring between ECU engine Check wiring for possible failure according to the wiring checking
speed sensor and controller procedure and repair it if necessary.
pressure sensor and controller
4 -Mechatro controller Check that the error is corrected after replacement of controller.
(Controller is broken by only applying power to grounding of signal.)
5 -Engine controller Check that the error is corrected after replacement of controller.

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 㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code H013

Trouble Accel potentiometer is disconnected.
Judging
The input voltage from accel potentiometer is less than 0.1V.
condition
Symptom LOW idling is fixed.
Control in the
LOW idling is fixed.
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 2 H-1 ACCEL VOLT.

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Accel potentiometer Measure the resistance between terminals of speed sensor. Normal
SE-16 value: 1.6 to 2.4 kilo-ohms
Turn the potentiometer and measure resistance between signal and GND.
2 -Wiring between accel Check wiring for possible failure according to the wiring checking
potentiometer and controller procedure and repair it if necessary.
CN-402F
CN-573M
CN-102F
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Error code H014

Trouble Accel potentiometer's power source is shortcut.
Judging
The input voltage from accel potentiometer is 4.7V or more.
condition
Symptom LOW idling is fixed.
Control in the
LOW idling is fixed.
event of failure 
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 2 H-1 ACCEL VOLT.

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Accel potentiometer Measure the resistance between terminals of accel potentiometer.
SE-16 1.6 to 2.4 kilo-ohms
Turn the potentiometer and measure resistance between signal and GND.
2 -Wiring between accel Check wiring for possible failure according to the wiring checking
potentiometer and controller procedure and repair it if necessary.
CN-402F
CN-573M
CN-102F
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-53
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㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code H023

Trouble Boom angle potentiometer's wiring is disconnected.
Judging
The input voltage from boom angle potentiometer is less than 0.1V.
condition
Symptom Indications of rating load and working radius of High-reach crane become abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 10 H-2 BOOM

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Boom angle potentiometer Measure the resistance between terminals of boom angle potentiometer.
SE-17 4.0 to 6.0 kilo-ohms
Turn the potentiometer and measure resistance between signal and GND.
Normal value: 0 to all resistance (4.0 to 6.0) kilo-ohms
2 -Wiring between accel Check wiring for possible failure according to the wiring checking
potentiometer and controller procedure and repair it if necessary.
CN-701F
CN-103F
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Error code H024

Trouble Boom angle potentiometer's power source is shortcut.
Judging
The input voltage from boom angle potentiometer is less than 0.1V.
condition
Symptom Indications of rating load and working radius of High-reach crane become abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 10 H-2 BOOM

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Boom angle potentiometer Measure the resistance between terminals of boom angle potentiometer.
SE-17 4.0 to 6.0 kilo-ohms
Turn the potentiometer and measure resistance between signal and GND.
Normal value: 0 to all resistance (4.0 to 6.0) kilo-ohms
2 - Wiring between boom angle Check wiring for possible failure according to the wiring checking
potentiometer and controller procedure and repair it if necessary.
CN-701F
CN-103F
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-54
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 㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code H033

Trouble Arm angle potentiometer's wiring is disconnected.
Judging
The input voltage from arm angle potentiometer is less than 0.1V.
condition
Symptom Indications of rating load and working radius of High-reach crane become abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 10 H-3 ARM

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Arm angle potentiometer Measure the resistance between terminals of arm angle potentiometer.
SE-19 4.0 to 6.0 kilo-ohms
Turn the potentiometer and measure resistance between signal and GND.
Normal value: 0 to all resistance (4.0 to 6.0) kilo-ohms
2 -Wiring between arm angle Check wiring for possible failure according to the wiring checking
potentiometer and controller procedure and repair it if necessary.
CN-701F
CN-103F
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Error code H034

Trouble Arm angle potentiometer's power source is shortcut.
Judging
The input voltage from arm angle potentiometer is less than 0.1V.
condition
Symptom Indications of rating load and working radius of High-reach crane become abnormal.
Control in the
Normal control
event of failure 
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 10 H-3 ARM

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Arm angle potentiometer Measure the resistance between terminals of arm angle potentiometer.
SE-19 4.0 to 6.0 kilo-ohms
Turn the potentiometer and measure resistance between signal and GND.
Normal value: 0 to all resistance (4.0 to 6.0) kilo-ohms
2 -Wiring between arm angle Check wiring for possible failure according to the wiring checking
potentiometer and controller procedure and repair it if necessary.
CN-701F
CN-103F
3 -Mechatro controller Check that the error is corrected after replacement of controller.

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㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code H091

Trouble Fuel sensor grounding is short-circuited.
Judging
The input voltage from fuel sensor is less than 0.1V.
condition
Symptom Warning for low fuel level is indicated.
Control in the
Fuel level becomes 0%.
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 8 H-9 FUEL LEVEL

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 - Fuel sensor potentiometer Move fuel sensor and measure the resistance between terminals of fuel
SE-15 sensor.
EMPTY 95 ohms to FULL 5 ohms
2 -Wiring between fuel Check wiring for possible failure according to the wiring checking
sensor and controller procedure and repair it if necessary.
CN-152F
CN-104F
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Error code H093

Trouble Fuel sensor's wiring is disconnection.
Judging
The input voltage from fuel sensor is 4.7V or more.
condition
Symptom Warning for low fuel level is indicated.
Control in the
Fuel sensor's wiring is disconnected.
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 8 H-9 FUEL LEVEL

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Fuel sensor potentiometer Move fuel sensor and measure the resistance between terminals of fuel
SE-15 sensor.
EMPTY 95 ohms to FULL 5 ohms
2 -Wiring between fuel Check wiring for possible failure according to the wiring checking
sensor and controller procedure and repair it if necessary.
CN-152F
CN-104F
3 -Mechatro controller Check that the error is corrected after replacement of controller.

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 㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉

Error code H101

Trouble Hydraulic oil temperature sensor grounding is short-circuited.
Judging
The input voltage from hydraulic oil temperature sensor is less than 0.1V.
condition
Symptom No change
Control in the
Hydraulic oil temperature is regarded as 0C degrees.
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 8 H-10 ᴓᴜᴶᴋᴭᴍᴵ

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Hydraulic oil temperature Move hydraulic oil temperature sensor and measure the resistance
sensor between terminals of hydraulic oil temperature sensor.
SE-21 EMPTY 95ohm ~ FULL 5ohm
2 -Wiring between hydraulic oil Check wiring for possible failure according to the wiring checking
temperature sensor and procedure and repair it if necessary.
controller
CN-294F
CN-104F
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Error code H103

Trouble Hydraulic oil temperature sensor's wiring is disconnected.
Judging
The input voltage from hydraulic oil temperature sensor is 4.7V or more.
condition
Symptom No change
Control in the
Hydraulic oil temperature is regarded as 0C degrees.
event of failure 
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 8 H-10 ᴓᴜᴶᴋᴭᴍᴵ

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Hydraulic oil temperature Move hydraulic oil temperature sensor and measure the resistance
sensor between terminals of hydraulic oil temperature sensor.
SE-21 EMPTY 95 ohm ~ FULL 5 ohm
2 -Wiring between hydraulic oil Check wiring for possible failure according to the wiring checking
temperature sensor and procedure and repair it if necessary.
controller
CN-294F
CN-104F
3 -Mechatro controller Check that the error is corrected after replacement of controller.

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Error code I111

Trouble Reception of CAN1 communication is abnormal. (Passive error)
Judging
Data from engine controller can not be received correctly.
condition
Symptom It has been affected little.
Control in the
Keep the last receiving condition.
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No.

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Wiring between ECU Check wiring for possible failure according to the wiring checking
and controller procedure and repair it if necessary.
CN-11F (There is a possibility of false disconnection.)
CN-12F
CN-101F
2 -Mechatro controller Check that the error is corrected after replacement of controller.

Error code I113

Trouble Reception of CAN1 communication is abnormal. (Time-out error)
Judging
Data from engine controller can not be received correctly.
condition
Symptom It has been affected little.
Control in the
It can be operated in condition that coolant temperature is 20C degrees.
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 2 G-5 WATER TEMP

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Wiring between ECU Check wiring for possible failure according to the wiring checking
and controller procedure and repair it if necessary.
CN-11F (There is a possibility of false disconnection.)
CN-12F
CN-101F
2 -Mechatro controller Check that the error is corrected after replacement of controller.

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Error code I121

Trouble Transmission of CAN1 communication is abnormal. (Busoff error)
Judging
Data from mechatro controller can not be received correctly.
condition
Symptom Almost no effect
Control in the
Normal control
event of failure
Returned in
Normal control
normal condition

Service Screen No.

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Wiring between ECU and Check wiring for possible failure according to the wiring checking
controller procedure and repair it if necessary.
CN-11F (There is a possibility of false disconnection.)
CN-12F
CN-101F
CN-33F
2 -Mechatro controller Check that the error is corrected after replacement of controller.

Error code I211

Trouble Reception of CAN2 communication is abnormal. (Busoff error)
Judging
Data from gauge cluster cannot be received correctly.
condition
Symptom Switches of gauge cluster can not be used.
Control in the
Normal control
event of failure
Returned in

Normal control
normal condition

Service Screen No.

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Wiring from gauge cluster and Check wiring for possible failure according to the wiring checking
controller procedure and repair it if necessary.
CN-601F (There is a possibility of false disconnection.)
CN-158F
CN2-1
CN-106F
CN-33F
2 -Mechatro controller Check that the error is corrected after replacement of controller.

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Error code I213

Trouble Reception of CAN2 communication is abnormal. (Time-out error)
Judging
Data from gauge cluster cannot be received correctly.
condition
Symptom Switches of gauge cluster can not be used.
Control in the
Normal control
event of failure
Returned in
Normal control
normal condition

Service Screen No.

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Wiring from gauge cluster and Check wiring for possible failure according to the wiring checking
controller procedure and repair it if necessary.
CN-601F (There is a possibility of false disconnection.)
CN-158F
CN2-1
CN-106F
CN-33F
2 -Mechatro controller Check that the error is corrected after replacement of controller.

Error code I221

Trouble Transmission of CAN2 communication is abnormal. (Busoff error)
Judging
Data from mechatro controller can not be received correctly.
condition
Symptom Gauge cluster can not be used.
Control in the
Normal control
event of failure
Returned in
Normal control
normal condition

Service Screen No.

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Wiring from gauge cluster and Check wiring for possible failure according to the wiring checking
controller procedure and repair it if necessary.
CN-601F (There is a possibility of false disconnection.)
CN-158F
CN2-1
CN-106F
CN-33F
2 -Mechatro controller Check that the error is corrected after replacement of controller.

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Error code I313

Trouble Reception of cluster communication is abnormal. (Time-out error)
Judging
Data from gauge cluster can not be received correctly.
condition
Symptom Switch operation of gauge cluster can not be done.
Control in the
Keep the condition after immediately key-on is operated.
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No.

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Wiring from gauge cluster and Check wiring for possible failure according to the wiring checking
controller procedure and repair it if necessary.
CN-600F (There is a possibility of false disconnection.)
CN-158F
CN2-1
CN-106F
CN-33F
2 -Mechatro controller Check that the error is corrected after replacement of controller.



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Error code K014

Trouble Battery relay contact welded
Judging The power 24V is continuously supplied to controller for 40 seconds or more while the key
condition switch ON signal turned OFF
Symptom The power on the battery relay secondary side does not turn OFF even if the key switch is
turned OFF.
Control in the
Normal control with key switch OFF
event of failure
Returned in Turn key switch ON.
normal condition Or when the power supply 24V to mechatro controller is stopped

Service Screen No. 4 K-1 AIS RELAY 2

diagnosis Screen No. 4 K-3 KEY SWITCH OFF
checking screen Screen No.
Checking object Checking contents and remedy
1 -Battery relay Turn key switch off and disconnect the connector (CN-256F) on the
R-1 battery relay coil. If 24V power lives on battery relay secondary side,
CN-256F check on battery relay for failure and replace it if failed.
2 -Auto idle stop relay 2 Turn off the key switch, and remove the connector (CN-256F) on the
R-24 battery relay coil side. If power of battery relay on secondary side falls,
-Alternator relay remove either auto idling stop relay 2 or alternator relay.
R-28 The failure may be occurred in case where the power falls after the
relay was removed, and therefore check on the relay unit and replace it
with new one if failed.
3 -Wiring between auto idle stop When K014 is left displayed with the relay removed, check that no power
relay/alternator relay and 24V is produced on relay (-) line according to the wiring checking
controller procedure and repair it if necessary.
CN-109F, CN2-1 When no failure is found after checking on wiring and K014 is left
-Fuse & relay box displayed, replace fuse/relay box.
E-1
4 -Mechatro controller Check that the error is corrected after replacement of controller.

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Error code Z010

Trouble Injector is broken.
Judging
condition
Symptom
Control in the
event of failure
Returned in 
normal condition

Service Screen No.

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1
2

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 㨇47. TROUBLESHOOTING (BY TROUBLE)㨉

47. TROUBLESHOOTING
(BY TROUBLE)
TABLE OF CONTENTS

47.1 HYDRAULIC SYSTEM ääääääääääääääääääääääääääääääääää47-3

47.2 ELECTRIC SYSTEMS ääääääääääääääääääääääääääääääääää47-38
47.2.1 WIRING CHECKING PROCEDURE ääääääääääääääääääääääääää47-38
47.2.2 TROUBLEääääääääääääääääääääääääääääääääääääää47-41
47.3 ENGINE RELATED TROUBLESHOOTING äääääääääääääääääääääääää47-45



Book Code No. 6/&(

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Issue Date of Issue Applicable Machines Remarks

SK330-9 : LC12-15001~ S5LC4732E01
First Edition June, 2013
SK350LC-9 : YC12-10001~ (NA)
SK330-9 : LC12-15001~ S5LC4732E02
Revision December, 2013
SK350(N)LC-9 : YC12-10002~ (NA / EUR)

July, 2014 SK350LC-9E : YC13-13001~

(NA)

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47.1 HYDRAULIC SYSTEM

Preface:
The troubleshooting for the failures shown below is explained here.
Identify the failure and trouble and carry forward the troubleshooting in order of the failure item number.

(1) All controls do not function/slow

(2) Engine down/stalled
(3) Move at lever neutral position
(4) Poor fine operability
(5) Slow boom up, insufficient power
(6) Slow boom down, insufficient power for lifting up body
(7) Slow arm in, insufficient power
(8) Slow independent arm out (in the air)
(9) Slow bucket digging
(10) Slow bucket dumping
(11) Swing operation not functioned/slow
(12) Noise during swing operation
(13) Swing on a slope drifts when control lever is in neutral position
(14) Swing drifts when swing operation is stopped
(15) Slow travel speed/weak
(16) Travel deviation
(17) Travel 1st/2nd speed not changed
(18) Travel parking on a slope is not held
(19) Travel does not run straightly when both crawlers and attachment operated simultaneously.
(20) Slow breaker (crusher) operation, weak power
(21) Option selector valve malfunction: not switched to breaker circuit
(22) Option selector valve malfunction: not switched to nibbler circuit



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(1) All controls do not function/slow

No. Sections Contents/normal value Corrective action, others
1 Fuse Check fuse No.4 If the fuse is blown out,
(10A) check on the
short-circuited section.
2 Safety lever lock Carry out service No.4 K-4 switch: Check action of switch
switch diagnosis Push down the lever and it turns by tester, or check that
on, push up and it turns off. the power voltage is
lowered by pushing the
lever down.
3 Safety lever lock Check that the Measure both terminals of Check solenoid unit for
switching solenoid is solenoid connector. 24V by pushing possible failure.
switched correctly the lever down, 0V by pushing it Check harness for
up possible failure.
4 Safety lever lock Carry out service No.4 K-4 lock lever: Check action of relay by
relay diagnosis Push down the lever and it turns tester
off, push up and it turns on.
5 Pilot pressure -Stop engine stop and key is on Check 5V power for
sensor position. All pilot low pressure controller
sensors are 0MPa to 0.1MPa.
6 Solenoid valve for Measure About 0MPa by pushing the lever Replace solenoid valve
safety lock lever pressure of up, and 4MPa or more by push it
solenoid A1 port down.
7 Pilot line filter Disassemble and Check filter for clogging Clean filter
check it visually
8 Pilot gear pump Measure pilot Check that it is 4MPa or more in Check gear pump and the
primary pressure high idling relief valve for possible
at gear pump failure
9 Multi control valve Change position Since all are blocked due to poor
(in case that switching performance, check that
travel is operable) the lever select pattern is set to
the proper position.
10 Actual measuring Carry out service -No.7 In case where the reading
current value of diagnosis D-1 P1 unload valve (cut valve) is largely differed from the
P1/P2 unload D-1 P2 unload valve (cut valve) actually measured value,
proportional valve -See Service Diagnosis Data List check proportional valve
Operation No.3 Boom up full lever and controller for possible
& relief failure.
11 Secondary pressure Measure the Check that P1/P2 unload secondary Replace proportional valve
of P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary 0.5 to 1.2MPa in boom up full
pressure directly lever and high idling operation
at the ports A7
and A5 of 8
sections solenoid
block

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No. Sections Contents/normal value Corrective action, others

12 Actual measuring Carry out service -No.6 In case where the reading
current value of diagnosis. E-1 P1 pump is largely differed from the
P1/P2 pump E-2 P2 pump actually measured value,
proportional valve -See Service Diagnosis Data List check proportional valve
Operation No.18 Travel right full and controller for possible
lever & idling failure.
Operation No.19 Travel left full
lever & idling
13 Secondary pressure Measure the Check that pump proportional Replace proportional valve
of pump pump valve secondary pressure is
proportional valve proportional valve 2.7MPa or more in right (left) travel
secondary full lever and high idling operation
pressure directly Right travel: P1 pump proportional
in idling operation. valve
(Ports a3, a4) Left travel: P2 pump proportional
valve
14 Main relief pressure Carry out service -See Service Diagnosis Data List Measure the relief
diagnosis Operation No.3 Boom up full lever pressure actually
& relief
15 Check set Check that P1 and P2 pump Reset or replace
pressure pressures are 32MPa or more in
boom up full lever, high idling and
H mode operation.
16 Pump regulator Visual check When removing, free from Replace
abnormal resistance against sliding.
Free from abnormal damage, etc
on outside surface
Spring free from breakage,
damage, etc.
17 Pump Visual check When removing, inside parts Replace
(cylinder block, piston, valve plate,
shaft, etc.) are free from abnormal
resistance against sliding,
abnormal damage, etc.



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(2) Engine down/stalled

No. Sections Contents/normal value Corrective action, others
1 Actual measuring Carry out service -No.6 In case where the reading
current value of diagnosis E-1 P1 pump is largely differed from the
P1/P2 pump E-2 P2 pump actually measured value,
proportional valve -See Service Diagnosis Data List check proportional valve
Operation No. 1 Operation is nil and controller for possible
failure.
2 Secondary pressure Measure the Check that P1/P2 pump Replace proportional valve
of P1, P2 pump pump proportional valve pressures are
proportional valve proportional valve within the range of 0.5 to 1.0MPa
secondary in control lever neutral and high
pressure directly idling operation.
(Ports a3, a4)
3 Pressure sensor Check pressure -See Service Diagnosis Data List Check pressure sensor
of P1, P2 pump Operation No.1 Operation is nil and replace it if necessary
Operation No.3 Boom up full lever
& relief
4 Pump regulator Visual check When removing, free from Replace
abnormal resistance against sliding
Free from abnormal damage, etc
on outside surface
Spring free from breakage,
damage, etc.
5 Pump Visual check When removing, inside parts Replace
(cylinder block, piston, valve plate,
shaft, etc.) are free from abnormal
resistance against sliding,
abnormal damage, etc.

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(3) Move at lever neutral position

No. Sections Contents/normal value Corrective action, others
1 Pilot pressure Carry out service Check that targeted pilot pressure Check remote control
sensor diagnosis of sensor is 0MPa in high idling valve
2 Remote control Check targeted Check that spool is free from Replace
valve remote control abnormal damage and spring is
valve free from breakage
3 Main spool Check targeted Check that spool is free from Replace
spool visually abnormal damage and spring is
free from breakage
4 Over load relief Check targeted Free from dust entered in port Replace
valve spool visually relief valve. Seat is free from
abnormality
5 Lock valve poppet Check targeted Seat is free from abnormality Replace
(in case of boom poppet visually
and arm)
6 Lock valve selector Exchange lock Check that the trouble is reversed Replace
(in case of boom valve selector of
and arm) boom/arm and
boom/arm
7 Holding valve spool Check that Free from abnormal resistance Replace
for boom smooth sliding of against sliding Do not pull spool out of
(in case of boom) spool in sleeve sleeve forcibly.
8 Holding valve Check targeted Filter free from abnormal Replace
relief valve for spool visually contamination
boom
(in case of boom)
9 Cylinder Check targeted Make sure of no problem of seals Replace cylinder or seals
cylinder visually by disassembling and investigation



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(4) Poor fine operability

No. Sections Contents/normal value Corrective action, others
1 Pressure sensor Carry out service -See Service Diagnosis Data List Replace pressure sensor
diagnosis Operation No. 1 Operation is nil
-All low pressure sensors are
0MPa to 0.1MPa
2 Actual measuring Carry out service -No.7 In case where the reading
current value of diagnosis D-1 P1 unload valve (cut valve) is largely differed from the
P1/P2 unload D-1 P2 unload valve (cut valve) actually measured value,
proportional valve -See Service Diagnosis Data List check proportional valve
Operation No. 1 Operation is nil and controller for possible
failure.
3 Secondary pressure Measure the Check that P1/P2 unloads Replace proportional valve
of unload proportional valve secondary pressures is within the
proportional valve secondary range of 2.7MPa or more in control
pressure directly lever neutral and high idling
at the ports A5 operation
and A7 of 8
sections solenoid
block
4 Actual measuring Carry out service -No.6 In case where the reading
current value of diagnosis E-1 P1 pump is largely differed from the
P1/P2 pump E-2 P2 pump actually measured value,
proportional valve -See Service Diagnosis Data List check proportional valve
Operation No. 1 Operation is nil and controller for possible
failure.
5 Secondary pressure Measure the Check that P1/P2 pump Replace proportional valve
of P1, P2 pump pump proportional valve pressures are Check regulator
proportional valve proportional valve within the range of 0.5 to 1.0MPa
secondary in control lever neutral and high
pressure directly. idling operation
(Ports a3, a4)
6 Command current Carry out service -No.12 D-15 In case where the reading
value of bypass diagnosis -See Service Diagnosis Data List. is largely differed from the
valve (Europe) No.1 operation is nil. actually measured value,
check proportional valve
and controller for
possible failure.
7 Proportional valve Measure the Control lever is in neutral and high Replace proportional valve
secondary pressure proportional valve idling.
of bypass valve secondary Secondary pressure is within the
(Europe) pressure directly range of 0.5 to 1.0MPa.
(G port)
8 Slow return check Visual check Check that slow return check Clean and replace
valve of pilot line valve installed on pilot line is free
(in case of boom from dust entered
up or arm out)
9 Spool of bypass Visual check When removing, there is no Replace the spool
valve (Europe) abnormal resistance against sliding. (Check on the casing side
Free from abnormal damage etc. for damage.)
on outside surface.
Spring should be free from
breakage.

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(5) Slow boom up, insufficient power

No. Sections Contents/normal value Corrective action, others
1 Boom up pressure Carry out service -See Service Diagnosis Data List Check and replace
sensor diagnosis Operation No.3 boom up full lever pressure sensor
and relief Check remote control
valve
2 Remote control Measure directly Check that pressure is 3.0MPa or Check remote control
valve remote control more in boom up full lever and valve
pressure of boom high idling operation When equipped with
up multi control valve, check
it while changing lever
pattern
3 Pump pressure Carry out service -See Service Diagnosis Data List When there is difference
sensor diagnosis for P1, Operation No.4 boom up full lever between P1 and P2 pump
P2 pump and in operation pressures, check high
pressures in pressure sensor.
operation.
4 Actual measuring Carry out service -No.7 In case where the reading
current value of diagnosis D-1 P1 unload valve (cut valve) is largely differed from the
P1/P2 unload D-1 P2 unload valve (cut valve) actually measured value,
proportional valve -See Service Diagnosis Data List check proportional valve
Operation No.3 Boom up full lever and controller for possible
& relief failure.
5 Secondary pressure Measure the Check that P1/P2 unload secondary Replace proportional valve
of P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary 0.5 to 1.2MPa in boom up full
pressure directly lever and high idling operation
at the ports A7
and A5 of 8
sections solenoid
block
6 Actual measuring Carry out service -No.6 In case where the reading
current value of diagnosis E-1 P1 pump is largely differed from the
P1/P2 pump E-2 P2 pump actually measured value,
proportional valve -See Service Diagnosis Data List check proportional valve
Operation No.4 boom up full lever and controller for possible
& in operation failure.
7 Secondary pressure Measure the Check that P1/P2 pump Replace proportional valve
of P1, P2 pump pump proportional valve pressures are 
proportional valve proportional valve within the range of 2.3 to 3.2MPa
secondary in boom up full lever and high
pressure directly idling operation
(Ports a3, a4)
8 P2 by-pass cut Visual check Poppet should be tightened. Clean and replace
valve Seated surface should be free from
<Trouble> damage and entry of foreign matter.
Only P2 pressure
is low.
9 Remote control Check targeted Check that spool is free from Replace
valve remote control abnormal damage and spring is
valve free from breakage

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No. Sections Contents/normal value Corrective action, others

10 Lock valve Visual check When removing, free from Replace
poppet<Trouble>Bot abnormal resistance against sliding (Check on the casing side
h P1 and P2 Free from abnormal damage, etc for damage)
pressures are low. on outside surface
11 Conflux check valve Visual check When removing, free from Replace
<Trouble> abnormal resistance against sliding (Check on the casing side
Only P2 pressure Free from abnormal damage, etc for damage)
is high. on outside surface
12 Holding valve for Visual check When removing, free from Replace
boom (poppet) abnormal resistance against sliding (Check on the casing side
<Trouble> Free from abnormal damage, etc for damage)
Both P1 and P2 on outside surface
pressures are high.
13 Boom spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against sliding (Check on the casing side
Only P1 pressure Spring is free from breakage. for damage)
is high.
14 Check boom Disassembly and Free from abnormal resistance Replace spool assembly
spool and investigation against sliding
recirculation Spring is free from breakage.
<Trouble>
Only P1 pressure
is low.
15 Conflux spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against sliding (Check on the casing side
Only P2 pressure Spring is free from breakage. for damage)
is high. Free from abnormal damage, etc
on outside surface
16 Main relief valve Check set -See Service Diagnosis Data List Reset or replace
<Trouble> pressure Operation No.3 boom up full lever
Relief pressure is and relief
low.
17 Over load relief Visual check Pressure is 32MPa or more in When only relief
valve (Head side) boom up full lever and high idling. pressure of boom up is
<Trouble> Free from dust entered in over low, replace valve
Relief pressure is load relief valve. Seat is free from
low. abnormality

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(6) Slow boom down/insufficient power for lifting up body

No. Sections Contents/normal value Corrective action, others
1 Boom down Carry out service -See Service Diagnosis Data List Check and replace
pressure sensor diagnosis Operation No.5 boom down full pressure sensor.
lever & in operation Check remote control
valve.
2 Remote control Measure remote Check that pressure is 3.0MPa or Check remote control
valve control pressure more in boom down full lever and valve
of boom down high idling operation When equipped with
directly multi control valve, check
it while changing lever
pattern.
3 Actual measuring Carry out service P1 unload valve (cut valve) In case where the reading
current value of P1 diagnosis -See Service Diagnosis Data List is largely differed from the
unload proportional Operation No.5 boom down full actually measured value,
valve lever & in operation check proportional valve
and controller for possible
failure.
4 Secondary pressure Measure the Check that P1 unload secondary Replace proportional valve
of P1 unload proportional valve pressures are within the range of
proportional valve secondary 1.1 to 1.4MPa in boom down full
pressure directly lever and high idling operation
at the ports A7 of
8 sections
solenoid block.
5 Actual measuring Carry out service -No.6 In case where the reading
current value of P1 diagnosis E-1 P1 pump is largely differed from the
pump proportional -See Service Diagnosis Data List actually measured value,
valve Operation No.5 boom down full check proportional valve
lever & in operation and controller for possible
failure.
6 Secondary pressure Measure the Check that P1 pump proportional Replace proportional valve
of P1 pump pump valve pressures are within the
proportional valve proportional valve range of 1.9 to 2.5MPa in boom
secondary down full lever and high idling
pressure directly operation
(Ports a3, a4)
7 Actual measuring Carry out service Check that the value is not change -Check pressure sensor of
current value of diagnosis regardless of operation travel 
travel straight -See Service Diagnosis Data List -In case where the
proportional valve Operation No. 1 Operation is nil reading is largely differed
Operation No.18 Travel right full from the actually
lever & idling measured value, check
Operation No.19 Travel left full proportional valve and
lever & idling controller for possible
failure.
8 Travel straight Measure directly High idling pressure is 0.8MPa or Replace proportional valve
proportional valve the travel straight less regardless neutral/operation
secondary pressure proportional valve
secondary
pressure.

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㨇47. TROUBLESHOOTING (BY TROUBLE)㨉

No. Sections Contents/normal value Corrective action, others

9 Command current Carry out service Check that the current value does -Check pressure sensor of
value of bypass diagnosis not change regardless of operation. travel.
valve (Europe) No.12 D-15 -In case where the
-See Service Diagnosis Data List. reading is largely differed
Operation No.1 is nil. from the actually
Operation No.18 is travel right in measured value, check
full lever and idling. proportional valve and
Operation No.19 is travel left in controller for possible
full lever and idling. failure.
10 Proportional valve Measure the High idling pressure is 0.8MPa or Replace proportional valve
secondary pressure proportional valve less regardless of neutral/operation.
of bypass valve secondary
(Europe) pressure directly
(G port)
11 Remote control Check targeted Check that spool is free from Replace
valve remote control abnormal damage and spring is
valve free from breakage
12 Lock valve poppet Visual check When removing, free from Replace
<Trouble> abnormal resistance against sliding (Check on the casing side
Boom down is low. Free from abnormal damage, etc for damage)
on outside surface
13 Holding valve Visual check When removing, free from Replace
(poppet) abnormal resistance against sliding (Check on the casing side
<Trouble> Free from abnormal damage, for damage)
Boom down is etc on outside surface
slow.
14 Boom spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against sliding (Check on the casing side
Boom down is Free from abnormal damage, etc for damage)
slow. on outside surface
Spring is free from breakage.
15 Check boom Disassembly and Free from abnormal resistance Replace spool assembly
spool and investigation against sliding
recirculation Spring is free from breakage.
<Trouble>
Machine can not
be lifted by
supporting with
boom.
16 Spool of bypass Visual check When removing, there is no Replace the spool
valve (Europe) abnormal resistance against sliding. (Check on the casing side
Free from abnormal damage etc. for damage.)
on outside surface.
Spring should be free from
breakage.
17 Main relief valve Check set -See Service Diagnosis Data List Reset or replace
<Trouble> pressure Operation No.3 boom up full lever
Relief pressure is and relief
low.

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 㨇47. TROUBLESHOOTING (BY TROUBLE)㨉

No. Sections Contents/normal value Corrective action, others

18 Over load relief Visual check Free from dust entered in port Replace
valve relief valve.
<Trouble> Seat is free from abnormality
Machine can not
be lifted by
supporting with
boom.

(7) Slow arm in, insufficient power

No. Sections Contents/normal value Corrective action, others
1 Arm in pressure Carry out service -See Service Diagnosis Data List Check and replace
sensor diagnosis Operation No.6 arm in full lever pressure sensor
and relief Check remote control
valve
2 Remote control Measure directly Check that pressure is 3.0MPa or Check remote control
valve pressure remote control more in arm in full lever and high valve
pressure of arm in idling operation When equipped with
multi control valve, check
it while changing lever
pattern
3 Pump pressure Carry out service -See Service Diagnosis Data List When there is difference
sensor diagnosis for P1, Operation No.7 arm in full lever between P1 and P2 pump
P2 pump and in operation pressures, check high
pressures in pressure sensor
operation.
4 Actual measuring Carry out service -No.7 In case where the reading
current value of diagnosis D-1 P1 unload valve (cut valve) is largely differed from the
P1/P2 unload D-1 P2 unload valve (cut valve) actually measured value,
proportional valve -See Service Diagnosis Data List check proportional valve
Operation No.6 Arm in full lever & and controller for possible
relief failure.
5 Secondary pressure Measure the Check that P1/P2 unload secondary Replace proportional valve
of P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary 0.5 to 1.2MPa in arm in full lever
pressure directly and high idling operation.
at the ports A7
and A5 of 8
sections solenoid 
block.
6 Actual measuring Carry out service -No.6 In case where the reading
current value of diagnosis E-1 P1 pump is largely differed from the
P1/P2 pump E-2 P2 pump actually measured value,
proportional valve -See Service Diagnosis Data List check proportional valve
Operation No.7 Arm in full lever & and controller for possible
in operation failure.

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㨇47. TROUBLESHOOTING (BY TROUBLE)㨉

No. Sections Contents/normal value Corrective action, others

7 Secondary pressure Measure the Check that P1/P2 pump Replace proportional valve
of P1, P2 pump pump proportional valve pressures are
proportional valve proportional valve 2.8MPa or more in arm in full lever
secondary and high idling operation.
pressure directly. (Secondary pressure is affected by
(Ports a3, a4) oil temperature and attachment
weight)
8 Actual measuring Carry out service -See Service Diagnosis Data List In case where the reading
current value of diagnosis Operation No.1 Operation is nil is largely differed from the
arm in spool 2 Operation No.6 Arm in full lever & actually measured value,
proportional valve relief check proportional valve
Operation No.7 Arm in full lever & and controller for possible
in operation failure.
9 Secondary pressure Measure directly Check that secondary pressure of Replace proportional valve
of arm in spool 2 the proportional proportional valve secondary
proportional valve valve secondary pressures are within the range of
pressure at the following
ports A8 (arm 2 Lever neutral: 0MPa
spool) of 8 Motion in the air: 1.7 to 2.2MPa
sections solenoid Arm in relief: 2.5MPa or more
block.
10 Actual measuring Carry out service Check that the value is not change -Check pressure sensor of
current value of diagnosis regardless of operation travel
travel straight -See Service Diagnosis Data List -In case where the
proportional valve Operation No. 1 Operation is nil reading is largely differed
Operation No.18 Travel right full from the actually
lever & idling measured value, check
Operation No.19 Travel left full proportional valve and
lever & idling controller for possible
failure.
11 Secondary pressure Measure directly 0.8MPa or less in high idling Replace proportional valve
of travel straight the proportional operation regardless of
proportional valve valve secondary neutral/operation
pressure at the
ports A6 (travel
straight) of 8
sections solenoid
block
12 Remote control Check targeted Check that spool is free from Replace
valve remote control abnormal damage and spring is
valve free from breakage
13 Main relief valve Check set -See Service Diagnosis Data List Reset or replace
<Trouble> pressure Operation No.3 boom up full lever
Relief pressure is and relief
low.
14 Over load relief Visual check Pressure is 32MPa or more in When only relief
valve (Head side) arm in and relief. pressure of arm in is
<Trouble> Free from dust entered in over low, replace valve
P1, P2 pressure is load relief valve.
low. Seat is free from abnormality

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 㨇47. TROUBLESHOOTING (BY TROUBLE)㨉

No. Sections Contents/normal value Corrective action, others

15 Over load relief Visual check (Rod Pressure is 32MPa or more in When only relief
valve side) arm out and relief. pressure of arm out is
<Trouble> Free from dust entered in over low, replace valve
P1, P2 pressure is load relief valve.
low. Seat is free from abnormality.
16 Arm 1 spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against sliding (Check on the casing side
P1, P2 pressure is Free from abnormal damage, etc for damage)
high. on outside surface
Spring is free from breakage.
17 Arm 2 spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against sliding (Check on the casing side
P1, P2 pressure Free from abnormal damage, etc for damage)
is high or low. on outside surface
Spring is free from breakage.
18 Check arm 2 spool Disassembly and Free from abnormal resistance Replace spool assembly
and recirculation investigation against sliding
<Trouble> Spring is free from breakage.
Arm in power is
poor.
19 Check lock valve Visual check Free from abnormal resistance Replace
poppet against sliding (Check on the casing side
<Trouble> Free from abnormal damage, etc for damage)
Both P1, P2 on outside surface
pressures are high.



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㨇47. TROUBLESHOOTING (BY TROUBLE)㨉

(8) Slow independent arm out (in the air)

No. Sections Contents/normal value Corrective action, others
1 Arm out pressure Carry out service -See Service Diagnosis Data List Check and replace
sensor diagnosis Operation No.8 arm out full lever pressure sensor
and relief Check remote control
valve
2 Remote control Measure directly Check that pressure is 3.0MPa or Check remote control
valve remote control more in arm out full lever and high valve
pressure of arm idling operation When equipped with
out multi control valve, check
it while changing lever
pattern
3 Pump pressure Carry out service -See Service Diagnosis Data List When there is difference
sensor diagnosis for P1, Operation No.9 arm out full lever between P1 and P2 pump
P2 pump and in operation pressures, check high
pressures in pressure sensor
operation.
4 Actual measuring Carry out service -No.7 In case where the reading
current value of diagnosis D-1 P1 unload valve (cut valve) is largely differed from the
P1/P2 unload D-1 P2 unload valve (cut valve) actually measured value,
proportional valve -See Service Diagnosis Data List check proportional valve
Operation No.8 Arm out full lever & and controller for possible
relief failure.
5 Secondary pressure Measure the Check that P1/P2 unload secondary Replace proportional valve
of P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary 0.5 to 1.2MPa in arm out full
pressure directly lever and high idling operation
at the ports A7
and A5 of 8
sections solenoid
block
6 Actual measuring Carry out service -No.6 In case where the reading
current value of diagnosis E-1 P1 pump is largely differed from the
P1/P2 pump E-2 P2 pump actually measured value,
proportional valve -See Service Diagnosis Data List check proportional valve
Operation No.9 Arm out full lever & and controller for possible
in operation failure.
7 Secondary pressure Measure the Check that P1/P2 pump Replace proportional valve
of P1, P2 pump pump proportional valve pressures are
proportional valve proportional valve within the range of 1.7 to 2.9MPa
secondary in arm out full lever and high idling
pressure directly operation
(Ports a3, a4) (Secondary pressure is affected by
oil temperature and attachment
weight)

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 㨇47. TROUBLESHOOTING (BY TROUBLE)㨉

No. Sections Contents/normal value Corrective action, others

8 Actual measuring Carry out service Check that the value is not change -Check pressure sensor of
current value of diagnosis regardless of operation travel
travel straight -See Service Diagnosis Data List -In case where the
proportional valve Operation No. 1 Operation is nil reading is largely differed
Operation No.18 Travel right full from the actually
lever & idling measured value, check
Operation No.19 Travel left full proportional valve and
lever & idling controller for possible
failure.
9 Secondary pressure Measure directly High idling pressure is 0.8MPa or Replace proportional valve
of travel straight the proportional less regardless of neutral/operation.
proportional valve valve secondary
pressure at the
ports A6 (travel
straight) of 8
sections solenoid
block
10 Remote control Check targeted Check that spool is free from Replace
valve remote control abnormal damage and spring is
valve free from breakage
11 Main relief valve Check set -See Service Diagnosis Data List Reset or replace
<Trouble> pressure Operation No.3 boom up full lever
Relief pressure is and relief
low.
12 Over load relief Visual check (Rod Pressure is 32MPa or more in When only relief
valve side) arm out and relief. pressure of arm out is
<Trouble> Free from dust entered in over low, replace valve
P1, P2 pressure is load relief valve. Seat is free from
low. abnormality
13 Arm 1 spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against sliding (Check on the casing side
P2 pressure is Free from abnormal damage, etc for damage)
high. on outside surface
Spring is free from breakage.
14 Arm 2 spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against sliding (Check on the casing side
P1 pressure is Free from abnormal damage, etc for damage)
high. on outside surface 
Spring is free from breakage.
15 Check arm 2 spool Disassembly and Free from abnormal resistance Replace spool assembly
and recirculation investigation against sliding
<Trouble> (spring side) Spring is free from breakage.
Both P1, P2
pressures are low.
16 Check lock valve Visual check Free from abnormal resistance Replace
poppet against sliding (Check on the casing side
<Trouble> Free from abnormal damage, etc for damage)
Both P1, P2 on outside surface
pressures are high.

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㨇47. TROUBLESHOOTING (BY TROUBLE)㨉

(9) Bucket digging is slow

No. Sections Contents/normal value Corrective action, others
1 Bucket digging Carry out service -See Service Diagnosis Data List Check and replace
pressure sensor diagnosis Operation No.12 bucket digging pressure sensor
full lever and relief Check remote control
valve
2 Remote control Measure directly Check that pressure is 3.0MPa or Check remote control
valve remote control more in bucket digging full lever valve
pressure of bucket and high idling operation When equipped with
digging multi control valve, check
it while changing lever
pattern
3 Pump pressure Carry out service -See Service Diagnosis Data List When there is difference
sensor diagnosis for P1, Operation No.13 Bucket digging full between P1 and P2 pump
P2 pump lever and in operation pressures, check high
pressures in pressure sensor
operation.
4 Actual measuring Carry out service -No.7 In case where the reading
current value of diagnosis D-1 P1 unload valve (cut valve) is largely differed from the
P1/P2 unload D-1 P2 unload valve (cut valve) actually measured value,
proportional valve -See Service Diagnosis Data List check proportional valve
Operation No.12 Bucket digging full and controller for possible
lever & relief failure.
5 Secondary pressure Measure the Check that P1/P2 unload secondary Replace proportional valve
of P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary 0.5 to 1.2MPa in bucket digging
pressure directly full lever and high idling operation
at the ports A7
and A5 of 8
sections solenoid
block
6 Actual measuring Carry out service -No.6 In case where the reading
current value of diagnosis E-1 P1 pump is largely differed from the
P1/P2 pump E-2 P2 pump actually measured value,
proportional valve -See Service Diagnosis Data List check proportional valve
Operation No.13 Bucket digging full and controller for possible
lever & in operation failure.
7 Secondary pressure Measure the Check that P1 pump proportional Replace proportional valve
of P1, P2 pump pump valve pressures is 2.7MPa or
proportional valve proportional valve more and P2 pump proportional
secondary valve pressure is 2.0 to 2.6MPa
pressure directly in bucket digging full lever and
(Ports a3, a4) high idling operation.
8 Attachment boost Carry out service No.3 F-7 POWER BOOST Check harness
solenoid command diagnosis Bucket digging COMP OFF, MEAS Replace solenoid valve
OFF
9 Attachment boost Measure switching Check that pressure is 0MPa in Replace solenoid valve
solenoid secondary valve secondary bucket digging full lever and high
pressure pressure idling operation

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 㨇47. TROUBLESHOOTING (BY TROUBLE)㨉

No. Sections Contents/normal value Corrective action, others

10 Actual measuring Carry out service -See Service Diagnosis Data List In case where the reading
current value of diagnosis Operation No.12 Bucket digging full is largely differed from the
travel straight lever & relief actually measured value,
proportional valve check proportional valve
and controller for possible
failure.
11 Secondary pressure Measure directly Check that travel straight secondary Replace proportional valve
of travel straight the proportional pressure is 2.7MPa or more in
proportional valve valve secondary bucket digging full lever and high
pressure at the idling operation
ports A6 (travel
straight) of 8
sections solenoid
block
12 P2 by-pass cut Visual check Poppet should be tightened. Clean or replace
valve Seated surface should be free from
<Trouble> damage and entry of foreign matter.
Only P2 pressure
is low.
13 Check stroke limiter Visual check When piston is removed from Replace
<Trouble> cover, it is free from abnormal (Check on the casing side
Both P1, P2 resistance against sliding for damage.)
pressures are high. Free from abnormal damage, etc
on outside surface
14 Remote control Check targeted Check that spool is free from Replace
valve remote control abnormal damage and spring is
valve free from breakage
15 Main relief valve Check set -See Service Diagnosis Data List Reset or replace
pressure Operation No.3 Boom up full lever
and relief
16 Travel straight spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against sliding (Check on the casing side
P2 pressure is Free from abnormal damage, etc for damage)
high. on outside surface
Spring is free from breakage.
17 Bucket spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against sliding (Check on the casing side
Both P1, P2 Free from abnormal damage, etc for damage) 
pressures are high. on outside surface
Spring is free from breakage.
18 Over load relief Check targeted Free from dust entered in over Replace
valve spool visually load relief valve.
Seat is free from abnormality.

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Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LC0033E04] [0518CsCshWbYs]
㨇47. TROUBLESHOOTING (BY TROUBLE)㨉

(10) Bucket dump is slow

No. Sections Contents/normal value Corrective action, others
1 Bucket dump Carry out service -See Service Diagnosis Data List Check and replace
pressure sensor diagnosis Operation No.14 Bucket dump full pressure sensor
lever and relief Check remote control
valve
2 Remote control Measure directly Check that pressure is 3.0MPa or Check remote control
valve remote control more in bucket dump full lever and valve
pressure of bucket high idling operation When equipped with
dump multi control valve, check
it while changing lever
pattern
3 Pump pressure Carry out service -See Service Diagnosis Data List When there is difference
sensor diagnosis for P1, Operation No.15 Bucket dump full between P1 and P2 pump
P2 pump lever and in operation pressures, check high
pressures in pressure sensor
operation.
4 Actual measuring Carry out service -No.7 In case where the reading
current value of diagnosis D-1 P1 unload valve (cut valve) is largely differed from the
P1/P2 unload D-1 P2 unload valve (cut valve) actually measured value,
proportional valve -See Service Diagnosis Data List check proportional valve
Operation No.14 Bucket dump full and controller for possible
lever & relief failure.
5 Secondary pressure Measure the Check that P1/P2 unload secondary Replace proportional valve
of P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary 0.5 to 1.2MPa in bucket dump full
pressure directly lever and high idling operation.
at the ports A7 Replace proportional valve
and A5 of 8
sections solenoid
block
6 Actual measuring Carry out service -No.6 In case where the reading
current value of diagnosis E-1 P1 pump is largely differed from the
P1/P2 pump E-2 P2 pump actually measured value,
proportional valve -See Service Diagnosis Data List check proportional valve
Carry out service Operation No.15 Bucket dump full and controller for possible
diagnosis. lever & in operation failure.
7 Secondary pressure Measure the Check that P1 pump proportional Replace proportional valve
of P1, P2 pump pump valve pressures is 2.7MPa or
proportional valve proportional valve more and P2 pump proportional
secondary valve pressure is 2.7MPa or more
pressure directly in bucket dump full lever and high
(Ports a3, a4) idling operation.
8 Actual measuring Carry out service -See Service Diagnosis Data List In case where the reading
current value of diagnosis Operation No.14 Bucket dump full is largely differed from the
travel straight lever & relief actually measured value,
proportional valve check proportional valve
and controller for possible
failure.

47-20
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 㨇47. TROUBLESHOOTING (BY TROUBLE)㨉

No. Sections Contents/normal value Corrective action, others

9 Secondary pressure Measure directly Check that travel straight secondary Replace proportional valve
of travel straight the proportional pressure is 2.7MPa or more in
proportional valve valve secondary bucket dump full lever and high
pressure at the idling operation
ports A6 (travel
straight) of 8
sections solenoid
block
10 P2 by-pass cut Visual check Poppet should be tightened. Clean and replace
valve Seated surface should be free from
<Trouble> damage and entry of foreign matter.
Only P2 pressure
is low.
11 Check stroke limiter Visual check Free from abnormal damage and Replace
<Trouble> wear on outside of piston inside (Check on the casing side
Pilot pressure is cover for damage.)
low.
12 Remote control Check targeted Check that spool is free from Replace
valve remote control abnormal damage and spring is
valve free from breakage
13 Main relief valve Check set -See Service Diagnosis Data List Reset or replace
<Trouble> pressure Operation No.3 Boom up full lever
Relief pressure is and relief
low.
14 Travel straight spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against sliding (Check on the casing side
P2 pressure is Free from abnormal damage, etc for damage)
high. on outside surface
15 Bucket spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against sliding (Check on the casing side
Both P1, P2 Free from abnormal damage, etc for damage)
pressures are high. on outside surface
Spring is free from breakage.
16 Over load relief Check targeted Free from dust entered in over Replace
valve spool visually load relief valve.
Seat is free from abnormality.



47-21
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㨇47. TROUBLESHOOTING (BY TROUBLE)㨉

(11) Swing does not move/slow

No. Sections Contents/normal value Corrective action, others
1 Swing pressure Carry out service -See Service Diagnosis Data List Check and replace
sensor diagnosis Operation No.11 Swing full lever pressure sensor
and in operation Check remote control
valve
2 Remote control Measure directly Check that pressure is 3.0MPa or Check remote control
valve remote control more in boom up full lever and valve
pressure of swing high idling operation When equipped with
multi control valve, check
it while changing lever
pattern
3 Swing parking Carry out service No.3 F-2 SWING-BRAKE Check swing pressure
brake solenoid diagnosis Lever neutral: COMP ON, MEAS sensor
ON Check harness
Swing: COMP OFF, MEAS OFF
4 Swing parking Measurement of Lever neutral: 0MPa Replace solenoid valve
brake solenoid solenoid valve A2 In operation: 4MPa or more
port
5 Shuttle valve Visual check No contamination on spool cover Clean or replace
<Trouble> (short side) and orifice
Pilot pressure is No damage on spool cover (long
low. side) and shuttle
6 Pump pressure Carry out service -See Service Diagnosis Data List Check high pressure
sensor diagnosis for P2 Operation No.11 Swing full lever sensor
pump pressures in and in operation
operation
7 Actual measuring Carry out service -No.7 D-2 P2 unload valve (cut In case where the reading
current value of P2 diagnosis valve) is largely differed from the
unload proportional -See Service Diagnosis Data List actually measured value,
valve Operation No.11 Swing full lever check proportional valve
& in operation and controller for possible
failure.
8 Secondary pressure Measure the Check that P2 unload secondary Replace proportional valve
of P2 unload proportional valve pressures are within the range of
proportional valve secondary 0.5 to 1.2MPa in swing full lever
pressure directly and high idling operation
at the ports A5 of
8 sections
solenoid block
9 Actual measuring Carry out service -No.6 E-2 P2 pump In case where the reading
current value of P2 diagnosis -See Service Diagnosis Data List is largely differed from the
pump proportional Operation No.11 Swing full lever actually measured value,
valve & in operation check proportional valve
and controller for possible
failure.
10 Secondary pressure Measure the Check that P2 pump proportional Replace proportional valve
of P2 pump pump valve pressure is 2.7MPa or more
proportional valve proportional valve in swing full lever and high idling
secondary operation
pressure directly
(Ports a3, a4)

47-22
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 㨇47. TROUBLESHOOTING (BY TROUBLE)㨉

No. Sections Contents/normal value Corrective action, others

11 Actual measuring Carry out service Check that the value is not change -Check pressure sensor of
current value of diagnosis regardless of operation travel
travel straight -See Service Diagnosis Data List -In case where the
proportional valve Operation No. 1 Operation is nil reading is largely differed
(Check this Operation No.18 Travel right full from the actually
trouble by only lever & idling measured value, check
swing operation) Operation No.19 Travel left full proportional valve and
lever & idling controller for possible
failure.
12 Secondary pressure Measure directly 0.8MPa or less in high idling Replace proportional valve
of travel straight the proportional operation regardless of
proportional valve valve secondary neutral/operation
(Check this pressure at the
trouble by only ports A6 (travel
swing operation) straight) of 8
sections solenoid
block
13 Command current Carry out service Check that the current value does Check pressure sensor of
value of bypass diagnosis not change regardless of operation. travel.
valve (Europe) No.15 D-15 In case where the reading
-See Service Diagnosis Data List. is largely differed from the
Operation No.1 is nil. actually measured value,
Operation No.18 is travel right in check proportional valve
full lever and idling. and controller for possible
Operation No.19 is travel left in failure.
full lever and idling.
14 Proportional valve Measure the High idling pressure is 0.8MPa or Replace proportional valve
secondary pressure proportional valve less regardless of neutral/operation.
of bypass valve secondary
(Europe) pressure directly
(G port)
15 Remote control Check targeted Check that spool is free from Replace
valve remote control abnormal damage and spring is
valve free from breakage
16 Travel straight spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against sliding (Check on the casing side
P2 pressure is low. Free from abnormal damage, etc for damage)
on outside surface
Spring is free from breakage.

17 Spool of bypass Visual check When removing, there is no Replace the spool
valve (Europe) abnormal resistance against sliding. (Check on the casing side
Free from abnormal damage etc. for damage.)
on outside surface.
Spring should be free from
breakage.
18 Swing spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against sliding (Check on the casing side
P2 pressure is Free from abnormal damage, etc for damage)
high. on outside surface
Spring is free from breakage.

47-23
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㨇47. TROUBLESHOOTING (BY TROUBLE)㨉

No. Sections Contents/normal value Corrective action, others

19 Swing relief valve Check set -See Service Diagnosis Data List Reset or replace
<Trouble> pressure Operation No.10 Swing full lever
Relief pressure is and relief
low.
20 Swing motor Visual check Inner parts (cylinder block, piston, Replace
valve brake etc) are to be free
from abnormal resistance against
sliding.
Free from abnormal damage, etc
on outside surface (brake plate etc)
21 Swing reduction Take sample oil Sampling oil does not include a Disassemble and inspect
gear oil from swing lot of metal powder. reduction gear
reduction gear
drain
22 Swing reduction Visual check Tooth surface is not worn Replace
abnormally and is not chipped.

(12) Noise occurred at swing operation

No. Sections Contents/normal value Corrective action, others
1 Swing parking Carry out service No.3 F-2 SWING-BRAKE Check swing pressure
brake solenoid diagnosis Lever neutral: COMP ON, MEAS sensor
ON Check harness
Swing: COMP OFF, MEAS OFF
2 Measurement of Lever neutral: 0MPa Replace solenoid valve
solenoid valve A2 In operation: 4MPa or more
port
3 Boost check valve Visual check When removing, free from Replace
(Sound of abnormal resistance against sliding
cavitation at Spring is free from breakage.
stopping)
4 By-pass check Visual check When removing, free from Replace
valve abnormal resistance against sliding
(Sound of Spring is free from breakage.
cavitation at
stopping)
5 Swing motor Visual check Disassemble and inspect abnormal Replace
(Brake valve/friction wear and scuffing
plate)
6 Swing motor piston Visual check When removing, free from Replace
abnormal resistance against sliding
Spring is free from breakage.
7 Swing reduction Take sample oil Sampling oil does not include a Disassemble and inspect
gear oil from swing lot of metal powder. reduction gear
reduction gear
drain.
8 Swing reduction Visual check Tooth surface has no abnormally Replace
worn and chipped.

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(13) Swing drifts on a slope while swing control lever is in neutral position
No. Sections Contents/normal value Corrective action, others
1 Swing pressure Carry out service -Engine stop & starter key ON Check and replace
sensor diagnosis All pilot low pressure sensors are pressure sensor
within range of 0 to 0.1MPa.
2 Remote control Check targeted Check that spool is free from Replace
valve remote control abnormal damage and spring is
valve free from breakage
3 Swing parking Carry out service No.3 F-2 SWING-BRAKE Check swing pressure
brake solenoid diagnosis Lever neutral: COMP ON, MEAS sensor
ON Check harness
Swing: COMP OFF, MEAS OFF Check parking brake
release switch
4 Measurement of Lever neutral: 0MPa Replace solenoid valve
solenoid valve A2 In operation: 4MPa or more
port
5 Swing motor Visual check Disassemble and inspect abnormal Replace
(Brake valve/friction wear and scuffing
plate)
6 Parking brake Visual check Piston and friction plate do not Replace
have abnormal resistance against
sliding
Free from spring damage

(14) Swing drifts at stopping

No. Sections Contents/normal value Corrective action, others
1 Shuttle valve Visual check No contamination on spool cover Clean or replace
<Trouble> (short side) and orifice. No damage
Pilot pressure is on spool cover (long side) and
low shuttle.
2 Swing pressure Carry out service -Engine stop & starter key ON Replace pressure sensor
sensor diagnosis All pilot low pressure sensors are
within range of 0 to 0.1MPa.
3 Swing relief valve Check set -See Service Diagnosis Data List Reset or replace
<Trouble> pressure Operation No.10 Swing full lever
Relief pressure is and relief
low.

4 Anti-reaction valve Visual check Free from dirt entering Clean or replace
Sliding part should be free from
foreign matter entering, abnormal
damage and wear.
5 Remote control Check targeted Check that spool is free from Replace
valve remote control abnormal damage and spring is
valve free from breakage
6 Swing motor Visual check Inner parts (cylinder block, piston, Replace
valve brake etc) are to be free
from abnormal resistance against
sliding.
Free from abnormal damage, etc
on outside surface (brake plate etc)

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(15) Travel speed is slow/poor

No. Sections Contents/normal value Corrective action, others
1 Travel right and left Carry out service -See Service Diagnosis Data List Check and replace
pressure sensor diagnosis Operation No.18 Travel right full pressure sensor
lever and idling Check remote control
Operation No.19 Travel left full valve
lever and idling
2 Remote control Measure directly Check that pressure is 2.1MPa or Check remote control
valve remote control more in travel right (left), forward valve
pressure of travel (reverse) full lever and high idling
right and left operation
3 Actual measuring Carry out service -No.7 In case where the reading
current value of diagnosis D-1 P1 unload valve (cut valve) is largely differed from the
P1/P2 unload D-1 P2 unload valve (cut valve) actually measured value,
proportional valve -See Service Diagnosis Data List check proportional valve
Operation No.18 Travel right full and controller for possible
lever & idling failure.
Operation No.19 Travel left full
lever & idling
4 Secondary pressure Measure the Check that P1/P2 unload secondary Replace proportional valve
of P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary followings in travel right (left),
pressure directly forward (reverse) full lever and high
at the ports A7 idling operation
and A5 of 8 Travel right (P1 unload): 0.5 to
sections solenoid 1.2MPa
block Travel left (P2 unload): 0.5 to
1.2MPa
5 Actual measuring Carry out service -No.6 In case where the reading
current value of diagnosis E-1 P1 pump is largely differed from the
P1/P2 pump E-2 P2 pump actually measured value,
proportional valve -See Service Diagnosis Data List check proportional valve
Operation No.18 Travel right full and controller for possible
lever & idling failure.
Operation No.19 Travel left full
lever & idling
6 Secondary pressure Measure the Check that P1/P2 unload secondary Replace proportional valve
of P1, P2 pump pump pressures are within the range of
proportional valve proportional valve followings in travel right (left),
secondary forward (reverse) full lever and high
pressure directly idling operation
(Ports a3, a4) Travel right (P1 pump): 2.7MPa or
more
Travel left (P2 pump): 2.7MPa or
more

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No. Sections Contents/normal value Corrective action, others

7 Actual measuring Carry out service Check that the value is not change -Check voltage of low
current value of diagnosis regardless of operation pressure sensor other
travel straight -See Service Diagnosis Data List than sensor for travel*-In
proportional valve Operation No. 1 Operation is nil case where the reading is
Operation No.18 Travel right full largely differed from the
lever & idling actually measured value,
Operation No.19 Travel left full check proportional valve
lever & idling and controller for possible
failure
8 Secondary pressure Measure directly 0.8MPa or less in high idling Replace proportional valve
of travel straight the proportional operation regardless of
proportional valve valve secondary neutral/operation
pressure
9 Command current Carry out service Check that the current value does -Check voltage of low
value of bypass diagnosis not change regardless of operation. pressure sensor other
valve (Europe) No.12 D-15 than sensor for travel.
-See Service Diagnosis Data List. -In case where the
Operation No.1 is nil. reading is largely differed
Operation No.18 is travel right in from the actually
full lever and idling. measured value, check
Operation No.19 is travel left in proportional valve and
full lever and idling. controller for possible
failure.
10 Proportional valve Measure the High idling pressure is 0.8MPa or Replace proportional valve
secondary pressure proportional valve less regardless of neutral/operation.
of bypass valve secondary
(Europe) pressure directly
(G port)
11 Remote control Check targeted Check that spool is free from Replace
valve remote control abnormal damage and spring is
valve free from breakage
Check sealing ability of shuttle
valve and entry of dust in orifice
12 Travel straight spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against sliding (Check on the casing side
P1 pressure is Free from abnormal damage, etc for damage)
high. on outside surface
Spring is free from breakage.

13 Travel spool Visual check of When removing, free from Replace
<Trouble> targeted spool abnormal resistance against sliding (Check on the casing side
Pump pressure is Free from abnormal damage, etc for damage)
high. on outside surface
Spring is free from breakage.
14 Spool of bypass Visual check When removing, there is no Replace the spool
valve (Europe) abnormal resistance against sliding. (Check on the casing side
Spring should be free from for damage.)
breakage.

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No. Sections Contents/normal value Corrective action, others

15 Travel motor relief Check set Check P1 and P2 pump pressures If P1 is low, right travel
valve pressure are 32MPa or more in right and motorAfs relief valve is
left travel levers full lever (relief failed.
operation at locked crawler belt) If P2 is low, left travel
and high idling motorAfs relief valve is
failed.
16 Travel motor Visual check Inner parts (piston, cylinder block, Replace
valve plate, brake valve spool) are
to be free from abnormal
resistance against sliding.
Free from abnormal damage, etc
on outside surface (brake plate etc)
17 Parking brake in Visual check When removing, free from Replace
travel motor abnormal resistance against sliding
No sticking on friction plate and
separator plate
18 Travel reduction Take sample oil Sampling oil does not include a Disassemble and inspect
gear oil from travel lot of metal powder. reduction gear
reduction gear
drain
19 Travel reduction Visual check Tooth surface is not worn Replace
abnormally and is not chipped.

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(16) Travel deviation

No. Sections Contents/normal value Corrective action, others
1 Travel right and left Carry out service -See Service Diagnosis Data List Check and replace
pressure sensor diagnosis Operation No.18 Travel right full pressure sensor
lever and idling Check remote control
Operation No.19 Travel left full valve
lever and idling
2 Remote control Measure directly Check that pressure is 2.1MPa or Check remote control
valve remote control more in travel right (left), forward valve
pressure of travel (reverse) full lever and high idling
right and left operation
3 Actual measuring Carry out service Check that the value is not change -Check voltage of low
current value of diagnosis regardless of operation pressure sensor other
travel straight -See Service Diagnosis Data List than sensor for travel
proportional valve Operation No. 1 Operation is nil -In case where the
Operation No.18 Travel right full reading is largely differed
lever & idling from the actually
Operation No.19 Travel left full measured value, check
lever & idling proportional valve and
controller for possible
failure.
4 Secondary pressure Measure directly 0.8MPa or less in high idling Replace proportional valve
of travel straight the proportional operation regardless of
proportional valve valve secondary neutral/operation
pressure
5 Actual measuring Carry out service -No.7 D-1 P1 unload valve (cut In case where the reading
current value of diagnosis valve) is largely differed from the
P1/P2 unload D-1 P2 unload valve (cut valve) actually measured value,
proportional valve -See Service Diagnosis Data List check proportional valve
Operation No.18 Travel right full and controller for possible
lever & idling failure.
Operation No.19 Travel left full
lever & idling
6 Secondary pressure Measure the Check that P1/P2 unload secondary Replace proportional valve
of P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary followings in travel right (left),
pressure directly forward (reverse) full lever and high
at the ports A7 idling operation
and A5 of 8
sections solenoid
Travel right (P1 unload): 0.5 to
1.2MPa

block Travel left (P2 unload): 0.5 to
1.2MPa
7 Actual measuring Carry out service -No.6 In case where the reading
current value of diagnosis E-1 P1 pump is largely differed from the
P1/P2 pump E-2 P2 pump actually measured value,
proportional valve -See Service Diagnosis Data List check proportional valve
Operation No.18 Travel right full and controller for possible
lever & idling failure.
Operation No.19 Travel left full
lever & idling

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No. Sections Contents/normal value Corrective action, others

8 Secondary pressure Measure the Check that P1/P2 unload secondary Replace proportional valve
of P1, P2 pump pump pressures are within the range of
proportional valve proportional valve followings in travel right (left),
secondary forward (reverse) full lever and high
pressure directly idling operation
(Ports a3, a4) Travel right (P1 pump): 2.7MPa or
more
Travel left (P2 pump): 2.7MPa or
more
9 Exchange P1 for Exchange Check the direction of deviation If the direction is
P2 delivery pipe of changed, inspect a
P1 for P2 pump. If the direction is
not changed, inspect a
valve and travel unit.
10 Remote control Check targeted Check that spool is free from Replace
valve remote control abnormal damage and spring is
valve free from breakage
Check sealing ability of shuttle
valve and entry of dust in orifice
11 Travel straight spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against sliding (Check on the casing side
P1 pressure is Free from abnormal damage, etc for damage)
high. on outside surface
Spring is free from breakage
12 Travel spool Visual check of When removing, free from Replace
<Trouble> targeted spool abnormal resistance against sliding (Check on the casing side
Pump pressure is Free from abnormal damage, etc for damage)
high. on outside surface
Spring is free from breakage
13 Travel motor relief Check set Check P1 and P2 pump pressures If P1 is low, right travel
valve pressure are 32MPa or more in right and motorAfs relief valve is
left travel levers full lever (relief failed.
operation at locked crawler belt) If P2 is low, left travel
and high idling motorAfs relief valve is
failed.
Replace as necessary
14 Travel motor Visual check Inner parts (piston, cylinder block, Replace
valve plate, brake valve spool) are
to be free from abnormal
resistance against sliding.
Free from abnormal damage, etc
on outside surface (brake plate etc)
15 Travel reduction Take sample oil Sampling oil does not include a Disassemble and inspect
gear oil from travel lot of metal powder. reduction gear
reduction gear
drain
16 Travel reduction Visual check Tooth surface is not worn Replace
abnormally and is not chipped.

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No. Sections Contents/normal value Corrective action, others

17 Pump regulator Visual check When removing, free from Replace
abnormal resistance against sliding
Free from abnormal damage, etc
on outside surface
Spring free from breakage,
damage, etc.
18 Pump Visual check When removing, inside parts Replace
(cylinder block, piston, valve plate,
shaft, etc.) are free from abnormal
resistance against sliding,
abnormal damage, etc.



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(17) Travel 1/2 speed cannot be switched

(In case of the traveling under heavy loading (for example traveling on a slope or traveling on a soft
ground), the speed may sometimes does not change from 1st to 2nd because this machine equips the
function of automatic speed change.)

No. Sections Contents/normal value Corrective action, others

1 Travel 1/2 speed Carry out service Switch travel 1/2 speed to 2nd Check pressure sensor
switching solenoid diagnosis speed No.3 F-3 1/2-TRAVEL Check harness
Lever neutral COMP OFF, MEAS Check travel 1/2 speed
OFF switch on gauge cluster
Travel operation COMP ON, MEAS
ON
2 Travel 1/2 speed Measure A3 port Lever neutral: 0MPa Replace solenoid valve
switching solenoid pressure on In operation: 4MPa or more
solenoid valve
3 1/2 speed Visual check Check that spool is free from Replace
switching spool in abnormal damage and spring is (Check on the casing side
travel motor free from breakage for damage)
4 1/2 speed Visual check Free from entry of dust Remove dust or replace
switching orifice in
travel motor
5 Tilting piston in Visual check Free from abnormal wear on piston Replace
travel motor and seal (Check on the casing side
for damage)

(18) Machine does not stay on a slope in traveling

No. Sections Contents/normal value Corrective action, others
1 Pilot pressure Carry out service -Engine stop & starter key switch Check pressure sensor
sensor diagnosis is ON and replace as necessary
Targeted pilot low pressure sensor Check remote control
is in range of 0 to 0.1MPa valve
2 Remote control Check targeted Check that spool is free from Replace
valve remote control abnormal damage and spring is
valve free from breakage
3 Parking brake in Visual check When removing, free from Replace
travel motor abnormal resistance against sliding
Spring free from breakage,
damage, etc.
4 Orifice of passage Visual check Free from entry of dust Remove dust or replace
for parking brake
in travel motor

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(19) Machine does not travel straight in simultaneous operation of traveling and attachment
No. Sections Contents/normal value Corrective action, others
1 Actual measuring Carry out service No.7 D-3 S-TRAVEL is should be -Check voltage of low
current value of diagnosis COMP 720mA and MEAS 690 to pressure sensor other
travel straight 750mA in both travel full lever than travel sensor-In
proportional valve and in boom up full lever at high case where the reading is
idling largely differed from the
actually measured value,
check proportional valve
and controller for possible
failure.
2 Secondary pressure Measure directly Check secondary pressure is within Replace proportional valve
of travel straight the proportional range of 2.6 to 3.0MPa in both
proportional valve valve secondary travel full lever and in boom up full
pressure lever at high idling
3 Command current Carry out service Travel right and left in full lever + -Check voltage of low
value of bypass diagnosis Boom-up in full lever + High idling pressure sensor other
valve (Europe) No.12 D-15 than sensor for travel.
Check that the current value is -In case where the
COMP 530mA and MEAS 530 ± reading is largely differed
30mA. from the actually
measured value, check
proportional valve and
controller for possible
failure.
4 Proportional valve Measure the Travel right and left in full lever + Replace proportional valve
secondary pressure proportional valve Boom-up in full lever + High idling
of bypass valve secondary Check that the secondary
(Europe) pressure directly pressure is within the range of 1.5
(G port) to 1.9MPa.
5 Travel straight spool Visual check When removing, free from Replace
abnormal resistance against sliding (Check on the casing side
Free from abnormal damage, etc for damage)
on outside surface
Spring is free from breakage.
6 Spool of bypass Visual check When removing, there is no Replace the spool
valve (Europe) abnormal resistance against sliding. (Check on the casing side
Free from abnormal damage etc. for damage.)
on outside surface.
Spring should be free from

breakage.

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(20) Breaker works slowly and power is poor

(In case of conflux, check p1 unload/pump and travel straight)

No. Sections Contents/normal value Corrective action, others

1 Pressure sensor for Carry out service -See Service Diagnosis Data List Check and replace
optional attachment diagnosis Operation No.16 P2 side OPT full pressure senso
lever and relief Check remote control
valve
2 Remote control Measure directly Check that pressure is 2.1MPa or Check remote control
valve remote control more in optional attachment full valve0
pressure of travel lever and high idling operation
right and left
3 Actual measuring Carry out service -See Service Diagnosis Data List -In case where the
current value of diagnosis Operation No.16 P2 side OPT full reading is largely differed
P1/P2 unload lever and relief from the actually
proportional valve measured value, check
proportional valve and
controller for possible
failure.
4 Secondary pressure Measure the Check that P1/P2 unload secondary Replace proportional valve
of P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary 0.5 to 1.2MPa
pressure directly
at the ports A7
and A5 of 8
sections solenoid
block
5 Actual measuring Carry out service -See Service Diagnosis Data List -Check voltage of low
current value of diagnosis Operation No.16 P2 side OPT full pressure sensor other
travel straight lever & relief than sensor for optional
proportional valve attachment
-In case where the
reading is largely differed
from the actually
measured value, check
proportional valve and
controller for possible
failure.
6 Secondary pressure Measure directly Check that travel straight secondary Replace proportional valve
of travel straight the proportional pressure is 2.7MPa or more in
proportional valve valve secondary optional attachment full lever and
pressure at the high idling operation
ports A6 (travel
straight) of 8
sections solenoid
block
7 P1 by-pass cut Visual check Poppet should be tightened. Clean or replace
valve Seated surface should be free from
<Trouble> damage and entry of foreign matter.
Only P1 pressure
is low.

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No. Sections Contents/normal value Corrective action, others

8 Relief pressure Check set -See Service Diagnosis Data List Reset or replace
pressure Operation No.16 P2 side OPT full
lever and relief
(Set value of factory shipment is
24.5MPa.)
9 Remote control Check targeted Check sealing ability of shuttle Replace
valve remote control valve and entry of dust in orifice.
valve
10 Travel straight spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against sliding (Check on the casing side
P1 pressure is Free from abnormal damage, etc for damage)
high. on outside surface
Spring is free from breakage.
11 Spool for optional Visual check When removing, free from Replace
attachment abnormal resistance against sliding (Check on the casing side
<Trouble> Free from abnormal damage, etc for damage)
P1, P2 pressures on outside surface
are high. Spring is free from breakage.
12 Over load relief Check targeted Free from dust entered in over Replace
valve spool visually load relief valve
Seat is free from abnormality.

(21) Selector valve for option malfunctions: Breaker circuit is not obtained.
(Indication of failure is displayed. For reference, see "Table : Action of optional selector solenoid valve")

No. Sections Contents/normal value Corrective action, others

1 N&B selector spool Visual check When removing, free from Replace
abnormal resistance against sliding (Check on the casing side
Free from abnormal damage, etc for damage)
on outside surface
Spring is free from breakage
2 N&B selector Screw for Check that the error indication is Replace solenoid valve
solenoid emergency disappeared by turning emergency
screw
3 N&B selector Carry out service -No.9 F-4 Option selector is B Check solenoid valve
solenoid diagnosis mode
COMP ON, MEAS ON
Check harness

Spool position BRK
Selector switch BRK
4 N&B selector Carry out service -No.13 B-11 Check pressure sensor
pressure sensor diagnosis Data List Check harness
3.0MPa at B mode and 0.0MPa
at A mode

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㨇47. TROUBLESHOOTING (BY TROUBLE)㨉

(22) Selector valve for option malfunctions: Nibbler circuit is not obtained.
(Indication of failure is displayed. For reference, see "Table : Action of optional selector solenoid valve")

No. Sections Contents/normal value Corrective action, others

1 N&B selector spool Visual check When removing, free from Replace
abnormal resistance against sliding (Check on the casing side
Free from abnormal damage, etc for damage)
on outside surface
Spring is free from breakage.
2 N&B selector Carry out service -No.9 F-4 Option selector is A Check solenoid valve
solenoid diagnosis mode Check harness
COMP OFF, MEAS OFF
Spool position N
Selector switch NIB

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 㨇47. TROUBLESHOOTING (BY TROUBLE)㨉

Action of optional selector solenoid valve

Safety Safety Optional Selector
lock lock selector valve Failure
Engine Work Spool Warning
No. lever lever valve detecting diagnosis
condition mode position display
SW's relay's COMP. pressure display
input output MEAS. sensor

1 Running ON OFF Nibbler OFF Nibbler Normal - -

"SELECTOR [F042]
2 Running ON OFF Nibbler ON Breaker Normal VALVE displayed
FAILURE" simultaneously
"SELECTOR
3 Running ON OFF Nibbler OFF Breaker Normal VALVE -
FAILURE"
[F042]
4 Running ON OFF Nibbler ON Nibbler Normal -
displayed
5 Running ON OFF Breaker ON Breaker Normal - -
"SELECTOR [F043]
6 Running ON OFF Breaker OFF Nibbler Normal VALVE displayed
FAILURE" simultaneously
"SELECTOR
7 Running ON OFF Breaker ON N&B Normal VALVE -
FAILURE"
[F043]
8 Running ON OFF Breaker OFF Breaker Normal -
displayed
"SELECTOR
[B113]
9 Running ON OFF - - - Failure VALVE
displayed
FAILURE"
10 Stopping - - - - - - - -
11 - OFF - - - - - - -
12 - - ON - - - - - -



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㨇47. TROUBLESHOOTING (BY TROUBLE)㨉

47.2 ELECTRIC SYSTEMS

47.2.1 WIRING CHECKING PROCEDURE

Check for continuity between connector terminals, presence or absences of short-circuit with other
wires, and presence or absences of short-circuit with machine body grounding.

(1)
Checking for disconnection between connectors.
(When both ends measurement is easy because
of short distance between connectors,)
Measure the resistance using tester.
Pull out opposite connector first.
When the resistance is zero (0), it is in normal
condition.

(When both ends measurement is difficult

because of long distance between connectors,)
Measure the resistance using tester.
Pull out opposite connector first.
Where the resistance is zero (0), if the
terminal on one side is connected to frame
body grounding with jumper wire, it is in normal
condition.
The resistance is 1M-ohm or more when the
terminal on one side is not connected to frame
body grounding with jumper wire, it is in normal
condition.

(2)
Checking for presence or absence of
short-circuit with machine body
Measure the resistance using tester.
Pull out opposite connector first.
When the resistance is 1M-ohm or more, it is
in normal condition.

(3)
Checking for presence or absence of
short-circuit between wirings.
Measure the resistance using tester.
Pull out opposite connector first.
When the resistance is 1M-ohm or more, it is
in normal condition.

(4)
Checking connector terminal for contact
Insert male terminal into female terminal unit,
and then check that the inserting force is
equivalent to other female terminals.

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If looseness is there, replace the female

terminal with new one.
Clean the dirt terminal.

Do not insert the male terminal the thickness differs. It may cause loose connection.

(5)
Caution which should be paid in measuring voltage
When measuring the power supply to electric equipment at connector position with the grounding
terminal contained inside of connector, measure the voltage between grounding inside of connector and
power terminal.
When measuring the voltage between frame body grounding and power source, the disconnection of
wiring to grounding inside of connector cannot be identified.
Since the voltage may vary between with connector connected and with connector not connected.
Measure the voltage with each connector connected whenever possible.

(6)
Checking the general view of connector

a. Check the terminal crimped condition.

Pull one electric cable with the about 3kg
force, and make sure that the cable does
not come out of the terminal.
When came out, replace the terminal and
crimp it again.
b. Check connector for imperfect insertion
Check that all top ends form a line on the
same position as seen from the connector
engaged side.
c. Check connector for imperfect insertion
Check that all top ends form a line on the
same position as seen from the connector
engaged side.


(7)
When abnormality occurs at intervals
When the abnormality situation can not be reoccurred during checking operation, try the following
operations.

a. Check that variable of display exists or not on the service diagnosis screen while shaking the
harness or giving shock by operating the machine.
b. Check that variables of resistance and voltage exist or not using tester while shaking the harness.
c. Turn starter switch on and apply electricity continuously, and check it again after the temperature
of wiring and equipment was raised.

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㨇47. TROUBLESHOOTING (BY TROUBLE)㨉

(8)
Checking on body grounding
Check attaching bolts of grounding terminal for
loosening.
And also check that there is no loose
connection due to corrosion.

There are multiple groundings like centralized

grounding box shown in the figure and battery
grounding, engine grounding, horn grounding
fixed together with horn, body grounding
placed on attaching section of boom working Block of grounding is located under floor
light. plate of cab

47-40
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 㨇47. TROUBLESHOOTING (BY TROUBLE)㨉

47.2.2 TROUBLE
(1) Engine does not stop.
(2) "CPU DATA COMMUNICATION ERROR" is displayed on multi display.
(3) Auto accel does not actuate. (The engine speed does not automatically slow down.)
(4) Auto accel does not actuate. (The engine speed does not automatically speed up.)
(5) Wiper does not function.



47-41
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㨇47. TROUBLESHOOTING (BY TROUBLE)㨉

(1) Engine does not stop.

No. Sections Contents/normal value Corrective action, others
1 Starter key switch Check signal of No.4 K-3 Key switch Check continuity between
starter key switch OFF at starter key switch OFF terminals of starter switch
ON by carrying position using tester
out service ON at starter key switch ON
diagnosis. position
2 Engine forcible When ON is No.4 K-3 Key switch Check on engine forcible
stop relay displayed with OFF at starter key switch OFF stop relay
the starter switch position
OFF, then pull out ON at starter key switch ON
R-25 engine position
forcible stop
relay and carry
out the service
diagnosis.
3 Wiring Voltage between 0V when starter switch is OFF Check harness
line No.762 Check diode D-9
among starter between starter switch
switch, engine and auto idling stop relay
forcible stop relay, 1
mechatro
controller and the
body grounding

(2) "CPU DATA COMMUNICATION ERROR" is displayed on multi display.

No. Sections Contents/normal value Corrective action, others
1 Fuse No.1 fuse (5A) Not blown fuse Check harness
Replace fuse
2 Mechatro controller Accel control Engine speed varies according to Check mechatro
accel potentiometer operation. controller and replace as
(Use remote control because the necessary
auto accel function is working.)
3 Wiring Transmission See "WIRING CHECKING Repair wiring
circuit line PROCEDURE"
No.770 from
mechatro
controller to
gauge cluster
4 Gauge cluster Gauge cluster Replace gauge cluster

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 㨇47. TROUBLESHOOTING (BY TROUBLE)㨉

(3) Auto accel does not actuate. (The engine speed does not automatically slow down).
No. Sections Contents/normal value Corrective action, others
1 Engine coolant Check engine No.2 G-5 WATER TEMP Replace engine coolant
temperature coolant uto accel does not work in the sensor
temperature by temperature -15C degrees or less.
carrying out Warm up and raise the coolant
service diagnosis. temperature to -15C degrees or
more
2 Gauge cluster Indication of auto Mark "Display/not display" for auto Replace gauge cluster
accel accel switches by auto accel switch
operation on gauge cluster.
3 Low pressure Service diagnosis Each control pressure of No.5 and Check low pressure sensor
sensor No.6 is in the range of 0 to
0.1MPa at control lever neutral
position.

(4) Auto accel does not actuate. (The engine speed does not automatically speed up.)
No. Sections Contents/normal value Corrective action, others
1 Low pressure Service diagnosis Each control pressure of No.5 and Check low pressure sensor
sensor No.6 is raised with control lever
operated.



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㨇47. TROUBLESHOOTING (BY TROUBLE)㨉

(5) Wiper does not function

47-44
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 㨇47. TROUBLESHOOTING (BY TROUBLE)㨉

47.3 ENGINE RELATED TROUBLESHOOTING



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㨇47. TROUBLESHOOTING (BY TROUBLE)㨉

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 㨇47. TROUBLESHOOTING (BY TROUBLE)㨉



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㨇47. TROUBLESHOOTING (BY TROUBLE)㨉

47-48
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 㨇51. ENGINE㨉

51. ENGINE
PREFACE

This service manual explains the single engine. Note that this manual is edited without modification by
based on the service manual of HINO MOTOR.

٨ The replacement interval of the engine parts described in the separate volume of the operator's
manual is different from that in the shop manual.The description in the operator's manual is a
correct replacement interval.

‫ޣ‬Example‫ޤ‬
The item "1. Routine inspection items (4)"in "Inspection of the DPF", at the page 10-14 in the
exhaust section of the engine chapter in the shop manual, is described as "Replace a hose
which has been used for 3 years or more with new one." But the same item in the operator's
manual is described as "2 years".

Book Code No. S5LC51E0

51-1
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㨇51. ENGINE㨉

Issue Date of Issue Applicable Machines Remarks

S5LC5133E01
First Edition July, 2014 SK350LC-9E : YC13-13001~
(NA)
S5LC5133E02
Revision April, 2016 SK350LC-9E : YC13-13001~
(NA)

51-2
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HINO DIESEL ENGINE
WORKSHOP MANUAL

J08E-VV

(Shovel)

KSS-T4J8-003E

2015.11
[S5LC0033E04] [0518CsCshWbYs]
[S5LC0033E04] [0518CsCshWbYs]
 GENERAL 1
STANDARD VALUE 2
PARTS TO BE PREPARED 3
ENGINE MOUNTING/DISMOUNTING 4
FUEL SYSTEM 5
EMISSION CONTROL 6
ELECTRICAL 7
INTAKE 8
ENGINE MECHANICAL 9
EXHAUST 10
COOLING 11
LUBRICATION 12
STARTING AND CHARGING 13
TURBOCHARGER 14
AIR COMPRESSOR 15
FAILURE DIAGNOSIS FOR EACH ENGINE STATUS 16
ENGINE DIAGNOSIS CODE 17

For your information:

This documentation does not contain any descriptions in

regard to the hatched part

"15. Air Compressors".

[S5LC0033E04] [0518CsCshWbYs]
[S5LC0033E04] [0518CsCshWbYs]
 GENERAL 1–1

ENGINE

1
1 GENERAL
General information

Warning................................................................... 1-2
How to read this manual ........................................ 1-3
Precautions for work ............................................... 1-8
Tightening of engine bolts and nuts ...................... 1-12
Tightening of flare nuts and hoses........................ 1-14
Taper thread sealant for piping ............................. 1-15
Assembly of joints and gaskets for piping ............. 1-16
Handling of liquid gasket....................................... 1-18
Failure diagnosis table for each problem .............. 1-19
Failure diagnosis procedures................................ 1-20
Failure diagnosis using Hino-DX........................... 1-22
Connection method of Hino-DX ............................ 1-27
Engine number ..................................................... 1-28

[S5LC0033E04] [0518CsCshWbYs]
1–2 GENERAL

Warning
JP30TCE010102001

Observe the following precautions to work safely and to prevent damage to customers' machine.

This manual is prepared for qualified service engineers who are recognized as technical expert. Those who are not
qualified, who are not appropriately trained, who performs service without appropriate tool or equipment, or who
perform service with the way not specified in this manual may not only damage the vehicle, but also put service
engineers and surrounding people in danger.
• Appropriate service and repair are essential to ensure safety of service engineers and safety and reliability of
vehicles. Be sure to use Hino genuine parts for replacement of parts. Do not use deteriorated parts in quality.
• Items described in this manual are the procedures to be observed in service and repair. For service and repair
according to this procedure, be sure to use the special tools designed for each purpose.
• If a method or a tool not recommended is used, safety of service engineers, and safety and reliability of vehicles
may be impaired. Never use a method or tool not recommended.
• This manual shows “Warning” and “Caution” for items that need to be observed so that accidents may not occur
during service or repair, or that damage to vehicle due to improper method may not impair safety and reliability of
vehicles. These instructions cannot give warning for all possible hazards. Note that items with “Warning” or
“Caution” are not absolute for safety.

[S5LC0033E04] [0518CsCshWbYs]
 GENERAL 1–3

How to read this manual

JP30TCE010102002

1. Scope of repair work

(1) Repair work is classified into three large categories of "Diagnosis", "Mounting/removal, replacement,
assembly˜disassembly and inspection˜adjustment" and "Final inspection".
(2) This manual describes "Diagnosis" in the first process and "Mounting/removal, replacement,
assembly˜disassembly and inspection˜adjustment" in the second process. Explanation of "Final inspection"
in the third process is omitted here.
(3) Although the following work is not described in this manual, it should be performed in actual work.
a. Jacking and lifting
b. Cleaning and washing of removed parts as required
c. Visual inspection

2. Standard value
(1) Standard value, limit, action and tightening torque described in the text are summarized in tables.

3. Items to be prepared
(1) Items to be prepared before work are SST, tools, gauges and lubricant, etc. These are listed in the list
section of items to be prepared. Items such as general tools, jack, rigid rack, etc. that are usually
equipped in general service shop are omitted.

4. How to read sections and titles

(1) Sections are classified according to J2008, SAE standard.
(2) For areas that show system names like "Engine control system", "Inspection", "Adjustment",
"Replacement", "Overhaul", etc. of components are described.
(3) For areas that show part names like "Injection pump", "Mounting/removal and disassembly" is described.

[S5LC0033E04] [0518CsCshWbYs]
1–4 GENERAL

5. How to read troubleshooting

(1) Failure diagnosis in this manual describes Step 2 and Step 3 below :

Hear from customers for conditions and environments of

(1) Question "Step 1"
failures and check the fact.

Perform diagnosis inspection, status inspection,

(2) Pre-inspection function inspection and basic inspection. Check the
"Step 2"
(3) Reproduction method failure status. If it is difficult to reproduce the problem
with status inspection, use the reproduction method.

(4) Troubleshooting for each Summarize inspection results obtained from Step 2.
diagnosis code Perform inspection systematically according to
"Step 3"
(5) Troubleshooting for each troubleshooting procedures for each diagnosis code or
failure status failure status.

Check if failure occurs again after repair. If it is difficult to

(6) Confirmation test "Step 4" reproduce a failure, perform the confirmation test under
the conditions and environment of the failure.

(2) Pre-inspection

• Pre-inspection is performed in the following steps :

Diagnosis inspection o Diagnosis deletion o Failure status check (Use the reproduction
method if not reproduced.) o Diagnosis reconfirmation
• Estimate the failure system before the reproduction test. Attach a tester and evaluate
estimated failure together with failure status. Refer to the troubleshooting chart for
Pre- estimated cause of a failure.
inspection • An error code is displayed if a failure occurs instantaneously. If any specific failure is not
found, perform troubleshooting using the reproduction method.
• Failure status check
If failure is reproduced, perform Step 2 o Step 3 o Step 4.
If failure is not reproduced, use the reproduction method (simulation of external
conditions or check of each wire harness and connector, etc.)

[S5LC0033E04] [0518CsCshWbYs]
 GENERAL 1–5

6. How to read explanation details

(1) Part layout

Example
ENGINE MECHANICAL [J08E] 9–17

Timing Gear Cover and Flywheel Housing

Part layout
JP04117090402003

Part name code

Part catalog Fig. No.

SAPH041170900182

1 Flywheel housing 4 End plate

Description of
2 Gasket* 5 Rear oil seal* part name code
3 Flywheel housing stay

*Parts not to be reused.

Left: Part name code (nut)
Tightening torque
A D
B E
C

It is the ID number for parts to prepare electronic data. It is not required for repair work.

SAPH30TCE0100001

[S5LC0033E04] [0518CsCshWbYs]
1–6 GENERAL

7. Definition of terms
Terms in this manual are defined as follows :
(1) Direction (Individual unit)
• Front/back direction
The power input side is front and the output side is back.
• Rotating direction
When viewed from the rear, the clockwise direction is right rotation and the counterclockwise direction is
left rotation.
• Vertical direction
With a unit mounted on the machine main unit, the upward direction is upper and the downward
direction is lower.
• Left/right direction
When viewed from the rear, the left direction is left and the right direction is right.
(2) Standard value ˜˜˜˜˜˜˜Basic dimension excluding tolerance and clearance generated by tolerances when two
parts are joined
(3) Repair limit˜˜˜It is the value requiring repair. Symbol of + or - with the value means increase or decrease to
the standard value.
(4) Operation limit˜˜˜It is the value requiring replacement. Symbol of + or - with the value means increase or
decrease to the standard value.
(5) Warning˜˜˜˜˜˜˜˜˜˜˜It is an item that may result in risk of human life or serious injury by incorrect handling.
(6) Caution˜˜˜˜˜˜˜˜˜˜˜It is an item that should not be performed including inhibited work or an item that require
attention in working procedures.
(7) Reference˜˜˜˜˜˜˜˜˜˜˜It is supplementary explanation in work.

[S5LC0033E04] [0518CsCshWbYs]
 GENERAL 1–7

8. Unit
(1) SI unit is used in this manual. SI unit is the international unit to unify the conventional different international
units into one unit per quantity and to promote smooth technical communications.
(2) This manual shows both the SI unit and conventional units. The conventional units are shown in { }.

Conversion value*1
Item SI unit Conventional unit
(1[Conventional unit] = X [SI unit])

Force N kgf 1kgf=9.80665N

Torque*2 N˜m kgf˜cm 1kgf˜cm=0.0980665N˜m

1kgf/cm2=98.0665kPa
kgf/cm2
Pressure Pa =0.0980665MPa

mmHg 1mmHg=0.133322kPa

r/min 1rpm=1r/min
Rotational speed rpm
min-1 1rpm=1min-1

Spring constant N/mm kgf/mm 1kgf/mm=980665N/mm

Volume L cc 1cc=1mL

Efficiency W PS 1PS=0.735499kW

Calorific value W˜h cal 1kcal=1.13279W˜h

Fuel consumption rate g/W˜h g/PS˜h 1g/PS˜h=1.3596g/kW˜h

*1 : X means the value when 1 [Conventional unit] is converted to the SI unit.

It is used as the conversion factor from the conventional unit to the SI unit.
*2 : The conversion value of the torque may vary depending on the unit.
Observe the standard values described for each unit.

[S5LC0033E04] [0518CsCshWbYs]
1–8 GENERAL

Safety information

Precautions for work

JP30TCE010101001

1. General precautions
To ensure safety in work and to prevent accidents, observe the following items :
(1) Appearance
a. Wear safety goggles.
b. Do not wear watch, necktie, ring, bracelet, necklace, etc. to prevent accident before work.
c. Bind long hair at the back.
d. Be sure to wear a cap and safety shoes.
(2) Safety work
a. Do not touch radiator, muffler, exhaust pipe, tail pipe, etc. after stop of the engine to prevent burn.
b. Do not put your clothes or tools near the rotating part (in particular, cooling fan or V–belt) during
operation of the engine.
c. Remove the starter key when the engine is not started.
d. Start the engine at a well ventilated place so that carbon monoxide may not be filled.
e. Since gas from the fuel or the battery is flammable, do not spark a fire or smoke a cigarette near the
area.
f. Since the battery fluid is poisonous and corrosive, be careful for handling.
g. Do not short-circuit the cable of the battery or starter. Otherwise, the cable may be burned or burn may occur.
h. If a tool or rag is left in the engine compartment, it may be bounced with a rotating part of the engine,
resulting in injury.
i. To tow a failure machine, refer to “Towing” in the "Operation manual" of the machine.

2. Precautions for service work

Pay attention to the following points before service work
(1) Preparation before disassembly
a. Prepare general tools, special tools and gauges before work.
b. To disassemble a complicated area, put a stamp or match mark on the location not functionally affected
to ease assembly. To repair the electric system, disconnect the cable from the minus terminal of the
battery before work.
c. Perform inspection according to the procedure in the text before disassembly.
(2) Inspection during disassembly
Every time parts are removed, check the area where the parts are assembled and check for deformation,
damage, wear or scratch.
(3) Arrangement of disassembled parts
Place removed parts neatly in order. Separate parts to be replaced from parts to be reused.
(4) Washing of disassembled parts
Clean and wash parts to be reused well.
(5) Inspection and measurement
Inspect and measure parts to be reused as required.
(6) Assembly
a. Keep the specified standard values (tightening torque, adjusting values, etc.) and assemble correct
parts in the correct order.
b. Be sure to use genuine parts for parts to be replaced.
c. Use new packing, gasket, O–ring and cotter pin.
d. Use seal gaskets for some areas where gaskets are used. Apply specified oil or grease to sliding areas
where application of oil is required, and apply specified grease to the oil seal lip before assembly.
(7) Check of adjustment
Make adjustments to the service standard values using a gauge or tester.

[S5LC0033E04] [0518CsCshWbYs]
 GENERAL 1–9

3. Precautions for electric system

(1) Removal of battery cable

a. In an electric system, remove the cable from the

battery minus (-) terminal to prevent burnout due to
short-circuit.
Loosen
b. When the battery cable is removed, the battery
terminal may be damaged. Loosen the nut completely
and never pry it for removal.

SAPH30TCE0100002

(2) Handling of electronic parts

a. Do not give impact on electronic parts such as

computer and relay.
b. Do not place electronic parts at a high temperature and
humidity area.
c. Do not expose electronic parts to water in washing of a
vehicle.

SAPH30TCE0100003

(3) Handling of wire harness

a. Mark clamps and clips to prevent interference of a wire

harness with body edge, sharp edge and bolts. Be sure
to reassemble it to the original position.
b. When parts are assembled, be careful not to pinch a
wire harness.

SAPH30TCE0100004

[S5LC0033E04] [0518CsCshWbYs]
1–10 GENERAL

(4) Handling of connector

a. When a connector is removed, hold the connector (as

shown by the arrow in the left) and pull it out. Do not pull
the wire harness.
b. Unlock the locking connector before pulling.
c. Insert the locking connector completely until it clicks.
d. To insert a test lead into the connector, insert it from the
back of the connector.
e. If it is difficult to insert a test lead from the back of the
connector, prepare a harness for inspection.

SAPH30TCE0100005

[S5LC0033E04] [0518CsCshWbYs]
 GENERAL 1–11

4. Precautions for electric welding

Inadvertent electric welding on a cab or frame may cause reverse welding current from the grounding
circuit, resulting in damage to electric and electronic parts. Observe the following items for electric
welding.
(1) Turn "OFF" the starter switch.
(2) Make sure that switches are "OFF".
(3) Disconnect the minus (-) terminal of the battery according to the removal procedure of the battery cable.
(4) Disconnect connectors of each computer.
(5) Remove all fuses. (For locations of fuses, refer to "Electrical Chapter".)
(6) Be sure to connect grounding of the electric welding machine near the welding area.
Connect grounding from a bolt (plated bolt) or a frame near the welding area.
Remove paint of the frame for connection of grounding from the frame.
The seal and the bearing etc. that please make sure do not enter between the weld and the ground
section.
(7) Other precautions
a. Put a cover on rubber hoses, wire harnesses, pipes, tires, etc. around the welding area so that they
may not be exposed to spatter.
b. Perform welding under appropriate conditions and minimize heat effect in the peripheral area. Also
maintain welding quality.
(8) After welding, connect and assemble in the order of the fuse and the minus terminal of the battery
disassembled. When paint is removed from a frame or cab, apply rust preventive coating with the same
color.
(9) After reassembly, check the function if it operates correctly.
General information

[S5LC0033E04] [0518CsCshWbYs]
1–12 GENERAL

Tightening of engine bolts and nuts

JP30TCE010102003

1. Tightening torque of general standard bolts

(1) For bolts with seatings
Unit : N˜m{kgf˜cm, lbf˜ft}

Screw diameter x Pitch 7T 9T

M8 x 1.25 (Coarse thread) 28.5 {290, 21} 36 {370, 27}

M10 x 1.25 (Fine thread) 60 {610, 44} 74.5 {760, 55}

M10 x 1.5 (Coarse thread) 55 {560, 41} 68.5 {700, 51}

M12 x 1.25 (Fine thread) 108 {1100, 80} 136 {1390, 101}

M12 x 1.75 (Coarse thread) 97 {990, 72} 125 {1280, 93}

M14 x 1.5 (Fine thread) 171.5 {1750, 127} 216 {2200, 160}

M14 x 2 (Coarse thread) 154 {1570, 114} 199 {2030, 147}

Remark Bolt with number “7” on the head Bolt with number “9” on the head

! CAUTION • 8T bolt is in accordance with 7T bolt.

(2) For bolts with washers

Unit : N˜m{kgf˜cm, lbf˜ft}

Screw diameter x Pitch 4T 7T 9T

M6 x 1 (Coarse thread) 6 {60, 4} 10 {100, 7} 13 {130, 9}

M8 x 1.25 (Coarse thread) 14 {140, 10} 25 {250, 18} 31 {320, 23}

M10 x 1.25 (Fine thread) 29 {300, 22} 51 {520, 38} 64 {650, 47}

M10 x 1.5 (Coarse thread) 26 {270, 20} 47 {480, 35} 59 {600, 43}

M12 x 1.25 (Fine thread) 54 {550, 40} 93 {950, 69} 118 {1200, 88}

M12 x 1.75 (Coarse thread) 49 {500, 36} 83 {850, 61} 108 {1100, 80}

M14 x 1.5 (Fine thread) 83 {850, 61} 147 {1500, 108} 186 {1900, 137}

M14 x 2 (Coarse thread) 74 {750, 54} 132 {1350, 98} 172 {1750, 127}

Bolt with number “4” on

the head Bolt with number ”7” on
Bolt with number “9” on
Remark Projection bolt Stud the head Stud with C
the head
with R surface at free surface at free end
end

! CAUTION • 8T bolt is in accordance with 7T bolt.

R surface (4T) C surface (7T)

SAPH30TCE0100006

[S5LC0033E04] [0518CsCshWbYs]
 GENERAL 1–13

2. Precoated bolt
Precoated bolt is the bolt with application of seal lock
agent at the thread.

(1) When re-application of lock agent is required

a. When precoated bolts are removed
b. When precoated bolts are moved due to tightening
Seal Lock Agent check (for loosening or tightening)

NOTICE • Check torque with the lower limit of the

SAPH30TCE0100007 tightening torque allowable value. If
movement is found, tighten the bolt
according to the procedure below.

(2) Re-use method of precoated bolt lock

a. Clean bolt and screw holes. (Clean screw holes for
replacement.)
b. Dry completely by blowing air.
c. Apply the specified seal lock agent to the thread of the
bolt.

3. Plastic region tightening method (angle method)

! CAUTION • Some engines are tightened with the plastic

region tightening method.
• Since it is different from the conventional
method, tighten it according to the instruction
in the text.

Example
One turn by 90q One turn by 90q Two turn by 90q Tighten it 90q
Tighten it 45q (Second time)
One turn by 45q (Second time)
Tighten it 90q
Tighten it 90q Tighten it 90q
(First time) (First time)

SAPH30TCE0100008

(1) Parts tightened

Cylinder head bolt, crankshaft main bearing cap bolt,
connecting rod bearing cap bolt, etc.

! CAUTION • Measure the overall length of the bolt before

assembly and replace the bolt if the length
exceeds the operation limit.
Apply engine oil to bolt seating and bolt
thread in assembly.

(2) Tightening method after tightening to seating torque

Tightening of 90q, 135q(90qonce and 45qonce) and
180q(90qtwice) is available.

[S5LC0033E04] [0518CsCshWbYs]
1–14 GENERAL

Tightening of flare nuts and hoses

JP30TCE010102004

1. Tightening torque of pipe flare nut

Unit : N˜m{kgf˜cm, lbf˜ft}

Pipe outer
diameter I4.76 I6.35 I8 I10 I12 I15

15r5 21r1 32r3 44r5 64r5 66r2.5

Tightening
{153r50, {214r10, {326r31, {449r51, {653r51, {673r25,
torque
11r3.6} 15r0.7} 24r2.2} 32r3.6} 47r3.6} 47r1.8}

2. Tightening torque of hoses

Unit : N˜m{kgf˜cm, lbf˜ft}

Hose outer diameter

Hose outer diameter Hose outer diameter
Type I13, I20, I22, fitting at
I10.5 fitting PF3/8 fitting
packing

21.5r1.5 {215r15, 15r1}

Air hose Only meter gauge 46r2.5 {469r25, 33r1.8} —
10 {100, 7}

Packing
Brake hose 46r2.5 {469r25, 33r1.8} —
51.5r7.5 {525r75, 15r1}

3. Lock nut tightening torque of brass joint

Unit : N˜m{kgf˜cm, lbf˜ft}

Screw nominal
M14 M16 M20 M22 M24
size

48r10 66r13 120r36 130r30 150r30

Tightening
{489r102, {673r204, {1224r367, {1326r306, {1530r306,
torque
35r7} 47r14} 89r26} 96r22} 110r22}

[S5LC0033E04] [0518CsCshWbYs]
 GENERAL 1–15

Taper thread sealant for piping

JP30TCE010102005

The taper thread of the air pipe joint has application of sealant
[Loctite # 575 (by Japan Loctite)]. Follow the procedures below for
connection or disconnection of pipes.

1. For disconnection
Removal of joint (Example: Use of magnetic valve)
Magnetic valve
(1) The sealant ( # Loctite 575) has strong sealing feature.
Frame Air pipe (Flare joint) The return torque of the taper joint is increased about 1.5
(No application of sealant) times the initial tightening torque. When the joint is
Since sealant is
disconnected, use a long wrench for disconnection
applied to this (2) When a joint at a poorly accessible area is replaced,
area, remove
accessories with remove accessories first and disconnect the joint.
the joint attached
Air hose

SAPH30TCE0100009

2. For connection

(1) For application of sealant ( # Loctite 575), wipe the

1/4 turn Amount of application: 0.1 g/piece
sealing area completely with a rag or thinner. Apply
sealant directly to about three ridges for quarter round
3 threads with offset of one ridge from the end. Tighten it according
1 thread
to the tightening torque in the table below.
Remove dirt completely from the mating part (female)
before tightening.

SAPH30TCE0100010 ! CAUTION • If your eye or skin comes in contact with

sealant, wash it off immediately with water.

Tightening torque of taper joint Unit : N˜m{kgf˜cm, lbf˜ft}

Screw diameter
Material
1/4 3/8 1/2

49r10 64r15
Steel {500r100, {650r150,
36r7} 47r10}

25r5 34r5 44r5

Aluminum
{250r50, {350r50, {450r50,
or brass
18r3} 25r3} 32r3}

(2) When a sealing tape is replaced with sealant, remove the

tape completely first as in (1).

! CAUTION • Be careful to prevent entry of dirt or foreign

matter in the pipe.

(3) If air leak is found after assembly with application of

sealant, air leak cannot be stopped with additional
tightening. Assemble the part again according to (1) and
(2).

