Vio27 35-2 (Us) (New Cabin) SVM

California California
Proposition 65 Warning Proposition 65 Warning

Diesel engine exhaust and some of its Battery posts, terminals and related
constituents are known to the State of accessories contain lead and lead
California to cause cancer, birth defects compounds, chemicals known to the
and other reproductive harm. State of California to cause cancer and
reproductive harm.
Wash hands after handling.
CONTENTS
CHAPTER 1
GENERAL CAUTIONS FOR MAINTENANCE WORK
1-1 Correct Work ...........................................................................................................................................................................1-1
1-2 Safety Precautions ..................................................................................................................................................................1-1
1-3 Preparations ............................................................................................................................................................................1-1
1-4 Cautions for Disassembly and Reassembly............................................................................................................................1-1
1-5 Cautions for Removal and Installation of Hydraulic Equipment ..............................................................................................1-2
1-6 Cautions for Removal and Installation of Hydraulic Piping......................................................................................................1-2
1-7 Cautions for Handling Seals....................................................................................................................................................1-3
1-8 Correct Installation of Hydraulic Hose .....................................................................................................................................1-3
1-9 Specifications of Hydraulic Hose.............................................................................................................................................1-6
1-10 Air Release of Hydraulic Equipment....................................................................................................................................1-11
CHAPTER 2
TECHNICAL DATA
2-1 Specifications ...................................................................................................................................................................... 2-1-1
2-2 Outline Drawing and Working Area ..................................................................................................................................... 2-2-1
2-2-1 Canopy type ............................................................................................................................................................... 2-2-1
2-2-2 Cabin type .................................................................................................................................................................. 2-2-5
2-3 Weight List of Main Parts .................................................................................................................................................... 2-3-1
2-4 Lifting Capacity List ............................................................................................................................................................. 2-4-1
CHAPTER 3
SERVICE STANDARDS
3-1 Machine Performance ......................................................................................................................................................... 3-1-1
3-2 Engine ................................................................................................................................................................................. 3-2-1
3-3 Undercarriage ..................................................................................................................................................................... 3-3-1
3-3-1 Rubber Crawler Specifications ................................................................................................................................... 3-3-1
3-3-2 Steel Crawler Specifications....................................................................................................................................... 3-3-2
3-3-3 Common Specifications of Steel & Rubber Crawlers ................................................................................................. 3-3-3
3-4 Controls ............................................................................................................................................................................... 3-4-1
3-5 Hydraulic Equipment ........................................................................................................................................................... 3-5-1
3-5-1 Hydraulic Cylinders .................................................................................................................................................... 3-5-1
3-6 Implement ........................................................................................................................................................................... 3-6-1
3-6-1 Front Attachments ...................................................................................................................................................... 3-6-1
3-6-2 Blade Moving Device.................................................................................................................................................. 3-6-3
3-6-3 Bucket Teeth .............................................................................................................................................................. 3-6-3
3-7 List of Tightening Torque .................................................................................................................................................... 3-7-1
3-7-1 Machine...................................................................................................................................................................... 3-7-1
3-7-2 Engine ........................................................................................................................................................................ 3-7-4
3-7-3 Tightening Torque for General Bolts and Nuts........................................................................................................... 3-7-4
CHAPTER 4
ENGINE
4-1 Measurement, Inspection and Adjustment .......................................................................................................................... 4-1-1
4-1-1 Measuring the Compression Pressure ....................................................................................................................... 4-1-1
4-1-2 Adjusting the Valve Clearance ................................................................................................................................... 4-1-2
4-1-3 Checking the V-belt Tension ...................................................................................................................................... 4-1-3
4-1-4 Checking the Fuel Injection Valve .............................................................................................................................. 4-1-3
4-1-5 Checking and adjusting the Fuel Injection Timing...................................................................................................... 4-1-5
4-1-6 Adjusting the Maximum (or Minimum) Idling Speed................................................................................................... 4-1-7
4-1-7 Checking the Cooling Water System and Radiator for Water Leakage ..................................................................... 4-1-7
4-1-8 Checking the Sensors ................................................................................................................................................ 4-1-8
4-2 Measurement Procedure, Service Data and Corrective Action........................................................................................... 4-2-1
4-2-1 Cylinder Head............................................................................................................................................................. 4-2-1
4-2-2 Cylinder Block ............................................................................................................................................................ 4-2-6
4-2-3 Valve Rocker Arm ...................................................................................................................................................... 4-2-8
4-2-4 Piston and Piston Rings ........................................................................................................................................... 4-2-10
4-2-5 Connecting Rod........................................................................................................................................................ 4-2-13
4-2-6 Cam shaft ................................................................................................................................................................. 4-2-16
4-2-7 Crank shaft ............................................................................................................................................................... 4-2-17
4-2-8 Gears........................................................................................................................................................................ 4-2-20
4-2-9 Trochoid Pump ......................................................................................................................................................... 4-2-21
4-3 Precautions for Reassembly ............................................................................................................................................... 4-3-1
4-4 Fuel Injection System .......................................................................................................................................................... 4-4-1
4-4-1 Fuel Injection Pump.................................................................................................................................................... 4-4-1
4-4-2 Fuel Injection Valve .................................................................................................................................................... 4-4-2
4-4-3 Governor Mechanism ................................................................................................................................................. 4-4-3
4-4-4 Specifications of Fuel Injection Pump ........................................................................................................................ 4-4-5
4-5 Electrical Equipment ........................................................................................................................................................... 4-5-1
4-5-1 Starter Motor .............................................................................................................................................................. 4-5-1
4-5-2 Alternator.................................................................................................................................................................... 4-5-3
4-5-3 Air Heater ................................................................................................................................................................... 4-5-4
CHAPTER 5
HYDRAULIC SYSTEM
5-1 Outline................................................................................................................................................................................. 5-1-1
5-1-1 Control Valve Operation ............................................................................................................................................. 5-1-4
5-1-2 Additional Operation of Control Valve ........................................................................................................................ 5-1-6
5-2 Hydraulic Circuit Schematic ................................................................................................................................................ 5-2-1
5-2-1 Quick Coupler............................................................................................................................................................. 5-2-1
5-2-2 W/O Quick Coupler .................................................................................................................................................... 5-2-3
5-3 Circuit Operation ................................................................................................................................................................. 5-3-1
5-3-1 Boom .......................................................................................................................................................................... 5-3-1
5-3-2 Arm............................................................................................................................................................................. 5-3-3
5-3-3 Bucket ........................................................................................................................................................................ 5-3-5
5-3-4 Swing.......................................................................................................................................................................... 5-3-7
5-3-5 Boom Swing ............................................................................................................................................................... 5-3-9
5-3-6 Blade ........................................................................................................................................................................ 5-3-11
5-3-7 Travel ....................................................................................................................................................................... 5-3-13
5-3-8 Non-Deviation Travel (with Boom, Arm, Bucket or Boom Swing Operation)............................................................ 5-3-15
5-3-9 Simultaneous Operation of Boom Up and Arm Retract............................................................................................ 5-3-17
5-3-10 Simultaneous Operation of Boom Up and Bucket.................................................................................................. 5-3-19
5-3-11 Simultaneous Operation of Arm and Bucket .......................................................................................................... 5-3-21
5-3-12 Simultaneous Operation of Boom Up and Swing ................................................................................................... 5-3-23
5-3-13 Hydraulic P.T.O. ..................................................................................................................................................... 5-3-25
5-3-14 Quick Coupler......................................................................................................................................................... 5-3-27
5-4 Pressure Adjustment ........................................................................................................................................................... 5-4-1
5-4-1 Relief Valves .............................................................................................................................................................. 5-4-1
5-4-2 Swing Brake Valve ..................................................................................................................................................... 5-4-3
5-4-3 Cut-Off Valve.............................................................................................................................................................. 5-4-4
CHAPTER 6
HYDRAULIC EQUIPMENT
6-1 Hydraulic Pump ................................................................................................................................................................... 6-1-1
6-1-1 ViO27-2 ...................................................................................................................................................................... 6-1-1
6-1-2 ViO35-2 .................................................................................................................................................................... 6-1-37
6-2 Control Valve....................................................................................................................................................................... 6-2-1
6-3 Pilot Valve ........................................................................................................................................................................... 6-3-1
6-4 Swing Motor ........................................................................................................................................................................ 6-4-1
6-5 Travel Motor ....................................................................................................................................................................... 6-5-1
6-5-1 ViO27-2 ...................................................................................................................................................................... 6-5-1
6-5-2 ViO35-2 .................................................................................................................................................................... 6-5-43
6-6 Pilot Check Valve (Quick Coupler Type) ............................................................................................................................. 6-6-1
CHAPTER 7
ADJUSTMENT AND REPAIR
7-1 Electrical Equipment of Machine and Engine...................................................................................................................... 7-1-1
7-1-1 Parts Layout of Electrical Equipment ......................................................................................................................... 7-1-1
7-1-2 Monitor and Alarm Systems ....................................................................................................................................... 7-1-3
7-1-3 Wiring Diagram........................................................................................................................................................... 7-1-6
7-1-4 Circuit description of engine start and stop, and battery charging ............................................................................. 7-1-7
7-1-5 Removal and Reinstallation of Engine ....................................................................................................................... 7-1-9
7-1-6 Removal and Reassembly of Starter Motor ............................................................................................................. 7-1-16
7-1-7 Removal and Reinstallation of Fuel Injection Pump................................................................................................. 7-1-17
7-2 Undercarriage ..................................................................................................................................................................... 7-2-1
7-2-1 Outline ........................................................................................................................................................................ 7-2-1
7-2-2 Major Parts ................................................................................................................................................................. 7-2-1
7-2-3 Points of Reassembly (Rubber Crawler Models) ....................................................................................................... 7-2-2
7-2-4 Points of Reassembly (Steel Crawler Models) ........................................................................................................... 7-2-3
7-2-5 Removal and Reinstallation of Crawler ...................................................................................................................... 7-2-5
7-2-6 Removal and Reinstallation of Travel Motor .............................................................................................................. 7-2-7
7-2-7 Disassembly and Reassembly of Idler ....................................................................................................................... 7-2-9
7-2-8 Disassembly and Reassembly of Track Roller......................................................................................................... 7-2-12
7-2-9 Disassembly and Reassembly of Carrier Roller ....................................................................................................... 7-2-15
7-2-10 Installation of Floating Seal .................................................................................................................................... 7-2-17
7-2-11 Drawings of Jigs ..................................................................................................................................................... 7-2-18
7-3 Controls ............................................................................................................................................................................... 7-3-1
7-3-1 Control Train............................................................................................................................................................... 7-3-1
7-3-2 Mechanical Control Linkage ....................................................................................................................................... 7-3-2
7-3-3 Adjustment of Travel Levers....................................................................................................................................... 7-3-4
7-3-4 Adjustment of Boom Swing Pedal .............................................................................................................................. 7-3-5
7-3-5 Adjustment of Blade Control Lever............................................................................................................................. 7-3-5
7-3-6 Adjustment of Lock Lever........................................................................................................................................... 7-3-6
7-3-7 Adjustment Procedure of Travel Alarm Switch........................................................................................................... 7-3-7
7-3-8 Adjustment Procedure of P.T.O. Pedal ...................................................................................................................... 7-3-8
7-3-9 Adjustment Procedure of P.T.O. Pedal Lock.............................................................................................................. 7-3-8
7-3-10 Adjustment of Accelerator Lever .............................................................................................................................. 7-3-9
7-4 Swing Bearing ..................................................................................................................................................................... 7-4-1
7-5 Hydraulic Equipment ........................................................................................................................................................... 7-5-1
7-5-1 Removal and Reinstallation of Hydraulic Pump ......................................................................................................... 7-5-1
7-5-2 Removal and Reinstallation of Control Valve ............................................................................................................. 7-5-3
7-5-3 Removal and Reinstallation of Swing Motor............................................................................................................... 7-5-6
7-5-4 Removal and Reinstallation of Swivel Joint................................................................................................................ 7-5-8
7-5-5 Disassembly and Reassembly of Swivel Joint ......................................................................................................... 7-5-11
7-5-6 Disassembly and Reassembly of Hydraulic Cylinders ............................................................................................. 7-5-14
7-5-7 Hydraulic Oil Tank .................................................................................................................................................... 7-5-18
7-5-8 Piping Layout............................................................................................................................................................ 7-5-25
7-6 Work Implements ................................................................................................................................................................ 7-6-1
7-6-1 Removal and Reinstallation of Work Implements....................................................................................................... 7-6-1
7-6-2 Quick Coupler............................................................................................................................................................. 7-6-8
7-7 Cabin ................................................................................................................................................................................... 7-7-1
7-7-1 Cabin .......................................................................................................................................................................... 7-7-1
7-8 New Cabin........................................................................................................................................................................... 7-8-1
7-8-1 Cabin ......................................................................................................................................................................... 7-8-1
CHAPTER 8
PERIODIC INSPECTION AND SERVICING
8-1 List of Periodic Inspection and Servicing.................................................................................................................................8-1
CHAPTER 9
FUEL, LUBE OIL AND GREASE RECOMMENDED
9. Fuel, Lube Oil and Grease Recommended ...............................................................................................................................9-1
CHAPTER 10
TROUBLESHOOTING
10-1 Non-Breakdowns............................................................................................................................................................. 10-1-1
10-1-1 Natural Release of Bucket...................................................................................................................................... 10-1-1
10-1-2 Discontinuous Arm Movement ............................................................................................................................... 10-1-1
10-1-3 Drifting of Upperstructure on Quick Travel Operation ............................................................................................ 10-1-2
10-1-4 Thermal Shock of Travel Motor .............................................................................................................................. 10-1-3
10-1-5 Elongation of Boom Swing Cylinder on 75 degrees Swing .................................................................................... 10-1-4
10-1-6 Telescopic Motion of Boom Swing Cylinder with Lock Lever Set to Lock Position ................................................ 10-1-5
10-1-7 Time Lag on Travel Speed Switching..................................................................................................................... 10-1-6
10-1-8 Fluctuation in Oil Level of Hydraulic Oil Tank Due to Temperature Change.......................................................... 10-1-7
10-1-9 Operation of Quick Coupler Cylinder (for Quick Coupler Type) ............................................................................. 10-1-8
10-2 Troubleshooting .............................................................................................................................................................. 10-2-1
10-2-1 Machine and Engine............................................................................................................................................... 10-2-1
10-2-2 Electrical Equipment on Panel ............................................................................................................................. 10-2-23
CHAPTER 11
REFERENCE DATA
11-1 Specifications for Attachment..............................................................................................................................................11-1
CHAPTER 1
GENERAL CAUTIONS FOR MAINTENANCE WORK
1-1 Correct Work............................................................................................1-1