[S5LC0033E04] [0518CsCshWbYs]
1–16 GENERAL

Assembly of joints and gaskets for piping

JP30TCE010102006

1. Tightening torque of joints

Unit : N˜m{kgf˜cm, lbf˜ft}

Sealing method

Metal sealing method

Screw size Gasket sealing method
(Flare pipe type, nipple connector type)
(Aluminum + Rubber or Copper)
Type A Type B

M8 13 {130, 9}

M10 20 {200, 14} 11 {110, 8}

M12 25 {250, 18} 20 {200, 14}

M14 25 {250, 18} 31 {320, 23}

M16 29 {300, 22} 39 {400, 29}

M18 39 {400, 29} 59 {600, 43}

M20 *39 {400, 29} 64 {650, 47} 20 {200, 14}

M24 69 {700, 51}

M28 *127 {1300, 94}

2. Joint assembly procedure and subsequent inspection

(1) Before assembly, make sure that there is no dirt or burr on the seating surface (mating part, pipe joint,
gasket, etc.).
(2) Since pipes have some degrees of freedom for assembly, the seating surface tends to incline. Tighten
pipes finally after temporary tightening to prevent leak.
(3) After tightening, apply the specified pressure to each pipe joint to ensure that there is no leak.
(4) Observe the values above for each tightening torque.
*When assembled soft washer # 4840FR-N (aluminum and rubber carbon pressure bonding) is loosened
or removed, be sure to replace it with a new part. This is not necessary for normal retightening.

[S5LC0033E04] [0518CsCshWbYs]
 GENERAL 1–17

3. Examples of joint methods in various pipes

Metal sealing method

Gasket sealing method Type A Type B
(Flare pipe type) (Nipple connector type)

Joint bolt Sealing surface: 3 places

Flare pipe
Gasket Connector Nut
Flare nut
Connector nipple
Joint bolt

Sealing surface
: 4 places
Flare connector
Gasket
One piece eye joint Gasket
with sleeve
Gasket Sealing surface
Gasket : 5 places Sealing surface: 5 places

Nut
Lock washer Bracket
Joint bolt
Nut

Sealing surface
: 8 places Connector nipple

Sealing surface: 1 place

Sealing surface: 1 place
Flare connector

Nut Lock washer

Box nut
3-way joint
Sealing surface
: 8 places

Joint pipe

Bracket
Sealing surface
: 3 places

One piece eye joint without sleeve

Joint bolt

Sealing surface: 4 places

Joint bolt

Joint pipe

Sealing surface: 6 places

[S5LC0033E04] [0518CsCshWbYs]
1–18 GENERAL

Handling of liquid gasket

JP30TCE010102007

1. Application of liquid gasket and part assembly procedure

(1) Remove old liquid gasket on each part and mating part completely. Clean the parts with a rag to prevent
deposit of oil, moisture, dirt, etc.
Be sure to overlap parts at the beginning and at the end of application.
(2) Be careful for offset with the mating part when a part applied with liquid gasket is assembled. Apply the
liquid gasket again if offset occurs.
(3) Assemble parts within 20 minutes after application of the liquid gasket.
If 20 minutes has passed, remove the liquid gasket and apply it again.
(4) Start the engine at least 15 minutes or more after assembly of parts.

2. Removal of parts
(1) When parts are removed, do not pry one place only. Remove parts by prying each other using collar or
clearance on the flange. When gasket is removed, be careful to prevent entry of gasket offal into the
engine.

3. Others
(1) When the liquid gasket is contained in a tube, use the accompanying winding tool. When it is contained in
a cartridge, use the application gun.

Winding tool
Application gun

Tube: 150 g Cartridge type: 300 g

For a tube, desired application width may be obtained from the cut position at the nozzle end.

1 : Approx. 2 mm at the 1st section cut

2 : Approx. 5 mm at the 2nd section cut

Nozzle of tube
General information
Description of function

[S5LC0033E04] [0518CsCshWbYs]
 GENERAL 1–19

Failure diagnosis table for each problem

JP30TCE010301001

Engine mechanical Causes and actions are described for each item.
JP03Z01020601001

Status Cause Action

Engine overheat (coolant) Insufficient coolant Replenish coolant
Faulty thermostat Replace thermostat
Water leak from cooling system Correction
Faulty coolant pump Repair or replace
Faulty head gasket Replace head gasket
Engine overheat Clogging of radiator Cleaning of radiator
(radiator) Corrosion of cooling system Clean and repair cooling system
Clogging of radiator core front part Clean radiator
Faulty radiator cap Replace radiator cap
Engine overheat (compression Non-synchronous injection timing Adjust injection timing.
pressure) Faulty fuel injection pressure Adjust injection pressure
Faulty fuel Replace with correct fuel
Faulty injector Replace injector
Engine overheat (lubrication Deterioration of engine oil Replace engine oil
unit) Faulty oil pump Replace oil pump
Insufficient engine oil Replenish engine oil
Large engine oil consumption Wear of piston ring and cylinder Replace piston ring and cylinder
(piston, cylinder liner and piston liner liner
ring) Damage to piston ring Replace piston ring and cylinder
liner
Faulty fixing of piston ring Replace piston ring and cylinder
liner
Faulty assembly of piston ring Replace piston ring and cylinder
liner
Faulty engine oil Replace engine oil
Faulty piston ring joint Reassemble piston ring
Large engine oil consumption Wear of valve stem Replace valve and valve guide
(valve and valve guide) Wear of vavle guide Replace valve guide
Faulty assembly of valve stem seal Replace stem seal
Excessive oil lubrication to rocker Inspection of clearance between
arm rocker arm and rocker arm shaft
Large engine oil consumption Faulty oil level gauge Replace with correct level gauge
(others) Excessive filling of engine oil Fill with appropriate amount of oil.
Leak of engine oil Repair or replace the part of oil
leak.
Piston seizure (in operation) Sudden stop of engine Perform warm-up before stop of
engine
Piston seizure (lubrication unit) Insufficient engine oil Replenish engine oil
Deterioration of engine oil Replace engine oil
Incorrect engine oil Replace with correct engine oil.
Low oil pressure Inspection of lubrication unit
Faulty oil pump Replace oil pump
Piston seizure Abnormal combustion Refer to overheat section.
Piston seizure Cooling unit Refer to overheat section.

SAPH30TCE0100024

[S5LC0033E04] [0518CsCshWbYs]
1–20 GENERAL

Failure diagnosis procedures

JP30TCE010301002

1. Display of failure code

(1) If the system has an error, the failure code is displayed on the multiple display of cluster gauge.

Multiple display

Job mode selecting switch

Buzzer stop switch

SAPH30TCE0100025

2. Deletion method of past failure

(1) To delete past failures of the engine ECU, use Hino-DX
on the PC. (Refer to "Hino-DX operation manual".)

SAPH30TCE0100026

3. Deletion of cluster gauge past failure

(1) Turn "ON" the starter switch during pushing the buzzer
stop switch.

(2) When pushing the enter key 3 times during pushing the
buzzer stop switch, the failure history mode is displayed.
(3) Press work mode selecting switch and the buzzer stop
switch at the same time for 10 seconds or more.
(4) When the display shows "No error", deletion is
completed.
SAPH30TCE0100027
(5) Turn "OFF" the starter switch.

[S5LC0033E04] [0518CsCshWbYs]
 GENERAL 1–21

4. How to read troubleshooting for each diagnosis monitor code

(1) "Diagnosis code table" and "Troubleshooting for each code" are described for each system that gives
output of the diagnosis monitor code. When the diagnosis monitor code is known, troubleshooting can be
started from the code list.

ENGINE DIAGNOSIS CODE [Engine Common] 3–15

Failure of main speed sensor (DTC code P0335/diagnosis monitor code 13)
JP03Z01030601004

1 Measurement of resistance between terminals

1. Set the starter key to "LOCK" and connect the signal check
B6 B B7 harness.

2. Remove the ECU side connector of the signal check harness

and meausre the resistance between terminal B6 and terminal
B7. Details of work
Standard value : Approx. 125.5 17 (20 dC)

NG [3] Go to measurement of resistance between sensor terminals.

SAPH03Z010300010

OK

2 Check of diagnosis code

1. Connect the ECU side connector of the signal check harness.

After deleting the past failure, output the diagnosis code again.

Standard : Normal

NG Contact failure of ECU connector, ECU failure,

short-circuit of harness

SAPH03Z010300011

OK

Normal

3 Measurement of resistance between terminals

1. Remove the connector of the main engine speed sensor and

measure the resistance between No. 1 and No. 2 terminals at
the sensor.

Standard value : Approx. 125.5 17 (20 dC)

NG Failure of main engine speed sensor

Indicates replacement of the main

SAPH03Z010300012
engine revolution sensor.

OK
Check the harness of the relevant circuit and repair the faulty area.

Harness disconnection or connector failure

SAPH30TCE0100028

[S5LC0033E04] [0518CsCshWbYs]
1–22 GENERAL

Failure diagnosis using Hino-DX

JP30TCE010301003

! CAUTION • Hino-DX is used for inspection and

adjustment of the system in addition to failure
diagnosis.

1. Hino-DX

(1) With Hino-DX, failure of the common rail fuel injection

system can be diagnosed. The interface box (Hino-Bowie
or DST-i) and the special cable are required for connection
to the vehicle.

SAPH30TCE0100029

2. List of failure diagnosis tools

Part name Part No. External shape General description and function

• Operating system (OS) :

Windows95,
Windows98 (IE5.0 or later),
Windows2000 (SP3, IE5.0 or
later), WindowsXP (SP1a, IE6.0
or later), WindowsVista*2,
Computer Windows7*2
—
(DOS/V standard)
• CPU and memory :
Conditions that assure
operation of the above
operating system
• Display : 800 x 600, 256 colors
or more

• Software and CD-ROM

NOTICE
• Install the software
Hino Diagnostic included in the Hino
eXplorer — Diagnostic eXplorer
(Hino-DX) (Hino-DX) into the
computer. For the
installation method, refer
to the instruction manual
included with the CD.

[S5LC0033E04] [0518CsCshWbYs]
 GENERAL 1–23

Part name Part No. External shape General description and function

• Computer interface

! CAUTION
• It is necessary to update
the hardware.

09993 - E9070 • The cable between the personal

Hino-Bowie
*1 computer and the Hino-Bowie is
bundled with the Hino-Bowie.
• Please use either RS-232C or
USB.
Cable bundled
to the Hino-Bowie

• The cable used for connect

between Hino-Bowie and the
adapter cable.
S0904-21220
Connection cable
(09042-1220)
Cable between
unit and Hino-Bowie

DENSO DST-i set • Computer interface

without LCD
95171-01020
without Bluetooth£

without LCD
95171-01040
with Bluetooth£

with LCD
95171-01030
without Bluetooth£

with LCD
95171-01050
with Bluetooth£

Interrupting installation between

Signal check unit side harness and ECU allows
09843-E4050
harness inspection with a tester rod while
the power is supplied.

*1: To use Hino-Bowie (interface box) 09993-E9070, update the hardware. For details, refer to the
user’s manual in the Hino-DX CD-ROM.
Keep updating the firmware (software built in the Hino-Bowie) using the software in the Hino-DX
CD-ROM. For details, refer to the user’s manual in the Hino-DX CD-ROM.
*2: Hino-DX (Ver. 3.0.5 or later), only when use DST-i.

[S5LC0033E04] [0518CsCshWbYs]
1–24 GENERAL

3. Conformity table for OS and interface

OK: Available
—: Disabled

Tier3 Tier4 Interim Tier4 Final

OS Software ver. Interface Reprog Reprog Reprog
Hino-DX Hino-DX Hino-DX
manager manager manager

DST-i OK OK OK OK OK OK

3.1.5 Bowie w/ CAN — — — — — —

Bowie w/o CAN — — — — — —

DST-i OK OK OK OK — —

3.1.0 Bowie w/ CAN — — — — — —

Bowie w/o CAN — — — — — —

7
DST-i OK OK OK OK — —

3.04/3.05 Bowie w/ CAN — — — — — —

Bowie w/o CAN — — — — — —

DST-i — — — — — —

1.0.9 Bowie w/ CAN — — — — — —

Bowie w/o CAN — — — — — —

DST-i OK OK OK OK OK OK

3.1.5 Bowie w/ CAN OK OK OK OK OK OK

Bowie w/o CAN OK OK — — — —

DST-i OK OK OK OK — —

3.1.0 Bowie w/ CAN OK OK OK OK — —

Bowie w/o CAN OK OK — — — —

XP
DST-i OK OK OK OK — —

3.04/3.05 Bowie w/ CAN OK OK OK OK — —

Bowie w/o CAN OK OK — — — —

DST-i OK OK — — — —

1.0.9 Bowie w/ CAN OK OK — — — —

Bowie w/o CAN OK OK — — — —

[S5LC0033E04] [0518CsCshWbYs]
 GENERAL 1–25

4. Connection of signal check harness

(1) To prevent damage to the ECU connector and to improve accessibility, connect the signal check harness
and put a testing lead on the signal check connector of the signal check harness for meaurement.

Engine ECU

Engine Machine
harness harness

Test lead

Signal check connector

SAPH30TCE0100038

a. Disconnect the connector from the ECU.

! CAUTION • Do not break the locking tab of the connector.

b. Connect the signal check harness to the engine harness, machine harness and engine ECU.
Part No.
09843 - E4050
Signal check harness (for engine control system)

[S5LC0033E04] [0518CsCshWbYs]
1–26 GENERAL

(2) Terminal No.

For the signal check harness connector, the ECU terminal number in the text is treated as follows :

Signal check harness(for engine control system)

Engine ECU

Engine side Machine side

harness harness

Engine Machine
harness harness

SAPH30TCE0100039

[S5LC0033E04] [0518CsCshWbYs]
 GENERAL 1–27

Connection method of Hino-DX

JP30TCE010301004

1. Removal of the maintenance cover

Maintenance cover (1) Remove the maintenance cover on the rear cover behind
the operator seat by pushing down the tab at the top (at
one location).

NOTICE • The engine fault diagnosis connector (16 P) is

on the inside.

SAPH30TCE0100040

2. Connection of Hino-DX
(1) Connect the engine failure diagnosis connector to the PC
Mechatronic contoroller which installed Hino–DX through the interface box (Hino-
Bowie or DST-i).

Special tool : 09993-E9070 Hino-Bowie

(Interface box)
S0904 - 21220 (09042-1220)
Connecting cable
95171-010** DST-i set
CD-ROM Hino-DX

(2) Set the starter key to "ON" and start Hino-DX.

Engine failure
diagnostic connector

SAPH30TCE0100041

Failure diagnosis connector

Interface box
(Hino-Bowie
or DST-i)

Connect to the failure diagnosis Connecting cable

connector at the unit side.
SAPH30TCE0100042

Setup layout
Layout

[S5LC0033E04] [0518CsCshWbYs]
1–28 GENERAL

Engine number
JP30TCE010401001

1. Engine type and engine number

(Example) (1) Engine type and engine number are stamped at the left
cylinder block when viewed from the cooling fan. For order
of parts, information of this number will facilitate
procedures smoothly.
Ex. J08E TA10003

Stamp position

SAPH30TCE0100043

[S5LC0033E04] [0518CsCshWbYs]
 STANDARD VALUE 2–1

ENGINE

2 STANDARD VALUE 2
Specification
System drawing
(performance)

Engine Mounting/Dismounting ................................. 2-2

Standard value........................................................ 2-2
Fuel System ................................................................ 2-3
Tightening torque.................................................... 2-3
Emission Control........................................................ 2-4
Tightening torque.................................................... 2-4
Electrical...................................................................... 2-5
Standard value........................................................ 2-5
Tightening torque.................................................... 2-5
Intake ........................................................................... 2-6
Tightening torque.................................................... 2-6
Engine Mechanical ..................................................... 2-7
Standard value........................................................ 2-7
Tightening torque.................................................. 2-13
Exhaust...................................................................... 2-14
Tightening torque.................................................. 2-14
Cooling ...................................................................... 2-15
Standard value...................................................... 2-15
Lubrication ................................................................ 2-15
Standard value...................................................... 2-16
Tightening torque.................................................. 2-17
Starting and Charging.............................................. 2-18
Standard value (starter) ........................................ 2-18
Tightening torque (starter) .................................... 2-19
Standard value (alternator 60A) ........................... 2-20
Tightening torque (alternator 60A)........................ 2-21
Turbocharger............................................................. 2-22
Standard value...................................................... 2-22
Tightening torque.................................................. 2-22

[S5LC0033E04] [0518CsCshWbYs]
2–2 STANDARD VALUE

Engine Mounting/Dismounting
Standard value
JP30TCE020205001

Unit : MPa {kgf/cm2, lbf/in.2}

Inspection item Standard value Repair limit Service limit Action

3.4 - 3.7 3.1 - 3.2

Compression pressure
{35 - 37, — {31 - 32,
(Engine revolution per cylinder: 280 r/min)
494 - 536} 450 - 464}

[S5LC0033E04] [0518CsCshWbYs]
 STANDARD VALUE 2–3

Fuel System
Tightening torque
JP30TCE020205002

Unit : N˜m{kgf˜cm, lbf˜ft}

Tightening area Tightening torque Remark

Injector clamp holder fixing bolt 25 {250, 18}

Supply pump - Bearing holder case 28.5 {290, 21}

Bearing holder case - Pump drive 28.5 {290, 21}

Supply pump coupling flange mounting nut 63.7 {650, 47}

Fuel filter (Engine side) air bleeding bolt 6.9 r 2 {70 r 20 , 5.0 r 1.4}

Fuel filter (Engine side) drain plug 6.9 r 2 {70 r 20 , 5.0 r 1.4}

Fuel filter (Engine side) center bolt 29.4 r 4.9 {300 r 50, 21.7 r 3.6}

Fuel filter (Engine side) case mounting bolt 55 {560, 40}

Supply pump drive - Flywheel housing 28.5 {290, 21}

Common rail mounting bolt 28.5 {290, 21}

Fuel filter (Machine side) air bleeding bolt 1.7 - 2.26 {17.3 - 23, 1.3 - 1.7}

Fuel filter (Machine side) element (reference) 10r1 {102r10, 21r0.7}

Fuel filter (Machine side) bowl (reference) 10r1 {102r10, 21r0.7}

Fuel filter (Machine side) drain plug 5r1 {51r10, 3.7r0.7}

Bearing holder mounting bolt 6.0-7.5 {60-75, 4.4-5.4}

Coupling mounting bolt 30-36 {305-360, 22-26}

Injection pump
Drive gear mounting nut 353 {3600, 260}
drive housing
Injection pump drive housing -
28.5 {290, 21}
Bearing case assembly

Pump drive idle gear mounting nut 108 {1100, 80}

[S5LC0033E04] [0518CsCshWbYs]
2–4 STANDARD VALUE

Emission Control
Tightening torque
JP30TCE020205003

Unit : N˜m{kgf˜cm, lbf˜ft}

Tightening area Tightening torque Remark

EGR cooler mounting bolt 36 {367, 26}

EGR pipe B and C mounting bolt 68.5 {700, 51}

EGR pipe A mounting bolt 55 {560, 41}

[S5LC0033E04] [0518CsCshWbYs]
 STANDARD VALUE 2–5

Electrical
Standard value
JP30TCE020205004

Inspection item Standard value Remark

3 - 5mm {0.1182 - 0.1968in.} Compression gauge

Deflection (Reference push force 98N S0944-41210
{10kgf, 22lbf}) (09444-1210) is used.
V ribbed belt tension MITSUBOSHI
adjustment BELTING LTD. Belt
1,372 N
Tension Tension Meter
{140kgf, 308 lbf}
(DOCTOR TENSION£
TYPE-III) is used.

Tightening torque
JP30TCE020205005

Unit : N˜m{kgf˜cm, lbf˜tt}

Tightening area Tightening torque Remark

Starter mounting nut and bolt 154 {1570, 114}

Alternator through bolt 83 {850, 61}

Alternator fixing nut at brace 51 {520, 38}

Alternator adjustment bolt 5.9 {60, 4}

Engine ECU mounting bolt 28.5 {290, 21}

Engine main revolution sensor 10 {102, 7.4}

Engine sub revolution sensor 4 - 6 {41 - 61, 3 - 4.4}

[S5LC0033E04] [0518CsCshWbYs]
2–6 STANDARD VALUE

Intake
Tightening torque
JP30TCE020205006

Unit : N˜m{kgf˜cm, lbf˜ft}

Tightening area Tightening torque Remark

Intake manifold mounting bolt 28.5 {290, 21}

Intake throttle valve mounting bolt 28.5 {290, 21}

Intake pipe - Intake manifold 55 {560, 41}

[S5LC0033E04] [0518CsCshWbYs]
 STANDARD VALUE 2–7

Engine Mechanical
Standard value
JP30TCE020205007

Unit : mm {in.}

Inspection item Standard value Repair limit Service limit Action

IN 0.30 {0.0118} — —
Valve clearance (cold)
EX 0.45 {0.0177} — —

0.01 - 0.08
Cylinder liner protrusion — —
{0.003 - 0.0031}

117 - 117.008
A — —
{4.6063 - 4.6066}

117.008 - 117.014
Cylinder block inner diameter B — —
{4.6066 - 4.6068}

117.014 - 117.022
C — —
{4.6068 - 4.6072}

116.982 - 116.99
A — —
{4.6056 - 4.6059}

116.99 - 116.996
Cylinder liner outer diameter B — —
{4.6059 - 4.6061}

116.996 - 117.004
C — —
{4.6061 - 4.6064}

Replace
112.15
Cylinder liner inner diameter 112 {4.4094} — cylinder
{4.4154}
liner

Piston outer diameter

111.9r0.008
(Pin hole 23mm {0.9055 in.} above the — —
{4.4055r0.0003}
lower end of the skirt Square direction)

Replace
0.053 - 0.077 cylinder
Piston clearance — —
{0.0021 - 0.0030} liner and
piston

0.30 - 0.40
Top — 1.5 {0.0591}
{0.0118 - 0.0157}
Cylinder liner
0.75 - 0.90 Replace
Joint for assembly Second — 1.5 {0.0591}
{0.0295 - 0.0354} piston ring
Clearance
0.15 - 0.30
Oil — 1.2 {0.0472}
Piston {0.0059 - 0.0118}
ring 2.848
Top 2.948 {0.1161} —
{0.1121}

Ring width B 1.9 Replace

Second 2 {0.0787} —
dimension {0.0748} piston ring

3.9
Oil 4 {0.1574} —
{0.1535}

[S5LC0033E04] [0518CsCshWbYs]
2–8 STANDARD VALUE

Inspection item Standard value Repair limit Service limit Action

Top Tapered shape — —

2.2
Second 2.0 {0.0787} — Replace
Piston ring groove {0.0866}
piston
4.1
Oil 4.0 {0.1574} —
{0.1614}
Piston 36.96 Replace
Piston pin outer diameter 37 {1.4567} —
{1.4551} piston pin

37.05 Replace
Piston boss inner diameter 37 {1.4567} —
{1.4587} piston

Replace
Clearance between piston pin 0.011 - 0.032 0.05
— piston pin
and piston boss {0.0005 - 0.0012} {0.0020}
or piston

Replace
37.1
Connecting rod bushing inner diameter 37 {1.4567} — connecting
{1.4606}
rod bushing

Replace
0.035 - 0.056 0.08 piston pin or
Connecting rod bushing oil clearance —
{0.0014 - 0.0022} {0.0031} connecting
rod bushing

64.3 Replace the

Crank pin outer diameter 65 {2.5590} —
{2.5315} crankshaft.

Replace
bearing for
0.031 - 0.082
Connecting rod oil clearance 0.2 {0.0079} — clearance
{0.0012 - 0.0032}
of 0.3 or
more

0.20 - 0.52 1.0 Replace

Connecting rod end play —
{0.0079 - 0.0204} {0.0394} crankshaft

79.3 Replace
Crank journal outer diameter 80 {3.1496} —
{3.1221} crankshaft
Crank- Replace
shaft bearing for
0.051 - 0.102
Crankshaft oil clearance 0.2 {0.0079} — clearance
{0.0020 - 0.0040}
of 0.3 or
more

37.0 Replace
Center journal width 36 {1.4173} —
{1.4567} crankshaft.

Replace
0.05 - 0.270 0.5 1.270 thrust
Crankshaft end play
{0.0020 - 0.0106} {0.0197} {0.0500} bearing or
crankshaft

0 - 0.1 0.15
Crankshaft runout — Replace
{0 - 0.0039} {0.0059}

[S5LC0033E04] [0518CsCshWbYs]
 STANDARD VALUE 2–9

Inspection item Standard value Repair limit Service limit Action

Camshaft journal outer 39.85

40 {1.5748} —
diameter {1.5689}
Replace
Camshaft bearing inner 40.15
40 {1.5748} — camshaft
diameter {1.5807}
or bearing
Camshaft bearing oil 0.020 - 0.063
— —
Clearance {0.0008 - 0.0025}

Cam- 49.987
IN 50.067 {1.9711} —
shaft {1.9680}
Cam height
52.024
EX 52.104 {2.0513} —
{2.0482} Replace
(7.987 camshaft
IN 8.067 {0.3176} —
{0.3144})
Cam lift
(10.024
EX 10.104 {0.3978} —
{0.3946})

0.100 - 0.178 Replace

Camshaft end play — —
Cam- {0.0039 - 0.0070} camshaft
shaft 0.04 Replace
Camshaft runout — 0.1 {0.0039}
{0.0016} camshaft

21.92 Replace
Rocker shaft outer diameter 22 {0.8661} —
{0.8630} rocker shaft

Replace
22.08
Rocker arm bushing inner diameter 22 {0.8661} — rocker arm
{0.8693}
bushing

Replace
rocker shaft
0.030 - 0.101 0.15
Rocker arm oil clearance — or rocker
{0.0012 - 0.0039} {0.0059}
arm
bushing

IN 7 {0.2756} — — Replace
Valve stem outer diameter
EX 7 {0.2756} — — valve

IN 7 {0.2756} — — Replace
Valve guide inner diameter
EX 7 {0.2756} — — valve guide

0.023 - 0.058
IN — — Replace
Oil clearance between valve guide {0.0009 - 0.0023}
valve or
and valve stem 0.050 - 0.083
EX — — valve guide
{0.0020 - 0.0033}

0.55 - 0.85
IN — 1.1 {0.0433} Replace
{0.0217 - 0.0335}
Valve sink valve and
1.15 - 1.45
EX — 1.7 {0.0669} valve seat
{0.0453 - 0.0571}

[S5LC0033E04] [0518CsCshWbYs]
2–10 STANDARD VALUE

Inspection item Standard value Repair limit Service limit Action

IN 30q Allowable angle 30q - 30q35'

Valve seat angle
EX 45q Allowable angle 45q - 45q30'
Correct
IN 30q Allowable angle 29q30 - 30q
Valve face angle
EX 45q Allowable angle 44q30 - 45q

A value
A 3.2 {0.1260} — added C
value or B
value added
Valve spring seat B 5.5 {0.2165} —
C value is
exceeding 1
mm {0.0394
C 1.0 {0.0394} —
in}.

Set length 44.8 {1.764} — —

129N
Set load — —
{13.1kgf}
Inner 64.6 61.6 Replace
Free length —
{2.5433} {2.4252} spring

2.0 Replace
Squareness — —
{0.0787} spring
Valve
spring 46.8
Set length — —
{1.8252}

314N
Set load — —
{32.0kgf}
Outer
75.7 72.7 Replace
Free length —
{2.9803} {2.8622} spring

2.0 Replace
Squareness — —
{0.0787} spring

[S5LC0033E04] [0518CsCshWbYs]
 STANDARD VALUE 2–11

Inspection item Standard value Repair limit Service limit Action

Main idle - Pump drive 0.032 - 0.096 0.30

—
idle {0.0013 - 0.0038} {0.0118}

Pump drive idle - 0.020 - 0.083 0.10

—
Pump drive {0.0008 - 0.0033} {0.0039}

0.030 - 0.113 0.30

Main idle - Sub-idle —
Back- {0.0012 - 0.0044} {0.0118}
lash 0.030 - 0.131 0.30
Sub-idle - Oil pump — Replace
{0.0012 - 0.0052} {0.0118}
gear
0.030 - 0.218 0.30
Sub-idle - Cam idle —
{0.0012 - 0.0086} {0.0118}

0.030 - 0.253 0.30

Cam idle - Cam —
{0.0012 - 0.0100} {0.0118}

Shaft outer diameter 57{2.2441} — —

Bushing inner
57{2.2441} — —
diameter

Replace
Clearance between 0.030 - 0.090 0.20
Timing — shaft or
Main shaft and bushing {0.0012 - 0.0035} {0.0079}
gear bushing
idle
Gear width 44 {1.7322} — —

Shaft length 44 {1.7322} — —

Replace
0.114 - 0.160 0.30
End play — shaft or
{0.0045 - 0.0063} {0.0118}
gear

Shaft outer diameter 50 {1.9685} — —

Bushing inner
50 {1.9685} — —
diameter

Replace
Clearance between 0.025 - 0.075 0.20
— shaft or
Sub- shaft and bushing {0.0010 - 0.0030} {0.0079}
bushing
idle
Gear width 22 {0.8661} — —

Shaft length 22 {0.8661} — —

Replace
0.040 - 0.120 0.30
End play — shaft or
{0.0016 - 0.0047} {0.0118}
gear

[S5LC0033E04] [0518CsCshWbYs]
2–12 STANDARD VALUE

Inspection item Standard value Repair limit Service limit Action

Shaft outer diameter 34 {1.3386} — —

Bushing inner
34 {1.3386} — —
diameter

Clearance between 0.025 - 0.075 0.20 Replace shaft

Cam —
shaft and bushing {0.0010 - 0.0030} {0.0079} or bushing
idle
Gear width 22 {8.6614} — —

Shaft length 22 {8.6614} — —

0.040 - 0.120 0.30 Replace thrust

End play —
Timing {0.0016 - 0.0047} {0.0118} plate or gear
gear Shaft outer diameter 34 {1.3386} — —

Bushing inner
34 {1.3386} — —
diameter

Pump Clearance between 0.025 - 0.057 0.10 Replace shaft

—
drive shaft and bushing {0.0010 - 0.0022} {0.0039} or bushing
idle Gear width 28.5 {0.9605} — —

Shaft length 28.5 {0.9605} — —

0.016 - 0.22
End play — —
{0.0006 - 0.0087}

Longitudinal Grinding is
0.2
direction — inhibited
{0.0079}
0.06 {0.0024} because
backlash
Flatness under cylinder head
between
Flatness above cylinder block
Lateral direction 0.2 cam idle –
— sub-idle
0.03 {0.0012} {0.0079}
gears is
changed.

0.15
Surface runout of flywheel — —
{0.0060}

Camshaft gear mounting bolt 30.0 {1.1811} — 30.5 {1.2010} Replace

108.0
Bearing cap bolt (Crankshaft mounting) 106.8 {4.2047} — Replace
{4.2520}

Connecting rod bolt 67.0 {2.6378} — 68.0 {2.6772} Replace

126.5
Head bolt 126 {4.9606} — Replace
{4.9803}

Valve timing

Exhaust valve open (before BDC) 54q

Exhaust valve close (after TDC) 13q

Intake valve open (before TDC) 14q

Intake valve close (after BDC) 30q

[S5LC0033E04] [0518CsCshWbYs]
 STANDARD VALUE 2–13

Tightening torque
JP30TCE020205008

Unit : N˜m{kgf˜cm, lbf˜ft}

Tightening area Tightening torque Remark

Crankshaft pulley mounting bolt 118 {1200, 87}

Head cover mounting bolt 28.5 {290, 21}

Camshaft bearing cap mounting bolt 28.5 {290, 21}

Union bolt of leakage pipe 13.5 {135, 10}

Injector harness mounting nut 28.5 {290, 21}

Camshaft gear mounting bolt 59 {600, 44}+90q Refer to the main text.

Camshaft housing mounting bolt 23 {230, 17}

Cylinder plug mounting torx bolt 6 {60, 4}

Rocker arm and crosshead adjusting screw lock

25 {250, 18}
nut

Rocker arm support bolt 59 {600, 44}

59 {600, 44}+90q+90q M12

Head bolt
59 {600, 44} M10

Cam idle gear shaft mounting bolt 108 {1100, 80}

Main bearing cap mounting bolt 69 {700, 51}+90q+45q Refer to the main text.

Connecting rod cap mounting nut 69 {700, 51}+90q+45q Refer to the main text.

Cooling jet mounting oil check valve 22 {220, 16}

Sub-idle gear shaft mounting bolt 108 {1100, 80}

Main idle gear shaft mounting bolt 172 {1750, 127}

Flywheel mounting bolt 186 {1900, 137} Refer to the main text.

196 {2000, 145} M16

Flywheel housing mounting bolt 55 {560, 41} M10

36 {370, 27} M8

Flywheel housing stay - Cylinder block 97 {990, 72} M12

Flywheel housing stay - Flywheel housing 171.5 {1750, 127} M14

Rear end plate torx bolt 55 {560, 41}

Supply pump bearing case mounting bolt 28.5 {290, 21}

Pump drive idle gear shaft mounting bolt 108 {1100, 80}

[S5LC0033E04] [0518CsCshWbYs]
2–14 STANDARD VALUE

Exhaust
Tightening torque
JP30TCE020205009

Unit : N˜m{kgf˜cm, lbf˜ft}

Tightening area Tightening torque Remark

Exhaust manifold mounting stud bolt 30 {300, 22}

Exhaust manifold mounting nut 53 {540, 40}

AdBlue/DEF SCR insulator mounting nut 27.6r5 {281r51, 20r4}

AdBlue/DEF SCR chamber mounting nut 64 {653, 47}

DPR cleaner insulator mounting nut 27.6r5 {281r51, 20r4}

DPR cleaner front muffling chamber mounting

64 {653, 47}
nut

DPR cleaner bracket mounting bolt 64 {653, 47}

AdBlue/DEF pump filter cover 20r5 {204r51, 15r4}

AdBlue/DEF pump coolant connector 5-6 {51-61, 4-5}

AdBlue/DEF pump mounting bolt 19.0r3.8 {194r39, 14r2.8}

AdBlue/DEF Injector coolant connector 5-6 {51-61, 4-5}

AdBlue/DEF Injector mounting nut 8r2 {82r20, 6r1.5}

Coolant cut off valve 26r2.6 {265r26.5, 19r1.9}

DPR differential pressure sensor flare nut 26r2.6 {265r26.5, 19r1.9}

DPR differential pressure sensor braket

52r5.2 {530r53, 38r3.8}
mounting nut

SCR upstream NOx sensor 50r10 {510r102, 37r7.4}

SCR downstream NOx sensor 50r10 {510r102, 37r7.4}

DOC downstream temperature sensor 30r3 {306r31, 22r2.2}

DPR downstream temperature sensor 30r3 {306r31, 22r2.2}

SCR upstream temperature sensor 30r3 {306r31, 22r2.2}

Muffler unit mounting nut 108r11 {1101r112, 80r8.1}

Muffler unit - Exhaust pipe 120r12 {1224r122, 88r8.8}

P-type clamp fixing nut 26r2.6 {265r26.5, 19r1.9}

P-type clamp fixing nut (for AdBlue/DEF pump) 23.5r2.4 {240r25, 17r1.8}

Muffler unit - Tail pipe 120r12 {1224r122, 88r8.8}

AdBlue/DEF pipe bracket bolt and nut 52r5.2 {530r53, 38r3.8}

NOx controller mounting bolt 9.6r1 {97.9r10.2, 7.1r0.7}

AdBlue/DEF tank drain plug 50r5 {510r51, 37r4}

DCU mounting bolt 10r2 {102r20, 21r1.4}

[S5LC0033E04] [0518CsCshWbYs]
 STANDARD VALUE 2–15

Cooling
Standard value
JP30TCE020205010

Standard Repair Service

Inspection item Action
value limit limit

74.5 - 78.5qC
Thermostat valve open temperature {166.1 - — — Replace
173.3qF}

Thermostat valve lift 13mm {0.5118

— — Replace
(Set temperature 90 qC) in.} or more

Inspection item Standard value Remark

3 - 5mm {0.1182 - 0.1968in.} Compression gauge

Deflection (Reference push force 98N S0944-41210
{10kgf, 22lbf}) (09444-1210) is used.
V ribbed belt tension MITSUBOSHI
adjustment BELTING LTD. Belt
1,372 N
Tension Tension Meter
{140kgf, 308 lbf}
(DOCTOR TENSION£
TYPE-III) is used.

Tightening torque
JP30TCE020205019

Unit : N˜m{kgf˜cm, lbf˜ft}

Tightening area Tightening torque Remark

Water inlet pipe (coolant pump) 29 {296, 21}

[S5LC0033E04] [0518CsCshWbYs]
2–16 STANDARD VALUE

Lubrication
Standard value
JP30TCE020205011

Unit : mm {in.}

Repair Service
Inspection item Standard value Action
limit limit

39.2kPa - 58.8kPa
{0.4kgf/cm2,
Oil pressure warning switch operation pressure 5.7lbf/in.2 - — —
0.6kgf/cm2,
8.5lbf/in.2}

Outer diameter of drive gear 54 {2.1260} — —

Cylinder block side

54 {2.1260} — —
Oil pump chamber inner diameter

Clearance between drive gear and cylinder 0.093 - 0.252 0.30 Replace drive
—
block {0.0037 - 0.0099} {0.0118} gear or oil pump

Drive gear width 43 {1.6929} — —

Depth of oil pump chamber

43 {1.6929} — —
(Cylinder block side)

0.047 - 0.15 0.15 Replace drive

Gasket use —
{0.0019 - 0.0059} {0.0059} gear or oil pump
Drive gear end play
-0.013 - 0.05
No gasket — —
{-0.0005 - 0.0020}
Oil
Outer diameter of drive gear shaft 18 {0.7087} — —
pump
Cylinder block hole diameter 18 {0.7087} — —

Clearance between drive gear shaft outer Replace drive

0.040 - 0.099
diameter and bushing inner diameter at — — gear or
{0.0016 - 0.0039}
cylinder block side bushing

Clearance between driven gear shaft outer 0.030 - 0.075 Replace oil
— —
diameter and cylinder block hole diameter {0.0012 - 0.0030} pump

Outer diameter of driven gear shaft 18 {0.7087} — —

Inner diameter of driven gear bushing 18 {0.7087} — —

Clearance between driven gear shaft outer 0.040 - 0.083 0.15 Replace oil
—
diameter and gear bushing inner diameter {0.0016 - 0.0033} {0.0059} pump or bushing

Backlash between drive gear and driven 0.073 - 0.207 0.30 Replace oil
—
gear {0.0029 - 0.0082} {0.0118} pump

[S5LC0033E04] [0518CsCshWbYs]
 STANDARD VALUE 2–17

Tightening torque
JP30TCE020205012

Unit : N˜m{kgf˜cm, lbf˜ft}

Tightening area Tightening torque Remark

Oil pan mounting bolt 30 {300, 22}

Oil strainer 31 {320, 23}

Oil pan drain valve 41 {420, 30}

Oil pump mounting bolt 28.5 {290, 21}

M14 24.5r4.9 {250r50, 18r4}

M20 24.5r4.9 {250r50, 18r4}

Oil circuit spring plug
Oil cooler M22 29.4r4.9 {300r50, 22r4}

M24 34.3r4.9 {350r50, 25r4}

Coolant drain plug 44.1r4.9 {450r50, 33r4}

Oil cooler case assembly mounting bolt 28.5 {290, 21}

Oil cooler element mounting nut 24.5r4.9 {250r50, 18r4}

Oil joint connector 78r4.9 {795r50, 57.5r4}

Union bolt (for oil joint) 107.9r9.8 {1100r100, 79.6r7}

[S5LC0033E04] [0518CsCshWbYs]
2–18 STANDARD VALUE

Starting and Charging

Standard value (starter)
JP30TCE020205013

Unit : mm {in.}

Standard
Inspection item Service limit Action
value

Resistance between coil lead Replace yoke

Yoke — 1k: or less
wire and yoke assembly
assembly
Brush length 18 {0.7087} 13 {0.5118} or less Replace brush

Resistance between
commutator and core 1M: or more 1k: or less
(Use 500V megger tester)
Replace armature
Commutator outer diameter 36 {1.4173} 34 {1.3386} or less assembly
Armature
Shaft outer diameter A 12 {0.4724} 11.98 {0.4717} or less
assembly
Shaft outer diameter B 9 {0.3543} 8.98 {0.3535} or less

0.5 - 0.8
Undercut depth {0.0197 - 0.2 {0.0079} or less Correct
0.0315}

Resistance between holder Replace holder

Holder — 1k: or less
and plate assembly
assembly
Brush length 18 {0.7087} 13 {0.5118} or less Replace brush

Shaft A 26 {1.0236} 25.9 {1.0197} or less

assembly Replace shaft
outer B 12.1 {0.4764} 12.04 {0.4740} or less assembly
diameter

Clutch assembly inner sleeve outer

25 {0.9843} 24.9 {0.9803} or less Replace
diameter

Metal bushing inner diameter of pinion case 25 {0.9843} 25.2 {0.9921} or more Replace brush

Metal bushing inner diameter of center Replace center

26 {1.0236} 26.2 {1.0315}
bracket bracket

Metal bushing inner diameter of shaft Replace shaft

9 {0.3543} 9.2 {0.3622}
assembly assembly

Replace
Bearing housing inner diameter of
28 {1.1024} 28.1 {1.1063} or more commutator end
commutator end frame
frame

Start Between C terminal and M

0.12 - 0.14: — Replace start
magnet terminal (P coil)
magnet switch
switch Between C terminal and body
1.13 - 1.25: — assembly
assembly (H coil)

[S5LC0033E04] [0518CsCshWbYs]
 STANDARD VALUE 2–19

Tightening torque (starter)

JP30TCE020205014

Unit : N˜m{kgf˜cm, lbf˜ft}

Tightening area Tightening torque Remark

M lead wire mounting nut 12.3 - 15.2 {125 - 155, 9 - 11}

Commutator end frame mounting through bolt 13.7 - 15.7 {139 - 160, 10 - 11}

Brush holder set bolts of commutator end frame 3.6 - 4.9 {37 - 49, 3 - 4}

Pinion case set bolts 3.6 - 4.9 {37 - 49, 3 - 4}

[S5LC0033E04] [0518CsCshWbYs]
2–20 STANDARD VALUE

Standard value (alternator 60A)

JP30TCE020205015

Standard Service
Inspection item Repair limit Action
value limit

Resistance between stator coil terminals

0.31 - 0.33: — — Replace
(U - V, V - W, W - U)

1M:or
more
Resistance between stator coil core and coil (Use 500V — — Replace
megger
tester)

Resistance of field coil 6.4 - 7.0: — — Replace

1M:or
more
Resistance between field coil core and coil (Use 500V — — Replace
megger
tester)

Ball bearing 25.0mm 24.98mm

—
Shaft outer diameter of insertion area {0.9843 in.} {0.9835 in.}
Replace
rotor assembly Roller bearing 17mm 16.98mm
—
insertion area {0.6693 in.} {0.6685 in.}

Forward Approx.
— —
Resistance between resistance value 10:
Replace
diode and rectifier holder Reverse
Infinite — —
resistance value

Forward Approx.
— —
Resistance between resistance value 10:
Replace
regulator terminals F - E Reverse
Infinite — —
resistance value

Approx.
B-E — — Check and re-
20:
assemble
Resistance between E-B Infinite — —
terminals B - E and P - E
P-E Approx. 7: — — Check and re-
E-P Infinite — — assemble

[S5LC0033E04] [0518CsCshWbYs]
 STANDARD VALUE 2–21

Tightening torque (alternator 60A)

JP30TCE020205016

Unit : N˜m{kgf˜cm, lbf˜ft}

Tightening area Tightening torque Remark

Bearing cover mounting bolt 1.9 - 2.5 {20 - 25, 1.4 - 1.8}

Pulley mounting nut 127 - 157 {1300 - 1600, 94 - 116}

Field coil - End frame 2.9 - 3.9 {30 - 39, 2 - 3}

Rectifier mounting bolt 1.9 - 2.5 {20 - 25, 1.4 - 1.8}

for regulator fix 1.6 - 2.3 {16 - 23, 1.2 - 1.6}

Regulator mounting bolt for coil lead wire 1.0 - 1.4 {10 - 14, 0.8 - 1.0}

for heat sink 1.0 - 1.4 {10 - 14, 0.8 - 1.0}

B terminal mounting nut (internal nut) 4.9 - 5.9 {50 - 60, 3.6 - 4.3}

Driver end frame - End frame 7.8 - 9.8 {80 - 100, 6 - 7}

Cover mounting bolt 3.3 - 4.4 {34 - 44, 2 - 3}

[S5LC0033E04] [0518CsCshWbYs]
2–22 STANDARD VALUE

Turbocharger
Standard value
JP30TCE020205017

Unit : mm {in.}

Inspection item Standard value Repair limit Service limit Action

0.040 - 0.085
Turbine shaft axial play {0.0016 - 0.0033} — —
(Only axial play)

Tightening torque
JP30TCE020205018

Unit : N˜m{kgf˜cm, lbf˜tt}

Tightening area Tightening torque Remark

Turbocharger mounting nut 56 {571, 41}

Intake pipe stay mounting bolt 28.5 {291, 21}

Oil outlet pipe mounting bolt 28.5 {291, 21}

Turbine outlet elbow mounting nut 60 {612, 44}

Oil inlet pipe union bolt 25 {255, 18}

Coolant pipe union bolt 25 {255, 18}

Oil inlet pipe mounting bolt 60 {612, 44}

[S5LC0033E04] [0518CsCshWbYs]
 PARTS TO BE PREPARED 3–1

ENGINE

3 PARTS TO BE PREPARED
Special tool (SST)

3
Engine Mounting/Dismounting ................................. 3-2
Special tool ............................................................. 3-2
Fuel System ................................................................ 3-3
Special tool. ........................................................... 3-3
Lubricant, etc. ........................................................ 3-3
Electrical...................................................................... 3-4
Special tool ............................................................. 3-4
Engine Mechanical ..................................................... 3-5
Special tool ............................................................. 3-5
Instruments ............................................................. 3-8
Lubricant, etc. ........................................................ 3-8
Exhaust........................................................................ 3-9
Lubricant, etc. ......................................................... 3-9
Cooling ...................................................................... 3-10
Special tool ........................................................... 3-10
Lubricant, etc. ...................................................... 3-10
Lubrication ................................................................ 3-11
Special tool ........................................................... 3-11
Lubricant, etc. ...................................................... 3-11
Starting and Charging.............................................. 3-12
Jig (reference dimensional drawing for manufacture)
............................................................................. 3-12
Tester and gauge .................................................. 3-13
Lubricant, etc. ...................................................... 3-13
Turbocharger............................................................. 3-14
Special tool ........................................................... 3-14
Engine Failure Diagnosis......................................... 3-15
Special tool ........................................................... 3-15

[S5LC0033E04] [0518CsCshWbYs]
3–2 PARTS TO BE PREPARED

Engine Mounting/Dismounting
Special tool
JP30TCE030901001

Shape Part No. Description Remark

S0949–11010
Wire rope For engine lifting
(09491–1010)

S0955–21030 Compression gauge adapter

(09552–1030) (3/4-16 UNF) Adjusting to screw size of air
gauge, the adapter which it
S0955–21060 Compression gauge adapter
selects
(09552–1060) (W16 ridges 18)

S0955–21110 Insert in the injector

Compression gauge adapter
(09552–1110) mounting area

[S5LC0033E04] [0518CsCshWbYs]
 PARTS TO BE PREPARED 3–3

Fuel System
Special tool
JP30TCE030901002

Shape Part No. Name Remark

S0965–01101 For injection pump drive

Bearing puller
(09650–1101) housing

S0965–01310 For injection pump drive

Bearing puller
(09650–1310) housing

Lubricant, etc.
JP30TCE030901003

Name Remark

Guide bolt SZ105–08067 (9069–08180) For supply pump positioning

[S5LC0033E04] [0518CsCshWbYs]
3–4 PARTS TO BE PREPARED

Electrical
Special tool
JP30TCE030901004

Shape Part No. Name Remark

S0944–41210 For V ribbed belt tension

Compression gauge
(09444–1210) adjustment

MITSUBOSHI BELTING LTD.

For V ribbed belt tension
– Belt Tension Meter (DOCTOR
adjustment
TENSION£ TYPE-III)

[S5LC0033E04] [0518CsCshWbYs]
 PARTS TO BE PREPARED 3–5

Engine Mechanical
Special tool
JP30TCE030901005

Shape Part No. Name Remark

S0942–01731 For crankshaft front oil seal

Oil seal puller
(09420–1731) removal

S0940–71030 For crankshaft front oil seal

Oil seal press
(09407–1030) press-fit

S0943–31070 For assembly/disassembly

Eye bolt
(09433–1070) of cylinder head

S0947–01170 For assembly/disassembly

Valve spring press
(09470–1170) of valve spring retainer

S0947–11520
Guide For valve guide press-fit
(09471–1520)

S0947–21210
Bar For nozzle seat clamping
(09472–1210)

For nozzle seat clamping

SN441-00610
Steel ball (together with S0947–21210
(9800–06100)
(09472–1210)

S0943–11020
Valve lapping tool For valve adjustment
(09431–1020)

S0947–22100 For valve stem seal

Bar
(09472–2100) mounting

[S5LC0033E04] [0518CsCshWbYs]
3–6 PARTS TO BE PREPARED

Shape Part No. Name Remark

S0942–02100 For removal and inspection

Cylinder liner puller
(09420–2100) of cylinder liner

S0944–21011 For assembly/disassembly

Piston ring expander
(09442–1011) of piston ring

For mounting of connecting

rod small end bushing
SH691–20825 (together with
Bolt
(9191–08252) S0940–21480(09402–1480)
or S0940–21540
(09402–1540))

For assembly/disassembly
S0940–21530
Press sub-assembly of connecting rod small end
(09402–1530)
bushing

For assembly/disassembly
of connecting rod small end
SL271–01036
Wing nut bushing (together with
(9233–10360)
09402–1530
(S0940-21530))

For assembly/disassembly
of connecting rod small end
S0948–11130
Guide bushing (together with
(09481–1130)
S0940–21540
(09402–1540))

For assembly/disassembly
S0940–21540
Spindle of connecting rod small end
(09402–1540)
bushing

For mounting of connecting

S0948–11540 rod small end bushing
Guide
(09481–1540) (together with S0940–21540
(09402–1540))

[S5LC0033E04] [0518CsCshWbYs]
 PARTS TO BE PREPARED 3–7

Shape Part No. Name Remark

S0944–11370
Piston ring holder For piston mounting
(09441–1370)

S0948–11340 For assembly/disassembly

Guide
(09481–1340) of flywheel

S0942–01742 For crankshaft rear oil seal

Oil seal puller
(09420–1742) removal

For main/sub idle gear

S0942–01100
Sliding hammer assembly and cam idle gear
(09420–1100)
shaft removal

S0941–11300 For assembly/disassembly

Socket wrench
(09411–1300) of Torx bolt

S0940–71040 For crankshaft rear oil seal

Oil seal press
(09407–1040) press-fit

S0947–11490
Guide For insertion of cylinder liner
(09471–1490)

SZ910–24098 For cooling jet inspection

Check bolt
(9001–24262) and adjustment

[S5LC0033E04] [0518CsCshWbYs]
3–8 PARTS TO BE PREPARED

Shape Part No. Name Remark

For cooling jet inspection

09219–E4010 Gauge
and adjustment

Instruments
JP30TCE030901006

Name Remark

Micrometer For measurement of part outer diameter

Cylinder gauge For measurement of part inner diameter

Thickness gauge For measurement of each clearance

Dial gauge For measurement of parts

Lubricant, etc.
JP30TCE030901007

Name Remark

Liquid gasket (Threebond TB1207B or equivalent :

For sealing of parts
Black)

Liquid gasket (Threebond TB1207D or equivalent :

For sealing of parts
Silver)

Liquid gasket (Threebond TB1211 or equivalent : White) For sealing of parts

Red lead Valve adjustment

Dye penetrant For inspection of crack

[S5LC0033E04] [0518CsCshWbYs]
 PARTS TO BE PREPARED 3–9

Exhaust
Lubricant, etc.
JP30TCE030901008

Name Remark

Anti-seize (NEVER-SEEZ Nickel Special Grade,

For installing DPR exhaust temperature sensor
BOSTIC FINDLEY (U.S.A.))

Mobil velocite oil No.6 or equivalent For application to O-rings

Loctite #262 For muffler unit mounting

Filter removal tool For AdBlue/DEF pump filter

AdBlue/DEF analyzer

PH litmus paper For AdBlue/DEF inspection

Refractometor

[S5LC0033E04] [0518CsCshWbYs]
3–10 PARTS TO BE PREPARED

Cooling
Special tool
JP30TCE030901009

Shape Part No. Name Remark

S0944–41210 For V ribbed belt tension

Compression gauge
(09444–1210) adjustment

MITSUBOSHI BELTING LTD.

For V ribbed belt tension
– Belt Tension Meter (DOCTOR
adjustment
TENSION£ TYPE-III)

Lubricant, etc.
JP30TCE030901010

Name Remark

Liquid gasket (Threebond TB1207B or equivalent :

For sealing of parts
Black)

[S5LC0033E04] [0518CsCshWbYs]
 PARTS TO BE PREPARED 3–11

Lubrication
Special tool
JP30TCE030901011

Shape Part No. Name Remark

S0950-31110
Oil filter wrench
(09503–1110)

Lubricant, etc.
JP30TCE030901012

Name Remark

Liquid gasket
(Threebond
TB1211 (white) or equivalent
For sealing of parts
TB1207B (black) or equivalent
TB1207D (silver) or equivalent
TB1207G (gray) or equivalent)

[S5LC0033E04] [0518CsCshWbYs]
3–12 PARTS TO BE PREPARED

Starting and Charging

Jig (reference dimensional drawing for manufacture)
JP30TCE030901013

This is used for assembly of alternator bearing. Reference dimensions are shown in the figures below:

Jig A (Roller bearing insertion jig) Jig B (Support jig) Unit : mm{in.}
φ23{20.827} φ25{0.984}
1C{0.039}

35{1.378}
50{1.964}

70{2.756}

50{1.964}
1C{0.039}
10 - 20 φ50{1.969}
+0.5{0.0196} {0.394 - 0.787}
φ19{0.748}
0
φ30{1.181}

Jig C
φ34{1.339}

20{0.787}

40{1.575}

10{0.394}
φ54{2.126}
φ60{2.362}

SAPH30TCE0300035

[S5LC0033E04] [0518CsCshWbYs]
 PARTS TO BE PREPARED 3–13

Tester and gauge

JP30TCE030901014

Starter

Name Remark

Circuit tester For measurement of parts

Micrometer For measurement of part outer diameter

Growler tester For inspection of armature

Cylinder gauge For measurement of part inner diameter

Megger tester For insulation

Alternator

Name Remark

Circuit tester For measurement of parts

Micrometer For measurement of parts

Regulator checker (G&M Machinery ICD-101D or

For inspection of regulator
equivalent)

Megger tester For insulation

Lubricant, etc.
JP30TCE030901015

Starter

Name Remark

Kyodo Yushi Multemp AC-N For lubrication of parts

Nisseki Mitsubishi Pyroknock #2 For lubrication of parts

Alternator

Name Remark

Soldering bit
For lead wire
Solder suction device

Screw lock (Threebond TB1344) For regulator mounting

[S5LC0033E04] [0518CsCshWbYs]
3–14 PARTS TO BE PREPARED

Turbocharger
Special tool
JP30TCE030901016

Shape Part No. Name Remark

S0944-41800
End play gauge
(09444-1800)

[S5LC0033E04] [0518CsCshWbYs]
 PARTS TO BE PREPARED 3–15

Engine Failure Diagnosis

Special tool
JP30TCE030901017

Part name Part No. External shape General description and function

• Operating system (OS) :

Windows95,
Windows98 (IE5.0 or later),
Windows2000 (SP3, IE5.0 or
later), WindowsXP (SP1a, IE6.0
or later), WindowsVista*2,
Computer Windows7*2
—
(DOS/V standard)
• CPU and memory :
Conditions that assure
operation of the above
operating system
• Display : 800 x 600, 256 colors
or more

• Software and CD-ROM

NOTICE
• Install the software
Hino Diagnostic included in the Hino
eXplorer — Diagnostic eXplorer
(Hino-DX) (Hino-DX) into the
computer. For the
installation method, refer
to the instruction manual
included with the CD.

• Computer interface

! CAUTION
• It is necessary to update
the hardware.

09993 - E9070 • The cable between the personal

Hino-Bowie
*1 computer and the Hino-Bowie is
bundled with the Hino-Bowie.
• Please use either RS-232C or
USB.
Cable bundled
to the Hino-Bowie

[S5LC0033E04] [0518CsCshWbYs]
3–16 PARTS TO BE PREPARED

Part name Part No. External shape General description and function

• The cable used for connect

between Hino-Bowie and the
adapter cable.
S0904-21220
Connection cable
(09042-1220)
Cable between
unit and Hino-Bowie

DENSO DST-i set • Computer interface

without LCD
95171-01020
without Bluetooth£

without LCD
95171-01040
with Bluetooth£

with LCD
95171-01030
without Bluetooth£

with LCD
95171-01050
with Bluetooth£

Interrupting installation between

Signal check unit side harness and ECU allows
09843-E4050
harness inspection with a tester rod while
the power is supplied.

Signal check Interrupting installation between unit side harness and DCU allows
09843-E9030
harness inspection with a tester rod while the power is supplied.

09843-E9030

*1: To use Hino-Bowie (interface box) 09993-E9070, update the hardware. For details, refer to the
user’s manual in the Hino-DX CD-ROM.
Keep updating the firmware (software built in the Hino-Bowie) using the software in the Hino-DX
CD-ROM. For details, refer to the user’s manual in the Hino-DX CD-ROM.
*2: Hino-DX (Ver. 3.0.5 or later), only when use DST-i.

[S5LC0033E04] [0518CsCshWbYs]
 PARTS TO BE PREPARED 3–17

1. Conformity table for OS and interface

OK: Available
—: Disabled

Tier3 Tier4 Interim Tier4 Final

OS Software ver. Interface Reprog Reprog Reprog
Hino-DX Hino-DX Hino-DX
manager manager manager

DST-i OK OK OK OK OK OK

3.1.5 Bowie w/ CAN — — — — — —

Bowie w/o CAN — — — — — —

DST-i OK OK OK OK — —

3.1.0 Bowie w/ CAN — — — — — —

Bowie w/o CAN — — — — — —

7
DST-i OK OK OK OK — —

3.04/3.05 Bowie w/ CAN — — — — — —

Bowie w/o CAN — — — — — —

DST-i — — — — — —

1.0.9 Bowie w/ CAN — — — — — —

Bowie w/o CAN — — — — — —

DST-i OK OK OK OK OK OK

3.1.5 Bowie w/ CAN OK OK OK OK OK OK

Bowie w/o CAN OK OK — — — —

DST-i OK OK OK OK — —

3.1.0 Bowie w/ CAN OK OK OK OK — —

Bowie w/o CAN OK OK — — — —

XP
DST-i OK OK OK OK — —

3.04/3.05 Bowie w/ CAN OK OK OK OK — —

Bowie w/o CAN OK OK — — — —

DST-i OK OK — — — —

1.0.9 Bowie w/ CAN OK OK — — — —

Bowie w/o CAN OK OK — — — —

[S5LC0033E04] [0518CsCshWbYs]
[S5LC0033E04] [0518CsCshWbYs]
 ENGINE MOUNTING/DISMOUNTING 4–1

ENGINE

4 ENGINE MOUNTING/DISMOUNTING
Service procedure
Overhaul item

Inspection Before Service ......................................... 4-2

Measurement of compression pressure ................. 4-2 4
Engine Mounting/Dismounting ................................. 4-4
Removal.................................................................. 4-4
Installation............................................................... 4-7
Work after installation ............................................. 4-7

[S5LC0033E04] [0518CsCshWbYs]
4–2 ENGINE MOUNTING/DISMOUNTING

Inspection Before Service

Measurement of compression pressure
JP30TCE040702001

NOTICE • Measure the compression pressure before

disassembly of the engine and record the result.
Regular measurement of the compression
pressure can tell the engine status.

1. Preparation before measurement

(1) Charge the battery completely.
(2) Check the valve clearance and adjust it when exceeding
the standard value.
(3) Warm the engine and set the water temperature to 80 qC
{176qF}.
(4) Remove the air cleaner.
(5) Remove the head cover.
(6) Remove all injectors.
(7) To prevent spread of engine oil, attach a jig which cuts a
head cover in half. (Cut it so that the camshaft may be
covered.)

2. Measurement

(1) Attach a special tool to the nozzle sheet of the cylinder

where the compression pressure is measured with nozzle
clamp and clamp fixing bolts.

Special Special tool : Compression gauge adapter

tool
Engine
Part No. Parts tightened
S0955–21110 Insert in the injector
SAPH30TCE0400002 (09552–1110) mounting area
S0955–21030
(09552–1030)
Adjusting to screw size of
(3/4-16 UNF)
air gauge, the adapter
S0955-21060
which it selects
(09552-1060)
(W16 ridges 18)

(2) Turn the starter and measure the compression pressure.

! CAUTION • Do not operate the starter for 15 seconds or

more.
• Since the air cleaner is removed, prevent
entry of dirt.

[S5LC0033E04] [0518CsCshWbYs]
ENGINE MOUNTING/DISMOUNTING 4–3

(3) Measure the compression pressure of each cylinder

continuously.

Engine revolution 280r/min

Unit MPa {kgf/cm2, lbf/in2}

Standard value Service limit

3.4 - 3.7 3.1 - 3.2

{35 - 37, 494 - 536} {31 - 32, 450 - 464}

(4) If the compression pressure is the service limit or less or if

the difference between cylinders is over the standard
value, overhaul the engine.
(5) After measurement, reassemble the removed parts.

[S5LC0033E04] [0518CsCshWbYs]
4–4 ENGINE MOUNTING/DISMOUNTING

Engine Mounting/Dismounting
Removal
JP30TCE040702002

1. Preliminary work before removal of engine

(1) Place the machine on a level ground.
(2) Remove the battery cable from the battery minus terminal.

2. Drain of coolant and engine oil

Right side of engine
(1) Drain coolant from the radiator drain cock and the oil
cooler drain plug.

NOTICE • Removal of the filler cap facilitates quick

drain.
• Connection of an appropriate hose to the oil
cooler drain pipe facilitates drain of coolant
Oil cooler drain plug
without spread.
SAPH30TCE0400003

! CAUTION • To prevent burn, drain coolant after the

temperature is sufficiently low.
• To dispose coolant, observe the specified
method (waste disposal) or the method with
attention to environment.

(2) Drain engine oil from the oil pan drain cock as required.

! CAUTION • To prevent burn, drain coolant after the

temperature is sufficiently low.
• Dispose coolant according to the specified
method (waste treatment) or with a method
considering the environment.

Drain cock
SAPH30TCE0400004

3. Removal of intake hose, intercooler hose and exhaust

pipe

(1) Loosen the clamp and remove the intake hose.

Intake manifold
(2) Remove nuts and remove the exhaust pipe.

! CAUTION • Close the opening of the intake manifold with

a packing tape to prevent entry of dirt inside
Cylinder head
Cover
the engine.

SAPH30TCE0400005

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE MOUNTING/DISMOUNTING 4–5

4. Disconnection of fuel hose

(1) Remove the fuel hoses (feed side and return side). Wrap
the removed hose with a plastic sheet with its end facing
upward to prevent spill of fuel.
HGGF
TGVWTP
! CAUTION • Wipe spilled fuel with a rag.

(T

5. Disconnection of water, engine oil pipes, etc.

SAPH30TCE0400006
(1) Disconnect the hose between the radiator and the engine.
(2) Disconnect the car heater pipe.
(3) Disconnect the oil filter pipe.

! CAUTION • Wipe off spilled water and engine oil with

waste.

6. Engine lifting (Lifting the engine single unit)

(1) Place a commercially available shackle and a special tool
wire rope with the engine hanger.

SAPH30TCE0400007

Special tool : S0949–11010(09491–1010) Wire rope

NOTICE • When only the rear of the engine is to be

hoisted, use the 2 hanger bolts shown in the
figure.

(2) Keep a little slack of the wire rope.

! CAUTION • Keep the wire inclination 30q from the vertical

line.

[S5LC0033E04] [0518CsCshWbYs]
4–6 ENGINE MOUNTING/DISMOUNTING

(3) When the wire is completely tense, make sure that the
Image wire is firmly engaged with the engine hanger. Then, lift
the engine slowly.

! CAUTION • Work carefully so that the engine may not

come in contact with the frame and others.

SAPH30TCE0400008

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE MOUNTING/DISMOUNTING 4–7

Installation
JP30TCE040702003

1. Connection of fuel hose

(1) Insert a fuel hose and fix it with a hose band.

Work after installation

JP30TCE040702004

1. Inspection of engine oil

(1) Make sure that the drain cock is closed.

(2) Pour engine oil.
(3) Check the amount of oil with an oil level gauge.
Engine oil amount (L{us gal})

Oil pan Oil filter and etc

Approx. 26{6.87} Approx. 2.5{0.66}

Filler cap

SAPH30TCE0400009 Oil quality

JASO DH-2

API CJ-4

ACEA E-6, E-9

HINO recommends these oil to the I-Tier 4 regulation

countries, and use ultralow sulfur fuel only.

Viscosity recommendations (SAE) ! CAUTION • In order to maintain a trouble-free functioning

-40 -22 -4 14 32 50 66 88 104 °F of the DPR (exhaust gas after treatment
-40 -30 -20 -10 0 10 20 30 40 °C
system) for a long time, it is recommended to
SAE 5W-30
use the specified (recommended) brand of
engine oil.
SAE 10W-30

SAE 15W-40

SAPH30TCE0400010

2. Air bleeding of fuel system

Please use the machine side priming pump. (1) Loosen the air venting bolt of the fuel filter, move the
priming pump forward and back to discharge the air from
the fuel system.

! CAUTION • The maintenance method differs according to

the fuel filter type.
Carefully check the type, then perform the
Do not use this priming pump. maintenance work.
SAPH30TCE0400011 • Machine side fuel filter.
Refer to the “5 FUEL SYSTEM, Fuel filter (Machine
side), Replacement of fuel filter element”

[S5LC0033E04] [0518CsCshWbYs]
[S5LC0033E04] [0518CsCshWbYs]
 FUEL SYSTEM 5–1

ENGINE

5 FUEL SYSTEM
Setup layout
Layout

Fuel System ................................................................ 5-2

Fuel system diagram............................................... 5-2
Part layout............................................................... 5-3
Fuel filter (Machine side) .......................................... 5-5 5
Part layout............................................................... 5-5
Water draining......................................................... 5-6
Replacement of fuel filter element .......................... 5-8
Fuel filter (Engine side) ........................................... 5-11
Part layout............................................................. 5-11
Overhaul ............................................................... 5-13
Supply pump............................................................. 5-19
Part layout............................................................. 5-19
Replacement......................................................... 5-20
Injector....................................................................... 5-32
Part layout............................................................. 5-32
Replacement......................................................... 5-33
Common rail.............................................................. 5-41
Part layout............................................................. 5-41
Inspection of the common rail ............................... 5-42
Replacement......................................................... 5-43

[S5LC0033E04] [0518CsCshWbYs]
5–2 FUEL SYSTEM

Fuel System
Fuel system diagram
JP30TCE050402001

Positive pressure
Negative pressure
Injector Return
Common rail

Supply pump

Suction
Feed pump
control valve

Engine mount
fuel filter

Over flow valve Fuel filter element

Engine side

Chassis side

Priming pump
Machine mount
Fuel filter fuel filter

Fuel cooler Fuel tank

SAPH30TCE0500001

[S5LC0033E04] [0518CsCshWbYs]
 FUEL SYSTEM 5–3

Part layout
JP30TCE050402002

SAPH30TCE0500002

1 Through feed pipe 4 Pressure feeding pipe

2 Return pipe No.1 5 Fuel feed pipe No.1
3 Return pipe 6 Gasket*

*Parts not to be reused.

[S5LC0033E04] [0518CsCshWbYs]
5–4 FUEL SYSTEM

SAPH30TCE0500003

1 Bearing holder case 6 Injection pipe

2 Supply pump 7 Common rail
3 Coupling flange 8 O-ring*
4 Coupling 9 Gasket*
5 Injector

*Parts not to be reused.

Tightening torque
A 28.5N˜m {290 kgf˜cm, 21 lbf˜ft} D 108N˜m {1,100 kgf˜cm, 80 lbf˜ft}
B 63.7N˜m {650 kgf˜cm, 47 lbf˜ft} E 25N˜m {250 kgf˜cm, 18 lbf˜ft}
C 353N˜m { 3,600kgf˜cm, 260 lbf˜ft}

[S5LC0033E04] [0518CsCshWbYs]
 FUEL SYSTEM 5–5

Fuel filter (Machine side)

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Part layout
JP30TCE050402003

! CAUTION • The maintenance method differs according to the fuel filter type. Carefully check the type,
then perform the maintenance work.

3, B

2, A

SAPH30TCE0500004

1 Fuel filter head 3 Fuel filter element

2 Water cup

Tightening torque
A Refer to the main text. B Refer to the main text.

[S5LC0033E04] [0518CsCshWbYs]
5–6 FUEL SYSTEM

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Water draining
JP30TCE050704001

! CAUTION • As air enters into the fuel piping during the

work, air bleeding must be performed after
completion of the work.
• Take care that no brake fluid or parts
containing organic solvents (parts cleaner,
paint, etc.) become attached to the cover,
since these substances can cause cracks.

1. Advance preparation
(1) Prepare a water container under the drain pipe.

2. Water draining of the fuel filter

Air bleeding bolt
(1) Loosen the fuel filter air bleeding bolt and the drain valve.
Discharge water at the bottom of the fuel filter case.

Priming pump ! CAUTION • Since discharged water contains fuel,

observe the local disposal procedure for
disposal.

Drain valve

SAPH30TCE0500005

NOTICE • Perform water draining when the float ring of

Water cup
the water cup has risen to the red line.

Red line
Float ring

SAPH30TCE0500006

(2) Close the drain valve.

[S5LC0033E04] [0518CsCshWbYs]
 FUEL SYSTEM 5–7

3. Air bleeding of the fuel system

! CAUTION • Take care that no dirt or water get into the

system during the work.

(1) Operate the priming pump and bleed the air from the
system.

! CAUTION • Make sure that the fuel filter air bleeding bolt
has been loosened.
• The air bleeding bolt has as a slit (groove) as
shown in the figure. As air will bleed out even
when the bolt is not removed completely,
perform priming work with the bolt loosened
to an intermediate position in order to prevent
the entry of foreign matter to the fuel system.

SAPH30TCE0500007

(2) Tighten the fuel filter air bleeding bolt.

Tightening torque :
1.7 - 2.26 N˜m {17.3 - 23 kgf˜cm, 1.3 - 1.7 lbf˜ft}

! CAUTION • After work, wipe off spilled water or fuel. After

start of the engine, make sure that there is no
fuel leak.

[S5LC0033E04] [0518CsCshWbYs]
5–8 FUEL SYSTEM

Replacement of fuel filter element

JP30TCE050704002

! CAUTION • The frequency for water draining and replacement of the fuel filter element differs
according to the fuel situation in the use region.
Replace the fuel filter element every 500 hours or when the engine output decreases,
whichever occurs first.
• Inspection of the fuel filter element and draining of water should be performed before each
start of operation.
• Always use HINO genuine parts filter element.
• Complete the work for removal and installation quickly to prevent entry of foreign matter to
the fuel system.
• Take care that no dirt or water get into the system during the work.
• As air enters into the fuel piping during the work, air bleeding must be performed after
completion of the work.
• Before assembly, make sure that there is no dirt the seating surface of the parts.
• Take care that no brake fluid or parts containing organic solvents (parts cleaner, paint, etc.)
become attached to the cover, since these substances can cause cracks.

1. Removal of water cup

(1) First bleed water from the fuel filter and then remove the water cup of the fuel filter.
Refer to the "Fuel filter (Machine side), Water draining“

! CAUTION • Completely remove any dust around the water cup.

2. Removal of fuel filter element

(1) Remove the fuel filter element.

! CAUTION • Completely remove any dust around the fuel filter head and especially around the air vent
bolt.
• Since the filter contains diesel oil, prepare a tray.

[S5LC0033E04] [0518CsCshWbYs]
 FUEL SYSTEM 5–9

3. Installation of fuel filter element and water cup

! CAUTION • Fuel filter element is not reused.

• As the gasket is included in the element kit, do not use a gasket again after it has been
removed once.
• The gasket is smaller on the side of the fuel filter head (approx. I90 mm{3.5433in.}) than on
the side of the water cup (approx. I105 mm{4.1339in.}). Take care not to install it the wrong
way round.
• Install the gasket after applying fuel to the surface of the gasket.
• Do not use a tool, but tighten by hand.

(1) The soiling and the foreign material of the clamp face are removed.
(2) Install the fuel filter element to the fuel filter head and turn the element 7/8 of a turn after the gasket comes
into contact with the fuel filter head.

Fuel filter head

Gasket

Element

Turn the element

7/8 turns
after the gasket comes
into contact.

SAPH30TCE0500008

[S5LC0033E04] [0518CsCshWbYs]
5–10 FUEL SYSTEM

(3) Install the water cup to the fuel filter element and turn the cup 3/4 of a turn after the gasket comes into
contact with the fuel filter element.

Element

Turn the water cup

3/4 turns
after the gasket comes
into contact. Gasket

Water cup

SAPH30TCE0500009

(4) Confirm that the drain valve has been tightened.

4. Bleeding air from the fuel system

Refer to the “Fuel filter (Machine side), Water draining”

[S5LC0033E04] [0518CsCshWbYs]
 FUEL SYSTEM 5–11

Fuel filter (Engine side)

Part layout
JP30TCE050704003

SAPH30TCE0500010

1 Fuel filter case 4 Fuel feed pipe No.1

2 Return pipe No.2 5 Fuel feed pipe No.2
3 Fuel feed pipe No.3 6 Gasket*

*Parts not to be reused.

Tightening torque
A 30N˜m{305kgf˜cm, 22 lbf˜ft} B 55N˜m{560kgf˜cm, 40 lbf˜ft}

[S5LC0033E04] [0518CsCshWbYs]
5–12 FUEL SYSTEM

4,B
2

1, A
5

1, A

SAPH30TCE0500011

1 Air bleeding plug (Drain plug) 4 Center bolt

1
2 O-ring* 5 Cap
3 Element*1 6 Priming pump*2

*1Parts not to be reused.

*2Do not use this priming pump. Please use the machine side priming pump for air bleeding of the fule
system.
Tightening torque
A 6.9r2N˜m B 29.4r4.9N˜m
{70r20kgf˜cm, 5.0r1.4 lbf˜ft} {300r50kgf˜cm, 21.7r3.6 lbf˜ft}

[S5LC0033E04] [0518CsCshWbYs]
 FUEL SYSTEM 5–13

Overhaul
JP30TCE050704004

Replace of the element

! CAUTION • Always use HINO genuine parts fuel filter

element.
• Take care that no dirt or water gets into the
system during the work.
• Before assembly, make sure that there is no
dirt on the seating surface of the parts.
• Always do air bleeding after replacing an
element.

1. Fuel discharging
(1) Prepare a container under the drain pipe.

Air breeding (2) Loosen the drain plug and the fuel filter air bleeding plug.
plug Discharge fuel from the drain pipe.
After discharging fuel completely and tighten the drain
Drain pipe plug.
Tightening torque :
Drain plug 6.9r2 N˜m {70r20 kgf˜cm, 5.0r1.4 lbf˜ft}

SAPH30TCE0500012 ! CAUTION • To dispose fuel, observe the specified method

(waste disposal) or the method with attention
to environment.
• Make sure that the drain plug is not damage
or corrosion.

2. Removal of the element

Cap (1) Remove the center bolt, and remove the O-rings (2 pcs.)
Center bolt
and caps from the fuel filter case.

Element (2) Remove the element.

O-ring
! CAUTION • When draining the fuel, drain all fuel from
inside the filter. When the element is replaced
Fuel filter case
without draining all fuel, there is the
possibility that unfiltered fuel remains in the
SAPH30TCE0500013 filter and flows to the engine side.
• Prepare a container for catching dripped fuel
from the filter that the fuel remains in the
case.

[S5LC0033E04] [0518CsCshWbYs]
5–14 FUEL SYSTEM

3. Installation of the element

Cap (1) Remove any dust around the fuel filter case inside and the
Center bolt
element fitting point of the cap inside.
(2) Install a new element in to the fuel filter case.
Element
O-ring
! CAUTION • When the element is replaced without
draining all fuel from the fuel filter case,
Fuel filter case unfiltered fuel remains in the fuel filter case;
make sure that the filter case does not
contain any remaining fuel.
SAPH30TCE0500014

(3) Applying fuel to a new O-ring and install them to the fuel
filter case groove.

! CAUTION • Do not reuse the fuel filter element.

• As the O-ring is included in the element kit, do
not use an O-ring again after it has been
removed once.

(4) Align the match mark and set the cap to the fuel filter case
Center bolt Cap
and tighten the center bolt.
Match mark
Tightening torque :
29.4r4.9 N˜m {300r50 kgf˜cm, 21.7r3.6 lbf˜ft}

! CAUTION • Be careful to prevent twisted damage of the

O-ring.
Fuel
filter case • Make sure the O-ring is fitted to the clamp
face.
SAPH30TCE0500015
• Match the match mark of the fuel filter cap at
the fuel filter case .

4. Air bleeding of the fuel system

Please use the machine side priming pump. (1) Move the priming pump forward and back to discharge the
air from the fuel system.

Refer to “Fuel filter (Machine side), Water draining“

Do not use this priming pump.

SAPH30TCE0500016

[S5LC0033E04] [0518CsCshWbYs]
 FUEL SYSTEM 5–15

Removal of the fuel filter case

! CAUTION • Take care that no dirt or water gets into the

system during the work.
1. Fuel discharging
(1) Prepare a container under the drain pipe.

Air breeding (2) Loosen the drain plug and the fuel filter air bleeding plug.
plug Discharge fuel from the drain pipe.
After discharging fuel completely and tighten the drain
Drain pipe plug.
Tightening torque :
Drain plug 6.9r2 N˜m {70r20 kgf˜cm, 5.0r1.4 lbf˜ft}

SAPH30TCE0500012 ! CAUTION • To dispose fuel, observe the specified method

(waste disposal) or the method with attention
to environment.

2. Disconnecting the harness

Water level warning switch
(1) Disconnect the connector of the water level warning
switch and the fuel temperature sensor.

Fuel
Engine harness temperature sensor
SAPH30TCE0500017

3. Removal of the fuel pipes

(1) Remove the union bolts (2pcs.) and disconnect the return
pipe No.2 from the fuel filter case.

Return pipe
No.㧞 NOTICE • Prepare a container and a rug under the fuel
pipe.

SAPH30TCE0500018

(2) Remove the union bolts (2pcs.) and disconnect the fuel
Fuel filter case feed pipe No.3 and the gasket from the fuel filter case.
Fuel feed pipe No.3
NOTICE • Prepare a container and a rug under the fuel
pipe.

(3) Remove the nuts and remove the clips.

Supply pump
SAPH30TCE0500019

[S5LC0033E04] [0518CsCshWbYs]
5–16 FUEL SYSTEM

(4) Remove the union bolts (2pcs.) and remove the fuel feed
pipe No.2 and the gasket from the fuel filter case.

Fuel feed pipe No.2 NOTICE • Prepare a container and a rug under the fuel
pipe.

(5) Remove the nuts and remove the clips.

SAPH30TCE0500020

4. Removal of the fuel filter case

Fuel filter case (1) Remove the bolts (2pcs.) and remove the fuel filter case.

! CAUTION • Prepare a container for catching the fuel that

the fuel remains in the case.

Bolt
SAPH30TCE0500021

[S5LC0033E04] [0518CsCshWbYs]
 FUEL SYSTEM 5–17

Installation of the fuel filter case

! CAUTION • Take care that no dirt or water gets into the

system during the work.
• Make sure that there is no dirt on the parts
connecting surface.
• As air enters into the fuel piping during the
work, air bleeding must be performed after
completion of the work.

1. Installation of the fuel filter case

Fuel filter case (1) Install the fuel filter case with bolts (2pcs.).

Tightening torque : 55 N˜m {560 kgf˜cm, 40 lbf˜ft}

Bolt
SAPH30TCE0500021

2. Installation of the fuel pipes

(1) Replace the gaskets by new ones and connect the fuel
feed pipe No.2 to the fuel filter case and fuel filter case
Fuel feed pipe No.2 with union bolts (2pcs.).

Tightening torque : 30 N˜m {305 kgf˜cm, 22 lbf˜ft}

(2) Install the clips and secure the fuel feed pipe No.2.
Tightening torque :
25 N˜m {255 kgf˜cm, 18 lbf˜ft} (Supply pump side)

SAPH30TCE0500020

(3) Replace the gaskets by new ones and connect the fuel
Fuel filter case feed pipe No.3 to the supply pump and the fuel filter case
Fuel feed pipe No.3 with union bolts (2pcs.).

Tightening torque :
30 N˜m {305 kgf˜cm, 22 lbf˜ft}
(Fuel filter side)
17.2r2.4 N˜m {175r25 kgf˜cm, 12.6r1.8 lbf˜ft}
(Supply pump side)
Supply pump
SAPH30TCE0500019

[S5LC0033E04] [0518CsCshWbYs]
5–18 FUEL SYSTEM

(4) Replace the gaskets for new ones and connect the return
pipe No.2 to the fuel filter case with union bolts (2pcs.).

Tightening torque : 30 N˜m {305 kgf˜cm, 22 lbf˜ft}

Return pipe
No.㧞 NOTICE • The union bolt on the side of the return pipe
No. 2 has a different thread pitch. The top of
the bolt is marked.

SAPH30TCE0500018

3. Connecting the harness

Water level warning switch
(1) Connect the connector of the water level warning switch
and the fuel temperature sensor.

! CAUTION • Before connecting the connector, confirm that

there are no signs of sparking on the terminal.

Fuel
Engine harness temperature sensor
SAPH30TCE0500017

4. Air bleeding of the fuel system

Please use the machine side priming pump. (1) Move the priming pump forward and back to discharge the
air from the fuel system.

Refer to “Fuel filter (Machine side), Water draining“

Do not use this priming pump.

SAPH30TCE0500016

[S5LC0033E04] [0518CsCshWbYs]
 FUEL SYSTEM 5–19

Supply pump
Part layout
JP30TCE050704005

SAPH30TCE0500022

1 Bearing holder case 4 Coupling flange

2 Injection pump drive housing 5 Coupling
3 Supply pump 6 O-ring

*Parts not to be reused.

Tightening torque
A 28.5N˜m {290 kgf˜cm, 21 lbf˜ft}

[S5LC0033E04] [0518CsCshWbYs]
5–20 FUEL SYSTEM

Replacement
JP30TCE050704006

Removal of the supply pump

! CAUTION • Take care that no dirt or water get into the

system during the work.

1. Fuel draining
(1) Prepare a water container under the drain pipe.
(2) Loosen the drain plug and the fuel filter air bleeding plug.
Air breeding Discharge fuel from the drain pipe.
plug
After discharging fuel completely and tighten the drain
Drain pipe
plug.

Tightening torque : 6.9r2.0 N˜m

Drain plug {70r20 kgf˜cm, 5.0r1.4 lbf˜ft}

SAPH30TCE0500012 ! CAUTION • To dispose fuel, observe the specified method

(waste disposal) or the method with attention
to environment.

2. Removal of the fuel filter case

(1) Remove the fuel filter case and fuel pipe.
Refer to the "Fuel filter (Engine side), Overhaul“.

3. Removal of the intake pipes

(1) Remove the intake pipes.
Refer to the “8 INTAKE“.

4. Disconnection of the wiring harness

Fuel temperature sensor (1) Disconnect the connectors of the suction control valve
and the fuel temperature sensor at the supply pump.

Suction control valve

SAPH30TCE0500023

5. Removal of the fuel pipes

(1) Remove the nuts and remove the clips.

(2) Remove the union bolts and disconnect the return pipe
No.1 connected to the pressure limiter, inlet manifold and
the supply pump.
Return pipe No.1

NOTICE • Prepare a container and waste cloth under the

Supply pump fuel pipe.

SAPH30TCE0500024

[S5LC0033E04] [0518CsCshWbYs]
 FUEL SYSTEM 5–21

6. Removal of the pressure feeding pipe

(1) Remove the nuts and remove the clips.
(2) Loosen the nuts and remove the pressure feeding pipe.
Pressure feeding
pipe
NOTICE • Prepare a container and waste cloth under the
fuel pipe.

SAPH30TCE0500025

7. Compression Top Dead Center setting of the No.1 cylinder

(1) Remove the nuts and remove the flywheel housing cover
from the flywheel housing.

Flywheel housing
cover

SAPH30TCE0500026

(2) Turn the flywheel clockwise in the engine direction and

align the No.1 cylinder mark to the pointer in the flywheel
housing inspection opening.
Flywheel
Refer to the "9 ENGINE MECANICAL, Cylinder head,
Replacement “.
1
Flywheel housing

SAPH30TCE0500027

(3) Remove the inspection window plug in the bearing holder

Bearing holder case
case of the supply pump.
Close
contact (4) Tighten the guide bolt very gently and make sure that the
٤ bolt seating comes in close contact with the bearing
SST holder.
Special tool : SZ105-08067 (9069-08180) Guide bolt
Raised
˜

SAPH30TCE0500028

[S5LC0033E04] [0518CsCshWbYs]
5–22 FUEL SYSTEM

! CAUTION • If it is raised, there must be contact other than

the stopper key for the coupling flange. Do
not tighten hard.

• If SST (guide bolt) is not touch the flange,

No.1 cylinder is not setting to the
Compression Top Dead Center.
Remove the SST (guide bolt), and rotate the
engine and then check again.
• When you rotate the crankshaft, always
remove the SST (guide bolt).
• Do not rotate the crankshaft with the SST
(guide bolt) inserted.

8. Removal of the supply pump

! CAUTION • Take care that no dirt or water get into the

Do not remove
the pipe A system during the work.
• Do not remove pipes A and B.

• Do not apply any force to pipes A and B of the

supply pump (The twist of the pipes causes
the fuel leakage.).
Do not remove
the pipe B • Do not carry the supply pump by holding
SAPH30TCE0500029
pipes A and B.

(1) Remove the bolts and remove the supply pump, coupling
Bearing holder case Coupling and O-ring from the injection pump drive housing.
Bolt
! CAUTION • When removing the supply pump remove the
supply pump together with the bearing holder
case.

Supply pump
O-ring Injection pump
drive housing
SAPH30TCE0500030

(2) Fix the coupling flange with a vice to prevent turning and
Bearing holder case
remove the coupling flange.

Shaft

Nut

Coupling flange

SAPH30TCE0500031

[S5LC0033E04] [0518CsCshWbYs]
 FUEL SYSTEM 5–23

(3) Remove the bearing holder case and the O-ring from the
Supply pump
supply pump.

O-ring

Bolt

Bearing holder case

SAPH30TCE0500032

Inspection of the supply pump

1. Inspection of the suction control valve and fuel

Fuel temperature sensor temperature sensor
(1) Inspect operation of the suction control valve and the fuel
temperature sensor using Hino-DX.
Suction control valve
If it is faulty, replace the supply pump.
(Refer to “Hino-DX operation manual”)

SAPH30TCE0500033

2. Inspection of the suction control valve

(1) Measure the resistance between terminals with a circuit
Suction control valve
tester. If the value exceeds the standard value, replace
the supply pump.

Standard value
7.65 - 8.15:
(at 20qC {68qF})

SAPH30TCE0500034

3. Inspection of the fuel temperature sensor resistance

Fuel
temperature sensor (1) Measure the resistance between terminals with a circuit
tester. If the value exceeds the standard value, replace
the supply pump.

Temperature (qC {qF}) Resistance (k:)

-20 {-4} 13.84 - 16.33

20 {68} 2.32 - 2.59

SAPH30TCE0500035 80 {176} 0.310 - 0.326

110 {230} 0.1399 - 0.1435

[S5LC0033E04] [0518CsCshWbYs]
5–24 FUEL SYSTEM

Overhaul of the injection pump drive housing

(If necessary when the injection pump was
removed)

1. Removal of the injection pump drive housing

(1) Remove the oil pipe from the injection pump drive
housing.
Oil pipe

Injection pump drive housing

SAPH30TCE0500036

(2) Remove the bolts (6pcs.) and remove the injection pump
One bolt from bearing case side drive housing from the bearing case on the flywheel
Injection pump O-ring housing.
drive housing

NOTICE • One bolt is installed from the bearing case

side.

Other bolts from housing side

SAPH30TCE0500037

2. Disassembly of the injection pump drive housing

Injection pump drive housing (1) Clamp the drive gear with aluminum plates using a vise,
Drive gear
and remove the nut and plate.

! CAUTION • Be careful not to damage the drive gear.

SAPH30TCE0500038

(2) Remove the injection pump drive gear from the injection
pump drive housing using the special tool.

Special tool : S0965-01101 (09650-1101)

Bearing puller

SAPH30TCE0500039

[S5LC0033E04] [0518CsCshWbYs]
 FUEL SYSTEM 5–25

(3) Remove the bearing holder mounting bolts.

(4) Remove the upper cover.

Upper cover (5) Remove the coupling.

Coupling

Mounting bolts

SAPH30TCE0500040

(6) Press out the shaft from the coupling side with the bearing
holder using a press.

! CAUTION • Not to dropped the shaft and not to damage

the shaft.

SAPH30TCE0500041

(7) Tap the bearing holder using a plastic hammer, and

remove the bearing holder from the shaft.

Shaft

Bearing holder

SAPH30TCE0500042

(8) Remove the main bearings (both sides) from the shaft
using the special tool.

Special tool Special tool : S0965-01101 (09650-1101)

Bearing puller (Supply pump side)

Special tool : S0965-01310 (09650-1310)

Main bearing Bearing puller (Drive gear side)

SAPH30TCE0500043

[S5LC0033E04] [0518CsCshWbYs]
5–26 FUEL SYSTEM

3. Inspection of the main bearings

(1) Hold the bearing inner race by hand and rotate the outer
race slowly. if it is not rotate smooth replace it.

SAPH30TCE0500044

4. Assembly of the injection pump drive housing

Hammer (1) Install the main bearings to the shaft (both sides) using a
installing jig and hammer.

Installing jig
Main bearing

Shaft

Main bearing

SAPH30TCE0500045

(2) Install the bearing holder to the shaft using a copper

hammer.

(3) Install the assembled shaft and bearing holder to the

crank case and tighten the bolts.

SAPH30TCE0500046

(4) Install the bearing holder mounting bolts.

Tightening torque : 6.0 - 7.5 N˜m
Upper cover {60 - 75 kgf˜cm, 4.4 - 5.4 lbf˜ft}

(5) Install the coupling and tighten the bolts.

Coupling Tightening torque : 30 - 36 N˜m
{305 - 360 kgf˜cm, 22 - 26 lbf˜ft}
Mounting bolts (6) Install the upper cover.

SAPH30TCE0500040

[S5LC0033E04] [0518CsCshWbYs]
 FUEL SYSTEM 5–27

(7) Put the key to the shaft, and insert the drive gear to the
Injection pump drive housing shaft correctly, and clamp the drive gear by a vise using a
Drive gear
aluminum plate, and tighten the nut.

Tightening torque : 353 N˜m {3,600 kgf˜cm, 260 lbf˜ft}

! CAUTION • Prevent faulty conditions on the drive gear

such as deformation, scratch, etc.

SAPH30TCE0500038

5. Installation of the injection pump drive housing

(1) Set the No.1 cylinder to the Compression Top Dead
Center.
Refer to the "9 ENGINE MECANICAL, Cylinder head,
Replacement “.

(2) Match the mark of the injection pump drive housing

casting mark to the coupling "O" mark.

"O" mark
carved seal

Casting mark

SAPH30TCE0500047

(3) Install a new O-ring to the groove of the injection pump

Injection pump
dirve housing drive housing.

! CAUTION • Make sure that there is no foreign matter in

the O-ring groove or other circumference.

If foreign matter is found clean it.

O-ring
SAPH30TCE0500048

(4) Install the injection pump drive housing to the bearing

One bolt from bearing case side case assembly on the flywheel housing.
Injection pump O-ring
drive housing Tightening torque : 28.5 N˜m {290 kgf˜cm, 21 lbf˜ft}

! CAUTION • Install the gear so as not to change the

position of the No.1 Top Dead Center.
• Take care not to drop the O-ring.

Other bolts from housing side

SAPH30TCE0500049

[S5LC0033E04] [0518CsCshWbYs]
5–28 FUEL SYSTEM

(5) Replace gaskets by new ones and install the oil pipe to
the injection pump drive housing.

Oil pipe

Injection pump drive housing

SAPH30TCE0500036

Installation of the supply pump

! CAUTION • Before assembly, make sure that there is no

dirt the seating surface of the parts.
• Take care that no dirt or water get into the
system during the work.
• As air enters into the fuel piping during the
work, air bleeding must be performed after
completion of the work.

1. Compression Top Dead Center setting of the No.1 cylinder

(1) Turn the flywheel clockwise in the engine direction so the
engraving of the cylinder is aligned with the pointer in the
Flywheel
flywheel housing inspection opening.
Refer to the "9 ENGINE MECANICAL, Cylinder head,
1
Flywheel housing Replacement “.

! CAUTION • Make sure that the No.1 cylinder is positioned

at the top dead center point of the
SAPH30TCE0500027
compression stroke.

2. Setting at the Top of the injection pump drive housing

(1) Match the casting mark of the supply pump drive with the
0 mark stamp "0" mark stamped at the front of the coupling.
at the front

Casting mark

SAPH30TCE0500050

[S5LC0033E04] [0518CsCshWbYs]
 FUEL SYSTEM 5–29

3. Installation of the supply pump

Supply pump
(1) Replace the O-ring by new one and install the bearing
holder case to the supply pump.
O-ring
Tightening torque : 28.5 N˜m {290 kgf˜cm, 21 lbf˜ft}

Bolt

Bearing holder case

SAPH30TCE0500051

(2) Install the coupling flange to the shaft.

Bearing holder case
(3) Fix the supply pump and install the coupling flange to the
shaft. Tighten nuts while fixing with a vice to prevent
Shaft
turning.

Tightening torque : 63.7 N˜m {650 kgf˜cm, 47 lbf˜ft}

Nut
! CAUTION • Do not use the guide bolt for stopper key of
the shaft.
Coupling flange

SAPH30TCE0500031

(4) Put the guide bolt into the bearing holder case to come in
Bearing holder case contact with the stopper key hole of the coupling flange.
Special tool : SZ105-08067 (9069-08180) Guide bolt

! CAUTION • Do not tighten the guide bolt by contact not

with the stopper key hole of the coupling or
Guide bolt do not use the stopper key with the non-
Coupring flange
specified guide bolt.
Stopper key hole • The specified guide bolt is designed to
SAPH30TCE0500052 prevent contact of the guide bolt end with the
deep end of the stopper key hole. (The end
clearance is 2 mm{0.0788in.})

(5) Replace the O-ring by new ones, install the supply pump
Bearing holder case Coupling drive, supply pump and coupling, then tighten the bolt.
Bolt
Tightening torque : 28.5 N˜m {290 kgf˜cm, 21 lbf˜ft}

! CAUTION • When installing the supply pump, do not

change the position "Compression Top Dead
Center setting of the No.1 cylinder" and
Supply pump "Injection pump drive housing casting mark"
O-ring Injection pump
drive housing and "O-mark at the front of the coupling".
SAPH30TCE0500053

[S5LC0033E04] [0518CsCshWbYs]
5–30 FUEL SYSTEM

(6) After confirming No.1 cylinder is a Compression Top Dead

Bearing holder case Center, remove the SST (guide bolt) and install the timing
check cover.

! CAUTION • Always install the timing check cover when

after completing assembly.
• When you rotate the crankshaft, always
SST
remove the SST (guide bolt).

• Do not crank the engine while the special tool

SAPH30TCE0500054
is inserted.

(7) Install the flywheel housing cover to the flywheel housing

with bolts.

Flywheel housing
cover

SAPH30TCE0500026

4. Installation of the pressure feeding pipe

(1) Install the new pressure feeding pipe.

Tightening torque :
Pressure feeding
pipe 44 N˜m {450 kgf˜cm, 32.5 lbf˜ft}
(Supply pump side)
44 N˜m {450 kgf˜cm, 32.5 lbf˜ft}
(Common rail side)

! CAUTION • Always replace the pressure feeding pipe by a

SAPH30TCE0500055 new one because the pipe is subjected to high
pressure; reusing the same pipe may result in
a fuel leak.

(2) Fit the clips (2pcs.) and fix the pressure feeding pipe.

5. Installation of the fuel pipe

(1) Replace the gasket by new ones, install the return pipe
No.1 to the supply pump, inlet manifold and the pressure
limiter.

Tightening torque :
Return pipe No.1
10.3r2.4 N˜m {105r25 kgf˜cm, 7.5r1.8 lbf˜ft}
(Supply pump side)
Supply pump
30 N˜m {305 kgf˜cm, 22 lbf˜ft}
(Inlet manifold side)
SAPH30TCE0500056
20 N˜m {205 kgf˜cm, 15 lbf˜ft}
(Pressure limiter side)
(2) Fit the clips (2pcs.) and fix the return pipe.

[S5LC0033E04] [0518CsCshWbYs]
 FUEL SYSTEM 5–31

6. Connecting of the wiring harness

Fuel temperature sensor (1) Connect the connectors to the fuel temperature sensor
and suction control valve of the supply pump.

! CAUTION • Before connecting the connector, confirm that

the terminal shows no signs of sparking.

7. Installation of the intake pipe

(1) Install the intake pipe.
Suction control valve
Refer to the “8 INTAKE“.
SAPH30TCE0500023

8. Installation of the fuel filter case

(1) Install the fuel filter case and the fuel pipes.
Refer to the "Fuel filter (Engine side), Overhaul“.

9. Air bleeding of the fuel system

Please use the machine side priming pump. (1) Move the priming pump to discharge the air from the fuel
system.

Refer to the “Fuel filter (Machine side), Water

draining“.

10. Update of supply pump learning value

(1) When the supply pump is replaced, update the learning
Do not use this priming pump.
value memorized in the engine ECU with the failure
SAPH30TCE0500016
diagnosis tool (Hino-DX) using PC. (Refer to "Hino-DX
operation manual".)

! CAUTION • If learning value is not updated, correct

common rail pressure is not controlled,
resulting in engine stall or high common rail
pressure. Therefore, when the supply pump is
replaced, be sure to update the learning
value.

• After work, start the engine and trial run,

make sure that there is no fuel leak around
the supply pump.

[S5LC0033E04] [0518CsCshWbYs]
5–32 FUEL SYSTEM

Injector
Part layout
JP30TCE050704007

SAPH30TCE0500057

1 Union bolt 2 Gasket*

*Parts not to be reused.

[S5LC0033E04] [0518CsCshWbYs]
 FUEL SYSTEM 5–33

åšä²óvóÃçÄñe
êÆî óvóÃ

Replacement
JP30TCE050704008

Removal of the injector

! CAUTION • Take care that no dirt or water get into the

system during the work.

1. Removal of the head cover

(1) Remove the head cover.
Refer to the “9 ENGINE MECHANICAL, Cylinder
head”.
2. Removal of the leakage pipe
Union bolts Union bolts (1) Remove the union bolts (7pcs.), and remove the leakage
pipe and the gaskets (7pcs.).

! CAUTION • The leakage pipe is twisted easily, be careful

for handling.

Leakage pipe

SAPH30TCE0500058

3. Removal of the injector harness

Injector (1) Disconnect the connectors from the each injectors.
harness Connector
bracket (2) Remove the nuts (7pcs.) and remove the injector harness
together with the injector harness bracket.
Injector
harness Nut
! CAUTION • The injector harness bracket is twisted easily,
be careful for handling.

SAPH30TCE0500059

NOTICE • Removal becomes easier when the connector

Connector
part of the camshaft housing is disconnected
last.

Injector Camshaft
harness housing

SAPH30TCE0500060

[S5LC0033E04] [0518CsCshWbYs]
5–34 FUEL SYSTEM

4. Removal of the injection pipes

(1) Remove the nuts (6pcs.) and remove the clips.

SAPH30TCE0500061

(2) Loosen the nuts of the injection pipes, and remove the
injection pipes (6pcs.) from the injector and common rail.

NOTICE • Prepare a container and waste cloth under the

fuel pipe.

! CAUTION • Do not reuse the injection pipe.

SAPH30TCE0500062

5. Removal of the injector

(1) Remove the bolts (2pcs.) and remove the injection pipe oil
Plate seals (6pcs.) and plates (6pcs.) from the cylinder head.

Injecton pipe
oil seal

Bolt

SAPH30TCE0500063

(2) Remove the mounting bolts of the injectors clamps, and

Injector remove the injectors and injector clamps.
Mounting
bolt

Injector
clamp

SAPH30TCE0500064

[S5LC0033E04] [0518CsCshWbYs]
 FUEL SYSTEM 5–35

Unit inspection

1. Resistance check
Megger tester
(1) Measure the resistance between the one side injector
terminal (No polarity) and upper body of the injector using
1,000V megger tester.
Upper body

! CAUTION • Do not measure between the terminal to

terminal using a megger tester. That the
injector will be damaged.

SAPH30TCE0500065 10M: or more

Standard value
(Use 1,000V
(normal temperature)
megger tester)

(2) Measure the resistance between the each terminals using

Circuit tester a circuit tester.

Standard value
Upper body 0.47r0.1:
(at 20qC {68qF})

(3) If resistance of the step (1)(2) exceed standard value

replace the injector.

SAPH30TCE0500066

2. Cleaning of the injector

(1) Use a shop towel to remove any sludge sticking to the
terminal part and its surroundings.

! CAUTION • When removing sludge, use dry cloth.

• Do not use cleaning fluids. (If cleaning fluids
are used, there is a possibility that a electrical
malfunction will occur.)

3. Cleaning inside the nozzle seat

Cylinder head (1) If sludge has accumulated inside the nozzle seat, spray it
with cleaning fluid, remove it by wiping with a shop towel,
Nozzle seat and then wash it again with cleaning fluid.

NOTICE • If the sludge has hardened, use a brush and

cleaning fluid for cleaning.
• Red lead can be used to check for contact.

(2) Confirm that the inside of the nozzle seat is free of sludge
SAPH30TCE0500067
and foreign matter.

[S5LC0033E04] [0518CsCshWbYs]
5–36 FUEL SYSTEM

Installation of the injector

! CAUTION • Take care that no dirt or water get into the

system during the work.
• Before assembly, make sure that there is no
dirt the seating surface of the parts.
• As air enters into the fuel piping during the
work, air bleeding must be performed after
completion of the work.

1. Installation of the injectors and injection pipes

(1) Apply the engine oil at a new O-ring and install it to the
injector, install the injector clamp and the injector
Mounting bolt Injector
temporarily.

! CAUTION • Apply engine oil to the O-ring and insert the

Injection pipe
O-ring so that it is not caught.
• Please use care as a damaged O-ring can
cause fuel leakage and starting the engine
may become impossible.
• Do not tighten the injector clamp until the
injection pipe has been installed
Plate Bolt
provisionally.
Injector clamp Injection pipe
oil seal (2) It covers the injector with a new injection pipe oil seal,
O-ring install the plate with bolts (2pcs.).

! CAUTION • Install the injection pipe oil seal so to the

injection nozzle that no unreasonable force is
applied. (When the positions of the injection
SAPH30TCE0500068 pipe oil seal and the injection nozzle are not
matched, oil leakage or faulty installation of
the injection pipe may be caused.)

(3) Install the injection pipes (6pcs.) to the injectors and

common rail temporarily.

! CAUTION • Always replace the pressure feed pipe by a

new one because the injection pipe is
subjected to high pressure; reusing the same
pipe may result in a fuel leak.
• Always follow the procedure exactly, because
a fuel leakage can be the result when the
SAPH30TCE0500062 injection pipe is not installed correctly.
• Fuel leakage causes engine damage.

[S5LC0033E04] [0518CsCshWbYs]
 FUEL SYSTEM 5–37

• Install so that the injector and the injection

Injection pipe pipe are in a straight line.
Injector clamp

Injector

SAPH30TCE0500069

NOTICE • Install so that the markings of the tightening

nuts for the flared parts of the injection pipes
are arranged in the indicated order.

Mark
Mark

Mark

Mark Mark Mark

SAPH30TCE0500070
(4) Tighten the mounting bolt of the injector clamp.

Mouting bolt Tightening torque : 25 N˜m {250 kgf˜cm, 18 lbf˜ft}

! CAUTION • An insufficient tightening torque can cause

gas leakage, nozzle seizure, etc.

Injector

Injector clamp

SAPH30TCE0500071

(5) Tighten the injection pipes at standard torque.

Tightening torque : 44 N˜m {450 kgf˜cm, 32.5 lbf˜ft}

SAPH30TCE0500062

[S5LC0033E04] [0518CsCshWbYs]
5–38 FUEL SYSTEM

(6) Fix the injection pipes with the clips by nuts (6pcs.).

SAPH30TCE0500061

2. Entry of injector correction value to the engine ECU (entry

using Hino-DX and QR code reader)
QR code

! CAUTION • When the injector is replaced, it is necessary

to enter the injector correction value (QR
code) described on the new injector to the
engine ECU. Incorrect entry of the correction
Injector
value may result in faulty engine.
• Incorrect entry of the correction value may
SAPH30TCE0500072 result in faulty engine.

NOTICE • Available entry methods of the injector

correction value are the PC tool and the QR
code reader.
• The work flow is described below. For detailed
procedures, refer to the Hino-DX operation
manual.

(1) Read the injector QR code with the scanner of the QR

code reader and prepare the correction data file.

[S5LC0033E04] [0518CsCshWbYs]
 FUEL SYSTEM 5–39

(2) Enter the injector correction value directly from the Hino-
DX to the engine ECU.

PC

QR code reader

Hino-Bowie
(Special interface)
Engine type code
(QR code)

Connector
New injector

ECU

SAPH30TCE0500073

3. Installation of the injector harness

Injector (1) Install the injector harness together with the injector
harness Connector
bracket bracket by bolts (7pcs.).

Injector (2) Connect the connectors of the injector harness.

harness Nut
! CAUTION • Before connecting the connector, confirm that
the terminal shows no signs of sparking.

SAPH30TCE0500074

NOTICE • Installation becomes easier when the

Connector
connector part of the camshaft housing is
connected first.

Injector Camshaft
harness housing

SAPH30TCE0500060

[S5LC0033E04] [0518CsCshWbYs]
5–40 FUEL SYSTEM

4. Installation of the leakage pipe

Union bolts Union bolts (1) Remove dirt and foreign matter around the mounting
surface.

(2) Use the union bolts (7 bolts) with new gaskets to install
the leakage pipes to the injector and the camshaft
housing.
Tightening torque : 12.3 N˜m {130 kgf˜cm, 9 lbf˜ft}
Leakage pipe
! CAUTION • Do not reuse the gasket.
SAPH30TCE0500058 • The leakage pipe is twisted easily, be careful
for handling.
• It is noted that the union bolt (6pcs.) of the
A:Injector side (M8 x 1.0) injector and the union bolt (1pc) of the
B:Camshaft housing side (M8 x 1.25)
camshaft housing are different bolt pitch.

Leakage pipe

SAPH30TCE0500075

• There is the "X" mark at the union bolt of the

camshaft housing.
Camshaft housing side
union bolt

SAPH30TCE0500076

5. Installation of the head cover

(1) Install the head cover.
Refer to the “9 ENGINE MECHANICAL, Cylinder
head”.

6. Air bleeding of the fuel system

Please use the machine side priming pump. (1) Move the priming pump to discharge the air from the fuel
system.

Refer to “Fuel filter (Machine side), Water draining”

åšä²óvóÃçÄñe
êÆî óvóÃ

Do not use this priming pump.

SAPH30TCE0500016

[S5LC0033E04] [0518CsCshWbYs]
 FUEL SYSTEM 5–41

Common rail
Part layout
JP30TCE050704009

SAPH30TCE0500077

1 Pressure limiter 3 Common rail pressure sensor

2 Flow damper

[S5LC0033E04] [0518CsCshWbYs]
5–42 FUEL SYSTEM

Inspection of the common rail

JP30TCE050704010

1. Inspection of the flow damper

(1) Start the engine, accelerate the engine from idling to full
throttle, check the DTC code "flow damper operated"
using the Hino-DX.
(2) If detect DTC code "flow damper operated", replace the
corresponded injector and recheck.
(3) If same DTC code are detected that corresponded injector
was replaced, replace the common rail assembly with the
flow damper.

2. Inspection of the pressure limiter

(1) Remove the union bolt from the pressure limiter.
Block pipe ends
(2) Block pipe ends at return pipe No.1 side by a bolt to
prevent fuel leak.

Pressure limiter

Union bolt

SAPH30TCE0500078

(3) Install the union bolt to the pressure limiter, and set the
vinyl hose to the union bolt.

(4) Put a container under the vinyl hose.

Pressure (5) Start the engine. If the fuel flows continuously, replace the
limiter
Union bolt
common rail assembly with the pressure limiter.

Vinyl hose

Container

SAPH30TCE0500079

3. Inspection of the common rail pressure sensor

  
(1) Measure the resistance between the terminals with a
circuit tester. If the value exceeds the standard value,
replace the common rail assembly.

Standard value (k:)

Measurement terminal when engine stopped
at 20qC {68qF}
  
1-2
SAPH30TCE0500080
1.05 - 3.55
5-6

2-3
6.7 - 18.7
4-5

[S5LC0033E04] [0518CsCshWbYs]
 FUEL SYSTEM 5–43

êÆî óvóÃ

Replacement
JP30TCE050704011

Removal of the common rail

! CAUTION • Take care that no dirt or water get into the

system during the work.

1. Disconnection of the harness

(1) Disconnect the connector at common rail pressure
sensor.

SAPH30TCE0500081

! CAUTION • Pull out the female connector from the male

Common rail side
Male connector connector during pushing the spring lock at
the female connector.

Harness side

Female connector
Spring lock
SAPH30TCE0500082

2. Disconnection of the fuel pipe

(1) Disconnect the union bolt, and remove the return pipe
No.1 from the pressure limiter.

NOTICE • Prepare a container and waste cloth under the

fuel pipe.

Pressure
3. Removal of the injection pipe
limiter (1) Remove the injection pipe from the common rail.
Refer to “Injector, Replacement”.
SAPH30TCE0500083

4. Removal of the pressure feed pipe

(1) Remove the pressure feed pipe from the common rail and
the supply pump.
Refer to “Supply pump, Replacement of the supply
pump”.

[S5LC0033E04] [0518CsCshWbYs]
5–44 FUEL SYSTEM

5. Removal of the common rail

(1) Remove the bolts (2pcs.) and remove the common rail
Common rail and the bracket from the intake manifold.
pressure sensor

! CAUTION • Put a vinyl cover to prevent entry dirt inside

Bracket
the common rail.
• Remove dirt from around each parts before
remove the common rail.
• Remove the common rail together with the
Flow damper
flow damper, the common rail pressure
Pressure
limitter sensor, and the pressure limiter.

Bolt NOTICE • Prepare a container and a waste cloth

removing the common rail.

Common rail

SAPH30TCE0500084

[S5LC0033E04] [0518CsCshWbYs]
 FUEL SYSTEM 5–45

Installation of the common rail

! CAUTION • Take care that no dirt or water get into the

system during the work.
• Before assembly, make sure that there is no
dirt the seating surface of the parts.
• As air enters into the fuel piping during the
work, air bleeding must be performed after
completion of the work.

1. Installation of the common rail

(1) Install the common rail and the bracket to the intake
Common rail manifold with bolts (2pcs.).
pressure sensor
Tightening torque :
Bracket
28.5 N˜m {290 kgf˜cm, 21 lbf˜ft}

2. Installation of the pressure feed pipe

(1) Install a new pressure feed pipe.
Refer to “Supply pump, Replacement of supply
Flow damper
pump”.
Pressure
limitter

Bolt

Common rail

SAPH30TCE0500084

[S5LC0033E04] [0518CsCshWbYs]
5–46 FUEL SYSTEM

3. Installation of the injection pipes

(1) Install new injection pipes (6pcs.) to the injector and the
common rail.

Refer to “Injector, Replacement“.

SAPH30TCE0500085

4. Installation of the fuel pipes

(1) Replace the gaskets by new ones and install the return
pipe No.1 to the pressure limiter with union bolts (2pcs.).
Refer to the “Supply pump, Replacement”.

Pressure
limitter
SAPH30TCE0500086

5. Connecting of the harness

(1) Connect the connector to the common rail pressure
sensor.

SAPH30TCE0500087

! CAUTION • Push the male connector to the female

Male connector
connector until the "CLICK" sounds are
Female connector heard.
Common
rail side
• Before connecting the connector, confirm that
the terminal shows no signs of sparking.

Spring lock

Harness side
SAPH30TCE0500088

[S5LC0033E04] [0518CsCshWbYs]
 FUEL SYSTEM 5–47

6. Air bleeding of the fuel system

Please use the machine side priming pump. (1) Move the priming pump to discharge the air from the fuel
system.

Refer to “Fuel filter (Machine side), Water draining”.

Do not use this priming pump.

SAPH30TCE0500016

[S5LC0033E04] [0518CsCshWbYs]
[S5LC0033E04] [0518CsCshWbYs]
 EMISSION CONTROL 6–1

ENGINE

6 EMISSION CONTROL
Setup layout
Layout

EGR.............................................................................. 6-2
Part layout............................................................... 6-2
Overhaul of the EGR valve and EGR cooler........... 6-3
Ventilator ..................................................................... 6-9
Part layout............................................................... 6-9

[S5LC0033E04] [0518CsCshWbYs]
6–2 EMISSION CONTROL

EGR
Part layout
JP30TCE060402001

SAPH30TCE0600001

1 Gasket* 6 EGR pipe C

2 Stay 7 EGR cooler
3 Clamp 8 EGR valve
4 EGR pipe A 9 Coolant hose
5 EGR pipe B

*Parts not to be reused.

Tightening torque
A 55N˜m{560kgf˜cm, 41 lbf˜ft} C 68.5N˜m{700kgf˜cm, 51 lbf˜ft}
B 36N˜m{367kgf˜cm, 26 lbf˜ft}
Service procedure
Replacement procedure item

[S5LC0033E04] [0518CsCshWbYs]
 EMISSION CONTROL 6–3

Overhaul of the EGR valve and EGR cooler

JP30TCE060704001

1. Removal of the EGR pipes

Gasket
(1) Remove the bolts (7pcs.) and remove the EGR pipe A
from the EGR cooler and the EGR valve.

EGR pipe A

Gasket

EGR cooler EGR valve

SAPH30TCE0600002

(2) Remove the bolts (5pcs.) and a nut, and remove the EGR
EGR pipe B pipe B and the gaskets (2pcs.) from the EGR cooler and
the exhaust manifold.

(3) Remove the bolts (5pcs.), and remove the EGR pipe C
and the gaskets (2pcs.) from the EGR cooler and the
exhaust manifold.

EGR pipe C
SAPH30TCE0600003

[S5LC0033E04] [0518CsCshWbYs]
6–4 EMISSION CONTROL

2. Disconnecting the coolant hoses

(1) Remove the clamp and remove the coolant hose from the
EGR cooler.
Clamp

Coolant
hose

EGR cooler
SAPH30TCE0600004

(2) Remove the clamps (2pcs.) and remove the coolant hose
Water Coolant hose from the EGR cooler and water outlet block.
outlet block

Clamp EGR cooler

SAPH30TCE0600005

(3) Remove the clamps (2pcs.) and remove the coolant hoses
Clamp
(2pcs.) from the EGR cooler.

Clamp
Coolant hose

SAPH30TCE0600006

3. Removal the EGR cooler

(1) Remove the bolts (4pcs.) and remove the EGR cooler
Shell area EGR cooler from the thermostat case.

! CAUTION • Do not hold the shell area when attaching or

removing the EGR.
This can cause deformation, damage, or other
problems.
Thermostat
case
SAPH30TCE0600007

4. Removal the intake pipe (intake side)

(1) Remove the intake pipe (intake side).
Refer to “8 INTAKE, Intake Manifold, Replacement”

[S5LC0033E04] [0518CsCshWbYs]
 EMISSION CONTROL 6–5

5. Removal the EGR valve

(1) Remove the EGR valve and gaskets from the intake pipe.
Gasket
EGR valve (2) Remove the nuts and remove the stay from the EGR
valve.
Intake pipe
Stay ! CAUTION • Do not step onto the EGR valve at the time of
engine maintenance.
• Do not loosen or remove bolts, nuts, and/or
snap rings of the EGR valve component parts.
SAPH30TCE0600008 Removal or loosening can cause performance
problems.
If disassembly with removal of bolts, nuts,
and/or snap rings has been performed, do not
try to reassemble, but replace the valve by a
new unit.
• Do not hold the link part when replacing the
EGR valve assembly. Holding the link part can
bend the link and can cause a malfunction.

Do not remove these bolts

Do not remove these nuts
Do not remove these snap rings
A

Link

A Section A - A

SAPH30TCE0600009

Inspection of the components

1. Inspection of the EGR cooler

(1) Check visually for crack or clogging of the unit gas
channel. If a faulty item is found, replace the EGR cooler
unit.

[S5LC0033E04] [0518CsCshWbYs]
6–6 EMISSION CONTROL

Installing of the EGR valve and the EGR cooler

1. Installation of the EGR cooler

(1) Install the stay to the EGR valve with the nuts.
Gasket
EGR valve (2) Replace the gasket by a new one and provisionally secure
the EGR valve at the intake pipe.
Intake pipe
Stay

SAPH30TCE0600008

2. Installation of the intake pipe (intake side)

(1) Install the intake pipe (intake side).
Refer to “8 INTAKE, Intake Manifold, Replacement”

3. Installation of the EGR cooler

(1) Install the EGR cooler to the thermostat case with the
Shell area EGR cooler bolts (4pcs.).

Tightening torque :
36 N˜m {367 kgf˜cm, 26 lbf˜ft}

! CAUTION • Do not hold the shell area when attaching or

removing the EGR.
Thermostat
case This can cause deformation, damage, or other
SAPH30TCE0600007 problems.

[S5LC0033E04] [0518CsCshWbYs]
 EMISSION CONTROL 6–7

4. Connecting of the coolant hoses

Clamp
(1) Connect the coolant hoses (2pcs.) to the EGR cooler with
the clamps (2pcs.).

Clamp
Coolant hose

SAPH30TCE0600006

(2) Connect the coolant hose to the EGR cooler and water
outlet block with the clamps (2pcs.).
Water Coolant hose
outlet block

EGR cooler
Clamp
SAPH30TCE0600010

(3) Connect the coolant hose to the EGR cooler with the
clamp.

Clamp

Coolant
hose

EGR cooler
SAPH30TCE0600004

[S5LC0033E04] [0518CsCshWbYs]
6–8 EMISSION CONTROL

5. Installation of the EGR pipes

EGR pipe B (1) Replace the gaskets by new ones (2pcs.) install the EGR
pipe C to the EGR cooler and the exhaust manifold with
the bolts (5psc.).

Tightening torque : 68.5 N˜m {700 kgf˜cm, 51 lbf˜ft}

(2) Replace the gaskets by new ones (2pcs.) and install the
EGR pipe B to the EGR cooler, the exhaust manifold with
the bolts (5psc.) and a nut.
EGR pipe C
Tightening torque : 68.5 N˜m {700 kgf˜cm, 51 lbf˜ft}
SAPH30TCE0600003

(3) Replace the gaskets by new ones (2pcs.) and install the
Gasket
EGR pipe A with the bolts (7psc.).

Tightening torque : 55 N˜m {560 kgf˜cm, 41 lbf˜ft}

EGR pipe A

Gasket

EGR cooler EGR valve

SAPH30TCE0600002

6. Inspection of the EGR cooler

(1) Check visually for crack or clogging of the unit gas
channel and the sub-coolant pipe.
If a faulty item is found, replace the EGR cooler unit.

7. Inspection of EGR (Inspection with Hino-DX)

(1) Inspect operation of the EGR valve on the vehicle using
Hino-DX. (Refer to the “Hino-DX operation manual”.)

[S5LC0033E04] [0518CsCshWbYs]
 EMISSION CONTROL 6–9

Ventilator
Setup layout
Layout

Part layout
JP30TCE060402002

NOTICE • This ventilator is maintenance free.

SAPH30TCE0600011

1 Ventilator 3 Ventilator pipe

2 Braket 4 O-ring*

*Parts not to be reused.

[S5LC0033E04] [0518CsCshWbYs]
[S5LC0033E04] [0518CsCshWbYs]
 ELECTRICAL 7–1

ENGINE

7 ELECTRICAL
Setup layout
Layout

Electrical System........................................................ 7-2

Part layout............................................................... 7-2
Layout of components............................................. 7-5
Inspection of components ....................................... 7-9
Installation of component ...................................... 7-11
Installation of starter ............................................. 7-13
Removal and installation of the alternator............. 7-14
Replacement of the Engine ECU .......................... 7-16
7

[S5LC0033E04] [0518CsCshWbYs]
7–2 ELECTRICAL

Electrical System
Part layout
JP30TCE070402001

SAPH30TCE0700001

1 Injector harness 5 Engine main revolution sensor

2 Water temperature sender gauge 6 Boost pressure sensor
3 Oil pressure warning switch 7 Intake temperature sensor
4 Engine sub-revolution sensor 8 Gasket*

*Parts not to be reused.

[S5LC0033E04] [0518CsCshWbYs]
 ELECTRICAL 7–3

SAPH30TCE0700002

1 Alternator bracket 3 Starter assembly

2 Alternator 4 V –belt

Tightening torque
A 83N˜m{850kgf˜cm, 61 lbf˜ft} C 154N˜m{1,570kgf˜cm, 114 lbf˜ft}
B 51N˜m{520kgf˜cm, 38 lbf˜ft}

[S5LC0033E04] [0518CsCshWbYs]
7–4 ELECTRICAL

SAPH30TCE0700003

1 Engine ECU

Tightening torque
A 28.5N˜m{290kgf˜cm, 21 lbf˜ft}

[S5LC0033E04] [0518CsCshWbYs]
 ELECTRICAL 7–5

Layout of components
JP30TCE070402002

FRONT VIEW

Boost pressure senser

Alternator
Intake throttle valve

V-belt

SAPH30TCE0700004

[S5LC0033E04] [0518CsCshWbYs]
7–6 ELECTRICAL

LEFT VIEW

SAPH30TCE0700005

[S5LC0033E04] [0518CsCshWbYs]
 ELECTRICAL 7–7

BACK VIEW

Engine main revolution sensor

Engine sub revolution sensor

Engine revolution sensor (for machine)

SAPH30TCE0700006

[S5LC0033E04] [0518CsCshWbYs]
7–8 ELECTRICAL

RIGHT VIEW

Water temperature sender gauge

Variable turbo actuator

(T
Oil pressure warning switch

SAPH30TCE0700007
Service procedure
Overhaul item

[S5LC0033E04] [0518CsCshWbYs]
 ELECTRICAL 7–9

Inspection of components
JP30TCE070702001

1. Inspection of oil pressure warning switch

(Laid out on the oil filter)

(1) Apply pressure with air or oil and check continuity

between terminals using a circuit tester. If it is faulty,
replace it.

Operation Conditions
• When the engine starts, the oil pressure rises, and after
the operating pressure is reached, the conductivity of
SAPH30TCE0700008
the oil pressure gauge is interrupted, which causes the
warning lamp to go out. When the oil pressure is lower
than the specified pressure, conductivity is established,
which causes the warning lamp to light up.
Characteristics

Oil pressure warning switch • The operating pressure of the oil pressure gauge is
between 39.2 kPa and 58.8 kPa.
39.2 - 58.8kPa
2 2
• Replace the oil pressure gauge when there is no
{0.4 - 0.6kgf/cm ,5.7 - 8.5 lbf/in } ON
2
conductivity below 39.2 kPa or when there is
2.9kPa{0.3kgf/cm ,
2
4.7lbf/in } conductivity above 58.8 kPa.
Within
OFF Toward pressure increase

SAPH30TCE0700009

2. Inspection of coolant temperature sender gauge

Coolant temperature sender gauge
(Installation on thermostat case)

Connector color: Dark (1) Heat the coolant temperature sender gauge using hot
water.
A (2) Measure the resistance between terminals using a circuit
tester. If it is faulty, replace the gauge.
Between A and C
C
B Resistance value
Temperature (qC{qF})
SAPH30TCE0700010
(:)

-20{-68} 13.84 - 16.33

20{68} 2.32 - 2.59

80{176} 0.31 - 0.326

110{230} 0.1399 - 0.1435

Between B and body

Resistance value
Temperature (qC{qF})
(:)

75{167} 79 - 92

100{212} 35.5 - 42.5

[S5LC0033E04] [0518CsCshWbYs]
7–10 ELECTRICAL

3. Inspection of glow plug

(1) Measure continuity between the body and the terminal

using a circuit tester. If it is faulty, replace the glow plug.

Standard value

Resistance value : :
(Normal temperature 2.7 - 3.5
20qC{68qF})

SAPH30TCE0700011

4. Inspection of suction control valve SCV and fuel

Fuel temperature sensor temperature sensor

(1) For inspection of the suction control valve (SCV) and the
Suction control valve fuel temperature sensor, refer to the chapter of "5 FUEL
SYSTEM".
Refer to “5 FUEL SYSTEM, Supply pump, Inspection
of supply pump”

SAPH30TCE0700012

5. Inspection of common rail pressure sensor

(1) For inspection of the common rail pressure sensor, refer

to the chapter of "5 FUEL SYSTEM".
Refer to “5 FUEL SYSTEM, Common rail, Inspection”

SAPH30TCE0700013

6. Inspection of injector
(1) For inspection and replacement of the injector, refer to
the chapter of "5 FUEL SYSTEM".
Refer to “5 FUEL SYSTEM, Common rail, Inspection”

[S5LC0033E04] [0518CsCshWbYs]
 ELECTRICAL 7–11

Installation of component
JP30TCE070702002

Installation of engine main revolution sensor

1. Installation of the engine main revolution sensor

Engine main revolution sensor
(1) Make sure that the sensor has the O-ring. Install the
sensor on the flywheel housing and the cam housing.

Tightening torque : 10 N˜m {102 kgf˜cm, 7.4 lbf˜ft}

! CAUTION • If the O-ring will be reused, make sure that the

o-ring is no sticking a foreign matter, no
damage, no deformation.
O-ring
NOTICE • This sensor is a flange type, gap does not
SAPH30TCE0700014
have to be adjusted.
• This O-ring can be used again.

2. Connection of the harness

Connector
(1) Connect the connector to the engine main revolution
sensor.

! CAUTION • Before connecting the connector, confirm that

there are no signs of sparking on the terminal.

Flywheel housing

SAPH30TCE0700015

[S5LC0033E04] [0518CsCshWbYs]
7–12 ELECTRICAL

Installation of the engine sub revolution sensor

1. Installation of the engine sub revolution sensor

Engine sub (1) Make sure that the sensor has the O-ring. Install the
revolution sensor
sensor to the cam housing upper side.
O-ring
Tightening torque : 4 - 6 N˜m {41 - 61 kgf˜cm, 3 - 4.4
lbf˜ft}

! CAUTION • If the O-ring will be reused, make sure that the

o-ring is no sticking a foreign matter, no
Cam housing
damage, no deformation.
SAPH30TCE0700016
NOTICE • This sensor is a flange type, gap does not
have to be adjusted.
• This O-ring can be used again.

2. Connection of the harness

Connector (1) Connect the connector to the engine sub revolution
sensor.

! CAUTION • Before connecting the connector, confirm that

Cam housing
there are no signs of sparking on the terminal.

SAPH30TCE0700017

[S5LC0033E04] [0518CsCshWbYs]
 ELECTRICAL 7–13

Installation of starter
JP30TCE070702003

1. Install the starter with bolts and nuts.

Tightening torque : 154 N˜m {1,570 kgf˜cm, 114 lbf˜ft}

SAPH30TCE0700018

[S5LC0033E04] [0518CsCshWbYs]
7–14 ELECTRICAL

Removal and installation of the alternator

JP30TCE070702004

1. Removal of the alternator.

(1) Remove the adjustment bolt.

Adjustment
bolt Brace (2) Remove the fixing nut(s) on the side of the brace.
(3) Remove the through bolt while supporting the alternator,
Brace side
fixing nut and remove the alternator.

! CAUTION • When the through bolt is removed, the

alternator falls. The alternator must be firmly
Through bolt
supported during the through bolt removal.
SAPH30TCE0700019

2. Installation of the alternator.

(A)
(1) Fasten the alternator provisionally with the through bolt
and the fixing nut on the side of the brace.
(2) Use the special tool and adjust the adjustment bolt so that
the V-belt is within the reference value at the measuring
position (A).

Measuring item Standard value

3 - 5mm
SAPH30TCE0700020 Deflection
{0.1182 - 0.1968in.}

1,372 N
Tension
{140 kgf, 308 lbf}

Special tool : S0944-41210 (09444-1210)

Compression gauge (used at the time
of measuring the deflection amount)
[ Reference push force
98N {10kgf, 22lbf} ]
MITSUBOSHI BELTING LTD.; Belt
Tension Meter (DOCTOR TENSION£
TYPE-III) (used at the time of
measuring the tension force)

! CAUTION • When the V-belt has been replaced by a new

one, the V-belt will become loose because of
initial run-in, so that the V-belt tension should
be adjusted again after running the engine for
3 to 5 minutes.

NOTICE • At the time of inspection, the new V-belt has

reached the value after complete initial
stretching. A new V-belt completes initial
stretching after running the engine for
approximately two hours.

[S5LC0033E04] [0518CsCshWbYs]
 ELECTRICAL 7–15

(3) After the adjustment, tighten all nuts and bolts securely.
Tightening torque :
83 N˜m {850 kgf˜cm, 61 lbf˜ft} (Through bolt)
51 N˜m {520 kgf˜cm, 38 lbf˜ft} (Fixing nuts at brace)
5.9 N˜m {60 kgf˜cm, 4 lbf˜ft} (Adjustment bolt)

! CAUTION • After the adjustment bolt has been tightened,

confirm that it is locked.
• When a tire lever is placed, do not place it
beyond the shaded area shown in the
alternator figure.

Alternator

SAPH30TCE0700021

[S5LC0033E04] [0518CsCshWbYs]
7–16 ELECTRICAL

Replacement of the Engine ECU

JP30TCE070702005

Removing the engine ECU connector

! CAUTION • Before replacement, wait until the engine

cools down as you may get burned. (Turn the
starter key to the "OFF" position and leave it
for more than 30 minutes to cool.)

1. Cleaning the engine ECU connector

Engine ECU (1) Check that the engine ECU connector is completely
connected to the engine ECU.

(2) Directly spray water around the engine ECU connector by

using a small spray bottle.

! CAUTION • Do not remove the connector while at work.

Connector NOTICE • If it is much dirty, squirt water at the

connector sliding portion and connector
SAPH30TCE0700022
surface.

(3) Blow air around the engine ECU connector and engine
ECU surface to remove dirt and foreign matter.

! CAUTION • Do not remove the connector while at work.

• Blow off water with air as much as possible
for drying.

(4) Using a small brush, carefully remove dirt and foreign

matter remaining at the sliding portion.

! CAUTION • Do not remove the connector while at work.

(5) Using a waste cloth, wipe off around the engine ECU
connector and engine ECU surface.

! CAUTION • Do not remove the connector while at work.

Sliding portion
Lever • Wipe up water thoroughly.
SAPH30TCE0700023 (6) If you feel the movement of the lever unsmooth, repeat
steps (1), (2), (3), (4) and (5).
(7) Disconnect the engine ECU connector and check it for
deposition of dirt and foreign matter.
a. Set the hook of the connector in the direction of the
arrow to release the lock.

Hook

SAPH30TCE0700024

[S5LC0033E04] [0518CsCshWbYs]
 ELECTRICAL 7–17

b. While pushing the primary latch of the connector, move

the lever in the direction of the arrow as shown in the
figure until a “click” is heard and then detach the
connector.

Primary latch
Lever

SAPH30TCE0700025

c. Pull out the connector straight.

! CAUTION • Do not insert and remove the connector more

than necessary.
• Do not give shocks to the engine ECU.
• Never detach the harness by holding and
pulling or prying as it may result in wire or
terminal deformation.
• Never insert a test lead from the rear of the
SAPH30TCE0700026
connector.
• Do not paint or apply grease or oil to the
connector to maintain its function and
durability.

NOTICE • If it cannot be pulled out with a light force,

check if the lever is fully open.

(8) If the side of the harness side connector is found dirty,

wipe it off with a moistened waste cloth while being careful
Wipe off not allowing dirt and foreign matter to drop.
Do not wipe

! CAUTION • Use a thoroughly wrung waste cloth.

• Do not wipe off the terminal opening.
Harness side • Do not directly spray water.
connector

SAPH30TCE0700027

(9) If the engine ECU side connector is found dirty, wipe off its
side with a moistened waste cloth.
Wipe off

Do not wipe ! CAUTION • Use a thoroughly wrung waste cloth.

• Do not wipe off the terminal opening.
• Do not directly spray water.
Engine ECU (10) Blow air on the terminal part inside the engine ECU side
side connector
connector to remove dirt and foreign matter.

SAPH30TCE0700028

[S5LC0033E04] [0518CsCshWbYs]
7–18 ELECTRICAL

Removal of the engine ECU

1. Removal of the engine ECU

Cylinder block (1) Remove the bolts (4pcs.) and remove the engine ECU
Rubber
and the rubber from the cylinder block.

! CAUTION • Protect the connector of the engine ECU with

a vinyl cover or similar to prevent the entry of
dirt or foreign matter.
• Do not subject the ECU to impacts.
Engine ECU • Do not use an engine ECU which has been
SAPH30TCE0700029 dropped.
• Do not touch the connector terminals with
bare hands.
• The engine ECU cannot be disassembled.
• Do not apply paint, oil, or fat to the surface of
the ECU and the connector part in order to
maintain the functions and the durability.

Installation of the engine ECU

1. Installation of the engine ECU

Cylinder block (1) Install the engine ECU and the rubber with the bolts (4pcs.)
Rubber
to the cylinder block. Tighten the bolts in diagonal order.

Tightening torque : 28.5 N˜m {290 kgf˜cm, 21 lbf˜ft}

! CAUTION • Protect the connector of the engine ECU with

a vinyl cover or similar to prevent the entry of
dirt or foreign matter.
Engine ECU • Do not subject the ECU to impacts.
SAPH30TCE0700029
• Do not use an engine ECU which has been
dropped.
• Do not touch the connector terminals with
bare hands.
• The engine ECU cannot be disassembled.
• Do not apply paint, oil, or fat to the surface of
the ECU and the connector part in order to
maintain the functions and the durability.
• Check that there is no dirt on the bosses (4
locations) on the rear of the engine ECU.

• Confirm that the filter (resin housing) on the

rear of the engine ECU is not broken or
Filter contaminated by oil.
(resin housing)

Boss

SAPH30TCE0700030

[S5LC0033E04] [0518CsCshWbYs]
 ELECTRICAL 7–19

Mounting the engine ECU connector

1. Attaching the engine ECU connector

(1) Check that the harness side connector lever is fully open
and place it straight on the engine ECU side connector.
Lever
! CAUTION • At this time, check that the lever is fully open.

SAPH30TCE0700031

NOTICE • Check that it is inserted along the wrong

fitting prevention keyway.

Wrong fitting prevention keyway

SAPH30TCE0700032

(2) Press the upper part of the harness side connector and
insert the connector uniformly.

Lever

SAPH30TCE0700033

[S5LC0033E04] [0518CsCshWbYs]
7–20 ELECTRICAL

(3) Move the lever in the direction of the arrow as shown in

the figure until a “click” is heard and attach the connector.

! CAUTION • If the lever cannot move smoothly, repeat

steps (1) and (2). Also drop a few drops of
water to the sliding portion to make it smooth.

Sliding portion Lever

SAPH30TCE0700034

(4) Move the hook in the direction of the arrow as shown in

the figure until a “click” is heard in order to lock the
connector.

Hook
SAPH30TCE0700035

[S5LC0033E04] [0518CsCshWbYs]
 INTAKE 8–1

ENGINE

8 INTAKE
Setup layout
Layout

Intake Manifold ........................................................... 8-2

Part layout............................................................... 8-2
Replacement........................................................... 8-3
Intake throttle valve .................................................... 8-5
Part layout............................................................... 8-5
Inspection ............................................................... 8-6
Replacement........................................................... 8-7

[S5LC0033E04] [0518CsCshWbYs]
8–2 INTAKE

Intake Manifold
Part layout
JP30TCE080402001

SAPH30TCE0800001

1 Intake pipe 3 Gasket*

2 Intake manifold

*Parts not to be reused.

Tightening torque
A 28.5N˜m {290kgf˜cm, 21 lbf˜ft} B 55N˜m {560kgf˜cm, 41 lbf˜ft}
Service procedure
Replacement procedure item

[S5LC0033E04] [0518CsCshWbYs]
 INTAKE 8–3

Replacement
JP30TCE080704001

1. Removal of intake manifold

(1) Remove bolts and nuts and remove the intake manifold.

2. Installation of intake manifold

(1) Clean inside of the intake manifold and the cylinder head.

(2) Assemble a new gasket.

! CAUTION • Install the gasket so that the protrusion may

come at the rear end stud bolt of the cylinder
head.

Protrusion
SAPH30TCE0800002

(3) Install the intake manifold and tighten it with bolts and
nuts.

Tightening torque : 28.5 N˜m {290 kgf˜cm, 21 lbf˜ft}

SAPH30TCE0800003

3. Installation of the intake pipe

EGR valve
(1) Install the stay to the EGR valve with the nut.
Gasket
Link (2) Replace the gaskets by new ones and provisionally install
the EGR valve to the intake pipe.
Intake pipe
Stay ! CAUTION • Do not hold the link part when replacing the
EGR valve assembly. Holding the link part can
bend the link and can cause a malfunction.

SAPH30TCE0800004

(3) Remove dust from the joint surfaces and apply liquid
gasket {Threebond TB1207B (black) or equivalent} to the
Intake manifold
joint surface.

! CAUTION • Apply it continuously.

• Apply the liquid gasket at the width of 1.5 to
2.5 mm{0.0591 to 0.0984 in.}.
• Install that within 20 minutes after application
Liquid gasket of the liquid gasket.
SAPH30TCE0800005

[S5LC0033E04] [0518CsCshWbYs]
8–4 INTAKE

(4) Install the intake pipe to the intake manifold with the bolts
(3pcs.), nuts (2pcs.) and the EGR valve.
Intake manifold
Tightening torque : 55 N˜m {560 kgf˜cm, 41 lbf˜ft}
Intake pipe
! CAUTION • Provisionally secure the EGR valve with bolts
so as not to drop the EGR valve.
After installing the intake pipe and remove the
temporary tightened bolts.
EGR valve

SAPH30TCE0800006

(5) Install the bracket to the cylinder block and the inlet pipe
with the bolts (4pcs.)

Tightening torque : 55 N˜m {560 kgf˜cm, 41 lbf˜ft}

Intake pipe

Bracket
Cylinder block
SAPH30TCE0800007

[S5LC0033E04] [0518CsCshWbYs]
 INTAKE 8–5

Intake throttle valve

Setup layout
Layout

Part layout
JP30TCE080402002

SAPH30TCE0800008

1 Intake throttle valve 2 Gasket*

*Parts not to be reused.

Tightening torque
A 28.5N˜m {290kgf˜cm, 21 lbf˜ft}
Service procedure
Replacement procedure item

[S5LC0033E04] [0518CsCshWbYs]
8–6 INTAKE

Inspection
JP30TCE080704002

1. Inspection of the intake throttle valve

(1) Inspect the intake throttle valve using Hino-DX.
Refer to the Hino-DX manual

[S5LC0033E04] [0518CsCshWbYs]
 INTAKE 8–7

Service procedure
Replacement procedure item

Replacement
JP30TCE080704003

Removal of the intake throttle valve

1. Removal of the inter cooler hose (outlet hose)

(1) Remove the inter cooler hose (outlet hose).

2. Removal of the harness

(1) Disconnect the connector from the intake throttle valve.

3. Removal of the intake throttle valve

(1) Remove the bolts (4pcs.) and remove the intake throttle
valve and gasket from the intake pipe.

Gasket

Intake pipe
(T
Intake throttle valve
SAPH30TCE0800009

Installation of the intake throttle valve

1. Install the intake throttle valve to the intake pipe

temporarily with a new gasket.
(1) Replace the gasket by new one, install the intake throttle
valve to the intake pipe temporarily, and tighten the bolts
in diagonal order.

Tightening torque : 28.5 N˜m {290 kgf˜cm, 21 lbf˜ft}

! CAUTION • Take care to install so that the valve is not

subjected to impact at the time of installation.
Do not use the valve when it has been
subjected to impact.
• Remove any remaining gasket traces from the
intake throttle valve mounting surface of the
intake pipe before installation.

2. Connecting of the harness

(1) Connect the connector to the intake throttle valve.

3. Connecting of the inter cooler hose (outlet hose)

(1) Connect the inter cooler hose (outlet hose).

[S5LC0033E04] [0518CsCshWbYs]
[S5LC0033E04] [0518CsCshWbYs]
 ENGINE MECHANICAL 9–1

ENGINE

9 ENGINE MECHANICAL
Setup layout
Layout

Cylinder Head ............................................................. 9-2

Part layout............................................................... 9-2
Replacement of cylinder head ................................ 9-4
Replacement of camshaft housing ......................... 9-8
Liquid gasket application procedure for cylinder
plug (only when cylinder plug is removed).............. 9-9
Replacement of head cover .................................. 9-10
Overhaul of cylinder head ..................................... 9-11
Cylinder Block .......................................................... 9-14
Part layout............................................................. 9-14
Overhaul ............................................................... 9-15
Timing Gear Cover and Flywheel Housing............. 9-19
Part layout............................................................. 9-19
Replacement of flywheel housing ......................... 9-21
9
Replacement of rear end plate ............................. 9-22
Replacement of crankshaft front oil seal............... 9-23
Replacement of crankshaft rear oil seal................ 9-25
Main Moving Parts.................................................... 9-27
Part layout............................................................. 9-27
Replacement of piston and connecting rod .......... 9-29
Inspection of piston and connecting rod ............... 9-34
Replacement of connecting rod bushing............... 9-37
Replacement of crankshaft ................................... 9-41
Inspection of crankshaft ........................................ 9-43
Replacement of crankshaft pulley......................... 9-46
Replacement of flywheel ...................................... 9-47
Camshaft and Idle Gear ........................................... 9-50
Part layout............................................................. 9-50
Removal of camshaft ............................................ 9-52
Disassembly of camshaft ...................................... 9-53
Inspection of camshaft and camshaft bearing ...... 9-54
Assembly of camshaft........................................... 9-55
Installation of camshaft ......................................... 9-56
Gear train layout ................................................... 9-57
Removal of timing gear ........................................ 9-58
Inspection of timing gear components .................. 9-59
Installation of timing gear...................................... 9-60
Overhaul of sub-idle gear (bearing case side) ...... 9-62
Inspection of installation status for each gear ...... 9-64
Valve System............................................................. 9-68
Part layout............................................................. 9-68
Overhaul of valve system...................................... 9-69
Adjustment of valve clearance .............................. 9-74

[S5LC0033E04] [0518CsCshWbYs]
9–2 ENGINE MECHANICAL

Cylinder Head
Part layout
JP30TCE090402001

SAPH30TCE0900001

1 Valve guide 4 Nozzle seat

2 Intake valve seat 5 Gasket*
3 Exhaust valve seat

*Parts not to be reused.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE MECHANICAL 9–3

SAPH30TCE0900002

1 Cylinder head assembly 6 Cylinder head cover

2 Camshaft housing 7 Head cover gasket*
3 Cylinder head gasket* 8 Oil filler cap
4 Camshaft housing gasket* 9 Pipe oil seal
5 Cylinder plug

*Parts not to be reused.

Tightening torque
A 59N˜m{600kgf˜cm, 44 lbf˜ft}+90q+90q E 28.5N˜m{290kgf˜cm, 21 lbf˜ft}
B 59N˜m{600kgf˜cm, 44 lbf˜ft} F 6N˜m{60kgf˜cm, 4 lbf˜ft}
C 28.5N˜m{290kgf˜cm, 21 lbf˜ft} G 30N˜m{305kgf˜cm, 22 lbf˜ft}
D 23N˜m{230kgf˜cm, 17 lbf˜ft}

Service procedure
Replacement procedure item

[S5LC0033E04] [0518CsCshWbYs]
9–4 ENGINE MECHANICAL

Replacement of cylinder head

JP30TCE090704001

1. Removal of cylinder head and head gasket

(1) Loosen the head bolts from outside to inside gradually (1/
4 turn for each) as shown in the order of the figure and
remove them.

SAPH30TCE0900003
(2) Remove the cylinder head using a special tool and hoist.
Figure is an Special tool : S0943–31070(09433–1070) Eye bolt
example of work.

NOTICE • If it is difficult to remove the cylinder head,

insert a chisel between the cylinder head and
the cylinder block, and move the chisel
vertically so that the contact surface may not
be damaged. Then, separate the cylinder
head.
SAPH30TCE0900004

2. Inspection of head bolt length

(1) Measure the underhead length of the head bolt (M12 only)
using vernier calipers. If it is beyond the service limit,
replace it with a new one.

Standard value (mm{in.}) Service limit (mm{in.})

Underhead length
126{4.9606 in.} 126.5{4.9803 in.}

SAPH30TCE0900005

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE MECHANICAL 9–5

3. Installation of head gasket and liquid gasket application

procedure
(1) Cut the rear end plate gasket to be flush with the surface
of the cylinder block upper surface using a scraper.
(2) Install the head gasket on the cylinder block and the
flywheel housing.

! CAUTION • Remove dirt, water or oil from the mounting

surfaces of the cylinder head and the cylinder
block before work.
• Never reuse the gasket. Otherwise, it may
damage the engine.
• The water hole seal ring of the head gasket is
susceptible to damage. Avoid contact with
hand or object.
Water hole seal ring
• Before installation of the head gasket, make
sure that there is no fall of or damage to the
seal ring.

SAPH30TCE0900006

(3) Apply appropriate amount of liquid gasket [Threebond

Application area of liquid gasket TB1211 (white) or equivalent] to the head gasket hole at
the joint surface between the cylinder block and the
The arrow
shape flywheel housing.
area is
different
from the ! CAUTION • Apply the liquid gasket so that the surface of
actual
shape. the liquid gasket may be raised on the head
gasket.

Application area of • Install the oil cooler within 20 minutes after

liquid gasket
application of the liquid gasket.
Liquid gasket
Cylinder head

Cylinder Flywheel Small

block housing

Rear end plate

Clearance

Too small

Clearance Clearance

Raised from upper

Section A - A surface

SAPH30TCE0900007

[S5LC0033E04] [0518CsCshWbYs]
9–6 ENGINE MECHANICAL

4. Installation of cylinder head

Figure is an (1) Clean the head bolt seat at the cylinder head upper
example of work. surface and the cylinder head lower surface.
(2) Apply engine oil to the head bolt seat and the bolt thread.
(3) Align the dowel pins of the cylinder block using a special
tool and hoist and mount the cylinder head.

! CAUTION • Before mounting the cylinder head, make

sure that there is no foreign matter in the
SAPH30TCE0900004
cylinder.
• When the cylinder head is mounted, be
careful for engagement between the cam idle
gear and the sub-idle gear. (Contact of gear
teeth with undue force may cause impact
mark or chipping, resulting in abnormal noise
or missing tooth.)

NOTICE • Mounting of the cylinder head with guide bolt

can prevent displacement of the liquid gasket.

Special tool : S0943–31070(09433–1070) Eye bolt

(4) Tighten head bolts M12 only in the order from the center
to outside.
Tightening torque : 59 N˜m {600 kgf˜cm, 44 lbf˜ft}

(5) After tightening M12 bolt, tighten the bolts again from the
center to outside.
Tightening torque : 59 N˜m {600 kgf˜cm, 44 lbf˜ft}

No. 1 to No. 26: M12 bolt

No. 27 to No. 29: M10 bolt
SAPH30TCE0900008

(6) Mark the heads of the head bolts (M12 only) using paint.
(7) Retighten the 90 deg head bolts (M12 only) in the same
order in (5).
(8) Retighten the 90 deg head bolts (M12 only) in the same
order.
(9) Make sure that all marks face the same direction.
Paint mark
! CAUTION • If a bolt is turned excessively in retightening,
do not loosen it.

SAPH30TCE0900009

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE MECHANICAL 9–7

(10) Tighten remaining head bolts (M10) in the order in the

figure.

Tightening torque : 59 N˜m {600 kgf˜cm, 44 lbf˜ft}

SAPH30TCE0900010

[S5LC0033E04] [0518CsCshWbYs]
9–8 ENGINE MECHANICAL

Replacement of camshaft housing

JP30TCE090704002

1. Removal of camshaft housing

(1) Remove bolts and remove the camshaft housing.

SAPH30TCE0900011

2. Installation of camshaft housing

(1) Install new gasket and camshaft housing.

Tightening torque : 23 N˜m {230 kgf˜cm, 17 lbf˜ft}

! CAUTION • Refer to the figure for the mounting bolt

position.

SAPH30TCE0900012

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE MECHANICAL 9–9

Liquid gasket application procedure for

cylinder plug (only when cylinder plug is
removed) JP30TCE090704003

1. Advance preparation
(1) Remove liquid gasket from the cylinder plug and the
camshaft housing.

2. Installation of the cylinder plug

(1) Apply the liquid gasket [Threebond TB1207B (black) or
equivalent] to the semi-circular areas at the front/rear
ends of the camshaft housing and install the cylinder plug.

{0.2362in.} Liquid gasket

SAPH30TCE0900013

(2) Tighten the Torx bolt.

Tightening torque : 6 N˜m {60 kgf˜cm, 4 lbf˜ft}

SAPH30TCE0900014

! CAUTION • Be sure to wipe protruding liquid gasket.

Area not applied with Cylinder plug
liquid gasket
• Make sure that the cylinder plug is seated
without inclination to the front or back.

Wipe Faulty Good

SAPH30TCE0900015

[S5LC0033E04] [0518CsCshWbYs]
9–10 ENGINE MECHANICAL

Replacement of head cover

JP30TCE090704004

1. Installation of head cover

(1) Remove liquid gasket near the side of the cylinder plug at
the front/rear ends of the camshaft housing, using a
scraper.

! CAUTION • If there is oil leak from the cylinder plug, do

not remove the cylinder plug.

SAPH30TCE0900016

(2) Wipe dirt (including liquid gasket) and oil on the joint
surfaces of the head cover and the camshaft housing.
Install a new gasket on the head cover.

Head cover shape is a representative model.

SAPH30TCE0900017

(3) Apply the liquid gasket [Threebond TB1207B(black) or

equivalent] near the side of the cylinder plug immediately
before installation of the head cover.

! CAUTION • Apply the liquid gasket at the width of 1.5 to

2.5 mm{0.0591 to 0.0984 in.}
• Install the oil cooler within 20 minutes after
application of the liquid gasket.
• Never apply the liquid gasket to the upper
SAPH30TCE0900018 semi-circle of the cylinder plug.

(4) Put the head cover on the camshaft housing and tighten
Head cover Bolt bolts.
Silent block
Tightening torque : 28.5 N˜m {290 kgf˜cm, 21 lbf˜ft}

NOTICE • Silent block the rubber is attached to the

Head cover
spacer
gasket Head cover lower Overhaul item

surface

Camshaft housing
SAPH30TCE0900019

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE MECHANICAL 9–11

Overhaul of cylinder head

JP30TCE090702001

1. Cleaning of cylinder head

(1) Remove carbon or other deposit using a scraper.

(2) Clean the cylinder head.

! CAUTION • To remove carbon or other deposit, do not

damage the lower surface of the cylinder
head.

SAPH30TCE0900020

2. Replacement of valve guide

Intake Exhaust
(1) Remove the valve stem seal.
(2) Remove the valve guide using a brass bar or press.
(3) When a new valve guide is assembled, do not pry the end
in assembly and press fit using a special tool.
Special tool : S0947–11520(09471–1520) Guide

! CAUTION • In press fit, be careful not to damage the

Lower surface of cylinder head
valve stem at the upper/lower ends of the
SAPH30TCE0900021
guide.
• In press fit, be sure to apply engine oil to the
circumference of the valve guide.

3. Replacement of valve seat

! CAUTION • The valve seat replacement procedure below

may damage the cylinder head depending on
the case. It is recommended that a request for
replacement be made to a machining vendor.

(1) If the valve seat is replaced, use an out-of-use valve.

Backing Valve seat After cutting three pieces from the valve circumference,
metal
weld them to the valve seat.

! CAUTION • Apply grease to protect the cylinder head

lower surface from welding spatter before
Electric welding
Valve work.
Cut three areas
from here. (2) Put a backup metal (e.g. brass bar) at the valve stem
head and pull out the valve seat using a press.
SAPH30TCE0900022
(3) Remove welding spatter or dirt on the valve seat surface.

[S5LC0033E04] [0518CsCshWbYs]
9–12 ENGINE MECHANICAL

(4) Heat the cylinder head to approx. 80 to 100 qC {176 to 212

qF} and strike the cooled valve seat into the mounting area
of the cylinder head.

SAPH30TCE0900023

(5) Apply small amount of lapping compound to the contact

surface between the valve and the valve seat.

(6) Strike gently while turning the valve using a special tool
for adjustment.
Special tool : S0943–11020(09431–1020)
Valve lapping tool

SAPH30TCE0900024

4. Replacement of nozzle seat

(1) Tap the nozzle seat from the cylinder head lower part.
Then, put an appropriate bolt inside.
(2) Hit the bolt head using a hammer and pull out the nozzle
seat toward the the cylinder head upper part.
(3) Remove the O-ring from the cylinder head.

! CAUTION • After pulling out the nozzle seat, be sure to

remove deposit such as remaining liquid
SAPH30TCE0900025 gasket or dirt.

(4) After attaching a new O-ring into the nozzle seat hole of
Cylinder head the cylinder head, apply the liquid gasket [Threebond
O-ring
TB1211 (white) or equivalent] at the lower part of a new
nozzle seat and assemble it on the cylinder head.

Nozzle sheet ! CAUTION • Be sure to replace the O-ring with a new part.
Reuse may cause water leak or gas leak,
resulting in overheat or crack of the cylinder
head.
SAPH30TCE0900026

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE MECHANICAL 9–13

(5) Clamp the nozzle seat using a special tool.

Bar Nozzle seat
Special tool : S0947-21210 (09472–1210) Bar
SN441-00610 (9800–06100) Steel ball

Cylinder
Head

Steel ball

Stamp out and clamp

SAPH30TCE0900027

5. Inspection of cylinder head

(1) Inspection of cylinder head distortion

a. Measure distortion of the cylinder head lower surface
and the manifold mounting surface using a ruler.

Standard value (mm{in.}) Service limit (mm{in.})

Longitudinal direction
0.2{0.0079}
0.06{0.0024}
Lateral direction
0.2{0.0079}
0.03{0.0012}

b. If the measurement value is beyond the service limit,

replace it.

! CAUTION • Repair of the lower surface by grinding can

change backlash of the timing gear. Do not
grind it.

SAPH30TCE0900028

(2) Inspection of cylinder head crack

a. With dye penetrant test method (red check), make sure
that there is no crack or damage in the cylinder head.
Setup layout
Layout

[S5LC0033E04] [0518CsCshWbYs]
9–14 ENGINE MECHANICAL

Cylinder Block
Part layout
JP30TCE090402002

SAPH30TCE0900029

1 Cooling jet 2 Cylinder liner

Tightening torque
A 69N˜m{700kgf˜cm, 51 lbf˜ft}+90q+45q B 22N˜m{220kgf˜cm, 16 lbf˜ft}
Service procedure
Overhaul item

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE MECHANICAL 9–15

Overhaul
JP30TCE090702002

1. Replacement of cylinder liner

(1) Put match marks on the flange surfaces of the cylinder

block and the cylinder liner using a oil based marker.

! CAUTION • Store removed cylinder liners for each

Match mark cylinder number.
• Never provide match marks with a punch.

SAPH30TCE0900030

(2) Pull out the cylinder liner toward the cylinder block upper
part using a special tool.

Special tool : S0942-02100(09420-2100)

Cylinder liner puller

! CAUTION • Be careful for handling of the cylinder liner.

Do not reuse the cylinder liner which has
been dropped.

SAPH30TCE0900031
• Do not touch the cooling jet during work.

(3) Apply engine oil to the inner bore of the cylinder block.

(4) Align the match mark of the cylinder liner with that of the
cylinder block. Install the cylinder liner using a special tool.
Special tool : S0947–11490(09471–1490) Guide

SAPH30TCE0900032

[S5LC0033E04] [0518CsCshWbYs]
9–16 ENGINE MECHANICAL

! CAUTION • When a new cylinder liner is installed, install

Liner identification mark
the cylinder liner with the same identification
mark (A, B, C) stamped on the cylinder block.
• The example in the figure shows that the #1
cylinder is a liner of B.

Engine type stamp Example:

Front of engine
SAPH30TCE0900033

$
#$%˴
OCTMKPIRQUKVKQP

SAPH30TCE0900034

2. Inspection of protrusion at cylinder liner flange

(1) Fix the cylinder liner using a special tool.

Tightening torque : 9.8 N˜m {100 kgf˜cm, 7 lbf˜ft}
(2) Measure protrusion of the flange using a dial gauge.
Special tool : S0942–02100(09420–2100) Cylinder
liner puller

0.01 - 0.08
Standard value (mm{in.})
SAPH30TCE0900035 {0.0004 - 0.0031}

3. Inspection and adjustment of cooling jet

Check bolt
(1) Remove the standard oil check valve and install the
cooling jet on the cylinder block using a special tool.
Special tool : SZ910–24098(9001–24262) Check bolt

Cooling jet

SAPH30TCE0900036

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE MECHANICAL 9–17

(2) Connect the injection test oil hose from the lower part of
the cylinder block to the special tool check bolt.

! CAUTION • Use new engine oil for injection of oil.

Check bolt

Oil hose

SAPH30TCE0900037

(3) Set a special tool on the cylinder block.

SST Special tool : 09219-E4010 Gauge

Cylinder block

SAPH30TCE0900038

(4) Inject oil from the nozzle of the cooling jet at the hydraulic
Oil injection unit (example)
Pressure pressure of 196kPa{2kgf/cm2, 28lbf/in.2}.
Regulator
Oil
Hose NOTICE • Refer to the drawing for the oil injection unit.
Air tank
(Oil tank) Compressed
Air gauge air

Air hose

To cooling jet Valve

SAPH30TCE0900039

(5) When the injection center hits within the specified line of
the gauge, it is considered normal.
Injection Gauge target circle
! CAUTION • Oil is susceptible to combustion due to
spread. Do not use fire near around.
• Work at well ventilated place.

Faulty Faulty Normal Normal

(6) Make sure that the jet position check gauge hole at the
tool assembly.
(7) If injection does not hit the target circle, replace a new
SAPH30TCE0900040
cooling jet for reinspection.
(8) Remove the check bolt and install the cooling jet on the
cylinder block using the genuine oil check valve.
Tightening torque : 22 N˜m {220 kgf˜cm, 16 lbf˜ft}
(9) After assembly of the piston, make sure that the cooling
jet does not interfere with the piston at the piston bottom
dead center.

[S5LC0033E04] [0518CsCshWbYs]
9–18 ENGINE MECHANICAL

4. Inspection of cylinder block

(1) Inspection of cylinder block distortion

a. Measure distortion on the cylinder block using a ruler.

Standard value (mm{in.}) Service limit (mm{in.})

Longitudinal direction
0.2{0.0079}
0.06{0.0024}
Lateral direction
0.2{0.0079}
0.03{0.0012}

b. If the measurement value is beyond the service limit,

replace it.

! CAUTION • Repair of the upper surace by grinding can

change backlash of the timing gear. Do not
grind it.

SAPH30TCE0900041

(2) Inspection of cylinder block crack

a. With dye penetrant test method (red check), make sure
that there is no crack or damage in the cylinder block.
Setup layout
Layout

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE MECHANICAL 9–19

Timing Gear Cover and Flywheel Housing

Part layout
JP30TCE090402003

SAPH30TCE0900042

1 Flywheel housing 4 End plate

2 Gasket* 5 Rear oil seal*
3 Flywheel housing stay

*Parts not to be reused.

Tightening torque
A 55N˜m{560kgf˜cm, 41 lbf˜ft} D 196N˜m{2,000kgf˜cm, 145 lbf˜ft}
B 97N˜m{990kgf˜cm, 72 lbf˜ft} E 36N˜m{370kgf˜cm, 27 lbf˜ft}
C 171.5N˜m{1,750kgf˜cm, 127 lbf˜ft}

[S5LC0033E04] [0518CsCshWbYs]
9–20 ENGINE MECHANICAL

SAPH30TCE0900043

1 Oil seal retainer 2 Front oil seal*

*Parts not to be reused.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE MECHANICAL 9–21

Service procedure
Overhaul item

Replacement of flywheel housing

JP30TCE090702003

1. Removal of flywheel housing

(1) Remove bolts and remove the flywheel housing.

! CAUTION • Remove bolts fixing the flywheel housing

from the cylinder block.
• Engines shipped before February 2012 are
equipped with Torx head bolts in the parts
marked with a star (✩). Use an E14 Torx
wrench and remove the bolts.
SAPH30TCE0900044

Shipped before Shipped after

February 2012 March 2012

SAPH30TCE0900045

2. Installation of flywheel housing

Liquid gasket
(1) Remove contamination from the joint surfaces of the
flywheel housing and the rear end plate using a scraper.
liquid
Gasket (2) Apply the liquid gasket [Threebond TB1207D (silver) or
equivalent] to the flywheel housing as shown in the figure.

! CAUTION • Apply it continuously.

• Apply the liquid gasket at the width of 1.5 to
2.5 mm{0.0591 to 0.0984 in.}.
SAPH30TCE0900046
• Install the oil cooler within 20 minutes after
application of the liquid gasket.

(3) Install the flywheel housing on the cylinder block with

B bolts.
A A
B C Tightening torque :
196 N˜m {2,000 kgf˜cm, 145 lbf˜ft} (Area A)
C
C 36 N˜m {370 kgf˜cm, 27 lbf˜ft} (Area B)
C
A A 55 N˜m {560 kgf˜cm, 41 lbf˜ft} (Area C)
A
A ! CAUTION • Tighten bolts fixing the flywheel housing from
the cylinder block.
SAPH30TCE0900047 • Engines shipped before February 2012 are
equipped with Torx head bolts in the parts
marked with a star (✩). Use an E14 Torx
wrench and tighten the bolts.

[S5LC0033E04] [0518CsCshWbYs]
9–22 ENGINE MECHANICAL

Replacement of rear end plate

JP30TCE090702004

1. Removal of rear end plate

(1) Remove bolts.

(2) Remove the Torx bolt using a special tool.
Special tool : S0941–11300(09411–1300)
Socket wrench

SAPH30TCE0900048

2. Installation of rear end plate

(1) Install the rear end plate and a new gasket with bolts.

! CAUTION • Make sure that there is no dirt or foreign

matter on the installation surface of the
cylinder block and the screw holes.

(2) Apply sealant (Super 5M or equivalent) to the thread of

the Torx bolt.
(3) Install the Torx bolt using a special tool.
Special tool : S0941–11300(09411–1300)
Socket wrench

Tightening torque : 55 N˜m {560 kgf˜cm, 41 lbf˜ft}

SAPH30TCE0900048

(4) Cut the rear end plate gasket with a scraper to be flush to
Gasket the upper/lower surfaces of the cylinder block.
Cylinder block Rear end plate

Flywheel housing

SAPH30TCE0900049

Replacement procedure item

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE MECHANICAL 9–23

Replacement of crankshaft front oil seal

JP30TCE090704005

1. Removal of crankshaft front oil seal

(1) Install the plate of the special tool oil seal puller on the
crankshaft using two crankshaft damper mounting bolts.

Special tool : S0942–01731(09420–1731)

Oil seal puller

SAPH30TCE0900050

(2) Hook the special tool oil seal puller with the tab of the
crankshaft front oil seal and install the hook on the plate of
the special tool oil seal puller with accompanying bolts.

SAPH30TCE0900051

(3) Remove two bolts which installed the plate of the special
tool oil seal puller on the crankshaft.

(4) Attach the accompanying center bolt to the special tool oil
seal puller and tighten it. Pull out the crankshaft front oil
seal.

SAPH30TCE0900052

2. Installation of crankshaft front oil seal

Guide
(1) Insert a new crankshaft oil seal into the guide of the oil
seal press.
Special tool : S0940–71030(09407–1030)
Oil seal press

! CAUTION • Be careful for front/rear directions of the

Oil seal crankshaft front oil seal. (The felt surface is at
the crankshaft damper side.)
SAPH30TCE0900053

[S5LC0033E04] [0518CsCshWbYs]
9–24 ENGINE MECHANICAL

(2) Remove contamination from the joint surface of the

crankshaft front oil seal and the cylinder block.

(3) Apply small amount of engine oil to the fitting area

(crankshaft and oil seal retainer side) of the crankshaft
front oil seal.
(4) Install the oil seal press guide inserting a new crankshaft
front oil seal with accompanying guide bolts on the
crankshaft.

SAPH30TCE0900054

(5) Align the oil seal press hole to the guide bolt and insert
the oil seal press.

(6) Attach the accompanying center bolt to the oil seal press
and tighten it until stop. Press fit the crankshaft front oil
seal.

SAPH30TCE0900055

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE MECHANICAL 9–25

Replacement of crankshaft rear oil seal

JP30TCE090704006

1. Removal of crankshaft rear oil seal

(1) Install the plate of the special tool oil seal puller on the
crankshaft using two flywheel assembly mounting bolts.
Special tool : S0942–01742 (09420–1742)
Oil seal puller

! CAUTION • Align the large hole of the plate with the collar
dowel of the crankshaft.

SAPH30TCE0900056

(2) Hook the oil seal puller with the tab of the crankshaft rear
oil seal and install the hook on the plate of the oil seal
puller with accompanying bolts.

(3) Remove two bolts which installed the plate of the oil seal
puller on the crankshaft.

SAPH30TCE0900057

(4) Attach the accompanying center bolt to the oil seal puller
and tighten it. Pull out the crankshaft rear oil seal.

SAPH30TCE0900058

2. Installation of crankshaft rear oil seal

Guide of oil seal press (1) Insert a new crankshaft rear oil seal into the guide of the
oil seal press.
Special tool : S0940–71040 (09407–1040)
Oil seal press

! CAUTION • Be careful for front/rear directions of the

Rear oil seal crankshaft rear oil seal. (The felt surface is at
the flywheel side.)
SAPH30TCE0900059

[S5LC0033E04] [0518CsCshWbYs]
9–26 ENGINE MECHANICAL

(2) Remove contamination from the joint surface of the

crankshaft rear oil seal and the flywheel housing

(3) Apply small amount of engine oil to the fitting area

(crankshaft and flywheel housing side) of the crankshaft
rear oil seal.
(4) Install the oil seal press guide inserting a new crankshaft
rear oil seal with accompanying guide bolts on the
crankshaft.

SAPH30TCE0900060 ! CAUTION • Align the large hole of the guide with the
collar dowel of the crankshaft.

(5) Align the oil seal press hole to the guide bolt and insert
the oil seal press.

SAPH30TCE0900061

(6) Attach the accompanying center bolt to the oil seal press
and tighten it until stop. Press fit the crankshaft rear oil
seal.
Setup layout
Layout

SAPH30TCE0900062

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE MECHANICAL 9–27

Main Moving Parts

Part layout
JP30TCE090402004

SAPH30TCE0900063

1 Thrust bearing 6 Crankshaft gear

2 Main bearing 7 piston ring
3 Connecting rod Bearing 8 Retainer ring*
4 Connecting rod assembly 9 Piston pin
5 Crankshaft 10 Piston

*Parts not to be reused.

Tightening torque
A 69N˜m{700kgf˜cm, 51 lbf˜ft}+90q+45q

[S5LC0033E04] [0518CsCshWbYs]
9–28 ENGINE MECHANICAL

SAPH30TCE0900064

1 Crankshaft damper 3 Ring gear

2 Flywheel assembly 4 Crankshaft pulley

*Parts not to be reused.

Tightening torque
A 186N˜m{1,900kgf˜cm, 137 lbf˜ft} B 118N˜m{1,200kgf˜cm, 87 lbf˜ft}

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE MECHANICAL 9–29

Service procedure
Overhaul item

Replacement of piston and connecting rod

JP30TCE090702005

1. Removal of piston
Figure is an
example of work. (1) Remove bolts and remove the connecting rod cap.

! CAUTION • Insert a large flat tip screwdriver into the

flywheel gear from the flywheel housing
inspection hole to prevent turning of the
crankshaft.
• Store removed connecting rod cap for each
cylinder number so that combinations of the
SAPH30TCE0900065 connecting rod and the connecting rod cap
may not be changed.

(2) Remove carbon on the cylinder liner inner surface with a

scraper or a sand paper (No. 150 or so) in the
circumferential direction.

! CAUTION • Do not damage parts lower than the carbon

deposit area.

(3) Fix the cylinder liner with bolts and a plate.

SAPH30TCE0900066

(4) Hit the connecting rod from underneath the engine using
a handle of a hammer. Remove the piston together with
the connecting rod.

! CAUTION • Store removed pistons and connecting rods

for each cylinder number.
• Be careful not to touch the cooling jet.

SAPH30TCE0900067

NOTICE • In removing the piston, rotate the connecting

Cooling jet
rod as shown in the figure. Do not bend the
cooling jet.

SAPH30TCE0900068

[S5LC0033E04] [0518CsCshWbYs]
9–30 ENGINE MECHANICAL

2. Disassembly of piston and connecting rod

(1) Remove the retainer ring using snap ring pliers.

(2) Remove the piston pin using the brass bar and disconnect
the piston from the connecting rod.

SAPH30TCE0900069

(3) Remove the piston ring using a special tool.

Special tool : S0944–21011(09442–1011)

Piston ring expander

! CAUTION • Since the piston ring is susceptible to

damage, be careful for handling.
• Store piston rings for each cylinder number.
• Store the piston rings so that the upper and
SAPH30TCE0900070 lower surfaces may be identified.

3. Assembly of piston and connecting rod

"0" mark position Piston
(1) Install the piston on the connecting rod so that the "0"
mark on the piston may be opposite to the match mark
Exhaust side Intake side
stamp on the connecting rod
(2) Install a new retainer ring using a snap ring pliers.
Oil hole
! CAUTION • Make sure that there is no backlash in the
Match mark retainer ring.
stamp

SAPH30TCE0900071

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE MECHANICAL 9–31

(3) Face the side with the piston ring identification print
upward and install in the order of the oil ring, second ring
and top ring using a special tool.

NOTICE • The identification print is present only on the

secondary ring and the top and bottom of the
top ring and the oil ring are not identified.
Top ring Second ring Oil ring
Upper surface
Special tool : S0944–21011(09442–1011)
Piston ring expander
Lower surface
(4) Connect the joint of the coil expander and fit the oil ring
Oil ring joint Clearance
inside the ring. Offset the coil expander joint with the ring
joint by 180 deg for installation.
(5) Allocate the joints of the piston ring with uniform intervals
Coil expander Ring
as shown in the figure.
Second ring

Oil ring Top ring

SAPH30TCE0900072

4. Installation of piston and connecting rod

Oil hole
Concave shape (1) Allocate the joints of the piston ring with uniform intervals
as shown in the figure.
Oil hole
(2) Install the connecting rod bearing to suit concave shape of
Bearing
the connecting rod.

! CAUTION • Make sure that the oil hole of the connecting

rod bearing is aligned with the oil hole of the
Connecting rod
connecting rod.
SAPH30TCE0900073

(3) Apply engine oil to the piston, cylinder liner and

connecting rod bearing and compress the piston ring
using a special tool.

Special tool : S0944–11370(09441–1370)

Piston ring holder

! CAUTION • Make sure that there is no deformation or

damage to the special tool piston ring holder.

SAPH30TCE0900074

[S5LC0033E04] [0518CsCshWbYs]
9–32 ENGINE MECHANICAL

(4) Insert the piston carefully so that the connecting rod may
not come in contact with the cooling jet.

! CAUTION • Face the "0" mark on the piston toward the

exhaust side for insertion.
• Set the crankshaft of the cylinder as the top
dead center for assembly.
• Do not damage the cylinder liner, crankshaft
and cooling jet during work.
SAPH30TCE0900075

(5) Install the connecting rod bearing to suit concave shape of

the connecting rod cap.
Cap

Bearing

SAPH30TCE0900076

(6) Align the match mark of the connecting rod cap with that
of the connecting rod and fix it with a dowel pin.
Match mark
Stamp ! CAUTION • Do not change the combination between the
connecting rod and the connecting rod cap.
1234 1234

SAPH30TCE0900077

(7) Measure the underhead length of the connecting rod bolt

using a vernier calipers. If it is out of the service limit,
replace it with a new one.

Standard value (mm{in.}) Service limit (mm{in.})

Underhead length
67.0{2.6378} 68.0{2.6772}

(8) Apply engine oil to the connecting rod bolt thread and the
seat and install it on the connecting rod.
SAPH30TCE0900078

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE MECHANICAL 9–33

(9) Tighten the connecting rod bolt and mark the bolt head in
Paint mark the same direction with paint.

Connecting rod cap Tightening torque : 69 N˜m {700 kgf˜cm, 51 lbf˜ft}

(10) Retighten the connecting rod bolt 90 q.
(11) Retighten the connecting rod bolt further 45 q.
45°
90° (12) Make sure that all marks are in the same direction.

! CAUTION • If a bolt is turned excessively in retightening,

do not loosen it.
SAPH30TCE0900079

[S5LC0033E04] [0518CsCshWbYs]
9–34 ENGINE MECHANICAL

Inspection procedure item

Inspection of piston and connecting rod

JP30TCE090703001

1. Inspection of piston clearance

(1) Measure the inner diameter of the cylinder liner sliding
surface using a cylinder gauge.

Standard value (mm{in.}) Service limit (mm{in.})

112{4.4094} 112.15{4.4154}

SAPH30TCE0900080

(2) Measure the piston outer diameter using a micrometer.

! CAUTION • The measuring position is 23 mm{0.9055 in.}

above the piston lower end and square to the
pin hole.

Standard value (mm{in.}) 111.9r0.008{4.4055r0.0003}

SAPH30TCE0900081

(3) Calculate the difference between the inner diameter of the

cylinder liner and the outer diameter of the piston. If it is beyond
the standard value, replace the cylinder liner and the piston.

Standard value (mm{in.}) 0.053 - 0.077{0.0021 - 0.0030}}

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE MECHANICAL 9–35

2. Inspection of clearance between piston ring and ring

groove
(1) Measure the piston ring width (B width) using a
micrometer. If it is beyond the service limit, replace the
piston ring.

Measuring Standard value Service limit

item (mm{in.}) (mm{in.})

Top ring 2.948{0.1161} 2.848{0.1121}

Second ring 2{0.0787} 1.9{0.0748}

SAPH30TCE0900082
Oil ring 4{0.1574} 3.9{0.1535}

(2) Measure the piston ring groove using a thickness gauge.

If it is out of the service limit, replace the piston.

Measuring Standard value Service limit

item (mm{in.}) (mm{in.})

Top ring groove Tapered shape —

Second ring groove 2.0{0.0787} 2.2{0.0866}

Oil ring groove 4.0{0.1574} 4.1{0.1614}

SAPH30TCE0900083

3. Inspection of piston ring joint clearance

(1) Use the piston to insert the piston ring horizontally to the
cylinder liner until it passes through the sliding surface.
(2) Measure the piston ring joint clearance using a thickness
Cylinder liner gauge. If it is out of the service limit, replace the piston
ring.

Measuring Service limit

Standard value (mm{in.})
item (mm{in.})
Piston Ring
0.30 - 0.40
Top ring 1.5{0.0591}
{0.0118 - 0.0157}

Second ring 0.75 - 0.90 {0.0295 - 0.0354} 1.5{0.0591}

SAPH30TCE0900084

0.15 - 0.30
Oil ring 1.2{0.0472}
{0.0059 - 0.0118}

[S5LC0033E04] [0518CsCshWbYs]
9–36 ENGINE MECHANICAL

4. Inspection of piston pin

(1) Measure the outer diameter of the contact area of the
piston pin with the piston boss using a micrometer.

Standard value (mm{in.}) Service limit (mm{in.})

37 {1.4567} 36.96{1.4551}

SAPH30TCE0900085

(2) Measure the piston boss inner diameter using a cylinder gauge.

Standard value (mm{in.}) Service limit (mm{in.})

37 {1.4567} 37.05{1.4587}

(3) Calculate the difference between the outer diameter of the

piston pin contact area with the piston boss and the inner
diameter of the piston boss. If it is out of the service limit,
replace the piston pin or piston.
SAPH30TCE0900086

Standard value (mm{in.}) Service limit (mm{in.})

0.011 - 0.032
0.05{0.0020}
{0.0005 - 0.0012}

(4) Using the cylinder gauge to measure the inner diameter of

the connecting rod bush.

Standard value Operation limit

(mm {in.}) (mm {in.})

37 {1.4567} 37.1 {1.4606}

SAPH30TCE0900087

(5) Calculate the difference between the inner diameter of the

connecting rod small end and the outer diameter of the
piston pin, and if it is beyond the service limit, replace the
connecting rod or the bush.

Standard value Operation limit

(mm {in.}) (mm {in.})

0.035L-0.056
0.08 {0.0031}
{0.0014L-0.0022}

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE MECHANICAL 9–37

Replacement procedure item

Replacement of connecting rod bushing

JP30TCE090704007

1. Removal of connecting rod bushing

(1) Put the special tool press sub-assembly together with the
Press
special tool guide nut and fix them using the special tool
Sub-assembly wing nut.
Wing nut

Special tool : S0948–11130 (09481–1130) Guide

Guide
S0940–21530 (09402–1530)
Press sub-assembly
SL271–01036 (9233-10360) Wing nut

! CAUTION • Face "H" mark of the guide upward for

SAPH30TCE0900088
assembly.
• Assemble it on a level table and make sure
that the lower end of the guide and the press
sub-assembly is flat.

(2) With the large end bearing removed, assemble the

connecting rod and put it on the assembled special tool.

SAPH30TCE0900089

(3) Install the special tool spindle on the bushing of the

connecting rod.

Groove
Spindle
Special tool : S0940–21540(09402–1540) Spindle

Connecting rod ! CAUTION • Align the press sub-assembly groove with the
special tool spindle groove for installation.
Press
Sub-assembly

SAPH30TCE0900090

[S5LC0033E04] [0518CsCshWbYs]
9–38 ENGINE MECHANICAL

(4) Remove the bushing of the connecting rod using a press.

! CAUTION • Move the press slowly.

SAPH30TCE0900091

(5) Check the small end of the connecting rod with the bush
removed, and see if there is deformation to the inner
diameter or scratches or dents on the inner surface.

! CAUTION • The presence of deformation, scratches or

dents indicates that the bush was not
properly installed.

(6) Chamfer one side of the connecting rod small end

uniformly according to the figure.
Chamfer
! CAUTION • Remove burr completely.
• After chamfering, remove dirt from the inner
surface at the small end and from the oil hole.

SAPH30TCE0900092

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE MECHANICAL 9–39

2. Installation of connecting rod bushing

(1) Install a new bushing on the special tool spindle and
install the special tool guide and the special tool bolt.
Groove
Special tool : S0940–21540 (09402–1540) Spindle
Spindle
S0948–11540 (09481–1540) Guide
SH691–20825 (9191–08252) Bolt
Bushing

Guide Tightening torque :

5 - 6 N˜m {50 - 70 kgf˜cm, 3.5 - 4 lbf˜ft}
Bolt

SAPH30TCE0900093
! CAUTION • Align grooves of the special tool guide and
the special tool spindle for installation.
• Make sure that the edge of the special tool
spindle and the special tool guide is in close
contact.

NOTICE • Using dry ice to cool the bush to -10qC (14qF)

before assembling it will improve the quality
of the assembled bush. Also, work quickly so
that the bush does not warm up during
assembling work.

(2) Align the connecting rod oil hole with the bushing oil hole
assembled on the special tool. Make sure that the groove
of the special tool spindle is in alignment with the groove
of the special tool press sub-assembly.
Groove
Oil hole ! CAUTION • Place the connecting rod so that the chamfer
side of the connecting rod small end inner
diameter may be the bushing side
• Apply engine oil to the inner diameter surface
SAPH30TCE0900094 of the connecting rod.

(3) Install the bushing on the connecting rod using a press.

! CAUTION • After press-fitting the bush, make sure there

are no machine burrs on the bush.

SAPH30TCE0900095

[S5LC0033E04] [0518CsCshWbYs]
9–40 ENGINE MECHANICAL

(4) Insert a rod with the diameter of 4 mm {0.1575 in.} from

the oil hole at the connecting rod large end and make sure
that it goes through the oil hole at the small end.

NOTICE • Displacement of oil holes may cause

insufficient lubrication, resulting in seizure.

SAPH30TCE0900096

(5) Insert a new piston pin and check if there is no drag or

backlash.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE MECHANICAL 9–41

Replacement of crankshaft
JP30TCE090704008

1. Removal of crankshaft

(1) Remove the main bearing cap and the crankshaft bearing.
Remove the crankshaft using a hoist.

! CAUTION • Since the part is heavy, be careful for

handling.
• Store removed main bearing caps and
crankshaft bearings for each cylinder number.

SAPH30TCE0900097

2. Installation of crankshaft

(1) Face the groove side (front) of the thrust bearing toward
the crankarm and the part number side (back) toward the
main bearing cap or the cylinder block. Install it on the
cylinder block and the main bearing cap.

! CAUTION • To prevent falling in assembly, apply engine

oil or grease to the back of the thrust bearing.

(2) Install the main bearing on the cylinder block and each
bearing cap.

! CAUTION • Assemble the bearing with oil hole on the

cylinder block and assemble the bearing
without oil hole on the cap.
• Apply new engine oil to the sliding surfaces of
each bearing.

(3) Align the crankshaft with the cylinder block.

SAPH30TCE0900098

(4) Align the main bearing cap which has the thrust bearing
Stamp number and the main bearing with the cylinder block.
Front of engine

! CAUTION • The pentagon mark on the main bearing cap

should face the front of the vehicle. Align in
1 2 3 4 5 6 7 the order of 1, 2, 3, 4, 5, 6 and 7 from the
front.
• Check the stamp number of each main
Stamp number bearing cap with the stamp number of the
SAPH30TCE0900099 cylinder block.

[S5LC0033E04] [0518CsCshWbYs]
9–42 ENGINE MECHANICAL

(5) Measure the underhead length of the bearing cap bolt

using a vernier calipers. If it is out of the service limit,
replace it with a new one.

Standard value (mm{in.}) Service limit (mm{in.})

Underhead length
106.8{4.2047} 108{4.2520}

SAPH30TCE0900078

(6) Apply engine oil to the bolt seat and the bolt thread of the
bearing cap bolt.

(7) Tighten the bearing cap bolt according to the sequence in

2 4 6 8 10 12 14 the figure.
Tightening torque : 69 N˜m {700 kgf˜cm, 51 lbf˜ft}
1 3 5 7 9 11 13
(8) Loosen the bearing cap fixing the thrust bearing and hit
the crankshaft gently at the front/rear end using a plastic
Front of engine hammer.
(9) Loosen all bearing cap bolts.
SAPH30TCE0900100
(10) Tighten the bearing cap bolt as in (7).
Tightening torque : 69 N˜m {700 kgf˜cm, 51 lbf˜ft}
(11) Mark bearing cap bolt heads in the same direction with
paint.
(12) Tighten 90 deg (1/4 turn) with the same order as in (7).
(13) Retighten 45 deg (1/8 turn) as in (7).
Paint mark
(14) Make sure that all paint marks are in the same direction.

! CAUTION • If it is excessively retightened, do not loosen

it.
45ࠑ
90ࠑ
(15) After tightening, hit the front/rear ends of the crankshaft
gently with a plastic hammer for initial fit.

SAPH30TCE0900101 ! CAUTION • Make sure that the crankshaft turns smoothly.

• Measure the end play of the crankshaft and
make sure that it is within the standard value.

Standard value Repair limit Service limit

(mm{in.}) (mm{in.}) (mm{in.})

0.05 - 0.270
0.5{0.0197} 1.270{0.0500}
{0.0020 - 0.0106}

Inspection procedure item

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE MECHANICAL 9–43

Inspection of crankshaft
JP30TCE090703002

1. Inspection of end play

(1) Measure the end play of the crankshaft using a dial
gauge. If it is beyond the repair limit, replace the thrust
bearing. If it is beyond the service limit, replace the
crankshaft.

Standard value Repair limit Service limit

(mm{in.}) (mm{in.}) (mm{in.})

0.05 - 0.270
SAPH30TCE0900102 0.5{0.0197} 1.270{0.0500}
{0.0020 - 0.0106}

NOTICE • Standard width of thrust

bearing2.5mm{0.0984in.}

2. Inspection of rotation runout

Figure is an
example of work. (1) Measure the crankshaft rotation runout using a dial
gauge. If it is beyond the repair limit, replace the
crankshaft.

Standard value (mm{in.}) Repair limit (mm{in.})

0 - 0.1{0 - 0.0039} 0.15{0.0059}

SAPH30TCE0900103

3. Inspection of journal wear

Measure two (1) Measure the outer diameter of the crankshaft journal
places. using a micrometer. If it is faulty, replace the crankshaft.
90ࠑ

Standard value (mm{in.}) Service limit (mm{in.})

80.0{3.1496} 79.3{3.1221}

SAPH30TCE0900104

(2) Measure the crankshaft center journal width using a

Figure is an vernier calipers. If it is out of the service limit, replace the
example of work.
crankshaft.

Standard value (mm{in.}) Service limit (mm{in.})

36{1.4173} 37.0{1.4567}

SAPH30TCE0900105

[S5LC0033E04] [0518CsCshWbYs]
9–44 ENGINE MECHANICAL

4. Inspection of crankshaft oil clearance

(1) Measure the outer diameter of the crankshaft journal

using a micrometer.
90

Standard value (mm{in.}) 80{3.1496}

SAPH30TCE0900106

(2) Do not install the crankshaft. Install the crankshaft bearing

and the main bearing cap on the cylinder block.

(3) Measure the crankshaft bearing inner diameter using a

cylinder gauge.
(4) Calculate the difference between the outer diameter of the
crankshaft journal and the inner diameter of the
crankshaft bearing. If it is beyond the repair limit, grind the
crankshaft or replace the crankshaft.

SAPH30TCE0900107
Standard value (mm{in.}) Repair limit (mm{in.})

0.051 - 0.102
0.2{0.0079}
{0.0020 - 0.0040}

(5) If grinding the crankshaft, adjust the dimension of fillet “R”

as shown below.
Radius is
incomplete. Radius is Crank pin
small. Step Step
R
2.5 to 3.0mm {0.0984 to 0.1181 in.}
Journal
2.5 to 3.0mm {0.0984 to 0.1181 in.}
Good Poor

SAPH30TCE0900108

5. Inspection of crack and damage on crankshaft and of oil

Figure is an hole
example of work.
(1) Check for crack or damage using dye penetrant. If a faulty
condition is found, replace the crankshaft.

SAPH30TCE0900109

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE MECHANICAL 9–45

(2) Check for clogging of the crankshaft oil hole. If faulty

Figure is an condition is found, replace the crankshaft.
example of work.

SAPH30TCE0900110

6. Inspection of pin wear

(1) Measure the outer diameter of the crankshaft crank pin

90°Measurement
at 2 places using a micrometer. If it is faulty, replace the crankshaft.

Standard value (mm{in.}) Service limit (mm{in.})

65{2.5590} 64.3{2.5315}

SAPH30TCE0900111

(2) If grinding the crankshaft, adjust the dimension of fillet “R”

as shown below.
Radius is
incomplete. Radius is Crank pin
small. Step Step
R
2.5 to 3.0mm {0.0984 to 0.1181 in.}
Journal
2.5 to 3.0mm {0.0984 to 0.1181 in.}
Good Poor

SAPH30TCE0900108

[S5LC0033E04] [0518CsCshWbYs]
9–46 ENGINE MECHANICAL

Replacement procedure item

Replacement of crankshaft pulley

JP30TCE090704009

1. Removal of crankshaft pulley

(1) Remove bolts and remove the crankshaft pulley.

NOTICE • Insert a large flat tip screwdriver into the

flywheel gear from the flywheel housing
inspection hole to prevent turning of the
crankshaft.

SAPH30TCE0900112

2. Installation of crankshaft pulley

(1) Apply engine oil to the bolt seat and the bolt thread of the
1 crankshaft pulley mounting bolt.
6 3 (2) Install the crankshaft pulley on the crankshaft and tighten
it according to the figure.
4 5 Tightening torque : 118 N˜m {1,200 kgf˜cm, 87 lbf˜ft}
2
NOTICE • Insert a large flat tip screwdriver into the
flywheel gear from the flywheel housing
SAPH30TCE0900113 inspection hole to prevent turning of the
crankshaft.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE MECHANICAL 9–47

Replacement of flywheel
JP30TCE090704010

1. Removal of flywheel
Engine revolution sensor
Flywheel
(1) Remove the engine revolution sensor.
Mounting bolt (2) Remove bolts fixing the flywheel.

NOTICE • Insert a large flat tip screwdriver into the

flywheel gear from the flywheel housing
inspection hole to prevent turning of the
crankshaft.

SAPH30TCE0900114

(3) Install a special tool into the bolt hole of the crankshaft to
remove the flywheel.

Special tool : S0948–11340(09481–1340) Guide

! CAUTION • Since the flywheel is heavy, be careful for

handling.
• Do not give impact to the special tool during
work.
SAPH30TCE0900115

2. Removal of ring gear

(1) Heat the entire ring gear circumference with a burner until
it is about 200 qC {392qF}.

! CAUTION • Do not touch the ring gear and the flywheel

with bare hand while they are hot.

SAPH30TCE0900116

(2) Hit the circumference of the ring gear gently using a

backing rod to remove the ring gear from the flywheel.

! CAUTION • Do not touch the ring gear and the flywheel

with bare hand while they are hot.

SAPH30TCE0900117

[S5LC0033E04] [0518CsCshWbYs]
9–48 ENGINE MECHANICAL

3. Installation of ring gear

(1) Heat the entire ring gear circumference with a burner until
it is about 200 qC {392qF}.

! CAUTION • Do not touch the ring gear and the flywheel

with bare hand while they are hot.

SAPH30TCE0900118

(2) Face the chamfered side toward the flywheel and install it
on the flywheel quickly.

! CAUTION • Do not touch the ring gear and the flywheel

with bare hand while they are hot.

SAPH30TCE0900119

4. Installation of flywheel

(1) Make sure that there is no burr or dirt on the joint surface
of the crankshaft and the flywheel and the screw hole.
(2) Install the special tool into the bolt hole of the crankshaft.
Special tool : S0948–11340(09481–1340) Guide

NOTICE • Install one special tool on the collar dowel

and the other at the opposite side of the collar
dowel.
SAPH30TCE0900120

(3) Insert the flywheel until it comes in contact with the collar
dowel of the crankshaft and adjust the position.

! CAUTION • Since the flywheel is heavy, be careful for

handling.
• Do not give impact to the special tool during
work.

(4) Insert the flywheel until it comes in contact with the

crankshaft.

(5) Apply engine oil to the bolt seat and the bolt thread of the
flywheel mounting bolt.

SAPH30TCE0900121

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE MECHANICAL 9–49

(6) Tighten 6 bolts by 2 to 3 threads temporarily with hand in

the bolt holes without installation of the special tool.

(7) Tighten 6 bolts gradually and tighten temporarily.

(8) Remove the special tool and tighten remaining two bolts
temporarily as in (6) and (7).

SAPH30TCE0900122

(9) Tighten the flywheel according to the order in the figure.

Tightening torque : 186 N˜m {1,900 kgf˜cm, 137 lbf˜ft}

1 NOTICE • Insert a large flat tip screwdriver into the
5 8
flywheel gear from the flywheel housing
3 4
inspection hole to prevent turning of the
7 6
2 crankshaft.

(10) Loosen all bolts.

(11) Tighten the bolts again.
SAPH30TCE0900123
Tightening torque : 186 N˜m {1,900 kgf˜cm, 137 lbf˜ft}
(12) Install the engine revolution sensor.
Setup layout
Layout

[S5LC0033E04] [0518CsCshWbYs]
9–50 ENGINE MECHANICAL

Camshaft and Idle Gear

Part layout
JP30TCE090402005

SAPH30TCE0900124

1 Camshaft assembly 4 Camshaft gear

2 Sub-idle gear 5 Thrust plate
3 Main idle gear 6 Idle gear shaft

Tightening torque
A 59N˜m{600kgf˜cm, 44 lbf˜ft}+90q B 172N˜m{1,750kgf˜cm, 127 lbf˜ft}

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE MECHANICAL 9–51

SAPH30TCE0900125

1 Cam idle gear 3 Idle gear shaft

2 Thrust plate

Tightening torque
A 108N˜m{1,100kgf˜cm, 80 lbf˜ft}

[S5LC0033E04] [0518CsCshWbYs]
9–52 ENGINE MECHANICAL

Service procedure
Overhaul item

Removal of camshaft
JP30TCE090702006

1. Removal of rocker arm and camshaft assembly

(1) Loosen the lock nut and turn the adjusting screw
completely.
Rock nut

! CAUTION • Removal without turning the adjusting screw

may bend the rocker shaft.

(2) Loosen the rocker arm support bolts gradually from the
center and remove the rocker arm and the rocker arm
shaft.
SAPH30TCE0900126

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE MECHANICAL 9–53

Disassembly of camshaft
JP30TCE090702007

1. Disassembly of camshaft
(1) Fix the camshaft gear using a vice to disassemble the
camshaft.

! CAUTION • Prevent faulty conditions on the gear such as

deformation, impact, scratch, etc.

SAPH30TCE0900127

[S5LC0033E04] [0518CsCshWbYs]
9–54 ENGINE MECHANICAL

Inspection of camshaft and camshaft

bearing
JP30TCE090702008

1. Inspection of cam height on camshaft

(1) Measure the cam height using a micrometer. If it is
beyond the service limit, replace the camshaft.

Measuring Standard value Service limit

item (mm{in.}) (mm{in.})

Cam IN 50.067{1.9711} 49.987{1.9680}

height EX 52.104{2.0513} 52.024{2.0482}

SAPH30TCE0900128 IN 8.067{0.3176} (7.987{0.3144})

Cam lift
EX 10.104{0.3978} (10.024{0.3946})

2. Inspection of camshaft runout

(1) Put the journal at both ends of the camshaft on the V

Camshaft runout measuring area
block.
(2) Put a dial gauge to each journal of the camshaft and
measure runout of the camshaft. If it is beyond the service
limit, replace the camshaft.

Standard value (mm{in.}) Service limit (mm{in.})

0.04{0.0016} 0.1{0.0039}
SAPH30TCE0900129

3. Inspection of camshaft bearing oil clearance

(1) Measure the outer diameter of the camshaft journal using
a micrometer.

Standard value (mm{in.}) Service limit (mm{in.})

40{1.5748} 39.85{1.5689}

(2) Measure the camshaft bearing inner diameter using a

cylinder gauge.
SAPH30TCE0900130

Standard value (mm{in.}) Service limit (mm{in.})

40{1.5748} 40.15{1.5807}

(3) Calculate the difference of the camshaft journal bearing

inner diameter. If it is beyond the standard value, replace
the camshaft or the camshaft bearing.

0.020 - 0.063
Standard value (mm{in.})
{0.0008 - 0.0025}

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE MECHANICAL 9–55

Assembly of camshaft
JP30TCE090702009

1. Measuring of the camshaft gear mounting bolt

(1) Measure the camshaft mounting bolt using a vernier
calipers. If it is out of the service limit, replace it with a
new one.

Standard value (mm{in.}) Service limit (mm{in.})

Underhead length 30.0{1.1811} 30.5{1.2010}

SAPH30TCE0900131

2. Assembly of the camshaft

(1) Fix the camshaft gear using a vice. Apply engine oil to the
seat and the bolt thread of the camshaft gear mounting
bolt.

(2) Set the dowel pin to the camshaft and the camshaft gear
and tighten the camshaft gear mounting bolt.
Tightening torque : 59 N˜m {600 kgf˜cm, 44 lbf˜ft}
(3) Retighten 90 deg (1/4 turn).

SAPH30TCE0900132 ! CAUTION • If it is excessively retightened, do not loosen

it.
• Prevent faulty conditions on the gear such as
deformation, impact, scratch, etc.

[S5LC0033E04] [0518CsCshWbYs]
9–56 ENGINE MECHANICAL

Installation of camshaft
JP30TCE090702010

1. Advance preparation
(1) Align the No. 1 cylinder to the compression top dead
center.

2. Installation of camshaft
Timing judgment drill hole
(1) Place the camshaft so that two holes at 180 degrees from
the three drilled holes of the camshaft gear may be
horizontal to the upper surface of the camshaft housing.

! CAUTION • Place a transparent plastic ruler or an edged

ruler on the upper surface of the camshaft
Ruler, etc. housing and the side of the camshaft gear.
Drilled hole to prevent incorrect assembly Make sure that the position of the foolproof
SAPH30TCE0900133 drilled hole is above the ruler.

(2) Coat the bearing parts with engine oil and then install the
camshaft bearing caps in numerical order 1-2-3-4-5 from
the front of the engine, making sure the three-sided mark
on the cap points forward.
1

(3) Make sure the crosshead is correctly laid across each

valve.

! CAUTION • To make sure the crosshead is correctly in

place, move it to the left and right by hand and
SAPH30TCE0900134 make sure it clicks against the valves.
• If the crosshead is not sitting properly on the
valves, it will push the upper seat and cause
the valve to drop out.

(4) Make sure the rocker arm is correctly assembled on the

rocker arm shaft.
(5) Fully unscrew the adjust screw on the end of the rocker
arm.

NOTICE • Securing the rocker arm and nozzle clamp

together with a string will facilitate installation
work.

(6) Apply engine oil to the cam threads and set the rocker
arm in position, making sure it is correctly laid on the
crosshead. Then, tighten the bolts in the sequence
shown in the figure, making several passes and gradually
tightening them each time.
Tightening torque : 28.5 N˜m {290 kgf˜cm, 21 lbf˜ft}

! CAUTION • After the bolts are tightened, make sure the

rocker arm moves smoothly.
Setup layout
Layout

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE MECHANICAL 9–57

Gear train layout

JP30TCE090402006

Camshaft gear

Main idle gear

Cam idle gear

Pump drive idle gear

Sub-idle gear

Oil pump gear

Crankshaft gear

Air compressor
drive gear
(supply pump
drive gear)

Match mark Match mark Match mark

SAPH30TCE0900135

[S5LC0033E04] [0518CsCshWbYs]
9–58 ENGINE MECHANICAL

Service procedure
Overhaul item

Removal of timing gear

JP30TCE090702011

1. Removal of main idle gear

(1) Remove the idle gear shaft mounting bolt and pull out the
main idle gear assembly using a special tool.

Special tool : S0942–01100(09420–1100)

Sliding hammer

(2) Remove the idle gear thrust plate.

(3) Remove the idle gear shaft from the main idle gear.

SAPH30TCE0900136

2. Removal of sub-idle gear

(1) Remove the idle gear shaft mounting bolt and the idle
gear thrust plate and pull out the sub-idle gear assembly
using a special tool.

Special tool : S0942–01100(09420–1100)

Sliding hammer

(2) Remove the idle gear thrust plate.

(3) Remove the idle gear shaft from the sub-idle gear.
SAPH30TCE0900137

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE MECHANICAL 9–59

Inspection of timing gear components

JP30TCE090702012

1. Inspection of clearance between idle gear shaft and idle

gear bushing
(1) Measure the idle gear shaft outer diameter using a
micrometer and the idle gear bushing inner diameter
using a cylinder gauge.

Standard value
Measuring item
(mm{in.})

Main idle Shaft outer diameter 57{2.2441}

gear shaft Bushing inner diameter 57{2.2441}

Sub-idle Shaft outer diameter 50{1.9685}

gear shaft Bushing inner diameter 50{1.9685}

Cam idle Shaft outer diameter 34{1.3386}

gear Bushing inner diameter 34{1.3386}

(2) Calculate the difference between the idle gear bushing

inner diameter and the idle gear shaft outer diameter. If it
SAPH30TCE0900138 is beyond the service limit, replace the idle gear shaft and
the idle gear bush.

Measuring Standard value Service limit

item (mm{in.}) (mm{in.})

Main idle gear 0.030 - 0.090

0.20{0.0079}
shaft {0.0012 - 0.0035}

Sub-idle gear 0.025 - 0.075

0.20{0.0079}
shaft {0.0010 - 0.0030}

0.025 - 0.075
Cam idle gear 0.20{0.0079}
{0.0010 - 0.0030}

[S5LC0033E04] [0518CsCshWbYs]
9–60 ENGINE MECHANICAL

Installation of timing gear

JP30TCE090702013

1. Installation of sub-idle gear

(1) Install the idle gear shaft on the sub-idle gear.
Thrust plate
(2) Install the idle gear thrust plate.
(3) Provide the lubricating hole of the idle gear shaft in the
Idle gear thrust
vertical direction.
plate
(4) Install the idle gear thrust plate on the idle gear shaft.
Lubricating
hole
Cylinder block

SAPH30TCE0900139

(5) Apply engine oil to the bolt seat and the bolt thread of the
idle gear shaft mounting bolt.
(6) Install the idle gear shaft mounting bolt.
Tightening torque : 108 N˜m {1,100 kgf˜cm, 80 lbf˜ft}

SAPH30TCE0900140

2. Installation of main idle gear

Idle gear thrust plate (1) Install the idle gear shaft on the main idle gear.
(2) Install the idle gear thrust plate.

Lubricating
hole
Cylinder
Block

SAPH30TCE0900141

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE MECHANICAL 9–61

(3) Face the lubricating hole of the idle gear shaft toward the
oil pan (downward). Install A in the figure by adjusting the
Sub-idle gear timing of the crankshaft gear and the main idle gear as in
the detailed drawing.

Oil pump
gear

A
Main idle gear

Crankshaft gear

Arrange drilled holes in line.

Detail

SAPH30TCE0900142

(4) Apply engine oil to the bolt seat and the bolt thread of the
idle gear shaft mounting bolt.

(5) Install the idle gear shaft mounting bolt.

Tightening torque : 172 N˜m {1,750 kgf˜cm, 127 lbf˜ft}
(6) Measure backlash and end play of each idle gear. Make
sure that it is within the standard value.

SAPH30TCE0900143

[S5LC0033E04] [0518CsCshWbYs]
9–62 ENGINE MECHANICAL

Overhaul of sub-idle gear (bearing case side)

JP30TCE090702014

1. Removal of bearing case assembly

(1) Remove the supply pump drive.
Refer to “5 FUEL SYSTEM, Supply pump,
Replacement of supply pump”
(2) Remove 5 bolts and remove the bearing case assembly.

! CAUTION • One bolt is tightened from the timing gear

case.

SAPH30TCE0900144

(3) Fix the bearing case with a vice.

SAPH30TCE0900145

(4) Remove the sub-idle gear shaft mounting bolt and pull out
the idle gear shaft using a sliding hammer.

SAPH30TCE0900146

(5) Remove the sub-idle gear.

(6) Remove the idle gear thrust plate.

SAPH30TCE0900147

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE MECHANICAL 9–63

2. Inspection of clearance between sub-idle gear shaft and

sub-idle gear bushing

(1) Measure the outer diameter of the idle gear shaft.

SAPH30TCE0900148

(2) Measure the inner diameter of the sub-idle gear.

(3) Calculate the clearance. If it is beyond the service limit

value, replace the shaft and the bushing.

Standard value (mm{in.}) Service limit (mm{in.})

0.025 - 0.057 0.010

{0.0010 - 0.0022} {0.0039}

SAPH30TCE0900149

3. Installation of bearing case assembly

(1) Install the idle gear thrust plate.

(2) Install the gear shaft on the sub-idle gear.
(3) Face the lubricating hole of the gear shaft downward and
install it on the bearing case.
(4) Install the sub-idle gear shaft mounting bolt.
Tightening torque : 108 N˜m {1,100 kgf˜cm, 80 lbf˜ft}

SAPH30TCE0900150

(5) Align two pins of the bearing case assembly with the
concave area of the flywheel housing for installation.

Tightening torque : 28.5 N˜m {290 kgf˜cm, 21 lbf˜ft}

! CAUTION • Be careful for fall of the O-ring

Inspection procedure item

SAPH30TCE0900151

[S5LC0033E04] [0518CsCshWbYs]
9–64 ENGINE MECHANICAL

Inspection of installation status for each

gear
JP30TCE090703003

1. Inspection of backlash between camshaft gear and cam

idle gear

(1) Insert a large flat tip screwdriver into the cam idle gear
from the side of the camshaft gear of the camshaft
housing to prevent turning of the cam idle gear.

SAPH30TCE0900152

(2) Measure backlash between the camshaft gear and the

cam idle gear using a dial gauge. If it is beyond the
service limit, replace each gear.

Standard value (mm{in.}) Service limit (mm{in.})

0.030 - 0.253
0.30{0.0118}
{0.0012 - 0.0100}

SAPH30TCE0900153

2. Inspection of camshaft end play

(1) Measure the end play of the camshaft using a thickness

gauge. If it is beyond the standard value, replace the
camshaft.

0.100 - 0.178
Standard value (mm)
{0.0039 - 0.0070}

SAPH30TCE0900154

3. Inspection of backlash between main idle gear and pump

drive idle gear

(1) Remove the supply pump drive at the bearing case.

Refer to “5 FUEL SYSTEM, Supply pump,
Replacement of supply pump”
(2) Insert a large flat tip screwdriver into the main idle gear
from the timing gear dust cover of the flywheel housing to
prevent turning of the main idle gear.

SAPH30TCE0900155

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE MECHANICAL 9–65

(3) Measure backlash between the main idle gear and the
pump drive idle gear using a dial gauge and a magnet
stand. If it is beyond the service limit, replace each gear.

NOTICE • If the magnet stand is not stable, provide a

steel plate for measurement using bolt holes
of the cylinder block.

Standard value (mm{in.}) Service limit (mm{in.})

SAPH30TCE0900156
0.032 - 0.096
0.30{0.0118}
{0.0013 - 0.0038}

4. Inspection of backlash between idle gear at bearing case

and supply pump drive gear
(1) Remove the supply pump drive.
Refer to “5 FUEL SYSTEM, Supply pump,
Replacement of supply pump”
(2) Remove the bearing case assembly.
(3) Fix the supply pump drive with a vice and install the
bearing case assembly.

(4) Measure backlash between the idle gear and the supply
pump drive gear using a dial gauge and a magnet stand. If
it is beyond the service limit, replace each gear.

Standard value (mm{in.}) Service limit (mm{in.})

0.020 - 0.083
0.10{0.0039}
{0.0008 - 0.0033}
SAPH30TCE0900157

5. Inspection of backlash between main idle gear and sub-

idle gear

(1) Insert a large flat tip screwdriver into the main idle gear
from the timing gear dust cover of the flywheel housing to
prevent turning of the main idle gear.

SAPH30TCE0900158

(2) Measure backlash between the main idle gear and the
sub-idle gear using a dial gauge and a magnet stand. If it
is beyond the service limit, replace each gear.

Standard value (mm{in.}) Service limit (mm{in.})

0.030 - 0.113
0.30{0.0118}
{0.0012 - 0.0044}

SAPH30TCE0900159

[S5LC0033E04] [0518CsCshWbYs]
9–66 ENGINE MECHANICAL

6. Inspection of backlash between sub-idle gear at cam idle

gear and oil pump gear

(1) Insert a large flat tip screwdriver into the sub-idle gear to
prevent turning of the sub-idle gear.

SAPH30TCE0900160

(2) Measure backlash between the sub-idle gear and the oil
pump gear using a dial gauge and a magnet stand. If it is
beyond the service limit, replace each gear.

Standard value (mm{in.}) Service limit (mm{in.})

0.030 - 0.131
0.30{0.0118}
{0.0012 - 0.0052}

SAPH30TCE0900161

7. Inspection of idle gear end play

(1) Measure the end play of each gear using a thickness

gauge. If it is beyond the service limit, replace each gear
or shaft.

Standard value Service limit

Measuring item
(mm{in.}) (mm{in.})

0.114 - 0.160
Main idle gear {0.0045 - 0.30{0.0118}
SAPH30TCE0900162
0.0063}

0.040 - 0.120
Sub-idle gear {0.0016 - 0.30{0.0118}
0.0047}

0.040 - 0.120
Cam idle gear {0.0016 - 0.30{0.0118}
0.0047}

8. Inspection of backlash between cam idle gear and sub-idle

gear
(1) Insert a large flat tip screwdriver into the sub-idle gear
from the side of the cam idle gear of the cylinder head to
prevent turning of the sub-idle gear.

SAPH30TCE0900163

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE MECHANICAL 9–67

(2) Measure backlash between the cam idle gear and the
sub-idle gear using a dial gauge. If it is beyond the service
limit, replace each gear.

Standard value (mm{in.}) Service limit (mm{in.})

0.030 - 0.218
0.30{0.0118}
{0.0012 - 0.0086}

Setup layout
Layout

SAPH30TCE0900164

[S5LC0033E04] [0518CsCshWbYs]
9–68 ENGINE MECHANICAL

Valve System
Part layout
JP30TCE090402007

SAPH30TCE0900165

1 Crosshead assembly 8 Valve seat upper

2 Adjusting screw 9 Rocker arm (intake)
3 Intake valve 10 Rocker arm (exhaust)
4 Exhaust valve 11 Rocker shaft
5 Outer spring 12 Rocker support
6 Inner spring 13 Valve stem seal*
7 Valve seat lower 14 Bush

*Parts not to be reused.