1-2 Safety Precautions...................................................................................1-1
1-3 Preparations ............................................................................................1-1
1-4 Cautions for Disassembly and Reassembly ............................................1-1
1-5 Cautions for Removal and Installation of Hydraulic Equipment ...............1-2
1-6 Cautions for Removal and Installation of Hydraulic Piping ......................1-2
1-7 Cautions for Handling Seals ....................................................................1-3
1-8 Correct Installation of Hydraulic Hose .....................................................1-3
1-9 Specifications of Hydraulic Hose .............................................................1-6
1-10 Air Release of Hydraulic Equipment ...................................................1-11
1. GENERAL CAUTIONS FOR
MAINTENANCE WORK
1. General Cautions for Maintenance Work
1-1 Correct Work
Correct work means the quickest possible completion of according to the correct procedures and the specified stan-
dards.
It is important when conducting certain operations always to bear in mind the equipment, tools, gauges, materials, oil
and grease, etc. that you must have ready, as well as items to be checked, adjusted, or disassembled, and cautions
to watch out for.
1-2 Safety Precautions
(1) Never attempt servicing while engine is running or immediately after stopping operation.
(2) Wear work cloths, safety shoes and helmet.
(3) Check the equipment and tools before use. Especially, be sure to check the crane, lifting equipment and tools.
(4) When working together with other persons, allocate everyone's share of job, arrange the signals and act in con-
cert with the other persons.
(5) The operation of the crane and slinging work must be performed by qualified persons.
(6) Do not enter or pass under the raised load.
(7) Lift and support the massive parts by crane before removing the installation bolts.
(8) Disconnect cables from battery before repairing the electric system.
(9) Remove the battery when welding the machine.
1-3 Preparations
(1) Check the service record of the machine. (That is, check how many months or hours the machine has been
used since the preceding overhaul, what was the trouble then and what parts were replaced.)
(2) Have all servicing tools ready, i.e., tools, measuring devices (which have received periodic maintenance), con-
tainers, oil & grease, etc.
(3) Have the service literature (operation manual, parts catalog, etc.) ready.
1-4 Cautions for Disassembly and Reassembly
(1) Clean the machine before disassembly.