Tightening torque
A 25N˜m{250kgf˜cm, 18 lbf˜ft}

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE MECHANICAL 9–69

Service procedure
Overhaul item

Overhaul of valve system

JP30TCE090702015

1. Removal of rocker arm and rocker arm shaft

(1) Loosen the lock nut and turn the adjusting screw
completely.
Lock nut
! CAUTION • Removal without turning the adjusting screw
may bend the rocker arm shaft.

SAPH30TCE0900166

(2) Loosen the rocker arm support bolts gradually from the
center and remove the rocker arm and the rocker arm
shaft.
ԝ ԛ ԙ Ԙ Ԛ Ԝ Ԟ

Rocker arm support

SAPH30TCE0900167

2. Installation of rocker arm and rocker arm shaft

(1) Make sure that the crosshead is correctly (covering) on

each valve.

! CAUTION • To ensure that the crosshead is correctly on

the valve, move the crosshead to left or right
with hand and confirm "clicking" sound.
• If the crosshead is offset from the valve in
assembly, the upper seat may be pressed,
SAPH30TCE0900168 resulting in fall of the valve.

(2) Make sure that the rocker arm is correctly assembled into
the rocker arm shaft.
(3) Turn the adjusting screw at the end of the rocker arm
Rocker arm
completely.

NOTICE • Bundling the rocker arm with a rubber band

eases installation.

Adjusting ! CAUTION • After installation, apply engine oil to the cam.

screw

Rubber band
SAPH30TCE0900169

[S5LC0033E04] [0518CsCshWbYs]
9–70 ENGINE MECHANICAL

(4) Place the rocker arm and the rocker arm shaft on the
camshaft housing and make sure that the rocker arm is
correctly on the crosshead. Tighten the rocker arm
support bolts gradually several times.

Tightening torque : 59 N˜m {600 kgf˜cm, 44 lbf˜ft}

! CAUTION • After tightening, make sure that the rocker

arm moves smoothly.
• Make sure that there is no undue force on the
SAPH30TCE0900170 injection pipe oil seal.
(Otherwise, oil leak or poor assembly of
injection pipe may occur.)

3. Inspection of rocker arm oil clearance

(1) Measure the outer diameter of the rocker shaft using a

micrometer.

Standard value (mm{in.}) Service limit (mm{in.})

22{0.8661} 21.92{0.8630}

(2) Measure the rocker arm bushing inner diameter using a

cylinder gauge.
SAPH30TCE0900171

Standard value (mm{in.}) Service limit (mm{in.})

22{0.8661} 22.08{0.8693}

(3) Calculate the difference between the outer diameter of the

rocker shaft and the inner diameter of the rocker arm
bushing. If it is beyond the standard value, replace the
rocker shaft or the rocker arm bushing.

Standard value (mm{in.}) Service limit (mm{in.})

0.030 - 0.101
0.15{0.0059}
{0.0012 - 0.0039}

4. Removal of valve spring

(1) Compress the valve spring using a special tool and

remove the valve spring retainer.
Special tool : S0947–01170(09470–1170)
Valve spring press

SAPH30TCE0900172

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE MECHANICAL 9–71

(2) Remove the intake and exhaust valves.

! CAUTION • Attach a tag with the applicable cylinder

number to the valve so that combinations of
the valve and the cylinder head may not be
mixed.

SAPH30TCE0900173

5. Replacement of valve stem seal

Stem seal Special tool (1) After removing the valve stem seal, assemble the valve
Valve spring spring lower seat. Apply engine oil to the lip and the inner
lower seat surface of the stem seal. Strike the valve guide using a
special tool until the special tool comes in contact with the
valve spring lower sea
Special tool : S0947–22100(09472–2100) Bar

! CAUTION • After assembly of the stem seal, make sure

that there is no deformation, crack or
inclination of the rubber.
Oil application
Rubber

SAPH30TCE0900174

(2) After striking, check the height.

22.5 - 23.0
Standard value (mm{in.})
+0.1{0.0039in.}
{0.8858 - 0.9055}
22.9mm{0.9022in.}
-0.4{0.0157in.}

SAPH30TCE0900175

[S5LC0033E04] [0518CsCshWbYs]
9–72 ENGINE MECHANICAL

6. Installation of valve spring

(1) Install the valve spring upper seat on the valve spring.
(2) Compress the valve spring using a special tool and install
the valve spring retainer.
Special tool : S0947–01170(09470–1170)
Valve spring press

! CAUTION • Apply engine oil to the contact surface of

each part before assembly.
SAPH30TCE0900176
• Be sure to assemble each valve at the original
cylinder position.
• When the valve spring is compressed, avoid
contact of the valve spring upper seat with the
valve stem seal.
• Since the valve spring has equal spacing,
vertical direction is not specified for
assembly.
• Check for scratch on the valve stem seal
when the valve is reused.

7. Inspection of valve spring

Clearance A
(1) Measure squareness of the valve spring using a square or
a thickness gauge. If it is beyond the service limit
(clearance A), replace the valve spring.

Clearance A (mm{in.}) 2.0{0.0787}

SAPH30TCE0900177

(2) Measure the free length of the valve spring using a vernier
calipers. If it is out of the service limit, replace the valve
spring.

Standard
Service limit
Measuring item value
(mm{in.})
(mm{in.})

Inner valve spring (64.6{2.5433}) 61.6{2.4252}

SAPH30TCE0900178 Outer valve spring (75.7{2.9803}) 72.7{2.8622}

The value in [ ] is the reference value.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE MECHANICAL 9–73

8. Inspection of oil clearance between valve guide and valve

stem

(1) Measure the outer diameter of the valve stem using a

micrometer.

Standard value
Measuring item
(mm{in.})

Intake valve stem 7{0.2756}

SAPH30TCE0900179 Exhaust valve stem 7{0.2756}

(2) Measure the valve guide inner diameter using a cylinder

gauge.

Standard value
Measuring item
(mm{in.})

Intake valve guide 7{0.2756}

Exhaust valve guide 7{0.2756}

(3) Calculate the difference between the valve system outer

SAPH30TCE0900180
diameter and the valve system inner diameter. If it is
beyond the standard value, replace the valve or the valve
guide.

Standard value
Measuring item
(mm{in.})

0.023 - 0.058
Intake valve oil clearance
{0.0009 - 0.0023}

Exhaust valve oil 0.050 - 0.083

clearance {0.0020 - 0.0033}

Attachment procedure item

[S5LC0033E04] [0518CsCshWbYs]
9–74 ENGINE MECHANICAL

Adjustment of valve clearance

JP30TCE090706001

1. Precautions before adjustment

! CAUTION • Before adjustment, make sure that bolts of

the cylinder head, rocker arm support,
nozzle clamp, camshaft housing and
camshaft bearing cap are tightened to the
specified torque.

2. Adjustment of valve clearance

(1) Make sure that there is no dirt between the crosshead and
the valve stem
(2) Turn the crankshaft in the forward direction and adjust the
cylinder to the compression top dead center.

! CAUTION • Make sure that there is a roller on the cam

base circle.

(3) Loosen the adjusting screw and the lock nut of the
Adjusting screw of rocker arm
Roller crosshead completely.
Cam base
circle Lock nut
Adjusting screw of
crosshead ! CAUTION • Provide the adjusting screw protrusion of 10
10 mm or more
mm or more from the top surface of the
crosshead. If the adjusting screw is not
completely separated from the valve stem,
Clearance correct adjustment is not allowed.
Close contact

Nut
SAPH30TCE0900181

(4) Insert a thickness gauge between the rocker arm and the
Rocker arm Thickness gauge crosshead and adjust the clearance with the adjusting
screw of the rocker arm. Tighten the lock nut.

Standard value IN 0.30mm{0.0118 in.}

(cold engine) EX 0.45mm{0.0177 in.}

Close contact Tightening torque : 25 N˜m {250 kgf˜cm, 18 lbf˜ft}

Crosshead
SAPH30TCE0900182

(5) Loosen the adjusting screw of the crosshead with the

Start thickness gauge inserted. Make sure that feel on the
Feel of thickness gauge

thickness gauge is not lighter.

(No move) Nut fixing position

! CAUTION • If it becomes lighter, make adjustments again

(Appropriate from the beginning.
contact)

Feel remains the same.

Loosening of adjusting screw Large

SAPH30TCE0900183

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE MECHANICAL 9–75

(6) Tighten the adjusting screw of the crosshead until the

thickness gauge does not move.

Close contact
Close contact

SAPH30TCE0900184

(7) While loosening the adjusting screw of the crosshead

Start gradually, tighten the lock nut of the crosshead at the
Feel of thickness gauge

position where feel on the thickness gauge is appropriate.

(No move) Nut fixing position
Tightening torque : 25 N˜m {250 kgf˜cm, 18 lbf˜ft}

(Appropriate ! CAUTION • Do not over-loosen the adjusting screw. Over-

contact)
loosening of the adjusting screw reproduces
Feel remains the same. the original status. Although feel on the
Loosening of adjusting screw Large thickness gauge is appropriate, there is
SAPH30TCE0900185 clearance between the adjusting screw and
the valve of the crosshead. Correct
adjustment is not allowed.

[S5LC0033E04] [0518CsCshWbYs]
[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–1

ENGINE

10 EXHAUST
Setup layout
Layout

Exhaust Manifold...................................................... 10-2

Part layout ............................................................. 10-2
Replacement......................................................... 10-3
AdBlue/DEF SCR & DPR .......................................... 10-4
Part layout ............................................................. 10-4
Sensor location ..................................................... 10-5
System block diagram........................................... 10-7
Explanation of Terms ............................................ 10-8
Caution notes for mounting and dismounting of
AdBlue/DEF and coolant piping .......................... 10-10
Inspection ........................................................... 10-12
Cleaning of DPR filter ......................................... 10-32
AdBlue/DEF SCR .................................................... 10-33
Replacement....................................................... 10-33
DPR Cleaner............................................................ 10-51
Replacement....................................................... 10-51
10
AdBlue/DEF pump .................................................. 10-69
Inspection ........................................................... 10-69
Replacement....................................................... 10-69
AdBlue/DEF injector............................................... 10-76
Inspection ........................................................... 10-76
Replacement....................................................... 10-76
AdBlue/DEF tank .................................................... 10-80
Inspection ........................................................... 10-80
Replacement....................................................... 10-81
Coolant cut-off valve .............................................. 10-83
Inspection ........................................................... 10-83
Replacement....................................................... 10-84
DCU.......................................................................... 10-88
Replacement....................................................... 10-88
Differential pressure sensor.................................. 10-92
Replacement....................................................... 10-92
NOx sensor ............................................................. 10-96
Inspection ........................................................... 10-96
Replacement....................................................... 10-96
DOC downstream temperature sensor............... 10-100
Replacement..................................................... 10-100
DPR downstream temperature sensor ............... 10-102
Replacement..................................................... 10-102
SCR uptream temperature sensor ...................... 10-106
Replacement..................................................... 10-106

[S5LC0033E04] [0518CsCshWbYs]
10–2 EXHAUST

Exhaust Manifold
Part layout
JP30J19100402001

SAPH30J191000001

1 Gasket* 2 Exhaust manifold

*Parts not to be reused.

Tightening torque
A 53N˜m{540kgf˜cm, 40 lbf˜ft}

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–3

Service procedure
Replacement procedure item

Replacement
JP30J19100704001

1. Removal of exhaust manifold

(1) Remove nuts and remove the exhaust manifold.

2. Replacement of stud bolt

(1) Remove dirt (e.g. sealant) at the female thread of the
cylinder head and clean the thread again with tap (M10 x
1.5).
(2) Use the Torx wrench to tighten a new stud bolt.
Tightening torque : 30 N˜m {300 kgf˜cm, 22 lbf˜ft}

! CAUTION • Excessive tightening with over torque may

cause crack in the cylinder head.

3. Installation of exhaust manifold

(1) Assemble a new gasket.

! CAUTION • Since a gasket has front and back, install the

black side on the exhaust manifold.

Black side
SAPH30J191000002

(2) Tighten the mounting nut of the exhaust manifold

according to the order in the figure.

New exhaust manifold installation case Tightening torque : 53 N˜m {540 kgf˜cm, 40 lbf˜ft}
18 17 16 15 14 13 12 11 10 9 8 7
! CAUTION • When nuts are tightened, prevent each spacer
from riding on the counterbore area of the
1 2 5 6 manifold flange.
3 4
• The tightening sequence of the exhaust
manifold varies between use of a new part
Exhaust manifold reuse installation case and reuse.
14 15 8 9 2 3 6 5 11 12 17 18
(3) Tighten the same nuts again according to the order in the
figure.
13 7 10 16 Tightening torque : 53 N˜m {540 kgf˜cm, 40 lbf˜ft}
1 4

! CAUTION • Be sure to retighten it.

Spacer

SAPH30J191000003

[S5LC0033E04] [0518CsCshWbYs]
10–4 EXHAUST

AdBlue/DEF SCR & DPR

ÉIÅ[ÉoÅ[ÉzÅ[ÉãçÄñe
êÆî€óvóÃ

Part layout
JP30J19100702001

SAPH30J191000004

NOTICE • DPR : Diesel Particulate active Reduction system

• SCR : Selective Catalytic Reduction

! CAUTION • The DPR cleaner and the AdBlue/DEF SCR must be handled with care as they are made
from ceramics, are heavy, and therefore may break easily.

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–5

Sensor location
JP30J19100702002

SCR upstream
temperature sensor

SCR downstream
NOx sensor

DOC downstream
temperature sensor

Fr

Upp

LH

DPR downstream
SCR upstream temperature sensor
NOx sensor

SAPH30J191000005

[S5LC0033E04] [0518CsCshWbYs]
10–6 EXHAUST

2 3

A B

2
1

7
4
8
6
1

B
2

Upp

2
LH
5
Fr
5

SAPH30J191000006

1 SCR chamber 2 Insulator

3 Rear silenser chamber 4 SCR
5 Rail 6 DPR chamber
7 DPR filter 8 Front silencer chamber

Tightening torque
A 64 N˜m{653 kgf˜cm, 47 lbf˜ft} B 27.6r5 N˜m{281r51 kgf˜cm, 20r4 lbf˜ft}

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–7

System block diagram

JP30J19100702003

DPR regeneration switch Fault code display

AdBlue/DEF indicator

Atmospheric pressure sensor

AdBlue/
Engine ECU DEF tank AdBlue/
Ambient air
temperature
DEF piping sensor

AdBlue/DEF level sensor

AdBlue/DEF temperature sensor
AdBlue/DEF pump Commu-
nication
AdBlue/DEF reverting valve wire
AdBlue/DEF pump motor DCU

AdBlue/DEF pressure
sensor (built-in)
AdBlue/DEF piping
Communication wire

SCR upstream SCR downstream

temperature sensor NOx sensor

NH3
SCR slip
catalyst

AdBlue/DEF
injector
DOC DPR

SCR upstream
DOC downstream NOx sensor
Differential pressure sensor
temperature sensor
DPR downstream
temperature sensor

SAPH30J191000007

[S5LC0033E04] [0518CsCshWbYs]
10–8 EXHAUST

Explanation of Terms
JP30J19100702004

! CAUTION • This manual uses the designations of the engine manufacturer.

• Please compare the conformity of each term with the designation of the machine
manufacturer, as shown in the following table.

Post-processing system

1
15
2
ENGINE 12 14

5 6

16
13 8 7
3 4 11

10

9 15

SAPH30J191000008

1. Conformity table

Designation of the engine manufacturer Designation of the machine manufacturer

1 DCU DCU

2 Muffler unit SCR unit

3 DOC DOC

4 DPR DPF

5 SCR SCR catalyst

6 NH3 slip catalyst NH3 slip catalyst

7 AdBlue/DEF tank DEF tank

8 AdBlue/DEF pump DEF supply module

9 Differential pressure sensor Differential pressure sensor

10 DOC downstream temperature sensor DPF inlet temperature sensor

11 DPR downstream temperature sensor DPF outlet temperature sensor

12 SCR upstream temperature sensor SCR temperature sensor

13 SCR upstream NOx sensor NOx sensor

14 SCR downstream NOx sensor NOx sensor

15 NOx controller NOx sensor controller

16 AdBlue/DEF injector DEF dosing module

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–9

AdBlue/DEF pump, AdBlue/DEF tank

D D

B
A

G
J
E
F H
I C

8
7

SAPH30J191000009

1. Conformity table

Designation of the engine manufacturer Designation of the machine manufacturer

7 AdBlue/DEF tank DEF tank

8 AdBlue/DEF pump DEF supply module

A AdBlue/DEF tank filler cap DEF tank fuller cap

B AdBlue/DEF sensor DEF sensor unit

C AdBlue/DEF drain plug DEF tank drain plug

D AdBlue/DEF line DEF line

E AdBlue/DEF pump filter DEF supply module filter

F AdBlue/DEF pump motor DEF pump motor

G AdBlue/DEF pressure sensor DEF pressure sensor

H AdBlue/DEF reverting valve DEF reverting valve

I AdBlue/DEF strainer DEF sensor strainer

J — DEF tank strainer

[S5LC0033E04] [0518CsCshWbYs]
10–10 EXHAUST

Caution notes for mounting and dismounting of AdBlue/DEF and

coolant piping
JP30J19100702005

1. The quick-joints used for AdBlue/DEF piping can cause leakage when they are being connected again
after being disconnected once, because AdBlue/DEF powder may adhere to the seal. When
reconnecting, confirm that there is no AdBlue/DEF powder or other foreign matter adhering to the seal.
Wash with warm water if any AdBlue/DEF powder is noticed.

2. When the work is performed without completion of after-run, the piping will be filled with AdBlue/DEF,
and AdBlue/DEF will flow out when a quick-connector is disconnected. Always confirm that the after-
run has been completed.

NOTICE • 'After-run' means that the injection of AdBlue/DEF has ended, but AdBlue/DEF remains in
the AdBlue/DEF pump and in the piping. After stopping the engine, the system returns
AdBlue/DEF to the AdBlue/DEF tank so that remaining AdBlue/DEF does not freeze in cold
weather, or dries to form crystals.

3. When work is performed directly after stopping the engine, there is the danger of high-temperature
coolant being sprayed out and causing burns. Always perform the work after the coolant temperature
has dropped sufficiently.

4. As the piping uses molded tubes, do not subject the tubes to excessive force at the time of work.

5. Avoid direct contact with AdBlue/DEF or cooling fluid that has flown from the piping. In case of
accidental contact, wash the affected areas thoroughly.

6. After disconnection, apply vinyl covers or similar to prevent entry of foreign matter into the piping.

7. After joints have been disconnected, immediately apply covers to prevent entry of foreign matter into
the AdBlue/DEF tank, AdBlue/DEF pump, and AdBlue/DEF injector.

8. When applying covers, use separate covers to prevent mixing of AdBlue/DEF and coolant.

9. When disconnecting a quick-connector is difficult, do not use excessive force, but first remove any dirt
which has become attached around the joint; using excessive force to separate a quick-connector can
damage it together with other parts.

10. The piping consists of coolant piping and AdBlue/DEF piping, and this unit cannot be disassembled.

11. When disconnecting a quick-connector is difficult, do not use excessive force, but first remove any dirt
which has become attached around the joint; using excessive force to separate a quick-connector can
damage it together with other parts.

12. Perform the work with all harness connectors connected. Working with disconnected parts can cause
rust, therefore it Is recommended to apply covers to the connectors to prevent contact with coolant or
AdBlue/DEF.

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–11

Quick connector

Male side
Quick connector lock Tube

SAPH30J191000010

13. Disconnect the quick connector

(1) Disconnect a quick-connector by pushing the lock from both sides.

! CAUTION • If the lock is not pushed correctly for disconnecting, the connecting part may break.
• Do not insert and twist a screwdriver or similar to disconnect.

14. Connect the quick connector

(1) To connect a quick-connector, confirm that the connector end part is free of dust, dirt, etc. Blow air etc. to
remove any adhering dirt etc. Insert the quick-connector all the way until it engages with a click.

! CAUTION • Remove any crystallized AdBlue/DEF from AdBlue/DEF piping by wiping with a shop towel
moistened with warm water or by washing with warm water.

[S5LC0033E04] [0518CsCshWbYs]
10–12 EXHAUST

Inspection
JP30J19100702006

1. Periodic inspection items

• The DPR system is to be inspected according to the following procedure.
(1) Confirm that there is no abnormal increase of the engine oil in the oil pan. (The X mark of the oil level
gauge shall not be exceeded.)

NOTICE • If the engine oil should have increased abnormally, there is the possibility that there is an
abnormality in the injection system or that unburned fuel has leaked through the gap
between the piston rings and the cylinder liner to the oil pan.

(2) Check for looseness of parts in the exhaust system (exhaust pipe, body flange) and for exhaust gas
leakage.
(3) Confirm that the external appearance of the exhaust gas temperature sensor harness is free of
abnormalities (broken covering, missing clips or clamps).
(4) Inspect the hoses of the DPR differential pressure sensor and confirm that they are free of deterioration
and cracks. Replace them with new parts if 3 years have passed. Check that the pipes are free of internal
clogging. (Apply compressed air from the pipe tip and confirm passage of the air.)
(5) Inspect DPR regeneration switch and the indicator lamp in the meter for a burned out bulb and wire breaks.
(When DPR regeneration switch is pressed with the engine stopped and the starter key set to ON, it is
normal when the lamp in the switch and the indicator lamp in the meter light up.)
(6) Check the exhaust gas pressure.

2. Time for inspection and maintenance for the exhaust gas pressure
(1) When using the Hino-DX, check the exhaust gas pressure every 4500 Hour and decide whether
maintenance is required or not.

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–13

DPR flow inspection regular situation

Shop visit for inspection First, perform steps 1 to 5, as shown in the periodic inspection schedule.
(Refer to 10-12 page)

!FTERWARDS CONNECT THE (INO $8 CHECK FOR PAST FAULTS CONFIRM THE $02
Periodic inspection (1 to 5) status, and in case of past fault DTCs, record them in the DX report.

In case of engine-related past faults, inspect the engine side first.

Hino-DX connection, DTC code confirmation

First, perform a basic inspection of the engine.

- Inspection of the injection quantity (at the time of idling)
Basic engine - Inspection of the fuel system (fuel filter clogging)
inspection - Inspection of the intake system
(air element clogging, air flow meter inspection)
OK - EGR inspection (confirmation of the ability to follow forced drive opening)
- VNT inspection (confirmation of the ability to follow forced drive opening)

In case of abnormalities on the engine side, inspect the engine side first.

NG: Regeneration was not completed.

Forced regeneration* Perform fault diagnosis on P2458/P2A2.

OK NG: The value of “DPR exhaust gas temperature (IN)” does not exceed 450°C [842°F]. If the system cannot
transition to the forced regeneration mode, inspect the following.
s .EUTRAL SWITCH CIRCUIT
s !CCELERATOR EMERGENCY CIRCUIT
s -ALFUNCTION OF LOCK LEVER AND SO ON

CAUTION:
Do not perform successive manual regeneration processes.
This is to prevent an accumulation of unburned HC in the EGR system.
If manual forced regeneration of the DPR twice or more often cannot be
avoided because of inspection, drive for approx. 10 minutes or operate the
engine for approx. 20 minutes with the idle volume set to MAX between the
regeneration processes.
This work must be performed because it is required to blow unburned HC
from the EGR and to prevent clogging etc. in the EGR system.

Differential
pressure confirmation DPR change or cleaning

NG: Standard value exceeded

OK

Leave the shop

SAPH30J191000152

! CAUTION • * "Forced regeneration" here aims to check the regeneration function of the DPR system.
Inspect the temperature surrounding the DPR cleaner using the Hino-DX.
• If you combust soot at the time of this inspection, use the DPR regeneration switch.
(See "About Manual Regeneration" in the Instruction Manual of the Machine.)

[S5LC0033E04] [0518CsCshWbYs]
10–14 EXHAUST

Inspection using the Hino-DX

1. Confirmation of the DTC code and DPR status

(1) Connect the Hino-DX and check for DTC codes of past faults. In case of past faults of the engine system,
inspect the engine side first.
(2) If there are past fault codes of the DPR system *2, perform output to the DX report and keep a record.
(3) Select "DPR inspection" in the Hino-DX function confirmation, perform the inspection, and check the "DPR
status display".
(4) If there are past or current faults of the DPR system and there are items shown as "ON" in the "DPR status
display", perform inspection as shown in the inspection flow shown at the time of "DPR inspection" display.
If there are no past faults and the "DPR status display" shows no items as "ON", go to the basic inspection
of the engine system.

2. Basic inspection of the engine

• In case of damage to the engine, check the condition of the engine itself, as there is the possibility that the
DPR performance may be compromised.
• Inspection of the injection system: Fuel injection quantity at the time of idle speed (No load).
• Inspection of the fuel system: Fuel filter clogging condition.
• Inspection of the intake system: Inspection of the air filter element clogging condition and air flow meter.
• Inspection of the EGR system: Using the Hino-DX to confirm the ability to follow the opening with forced drive.
• Inspection of the VNT: Using the Hino-DX to confirm the ability to follow the nozzle opening with forced drive.

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–15

3. Inspection of DPR with manually forced regeneration

• Together with confirmation of the temperature rise condition in the DPR filter, excess soot in the filter is
burned for inspection of the differential pressure in the DPR filter.
(1) Perform "Manual forced regeneration" from the manual forced regeneration screen of the Hino-DX.
(2) Press the "DPR regeneration switch" of the DPR after confirming that there is no combustible matter
around the machine and the exhaust pipes.
Intermediate cancellation of the regeneration is possible by lightly depressing the accelerator pedal. If
intermediate cancellation is desired or if successive regeneration is to be performed, set the idle volume to
MAX and leave it for approx. 20 minutes. This work must be performed because it is required to blow
unburned HC from the EGR system and to prevent clogging etc. in the EGR system etc.

Intermediate cancellation of the regeneration is possible by lightly depressing the accelerator pedal. If
intermediate cancellation is desired or if successive regeneration is to be performed, set the idle volume to MAX
and leave it for approx. 20 minutes. This work must be performed because it is required to blow unburned HC
from the EGR system and to prevent clogging etc. in the EGR system etc.
When the time until completion of regeneration is long (30 minutes or more), or when P2458 (DPR manual
regeneration fault) appears, perform inspection as shown in the inspection flow shown at the time of "DPR
inspection" display.

4. Differential pressure inspection

(1) Inspection of the DPR differential pressure is performed after manual regeneration, but when the exhaust
gas temperature is high, accurate measuring is not possible; for this reason, the inspection must be
performed when the exhaust gas temperature at the DPR inlet side is approximately 200 qC or less.
(2) Select "DPR inspection" in the Hino-DX function confirmation, perform the inspection, and then check the
DPR differential pressure at the "DPR status display" screen.
(3) As the engine speed increases with Hino-DX operation and the DPR differential pressure is displayed,
record this value and then stop the DPR differential pressure check according to the Hino-DX instructions.
(4) If the recorded DPR differential pressure exceeds the standard value, clean or replace the DPR cleaner
part.
(5) If there is no change of the differential pressure, perform the following inspections.
a. Check the differential pressure hose for holes and cracks. Replace hoses if 3 years have passed.
b. Check the hose clamps for disengagement or looseness.
c. Check that the differential pressure pipe is free of clogging. (Apply compressed air from the DPR cleaner
side of the differential pressure pipe and confirm the passage of the air.)
d. Perform an electric check of the differential pressure sensor and replace the sensor in case of an
abnormality.

[S5LC0033E04] [0518CsCshWbYs]
10–16 EXHAUST

5. DTC code list

DIAGNOSTIC TROUBLE CODE TROUBLE

P200C DPR over temperature

P244B Excessive DPR differential pressure

P244F DPR differential pressure drop

DPR system faults*
P2458 DPR regeneration duration

P2463 DPR clogged

P24A2 DPR regeneration incomplete by fuel consumption over

P0545 DOC downstream temperature sensor - out of range

(Out of range low)

P0546 DOC downstream temperature sensor - out of range

(Out of range high)
Sensor system fault P1427 Differential pressure sensor - out of range (Out of range low)
related to the DPR
P1428 Differential pressure sensor - out of range (Out of range high)
system
P2032 DPR downstream temperature sensor - out of range
(Out of range low)

P2033 DPR downstream temperature sensor - out of range

(Out of range high)

P0122 Intake throttle valve-opening sensor 1 out of range

(Out of range low)

P0123 Intake throttle valve position sensor 1 out of range

(Out of range high)

P1681 Failure of the magnetic valve system of the exhaust control valve (wire break)
Failure of DPR-
P1682 Failure of the magnetic valve system of the exhaust control valve (short-circuit)
related parts
P2100 DC motor for intake throttle valve - circuit
[Open circuit (circuit low)]

P2101 Intake throttle valve - functional

P2103 DC motor for intake throttle valve - circuit

[Short circuit (circuit high)]

P2200 Failure of the SCR upstream NOx sensor

P2205 Failure of the SCR upstream NOx sensor of the heater

P2213 Failure of the SCR downstream NOx sensor

Failure of SCR- P2218 Failure of the SCR downstream NOx sensor of the heater
related parts
P242C Failure of the SCR upstream temperature sensor (short-circuit) (third from
upstream)

P242D Failure of SCR upstream temperature sensor (wire break) (third from
upstream)

• In case of a failure of the DPR system, perform inspection according to the “inspection flow” on the pext page
when the menu "DPR inspection" is displayed.

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–17

6. Standard values for basic inspection of the engine

Standard values for basic inspection of the engine

Idle speed 800r/min Standard injection quantity 10 to 30 mm3/ct˜cyl

Correction range between cylinders (guide

r5 mm3/ct˜cyl
value)

Standard values for inspection Complete closing with an instruction for complete closing. The ability to follow with
of the EGR system forced drive shall be within r5 %.

Standard values for inspection The ability to follow with forced drive shall be within r5 %.
of the VNT system

7. Standard values for inspection of the DPR differential pressure

Engine speed with no load Differential pressure

(rpm) (kPa)

2,000 10 or less

[S5LC0033E04] [0518CsCshWbYs]
10–18 EXHAUST

Inspection flow when the "DPR inspection" menu is displayed.

Shop visit for inspection In case of a DTC code, record it in the DX report and then check according to
the following procedure.

In case of a DTC code of the engine system, inspect the engine system first.
DTC code confirmation
In case of a DTC code of the DPR system, confirm the contents of the DPR
status display after inspection of the engine system.

- Inspection of the injection quantity (at the time of idling)

Basic inspection
- Inspection of the fuel system (fuel filter clogging)
of the engine
- Inspection of the intake system (air filter element clogging, air flow meter
inspection)
- EGR inspection (confirmation of the ability to follow forced drive opening)
- VNT inspection (confirmation of the ability to follow forced drive opening)

Confirmation of the "DPR status display" screen

[Status display] [Cause system] [Inspection part]

DPR abnormal ON/OFF ON/OFF DPR defective or DPR disassembly inspection
breakage flag abnormal differential pressure Black smoke and oil leakage at the engine side
sensor system (P244F) Fuel leakage inspection
Differential pressure sensor inspection

Abnormal DOC ON/OFF Detection of abnormal heating of DPR disassembly inspection

temperature flag the prestige catalyst Black smoke and oil leakage on the engine side
Fuel leakage inspection
Temperature sensor inspection
Abnormal DPR ON/OFF Detection of abnormal heating of
temperature flag the DPR filter (P200C)

Excessive DPR ON/OFF Detection of abnormal DPR DPR filter disassembly and cleaning
differential pressure flag differential pressure (P244B) Black smoke, injection quantity on the engine side
Inspection of the EGR system
Inspection related to the differential pressure pipe

Clogging danger level ON/OFF Abnormal soot deposition to the

flag DPR filter (P2463) or (P244B)

Clogging alarm level ON/OFF DPR manual regeneration switch Confirmation of the switch activation
flag not activated, or failure of the Switch system failure inspection
switch system (P2463) (Wire break, short-circuit)

Defective manual ON/OFF DPR manual regeneration was DPR filter disassembly and cleaning
regeneration flag not completed (P2458) Inspection of the engine system
Inspection of injection quantity, exhaust brake, and
EGR system
History flag for ON/OFF There is a record showing
incomplete auto- incomplete DPR auto-
regeneration processes regeneration processes

Excessive fuel addition ON/OFF There is a record showing Confirmation of the switch operation method
quantity flag frequent interruption during DPR
manual regeneration switch
operation (P24A2)

SAPH30J191000012

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–19

Check the DPR status using Hino-DX

1. Check the DPR status

(1) Select the "DPR Check (D)" menu in "Check functions (E)" from the Hino-DX menu bar.

Select

SAPH30J191000013

[S5LC0033E04] [0518CsCshWbYs]
10–20 EXHAUST

(2) The "DPR status display" window will appear.

Before resetting all the DPR items, be sure to stop the engine, press the brake switch
and set the lever in the lock position. After that, set the starter key to ON.

SAPH30J191000014
a. If DPR is normal, the values in the Data display "Status" are OFF.
b. If "ON" is displayed in the Data display, clean, replace or maintenance the DPR suitably. If the DPR
services are complete, then click "Reset all DPR items (R)" button to clear the values (=[OFF]).

! CAUTION • Before doing the "Reset all DPR items (R)", stop the engine, select the neutral gear and set
the starter key to the ON position.

NOTICE • If manual forced regeneration is performed again for some reason during regeneration after
all DPR items were reset through fault diagnosis, resetting is not required from the second
time and after.
The same condition is used after the initial resetting has been completed.

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–21

2. Manual forced regeneration

• Manual regeneration is a regeneration mode that forcefully operates the soot combustion treatment function.

! CAUTION • Never stop the unit near any flammable material, including high grass or leaves, during
manual regeneration.
• Extreme heat from the exhaust outlet could cause a fire resulting in personal injury and
property damage.
• Always keep all flammable materials away from the DPR cleaner, exhaust pipe and tail
pipes.
• Never touch the DPR cleaner, exhaust pipe or tail pipe during regeneration. Severe burns
and/or other personal injuries could occur.

• More fuel than usual is contained in the air returned through the EGR to the intake side
during DPR regeneration. If you stop the engine soon after regeneration, this fuel will
congeal, which may influence subsequent engine operation. In order to clean the air in the
engine that contains fuel, be sure to perform the 10-minuite scavenging drive after
regeneration has been completed.

• Manual regeneration can be performed even if a small amount of soot has accumulated, so this mode can be
used to inspect the regeneration system.
• When you combust soot using the manual regeneration mode, start the mode using the DPR regeneration
switch in the cabin.㻌㻔㻔"㼍"㻌㼛㼚㻌㼚㼑㼤㼠㻌㼜㼍㼓㼑㻚㻕
When you inspect the system, start the regeneration mode using the Hino-DX.㻌㻔㻔"㼎"㻌㼛㼚㻌㼠㼔㼑㻌㼚㼑㼤㼠㻌㼜㼍㼓㼑㻚㻕

NOTICE • This section mainly explains the manual forced regeneration procedure using the Hino-DX.

[S5LC0033E04] [0518CsCshWbYs]
10–22 EXHAUST

a. When you combust soot

• If the manual generation coution appears in the multifunctional display, do not use the Hino-DX, but use
the DPR regeneration switch in the cabin for regeneration.

DPR regeneration switch

SAPH30J191000153

• To perform manual forced regeneration, set the attachment of the machine to the parking attitude, stop
the engine, lift up the lock lever and set the starter key to [ON].
• Press the DPR regeneration switch to operate the hydraulic pump relief. "Regenerating" appears on the
screen of the multifunctional display.
• When the hydraulic pump relief operation has been completed and "Regenerating" on the screen goes
out, soot combustion is completed.

b. When you inspect the DPR system

• You can confirm the whole DPR system condition using the Hino-DX.
• The Hino-DX displays engine data in the regeneration operation on the screen. The operation status can
be understood by analyzing the data values.

! CAUTION • The manual forced generation function using the Hino-DX aims to inspect system
operation. If the manual generation coution appears in the multifunctional display, do not
use the Hino-DX, but use the DPR regeneration switch in the cabin for regeneration.
• If any fault code concerning the DPR is detected, refer to the fault diagnosis documents
and be sure to change or clean the DPR cleaner. After that, inspect the whole system
condition using the manual forced generation mode of the Hino-DX.

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–23

(1) Connect the Hino-DX to the machine and set the starter key to [ON].

! CAUTION • Flag setting by "Set (C)" o "Customize (C)" o "10-sec DPR lamp blinking / Identifying
setting status" is unnecessary. If you set the flag, ensure to return the setting to "0".

(2) Select the "DPR check (D)" menu in "Check functions (E)" from the Hino-DX menu bar.

Select

SAPH30J191000016

[S5LC0033E04] [0518CsCshWbYs]
10–24 EXHAUST

(3) Click the "Reset all DPR items (R)" button in the DPR status display window to reset the values, and then
click the "Manual forced regeneration (E)" button.

! CAUTION • To perform manual forced regeneration, stop the engine, lift up the lock lever and set the
starter key to [ON].

Before resetting all the DPR items, be sure to stop the engine, press the brake switch
and set the lever in the lock position. After that, set the starter key to ON.

SAPH30J191000017

(4) Verify the contents of the displayed caution note, set a check mark for "Comprehended", and then click the
"Next (N)" button.

SAPH30J191000018

! CAUTION • If you continuously perform manual forced regeneration, perform a 10-minuite scavenging
drive before the next regeneration cycle.

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–25

(5) After "Manual forced regeneration" appears on the screen, make sure safety around the machine and start
the engine.

! CAUTION • Make the machine to the parking attitude and lift up the lock lever in the idle state.

a. After parking the machine in a safe place, keep idling with the gear set in the
neutral position and turn off the PTO.
b. Be sure to press the brake switch and to set the lever in the lock position.

SAPH30J191000019

a. If you press the DPR regeneration switch in the cabin , manual forced generation will starts.

DPR regeneration switch

SAPH30J191000153

NOTICE • When the "Regenerating" mark does not appear on the cluster or the engine speed does
not idle up even if the DPR regeneration switch is pressed, you cannot proceed to forced
generation.
In such cases, inspect the neutral switch circuit, accelerator emergency circuit,
malfunction of the lock lever and so on.

[S5LC0033E04] [0518CsCshWbYs]
10–26 EXHAUST

(6) End manual forced regeneration from the screen of the Hino-DX.
a. After starting regeneration, pay attention to the values in the data display on the screen. If the value of
the "DPR exhaust gas temperature (IN)" exceeds 450qC [842qF], the DPR system operates properly.
Click the "Close (C)" button to end manual forced regeneration.

! CAUTION • Scavenging drive starts. Do not stop the engine here.

NOTICE 1. The regeneration mode does not operate properly.

• If the temperature does not reach 450qC [842qF] in about 30 minutes after starting
regeneration, the oxidation catalyst in the previous step may not be functioning. Click
the "Close (C)" button to cancel manual forced regeneration and perform the fault
diagnosis on P2458/P24A2 in Section 17.
• If any DTC code occurs during regeneration, click the "Close (C)" button to cancel
manual forced regeneration and first repair the fault indicated by the code.
2. Regeneration of filters
• The forced regeneration mode using the Hino-DX serves to check the operation of the
whole DPR system, but as a function, it can also regenerate the filter by combusting
soot.
When the temperature rise to 450qC [842qF] is confirmed, wait for a while without
ending end the mode. After soot combustion is completed, the screen transitions to
that shown in ["b" on next page].
• When soot combustion has been completed, the engine speed lowers and the hydraulic
relief valve closes. However, the regeneration mode may not stop automatically and
may repeat operation even if regeneration has been completed.
When you hear the closing sound of the hydraulic relief valve, combustion treatment
has been completed. Click the "Close (C)" button to end manual forced regeneration.

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–27

The forced regeneration is in progress and that you have to wait for a while.
a. When soot combustion is being performed
When soot combustion is completed, the regeneration mode will automatically turn off.
Some machines might open or close their relief valves when the regeneration is completed.
After the hydraulic relief starts and then the operating noise of the relief valve is
heard, press [Cancel] button to stop the manual forced regeneration.
<<CAUTION>>
After the manual forced regeneration is stopped, there may be a case where the hydraulic
relief automatically starts again. Note that the regeneration is completed when the
hydraulic relief ends.
If this happens, press [Cancel] button to abort the regeneration.
b. When the inspection on the DPR system is being conducted
After starting the regeneration process, confirm that the value of "DPR Exhaust temperature
(IN)" has risen to 450 C {842 F} or higher, then press the regeneration or [Cancel]
button to stop the regeneration.

a. After parking the machine in a safe place, keep idling with the gear set in the
neutral position and turn off the PTO.
b. Be sure to press the brake switch and to set the lever in the lock position.

SAPH30J191000022

[S5LC0033E04] [0518CsCshWbYs]
10–28 EXHAUST

b. When the process up through the soot combustion treatment has been completed, the following
explanation appears. Click the "Close (C)" button to end manual forced regeneration.

! CAUTION • Scavenging drive starts. Do not stop the engine here.

a. After parking the machine in a safe place, keep idling with the gear set in the
neutral position and turn off the PTO.
b. Be sure to press the brake switch and to set the lever in the lock position.

SAPH30J191000023

(7) When the caution box appears, check the content and perform a 10-minuite scavenging drive. The
scavenging drive is completed in 10 minutes. Operate the starter key to stop the engine.
After scavenging drive has been completed, set a check mark for "Comprehended" and click the "Exit (X)"
button.

SAPH30J191000024

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–29

(8) This completes the manual forced regeneration process. When all stages of the manual forced
regeneration have been completed, carry out the differential pressure check.

NOTICE • You can stop manual forced regeneration also by pressing the "DPR manual regeneration"
button in the cabin. In this case, the caution about the scavenging drive does not appear
but the 10-minuite scavenging drive should be performed.

DPR regeneration switch

SAPH30J191000153

[S5LC0033E04] [0518CsCshWbYs]
10–30 EXHAUST

3. DPR differential pressure check

(1) If you click the "DPR differential pressure check (D)" button, you can measure the soot clogging status of
the DPR as it’s differential pressure and whether it is necessary to do maintenance or not can be checked.

Before resetting all the DPR items, be sure to stop the engine, press the brake switch
and set the lever in the lock position. After that, set the starter key to ON.

SAPH30J191000154

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–31

a. If you click “DPR differential pressure check (D)” button, DPR differential pressure check window will be
shown.
b. Click the “Execute (E)” button.
c. Engine rotation will go up automatically to maximum and DPR differential pressure will be recorded.

a. After parking the machine in a safe place, keep idling with the gear set in the
neutral position and turn off the PTO.
b. Be sure to press the brake switch and to set the lever in the lock position.

SAPH30J191000155
d. Click the “Stop (E)” button and you are finished measuring.

NOTICE • Every time you click the "Execute (E)" and "Stop (E)" button, the display will change
"Execute (E)" and "Stop (E)" alternately.

Switch indicate item

SAPH30J191000156

[S5LC0033E04] [0518CsCshWbYs]
10–32 EXHAUST

Cleaning of DPR filter

JP30J19100702007

1. Cleaning method
(1) Use a dedicated cleaning machine to perform filter
cleaning. Never clean the filter elsewhere. For the
cleaning method, refer to the cleaning machine handling
manual.

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–33

AdBlue/DEF SCR
Replacement
JP30J19100402002

! WARNING • As there is the danger of burns, perform the

replacement work after cooling down. (Wait
for 30 minutes or more after the starter key
has been set to the "OFF" position.)

! CAUTION • The DPR cleaner and the AdBlue/DEF SCR

must be handled with care as they are made
from ceramics, are heavy, and may break
easily.

Removal of the AdBlue/DEF SCR

1. Disconnecting the AdBlue/DEF injector hose and harness

Torx bolt (1) Remove the hose clamp, then disconnect the 2 coolant
hoses and the AdBlue/DEF hose from the AdBlue/DEF
injector.

! CAUTION • Refer to "Caution notes for mounting and

dismounting of AdBlue/DEF and coolant
piping". 10–10 page

NOTICE • Prepare a container and a shop towel, as

SAPH30J191000029
coolant will spill when the hoses are
disconnected.
• Close the hose with a blind plug as coolant
will flow from the hose.
• Install a protective cap on the AdBlue/DEF
injector.

• Do not loosen the Torx bolt shown in the

figure.

(2) Disconnect the harness connector from the AdBlue/DEF

injector.

SAPH30J191000030

[S5LC0033E04] [0518CsCshWbYs]
10–34 EXHAUST

2. Disconnecting the connector of the NOx sensor

(1) Remove the P-type clamp and the holding band from the
harness of the NOx sensor.

Holding band
P-type clamp

Front

P-type clamp Holding band

SAPH30J191000031
(2) Remove the 4 bolts and remove the 2 NOx controllers
from the base.

SAPH30J191000032

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–35

(3) Disconnect the connector of the harness on the machine

side from the NOx controller.

! CAUTION • Mark the components to ensure that the

upstream and the downstream side can be re-
installed in their correct locations.
• The NOx sensor and the NOx controller
cannot be disconnected. Always pull the
indicated connector.

View A

A
Do not disconnect

NOx sensor
NOx controller
SAPH30J191000033

[S5LC0033E04] [0518CsCshWbYs]
10–36 EXHAUST

3. Disconnecting the connector of the exhaust gas DPR

downstream temperature sensor
(1) Remove the P-type clamp and the holding band from the
harness of the exhaust gas DPR downstream
temperature sensor.

P-type clamp

Holding band

Holding band P-type clamp

SAPH30J191000034
(2) Disconnect the connector of the harness on the machine
side from the connector of the exhaust gas DPR
downstream temperature sensor.

SAPH30J191000035

4. Removal of the AdBlue/DEF pipe bracket

(1) Remove the 2 bolts and remove the AdBlue/DEF pipe
bracket from the muffler unit.

SAPH30J191000036

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–37

5. Disconnecting the connector of the exhaust gas DOC

P-type clamp
downstream temperature sensor
(1) Remove the P-type clamp and the holding band from the
harness of the exhaust gas DOC downstream
temperature sensor.

(2) Disconnect the connector of the harness on the machine

side from the connector of the exhaust gas DOC
downstream temperature sensor.
Holding band
SAPH30J191000037

6. Removal of the differential pressure sensor bracket

(1) Remove the hose clamp, and then disconnect the 2
differential pressure sensor hoses from the AdBlue/DEF
injector.

SAPH30J191000038

(2) Remove the bolt and the nut, and then remove the
differential pressure bracket from the hanger of the muffler
unit.

Differential pressure bracket

SAPH30J191000039

[S5LC0033E04] [0518CsCshWbYs]
10–38 EXHAUST

7. Disconnecting the connector of the exhaust gas SCR

upstream temperature sensor
(1) Remove the P-type clamp and the holding band from the
harness of the exhaust gas SCR upstream temperature
sensor.
(2) Disconnect the connector of the harness on the machine
side from the connector of the exhaust gas SCR upstream
temperature sensor.
P-type clamp
Connector Holding band
SAPH30J191000040

(3) Remove the clamp from the connector part of the SCR
Connector upstream temperature sensor.

Clamp

SAPH30J191000041

8. Removal of the exhaust pipe

(1) Remove the bolt and the nut, and then remove the
exhaust pipe from the muffler unit.

SAPH30J191000042

9. Removal of the tailpipe

(1) Remove the bolt and the nut, and then remove the tailpipe
from the muffler unit.

SAPH30J191000043

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–39

10. Removal of the muffler unit

(1) Remove the cap screws and the nuts (8 locations), and
then remove the muffler unit from the base.

NOTICE • The following attaching parts are installed at

each location:
Nut x 1
Cap screw x 1
Plate x 1
SAPH30J191000044
Spacer x 1
Mount rubber x 2

11. Disassembly of the AdBlue/DEF SCR

Bracket
(1) Apply matching marks to the connection parts between
rear silencer chamber and AdBlue/DEF SCR.

(2) Remove the 10 bolts and the 10 nuts and remove the rear
silencer chamber, the bracket, and the gasket from the
AdBlue/DEF SCR.
Upp
NOTICE • Applying matching marks to the bracket
LH Fr
Matching mark
facilitates the work at the time of installation.
SAPH30J191000045

(3) Apply matching marks to the connection parts between

Bracket the AdBlue/DEF SCR chamber and AdBlue/DEF SCR.

(4) Remove the 10 bolts and the 10 nuts and remove the
AdBlue/DEF SCR chamber, the 2 brackets, and the
gasket from the AdBlue/DEF SCR.
Upp
NOTICE • Applying matching marks to the brackets
facilitates the work at the time of installation.
LH

Matching mark Fn
• When the marking of the gas flow direction
SAPH30J191000046 cannot be seen easily, marking the flow
direction can facilitate the work at the time of
installation.

12. Insulator removal

(1) Remove the 6 bolts and the 6 nuts and remove the 2
insulators from the AdBlue/DEF SCR.

! CAUTION • Do not touch the insulator on the lower side of

the vehicle directly because it contains glass
fibers.

NOTICE • Mark the AdBlue/DEF SCR so that the top and

bottom section can be identified easily.
SAPH30J191000047

[S5LC0033E04] [0518CsCshWbYs]
10–40 EXHAUST

Installation of the AdBlue/DEF SCR

! CAUTION • The DPR cleaner and the AdBlue/DEF SCR

must be handled with care as they are made
from ceramics, are heavy, and may break
easily.

1. Insulator installation
(1) Install the 2 insulators with 6 bolts and 6 nuts to the
AdBlue/DEF SCR.

! CAUTION • Do not touch the insulators on the lower side

of the vehicle directly because they contain
glass fibers.
• Do not confuse the insulators in vertical
direction.
SAPH30J191000047

• Install the insulator so that the stamp "GAS

FLOW o" of the AdBlue/DEF SCR case can be
seen.

SAPH30J191000048

• Mount the insulator with the recessed part

Bracket convex portion
matched to the projection of the bracket on
the AdBlue/DEF SCR body.

Insulator recess
SAPH30J191000049

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–41

2. AdBlue/DEF SCR installation

AdBlue/DEF SCR chamber (1) Match the "GAS FLOW o" mark on the AdBlue/DEF SCR
plate with the exhaust gas flow direction.

AdBlue/DEF SCR
SAPH30J191000050

(2) Line up the matching marks and use a new gasket, 10

Bracket new bolts, and 10 new nuts to provisionally secure the
AdBlue/DEF SCR chamber and the 2 brackets to the
AdBlue/DEF SCR.

! CAUTION • Always replace the gasket, the bolts, and the

Upp nuts with new parts to prevent leakage of
exhaust gas and AdBlue/DEF.
LH

Matching mark Fn (3) Diagonally tighten the 10 bolts and 10 nuts previously
SAPH30J191000046 tightened provisionally. (Tighten twice.)
Tightening torque : 64 N˜m {653 kgf˜cm, 47 lbf˜ft}
(4) Line up the matching marks and use a new gasket, 10
Bracket
new bolts, and 10 new nuts to provisionally secure the
rear silencer chamber, and the bracket to the AdBlue/DEF
SCR.

! CAUTION • Always replace the gasket, the bolts, and the

nuts with new parts to prevent leakage of
Upp
exhaust gas.
LH Fr
Matching mark (5) Diagonally tighten the 10 bolts and 10 nuts previously
SAPH30J191000045
tightened provisionally. (Tighten twice.)
Tightening torque : 64 N˜m {653 kgf˜cm, 47 lbf˜ft}

[S5LC0033E04] [0518CsCshWbYs]
10–42 EXHAUST

3. Mounting the muffler unit

(1) Place the mount rubbers at the muffler unit installation
holes of the bracket.

SAPH30J191000051

(2) Place the muffler unit onto the mount rubbers.

SAPH30J191000052

(3) Set the plate to the mount rubber on the underside of the
bracket, and install the spacer at the center.
Secure the cap screw with the nut and a washer.

Nut
Muffler unit (Stand)
Mount rubber
Base
Mount rubber
Spacer
Plate
Washer
Cap screw

SAPH30J191000053
(4) Tighten the cap screws provisionally in the order shown in
the figure.

(5) Apply Loctite #262 to the threaded part of the cap screws
and tighten the cap screws in the order shown in the
figure to the specified torque.
Tightening torque :
108r11 N˜m {1,101r112 kgf˜cm, 80r8.1 lbf˜ft}

SAPH30J191000054

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–43

4. Installation of the exhaust pipe

(1) Replace the gasket with a new part, and then install the
exhaust pipe to the muffler unit, using bolts and nuts.

Tightening torque :
120r12 N˜m {1,224r122 kgf˜cm, 88r8.8 lbf˜ft}

Gasket

SAPH30J191000055

5. Connecting the connector of the exhaust gas SCR

upstream temperature sensor
(1) Install the clamp to the connector part of the SCR
Connector upstream temperature sensor.

Clamp

SAPH30J191000056

(2) Connect the connector of the exhaust gas SCR upstream

temperature sensor with the socket of the harness on the
machine side.
(3) Secure the harness of the exhaust gas SCR upstream
temperature sensor with a P-type clamp and a holding
band.

Tightening torque :
P-type clamp 26r2.6 N˜m {265r26.5 kgf˜cm, 19r1.9 lbf˜ft}
Connector Holding band
SAPH30J191000057

[S5LC0033E04] [0518CsCshWbYs]
10–44 EXHAUST

6. Installation of the tailpipe

(1) Replace the gasket with a new part, and then install the
tailpipe on the muffler unit with the bolts and nuts.
Tightening torque :
120r12 N˜m {1,224r122 kgf˜cm, 88r8.8 lbf˜ft}

Gasket

SAPH30J191000058

7. Installation of the differential pressure sensor bracket

(1) Install the differential pressure sensor bracket to the
muffler hanger, using bolts and nuts.
Tightening torque :
52r5.2 N˜m {530r53 kgf˜cm, 38r3.8 lbf˜ft}

Differential pressure bracket

SAPH30J191000039

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–45

(2) Connect the hoses of the differential pressure sensor (2

locations) with the muffler unit and secure them with hose
clamps.


! CAUTION • Connect so that the installation positions of

the 2 hoses are correct.
• When the hoses of the DPR differential
pressure sensor are inserted incorrectly, the
DPR does not operate properly.
• Take care that the hoses are not twisted.

A 28mm {1.10in}
B 16mm
{0.63in}

A: Hose insertion allowance

B: Hose clamp insertion position

SAPH30J191000059

[S5LC0033E04] [0518CsCshWbYs]
10–46 EXHAUST

8. Connecting the connector of the exhaust gas DOC

P-type clamp
downstream temperature sensor
(1) Connect the connector of the DOC downstream
temperature sensor with the socket of the harness on the
machine side.

(2) Connect the exhaust gas DOC downstream temperature

sensor with the harness on the machine side, and then
bundle and secure it with a P-type clamp and a holding
Holding band band.
SAPH30J191000037
Tightening torque :
26r2.6 N˜m {265r26.5 kgf˜cm, 19r1.9 lbf˜ft}

! CAUTION • When bundling the harness, fix it in the

orientation shown in the figure, so that there
is no contact with the lock side of the
connector.

LOCK

SAPH30J191000060

9. Installation of the AdBlue/DEF pipe bracket

(1) Install the AdBlue/DEF pipe bracket with 2 bolts on the
muffler unit.

Tightening torque :
52r5.2 N˜m {530r53 kgf˜cm, 38r3.8 lbf˜ft}

SAPH30J191000061

10. Connecting the connector of the exhaust gas DPR

downstream temperature sensor
(1) Connect the connector of the exhaust gas DPR
downstream temperature sensor with the socket of the
harness on the machine side.

SAPH30J191000035

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–47

(2) Bundle the harness of the exhaust gas DPR downstream

temperature sensor and fix it with a P-type clamp and a
bundling band.

! CAUTION • When bundling the harness, fix it in the

orientation shown in the figure, so that there
is no contact with the lock side of the
connector.

Tightening torque :
26r2.6 N˜m {265r26.5 kgf˜cm, 19r1.9 lbf˜ft}

LOCK

SAPH30J191000060

P-type clamp

Holding band

Holding band P-type clamp

SAPH30J191000034

[S5LC0033E04] [0518CsCshWbYs]
10–48 EXHAUST

11. Connecting the connector of the NOx sensor

(1) Connect the connector of the harness on the machine
side with the socket of the NOx Controller.

! CAUTION • Connect the upstream and the downstream

side correctly.

View A

A
SAPH30J191000062
(2) Install the 2 NOx controllers with 4 bolts on the base.

Tightening torque :
9.6r1 N˜m {97.9r10.2 kgf˜cm, 7.1r0.7 lbf˜ft}

SAPH30J191000032

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–49

(3) Secure the harness of the NOx sensor with a P-type

clamp and a holding band.
Tightening torque :
26r2.6 N˜m {265r26.5 kgf˜cm, 19r1.9 lbf˜ft}

! CAUTION • Install the harness cover, leaving some slack

on the sensor side, so that the harness wire
cannot be seen.
• When installing the clips, take care that the
NOx sensor lead wires do not interfere with
the bracket, the bolts, etc.
• Confirm that the lead wires are not under
tension.

Holding band
P-type clamp

Front

P-type clamp Holding band

SAPH30J191000031

12. Connecting the AdBlue/DEF injector hose and harness

(1) Connect the connector of the harness with the AdBlue/
DEF injector.

SAPH30J191000063

[S5LC0033E04] [0518CsCshWbYs]
10–50 EXHAUST

(2) Connect the 2 coolant hoses and the AdBlue/DEF hose

with the AdBlue/DEF injector and secure them with hose
clamps.

! CAUTION • Refer to "Caution notes for mounting and

dismounting of AdBlue/DEF and coolant
piping". 10–10 page

SAPH30J191000064

13. Exhaust gas leakage inspection

(1) Start the engine and inspect for exhaust gas leak

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–51

DPR Cleaner
Replacement
JP30J19100402003

! WARNING • As there is the danger of burns, perform the

replacement work after cooling down. (Wait
for 30 minutes or more after the starter key
has been set to the "OFF" position.)

! CAUTION • The DPR cleaner and the AdBlue/DEF SCR

must be handled with care as they are made
from ceramics, are heavy, and may break
easily.

Removal of the DPR cleaner

1. Disconnecting the AdBlue/DEF injector hose and harness

Torx bolt (1) Remove the hose clamp, then disconnect the 2 coolant
hoses and the AdBlue/DEF hose from the AdBlue/DEF
injector.

! CAUTION • Refer to "Caution notes for mounting and

dismounting of AdBlue/DEF and coolant
piping". 10–10 page

NOTICE • Prepare a container and a shop towel, as

SAPH30J191000029
coolant will spill when the hoses are
disconnected.
• Close the hose with a blind plug as coolant
will flow from the hose.
• Install a protective cap on the AdBlue/DEF
injector.

• Do not loosen the Torx bolt shown in the

figure.

(2) Disconnect the harness connector from the AdBlue/DEF

injector.

SAPH30J191000030

[S5LC0033E04] [0518CsCshWbYs]
10–52 EXHAUST

2. Disconnecting the connector of the NOx sensor

(1) Remove the P-type clamp and the holding band from the
harness of the NOx sensor.

Holding band
P-type clamp

Front

P-type clamp Holding band

SAPH30J191000031
(2) Remove the 4 bolts and remove the 2 NOx controllers
from the base.

SAPH30J191000032

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–53

(3) Disconnect the connector of the harness on the machine

side from the NOx controller.

! CAUTION • Mark the components to ensure that the

upstream and the downstream side can be re-
installed in their correct locations.
• The NOx sensor and the NOx controller
cannot be disconnected. Always pull the
indicated connector.

View A

A
Do not disconnect

NOx sensor
NOx controller
SAPH30J191000033

[S5LC0033E04] [0518CsCshWbYs]
10–54 EXHAUST

3. Disconnecting the connector of the exhaust gas DPR

downstream temperature sensor
(1) Remove the P-type clamp and the holding band from the
harness of the exhaust gas DPR downstream
temperature sensor.

P-type clamp

Holding band

Holding band P-type clamp

SAPH30J191000034
(2) Disconnect the connector of the harness on the machine
side from the connector of the exhaust gas DPR
downstream temperature sensor.

SAPH30J191000035

4. Removal of the AdBlue/DEF pipe bracket

(1) Remove the 2 bolts and remove the AdBlue/DEF pipe
bracket from the muffler unit.

SAPH30J191000036

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–55

5. Disconnecting the connector of the exhaust gas DOC

P-type clamp
downstream temperature sensor
(1) Remove the P-type clamp and the holding band from the
harness of the exhaust gas DOC downstream
temperature sensor.

(2) Disconnect the connector of the harness on the machine

side from the connector of the exhaust gas DOC
downstream temperature sensor.
Holding band
SAPH30J191000037

6. Removal of the differential pressure sensor bracket

(1) Remove the hose clamp, and then disconnect the 2
differential pressure sensor hoses from the AdBlue/DEF
injector.

SAPH30J191000038

(2) Remove the bolt and the nut, and then remove the
differential pressure bracket from the hanger of the muffler
unit.

Differential pressure bracket

SAPH30J191000039

[S5LC0033E04] [0518CsCshWbYs]
10–56 EXHAUST

7. Disconnecting the connector of the exhaust gas SCR

upstream temperature sensor
(1) Remove the P-type clamp and the holding band from the
harness of the exhaust gas SCR upstream temperature
sensor.
(2) Disconnect the connector of the harness on the machine
side from the connector of the exhaust gas SCR upstream
temperature sensor.
P-type clamp
Connector Holding band
SAPH30J191000040

(3) Remove the clamp from the connector part of the SCR
Connector upstream temperature sensor.

Clamp

SAPH30J191000041

8. Removal of the exhaust pipe

(1) Remove the bolt and the nut, and then remove the
exhaust pipe from the muffler unit.

SAPH30J191000042

9. Removal of the tailpipe

(1) Remove the bolt and the nut, and then remove the tailpipe
from the muffler unit.

SAPH30J191000043

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–57

10. Removal of the muffler unit

(1) Remove the cap screws and the nuts (8 locations), and
then remove the muffler unit from the base.

NOTICE • The following attaching parts are installed at

each location:
Nut x 1
Cap screw x 1
Plate x 1
SAPH30J191000044
Spacer x 1
Mount rubber x 2

11. Disassembly of the DPR cleaner

(1) Apply matching marks to the connection parts related to
Bracket
the DPR camber and the DPR cleaner.

(2) Remove the 10 bolts and the 10 nuts and remove the
DPR chamber, the bracket, and the gasket from the DPR
cleaner.
Z Matching
mark NOTICE • Applying matching marks to the bracket
X
facilitates the work at the time of installation.
Y
SAPH30J191000065

(3) Apply matching marks to the connection parts related to

Bracket the front silencer chamber and the DPR cleaner.
Matching
mark NOTICE • Applying matching marks to the bracket
facilitates the work at the time of installation.
• When the marking of the gas flow direction
Z cannot be seen easily, marking the flow
direction can facilitate the work at the time of
Y X installation.
SAPH30J191000066
(4) Remove the 10 bolts and the 10 nuts and remove the front
silencer chamber, the bracket, and the gasket from the
DPR cleaner.

12. Insulator removal

(1) Remove the 4 bolts and the 4 nuts and remove the 2
insulators from the DPR cleaner.

! CAUTION • Do not touch the insulators on the lower side

of the vehicle directly because they contain
fibers.

Insulator DPR cleaner

SAPH30J191000067

[S5LC0033E04] [0518CsCshWbYs]
10–58 EXHAUST

Installation of the DPR cleaner

! CAUTION • The DPR cleaner must be handled with care

as it is made from ceramics, is heavy, and
may break easily.

1. Insulator installation
(1) Install the 2 insulators with 4 bolts and 4 nuts to the DPR
cleaner.

Tightening torque :
27.6r5 N˜m {281r51 kgf˜cm, 20r4 lbf˜ft}

! CAUTION • Do not touch the insulators on the lower side

of the vehicle directly because they contain
Insulator DPR cleaner glass fibers.
SAPH30J191000068 • Do not confuse the insulators in vertical
direction.
• Install the insulator so that the stamp "GAS
FLOW o" of the DPR cleaner case can be
Insulator seen.

DPR cleaner
SAPH30J191000069

2. Installation of the DPR cleaner

Front silencer chamber (1) Match the "GAS FLOW o" mark on the DPR cleaner
plate with the exhaust gas flow direction.

DPR cleaner
SAPH30J191000070

(2) Line up the matching marks and use a new gasket, 10

Bracket new bolts, and 10 new nuts to provisionally secure the
Matching front silencer chamber and the bracket to the DPR
mark cleaner.

! CAUTION • Always replace the gasket, the bolts, and the

Z nuts with new parts to prevent leakage of
exhaust gas.
Y X

SAPH30J191000066

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–59

(3) Diagonally tighten the 10 bolts and 10 nuts previously

tightened provisionally. (Tighten twice.)
Tightening torque : 64 N˜m {653 kgf˜cm, 47 lbf˜ft}
(4) Line up the matching marks and use a new gasket, 10
new bolts, and 10 new nuts to provisionally secure the
Bracket
DPR chamber and the bracket to the DPR cleaner.

! CAUTION • Always replace the gasket, the bolts, and the

nuts with new parts to prevent leakage of
Matching exhaust gas.
Z
mark
(5) Diagonally tighten the 10 bolts and 10 nuts previously
Y
X tightened provisionally. (Tighten twice.)
SAPH30J191000065 Tightening torque : 64 N˜m {653 kgf˜cm, 47 lbf˜ft}

[S5LC0033E04] [0518CsCshWbYs]
10–60 EXHAUST

3. Mounting the muffler unit

(1) Place the mount rubbers at the muffler unit installation
holes of the bracket.

SAPH30J191000051

(2) Place the muffler unit onto the mount rubbers.

SAPH30J191000052

(3) Set the plate to the mount rubber on the underside of the
bracket, and install the spacer at the center.
Secure the cap screw with the nut and a washer.

Nut
Muffler unit (Stand)
Mount rubber
Base
Mount rubber
Spacer
Plate
Washer
Cap screw

SAPH30J191000053
(4) Tighten the cap screws provisionally in the order shown in
the figure.

(5) Apply Locktite #262 to the threaded part of the cap screws
and tighten the cap screws in the order shown in the
figure to the specified torque.
Tightening torque :
108r11 N˜m {1,101r112 kgf˜cm, 80r8.1 lbf˜ft}

SAPH30J191000054

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–61

4. Installation of the exhaust pipe

(1) Replace the gasket with a new part, and then install the
exhaust pipe to the muffler unit, using bolts and nuts.

Tightening torque :
120r12 N˜m {1,224r122 kgf˜cm, 88r8.8 lbf˜ft}

Gasket

SAPH30J191000055

5. Connecting the connector of the exhaust gas SCR

upstream temperature sensor
(1) Install the clamp to the connector part of the SCR
Connector upstream temperature sensor.

Clamp

SAPH30J191000056

(2) Connect the connector of the exhaust gas SCR upstream

temperature sensor with the socket of the harness on the
machine side.
(3) Secure the harness of the exhaust gas SCR upstream
temperature sensor with a P-type clamp and a holding
band.

Tightening torque :
P-type clamp 26r2.6 N˜m {265r26.5 kgf˜cm, 19r1.9 lbf˜ft}
Connector Holding band
SAPH30J191000057

[S5LC0033E04] [0518CsCshWbYs]
10–62 EXHAUST

6. Installation of the tailpipe

(1) Replace the gasket with a new part, and then install the
tailpipe on the muffler unit with the bolts and nuts.
Tightening torque :
120r12 N˜m {1,224r122 kgf˜cm, 88r8.8 lbf˜ft}

Gasket

SAPH30J191000058

7. Installation of the differential pressure sensor bracket

(1) Install the differential pressure sensor bracket to the
muffler hanger, using bolts and nuts.
Tightening torque :
52r5.2 N˜m {530r53 kgf˜cm, 38r3.8 lbf˜ft}

Differential pressure bracket

SAPH30J191000039

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–63

(2) Connect the hoses of the differential pressure sensor (2

locations) with the muffler unit and secure them with hose
clamps.

A 28mm {1.10in}
B 16mm
{0.63in}

A: Hose insertion allowance

B: Hose clamp insertion position

SAPH30J191000059

8. Connecting the connector of the exhaust gas DOC

P-type clamp
downstream temperature sensor
(1) Connect the connector of the DOC downstream
temperature sensor with the socket of the harness on the
machine side.

(2) Connect the exhaust gas DOC downstream temperature

sensor with the harness on the machine side, and then
bundle and secure it with a P-type clamp and a holding
Holding band band.
SAPH30J191000037
Tightening torque :
26r2.6 N˜m {265r26.5 kgf˜cm, 19r1.9 lbf˜ft}

! CAUTION • When bundling the harness, fix it in the

orientation shown in the figure, so that there
is no contact with the lock side of the
connector.

LOCK

SAPH30J191000060

[S5LC0033E04] [0518CsCshWbYs]
10–64 EXHAUST

9. Installation of the AdBlue/DEF pipe bracket

(1) Install the AdBlue/DEF pipe bracket with 2 bolts on the
muffler unit.

Tightening torque :
52r5.2 N˜m {530r53 kgf˜cm, 38r3.8 lbf˜ft}

SAPH30J191000061

10. Connecting the connector of the exhaust gas DPR

downstream temperature sensor
(1) Connect the connector of the exhaust gas DPR
downstream temperature sensor with the socket of the
harness on the machine side.

SAPH30J191000035

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–65

(2) Bundle the harness of the exhaust gas DPR downstream

temperature sensor and fix it with a P-type clamp and a
bundling band.

! CAUTION • When bundling the harness, fix it in the

orientation shown in the figure, so that there
is no contact with the lock side of the
connector.

Tightening torque :
26r2.6 N˜m {265r26.5 kgf˜cm, 19r1.9 lbf˜ft}

LOCK

SAPH30J191000060

P-type clamp

Holding band

Holding band P-type clamp

SAPH30J191000034

[S5LC0033E04] [0518CsCshWbYs]
10–66 EXHAUST

11. Connecting the connector of the NOx sensor

(1) Connect the connector of the harness on the machine
side with the socket of the NOx Controller.

! CAUTION • Connect the upstream and the downstream

side correctly.

View A

A
SAPH30J191000062
(2) Install the 2 NOx controllers with 4 bolts on the base.

Tightening torque :
9.6r1 N˜m {97.9r10.2 kgf˜cm, 7.1r0.7 lbf˜ft}

SAPH30J191000032

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–67

(3) Secure the harness of the NOx sensor with a P-type

clamp and a holding band.
Tightening torque :
26r2.6 N˜m {265r26.5 kgf˜cm, 19r1.9 lbf˜ft}

! CAUTION • Install the harness cover, leaving some slack

on the sensor side, so that the harness wire
cannot be seen.
• When installing the clips, take care that the
NOx sensor lead wires do not interfere with
the bracket, the bolts, etc.
• Confirm that the lead wires are not under
tension.

Holding band
P-type clamp

Front

P-type clamp Holding band

SAPH30J191000031

12. Connecting the AdBlue/DEF injector hose and harness

(1) Connect the connector of the harness with the AdBlue/
DEF injector.

SAPH30J191000063

[S5LC0033E04] [0518CsCshWbYs]
10–68 EXHAUST

(2) Connect the 2 coolant hoses and the AdBlue/DEF hose

with the AdBlue/DEF injector and secure them with hose
clamps.

! CAUTION • Refer to "Caution notes for mounting and

dismounting of AdBlue/DEF and coolant
piping". 10–10 page

SAPH30J191000064

13. Exhaust gas leakage inspection

(1) Start the engine and inspect for exhaust gas leak.

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–69

AdBlue/DEF pump
Inspection
JP30J19100402004

1. Inspection of the AdBlue/DEF pump

(1) Use the Hino-DX and inspect the AdBlue/DEF pump.

Replacement
JP30J19100402005

Filter replacement

! CAUTION • Set the starter key to "OFF" and perform the

work after waiting for a sufficient time to
complete the after-run (returning the AdBlue/
DEF to the AdBlue/DEF tank).

1. Filter removal
AdBlue/DEF pump
(1) Use a 27 mm (12-point) box spanner to rotate the filter
cover counterclockwise, and then remove it from the
AdBlue/DEF pump.

! CAUTION • Prepare a container and a shop towel as

AdBlue/DEF will spill when the filter cover is
removed.
Filter cover
SAPH30J191000071

(2) Remove the equalizer from the AdBlue/DEF pump.

AdBlue/DEF pump
! CAUTION • When a screwdriver or similar is used with
excessive force at the time of replacement of
the AdBlue/DEF pump filter and the equalizer,
the AdBlue/DEF pump body may be damaged
and AdBlue/DEF leakage may be caused.

O-ring Equalizer
SAPH30J191000072

(3) Check color of the filter inside (Gray or Black).

SAPH30J191000073

[S5LC0033E04] [0518CsCshWbYs]
10–70 EXHAUST

(4) Select edge.

Filter removal tool

SAPH30J191000074

(5) Insert edge completely according to the filter color until a

click is felt, or heard, indicating that tool is completely
inserted.

SAPH30J191000075

(6) Draw out the filter from the AdBlue/DEF pump using the
filter removal tool.

SAPH30J191000076

(7) Cleaning of the surface with water only.

SAPH30J191000077

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–71

2. Filter installation
AdBlue/DEF pump (1) Apply Mobil velocite Oil No. 6 or equivalent to new O-ring.
O-ring
(2) Replace with a new filter and insert it into the AdBlue/DEF
pump.

Filter
SAPH30J191000078

(3) Apply Mobil velocite Oil No. 6 or equivalent to new O-ring.

AdBlue/DEF pump
(4) Replace with a new equalizer and insert it into the AdBlue/
DEF pump.

O-ring Equalizer
SAPH30J191000079

(5) Use a 27 mm (12-point) box spanner to rotate the filter

AdBlue/DEF pump cover clockwise and install it on the AdBlue/DEF pump.

Tightening torque :
20r5 N˜m {204r51 kgf˜cm, 15r4 lbf˜ft}

Filter cover
SAPH30J191000080

[S5LC0033E04] [0518CsCshWbYs]
10–72 EXHAUST

AdBlue/DEF pump removal

! CAUTION • Set the starter key to "OFF" and perform the

work after waiting for a sufficient time to
complete the after-run (returning the AdBlue/
DEF to the AdBlue/DEF tank).

1. Harness disconnection
P-type clamp
(1) Remove the P-type clamp and the holding band from the
harness of the AdBlue/DEF pump.
(2) Disconnect the harness connector from the AdBlue/DEF
pump.

Holding band
Connector
SAPH30J191000081

2. Hose disconnection
(1) Disconnect the hose from the AdBlue/DEF pump.

! CAUTION • Refer to "Caution notes for mounting and

dismounting of AdBlue/DEF and coolant
piping". 10–10 page

NOTICE • Prepare a container and a shop towel, as

coolant will spill when the hoses are
disconnected.
SAPH30J191000082
• Close the hose with a blind plug as coolant
will flow from the hose.
• Install a protective cap on the AdBlue/DEF
injector.

3. AdBlue/DEF pump removal

(1) Remove the bolts, and then remove the AdBlue/DEF
pump from the machine.

SAPH30J191000083

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–73

AdBlue/DEF pump installation

1. AdBlue/DEF pump installation

(1) Install the AdBlue/DEF pump on the machine, using the
bolts.

Tightening torque :
19r3.8 N˜m {194r39 kgf˜cm, 14r2.8 lbf˜ft}

SAPH30J191000084

[S5LC0033E04] [0518CsCshWbYs]
10–74 EXHAUST

2. Hose connection

(1) Connect the hose to the AdBlue/DEF pump.

! CAUTION • Refer to "Caution notes for mounting and

dismounting of AdBlue/DEF and coolant
piping". 10–10 page

SAPH30J191000085

! CAUTION • The hoses can be identified by the color of the

tapes. Please refer to the figure and install at
2
3 the correct position.

Identification
Port Application
5
color

AdBlue/DEF
1 Pink
1 (outlet)
4
SAPH30J191000086
AdBlue/DEF
2 Orange
(backflow)

AdBlue/DEF
3 White
(inlet)

4 Coolant Brown

5 Coolant Yellow

• Connect each hose at the angle shown in the

figure.

Green
30

20 25

30

SAPH30J191000087

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–75

3. Harness connection
P-type clamp (1) Connect the harness connector with the AdBlue/DEF
pump.
(2) Secure the harness of the AdBlue/DEF pump with a P-
type clamp and a holding band.


! CAUTION • Secure the holding bands matching the white

tape.
Holding band
Connector
Tightening torque :
SAPH30J191000088 23.5r2.4 N˜m {240r25 kgf˜cm, 17r1.8 lbf˜ft}

4. Fill in coolant
(1) Check the coolant quantity and replenish if it is not
sufficient.

[S5LC0033E04] [0518CsCshWbYs]
10–76 EXHAUST

AdBlue/DEF injector
Inspection
JP30J19100402006

1. AdBlue/DEF injector inspection

(1) Use the Hino-DX and inspect the AdBlue/DEF injector.

Replacement
JP30J19100402007

AdBlue/DEF injector removal

! CAUTION • Set the starter key to "OFF" and perform the

work after waiting for a sufficient time to
complete the after-run (returning the AdBlue/
DEF to the AdBlue/DEF tank).

1. Hose disconnection
Torx bolt
! CAUTION • Refer to "Caution notes for mounting and
dismounting of AdBlue/DEF and coolant
piping". 10–10 page

(1) Remove the hose clamp, and then disconnect the 2

coolant hoses and the AdBlue/DEF hose from the AdBlue/
DEF injector.

NOTICE • Prepare a container and a shop towel, as

SAPH30J191000029
coolant will spill when the hoses are
disconnected.
• Close the hose with a blind plug as coolant
will flow from the hose.
• Install a protective cap on the AdBlue/DEF
injector.

• Do not loosen the Torx bolt shown in the

figure.

2. Harness disconnection
(1) Disconnect the harness connector from the AdBlue/DEF
injector.

SAPH30J191000089

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–77

3. AdBlue/DEF injector removal

(1) Remove the 3 nuts, and then remove the AdBlue/DEF
injector from the muffler unit.

! CAUTION • Close the opening of the AdBlue/DEF injector

mounting part with tape or similar.

SAPH30J191000090

(2) Use pliers to raise the 3 retaining tabs of the gasket, and
Gasket then remove the gasket from the AdBlue/DEF injector.

! CAUTION • Do not use pointed pliers.

AdBlue/
Retaining tab
DEF injector
SAPH30J191000091

(3) Clean the surfaces of the sealing interface of the AdBlue/

Orifice plate DEF injector.
Sealing interface
! CAUTION • Take care not to scratch the sealing interface
surfaces.
• Do not touch the orifice plate.

AdBlue/DEF injector

SAPH30J191000092

4. Connector disconnection
Coolant (1) Use a 15 mm {0.59 in.} spanner and disconnect the 2
connector
coolant connectors from the AdBlue/DEF injector.
20 mm
{0.79 in.}
(2) Remove the O-ring from the coolant connector.
70 mm {2.76 in.}

O-ring

AdBlue/
DEF injector
SAPH30J191000093

[S5LC0033E04] [0518CsCshWbYs]
10–78 EXHAUST

AdBlue/DEF injector installation

1. Connector connection
Coolant (1) Apply Mobil Velocite Oil No. 6 or equivalent to 2 new O-
connector
rings and install them on the 2 coolant connectors.
20 mm
{0.79 in.}
(2) Use a 15 mm {0.59 in.} spanner and connect the coolant

70 mm {2.76 in.}
connector to the AdBlue/DEF injector.
O-ring Tightening torque :
5-6 N˜m {51-61 kgf˜cm, 4-5 lbf˜ft}
AdBlue/
DEF injector
SAPH30J191000094

2. AdBlue/DEF injector installation

Gasket (1) Place a new gasket onto the sealing interface and install it
by pressing it down.

! CAUTION • The gasket cannot be reused because the

retaining tabs are deformed.

AdBlue/ • Take care not to damage the gasket.

DEF injector
• Confirm that the 3 retaining tabs of the gasket
engage the retaining tabs of the AdBlue/DEF
SAPH30J191000095 injector.
(2) Install the AdBlue/DEF injector with 3 nuts to the muffler
unit.

Tightening torque :
8r2 N˜m {82r20 kgf˜cm, 6r1.5 lbf˜ft}

SAPH30J191000096

3. Harness connection
(1) Connect the connector of the harness to the AdBlue/DEF
injector.

SAPH30J191000097

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–79

4. Hose connection

! CAUTION • Refer to "Caution notes for mounting and

dismounting of AdBlue/DEF and coolant
piping". 10–10 page

(1) Connect the 2 coolant hoses and the AdBlue/DEF hose

with the AdBlue/DEF injector, and then secure them with
hose clamps.

SAPH30J191000098

5. Fill in coolant
(1) Check the coolant quantity and replenish if it is not
sufficient.

[S5LC0033E04] [0518CsCshWbYs]
10–80 EXHAUST

AdBlue/DEF tank
Inspection
JP30J19100402008

AdBlue/DEF concentration inspection

! CAUTION • There are 3 inspection methods for the

AdBlue/DEF: AdBlue/DEF analyzer
inspection, pH litmus paper inspection, and
refractive index measuring inspection. Use
one of these methods for the inspection.

1. AdBlue/DEF analyzer inspection

(1) Sample the AdBlue/DEF, drip it into the AdBlue/DEF
analyzer, measure the AdBlue/DEF concentration, and
replace the AdBlue/DEF if it is not at the reference value.

Standard value (%) 32.5

SAPH30J191000099

2. pH litmus paper inspection

(1) Sample the AdBlue/DEF, drip it onto the pH litmus paper,
measure the color change, and replace the AdBlue/DEF if
it is not at the reference value.

Concentration (%) Standard value (number)

32.5 9

SAPH30J191000100

3. Refractive index measuring inspection

1.40 (1) Sample the AdBlue/DEF, put a few drops into the
1.35 refractometer, measure the refractive index, and replace
Battery fluid

1.30
the AdBlue/DEF if it is not at the reference value.
Freezing point
Antifreeze

1.25
1.20
1.15
1.10
Concentration (%) Standard value (%)
Specific gravity

32.5 1.3817 to 1.384

1.00

SAPH30J191000101

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–81

Replacement
JP30J19100402009

AdBlue/DEF replacement

! CAUTION • After the starter key has been set to "OFF",

wait for a sufficient time to complete the after-
run (return of the AdBlue/DEF solution to the
AdBlue/DEF tank) after setting the starter key
to "OFF" and then perform the work.

1. Discharging of AdBlue/DEF
(1) Remove the 2 bolts, and then remove the cover plate from
the machine.

(2) Use a hexagon socket wrench with a width across flats of

10 mm to loosen the drain plug and discharge the AdBlue/
DEF.

! CAUTION • For disposal of AdBlue/DEF, observe the

specified methods (waste processing) and
pay attention to the protection of the
environment.

2. Filling of AdBlue/DEF
(1) Install the drain plug on the AdBlue/DEF tank, using a
hexagon socket wrench with a width across flats of 10
mm.
Tightening torque :
Cover plate
50r5 N˜m {510r51 kgf˜cm, 37r4 lbf˜ft}
(2) Install the cover plate on the machine, using the 2 bolts.

SAPH30J191000102

[S5LC0033E04] [0518CsCshWbYs]
10–82 EXHAUST

(3) Remove the filler cap and fill in AdBlue/DEF.

SAPH30J191000103

! CAUTION • Fill only AdBlue/DEF into the AdBlue/DEF tank.

• When filling AdBlue/DEF into the AdBlue/DEF tank, do not fill to a level above the F-line of
the level gauge on the left side of the tank.
AdBlue/DEF will overflow when this level is exceeded.
• If AdBlue/DEF should overflow from the AdBlue/DEF tank or if it should adhere to the
AdBlue/DEF tank or surrounding parts at the time of filling, immediately wipe it off with a
shop towel or similar. If it is left as it is, the AdBlue/DEF will crystallize and become white, it
will become difficult to remove by wiping, so it should be wiped off while liquid. Difficult-to-
remove crystals can be removed more easily by wiping with a shop towel moistened with
warm water.
• When filling-in AdBlue/DEF, take care to prevent the entry of dust etc. into the AdBlue/DEF
tank. Entry of dust etc. can cause failure of the AdBlue/DEF pump and/or clogging of the
piping and the AdBlue/DEF injector.
• If tightening of the filler cap of the AdBlue/DEF tank has become difficult because of
AdBlue/DEF crystals sticking to the filling port, do not apply excessive force, but tighten
after removing the crystals with a shop towel or similar. At such a time, take care that no
shop towel scraps or similar get into the AdBlue/DEF tank.
• For disposal of AdBlue/DEF, observe the specified methods (waste processing) and pay
attention to the protection of the environment.
• As AdBlue/DEF expands when it freezes, the tank will rupture in case of freezing when
AdBlue/DEF is filled in to the max. level or higher.
• When AdBlue/DEF is filled in with the machine in inclined condition, AdBlue/DEF may
overflow before the max. level of the level gauge is reached.
• Check the level gauge after waiting for at least 1 minute after the key was set to ON.

1 Full tank level

Level 5 and more

2
(Warning is release. Engine output is restored.)

3 Level 2 (Warning)

4 Level 1 (Engine output is restricted.)

5 Level 0 (Idle fixed)

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–83

Coolant cut-off valve

Inspection
JP30J19100402010

1. Coolant cut-off valve inspection

(1) Use the Hino-DX and inspect the coolant cut-off valve.

[S5LC0033E04] [0518CsCshWbYs]
10–84 EXHAUST

Replacement
JP30J19100402011

Coolant cut-off valve removal

1. Removal of the under-cover

(1) Remove the 2 bolts and remove the under-cover from the
machine.

SAPH30J191000109

2. Hose disconnection

! CAUTION • Refer to "Caution notes for mounting and

dismounting of AdBlue/DEF and coolant
piping". 10–10 page

(1) Remove the hose clamp, and then disconnect the 2 hoses
from the coolant cut-off valve.

IN OUT NOTICE • Prepare a container and a shop towel as

coolant will spill when the hoses are
SAPH30J191000110
disconnected.
• Close the hose with a blind plug as coolant
will flow from the hose.
• Close the coolant cut-off valve with blind
plugs as coolant will flow from the valve.
• After disconnection, apply vinyl covers or
similar to prevent entry of foreign matter into
the piping.

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–85

3. Harness disconnection
(1) Disconnect the harness connector from the coolant cut-off
valve.

SAPH30J191000111

4. Removal of the coolant cut-off valve

(1) Remove the 2 bolts and remove the coolant cut-off valve
from the machine.

SAPH30J191000112

[S5LC0033E04] [0518CsCshWbYs]
10–86 EXHAUST

Coolant cut-off valve installation

1. Installation of the coolant cut-off valve

(1) Install the coolant cut-off valve on the machine, using the
2 bolts.

Tightening torque :
26r2.6 N˜m {265r26.5 kgf˜cm, 19r1.9 lbf˜ft}

SAPH30J191000113

2. Harness connection
(1) Connect the harness connector with the coolant cut-off
valve.

SAPH30J191000114

3. Hose connection

! CAUTION • Refer to "Caution notes for mounting and

dismounting of AdBlue/DEF and coolant
piping". 10–10 page

(1) Connect the 2 hoses to the coolant cut-off valve, and then
secure them with hose clamps.

SAPH30J191000115

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–87

4. Installation of the under-cover

(1) Install the under-cover on the machine, using the 2 bolts.

SAPH30J191000109

5. Fill in coolant
(1) Check the coolant quantity and replenish if it is not
sufficient.

[S5LC0033E04] [0518CsCshWbYs]
10–88 EXHAUST

DCU
Replacement
JP30J19100402012

DCU removal

1. Connector disconnection
(1) Remove the holding band from the harness of the DCU.

Holding band

SAPH30J191000116
(2) Move the slide in the direction indicated by an arrow until
86-pole connector Slide a "Click" is heard, and then disconnect the connector.

53-pole connector

Slide
SAPH30J191000117

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–89

(3) Pull the connector in a straight line.

86-pole connector Slide
! CAUTION • Avoid unnecessary connector disconnection
and connection.
• Pulling on the harness or disconnecting with
twisting must be avoided because it can
cause wire breaks or terminal deformation.
• Never insert a test probe from the rear of the
connector.
53-pole connector • Do not apply paint, oil, or fat to the connector
part in order to maintain the functions and the
durability.

NOTICE • If pulling with a light force is not possible,

check that the slide has opened completely.

Slide
SAPH30J191000118

2. DCU removal
(1) Remove the 4 bolts, and then remove the DCU from the
machine.

SAPH30J191000119

[S5LC0033E04] [0518CsCshWbYs]
10–90 EXHAUST

DCU installation

1. DCU installation
(1) Install the DCU on the machine, using the 4 bolts.

Tightening torque :
10.0r2 N˜m {102r20 kgf˜cm, 21r1.4 lbf˜ft}

SAPH30J191000120

2. DCU connector connection

86-pole connector Slide (1) Confirm that the slide of the connector on the harness
side is completely open and place the connector straight
onto the connector on the DCU side.

! CAUTION • At this time, confirm that the slide is

completely open.
Connector on
(2) Press the part above the connector on the harness side
the harness
side and insert the connector uniformly.
53-pole connector Connector on
the DCU side

Connector on
the harness
side
Connector on
Slide
the DCU side
SAPH30J191000121

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–91

(3) Move the slide in the direction indicated by an arrow until

86-pole connector Slide a "Click" is heard, and then connect the connector.

! CAUTION • Repeat steps (1) and (2) if the slide does not
move smoothly.

53-pole connector

Slide
SAPH30J191000122

• As a gap may be caused when the sliding part

Slide part is inclined, make sure to insert the sliding
part exactly parallel to the connector.

When normal
Slide part

When inclined
SAPH30J191000123

(4) Secure the harness of the DCU with a holding band.

SAPH30J191000124

[S5LC0033E04] [0518CsCshWbYs]
10–92 EXHAUST

Differential pressure sensor

Replacement
JP30J19100402013

Differential pressure sensor removal

1. Harness disconnection
(1) Remove the holding band, and then disconnect the
harness connector from the differential pressure sensor.

SAPH30J191000125

2. Hose disconnection
(1) Remove the hose clamp, and then disconnect the 2 hoses
from the differential pressure sensor.


! CAUTION • Mark the components, so that the 2 hoses can

be re-installed in their correct locations.

SAPH30J191000126

3. DPR differential pressure sensor removal

(1) Remove the nut, and then remove the differential pressure
sensor from the bracket.

SAPH30J191000127

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–93

Inspection

1. Resistance inspection
(1) Use a circuit tester to measure the resistance of the
differential pressure sensor, and replace the sensor if the
standard value is exceeded.

Measuring item Standard value (k:)

C

B
AlB 15
Differential
pressure sensor A BlC 15
SAPH30J191000128

[S5LC0033E04] [0518CsCshWbYs]
10–94 EXHAUST

Differential pressure sensor installation

1. Installation of the differential pressure sensor

(1) Install the differential pressure sensor on the bracket,
using the nut.

Tightening torque :
26r2.6 N˜m {265r26.5 kgf˜cm, 19r1.9 lbf˜ft}

SAPH30J191000129

2. Hose connection
(1) Connect the 2 hoses to the differential pressure sensor,
and then secure them with hose clamps.


! CAUTION • Connect so that the installation positions of

the 2 hoses are correct.
• When the hoses of the DPR differential
pressure sensor are inserted incorrectly, the
DPR does not operate properly.
• Take care that the hoses are not twisted.

B 16mm {0.63in}

A 20mm
{0.79in}

A: Hose insertion allowance

B: Hose clamp insertion position

SAPH30J191000130

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–95

3. Harness connection
(1) Connect the harness connector with the differential
pressure sensor, and then secure it with a holding band.

SAPH30J191000131

[S5LC0033E04] [0518CsCshWbYs]
10–96 EXHAUST

NOx sensor
Inspection
JP30J19100402014

1. Inspection of the NOx sensor

(1) Use the Hino-DX and inspect the NOx sensor.

Replacement
JP30J19100402015

Removal of the NOx sensor

1. Removal of the NOx sensor

(1) Remove the P-type clamp and the holding band from the
harness of the NOx sensor.

Holding band
P-type clamp

Front

P-type clamp Holding band

SAPH30J191000031
(2) Remove the upstream and the downstream NOx sensor
from the muffler unit.


! CAUTION • Mark the components, so that the upstream

and the downstream side can be re-installed
in their correct locations.

SAPH30J191000132

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–97

2. Removal of the NOx controller

(1) Remove the 4 bolts and remove the 2 NOx controllers
from the base.

SAPH30J191000133

(2) Disconnect the connector of the harness on the machine

side from the NOx controller.

! CAUTION • Mark the components to ensure that the

upstream and the downstream side can be re-
installed in their correct locations.
• The NOx sensor and the NOx controller
cannot be disconnected. Always pull the
indicated connector.

View A

A
Do not disconnect

NOx sensor
NOx controller
SAPH30J191000033

[S5LC0033E04] [0518CsCshWbYs]
10–98 EXHAUST

Installation of the NOx sensor

1. Installation of the NOx controller

(1) Connect the connector of the harness on the machine
side with the socket of the NOx controller.


! CAUTION • Install the upstream and the downstream side

correctly.

View A

A
SAPH30J191000062
(2) Remove the 4 bolts and remove the 2 NOx controllers
from the base.
Tightening torque :
9.6r1 N˜m {97.9r10.2 kgf˜cm, 7.1r0.7 lbf˜ft}

SAPH30J191000134

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–99

2. Installation of the NOx sensors

(1) Install the upstream and the downstream NOx sensor on
the muffler unit.

Tightening torque :
50r10 N˜m {510r102 kgf˜cm, 37r7.4 lbf˜ft}


! CAUTION • Install the upstream and the downstream side

correctly.
• In case of reuse, remove any old anti-seize
SAPH30J191000135 agent from the NOx sensor and apply new
anti-seize agent (WEICON Anti-Seize ASW
High-Tech Assembly Paste or equivalent) to
the threaded part.
• New parts have anti-seize agent applied.
• Take care that the harness of the NOx sensor
is not twisted.

(2) Secure the harness of the NOx sensor with a P-type

clamp and a holding band.
Tightening torque :
26r2.6 N˜m {265r26.5 kgf˜cm, 19r1.9 lbf˜ft}

! CAUTION • When installing the clips, take care that the

NOx sensor lead wires do not interfere with
the bracket, the bolts, etc.
• Confirm that the lead wires are not under
tension.
• Install the harness cover, leaving some slack
on the sensor side, so that the harness wire
cannot be seen.

SAPH30J191000136

[S5LC0033E04] [0518CsCshWbYs]
10–100 EXHAUST

DOC downstream temperature sensor

Replacement
JP30J19100402016

Removal of the DOC downstream temperature

sensor

1. Harness disconnection
P-type clamp
(1) Remove the P-type clamp and the holding band from the
harness of the exhaust gas DOC downstream
temperature sensor.

(2) Disconnect the connector of the harness on the machine

side from the exhaust gas DOC downstream temperature
sensor.

Holding band
SAPH30J191000137

2. Disconnecting the exhaust gas DOC downstream

temperature sensor
(1) Remove the exhaust gas DOC downstream temperature
sensor from the muffler unit.

SAPH30J191000138

Inspection

1. Resistance inspection
Thermometer DOC downstream
temperature sensor (1) Use water and a circuit tester to measure the resistance
between the terminals, and replace the sensor if the
㧮
standard value is exceeded.
㧭

㧭 Temperature (qC{qF}) Standard value (k:)

20{68} 13.7 to 29.8

Heat source 㧮 50{122} 7.13 to 13.7

SAPH30J191000139
80{176} 4.1 to 7.13

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–101

Installation of the DOC downstream temperature

sensor

1. Installation of the exhaust gas DOC downstream

temperature sensor
(1) Install the exhaust gas DOC downstream temperature
sensor on the muffler unit.

Tightening torque :
30r3 N˜m {306r31 kgf˜cm, 22r2.2 lbf˜ft}

! CAUTION • In case of reuse, remove any old anti-seize

agent from the DOC downstream temperature
SAPH30J191000140 sensor and apply new anti-seize agent (Bostik
Never-Seez Nickel Special Grade or
equivalent) to the threaded part.
• New parts have anti-seize agent applied.
• Do not reuse sensors that have been exposed
to strong impacts, which have been dropped,
or which have a deformed detection part.

Detection pin

SAPH30J191000141

2. Harness connection
(1) Connect the exhaust gas DOC downstream temperature
sensor harness with the harness on the machine side,
and then secure it with a P-type clamp and a holding
band.

Tightening torque :
26r2.6 N˜m {265r26.5 kgf˜cm, 19r1.9 lbf˜ft}

SAPH30J191000142

! CAUTION • Take care that the harness of the DOC

downstream temperature sensor is not
twisted.

• When bundling the harness, fix it in the

orientation shown in the figure, so that there
is no contact with the lock side of the
connector.
LOCK

SAPH30J191000060

[S5LC0033E04] [0518CsCshWbYs]
10–102 EXHAUST

DPR downstream temperature sensor

Replacement
-3-

Removal of the DPR downstream temperature

sensor

1. Disconnecting the connector of the exhaust gas DPR

downstream temperature sensor
(1) Remove the P-type clamp and the holding band from the
harness of the exhaust gas DPR downstream
temperature sensor.

P-type clamp

Holding band

Holding band P-type clamp

SAPH30J191000143

(2) Disconnect the connector of the harness on the machine

side from the connector of the exhaust gas DPR
downstream temperature sensor.

2. Removal of the exhaust gas DPR downstream temperature

sensor
(1) Remove the exhaust gas DPR downstream temperature
sensor from the muffler unit.

SAPH30J191000144

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–103

Inspection

1. Resistance inspection
Thermometer DPR downstream
temperature sensor (1) Use water and a circuit tester to measure the resistance
between the terminals, and replace the sensor if the
㧮
standard value is exceeded.
㧭

㧭 Temperature (qC{qF}) Standard value (k:)

20{68} 13.7 to 29.8

Heat source 㧮 50{122} 7.13 to 13.7

SAPH30J191000145
80{176} 4.1 to 7.13

[S5LC0033E04] [0518CsCshWbYs]
10–104 EXHAUST

Installation of the DPR downstream temperature

sensor

1. Installation of the DPR downstream temperature sensor

(1) Install the exhaust gas DPR downstream temperature
sensor on the muffler unit.

Tightening torque :
30r3 N˜m {306r31 kgf˜cm, 22r2.2 lbf˜ft}

! CAUTION • In case of reuse, remove any old anti-seize

agent from the DPR downstream temperature
sensor and apply new anti-seize agent (Bostik
SAPH30J191000146 Never-Seez Nickel Special Grade or
equivalent) to the threaded part.
• New parts have anti-seize agent applied.
• Do not reuse sensors that have been exposed
to strong impacts, which have been dropped,
or which have a deformed detection part.

Detection pin

SAPH30J191000141

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–105

2. Connecting the connector of the exhaust gas DPR

downstream temperature sensor
(1) Bundle the connector of the exhaust gas DPR
downstream temperature sensor and fix it with a P-type
clamp and a bundling band.
(2) Secure the harness of the exhaust gas DPR downstream
temperature sensor with a P-type clamp and a holding
band.
Tightening torque :
26r2.6 N˜m {265r26.5 kgf˜cm, 19r1.9 lbf˜ft}

! CAUTION • Take care that the harness of the DPR

downstream temperature sensor is not
twisted.

• When bundling the harness, fix it in the

orientation shown in the figure, so that there
is no contact with the lock side of the
connector.

LOCK

SAPH30J191000060

P-type clamp

Holding band

Holding band P-type clamp

SAPH30J191000034

[S5LC0033E04] [0518CsCshWbYs]
10–106 EXHAUST

SCR upstream temperature sensor

Replacement
JP30J19100402018

Removal of the SCR upstream temperature sensor

1. Disconnecting the connector of the exhaust gas SCR

P-type clamp
upstream temperature sensor
(1) Remove the P-type clamp and the holding band from the
harness of the exhaust gas SCR upstream temperature
sensor.
(2) Disconnect the connector of the harness on the machine
side from the connector of the exhaust gas SCR upstream
temperature sensor.

Holding band
SAPH30J191000147

2. Removal of the exhaust gas SCR upstream temperature

sensor
(1) Remove the exhaust gas SCR upstream temperature
sensor from the muffler unit.

SAPH30J191000148

(2) Remove the clamp from the connector part of the SCR
Connector upstream temperature sensor.

Clamp

SAPH30J191000041

[S5LC0033E04] [0518CsCshWbYs]
 EXHAUST 10–107

Inspection

1. Resistance inspection
SCR upstream
Thermometer temperature sensor (1) Use water and a circuit tester to measure the resistance
between the terminals, and replace the sensor if the
㧮
㧭
standard value is exceeded.

㧭 Temperature (qC{qF}) Standard value (:)

50{122} 235 to 244

Heat source 㧮
SAPH30J191000149

[S5LC0033E04] [0518CsCshWbYs]
10–108 EXHAUST

Installation of the SCR upstream temperature

sensor

1. Installation of the exhaust gas SCR upstream temperature

sensor
(1) Remove the line branches from the connector part of the
Connector SCR upstream temperature sensor.

Clamp

SAPH30J191000056

(2) Install the exhaust gas SCR upstream temperature sensor

on the muffler unit.

Tightening torque :
30r3 N˜m {306r31 kgf˜cm, 22r2.2 lbf˜ft}

! CAUTION • In case of reuse, remove any old anti-seize

agent from the temperature sensor upstream
of the SCR and apply new anti-seize agent
(Bostik Never-Seez Nickel Special Grade or
SAPH30J191000150 equivalent) to the threaded part.
• New parts have anti-seize agent applied.
• Do not reuse sensors that have been exposed
to strong impacts, which have been dropped,
or which have a deformed detection part.

Detection pin

SAPH30J191000151

2. Connecting the connector of the exhaust gas SCR

P-type clamp
upstream temperature sensor
(1) Connect the connector of the exhaust gas SCR upstream
temperature sensor with the socket of the harness on the
machine side.

! CAUTION • Take care that the harness of the SCR

upstream temperature sensor is not twisted.

(2) Secure the harness of the exhaust gas SCR upstream

Holding band
SAPH30J191000147 temperature sensor with a P-type clamp and a holding
band.

[S5LC0033E04] [0518CsCshWbYs]
 COOLING 11–1

ENGINE

11 COOLING
System drawing

Cooling System ........................................................ 11-2

Cooling system drawing........................................ 11-2
Part layout............................................................. 11-3
Replacement of thermostat case .......................... 11-4
Adjustment of the fan belt tension......................... 11-7
Replacement of coolant pump .............................. 11-8

11

[S5LC0033E04] [0518CsCshWbYs]
11–2 COOLING

Cooling System
Cooling system drawing
JP30TCE110803001

Reserver tank

Radiator cap

EGR cooler

Thermostat
Radiator

cover (Outlet)
Coolant
temperature
gauge
Thermostat
case Cylinder head

Thermostat
cover (Inlet) Thermostat Turbocharger

Cylinder block

Drain cock

Coolant pump
Oil cooler
For engine cooling
Cooling except
for engine Drain cock
Air bleeding

AdBlue / DEF injector

AdBule / DEF pump AdBlue / DEF tank Coolant cut off valve

SAPH30TCE1100001
Setup layout
Layout

[S5LC0033E04] [0518CsCshWbYs]
 COOLING 11–3

Part layout
JP30TCE110402001

SAPH30TCE1100002

1 Coolant pump 5 O-ring*

2 Thermostat case 6 Thermostat
3 Thermostat case cover 7 Water inlet pipe
4 Gasket*

*Parts not to be reused.

Tightening torque
A 29N˜m {296kgf˜cm, 21 lbf˜ft}
Service procedure
Replacement procedure item

[S5LC0033E04] [0518CsCshWbYs]
11–4 COOLING

Replacement of thermostat case

JP30TCE110704001

1. Removal of the thermostat case

Cylinder
head (1) Remove the bolts (7pcs.), and remove the thermostat
case and the O-ring from the cylinder head and the
coolant pump.
O-ring
NOTICE • Prepare a container and a waste cloth for
spilling coolant at removing the thermostat
Coolant
case.
Thermostat case pump

SAPH30TCE1100003

2. Inspection of the thermostat

Wire Thermometer (1) Warm up the thermostat as shown figure.

! CAUTION • Support the thermostat at center of the

container by wire for keep at a distance from
the heat source.
• Mix it to even up the temperature.
Thermostat Valve lift

Heat source
SAPH30TCE1100004

(2) Measure the temperature at valve opening temperature

T1 : Valve opening temperature (start of valve opening) (T1).
T2: Full open lift inspection temperature

OO Thermostat valve

74.5 - 78.5qC
opening standard
Valve lift

{166.1 - 173.3qF}
temperature:T1

0°C{32°F} T1°C{°F} T2°C{°F} Temperature

SAPH30TCE1100005

NOTICE • The thermostat valve opening temperature

Jiggle valve
(T1) is stamped into the thermostat seat.

Opening
temperature

SAPH30TCE1100006

[S5LC0033E04] [0518CsCshWbYs]
 COOLING 11–5

(3) Warm up the thermostat at fully open temperature (T2) of

the valve, measure the lift of the thermostat valve.

Thermostat valve full

open standard Valve lift : L
L1 At cold open
L2 :Temperature at (T2)°C{°F} temperature:T2
L : Valve lift
㧸 13mm {0.5118in.}
㧸 90qC {194qF}
㧸 or more

SAPH30TCE1100007
(4) Immerse the opened thermostat in water at normal
temperature. If it completely closes within 5 minutes, it is
satisfactory.
(5) If a faulty item is found, replace the thermostat.

3. Installation of the thermostat case

(1) Use a scraper to remove dirt from the connection surfaces
Thermostat case
of the thermostat case and the cylinder head.
(2) Apply liquid gasket (Three Bond TB1207B: Black or
equivalent) to the thermostat case.

! CAUTION • Apply without breaks.

• Apply liquid gasket with a width of 1.5 to 2.5
Liquid gasket
mm.
SAPH30TCE1100008 • Install within 20 minutes of applying liquid
gasket.

(3) Install a new O-ring in the groove at the top of the coolant
Bolt 2 Cylinder
head pump.
Bolt 1 (4) Insert the thermostat case mounting bolts 1 (4 bolts) in
advance into the thermostat case.
O-ring (5) Match the thermostat case to the mounting position and
provisionally tighten the mounting bolts 1 (4 bolts) to the
Coolant cylinder head.
6JGTOQUVCVECUG pump
(6) Provisionally tighten the mounting bolts 2 (3 bolts) to the
coolant pump.
SAPH30TCE1100009
(7) Securely tighten the mounting bolts 1 (4 bolts) to the
cylinder head and the mounting bolts 2 (3 bolts) to the
coolant pump in this order.

4. Installing of the thermostat

Thremostat (1) Replace the gasket with new ones, and install the
Gasket thermostat and the coolant pipe to the thermostat case.

Thremostat case

Coolant pipe

SAPH30TCE1100010

[S5LC0033E04] [0518CsCshWbYs]
11–6 COOLING

! CAUTION • As a wrong gasket installation can cause

Flange
water leakage, make sure during assembly
Thermostat
that it is clamped to the flange part of the
thermostat.

Gasket
SAPH30TCE1100011

• Install the thermostat with the jiggle valve at

TOP the top.
Jiggle valve

SAPH30TCE1100012

[S5LC0033E04] [0518CsCshWbYs]
 COOLING 11–7

Adjustment of the fan belt tension

JP30TCE110705001

1. Adjustment of the fan belt tension.

(A)
(1) Use the special tool and check the fan belt tension at the
measuring position (A).

Measuring item Standard value

3 - 5mm
Deflection
{0.1182 - 0.1968in.}

1,372 N
Tension
SAPH30TCE1100013 {140 kgf, 308 lbf}

Special tool : S0944-41210 (09444-1210)

Compression gauge (used at the time
of measuring the deflection amount)
[ Reference push force
98N {10kgf, 22lbf} ]
MITSUBOSHI BELTING LTD.; Belt
Tension Meter (DOCTOR TENSION£
TYPE-III) (used at the time of
measuring the tension force)

! CAUTION • When the fan belt has been replaced by a new

one, the fan belt will become loose because of
initial run-in, so that the fan belt tension
should be adjusted again after running the
engine for 3 to 5 minutes.

NOTICE • At the time of inspection, the new fan belt has

reached the value after complete initial
stretching. A new fan belt completes initial
stretching after running the engine for
approximately two hours.

(2) If the tension is not within the standard value, adjust with
the adjustment bolt (M8) or replace the fan belt.

NOTICE • When the adjustment bolt is tightened, the

tension pulley moves in tensioning direction.
Replacement procedure item

[S5LC0033E04] [0518CsCshWbYs]
11–8 COOLING

Replacement of coolant pump

JP30TCE110704002

1. Removal of coolant pump

(1) Remove bolts and remove the coolant pump.

SAPH30TCE1100014

2. Installation of coolant pump

Coolant pump
(1) Remove contamination on the joint surface between the
coolant pump and the cylinder block using a scraper and
degrease the surface.
(2) Apply the liquid gasket [Threebond TB1207B (black) or
equivalent] to the coolant pump as shown in the figure.

! CAUTION • Apply it continuously.

Liquid gasket
• Apply the liquid gasket at the width of 2 to
SAPH30TCE1100015 3mm{0.0787 to 0.1181in.}.
• Install the coolant pump within 20 minutes
after application of the liquid gasket.
• Fill the groove on the water pump flange with
the liquid gasket.

(3) Install the coolant pump to the dowel pin of the cylinder
block.

NOTICE • When the coolant pump is installed using a

guide bolt, displacement of the liquid gasket
does not occur.

SAPH30TCE1100014

[S5LC0033E04] [0518CsCshWbYs]
 LUBRICATION 12–1

ENGINE

12 LUBRICATION
System drawing

Oil Cooler, Oil Filter and Oil Pump.......................... 12-2

System drawing .................................................... 12-2
Part layout............................................................. 12-3
Replacement of oil cooler ..................................... 12-5
Overhaul of oil cooler ............................................ 12-7
Replacement of oil pump ...................................... 12-9
Overhaul of oil pump........................................... 12-10
Replacement of oil strainer ................................. 12-14
Oil Filter ................................................................... 12-15
Part layout........................................................... 12-15
Replacement....................................................... 12-16
Oil Pan ..................................................................... 12-20
Part layout........................................................... 12-20
Replacement....................................................... 12-21
Inspection of lubrication status ........................... 12-22

12

[S5LC0033E04] [0518CsCshWbYs]
12–2 LUBRICATION

Oil Cooler, Oil Filter and Oil Pump

System drawing
JP30TCE120805001

Roller pin

Cam Roller

Adjusting
Valve Crosshead Rocker arm Rocker arm shaft
screw

Camshaft
Oil pan

Cam idle
gear shaft

Sub-idle
gear shaft

Turbocharger
Strainer

Oil pump Oil cooler Oil filter Main

oil hole

Connecting
Piston pin rod Crankshaft

Cooling jet Sub-oil

(Check valve) hole

Main idle
gear shaft

: Lubrication
: Return

SAPH30TCE1200001
Setup layout
Layout

[S5LC0033E04] [0518CsCshWbYs]
 LUBRICATION 12–3

Part layout
JP30TCE120402001

SAPH30TCE1200002

1 Oil pump assembly 5 Relief valve

2 Oil strainer 6 Oil cooler
3 Gasket* 7 Cotter pin*
4 Spring 8 O-ring*

*Parts not to be reused.

Tightening torque
A 28.5N˜m {290kgf˜cm, 21 lbf˜ft} C 28.5N˜m {290kgf˜cm, 21 lbf˜ft}
B 31N˜m {320kgf˜cm, 23 lbf˜ft}

[S5LC0033E04] [0518CsCshWbYs]
12–4 LUBRICATION

JP30TCE120402002

SAPH30TCE1200003

1 Drain plug 5 Gasket*

2 Safety valve 6 O-ring*
3 Oil cooler case 7 Joint connector
4 Oil cooler element 8 Bolt

*Parts not to be reused.

Tightening torque
A 44.1r4.9N˜m {450r50kgf˜cm, 33r4 lbf˜ft} B 107.9r9.8N˜m {1100r100kgf˜cm, 79.6r7
lbf˜ft}
C 78r4.9N˜m {795r50kgf˜cm, 57.5r4 lbf˜ft}
Service procedure
Replacement procedure item

[S5LC0033E04] [0518CsCshWbYs]
 LUBRICATION 12–5

Replacement of oil cooler

JP30TCE120704001

1. Removal of oil cooler

(1) Remove bolts and remove the oil cooler.

SAPH30TCE1200004

(2) If it is difficult to remove the oil cooler due to liquid gasket

Figure is an sticking to the cylinder block, put a flat tip screwdriver at
example of work.
the protrusion in the figure for removal.

SAPH30TCE1200005

2. Installation of oil cooler

D-Ring (1) Assemble the new D-ring into the D-ring groove of the oil
Block
Oil cooler cooler.

! CAUTION • Face the D-ring flat area toward the oil cooler.

Flat area

SAPH30TCE1200006

(2) Remove contamination on the joint surface between the

oil cooler and the cylinder block using a scraper. Apply the
Liquid gasket
liquid gasket [Threebond TB1207B (black) or equivalent]
to the oil cooler as shown in the figure.

! CAUTION • Apply it continuously.

• Apply the liquid gasket at the width of 1.5 to
2.5 mm{0.0590 to 0.0984 in.}.
• Install the oil cooler within 20 minutes after
SAPH30TCE1200007 application of the liquid gasket.

[S5LC0033E04] [0518CsCshWbYs]
12–6 LUBRICATION

(3) Insert the positioning stud into the screw hole of the
cylinder block and install the oil cooler.

(4) After temporary tightening with bolts, remove the

positioning stud and tighten bolts.
Tightening torque :
28.5 N˜m {290 kgf˜cm, 21, lbf˜ft}

! CAUTION • Tighten together with the alternator ground.

• Be sure to connect the turbocharger
SAPH30TCE1200008 lubricating oil hose.

(5) Install the drain plug.

Tightening torque :
44.1r4.9 N˜m {450r50 kgf˜cm, 33r4 lbf˜ft}

SAPH30TCE1200009

[S5LC0033E04] [0518CsCshWbYs]
 LUBRICATION 12–7

Overhaul item

Overhaul of oil cooler

JP30TCE120702001

1. Removal of oil cooler element

(1) Remove nuts and remove the oil cooler element.

2. Inspection of oil cooler element

(1) Wash water and oil channels with kerosene oil or washing
fluid.
(2) Check for crack or deformation on the stud bolt mounting
area and element visually.
(3) Blow air of approx. 49kPa {0.5kgf/cm2 7.1 lbf/in2} into the
SAPH30TCE1200010 oil channel to check for leak from parts. If crack, leak or
deformation is found, replace it with a new part.

3. Disassembly of oil cooler case

! CAUTION • Disassembly immediately after stop of the

engine may cause blowout of engine oil.

(1) Remove valve spring plugs and safety valves using a

hexagonal wrench.

SAPH30TCE1200011

(2) Remove the oil pressure warning switch.

Soft washer

Hydraulic pressure
warning switch

SAPH30TCE1200012

4. Inspection of safety valve wear and damage

(1) If wear or damage is found, replace it.

SAPH30TCE1200013

[S5LC0033E04] [0518CsCshWbYs]
12–8 LUBRICATION

5. Inspection of oil pressure warning switch

(1) For inspection of oil pressure warning switch,
Refer to "7 ELECTRICAL, Electrical System,
Inspection of components".

6. Assembly of oil cooler case

(1) Install a new O-ring and install valve spring plugs and
safety valves using a hexagonal wrench.

Tightening torque :
24.5r4.9 N˜m {250r50 kgf˜cm, 18r4 lbf˜ft} (M14, M20)
29.4r4.9 N˜m {300r50 kgf˜cm, 22r4 lbf˜ft} (M22)
34.3r4.9 N˜m {350r50 kgf˜cm, 25r4 lbf˜ft} (M24)

SAPH30TCE1200011

(2) Apply the liquid gasket [Threebond TB1211 (white) or

equivalent] to the sealing surface of a new soft washer.

(3) Install the soft washer in (2) and the hydraulic pressure
Soft washer warning switch.

Hydraulic pressure
warning switch

SAPH30TCE1200012

7. Installation of oil cooler element

(1) Assemble new gasket and new O-ring and assemble the
oil cooler element with nuts.

Tightening torque :
24.5r4.9 N˜m {250r50 kgf˜cm, 18r4 lbf˜ft}

! CAUTION • In handling the oil cooler element, be careful

not to give damage to it.

SAPH30TCE1200010 Replacement procedure item

[S5LC0033E04] [0518CsCshWbYs]
 LUBRICATION 12–9

Replacement of oil pump

JP30TCE120704002

1. Removal of oil pump

(1) Dismount the engine from the vehicle.
(2) Remove the flywheel.
(3) Remove the flywheel housing.
(4) Remove the timing gear.
(5) Remove the oil pump.

2. Installation of oil pump

(1) Apply engine oil to the pump case and the bearing
(shaded area) of the cylinder block.

! CAUTION • Without application of engine oil, poor oil

suction may occur at the initial start,
Application of engine oil resulting in seizure or abnormal wear.
(Shaded area)

SAPH30TCE1200014

(2) To prevent bolt hole offset of the gasket, apply engine oil
to the cylinder block in advance and place and fix the
gasket.

! CAUTION • Assembly with offset gasket may cause faulty

sealing. Oil in the oil pump may be completely
discharged when the engine stops. Faulty
sealing may cause insufficient suction of oil
at initial revolution of engine restart,
resulting in seizure or abnormal wear.

(3) Tighten the oil pump according to the order in the figure.
Tightening torque : 28.5 N˜m {290 kgf˜cm, 21 lbf˜ft}

! CAUTION • If the tightening order is not observed, the oil

Gasket
pump may be damaged.
Oil pump • After tightening, make sure that the gear can
be turned with hand.
Overhaul item

SAPH30TCE1200015

[S5LC0033E04] [0518CsCshWbYs]
12–10 LUBRICATION

Overhaul of oil pump

JP30TCE120702002

1. Remove the driven gear.

SAPH30TCE1200016

2. Remove the cotter pin and remove seat 2, seat 1, relief

valve spring and safety valve.

! CAUTION • When the cotter pin is removed, seat 2 and

the relief valve spring may eject out.

SAPH30TCE1200017

3. Inspection of clearance between drive gear and cylinder

block

(1) Measure the outer diameter of the drive gear and the
inner diameter of the pump chamber at cylinder block.

Standard value
Measuring area
(mm{in.})

Outer diameter of drive gear 54{2.1260}

SAPH30TCE1200018 Inner diameter of pump chamber

54{2.1260}
at cylinder block

(2) Calculate the difference between the outer diameter of the

drive gear and the inner diameter of the pump chamber at
the cylinder block. If it is beyond the service limit, replace
the oil pump assembly.

Standard value (mm{in.}) Service limit (mm{in.})

0.093 - 0.252
0.30{0.0118}
{0.0037 -0.0099}

SAPH30TCE1200019

[S5LC0033E04] [0518CsCshWbYs]
 LUBRICATION 12–11

4. End play inspection between drive gear and cylinder block

(1) Measure the drive gear width and the pump chamber
depth at the cylinder block using a depth gauge.

Standard value
Measuring area
(mm{in.})

Width of drive gear 43{1.6929}

Depth of pump chamber at

43{1.6929}
SAPH30TCE1200020 cylinder block

(2) Calculate the difference between the depth of the drive

gear and the pump chamber depth at the cylinder block. If
it is beyond the service limit, replace the oil pump
assembly.

Service limit
Standard value (mm{in.})
(mm{in.})

0.047 - 0.15
Gasket use 0.15{0.0059}
{0.0019 - 0.0059}
SAPH30TCE1200021

-0.013 - 0.05
No gasket —
{-0.0005 - 0.0020}

5. Inspection of clearance between outer diameter of drive

gear shaft and cylinder block hole diameter

(1) Measure the outer diameter of the drive gear shaft using a
micrometer and measure the cylinder block hole diameter
using a cylinder gauge.

Standard value
Measuring area
(mm{in.})

Outer diameter of drive gear shaft 18{0.7087}

SAPH30TCE1200022

Cylinder block hole diameter 18{0.7087}

(2) Calculate the difference between the outer diameter of the

drive gear and the cylinder block hole diameter. If it is
beyond the service limit, replace the oil pump assembly.

0.040 - 0.099
Standard value (mm{in.})
{0.0016 - 0.0039}

SAPH30TCE1200023

[S5LC0033E04] [0518CsCshWbYs]
12–12 LUBRICATION

6. Inspection of clearance betweeen outer diameter of driven

gear shaft and inner diameter of driven gear bushing

(1) Measure the outer diameter of the driven gear shaft using
a micrometer and measure the inner diameter of the
driven gear bushing using a cylinder gauge.

Standard value
Measuring area
(mm{in.})

Outer diameter of driven gear

SAPH30TCE1200024 18{0.7087}
shaft

Cylinder block hole diameter 18{0.7087}

(2) Calculate the difference between the outer diameter of the

driven gear and the cylinder block hole diameter. If it is
beyond the service limit, replace the oil pump assembly.

0.030 - 0.075
Standard value (mm{in.})
{0.0012 - 0.0030}

SAPH30TCE1200025

7. Inspection of clearance betweeen outer diameter of driven

gear shaft and inner diameter of driven gear bushing

(1) Measure the outer diameter of the driven gear shaft using
a micrometer and measure the inner diameter of the
driven gear bushing using a cylinder gauge.

Standard value
Measuring area
(mm{in.})

Outer diameter of driven gear

SAPH30TCE1200024 18{0.7087}
shaft

Inner diameter of driven gear

18{0.7087}
bushing

(2) Calculate the difference between the outer diameter of the

driven gear shaft and the inner diameter of the driven gear
bushing. If it is beyond the service limit, replace the oil
pump assembly or the driven gear bushing.

Standard value (mm{in.}) Service limit (mm{in.})

0.040 - 0.083
0.15{0.0059}
{0.0016 - 0.0033}

SAPH30TCE1200026

[S5LC0033E04] [0518CsCshWbYs]
 LUBRICATION 12–13

8. Inspection of drive gear backlash

(1) Fix the oil pump assembly with a vice.

(2) Measure backlash between the drive gear and the driven
gear using a dial gauge. If it is beyond the service limit,
replace the oil pump assembly.

Standard value (mm{in.}) Service limit (mm{in.})

0.073 - 0.207
0.30{0.0118}
{0.0029 - 0.0082}
SAPH30TCE1200027

9. Assembly of oil pump

(1) Install the safety valve, relief valve, seat 1 and seat 2 on
the oil pump cover assembly with new cotter pins.

SAPH30TCE1200017

(2) Install the driven gear.

SAPH30TCE1200016

[S5LC0033E04] [0518CsCshWbYs]
12–14 LUBRICATION

Replacement procedure item

Replacement of oil strainer

JP30TCE120704003

1. Removal of oil strainer

(1) Remove bolts and remove the oil strainer.

2. Installation of oil strainer

(1) Install the oil strainer.
Tightening torque : 31 N˜m {320 kgf˜cm, 23 lbf˜ft}

SAPH30TCE1200028

[S5LC0033E04] [0518CsCshWbYs]
 LUBRICATION 12–15

Oil Filter
Setup layout
Layout

Part layout
JP30TCE120402003

SAPH30TCE1200029

15600 Oil filter assembly 15660 Oil filter warning switch

15607 Oil filter element* Z3012 O-ring*
15620 Oil filter head

*Parts not to be reused.

[S5LC0033E04] [0518CsCshWbYs]
12–16 LUBRICATION

Replacement
JP30TCE120402004

Replacement of the oil filter

NOTICE • The shape of brackets and hose joints in the

illustrations and the hose routing differ
according to the model.
• Completely remove any dust around the oil
filter before removing.

1. Engine oil draining

(1) Prepare a tray or another container to receive engine oil,
loosen the drain plug at the lower end of the oil filter, and
drain the engine oil.

! CAUTION • When draining the engine oil, follow the

specified method (waste processing) or an
Drain plug environment-friendly method.
• To prevent burn, drain the engine oil after the
SAPH30TCE1200030 oil temperature is sufficiently low.

2. Removal of the oil filter

(1) Remove the oil filter from the oil filter head using a special
tool.

Special tool : S0950-31110 (09503-1110)

Oil filter wrench

Oil filter

SAPH30TCE1200031

! CAUTION • Make sure that there is no O-rings left at the

oil cooler case.

(2) Remove any dust or dirt around the seal area of the oil
O-rings filter head (contacting point of the element gasket).
Outside
Inside

SAPH30TCE1200032

[S5LC0033E04] [0518CsCshWbYs]
 LUBRICATION 12–17

3. Installation of the oil filter element

(1) Remove contamination or foreign matter on the mounting

surface of the oil filter head.
(2) Apply engine oil thinly to the O-rings (large˜small) for a
new oil filter.
(3) Turn the oil filter lightly to the right rotation by the hand
Oil filter until the O-ring touch to the oil filter head.
Tighten by
1 to 3/4 turn ! CAUTION • Always replace the O-rings by new one that
SAPH30TCE1200033 bundled to kit.
• In installation, be careful that the O-ring may
not be damaged by distortion.
• Do not reuse the O-rings.

(4) Tighten the oil filter using the special tool by 3/4 to 1
rotation.
Special tool : S0950-31110 (09503-1110)
Oil filter wrench

4. Engine oil filling

(1) Confirm that the drain plug at the lower end of the oil filter
has been tightened, and then fill in engine oil while looking
at the oil level gauge.
Refer to the "4 ENGINE MOUNTING/DISMOUNTING,
work after installation, engine oil inspection" .
(2) After the oil filter replacing, start the engine for entering
the oil to the filter and check the engine oil level.

! CAUTION • After the oil filter replacing, start the engine

and confirm "no oil leaking" around the oil
filter. The oil leak causes a fire.

[S5LC0033E04] [0518CsCshWbYs]
12–18 LUBRICATION

Replacement of the remote oil hoses

1. Disconnecting the oil hose

! CAUTION • When disconnecting the oil hose, receive the

oil remaining in the hose in a container and
plug the end of the hose with a shop towel or
similar.

(1) Secure the joint securely with a hand vise or similar,

loosen the nuts of the oil hoses, and disconnect the oil
hoses. (Inlet and outlet)

Oil hose

Oil hose

Joint
(Do not remove)

Joint
(Do not remove)

Oil hose

SAPH30TCE1200034

! CAUTION • When working with 2 spanners, use spanners

with the same length for the moment arm to
make spanner control easier.

NOTICE • Do not remove the joints.

[S5LC0033E04] [0518CsCshWbYs]
 LUBRICATION 12–19

2. Connecting the oil hose

(1) Secure the joint securely with a hand vise or similar,
tighten the nuts of the oil hoses, and connect the oil
hoses. (Inlet and outlet)

Oil hose

Oil hose

Joint
(Do not remove)

Joint
(Do not remove)

Oil hose

SAPH30TCE1200035

! CAUTION • When working with 2 spanners, use spanners

with the same length for the moment arm to
make spanner control easier.
• If the joint part has been loosened, replace
the O-ring by a new one.

NOTICE • Refer to the workshop manual (machine side)

for the tightening torque.

[S5LC0033E04] [0518CsCshWbYs]
12–20 LUBRICATION

Oil Pan
Setup layout
Layout

Part layout
JP30TCE120402005

SAPH30TCE1200036

1 Oil pan assembly 3 Drain valve

2 Oil pan gasket* 4 Gasket*

*Parts not to be reused.

Tightening torque
A 41N˜m {420kgf˜cm, 30 lbf˜ft} B 30N˜m {300kgf˜cm, 22 lbf˜ft}
Service procedure
Replacement procedure item

[S5LC0033E04] [0518CsCshWbYs]
 LUBRICATION 12–21

Replacement
JP30TCE120704004

1. Installation of oil pan

Bolt tightening direction (1) Cut the gasket of the rear end plate to be flush to the
cylinder block lower surface using a scraper.
(2) Make sure that there is no deformation, dirt or oil on the
joint surface between the cylinder block and the oil pan.
Apply liquid gasket [Threebond TB1207D (silver),
TB1217G (gray) or equivalent] to the front rear end of the
Rear cylinder block lower surface.
(3) Insert several stud bolts (70 mm{2.7559 in.} or larger) for
Protrusion
positioning into the cylinder block screw hole.
Front (4) Position the gasket protrusion at the intake side and the
flywheel housing (printed seal surface at cylinder block).
Align the new gasket and oil pan to the cylinder block
lower surface and tighten bolts in the arrow order of the
figure.
Tightening torque :
19.6 - 24.5 N˜m {200 - 250 kgf˜cm, 14 - 18 lbf˜ft}
Liquid gasket applying position (5) Remove positioning stud bolts and install the correct bolts.
(6) Tighten bolts in the arrow order of the figure.
SAPH30TCE1200037
Tightening torque : 30 N˜m {300 kgf˜cm, 22 lbf˜ft}

! CAUTION • Check if the washer is not riding on the

flange.
• Make sure that the printed seal is not peeled
or damaged before installation of the gasket.
Inspection procedure item

[S5LC0033E04] [0518CsCshWbYs]
12–22 LUBRICATION

Inspection of lubrication status

JP30TCE120703001

1. Inspection of valve system

! CAUTION • Perform inspection with the water

temperature at 60 qC{140qF}.

(1) Remove the head cover.

! CAUTION • To prevent spread of engine oil, attach a jig

which cuts a head cover in half. Cut it to the
degree that the camshaft is covered.

(2) Adjust the engine revolution to the standard idling

revolution [1,000r/min{rpm}].
(3) After start of the engine, make sure that oil is supplied to
the areas below of all rocker arms within about 10
seconds.
• Roller and cam surface
• Cross head and spring upper seat surface through
adjusting screw

! CAUTION • If time until lubrication is long or if lubrication

is not performed, the oil pressure may be low
SAPH30TCE1200038
or the oil channel may be clogged. Seizure,
abnormal wear or abnormal noise may occur
due to insufficient lubrication.

[S5LC0033E04] [0518CsCshWbYs]
 STARTING AND CHARGING 13–1

ENGINE

13 STARTING AND CHARGING

Setup layout
Layout

Starter........................................................................ 13-2
Part layout............................................................. 13-2
Disassembly.......................................................... 13-3
Inspection of components ..................................... 13-9
Assembly ............................................................ 13-14
Alternator (60A) ...................................................... 13-21
Part layout (60A) ................................................. 13-21
Circuit drawing (60A) .......................................... 13-22
Disassembly (60A).............................................. 13-23
Inspection of components (60A) ......................... 13-27
Assembly (60A)................................................... 13-30
Inspection after assembly (60A) ......................... 13-34

13

[S5LC0033E04] [0518CsCshWbYs]
13–2 STARTING AND CHARGING

Starter
Part layout
JP30TCE130402001

SAPH30TCE1300001

1 Clutch sub-assembly 12 Brush

2 Bushing 13 Spring
3 Lever 14 Center bracket
4 Start drive housing 15 Armature assembly
5 Packing* 16 Retainer clip*
6 Plate 17 Dust protector
7 Cover 18 Pinion
8 Yoke assembly 19 Bearing*
9 Commutator end frame 20 Shaft assembly
10 Packing* 21 Planetary gear
11 Brush holder assembly 22 Internal gear

*Parts not to be reused.

Tightening torque
A 3.6-4.9N˜m{37-49kgf˜cm, 3-4 lbf˜ft} C 3.6-4.9N˜m{37-49kgf˜cm, 3-4 lbf˜ft}
B 13.7-15.7N˜m
{139-160kgf˜cm, 10-11 lbf˜ft}
Service procedure
Overhaul item

[S5LC0033E04] [0518CsCshWbYs]
 STARTING AND CHARGING 13–3

Disassembly
JP30TCE130702001

NOTICE • Fix the starter on the working table to ease

accessibility.

1. Removal of lead wire

M lead wire
(1) Remove the cap of the M terminal.
M terminal
(2) Remove nuts and remove the M lead wire.

SAPH30TCE1300002

2. Removal of commutator end frame

Through bolt (1) Loosen and remove two through bolts.

Commutator end
frame

SAPH30TCE1300003

(2) Remove two set bolts and remove the commutator end
frame.
Set bolt
! CAUTION • Hold the M lead wire and remove the
commutator end frame by lifting.

SAPH30TCE1300004

[S5LC0033E04] [0518CsCshWbYs]
13–4 STARTING AND CHARGING

3. Removal of brush holder assembly

Brush holder
Assembly (1) Lift the spring using a flat tip screwdriver or pliers.
Remove four brushes from the brush holder assembly.

! CAUTION • Do not cut the brush lead fixing clamp.

(2) Remove the brush holder assembly from the armature

assembly.
Spring
Brush

Brush lead
Clamp

SAPH30TCE1300005

4. Removal of yoke assembly

M lead wire (1) Remove the yoke assembly from the center bracket
Yoke assembly
assembly.

! CAUTION • Do not hold the M lead wire and hold the yoke
assembly outer diameter for removal.

Center bracket
assembly

SAPH30TCE1300006

5. Removal of packing
Yoke assembly (1) Remove the packing from the centering parts at both ends
of the yoke assembly.

! CAUTION • Damaged packing must not be resued.

Replace it with a new part.

Packing Packing

SAPH30TCE1300007

[S5LC0033E04] [0518CsCshWbYs]
 STARTING AND CHARGING 13–5

6. Removal of armature assembly

(1) Remove the armature assembly by lifting.
Armature
assembly
! CAUTION • When the armature assembly is removed, the
washer at the end of the gear may be dropped
and lost. Be careful for handling.
Center bracket
assembly

SAPH30TCE1300008

7. Removal of rear bearing

(1) Pull out the bearing of the armature assembly using a
Rear bearing puller or press.

! CAUTION • Removed bearing must not be reused.

Replace it with a new one.

Puller

SAPH30TCE1300009

8. Removal of cover
Packing Cover (1) Remove the cover from the center bracket assembly.
(2) Remove the packing.

! CAUTION • Damaged packing must not be resued.

Replace it with a new part.

SAPH30TCE1300010

9. Removal of planetary gear

(1) Remove the planetary gear from the carrier pin.

Planetary gear ! CAUTION • Make sure that the gear is not damaged or
chipped.
Carrier pin

SAPH30TCE1300011

[S5LC0033E04] [0518CsCshWbYs]
13–6 STARTING AND CHARGING

10. Removal of internal gear

(1) Remove the internal gear from the center bracket.

! CAUTION • Make sure that the gear is not damaged or

chipped.
Internal gear

Center bracket

SAPH30TCE1300012

11. Removal of shim washer

(1) Remove the shim washer from the center bracket.

Shim

SAPH30TCE1300013

12. Removal of pinion

(1) Remove the retainer clip using a tool such as snap ring
pliers.

Retainer clip ! CAUTION • Retainer clip must not be reused. Replace it

Pinion stopper
with a new one.

NOTICE • Push upward or pull out the chipped part of

the clip mouth.
Pinion
SAPH30TCE1300014

(2) Remove the pinion stopper.

(3) Remove the pinion.
Pinion stopper
! CAUTION • Make sure that the gear is not damaged or
Pinion chipped.

SAPH30TCE1300015

[S5LC0033E04] [0518CsCshWbYs]
 STARTING AND CHARGING 13–7

13. Removal of center bracket

Center bracket
(1) Remove two set bolts at the switch using a box
screwdriver or offset wrench.
(2) Lift and remove the center bracket.
Clutch
assembly

SAPH30TCE1300016

14. Removal of lever

(1) Hold the lever holder and press the entire lever to the
Plunger clutch. Remove the link with the plunger.

Holder

Lever assembly

SAPH30TCE1300017

(2) Turn and pull out the lever assembly using the clutch as
the axis.

Lever assembly

SAPH30TCE1300018

15. Removal of brake plate

(1) Hold the clutch case outer diameter and slide the clutch
assembly upward. Pinch the clip end fixing the brake plate
and remove it by bending.

SAPH30TCE1300019

[S5LC0033E04] [0518CsCshWbYs]
13–8 STARTING AND CHARGING

(2) Remove the brake plate.

Brake plate

SAPH30TCE1300020

16. Removal of clutch assembly

(1) While pressing the clutch assembly to the center bracket
Clutch assembly
assembly, offset the helical spline by one tooth.
Pull out the clutch assembly upward from the offset
Center bracket position and remove it.
assembly

SAPH30TCE1300021

17. Removal of shaft assembly

Washer
(1) Turn the center bracket assembly upside down. Hold the
carrier plate and pull out the shaft assembly.

! CAUTION • Washers are available at the upper and lower

parts of the carrier plate. Be careful for loss of
the washers.
Shaft assembly

SAPH30TCE1300022

18. Removal of packing

(1) Turn the center bracket upside down again and remove
the packing.

! CAUTION • Packing must not be reused.

Packing

SAPH30TCE1300023

Inspection procedure item

[S5LC0033E04] [0518CsCshWbYs]
 STARTING AND CHARGING 13–9

Inspection of components
JP30TCE130703001

1. Inspection of yoke assembly

(1) Make sure that the coil lead wire has electric continuity
using a circuit tester.
(2) Make sure that there is no discoloration at the coil.

SAPH30TCE1300024

(3) Measure the resistance between the coil lead wire and the
Tester rod yoke with a circuit tester and check insulation.
When the value is below the service limit, replace it.
Feed coil
Service limit 1k: or less

! CAUTION • After cleaning and drying, take

Yoke assembly measurements.

SAPH30TCE1300025

(4) Measure the brush length using vernier calipers.

When the value is below the service limit, replace it.

Standard value (mm{in.}) Service limit (mm{in.})

18{0.7087} 13{0.5118} or less

SAPH30TCE1300026

2. Inspection of armature assembly

Piece of steel
(1) Turn the armature assembly using a commercially
available growler tester and put a piece of steel on the
armature assembly. Make sure that the steel piece is not
vibrating on the core circumference.

Growler tester

SAPH30TCE1300027

[S5LC0033E04] [0518CsCshWbYs]
13–10 STARTING AND CHARGING

(2) Make sure that adjacent segments of the commutator

have electric continuity using a circuit tester.
(3) Make sure that there is no discoloration at the coil.

SAPH30TCE1300028

(4) Measure the resistance between the commutator and the

Megger tester core using a circuit tester and check insulation.
When the value is below the service limit, replace it.
Core
Standard value Service limit

1k: or less
1M: or more
(Use 500V megger tester)

Commutator ! CAUTION • After cleaning and drying, take

SAPH30TCE1300029 measurements.

(5) Measure the commutator outer diameter using vernier

calipers.
When the value is below the service limit, replace it.

! CAUTION • After removing roughness on the surface

(after polishing), take measurements.

Commutator outer diameter

Standard value (mm{in.}) Service limit (mm{in.})

Commutator
SAPH30TCE1300030 36{1.4173} 34{1.3386} or less

(6) Measure the undercut depth between segments. If the

undercut depth is beyond the service limit, repair it.

Standard value (mm{in.}) Service limit (mm{in.})

Undercut length:
0.5 to 0.8 mm 0.5 - 0.8{0.0197 - 0.0315} 0.2{0.0079} or less
Segment {0.0197 - 0.0315}

! CAUTION • In repair, do not leave insulation material at

the end of the segment.
Insulating material
SAPH30TCE1300031

[S5LC0033E04] [0518CsCshWbYs]
 STARTING AND CHARGING 13–11

(7) Measure the shaft outer diameter using a micrometer. If it

is beyond the service limit, replace the shaft.

A Standard value Service limit

Measuring area
(mm{in.}) (mm{in.})
B 11.98{0.4717} or
Area A 12{0.4724}
less

8.98{0.3535} or
Area B 9{0.3543}
SAPH30TCE1300032 less

3. Inspection of brush holder assembly

(1) Measure the resistance between the holder (plus) and the
plate using a circuit tester and check insulation.
When the value is below the service limit, replace it.

Service limit 1k: or less

! CAUTION • After cleaning and drying, take

measurements.
SAPH30TCE1300033

(2) Measure the brush length using vernier calipers.

Brush Spring When the value is below the service limit, replace it.

Standard value (mm{in.}) Service limit (mm{in.})

18{0.7087} 13{0.5118} or less

(3) Make sure that the spring has pressure.

Brush

SAPH30TCE1300034

4. Inspection of shaft assembly

(1) Measure the outer diameter of the shaft using a
micrometer
If it is beyond the service limit, replace the shaft.
B A
Standard value Service limit
Measuring area
(mm{in.}) (mm{in.})

25.90{1.0197} or
Area A 26{1.0236}
less
SAPH30TCE1300035

12.04{0.4740} or
Area B 12.1{0.4764}
less

[S5LC0033E04] [0518CsCshWbYs]
13–12 STARTING AND CHARGING

5. Inspection of clutch assembly

(1) Measure the outer diameter of the inner sleeve using a
micrometer.
If it is beyond the service limit, replace the clutch
assembly.

Standard value (mm{in.}) Service limit (mm{in.})

25{0.9843} 24.9{0.9803} or less

SAPH30TCE1300036

6. Inspection of bearing
(1) Measure the bearing metal inner diameter (1 in the figure)
of the pinion case using a cylinder gauge. If it is beyond
the service limit, replace the bushing.

1
Standard value (mm{in.}) Service limit (mm{in.})

25{0.9843} 25.2{0.9921} or more

SAPH30TCE1300037

(2) Measure the bearing metal inner diameter (2 in the figure)

of the center bracket using a cylinder gauge. If it is beyond
the service limit, replace the center bracket.

Standard value (mm{in.}) Service limit (mm{in.})

2 26{1.0236} 26.2{1.0315}

SAPH30TCE1300038

(3) Measure the bearing metal inner diameter (3 in the figure)

3 4 of the shaft assembly using a cylinder gauge. If it is
beyond the service limit, replace the shaft assembly.

Standard value (mm{in.}) Service limit (mm{in.})

9{0.3543} 9.2{0.3622}

(4) Measure the bearing housing inner diameter (4 in the

figure) of the commutator end frame using a cylinder
SAPH30TCE1300039
gauge. If it is beyond the service limit, replace the
commutator end frame.

Standard value (mm{in.}) Service limit (mm{in.})

28{1.1024} 28.1{1.1063} or more

[S5LC0033E04] [0518CsCshWbYs]
 STARTING AND CHARGING 13–13

7. Inspection of start magnet switch assembly (resistance of

C terminal
P coil)
M terminal (1) Measure the P coil resistance between the C terminal and
the M terminal using a circuit tester.
If it is beyond the service limit, replace the start magnet
switch.

Standard value (:) 0.12 - 0.14

SAPH30TCE1300040

8. Inspection of start magnet switch assembly (resistance of

H coil)
(1) Measure the H coil resistance between the C terminal and
C terminal the body using a circuit tester.
If it is beyond the service limit, replace the start magnet
switch.

Body
Standard value (:) 1.13 - 1.25

SAPH30TCE1300041

9. Inspection of start magnet switch assembly (electric

continuity inspection)
M terminal (1) Check electric continuity between the B terminal and the
M terminal using a circuit tester, and make sure that there
is no electric continuity.

B terminal

SAPH30TCE1300042

(2) Push the end of the start magnet switch assembly (close
the internal contact) and make sure that there is electric
continuity between the B terminal and the M terminal
using a circuit tester.

SAPH30TCE1300043

Overhaul item

[S5LC0033E04] [0518CsCshWbYs]
13–14 STARTING AND CHARGING

Assembly
JP30TCE130702002

1. Installation of packing
(1) Install a new packing on the center bracket assembly.

Packing

SAPH30TCE1300023

2. Installation of shaft assembly

Washer
(1) Turn the center bracket assembly upside down and hold
the carrier plate. Lubricate parts (refer to the lubrication
point drawing and the lubrication list) and install the shaft
assembly.

! CAUTION • Washers are available at the upper and lower

Shaft assembly parts of the carrier plate. Be careful for loss of
the washers.
SAPH30TCE1300022

3. Installation of clutch assembly

(1) Lubricate parts (refer to the lubrication point drawing and
Clutch assembly
the lubrication list) and insert the clutch assembly into the
center bracket assembly.
Center bracket
assembly

SAPH30TCE1300044

4. Installation of brake plate

(1) Lubricate parts (refer to the lubrication point drawing and
the lubrication list) and install the brake plate.

Brake plate

SAPH30TCE1300045

[S5LC0033E04] [0518CsCshWbYs]
 STARTING AND CHARGING 13–15

5. Installation of lever
(1) Lubricate parts (refer to the lubrication point drawing and
the lubrication list). Turn and install the lever assembly
using the clutch as the axis.

Lever assembly

SAPH30TCE1300018

6. Installation of pinion case

Center bracket
(1) Install two set bolts at the switch using a box screwdriver
or offset wrench.
Tightening torque :
Clutch 3.6 - 4.9 N˜m {37 - 49 kgf˜cm, 3 - 4 lbf˜ft}
assembly

SAPH30TCE1300016

7. Installation of pinion
(1) Lubricate parts (refer to the lubrication point drawing and
Pinion stopper the lubrication list) and install the pinion and the pinion
stopper.
Pinion

SAPH30TCE1300015

(2) Install the retainer clip using a tool such as snap ring
pliers.

Retainer clip

Pinion stopper

Pinion
SAPH30TCE1300014

[S5LC0033E04] [0518CsCshWbYs]
13–16 STARTING AND CHARGING

8. Installation of shim washer

(1) Lubricate parts (refer to the lubrication point drawing and
the lubrication list) and install the shim washer on the
center bracket.
Shim

SAPH30TCE1300013

9. Removal of internal gear

(1) Lubricate parts (refer to the lubrication point drawing and
the lubrication list) and install the internal gear on the
center bracket.

Internal gear

Center bracket

SAPH30TCE1300012

10. Installation of planetary gear

(1) Lubricate parts (refer to the lubrication point drawing and
the lubrication list) and install the planetary gear on the
Planetary gear carrier pin.
Carrier pin

SAPH30TCE1300011

11. Installation of cover

Packing Cover (1) Install a new packing.
(2) Install the cover on the center bracket assembly.

SAPH30TCE1300010

12. Installation of rear bearing

(1) Install the bearing on the armature assembly using a
press.

! CAUTION • When the bearing is removed, replace it with

a new one.

[S5LC0033E04] [0518CsCshWbYs]
 STARTING AND CHARGING 13–17

13. Installation of armature assembly

(1) Install the armature assembly.
Armature
assembly
! CAUTION • When the armature assembly is installed, the
washer at the end of the gear may be dropped
and lost. Be careful for handling.
Center bracket
assembly

SAPH30TCE1300008

14. Installation of packing

Yoke assembly (1) Install a new packing on the centering location at both
ends of the yoke assembly.

! CAUTION • Damaged packing must not be resued.

Replace it with a new part.

Packing Packing

SAPH30TCE1300007

15. Installation of yoke assembly

M lead wire (1) Install the yoke assembly on the center bracket assembly.
Yoke assembly

Center bracket
assembly

SAPH30TCE1300006

[S5LC0033E04] [0518CsCshWbYs]
13–18 STARTING AND CHARGING

16. Installation of brush holder assembly

Brush holder
Assembly (1) Lift the spring using a flat tip screwdriver, long-nose pliers
or pliers. Install four brushes on the brush holder
assembly.

Spring
Brush

Brush lead
Clamp

SAPH30TCE1300005

17. Installation of commutator end frame

Through bolt (1) Tighten the through bolt of the commutator end frame.

Tightening torque :
13.7 - 15.7 N˜m {139 - 160 kgf˜cm, 10 - 11 lbf˜ft}

Commutator end
frame

SAPH30TCE1300003

(2) Tighten two set bolts.

Tightening torque :
Set bolt
3.6 - 4.9 N˜m {37 - 49 kgf˜cm, 3 - 4 lbf˜ft}

! CAUTION • Hold the M lead wire and remove the

commutator end frame by lifting.

SAPH30TCE1300004

[S5LC0033E04] [0518CsCshWbYs]
 STARTING AND CHARGING 13–19

18. Installation of lead wire

M lead wire (1) Install the M lead wire.
M terminal
Tightening torque :
12.3 - 15.2 N˜m {125 - 155 kgf˜cm, 9 - 11 lbf˜ft}

SAPH30TCE1300002

19. Lubrication
Refer to the following figure and table for lubricant to be applied.

! CAUTION • There shall be no lubricant on the commutator surface, brush and contact.

Figure of lubricating locations

SAPH30TCE1300046

[S5LC0033E04] [0518CsCshWbYs]
13–20 STARTING AND CHARGING

Table of lubricant

Amount Lubricant
Code Lubricating point Lubricant used Remark
(g{oz}) manufacturer

Pinion case metal 0.8 - 1.5

1 Multemp AC-N Kyodo Yushi
and grease reservoir {0.03 - 0.05}

Bracket center metal 0.5 - 1.5

2 Multemp AC-N Kyodo Yushi
and grease reservoir {0.03 - 0.05}

0.2 - 0.5 Applied to both sides

3 Shim washer Multemp AC-N Kyodo Yushi
{0.01 - 0.02} of washer.

0.5 - 1
4 Armature front metal Multemp AC-N Kyodo Yushi
{0.02 - 0.04}

0.2 - 0.5 Applied to both sides

5 Shim washer Multemp AC-N Kyodo Yushi
{0.01 - 0.02} of washer.

Internal gear
7 -11
6 Armature gear Multemp AC-N Kyodo Yushi
{0.25 - 0.39}
Planetary gear

Pinion straight 0.5 - 1

7 Multemp AC-N Kyodo Yushi
Spline {0.02 - 0.04}

0.3 - 0.6
8 Inner sleeve metal Multemp AC-N Kyodo Yushi
{0.01 - 0.02}

0.5 - 1
9 Helical spline Multemp AC-N Kyodo Yushi
{0.02 - 0.04}

Clutch case lever 1-2 Nippon Oil

10 Pyroknock No.2
shifter {0.04 - 0.07} Corporation

Bracket rear bearing 0.2 - 0.5 Nippon Oil

11 Pyroknock No.2
housing {0.01 - 0.02} Corporation

1-2
12 Planetary gear metal Multemp AC-N Kyodo Yushi
{0.04 - 0.07}

0.4 - 0.8
13 Lever holder Multemp AC-N Kyodo Yushi
{0.01 - 0.03}

Assemble the roller

after application of
0.2 - 0.5 Nippon Oil
14 Lever roller rod Pyroknock No.2 grease to prevent fall
{0.01 - 0.02} Corporation
of the roller in
assembly.

Setup layout
Layout

[S5LC0033E04] [0518CsCshWbYs]
 STARTING AND CHARGING 13–21

Alternator (60A)
Part layout (60A)
JP30TCE130402002

SAPH30TCE1300047

1 Field coil 9 Cover

2 Drive end frame 10 Stator coil
3 Bearing cover 11 Collar
4 Rotor assembly 12 Pulley
5 Rectifier cathode 13 Fan
6 Rectifier anode 14 Regulator
7 End frame 15 Front bearing
8 Insulator 16 Rear bearing

Tightening torque
A 1.9 - 2.5N˜m D 127 - 157N˜m
{20 - 25kgf˜cm, 1.4 - 1.8 lbf˜ft} {1,300 - 1,600kgf˜cm, 94- 116 lbf˜ft}
B 2.9 - 3.9N˜m E 7.8 - 9.8N˜m
{30 - 39kgf˜cm, 2 - 3 lbf˜ft} {80 - 100kgf˜cm, 6 - 7 lbf˜ft}
C 4.9 - 5.9N˜m F 3.3 -4.4N˜m
{50 - 60kgf˜cm, 3.6 - 4.3 lbf˜ft} {33 - 44kgf˜cm, 2 - 3 lbf˜ft}
(Internal nut)
System drawing

[S5LC0033E04] [0518CsCshWbYs]
13–22 STARTING AND CHARGING

Circuit drawing (60A)

JP30TCE130803001

Diode
B Fuse Load

L Lamp㧔1.4 to 3W㧕

Feild coil R
Starter switch
Regulator C

Stator coil Battery

24V

E
Alternator

SAPH30TCE1300048
Service procedure
Overhaul item

[S5LC0033E04] [0518CsCshWbYs]
 STARTING AND CHARGING 13–23

Disassembly (60A)
JP30TCE130702003

1. Disconnection of the drive end frame from the end frame

Cover Tab Drive end
frame ! CAUTION • Place a rubber mat and perform work on the
mat.

(1) Remove the bolts and remove the cover from the drive
end frame.

! CAUTION • Be careful not to break the tab with excessive

force when pressing the tabs of the cover for
Bolt Tab
removal.
SAPH30TCE1300049
• Do not push the tabs by screwdriver.

(2) Remove 3 through bolts and disconnect the drive end

End frame side frame from the end frame.

Drive end
frame side
SAPH30TCE1300050

2. Disassembly of drive end frame

Fan
(1) Remove the nuts and remove the pulley, fan and collar.

Pulley ! CAUTION • Tie around a general V –belt in the pulley

groove and fix the pulley with a vice.
8-belt
• Do not reuse if outer frame of the pulley was
damaged.

SAPH30TCE1300051

(2) Remove the rotor assembly from the drive end frame
using a press.

! CAUTION • Do not damage the end of the thread.

• Support the rotor assembly to prevent fall of
the rotor assembly.
• Take care not to damage the bracket and the
front stator spigot part (A).

SAPH30TCE1300052

[S5LC0033E04] [0518CsCshWbYs]
13–24 STARTING AND CHARGING

(3) Remove the screws (3pcs.) and remove the bearing cover
from the drive end frame.
Bearing cover

SAPH30TCE1300053

(4) Remove the front bearing from the drive end frame using
a press or jig C.

! CAUTION • Place jig C at the inner race of the front

bearing.
• Removed bearing must not be reused.

SAPH30TCE1300054

3. Disassembly of end frame

(1) Remove solder of the lead wire connecting the stator coil
and the diode using a soldering bit and suction line or a
solder suction device.

! CAUTION • At solder of the stator coil and the diode, the

end of the diode is clamped. Do not damage
the diode by prying. Deformed diode must not
Solder
be reused.
SAPH30TCE1300055 • Perform soldering in a short time (within 5
seconds).
• Re-using this part is not possible when the
stator lead has been cut.

(2) Remove the stator coil from the end frame.

! CAUTION • Do not damage the stator coil.

End frame

Stator coil

SAPH30TCE1300056

[S5LC0033E04] [0518CsCshWbYs]
 STARTING AND CHARGING 13–25

(3) Remove the regulator connecting bolts (3pcs.) and the

Regulator regulator fixing bolts (2pcs.), and remove the regulator.

! CAUTION • As Screw-lock has been applied to the two

regulator fixing bolts, the torque required to
loosen the bolts is high; care must be taken
not to strip the bolt thread.

SAPH30TCE1300057

(4) Loosen the nut at the B terminal.

! CAUTION • Loosen the nut to some extent and do not

remove it from the B terminal.

Nut

SAPH30TCE1300058

(5) Remove the bolts (4pcs.) and remove the rectifier anode
and rectifier cathode.

! CAUTION • As Screw-lock has been applied, the torque

required to loosen the bolts is high; care must
be taken not to strip the bolt thread.

Rectifier

SAPH30TCE1300059

(6) Remove the bolts (3pcs.) and remove the field coil from
the end frame.

! CAUTION • Take care not to damage the coil.

Field coil
End frame

SAPH30TCE1300060

[S5LC0033E04] [0518CsCshWbYs]
13–26 STARTING AND CHARGING

(7) Remove the rear bearing from the end frame using a
press and jig A.
Jig A
! CAUTION • When the inner surface of the bearing hole of
the end frame etc. has been damaged when
pulling the bearing, the end frame cannot be
reused.
• Removed bearing must not be reused.

SAPH30TCE1300061

[S5LC0033E04] [0518CsCshWbYs]
 STARTING AND CHARGING 13–27

Inspection procedure item

Inspection of components (60A)

JP30TCE130703002

1. Inspection of stator coil and field coil

㨃
! CAUTION • Place a rubber mat and perform work on the
mat.

㨂 㨁 (1) Measure the resistance between the U - V, V - W, W - U

terminals of the stator coil using a circuit tester, if the
Wiring diagram
value exceeds the standard value, replace it.

Stator coil Standard value (:) 0.31 - 0.33

SAPH30TCE1300062

(2) Measure the resistance between the terminal of the stator

Megger tester
coil core and each terminals using a 500V megger tester,
if the value exceeds the standard value, replace it.
Stator coil

1 or more
Standard value (M:)
(Use 500V megger tester)

! CAUTION • Do not reuse if the coil was damaged.

• Do not damage the circumferential surface of
SAPH30TCE1300063
the coil.
• Damaged coil circumference must not be
reused.
• Do not use an organic solvent at the coil
cleaning, the coil may be damaged.
• Do not measure between the terminal to other
terminal, stator coil may be damaged.

[S5LC0033E04] [0518CsCshWbYs]
13–28 STARTING AND CHARGING

(3) Measure the resistance at the field coil using a circuit

tester, if the value exceed the standard value, replace it.

Standard value (:) 6.4 - 7.0

! CAUTION • Do not reuse if the coil was damaged.

Field coil • Do not damage the circumferential surface of

the coil.
SAPH30TCE1300064
• Damaged coil circumference must not be
reused.
• Do not use an organic solvent at the coil
cleaning, the coil may be damaged.

(4) Measure the resistance between the field coil core and
the coil using a megger tester, if the value exceed the
Megger tester standard value, replace it.

1 or more
Standard value (M:)
(Use 500V megger tester)

! CAUTION • Do not measure between the coils, the field

Field coil
coil may be damaged.
SAPH30TCE1300065

2. Inspection of rotor assembly

(1) Measure the outer diameter of the shaft of the front
bearing insertion portion of the rotor assembly using a
micrometer, if value exceed the service limit, replace it.

Standard value (mm{in.}) Service limit (mm{in.})

25.0{0.9843} 24.98{0.9835}
Micrometer

SAPH30TCE1300066

(2) Measure the outer diameter of the shaft of the rear

bearing insertion portion of the rotor assembly using a
micrometer, if value exceed the service limit, replace it.

Standard value (mm{in.}) Service limit (mm{in.})

17.0{0.6693} 16.98{0.6685}

Micrometer

SAPH30TCE1300067

[S5LC0033E04] [0518CsCshWbYs]
 STARTING AND CHARGING 13–29

3. Inspection of the diode and the regulator

(1) Measure the resistance between the cathode of the diode
and rectifier holder portion using a circuit tester, if value
exceed the standard value, replace it.

Measuring direction Standard value

Forward resistance value Approx. 10 :

Rectifier Reverse resistance value Infinite
SAPH30TCE1300068

! CAUTION • Do not use a digital tester.

(2) Measure the resistance between the terminals F - E of the

regulator using a circuit tester, if value exceed the
standard value, replace it.

Measuring direction Standard value

㧲 Forward resistance value Approx. 10 :

Back
view Reverse resistance value Infinite

SAPH30TCE1300069 ! CAUTION • Do not use a digital tester.

[S5LC0033E04] [0518CsCshWbYs]
13–30 STARTING AND CHARGING

Overhaul item

Assembly (60A)
JP30TCE130702004

1. Assembly of the drive end frame

! CAUTION • Place a rubber mat and perform work on the

mat.

(1) Press fit a new front bearing into the drive end frame
using a press and jig C.

! CAUTION • Place jig C at the outer race of the front

bearing.

SAPH30TCE1300070
• Do not reuse the bearing.

(2) Install the bearing cover to the drive end frame by screws
Screw (3pcs.).

Tightening torque :
1.9 - 2.5 N˜m {20 - 25 kgf˜cm, 1.4 - 1.8 lbf˜ft}

Bearing cover

Drive end frame

SAPH30TCE1300071

(3) Press fit the rotor assembly to the drive end frame using a
press.

! CAUTION • Always fit the inner race part of the bearing

when press-fitting.
• Do not damage the shaft.

SAPH30TCE1300072

(4) Tie around a general V-belt in the pulley groove and fix the
Fan
Rotor
pulley with a vice.
assembly (5) Install the collar, fan and pulley on the shaft of the rotor
Pulley
assembly.

Tightening torque :
V-belt
127 - 157 N˜m {1,300 - 1,600 kgf˜cm, 94 - 116 lbf˜ft}

! CAUTION • Do not reuse if outer frame of the pulley was

damaged.
SAPH30TCE1300073

[S5LC0033E04] [0518CsCshWbYs]
 STARTING AND CHARGING 13–31

2. Assembly of the end frame

(1) Press fit a new rear bearing into the end frame using a
press, jig A and jig B.

! CAUTION • Press fit until jig A comes in contact with the

end frame.
• Reuse is not possible when the bearing case
is deformed at the time of press-fitting.

SAPH30TCE1300074

(2) Install the field coil on the end frame.

Tightening torque :
2.9 - 3.9 N˜m {30 - 39 kgf˜cm, 2 - 3 lbf˜ft}

! CAUTION • Tighten bolts finally after temporary

tightening. Tighten them evenly.

Field coil
End frame
SAPH30TCE1300075

(3) Assemble the stator coil on the end frame temporarily.

! CAUTION • Do not damage the stator coil during work.

End frame

Stator coil

SAPH30TCE1300076

(4) Apply screw lock (Three bond TB1344) to the end of the
rectifier mounting bolts, and install the rectifier to the end
frame.

Tightening torque :
1.9 - 2.5 N˜m {20 - 25 kgf˜cm, 1.4 - 1.8 lbf˜ft}

Rectifier

SAPH30TCE1300077

[S5LC0033E04] [0518CsCshWbYs]
13–32 STARTING AND CHARGING

(5) Apply screw lock (Three bond TB1344) to the end of the
Regulator regulator mounting bolts, and install the regulator to the
end frame.

Tightening torque :
1.6 - 2.3 N˜m {16 - 23 kgf˜cm, 1.2 - 1.6 lbf˜ft}
(Regulator fix)
1.0 - 1.4 N˜m {10 - 14 kgf˜cm, 0.8 - 1.0 lbf˜ft}
(Coil lead wire connecting)
1.0 - 1.4 N˜m {10 - 14 kgf˜cm, 0.8 - 1.0 lbf˜ft}
SAPH30TCE1300078
(Heat sink connecting)
(6) Solder the lead wire connecting the stator coil and the
diode using a solder bit.

! CAUTION • Perform soldering after tightening of bolts.

• Insert the lead wire of the stator coil into the
end of the diode, and bend and fix the end of
the diode, before soldering it.

Solder • Perform soldering in a short time (within 5

seconds).
SAPH30TCE1300079

(7) Tighten the nut inside the B terminal.

Tightening torque :
4.9 - 5.9 N˜m {50 - 60 kgf˜cm, 3.6 - 4.3 lbf˜ft}

NOTICE • After installation of the alternator, connect the

wire and tighten the outside nut.

Tightening torque :
3.2 - 4.4 N˜m {3 - 4 kgf˜cm, 2.3 - 3.2 lbf˜ft}
Nut

SAPH30TCE1300080 ! CAUTION • Do not break the insulator by tightening with

excessive force.

3. Joint of the drive end frame and the end frame

End frame side (1) Joint the drive end frame and the end frame by through
bolts (3pcs.).

Tightening torque :
7.8 - 9.8 N˜m {80 - 100 kgf˜cm, 6 - 7 lbf˜ft}

! CAUTION • Tighten bolts evenly.

Drive end
frame side

SAPH30TCE1300081

[S5LC0033E04] [0518CsCshWbYs]
 STARTING AND CHARGING 13–33

(2) Match the position of the tab, and install the cover to the
Cover Tab
Drive end dive end frame, fix the cover with the bolt.
frame
Tightening torque :
3.3 - 4.4 N˜m {34 - 44 kgf˜cm, 2 - 3 lbf˜ft}

! CAUTION • Do not hit the cover, the tab may be broken.

Bolt Tab
SAPH30TCE1300082

[S5LC0033E04] [0518CsCshWbYs]
13–34 STARTING AND CHARGING

Inspection procedure item

Inspection after assembly (60A)

JP30TCE130703003

1. Inspection of rotation

! CAUTION • Place a rubber mat and perform work on the

mat.

(1) Turn the pulley with hand to check if there is no

interference with internal parts and if rotation is smooth.

Pulley

SAPH30TCE1300083

(2) Measure the resistance between B - E terminals and

between P - E terminals using a circuit tester, if it is
exceeds the standard value (e.g. 0:), disassemble it
again and reassemble the unit correctly.

Circuit tester lead

Standard value
(+) (-)

B E Approx. 20 :
SAPH30TCE1300084
E B Infinite

P E Approx.7 :

E P Infinite

Connector lock

4 %

. 2

Connector details Connector lock

'
SAPH30TCE1300085

[S5LC0033E04] [0518CsCshWbYs]
 TURBOCHARGER 14–1

ENGINE

14 TURBOCHARGER
Setup layout
Layout

Turbocharger Assembly........................................... 14-2

Part layout............................................................. 14-2
Inspection ............................................................. 14-5
Replacement......................................................... 14-6

14

[S5LC0033E04] [0518CsCshWbYs]
14–2 TURBOCHARGER

Turbocharger Assembly
Part layout
JP30TCE140402001

A A
5 B 1

A 4 3 2
SAPH30TCE1400001

1 Intake pipe stay 4 Oil outlet pipe

2 Turbocharger assembly 5 Bracket
3 Turbine outlet elbow 6 Gasket*

*Parts not to be reused.

Tightening torque
A 28.5N˜m{291kgf˜cm, 21 lbf˜ft} B 60N˜m{612kgf˜cm, 44 lbf˜ft}

[S5LC0033E04] [0518CsCshWbYs]
 TURBOCHARGER 14–3

3,A 3,A 2 B

1 3,A
SAPH30TCE1400002

1 Coolant pipe 3 Gasket*

2 Oil inlet pipe

*Parts not to be reused.

Tightening torque
A 25N˜m{255kgf˜cm, 18 lbf˜ft} B 60N˜m{612kgf˜cm, 44 lbf˜ft}

[S5LC0033E04] [0518CsCshWbYs]
14–4 TURBOCHARGER

1
2,B
A

2,B

View Z
SAPH30TCE1400003

1 Coolant pipe 2 Gasket*

*Parts not to be reused.

Tightening torque
A 56N˜m{571kgf˜cm, 41 lbf˜ft} B 25N˜m{255kgf˜cm, 18 lbf˜ft}

[S5LC0033E04] [0518CsCshWbYs]
 TURBOCHARGER 14–5

Maintenance
List of maintenance
inspection
inspection
(preventive service)

Inspection
JP30TCE140501001

1. Inspection of turbine shaft axial play

(1) Inspect axial play of the turbine shaft at the exhaust side
using a special tool.

Special tool : S0944-41800(09444-1800)

Tool assembly

(2) If the measurement value is beyond the standard value,

ask the manufacturer to overhaul the unit.

SAPH30TCE1400004 0.040 - 0.085

Standard value (mm{in.}) {0.0016 - 0.0033}
(Only axial play)

NOTICE • Since the assembly is replaced, disassembly

and inspection are not allowed.
Service procedure
Replacement procedure item

[S5LC0033E04] [0518CsCshWbYs]
14–6 TURBOCHARGER

Replacement
JP30TCE140704001

1. Removal
(1) Remove the boost pipe and the intake pipe.
(2) Disconnect all pipes connected to the turbocharger.

! CAUTION • Loosen union bolt of the coolant pipe, drain

coolant and remove the pipe. Disconnect the
lower pipe similarly and remove the oil pipe.
• After removing pipes, be sure to seal oil
holes, water holes and cylinder block holes
to prevent entry of dirt.

(3) Remove the bolts fixing the exhaust pipe and the
turbocharger and remove the turbocharger.

! CAUTION • After removal, seal holes both at the exhaust

manifold and the exhaust pipe to prevent
entry of foreign matter.
• If a stud bolt is sticking, remove and replace
the stud bolt using a commercially available
stud remover.

2. Installation
(1) Before installation on the engine, pour new engine oil from
the oil inlet and turn the turbocharger with hand to
lubricate the journal bearing and the thrust bearing.
(2) Replace the o-ring by new ones, and assemble the
exhaust pipe and the turbocharger, and install the
turbocharger on the engine.
Tightening torque :
56 N˜m {570 kgf˜cm, 41 lbf˜ft}
(Turbocharger to exhaust manifold)

! CAUTION • Make sure that there is no dirt or foreign

matter in the exhaust pipe system.
• As heat-resistant steel is used for the bolts
and nuts, take care that they do not become
mixed up with standard bolts and nuts.

(3) Replace the gasket by new ones, install the coolant pipe
and the oil pipe to the turbocharger.

! CAUTION • Clean the pipes and confirm that they are not
crushed and that the inside of the pipes is
free of dirt and foreign matter.
• Do not use a sealing agent at the installation
surfaces of oil pipes and fuel pipes and at the
connection parts of coolant hoses and
coolant pipes; small particles can cause
clogging, loose connections, damage to
components, as well as other malfunctions.

[S5LC0033E04] [0518CsCshWbYs]
 TURBOCHARGER 14–7

(4) Install the boost pipe and the intake pipe.

! CAUTION • Confirm that the inside of the intake system is

free of dirt and foreign matter.
Do not use a sealing agent at the air intake of
the air pipe; small particles can cause
clogging, loose connections, damage to
components, as well as other malfunctions.
• Install correctly to prevent leak of air from
intake pipe and air hose connections.

[S5LC0033E04] [0518CsCshWbYs]
[S5LC0033E04] [0518CsCshWbYs]
 FAILURE DIAGNOSIS FOR EACH ENGINE STATUS 16–1

ENGINE

16 FAILURE DIAGNOSIS FOR EACH ENGINE

STATUS
Failure diagnosis list

FAILURE DIAGNOSIS FOR EACH ENGINE STATUS

.................................................................................... 16-2
Engine mechanical ............................................... 16-2
Alternator .............................................................. 16-5
Starter ................................................................... 16-6
Turbocharger......................................................... 16-7
DPR filter .............................................................. 16-9

16

[S5LC0033E04] [0518CsCshWbYs]
16–2 FAILURE DIAGNOSIS FOR EACH ENGINE STATUS

FAILURE DIAGNOSIS FOR EACH ENGINE STATUS

Engine mechanical
JP31TCE160601001

Status Cause Action

Engine overheat (coolant) Insufficient coolant Replenish coolant
Faulty thermostat Replace thermostat
Water leak from cooling system Correction
Faulty coolant pump Repair or replace
Faulty head gasket Replace head gasket
Engine overheat Clogging of radiator Cleaning of radiator
(radiator) Corrosion of cooling system Clean and repair cooling system
Clogging of radiator core front part Clean radiator
Faulty radiator cap Replace radiator cap
Engine overheat (lubrication Deterioration of engine oil Replace engine oil
unit) Faulty oil pump Replace oil pump
Insufficient engine oil Replenish engine oil
Large engine oil consumption Wear of piston ring and cylinder Replace piston ring and cylinder
(piston, cylinder liner and piston liner liner
ring) Damage to piston ring Replace piston ring and cylinder liner
Faulty fixing of piston ring Replace piston ring and cylinder liner
Faulty assembly of piston ring Replace piston ring and cylinder
liner
Faulty engine oil Replace engine oil
Faulty piston ring joint Reassemble piston ring
Large engine oil consumption Wear of valve stem Replace valve and valve guide
(valve and valve guide) Wear of valve guide Replace valve guide
Faulty assembly of valve stem seal Replace stem seal
Excessive oil lubrication to rocker Inspection of clearance between
arm rocker arm and rocker arm shaft
Large engine oil consumption Faulty oil level gauge Replace with correct level gauge
(others) Excessive filling of engine oil Fill with appropriate amount of oil.
Leak of engine oil Repair or replace the part of oil
leak.
Piston seizure (in operation) Sudden stop of engine Perform warm-up before stop of
engine
Piston seizure (lubrication unit) Insufficient engine oil Replenish engine oil
Deterioration of engine oil Replace engine oil
Incorrect engine oil Replace with correct engine oil.
Low oil pressure Inspection of lubrication unit
Faulty oil pump Replace oil pump
Piston seizure Abnormal combustion Refer to overheat section.
Piston seizure Cooling unit Refer to overheat section.
Insufficient engine power (air Clogging of air cleaner element Clean or replace air cleaner
cleaner) element
Insufficient engine power Overheat Refer to overheat section.

[S5LC0033E04] [0518CsCshWbYs]
 FAILURE DIAGNOSIS FOR EACH ENGINE STATUS 16–3

Status Cause Action

Insufficient engine power (fuel Faulty injection of injector Replace injector
unit) Faulty injector due to deposit of Replace injector
carbon
Entry of air into fuel system Air bleeding of fuel system
Faulty fuel filter Replace element
Faulty fuel Replace with correct fuel
Insufficient engine power Abnormal compression pressure Refer to overheat section.
Insufficient engine power Piston, cylinder liner and piston Refer to large engine oil
ring consumption section.
Faulty engine start (electric unit) Faulty battery Check battery
Faulty wiring of starter Replace starter wiring
Loose battery cable Tighten battery terminal connection
or replace cable
Faulty operation of starter Replace starter assembly
Faulty start assist unit Replace start assist unit
Faulty engine start (air cleaner) Clogging of air cleaner element Clean or replace air cleaner
element
Faulty engine start (fuel unit) Insufficient fuel Replenish fuel and bleed air from
fuel system
Clogging of fuel system Clean fuel system.
Air entering from connection of fuel Check sealing parts and replace
system
Clogging of fuel filter Replace fuel filter and air bleeding
of fuel system
Faulty fuel from fuel system Check and replace sealing parts
Fuel freezing Warm up fuel pipes by hot water
(60qC {140qF} below)
Water in fuel tank Discharge water
Water in fuel filter Discharge water
Faulty engine start (lubrication Excessive viscosity of engine oil Replace with engine oil with correct
unit) viscosity
Faulty engine start (others) Piston seizure Replace piston, piston ring and
cylinder liner
Bearing seizure Replace bearing and crankshaft

Low compression pressure Overhaul engine

Damage to ring gear Replace ring gear and replace
starter pinion gear.

[S5LC0033E04] [0518CsCshWbYs]
16–4 FAILURE DIAGNOSIS FOR EACH ENGINE STATUS

Status Cause Action

Faulty idling (fuel system) Insufficient fuel Replenish fuel and bleed air from
fuel system
Clogging of fuel system Clean fuel system.
Air entering from connection of fuel Check sealing parts and replace
system
Clogging of fuel filter Replace fuel filter and air bleeding
of fuel system
Faulty fuel from fuel system Check and replace sealing parts
Fuel freezing Warm up fuel pipes by hot water
(60qC {140qF} below)
Water in fuel tank Discharge water
Water in fuel filter Discharge water
Faulty idling (engine) Faulty valve clearance Adjustment of valve clearance
Faulty contact of valve seat Adjust or replace valve and valve
seat.
Low coolant temperature Perform warm-up.
Large variation of compression Overhaul engine
pressure between cylinders
Training of engine difference not Perform training of engine
performed after exchange of the difference after exchange of the
engine ECU engine ECU
Gas leak (head gasket) Reuse Replace gasket.
Damage Replace gasket.
Replace gasket. Replace gasket.
Gas leak (head bolt) Loose head bolt Tighten bolt.
Incorrect tightening sequence or Tighten bolt to correct torque
incorrect tightening torque according to the correct tightening
sequence.
Extension of head bolt Replace bolt.
Gas leak (cylinder block) Crack Replace cylinder block.
Distortion of cylinder block upper Repair or replace cylinder block.
surface
Depression of cylinder liner insertion Replace cylinder liner or block.
(insufficient protrusion of cylinder liner)
Gas leak (cylinder head) Crack of cylinder head Replace cylinder head.
Distortion of cylinder head lower Repair or replace cylinder head.
surface
Gas leak (cylinder liner) Crack of cylinder liner Replace cylinder liner.
Corrosion of cylinder liner Replace cylinder liner.
Insufficient protrusion of cylinder Replace cylinder liner or block.
liner

[S5LC0033E04] [0518CsCshWbYs]
 FAILURE DIAGNOSIS FOR EACH ENGINE STATUS 16–5

Alternator
JP31TCE160601002

Status Cause Action

Lamp is ON. o Charge current Faulty regulator (open PTr) Replace regulator.
does not run (alternator). Faulty stator coil (disconnection, Replace stator coil.
rare shorting)
Fault feed coil (disconnection, rare Replace feed coil.
shorting)
Faulty diode (open, shorting) Replace rectifier.
Disconnection or poor contact of Repair or replace lead wire.
lead wire (plate, support, etc.)
Lamp is ON. o Charge current Disconnection of wire (fuse) Replace wire (fuse).
does not run (wiring).
Lamp is ON. o Voltmeter Faulty regulator (shorting of PTr) Replace regulator.
indicates 29V or more Faulty tightening of voltage Repair, replace voltage detection
(alternator). detection circuit (e.g. support) circuit or replace regulator.
Lamp is ON. o Charge current is Faulty regulator (open Tr) Replace regulator.
correctly running (alternator).
Lamp is OFF. o Charge current Faulty stator coil (disconnection of 1 Replace stator coil.
is always limited. o Battery goes phase, rare shorting)
flat (alternator). Faulty diode (open, shorting) Replace rectifier.
Disconnection or poor contact of Repair or replace lead wire.
lead wire (plate, support, etc.)
Lamp is OFF. o Charge current Operation load is large (Load Reduce load
is always limited. o Battery goes balance is poor).
flat (operation load).
Lamp is OFF. o Charge current Faulty regulator (shorting of PTr) Replace regulator.
is always large. o Battery fluid Faulty tightening of voltage Repair or replace voltage detection
runs short in a short period of detection circuit (e.g. support) circuit.
time (alternator).
Lamp is OFF. o Charge current Battery is close to the service life. Replace battery.
is always large. o Battery fluid
runs short in a short period of
time (battery).
Others o Abnormal noise Faulty stator coil (rare shorting, Replace stator coil.
(alternator) grounding)
Contact of inner surface (faulty Repair or replace bearing.
bearing, wear of bracket)
Others o Abnormal noise (V belt) Faulty tension of V belt (belt slip) Correction

[S5LC0033E04] [0518CsCshWbYs]
16–6 FAILURE DIAGNOSIS FOR EACH ENGINE STATUS

Starter
JP31TCE160601003

Status Cause Action

Starter does not turn. Turning is Faulty connection of starter key Repair connecting area.
low. Flat battery Charge or replace.
Disconnection, loosening or After cleaning, tighten.
corrosion of battery terminal
Grounding wire is disconnected. Be sure to connect it.
Use of incorrect engine oil Replace with correct oil.
Faulty contact of start magnet Replace start magnet switch
switch assembly. assembly
Faulty contact or failure of starter Replace starter relay.
relay
Wear of starter brush Replace brush
Seizure of commutator Repair commutator.
Wear of commutator Undercut
Shorting of armature Replace armature assembly
Insufficient tension of brush spring Replace brush spring.
Faulty operation of clutch Clean or replace.

[S5LC0033E04] [0518CsCshWbYs]
 FAILURE DIAGNOSIS FOR EACH ENGINE STATUS 16–7

Turbocharger
JP31TCE160601004

Status Cause Action

Oil is quickly reduced Seal ring is excessively worn or damaged Disassemble and repair
due to excessive wear of the bearing. turbocharger.
Engine oil enters into exhaust gas Check and service engine parts.
before the turbocharger.
Clogged or damaged of oil return Repair or replace oil pipes.
pipe, then engine oil is entering to
blower side or turbine side.
Blower Impeller back side vacuum Check or replace oil pipes, replace
is excessive incease, then engine or cleaning air cleaner element.
oil is entering to blower side.
Low engine output Gas leak from exhaust system Check and repair faulty areas.
parts
Clogging of air inlet Repair air inlet.
Gas leak from exhaust system Check and repair faulty areas.
parts
Clogging or damaging of exhaust Repair exhaust system.
system, then revolution of the turbo-
charger doesn't increase
Air leak from the blower side Repair blower side.
Contamination of or damage to Replace turbocharger.
turbocharger
Operation defect of VG assembly Check using Hino-DX.
Seizure of bearing (lack lubrication Check lubrication system and
or clogging of oil pipe) repair, replace engine oil and
turbocharger.
Seizure of bearing (Too hot oil Check lubrication system and
temperature) repair, replace engine oil and
turbocharger.
Seizure of bearing (Turbine is Check lubrication system and
eccentricity) repair, replace engine oil and
turbocharger.
Seizure of bearing (Rapid stop from Drive correctly, according to the
high load condition) attention of the driver's manual,
replace turbocharger.

[S5LC0033E04] [0518CsCshWbYs]
16–8 FAILURE DIAGNOSIS FOR EACH ENGINE STATUS

Status Cause Action

Acceleration (follow-up of Carbon deposit at the turbine (disc Replace engine oil and
turbocharger) is poor (slow). sealing area) makes revolution of turbocharger.
the turbine heavy.
Air and gas leak from intake/ Check and repair faulty areas.
exhaust system parts
Lack of fuel. Check fuel system and be good
condition.
Operation defect of VG assembly Check using Hino-DX.
Seizure of bearing (lack lubrication Check lubrication system and
or clogging of oil pipe) repair, replace engine oil and
turbocharger.
Seizure of bearing (Too hot oil Check lubrication system and
temperature) repair, replace engine oil and
turbocharger.
Abnormal noise If the gas passage is extremely Replace turbocharger.
narrowed due to clogging at the
turbine case nozzle or if acceleration
is performed, reverse flow (usually
called surging) occurs due to clogging
of blower discharge air.
Revolving part is in contact. Replace turbocharger.
Operation defect of VG assembly Check using Hino-DX.
Air and gas leak from intake/ Check and repair faulty areas.
exhaust system parts
Vibration Loosening between turbocharger Check the turbocharger mounting
and intake/exhaust pipe and status and repair faulty areas.
between oil pipe and mounting area
Failure of metal, contact between Replace turbocharger. Remove
revolving part and peripheral parts, foreign matter completely, if any.
or damage to the blower impeller of
the turbine rotor due to entry of
foreign matter is found.
Balance of revolving body is poor. Replace revolving body.

[S5LC0033E04] [0518CsCshWbYs]
 FAILURE DIAGNOSIS FOR EACH ENGINE STATUS 16–9

DPR filter
JP31TCE160601005

Status Cause Action

DPR damaged or melted DPR filter was cracked Replace DPR filter
DPR filter was melted Replace DPR filter

[S5LC0033E04] [0518CsCshWbYs]
[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–1

ENGINE

17 ENGINE DIAGNOSIS CODE

General information

Engine ECU ............................................................... 17-4 DTC code P0192 [74]

Precautions ........................................................... 17-4 ............................................................................ 17-91
System block diagram........................................... 17-5 DTC code P0193 [74]
Inspection ............................................................. 17-6 ............................................................................ 17-96
Table of failure code ............................................ 17-22 DTC code P0200 [71]
Signal check harness.......................................... 17-26 DTC code P0611 [71]
Computer pin arrangement ................................. 17-28 DTC code P0605 [3]
Check the ECU power supply voltage DTC code P0606 [3]
............................................................................ 17-36 DTC code P0607 [3]
Check the ground .......................................................................... 17-100
............................................................................ 17-37 DTC code P0201 [61]
DTC code P0016 [13] DTC code P0202 [62]
............................................................................ 17-38 DTC code P0203 [63]
DTC code P0045 [35] DTC code P0204 [64]
DTC code P00AF [35] DTC code P0205 [65]
............................................................................ 17-39 DTC code P0206 [66]
DTC code P0087 [76] .......................................................................... 17-101
DTC code P0088 [76] DTC code P0217 [6]
DTC code P2635 [76] .......................................................................... 17-104
............................................................................ 17-41 DTC code P0219 [7]
DTC code P0088 [69] .......................................................................... 17-105
............................................................................ 17-48 DTC code P0234 [34]
DTC code P0096 [18] .......................................................................... 17-106
............................................................................ 17-49 DTC code P0237 [25]
DTC code P0097 [18] .......................................................................... 17-108
DTC code P0098 [18] DTC code P0263 [61]
............................................................................ 17-56 DTC code P0266 [62]
DTC code P0101 [17] DTC code P0269 [63]
............................................................................ 17-60 DTC code P0272 [64]
DTC code P0104 [17] DTC code P0275 [65]
............................................................................ 17-65 DTC code P0278 [66]
DTC code P0106 [25] .......................................................................... 17-112
............................................................................ 17-66 DTC code P0335 [13] 17
DTC code P0108 [25] .......................................................................... 17-114
............................................................................ 17-70 DTC code P0336 [13]
DTC code P0112 [17] .......................................................................... 17-116
DTC code P0113 [17] DTC code P0340 [12]
............................................................................ 17-74 .......................................................................... 17-118
DTC code P0117 [11] DTC code P0341 [12]
DTC code P0118 [11] .......................................................................... 17-119
............................................................................ 17-77 DTC code P0401 [85]
DTC code P0122 [32] .......................................................................... 17-121
............................................................................ 17-80 DTC code P0540 [53]
DTC code P0123 [32] .......................................................................... 17-127
............................................................................ 17-84 DTC code P0545 [27]
DTC code P0182 [14] .......................................................................... 17-129
DTC code P0183 [14] DTC code P0546 [27]
............................................................................ 17-88 .......................................................................... 17-131

[S5LC0033E04] [0518CsCshWbYs]
 17–2 ENGINE DIAGNOSIS CODE

DTC code P0617 [45] DTC code P2100 [31]

..........................................................................17-133 DTC code P2103 [31]
DTC code P0628 [73] ..........................................................................17-198
DTC code P0629 [75] DTC code P2101 [31]
..........................................................................17-134 ..........................................................................17-200
DTC code P0642 [5] DTC code P2121 [22]
..........................................................................17-136 DTC code P2126 [22]
DTC code P0643 [5] ..........................................................................17-201
..........................................................................17-137 DTC code P2122 [22]
DTC code P0652 [5] DTC code P2123 [22]
..........................................................................17-138 ..........................................................................17-203
DTC code P0653 [5] DTC code P2127 [22]
..........................................................................17-139 DTC code P2128 [22]
DTC code P0686 [51] ..........................................................................17-204
..........................................................................17-140 DTC code P2228 [15]
DTC code P06D3 [5] DTC code P2229 [15]
..........................................................................17-141 ..........................................................................17-205
DTC code P06D4 [5] DTC code P244A [91]
..........................................................................17-143 ..........................................................................17-206
DTC code P1133 [23] DTC code P244B [92]
..........................................................................17-144 ..........................................................................17-212
DTC code P1197 [74] DTC code P2458 [93]
DTC code P1198 [74] DTC code P24A2 [93]
..........................................................................17-147 ..........................................................................17-216
DTC code P119F [74] DTC code P2463 [92]
..........................................................................17-154 ..........................................................................17-221
DTC code P1211 [68] DTC code U0073 [8]
..........................................................................17-157 ..........................................................................17-224
DTC code P1212 [68] DTC code U010E [8]
..........................................................................17-159 ..........................................................................17-225
DTC code P1214 [68] DTC code U029D [8]
..........................................................................17-161 ..........................................................................17-229
DTC code P1215 [68] DTC code U029E [8]
..........................................................................17-163 ..........................................................................17-233
DTC code P1427 [28] DTC code U02A2 [8]
..........................................................................17-165 ..........................................................................17-237
DTC code P1428 [28] DTC code U1001 [9]
..........................................................................17-169 ..........................................................................17-241
DTC code P1458 [81] DTC code U110A [9]
..........................................................................17-173 ..........................................................................17-242

17
DTC code P1459 [81] DTC code U1122 [8]
.........................................................................17-175 ..........................................................................17-243
DTC code P1601 [2] DTC code U1123 [8]
.........................................................................17-176 ..........................................................................17-244
DTC code P200C [91] AdBlue / DEF SCR.................................................17-246
..........................................................................17-177 Caution notes in regard to
DTC code P2032 [27] troubleshooting ..................................................17-246
..........................................................................17-184 System block diagram .......................................17-248
DTC code P2033 [27] Explanation of Terms.........................................17-249
..........................................................................17-188 Signal check harness ........................................17-251
DTC code P203F [95] Pre-inspection ...................................................17-253
..........................................................................17-192 Inspection ..........................................................17-257
DTC code P204F [97] Table of failure code ..........................................17-267
..........................................................................17-194 DTC code P0071...............................................17-269
DTC code P207F [95] DTC code P0072
..........................................................................17-195 DTC code P0073...............................................17-277
DTC code P0562

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–3

DTC code P0563 .............................................. 17-279 DTC code U029D.............................................. 17-365

DTC code P060C.............................................. 17-281 DTC code U029E.............................................. 17-369
DTC code P062F .............................................. 17-282 DTC code U02A2.............................................. 17-373
DTC code P0667 .............................................. 17-283 DTC code U0597 .............................................. 17-377
DTC code P0668 .............................................. 17-284
DTC code P0669 .............................................. 17-285
DTC code P068A .............................................. 17-286
DTC code P142A
DTC code P208A
DTC code P208C
DTC code P208D.............................................. 17-287
DTC code P142B .............................................. 17-289
DTC code P202E .............................................. 17-292
DTC code P203B
DTC code P203C
DTC code P203D.............................................. 17-294
DTC code P2044
DTC code P2045 .............................................. 17-295
DTC code P2047 .............................................. 17-296
DTC code P2048
DTC code P2049 .............................................. 17-297
DTC code P204B .............................................. 17-298
DTC code P204C
DTC code P204D.............................................. 17-299
DTC code P205B .............................................. 17-300
DTC code P205C
DTC code P205D.............................................. 17-303
DTC code P206A .............................................. 17-304
DTC code P208B .............................................. 17-305
DTC code P20A0
DTC code P20A2
DTC code P20A3 .............................................. 17-306
DTC code P20A1 .............................................. 17-307
DTC code P20B1
DTC code P20B3
DTC code P20B4 .............................................. 17-308
DTC code P20B2 .............................................. 17-309
DTC code P20E8 .............................................. 17-311
DTC code P20E9 .............................................. 17-315
DTC code P20F4 .............................................. 17-319

17
DTC code P2201 .............................................. 17-321
DTC code P2202 .............................................. 17-324
DTC code P2203 .............................................. 17-325
DTC code P2204 .............................................. 17-326
DTC code P2209 .............................................. 17-329
DTC code P2212 .............................................. 17-331
DTC code P2214 .............................................. 17-335
DTC code P2215 .............................................. 17-338
DTC code P2216 .............................................. 17-339
DTC code P2222 .............................................. 17-340
DTC code P2481 .............................................. 17-342
DTC code P2482 .............................................. 17-345
DTC code P2483 .............................................. 17-348
DTC code P2510 .............................................. 17-351
DTC code U0029 .............................................. 17-353
DTC code U0038 .............................................. 17-357
DTC code U0100 .............................................. 17-364

[S5LC0033E04] [0518CsCshWbYs]
17–4 ENGINE DIAGNOSIS CODE

Engine ECU
Precautions
JP31J19170102001

! CAUTION • Make sure that each connector is connected

before inspection.
• Do not place a tester rod on the connecting
surface of the connector. Otherwise,
terminals are damaged or short-circuited.
• Delete the past failure memory after
recording. Perform failure diagnosis again to
check current failure.
• After failure analysis, delete the past failure
memory. If the past failure memory is not
deleted, the failure indicator lamp remains
ON.
• All connector drawings are viewed from the
connecting surface. Place the tester rod from
the back.
System drawing

SAPH31J191700001

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–5

System block diagram

JP31J19170803001

ACT Relay FUSE

Each Sensor Power
Main relay
Key switch signal FUSE
Starter signal

Battery
Accelerator signal 1, 2 Diagnosis switch
Check engine lamp
Glow relay
DPR indicator lamp

O
Neutral switch U
T
P
DPR regeneration switch
U
T
Volume for Supply pump
emergency accelerator
SCV drive signal

Injector drive signal T

I CAN communication 250K

N (Variable geometry Turbocharger/Linear EGR)
P
Intake throttle valve drive signal
U
CAN communication 500K Outside
T O send and receive
t communication DCU
h CAN communication 500K
e
PC Diagnosis
r
s
Differential pressure sensor

Exhaust gas temperature sensor Diagnosis tool

Engine speed main sensor Fuel temperature sensor (Supply pump)

Engine speed sub sensor Intake throttle valve position sensor
Boost pressure sensor
Common rail Exhaust gas temperature sensor
pressure sensor1
Common rail
pressure sensor2 Air flow meter
(Intake air
temperature)
Intake manifold
temperature

temperature

P
Intake throttle valve
sensor

sensor
Water

Common T System
rail DC Motor
Air flow
meter Intake throttle valve
P T T
G
Engine
N
DPR Cleaner
EGR System VNT System
Turbocharger T P T
EGR
Variable geometry DC Motor
DC Motor actuator

SAPH31J191700002
Service procedure
Inspection procedure item

[S5LC0033E04] [0518CsCshWbYs]
17–6 ENGINE DIAGNOSIS CODE

Inspection
JP31J19170703001

Pre-inspection

1. Pre-inspection
(1) If an error occurs on the system, The DTC code is
indicated in the console panel.

NOTICE • DTC codes of the engine ECU are displayed

on the multi-display when the starter switch is
set to ON, even when the Hino-DX is not
connected.

(2) Reading of failure code

a. Connection of Hino-DX
1. Remove the maintenance cover on the rear cover
Maintenance cover behind the operator seat by pushing down the tab at
the top (at one location).

NOTICE • The engine fault diagnosis connector (16 P) is

on the inside.

SAPH31J191700003

2. Connect the engine failure diagnosis connector to

the personal computer which installed Hino-DX
Mechatronic contoroller through the interface box.

Engine failure
diagnostic connector

SAPH31J191700004

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–7

3. Set the starter key to "ON" and start Hino-DX.

Failure diagnosis connector
Special tool : 09993-E9070 Hino-Bowie
(Interface box)
09042-1220 Connecting cable
95171-010** DENSO DST-i set
Hino-Bowie CD-ROM Hino-DX
or DST-i

Connect to the failure diagnosis Connecting cable

connector at the machine side.
SAPH31J191700005

Past failure deletion method

1. Past failure deletion method

(1) To delete past failures of the engine ECU, use Hino-DX on
the personal computer. (Refer to "Hino-DX operation
manual".)

SAPH31J191700006

[S5LC0033E04] [0518CsCshWbYs]
17–8 ENGINE DIAGNOSIS CODE

List of failure diagnosis tools

1. List of failure diagnosis tools

Part name Part No. External shape General description and function

• Operating system(OS) :
Windows95,
Windows98 (IE5.0 or later),
Windows2000 (SP3, IE5.0 or
later), WindowsXP (SP1a, IE6.0
or later), WindowsVista*2,
Computer Windows7*2
—
(DOS/V standard)
• CPU and memory :
Conditions that assure
operation of the above
operating system
• Display : 800 x 600, 256 colors
or more

• Software and CD-ROM

NOTICE
• Install the software
Hino Diagnostic included in the Hino
eXplorer — Diagnostic eXplorer
(Hino-DX) (Hino-DX) into the
computer. For the
installation method, refer
to the instruction manual
included with the CD.

• Computer interface

! CAUTION
• It is necessary to update
the hardware.

09993 - E9070 • The cable between the personal

Hino-Bowie
*1 computer and the Hino-Bowie is
bundled with the Hino-Bowie.
• Please use either RS-232C or
USB.
Cable bundled
to the Hino-Bowie

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–9

Part name Part No. External shape General description and function

• The cable used for connect

between Hino-Bowie and the
adapter cable.
S0904-21220
Connection cable
(09042-1220)
Cable between
unit and Hino-Bowie

DENSO DST-i set • Computer interface

without LCD
without 95171-01020
Bluetooth£

without LCD
95171-01040
with Bluetooth£

with LCD
without 95171-01030
Bluetooth£

with LCD
95171-01050
with Bluetooth£

Interrupting installation between

unit side harness and ECU allows
Signal check inspection with a tester rod while
09843-E4050
harness the power is supplied.

Signal check Interrupting installation between unit side harness and DCU allows
09843-E9030
harness inspection with a tester rod while the power is supplied.

09843-E9030

*1: To use Hino-Bowie (interface box) 09993-E9070,

update the hardware. For details, refer to the user’s
manual in the Hino-DX CD-ROM.
Keep updating the firmware (software built in the
Hino-Bowie) using the software in the Hino-DX CD-
ROM. For details, refer to the user’s manual in the
Hino-DX CD-ROM.
*2: Hino-DX (Ver. 3.0.5 or later), only when use DST-i.

[S5LC0033E04] [0518CsCshWbYs]
17–10 ENGINE DIAGNOSIS CODE

2. Conformity table for OS and interface

OK: Available
—: Disabled

Tier3 Tier4 Interim Tier4 Final

OS Software ver. Interface Reprog Reprog Reprog
Hino-DX Hino-DX Hino-DX
manager manager manager

DST-i OK OK OK OK OK OK

3.1.5 Bowie w/ CAN — — — — — —

Bowie w/o CAN — — — — — —

DST-i OK OK OK OK — —

3.1.0 Bowie w/ CAN — — — — — —

Bowie w/o CAN — — — — — —

7
DST-i OK OK OK OK — —

3.04/3.05 Bowie w/ CAN — — — — — —

Bowie w/o CAN — — — — — —

DST-i — — — — — —

1.0.9 Bowie w/ CAN — — — — — —

Bowie w/o CAN — — — — — —

DST-i OK OK OK OK OK OK

3.1.5 Bowie w/ CAN OK OK OK OK OK OK

Bowie w/o CAN OK OK — — — —

DST-i OK OK OK OK — —

3.1.0 Bowie w/ CAN OK OK OK OK — —

Bowie w/o CAN OK OK — — — —

XP
DST-i OK OK OK OK — —

3.04/3.05 Bowie w/ CAN OK OK OK OK — —

Bowie w/o CAN OK OK — — — —

DST-i OK OK — — — —

1.0.9 Bowie w/ CAN OK OK — — — —

Bowie w/o CAN OK OK — — — —

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–11

3. Manual forced regeneration

• Manual regeneration is a regeneration mode that forcefully operates the soot combustion treatment function.

! CAUTION • Never stop the unit near any flammable material, including high grass or leaves, during
manual regeneration.
• Extreme heat from the exhaust outlet could cause a fire resulting in personal injury and
property damage.
• Always keep all flammable materials away from the DPR cleaner, exhaust pipe and tail
pipes.
• Never touch the DPR cleaner, exhaust pipe or tail pipe during regeneration. Severe burns
and/or other personal injuries could occur.

• More fuel than usual is contained in the air returned through the EGR to the intake side
during DPR regeneration. If you stop the engine soon after regeneration, this fuel will
congeal, which may influence subsequent engine operation. In order to clean the air in the
engine that contains fuel, be sure to perform the 10-minuite scavenging drive after
regeneration has been completed.

• Manual regeneration can be performed even if a small amount of soot has accumulated, so this mode can be
used to inspect the regeneration system.
• When you combust soot using the manual regeneration mode, start the mode using the DPR regeneration
switch in the cabin.㻌㻔㻔"㼍"㻌㼛㼚㻌㼚㼑㼤㼠㻌㼜㼍㼓㼑㻚㻕
When you inspect the system, start the regeneration mode using the Hino-DX.㻌㻔㻔"㼎"㻌㼛㼚㻌㼠㼔㼑㻌㼚㼑㼤㼠㻌㼜㼍㼓㼑㻚㻕

NOTICE • This section mainly explains the manual forced regeneration procedure using the Hino-DX.

[S5LC0033E04] [0518CsCshWbYs]
17–12 ENGINE DIAGNOSIS CODE

a. When you combust soot

• If the manual generation coution appears in the multifunctional display, do not use the Hino-DX, but use
the DPR regeneration switch in the cabin for regeneration.

DPR regeneration switch

SAPH31J191700387

• To perform manual forced regeneration, set the attachment of the machine to the parking attitude, stop
the engine, lift up the lock lever and set the starter key to [ON].
• Press the DPR regeneration switch to operate the hydraulic pump relief. "Regenerating" appears on the
screen of the multifunctional display.
• When the hydraulic pump relief operation has been completed and "Regenerating" on the screen goes
out, soot combustion is completed.

b. When you inspect the DPR system

• You can confirm the whole DPR system condition using the Hino-DX.
• The Hino-DX displays engine data in the regeneration operation on the screen. The operation status can
be understood by analyzing the data values.

! CAUTION • The manual forced generation function using the Hino-DX aims to inspect system
operation. If the manual generation coution appears in the multifunctional display, do not
use the Hino-DX, but use the DPR regeneration switch in the cabin for regeneration.
• If any fault code concerning the DPR is detected, refer to the fault diagnosis documents
and be sure to change or clean the DPR cleaner. After that, inspect the whole system
condition using the manual forced generation mode of the Hino-DX.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–13

(1) Connect the Hino-DX to the machine and set the starter key to [ON].

! CAUTION • Flag setting by "Set (C)" o "Customize (C)" o "10-sec DPR lamp blinking / Identifying
setting status" is unnecessary. If you set the flag, ensure to return the setting to "0".

(2) Select the "DPR check (D)" menu in "Check functions (E)" from the Hino-DX menu bar.

Select

SAPH31J191700016
(3) Click the "Reset all DPR items (R)" button in the DPR status display window to reset the values, and then
click the "Manual forced regeneration (E)" button.

! CAUTION • To perform manual forced regeneration, stop the engine, lift up the lock lever and set the
starter key to [ON].

[S5LC0033E04] [0518CsCshWbYs]
17–14 ENGINE DIAGNOSIS CODE

Before resetting all the DPR items, be sure to stop the engine, press the brake switch
and set the lever in the lock position. After that, set the starter key to ON.

SAPH31J191700017

(4) Verify the contents of the displayed caution note, set a check mark for "Comprehended", and then click the
"Next (N)" button.

SAPH31J191700018

! CAUTION • If you continuously perform manual forced regeneration, perform a 10-minuite scavenging
drive before the next regeneration cycle.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–15

(5) After "Manual forced regeneration" appears on the screen, make sure safety around the machine and start
the engine.

! CAUTION • Make the machine to the parking attitude and lift up the lock lever in the idle state.

a. After parking the machine in a safe place, keep idling with the gear set in the
neutral position and turn off the PTO.
b. Be sure to press the brake switch and to set the lever in the lock position.

SAPH31J191700019

a. If you press the DPR regeneration switch in the cabin , manual forced generation will starts.

DPR regeneration switch

SAPH31J191700387

NOTICE • When the "Regenerating" mark does not appear on the cluster or the engine speed does
not idle up even if the DPR regeneration switch is pressed, you cannot proceed to forced
generation.
In such cases, inspect the neutral switch circuit, accelerator emergency circuit,
malfunction of the lock lever and so on.

[S5LC0033E04] [0518CsCshWbYs]
17–16 ENGINE DIAGNOSIS CODE

(6) End manual forced regeneration from the screen of the Hino-DX.
a. After starting regeneration, pay attention to the values in the data display on the screen. If the value of
the "DPR exhaust gas temperature (IN)" exceeds 450qC [842qF], the DPR system operates properly.
Click the "Close (C)" button to end manual forced regeneration.

! CAUTION • Scavenging drive starts. Do not stop the engine here.

NOTICE 1. The regeneration mode does not operate properly.

• If the temperature does not reach 450qC [842qF] in about 30 minutes after starting
regeneration, the oxidation catalyst in the previous step may not be functioning. Click
the "Close (C)" button to cancel manual forced regeneration and perform the fault
diagnosis on P2458/P24A2 in Section 17.
• If any DTC code occurs during regeneration, click the "Close (C)" button to cancel
manual forced regeneration and first repair the fault indicated by the code.
2. Regeneration of filters
• The forced regeneration mode using the Hino-DX serves to check the operation of the
whole DPR system, but as a function, it can also regenerate the filter by combusting
soot.
When the temperature rise to 450qC [842qF] is confirmed, wait for a while without
ending end the mode. After soot combustion is completed, the screen transitions to
that shown in ["b" on next page].
• When soot combustion has been completed, the engine speed lowers and the hydraulic
relief valve closes. However, the regeneration mode may not stop automatically and
may repeat operation even if regeneration has been completed.
When you hear the closing sound of the hydraulic relief valve, combustion treatment
has been completed. Click the "Close (C)" button to end manual forced regeneration.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–17

The forced regeneration is in progress and that you have to wait for a while.
a. When soot combustion is being performed
When soot combustion is completed, the regeneration mode will automatically turn off.
Some machines might open or close their relief valves when the regeneration is completed.
After the hydraulic relief starts and then the operating noise of the relief valve is
heard, press [Cancel] button to stop the manual forced regeneration.
<<CAUTION>>
After the manual forced regeneration is stopped, there may be a case where the hydraulic
relief automatically starts again. Note that the regeneration is completed when the
hydraulic relief ends.
If this happens, press [Cancel] button to abort the regeneration.
b. When the inspection on the DPR system is being conducted
After starting the regeneration process, confirm that the value of "DPR Exhaust temperature
(IN)" has risen to 450 C {842 F} or higher, then press the regeneration or [Cancel]
button to stop the regeneration.

a. After parking the machine in a safe place, keep idling with the gear set in the
neutral position and turn off the PTO.
b. Be sure to press the brake switch and to set the lever in the lock position.

SAPH31J191700022

[S5LC0033E04] [0518CsCshWbYs]
17–18 ENGINE DIAGNOSIS CODE

b. When the process up through the soot combustion treatment has been completed, the following
explanation appears. Click the "Close (C)" button to end manual forced regeneration.

! CAUTION • Scavenging drive starts. Do not stop the engine here.

a. After parking the machine in a safe place, keep idling with the gear set in the
neutral position and turn off the PTO.
b. Be sure to press the brake switch and to set the lever in the lock position.

SAPH31J191700023

(7) When the caution box appears, check the content and perform a 10-minuite scavenging drive. The
scavenging drive is completed in 10 minutes. Operate the starter key to stop the engine.
After scavenging drive has been completed, set a check mark for "Comprehended" and click the "Exit (X)"
button.

SAPH31J191700024

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–19

(8) This completes the manual forced regeneration process. When all stages of the manual forced
regeneration have been completed, carry out the differential pressure check.

NOTICE • You can stop manual forced regeneration also by pressing the "DPR manual regeneration"
button in the cabin. In this case, the caution about the scavenging drive does not appear
but the 10-minuite scavenging drive should be performed.

DPR regeneration switch

SAPH31J191700387

[S5LC0033E04] [0518CsCshWbYs]
17–20 ENGINE DIAGNOSIS CODE

4. DPR differential pressure check

(1) If you click the "DPR differential pressure check (D)" button, you can measure the soot clogging status of
the DPR as it’s differential pressure and whether it is necessary to do maintenance or not can be checked.

Before resetting all the DPR items, be sure to stop the engine, press the brake switch
and set the lever in the lock position. After that, set the starter key to ON.

SAPH31J191700026

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–21

a. If you click “DPR differential pressure check (D)” button, DPR differential pressure check window will be
shown.
b. Click the “Execute (E)” button.
c. Engine rotation will go up automatically to maximum and DPR differential pressure will be recorded.

a. After parking the machine in a safe place, keep idling with the gear set in the
neutral position and turn off the PTO.
b. Be sure to press the brake switch and to set the lever in the lock position.

SAPH31J191700027
d. Click the “Stop (E)” button and you are finished measuring.

NOTICE • Every time you click the "Execute (E)" and "Stop (E)" button, the display will change
"Execute (E)" and "Stop (E)" alternately.

Switch indicate item

SAPH31J191700028

[S5LC0033E04] [0518CsCshWbYs]
17–22 ENGINE DIAGNOSIS CODE

Failure diagnosis

Table of failure code

JP31J19170601001

NOTICE • The P0000 of "P0000 [00]" in this text indicates an SAE code, and [00] indicates a 2-digit
code of TCCS.