(2) Check and record the condition of the machine before disassembly :
• Model, machine number, operation hours
• Reasons for repair, history of repair
• Contamination of filters
• Fuel and oil condition
• Damage to parts, etc.
(3) Place alignment marks on the necessary parts to facilitate reassembly.
(4) Clean all the removed parts and new replacement parts and put them in order.
(5) Use new seals, split pins, etc. for reassembly.
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MAINTENANCE WORK
(6) Keep the parts apt to be damaged by water or oil apart from the oily or wet parts.
e.g.: Electrical parts, rubber parts, V-belts, etc.
(7) Use the jig for press-fitting the bearings, bushes and oil seals. When
using a hammer, use a pad block.
(8) Clean the joint surface of all parts and keep them free from dust.
(9) Wind the sealing tape securely, leaving a space of one or two
threads from the tip of the male screw. The tape should have an
overlap of about 10 mm.
1-5 Cautions for Removal and Installation of Hydraulic Equipment
(1) Check that the hydraulic oil temperature is low enough.

(2) Release air from the hydraulic tank to prevent the hydraulic oil from flowing out.
(3) Be sure to plug open the ends of hydraulic components to prevent dust from entering.
(4) Be sure to wipe hydraulic oil from the hydraulic components so that it will not be mistaken for an oil leak.
(5) Take care not to damage the plating on the cylinder rod.
(6) Remove or install cylinders with rods fully retracted.
(7) Be sure to release air after installing the hydraulic cylinders.
• Run the engine at a low speed. Extend and retract the cylinders 4 to 5 times up to 50 to 100 mm from the end
of the stroke. Then, fully extend and retract.
(8) Be sure to pressurize the hydraulic tank after installing the hydraulic components (in the case of the sealed
hydraulic tank). Otherwise, hydraulic pumps might suffer cavitation and their life will be shortened.
• To pressurize the hydraulic tank, fully extend each cylinder and tighten the oil filter port plugs.
1-6 Cautions for Removal and Installation of Hydraulic Piping
(1) Installation of hydraulic hose

Take care not to twist the hoses. (Judge whether or not the hose is twisted by
the hose mark.) For hoses with a metal fitting, use two wrenches to prevent
twisting.
Use one to fix the hose, and the other to tighten the fitting to the specified
tightening torque. Carefully check that the hoses do not come in contact after
tightening. If any contact is found, correct it or use tubes.
(2) When installing hoses, first tighten to the specified torque and then loosen
them a little. Then retighten to the specified torque.
• Break in the installed parts before tightening (except those using seal tapes).
(3) When installing pipes, turn the nuts more 1/4 to 1/2 turn after they reach the sharp torque rise point.
(4) When installing or removing hoses, use two wrenches, one to fasten the hose and the other to tighten or loosen
the hose to prevent twisting.
(5) Check for oil leakage by applying max. pressure 5 to 6 times after attaching hydraulic hoses or pipes.
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MAINTENANCE WORK
1-7 Cautions for Handling Seals
(1) Clean out grooves of O-rings. Remove burrs or dust if any.
(2) Take care not to twist O-rings. Correct by your finger if it is twisted.
(3) Take care not to damage seals when inserting.
(4) Handling of floating seals :
• Completely wipe off all the oil from the O-ring and housing after detaching the floating seals.
• Before installing, apply a little gear oil to the matching face of the housing.
• Turn the seals two or three times after installation to break them in.
(5) Apply grease to the lip of the oil seals to prevent wear.
1-8 Correct Installation of Hydraulic Hose
In order to mount the hydraulic hose most effectively and economically, observe the following cautions.
(1) When a hose is used at the minimum bending radius, use elbows to avoid sharp bending.
(2) To prevent twisting, the hose should be bent in the same direction as it moves.
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MAINTENANCE WORK
(3) When the hose is pressurized, the hose length varies slightly at the bend. Allow this change to occur and do not
try to fasten the bend.
(4) It is necessary for the hose to have ample slackness for elongation and contraction, because its length will
change by +2 % to -4 % when used at high pressure.
(5) Use the proper adapters, not pipes, in order to reduce the number and length of joints and improve the external
appearance.
(6) Use an elbow to prevent excessive twisting or bending of the hose.
(7) Use adapters to make the hose as straight as possible. The outside appearance can be improved by avoiding
the use of hoses that are too long.
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MAINTENANCE WORK
(8) The hose should be slightly longer than is absolutely necessary. The extra allows smoother movement of the
hose and prevents sharp bending.
(9) When a bent hose is attached to two different planes, fix as shown in the diagram to prevent twisting.
(10) Use the marking on the hose as a guide to prevent twisting during installation.
Twisting of metal fitting with union nuts should be with a wrench on the hexagonal parts.
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MAINTENANCE WORK
1-9 Specifications of Hydraulic Hose
Two types of hydraulic hoses are used in Yanmar Construction Machinery : the standard parts specified in the
Yanmar Industrial Standards (YIS) and special parts for the respective models. Specifications of the hydraulic hoses
can be known by the code number or part descriptions as explained below. (For the parts number, please refer to
our Parts Catalog.)
(1) Yanmar Standard Type
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MAINTENANCE WORK
1) Type of Hose (Hose Dia. & Recommended Working Pressure)
Working
Inner dia. Outer dia.
Type of hose Hose dia. pressure
[in. (mm)] [in. (mm)]
[PSI (MPa)]
02 0.25 (6.3) 0.53 (13.5) 2489 (17.2)
1
03 0.37 (9.5) 0.69 (17.5) 1991 (13.7)
(SAE J517, 100R1)
04 0.50 (12.7) 0.81 (20.6) 1564 (10.8)
02 0.25 (6.3) 0.59 (15.1) 4266 (29.4)
2
03 0.37 (9.5) 0.75 (19.1) 3484 (24.0)
(SAE J517,100R7)
04 0.50 (12.7) 0.87 (22.2) 2986 (20.6)
02 0.25 (6.3) 0.49 (12.5) 2986 (20.6)
1
03 0.37 (9.5) 0.65 (16.6) 2489 (17.2)
(SAE J517, 100R6)
04 0.50 (12.7) 0.81 (20.7) 1991 (13.7)
2 03 0.37 (9.5) 0.68 (17.2) 2986 (20.6)
(SAE J517,100R7) 04 0.50 (12.7) 0.84 (21.4) 2986 (20.6)
02 0.25 (6.3) 0.50 (12.7) 427 (2.9)
03 0.37 (9.5) 0.63 (15.9) 427 (2.9)
04 0.50 (12.7) 0.78 (19.8) 427 (2.9)
1 05 0.63 (15.9) 0.91 (23.0) 427 (2.9)
(SAE J517,100R6) 06 0.75 (19.0) 1.25 (31.8) 427 (2.9)
10 1.00 (25.4) 1.50 (38.1) 427 (2.9)
12 1.25 (31.8) 1.75 (44.5) 427 (2.9)
14 1.50 (38.1) 2.04 (51.9) 427 (2.9)
2) Total Length of Hose [Unit : in. (cm)]
3) Hose Dia. (Unit : inch)
02....1/4'' 05....5/8'' 12....1 1/4''