SAE TCCS 2-DIGT TROUBLE

CODE CODE (Estimated failure cause)

Engine speed main sensor and Engine speed sub sensor -

P0016 13
rationality

Nozzle position sensor failure

DC motor open circuit
DC motor short circuit
P0045 35
Nozzle stuck
Nozzle operating range failure
Initialization failure

P0087 76 Fuel system pressure control - low

P0088 76 Fuel system pressure control - high

P0088 69 Excessive common rail pressure

P0096 18 Intake air temperature sensor (intake manifold) - rationality

Intake air temperature sensor (intake manifold) - out of range (Out
P0097 18
of range low)

Intake air temperature sensor (intake manifold) - out of range (Out

P0098 18
of range high)

VNT controller CAN communication (ECM)

P00AF 35 Power supply failure
EEPROM failure

P0101 17 Air flow sensor - rationality

P0104 17 Air flow sensor - out of range

P0106 25 Boost pressure sensor - rationality

P0108 25 Boost pressure sensor - out of range (Out of range high)

Intake air temperature sensor (air flow sensor built-in) - out of range
P0112 17
(Out of range low)

Intake air temperature sensor (air flow sensor built-in) - out of range
P0113 17
(Out of range high)
Engine coolant temperature sensor - out of range
P0117 11
(Out of range low)

Engine coolant temperature sensor - out of range

P0118 11
(Out of range high)

Intake throttle valve position sensor 1 - out of range

P0122 32
(Out of range low)

Intake throttle valve position sensor 1 out of range

P0123 32
(Out of range high)

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–23

SAE TCCS 2-DIGT TROUBLE

CODE CODE (Estimated failure cause)

P0182 14 Fuel temperature sensor Low

P0183 14 Fuel temperature sensor High

Common rail pressure sensor (main) - out of range (Out of range

P0192 74
low)

Common rail pressure sensor (main) - out of range (Out of range

P0193 74
high)

P0200 71 Fuel injector driver charge circuit - circuit (circuit high)

P0201 61 Fuel injector - disconnection (#1cyl)

P0202 62 Fuel injector - disconnection (#2cyl)

P0203 63 Fuel injector - disconnection (#3cyl)

P0204 64 Fuel injector - disconnection (#4cyl)

P0205 65 Fuel injector - disconnection (#5cyl)

P0206 66 Fuel injector - disconnection (#6cyl)

P0217 6 Engine coolant over temperature condition

P0219 7 Engine overspeed condition

P0234 34 Overboost

P0237 25 Boost pressure sensor - out of range (Out of range low)

P0263 61 Injection quantity and timing (#1cyl)

P0266 62 Injection quantity and timing (#2cyl)

P0269 63 Injection quantity and timing (#3cyl)

P0272 64 Injection quantity and timing (#4cyl)

P0275 65 Injection quantity and timing (#5cyl)

P0278 66 Injection quantity and timing (#6cyl)

P0335 13 Engine speed main sensor - disconnection

P0336 13 Engine speed main sensor - rationality

P0340 12 Engine speed sub sensor - disconnection

P0341 12 Engine speed sub sensor - rationality

P0401 85 EGR low flow

P0540 53 Air intake heater circuit malfunction

DOC downstream temperature sensor - out of range
P0545 27
(Out of range low)

DOC downstream temperature sensor - out of range

P0546 27
(Out of range high)

P0605 3 Flash ROM error

P0606 3 Control module processor

P0607 3 Control module performance

[S5LC0033E04] [0518CsCshWbYs]
17–24 ENGINE DIAGNOSIS CODE

SAE TCCS 2-DIGT TROUBLE

CODE CODE (Estimated failure cause)

P0611 71 Fuel injector driver charge circuit - circuit (Circuit low)

P0617 45 Starter switch - rationality

P0628 73 Suction control valve for fuel supply pump - circuit (Circuit low)

P0629 75 Suction control valve for fuel supply pump - circuit (Circuit high)

P0642 5 ECU sensor supply 1 failure (low)

P0643 5 ECU sensor supply 1 failure (high)

P0652 5 ECU sensor supply 2 failure (low)

P0653 5 ECU sensor supply 2 failure (high)

P0686 51 ECU Power relay control circuit high

P06D3 5 Air flow sensor power supply failure Short to GND

P06D4 5 Air flow sensor power supply failure (high)

P1133 23 P.T.O. accelerator sensor (Hi)

P1197 74 Common rail pressure sensor (sub) - out of range (Out of range low)

Common rail pressure sensor (sub) - out of range (Out of range

P1198 74
high)

P119F 74 Common rail pressure sensor - rationality

P1211 68 Fuel injector driver circuit 1 - circuit (Circuit low)

P1212 68 Fuel injector driver circuit 1 - circuit (Circuit high)

P1214 68 Fuel injector driver circuit 2 - circuit (Circuit low)

P1215 68 Fuel injector driver circuit 2 - circuit (Circuit high)

P1427 28 Differential pressure sensor - out of range (Out of range low)

P1428 28 Differential pressure sensor - out of range (Out of range high)

Valve position control failure - DC motor out of range, functional

P1458 81 Valve link failure
Low battery voltage

P1459 81 EGR actuator malfunction 2

P1601 2 Fuel injector adjustment data error

P200C 91 DPR over temperature

DPR downstream temperature sensor - out of range

P2032 27
(Out of range low)

DPR downstream temperature sensor - out of range

P2033 27
(Out of range high)

P203F 95 Empty reductant tank

P204F 97 Reductant system performance

P207F 95 Improper reductant

DC motor for intake throttle valve - circuit

P2100 31
[Open circuit (circuit low)]

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–25

SAE TCCS 2-DIGT TROUBLE

CODE CODE (Estimated failure cause)

P2101 31 Intake throttle valve - functional

DC motor for intake throttle valve - circuit

P2103 31
[Short circuit (circuit high)]

P2121 22 Accelerator sensor 1 malfunction

Accelerator pedal position sensor 1 - out of range

P2122 22
(Out of range low)

Accelerator pedal position sensor 1 - out of range

P2123 22
(Out of range high)

P2126 22 Accelerator sensor 2 malfunction

Accelerator pedal position sensor 2 - out of range

P2127 22
(Out of range low)

Accelerator pedal position sensor 2 - out of range

P2128 22
(Out of range high)

P2228 15 Barometric pressure sensor - out of range (Out of range low)

P2229 15 Barometric pressure sensor - out of range (Out of range high)

P244A 91 DPR differential pressure drop

P244B 92 Excessive DPR differential pressure

P2458 93 DPR regeneration duration

P2463 92 DPR clogged

P24A2 93 DPR regeneration incomplete by fuel consumption over

P2635 76 Supply Pump "A" low flow / performance

Engine ECU CAN communication bus for Emission control system -

U0073 8
bus off

U010E 8 Engine ECU CAN communication (DCU)

U029D 8 Engine ECU CAN communication (SCR upstream NOx sensor)

U029E 8 Engine ECU CAN communication (SCR downstream NOx sensor)

U02A2 8 Engine ECU CAN communication (AdBlue/DEF tank sensor)

U1001 9 Engine ECU CAN communication bus for vehicle control - bus off

U110A 9 Engine ECU CAN communication (Vehicle control controller)

U1122 8 Engine ECU CAN communication (EGR valve controller)

U1123 8 Engine ECU CAN communication (VNT controller)

[S5LC0033E04] [0518CsCshWbYs]
17–26 ENGINE DIAGNOSIS CODE

Function, movement
Description of function
and operation

Signal check harness

JP31J19170301001

1. Signal check harness

! CAUTION • When measuring terminal of the engine ECU,

connect the signal check harness to prevent
damage to the connector. Place the tester rod
on the contact box of the signal check
harness for measurement.

NOTICE • Terminal numbers in the text and the

illustrations correspond as shown below in
the "Computer pin arrangement".

COMPUTER (ECU) TERMINAL SIGNAL

COMPUTER (ECU) TERMINAL No.
V
Main/
Power supply 1 Glow
Starter cut relay Actuator power - P.T.O. cut relay -
(+BF) (indic
relay 1

V1 +BF1 V2 STCR V3 MRL1 V4 - V5 ARL1 V6 - V7

CAN CA
Machine speed Glow pulg
Neutral switch Starter signal Starter switch 1 communication commu
pulse converter (Signal)
line lin
V11 NUSW V12 ST V13 SSWS V14 VS V15 GCUS V16 CA1L V17

Main/
Power supply 2
- Actuator power - - - Diagno
(+BF)
relay 2

V21 +BF2 V22 - V23 MRL2 V24 - V25 - V26 - V27

Engine stop Glow pulg CAN CA

P.T.O switch 1 Starter switch 2 - (Signal) communication commu
switch
line lin
V31 PTO V32 STOP V33 SWSS V34 - V35 GCUD V36 CA1H V37

EXAMPLE: V23 TERMINAL

V
V (1 to 40)
SIGNAL CHECK
HARNESS
(CONTACT BOX) 1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40
V23

SAPH31J191700029

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–27

2. Connection of signal check harness

(1) Set the starter key to "OFF" and disconnect the connector
from the engine ECU.
(2) Connect the signal check harness to the engine ECU and
the unit side harness.

UPP

COMPUTER (ENGINE ECU)

CONNECTOR CONNECTOR
(ENGINE ECU SIDE) (ENGINE ECU SIDE)

ENGINE UNIT
SIDE SIDE

CONNECTOR
CONNECTOR
(ENGINE SUB
(ENGINE SUB
HARNESS SIDE)
HARNESS SIDE)

RED WHITE

E ENGINE SUB HARNESS

V

TERMINAL TERMINAL
E01-E40 V01-V40

BLUE E V

BLACK
TERMINAL TERMINAL
TEST LEAD
E41-E80 V41-V80

SIGNAL CHECK SIGNAL CHECK

HARNESS HARNESS
(ENGINE SIDE) (UNIT SIDE)

09843-E4060 CONTACT BOX 09843-E4020

SIGNAL CHECK HARNESS ASSEMBLY

09843-E4050

SAPH31J191700030

Special tool : Signal check harness (09843-E4050)

[S5LC0033E04] [0518CsCshWbYs]
 17–28

V
Power supply 1 Main/ Check engine
- Actuator power - - - - DPR refresh light warning light -
(+BF)
Computer pin arrangement

relay 1

V1 +BF1 V2 - V3 MRL1 V4 - V5 - V6 - V7 - V8 DPF V9 CE/G V10 -

Wiring

CAN
Specification
diagram

Power supply 1
Neutral switch Starter signal Starter switch 1 - - communication - (+B) - -
(performance)

line

V11 NUSW V12 ST V13 SSWS V14 - V15 - V16 CA1L V17 - V18 VB1 V19 - V20 -

Power supply 2 Main/

Glow -
(+BF) - Actuator power - - - -
relay 2 Relay

[S5LC0033E04] [0518CsCshWbYs]
V21 +BF2 V22 - V23 MRL2 V24 GRY1 V25 V26 - V27 - V28 - V29 - V30 -
ENGINE DIAGNOSIS CODE

CAN
Power supply 2
- - Starter switch 2 - - communication - Power ground 1 Signal ground 1
(+B)
line

V31 - V32 - V33 SWSS V34 - V35 - V36 CA1H V37 - V38 VB2 V39 PGD1 V40 CGD1

SAPH31J191700031
JP31J19170201001
 ENGINE DIAGNOSIS CODE 17–29

TERMINAL TERMINAL TERMINAL TERMINAL

SIGNAL SIGNAL
No. SIGNAL No. SIGNAL
V1 +BF1 Power supply 1 (+BF) V21 +BF2 Power supply 2 (+BF)

V2 – – V22 – –

Main / Actuator power Main / Actuator power

V3 MRL1 V23 MRL2
relay 1 relay 2

V4 – – V24 GRY1 Glow relay

V5 – – V25 – –

V6 – – V26 – –

V7 – – V27 – –

V8 DPR DPR refresh light V28 – –

Check engine warning

V9 CE/G V29 – –
light
V10 – – V30 – –

V11 NUSW Neutral switch V31 – –

V12 ST Starter signal V32 – –

V13 SSWS Starter switch 1 V33 SWSS Starter switch 2

V14 – – V34 – –

V15 – – V35 – –
CAN communication line CAN communication line
V16 CA1L V36 CA1H
Low High

V17 – – V37 – –

V18 VB1 Power supply 1 (+B) V38 VB2 Power supply 2 (+B)

V19 – – V39 PGD1 Power ground 1

V20 – – V40 CGD1 Signal ground 1

[S5LC0033E04] [0518CsCshWbYs]
 17–30

V
Accelerator Sensor power
- - - - Sensor ground 7 Sensor ground 9 - -
sensor 1 supply 3

V41 - V42 - V43 - V44 - V45 ADG7 V46 ADG9 V47 ACS1 V48 - V49 - V50 AVC3

Sensor power Clucth DPR refresh DPR downstream Power supply 3

- - - temperature sensor
Power ground 2 Signal ground 2
supply 4 switch switch (+B)

V51 AVC4 V52 - V53 - V54 - V55 CLSW V56 DPSW V57 ET4+ V58 VB3 V59 PGD2 V60 CGD2

P.T.O. DPR differential

Accelerator DOC downstream
- - - - Sensor ground 8 - acceclerator
sensor 2 temperature sensor pressure sensor
sensor

[S5LC0033E04] [0518CsCshWbYs]
V61 - V62 - V63 - V64 - V65 ADG8 V66 - V67 ACS2 V68 ASCS V69 ET3+ V70 EXPS
ENGINE DIAGNOSIS CODE

Sensor power Power supply 4

- - - - - - Power ground 3 Power ground 4
supply 5 (+B)

V71 AVC5 V72 - V73 - V74 - V75 - V76 - V77 - V78 VB4 V79 PGD3 V80 PGD4

SAPH31J191700032
 ENGINE DIAGNOSIS CODE 17–31

TERMINAL TERMINAL TERMINAL TERMINAL

SIGNAL SIGNAL
No. SIGNAL No. SIGNAL

V41 – – V61 – –

V42 – – V62 – –

V43 – – V63 – –

V44 – – V64 – –

Sensor ground 7
Sensor ground 8
V45 ADG7 (Accelerator sensor 1, V65 ADG8
(Accelerator sensor 2)
P.T.O. accelerator sensor)

Sensor ground 9
(Exhaust gas temperature
V46 ADG9 V66 – –
sensor, DPR differential
pressure sensor)

Accelerator sensor signal Accelerator sensor signal

V47 ACS1 V67 ACS2
1 2

P.T.O. accelerator sensor

V48 – – V68 ASCS
signal
DOC downstream
V49 – – V69 ET3+
temperature sensor

DPR differential pressure

V50 AVC3 Sensor power supply 3 V70 EXPS
sensor

Sensor power supply 5

(P.T.O. accelerator
V51 AVC4 Sensor power supply 4 V71 AVC5
sensor, DPR differential
pressure sensor)

V52 – – V72 – –

V53 – – V73 – –

V54 – – V74 – –

V55 CLSW Clutch switch V75 – –

V56 DPSW DPR refresh switch V76 – –

DPR downstream
V57 ET4+ V77 – –
temperature sensor
V58 VB3 Power supply 3 (+B) V78 VB4 Power supply 4 (+B)

V59 PGD2 Power ground 2 V79 PGD3 Power ground 3

V60 CGD2 Signal ground 2 V80 PGD4 Power ground 4

[S5LC0033E04] [0518CsCshWbYs]
 17–32

E
Intake throttle Suction control Suction control
valve motor (+) - - - - - - - valve (Main) valve (Main)

E1 MOT+ E2 - E3 - E4 - E5 - E6 - E7 - E8 - E9 SPV1 E10 SPV2

No.1, No.2, No.3 No.1 Fuel injector No.2 Fuel injector No.3 Fuel injector No.4, No.5, No.6 No.4 Fuel injector No.6 Fuel injector
Air flow sensor Sensor power Fuel injector Fuel injector
- drive signal drive signal drive signal drive signal drive signal
(Power) supply 1 power supply power supply
(Main) (Main) (Main) (Main) (Main) (Main) (Main)

E11 - E12 AFVB E13 AVC1 E14 IJ1+ E15 INJ1 E16 INJ3 E17 INJ5 E18 IN2+ E19 INJ2 E20 INJ4

Intake throttle Suction control Suction control

valve motor (-) - - - - - - - valve (Sub) valve (Sub)

[S5LC0033E04] [0518CsCshWbYs]
E21 MOT- E22 - E23 - E24 - E25 - E26 - E27 - E28 - E29 SP1S E30 SP2S
ENGINE DIAGNOSIS CODE

No.1, No.2, No.3 No.1 Fuel injector No.2 Fuel injector No.3 Fuel injector No.4, No.5, No.6 No.4 Fuel injector No.6 Fuel injector
Sensor power Fuel injector Fuel injector
- - power supply drive signal drive signal drive signal drive signal drive signal
supply 2 power supply
(Sub) (Sub) (Sub) (Sub) (Sub) (Sub) (Sub)

E31 - E32 - E33 AVC2 E34 I1+S E35 IJ01 E36 IJ03 E37 IJ05 E38 I2+S E39 IJ02 E40 IJ04

SAPH31J191700033
 ENGINE DIAGNOSIS CODE 17–33

TERMINAL TERMINAL TERMINAL TERMINAL

SIGNAL SIGNAL
No. SIGNAL No. SIGNAL

Intake throttle valve Intake throttle valve

E1 MOT+ E21 MOT-
motor (+) motor (-)

E2 – – E22 – –

E3 – – E23 – –

E4 – – E24 – –

E5 – – E25 – –

E6 – – E26 – –

E7 – – E27 – –

E8 – – E28 – –

Suction control valve Suction control valve

E9 SPV1 E29 SP1S
(Main) (Sub)

Suction control valve Suction control valve

E10 SPV2 E30 SP2S
(Main) (Sub)

E11 – – E31 – –
E12 AFVB Air flow sensor (Power) E32 – –

Sensor power supply 2

(for Boost pressure
Sensor power supply 1
sensor, Intake throttle
E13 AVC1 (for Common rail E33 AVC2
valve position sensor,
pressure sensor 1)
Common rail pressure
sensor 2)

No.1, 2, 3 Fuel injector No.1, 2, 3 Fuel injector

E14 IJ1+ E34 I1+S
power supply (Main) power supply (Sub)
No.1 Fuel injector drive No.1 Fuel injector drive
E15 INJ1 E35 IJ01
signal (Main) signal (Sub)

No.2 Fuel injector drive No.2 Fuel injector drive

E16 INJ3 E36 IJ03
signal (Main) signal (Sub)

No.3 Fuel injector drive No.3 Fuel injector drive

E17 INJ5 E37 IJ05
signal (Main) signal (Sub)

No.4, 5, 6 Fuel injector No.4, 5, 6 Fuel injector

E18 IN2+ E38 I2+S
power supply (Main) power supply (Sub)

No.4 Fuel injector drive No.4 Fuel injector drive

E19 INJ2 E39 IJ02
signal (Main) signal (Sub)

No.6 Fuel injector drive No.6 Fuel injector drive

E20 INJ4 E40 IJ04
signal (Main) signal (Sub)

[S5LC0033E04] [0518CsCshWbYs]
 17–34

E
Intake air Common rail
- - - temperature sensor Fuel temperature pressure
- - -
(Air flow sensor -
sensor 1 (Main)
sensor built-in)
E41 - E42 - E43 - E44 - E45 - E46 - E47 THA+ E48 THF+ E49 PCR1 E50 -

CAN No.5 Fuel injector

G sensor G sensor
- Ne sensor (+) - Sensor ground 1 Sensor ground 3 Sensor ground 5 communication drive signal
(Supply) (Ground)
line (Main)

E51 - E52 NE1+ E53 GVCC E54 GGND E55 - E56 AGD1 E57 AGD3 E58 AGD5 E59 CA3H E60 INJ6

Intake throttle Intake manifold Common rail Common rail Coolant Common rail
Boost pressure
- valve position temparature pressure pressure temperature pressure - -
sensor
sensor 1 sensor (+) sensor 2 (Main) sensor 2 (Sub) sensor sensor 1 (Sub)

[S5LC0033E04] [0518CsCshWbYs]
E61 - E62 DTS1 E63 ATI+ E64 PCR3 E65 PCR4 E66 THW+ E67 PIM E68 PCR2 E69 - E70 -
ENGINE DIAGNOSIS CODE

CAN No.5 Fuel injector

NE sensor (-) G sensor Air flow sensor
- NE sensor (SLD) Sensor ground 2 Sensor ground 4 Sensor ground 6 communication drive signal
(Signal) (Signal)
line (Sub)
E71 - E72 NE1- E73 G3+ E74 AFSI E75 NESD E76 AGD2 E77 AGD4 E78 AGD6 E79 CA3L E80 IJ06

SAPH31J191700034
 ENGINE DIAGNOSIS CODE 17–35

TERMINAL TERMINAL TERMINAL TERMINAL

SIGNAL SIGNAL
No. SIGNAL No. SIGNAL

E41 – – E61 – –
Intake throttle valve
E42 – – E62 DTS1
position sensor 1

Intake manifold
E43 – – E63 ATI+
temperature sensor (+)

Common rail pressure

E44 – – E64 PCR3
sensor 2 (Main)

Common rail pressure

E45 – – E65 PCR4
sensor 2 (Sub)

Coolant temperature
E46 – – E66 THW+
sensor

Intake air temperature

E47 THA+ sensor E67 PIM Boost pressure sensor
(Air flow sensor built-in)
Common rail pressure
E48 THF+ Fuel temperature sensor E68 PCR2
sensor 1 (Sub)

Common rail pressure

E49 PCR1 E69 – –
sensor 1 (Main)

E50 – – E70 – –
E51 – – E71 – –
E52 NE1+ NE sensor (+) E72 NE1- NE sensor (-)

E53 GVCC G sensor (Supply) E73 G3+ G sensor (Signal)

E54 GGND G sensor (Ground) E74 AFSI Air flow sensor (Signal)

E55 – – E75 NESD NE sensor (SLD)

Sensor ground 2
Sensor ground 1
(for Fuel temperature
E56 AGD1 (for Common rail E76 AGD2
sensor, Common rail
pressure sensor 1)
pressure sensor 2)

Sensor ground 3 Sensor ground 4

E57 AGD3 (for Intake throttle valve E77 AGD4 (for Boost pressure
position sensor) sensor)

Sensor ground 5
Sensor ground 6
(for Coolant temperature
E58 AGD5 E78 AGD6 (for Air flow sensor
sensor, Intake air
signal)
temperature sensor)

CAN communication line CAN communication line

E59 CA3H (EGR valve drive, VNT E79 CA3L (EGR valve drive, VNT
drive) drive)

No.5 Fuel injector drive No.5 Fuel injector drive

E60 INJ6 E80 IJ06
signal (Main) signal (Sub)

[S5LC0033E04] [0518CsCshWbYs]
17–36 ENGINE DIAGNOSIS CODE

Failure diagnosis list

Check the ECU power supply voltage

JP31J19170601002

1 Measurement of voltage between terminals

1. Set the starter key to "OFF" and connect the signal check
harness to the engine ECU.
2. Turn the starter key "ON" and measure voltage between
㨂 V18 㨂 terminals .
V58,V59

Terminal to measure the voltage

V38,39 V78,79,80 + Side - Side
V18, V38, V58, V78 V39, V59, V79, V80

Standard value: 20 V or more

SAPH31J191700035

NO • 0 V : Blown fuse, harness failure, ground failure,

etc.
• 20 V or less : Battery deterioration, ground
failure, etc.

YES

Normal

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–37

Check the ground

JP31J19170601003

1 Measurement of resistance between terminals

1. Set the starter key to "OFF" and connect the signal check
harness.
2. Disconnect the ECU side connector of the signal check
㨂 㨂 harness and measure the resistance between terminals V39,
V59
V59, V79, V80 and the terminal (-) of the battery.
V79,80
Standard value: 1 : or less
V39

Frame
SAPH31J191700036

NO Disconnection of ground harness, contact failure,

etc.

YES

Normal

[S5LC0033E04] [0518CsCshWbYs]
17–38 ENGINE DIAGNOSIS CODE

DTC code P0016 [13]

Engine speed main sensor and Engine speed sub sensor - rationality
JP31J19170601004

1 Check that the cam gear is properly assembled

NO Assemble the cam gear normally

YES

2 Check that the flywheel is assembled

NO Assemble the flywheel normally

YES

3 Check that engine speed main sensor and engine speed sub sensor are installed in proper locations
respectively

NO Install the NE sensor and G sensor in proper

locations respectively

YES

Delete the DTC and reload

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–39

DTC code P0045 [35]

Nozzle position sensor failure
DC motor open circuit
DC motor short circuit
Nozzle stuck
Nozzle operating range failure
Initialization failure
DTC code P00AF [35]
VNT controller CAN communication (ECM)
Power supply failure
EEPROM failure
JP31J19170601005

1 Check the VNT

1. Connect the PC DIAGNOSIS TOOL (Hino-DX).

2. Set the starter switch "ON" position.

3. Select the "VNT" menu and check the VNT.

Standard: Max. 2 sec. delay in opening

SAPH31J191700037

NO Fault in turbocharger

YES

[S5LC0033E04] [0518CsCshWbYs]
17–40 ENGINE DIAGNOSIS CODE

2 Check connection of the connector

1. Check connection of the VNT controller connector and the VNT

actuator connector.

2. Set the starter switch to "OFF" position and then to "ON"

position again.

3. Check that no malfunction codes exist.

NO Proceed to 3

YES

Normal

3 Measuring voltage between sensor terminals

1. Set the starter switch "OFF" position.

2. Disconnect the connectors of VNT controller.

3. Set the starter switch "ON" position.

4. Measure the voltage between 24V and GND terminal of VNT
controller connector (engine sub harness side).
GND +24V Standard value: 19V or more

SAPH31J191700038

NO Fault in harness

YES

Fault in turbocharger

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–41

DTC code P0087 [76]

Fuel system pressure control - low
DTC code P0088 [76]
Fuel system pressure control - high
DTC code P2635 [76]
Supply pump "A" low flow / performance
JP31J19170601006

1 Check the fuel

1. Check that suitable fuel at region temperature is used.

NO Replace to suitable fuel

YES

2 Check the fuel filter and fuel pipe for fuel leakage

1. Check the fuel filter and fuel pipe for fuel oozing and leakage.

NO • Defective fuel filter

• Defective fuel pipe

YES

3 Check the fuel tank for clogging of the air hole and the remaining amount

1. Check the air hole for clogging.

2. Check if fuel is sufficiently supplied.

NO • Clogging of the air hole

• Insufficient fuel supply

YES

4 Check the supply pump for fuel leakage

1. Check the supply pump for fuel oozing and leakage.

NO Faulty supply pump

YES

[S5LC0033E04] [0518CsCshWbYs]
17–42 ENGINE DIAGNOSIS CODE

5 Measuring resistance between terminals

1. Set the starter switch to "OFF" position.

2. Connect the signal check harness on the engine side.

3. Disconnect the connector on the engine ECU side.

4. Measure the resistance between the terminals.
E9
㧱 E10
Terminals to measure the resistance
SPV1 (E9) l SP2S (E30)
E30 SPV1 (E9) l SPV2 (E10)
E29
SP1S (E29) l SP2S (E30)
SP1S (E29) l SPV2 (E10)

Standard value: 7.65 - 8.15 : (20qC {68qF})

SAPH31J191700039

NO Faulty SCV

YES

6 Check the DTC

1. Check that no other DTC exist.

NO Check with other diagnosis codes

YES

7 Using the Hino-DX, check the actual common rail pressure at the engine start while monitoring

1. Connect the PC DIAGNOSIS TOOL (Hino-DX).

2. Start the engine while monitoring the actual common rail
Actual common rail pressure
Specified common rail pressure pressure.
Common rail pressure

222MP䠽
Standard:
The pressure limiter is
open reducing the pressure. The peak of the actual common rail pressure is 222
MPa {2,262 kgf/cm2, 32,301 lbf/in2} or under
Idling

Starter 䠫䠪 (Engine starting) Hour

SAPH31J191700040

NO Proceed to 13

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–43

8 Using the Hino-DX, check the actual common ril pressure during driving while monitoring

1. Check the actual injection pressure while depressing the

accelerator pedal.

2. Check that there are no characteristics shown in Fig.1, Fig.2,

Fig.3 and Fig.4.

Actual common rail pressure

Specified common rail pressure
Common rail pressure

Depress the Depress the Depress the Depress the

accelerator pedal. accelerator pedal. accelerator pedal. accelerator pedal.

Idling Idling
Release the Idling
Release the Release the accelerator pedal.
Release the
accelerator pedal. accelerator pedal. accelerator pedal.
Hour
[Fig. 1] [Fig. 2]

222MPa 222MPa
After start, extremely high
actual common rail pressure Not start
than the specified common rail Slow start
pressure is directed not hard vacuum. Actual common rail pressure remains low even if start.

Idling Idling

Starter ON (Engine starting) Starter ON (Engine starting)

[Fig. 3] [Fig. 4]
SAPH31J191700041

NO Restudy the supply pump

(If there is no improvement after restudying, proceed
to 9)

YES

[S5LC0033E04] [0518CsCshWbYs]
17–44 ENGINE DIAGNOSIS CODE

9 Using the Hino-DX, check the leakage of fuel

1. Lower the pressure while monitoring the actual common rail

pressure.
2. Check that the pressure is reduced when the actual common
Actual common rail pressure
Specified common rail pressure rail pressure exceeds 222 MPa {2,262 kgf/cm2, 32,301 lbf/in2} .
Common rail pressure

222MPᵞ
Depress the
accelerqtor pedal.

Release the
accelerator pedal.

Hour
SAPH31J191700042

NO • If the pressure is reduced without the actual.

common rail pressure exceeding 222 MPa {2,262
kgf/cm2, 32,301 lbf/in2}, proceed to 11.
• If the actual common rail pressure does not rise to
200 MPa {2,038 kgf/cm2, 29,100 lbf/in2}, hold the
pressure limiter pipe and check for flow of fuel.
a. The pressure limiter is defective if there is flow
of fuel.
b. If there is no flow of fuel, proceed to 11.

YES

10 Check the injector leak pipe for clogging

NO Defective leak pipe

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–45

11 Using the Hino-DX, check the specified common rail pressure and actual injection pressure while
monitoring

1. While monitoring the common rail pressure, gradually increase

the engine speed from idle to wide open throttle.

2. Check if the specified common rail pressure corresponds to the

actual common rail pressure.

Actual common rail pressure

Specified common rail pressure
Common rail pressure

Gradually increase the engine Gradually increase the engine

engine speed
speed while depressing the speed while depressing the engine speed
WOT
accelerator pedal. accelerator pedal. WOT

engine speed
The actual common rail pressure engine speed
1,000rpm
become unstable from specific 1,000rpm
Low actual common rail pressure
rotation and fails to follow the The differential is larger on the
specified common rail pressure. high speed side.

Hour
SAPH31J191700043

NO • The specified common rail pressure does not

correspond to the actual common rail pressure at
high speed.
• The specified common rail pressure does not
correspond to the actual common rail pressure in
the full range.
a. The actual common rail pressure is lower than
the specified common rail pressure in the full
range.
o Faulty supply pump
b. The SCV is defective for other than a.

YES

12 Check the scv harness for disconnection

1. Shake the harness between the SCV and ECU and check that
the specified injection quantity and actual injection quantity are
unaffected.

NO Faulty harness

YES

Faulty SCV

[S5LC0033E04] [0518CsCshWbYs]
17–46 ENGINE DIAGNOSIS CODE

13 Using the Hino-DX, check the actual common rail pressure during driving while monitoring

1. Check if the specified common rail pressure corresponds to the

Actual common rail pressure
Specified common rail pressure actual common rail pressure while depressing the accelerator
Common rail pressure

Depress the
pedal.
Depress the
accelerator pedal. accelerator pedal.

Release the
Idling accelerator pedal. Release the
accelerator pedal.

Hour
SAPH31J191700044

NO Faulty SCV

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–47

14 Check the voltage between terminals

1. Set the starter switch to "OFF" position and connect the signal
check harness.

2. Start the engine.

3. Perform warm-up until the coolant temperature gauge moves.

4. At engine speed idling. The target pressure (P FIN) =

APPROX. 35 MPa {357 kgf/cm2, 5,093 lbf/in2} (APPROX. 1.5
V)
5. Measure the voltage between PCR1 (E49), PCR2 (E68) and
AGD1 (E56) terminals.
E68
E56 㧱 E49
Standard value: less than 1.56 V

SAPH31J191700045

6. Measure the voltage between PCR3 (E64), PCR4 (E65) and

E64 E65 AGD2 (E76) terminals.
E
E76 Standard value: less than 1.56 V

SAPH31J191700046

NO Faulty common rail pressure sensor

YES

Faulty SCV

15 Check the fuel filter and fuel pipe for clogging

NO • Faulty fuel filter

• Faulty fuel pipe

YES

Faulty supply pump

[S5LC0033E04] [0518CsCshWbYs]
17–48 ENGINE DIAGNOSIS CODE

DTC code P0088 [69]

Excessive common rail pressure
JP31J19170601007

1 Measuring voltage between terminals

1. Set the starter switch "OFF" position.

2. Connect the signal check harness on the engine ECU.

3. Set the starter switch "ON" position.

4. Measure voltage between the terminals PCR3 (E64), PCR4
E64 E65 (E65) and AGD 2(E76).
E
E76 Standard value: 0.75-0.95 V

SAPH31J191700047

5. Measure voltage between the terminals PCR2 (E68), PCR1

(E49) and AGD1 (E56).
E68
E56 㧱 E49
Standard value: 1.25-1.45 V

SAPH31J191700048

NO • Bad contact of harness or connectors

• Fault in engine ECU

YES

Faulty common rail pressure sensor

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–49

DTC code P0096 [18]

Intake air temperature sensor (intake manifold) - rationality

JP31J19170601008

1 Inspect the intake air temperature sensor (intake manifold)

1. Set the starter switch to the "OFF" position.

2. Connect the machine to Hino-DX.

Select
Engine 3. Set the starter switch to the "ON" position.

4. Select [Engine] and check if any DTC other than P0096 (for
example, P0401, P0402, P0404, P0234, P0299, P22D3, turbo,
EGR DTC) has been detected in [Fault Information].

SAPH31J191700049 NOTICE • Intake air temperature sensor (intercooler

outlet) characteristic abnormality judgement
is performed based on the boost pressure
and EGR rate data.
• If EGR system or Turbo DTC are detected,
perform another failure diagnosis starting
from the first DTC associated with the
malfunction.

NO Go to the diagnostic procedure of a related DTC.

YES

2 Inspect the intake air temperature sensor (intake manifold) connector

1. Check the connection of the intake air temperature sensor

(intake manifold) connector (Looseness and poor contact).

NO Connect securely, repair if needed.

YES

[S5LC0033E04] [0518CsCshWbYs]
17–50 ENGINE DIAGNOSIS CODE

3 Inspect the intake air temperature sensor (intake manifold)

1. Set the starter switch "Check the installation of the intake air
temperature sensor (intake manifold)." position.

2. Make sure there is no dirt or damage to the intake air

temperature sensor (intake manifold).

NO Clean the intake air temperature sensor (intake

manifold) and install it properly.
If damaged, replace the intake air temperature
sensor (intake manifold).

YES

4 Inspect the intake air temperature sensor (intake manifold) unit

1. Set the starter switch to the "OFF" position.

THG E2
2. Disconnect the intake air temperature sensor (intake manifold)
connector.

3. Use the electrical tester to measure the resistance between the

terminals of the intake air temperature sensor (intake manifold).

Measurement Tester
Standard values
conditions connections
SAPH31J191700050

Intake air
50 qC {122 qF}:
temperature
Starter switch: 2.202 k:
sensor (intake
OFF 100 qC {212 qF}:
manifold)
508.1 :
THG – E2

NO Replace the intake air temperature sensor (intake

manifold).

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–51

5 Inspect the intake air temperature sensor (intake manifold) power supply

1. Set the starter switch to the "ON" position.

E2 THG
2. Use the electrical tester to measure the voltage between the
terminals of the intake air temperature sensor (intake manifold)
machine-side connector.

Measurement Tester
Standard values
conditions connections
Intake air
SAPH31J191700051 temperature
sensor (intake
Starter switch:
manifold) 4.5 – 5.5 V
ON
machine-side
connector
THG- – E2

NO Go to step 6.

YES

Go to step 8.

6 Inspect for short-circuit of the intake air temperature sensor (intake manifold) harness

1. Set the starter switch to the "OFF" position.

E E76
E63
2. Connect the signal check harness to the engine ECU. (Do not
connect harness to the ECU.)

3. Use the electrical tester to measure the resistance between the

terminals of the engine ECU (signal check harness) and
ground.

Measurement Tester
SAPH31J191700052 Standard values
conditions connections

Engine ECU
(signal check
harness)
Starter switch:
ATI+(E63) – f:
OFF
Ground
AGD2(E76) –
Ground

NO Repair or replace the harness.

YES

[S5LC0033E04] [0518CsCshWbYs]
17–52 ENGINE DIAGNOSIS CODE

7 Inspect disconnection of the intake air temperature sensor (intake manifold) harness

1. Connect the intake air temperature sensor (intake manifold)

E connector.
E76
E63
2. Use the electrical tester to measure the resistance between the
terminals of the engine ECU (signal check harness).

Measurement Tester
Standard values
conditions connections
Engine ECU
SAPH31J191700053
50 qC {122 qF}:
(signal check
Starter switch: 2.202 k:
harness)
OFF 100 qC {212 qF}:
ATI+(E63) –
508.1 :
AGD2(E76)

NO Repair or replace the harness.

YES

8 Inspect the intake air temperature sensor (air flow sensor built-in)

1. Check the installation of the intake air temperature sensor (air

flow sensor built-in).

2. Make sure there is no dirt or damage to intake air temperature

sensor (air flow sensor built-in).

NO If the intake air temperature sensor (air flow sensor

built-in) is dirty, clogged, or damaged, replace the air
flow sensor.

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–53

9 Inspect the intake air temperature sensor (air flow sensor built-in) unit

1. Set the starter switch to the "OFF" position.

AFT- AFT+
2. Disconnect the intake air temperature sensor (air flow sensor
built-in) connector.

3. Use the electrical tester to measure the resistance between the

terminals of the intake air temperature sensor (air flow sensor
built-in).

Measurement Tester
SAPH31J191700054 Standard values
conditions connections
Intake air
20 qC {68 qF}:
temperature
Starter switch: 2.45 k:
sensor (air flow
OFF 60 qC {140 qF}:
sensor built-in)
0.58 k:
AFT+ – AFT-

NO Replace the intake air temperature sensor (air flow

sensor built-in).

YES

10 Inspect the intake air temperature sensor (intercooler outlet)

1. Check the installation of the intake air temperature sensor

(intercooler outlet).

2. Make sure there is no dirt or damage to intake air temperature

sensor (intercooler outlet).

NO Clean the intake air temperature sensor (intercooler

outlet) and install it properly.
If damaged, replace the intake air temperature
sensor (intercooler outlet)

YES

[S5LC0033E04] [0518CsCshWbYs]
17–54 ENGINE DIAGNOSIS CODE

11 Inspect the intake air temperature sensor (intercooler outlet) unit

1. Set the starter switch to the "OFF" position.

THG E2
2. Disconnect the intake air temperature sensor (intercooler
outlet) connector.

3. Use the electrical tester to measure the resistance between the

terminals of the intake air temperature sensor (intercooler
outlet).

Measurement Tester
SAPH31J191700055 Standard values
conditions connections
Intake air
temperature 50 qC {122 qF}:
Starter switch: sensor 2.202 k:
OFF (intercooler 100 qC {212 qF}:
outlet) 508.1 :
THG – E2

NO Replace the intake air temperature sensor

(intercooler outlet).

YES

12 Inspect the boost pressure sensor hose.

1. Make sure the boost pressure sensor hose is not clogged,

ruptured, or cracked.

2. Make sure the pipe on the intake manifold side is not clogged.

NO 1. Replace the boost pressure sensor hose.

2. Clean the intake manifold pipe.

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–55

13 Inspect the boost pressure sensor power supply system

1. Set the starter switch to the "OFF" position.

GND VCC 2. Disconnect the boost pressure sensor connector.

3. Set the starter switch to the "ON" position.

4. Use the electrical tester to measure the voltage between the

terminals of the boost pressure sensor machine-side
connector.

SAPH31J191700056
Measurement Tester
Standard values
conditions connections

Boost pressure
sensor
Starter switch:
machine-side 4.75 – 5.25 V
ON
connector
VCC – GND

NO Inspect the wire harness and engine ECU sensor

power supply output valve.

YES

14 Check the DTC detected (Engine ECU) [Hino-DX]

1. Perform engine warm-up. (engine coolant temperature: 60 qC

{140 qF} or more)

Select 2. Stop the engine and set the starter switch to the "OFF"
Engine position.

3. Connect the machine to Hino-DX.

4. Set the starter switch to the "ON" position.

SAPH31J191700057
5. Select [Engine] and check if P0096 has been detected in [Fault
Information].

NO Replace the engine ECU.

YES

Procedure completed.

[S5LC0033E04] [0518CsCshWbYs]
17–56 ENGINE DIAGNOSIS CODE

DTC code P0097 [18]

Intake air temperature sensor (intake manifold) - out of range (Out of range
low)
DTC code P0098 [18]
Intake air temperature sensor (intake manifold) - out of range (Out of range
high)
JP31J19170601009

1 Inspect the intake air temperature sensor (intake manifold) connector

1. Check the connection of the intake air temperature sensor

(intake manifold) connector (Looseness and poor contact).

NO Connect securely, repair if needed.

YES

2 Inspect the intake air temperature sensor (intake manifold)

1. Check the installation of the intake air temperature sensor

(intake manifold).

2. Make sure there is no dirt or damage to the intake air

temperature sensor (intake manifold).

NO Remove all contaminants and clogging.

Replace if damaged.

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–57

3 Inspect the intake air temperature sensor (intake manifold) unit

1. Set the starter switch to the "OFF" position.

THG E2
2. Disconnect the intake air temperature sensor (intake manifold)
connector.

3. Use the electrical tester to measure the resistance between the

terminals of the intake air temperature sensor (intake manifold).

Measurement Tester
Standard values
conditions connections
SAPH31J191700058

Intake air
50 qC {122 qF}:
temperature
Starter switch: 2.202 k:
sensor (intake
OFF 100 qC {212 qF}:
manifold)
508.1 :
THG – E2

NO Replace the intake air temperature sensor (intake

manifold).

YES

4 Inspect the sensor power supply

1. Set the starter switch to the "ON" position.

E2 THG
2. Use the electrical tester to measure the voltage between the
terminals of the intake air temperature sensor (intake manifold)
machine-side connector.

Measurement Tester
Standard values
conditions connections

Intake air
SAPH31J191700059 temperature
sensor (intake
Starter switch:
manifold) 4.5 – 5.5 V
ON
machine-side
connector
THG – E2

NO Go to step 5.

YES

Go to step 7.

[S5LC0033E04] [0518CsCshWbYs]
17–58 ENGINE DIAGNOSIS CODE

5 Inspect for short-circuit of the intake air temperature sensor (intake manifold) harness

1. Set the starter switch to the "OFF" position.

E E76
E63
2. Connect the signal check harness to the engine ECU. (Do not
connect the harness to the ECU.)

3. Use the electrical tester to measure the resistance between the

terminals of the engine ECU (signal check harness) and
ground.

Measurement Tester
SAPH31J191700060 Standard values
conditions connections
Engine ECU
(signal check
harness)
Starter switch:
ATI+(E63) – f:
OFF
Ground
AGD2(E76) –
Ground

NO Repair or replace the harness.

YES

6 Inspect disconnection of the intake air temperature sensor (intake manifold) harness

1. Connect the intake air temperature sensor (intake manifold)

E connector.
E76
E63
2. Use the electrical tester to measure the resistance between the
terminals of the engine ECU (signal check harness).

Measurement Tester
Standard values
conditions connections

Engine ECU
SAPH31J191700061
50 qC {122 qF}:
(signal check
Starter switch: 2.202 k:
harness)
OFF 100 qC {212 qF}:
ATI+(E63) –
508.1 :
AGD2(E76)

NO Repair or replace the harness.

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–59

7 Check the DTC detected (Engine ECU) [Hino-DX]

1. Perform engine warm-up. (engine coolant temperature: 60 qC

{140 qF} or more)

Select 2. Stop the engine and set the starter switch to the "OFF"
Engine position.

3. Connect the machine to Hino-DX.

4. Set the starter switch to the "ON" position.

SAPH31J191700062
5. Select [Engine] and check if the DTC (P0097 or P0098) has
been detected in [Fault Information].

NO Replace the engine ECU.

YES

Procedure completed.

[S5LC0033E04] [0518CsCshWbYs]
17–60 ENGINE DIAGNOSIS CODE

DTC code P0101 [17]

Air flow sensor - rationality

JP31J19170601010

1 Inspect the air cleaner element

1. Check the air cleaner element is dirty, clogged or damaged.

2. Make sure the element is a Hino genuine part.

NO Clean or replace the air cleaner element.

YES

2 Check the intake system

1. Check the intake hose and verify that there are no

disconnections, clogging, punctures, or cracks.

2. Check the breather hose and verify that there are no

disconnections, clogging, punctures, or cracks.

3. Check the intercooler hose and verify that there are no

disconnections, clogging, punctures, or cracks.

NO Repair or replace the intake system hoses.

YES

3 Inspect the air flow sensor

1. Check the installation of the air flow sensor.

2. Make sure there is no dirt or damage to the air flow sensor.

NO If dirt, clogging or damage was found in sensing unit,

replace the air flow sensor.

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–61

4 Inspect for short-circuits in wire harness of air flow sensor

1. Set the starter switch to the "OFF" position.

E E
E12
2. Disconnect the air flow sensor connector.

E74 E78 3. Connect the signal check harness to the engine ECU machine-
side harness. (Do not connect harness to the ECU.)

4. Use the electrical tester to measure the resistance between the

engine ECU (signal check harness) terminals and ground.

SAPH31J191700063
Measurement Tester
Standard values
conditions connections
Engine ECU
(signal check
harness)
AFVB(E12) –
Starter switch:
Ground f:
OFF
AFSI(E74) –
Ground
AGD6(E78) –
Ground

NO Repair or replace the harness.

YES

[S5LC0033E04] [0518CsCshWbYs]
17–62 ENGINE DIAGNOSIS CODE

5 Inspect for disconnection in wire harness of air flow sensor

1. Use the electrical tester to measure the resistance between the

engine ECU (signal check harness) terminal and the air flow
sensor machine-side connector terminal.

E Measurement Tester
E12 Standard values
conditions connections
Engine ECU
ASGD AFGD (signal check
E
AFSG
harness) – air
flow sensor
E74 E78 machine-side
Starter switch: connector
1 : or less
OFF AFVB(E12) –
AFVB
AFSI(E74) –
AFSG
AGD6(E78) –
AGGD

SAPH31J191700064
NO Repair or replace the harness.

YES

6 Replace the air flow sensor [Hino-DX]

1. Set the starter switch to the "OFF" position.

2. Replace the air flow sensor with a new one.

Select 3. Start the engine.

Engine

4. After thirty seconds, stop the engine and set the starter switch
to the "OFF" position.

5. Set the starter switch to the "ON" position.

SAPH31J191700065

6. Select [Engine] and check if P0101 has been detected in [Fault

Information].

NO Go to step 7.

YES

Procedure completed.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–63

7 Inspect the EGR valve

1. Check the EGR valve for damage due to foreign substances.

2. Check if there is soot obstructing the exhaust gas passageway

inlet or outlet.

NO Remove foreign substances and clean the valve.

Replace the EGR valve if it is damaged.

YES

8 Check the response delay of the EGR valve [Hino-DX]

1. Set the starter switch to the "ON" position.

(1) 2. Check the time lag (following characteristics) of the target EGR
valve opening and actual EGR valve opening.
(2)
! CAUTION • Perform the inspection while the engine is
stopped to avoid engine damages.

<Inspection procedure>
1. Select [Check functions].
2. Select [EGR check].
(3)
3. Click [Check start].
4. Click [EGR opening UP]:

(4) (5) • Check each step from 0 % – 100 % of the time lag (following
characteristics) of the target EGR valve opening and actual
EGR valve opening.
5. Click [EGR opening DOWN]:
• Check each step from 100 % – 0 % of the time lag (following
characteristics) of the target EGR valve opening and actual
SAPH31J191700066 EGR valve opening.

NOTICE • In EGR openings from 0 % – 100 %, 1 step

corresponds to a 10 % change.

Standard values

The response delay should be less than 5 seconds.

NO Replace the EGR valve.

YES

[S5LC0033E04] [0518CsCshWbYs]
17–64 ENGINE DIAGNOSIS CODE

9 Inspect the intake throttle valve

1. Stop the engine.

2. Check the operating status of the intake throttle valve (for

incorrect opening or sticky valve).

NOTICE • Please confirm the items listed in the DTC

codes P2100 and P2103 of this document.

NO Replace the intake throttle valve.

YES

10 Inspect the intercooler

1. Check if there is an obstruction due to clogging inside the

intercooler.

NO Remove foreign substances and clean the

intercooler.
Replace the intercooler if it is damaged.

YES

11 Check the DTC detected (Engine ECU) [Hino-DX]

1. Warm-up the engine. (engine coolant temperature: 60 qC {140

qF} or more)

2. Stop the engine.

Select
Engine
3. Set the starter switch to the "ON" position.

4. Select [Engine] and check if P0101 has been detected in [Fault

Information].

SAPH31J191700067
NO Replace the engine ECU.

YES

Procedure completed.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–65

DTC code P0104 [17]

Air flow sensor - out of range
JP31J19170601011

1 Check installation of the connector

1. Check that the air flow sensor connector is properly installed.

NO Faulty connector

YES

2 Check a DTC code

1. Make sure that air flow sensor power supply failure code
(P06D3 [5], P06D4 [5]) is not output.

NO Proceed to air flow sensor power supply failure

diagnosis method (P06D3 [5], P06D4 [5])

YES

3 Measuring frequency between terminals

1. Set the starter switch "OFF" position.

2. Connect the signal check harness on the engine side.

3. Measure frequency between the terminals AFSI (E74) and
E74 E78 AGD6 (E78) while idling. (No load)
E

Standard value

Idling revolution
Frequency
(No load)
(kHz)
(r/min)

1,000 5-6
SAPH31J191700068

NO Fault in air flow sensor

YES

Fault in engine ECU

[S5LC0033E04] [0518CsCshWbYs]
17–66 ENGINE DIAGNOSIS CODE

DTC code P0106 [25]

Boost pressure sensor - rationality

JP31J19170601012

1 Inspect the boost pressure sensor connector

1. Check the connection of the boost pressure sensor connector

(Looseness and poor contact).

NO Connect securely, repair if needed.

YES

2 Inspect the boost pressure sensor

1. Check the installation of the boost pressure sensor.

2. Make sure there is no dirt or damage to the boost pressure

sensor.

3. Make sure there is no dirt, damage or clogging in the pipes or

hoses unit of the boost pressure sensor.

NO If dirt, clogging or damage was found in sensing unit,

replace the boost pressure sensor.

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–67

3 Inspect for short-circuits in wire harness of boost pressure sensor

1. Set the starter switch to the "OFF" position.

E E67 E
E77
E33
2. Disconnect the boost pressure sensor connector.

3. Connect the signal check harness to the engine ECU machine-

side harness. (Do not connect harness to the ECU.)

4. Use the electrical tester to measure the resistance between

each terminal in the engine ECU (signal check harness) and
ground.
SAPH31J191700069

Measurement Tester
Standard values
conditions connections
Engine ECU
(signal check
harness)
AVC2(E33) –
Starter switch:
Ground 1:
OFF
PIM(E67) –
Ground
AGD4(E77) –
Ground

NO Repair or replace the harness.

YES

[S5LC0033E04] [0518CsCshWbYs]
17–68 ENGINE DIAGNOSIS CODE

4 Inspect for disconnection in wire harness of boost pressure sensor

1. Use the electrical tester to measure the resistance between the

engine ECU (signal check harness) and boost pressure sensor
machine-side connector terminals.

E 2. Disconnect the intake air temperature sensor (intake manifold)

E33 connector.
SIG
GND VCC
Measurement Tester
E67 Standard values
E E77 conditions connections

Engine ECU
(signal check
harness) –
boost pressure
sensor
Starter switch: machine-side
1:
OFF connector
AVC2(E33) –
VCC
PIM(E67) – SIG
SAPH31J191700070 AGD4(E77) –
GND

NO Repair or replace the harness.

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–69

5 Inspect the boost pressure sensor power supply

1. Connect the engine ECU machine-side harness to the engine

ECU.
GND VCC

2. Set the starter switch to the "ON" position.

3. Use the electrical tester to measure the voltage between the

terminals of the boost pressure sensor machine-side
connector.

Measurement Tester
SAPH31J191700071 Standard values
conditions connections
Boost pressure
sensor
Starter switch:
machine-side 4.75 – 5.25 V
ON
connector
VCC – GND

NO Replace the engine ECU.

YES

Replace the boost pressure sensor.

Go to step 6 after replacement.

6 Check the DTC detected (Engine ECU) [Hino-DX]

1. Warm-up the engine (engine coolant temperature: 60 qC {140

qF} or more)

Select 2. Stop the engine.

Engine
3. Set the starter switch to the "ON" position.

4. Select [Engine] and check if P0106 has been detected in [Fault

Information].

SAPH31J191700072
NO Replace the engine ECU.

YES

Procedure completed.

[S5LC0033E04] [0518CsCshWbYs]
17–70 ENGINE DIAGNOSIS CODE

DTC code P0108 [25]

Boost pressure sensor - out of range (Out of range high)
JP31J19170601013

1 Measuring resistance between sensor terminals

1. Set the starter switch "OFF" position.

2. Disconnect the connector of boost pressure sensor.

3. Measure the resistance between VCC and SIG terminal of the
boost pressure sensor connector.

NOTICE • If it is difficult to check only the sensor,

proceed to Step 5.

Standard value: 2-15 k:

SAPH31J191700073

NO Fault in boost pressure sensor

YES

2 Measuring resistance between sensor terminals

1. Measure resistance between the terminals SIG and GND of the

boost pressure sensor connector (engine sub harness side).

Standard value: 209-231 k:

SAPH31J191700074

NO • Fault in harness
• Irregular contact of connectors

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–71

3 Measuring resistance between sensor terminals

1. Measure resistance between the terminals VCC and SIG of the

boost pressure sensor connector (engine sub harness side).

Standard value: f :

SAPH31J191700075

NO Fault in harness

YES

4 Measuring resistance between terminals

1. Connect the signal check harness on the engine side.

2. Disconnect the connector on the engine sub harness side.

3. Measure resistance between the terminals AVC2 (E33) and
PIM (E67).
㧱 E67 㧱
E33 Standard value: f :

SAPH31J191700076

NO Fault in engine harness

YES

[S5LC0033E04] [0518CsCshWbYs]
17–72 ENGINE DIAGNOSIS CODE

5 Measuring resistance between terminals

1. Connect the boost pressure sensor connector.

2. Connect the signal check harness on the engine side.

3. Disconnect the connector on the engine ECU side.

4. Measure resistance between the terminals AVC2 (E33) and
PIM (E67).
㧱 E67 㧱
E33 Standard value: 2-15 k:

SAPH31J191700077

NO • Fault in harness
• Fault in boost pressure sensor

YES

6 Measuring resistance between terminals

1. Measure resistance between the terminals AGD4 (E77) and

PIM (E67).
㧱 E67
E77 Standard value: 2-15 k:

SAPH31J191700078

NO • Fault in harness
• Irregular contact of connectors

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–73

7 Check a malfunction code

1. Connect the connector on the engine ECU side.

2. Set the starter switch "ON" position.

3. Make sure that the malfunction code P0237 is present.

NO Fault in engine ECU

YES

Clear and recheck the DTC

[S5LC0033E04] [0518CsCshWbYs]
17–74 ENGINE DIAGNOSIS CODE

DTC code P0112 [17]

Intake air temperature sensor (air flow sensor built-in) - out of range
(Out of range low)
DTC code P0113 [17]
Intake air temperature sensor (air flow sensor built-in) - out of range
(Out of range high)
JP31J19170601014

1 Check the intake air temperature sensor

1. Set the starter switch to "OFF" position.

2. Disconnect the connector of intake air temperature sensor (air

flow sensor built-in).
3. Measure the resistance between AFT+ and AFT- terminal of
the intake air temperature sensor (air flow sensor built-in).

NOTICE • If it is difficult to check only the sensor,

proceed to Step 3.

Standard value

Outside air temperature

Resistance
(qC{qF})
SAPH31J191700079
16.0 k: -20 {-4}

2.45 : 20 {68}

0.58 : 60 {140}

NO Fault in intake air temperature sensor

(air flow sensor built-in)

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–75

2 Measuring voltage between sensor terminals

1. Set the starter switch to "ON" position.

2. Measure the voltage between IAT+ and IAT- terminal of the

intake air temperature sensor (air flow sensor built-in) (engine
sub harness side).

Standard value: 4.5-5.5 V

SAPH31J191700080

NO Proceed to 3

YES

Bad contact of connectors

3 Measuring resistance between terminals

1. Set the starter switch to "OFF" position.

2. Connect the signal check harness on the engine side.

3. Disconnect the connector on the engine ECU side.

4. Measure resistance between the terminals THA+ (E47) and
AGD5 (E58).
E47 㧱 E58

Standard value

Outside air temperature

Resistance
(qC{qF})

16.0 k: -20 {-4}

2.45 : 20 {68}
SAPH31J191700081

0.58 : 60 {140}

NO Fault in intake air temperature sensor

(air flow sensor built-in)

YES

[S5LC0033E04] [0518CsCshWbYs]
17–76 ENGINE DIAGNOSIS CODE

4 Measuring voltage between terminals

1. Connect the connector on the engine ECU side.

2. Disconnect the connector on the engine sub harness side.

3. Set the starter switch to "ON" position.

4. Measure voltage between the terminals THA+ (E47) and AGD5
(E58).
E47 㧱 E58
Standard value: 4.5-5.5 V

SAPH31J191700082

NO • Fault in engine ECU

• Faulty ECU connector

YES

Bad contact of connectors

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–77

DTC code P0117 [11]

Engine coolant temperature sensor - out of range (Out of range low)
DTC code P0118 [11]
Engine coolant temperature sensor - out of range (Out of range high)
JP31J19170601015

1 Measuring resistance between sensor terminals

1. Set the starter switch to "OFF" position.

2. Disconnect the coolant temperature sensor connector.

3. Measure resistance between the terminals WTM+ and WTM-
of the engine coolant temperature sensor.

NOTICE • If it is difficult to check only the sensor,

proceed to Step 3.

Standard value

Water temperature
Resistance
(qC{qF})
SAPH31J191700083
2.45 k: 20 {68}

1.15 k: 40 {104}
584 : 60 {140}

318 : 80 {176}

NO Fault in engine coolant temperature sensor

YES

[S5LC0033E04] [0518CsCshWbYs]
17–78 ENGINE DIAGNOSIS CODE

2 Measuring voltage between sensor terminals

1. Set the starter switch to "ON" position.

2. Measure voltage between the terminals WT+ and WT- of the
engine coolant temperature sensor connector (engine sub
harness side).

Standard value: 4.5-5.5 V

SAPH31J191700084

NO Proceed to 3

YES

Bad contact of connectors

3 Measuring resistance between terminals

1. Set the starter switch to "OFF" position.

2. Connect the signal check harness on the engine side.

3. Disconnect the connector on the engine ECU side.

4. Measure resistance between the terminals THW+ (E66) and
AGD5 (E58).
E66 㧱 E58

Standard value

Water temperature
Resistance
(qC{qF})

2.45 k: 20 {68}

1.15 k: 40 {104}
SAPH31J191700085

584 : 60 {140}

318 : 80 {176}

NO • Fault in engine coolant temperature sensor

• Fault in harness

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–79

4 Measuring voltage between terminals

1. Connect the connector on the engine ECU side.

2. Disconnect the connector on the engine sub harness side.

3. Set the starter switch to "ON" position.

4. Measure voltage between the terminals THW+ (E66) and
AGD5 (E58).
E66 㧱 E58
Standard value: 4.5-5.5 V

SAPH31J191700086

NO • Fault in engine ECU

• Faulty ECU connector

YES

Bad contact of connectors

[S5LC0033E04] [0518CsCshWbYs]
17–80 ENGINE DIAGNOSIS CODE

DTC code P0122 [32]

Intake throttle valve position sensor 1 - out of range (Out of range low)
JP31J19170601016

1 Measuring resistance between sensor terminals

1. Set the starter switch to "OFF" position.

2. Disconnect the connector of the intake throttle valve position

sensor 1 connector.
3. Check continuity between the terminals VCC and DTS1 of the
DTS1 VCC intake throttle valve position sensor 1 connector.

NOTICE • If it is difficult to check only the sensor,

proceed to Step 4.

Standard value: Approx. 180 :

SAPH31J191700087

4. Check continuity between the terminals VCC and GND of the

VCC GND intake throttle valve position sensor 1 connector.

Standard value: Approx. 3 k:

SAPH31J191700088

5. Check continuity between the terminals DTS1 and GND of the

DTS1 GND intake throttle valve position sensor 1 connector.

Standard value: Approx. 3 k:

SAPH31J191700089

NO Fault in intake throttle valve position sensor 1

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–81

2 Measuring resistance between sensor terminals

1. Measure resistance between the terminals SIG1 and GND of

GND SIG1
the intake throttle valve position sensor 1 connector (engine
sub harness side).

Standard value: Approx. 25-35 k:

SAPH31J191700090

NO • Fault in harness
• Irregular contact of connectors

YES

3 Measuring voltage between sensor terminals

1. Set the starter switch to "ON" position.

2. Measure voltage between the terminals VCC and GND of the
intake throttle valve position sensor 1 connector (engine sub
GND
harness side).
VCC

Standard value: 4.5-5.5 V

SAPH31J191700091

NO • Fault in harness
• Irregular contact of connectors

YES

Bad contact of connectors

[S5LC0033E04] [0518CsCshWbYs]
17–82 ENGINE DIAGNOSIS CODE

4 Measuring resistance between terminals

1. Set the starter switch to "OFF" position.

2. Connect the signal check harness on the engine side.

3. Disconnect the connector on the engine ECU side.

4. Measure resistance between the terminals AVC2 (E33) and
DTS1 (E62).
㧱 㧱 E62
E33 Standard value: 2 : or more

SAPH31J191700092

5. Measure resistance between the terminals AVC2 (E33) and

AGD3 (E57).
㧱 㧱 E57
E33 Standard value: Approx. 3 k:

SAPH31J191700093

6. Measure resistance between the terminals DTS1 (E62) and

AGD3 (E57).
㧱 E57
E62
Standard value: f :

SAPH31J191700094

NO • Fault in harness
• Fault in intake throttle valve position sensor 1

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–83

5 Measuring voltage between terminals

1. Connect the connectors on the engine ECU side.

2. Disconnect the connector on the engine sub harness side.

3. Set the starter switch to "ON" position.

4. Measure voltage between the terminals AVC2 (E33) and AGD3
(E57).
㧱 㧱 E57
Standard value: 4.5-5.5 V
E33

SAPH31J191700095

NO • Fault in engine ECU

• Faulty ECU connector

YES

6 Measuring resistance between terminals

1. Measure resistance between the terminals DTS1 (E62) and

AGD3 (E57).
㧱 E57
E62
Standard value: Approx. 25-35 k:

SAPH31J191700096

NO • Fault in engine ECU

• Faulty ECU connector

YES

Bad contact of connectors

[S5LC0033E04] [0518CsCshWbYs]
17–84 ENGINE DIAGNOSIS CODE

DTC code P0123 [32]

Intake throttle valve position sensor 1 - out of range (Out of range high)
JP31J19170601017

1 Measuring resistance between sensor terminals

1. Set the starter switch "OFF" position.

2. Disconnect the connector of the intake throttle valve position

sensor 1.
3. Measure resistance between the terminals VCC and DTS1 of
DTS1 VCC the intake throttle valve position sensor 1 connector.

NOTICE • If it is difficult to check only the sensor,

proceed to Step 5.

Standard value: Approx. 180 :

SAPH31J191700087

4. Check continuity between the terminals VCC and GND of the

VCC GND intake throttle valve position sensor 1 connector.

Standard value: Approx. 3 k:

SAPH31J191700088

5. Check continuity between the terminals DTS1 and GND of the

DTS1 GND intake throttle valve position sensor 1 connector.

Standard value: Approx. 3 k:

SAPH31J191700089

NO Fault in intake throttle valve position sensor 1

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–85

2 Measuring resistance between sensor terminals

1. Measure resistance between the terminals SIG1 and GND of

GND SIG1
the intake throttle valve position sensor 1 connector (engine
sub harness side).

Standard value: Approx. 25-35 k:

SAPH31J191700090

NO • Fault in harness
• Irregular contact of connectors

YES

3 Measuring resistance between sensor terminals

1. Measure resistance between the terminals VCC and SIG1 of

VCC SIG1 the intake throttle valve position sensor 1 connector (engine
sub harness side).

Standard value: f :

SAPH31J191700097

NO Fault in harness

YES

[S5LC0033E04] [0518CsCshWbYs]
17–86 ENGINE DIAGNOSIS CODE

4 Measuring resistance between terminals

1. Connect the signal check harness on the engine side.

2. Disconnect the connector on the engine sub harness side.

3. Measure resistance between the terminals AVC2 (E33) and
DTS1 (E62).
㧱 㧱
E33 E62 Standard value: f :

SAPH31J191700098

NO Fault in engine ECU

YES

5 Measuring resistance between terminals

1. Connect the intake throttle valve position sensor 1.

2. Connect the signal check harness on the engine side.

3. Disconnect the connector on the engine ECU side.

4. Measure resistance between the terminals AVC2 (E33) and
DTS1 (E62).
㧱 㧱
E33 E62 Standard value: 2 : or more

SAPH31J191700099

NO • Fault in harness
• Fault in intake throttle valve position sensor 1

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–87

6 Measuring resistance between terminals

1. Measure resistance between the terminals AGD3 (E57) and

㧱 E57 DTS1 (E62).
E62
Standard value: Approx. 3 k:

SAPH31J191700100

NO • Fault in harness
• Irregular contact of connectors

YES

7 Check a malfunction code

1. Connect the connector on the engine ECU side.

2. Set the starter switch "ON" position.

3. Make sure that the malfunction code P0122 is present.

NO Fault in engine ECU

YES

Clear and recheck the DTC

[S5LC0033E04] [0518CsCshWbYs]
17–88 ENGINE DIAGNOSIS CODE

DTC code P0182 [14]

Fuel temperature sensor Low
DTC code P0183 [14]
Fuel temperature sensor High
JP31J19170601018

1 Measuring resistance between sensor terminals

1. Set the starter switch to "OFF" position.

2. Disconnect the fuel temperature sensor connector.

3. Measure resistance between the terminals THF+ and THF- of
the fuel temperature sensor connector.
THF- THF+

NOTICE • If it is difficult to check only the sensor,

proceed to Step 3.

Standard value

Fuel temperature in
Resistance (k:)
measurement (qC{qF})
SAPH31J191700101
-20 {-4} 13.84-16.33

20 {68} 2.32-2.59

80 {176} 0.31-0.326

110 {230} 0.1399-0.1435

NO Fault in fuel temperature sensor

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–89

2 Measuring voltage between sensor terminals

1. Set the starter switch to "ON" position.

2. Measure voltage between the terminals THF+ and THF- of the
THF+ THF- fuel temperature sensor connector (engine sub harness side).

Standard value: 4.5-5.5 V

SAPH31J191700102

NO Proceed to 3

YES

Bad contact of connectors

3 Measuring resistance between terminals

1. Set the starter switch to "OFF" position.

2. Connect the signal check harness on the engine side.

3. Disconnect the connector on the engine ECU side.

4. Set the starter switch to "ON" position.

5. Measure resistance between the terminals THF+ (E48) and
AGD2 (E76).
E76 E E48

Standard value

Fuel temperature in
Resistance (k:)
measurement (qC{qF})

-20 {-4} 13.84-16.33

20 {68} 2.32-2.59
SAPH31J191700103

80 {176} 0.31-0.326

110 {230} 0.1399-0.1435

NO • Fault in fuel temperature sensor

• Fault in harness

YES

[S5LC0033E04] [0518CsCshWbYs]
17–90 ENGINE DIAGNOSIS CODE

4 Measuring voltage between terminals

1. Set the starter switch to "OFF" position.

2. Connect the connector on the engine ECU side.

3. Disconnect the connector on the engine sub harness side.

4. Set the starter switch to "ON" position.

5. Measure voltage between the terminals THF+ (E48) and AGD2
E E48 (E76).
E76
Standard value: 4.5-5.5 V

SAPH31J191700104

NO • Fault in engine ECU

• Faulty ECU connector

YES

Bad connect of connectors

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–91

DTC code P0192 [74]

Common rail pressure sensor (main) - out of range (Out of range low)
JP31J19170601019

1 Measuring resistance between sensor terminals

1. Set the starter switch to "OFF" position.

2. Disconnect the common rail pressure sensor connector.

3. Check continuity between the terminals PCR+ and PCR of the
common rail pressure sensor (main) connector.
PCR- PCR PCR+
(main) (main) (main) Standard value: 1.05-3.55 k:
PCR+ PCR PCR-
(sub) (sub) (sub)

SAPH31J191700105

4. Check continuity between the terminals PCR and PCR- of the

common rail pressure sensor (main) connector.
PCR- PCR PCR+
(main) (main) (main) Standard value: 6.7-18.7 k:
PCR+ PCR PCR-
(sub) (sub) (sub)

SAPH31J191700106

NO Fault in common rail pressure sensor

YES

[S5LC0033E04] [0518CsCshWbYs]
17–92 ENGINE DIAGNOSIS CODE

2 Check the continuity of harness

1. Disconnect the engine ECU connector.

2. Check continuity between the terminals ECU GND and VCC of
VCC the common rail pressure sensor (main) connector on the
GROUND
engine sub harness side.

NOTICE • If it is difficult to check only the sensor,

proceed to Step 3.

Standard value: f :

SAPH31J191700107

3. Check continuity between the terminals ECU GND and SIG of

SIG the common rail pressure sensor (main) connector on the
GROUND
harness side.

Standard value: f :

SAPH31J191700108

NO Fault in harness

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–93

3 Measuring resistance between terminals

1. Set the starter switch to "OFF" position.

2. Connect the signal check harness on the engine side.

3. Disconnect the connector on the engine ECU side.

4. Measure resistance between the terminals AVC2 (E33) and
E ECU GND.
GROUND E33
Standard value: f :

SAPH31J191700109

5. Measure resistance between the terminals PCR3 (E64), PCR4

E64 E (E65) and ECU GND.
E65
GROUND
Standard value: f :

SAPH31J191700110

NO Fault in harness

YES

[S5LC0033E04] [0518CsCshWbYs]
17–94 ENGINE DIAGNOSIS CODE

4 Measuring resistance between terminals

1. Connect the signal check harness on the engine side.

2. Disconnect the connector on the engine ECU side.

3. Measure resistance between the terminals AVC2 (E33) and
E E AGD2 (E76).
E33 E76
Standard value: 2 : or more

SAPH31J191700111

4. Measure resistance between the terminals PCR3 (E64), PCR4

(E65) and AGD2 (E76).
E65 E
E64 E76
Standard value: 2 : or more

SAPH31J191700112

NO Faulty common rail pressure sensor

YES

5 Measuring resistance between terminals

1. Connect the signal check harness on the engine ECU side.

2. Measure resistance between the terminals AVC2 (E33), PCR3
E E (E64) and PCR4 (E65).
E65
E33 E64
Standard value: 200-250 k:

SAPH31J191700113

NO Fault in engine ECU (ECU connector)

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–95

6 Measuring voltage between terminals

1. Set the starter switch to "ON" position.

2. Measure voltage between the terminals AVC2 (E33) and AGD2
E E (E76).
E33 E76
Standard value: 4.5-5.5 V

SAPH31J191700114

NO Fault in engine ECU (ECU connector)

YES

Replace the engine ECU

[S5LC0033E04] [0518CsCshWbYs]
17–96 ENGINE DIAGNOSIS CODE

DTC code P0193 [74]

Common rail pressure sensor (main) - out of range (Out of range high)
JP31J19170601020

1 Measuring resistance between sensor terminals

1. Set the starter switch to "OFF" position.

2. Disconnect the common rail pressure sensor connector.

3. Check continuity between the terminals PCR+ and PCR of the
common rail pressure sensor (main) connector.
PCR- PCR PCR+
(main) (main) (main)
Standard value: 1.05-3.55 k:
PCR+ PCR PCR-
(sub) (sub) (sub)

SAPH31J191700115

4. Check continuity between the terminals PCR and PCR- of the

common rail pressure sensor (main) connector.
PCR- PCR PCR+
(main) (main) (main) Standard value: 6.7-18.7 k:
PCR+ PCR PCR-
(sub) (sub) (sub)

SAPH31J191700116

NO Fault in common rail pressure sensor

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–97

2 Measuring voltage between sensor terminals

1. Set the starter switch to "ON" position.

2. Check voltage between the terminals VCC and GND of the
GND common rail pressure sensor (main) connector on the engine
VCC
sub harness side.

Standard value: 4.5-5.5 V

SAPH31J191700117

3. Check voltage between the terminals SIG and GND of the

SIG GND common rail pressure sensor (main) connector on the engine
sub harness side.

Standard value: 4.5-5.5 V

SAPH31J191700118

NO Proceed to 3

YES

Improper connection of connector

[S5LC0033E04] [0518CsCshWbYs]
17–98 ENGINE DIAGNOSIS CODE

3 Measuring resistance between terminals

1. Connect the signal check harness on the engine side (blue).

2. Disconnect the connector on the engine ECU side.

3. Measure resistance between the terminals AVC2 (E33), PCR3
E E (E64) and PCR4 (E65).
E65
E33 E64
Standard value: 2 : or more

SAPH31J191700119

4. Measure resistance between the terminals AGD2 (E76), PCR3

E65 E (E64) and PCR4 (E65).
E64 E76
Standard value: 2 : or more

SAPH31J191700120

NO • Improper connection of connector

• Fault in harness

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–99

4 Measuring resistance between terminals

1. Disconnect the connector on the engine sub harness side.

2. Connect the signal check harness on the engine ECU side.

3. Measure resistance between the terminals AVC2 (E33), PCR3
E E (E64) and PCR4 (E65).
E65
E33 E64
Standard value: 200-250 k:

SAPH31J191700121

NO Fault in engine ECU

YES

5 Measuring voltage between terminals

1. Set the starter switch to "ON" position.

2. Measure voltage between the terminals AVC2 (E33) and AGD2
E E (E76).
E33 E76
Standard value: 4.5-5.5 V

SAPH31J191700122

3. Measure voltage between the terminals PCR3 (E64), PCR4

E65 E (E65) and AGD2 (E76).
E64 E76
Standard value: 4.5-5.5 V

NO • Fault in engine ECU

• Fault in engine ECU connector

SAPH31J191700123

YES

Replace the common assembly and harness

[S5LC0033E04] [0518CsCshWbYs]
17–100 ENGINE DIAGNOSIS CODE

DTC code P0200 [71]

Fuel injector driver charge circuit - circuit (Circuit high)
DTC code P0611 [71]
Fuel injector driver charge circuit - circuit (Circuit low)
DTC code P0605 [3]
Flash ROM error
DTC code P0606 [3]
Control Module Processor
DTC code P0607 [3]
Control Module Performance
JP31J19170601021

1 Check a malfunction code

1. After the starter switch is positioned on the "OFF" once, it

should be turned to "ON" position again.

2. After erasing the DTC, check that the same code is displayed
again.

NO Fault in engine ECU

YES

Normal (Temporary malfunction because of radio interference noise)

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–101

DTC code P0201 [61]

Fuel injector - disconnection (#1cyl)
DTC code P0202 [62]
Fuel injector - disconnection (#2cyl)
DTC code P0203 [63]
Fuel injector - disconnection (#3cyl)
DTC code P0204 [64]
Fuel injector - disconnection (#4cyl)
DTC code P0205 [65]
Fuel injector - disconnection (#5cyl)
DTC code P0206 [66]
Fuel injector - disconnection (#6cyl)
JP31J19170601022

1 Measurement of resistance between terminals

1. Set the starter key to "OFF" and connect the signal check
㧱 㧱 harness.

2. Disconnect the ECU side connector of the signal check

harness and measure the resistance between terminals.

SAPH31J191700124

P0201 P0202 P0203 P0204 P0205 P0206

DTC code
[61] [62] [63] [64] [65] [66]

Failure position (injector) #1 #2 #3 #4 #5 #6

E14 l E15 E14 l E16 E14 l E17 E18 l E19 E18 l E60 E18 l E20
Terminal to measure E15 l E34 E16 l E34 E17 l E34 E19 l E38 E38 l E60 E20 l E38
resistance E14 l E35 E14 l E36 E14 l E37 E18 l E39 E18 l E80 E18 l E40
E34 l E35 E34 l E36 E34 l E37 E38 l E39 E38 l E80 E38 l E40

Standard value: 2 : or less

NO [3] Go to measurement of resistance between

injector terminals

YES

[S5LC0033E04] [0518CsCshWbYs]
17–102 ENGINE DIAGNOSIS CODE

2 Check of diagnosis code

1. Set the starter key to "OFF" and connect the ECU side
connector of the signal check harness.
2. Start the engine and delete the past failures with the failure
diagnosis tool (Hino-DX) using PC.

SAPH31J191700125

3. If the same failure code is output again, replace the engine

ECU. If the normal code is output, it is considered that a
temporary error has occurred.

3 Measurement of resistance between injector terminals

1. Disconnect the injector connector at the cylinder head.

2. Measure the resistance between terminals of the injector
clustered connector (male) at the cylinder head.

SAPH31J191700126

P0201 P0202 P0203 P0204 P0205 P0206

DTC code
[61] [62] [63] [64] [65] [66]

Failure area (injector) #1 #2 #3 #4 #5 #6

Terminal to measure
11 l 12 3l4 5l6 7l8 1l2 9 l 10
resistance

Standard value: 2 : or less

NO [4] Go to measurement of resistance between

injector terminals

YES

Engine sub harness disconnection (Check the harness between the ECU and the injector clustered connector)

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–103

4 Measurement of resistance between injector terminals

1. Remove the head cover and disconnect the injector connector

(injector side) of the cylinder indicated by the failure code.
2. Measure the resistance between the No. 1 terminal and the No.
2 terminal.

Standard value: 0.47 r 0.1 : (20qC{68 qF})

SAPH31J191700127

NO [5] Go to measurement of resistance between

injector terminals

YES

Contact failure of harness or connector inside the head cover

(Check the connector or the harness in the head cover)

5 Measurement of resistance between injector terminals

1. Remove the terminal cap of the injector of the cylinder

indicated by the failure code and measure the insulation
resistance between the terminal and the upper body.

Standard value: 10 M: or more

2. Measure the resistance between terminals.

Standard value: 0.47 r 0.1 : (20qC{68 qF})

SAPH31J191700128

NO Injector TWV coil disconnection

(Replace the injector assembly)

YES

Injector harness disconnection

(Replace the injector harness)

[S5LC0033E04] [0518CsCshWbYs]
17–104 ENGINE DIAGNOSIS CODE

DTC code P0217 [6]

Engine coolant over temperature condition
JP31J19170601023

1 Check the coolant temperature sensor

1. Set the starter switch to "OFF".

2. Disconnect the connector of engine coolant temperature

sensor.
3. Measure the resistance between terminals.

NOTICE • Measure the resistance under any of the

following conditions.

Standard value

Water temperature
Resistance
(qC{qF})

SAPH31J191700129
2.45 k: 20 {68}

1.15 k: 40 {104}

584 : 60 {140}

318 : 80 {176}

NO Fault in engine coolant temperature sensor

YES

Fault in engine cooling system

NOTICE • This code will be displayed when the coolant temperature sensor operates normally and
coolant temperature ascends over 115qC {239qF}. Also, while the DTC is being detected,
Max. volume of fuel injection will be limited and will return back to normal control volume
when it descends less than 80qC {176qF}.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–105

DTC code P0219 [7]

Engine overspeed condition
JP31J19170601024

1 Inspection item

1. The DTC will be displayed, once detected over 3100 r/min. in

the engine revolution. Also, the fuel injection will be suspended
during the DTC to be detected and the fuel injection will be
resumed when Engine revolution goes down less than 2700 r/
min.

NOTICE • The DTC aim is not for detecting the engine

over-run under abnormal operation of the
system, but for storing in memory the high
revolution of the engine. (For detection of
wrong shifting, etc.) Also, there is a case in
which "over-run" will be detected by
misunderstanding the engine revolution, with
a noise to be generated by harness
malfunction and its modification.

[S5LC0033E04] [0518CsCshWbYs]
17–106 ENGINE DIAGNOSIS CODE

DTC code P0234 [34]

Overboost
JP31J19170601025

1 Use the Hino-DX to inspect the VNT

1. Connect the PC DIAGNOSIS TOOL (Hino-DX).

SAPH31J191700130

2. Set the starter switch "ON" position.

3. Check that no other codes (P0045, P00AF, P0108, P0237 and

U1123) exist.
If a DTC code is issued, follow each diagnostic flow.

4. Inspect the VNT.

Standard: Max. 2 sec. delay in opening

NO • Faulty VNT controller

• Faulty turbocharger

YES

2 Check exhaust system parts

1. Check that exhaust system parts are not modified or blocked.

NO Faulty exhaust system parts

YES

3 Check the boost pressure sensor hose

1. Check the boost pressure sensor hose for looseness or

damage.

NO Faulty boost pressure sensor hose

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–107

4 Use the Hino-DX to inspect the EGR

1. Inspect the EGR.

Standard:
Actual opening must follow required opening

SAPH31J191700130

NO Proceed to inspect the EGR valve

YES

Proceed to inspect the boost pressure sensor

[S5LC0033E04] [0518CsCshWbYs]
17–108 ENGINE DIAGNOSIS CODE

DTC code P0237 [25]

Boost pressure sensor - out of range (Out of range low)
JP31J19170601026

1 Measuring resistance between sensor terminals

1. Set the starter switch to "OFF" position.

2. Disconnect the connector boost pressure sensor.

3. Check continuity between the terminals VCC and SIG of the
boost pressure sensor connector.

NOTICE • If it is difficult to check only the sensor,

proceed to Step 4.

Standard value: 2-15 k:

SAPH31J191700131

4. Check continuity between the terminals SIG and GND of the

boost pressure sensor connector.

Standard value: 2-15 k:

SAPH31J191700132

NO Fault in boost pressure sensor

YES

2 Measuring resistance between sensor terminals

1. Measure resistance between the terminals SIG and GND of the

boost pressure sensor connector (engine sub harness side).

Standard value: 209-231 k:

NO Proceed to 4

SAPH31J191700133

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–109

3 Measuring voltage between terminals

1. Set the starter switch to "ON" position.

2. Measure voltage between the terminals VCC and GND of the
boost pressure sensor connector (engine sub harness side).

Standard value: 4.5-5.5 V

NO Proceed to 4

SAPH31J191700134

YES

Bad contact of harness connector

[S5LC0033E04] [0518CsCshWbYs]
17–110 ENGINE DIAGNOSIS CODE

4 Measuring resistance between terminals

1. Set the starter switch to "OFF" position.

2. Connect the signal check harness on the engine side.

3. Disconnect the connector on the engine ECU side.

4. Measure resistance between the terminals AVC2 (E33) and
PIM (E67).
㧱 㧱 E67
Standard value: 2-15 k:
E33

SAPH31J191700135

5. Measure resistance between the terminals AVC2 (E33) and

AGD4 (E77).
㧱 㧱
E77
E33
Standard value: 2-15 k:

SAPH31J191700136

6. Measure resistance between the terminal PIM (E67) and AGD4

㧱 (E77).
E67
E77
Standard value: f :

SAPH31J191700137

NO • Faulty harness
• Fault in boost pressure sensor

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–111

5 Measuring voltage between terminals

1. Connect the connectors on the engine ECU side.

2. Disconnect the connector on the harness side.

3. Set the starter switch to "ON" position.

4. Measure voltage between the terminals AVC2 (E33) and ADG4
(E77).
㧱 㧱 E77
E33 Standard value: 4.5-5.5 V

SAPH31J191700138

NO Fault in engine ECU

YES

6 Measuring resistance between terminals

1. Measure resistance between the terminals PIM (E67) and

AGD4 (E77).
㧱 E67
E77 Standard value: 209-231 k:

SAPH31J191700139

NO Fault in engine ECU

YES

Bad contact of harness connector

[S5LC0033E04] [0518CsCshWbYs]
17–112 ENGINE DIAGNOSIS CODE

DTC code P0263 [61]

Injection quantity and timing (#1cyl)
DTC code P0266 [62]
Injection quantity and timing (#2cyl)
DTC code P0269 [63]
Injection quantity and timing (#3cyl)
DTC code P0272 [64]
Injection quantity and timing (#4cyl)
DTC code P0275 [65]
Injection quantity and timing (#5cyl)
DTC code P0278 [66]
Injection quantity and timing (#6cyl)

JP31J19170601027

1 Check the flow damper

1. Turn the starter switch to "OFF" position. Stop the engine.

2. Wait for about 30 seconds and then start the engine.

3. Perform warm-up until the coolant temperature becomes 60qC

{140qF} or higher. And erase the DTC.

4. If the same DTC is displayed again after erasing it, replace the
common rail.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–113

2 Recheck the DTC

1. Check that the other DTC is not displayed.

• If the other DTC is displayed, repair the trouble.
• If the same DTC is displayed again, it is possibly from the
following problems.
a
b a. Excessive fuel flow will cause fuel leakage from injection
pipe (between flow damper and injector) by bending,
cracking and pipe connection looseness.
o Check leakage.
b. Excessive or shortage fuel flow will cause injector
operation malfunction.
o Check by replacing the injector.
c. Shortage fuel flow will cause clogging of the fuel supply
system.
o Check fuel filter.

SAPH31J191700140

2. The above problems can be diagnosed using the "Data

Monitor" menu to determine the cylinder contribution quantity
and "Activation Test" menu to stop the injector.

(1) When there is a cylinder whose cylinder contribution is

larger than other cylinders (the engine behavior will not
change even if fuel injection is stopped by active test for
the cylinder), the cylinder will not contribute to the engine
rotation.
o Inspecting the injector harness (disconnection)
SAPH31J191700141
o Checking the piston for compression leakage
(2) When there is a cylinder whose cylinder contribution is
smaller than other cylinders, the contribution of the
cylinder to the engine rotation is excessive.
o Inspecting the injector harness (+B short circuit)

[S5LC0033E04] [0518CsCshWbYs]
17–114 ENGINE DIAGNOSIS CODE

DTC code P0335 [13]

Engine speed main sensor - disconnection
JP31J19170601028

1 Measuring resistance between terminals

1. Set the starter switch to "OFF" and connect the signal check
harness.

2. Disconnect the signal check harness connector on the engine

ECU side.
3. Measure the resistance between NE1+ (E52) and NE1- (E72)
㧱 terminals.
E52
E72 Standard value: 108.5-142.5 : at 20qC {68qF}

SAPH31J191700142

NO Proceed to 3

YES

2 Recheck the DTC

1. Connect the signal check harness connector on the engine

ECU side.

2. Erase the DTC.

3. No DTC code must be output again.

NO • Bad contact of ECU connectors

• Fault in engine ECU
• Malfunction of harness (Short circuit)

YES

Clear and recheck the DTC

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–115

3 Check the engine speed main sensor

1. Disconnect the connectors of engine speed main sensor.

2. Measure the resistance between terminals of engine speed
main sensor.

Standard value: 108.5-142.5 : at 20qC {68qF}

SAPH31J191700143

NO Fault in engine speed main sensor

YES

Harness disconnection
Bad contact of connectors

[S5LC0033E04] [0518CsCshWbYs]
17–116 ENGINE DIAGNOSIS CODE

DTC code P0336 [13]

Engine speed main sensor - rationality
JP31J19170601029

1 Check the input pulse generation to engine ECU

1. Set the starter switch to "OFF" and connect the signal check
harness.

2. Start the engine.

3. Measure the pulse generation between NE1+ (E52) and NE1-
㧱 (E72) terminals using an oscilloscope.
E52
E72 Standard: 56 pulse

SAPH31J191700144

1 rotation

56 peaks (pulse)

0V

No pulse (No gear tooth)

SAPH31J191700145

4. After measurement, stop the engine.

NO Proceed to 2

YES

Fault in engine ECU

Malfunction of ECU connectors

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–117

2 Measuring resistance between sensor terminals

1. Connector of engine speed main sensor remains connected.

NE+ 2. Measure the resistance between NE- main sensor connector

(engine sub harness side) and signal check harness NE1-
NE-
(E72).
E E72
E52 In same way, measure the resistance between NE+ main
sensor connector (engine sub harness side) and signal check
harness NE1+ (E52).

Standard value: Less than 2 :

SAPH31J191700146

NO Fault in harness

YES

3 Check the output pulse generation from sensor

1. Connector of engine speed main sensor remains connected.

2. Start the engine.

3. Measure the pulse generation between terminals using an

oscilloscope.

Standard: 56 pulse

SAPH31J191700147

1 rotation

56 peaks (pulse)

0V

No pulse (No gear tooth)

SAPH31J191700145

4. After measurement, stop the engine.

NO • Engine speed main senor malfunction

• Flywheel signal hole abnormal

YES

Bad contact of connector

[S5LC0033E04] [0518CsCshWbYs]
17–118 ENGINE DIAGNOSIS CODE

DTC code P0340 [12]

Engine speed main sensor - disconnection
JP31J19170601030

1 Measuring voltage between terminals

1. Set the starter switch to "OFF" position.

2. Connect the signal check harness on the engine side.

3. Disconnect the connector on the engine sub harness side.

4. Set the starter switch to "ON" position.

5. Measure voltage between the terminals CGND (E54) and
GVCC (E53).
E53 㧱 Standard value: 4.5-5.5 V

E54

SAPH31J191700148

NO • Bad contact of ECU connectors

• Fault in engine ECU

YES

Fault in engine speed sub sensor

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–119

DTC code P0341 [12]

Engine speed sub sensor - rationality
JP31J19170601031

1 Measuring the input waveform on the engine ECU side

1. Set the starter key to "OFF" and connect the signal check
harness.

2. Start the engine.

3. Measure the waveform between terminals E54 and E73 of the

E54 㧱 signal check harness.

E73 Standard
Seven pulses from excess tooth to excess tooth

SAPH31J191700149

2 rotation

5V

0V

SAPH31J191700150

4. Stop the engine after measuring.

NO Go to [2] Measuring the output waveform on the

sensor side

YES

Defective engine ECU, defective ECU connector

[S5LC0033E04] [0518CsCshWbYs]
17–120 ENGINE DIAGNOSIS CODE

2 Measuring the output waveform on the sensor side

1. Leave the connector of the engine auxiliary rotation sensor

connected.

2. Start the engine.

3. Measure the waveform between terminal SIG of the engine
auxiliary rotation sensor connector (unit harness side) and
terminal GND.

! CAUTION • The connector of the engine auxiliary rotation

sensor is shown from the engagement side.

Standard
Seven pulses from excess tooth to excess tooth

SAPH31J191700151

2 rotation

5V

0V

SAPH31J191700150

4. Stop the engine after measuring.

NO Defective engine auxiliary rotations sensor or

defective pulser

YES

Defective connector contact

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–121

DTC code P0401 [85]

EGR low flow
JP31J19170601032

1 Inspect the air cleaner element

1. Check the air cleaner element for dirt, clogging, or damage.

NO Clean or replace the air cleaner element.

YES

2 Inspect the air flow sensor

1. Check the installation of the air flow sensor.

2. Make sure there is no dirt or damage to the air flow sensor.

NO If damaged, replace the air flow sensor.

YES

3 Inspect the boost pressure sensor

1. Check the installation of the boost pressure sensor.

2. Make sure there is no dirt or damage to the boost pressure

sensor.

NO Clean the boost pressure sensor and install it

properly.
If damaged, replace the boost pressure sensor.

YES

[S5LC0033E04] [0518CsCshWbYs]
17–122 ENGINE DIAGNOSIS CODE

4 Check the boost pressure sensor output signal [Hino-DX]

1. Set the starter switch to the "OFF" position.

2. Connect the machine to Hino-DX.

Select
Engine 3. Start the engine.

4. Select [Engine] from the menu.

5. Select [Actual boost pressure] from the [Data Monitor] menu.

SAPH31J191700152
6. Race the engine from idle to NMR and verify that the boost
pressure output signal varies.
Standard value:
There is no abnormal change in the sensor output
signal.
(The pressure sensor signal response changes
according to the engine speed)

NO Replace the boost pressure sensor.

YES

5 Inspect the intake air temperature sensor (intake manifold)

1. Check the installation of the intake air temperature sensor

(intake manifold).

2. Make sure there is no dirt or damage to the intake air

temperature sensor (intake manifold).

NO Clean the intake air temperature sensor (intake

manifold) and install it properly.
If damaged, replace the intake air temperature
sensor (intake manifold).

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–123

6 Inspect the intake air temperature sensor (intake manifold) unit

1. Set the starter switch to the "OFF" position.

THG E2
2. Disconnect the intake air temperature sensor (intake manifold)
connector.

3. Use the electrical tester to measure the resistance between the

terminals of the intake air temperature sensor (intake manifold).

Measurement Tester
Standard values
conditions connections
SAPH31J191700153

Intake air
20 qC {68 qF}:
temperature
Starter switch: 7.336 – 5.794 k:
sensor (intake
OFF 50 qC {122 qF}:
manifold)
2.435 – 2.41 k:
THG – E2

NO Replace the intake air temperature sensor (intake

manifold).

YES

[S5LC0033E04] [0518CsCshWbYs]
17–124 ENGINE DIAGNOSIS CODE

7 Inspect the response delay of the EGR valve [Hino-DX]

1. Select [Check functions] and then [EGR check] from the menu,
then inspect the response delay at the Target EGR position and
(1) Actual EGR position.

(2) ! CAUTION • Perform the inspection while the engine is

stopped to avoid damages.

<Inspection procedure>
1. Select [Check functions].
2. Select [EGR check].
(3) 3. Click [Check start].
4. Click [EGR opening UP]:
• Check each step from 0 % – 100 % of the time lag (following
(4) (5) characteristics) of the target EGR valve opening and actual
EGR valve opening.
5. Click [EGR opening DOWN]:
• Check each step from 100 % – 0 % of the time lag (following
characteristics) of the target EGR valve opening and actual
EGR valve opening.
SAPH31J191700154

NOTICE • In EGR openings from 0 % – 100 %, 1 step

corresponds to a 10 % change.

Standard values

From the Target EGR position to the Actual EGR

position, the response delay should be within 5
seconds.

NO Replace the EGR valve.

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–125

8 Inspect the EGR cooler

1. Check if soot is obstructing the inlet/outlet of the EGR cooler

gas passageway.

2. Check if there are foreign substances stuck to the EGR cooler

coolant passageway.

3. Check the EGR cooler coolant passageway for obstruction due

to deformation or other damage.

4. Check if coolant is leaking from the EGR cooler.

NO Remove the soot in the inlet/outlet of the gas

passageway, or repair or replace the faulty part.

YES

9 Inspect the EGR valve

1. Check the EGR valve for damage due to incursion of foreign

substances.

2. Check if the inlet/outlet of the exhaust gas passageway is

obstructed by soot.

NO Remove foreign substances and clean the

passageway.
Replace the EGR valve if it is damaged.

YES

10 Inspect the SCV

1. Perform an SCV test and a malfunction reproduction test.

• For a detailed procedure, refer to the separate "SCV free
acceleration test" in the following pages.

NO Repair or replace the faulty part.

YES

[S5LC0033E04] [0518CsCshWbYs]
17–126 ENGINE DIAGNOSIS CODE

11 Inspect the injector [Hino-DX]

Check the injection quantity and the rotational fluctuation.

1. Start the engine.

2. Select [Injection quantity] from [Data Monitor] on Hino-DX

menu and measure the fuel injection quantity.

3. Select [Engine speed] from [Data Monitor] on Hino-DX menu

and measure the engine speed fluctuation.

Standard value

Engine speed (No load) Injection quantity

(r/min) (q)
800 10 to 30

NO Replace the injector.

YES

12 Check the DTC detected (Engine ECU) [Hino-DX]

1. Perform engine warm-up. (engine coolant temperature: 60 qC

{140 qF} or more)

Select 2. Stop the engine.

Engine
3. Set the starter switch to the "ON" position.

4. Select [Engine] and check if P0401 has been detected in [Fault

Information].

SAPH31J191700155
NO Replace the engine ECU.

YES

Replace the engine ECU.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–127

DTC code P0540 [53]

Air intake heater circuit malfunction
JP31J19170601033

1 Measurement of resistance between terminals

1. Set the starter key to "OFF" and connect the signal check
harness.
2. Disconnect the ECU side connector of the signal check
㨂 V harness and measure the resistance between terminals.
V24 V59

Terminal to measure the resistance

V39 V79, + Side - Side
V80
V24 V39, V59, V79, V80

Standard value: 25 r 2.5 :

SAPH31J191700156

Signal check harness

E
Heater relay C
U

SAPH31J191700157

NO [2] Go to measurement of relay resistance

YES

Engine ECU failure, ECU connector failure

[S5LC0033E04] [0518CsCshWbYs]
17–128 ENGINE DIAGNOSIS CODE

2 Measurement of relay resistance

1. Remove the heater relay and measure the resistance between

terminals (parts side).

Standard value: 24.8 r 0.5 :

SAPH31J191700158

NO Heater relay failure

YES

Harness failure, connector failure

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–129

DTC code P0545 [27]

DOC downstream temperature sensor - out of range (Out of range low)
JP31J19170601034

1 Measuring resistance between sensor terminals

1. Set the starter to the "OFF" position.

2. Disconnect the DOC downstream temperature sensor

connector.
3. Measure resistance between the terminals TEX3 and GND3 of
GND3 TEX3 the DOC downstream temperature sensor.

NOTICE • If it is difficult to check only the sensor,

proceed to Step 3.

Standard value

Temperature (qC{qF}) Resistance

SAPH31J191700159
20 {68} 13.7 - 29.8 k:

50 {122} 7.13 - 13.7 k:

80 {176} 4.1 - 7.13 k:

NO Faulty DOC downstream temperature sensor

YES

2 Measuring voltage between sensor terminals

1. Set the starter switch to "ON" position.

2. Measure voltage between the terminals LCY and LCZ of the
LCZ LCY DOC downstream temperature sensor connector (engine sub
harness side).
Standard value: 4.5-5.5 V

SAPH31J191700160

NO Proceed to 4

YES

Bad contact of connectors

[S5LC0033E04] [0518CsCshWbYs]
17–130 ENGINE DIAGNOSIS CODE

3 Measuring resistance between terminals

1. Set the starter switch to "OFF" position.

V46 V69 2. Connect the signal check harness on the unit side.
V
3. Disconnect the connector on the engine ECU side.

4. Measure resistance between the terminals ET3+ (V69) and

ADG9 (V46).

Standard value
SAPH31J191700161

Temperature (qC{qF}) Resistance

20 {68} 13.7 - 29.8 k:

50 {122} 7.13 - 13.7 k:

80 {176} 4.1 - 7.13 k:

NO • Faulty DOC downstream temperature sensor

• Faulty harness
• Faulty sensor connector

YES

Fault in engine ECU

4 Measuring voltage between terminals

1. Set the starter switch to "OFF" position.

V46
V69 2. Connect the signal check harness on the unit side.
V
3. Set the starter switch to "ON" position.

4. Measure voltage between the terminals ET3+ (V69) and ADG9

(V46).
Standard value: 4.5-5.5 V

SAPH31J191700162

NO • Fault in engine ECU

• Faulty ECU connector

YES

Fault in harness

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–131

DTC code P0546 [27]

DOC downstream temperature sensor - out of range
(Out of range high)
JP31J19170601035

1 Measuring resistance between sensor terminals

1. Set the starter to the "OFF" position.

2. Disconnect the DOC downstream temperature sensor

connector.
3. Measure resistance between the terminals TEX3 and GND3 of
GND3 TEX3 the DOC downstream temperature sensor.

NOTICE • If it is difficult to check only the sensor,

proceed to Step 3.

Standard value

Temperature (qC{qF}) Resistance

SAPH31J191700159
20 {68} 13.7 - 29.8 k:

50 {122} 7.13 - 13.7 k:

80 {176} 4.1 - 7.13 k:

NO Faulty DOC downstream temperature sensor

YES

2 Measuring voltage between sensor terminals

1. Set the starter switch to "ON" position.

2. Measure voltage between the terminals LCY and LCZ of the
LCZ LCY DOC downstream temperature sensor connector (engine sub
harness side).
Standard value: 4.5-5.5 V

SAPH31J191700160

NO Proceed to 4

YES

Bad contact of connectors

[S5LC0033E04] [0518CsCshWbYs]
17–132 ENGINE DIAGNOSIS CODE

3 Measuring resistance between terminals

1. Set the starter switch to "OFF" position.

V46 V69 2. Connect the signal check harness on the unit side.
V
3. Disconnect the connector on the engine ECU side.

4. Measure resistance between the terminals ET3+ (V69) and

ADG9 (V46).

Standard value
SAPH31J191700161

Temperature (qC{qF}) Resistance

20 {68} 13.7 - 29.8 k:

50 {122} 7.13 - 13.7 k:

80 {176} 4.1 - 7.13 k:

NO • Faulty DOC downstream temperature sensor

• Faulty harness
• Faulty sensor connector

YES

Fault in engine ECU

4 Measuring voltage between terminals

1. Set the starter switch to "OFF" position.

V46
V69 2. Connect the signal check harness on the unit side.
V
3. Set the starter switch to "ON" position.

4. Measure voltage between the terminals ET3+ (V69) and ADG9

(V46).

Standard value: 4.5-5.5 V

SAPH31J191700162

NO • Fault in engine ECU

• Faulty ECU connector

YES

Fault in harness

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–133

DTC code P0617 [45]

Starter switch - rationality
JP31J19170601036

1 Inspection

1. Prior check and check to see that there is no abnormal.

2. Use Hino-DX to call up the start switch on the data monitor,

then confirm that the switch is synchronized with the actual
start switch operation.

NO Repair the trouble

YES

2 Check the starter switch

1. Check the starter switch and check to see that there is no

abnormal.

NO • Trouble of connector
• Trouble of harness

YES

Clear and recheck the DTC

[S5LC0033E04] [0518CsCshWbYs]
17–134 ENGINE DIAGNOSIS CODE

DTC code P0628 [73]

Suction control valve for fuel supply pump - circuit (circuit low)
DTC code P0629 [75]
Suction control valve for fuel supply pump - circuit (circuit high)
JP31J19170601037

1 Measurement of resistance between terminals

1. Set the starter key to "OFF", connect the signal check harness
and disconnect the ECU side connector.
2. Measure the resistance between terminals of the signal check
E9
㧱 E10 harness.

Terminal to measure the resistance

E30 E9 (SPV1) l E30 (SP2S)
E29
E9 (SPV1) l E10 (SPV2)
E29 (SP1S) l E30 (SP2S)
E29 (SP1S) l E10 (SPV2)

SAPH31J191700039 Standard value: 7.9 r 0.25 : (20 qC{68 qF})

NO [2] Go to measurement of resistance between

terminals

YES

[4] Go to measurement of voltage between terminals

2 Measurement of resistance between terminals

1. Disconnect the SCV harness and measure the resistance

between terminals (parts side).

Standard value: 7.9 r 0.25 : (20 qC{68 qF})

SAPH31J191700163

NO Failure of SCV

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–135

3 Measurement of resistance between terminals

1. Measure the resistance between terminals of the signal check

SCVL harness and the SCV connector (at engine sub harness side).
㧱 E10

Terminal to measure the resistance

Signal check harness SCV
E30
E10 (SPV2)
No.1 (SCVL)
E30 (SP2S)
E9 (SPV1)
No.2 (SCVH)
E29 (SP1S)
SAPH31J191700164

Standard value: 1 : or less

SCVH NO Harness disconnection, bad contact of harness

㧱 E9
connector

E29

SAPH31J191700165

YES

4 Measurement of voltage between terminals

1. Connect the signal check harness on the engine ECU side.

2. Turn "ON" the starter key.

3. Measure voltage between terminal V59 and terminals E10/E30
of the signal check harness.
㨂 V59 㧱 E10

! CAUTION • After turning "ON" the starter key, take

measurements within 40 seconds.
E30
Standard value: Pulse wave-shape by 24V l 0V

SAPH31J191700166

4. Stop the engine after measuring.

NO Fault in engine ECU (ECU connector)

YES

Fault in engine ECU

[S5LC0033E04] [0518CsCshWbYs]
17–136 ENGINE DIAGNOSIS CODE

DTC code P0642 [5]

ECU sensor supply 1 failure (low)
JP31J19170601038

1 Inspection item

1. Boost pressure sensor connector, Intake throttle valve position

sensor 1 connector, common rail pressure sensor 1 connector,
Camshaft position sensor connector by removing each of one,
P0642 fault code disappears things check.

NOTICE • When sensor power supply 1 fails, the trouble

code of P0122, P0193, P0237, P0340 occurs
other than a trouble code of P0642.

NO Proceed to 2

YES

2 Measure the continuity between terminals

1. Set the starter switch to "OFF" position.

2. Connect the signal check harness.

3. Disconnect the connector on the engine sub harness side and

sensor side (Boost pressure sensor, Intake throttle valve
position sensor, common rail pressure sensor (main),
Camshaft position sensor).
4. Measure the resistance between the terminals AVC2 (E33),
E53 E56 GVCC (E53), AVC4 (V51) and AGD1 (E56).
㨂 E33 㧱 㧱
V51
Terminal to measure the resistance
+ Side - Side
E33
E53 E56
V51

SAPH31J191700167 Standard value: f :

NO Faulty harness

YES

Fault in engine ECU

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–137

DTC code P0643 [5]

ECU sensor supply 1 failure (high)
JP31J19170601039

1 Measure the voltage

1. Set the starter switch to "OFF" position.

2. Connect the signal check harness.

3. Set the starter switch to "ON" position.

4. Measure the voltage between the terminals AVC2 (E33),
E53 E56 GVCC (E53), AVC4 (V51) and AGD1 (E56).
㨂 E33 㧱 㧱
V51
Terminal to measure the voltage
+ Side - Side
E33
E53 E56
V51

SAPH31J191700168 Standard value: 4.9-5.1 V

NO Faulty harness

YES

Fault in engine ECU

[S5LC0033E04] [0518CsCshWbYs]
17–138 ENGINE DIAGNOSIS CODE

DTC code P0652 [5]

ECU sensor supply 2 failure (low)
JP31J19170601040

1 Inspection item

1. Common rail pressure sensor (sub) connector, Differential

pressure sensor connector, P.T.O. accelerator sensor
connector by removing each of one, P0652 fault code
disappears things check.

NOTICE • When sensor power supply 2 fails, the trouble

code of P1198, P1428 occurs other than a
trouble code of P0652.

NO Proceed to 2

YES

Faulty sensor fault code disappears when remove

2 Measure the continuity between terminals

1. Set the starter switch to "OFF" position.

2. Connect the signal check harness.

3. Disconnect the connector on the engine sub harness side.

4. Measure the resistance between the terminals AVC1 (E13),
V50 AVC3 (V50), AVC5 (V71) and AGD1 (E56).
㨂 㧱 E56 㧱

V71
Terminal to measure the resistance
+ Side - Side
E13
E33
V50 E56
V71

SAPH31J191700169 Standard value: f :

NO Faulty harness

YES

Fault in engine ECU

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–139

DTC code P0653 [5]

ECU sensor supply 2 failure (high)
JP31J19170601041

1 Measure the voltage

1. Set the starter switch to "OFF" position.

2. Connect the signal check harness.

3. Set the starter switch to "ON" position.

4. Measure the voltage between the terminals AVC1 (E13), AVC3
V50 (V50), AVC5 (V71) and AGD1 (E56).
㨂 㧱 E56 㧱
Terminal to measure the voltage
V71
+ Side - Side
E13
E13
V50 E56
V71

SAPH31J191700170 Standard value: 4.9-5.1 V

NO Faulty harness

YES

Fault in engine ECU

[S5LC0033E04] [0518CsCshWbYs]
17–140 ENGINE DIAGNOSIS CODE

DTC code P0686 [51]

ECU Power relay control circuit high
JP31J19170601042

1 Measuring voltage between terminals

1. Set the starter switch to "OFF" and connect the signal check
harness.

2. Set the starter to "ON" position.

3. Measure the voltage between MRL1 (V3), MRL2 (V23)
terminals and Chassis GND.
V3 V
V23 Standard value: 19 V or more

SAPH31J191700171

NO Fault in harness or mechatronic controller

YES

Fault in engine ECU

Malfunction of ECU connectors

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–141

DTC code P06D3 [5]

Air flow sensor power supply failure Short to GND
JP31J19170601043

1 Check a malfunction code

1. Set the starter switch to "OFF" position.

2. Disconnect the air flow sensor connector.

3. Set the starter switch to "ON" position.

4. Check that P06D3 [5] is no longer present.

NO Proceed to 2

YES

Faulty air flow sensor

2 Check the continuity in harness

1. Set the starter switch to "OFF" position.

2. Connect the signal check harness.

3. Measure the resistance between the terminals AFVB (E12)
and PGD4 (V80).
㧱 㨂
E12
V80 Standard value: f :

SAPH31J191700172

NO Proceed to 3

YES

Faulty harness

[S5LC0033E04] [0518CsCshWbYs]
17–142 ENGINE DIAGNOSIS CODE

3 Measure the voltage between terminals

1. Set the starter switch to "ON" position.

2. Measure the voltage between the terminals AFVB (E12) and
PGD4 (V80).
㧱 㨂
E12
V80 Standard value: 11.5-13.5 V

SAPH31J191700173

NO Fault in engine ECU

YES

Faulty ECU connector

Faulty harness

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–143

DTC code P06D4 [5]

Air flow sensor power supply failure (high)
JP31J19170601044

1 Measure the voltage between terminals

1. Set the starter switch to "OFF" position.

2. Connect the signal check harness on the engine side.

3. Set the starter switch to "ON" position.

4. Measure the voltage between the terminals AFVB (E12) and
E56
AGD1 (E56).
㧱 㧱
E12
Standard value: 11.5-13.5 V

SAPH31J191700174

NO Proceed to 2

YES

Fault in engine ECU

2 Check the battery

1. Check the battery voltage.

Standard value: 19 V or more

NO Check the battery

YES

Fault in engine ECU

[S5LC0033E04] [0518CsCshWbYs]
17–144 ENGINE DIAGNOSIS CODE

DTC code P1133 [23]

P.T.O accelerator sensor (Hi)
JP31J19170601045

1 Measuring resistance between volume for emergency accelerator terminals

1. Set the starter switch to "OFF" position.

2. Disconnect the volume for emergency accelerator connector.

3. Measure resistance between the terminals of volume for
5V emergency accelerator connector.

NOTICE • If it is difficult to check only the sensor,

proceed to Step 4.
GND
SIG Standard value

Resistance
Volume Terminals
value
SAPH31J191700175
GND - SIG 0:
Lo
GND - 5 V 3.1 k:

GND - SIG 2 k:
Hi
SIG - 5 V 1.1 k:

NO Faulty volume for emergency accelerator

YES

2 Measuring resistance between terminals

1. Measure resistance between the terminals SIG and GND of the

volume for emergency accelerator connector (engine sub
SIG GND
harness side).

NOTICE • If it is difficult to check only the sensor,

proceed to Step 5.

Standard value: 740-760 k:

SAPH31J191700176

NO • Fault in harness
• Irregular contact of connectors

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–145

3 Measuring resistance between sensor terminals

1. Measure resistance between the terminals 5V and SIG of the

5V
volume for emergency accelerator connector (engine sub
SIG harness side).

Standard value: f :

SAPH31J191700177

NO Faulty harness

YES

4 Measuring resistance between terminals

1. Connect the signal check harness on the unit side.

2. Disconnect the connector on the engine ECU side.

3. Measure resistance between the terminals ASCS (V68) and
AVC5 (V71).
㨂
V68
V71 Standard value: f :

SAPH31J191700178

NO Faulty harness

YES

[S5LC0033E04] [0518CsCshWbYs]
17–146 ENGINE DIAGNOSIS CODE

5 Measuring resistance between terminals

1. Connect the emergency accelerator volume and set [Lo]

position.
2. Measure resistance between the terminals ASCS (V68) and
AVC5 (V71).
㨂
V68
V71 Standard value: 1.1 k: or more

SAPH31J191700178

NO Fault in emergency accelerator connector terminal

YES

6 Measuring resistance between terminals

1. Measure resistance between the terminals ADG7 (V45) and

ASCS (V68).
V45 㨂 V68
Standard value: 2: less than

SAPH31J191700179

NO • Faulty harness
• Irregular contact of connectors

YES

Fault in engine ECU

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–147

DTC code P1197 [74]

Common rail pressure sensor (sub) - out of range (Out of range low)
DTC code P1198 [74]
Common rail pressure sensor (sub) - out of range (Out of range high)

JP31J19170601046

1 Inspect the common rail pressure sensor connector

1. Check the connection of the common rail pressure sensor

connector (Looseness and poor contact).

NO Connect securely, repair if needed.

YES

2 Inspect the common rail pressure sensor

1. Check the installation of the common rail pressure sensor.

2. Make sure there is no dirt or damage to the common rail

pressure sensor.

NO Clean the common rail pressure sensor and install it

properly.
If damaged, replace the common rail pressure
sensor.

YES

[S5LC0033E04] [0518CsCshWbYs]
17–148 ENGINE DIAGNOSIS CODE

3 Inspect the common rail pressure sensor unit

1. Set the starter switch to "OFF" position.

2. Disconnect the common rail pressure sensor connector.

3. Check continuity between the terminals PCR+(sub) and
PCR(sub) of the common rail pressure sensor (sub) connector.
PCR- PCR PCR+
(main) (main) (main)
Standard value: 1.05-3.55 k:
PCR+ PCR PCR-
(sub) (sub) (sub)

SAPH31J191700180

4. Check continuity between the terminals PCR(sub) and PCR-

(sub) of the common rail pressure sensor (sub) connector.
PCR- PCR PCR+
(main) (main) (main)
Standard value: 6.7-18.7 k:
PCR+ PCR PCR-
(sub) (sub) (sub)

SAPH31J191700181

NO Fault in common rail pressure sensor

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–149

4 Inspect short-circuit of the common rail pressure sensor harness

1. Set the starter switch to the "OFF" position.

2. Disconnect the engine ECU connector.

3. Check continuity between the terminals ECU GND and VCC of
the common rail pressure sensor (sub) connector on the
VCC
ECU GND
harness side.

NOTICE • If it is difficult to check only the sensor,

proceed to step 3.

Standard value: f :

SAPH31J191700182

4. Check continuity between the terminals ECU GND and SIG of

SIG the common rail pressure sensor (sub) connector on the
ECU GND
harness side.

Standard value: f :

SAPH31J191700183

NO Fault in harness

YES

[S5LC0033E04] [0518CsCshWbYs]
17–150 ENGINE DIAGNOSIS CODE

5 Inspect the short-circuit of the common rail pressure sensor harness

1. Set the starter key to "OFF" and connect the signal check
harness on the engine ECU.
2. Measure resistance between the terminals AVC1 (E13) and
ECU GND.
㧱
E13 ECU GND Standard value: f :

SAPH31J191700184

3. Measure resistance between the terminals PCR1 (E49), PCR2

㧱 (E68) and ECU GND.
E49
E68 ECU GND Standard value: f :

SAPH31J191700185

NO Fault in harness

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–151

6 Inspect disconnection of the common rail pressure sensor harness

1. Connect the signal check harness on the engine side.

2. Disconnect the connector on the engine ECU side.

3. Connect the common rail pressure sensor connector.

4. Measure resistance between the terminals AVC1 (E13) and
AGD1 (E56).
E13 㧱 㧱 E56
Standard value: 2 : or more

SAPH31J191700186

5. Measure resistance between the terminals PCR1 (E49), PCR2

E49 (E68) and AGD1 (E56).
E56 㧱 E68
Standard value: 2 : or more

SAPH31J191700187

NO Fault in common rail pressure sensor

YES

[S5LC0033E04] [0518CsCshWbYs]
17–152 ENGINE DIAGNOSIS CODE

7 Inspect the common rail pressure sensor signal circuit

1. Connect the signal check harness on the engine ECU side.

2. Measure resistance between the terminals AVC1 (E13), PCR1
(E49) and PCR2 (E68).
E13
㧱 㧱 E49
E68 Standard value: 200-250 k:

SAPH31J191700188

NO Fault in engine ECU (ECU connector)

YES

8 Measuring voltage between terminals

1. Set the starter switch to "ON" position.

2. Measure voltage between the terminals AVC1 (E13) and AGD1
(E56).
E13
㧱 㧱 E56
Standard value: 4.5-5.5 V

SAPH31J191700189

NO Fault in engine ECU (ECU connector)

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–153

9 Check the DTC detected (Engine ECU) [Hino-DX]

1. Perform an engine warm-up. (engine coolant temperature: 60

qC {140 qF} or more)

Select 2. Stop the engine and set the starter switch to the "OFF"
Engine position.

3. Connect the machine to Hino-DX.

4. Set the starter switch to the "ON" position.

SAPH31J191700190
5. Select [Engine] and check if P1197 or P1198 has been
detected in [Fault Information].

NO Replace the engine ECU.

YES

Procedure completed.

[S5LC0033E04] [0518CsCshWbYs]
17–154 ENGINE DIAGNOSIS CODE

DTC code P119F [74]

Common rail pressure sensor - rationality
JP31J19170601047

1 Check the DTC detected 1 (Engine ECU) [Hino-DX]

1. Set the starter switch to the "OFF" position.

2. Connect the machine to Hino-DX.

Select 3. Set the starter switch to the "ON" position.

Engine

4. Select [Engine] and check if any DTC other than P119F (for
example, P0192, P0193) have been detected in [Fault
Information].

SAPH31J191700191
NO Go to the diagnostic procedure of a related DTC.

YES

2 Inspect the common rail pressure sensor connector

1. Check the connection of the common rail pressure sensor

connector (Looseness and poor contact).

NO Connect securely, repair if needed.

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–155

3 Inspect the sensor power supply

1. Set the starter switch to the "OFF" position.

2. Connect the signal check harness to the engine ECU.

3. Disconnect the common rail pressure sensor connector.

4. Set the starter switch to the "ON" position.

5. Use the electrical tester to measure the voltage between the
E E49 terminals of the engine ECU (signal check harness).
E65
E64
Terminal to measure the voltage
+ Side - Side
PCR3 (E64)
PCR1 (E49)
PCR4 (E65)
PCR3 (E64)
PCR2 (E68)
PCR4 (E65)
SAPH31J191700192

Standard value: 0.3-0.7 V

E NO Replace the engine ECU.

E65 E68
E64

SAPH31J191700193

YES

[S5LC0033E04] [0518CsCshWbYs]
17–156 ENGINE DIAGNOSIS CODE

4 Inspect the signal of the common rail pressure sensor

1. Set the starter switch to the "OFF" position.

2. Connect the common rail pressure sensor connector.

3. Set the starter switch to the "ON" position.

4. Use the electrical tester to measure the voltage between the
E13 E terminals of the engine ECU (signal check harness).
E49
E56 E
Terminal to measure the voltage
+ Side - Side

E68
AVC1 (E13)
PCR1 (E49) AGD1 (E56)
PCR2 (E68)
AVC2 (E33)
SAPH31J191700194
PCR3 (E64) AGD2 (E76)
PCR4 (E65)

Standard value: 4.5-5.5 V

E65
E33 E E E76 NO Replace the common rail pressure sensor.
E64

SAPH31J191700195

YES

5 Check the DTC detected 2(Engine ECU) [Hino-DX]

1. Perform engine warm-up. (engine coolant temperature: 60 qC

{140 qF} or more)

Select 2. Stop the engine and set the starter switch to the "ON" position.
Engine
3. Select [Engine] and check if P119F has been detected in [Fault
Information].

NO Replace the engine ECU.

SAPH31J191700196

YES

Procedure completed.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–157

DTC code P1211 [68]

Fuel injector driver circuit 1 - circuit (Circuit low)
JP31J19170601048

1 Measuring resistance between terminals

1. Set the starter switch to "OFF" and connect the signal check
harness.

2. Disconnect the signal check harness connector on the engine

ECU side.
3. Measure the resistance between the terminals of ECU
E14 㧱 connector.
E34

+ side - side

ECU CASE GND IJ1+ (E14)

(ECU MOUNTING BOLT) ECU case GND
I1+S (E34)

Standard value: f :

SAPH31J191700197

NO Proceed to (3)

YES

2 Check of failure code

1. Turn the starter switch to "OFF" position.

Reconnect all the connectors.

2. Start the engine and erase the DTC.

3. If the same DTC is displayed, replace ECU. If no DTC is

displayed, a temporary failure would have occurred.

[S5LC0033E04] [0518CsCshWbYs]
17–158 ENGINE DIAGNOSIS CODE

3 Measurement of resistance between injector terminals

1. Turn the starter switch to "OFF" position (with all connectors of

ECU disconnected).

2. Disconnect the injector connector that is located on the front

side of the cam housing.
3. Measure the resistance between the pins of injector connector
(engine sub harness side) and ECU case GND.

1 2 3 4 ! CAUTION • Measure the resistance of this connector from

5 6 7 8 the connector terminals (female).
9 10 11 12 • Do not damage the connector terminals.

A ARROW VIEW A Failure position

(JUDGMENT DIRECTION)
(breaking + side - side
SAPH31J191700198 position)

11
No.1 injector
12

3
No.2 injector ECU case GND
4

5
No.3 injector
6

Standard value: f :

NO Fault in harness
(It is defective the harness which resistance value is
out of the standard)

YES

Check the harness in the head cover

(A short-circuit would occur between the harness in the head cover and the GND line)

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–159

DTC code P1212 [68]

Fuel injector driver circuit 1 - circuit (Circuit high)
JP31J19170601049

1 Measuring voltage between terminals

1. Set the starter switch to "OFF" and connect the signal check
harness.

2. Turn "ON" the starter switch.

3. Measure the voltage between the terminals of ECU connector
E14 E and ECU case GND.
E34
! CAUTION • Make sure that failure code which is
concerned with engine ECU is not output.
ECU CASE GND
(ECU MOUNTING BOLT)
+ side - side

IJ1+ (E14)
ECU case GND
I1+S (E34)
SAPH31J191700199

Standard value: Less than battery voltage x 3/4 V

NO Proceed to (3)

YES

2 Check of failure code

1. Turn the starter switch to "OFF" position.

Reconnect all the connectors.

2. Start the engine and erase the DTC.

3. If the same DTC is displayed, replace ECU. If no DTC is

displayed, a temporary failure would have occurred.

[S5LC0033E04] [0518CsCshWbYs]
17–160 ENGINE DIAGNOSIS CODE

3 Measurement of voltage between injector terminals

1. Turn the starter switch to "OFF" position.

2. Disconnect the injector connector that is located on the front

side of the cam housing. Turn the starter switch to "ON"
position.
3. Measure the voltage between the pins of injector connector
(engine sub harness side) and ECU case GND.

1 2 3 4 ! CAUTION • Measure the voltage of this connector from

5 6 7 8 the connector terminals (female).
9 10 11 12 • Do not damage the connector terminals.
• Make sure that failure code which is
A ARROW VIEW A concerned with engine ECU is not output.
(JUDGMENT DIRECTION)

SAPH31J191700200
Failure position
(breaking + side - side
position)

No.1 injector 11

No.2 injector 3 ECU case GND

No.3 injector 6

Standard value: Less than battery voltage x 3/4 V

NO Fault in harness
(It is defective the harness which voltage value is out
of the standard)

YES

Check the harness in the head cover

(A short-circuit would occur between the harness in the head cover and the power source line)

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–161

DTC code P1214 [68]

Fuel injector driver circuit 2 - circuit (Circuit low)
JP31J19170601050

1 Measuring resistance between terminals

1. Set the starter switch to "OFF" and connect the signal check
harness.

2. Disconnect the signal check harness connector on the engine

ECU side.
3. Measure the resistance between the terminals of ECU
E E18 connector.
E38

+ side - side

ECU CASE GND IJ2+ (E18)

(ECU MOUNTING BOLT) ECU case GND
I2+S (E38)

Standard value: f :

SAPH31J191700201

NO Proceed to (3)

YES

2 Check of failure code

1. Turn the starter switch to "OFF" position.

Reconnect all the connectors.

2. Start the engine and erase the DTC.

3. If the same DTC is displayed, replace ECU. If no DTC is

displayed, a temporary failure would have occurred.

[S5LC0033E04] [0518CsCshWbYs]
17–162 ENGINE DIAGNOSIS CODE

3 Measurement of resistance between injector terminals

1. Turn the starter switch to "OFF" position (with all connectors of

ECU disconnected).

2. Disconnect the injector connector that is located on the front

side of the cam housing.
3. Measure the resistance between the pins of injector connector
(engine sub harness side) and ECU case GND.

1 2 3 4 ! CAUTION • Measure the resistance of this connector from

5 6 7 8 the connector terminals (female).
9 10 11 12 • Do not damage the connector terminals.

A ARROW VIEW A Failure position

(JUDGMENT DIRECTION)
(breaking + side - side
SAPH31J191700202 position)

7
No.4 injector
8

1
No.5 injector ECU case GND
2

9
No.6 injector
10

Standard value: f :

NO Fault in harness
(It is defective the harness which resistance value is
out of the standard)

YES

Check the harness in the head cover

(A short-circuit would occur between the harness in the head cover and the GND line)

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–163

DTC code P1215 [68]

Fuel injector driver circuit 2 - circuit (Circuit high)
JP31J19170601051

1 Measuring voltage between terminals

1. Set the starter switch to "OFF" and connect the signal check
harness.

2. Turn "ON" the starter switch.

3. Measure the voltage between the terminals of ECU connector
E E18 and ECU case GND.
E38
! CAUTION • Make sure that failure code which is
concerned with engine ECU is not output.
ECU CASE GND
(ECU MOUNTING BOLT)
+ side - side
IJ2+ (E18)
ECU case GND
I2+S (E38)
SAPH31J191700203
Standard value: Less than battery voltage x 3/4 V

NO Proceed to (3)

YES

2 Check of failure code

1. Turn the starter switch to "OFF" position.

Reconnect all the connectors.

2. Start the engine and erase the DTC.

3. If the same DTC is displayed, replace ECU. If no DTC is

displayed, a temporary failure would have occurred.

[S5LC0033E04] [0518CsCshWbYs]
17–164 ENGINE DIAGNOSIS CODE

3 Measurement of voltage between injector terminals

1. Turn the starter switch to "OFF" position.

2. Disconnect the injector connector that is located on the front

side of the cam housing. Turn the starter switch to "ON"
position.
3. Measure the voltage between the pins of injector connector
(engine sub harness side) and ECU case GND.

1 2 3 4 ! CAUTION • Measure the voltage of this connector from

5 6 7 8 the connector terminals (female).
9 10 11 12 • Do not damage the connector terminals.
• Make sure that failure code which is
A ARROW VIEW A concerned with engine ECU is not output.
(JUDGMENT DIRECTION)

SAPH31J191700204 Failure position

(breaking + side - side
position)
No.4 injector 7
No.5 injector 2 ECU case GND
No.6 injector 10

Standard value: Less than battery voltage x 3/4 V

NO Fault in harness
(It is defective the harness which voltage value is out
of the standard)

YES

Check the harness in the head cover

(A short-circuit would occur between the harness in the head cover and the power source line)

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–165

DTC code P1427 [28]

Differential pressure sensor - out of range (Out of range low)
JP31J19170601052

1 Measuring resistance between sensor terminals

1. Set the starter switch to "OFF" position.

2. Disconnect the differential pressure sensor connector.

3. Check continuity between the terminals VCC and GND of the
VCC GND differential pressure sensor connector.

Standard value: 2 - 15 k:

SAPH31J191700205

4. Check continuity between the terminals VOUT and GND of the

VOUT GND differential pressure sensor connector.

Standard value: 2 - 15 k:

SAPH31J191700206

NO Faulty differential pressure sensor

YES

[S5LC0033E04] [0518CsCshWbYs]
17–166 ENGINE DIAGNOSIS CODE

2 Check the continuity of harness

1. Disconnect the engine ECU connector.

2. Check continuity between the terminals ECU GND and VCC of
the differential pressure sensor connector on the engine sub
VCC
GROUND
harness side.

Standard value: f :

SAPH31J191700207

3. Check continuity between the terminals ECU GND and SIG of

SIG the differential pressure sensor connector on the engine sub
GROUND
harness side.

Standard value: f :

SAPH31J191700208

NO Fault in harness

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–167

3 Measuring resistance between terminals

1. Disconnect the connector on the engine ECU side.

2. Disconnect the differential pressure sensor.

3. Measure resistance between the terminals AVC5 (V71) and
㨂 V46 ADG9 (V46).

V71 Standard value: f :

SAPH31J191700209

4. Measure resistance between the terminals EXPS (V70) and

AGD9 (V46).
㨂 V46
V70 Standard value: f :

SAPH31J191700210

NO • Fault in harness
• Irregular contact of connector

YES

[S5LC0033E04] [0518CsCshWbYs]
17–168 ENGINE DIAGNOSIS CODE

4 Measuring resistance between terminals

1. Set the starter switch to "OFF" position.

2. Also connect the signal check harness on the engine ECU

side.

3. Disconnect the differential pressure sensor connector.

4. Measure resistance between the terminals AVC5 (V71) and
㨂 EXPS (V70).
V70
V71 Standard value: 200-250 k:

SAPH31J191700211

NO Fault in engine ECU

YES

5 Measuring voltage between terminals

1. Set the starter switch to "ON" position.

2. Measure voltage between the terminals AVC5 (V71) and AGD9
㨂 V46 (V46).

V71 Standard value: 4.5-5.5 V

SAPH31J191700212

NO Fault in engine ECU

YES

Clear and recheck the DTC

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–169

DTC code P1428 [28]

Differential pressure sensor - out of range (Out of range high)
JP31J19170601053

1 Measuring resistance between sensor terminals

1. Set the starter switch to "OFF" position.

2. Disconnect the differential pressure sensor connector.

3. Check continuity between the terminals VCC and GND of the
VCC GND differential pressure sensor connector.

Standard value: 2-15 k:

SAPH31J191700205

4. Check continuity between the terminals VOUT and GND of the

VOUT GND differential pressure sensor connector.

Standard value: 2-15 k:

SAPH31J191700206

NO Faulty differential pressure sensor

YES

[S5LC0033E04] [0518CsCshWbYs]
17–170 ENGINE DIAGNOSIS CODE

2 Measuring voltage between sensor terminals

1. Set the starter switch to "ON" position.

2. Check voltage between the terminals VCC and GND of the
VCC GND differential sensor connector on the engine sub harness side.

Standard value: 4.5-5.5 V

SAPH31J191700213

3. Check voltage between the terminals SIG and GND of the

SIG differential sensor connector on the engine sub harness side.
GND
Standard value: 4.5-5.5 V

NO Proceed to 3

SAPH31J191700214

YES

Improper connection of connector

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–171

3 Measuring resistance between terminals

1. Set the starter switch to "OFF" position.

2. Connect the signal check harness on the unit side.

3. Disconnect the connector on the engine ECU side.

4. Measure resistance between the terminals AVC5 (V71) and
㨂 EXPS (V70).
V70
V71 Standard value: f :

SAPH31J191700215

5. Measure resistance between the terminals AGD9 (V46) and

EXPS (V70).
㨂 V46
V70 Standard value: f :

SAPH31J191700216

NO • Improper connection of connector

• Fault in harness

YES

[S5LC0033E04] [0518CsCshWbYs]
17–172 ENGINE DIAGNOSIS CODE

4 Measuring resistance between terminals

1. Disconnect the connector on the engine sub harness side and

㨂 connect the engine ECU side.
V70
V71
2. Measure resistance between the terminals AVC5 (V71) and
EXPS (V70).

Standard value: 200-250 k:

SAPH31J191700217

NO Fault in engine ECU

YES

5 Measuring voltage between terminals

1. Set the starter switch to "ON" position.

2. Measure voltage between the terminals AVC5 (V71) and AGD9
㨂 V46 (V46).

V71 Standard value: 4.5-5.5 V

SAPH31J191700218

3. Measure voltage between the terminals EXPS (V70) and

AGD9 (V46).
㨂 V46
V70 Standard value: 4.5-5.5 V

SAPH31J191700219

NO Fault in engine ECU

YES

Clear and recheck the DTC

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–173

DTC code P1458 [81]

Valve position control failure - DC motor out of range, functional
Valve link failure
Low battery voltage
JP31J19170601054

1 Check the EGR valve link

1. Remove the EGR valve and check for any foreign matters

NO • Remove foreign matters, if any

• Faulty EGR valve

YES

2 Measuring voltage between sensor terminals

1. Set the starter switch to "OFF" position.

2. Disconnect the EGR valve connector.

3. Set the starter switch to "ON" position.

4. Measure voltage between the terminals EGRV and EGRG of
the EGR valve connector (engine sub harness side).
EGRV EGRG

NOTICE • If it is difficult to check only the sensor,

proceed to step 3.

Standard value: 19 V or more

SAPH31J191700220

NO • Faulty harness
• Faulty battery

YES

[S5LC0033E04] [0518CsCshWbYs]
17–174 ENGINE DIAGNOSIS CODE

3 Inspect the EGR valve

1. Connect the PC DIAGNOSIS TOOL (Hino-DX).

2. Set the starter switch to "ON" position.

3. Functional check.

4. Inspect the EGR.

5. For the forcibly driven item, check the data monitor value to see
if the opening of the EGR valve is driven as indicated by the
SAPH31J191700037
specified value.

NO Faulty EGR valve

YES

Fault in harness
Fault in engine ECU

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–175

DTC code P1459 [81]

EGR actuator malfunction 2
JP31J19170601055

1 Use the Hino-DX to inspect the EGR valve

1. Connect the PC DIAGNOSIS TOOL (Hino-DX).

2. Set the starter switch to "ON" position.

3. Functional check.

4. Inspect the EGR.

5. For the forcibly driven item, check the data monitor value to see
if the opening of the EGR valve is driven as indicated by the
SAPH31J191700037
specified value.

NO Faulty EGR valve

YES

Fault in harness
Fault in engine ECU

[S5LC0033E04] [0518CsCshWbYs]
17–176 ENGINE DIAGNOSIS CODE

DTC code P1601 [2]

Fuel Injector adjustment data error
JP31J19170601056

1 Check injector replaced record

1. Check injector replaced record.

Standard
No replace record : Go to YES
Replaced record was found, or not clear : Go to NO

NO Proceed to 3

YES

2 Inspection of QR code

1. Re-input the registration QR code date of the service server.

2. Erase the DTC memory, and recheck DTC code. Confirm that
DTC code P1601 [2] is not displayed.
Standard
Not displayed

NO Proceed to 3

YES

Normal

3 Inspection of QR code

1. Read the QR code date of the injectors using Hino-DX, re-input

QR code date.

2. Erase the DTC memory, and recheck DTC code. Confirm that
DTC code P1601 [2] is not displayed.
Standard
Not displayed

NO Replace engine ECU

SAPH31J191700221

YES

Normal

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–177

DTC code P200C [91]

DPR over temperature
JP31J19170601057

1 Check the DTC detected (Engine) [Hino-DX]

1. Set the starter switch to the "OFF" position.

2. Connect the machine to Hino-DX.

Select
Engine

SAPH31J191700222

3. Set the starter switch to the "ON" position.

4. Select [Engine] and check if any DTC other than P200C (for
example P2032, P2033) has been detected in [Fault
Information].
Standard: Only the DTC code "P200C" has been
displayed.

NO Should any other code(s) be displayed, repair the

malfunction the relevant code(s) indicate before
proceeding to the next step.

YES

2 Inspect the DOC downstream temperature sensor connector

1. Check the connection of the DOC downstream temperature

sensor connector.
Standard: The absence of poor contact.

NO Connect securely or repair if needed.

After that, proceed to the step 3.

YES

[S5LC0033E04] [0518CsCshWbYs]
17–178 ENGINE DIAGNOSIS CODE

3 Inspect the outside of the DOC downstream temperature sensor

1. Check the installation of the DOC downstream temperature

sensor.

2. Inspect the sensing part of the DOC downstream temperature

sensor.
Standard: The absence of dirt or damage.

NO Clean the sensing unit and install it properly.

If damaged, replace the DOC downstream
temperature sensor.
After that, proceed to the step 4.

YES

4 Inspect the DOC downstream temperature sensor unit

1. Set the starter key to the "OFF" position.

2. Disconnect the DOC downstream temperature sensor

connector.
3. Use the electrical tester to measure the resistance between the
GND1 TEX1 terminals of the DOC downstream temperature sensor.

Measurement Tester
Standard values
conditions connections
20°C{68°F}
DOC
13.7 –29.8 Ω
downstream
Starter switch: 50 °C{122 °F}
temperature
OFF 7.13 –13.7 kΩ
SAPH31J191700223 sensor
80 °C{176 °F}
TEX1 – GND1
4.13–7.13kΩ

NO Replace the DOC downstream temperature sensor

and proceed to step 10.

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–179

5 Inspect the DPR downstream temperature sensor connector

1. Check the connection of the DPR downstream temperature

sensor connector.
Standard: The absence of poor contact.

NO Connect securely or repair if needed.

After that, proceed to the step 6.

YES

6 Inspect the outside of the DPR downstream temperature sensor

1. Check the installation of the DPR downstream temperature

sensor.

2. Inspect the sensing part of the DPR downstream temperature

sensor.
Standard: The absence of dirt or damage.

NO Clean the sensing unit and install it properly.

If damaged, replace the DPR downstream
temperature sensor.
After that, proceed to the step 7.

YES

[S5LC0033E04] [0518CsCshWbYs]
17–180 ENGINE DIAGNOSIS CODE

7 Inspect the DPR downstream temperature sensor unit

1. Set the starter switch to the "OFF" position.

2. Disconnect the DPR downstream temperature sensor

connector.
3. Use the electrical tester to measure the resistance between the
THC0 E2 terminals of the DPR downstream temperature sensor.

Measurement Tester
Standard values
conditions connections
20 °C {68 °F}
DPR
13.7 – 29.8 Ω
downstream
Starter switch: 50 °C {122 °F}
temperature
OFF 7.13 – 13.7 kΩ
SAPH31J191700224 sensor
80 °C {176 °F}
THC0 – E2
4.13 – 7.13 kΩ

NO Replace the DPR downstream temperature sensor

and proceed to the step 10.

YES

8 Basic inspection of the engine

1. Inspect each part of the engine to determine whether there are

factor(s) that deteriorate the exhaust gas.
Standard: The absence of defects.

NO Repair or replace faulty part(s).

After that, proceed to the step 9.

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–181

9 Inspect the injector [Hino-DX]

Check the injection quantity and the rotational fluctuation.

1. Start the engine.

2. Select [Injection quantity] from the [Data Monitor] menu and

measure the injection quantity.

3. Select [Engine speed] from the [Data Monitor] menu and

measure the rotational fluctuation.

! CAUTION • Inspect after engine warm-up.

Standard value

Engine speed Injection quantity

(r/min) (q)
800 10 to 30

NO Replace the injector.

After that, proceed to the step 10.

YES

Proceed to the step 11.

10 Inspection of the tail pipe

1. Make sure of the absence of soot at the outlet of the tail pipe.
Standard: The absence of soot leakage.

NO Clean or replace the DPR filter and perform manual

forced regeneration.

NOTICE • You do not have to implement

the differential pressure check
after performing manual forced
regeneration.

After that, proceed to the step 13.

YES

[S5LC0033E04] [0518CsCshWbYs]
17–182 ENGINE DIAGNOSIS CODE

11 DPR forced regeneration

1. Use Hino-DX to perform manual forced regeneration, making

sure that the DPR system functions correctly (Refer to page
17-11).

NOTICE • If the system does not enter the regeneration

mode, check whether the neutral switch or
emergency accelerator circuits function
correctly, or whether the lock lever is in the
correct position.

Standard: the value of DPR exhaust temperature (IN)

has risen 450°C {842°F} or higher.

NO 1. If the value does not reach to 450°C {842°F}

about 30 minutes after the regeneration starts, it
is possible for the oxidation catalyst in the
preceding stage not to function. In this case, the
procedures indicated by the code P2458/P24A2
should be conducted.
2. If a DTC code is displayed, abort the manual
forced regeneration process and then address
the problem indicated by the DTC code.

YES

12 Inspection of the differential pressure

1. Inspect the differential pressure of the DPR.

Standard value

Engine speed Differential pressure

(r/min) (kPa)
2000 Below 10

NO Replace the DPR filter and perform manual forced

regeneration.

NOTICE • You do not have to implement

the differential pressure check
after performing manual forced
regeneration.

After that, proceed to the step 13.

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–183

13 Check the DTC detected (Engine) [Hino-DX]

1. Set the starter key to the "ON" position.

2. Select [Engine] and check if P2C has been detected.

Standard: The absence of the indication "P200C".

Select
Engine

SAPH31J191700222

NO Replace the engine ECU.

YES

Procedure completed.

[S5LC0033E04] [0518CsCshWbYs]
17–184 ENGINE DIAGNOSIS CODE

DTC code P2032 [27]

DPR downstream temperature sensor - out of range
(Out of range low)
JP31J19170601058

1 Measuring resistance between sensor terminals

1. Set the starter to the "OFF" position.

2. Disconnect the DPR downstream temperature sensor

connector.
3. Measure resistance between the terminals TEX3 and GND3 of
GND3 TEX3 the DPR downstream temperature sensor.

NOTICE • If it is difficult to check only the sensor,

proceed to Step 3.

Standard value

Temperature (°C{°F}) Resistance

SAPH31J191700225
20 {68} 13.7 - 29.8 kΩ

50 {122} 7.13 - 13.7 kΩ

80 {176} 4.1 - 7.13 kΩ

Exhaust gas temperature sensor characteristic

Resistance(Ω)

Temperature(C)
SAPH31J191700226

NO Faulty DPR downstream temperature sensor

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–185

2 Measuring voltage between sensor terminals

1. Set the starter switch to "ON" position.

2. Measure voltage between the terminals LCY and LCZ of the
LCZ LCY DPR downstream temperature sensor connector (engine sub
harness side).

Standard value: 4.5-5.5 V

SAPH31J191700227

NO Proceed to 4

YES

Bad contact of connectors

[S5LC0033E04] [0518CsCshWbYs]
17–186 ENGINE DIAGNOSIS CODE

3 Measuring resistance between terminals

1. Set the starter switch to "OFF" position.

2. Connect the signal check harness on the unit side.

3. Disconnect the connector on the engine ECU side.

4. Measure resistance between the terminals ET2+ (V49) and
ADG9 (V46).
V46 V49
V
Standard value

Temperature (°C{°F}) Resistance

20 {68} 13.7 - 29.8 kΩ

50 {122} 7.13 - 13.7 kΩ

SAPH31J191700228 80 {176} 4.1 - 7.13 kΩ

Exhaust gas temperature sensor characteristic

Resistance(Ω)

Temperature(C)
SAPH31J191700226

NO • Faulty DPR downstream temperature sensor

• Faulty harness
• Faulty sensor connector

YES

Fault in engine ECU

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–187

4 Measuring voltage between terminals

1. Set the starter switch to "OFF" position.

2. Connect the signal check harness on the unit side.

3. Set the starter switch to "ON" position.

4. Measure voltage between the terminals ET2+ (V49) and ADG9
(V46).
V46
V49
V Standard value: 4.5-5.5 V

SAPH31J191700229

NO • Fault in engine ECU

• Faulty ECU connector

YES

Faulty harness

[S5LC0033E04] [0518CsCshWbYs]
17–188 ENGINE DIAGNOSIS CODE

DTC code P2033 [27]

DPR downstream temperature sensor - out of range
(Out of range high)
JP31J19170601059

1 Measuring resistance between sensor terminals

1. Set the starter to the "OFF" position.

2. Disconnect the DPR downstream temperature sensor

connector.
3. Measure resistance between the terminals TEX3 and GND3 of
GND3 TEX3 the DPR downstream temperature sensor.

NOTICE • If it is difficult to check only the sensor,

proceed to Step 3.

Standard value

Temperature (°C{°F}) Resistance

SAPH31J191700225
20 {68} 13.7 - 29.8 kΩ

50 {122} 7.13 - 13.7 kΩ

80 {176} 4.1 - 7.13 kΩ

Exhaust gas temperature sensor characteristic

Resistance(Ω)

Temperature(C)
SAPH31J191700226

NO Faulty DPR downstream temperature sensor

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–189

2 Measuring voltage between sensor terminals

1. Set the starter switch to "ON" position.

2. Measure voltage between the terminals LCY and LCZ of the
LCZ LCY DPR downstream temperature sensor connector (engine sub
harness side).

Standard value: 4.5-5.5 V

SAPH31J191700227

NO Proceed to 4

YES

Bad contact of connectors

[S5LC0033E04] [0518CsCshWbYs]
17–190 ENGINE DIAGNOSIS CODE

3 Measuring resistance between terminals

1. Set the starter switch to "OFF" position.

2. Connect the signal check harness on the unit side.

3. Disconnect the connector on the engine ECU side.

4. Measure resistance between the terminals ET2+ (V49) and
ADG9 (V46).
V46 V49
V
Standard value

Temperature (°C{°F}) Resistance

20 {68} 13.7 - 29.8 kΩ

50 {122} 7.13 - 13.7 kΩ

SAPH31J191700228 80 {176} 4.1 - 7.13 kΩ

Exhaust gas temperature sensor characteristic

Resistance(Ω)

Temperature(C)
SAPH31J191700226

NO • Faulty DPR downstream temperature sensor

• Faulty harness
• Faulty sensor connector

YES

Fault in engine ECU

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–191

4 Measuring voltage between terminals

1. Set the starter switch to "OFF" position.

2. Connect the signal check harness on the unit side.

3. Set the starter switch to "ON" position.

4. Measure voltage between the terminals ET2+ (V49) and ADG9
(V46).
V46
V49
V Standard value: 4.5-5.5 V

SAPH31J191700229

NO • Fault in engine ECU

• Faulty ECU connector

YES

Faulty harness

[S5LC0033E04] [0518CsCshWbYs]
17–192 ENGINE DIAGNOSIS CODE

DTC code P203F [95]

Empty reductant tank

JP31J19170601060

1 Inspect the AdBlue/DEF tank

1. Fill the AdBlue/DEF tank to the Full level.

Standard value: AdBlue/DEF level indicator indicate

20 Level.

NO Go to step 2.

Level 20 (Green)
SAPH31J191700230

YES

Procedure completed.

2 Inspect the AdBlue/DEF tank level sensor connector

1. Check the connection of the AdBlue/DEF tank level sensor

connector (Looseness and poor contact).

NO Go to step 3.

YES

3 Inspect the AdBlue/DEF tank level sensor

1. Check if the AdBlue/DEF tank level sensor float is stuck or

damaged.

NO Go to step 4.

YES

Replace the AdBlue/DEF tank level sensor.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–193

4 Check the DTC detected (Engine) [Hino-DX]

1. Connect the machine to Hino-DX.

2. Set the starter switch to the "ON" position.

Select
Engine 3. Select [Engine] and check if a CAN communication system
malfunction (U02A2) has been detected in [Fault Information].

NO Go to the diagnostic procedure of a related DTC.

SAPH31J191700231

YES

Replace the AdBlue/DEF tank level sensor, and go to step 5.

5 Check the DTC detected (Engine ECU) [Hino-DX]

1. Connect the machine to Hino-DX.

2. Set the starter switch to the "ON" position.

Select
Engine 3. Select [Engine] and check if P203F has been detected in [Fault
Information].

NO Replace the engine ECU.

SAPH31J191700232

YES

Procedure completed.

[S5LC0033E04] [0518CsCshWbYs]
17–194 ENGINE DIAGNOSIS CODE

DTC code P204F [97]

Reductant System Performance

JP31J19170601061

1 Check the DTC detected (Engine ECU) [Hino-DX]

1. Set the starter switch to the "OFF" position.

2. Connect the machine to Hino-DX.

Select
Engine 3. Set the starter switch to the "ON" position.

4. Select [Engine] and check if P204F has been detected in [Fault

Information].

NO Go to the DTC separate diagnosis of the AdBlue/

SAPH31J191700233
DEF SCR system (DCU).

YES

Procedure completed.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–195

DTC code P207F [95]

Improper reductant
JP31J19170601062

1 AdBlue/DEF inspection

1. Take a sample of the AdBlue/DEF, let it drip into the AdBlue/

DEF analyzer, and then check the AdBlue/DEF concentration
and color.

2. Make sure that the measured value is within the standard

specification.

NOTICE • There are three inspection methods for the

AdBlue/DEF: AdBlue/DEF analyzer
inspection, pH litmus paper inspection, and
SAPH31J191700234
refractive index measuring inspection.

Standard value
Concentration: 32.5±2.5%
Color: Colorless, clear

NO Replacement with normal AdBlue/DEF

If the AdBlue/DEF has deteriorated, set the starter
key to "ON" to drain the AdBlue/DEF via the tank
outlet. After all the deteriorated AdBlue/DEF has
drained from the pipes, fill in 35 liters or more of
clean AdBlue/DEF.
Go to step 2.

YES

Go to step 3.

2 DTC code reading

1. Check if the DTC code P207F is detected.

Standard: The DTC code P207F is not detected.

NO Go to step 3.

YES

Procedure completed.

[S5LC0033E04] [0518CsCshWbYs]
17–196 ENGINE DIAGNOSIS CODE

3 AdBlue/DEF tank inspection

1. Remove the AdBlue/DEF tank from the machine.

2. Remove the AdBlue/DEF quality sensor from the AdBlue/DEF

tank.

3. Discharge the AdBlue/DEF from the AdBlue/DEF tank and

check the inside of the tank for foreign matter.
Standard: No problems

NO Remove the foreign matter, wash the inside of the

AdBlue/DEF tank, and then go to step 4.

! CAUTION • Wash the inside of the AdBlue/

DEF tank with distilled water or
with diluted AdBlue/DEF.

YES

4 Inspection of the AdBlue/DEF quality sensor

1. Confirm that the measuring part is free of dirt, clogging, and

damage.

Standard: No problems
AdBlue/DEF quality
sensor measuring part NO Clean the measuring part of the AdBlue/DEF quality
sensor, and then go to step 5.

! CAUTION • If the measuring part is

contaminated with oil or grease,
SAPH31J191700235
wash it with an alcohol-based
washing fluid.

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–197

5 DTC code reading

1. Install the AdBlue/DEF quality sensor provisionally in the

AdBlue/DEF tank, then mount it on the machine. (Mount it in
such a way that the connector of the AdBlue/DEF quality
sensor can be connected.)

2. Fill AdBlue/DEF with the specified concentration into the tank.

3. Turn the starter key to "ON" and wait for 10 minutes.

4. Check the instrument cluster monitor for detection of the DTC

code P207F.
Standard: The DTC code P207F is not detected.

NO Replace the AdBlue/DEF quality sensor.

YES

Procedure completed.

[S5LC0033E04] [0518CsCshWbYs]
17–198 ENGINE DIAGNOSIS CODE

DTC code P2100 [31]

DC motor for intake throttle valve - circuit [Open circuit (circuit low)]
DTC code P2103 [31]
DC motor for intake throttle valve - circuit [Short circuit (circuit high)]
JP31J19170601063

1 Measuring voltage between sensor terminals

1. Set the starter switch to "OFF" position.

2. Disconnect the connector of intake throttle valve.

3. Set the starter switch to "ON" position.

4. Measure voltage between the terminals MOT+ and MOT- of the
MOT+ intake throttle valve connector (engine sub harness side).
MOT-
Standard value: 19V or more

SAPH31J191700236

NO Fault in harness

YES

2 Check the intake throttle valve

1. Disconnect the intake throttle from the intercooler so that the

intake throttle valve will be visible.

2. Check the intake throttle valve for dragged foreign matters.

3. Remove all foreign matters if any.

4. Set the starter switch to "ON" position.

(The engine does not start running.)

5. Set the starter switch to "OFF" position and check that the
intake throttle valve functions.

NO Proceed to 3

YES

Clear and recheck the DTC

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–199

3 Inspect the intake throttle valve

1. Connect the PC DIAGNOSIS TOOL (Hino-DX).

SAPH31J191700037

2. Set the starter switch to "ON" position.

3. Inspect the intake throttle valve.

NO Faulty intake throttle valve

YES

Fault in harness
Fault in engine ECU

[S5LC0033E04] [0518CsCshWbYs]
17–200 ENGINE DIAGNOSIS CODE

DTC code P2101 [31]

Intake throttle valve - functional
JP31J19170601064

1 Check the intake throttle valve

1. Remove intercooler hose above intake throttle so that the

intake throttle valve will be visible.

2. Check the intake throttle valve for dragged foreign matters.

3. Remove all foreign matters if any.

4. Set the starter switch to "ON" position.

(The engine does not start running.)

5. Set the starter switch to "OFF" position and check that the
intake throttle valve functions.

NO Proceed to 2

YES

Clear and recheck the DTC

2 Inspect the intake throttle valve

1. Connect the PC DIAGNOSIS TOOL (Hino-DX).

SAPH31J191700037

2. Set the starter switch to "ON" position.

3. Inspect the intake throttle valve.

NO Faulty intake throttle valve

YES

Fault in harness
Fault in engine ECU

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–201

DTC code P2121 [22]

Accelerator sensor 1 malfunction
DTC code P2126 [22]
Accelerator sensor 2 malfunction
JP31J19170601065

1 Measuring voltage between terminals

1. Set the starter key to "OFF" and connect the signal check
harness to the engine ECU.

2. Set the cluster mode to "H" and select the "Lo idle" position.

3. Set the starter key to "ON" and measure the voltage between
terminal.

Terminal to measure the resistance

DTC code + Side - Side
P2121 V47 V45
P2126 V67 V65

Accelerator sensor 1 Accelerator sensor 2

V45 V V47 V65 V V67

SAPH31J191700237

Standard value (P2121 and P2126)

Engine
Voltage
Measuring item revolution
(V)
(r/min)
Low idle 1,000 Approx. 1.4
High idle 2,100 Approx. 3.5

4. Confirm that the difference in voltage between accelerator

sensor 1 and accelerator sensor 2 is 0.5V less than.
Standard value: 0.5 V less than

NO Proceed to 2

YES

Fault in engine ECU

[S5LC0033E04] [0518CsCshWbYs]
17–202 ENGINE DIAGNOSIS CODE

2 Measuring voltage at the output port of the mechatronic controller

1. Disconnect the 28PIN connector of the mechatronic controller.

2. Measure the voltage between terminal.

Terminal to measure the resistance

DTC code + Side - Side
P2121 781 785
P2126 782 786

Accelerator sensor 1 Accelerator sensor 2

785 781 786 782

SAPH31J191700238

Standard value (P2121 and P2126)

Engine
Voltage
Measuring item revolution
(V)
(r/min)
Low idle 1,000 Approx. 1.4
High idle 2,100 Approx. 3.5

NO Fault in mechatronic controller

YES

Disconnection of harness, short-circuit of harness

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–203

DTC code P2122 [22]

Accelerator pedal position sensor 1 - out of range (Out of range low)
DTC code P2123 [22]
Accelerator pedal position sensor 1 - out of range (Out of range high)
JP31J19170601066

1 Measurement of voltage between terminals

1. While increasing the throttle, measure the voltage between

terminal V47 and terminal V45 of the signal check harness.
V45 V V47

Standard value

Engine
Voltage
Measuring item revolution
(V)
(r/min)
Low idle 1,000 Approx. 1.4
SAPH31J191700239
High idle 2,100 Approx. 3.5

NO Defective mechatronic controller

YES

Harness failure

2 Measuring voltage at the output port of the mechatronic controller

1. With the starter key set to "ON", do not open the throttle and
measure the voltage between pin 25 (781) of the pin connector
V45 V
28 of the mechatronic controller and V45 of the signal check
781
harness.
When an abnormal value is detected, the mechatronic
controller becomes defective.

Abnormal value
: 0.3 V or less
SAPH31J191700240 : 4.8 V or more

NO Engine ECU failure, ECU connector failure or

disconnection of harness, short-circuit of harness

YES

Defective mechatronic controller

[S5LC0033E04] [0518CsCshWbYs]
17–204 ENGINE DIAGNOSIS CODE

DTC code P2127 [22]

Accelerator pedal position sensor 2 - out of range (Out of range low)
DTC code P2128 [22]
Accelerator pedal position sensor 2 - out of range (Out of range high)
JP31J19170601067

1 Measurement of voltage between terminals

1. While increasing the throttle, measure the voltage between

terminal V67 and terminal V65 of the signal check harness.
V65 V V67

Standard value

Engine
Voltage
Measuring item revolution
(V)
(r/min)
Low idle 1,000 Approx. 1.4
SAPH31J191700241
High idle 2,100 Approx. 3.5

NO Defective mechatronic controller

YES

Harness failure

2 Measuring voltage at the output port of the mechatronic controller

1. With the starter key set to "ON", do not open the throttle and
measure the voltage between pin 27 (782) of the pin connector
782 V
V65 28 of the mechatronic controller and V65 of the signal check
harness.
When an abnormal value is detected, the mechatronic
controller becomes defective.

Abnormal value
: 0.3 V or less
SAPH31J191700242 : 4.8 V or more

NO Engine ECU failure, ECU connector failure or

disconnection of harness, short-circuit of harness

YES

Defective mechatronic controller

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–205

DTC code P2228 [15]

Barometric pressure sensor - out of range (Out of range low)
DTC code P2229 [15]
Barometric pressure sensor - out of range (Out of range high)
JP31J19170601068

1 Check of diagnosis code

1. Check that no other diagnosis codes exist.

2. After the starter switch is positioned on the "OFF" once, it

should be turned to "ON" position again.

3. After erasing the DTC, check that the same code is displayed
again.

NO Fault in engine ECU

YES

Normal
(Temporary malfunction because of radio interference noise)

[S5LC0033E04] [0518CsCshWbYs]
17–206 ENGINE DIAGNOSIS CODE

DTC code P244A [91]

DPR differential pressure drop
JP31J19170601069

1 Check the DTC detected (Engine) [Hino-DX]

1. Set the starter switch to "OFF" position.

2. Connect the machine to Hino-DX.

Select
Engine

SAPH31J191700222

3. Set the starter switch to the "ON" position.

4. Select [Engine] and check if DTC code has been detected.

Standard: Only the DTC code "P244A" is displayed.

NO Should any other code(s) be displayed, repair the

malfunction the relevant code(s) indicate before
proceeding to the next step.

ÙÅÓ

² Inspection of the DPR differential pressure pipe and hose

±® Check the differential pressure pipe and hose for clogging.

Standard: The absence of clogging

NO Repair or replace, proceed to the step 3.

ÙÅÓ

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–207

3 Inspection of the DPR differential pressure sensor

±® Use a circuit tester to measure the resistance between the

terminals of the DPR differential pressure sensor.

Measurement item Standard value (kΩ)

A↔B 2 to 15
C
B↔C 2 to 15
B
Differential pressure sensor A
NO Replace the DPR differential pressure sensor and
SAPH31J191700243
proceed to the step 10.

ÙÅÓ

4 Check for exhaust gas leakage

±® Check the muffler body and flange surface for gas leakage.
Standard value: The absence of leakage

NO Secure the connection part even tighter.

Replace the gasket with a new one.
After that, proceed to the step 10.

ÙÅÓ

5 Inspection of the DOC downstream temperature sensor connector

±® Check the connection of the DOC downstream temperature

sensor connector.
Standard: The absence of poor contact.

NO Connect securely or repair if needed.

After that, proceed to the step 6.

ÙÅÓ

[S5LC0033E04] [0518CsCshWbYs]
17–208 ENGINE DIAGNOSIS CODE

6 Inspection of the outside of the DOC downstream temperature sensor

±® Check the installation of the DOC downstream temperature

sensor.

2. Inspect the sensing part of the DOC downstream temperature

sensor.
Standard: The absence of dirt or damage.

NO Clean the sensing unit and install it properly.

If damaged, replace the DOC downstream
temperature sensor.
After that, proceed to the step 7.

ÙÅÓ

7 Inspection of the DOC downstream temperature sensor unit

±® Set the starter switch to "OFF" position.

²® Disconnect the DOC downstream sensor connector.

3. Use a circuit tester to measure the resistance between the
GND1 TEX1 terminals of the DOC downstream temperature sensor.

Measurement Tester
Standard values
conditions connections

20°C{68°F}
DOC
13.7 –29.8 Ω
downstream
Starter switch: 50 °C{122 °F}
temperature
OFF 7.13 –13.7 kΩ
SAPH31J191700223 sensor
80 °C{176 °F}
TEX1 – GND1
4.13–7.13kΩ

NO Replace the DOC downstream temperature sensor

and proceed to step 10.

ÙÅÓ

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–209

8 Basic inspection of the engine

±® Inspect each part of the engine to determine whether there are

factor(s) that deteriorate the exhaust gas.
Standard: The absence of defects.

NO Repair or replace faulty part(s).

After that, proceed to the step 9.

ÙÅÓ

9 Inspect the injector [Hino-DX]

Check the injection quantity and the rotational fluctuation.

1. Start the engine.

2. Select [Injection quantity] from the [Data Monitor] menu and

measure the injection quantity.

3. Select [Engine speed] from the [Data Monitor] menu and

measure the rotational fluctuation.

! CAUTION • Inspect after engine warm-up.

Standard value

Engine speed Injection quantity

(r/min) (q)
800 10 to 30

NO Replace the injector.

After that, proceed to the step 10.

ÙÅÓ

Proceed to the step 11.

[S5LC0033E04] [0518CsCshWbYs]
17–210 ENGINE DIAGNOSIS CODE

10 Inspect the tail pipe

±® Make sure of the absence of soot at the outlet of the tail pipe.
Standard: The absence of soot

NO Replace the DPR filter and perform manual forced

regeneration.

NOTICE • You do not have to implement

the differential pressure check
after performing manual forced
regeneration.

After that, proceed to the step 13.

ÙÅÓ

11 DPR forced regeneration

1. Use Hino-DX to perform manual forced regeneration, making

sure that the DPR system functions correctly (Refer to page
17-11).

NOTICE • If the system does not enter the regeneration

mode, check whether the neutral switch or
emergency accelerator circuits function
correctly, or whether the lock lever is in the
correct position.

Standard: the value of DPR exhaust temperature (IN)

has risen 450°C {842°F} or higher.

NO 1. If the value does not reach to 450°C {842°F}

about 30 minutes after the regeneration starts, it
is possible for the oxidation catalyst in the
preceding stage not to function. In this case, the
procedures indicated by the code P2458/P24A2
should be conducted.
2. If a DTC code is displayed, abort the manual
forced regeneration process and then address
the problem indicated by the DTC code.

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–211

12 Inspection of the differential pressure

1. Inspect the differential pressure of the DPR.

Standard value

Engine speed Differential pressure

(r/min) (kPa)
2000 Below 10

NO Replace the DPR filter and perform manual forced

regeneration.

NOTICE • You do not have to implement

the differential pressure check
after performing manual forced
regeneration.

After that, proceed to the step 13.

ÙÅÓ

13 Check the DTC detected (Engine) [Hino-DX]

1. Set the starter switch to the "ON" position.

2. Select [Engine] and check if P244A has been detected.

Standard: The absence of the indication "P244A".

Select
Engine

SAPH31J191700222

NO Replace the engine ECU.

ÙÅÓ

Procedure completed.

[S5LC0033E04] [0518CsCshWbYs]
17–212 ENGINE DIAGNOSIS CODE

DTC code P244B [92]

Excessive DPR differential pressure
JP31J19170601070

1 Check the DTC detected (Engine) [Hino-DX]

1. Set the starter switch to "OFF" position.

2. Connect the machine to Hino-DX.

Select
Engine

SAPH31J191700222

3. Set the starter switch to the "ON" position.

4. Select [Engine] and check if P2458, P24A2, P0545, P0546 has

been detected.
Standard: The absence of defects.

NO Should DTC code(s) be displayed, repair the

malfunction the relevant code(s) indicate before
proceeding to the next step.

ÙÅÓ

2 DTC code confirmation

1. Check for a previous indication of the DTC code [P2463].

Standard: The absence of P2463 previously indicating

NO Proceed to the step 8.

ÙÅÓ

3 Inspection of the DPR differential pressure pipe and hose

1. Check the pipe and hose for clogging.

Standard: The absence of clogging

NO Repair or replace and proceed to the step 4.

ÙÅÓ

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–213

4 Inspection of the DPR differential pressure sensor

1. Use a circuit tester to measure the resistance between the

terminals of the DPR differential pressure sensor.

Measurement item Standard value (kΩ)

A↔B 2 to 15
C
B↔C 2 to 15
B
Differential pressure sensor A
NO Replace the DPR differential pressure sensor,
SAPH31J191700244
proceed to the step 5.

ÙÅÓ

5 Basic inspection of the engine

±® Inspect each part of the engine to determine whether there are

factor(s) that deteriorate the exhaust gas.
Standard: The absence of defects.

NO Repair or replace faulty part(s).

After that, proceed to the step 6.

ÙÅÓ

6 Inspect the injector [Hino-DX]

Check the injection quantity and the rotational fluctuation.

1. Start the engine.

2. Select [Injection quantity] from the [Data Monitor] menu and

measure the injection quantity.

3. Select [Engine speed] from the [Data Monitor] menu and

measure the rotational fluctuation.

! CAUTION • Inspect after engine warm-up.

Standard value

Engine speed Injection quantity

(r/min) (q)
800 10 to 30

NO Replace the injector.

After that, proceed to the step 7.

ÙÅÓ

[S5LC0033E04] [0518CsCshWbYs]
17–214 ENGINE DIAGNOSIS CODE

7 Check for black smoke

1. Check the exhaust pipe for black smoke.

Standard: The absence of black smoke

NO Make sure that there is very little smoke: if

necessary, inspect the engine for leakage of engine
oil.
After that, proceed to the step 8.

ÙÅÓ

8 Cleaning or replacing the DPR filter

1. Clean or replace the DPR filter.

Standard: The absence of soot leakage

NO Clean or replace the DPR, and then go to step 9.

If cleaning, restore to new-part condition.

ÙÅÓ

9 DPR forced regeneration

1. Use Hino-DX to perform manual forced regeneration, making

sure that the DPR system functions correctly (Refer to page
17-11).

NOTICE • If the system does not enter the regeneration

mode, check whether the neutral switch or
emergency accelerator circuits function
correctly, or whether the lock lever is in the
correct position.

Standard: the value of DPR exhaust temperature (IN)

has risen 450°C {842°F} or higher.

NO 1. If the value does not reach to 450°C {842°F}

about 30 minutes after the regeneration starts, it
is possible for the oxidation catalyst in the
preceding stage not to function. In this case, the
procedures indicated by the code P2458/P24A2
should be conducted.
2. If a DTC code is displayed, abort the manual
forced regeneration process and then address
the problem indicated by the DTC code.

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–215

10 Check the DTC detected (Engine) [Hino-DX]

1. Set the starter switch to the "ON" position.

2. Select [Engine] and check if P244B has been detected.

Standard: The absence of the indication "P244B".

Select
Engine

SAPH31J191700222

NO Replace the engine ECU.

ÙÅÓ

Procedure completed.

[S5LC0033E04] [0518CsCshWbYs]
17–216 ENGINE DIAGNOSIS CODE

DTC code P2458 [93]

DPR regeneration duration
DTC code P24A2 [93]
DPR regeneration incomplete by fuel consumption over
JP31J19170601071

1 Inspect the DPR downstream temperature sensor connector

1. Check the connection of the DOC downstream temperature

sensor connector.
Standard: The absence of poor contact.

NO Connect securely or repair if needed.

After that, proceed to the step 2.

ÙÅÓ

2 Inspection of the outside of the DOC downstream temperature sensor

1. Check the installation of the DOC downstream temperature

sensor.

2. Inspect the sensing part of the DOC downstream temperature

sensor.
Standard: The absence of dirt or damage.

NO Clean the sensing unit and install it properly.

If damaged, replace the DOC downstream
temperature sensor.
After that, proceed to the step 3.

ÙÅÓ

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–217

3 Inspection of the DOC downstream temperature sensor unit

1. Set the starter switch to "OFF" position.

2. Disconnect the DOC downstream sensor connector.

3. Use a circuit tester to measure the resistance between the
GND1 TEX1 terminals of the DOC downstream temperature sensor.

Measurement Tester
Standard values
conditions connections
20°C{68°F}
DOC
13.7 –29.8 Ω
downstream
Starter switch: 50 °C{122 °F}
temperature
OFF 7.13 –13.7 kΩ
SAPH31J191700223 sensor
80 °C{176 °F}
TEX1 – GND1
4.13–7.13kΩ

NO Replace the DOC downstream temperature sensor

and proceed to step 7.

ÙÅÓ

4 Check for exhaust gas leakage

1. Check the muffler body and flange surface for gas leakage.
Standard value: The absence of leakage

NO Secure the connection part even tighter.

Replace the gasket with a new one.
After that, proceed to the step 7.

ÙÅÓ

5 Basic inspection of the engine

1. Inspect each part of the engine to determine whether there are

fact(s) that deteriorate the exhaust gas.
Standard: The absence of defects.

NO Repair or replace faulty part(s).

After that, proceed to the step 6.

ÙÅÓ

[S5LC0033E04] [0518CsCshWbYs]
17–218 ENGINE DIAGNOSIS CODE

6 Inspect the injector [Hino-DX]

Check the injection quantity and the rotational fluctuation.

1. Start the engine.

2. Select [Injection quantity] from the [Data Monitor] menu and

measure the injection quantity.

3. Select [Engine speed] from the [Data Monitor] menu and

measure the rotational fluctuation.

! CAUTION • Inspect after engine warm-up.

Standard value

Engine speed Injection quantity

(r/min) (q)
800 10 to 30

NO Replace the injector.

After that, proceed to the step 7.

ÙÅÓ

7 Check for soot leakage

1. Inspect the rear of the DPR filter.

Standard: The absence of soot leakage

NO Replace the DPR filter and perform manual forced

regeneration.

NOTICE • You do not have to implement

the differential pressure check
after performing manual forced
regeneration.

After that, proceed to the step 10.

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–219

8 DPR forced regeneration

1. Use Hino-DX to perform manual forced regeneration, making

sure that the DPR system functions correctly (Refer to page
17-11).

NOTICE • If the system does not enter the regeneration

mode, check whether the neutral switch or
emergency accelerator circuits functions
correctly, or whether the lock lever is in the
correct position.

Standard: the value of DPR exhaust temperature (IN)

has risen 450°C {842°F} or higher.

NO Replace the DPR filter and perform manual forced

regeneration.

NOTICE • You do not have to implement

the differential pressure check
after performing manual forced
regeneration.

After that, proceed to the step 10.

YES

9 Inspection of the differential pressure

1. Inspect the differential pressure of the DPR.

Standard value

Engine speed Differential pressure

(r/min) (kPa)
2000 Below 10

NO Replace the DPR filter and perform manual forced

regeneration.

NOTICE • You do not have to implement

the differential pressure check
after performing manual forced
regeneration.

After that, proceed to the step 10.

ÙÅÓ

[S5LC0033E04] [0518CsCshWbYs]
17–220 ENGINE DIAGNOSIS CODE

10 Check the DTC detected (Engine) [Hino-DX]

1. Set the starter switch to the "ON" position.

2. Select [Engine] and check if P2458/P24A2 has been detected
in [Fault Information].

Standard: The absence of the indication "P2458/

Select P24A2".
Engine

SAPH31J191700222

NO Replace the engine ECU.

ÙÅÓ

Procedure completed.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–221

DTC code P2463 [92]

DPR clogged
JP31J19170601072

1 Check the DTC detected (Engine) [Hino-DX]

1. Set the starter switch to "OFF" position.

2. Connect the machine to Hino-DX.

Select
Engine

SAPH31J191700245

3. Set the starter switch to the "ON" position.

4. Select [Engine] and check if P2458, P24A2, P0545 or P0546

has been detected.
Standard: The absence of defects.

NO Should DTC code(s) be displayed, repair the

malfunction the relevant code(s) indicate before
proceeding to the next step.

ÙÅÓ

2 Inspect the tail pipe

±® Make sure of the absence of soot at the outlet of the tail pipe.
Standard: The absence of soot leakage

NO Replace the DPR filter and perform manual forced

regeneration.

NOTICE • You do not have to implement

the differential pressure check
after performing manual forced
regeneration.

After that, proceed to the step 5.

ÙÅÓ

[S5LC0033E04] [0518CsCshWbYs]
17–222 ENGINE DIAGNOSIS CODE

3 DPR forced regeneration

1. Use Hino-DX to perform manual forced regeneration, making

sure that the DPR system functions correctly (Refer to page
17-11).

NOTICE • If the system does not enter the regeneration

mode, check whether the neutral switch or
emergency accelerator circuits functions
correctly, or whether the lock lever is in the
correct position.

Standard: the value of DPR exhaust temperature (IN)

has risen 450°C {842°F} or higher.

NO 1. If the value does not reach to 450°C {842°F}

about 30 minutes after the regeneration starts, it
is possible for the oxidation catalyst in the
preceding stage not to function. In this case, the
procedures indicated by the code P2458/P24A2
should be conducted.
2. If a DTC code is displayed, abort the manual
forced regeneration process and then address
the problem indicated by the DTC code.

YES

4 Inspection of the differential pressure

1. Inspect the differential pressure of the DPR.

Standard value

Engine speed Differential pressure

(r/min) (kPa)
2000 Below 10

NO Replace the DPR filter and perform manual forced

regeneration.

NOTICE • You do not have to implement

the differential pressure check
after performing manual forced
regeneration.

After that, proceed to the step 5.

ÙÅÓ

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–223

5 Check the DTC detected (Engine) [Hino-DX]

1. Set the starter switch to the "ON" position.

2. Select [Engine] and check if P2463 has been detected.

Standard: The absence of the indication "P2463".

Select
Engine

SAPH31J191700222

NO Replace the engine ECU.

ÙÅÓ

Procedure completed.

[S5LC0033E04] [0518CsCshWbYs]
17–224 ENGINE DIAGNOSIS CODE

DTC code U0073 [8]

Engine ECU CAN communication bus for Emission control system - bus off
JP31J19170601073

1 Check the termination resistor

1. Check that it is installed.

2. Check that the resistance is as much as 120Ω .

3. Check that the connectors have no poor contact.

NO Repair the trouble

YES

2 Checking each ECU

1. Remove the EGR, VNT and check the diagnosis of U0073 is

restored.

NOTICE • Before detaching the ECU, turn the key OFF.

NO Proceed to the communication blackout diagnostic

flow of each ECU.
If abnormalities are still not found, replace each
ECU.

YES

Replace the ECU

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–225

DTC code U010E [8]

Engine ECU CAN communication (DCU)

JP31J19170601074

1 Inspect the connector

1. Check the connection of the engine joint connector and DCU

connector (Looseness and poor contact).

NO Repair or replace the faulty part, and go to step 2.

CANL CANH
K29 K28

GND SIG VCC

KSL KSK KSJ

GND2 TEX2 GND1 TEX1

KSH KSG KSF KSE

Engine joint connector

SAPH31J191700246

YES

Connect securely, and go to step 2.

2 Check the DTC detected [Hino-DX]

1. Set the starter switch to the "ON" position.

2. Select [Engine] and check if U010E has been detected in [Fault

Select Information].
Engine
DCU
3. Select [DCU] and check if U0029 has been detected in [Fault
Information]

NO Go to step 3.
SAPH31J191700247

YES

Procedure completed.

[S5LC0033E04] [0518CsCshWbYs]
17–226 ENGINE DIAGNOSIS CODE

3 Check harness in CAN H-line between engine joint connector and DCU

1. Set the starter switch to the "OFF" position.

2. Disconnect the engine joint connector and DCU (53P)

K28
connector.
+B2 GND4 GND1
LEP LEW LET

CANL CANH
+B3 GND5 GND2 K29 K28
LEQ LEX LEU
3. Use the electrical tester to measure the resistance between the
GND SIG VCC
+B4 +B1 GND3
LER LEN LEV KSL KSK KSJ
engine joint connector K28 terminal and the DCU machine-side
GND2 TEX2 GND1 TEX1
KSH KSG KSF KSE
connector (53P) CAH0 terminal.
CAH1
LF5 Standard value: 1 Ω or less
CAL1
LF6

TE1B
CAH0
LF2

TE1A CAH0
LF1 LEY

TE2B CAL0
LF4 LEZ

TE2A
LF3

ISGW
LES

SAPH31J191700248

NO Disconnection or faulty continuity in CAN H-line

between engine joint connector and DCU.
Repair or replace the harness.

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–227

4 Check harness in CAN L-line between engine joint connector and DCU

1. Use the electrical tester to measure the resistance between the

engine joint connector K29 terminal and the DCU machine-side
connector (53P) CAL0 terminal.
K29
+B2
LEP
GND4
LEW
GND1
LET
Standard value: 1 Ω or less
CANL CANH
+B3 GND5 GND2 K29 K28
LEQ LEX LEU

GND SIG VCC

+B4 +B1 GND3
LER LEN LEV KSL KSK KSJ

GND2 TEX2 GND1 TEX1

KSH KSG KSF KSE

CAH1
LF5

CAL1
LF6

TE1B
LF2

TE1A CAH0
CAL0
LF1 LEY

TE2B CAL0
LF4 LEZ

TE2A
LF3

ISGW
LES

SAPH31J191700249

NO Disconnection or faulty continuity in CAN L-line

between engine joint connector and DCU.
Repair or replace the harness.

YES

[S5LC0033E04] [0518CsCshWbYs]
17–228 ENGINE DIAGNOSIS CODE

5 Check the DCU power supply

1. Connect the engine joint connector and DCU (53P) connector.

GND1 2. Set the starter switch to the "ON" position.

+B3

+B2
LEP
GND4
LEW
GND1
LET
3. Connect the signal check harness, and use the electrical tester
+B3
LEQ
GND5
LEX
GND2
LEU
to measure the voltage between the terminals of the DCU.
+B4
LER
+B1
LEN
GND3
LEV
Standard value: 19 – 32 V

NO Check the DCU power supply circuit.

CAH1
LF5

CAL1
LF6

TE1B
LF2

TE1A CAH0
LF1 LEY

TE2B CAL0
LF4 LEZ

TE2A
LF3

ISGW
LES

SAPH31J191700250

YES

6 Inspect the DCU [Hino-DX]

1. Set the starter switch to the "OFF" position.

2. Connect DCU (53P) connector.

Select
Engine 3. Set the starter switch to the "ON" position.
DCU

4. Select [Engine] and check if U010E has been detected in [Fault

Information].

5. Select [DCU] and check if U0029 has been detected in [Fault

SAPH31J191700251
Information]

NO Replace the DCU.

YES

Procedure completed.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–229

DTC code U029D [8]

Engine ECU CAN communication (SCR upstream NOx sensor)

JP31J19170601075

1 SCR upstream NOx sensor connector check

1. Set the starter switch to the "OFF" position.

2. Check for NOx sensor connector looseness.

3. Disconnect the NOx sensor connector and check the connector

pins for damage and rust.
Standard:
Connector disconnected or loose.
Connector pins damaged or rusted.
SAPH31J191700252
NO Go to step 2.

YES

Connector disconnected or loose.

→Reconnect the connector.
Connector pins damaged or rusted.
→Replace damaged parts.

2 NOx sensor ground check

1. Set the starter switch to the "OFF" position.

GND CANH CANL GND VCC

LGU LE9 LE8 LE7 LE6 2. Disconnect the NOx sensor connector.

3. Set the starter switch to the "ON" position.

4. Measure the voltage between GND LE7 (chassis side of the

NOx sensor connector) and the minus terminal of the battery
Battery with a circuit tester.
Standard value: Below 1V
SAPH31J191700253

NO Repair or replace of the ground circuit (harness).

YES

[S5LC0033E04] [0518CsCshWbYs]
17–230 ENGINE DIAGNOSIS CODE

3 NOx sensor ground check

1. Set the starter switch to the "OFF" position.

GND CANH CANL GND VCC

LGU LE9 LE8 LE7 LE6 2. Disconnect NOx sensor connector.

3. Set the starter switch to the "ON" position.

4. Measure the voltage between GND LGU (chassis side of the

NOx sensor connector) and the minus terminal of the battery
Battery with a circuit tester.
Standard value: Below 1V
SAPH31J191700254

NO Repair or replace of the ground circuit (harness).

YES

4 NOx sensor power supply voltage check

1. Set the starter switch to the "OFF" position.

GND CANH CANL GND VCC

LGU LE9 LE8 LE7 LE6 2. Disconnect NOx sensor connector.

3. Set the starter switch to the "ON" position.

4. Measure the voltage between VCC LE6 (chassis side of the

NOx sensor connector) and the minus terminal of the battery
Battery with a circuit tester.
Standard value: 19 – 32 V
SAPH31J191700255

NO Repair or replace of the power supply circuit

(harness, fuse, etc.).

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–231

5 Harness check between DCU and NOx controller (CANL line)

1. Set the starter switch to the "OFF" position.

CANH CANL GND VCC 2. Disconnect NOx sensor connector.

LED LEC LEB LEA

3. Disconnect the connector of the DCU.

+B2 GND4 GND1
LEP LEW LET
4. Measure the resistance between CANL LE8 (chassis side of
+B3 GND5 GND2

the NOx sensor connector) and CAH0 LEZ (chassis side of the
LEQ LEX LEU

+B4 +B1 GND3

DCU connector) with a circuit tester.

LER LEN LEV

Standard value: Below 1 Ω

CAH1
LF5

CAL1
LF6

TE1B
LF2
NO Repair or replace of the CAN harness between DCU
TE1A
LF1
CAH0
LEY and NOx controller.
TE2B CAL0
LF4 LEZ

TE2A
LF3

ISGW
LES

SAPH31J191700256

YES

6 Harness check between DCU and NOx controller (CANH line)

1. Set the starter switch to the "OFF" position.

GND CANH CANL GND VCC 2. Disconnect NOx sensor connector.

LGU LE9 LE8 LE7 LE6

3. Disconnect the connector of the DCU.

+B2 GND4 GND1
LEP LEW LET
4. Measure the resistance between CANH LE9 (chassis side of
+B3 GND5 GND2
LEQ LEX LEU
the NOx sensor connector) and CAH0 LEY (chassis side of the
+B4 +B1 GND3

DCU connector) with a circuit tester.

LER LEN LEV

Standard value: Below 1 Ω

CAH1
LF5

CAL1
LF6

TE1B
LF2
NO Repair or replace of the CAN harness between DCU
TE1A
LF1
CAH0
LEY and NOx controller.
TE2B CAL0
LF4 LEZ

TE2A
LF3

ISGW
LES

SAPH31J191700257

YES

[S5LC0033E04] [0518CsCshWbYs]
17–232 ENGINE DIAGNOSIS CODE

7 DTC check when the SCR upstream NOx sensor and the SCR downstream NOx sensor have been
switched

1. Set the starter switch to the "OFF" position.

2. Disconnect the connectors of SCR upstream NOx sensor and

SCR downstream NOx sensor.

3. Switch the arrangement of SCR upstream NOx sensor and

SCR downstream NOx sensor.

4. Set the starter switch to the "ON" position.

SAPH31J191700258
5. Connect Hino-DX to the machine.

6. Select "DCU".

7. After the DTC has been cleared, read the DTC again.

NOTICE • When the DTC U029E and U029D are detected

simultaneously, perform steps from 5 to 6
again.

NO Replace the DCU.

SAPH31J191700259

YES

Replace the SCR upstream NOx sensor.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–233

DTC code U029E [8]

Engine ECU CAN communication (SCR downstream NOx sensor)

JP31J19170601076

1 SCR downstream NOx sensor connector check

1. Set the starter switch to the "OFF" position.

2. Check for NOx sensor connector looseness.

3. Disconnect the NOx sensor connector and check the connector

pins for damage and rust.
Standard:
Connector disconnected or loose.
Connector pins damaged or rusted.
SAPH31J191700260
NO Go to step 2.

YES

Connector disconnected or loose.

→Reconnect the connector.
Connector pins damaged or rusted.
→Replace damaged parts.

2 NOx sensor ground check

1. Set the starter switch to the "OFF" position.

CANH CANL GND VCC

LED LEC LEB LEA 2. Disconnect the NOx sensor connector.

3. Set the starter switch to the "ON" position.

4. Measure the voltage between GND LEB (chassis side of the

NOx sensor connector) and the minus terminal of the battery
Battery with a circuit tester.
Standard value: Below 1V
SAPH31J191700261

NO Repair or replace of the ground circuit (harness).

YES

[S5LC0033E04] [0518CsCshWbYs]
17–234 ENGINE DIAGNOSIS CODE

3 NOx sensor power supply voltage check

1. Set the starter switch to the "OFF" position.

CANH CANL GND VCC

LED LEC LEB LEA 2. Disconnect NOx sensor connector.

3. Set the starter switch to the "ON" position.

4. Measure the voltage between VCC LEA (chassis side of the

NOx sensor connector) and the minus terminal of the battery
Battery with a circuit tester.
Standard value: 19 – 32 V
SAPH31J191700262

NO Repair or replace of the power supply circuit

(harness, fuse, etc.).

YES

4 Harness check between DCU and NOx controller (CANL line)

1. Set the starter switch to the "OFF" position.

CANH CANL GND VCC 2. Disconnect NOx sensor connector.

LED LEC LEB LEA

3. Disconnect the connector of the DCU.

+B2 GND4 GND1
LEP LEW LET
4. Measure the resistance between CANL LEC (chassis side of
+B3 GND5 GND2

the NOx sensor connector) and CAH0 LEZ (chassis side of the
LEQ LEX LEU

+B4 +B1 GND3

DCU connector) with a circuit tester.

LER LEN LEV

Standard value: Below 1 Ω

CAH1
LF5

CAL1
LF6

TE1B
LF2
NO Repair or replace of the CAN harness between DCU
TE1A
LF1
CAH0
LEY and NOx controller.
TE2B CAL0
LF4 LEZ

TE2A
LF3

ISGW
LES

SAPH31J191700256

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–235

5 Harness check between DCU and NOx controller (CANH line)

1. Set the starter switch to the "OFF" position.

CANH CANL GND VCC 2. Disconnect NOx sensor connector.

LED LEC LEB LEA

3. Set the starter switch to the "ON" position.

+B2 GND4 GND1
LEP LEW LET
4. Measure the resistance between CANH LED (chassis side of
+B3 GND5 GND2

the NOx sensor connector) and CAH0 LEY (chassis side of the
LEQ LEX LEU

+B4 +B1 GND3

DCU connector) with a circuit tester.

LER LEN LEV

Standard value: Below 1 Ω

CAH1
LF5

CAL1
LF6

TE1B
LF2
NO Repair or replace the CAN harness between DCU
TE1A
LF1
CAH0
LEY and NOx controller.
TE2B CAL0
LF4 LEZ

TE2A
LF3

ISGW
LES

SAPH31J191700263

YES

[S5LC0033E04] [0518CsCshWbYs]
17–236 ENGINE DIAGNOSIS CODE

6 DTC check when the SCR upstream NOx sensor and the SCR downstream NOx sensor have been
switched

1. Set the starter switch to the "OFF" position.

2. Disconnect the connectors of SCR upstream NOx sensor and

SCR downstream NOx sensor.

3. Switch the arrangement of SCR upstream NOx sensor and

SCR downstream NOx sensor.

4. Set the starter switch to the "ON" position.

SAPH31J191700264
5. Connect Hino-DX to the machine.

6. Select "DCU".

7. After the DTC has been cleared, read the DTC again.

When the DTC U029E and U029D are detected simultaneously,

perform steps from 4 to 5 again.

NO Replace the DCU.

SAPH31J191700265

YES

Replace the SCR downstream NOx sensor.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–237

DTC code U02A2 [8]

Engine ECU CAN communication (AdBlue/DEF tank sensor)

JP31J19170601077

1 Inspect the connector

1. Check the connection of the DCU connector and AdBlue/DEF

sensor connector (Looseness and poor contact).

DCU connector
AdBlue/DEF sensor connector
SAPH31J191700266

NO Repair or replace the faulty part, and go to step 2.

YES

Connect securely, and go to step 2.

2 Check the DTC detected [Hino-DX]

1. Set the starter switch to the "ON" position.

2. Select [Engine] and [DCU], and check if U02A2 has been

Select detected in [Fault Information].
Engine
DCU
NO Go to step 3.

SAPH31J191700267

YES

Procedure completed.

[S5LC0033E04] [0518CsCshWbYs]
17–238 ENGINE DIAGNOSIS CODE

3 Inspect the AdBlue/DEF sensor harness (GND circuit)

1. Set the starter switch to the "OFF" position.

2. Disconnection the AdBlue/DEF sensor connector.

3. Use the electrical tester to measure the resistance between the

GND terminal in the AdBlue/DEF sensor machine-side (upper-
side) connector and the ground.

Measurement Tester
Standard values
conditions connections
AdBlue/DEF
sensor
Starter switch: machine-side
1 Ω or less
OFF connector –
Ground
GND – Ground
GND

NO Inspect the AdBlue/DEF sensor ground circuit.

SAPH31J191700268

YES

4 Inspect the AdBlue/DEF sensor harness (Power supply circuit)

1. Set the starter switch to the "ON" position.

2. Use the electrical tester to measure the voltage between the

terminals of the AdBlue/DEF sensor machine-side (upper-side)
connector.

Measurement Tester
Standard values
conditions connections

AdBlue/DEF
sensor
VCC Starter switch:
machine-side 19 – 32 V
ON
connector
GND VCC – GND

NO Inspect the AdBlue/DEF sensor power supply circuit.

(between fuse and relay block and AdBlue/DEF
sensor)

SAPH31J191700269

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–239

5 Inspect for disconnection in CAN H-line between the DCU and AdBlue/DEF sensor

1. Set the starter switch to the "OFF" position.

2. Disconnect the DCU connector.

3. Connect the signal check harness, and use the electrical tester
+B2
LEP
GND4
LEW
GND1
LET
PIN2 to measure the resistance between the DCU terminal and PIN2
+B3
LEQ
GND5
LEX
GND2
LEU terminal of the AdBlue/DEF sensor.
+B4
LER
+B1
LEN
GND3
LEV Standard value: 1 Ω or less

CAH1
LF5
CAH0 NO Disconnection or faulty continuity in CAN H-line
CAL1
LF6
between the DCU and AdBlue/DEF sensor. Repair
TE1B
LF2

TE1A
LF1
CAH0
LEY
or replace the harness.
TE2B CAL0
LF4 LEZ

TE2A
LF3

ISGW
LES

SAPH31J191700270

YES

6 Check for disconnection in CAN L-line between the DCU and AdBlue/DEF sensor

1. Connect the signal check harness, and use the electrical tester
to measure the resistance between the DCU terminal and PIN1
terminal of the AdBlue/DEF sensor.

Standard value: 1 Ω or less

+B2 GND4 GND1
LEP LEW LET
PIN1
NO Disconnection or faulty continuity in CAN L-line
+B3 GND5 GND2
LEQ LEX LEU

+B4 +B1 GND3

between the DCU and AdBlue/DEF sensor. Repair
LER LEN LEV

or replace the harness.

CAH1
LF5

CAL1
CAL0
LF6

TE1B
LF2

TE1A CAH0
LF1 LEY

TE2B CAL0
LF4 LEZ

TE2A
LF3

ISGW
LES

SAPH31J191700271

YES

[S5LC0033E04] [0518CsCshWbYs]
17–240 ENGINE DIAGNOSIS CODE

7 Inspect the AdBlue/DEF sensor [Hino-DX]

1. Connect the DCU and AdBlue/DEF sensor connector.

2. Set the starter switch to the "ON" position.

Select
Engine 3. Select [Engine] and [DCU], and check if U02A2 has been
DCU
detected in [Fault Information].

NO Replace the AdBlue/DEF sensor.

SAPH31J191700272

YES

Procedure completed.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–241

DTC code U1001 [9]

Engine ECU CAN communication bus for Vehicle control - bus off
JP31J19170601078

1 Checking each ECU

1. Remove the unit side controller and check the diagnosis of

U1001 is restored.

NO Proceed to the communication blackout diagnostic

flow of each ECU.
If abnormalities are still not found, replace each
ECU.

YES

Replace the engine ECU

[S5LC0033E04] [0518CsCshWbYs]
17–242 ENGINE DIAGNOSIS CODE

DTC code U110A [9]

Engine ECU CAN communication (vehicle control controller)
JP31J19170601079

1 Inspection of the fuse power supply circuit of the unit side controller

1. Check the power supply circuit of the unit side controller.

NO Check the unit side controller main relay and fuse

power supply circuit.

YES

2 Check a malfunction code

1. Since the following actuators and switches are connected in

the downstream of the actuator power relay, more than one
malfunction code or functional failure can occur.
Check the supply circuit from the actuator power relay.

Sensor Case
EGR actuator U1122
VNT actuator U1123
Manual regeneration
DPR regeneration switch
failure of DPR

NO Check the CAN harness

YES

Replace the unit side controller

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–243

DTC code U1122 [8]

Engine ECU CAN communication (EGR valve controller)
JP31J19170601080

1 Check that the actuator relay has no malfunction

1. Check that the actuator relay has no malfunction.

NO Check the actuator relay and fuse circuit

YES

2 Check a malfunction code

1. Since the following actuators and switches are connected in

the downstream of the actuator power relay, more than one
malfunction code or functional failure can occur.
Check the supply circuit from the actuator power relay.

Sensor Case
EGR actuator U1122
VNT actuator U1123
Manual regeneration
DPR regeneration switch
failure of DPR

NO Check the CAN harness

YES

3 Measure voltage of the EGR actuator

1. Set the starter switch to "OFF" position.

2. Disconnect the EGR actuator connector.

3. Measure voltage between the terminals EGRV and EGRG of

the EGR actuator connector (engine sub harness side).

Standard value: 19 V or more

SAPH31J191700273

NO Fault in harness

YES

Faulty EGR actuator

[S5LC0033E04] [0518CsCshWbYs]
17–244 ENGINE DIAGNOSIS CODE

DTC code U1123 [8]

Engine ECU CAN communication (VNT controller)
JP31J19170601081

1 Check that the actuator relay has no malfunction

1. Check that the actuator relay has no malfunction.

NO Check the actuator relay and fuse circuit

YES

2 Check a malfunction code

1. Since the following actuators and switches are connected in

the downstream of the actuator power relay, more than one
malfunction code or functional failure can occur.
Check the supply circuit from the actuator power relay.

Sensor Case
EGR actuator U1122
VNT actuator U1123
Manual regeneration
DPR regeneration switch
failure of DPR

NO Check the CAN harness

YES

3 Measuring voltage between sensor terminals

1. Set the starter switch to "OFF" position.

2. Connect the signal check harness.

GND +24V

3. Disconnect the VNT controller connector.

4. Set the starter switch to "ON" position.

5. Check voltage between the terminals +24V and GND of the

VNT controller connector.
SAPH31J191700038
Standard value: 19 V or more

NO Fault in harness

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–245

4 Check the continuity of harness

1. Check continuity between the terminals VNTH and VNTL of the

VNTH VNT controller connector and the terminals CA3H (E59) and
㧱 E59 CA3L (E79) of the signal check harness respectively.
VNTL
E79

Terminals to measure the resistance

VNT controller side Signal check harness side
VNTH CA3H
VNTL CA3L

SAPH31J191700274 Standard value: 2 Ω or less

NO Fault in harness

YES

Fault VNT controller

[S5LC0033E04] [0518CsCshWbYs]
17–246 ENGINE DIAGNOSIS CODE

AdBlue / DEF SCR

AdBule / DEF SCR

Caution notes in regard to troubleshooting

JP31J19170901001

• Before performing inspection work, confirm that all connectors are engaged securely.
• Always set the starter key to the OFF position before disconnecting connectors.
• Do not repair parts which show signs of damage, but replace them.
• Record the past fault memory before deleting it, perform fault analysis again, and confirm the current faults.
• After completion of fault analysis, delete the past fault memory.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–247

1. Connector Drawings and Terminal Measuring

Lock
Connector indication
In the connector drawings of this manual, the connectors are
shown with the lock at the top and seen from the engagement
side.

Engagement side
Male connector Female connector Connector terminals numbers
When a pair of connectors is seen from the engagement side,
the terminal numbers of both connectors are symmetrical (left
and right reversed).
3 2 1 1 2 3 In this manual, the male connector has the terminal No. 1 at
the right top and the female connector has the terminal No. 1
6 5 4 4 5 6
at the left top.

Male connector Female connector

Caution notes in regard to terminal measuring
Unless specified otherwise, the connector drawings are
shown from the engagement side, but the test probe should
be inserted from the rear.
When the test probe cannot be inserted from the rear in the
case of waterproof connectors etc., it should be inserted
carefully from the front so that the terminal is not damaged.

For connectors provided with a signal check harness for

terminal measuring, the test probe should not be applied
directly from the front or the rear, but terminal measuring
should be performed at the contact box of the connected
signal check harness.

Connector drawings and measuring side

㸿 1 2
4 3 The connector drawings in this manual are shown seen from
5 6
the engagement side, and when the terminal No. 1 of a
View in direction A female connector is to be measured, it is shown at the left top
position as seen from the engagement side.
3 2 At the time of actual measuring: when the test probe is
6 1
5 4 inserted from the rear of the connector, the terminal No. 1 of a
female connector is the top right position as seen from the
rear.
㹀 View in direction B

SAPH31J191700275

NOTICE • When the connector is small and measuring with a normal test probe is difficult, use a
paper clip, a safety pin, a thin wire, etc. to create a check pin.

[S5LC0033E04] [0518CsCshWbYs]
17–248 ENGINE DIAGNOSIS CODE

System block diagram

JP31J19170901002

Check Engine Lamp

Construction machine
DPR Switch
ECU
Information(CAN)
ECU

Common Rail Coolant

Fuel Injection Cut off
EGR Valve System Valve
Boost Ambient
Pressure Temp.
Intake
Sensor Sensor
Temp.
Sensor
Coolant Line
Intake
Throttle

DCU
Air Flow AdBlue/DEF
Sensor Pump
NH3 AdBlue/
slip DEF
SCR catalyst injector

Differential DOC DPR

Pressure
Sensor

AdBlue/DEF
: Exhaust Gas Temp. Sensor
Tank with
: NOx Sensor Temp. sensor
Quality sensor

SAPH31J191700276

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–249

Explanation of Terms
JP31J19170901003

! CAUTION • This manual uses the designations of the engine manufacturer.

• Please compare the conformity of each term with the designation of the machine
manufacturer, as shown in the following table.

Post-processing system

1
15
2
ENGINE 12 14

5 6

16
13 8 7
3 4 11

10

9 15

SAPH31J191700277

1. Conformity table

Designation of the engine manufacturer Designation of the machine manufacturer

1 DCU DCU

2 Muffler unit SCR unit

3 DOC DOC

4 DPR DPF

5 SCR SCR catalyst

6 NH3 slip catalyst NH3 slip catalyst

7 AdBlue/DEF tank DEF tank

8 AdBlue/DEF pump DEF supply module

9 Differential pressure sensor Differential pressure sensor

10 DOC downstream temperature sensor DPF inlet temperature sensor

11 DPR downstream temperature sensor DPF outlet temperature sensor

12 SCR upstream temperature sensor SCR temperature sensor

13 SCR upstream NOx sensor NOx sensor

14 SCR downstream NOx sensor NOx sensor

15 NOx controller NOx sensor controller

16 AdBlue/DEF injector DEF dosing module

[S5LC0033E04] [0518CsCshWbYs]
17–250 ENGINE DIAGNOSIS CODE

AdBlue/DEF pump, AdBlue/DEF tank

1. Conformity table

D D

B
A

G
J
E
F H
I C

8
7

SAPH31J191700278

Designation of the engine manufacturer Designation of the machine manufacturer

7 AdBlue/DEF tank DEF tank

8 AdBlue/DEF pump DEF supply module

A AdBlue/DEF tank filler cap DEF tank fuller cap

B AdBlue/DEF sensor DEF sensor unit

C AdBlue/DEF drain plug DEF tank drain plug

D AdBlue/DEF line DEF line

E AdBlue/DEF pump filter DEF supply module filter

F AdBlue/DEF pump motor DEF pump motor

G AdBlue/DEF pressure sensor DEF pressure sensor

H AdBlue/DEF reverting valve DEF reverting valve

I AdBlue/DEF strainer DEF sensor strainer

J — DEF tank strainer

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–251

Signal check harness

JP31J19170901004

DCU

53-pin connector

11 12 14 15
1 2 3 Machine harness
4 5 6
7 8 9 View in
46 47 48 49 52
arrow direction

SAPH31J191700279

Abbreviati Abbreviati
No. Signal name No. Signal name
on on

CAN communication H line

1 GND1 GND1 11 CAH1
(machine)

CAN communication L line

2 GND2 GND2 12 CAL1
(machine)

CAN communication H line

3 GND3 GND3 14 CAH0
(engine)

CAN communication L line

4 GND4 GND4 15 CAL0
(engine)

5 GND5 GND5 46 TE1B CAN switch 1B

6 +B1 Power supply 1 47 TE1A CAN switch 1A

7 +B2 Power supply 2 48 TE2B CAN switch 2B

8 +B3 Power supply 3 49 TE2A CAN switch 2A

9 +B4 Power supply 4 52 IGSW IG power supply

* Terminals other than the above are not connected.

[S5LC0033E04] [0518CsCshWbYs]
17–252 ENGINE DIAGNOSIS CODE

86-pin connector

8 12 171819 24 26 Machine harness

323334 3839 46
5859 65 View in
79 8586 arrow direction

SAPH31J191700280

Abbreviati Abbreviati
No. Signal name No. Signal name
on on

Ambient air temperature

8 WMV+ Coolant cut-off valve 38 ATS- sensor
(–)

Ambient air temperature

12 DML AdBlue/DEF injector L 39 ATSS sensor
(+)

AdBlue/DEF pressure sensor AdBlue/DEF pump motor

17 PSRS 46 PMP+
signal (+)

AdBlue/DEF pressure sensor

AdBlue/DEF sensor
18 PSR- signal 58 WSR-
(–)
(–)
AdBlue/DEF pressure sensor
AdBlue/AdBlue/DEF sensor
19 PSR+ signal 59 WSIG
(level)
(+)

AdBlue/AdBlue pump
AdBlue/DEF pump motor
24 PMPS 65 PMV- reverting valve
signal
(–)

AdBlue/DEF pump motor AdBlue/DEF sensor

26 PMP- 79 TEMP
(–) (temperature)

Coolant cut-off valve

32 DMH AdBlue/DEF injector H 85 WMV-
(–)

SCR upstream temperature AdBlue/DEF pump reverting

33 EXT+ sensor 86 PMV+ valve
(+) (+)

SCR upstream temperature

34 EXT- sensor
(–)

* Terminals other than the above are not connected.

[S5LC0033E04] [0518CsCshWbYs]
ENGINE DIAGNOSIS CODE 17–253

Pre-inspection
JP31J19170901005

1. Confirmation of the display contents of indicator lamps

and the multi-information display
(1) If warnings are shown by indicator lamps and the multi-
information display, perform the following inspections
because there are abnormalities in the system.

NOTICE • If the lamp does not go out or flashes after

engine start, inspect as described below
because there is an abnormality in the
system.

[S5LC0033E04] [0518CsCshWbYs]
17–254 ENGINE DIAGNOSIS CODE

2. Warning indication and status when lit

(1) AdBlue/DEF quality warning and output limitation

Indication contents Warning contents

Stage 1
(at the time of Displayed when AdBlue/DEF with insufficient quality
abnormality is detected; the buzzer sounds intermittently.
detection)

Displayed alternately when 1 hour has passed after

Stage 2 detection of AdBlue/DEF with insufficient quality: the
(1 hour after engine speed is limited to 60 %, the engine torque is
abnormality limited to 50 %, and the buzzer sounds intermittently.
detection) At this stage, the buzzer cannot be stopped with the
buzzer stop switch.

Displayed when 3.5 hours have passed after

Stage 3
detection of AdBlue/DEF with insufficient quality: the
(3.5 hours after
engine speed is limited to the min. speed, and the
abnormality
buzzer sounds continuously.
detection)
At this stage, the buzzer cannot be stopped with the
(4 hours after
buzzer stop switch.
abnormality
When 4 hours have passed after detection, machine
detection)
operation becomes impossible.

(2) AdBlue/DEF residual quantity warning and output

restriction

Indication contents Warning contents

Displayed when the AdBlue/DEF residual quantity

gauge reaches level 2 (yellow); the buzzer sounds
Stage 1 intermittently.
At this stage, the buzzer can be stopped with the
buzzer stop switch.

Displayed alternately when the AdBlue/DEF residual

quantity gauge reaches level 1 (red): the engine
speed is limited to 60 %, the engine torque is limited
Stage 2
to 50 %, and the buzzer sounds intermittently.
At this stage, the buzzer cannot be stopped with the
buzzer stop switch.
Displayed when the AdBlue/DEF residual quantity
gauge reaches level 0 (no display): the engine speed
is fixed to the min. speed, and the buzzer sounds
continuously.
Stage 3
At this stage, the buzzer cannot be stopped with the
buzzer stop switch.
When 4 hours have passed after detection, machine
operation becomes impossible.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–255

(3) AdBlue/DEF SCR system equipment fault warning and

output limitation

Indication contents Warning contents

When a machine failure or

Exhaust gas (NOx) improper use has been
control system detected and the engine
equipment failure torque has been limited to
75 %, a message reading
"Failed equipment type", a
Stage 1 message reading "Engine
(at the time of AdBlue/DEF injection torque limitation", and a
abnormality equipment failure "Fault code" that can be
detection) used for trouble-shooting
are displayed one after
another, and the buzzer
sounds intermittently.
EGR valve failure At this stage, the buzzer
can be stopped with the
buzzer stop switch

When 1 hour has passed

Exhaust gas (NOx) after detection of
control system equipment failure or
equipment failure improper use, the engine
speed has been limited to
60 %, and the engine
torque has been limited to
50 %, a message reading
AdBlue/DEF injection
"Failed equipment type", a
equipment failure
message reading "Engine
Stage 2
output limitation", and a
"Fault code" that can be
used for trouble-shooting
are displayed one after
another; during this time,
EGR valve failure the buzzer sounds
intermittently.
At this stage, the buzzer
cannot be stopped with the
buzzer stop switch.

[S5LC0033E04] [0518CsCshWbYs]
17–256 ENGINE DIAGNOSIS CODE

Indication contents Warning contents

When 3.5 hours have

Exhaust gas (NOx) passed after detection of
control system equipment failure or
equipment failure improper use, and the
engine speed has been
fixed to the minimum
speed, a message reading
"Failed equipment type", a
AdBlue/DEF injection
message reading "Engine
equipment failure
output limitation", and a
"Fault code" that can be
Stage 3
used for trouble-shooting
are displayed one after
another, and the buzzer
sounds intermittently.
At this stage, the buzzer
EGR valve failure cannot be stopped with the
buzzer stop switch.
When 4 hours have
passed after detection,
machine operation
becomes impossible.

! CAUTION • When other faults also occur at the same

time, they may not be shown in the multi-
information display. Even when not displayed
in the multi-information display, inspection is
required when an indicator lamp lights.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–257

Inspection
JP31J19170901006

1. Pre-inspection
(1) If an error occurs on the system, The DTC code is
indicated in the console panel.
(2) Reading of failure code
a. Connection of Hino-DX
1. Remove the maintenance cover on the rear cover
Maintenance cover behind the operator seat by pushing down the tab at
the top (at one location).

NOTICE • The engine fault diagnosis connector (16 P) is

on the inside.

SAPH31J191700003

2. Connect the engine failure diagnosis connector to

the personal computer which installed Hino-DX
Mechatronic contoroller through the interface box.

Engine failure
diagnostic connector

SAPH31J191700004

3. Set the starter key to "ON" and start Hino-DX.

Failure diagnosis connector
Special tool : 09993-E9070 Hino-Bowie
(Interface box)
09042-1220 Connecting cable
95171-010** DENSO DST-i set
Hino-Bowie CD-ROM Hino-DX
or DST-i

Connecting cable
Connect to the failure diagnosis
connector at the machine side.
SAPH31J191700005

[S5LC0033E04] [0518CsCshWbYs]
17–258 ENGINE DIAGNOSIS CODE

2. Past failure deletion method

(1) To delete past failures of the engine ECU, use Hino-DX on
the personal computer. (Refer to "Hino-DX operation
manual".)

SAPH31J191700006

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–259

3. List of failure diagnosis tools

Part name Part No. External shape General description and function

• Operating system(OS) :
Windows95,
Windows98 (IE5.0 or later),
Windows2000 (SP3, IE5.0 or
later), WindowsXP (SP1a, IE6.0
or later), WindowsVista*2,
Computer Windows7*2
—
(DOS/V standard)
• CPU and memory :
Conditions that assure
operation of the above
operating system
• Display : 800 x 600, 256 colors
or more

• Software and CD-ROM

NOTICE
• Install the software
Hino Diagnostic included in the Hino
eXplorer — Diagnostic eXplorer
(Hino-DX) (Hino-DX) into the
computer. For the
installation method, refer
to the instruction manual
included with the CD.

• Computer interface

! CAUTION
• It is necessary to update
the hardware.

09993 - E9070 • The cable between the personal

Hino-Bowie
*1 computer and the Hino-Bowie is
bundled with the Hino-Bowie.
• Please use either RS-232C or
USB.
Cable bundled
to the Hino-Bowie

• The cable used for connect

between Hino-Bowie and the
adapter cable.
S0904-21220
Connection cable
(09042-1220)
Cable between
unit and Hino-Bowie

[S5LC0033E04] [0518CsCshWbYs]
17–260 ENGINE DIAGNOSIS CODE

Part name Part No. External shape General description and function

DENSO DST-i set • Computer interface

without LCD
without 95171-01020
Bluetooth£

without LCD
95171-01040
with Bluetooth£

with LCD
without 95171-01030
Bluetooth£

with LCD
95171-01050
with Bluetooth£

Signal check Interrupting installation between unit side harness and DCU allows
09843-E9030
harness inspection with a tester rod while the power is supplied.

09843-E9030

*1: To use Hino-Bowie (interface box) 09993-E9070,

update the hardware. For details, refer to the user’s
manual in the Hino-DX CD-ROM.
Keep updating the firmware (software built in the
Hino-Bowie) using the software in the Hino-DX CD-
ROM. For details, refer to the user’s manual in the
Hino-DX CD-ROM.
*2: Hino-DX (Ver. 3.0.5 or later), only when use DST-i.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–261

4. Conformity table for OS and interface

OK: Available
—: Disabled

Tier3 Tier4 Interim Tier4 Final

OS Software ver. Interface Reprog Reprog Reprog
Hino-DX Hino-DX Hino-DX
manager manager manager

DST-i OK OK OK OK OK OK

3.1.5 Bowie w/ CAN — — — — — —

Bowie w/o CAN — — — — — —

DST-i OK OK OK OK — —

3.1.0 Bowie w/ CAN — — — — — —

Bowie w/o CAN — — — — — —

7
DST-i OK OK OK OK — —

3.04/3.05 Bowie w/ CAN — — — — — —

Bowie w/o CAN — — — — — —

DST-i — — — — — —

1.0.9 Bowie w/ CAN — — — — — —

Bowie w/o CAN — — — — — —

DST-i OK OK OK OK OK OK

3.1.5 Bowie w/ CAN OK OK OK OK OK OK

Bowie w/o CAN OK OK — — — —

DST-i OK OK OK OK — —

3.1.0 Bowie w/ CAN OK OK OK OK — —

Bowie w/o CAN OK OK — — — —

XP
DST-i OK OK OK OK — —

3.04/3.05 Bowie w/ CAN OK OK OK OK — —

Bowie w/o CAN OK OK — — — —

DST-i OK OK — — — —

1.0.9 Bowie w/ CAN OK OK — — — —

Bowie w/o CAN OK OK — — — —

[S5LC0033E04] [0518CsCshWbYs]
17–262 ENGINE DIAGNOSIS CODE

AdBlue/DEF leak test

1. AdBlue/DEF leak test

• Activate the AdBlue/DEF pump and an operating state which permits the addition of AdBlue/DEF.
• Inspect the AdBlue/DEF SCR system for normal operation and AdBlue/DEF leakage.