03....3/8'' 06....3/4'' 14....1 1/2''
04....1/2'' 10....1
Note :
Please note that these code numbers are different from those for the equivalent diameters for special parts on the
next page.
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MAINTENANCE WORK
4) Combination of Fitting
Fitting 60 degrees bent type.

Code No.
type Taper pipe thread Straight pipe thread
A D
R (PT) G (PF) with male 30
1 A·B degrees seat
3 A·E
Straight pipe thread 45 degrees bent type.
G (PF) with male 30 Straight pipe thread
B E
4 B·B degrees seat G (PF) with male 30
degrees seat
5 B·C
90 degrees bent type.

6 B·E Straight pipe thread
C
G (PF) with male 30
7 B·D degrees seat
List of pipe threads

Symbol Name
Straight pipe
G (PF)
thread
Male taper pipe
R (PT)
thread
Female taper
Rc (PT)
pipe thread
Note :
All the hoses with fittings other than those listed above are special parts.
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MAINTENANCE WORK
(2) Special Parts
The example hose, P 2 06 AB 075 W stands for :

2 3 4 5 6 7
2 Material : Plastic
3 Working pressure : 2489 to 2986 PSI (17.2 to 20.6 MPa)
4 Nominal dia. : 3 / 8"
5 Fitting type : Taper pipe thread R (PT) and straight pipe thread G (PF) with male 30 degrees seat.
6 Length : 29.5 in. (75 cm)
7 Hose protector : Coil spring
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MAINTENANCE WORK
5 Combination of fitting
Fitting type Code Fitting type Code

Taper pipe thread R (PT) A UNF thread with female P
37 degrees seat
Straight pipe thread G 60 degrees bent type.

(PF) with male 30 B UNF thread with female Q
degrees seat 37 degrees seat

Straight pipe thread G 45 degrees bent type.
(PF) with male 30 C UNF thread with female R
degrees seat 37 degrees seat
60 degrees bent type. UNF, thread with O-ring

Straight pipe thread G groove
D S
(PF) with male 30
degrees seat
Straight pipe thread G One-touch fitting (male)
E T
(PF) with male 30
degrees seat
Straight pipe thread G
(PF) with male 30 F
degrees seat
90 degrees elbow straight
pipe thread male 30 V
degrees seat
O-ring flange type G
90 degrees bent O-ring

flange type H
Eyejoint with O-ring
W
45 degrees bent O-ring groove
45
flange type J
Straight pipe thread with

Straight pipe thread, jam nut female 30
female 30 degrees seat K degrees seat X
with O-ring groove
30 30 degrees bent type.

Straight pipe thread G
L
(PF) with male 30 90 degrees elbow straight
G PF degrees seat pipe thread with gauge Z
port plug male 30
Taper pipe thread NPTF M degrees seat
Without fitting Y
UNF, thread with female Note :
37 degrees seat N
According to the combination of bending or elbow fittings, some
hoses require drawings or original hoses to locally manufacture.
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MAINTENANCE WORK
1-10 Air Release of Hydraulic Equipment
When operating the machine after disassembly or parts replacement of the hydraulic equipment, piping, etc., be
sure to release air from the hydraulic system. This is necessary to prevent seizure and cavitation of the hydraulic
equipment. If the air is left in the hydraulic system, the air is compressed or expanded depending on the load, having
an adverse effect on the smooth operation of the hydraulic equipment and shortening the service life.
1. Air Release of Variable Displacement Piston Pumps

1) Put a Specified Quantity of Hydraulic Oil Into the Hydraulic Oil Tank.
Note :
1. Set the machine at the oil level check position.
2. Refer to the hydraulic oil supply procedure for how to put hydraulic oil into the tank.
2) Keep the Oil Supply Cap of the Hydraulic Oil Tank Removed.
3) Install the Air Bleeder Hose onto the Bleeder Valve
and Loosen the Bleeder Valve Half a Turn. (Inside
Diameter of the Hose : 0.20 in. [5 mm])
Note :
Since the top end of the bleeder valve is acting as a
seat surface, the air is released only by loosening the
bleeder valve.
4) Check that All the Air has been Released from the
Bleeder Valve.
5) Tighten the Bleeder Valve, Remove the Hose and
Install the Cap on the Bleeder Valve.
Bleeder valve Width across flats : 0.40 in. (10 mm)

Tightening torque 3.61 to 5.06 ft·lbf (4.9 to 6.7 N·m)
2. Air Release of Each Hydraulic Component

Run the engine at medium speed and activate the respective circuits for about 10 to 15 minutes.
3. Air Release of Hydraulic Cylinders

1) Set the Engine Speed at Low Idling Range.
2) Extend and Retract the Cylinder Up to 1.97 to 3.9 in. (50 to 100 mm) from Each Stroke End Slowly 4 or 5
Times.
Note :
The extension and retraction stroke is up to 1.97 in. (50 mm) from each stroke end for the blade cylinder.
3) Then, Fully Extend and Retract the Cylinder 3 or 4 Times.
1-11 4720103
CHAPTER 2
TECHNICAL DATA
2-1 Specifications....................................................................................... 2-1-1