2. Preparations
• Connect the Hino-DX and delete the fault information.
• When the AdBlue/DEF tank temperature is -5 °C {23 °F} or lower, perform warm-up to raise it to 10 °C {50 °F}
or higher.

NOTICE • When the DCU registers a below-zero temperature for the AdBlue/DEF, this function does
not operate. Due to the possibility that the pipe may freeze, the guide value for a freezing
condition has been set higher than the actual AdBlue/DEF freezing temperature (-11 °C {12
°F}).

3. Work procedure
Perform the test with the engine stopped.
(1) Turn the starter key to ON and connect the Hino-DX to the DCU. Select [Aqueous urea solution addition
test] from [Check functions].
(2) Select [Leak test].

Leak test

SAPH31J191700295

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–263

(3) After the AdBlue/DEF pressure has increased, make sure that there is an indication of 850 kPa {8.66 kgf/
cm2, 123.7 lbf/in2} to 950 kPa {9.68 kgf/cm2, 138.2 lbf/in2} after the AdBlue/DEF pressure has stabilized.

NOTICE • Please perform an inspection according to the diagnosis procedure of P20E8 and P20E9 if
there is no pressure.

850 to 950 [kPa]

AdBlue/DEF pump pressure [kPa]

60 [sec] or more

Directly after the pressure increase,

the pressure changes once to
950 [kPa] or higher.

Time [sec]
SAPH31J191700296
(4) Press the button [Close]. The pressure drops and the reverting valve operates.

Close

SAPH31J191700297
(5) The inspection is completed when it has been confirmed that no DTC codes are generated after updating
the fault information.
If DTC codes are generated, inspect according to the respective diagnosis procedure.

[S5LC0033E04] [0518CsCshWbYs]
17–264 ENGINE DIAGNOSIS CODE

AdBlue/DEF addition test

1. AdBlue/DEF addition test

• AdBlue/DEF is injected forcibly, and checking is done whether correct control is possible or not.

2. Preparations
• Prepare the AdBlue/DEF measuring vessel.
The size of the measuring vessel should be sufficient to avoid any spillage when AdBlue/DEF is sprayed from
the injector.
• Disconnect the AdBlue/DEF injector from the muffler assembly. Refer to "Exhaust, AdBlue/DEF injector,
replacement"

! CAUTION • Always perform the addition test after removing the AdBlue/DEF injector.
When the test is performed with the AdBlue/DEF injector installed on the muffler, AdBlue/
DEF accumulates in the muffler, which leads to a deterioration of the AdBlue/DEF SCR.

• Connect the Hino-DX and delete the fault information.

• When the AdBlue/DEF tank temperature is -5 °C {23 °F} or lower, perform warm-up to raise it to 10 °C {50 °F}
or higher.

NOTICE • When the DCU registers a below-zero temperature for the AdBlue/DEF, this function does
not operate. Due to the possibility that the pipe may freeze, the guide value for a freezing
condition has been set higher than the actual AdBlue/DEF freezing temperature (-11 °C {12
°F}).

3. Work procedure
• Perform the test with the engine stopped.
• The test pattern shows three different quantities for adding, but the operation procedure is the same.
– Pattern 1 Addition quantity: 30 cc
– Pattern 2 Addition quantity: 50 cc
– Pattern 3 Addition quantity: 150 cc

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–265

(1) Turn the starter key to ON and connect the Hino-DX to [DCU].
Select [Aqueous urea solution addition test] from [Function confirmation].
(2) Set up the injector and the measuring vessel, and select the test pattern on the Hino-DX screen.

Test pattern

SAPH31J191700298
(3) The quantity corresponding to the selected pattern is injected from the injector.
After completion of injection, measure the AdBlue/DEF quantity in the measuring vessel.

Standard value

Pattern Addition quantity (cc)

1 25 to 30

2 42 to 50
3 128 to 150

[S5LC0033E04] [0518CsCshWbYs]
17–266 ENGINE DIAGNOSIS CODE

(4) Press the button [Close]. The pressure drops and the reverting valve operates.

Close

SAPH31J191700299

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–267

Table of failure code

JP31J19170901007

NOTICE • When the DCU has indicated a DTC code other than P203F, P207F, or P20EE, a DCU data
selection abnormality (DTC code P204F) has occurred in the engine ECU.

DTC Code Detection item

P0071 Ambient air temperature sensor - rationality

P0072 Ambient air temperature sensor failure [Low]

P0073 Ambient air temperature sensor failure [High]

P0562 Battery failure [Low]

P0563 Battery failure [High]

P060C Dosing control unit failure

P062F Dosing control unit failure

P0667 Abnormal temperature sensor of the dosing control unit

P0668 Dosing control unit temperature sensor failure [Low]

P0669 Dosing control unit temperature sensor failure [High]

P068A Main relay failure

P142A AdBlue/DEF pump temperature sensor failure

P142B Abnormal AdBlue/DEF pump temperature sensor

P202E Abnormal AdBlue/DEF injector

P203B AdBlue/DEF tank level sensor failure

P203C AdBlue/DEF tank level sensor failure [Low]

P203D AdBlue/DEF tank level sensor failure [High]

P2044 AdBlue/DEF tank temperature sensor - out of range (Out of range low)

P2045 AdBlue/DEF tank temperature sensor - out of range (Out of range high)

P2047 AdBlue/DEF injector failure

P2048 AdBlue/DEF injector failure [Low]

P2049 AdBlue/DEF injector failure [High]

P204B Abnormal AdBlue/DEF pressure sensor

P204C AdBlue/DEF pressure sensor failure [Low]

P204D AdBlue/DEF pressure sensor failure [High]

P205B Abnormal AdBlue/DEF tank temperature sensor

P205C AdBlue/DEF tank temperature sensor failure [Low]

P205D AdBlue/DEF tank temperature sensor failure [High]

P206A Reductant quality sensor - malfunction

P208A AdBlue/DEF pump motor failure [Open]

P208B Abnormal AdBlue/DEF pump motor

P208C AdBlue/DEF pump motor failure [Low]

[S5LC0033E04] [0518CsCshWbYs]
17–268 ENGINE DIAGNOSIS CODE

DTC Code Detection item

P208D AdBlue/DEF pump motor failure [High]

P20A0 AdBlue/DEF pump reverting valve failure [Open]

P20A1 Reverting valve for AdBlue/DEF pump stuck close

P20A2 AdBlue/DEF pump reverting valve failure [Low]

P20A3 AdBlue/DEF pump reverting valve failure [High]

P20B1 Coolant cut-off valve failure [Open]

P20B2 Coolant cut-off valve failure

P20B3 Coolant cut-off valve failure [Low]

P20B4 Coolant cut-off valve failure [High]

P20E8 Abnormal AdBlue/DEF piping pressure [Low]

P20E9 Abnormal AdBlue/DEF piping pressure [High]

P20F4 AdBlue/DEF consumption failure

P2201 SCR upstream NOx sensor - Performance and Monitoring capability

P2202 Failure of the upstream NOx sensor

P2203 SCR upstream NOx sensor and Heater - Circuit (Circuit short)

P2204 SCR upstream NOx sensor - Feedback

P2209 Abnormal upstream NOx sensor heater

P2212 SCR downstream NOx sensor - Feedback

P2214 SCR downstream NOx sensor - Performance and Monitoring capability

P2215 Abnormal downstream NOx sensor

P2216 SCR downstream NOx sensor - and Heater - Circuit (Circuit short)

P2222 Abnormal downstream NOx sensor heater

P2481 SCR upstream temperature sensor - out of range (Out of range low)

P2482 SCR upstream temperature sensor - out of range (Out of range high)
P2483 SCR upstream temperature sensor - rationality

P2510 DCU Power Relay Sense Circuit Range/ Performance

U0029 Vehicle Communication Bus A Performance

U0038 Vehicle Communication Bus B Performance

U0100 Faulty CAN communication

U029D Engine ECU CAN communication (SCR upstream NOx sensor)

U029E Engine ECU CAN communication (SCR downstream NOx sensor)

U02A2 DCU CAN communication (AdBlue/DEF tank sensor)

U0597 DCU failure

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–269

DTC code P0071

Ambient air temperature sensor - rationality

JP31J19170901008

1 Inspect the ambient air temperature sensor connector

1. Check the connection of the ambient air temperature sensor

connector (Looseness and poor contact).

NO Connect securely, repair if needed.

YES

2 Inspect the connector of the external resistor

1. Check the connection of the external resistor connector

(Looseness and poor contact).

NO Connect securely, repair if needed.

YES

3 Inspect the DCU 86P connector

1. Check the connection of the DCU 86P connector (Looseness

and poor contact).

NO Connect securely, repair if needed.

YES

4 Inspect the ambient air temperature sensor

1. Check the installation of the ambient air temperature sensor.

2. Make sure there is no dirt or damage to the ambient air

temperature sensor.

NO Clean the ambient air temperature sensor and install

it properly. If damaged, replace the ambient air
temperature.

YES

[S5LC0033E04] [0518CsCshWbYs]
17–270 ENGINE DIAGNOSIS CODE

5 Inspect the ambient air temperature sensor unit

1. Set the starter switch to the "OFF" position.

HH1+ HH1-
2. Disconnect the ambient air temperature sensor connector.

3. Use the electrical tester to measure the resistance between the

terminals of the ambient air temperature sensor.

Measurement Tester
Standard values
conditions connections

SAPH31J191700300 Ambient air

5,500 ± 275 Ω (0 °C {32 °F})
Starter temperature
3,365 ± 168.25 Ω (10 °C {50 °F})
switch: OFF sensor
1,700 ± 85 Ω (25 °C {77 °F})
HH1+ – HH1-

NO Replace the ambient air temperature sensor.

YES

6 Inspect the external resistor unit

1. Disconnect the external resistor connector.

ER- ER+
2. Use the electrical tester to measure the resistance between the
terminals of the external resistor.

Measurement Tester
Standard values
conditions connections

External
Starter switch:
resistor 2 kΩ
OFF
SAPH31J191700301 ER+ – ER-

NO Replace the external resistor.

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–271

7 Inspect the sensor power supply

1. Connect the external resistor connector.

2. Set the starter switch to the "ON" position.

HH1+ HH1+ HH1-
LJK LGK
HH1-
3. Use the electrical tester to measure the voltage between the
terminals of the ambient air temperature sensor machine-side
connector.

Measurement Tester
Standard values
conditions connections
SAPH31J191700302

Ambient air
temperature
Starter switch: sensor
4.5 – 5.5 V
ON machine-side
connector
HH1+ – HH1-

NO Go to step 8.

YES

Go to step 10.

[S5LC0033E04] [0518CsCshWbYs]
17–272 ENGINE DIAGNOSIS CODE

8 Inspect for short-circuit in the ambient air temperature sensor harness

1. Set the starter switch to the "OFF" position.

2. Disconnect the DCU 86P connector.

3. Connect the signal check harness and use the electrical tester
to measure the resistance between the terminals of the DCU
86P machine-side connector and the ground.

ATS- ATSS

SAPH31J191700303

Measurement Tester
Standard values
conditions connections

DCU 86P
machine-side
Starter switch:
connector ∞Ω
OFF
ATSS – Ground
ATS- – Ground

NO Repair or replace the harness.

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–273

9 Inspect for disconnections of the ambient air temperature sensor harness

1. Connect the ambient air temperature sensor connector.

2. Connect the signal check harness and use the electrical tester
to measure the resistance between the terminals of the DCU
86P machine-side connector.

ATS- ATSS

SAPH31J191700304

Measurement Tester
Standard values
conditions connections

5,500 ± 275 Ω (0
DCU 86P °C {32 °F})
Starter switch: machine-side 3,365 ± 168.25 Ω
OFF connector (10 °C {50 °F})
ATSS – ATS- 1,700 ± 85 Ω (25
°C {77 °F})

NO Repair or replace the harness.

YES

10 Inspect the engine coolant temperature sensor connector

1. Check the connection of the engine coolant temperature

sensor connector (Looseness and poor contact).

NO Connect securely, repair if needed.

YES

[S5LC0033E04] [0518CsCshWbYs]
17–274 ENGINE DIAGNOSIS CODE

11 Inspect the engine coolant temperature sensor

1. Check the installation of the engine coolant temperature

sensor.

2. Make sure there is no dirt or damage to the engine coolant

temperature sensor.

NO Clean the engine coolant temperature sensor and

install it properly. If damaged, replace the engine
coolant temperature sensor.

YES

12 Inspect the engine coolant temperature sensor unit

1. Disconnect the engine coolant temperature sensor connector.

WTM- WTM+
2. Use the electrical tester to measure the resistance between the
terminals of the engine coolant temperature sensor.

Measurement Tester
Standard values
conditions connections
Engine coolant 20 °C {68 °F}:
Starter switch: temperature 2.59 – 2.32 kΩ
SAPH31J191700305 OFF sensor 80 °C {176 °F}:
WTM+ – WTM- 0.326 – 0.310 kΩ

NO Replace the engine coolant temperature sensor.

YES

13 Inspect the SCR upstream temperature sensor connector

1. Check the connection of the SCR upstream temperature

sensor connector (Looseness and poor contact).

NO Connect securely, repair if needed.

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–275

14 Inspect the SCR upstream temperature sensor

1. Check the installation of the SCR upstream temperature

sensor.

2. Make sure there is no dirt or damage to the SCR upstream

temperature sensor.

NO Clean the exhaust gas temperature sensor and

install it properly. If damaged, replace the SCR
upstream temperature sensor.

YES

15 Inspect the SCR upstream temperature sensor unit

1. Set the starter switch to the "OFF" position.

FAT- FAT+
2. Disconnect the SCR upstream temperature sensor connector.

3. Use the electrical tester to measure the resistance between the

terminals of the SCR upstream temperature sensor.

Measurement Tester
Standard values
conditions connections

SAPH31J191700306 SCR upstream

Starter switch: temperature 20 °C {68 °F}:
OFF sensor 220 Ω
FAT+ – FAT-

NO Replace the SCR upstream temperature sensor.

YES

16 Check the DTC detected (DCU)

1. Check the connection of the AdBlue/DEF pump temperature

sensor connector (Looseness and poor contact).

NO Connect securely, repair if needed.

YES

[S5LC0033E04] [0518CsCshWbYs]
17–276 ENGINE DIAGNOSIS CODE

17 Inspect the SCR upstream temperature sensor

1. Perform an engine warm-up. (Water temperature: 60 °C {140

°F} or more)

Select 2. Stop the engine.

DCU
3. Set the starter switch to the "ON" position.

4. Select [DCU] and check if P0071 has been detected in [Fault

Information].

SAPH31J191700307
NO Replace the DCU.

YES

Procedure completed.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–277

DTC code P0072

Ambient air temperature sensor failure [Low]

DTC code P0073

Ambient air temperature sensor failure [High]
JP31J19170901009

1 Resistance measuring for the ambient air temperature sensor

1. Measure the resistance between terminals 1 and 2 of the

connector of the ambient air temperature sensor (on the
component side).

Standard value
5,500 ± 275 Ω (0 °C {32 °F})
3,365 ± 168.25 Ω (10 °C {50 °F})
1,700 ± 85 Ω (25 °C {77 °F})

NO Abnormal ambient air temperature sensor

SAPH31J191700308

YES

2 Resistance measuring for external resistance + ambient temperature sensor

1. Connect the connector of the ambient air temperature sensor.

2. Measure the resistance between terminals 38 and 39 of the 86-

pin connector of the DCU (on the machine harness side).

Standard value:Standard value: (A) + (B)

(A) (B)

Ambient air Ambient air

External
temperature temperature
SAPH31J191700309 resistance (Ω)
°C (°F) sensor (Ω)

0 (32) 5,500 ± 275

10 (50) 3,365 ± 168.25 2,000 ± 100

25 (77) 1,700 ± 85

NO Harness abnormal

YES

[S5LC0033E04] [0518CsCshWbYs]
17–278 ENGINE DIAGNOSIS CODE

3 Diagnosis trouble code reconfirmation

1. After deleting the past faults in the ECU with Hino-DX,

indicated the current failure again.

2. Replace the DCU if the same diagnosis trouble code is

indicated.
(After replacement, perform a DPR forced regeneration.)

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–279

DTC code P0562

Battery failure [Low]
DTC code P0563
Battery failure [High]
JP31J19170901010

1 Battery voltage measuring

1. Measure the voltage between the battery terminals.

Standard value: Approx. 19 – 32 V

NO Battery abnormal

YES

2 Measuring the voltage between terminals

1. Set the starter key to "OFF", and then disconnect pin 53 of the
Chassis GND
DCU.

2. Set the starter key to "ON", and then measure the voltage
between the following terminals of the DCU 53-pin connector
(on the machine harness side) and chassis GND.

Terminal 6
Terminal 7
Chassis GND
SAPH31J191700310 Terminal 8
Terminal 9

Standard value: 19 – 32 V

NO Harness abnormal

YES

[S5LC0033E04] [0518CsCshWbYs]
17–280 ENGINE DIAGNOSIS CODE

3 Conductivity measuring between terminals

1. Set the starter key to "OFF", and then measure the conductivity
Chassis GND
between the following terminals of the DCU 53-pin connector
(on the machine harness side) and chassis GND.

Terminal 1
Terminal 2
Terminal 3 Chassis GND
Terminal 4
Terminal 5
SAPH31J191700311

Standard: Conductivity

NO Harness abnormal

YES

DCU replacement (after replacement, perform a DPR forced regeneration)

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–281

DTC code P060C

Dosing control unit failure
JP31J19170901011

1 Diagnosis trouble code reconfirmation

1. Set the starter key from "ON" to "OFF", and then wait until the
main relay of the DCU switches off. (After completion of the
pump after-run drive : 5 minutes)

2. Use the Hino-DX to delete past failures, and if the same

diagnosis trouble code is indicated again after engine start,
replace the DCU.
(After replacement, perform a "Leak test".)

[S5LC0033E04] [0518CsCshWbYs]
17–282 ENGINE DIAGNOSIS CODE

DTC code P062F

Dosing control unit failure
JP31J19170901012

1 Diagnosis trouble code reconfirmation

1. Set the starter key from "ON" to "OFF", and then wait until the
main relay of the DCU switches off. (After completion of the
pump after-run drive : 5 minutes)

2. Use the Hino-DX to delete past failures, and if the same

diagnosis trouble code is indicated again after engine start,
replace the DCU.
(After replacement, perform a "Leak test".)

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–283

DTC code P0667

Abnormal temperature sensor of the dosing control unit
JP31J19170901013

1 DCU replacement

1. Replace the DCU. (After replacement, perform a "Leak test".)

[S5LC0033E04] [0518CsCshWbYs]
17–284 ENGINE DIAGNOSIS CODE

DTC code P0668

Dosing control unit temperature sensor failure [Low]
JP31J19170901014

1 DCU replacement

1. Replace the DCU. (After replacement, perform a "Leak test".)

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–285

DTC code P0669

Dosing control unit temperature sensor failure [High]
JP31J19170901015

1 DCU replacement

1. Replace the DCU. (After replacement, perform a "Leak test".)

[S5LC0033E04] [0518CsCshWbYs]
17–286 ENGINE DIAGNOSIS CODE

DTC code P068A

Main relay failure
JP31J19170901016

1 Diagnosis trouble code reconfirmation

1. Set the starter key from "ON" to "OFF", and then wait until the
main relay of the DCU switches off. (After completion of the
pump after-run drive : 5 minutes)

2. Use the Hino-DX to delete past failures, and if the same

diagnosis trouble code is indicated again after engine start,
replace the DCU.
(After replacement, perform a "Leak test".)

NOTICE • If the battery switch is turned OFF or a battery

terminal is disconnected during the DCU
shutdown process, Diagnostic Code P068A
may be detected.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–287

DTC code P142A

AdBlue/DEF pump temperature sensor failure
DTC code P208A
AdBlue/DEF pump motor failure [Open]
DTC code P208C
AdBlue/DEF pump motor failure [Low]
DTC code P208D
AdBlue/DEF pump motor failure [High]
JP31J19170901017

1 Conductivity measuring between terminals

1. Set the starter key to "OFF", and then disconnect the 86-pin
26 10 11
24 9 connector of the DCU and the AdBlue/DEF pump connector.

2. Measure the conductivity between the following terminals of

46
the DCU 86-pin connector (on the machine harness side) and
the AdBlue/DEF pump connector (on the machine harness
side).

DCU 86-pin connector AdBlue/DEF pump

SAPH31J191700312 Terminal 24 Terminal 9
Terminal 26 Terminal 11
Terminal 46 Terminal 10

Standard: Conductivity

NO Harness abnormal

YES

2 DCU inspection

1. Connect the connector of the AdBlue/DEF pump.

2. Connect a new DCU, set the starter key to "ON", and then
check for output of the DTC code P142A.
Standard: No P142A output

NO Go to [3] AdBlue/DEF pump inspection

YES

As the DCU before the replacement was abnormal, install the new DCU (after replacement, perform a DPR forced
regeneration)

[S5LC0033E04] [0518CsCshWbYs]
17–288 ENGINE DIAGNOSIS CODE

3 AdBlue/DEF pump inspection

1. Return the original DCU and replace the AdBlue/DEF pump.

2. Set the starter key to "ON", and then check for output of the
DTC code P142A.
Standard: No P142A output

NO DCU replacement (after replacement, perform a

DPR forced regeneration)

YES

Normal

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–289

DTC code P142B

Abnormal AdBlue/DEF pump temperature sensor
JP31J19170901018

NOTICE • For correction of the abnormality using the following procedure, use the Hino-DX to delete
past faults, then set the starter key to "ON", and then make sure that the DTC code P142B
is not indicated.

1 Resistance measuring for the ambient air temperature sensor

1. Set the starter key to "OFF", and then disconnect the connector
of the ambient air temperature sensor.

2. Measure the resistance between terminals 1 and 2 of the

connector of the ambient air temperature sensor (on the
component side).

Standard value
5,500 ± 275 Ω (0 °C {32 °F})
3,365 ± 168.25 Ω (10 °C {50 °F})
SAPH31J191700313
1,700 ± 85 Ω (25 °C {77 °F})

NO Abnormal ambient air temperature sensor

YES

2 Resistance measuring for external resistance + ambient temperature sensor

1. Set the starter key to "OFF", connect the connector of the

ambient air temperature sensor, and then disconnect the 86-
pin connector of the DCU.

2. Measure the resistance between terminals 38 and 39 of the 86-

pin connector of the DCU (on the machine harness side).

Standard value: (A) + (B)

(A) (B)
SAPH31J191700314
Ambient air Ambient air
External
temperature temperature
resistance (Ω)
°C (°F) sensor (Ω)

0 (32) 5,500 ± 275

10 (50) 3,365 ± 168.25 2,000 ± 100

25 (77) 1,700 ± 85

NO Abnormal external resistance

YES

[S5LC0033E04] [0518CsCshWbYs]
17–290 ENGINE DIAGNOSIS CODE

3 Resistance measuring for the SCR upstream temperature sensor

1. Set the starter key to "OFF", and then disconnect the connector
of the SCR upstream temperature sensor.

2. Measure the resistance between terminals 1 and 2 of the

connector of the ambient air temperature sensor (SCR
upstream) (on the component side).

Standard value
197.67 to 205.33 Ω (0 °C {32 °F})
216.77 to 224.37 Ω (25 °C {77 °F})
SAPH31J191700315
235.73 to 243.25 Ω (50 °C {122 °F})

NO Abnormal SCR upstream temperature sensor

YES

4 Engine coolant temperature sensor resistance measuring

1. Set the starter key to "OFF", and then disconnect the connector
of the engine coolant temperature sensor.

2. Measure the resistance between terminals 1 and 3 of the

connector of the engine coolant temperature sensor (on the
component side).

Standard value (measure one of the following points)

: 2.45 kΩ (water temperature 20 °C {68 °F})
: 1.15 kΩ (water temperature 40 °C {104 °F})
SAPH31J191700316
: 584 Ω (water temperature 60 °C {140 °F})
: 318 Ω (water temperature 80 °C {176 °F})

NO Abnormal engine coolant temperature sensor

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–291

5 Inspect the coolant cut-off valve

1. Turn the starter key to "OFF", and then connect all connectors.

2. Turn the starter key from "OFF" directly to engine start.

3. Immediately after starting the engine, confirm by touch that the

pressure in the coolant piping on the downstream side of the
cut-off valve rises.

4. After 20 seconds, confirm by touch that the pressure in the

coolant piping on the downstream side of the cut-off valve is
released.

! CAUTION • Be careful to avoid burns from hot engine

coolant.

NO Go to [6] Coolant piping inspection

YES

AdBlue/DEF pump replacement

6 Coolant piping inspection

1. Inspect the coolant piping for breakage, bending, and leakage.

2. Disconnect the joints on both ends of the coolant piping, blow

in air from one side and confirm that it comes out at the other
side.

NO Coolant piping replacement

YES

Coolant cut-off valve replacement

[S5LC0033E04] [0518CsCshWbYs]
17–292 ENGINE DIAGNOSIS CODE

DTC code P202E

Abnormal AdBlue/DEF injector
JP31J19170901019

NOTICE • To correct an abnormality using the following procedure, check the AdBlue/DEF addition
quantity first, and then check again for a fault indication.

1 AdBlue/DEF piping inspection

1. Inspect the AdBlue/DEF piping (between pump and injector) for

breakage, bending, and collapsed sections.

2. Disconnect the joints on both ends of the AdBlue/DEF piping

(between pump and injector), blow in air from one side and
confirm that it comes out at the other side.

! CAUTION • Before the start of work, operate the air gun

once or twice to remove dirt and foreign
matter sticking to the tip of the air gun.

NO Replace AdBlue/DEF piping (Pump ↔ Injector) and

go to step [2].

YES

2 AdBlue/DEF addition quantity inspection

1. Remove the injector from the muffler.

2. Connect the macine to Hino-DX and select [DCU].

Perform the AdBlue/DEF addition test from activation test.
Standard: The AdBlue/DEF addition quantity is within
the limits.

NO Go to step [3].
If AdBlue/DEF pressure is abnormal, proceed to
failure diagnosis method (P20E8, P20E9).

YES

Normal (clogging from AdBlue/DEF crystallization is a possibility)

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–293

3 Inspection of the AdBlue/DEF addition quantity

1. Replace the AdBlue/DEF injector with new one and check the
AdBlue/DEF addition quantity.
(1) With the injector disconnected from the muffler, perform
the AdBlue/DEF addition test again.
Standard: The AdBlue/DEF addition quantity is within
the limits.

NO Replace AdBlue/DEF piping (Pump ↔ Injector) and

go to step [2].

YES

Install a new AdBlue/DEF injector.

[S5LC0033E04] [0518CsCshWbYs]
17–294 ENGINE DIAGNOSIS CODE

DTC code P203B

AdBlue/DEF tank level sensor failure
DTC code P203C
AdBlue/DEF tank level sensor failure [Low]
DTC code P203D
AdBlue/DEF tank level sensor failure [High]
JP31J19170901020

1 Check the DTC detected (Engine) [Hino-DX]

1. Connect the machine to Hino-DX.

2. Set the starter switch to the "ON" position.

Select 3. Select [Engine] and check if any DTC other than P203B,
Engine
P203C or P203D has been detected in [Fault Information].

NO Go to diagnosis procedure of a related DTC.

SAPH31J191700317

YES

Replace the AdBlue/DEF tank unit sensor.

After replacement, set the starter switch to the "ON" positon and make sure that no DTC code is detected.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–295

DTC code P2044

AdBlue/DEF tank temperature sensor - out of range (Out of range low)
DTC code P2045
AdBlue/DEF tank temperature sensor - out of range (Out of range high)
JP31J19170901021

1 Check the DTC detected (Engine) [Hino-DX]

1. Connect the machine to Hino-DX.

2. Set the starter switch to the "ON" position.

Select 3. Select [Engine] and check if any DTC other than P2044 or
Engine
P2045 has been detected in [Fault Information].

NO Go to diagnosis procedure of a related DTC.

SAPH31J191700317

YES

Replace the AdBlue/DEF tank unit sensor.

After replacement, set the starter switch to the "ON" positon and make sure that no DTC code is detected.

[S5LC0033E04] [0518CsCshWbYs]
17–296 ENGINE DIAGNOSIS CODE

DTC code P2047

AdBlue/DEF injector failure
JP31J19170901022

1 AdBlue/DEF addition quantity inspection

1. Inspect the injector AdBlue/DEF addition quantity.

NO Abnormal AdBlue/DEF injector

YES

Normal (Temporary clogging from AdBlue/DEF crystallization)

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–297

DTC code P2048

AdBlue/DEF injector failure [Low]
DTC code P2049
AdBlue/DEF injector failure [High]
JP31J19170901023

1 Resistance measuring between terminals

1. Set the starter key to "OFF", and then disconnect the connector
of the AdBlue/DEF injector.

2. Measure the resistance between terminals 1 and 2 of the

connector of the AdBlue/DEF injector (on the component side).

Standard value: 11.4 to 12.6 Ω (20 °C {68 °F})

NO Abnormal AdBlue/DEF injector

SAPH31J191700318

YES

2 Resistance measuring between terminals

1. Set the starter key to "OFF", connect the connector of the

AdBlue/DEF injector, and then disconnect the 86-pin connector
of the DCU.

2. Measure the resistance between terminals 12 and 32 of the 86-

pin connector of the DCU (on the machine harness side).

Standard value: 11.4 to 12.6 Ω (20 °C {68 °F})

NO Harness abnormal
SAPH31J191700319

YES

DCU replacement (after replacement, perform a DPR forced regeneration)

[S5LC0033E04] [0518CsCshWbYs]
17–298 ENGINE DIAGNOSIS CODE

DTC code P204B

Abnormal AdBlue/DEF pressure sensor
JP31J19170901024

1 Diagnosis trouble code confirmation

1. Stop the engine, wait for some time, set the starter key to "ON",
and then check for output of the DTC code P204B as a past
fault.
(Monitor the pressure with the Hino-DX and confirm that it is –
50 kPa {–0.5 kgf/cm2, –7.3 lbf/in2} to 50 kPa {0.5 kgf/cm2, 7.3
lbf/in2}.)

NO Abnormal AdBlue/DEF pump

YES

Normal (this was caused by setting the starter key to "ON" before returning to the equivalent of atmospheric
pressure)

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–299

DTC code P204C

AdBlue/DEF pressure sensor failure [Low]
DTC code P204D
AdBlue/DEF pressure sensor failure [High]
JP31J19170901025

1 Conductivity measuring between terminals

1. Set the starter key to "OFF", and then disconnect the 86-pin
18 19 4 5
17 3 connector of the DCU and the AdBlue/DEF pump connector.

2. Measure the conductivity between the following terminals of

the DCU 86-pin connector (on the machine harness side) and
the AdBlue/DEF pump connector (on the machine harness
side).

DCU 86-pin connector AdBlue/DEF pump

SAPH31J191700320 Terminal 17 Terminal 4
Terminal 18 Terminal 3
Terminal 19 Terminal 5

Standard: Conductivity

NO Harness abnormal

YES

2 Resistance measuring between terminals

1. Set the starter key to "OFF", and then connect the connector of
the AdBlue/DEF pump.

2. Measure the resistance between the following terminals of the

86-pin connector of the DCU (on the machine harness side).

Measuring terminals Standard value

Terminal 17 Terminal 18 324 to 396 kΩ
Terminal 17 Terminal 19 144 to 176 kΩ
SAPH31J191700321 Terminal 18 Terminal 19 180 to 220 kΩ

NO Abnormal AdBlue/DEF pump

YES

DCU replacement (after replacement, perform a DPR forced regeneration)

[S5LC0033E04] [0518CsCshWbYs]
17–300 ENGINE DIAGNOSIS CODE

DTC code P205B

Abnormal AdBlue/DEF tank temperature sensor
JP31J19170901026

NOTICE • For correction of the abnormality using the following procedure, use the Hino-DX to delete
past faults, then set the starter key to "ON", and then make sure that the DTC code P205B
is not indicated.

1 AdBlue/DEF temperature inspection

1. Use the Hino-DX to monitor the temperature of the AdBlue/

DEF tank.

2. Place a thermometer into the AdBlue/DEF tank and compare

with the Hino-DX value.
Standard value: Approximately the same value

NO Abnormal AdBlue/DEF tank temperature sensor

YES

2 Resistance measuring for the ambient air temperature sensor

1. Set the starter key to "OFF", and then disconnect the connector
of the ambient air temperature sensor.

2. Measure the resistance between terminals 1 and 2 of the

connector of the ambient air temperature sensor (on the
component side).

Standard value
5,500 ± 275 Ω (0 °C {32 °F})
3,365 ± 168.25 Ω (10 °C {50 °F})
SAPH31J191700322
1,700 ± 85 Ω (25 °C {77 °F})

NO Abnormal ambient air temperature sensor

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–301

3 Resistance measuring for external resistance + ambient temperature sensor

1. Set the starter key to "OFF", connect the connector of the

ambient air temperature sensor, and then disconnect the 86-
pin connector of the DCU.

2. Measure the resistance between terminals 38 and 39 of the 86-

pin connector of the DCU (on the machine harness side).

Standard value: (A) + (B)

(A) (B)
SAPH31J191700323
Ambient air Ambient air
External
temperature temperature
resistance (Ω)
°C (°F) sensor (Ω)

0 (32) 5,500 ± 275

10 (50) 3,365 ± 168.25 2,000 ± 100

25 (77) 1,700 ± 85

NO Abnormal external resistance

YES

4 Resistance measuring for the SCR upstream temperature sensor

1. Set the starter key to "OFF", and then disconnect the connector
of the SCR upstream temperature sensor.

2. Measure the resistance between terminals 1 and 2 of the

connector of the ambient air temperature sensor (SCR
upstream) (on the component side).

Standard value
197.67 to 205.33 Ω (0 °C {32 °F})
216.77 to 224.37 Ω (25 °C {77 °F})
SAPH31J191700324
235.73 to 243.25 Ω (50 °C {122 °F})

NO Abnormal SCR upstream temperature sensor

YES

[S5LC0033E04] [0518CsCshWbYs]
17–302 ENGINE DIAGNOSIS CODE

5 Engine coolant temperature sensor resistance measuring

1. Set the starter key to "OFF", and then disconnect the connector
of the engine coolant temperature sensor.

2. Measure the resistance between terminals 1 and 2 of the

connector of the engine coolant temperature sensor (on the
component side).

Standard value (measure one of the following points)

: 2.45 kΩ (water temperature 20 °C {68 °F})
: 1.15 kΩ (water temperature 40 °C {104 °F})
SAPH31J191700325
: 584 Ω (water temperature 60 °C {140 °F})
: 318 Ω (water temperature 80 °C {176 °F})

NO Abnormal engine coolant temperature sensor

YES

6 Diagnosis trouble code reconfirmation

1. After deleting the past faults in the ECU with Hino-DX, indicate
the current failure code again.

2. Replace the DCU if the same diagnosis trouble code is

indicated.
(After replacement, perform "Leak test".)

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–303

DTC code P205C

AdBlue/DEF tank temperature sensor failure [Low]
DTC code P205D
AdBlue/DEF tank temperature sensor failure [High]
JP31J19170901027

1 Check the DTC detected (Engine) [Hino-DX]

1. Connect the machine to Hino-DX.

2. Set the starter switch to the "ON" position.

Select 3. Select [Engine] and check if a CAN communication system

Engine
malfunction (U02A2) has been detected in [Fault Information].

NO Replace the AdBlue/DEF tank unit sensor.

After replacement, set the starter switch to the "ON"
SAPH31J191700317
positon and make sure that no DTC code is
detected.

YES

Go to diagnosis procedure of a related DTC.

[S5LC0033E04] [0518CsCshWbYs]
17–304 ENGINE DIAGNOSIS CODE

DTC code P206A

Reductant quality sensor - malfunction
JP31J19170901028

1 Check the DTC detected (Engine) [Hino-DX]

1. Connect the machine to Hino-DX.

2. Set the starter switch to the "ON" position.

Select 3. Select [Engine] and check if any DTC other than P206A have
Engine
been detected in [Fault Information].

NO Go to diagnosis procedure of a related DTC.

SAPH31J191700326

YES

Replace the AdBlue/DEF quality sensor.

After replacement, set the starter switch to the "ON" positon and make sure that no DTC code is detected.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–305

DTC code P208B

Abnormal AdBlue/DEF pump motor
JP31J19170901029

1 AdBlue/DEF pump replacement

1. Replace the AdBlue/DEF pump.

2. After replacement, perform a "Leak test".

[S5LC0033E04] [0518CsCshWbYs]
17–306 ENGINE DIAGNOSIS CODE

DTC code P20A0

AdBlue/DEF pump reverting valve failure [Open]
DTC code P20A2
AdBlue/DEF pump reverting valve failure [Low]
DTC code P20A3
AdBlue/DEF pump reverting valve failure [High]
JP31J19170901030

1 Conductivity measuring between terminals

1. Set the starter key to "OFF", and then disconnect the 86-pin
7
65 86 8 connector of the DCU and the AdBlue/DEF pump connector.

2. Measure the conductivity between the following terminals of

the DCU 86-pin connector (on the machine harness side) and
the AdBlue/DEF pump connector (on the machine harness
side).

DCU 86-pin connector AdBlue/DEF pump

SAPH31J191700327 Terminal 65 Terminal 7
Terminal 86 Terminal 8

Standard: Conductivity

NO Harness abnormal

YES

2 Resistance measuring between terminals

1. Set the starter key to "OFF", and then connect the connector of
the AdBlue/DEF pump.

2. Measure the resistance between terminals 65 and 86 of the 86-

pin connector of the DCU (on the machine harness side).

Standard value: 17.29 to 19.11 Ω (23 °C {74 °F})

NO Abnormal AdBlue/DEF pump

SAPH31J191700328

YES

DCU replacement (after replacement, perform a DPR forced regeneration)

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–307

DTC code P20A1

Reverting valve for AdBlue/DEF pump stuck close

JP31J19170901031

1 Check the operation of the AdBlue/DEF pump (reverting valve) [Hino-DX]

1. Set the starter switch to the "OFF" position.

2. Connect the machine to Hino-DX.

Select 3. Set the starter switch to the "ON" position.

DCU

4. Select [DCU] from the menu.

5. Select [Reverting valve] from [Activation Test] and check the

operating sound of the reverting valve.
SAPH31J191700329

NO Replace AdBlue/DEF pump.

YES

2 Inspect the AdBlue/DEF pump (reverting valve) [Hino-DX]

1. Select [DEF pump position] from the [Activation Test] menu and
operate the AdBlue/DEF pump.

2. Select [DEF pump pressure] from the [Data Monitor] menu and
Select
DCU check the AdBlue/DEF pressure after the completion of a "Leak
test".
Standard value (AdBlue/DEF pressure) :
Less than 50 kPa {0.5 kgf/cm2, 7.3 lbf/in2}

SAPH31J191700330 NO Replace the AdBlue/DEF pump.

YES

3 Inspect the AdBlue/DEF tank

1. Disconnect the breather hose and check if it is not clogged,

punctured, or cracked.

NO Replace the breather hose.

YES

Procedure completed.

[S5LC0033E04] [0518CsCshWbYs]
17–308 ENGINE DIAGNOSIS CODE

DTC code P20B1

Coolant cut-off valve failure [Open]
DTC code P20B3
Coolant cut-off valve failure [Low]
DTC code P20B4
Coolant cut-off valve failure [High]
JP31J19170901032

1 Resistance measuring between terminals

1. Set the starter key to "OFF", and then disconnect the connector
of the coolant cut-off valve.

2. Measure the resistance between terminals 1 and 2 of the

connector of the coolant cut-off valve (on the component side).

Standard value: 25.9 to 28.7 Ω (20 °C {68 °F})

NO Abnormal coolant cut-off valve

SAPH31J191700331

YES

2 Resistance measuring between terminals

1. Set the starter key to "OFF", connect the connector of the

coolant cut-off valve, and then disconnect the 86-pin connector
of the DCU.

2. Measure the resistance between terminals 8 and 85 of the 86-

pin connector of the DCU (on the machine harness side).

Standard value: 25.9 to 28.7 Ω (20 °C {68 °F})

NO Harness abnormal
SAPH31J191700332

YES

DCU replacement (after replacement, perform a DPR forced regeneration)

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–309

DTC code P20B2

Coolant cut-off valve failure
JP31J19170901033

1 AdBlue/DEF temperature inspection

1. Use the Hino-DX to monitor the temperature of the AdBlue/

DEF tank.

2. Place a thermometer into the AdBlue/DEF tank and compare

with the Hino-DX value.
Standard value: Approximately the same value

NO Abnormal AdBlue/DEF tank temperature sensor

YES

2 Engine coolant temperature sensor resistance measuring

1. Set the starter key to "OFF", and then disconnect the connector
of the engine coolant temperature sensor.

2. Measure the resistance between terminals 1 and 2 of the

connector of the engine coolant temperature sensor (on the
component side).

Standard value (measure one of the following points)

: 2.45k Ω (water temperature 20 °C {68 °F})
: 1.15k Ω (water temperature 40 °C {104 °F})
SAPH31J191700333
: 584 Ω (water temperature 60 °C {140 °F})
: 318 Ω (water temperature 80 °C {176 °F})

NO Abnormal engine coolant temperature sensor

YES

3 AdBlue/DEF tank temperature inspection

1. Set the starter key to "OFF", and then connect all connectors.

2. Use the Hino-DX and raise the coolant temperature while

monitoring the AdBlue/DEF tank temperature and the coolant
temperature.
Standard: The AdBlue/DEF tank temperature does not
rise.

NO Coolant cut-off valve replacement

YES

[S5LC0033E04] [0518CsCshWbYs]
17–310 ENGINE DIAGNOSIS CODE

4 Coolant cut-off valve inspection

1. Set the starter key from "OFF" directly to engine start.

2. Directly after starting the engine, confirm by touch that the
pressure in the coolant piping on the downstream side of the
cut-off valve rises.

3. After confirming that cooling water has been flowing, confirm

by touch that the water temperature has increased after warm-
up; also check the hose downstream of the cut-off valve for
pulsation and temperature.

! CAUTION • Be careful of burns from hot engine coolant.

SAPH31J191700334

NO Go to [5] Coolant piping inspection

YES

Normal

5 Coolant piping inspection

1. Inspect the coolant piping for breakage, bending, and leakage.

2. Disconnect the joints on both ends of the coolant piping, blow

in air from one side and confirm that it comes out at the other
side.

NO Coolant piping replacement

YES

Coolant cut-off valve replacement

NOTICE • In order to confirm the return to normal operation, a certain amount of driving and certain
pre-conditions are required; therefore, observe the condition for some time.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–311

DTC code P20E8

Abnormal AdBlue/DEF piping pressure [Low]
JP31J19170901034

NOTICE • For correction of the abnormality using the following procedure, check the AdBlue/DEF
addition quantity and confirm that there is no problem.

1 AdBlue/DEF residual quantity inspection

1. Check that the AdBlue/DEF tank is not empty by AdBlue/DEF

reserve indicator.

NO Fill in water

Level 3-20 (Green)

Level 2 (Yellow)

Level 1 (Red)

Level 0 (No display)

SAPH31J191700335

YES

2 AdBlue/DEF piping inspection

1. Inspect the AdBlue/DEF piping for breakage, bending, and

leakage.

NO AdBlue/DEF piping replacement

YES

3 AdBlue/DEF filter inspection

1. Inspect the filter of the AdBlue/DEF pump for clogging.

NO AdBlue/DEF filter replacement

YES

[S5LC0033E04] [0518CsCshWbYs]
17–312 ENGINE DIAGNOSIS CODE

4 AdBlue/DEF pressure sensor resistance measuring

1. Set the starter key to "OFF", and then disconnect the 86-pin
connector of the DCU.

2. Measure the resistance between the following terminals of the

86-pin connector of the DCU (on the machine harness side).

Measuring terminals Standard value

Terminal 17 Terminal 18 324 to 396 kΩ
Terminal 17 Terminal 19 144 to 176 kΩ
SAPH31J191700336 Terminal 18 Terminal 19 180 to 220 kΩ

NO AdBlue/DEF pump replacement

YES

5 AdBlue/DEF strainer inspection

1. Remove the AdBlue/DEF tank sensors (temperature, level

quality) from the tank and inspect the AdBlue/DEF strainer at
the base for clogging.

NO Filter cleaning

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–313

6 AdBlue/DEF piping inspection

1. Disconnect the joints on both ends of the AdBlue/DEF piping,

blow in air from one side and confirm that it comes out at the
other side.

AdBlue/DEF tank

Pull off this piping.

AdBlue/DEF pump

Pull off this piping, and then blow air from

the AdBlue/DEF pump side (white tape side).

SAPH31J191700337

! CAUTION • Before the start of work, operate the air gun

once or twice to remove dirt and foreign
matter sticking to the tip of the air gun.

NO AdBlue/DEF piping replacement

YES

[S5LC0033E04] [0518CsCshWbYs]
17–314 ENGINE DIAGNOSIS CODE

7 AdBlue/DEF addition quantity inspection

1. Inspect the injector AdBlue/DEF addition quantity.

(1) With the injector disconnected from the muffler, perform a
DPR forced regeneration, and confirm that AdBlue/DEF is
positively added by the injector.

2. After completion of the inspection, with the injector connected

to the muffler, perform a DPR forced regeneration.

NO Go to [8] Reinspection of the AdBlue/DEF addition

quantity

YES

Normal

8 Reinspection of the AdBlue/DEF addition quantity

1. Replace the inlet connector of the AdBlue/DEF pump and

Inlet connector again inspect the AdBlue/DEF addition quantity.

(1) With the injector disconnected from the muffler, perform a

DPR forced regeneration, and confirm that AdBlue/DEF is
positively added by the injector.

2. After completion of the inspection, with the injector connected

to the muffler, perform a DPR forced regeneration.

SAPH31J191700338

NO AdBlue/DEF pump replacement

YES

Normal

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–315

DTC code P20E9

Abnormal AdBlue/DEF piping pressure [High]
JP31J19170901035

NOTICE • For correction of the abnormality using the following procedure, check the AdBlue/DEF
addition quantity and confirm that there is no problem.

1 AdBlue/DEF residual quantity inspection

1. Check that the AdBlue/DEF tank is not empty by AdBlue/DEF

reserve indicator.

NO Fill in water

Level 3-20 (Green)

Level 2 (Yellow)

Level 1 (Red)

Level 0 (No display)

SAPH31J191700335

YES

2 AdBlue/DEF piping inspection

1. Inspect the AdBlue/DEF piping for breakage, bending, and

leakage.

NO AdBlue/DEF piping replacement

YES

3 AdBlue/DEF filter inspection

1. Inspect the filter of the AdBlue/DEF pump for clogging.

NO AdBlue/DEF filter replacement

YES

[S5LC0033E04] [0518CsCshWbYs]
17–316 ENGINE DIAGNOSIS CODE

4 AdBlue/DEF pressure sensor resistance measuring

1. Set the starter key to "OFF", and then disconnect the 86-pin
connector of the DCU.

2. Measure the resistance between the following terminals of the

86-pin connector of the DCU (on the machine harness side).

Measuring terminals Standard value

Terminal 17 Terminal 18 324 to 396 kΩ
Terminal 17 Terminal 19 144 to 176 kΩ
SAPH31J191700336 Terminal 18 Terminal 19 180 to 220 kΩ

NO AdBlue/DEF pump replacement

YES

5 AdBlue/DEF strainer inspection

1. Remove the AdBlue/DEF tank sensors (temperature, level

quality) from the tank and inspect the AdBlue/DEF strainer at
the base for clogging.

NO Filter cleaning

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–317

6 AdBlue/DEF piping inspection

1. Disconnect the joints on both ends of the AdBlue/DEF piping,

blow in air from one side and confirm that it comes out at the
other side.

AdBlue/DEF tank

Pull off this piping.

AdBlue/DEF pump

Pull off this piping, and then blow air from

the AdBlue/DEF pump side (white tape side).

SAPH31J191700337

! CAUTION • Before the start of work, operate the air gun

once or twice to remove dirt and foreign
matter sticking to the tip of the air gun.

NO AdBlue/DEF piping replacement

YES

[S5LC0033E04] [0518CsCshWbYs]
17–318 ENGINE DIAGNOSIS CODE

7 AdBlue/DEF addition quantity inspection

1. Inspect the injector AdBlue/DEF addition quantity.

(1) With the injector disconnected from the muffler, perform a
DPR forced regeneration, and confirm that AdBlue/DEF is
positively added by the injector.

2. After completion of the inspection, with the injector connected

to the muffler, perform a DPR forced regeneration.

NO Go to [8] Reinspection of the AdBlue/DEF addition

quantity

YES

Normal

8 Reinspection of the AdBlue/DEF addition quantity

1. Replace the inlet connector of the AdBlue/DEF pump and

Inlet connector again inspect the AdBlue/DEF addition quantity.

(1) With the injector disconnected from the muffler, perform a

DPR forced regeneration, and confirm that AdBlue/DEF is
positively added by the injector.

2. After completion of the inspection, with the injector connected

to the muffler, perform a DPR forced regeneration.

SAPH31J191700338

NO AdBlue/DEF pump replacement

YES

Normal

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–319

DTC code P20F4

AdBlue/DEF consumption failure

JP31J19170901036

1 Inspect the AdBlue/DEF pipe (pump ↔ injector)

1. Check the AdBlue/DEF pipe (pressure line) and check if there

are no disconnections, clogging, corrosion, or cracks.

NO Replace the AdBlue/DEF pipe.

YES

2 Inspect AdBlue/DEF injector 1 [Hino-DX]

1. Set the starter switch to the "OFF" position.

(1)

(2) 2. Remove the AdBlue/DEF injector from the muffler.

3. Set the starter switch to the "ON" position.

4. Select [DCU].

5. Select [Check functions] on Hino-DX menu and check the

operation of the AdBlue/DEF injector.
(3)
Standard: The AdBlue/DEF addition quantity is within
the limit.

NO If AdBlue/DEF pressure is abnormal, proceed to

failure diagnosis method (P20E8, P20E9).
Go to step 3.

SAPH31J191700339

YES

Procedure completed. AdBlue/DEF crystal clogging is considered resolved.

[S5LC0033E04] [0518CsCshWbYs]
17–320 ENGINE DIAGNOSIS CODE

3 Inspect the AdBlue/DEF injector 2 [Hino-DX]

1. Set the starter switch to the "OFF" position.

2. Replace AdBlue/DEF injector with a new one. (Do not install it

on the muffler.)
Select
DCU
3. Set the starter switch to the "ON" position.

4. Perform DEF addition test as same as step 2.

Standard: The AdBlue/DEF addition quantity is within
the limit.
SAPH31J191700340

NO Replace AdBlue/DEF piping (Pump ↔ Injector) and

go to step 2.

YES

New injector installed in the muffler. Procedure completed.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–321

DTC code P2201

SCR upstream NOx sensor - Performance and Monitoring capability

JP31J19170901037

1 Check the DTC detected (DCU) [Hino-DX]

1. Set the starter switch to the "OFF" position.

2. Connect the machine to Hino-DX.

Select 3. Set the starter switch to the "ON" position.

DCU

4. Select [DCU] and check if any DTC other than P2201 (for
example P2202, P2209, U029D) has been detected in [Fault
Information].

SAPH31J191700341
5. Make sure that DTC which is concerned with engine is not
output. (CAN, Air flow sensor, Coolant temperature sensor)

NO Go to diagnosis procedure of a related DTC.

YES

2 Inspect the SCR upstream NOx sensor

1. Set the starter switch to the "OFF" position.

2. Remove the SCR upstream NOx sensor and SCR downstream

NOx sensor.

3. Install NOx sensors 1 and 2 in the machine, in their opposite

location.
4. Set the starter switch to the "ON" position.

5. Erase the malfunction history using Hino-DX.

Select 6. Perform a DPR forced regeneration.

DCU

7. Select [DCU] and check if P2201 has been detected in [Fault

Information].

NO Replace the SCR upstream NOx sensor.

SAPH31J191700342

YES

[S5LC0033E04] [0518CsCshWbYs]
17–322 ENGINE DIAGNOSIS CODE

3 Inspect the engine coolant temperature sensor

1. Check the installation of the engine coolant temperature sensor

(Looseness and poor contact).

2. Make sure there is no dirt or damage to the engine coolant

temperature sensor.

NO If damaged, replace the engine coolant sensor.

YES

4 Check the coolant temperature sensor

1. Set the starter switch to "OFF" position.

2. Disconnect the coolant temperature sensor connector.

3. Measure resistance between the terminals WTM+ and WTM-
of the engine coolant temperature sensor.

Standard value

Water temperature
Resistance
(°C{°F})

2.45 kΩ 20 {68}

1.15 kΩ 40 {104}
SAPH31J191700083

584 Ω 60 {140}

318 Ω 80 {176}

NO Replace the engine coolant temperature sensor.

YES

5 Inspect the air flow sensor

1. Check the installation of the air flow sensor.

2. Make sure there is no dirt or damage to the air flow sensor.

NO If dirt, clogging or damage in the sensing unit was

found, replace the air flow sensor.

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–323

6 Inspect the SCR upstream NOx sensor [Hino-DX]

1. Replace SCR upstream NOx sensor with a new sensor.

2. Set the starter switch to the "ON" position.

Select
3. Erase the malfunction history using Hino-DX.
DCU

4. Perform a DPR forced regeneration.

5. Select [DCU] and check if P2201 has been detected in [Fault

Information].
SAPH31J191700343

NO Replace the DCU.

YES

Procedure completed.

[S5LC0033E04] [0518CsCshWbYs]
17–324 ENGINE DIAGNOSIS CODE

DTC code P2202

Failure of the upstream NOx sensor
JP31J19170901038

1 Inspect the CAN communication Line

1. Set the starter key to "OFF", and then disconnect the connector
of the upstream NOx sensor.

2. Measure the resistance between terminals 2 and 3 of the

connector of the upstream NOx sensor (on the machine
harness side).

Standard value: Approx. 60 Ω

SAPH31J191700344 NO Harness abnormal

YES

2 Conductivity measuring between terminals

1. Set the starter key to "OFF", and then measure the conductivity
between terminals 1 and 4 of the connector of the upstream
NOx sensor (on the machine harness side).

Standard: Continuity

NO Harness abnormal

SAPH31J191700345

YES

3 Voltage measuring between terminals

1. Set the starter key to "ON", and then measure the voltage
between terminal 5 and terminals 1 and 4 of the connector of
the upstream NOx sensor (on the machine harness side).

Standard value: 19 - 32 V

NO Abnormal harness or abnormal battery

SAPH31J191700346

YES

Abnormal upstream NOx sensor

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–325

DTC code P2203

SCR upstream NOx sensor and Heater - Circuit (Circuit short)

JP31J19170901039

1 Check the DTC detected (DCU) [Hino-DX]

1. Connect the machine to Hino-DX.

2. Set the starter switch to the "ON" position.

Select 3. Select [DCU] and check if a CAN communication system

DCU
malfunction (U029D) has been detected in [Fault Information].

NO Go to the diagnostic procedure of a related DTC.

SAPH31J191700347

YES

Replace the SCR upstream NOx sensor.

[S5LC0033E04] [0518CsCshWbYs]
17–326 ENGINE DIAGNOSIS CODE

DTC code P2204

SCR upstream NOx sensor - Feedback

JP31J19170901040

1 Check the DTC detected (DCU) [Hino-DX]

1. Set the starter switch to the "OFF" position.

2. Connect the machine to Hino-DX.

Select 3. Set the starter switch to the "ON" position.

DCU

4. Select [DCU] and check if any DTC other than P2201 (for
example P2202, P2209, U029D) has been detected in [Fault
Information].

SAPH31J191700348
NO Go to diagnosis procedure of a related DTC.

YES

2 Inspect the SCR upstream NOx sensor [Hino-DX]

1. Set the starter switch to the "OFF" position.

2. Disconnect the SCR upstream NOx sensor and SCR

downstream NOx sensor.
Select
DCU
3. Install NOx sensors 1 and 2 in the machine, in their opposite
location.

4. Set the starter switch to the "ON" position.

SAPH31J191700349
5. Erase the malfunction history using Hino-DX.

6. Perform the DPR forced regeneration.

7. Select [DCU] and check if P2204 has been detected in [Fault

Information].

NO Go to step 3.

YES

Replace the SCR upstream NOx sensor.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–327

3 Inspect the engine coolant temperature sensor

1. Check the installation of the engine coolant temperature

sensor.

2. Make sure there is no dirt or damage to the engine coolant

temperature sensor.

NO Clean the engine coolant temperature sensor and

install it properly. If damaged, replace the engine
coolant temperature sensor.

YES

4 Check the engine coolant temperature sensor output signal [Hino-DX]

1. Set the starter switch to "OFF" position.

2. Disconnect the coolant temperature sensor connector.

3. Measure resistance between the terminals WTM+ and WTM-
of the engine coolant temperature sensor.

Standard value

Water temperature
Resistance
(°C{°F})

2.45 kΩ 20 {68}

1.15 kΩ 40 {104}
SAPH31J191700083

584 Ω 60 {140}

318 Ω 80 {176}

NO Replace the engine coolant temperature sensor.

YES

5 Inspect the air flow sensor

1. Check the installation of the air flow sensor.

2. Make sure there is no dirt or damage to the air flow sensor.

NO If dirt, clogging or damage in the sensing unit was

found, replace the air flow sensor.

YES

[S5LC0033E04] [0518CsCshWbYs]
17–328 ENGINE DIAGNOSIS CODE

6 Inspection of the SCR upstream NOx sensor [Hino-DX]

1. Replace SCR upstream NOx sensor with a new sensor.

2. Set the starter switch to the "ON" position.

Select
3. Select [DCU] and check if P2204 has been detected in [Fault
DCU
Information].

NO SCR upstream NOx sensor failure. Install a new

SCR upstream NOx sensor.
SAPH31J191700350

YES

Replace the DCU.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–329

DTC code P2209

Abnormal upstream NOx sensor heater
JP31J19170901041

1 NOx sensor inspection

1. Inspect according to the same method as for an upstream NOx

sensor failure (DTC code P2202).

NO Harness abnormal

YES

2 NOx sensor replacement

1. Replace the upstream NOx sensor.

3 Resistance measuring for the SCR upstream temperature sensor

1. Set the starter key to "OFF", and then disconnect the connector
of the SCR upstream temperature sensor.

2. Measure the resistance between terminals 1 and 2 of the

connector of the SCR upstream temperature sensor (on the
component side).

Standard value
197.67 to 205.33 Ω (0 °C {32 °F})
216.77 to 224.37 Ω (25 °C {77 °F})
SAPH31J191700351
235.73 to 243.25 Ω (50 °C {122 °F})

NO Abnormal SCR upstream temperature sensor

YES

[S5LC0033E04] [0518CsCshWbYs]
17–330 ENGINE DIAGNOSIS CODE

4 Engine coolant temperature sensor resistance measuring

1. Set the starter key to "OFF", and then disconnect the connector
of the engine coolant temperature sensor.

2. Measure the resistance between terminals 1 and 2 of the

connector of the engine coolant temperature sensor (on the
component side).

Standard value (measure according to one of the

following items)
: 2.45 kΩ (water temperature 20 °C {68 °F})
SAPH31J191700352
: 1.15 kΩ (water temperature 40 °C {104 °F})
: 584 Ω (water temperature 60 °C {140 °F})
: 318 Ω (êÖwater temperature 80 °C {176 °F})

NO Abnormal engine coolant temperature sensor

YES

Perform a DPR forced regeneration and confirm that the DTC code P2209 is not indicated.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–331

DTC code P2212

SCR downstream NOx sensor - Feedback

JP31J19170901042

1 Check the DTC detected (DCU) [Hino-DX]

1. Set the starter switch to the "OFF" position.

2. Connect the machine to Hino-DX.

Select 3. Set the starter switch to the "ON" position.

DCU

4. Select [DCU] and check if any DTC other than P2212 (for
example, P2215, P2216, P2222, U029E) has been detected in
[Fault Information].

SAPH31J191700353
NO Go to diagnosis procedure of a related DTC.

YES

2 Inspect the SCR downstream NOx sensor [Hino-DX]

1. Set the starter switch to the "OFF" position.

2. Disconnect the SCR upstream NOx sensor and SCR

downstream NOx sensor.
Select
DCU
3. Install NOx sensors 1 and 2 in the machine, in their opposite
location.

4. Set the starter switch to the "ON" position.

SAPH31J191700354
5. Erase the malfunction history using Hino-DX.

6. Perform a DPR forced regeneration.

7. Select [DCU] and check if P2212 has been detected in [Fault

Information].

NO Go to step 3.

YES

Replace the SCR downstream NOx sensor.

[S5LC0033E04] [0518CsCshWbYs]
17–332 ENGINE DIAGNOSIS CODE

3 Inspect the engine coolant temperature sensor

1. Check the installation of the engine coolant temperature sensor

is properly installed.

2. Make sure there is no dirt or damage to the engine coolant

temperature sensor.

NO Clean the engine coolant temperature sensor and

install it properly. If damaged, replace the engine
coolant temperature sensor.

YES

4 Check the engine coolant temperature sensor output signal [Hino-DX]

1. Set the starter switch to the "ON" position.

2. Select [Engine].

Select
3. Select [Engine coolant temperature] from [Data Monitor] on the
Engine
menu.

4. When the engine coolant temperature (actual measured value)

is 50 °C {122 °F}, check if the temperature output by the
coolant temperature sensor is 50 °C {122 °F}.
SAPH31J191700355
Standard value (Engine coolant temperature sensor
output value):
50 °C {122 °F}

NO Replace the engine coolant temperature sensor.

YES

5 Inspect the air flow sensor

1. Check the installation of the air flow sensor.

2. Make sure there is no dirt or damage to the air flow sensor.

NO If dirt, clogging or damage in the sensing unit was

found, replace the air flow sensor.

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–333

6 Inspect the boost pressure sensor

1. Check the installation of the boost pressure sensor.

2. Make sure there is no dirt or damage to the boost pressure

sensor.

NO If dirt, clogging or damage in the sensing unit was

found, replace the boost pressure sensor.

YES

7 Check the boost pressure sensor output signal [Hino-DX]

1. Start the engine.

2. Select [Engine] on the Hino-DX.

Select
3. Select [Actual boost pressure] from [Data Monitor] on the
Engine
menu.

4. Race the engine from idle to No-Load Maximum and check if

the boost pressure output signal varies.
Standard value (Boost pressure sensor output value):
SAPH31J191700356
There is no abnormal change in the sensor output
signal. (The pressure sensor signal changes
according to the engine speed)

NO Replace the boost pressure sensor.

YES

8 Inspect the intake manifold temperature sensor

1. Check the installation of the intake manifold temperature

sensor.

2. Make sure there is no dirt or damage to the intake manifold

temperature sensor.

NO Clean the intake manifold temperature sensor and

install it properly. If damaged, replace the intake
manifold temperature sensor.

YES

[S5LC0033E04] [0518CsCshWbYs]
17–334 ENGINE DIAGNOSIS CODE

9 Inspect the Intake manifold temperature sensor unit

1. Set the starter switch to the "OFF" position.

THG E2
2. Disconnect the intake manifold temperature sensor connector.

3. Use the electrical tester to measure the resistance between the

terminals of the intake manifold temperature sensor.

Measurement Tester
Standard values
conditions connections

SAPH31J191700357 Intake manifold 20 °C {68 °F}:

Starter switch: temperature 7.336 – 5.794 kΩ
OFF sensor 50 °C {122 °F}:
THG – E2 2.435 – 2.41 kΩ

NO Replace the Intake manifold temperature sensor.

YES

10 Inspection of the SCR downstream NOx sensor [Hino-DX]

1. Replace SCR downstream NOx sensor with a new sensor.

2. Set the starter switch to the "ON" position.

Select 3. Select [DCU] and check if P2212 has been detected in [Fault
DCU
Information].

NO Replace the DCU.

SAPH31J191700358

YES

SCR downstream NOx sensor is faulty. Install a new SCR downstream NOx sensor.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–335

DTC code P2214

SCR downstream NOx sensor - Performance and Monitoring capability

JP31J19170901043

1 Check the DTC detected [Hino-DX]

1. Connect the machine to Hino-DX.

Check that engine failure codes (Air flow sensor, DPR
downstream temperature sensor, CAN) and DCU failure codes
(NOx controller upstream of the SCR, SCR upstream
temperature sensor) are not output.

NO Go to the diagnostic procedure of a related DTC.

YES

2 Inspect the exhaust pipe

1. Check the exhaust pipe and make sure it has no cracks or

exhaust leaks (soot leaks), and verify that coupling flanges are
properly tightened.

NO Repair or replace the exhaust pipe.

YES

3 Inspect the air flow sensor connector

1. Check the connection of the air flow sensor connector.

(Looseness and poor contact)

NO Connect securely, repair if needed.

YES

4 Inspect the air flow sensor

1. Check the installation of the air flow sensor.

2. Make sure there is no dirt or damage to the air flow sensor.

NO If damaged, replace the air flow sensor.

YES

[S5LC0033E04] [0518CsCshWbYs]
17–336 ENGINE DIAGNOSIS CODE

5 Inspect the SCR upstream temperature sensor connector

1. Check the connection of the SCR upstream temperature

sensor connector. (Looseness and poor contact)

NO Connect securely, repair if needed.

YES

6 Inspect the SCR upstream temperature sensor

1. Check the installation of the SCR upstream temperature

sensor.

2. Make sure there is no dirt or damage to the SCR upstream

temperature sensor.

NO Clean the SCR upstream temperature sensor and

install it properly.

YES

7 Inspect the SCR upstream temperature sensor unit

1. Set the starter switch to the "OFF" position.

FAT- FAT+
2. Disconnect the SCR upstream temperature sensor connector.

3. Use the electrical tester to measure the resistance between the

terminals of the SCR upstream temperature sensor.

Measurement Tester
Standard values
conditions connections

SAPH31J191700359 SCR upstream

Starter switch: temperature 20 °C {68 °F} :
OFF sensor 220 Ω
FAT+ – FAT-

NO Replace the SCR upstream temperature sensor.

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–337

8 Inspect the SCR upstream temperature sensor connector

1. Check the connection of the SCR upstream temperature

sensor connector. (Looseness and poor contact)

NO Connect securely, repair if needed.

YES

9 Inspect the SCR upstream temperature sensor

1. Check the installation of the SCR upstream temperature

sensor.

2. Make sure there is no dirt or damage to the SCR upstream

temperature sensor.

NO Replace the SCR upstream temperature sensor.

YES

10 Inspect the SCR upstream temperature sensor unit

1. Disconnect the SCR upstream temperature sensor connector.

TEX1 GND1
2. Use the electrical tester to measure the resistance between the
terminals of the SCR upstream temperature sensor.

Measurement Tester
Standard values
conditions connections
20 °C {68 °F}:
SCR upstream 13.7 – 29.8 kΩ
SAPH31J191700360 Starter switch: temperature 50 °C {122 °F}:
OFF sensor 7.13 – 13.7 kΩ
TEX1 – GND1 80 °C {176 °F}:
4.1 – 7.13 kΩ

NO Replace the SCR upstream temperature sensor.

YES

Replace the SCR downstream NOx sensor.

[S5LC0033E04] [0518CsCshWbYs]
17–338 ENGINE DIAGNOSIS CODE

DTC code P2215

Failure of the downstream NOx sensor
JP31J19170901044

1 Instect the CAN communication line

1. Set the starter key to "OFF", and then disconnect the connector
of the downstream NOx sensor.

2. Measure the resistance between terminals 2 and 3 of the

connector of the downstream NOx sensor (on the machine
harness side).

Standard value: Approx. 60 Ω

NO Harness abnormal
SAPH31J191700361

YES

2 Voltage measuring between terminals

1. Set the starter key to "ON", and then measure the voltage
between terminals 5 and 4 of the connector of the downstream
NOx sensor (on the machine harness side).

Standard value: 19 - 32 V

NO Abnormal harness or abnormal battery

SAPH31J191700362

YES

Abnormal downstream NOx sensor

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–339

DTC code P2216

SCR downstream NOx sensor - and Heater - Circuit (Circuit short)

JP31J19170901045

1 Check the DTC detected (DCU) [Hino-DX]

1. Connect the machine to Hino-DX.

2. Set the starter switch to the "ON" position.

Select 3. Select [DCU] and check if any DTC other than P2216 has been
DCU
detected in [Fault Information].

NO Go to the diagnostic procedure of a related DTC.

SAPH31J191700363

YES

Replace the SCR downstream NOx sensor.

[S5LC0033E04] [0518CsCshWbYs]
17–340 ENGINE DIAGNOSIS CODE

DTC code P2222

Abnormal downstream NOx sensor heater
JP31J19170901046

1 NOx sensor inspection

1. Inspect according to the same method as for a downstream

NOx sensor failure (DTC code P2215).

NO Harness abnormal

YES

2 NOx sensor replacement

1. Replace the downstream NOx sensor.

3 Resistance measuring for the SCR upstream temperature sensor

1. Set the starter key to "OFF", and then disconnect the connector
of the SCR upstream temperature sensor.

2. Measure the resistance between terminals 1 and 2 of the

connector of the SCR upstream temperature sensor (on the
component side).

Standard value
197.67 to 205.33 Ω (0 °C {32 °F})
216.77 to 224.37 Ω (25 °C {77 °F})
SAPH31J191700364
235.73 to 243.25 Ω (50 °C {122 °F})

NO Abnormal SCR upstream temperature sensor

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–341

4 Engine coolant temperature sensor resistance measuring

1. Set the starter key to "OFF", and then disconnect the connector
of the engine coolant temperature sensor.

2. Measure the resistance between terminals 1 and 2 of the

connector of the engine coolant temperature sensor (on the
component side).

Standard value (measure one of the following points)

: 2.45 kΩ (water temperature 20 °C {68 °F})
: 1.15 kΩ (water temperature 40 °C {104 °F})
SAPH31J191700365
: 584 Ω (water temperature 60 °C {140 °F})
: 318 Ω (water temperature 80 °C {176 °F})

NO Abnormal engine coolant temperature sensor

YES

Perform a DPR forced regeneration and confirm that the DTC code P2222 is not indicated.

[S5LC0033E04] [0518CsCshWbYs]
17–342 ENGINE DIAGNOSIS CODE

DTC code P2481

SCR upstream temperature sensor - out of range (Out of range low)

JP31J19170901047

1 Inspect the SCR upstream temperature sensor connector

1. Check the connection of the SCR upstream temperature

sensor connector (Looseness and poor contact).

NO Connect securely, repair if needed.

YES

2 Inspect the SCR upstream temperature sensor

1. Check the installation of the SCR upstream temperature

sensor.

2. Make sure there is no dirt or damage to the SCR upstream

temperature sensor.

NO Clean the SCR upstream temperature sensor and

install it properly. If damaged, replace the SCR
upstream temperature sensor.

YES

3 Inspect the SCR upstream temperature sensor unit

1. Set the starter switch to the "OFF" position.

FAT- FAT+
2. Disconnect the SCR upstream temperature sensor connector.

3. Use the electrical tester to measure the resistance between the

terminals of the SCR upstream temperature sensor.

Measurement Tester
Standard values
conditions connections

SAPH31J191700366 Exhaust gas

Starter switch: temperature 20 °C {68 °F}:
OFF sensor 220 Ω
FAT+ – FAT-

NO Replace the SCR upstream temperature sensor.

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–343

4 Inspect for short-circuit in the SCR upstream temperature sensor harness

1. Set the starter switch to the "OFF" position.

2. Disconnect the DCU 86P connector.

3. Use the electrical tester to measure the resistance between the

terminals of the DCU 86P machine-side connector and the
ground.

EXT+ EXT-

SAPH31J191700367

Measurement Tester
Standard values
conditions connections

DCU 86P
machine-side
Starter switch:
connector ∞Ω
OFF
EXT+ – Ground
EXT- – Ground

NO Repair or replace the harness.

YES

[S5LC0033E04] [0518CsCshWbYs]
17–344 ENGINE DIAGNOSIS CODE

5 Inspect disconnection of the SCR upstream temperature sensor harness

1. Connect the SCR upstream temperature sensor connector.

2. Connect the signal check harness and use the electrical tester
to measure the resistance between the terminals of the DCU
86P machine-side connector.

EXT+ EXT-

SAPH31J191700368

Measurement Tester
Standard values
conditions connections

DCU 86P
Starter switch: machine-side 20 °C {68 °F}:
OFF connector 220 Ω
EXT+ – EXT-

NO Repair or replace the harness.

YES

6 Check the DTC detected (DCU) [Hino-DX]

1. Perform an engine warm-up. (Coolant temperature: 60 °C {140

°F} or more)

2. Stop the engine and set the starter switch to the "OFF"
Select
DCU position.

3. Connect the machine to Hino-DX.

4. Set the starter switch to the "ON" position.

SAPH31J191700369
5. Select [DCU] and check if P2481 has been detected in [Fault
Information].

NO Replace the DCU.

YES

Procedure completed.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–345

DTC code P2482

SCR upstream temperature sensor - out of range (Out of range high)

JP31J19170901048

1 Inspect the SCR upstream temperature sensor connector

1. Check the connection of the SCR upstream temperature

sensor connector (Looseness and poor contact).

NO Connect securely, repair if needed.

YES

2 Inspect the SCR upstream temperature sensor

1. Check the installation of the SCR upstream temperature

sensor.

2. Make sure there is no dirt or damage to the SCR upstream

temperature sensor.

NO Clean the SCR upstream temperature sensor and

install it properly. If damaged, replace the SCR
upstream temperature sensor.

YES

3 Inspect the SCR upstream temperature sensor unit

1. Set the starter switch to the "OFF" position.

FAT- FAT+
2. Disconnect the SCR upstream temperature sensor connector.

3. Use the electrical tester to measure the resistance between the

terminals of the SCR upstream temperature sensor.

Measurement Tester
Standard values
conditions connections

SAPH31J191700370 SCR upstream

Starter switch: temperature 20 °C {68 °F}:
OFF sensor 220 Ω
FAT+ – FAT-

NO Replace the SCR upstream temperature sensor.

YES

[S5LC0033E04] [0518CsCshWbYs]
17–346 ENGINE DIAGNOSIS CODE

4 Inspect for short-circuit in the SCR upstream temperature sensor harness

1. Disconnect the DCU 86P connector.

2. Connect the signal check harness and use the electrical tester
to measure the resistance between the terminals of the DCU
86P machine-side connector and the ground.

EXT+ EXT-

SAPH31J191700371

Measurement Tester
Standard values
conditions connections

DCU 86P
machine-side
Starter switch:
connector ∞Ω
OFF
EXT+ – Ground
EXT- – Ground

NO Repair or replace the harness.

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–347

5 Inspect disconnection of the SCR upstream temperature sensor harness

1. Connect the SCR upstream temperature sensor connector.

2. Connect the signal check harness and use the electrical tester
to measure the resistance between the terminals of the DCU
86P machine-side connector.

EXT+ EXT-

SAPH31J191700372

Measurement Tester
Standard values
conditions connections

DCU 86P
Starter switch: machine-side 20 °C {68 °F}:
OFF connector 220 Ω
EXT+ – EXT-

NO Repair or replace the harness.

YES

6 Check the DTC detected (DCU) [Hino-DX]

1. Perform an engine warm-up. (Coolant temperature: 60 °C {140

°F} or more)

2. Stop the engine and set the starter switch to the "OFF"
Select
DCU position.

3. Connect the machine to Hino-DX.

4. Set the starter switch to the "ON" position.

SAPH31J191700373
5. Select [DCU] and check if P2482 has been detected in [Fault
Information].

NO Replace the DCU.

YES

Procedure completed.

[S5LC0033E04] [0518CsCshWbYs]
17–348 ENGINE DIAGNOSIS CODE

DTC code P2483

SCR upstream temperature sensor - rationality

JP31J19170901049

1 Check the DTC detected [Hino-DX]

1. Connect the engine to Hino-DX.

2. Make sure that DTC codes (U010E, P2032, P2033) is not

output.

NO Go to the diagnostic procedure of a related DTC.

YES

2 Inspect the SCR upstream temperature sensor connector

1. Check the connection of the SCR upstream temperature

sensor connector (Looseness and poor contact).

NO Connect securely, repair if needed.

YES

3 Inspect the SCR upstream temperature sensor

1. Check the installation of the SCR upstream temperature

sensor.

2. Make sure there is no dirt or damage to the SCR upstream

temperature sensor.

NO Clean the SCR upstream temperature sensor and

install it properly. If damaged, replace the SCR
upstream temperature sensor.

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–349

4 Inspect the SCR upstream temperature sensor unit

1. Set the starter switch to the "OFF" position.

FAT- FAT+
2. Disconnect the SCR upstream temperature sensor connector.

3. Use the electrical tester to measure the resistance between the

terminals of the SCR upstream temperature sensor.

Measurement Tester
Standard values
conditions connections

SAPH31J191700374 SCR upstream

Starter switch: temperature 20 °C {68 °F}:
OFF sensor 220 Ω
FAT+ – FAT-

NO Replace the SCR upstream temperature sensor.

YES

5 Inspect the SCR upstream temperature sensor connector

1. Check the connection of the SCR upstream temperature

sensor connector (Looseness and poor contact).

NO Connect securely, repair if needed.

YES

6 Inspect the SCR upstream temperature sensor

1. Check the installation of the SCR upstream temperature

sensor.

2. Make sure there is no dirt or damage to the SCR upstream

temperature sensor.

NO Clean the SCR upstream temperature sensor and

install it properly. If damaged, replace the SCR
upstream temperature sensor.

YES

[S5LC0033E04] [0518CsCshWbYs]
17–350 ENGINE DIAGNOSIS CODE

7 Inspect the SCR upstream temperature sensor unit

1. Disconnect the SCR upstream temperature sensor connector.

TEX1 GND1
2. Use the electrical tester to measure the resistance between the
terminals of the SCR upstream temperature sensor.

Measurement Tester
Standard values
conditions connections
20 °C {68 °F}:
SCR upstream 13.7 – 29.8 kΩ
SAPH31J191700375 Starter switch: temperature 50 °C {122°F}:
OFF sensor 7.13 – 13.7 kΩ
TEX1 – GND1 80 °C {176 °F}:
4.1 – 7.13 kΩ

NO Replace the SCR upstream temperature sensor.

YES

8 Inspect the air flow sensor

1. Check the installation of the air flow sensor.

2. Make sure there is no dirt or damage to the air flow sensor.

NO If dirt, clogging or damage in the sensing unit was

found, replace the air flow sensor.

YES

Procedure completed.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–351

DTC code P2510

DCU Power Relay Sense Circuit Range/ Performance

JP31J19170901050

1 Check the DTC detected (DCU) [Hino-DX]

1. Connect the machine to Hino-DX.

2. Set the starter switch to the "ON" position.

Select 3. Select [DCU] and check if any DTC other than P2510 (for
DCU
example, P0562) has been detected in [Fault Information].

NO Go to diagnosis procedure of a related DTC.

SAPH31J191700376

YES

2 Inspect the DCU power supply circuit

1. Set the starter switch to the "OFF" position.

DCU 53 Pin connector 2. Disconnect the DCU 53P connector.

+B2 GND4 GND1

LEP LEW LET 3. Set the starter switch to the "ON" position.
+B2 GND4 GND1
LEP LEW LET

+B3 GND5 GND2

+B3
LEQ
GND5
LEX
GND2
LEU LEQ LEX LEU 4. Connect the signal check harness and use the electrical tester
+B4
LER
+B1
LEN
GND3
LEV to measure the voltage between the each terminal of DCU 53P
+B4 +B1 GND3
LER LEN LEV
machine-side connector and the battery minus (BAT-).
CAH1
LF5

CAL1
LF6 Measurement Tester
TE1B
LF2
Standard values
TE1A
LF1
CAH0
LEY
conditions connections
TE2B CAL0
LF4 LEZ

TE2A
LF3
DCU 53P
machine-side
IGSW
connector –
LES

Starter switch: BAT-

Battery 19 – 32 V
ON +B1 – BAT-
+B2 – BAT-
+B3 – BAT-
+B4 – BAT-
SAPH31J191700377

NO Inspect or repair the power supply circuit (harness).

YES

[S5LC0033E04] [0518CsCshWbYs]
17–352 ENGINE DIAGNOSIS CODE

3 Check the DTC detected (DCU) [Hino-DX]

1. Set the starter switch to the "ON" position.

2. Select [DCU].

Select 3. Erase the malfunction history using Hino-DX.

DCU
4. Start up the engine.

5. Keep the machine connecting to Hino-DX and set the starter

switch to the "OFF" position.

When communicat-
ion with the DCU is 6. After checking that communication between Hino-DX and the
interrupted while DCU has been disconnected, set the starter switch to the "ON"
the DCU is connec-
ted to the Hino-DX, position again.
the connection
symbol at the left
bottom of the Hino- 7. Select [DCU] and check if P2510 has been detected in [Fault
DX screen (figure Information].
on the left) becom-
es disconnected.
NO Replace the DCU.

SAPH31J191700378

YES

Procedure completed.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–353

DTC code U0029

Vehicle Communication Bus A Performance

JP31J19170901051

1 Inspect the connector

1. Check the connection of the engine joint connector and DCU

connector (Looseness and poor contact).

NO Repair or replace the faulty part, and go to step 2.

CANL CANH
K29 K28

GND SIG VCC

KSL KSK KSJ

GND2 TEX2 GND1 TEX1

KSH KSG KSF KSE

Engine joint connector

SAPH31J191700246

YES

Connect securely, and go to step 2.

2 Check the DTC detected [Hino-DX]

1. Set the starter switch to the "ON" position.

2. Select [Engine] and check if U010E has been detected in [Fault

Select Information].
Engine
DCU
3. Select [DCU] and check if U0029 has been detected in [Fault
Information]

NO Go to step 3.
SAPH31J191700247

YES

Procedure completed.

[S5LC0033E04] [0518CsCshWbYs]
17–354 ENGINE DIAGNOSIS CODE

3 Check harness in CAN H-line between engine joint connector and DCU

1. Set the starter switch to the "OFF" position.

2. Disconnect the engine joint connector and DCU (53P)

K28
connector.
+B2 GND4 GND1
LEP LEW LET

CANL CANH
+B3 GND5 GND2 K29 K28
LEQ LEX LEU
3. Use the electrical tester to measure the resistance between the
GND SIG VCC
+B4 +B1 GND3
LER LEN LEV KSL KSK KSJ
engine joint connector K28 terminal and the DCU machine-side
GND2 TEX2 GND1 TEX1
KSH KSG KSF KSE
connector (53P) CAH0 terminal.
CAH1
LF5 Standard value: 1 Ω or less
CAL1
LF6

TE1B
CAH0
LF2

TE1A CAH0
LF1 LEY

TE2B CAL0
LF4 LEZ

TE2A
LF3

ISGW
LES

SAPH31J191700248

NO Disconnection or faulty continuity in CAN H-line

between engine joint connector and DCU.
Repair or replace the harness.

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–355

4 Check harness in CAN L-line between engine joint connector and DCU

1. Use the electrical tester to measure the resistance between the

engine joint connector K29 terminal and the DCU machine-side
connector (53P) CAL0 terminal.
K29
+B2
LEP
GND4
LEW
GND1
LET
Standard value: 1 Ω or less
CANL CANH
+B3 GND5 GND2 K29 K28
LEQ LEX LEU

GND SIG VCC

+B4 +B1 GND3
LER LEN LEV KSL KSK KSJ

GND2 TEX2 GND1 TEX1

KSH KSG KSF KSE

CAH1
LF5

CAL1
LF6

TE1B
LF2

TE1A CAH0
CAL0
LF1 LEY

TE2B CAL0
LF4 LEZ

TE2A
LF3

ISGW
LES

SAPH31J191700249

NO Disconnection or faulty continuity in CAN L-line

between engine joint connector and DCU.
Repair or replace the harness.

YES

[S5LC0033E04] [0518CsCshWbYs]
17–356 ENGINE DIAGNOSIS CODE

5 Check the DCU power supply

1. Connect the engine joint connector and DCU (53P) connector.

GND1 2. Set the starter switch to the "ON" position.

+B3

+B2
LEP
GND4
LEW
GND1
LET
3. Connect the signal check harness, and use the electrical tester
+B3
LEQ
GND5
LEX
GND2
LEU
to measure the voltage between the terminals of the DCU.
+B4
LER
+B1
LEN
GND3
LEV
Standard value: 19 – 32 V

NO Check the DCU power supply circuit.

CAH1
LF5

CAL1
LF6

TE1B
LF2

TE1A CAH0
LF1 LEY

TE2B CAL0
LF4 LEZ

TE2A
LF3

ISGW
LES

SAPH31J191700250

YES

6 Inspect the DCU [Hino-DX]

1. Set the starter switch to the "OFF" position.

2. Connect DCU (53P) connector.

Select
Engine 3. Set the starter switch to the "ON" position.
DCU

4. Select [Engine] and check if U010E has been detected in [Fault

Information].

5. Select [DCU] and check if U0029 has been detected in [Fault

SAPH31J191700251
Information]

NO Replace the DCU.

YES

Procedure completed.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–357

DTC code U0038

Vehicle Communication Bus B Performance

JP31J19170901052

1 Inspect the connector

1. Check the connection of the DCU CAN line harness

connectors (Looseness and poor contact).

Machine-side harness

Engine side View A

DCU connector
Mechatro controller

SAPH31J191700379

NO Repair or replace the faulty part, and go to step 2.

YES

Connect securely, and go to step 2.

[S5LC0033E04] [0518CsCshWbYs]
17–358 ENGINE DIAGNOSIS CODE

2 Check the DTC detected [Hino-DX]

1. Set the starter switch to the "ON" position.

2. Select [DCU] and check if U0038 has been detected in [Fault

Information].
Select
DCU
NO Go to step 3.

SAPH31J191700380

YES

Procedure completed.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–359

3 Check harness in CAN line between Mechatro controller and DCU

1. Set the starter switch to the "OFF" position.

2. Disconnect the Mechatro controller CN-101F and DCU 53P

connector.

3. Use the electrical tester to measure the resistance machine-

side harness between the CN-101F connector 520A terminal
and the DCU 53P connector CAH1 terminal, CN-101F
connector 521A terminal and DCU 53P connector CAL1
terminal.

CAH1
CAL1

+B2 GND4 GND1

LEP LEW LET

+B3 GND5 GND2

LEQ LEX LEU

+B4 +B1 GND3

LER LEN LEV

CAH1
LF5
520A 521A
CAL1
LF6

TE1B
LF2

TE1A CAH0
LF1 LEY

TE2B CAL0
LF4 LEZ

TE2A
LF3

IGSW
LES

Mechatro controller

SAPH31J191700381

Standard value: 1 Ω or less

NO Go to step 5.

YES

[S5LC0033E04] [0518CsCshWbYs]
17–360 ENGINE DIAGNOSIS CODE

4 Check harness in CAN line between engine joint connector CN-12F and DCU

1. Use the electrical tester to measure the resistance between the

CN-12F connector 5200 terminal and the DCU 53P connector
CAH1 terminal, CN-12F connector 5210 terminal and the DCU
53P CAL1 terminal.

Machine-side harness

CAH1
CAL1

+B2 GND4 GND1

LEP LEW LET

+B3 GND5 GND2

LEQ LEX LEU

+B4 +B1 GND3

LER LEN LEV

CAH1
LF5

CAL1
LF6

TE1B
LF2

TE1A CAH0
LF1 LEY

TE2B CAL0
LF4 LEZ

TE2A
LF3

5210

IGSW
LES

5200

CN-12F

SAPH31J191700382

Standard value: 1 Ω or less

NO Disconnection or poor continuity in CAN line

between engine joint connector and DCU. Repair or
replace the harness.
Go to step 8.

YES

Replace the DCU.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–361

5 Check harness in CAN line between CN-101F and CN-158M

1. Use the electrical tester to measure the resistance between the

CN-101F connector 520A terminal and the CN-158M
connector 520A terminal, CN-101F connector 521A terminal
and the CN-158M 521A terminal.

CN-158M

CN-101F

520A
521A 521A

CN-101F CN-158M

520A

SAPH31J191700383

Standard value: 1 Ω or less

NO Disconnection or poor continuity in CAN line

between CN-101F connector and CN-158M. Repair
or replace the harness.
Go to step 7.

YES

[S5LC0033E04] [0518CsCshWbYs]
17–362 ENGINE DIAGNOSIS CODE

6 Check harness in CAN line between CN-158F and DCU

1. Use the electrical tester to measure the resistance between the

CN-158F connector 520A terminal and the DCU 53P connector
CAH1 terminal, CN-158F connector 521A terminal and the
DCU 53P CAL1 terminal.

CN-158F

CAH1
CAL1

+B2 GND4 GND1

LEP LEW LET

+B3 GND5 GND2

LEQ LEX LEU

+B4 +B1 GND3

LER LEN LEV

520A
CAH1
LF5

CAL1
LF6

TE1B
LF2

TE1A CAH0
LF1 LEY

TE2B CAL0
LF4 LEZ

TE2A
LF3

IGSW
LES

CN-158F

521A

SAPH31J191700384

Standard value: 1 Ω or less

NO Disconnection or poor continuity in CAN line

between CN-158F connector and DCU. Repair or
replace the harness.
Go to step 8.

YES

Replace the DCU.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–363

7 Check the DTC detected [Hino-DX]

1. Set the starter switch to the "ON" position.

2. Select [DCU] and check if U0038 has been detected in [Fault

Information].
Select
DCU
NO Go to step 6.

SAPH31J191700380

YES

Procedure completed.

8 Check the DCU power supply

1. Connect the engine joint connector and DCU 53P connector.

GND1
+B3
2. Set the starter switch to the "ON" position.

3. Connect the signal check harness, and use the electrical tester
to measure the voltage between the terminals of the DCU.
Standard value: 19 – 32 V

NO Check the DCU power supply circuit.

SAPH31J191700385

YES

9 Inspect the DCU [Hino-DX]

1. Set the starter switch to the "OFF" position.

2. Connect the DCU 53P connector.

Select 3. Set the starter switch to the "ON" position.

DCU

4. Select [DCU] and check if U0038 has been detected in [Fault

Information].

NO Replace the DCU.

SAPH31J191700386

YES

Procedure completed.

[S5LC0033E04] [0518CsCshWbYs]
17–364 ENGINE DIAGNOSIS CODE

DTC code U0100

Faulty CAN communication
JP31J19170901053

NOTICE • For correction of the abnormality using the following procedure, use the Hino-DX to delete
past faults, then set the starter key to "ON", and then make sure that the DTC code U0100 is
not indicated.

1 Inspection of the CAN communication line

1. Inspect the CAN communication line.

YES

2 Engine ECU inspection

1. Check the DTC code of the engine ECU and confirm that there
is no abnormality.

NO Perform fault diagnosis for the DTC code that was

indicated.

YES

DCU replacement (after replacement, using the Hino-DX, perform a "Leak test")

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–365

DTC code U029D

Engine ECU CAN communication (SCR upstream NOx sensor)

JP31J19170901054

1 SCR upstream NOx sensor connector check

1. Set the starter switch to the "OFF" position.

2. Check for NOx sensor connector looseness.

3. Disconnect the NOx sensor connector and check the connector

pins for damage and rust.
Standard:
Connector disconnected or loose.
Connector pins damaged or rusted.
SAPH31J191700252
NO Go to step 2.

YES

Connector disconnected or loose.

→Reconnect the connector.
Connector pins damaged or rusted.
→Replace damaged parts.

2 NOx sensor ground check

1. Set the starter switch to the "OFF" position.

GND CANH CANL GND VCC

LGU LE9 LE8 LE7 LE6 2. Disconnect the NOx sensor connector.

3. Set the starter switch to the "ON" position.

4. Measure the voltage between GND LE7 (chassis side of the

NOx sensor connector) and the minus terminal of the battery
Battery with a circuit tester.
Standard value: Below 1V
SAPH31J191700253

NO Repair or replace of the ground circuit (harness).

YES

[S5LC0033E04] [0518CsCshWbYs]
17–366 ENGINE DIAGNOSIS CODE

3 NOx sensor ground check

1. Set the starter switch to the "OFF" position.

GND CANH CANL GND VCC

LGU LE9 LE8 LE7 LE6 2. Disconnect NOx sensor connector.

3. Set the starter switch to the "ON" position.

4. Measure the voltage between GND LGU (chassis side of the

NOx sensor connector) and the minus terminal of the battery
Battery with a circuit tester.
Standard value: Below 1V
SAPH31J191700254

NO Repair or replace of the ground circuit (harness).

YES

4 NOx sensor power supply voltage check

1. Set the starter switch to the "OFF" position.

GND CANH CANL GND VCC

LGU LE9 LE8 LE7 LE6 2. Disconnect NOx sensor connector.

3. Set the starter switch to the "ON" position.

4. Measure the voltage between VCC LE6 (chassis side of the

NOx sensor connector) and the minus terminal of the battery
Battery with a circuit tester.
Standard value: 19 – 32 V
SAPH31J191700255

NO Repair or replace of the power supply circuit

(harness, fuse, etc.).

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–367

5 Harness check between DCU and NOx controller (CANL line)

1. Set the starter switch to the "OFF" position.

CANH CANL GND VCC 2. Disconnect NOx sensor connector.

LED LEC LEB LEA

3. Disconnect the connector of the DCU.

+B2 GND4 GND1
LEP LEW LET
4. Measure the resistance between CANL LE8 (chassis side of
+B3 GND5 GND2

the NOx sensor connector) and CAH0 LEZ (chassis side of the
LEQ LEX LEU

+B4 +B1 GND3

DCU connector) with a circuit tester.

LER LEN LEV

Standard value: Below 1 Ω

CAH1
LF5

CAL1
LF6

TE1B
LF2
NO Repair or replace of the CAN harness between DCU
TE1A
LF1
CAH0
LEY and NOx controller.
TE2B CAL0
LF4 LEZ

TE2A
LF3

ISGW
LES

SAPH31J191700256

YES

6 Harness check between DCU and NOx controller (CANH line)

1. Set the starter switch to the "OFF" position.

GND CANH CANL GND VCC 2. Disconnect NOx sensor connector.

LGU LE9 LE8 LE7 LE6

3. Disconnect the connector of the DCU.

+B2 GND4 GND1
LEP LEW LET
4. Measure the resistance between CANH LE9 (chassis side of
+B3 GND5 GND2
LEQ LEX LEU
the NOx sensor connector) and CAH0 LEY (chassis side of the
+B4 +B1 GND3

DCU connector) with a circuit tester.

LER LEN LEV

Standard value: Below 1 Ω

CAH1
LF5

CAL1
LF6

TE1B
LF2
NO Repair or replace of the CAN harness between DCU
TE1A
LF1
CAH0
LEY and NOx controller.
TE2B CAL0
LF4 LEZ

TE2A
LF3

ISGW
LES

SAPH31J191700257

YES

[S5LC0033E04] [0518CsCshWbYs]
17–368 ENGINE DIAGNOSIS CODE

7 DTC check when the SCR upstream NOx sensor and the SCR downstream NOx sensor have been
switched

1. Set the starter switch to the "OFF" position.

2. Disconnect the connectors of SCR upstream NOx sensor and

SCR downstream NOx sensor.

3. Switch the arrangement of SCR upstream NOx sensor and

SCR downstream NOx sensor.

4. Set the starter switch to the "ON" position.

SAPH31J191700258
5. Connect Hino-DX to the machine.

6. Select "DCU".

7. After the DTC has been cleared, read the DTC again.

NOTICE • When the DTC U029E and U029D are detected

simultaneously, perform steps from 5 to 6
again.

NO Replace the DCU.

SAPH31J191700259

YES

Replace the SCR upstream NOx sensor.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–369

DTC code U029E

Engine ECU CAN communication (SCR downstream NOx sensor)

JP31J19170901055

1 SCR downstream NOx sensor connector check

1. Set the starter switch to the "OFF" position.

2. Check for NOx sensor connector looseness.

3. Disconnect the NOx sensor connector and check the connector

pins for damage and rust.
Standard:
Connector disconnected or loose.
Connector pins damaged or rusted.
SAPH31J191700260
NO Go to step 2.

YES

Connector disconnected or loose.

→Reconnect the connector.
Connector pins damaged or rusted.
→Replace damaged parts.

2 NOx sensor ground check

1. Set the starter switch to the "OFF" position.

CANH CANL GND VCC

LED LEC LEB LEA 2. Disconnect the NOx sensor connector.

3. Set the starter switch to the "ON" position.

4. Measure the voltage between GND LEB (chassis side of the

NOx sensor connector) and the minus terminal of the battery
Battery with a circuit tester.
Standard value: Below 1V
SAPH31J191700261

NO Repair or replace of the ground circuit (harness).

YES

[S5LC0033E04] [0518CsCshWbYs]
17–370 ENGINE DIAGNOSIS CODE

3 NOx sensor power supply voltage check

1. Set the starter switch to the "OFF" position.

CANH CANL GND VCC

LED LEC LEB LEA 2. Disconnect NOx sensor connector.

3. Set the starter switch to the "ON" position.

4. Measure the voltage between VCC LEA (chassis side of the

NOx sensor connector) and the minus terminal of the battery
Battery with a circuit tester.
Standard value: 19 – 32 V
SAPH31J191700262

NO Repair or replace of the power supply circuit

(harness, fuse, etc.).

YES

4 Harness check between DCU and NOx controller (CANL line)

1. Set the starter switch to the "OFF" position.

CANH CANL GND VCC 2. Disconnect NOx sensor connector.

LED LEC LEB LEA

3. Disconnect the connector of the DCU.

+B2 GND4 GND1
LEP LEW LET
4. Measure the resistance between CANL LEC (chassis side of
+B3 GND5 GND2

the NOx sensor connector) and CAH0 LEZ (chassis side of the
LEQ LEX LEU

+B4 +B1 GND3

DCU connector) with a circuit tester.

LER LEN LEV

Standard value: Below 1 Ω

CAH1
LF5

CAL1
LF6

TE1B
LF2
NO Repair or replace of the CAN harness between DCU
TE1A
LF1
CAH0
LEY and NOx controller.
TE2B CAL0
LF4 LEZ

TE2A
LF3

ISGW
LES

SAPH31J191700256

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–371

5 Harness check between DCU and NOx controller (CANH line)

1. Set the starter switch to the "OFF" position.

CANH CANL GND VCC 2. Disconnect NOx sensor connector.

LED LEC LEB LEA

3. Set the starter switch to the "ON" position.

+B2 GND4 GND1
LEP LEW LET
4. Measure the resistance between CANH LED (chassis side of
+B3 GND5 GND2

the NOx sensor connector) and CAH0 LEY (chassis side of the
LEQ LEX LEU

+B4 +B1 GND3

DCU connector) with a circuit tester.

LER LEN LEV

Standard value: Below 1 Ω

CAH1
LF5

CAL1
LF6

TE1B
LF2
NO Repair or replace the CAN harness between DCU
TE1A
LF1
CAH0
LEY and NOx controller.
TE2B CAL0
LF4 LEZ

TE2A
LF3

ISGW
LES

SAPH31J191700263

YES

[S5LC0033E04] [0518CsCshWbYs]
17–372 ENGINE DIAGNOSIS CODE

6 DTC check when the SCR upstream NOx sensor and the SCR downstream NOx sensor have been
switched

1. Set the starter switch to the "OFF" position.

2. Disconnect the connectors of SCR upstream NOx sensor and

SCR downstream NOx sensor.

3. Switch the arrangement of SCR upstream NOx sensor and

SCR downstream NOx sensor.

4. Set the starter switch to the "ON" position.

SAPH31J191700264
5. Connect Hino-DX to the machine.

6. Select "DCU".

7. After the DTC has been cleared, read the DTC again.

When the DTC U029E and U029D are detected simultaneously,

perform steps from 4 to 5 again.

NO Replace the DCU.

SAPH31J191700265

YES

Replace the SCR downstream NOx sensor.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–373

DTC code U02A2

DCU CAN communication (AdBlue/DEF tank sensor)

JP31J19170901056

1 Inspect the connector

1. Check the connection of the DCU connector and AdBlue/DEF

sensor connector (Looseness and poor contact).

DCU connector
AdBlue/DEF sensor connector
SAPH31J191700266

NO Repair or replace the faulty part, and go to step 2.

YES

Connect securely, and go to step 2.

2 Check the DTC detected [Hino-DX]

1. Set the starter switch to the "ON" position.

2. Select [Engine] and [DCU], and check if U02A2 has been

Select detected in [Fault Information].
Engine
DCU
NO Go to step 3.

SAPH31J191700267

YES

Procedure completed.

[S5LC0033E04] [0518CsCshWbYs]
17–374 ENGINE DIAGNOSIS CODE

3 Inspect the AdBlue/DEF sensor harness (GND circuit)

1. Set the starter switch to the "OFF" position.

2. Disconnection the AdBlue/DEF sensor connector.

3. Use the electrical tester to measure the resistance between the

GND terminal in the AdBlue/DEF sensor machine-side (upper-
side) connector and the ground.

Measurement Tester
Standard values
conditions connections
AdBlue/DEF
sensor
Starter switch: machine-side
1 Ω or less
OFF connector –
Ground
GND – Ground
GND

NO Inspect the AdBlue/DEF sensor ground circuit.

SAPH31J191700268

YES

4 Inspect the AdBlue/DEF sensor harness (Power supply circuit)

1. Set the starter switch to the "ON" position.

2. Use the electrical tester to measure the voltage between the

terminals of the AdBlue/DEF sensor machine-side (upper-side)
connector.

Measurement Tester
Standard values
conditions connections

AdBlue/DEF
sensor
VCC Starter switch:
machine-side 19 – 32 V
ON
connector
GND VCC – GND

NO Inspect the AdBlue/DEF sensor power supply circuit.

(between fuse and relay block and AdBlue/DEF
sensor)

SAPH31J191700269

YES

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–375

5 Inspect for disconnection in CAN H-line between the DCU and AdBlue/DEF sensor

1. Set the starter switch to the "OFF" position.

2. Disconnect the DCU connector.

3. Connect the signal check harness, and use the electrical tester
+B2
LEP
GND4
LEW
GND1
LET
PIN2 to measure the resistance between the DCU terminal and PIN2
+B3
LEQ
GND5
LEX
GND2
LEU terminal of the AdBlue/DEF sensor.
+B4
LER
+B1
LEN
GND3
LEV Standard value: 1 Ω or less

CAH1
LF5
CAH0 NO Disconnection or faulty continuity in CAN H-line
CAL1
LF6
between the DCU and AdBlue/DEF sensor. Repair
TE1B
LF2

TE1A
LF1
CAH0
LEY
or replace the harness.
TE2B CAL0
LF4 LEZ

TE2A
LF3

ISGW
LES

SAPH31J191700270

YES

6 Check for disconnection in CAN L-line between the DCU and AdBlue/DEF sensor

1. Connect the signal check harness, and use the electrical tester
to measure the resistance between the DCU terminal and PIN1
terminal of the AdBlue/DEF sensor.

Standard value: 1 Ω or less

+B2 GND4 GND1
LEP LEW LET
PIN1
NO Disconnection or faulty continuity in CAN L-line
+B3 GND5 GND2
LEQ LEX LEU

+B4 +B1 GND3

between the DCU and AdBlue/DEF sensor. Repair
LER LEN LEV

or replace the harness.

CAH1
LF5

CAL1
CAL0
LF6

TE1B
LF2

TE1A CAH0
LF1 LEY

TE2B CAL0
LF4 LEZ

TE2A
LF3

ISGW
LES

SAPH31J191700271

YES

[S5LC0033E04] [0518CsCshWbYs]
17–376 ENGINE DIAGNOSIS CODE

7 Inspect the AdBlue/DEF sensor [Hino-DX]

1. Connect the DCU and AdBlue/DEF sensor connector.

2. Set the starter switch to the "ON" position.

Select
Engine 3. Select [Engine] and [DCU], and check if U02A2 has been
DCU
detected in [Fault Information].

NO Replace the AdBlue/DEF sensor.

SAPH31J191700272

YES

Procedure completed.

[S5LC0033E04] [0518CsCshWbYs]
 ENGINE DIAGNOSIS CODE 17–377

DTC code U0597

DCU failure
JP31J19170901057

1 DCU replacement

1. Replace the DCU. (After replacement, perform a "Leak test".)

2. Confirm that the DTC code U0597 is not indicated.

[S5LC0033E04] [0518CsCshWbYs]
[S5LC0033E04] [0518CsCshWbYs]
 2015
All rights reserved. This manual may not be reproduced or copied in
whole or in part, without the written permission of Hino Motors, Ltd.
PRINTED IN JAPAN

Pub. No. KSS-T4J8-003E Nov. 2015

[S5LC0033E04] [0518CsCshWbYs]
[S5LC0033E04] [0518CsCshWbYs]