2-2 Outline Drawing and Working Area ..................................................... 2-2-1
2-2-1 Canopy type............................................................................... 2-2-1
2-2-2 Cabin type.................................................................................. 2-2-5
2-3 Weight List of Main Parts..................................................................... 2-3-1
2-4 Lifting Capacity List.............................................................................. 2-4-1
2. TECHNICAL DATA
2. Technical Data
2-1 Specifications
Note : < > : W/O Quick coupler type
Item Unit ViO27-2
Main specifications of machine
Dimensions
Overall length (Transportation position) in. (mm) 162.6 (4130) <161.4 (4100)>
Transportation position in. (mm) 99.6 (2530)
Overall height
Cabin Traveling position in. (mm) 99.6 (2530)
Overall width Full machine width in. (mm) 61.0 (1550)
Overall height
Canopy Traveling position in. (mm) 98.4 (2500)
Tumbler center distance (rubber/steel) in. (mm) 61.6 (1564)/61.3 (1558)
Track gauge in. (mm) 51.6 (1310)
Minimum ground clearance in. (mm) 12.6 (320)
Traveling performance
Low speed (Forward/Reverse) MPH (km/hr) 1.62 (2.6)
Steel crawler
Travel High speed (Forward/Reverse) MPH (km/hr) 2.80 (4.5)
speed Low speed (Forward/Reverse) MPH (km/hr) 1.74 (2.8)
Rubber crawler
High speed (Forward/Reverse) MPH (km/hr) 2.92 (4.7)
Permissible water depth limit in. (mm) 19.7 (500)
Work performance
Width (Standard) in. (mm) 19.3 (490)
Bucket (Standard. JIS heaped capacity) cu.ft. (cu.m) 2.82 (0.08)
Number of teeth / Installation method pcs. 3 / rubber pin lock type
Maximum With blade raised in. (mm) 106.3 (2700) <102.4 (2600)>
digging
depth With blade on the ground in. (mm) 112.2 (2850) <108.3 (2750)>
Maximum depth of vertically digging in. (mm) 86.6 (2200) <86.6 (2200)>
109 (2770)/109 (2770)
Maximum dumping height (canopy/cabin) in. (mm)
<111.4 (2830)/111.4 (2830)>
79.9 (2030)/79.9 (2030)
Minimum front swing radius (with boom in front) (canopy/cabin) in. (mm)
<74.8 (1900)/74.8 (1900)>
Minimum front swing radius Cabin in. (mm) 65.7 (1670) <61.0 (1550)>
(at 75 degrees right boom swing) Canopy in. (mm) 65.7 (1670) <61.0 (1550)>
Rear end swing radius in. (mm) 30.1 (765)
Left degrees 50
Cabin
Right degrees 75
Boom swing angle
Left degrees 50
Canopy
Right degrees 75
Bucket lbs. (kN) 4961 (22.1) <5292 (23.5)>
Maximum digging force
Arm lbs. (kN) 3308 (14.7) <3418 (15.2)>
Maximum tractive force (Oil pressure force) (steel/rubber) lbs. (kN) 5998 (26.7)/5513 (24.5)
Maximum swing inclination angle (with standard bucket) degrees 20
2-1-1 4720103
2. TECHNICAL DATA

Item Unit ViO27-2
Work performance
Swing speed rpm 10
Fuel consumption in practical operation Gals/h (L/h) 1.00 (3.8)
Blade
Width!Height in. (mm) 61.0 (1550)!13.6 (345)
Capacity cu.ft. (cu.m) 6.36 (0.18)
Blade
Lift above ground level in. (mm) 13.8 (350)
Digging depth in. (mm) 12.6 (320)
Mean contact pressure
Cabin PSI (KPa) 4.1 (28.4)
Steel crawler
Canopy PSI (KPa) 4.0 (27.5)
JIS
Rubber crawler
Mass
Cabin lbs. (kg) 6836 (3100)
Steel crawler
Canopy lbs. (kg) 6549 (2970)
Operating mass
Cabin lbs. (kg) 6571 (2980)
Rubber crawler
Canopy lbs. (kg) 6284 (2850)
Cabin lbs. (kg) 5350 (2425)
Steel crawler
Canopy lbs. (kg) 5060 (2295)
Base machine dry mass
Cabin lbs. (kg) 5085 (2305)
Rubber crawler
Canopy lbs. (kg) 4975 (2175)
Hydraulic equipment
Hydraulic pump
Engine → Coupling →
Drive method
Pump (Direct drive)
Variable displacement piston pumps
Type of main pump
+ Gear pumps
Variable displacement piston pump :
Number of pumps
2 + Gear pump : 2
cu.in./rev 0.79 (13)!2 , 0.49 (8.1)!1,
Theoretical discharge volume
(cu.cm/rev) 0.30 (4.9)!1
2986 (20.6)!2, 2986 (20.6)!1,
Maximum allowable pressure PSI (MPa)
640 (4.4)!1
Control valve
Number of connected valves pcs. 11
P1, P2 PSI (MPa) 2986 (20.6)
System relief set pressure
P3 PSI (MPa) 2986 (20.6)
Boom (at rod end) PSI (MPa) 3413 (23.5)
Boom (at bottom end) PSI (MPa) 3697 (25.5)
Circuit relief set pressure
Arm (at rod end) PSI (MPa) 3697 (25.5)
Arm (at bottom end) PSI (MPa) 3413 (23.5)
2-1-2 4720103
2. TECHNICAL DATA

Item Unit ViO27-2
Hydraulic equipment
Control valve
Bucket (at rod end) PSI (MPa) 3697 (25.5)
Bucket (at bottom end) PSI (MPa) 3697 (25.5)
Boom swing (at rod end) PSI (MPa) 3697 (25.5)
Boom swing (at bottom end) PSI (MPa) -
Blade (at rod end) PSI (MPa) 1422 (9.81)
Blade (at bottom end) PSI (MPa) -
Cylinder
22.6 (573)-canopy,
Stroke in. (mm)
21.7 (550)-cabin
Inside diameter in. (mm) Ø2.95 (Ø75)
Boom
Piston rod diameter in. (mm) Ø1.57 (Ø40)
Up (Ground → Max.) sec. 1.8 (canopy)/1.8 (cabin)
Speed
Down (Max. → Ground) sec. 2.3 (canopy)/1.8 (cabin)
Stroke in. (mm) 19.4 (494)
Arm Piston rod diameter in. (mm) Ø1.77 (Ø45)
Full stroke for digging sec. 2.6
Speed
Full stroke for dumping sec. 2.1
Stroke in. (mm) 20.2 (512)
Inside diameter in. (mm) Ø2.60 (65) <Ø2.36 (60)>
Bucket Piston rod diameter in. (mm) Ø1.38 (35)
Full stroke for digging sec. 3.1 <2.7>
Speed
Full stroke for dumping sec. 2.1 <1.8>
Stroke in. (mm) 7.09 (180)
Blade Piston rod diameter in. (mm) Ø1.57 (Ø40)
Up (Ground → Max.) sec. 1.3
Speed
Down (Max. → Ground) sec. 1.2
Stroke in. (mm) 18.1 (460)
Boom swing Piston rod diameter in. (mm) Ø1.57 (Ø40)
Full stroke to the right sec. 5.1
Speed
Full stroke to the left sec. 5.1
Stroke in. (mm) 3.03 (77)
Quick
coupler
Speed
Swivel joint
Swivel joint port diameter!Number inch!pcs. 3/8!4, 1/4!6
2-1-3 4720103
2. TECHNICAL DATA

Item Unit ViO27-2
Hydraulic equipment
Motor
Type Fixed displacement piston motor
cu.in./rev
Displacement 16.5 (271)
Swing motor (cu.cm/rev)
Type Cross relief valve
Brake valve
Relief set pressure PSI (MPa) 2275 (15.7)
Type Variable displacement piston motor
cu.in./rev
Displacement (Low/High) 1.12 (18.4)/0.65 (10.6)
(cu.cm/rev)
Travel motor Type Counterbalance valve
Brake valve
Planetary gear
Type of reduction gear
(with double-reduction mechanism)
Hydraulic oil tank
11.1 (42)
Tank capacity Gals (L)
[tank:9.24 (35), others: 1.85 (7)]
Type CT-12W
Suction filter Filtration area sq.in. (sq.cm) 108.0 (697)
Filtration accuracy Meshes 150
Type Y2502
Filtration area sq.in. (sq.cm) 706.8 (4560)
Return filter
Filtration accuracy µ 10
By-pass valve opening pressure PSI (MPa) 21.3 (0.15)
Locking device
Lever lock Oil pressure controlled
Boom swing lock Pedal guard
Swing lock Mechanical brake
Swing device
Planetary gear
Swing bearing
(with reduction mechanism)
Swing motor shaft gear →
Power transmission
Swing gear
Type of brake Oil pressure controlled
Brake mounting position Swing motor
Undercarriage
Shoe width in. (mm) 11.8 (300)
Type Double grouser
Grouser
Height in. (mm) 0.65 (16.5)
Steel
Shoe and link mounting method Welding
crawler
Link pitch in. (mm) 4.0 (101.6)
Number of shoes (One side) pcs. 41
Crawler drive method Pin driving
2-1-4 4720103
2. TECHNICAL DATA

Item Unit ViO27-2
Undercarriage
Rubber
Lug height in. (mm) 0.94 (24)
crawler
Core metal pitch in. (mm) 2.19 (55.5)
Manner of support Overhung type
Carrier roller Quantity (One side) pcs. 1
(Upper
roller) Bearing Ball bearing
Sealing QLF
Number of shoe slide plates (One side) pcs. -
Track roller Quantity (One side) pcs. 4

(Lower Bearing Ball bearing
roller) Sealing QLF
Quantity (One side) pcs. 1
Idler Bearing Bush
Sealing Floating seal
Number of Steel crawler pcs. 21
sprocket
teeth Rubber crawler pcs. 21
Crawler tension adjustment Grease adjuster

Engine
Main specifications
Engine model 3TNE78A-EBV
Vertical type series water-cooled
Type
4 cycle diesel engine
Combustion system Direct injection
pcs. - in.!in.
Number of cylinders - Bore!Stroke 3-3.07!3.30 (78!84)
(mm!mm)
Total displacement cu.in. (cu.cm) 73.4 (1204)
HP/rpm
Rated output / engine speed 21.5/2400 (16.0/2400)
(KW/rpm)
ft•lbf/rpm
Maximum torque / engine speed 53.5/1600 (72.6/1600)
(N•m/rpm)
lbs./HP•h
Specific fuel consumption 0.392 (175)
(g/PS•h)
Maximum idling speed rpm 2520 to 2580 (in loaded state)
Minimum idling speed rpm 1025 to 1075 (in loaded state)
Engine dry mass (excluding air cleaner and silencer) lbs. (kg) 286.7 (130)
Lubricating method Forced lubrication by trochoid pump
lbs./HP•h
Specific lubricating oil consumption 0.0013 or less (0.588 or less)
(g/PS•h)
Compression pressure PSI (MPa) 455.0 (3.13) at 250 rpm
Cylinder head
Open bTDC degrees 10 to 20
Intake valve
Close aBDC degrees 40 to 50
Open bBDC degrees 51 to 61
Exhaust valve
Close aTDC degrees 13 to 23
2-1-5 4720103
2. TECHNICAL DATA

Item Unit ViO27-2
Engine
Cylinder head
Intake valve clearance (Cold engine) in. (mm) 0.0079 (0.2)
Exhaust valve clearance (Cold engine) in. (mm) 0.0079 (0.2)
Intake valve seat angle degrees 120
Exhaust valve seat angle degrees 90
Piston
Ring shape Barrel face (chrome-plated)
First compression ring
Ring quantity pcs. 3
Ring shape Taper face
Second compression ring
Ring shape Bevel cutter (with coil )
Oil-ring
Governor
Name Mechanical all speed type
Type Centrifugal type
Fuel feed system
Filter paper with automatic
Fuel filter
air release device
Fuel filter filtration area sq.in. (sq.cm) 67.0 (432)
Oil/water separator Screen (100 mesh)
Feed pump Mechanical diaphragm type
Lubrication system
Lubrication pump Trochoid pump
LO pressure regulating valve opening pressure PSI (MPa) 42.7 to 56.9 (0.29 to 0.39)
LO filter Full flow filter
LO filter filtration area sq.in. (sq.cm) 186 (1200)
Filter valve opening pressure PSI (MPa) 11.4 to 17.1 (0.08 to 0.12)
Operating pressure of alarm switch PSI (MPa) 5.69 to 8.53 (0.04 to 0.06)
Cooling device
Cooling system Water-cooling (Radiator)
Fan belt size A38
Thermostat opening temperature ºF (ºC) 159.8 (71)
Thermostat full-open temperature ºF (ºC) 185 (85)
Radiator cap pressure PSI (MPa) 12.80 (0.089)
pcs.!Øin.
Radiator fan 6!13.8 (Ø350)
(mm)
Operating temperature of water temperature alarm switch ºF (ºC) 224.6 to 235.4 (107 to 113)
Air cleaner
Type Cyclone type
Filtration area sq.ft. (sq.m) 9.7 (0.9)
2-1-6 4720103
2. TECHNICAL DATA

Item Unit ViO27-2
Engine
Fuel injection pump
Injection pump type YPES-3CL
Injection pump plunger diameter in. (mm) Ø0.30 (Ø7.5)
Injection pump cam lifting height in. (mm) 0.28 (7.0)
Fuel injection timing (FID) degrees 14
Firing order 1→3→2
Nozzle
Type YDLLA-P
Øin.
Nozzle hole diameter!Number of holes Ø0.0086 (0.22)!1
(mm)!pcs.
Spray angle degrees 150
Fuel injection pressure PSI (MPa) 2702 to 2986 (18.6 to 20.6)
Turbocharger
Type -
Revolution speed rpm -
Turbocharging pressure PSI (MPa) -
Starting device
Cold starting aids Air heater
Starting aids capacity V-W DC12-400
Battery type 65B24L
Battery voltage - 5 hrs rate capacity V-Ah 12-40
Electrical equipment
Type Magnet
Alternator Nominal output V-A 12-40
Rated speed rpm 5000
Type
Regulator
Regulation voltage V 14.0 to 15.0
Type Reduction type
Starter motor Nominal output V-kW 12-1.2
Engagement Magnet shift
Hour meter V-W 12-12
Horn V-W 12-48
Fuse A!pcs. 30!1, 15!2, 5!1
Battery charge alarm lamp V-W 12-2
Monitor lamps Engine oil pressure alarm lamp V-W 12-2
Water temperature alarm lamp V-W 12-2
Headlight V-W 12-55
Boom light V-W 12-55
Room lamp (for cabin) V-W 12-5
Wiper motor (for cabin) V-W 12-24
Cabin heater (for cabin) V-W 12-60
2-1-7 4720103
2. TECHNICAL DATA

Item Unit ViO35-2
Dimensions
Overall length (Transportation position) in. (mm) 180.9 (4595)
Overall height
Cabin Traveling position in. (mm) 99.6 (2530)
Overall height
Canopy Traveling position in. (mm) 98.8 (2510)
Tumbler center distance (steel/rubber) in. (mm) 65.9 (1675)/65.4 (1660)
Track gauge in. (mm) 51.6 (1310)
Minimum ground clearance in. (mm) 12.6 (320)
Traveling performance
Low speed (Forward/Reverse) MPH (km/hr) 1.55 (2.5)
Steel crawler
Travel High speed (Forward/Reverse) MPH (km/hr) 2.73 (4.4)
speed Low speed (Forward/Reverse) MPH (km/hr) 1.68 (2.7)
Rubber crawler
High speed (Forward/Reverse) MPH (km/hr) 2.86 (4.6)
Permissible water depth limit in. (mm) 19.7 (500)
Work performance
Width (Standard) in. (mm) 23.2 (590)
Bucket (Standard. JIS heaped capacity) cu.ft. (cu.m) 3.88 (0.11)
Number of teeth / Installation method pcs. 4 (rubber pin lock type)
Maximum With blade raised in. (mm) 126.0 (3200) <124.0 (3150)>
digging
depth With blade on the ground in. (mm) 131.9 (3350) <129.9 (3300)>
Maximum depth of vertically digging in. (mm) 106.3 (2700) <106.3 (2700)>
128.3 (3260)/128.3 (3260)
Maximum dumping height (canopy/cabin) in. (mm)
<134.6 (3420)/134.6 (3420)>
80.3 (2040)/80.3 (2040)
Minimum front swing radius (with boom in front) (canopy/cabin) in. (mm)
<78.0 (1980)/78.0 (1980)>
Minimum front swing radius Cabin in. (mm) 67.3 (1710) <63.8 (1620)>
(at 75 degrees right boom swing) Canopy in. (mm) 67.3 (1710) <63.8 (1620)>
Rear end swing radius in. (mm) 30.5 (775)
Left degrees 50
Cabin
Right degrees 75
Boom swing angle
Left degrees 50
Canopy
Right degrees 75
Bucket lbs. (kN) 5733 (25.5) <6174 (27.5)>
Maximum digging force
Arm lbs. (kN) 4189 (18.6) <4189 (18.6)>
Maximum tractive force (Oil pressure force) (steel/rubber) lbs. (kN) 7386 (32.9)/6835 (30.4)
Maximum swing inclination angle (with standard bucket) degrees 20
2-1-8 4720103
2. TECHNICAL DATA

Item Unit ViO35-2
Work performance
Swing speed rpm 10
Fuel consumption in practical operation Gals/h (L/h) 1.11 (4.2)
Blade
Width!Height in. (mm) 61.0 (1550)!14.6 (370)
Capacity cu.ft. (cu.m) 7.41 (0.21)
Blade
Lift above ground level in. (mm) 17.1 (435)
Digging depth in. (mm) 14.2 (360)
Mean contact pressure
Steel crawler
JIS
Rubber crawler
Mass
Cabin lbs. (kg) 8181 (3710)
Steel crawler
Canopy lbs. (kg) 7894 (3580)
Operating mass
Cabin lbs. (kg) 8004 (3630)
Rubber crawler
Canopy lbs. (kg) 7718 (3500)
Cabin lbs. (kg) 6415 (2910)
Steel crawler
Canopy lbs. (kg) 6130 (2780)
Base machine dry mass
Cabin lbs. (kg) 6240 (2830)
Rubber crawler
Canopy lbs. (kg) 5955 (2700)
Hydraulic equipment
Hydraulic pump
Engine → Coupling →
Drive method
Pump (Direct drive)
Variable displacement piston pumps
Type of main pump
+ Gear pumps
Variable displacement piston pump :
Number of pumps
2 + Gear pump : 2
cu.in./rev 0.95 (15.5)!2 , 0.58 (9.5)!1,
Theoretical discharge volume
(cu.cm/rev) 0.27 (4.5)!1
2986 (20.6)!2, 2986 (20.6)!1,
Maximum allowable pressure PSI (MPa)
26.6 (29.4)!1
Control valve
Number of connected valves pcs. 11
P1, P2 PSI (MPa) 2986 (20.6)
System relief set pressure
P3 PSI (MPa) 2986 (20.6)
Boom (at rod end) PSI (MPa) 3413 (23.5)
Boom (at bottom end) PSI (MPa) 3697 (25.5)
Arm (at rod end) PSI (MPa) 3697 (25.5)
Arm (at bottom end) PSI (MPa) 3413 (23.5)
2-1-9 4720103
2. TECHNICAL DATA

Item Unit ViO35-2
Hydraulic equipment
Control valve
Bucket (at rod end) PSI (MPa) 3697 (25.5)
Bucket (at bottom end) PSI (MPa) 3697 (25.5)
Boom swing (at rod end) PSI (MPa) 3697 (25.5)
Boom swing (at bottom end) PSI (MPa) -
Blade (at rod end) PSI (MPa) 1422 (9.81)
Blade (at bottom end) PSI (MPa) -
Cylinder
25.4 (646)-canopy,
Stroke in. (mm)
24.5 (623)-cabin
Boom
Up (Ground → Max.) sec. 2.2 (canopy)/1.9 (cabin)
Speed
Down (Max. → Ground) sec. 2.5 (canopy)/2.1 (cabin)
Stroke in. (mm) 20.3 (516)
Arm Piston rod diameter in. (mm) Ø1.97 (Ø50)
Full stroke for digging sec. 2.6
Speed
Full stroke for dumping sec. 1.7
Stroke in. (mm) 20.2 (512)
Inside diameter in. (mm) Ø2.76 (Ø70) <Ø2.56 (Ø65)>
Bucket Piston rod diameter in. (mm) Ø1.57 (Ø40)
Full stroke for digging sec. 3.1 <2.6>
Speed
Full stroke for dumping sec. 2.1 <1.8>
Stroke in. (mm) 7.09 (180)
Blade Piston rod diameter in. (mm) Ø1.57 (Ø40)
Up (Ground → Max.) sec. 1.4
Speed
Down (Max. → Ground) sec. 1.0
Stroke in. (mm) 18.1 (460)
Boom swing Piston rod diameter in. (mm) Ø1.57 (Ø40)
Speed
Stroke in. (mm) 3.03 (77)
Quick
coupler
Speed
Swivel joint
Swivel joint port diameter!Number inch!pcs. 3/8!4, 1/4!6
2-1-10 4720103
2. TECHNICAL DATA

Item Unit ViO35-2
Hydraulic equipment
Motor
Type Fixed displacement piston motor
cu.in./rev
Displacement 19.6 (321)
Swing motor (cu.cm/rev)
Type Cross relief valve
Brake valve
Type Variable displacement piston motor
cu.in./rev
Displacement (Low/High) 1.12 (18.4)/0.65 (10.6)
(cu.cm/rev)
Travel motor Type Counterbalance valve
Brake valve
Relief set pressure PSI (MPa)
Planetary gear
Type of reduction gear
(with double-reduction mechanism)
Hydraulic oil tank
11.1 (42)
Tank capacity Gals (L)
[tank:9.24 (35), others: 1.85 (7)]
Type CT-12W
Suction filter Filtration area sq.in. (sq.cm) 108.0 (697)
Filtration accuracy Meshes 150
Type Y2502
Filtration area sq.in. (sq.cm) 706.8 (4560)
Return filter
Filtration accuracy µ 10
By-pass valve opening pressure PSI (MPa) 21.3 (0.15)
Locking device
Lever lock Oil pressure controlled
Boom swing lock Pedal guard
Swing lock Mechanical brake
Swing device
Planetary gear
Swing bearing
(with reduction mechanism)
Swing motor shaft gear →
Power transmission
Swing gear
Type of brake Oil pressure controlled
Brake mounting position Swing motor
Undercarriage
Type Double grouser
Grouser
Height in. (mm) 0.65 (16.5)
Steel
Shoe and link mounting method Welding
crawler
Link pitch in. (mm) 4.0 (101.6)
Number of shoes (One side) pcs. 43
Crawler drive method Pin driving
2-1-11 4720103
2. TECHNICAL DATA

Item Unit ViO35-2
Undercarriage
Rubber
Lug height in. (mm) 0.94 (24)
crawler
Core metal pitch in. (mm) 2.19 (55.5)
Manner of support Overhung type
Carrier roller Quantity (One side) pcs. 1
(Upper
roller) Bearing Ball bearing
Sealing QLF
Number of shoe slide plates (One side) pcs. -
Track roller Quantity (One side) pcs. 4

(Lower Bearing Ball bearing
roller) Sealing QLF
Quantity (One side) pcs. 1
Idler Bearing Bush
Sealing Floating seal
Number of Steel crawler pcs. 21
sprocket
teeth Rubber crawler pcs. 21
Crawler tension adjustment Grease adjuster

Engine
Main specifications
Engine model 3TNE82A-EBVB
Vertical type series water-cooled
Type
4 cycle diesel engine
Combustion system Direct injection
pcs. - in.!in.
Number of cylinders - Bore!Stroke 3 - Ø3.23!3.31 (Ø3 - 82!84)
(mm!mm)
Total displacement cu.in. (cu.cm) 81.13 (1330)
HP/rpm 24.7/2500
Rated output / engine speed
(KW/rpm) (18.4/2500)
ft•lbf/rpm 61.5/1700 to 1900
Maximum torque / engine speed
(N•m/rpm) (83.4/1700 to 1900)
lbs./HP•h
Specific fuel consumption 0.404 (180)
(g/PS•h)
Maximum idling speed rpm 2620 to 2680 (in loaded state)
Minimum idling speed rpm 1025 to 1075 (in loaded state)
Engine dry mass (excluding air cleaner and silencer) lbs. (kg) 282.2 (128)
Lubricating method Forced lubrication by trochoid pump
lbs./HP•h
Specific lubricating oil consumption 0.0013 or less (0.588 or less)
(g/PS•h)
Compression pressure PSI (MPa) 440.8 (3.04) at 300 rpm
Cylinder head
Open bTDC degrees 10 to 20
Intake valve
Close aBDC degrees 40 to 50
Open bBDC degrees 51 to 61
Exhaust valve
Close aTDC degrees 13 to 23
2-1-12 4720103
2. TECHNICAL DATA

Item Unit ViO35-2
Engine
Cylinder head
Intake valve clearance (Cold engine) in. (mm) 0.0079 (0.2)
Exhaust valve clearance (Cold engine) in. (mm) 0.0079 (0.2)
Intake valve seat angle degrees 120
Exhaust valve seat angle degrees 90
Piston
Ring shape Barrel face (chrome-plated)
First compression ring
Ring shape Taper face
Second compression ring
Ring shape Bevel cutter (with coil expander)
Oil-ring
Governor
Name Mechanical all speed type
Type Centrifugal type
Fuel feed system
Filter paper with automatic
Fuel filter
air release device
Fuel filter filtration area sq.in. (sq.cm) 67.0 (432)
Oil/water separator Mesh filter
Feed pump Electrical
Lubrication system
Lubrication pump Trochoid pump
LO pressure regulating valve opening pressure PSI (MPa) 42.7 to 56.9 (0.29 to 0.39)
LO filter Full flow filter
LO filter filtration area sq.in. (sq.cm) 186 (1200)
Filter valve opening pressure PSI (MPa) 11.4 to 17.1 (0.08 to 0.12)
Operating pressure of alarm switch PSI (MPa) 5.69 to 8.53 (0.04 to 0.06)
Cooling device
Cooling system Water-cooling (Radiator)
Fan belt size A39 (RPF-E)
Thermostat opening temperature ºF (ºC) 159.8 (71)
Thermostat full-open temperature ºF (ºC) 185 (85)
Radiator cap pressure PSI (MPa) 12.80 (0.089)
pcs.!Øin.
Radiator fan 7!13.8 (Ø350)
(mm)
Operating temperature of water temperature alarm switch ºF (ºC) 224.6 to 235.4 (107 to 113)
Air cleaner
Type Cyclone type
Filtration area sq.ft. (sq.m) 9.7 (0.9)
2-1-13 4720103
2. TECHNICAL DATA

Item Unit ViO35-2
Engine
Fuel injection pump
Injection pump type YPES-3CL
Injection pump plunger diameter in. (mm) Ø0.30 (Ø7.5)
Injection pump cam lifting height in. (mm) 0.28 (7.0)
Fuel injection timing (FID) degrees 11 to 13
Firing order 1→3→2
Nozzle
Type YDLLA-P
Øin.
Nozzle hole diameter!Number of holes Ø0.0087 (0.22)!4
(mm)!pcs.
Fuel injection pressure PSI (MPa) 2701 to 2986 (18.6 to 20.6)
Turbocharger
Type -
Revolution speed rpm -
Turbocharging pressure PSI (MPa) -
Starting device
Cold starting aids Air heater
Starting aids capacity V-W DC12-400
Battery type 65B24L
Battery voltage - 5 hrs rate capacity V-Ah 12-40
Electrical equipment
Type Magnet
Alternator Nominal output V-A 12-40
Rated speed rpm 5000
Type Contained in alternator
Regulator
Regulation voltage V
Type Reduction type
Starter motor Nominal output V-kW 12-1.2
Engagement Magnet shift
Hour meter V-W 12-12
Horn V-W 12-48
Fuse A!pcs. 30!1, 15!5, 5!1
Battery charge alarm lamp V-W 12-2
Monitor lamps Engine oil pressure alarm lamp V-W 12-2
Water temperature alarm lamp V-W 12-2
Headlight V-W 12-55
Boom light V-W 12-55
Room lamp (for cabin) V-W 12-5
Wiper motor (for cabin) V-W 12-24
Cabin heater (for cabin) V-W 12-60
2-1-14 4720103
2. TECHNICAL DATA
2-2 Outline Drawing and Working Area
2-2-1 Canopy type
in. (mm)
2-2-1 4720103
2. TECHNICAL DATA
in. (mm)
2-2-2 4720103
2. TECHNICAL DATA
in. (mm)
2-2-3 4720103
2. TECHNICAL DATA
in. (mm)
2-2-4 4720103
2. TECHNICAL DATA
2-2-2 Cabin type
in. (mm)
2-2-5 4720103
2. TECHNICAL DATA
in. (mm)
2-2-6 4720103
2. TECHNICAL DATA
in. (mm)
2-2-7 4720103
2. TECHNICAL DATA
in. (mm)
2-2-8 4720103
2. TECHNICAL DATA
2-3 Weight List of Main Parts

[Unit : lbs. (kg)]
ViO27-2 (US
Canopy Cabin
Equipment No. Part
Steel Rubber Steel Rubber
crawler crawler crawler crawler
Front implement
1 Bucket Ass’y 189.6 (86)
2 Bucket arm & link Ass’y 37.5 (17)
3 Bucket cylinder Ass’y 48.5 (22) <39.7 (18)>
4 Arm Ass’y 112.4 (51) <113.5 (51.5)>
5 Arm cylinder Ass’y 57.3 (26)
6 Boom Ass’y 231.5 (105)
7 Boom cylinder Ass’y 59.5 (27)
8 Boom bracket Ass’y 169.8 (77)
9 Quick coupler Ass’y 66.2 (30)
Undercarriage
46.3×2 49.6×2 46.3×2 49.6×2
1 Idler Ass’y
[(21)×2] [(22.5)×2] [(21)×2] [(22.5)×2]
5.51×2 5.51×2
2 Crawler guard Ass’y − −
[(2.5)×2] [(2.5)×2]
3 Crawler adjuster Ass’y 37.5 (17) × 2
4 Track roller Ass’y 17.1 (7.75) × 8
5 Sprocket Ass’y 16.5 (7.5) × 2
6 Carrier roller Ass’y 6.61 (3) × 2
7 Track frame Ass’y 674.7 (306)
374.9×2 242.6×2 374.9×2 242.6×2
8 Steel crawler & Rubber crawler Ass’y
[(170)×2] [(110)×2] [(170)×2] [(110)×2]
9 Blade cylinder Ass’y 35.3 (16)
10 Blade Ass’y 319.7 (145)
11 Travel motor Ass’y 63.9 (29) × 2
12 Swing bearing Ass’y 103.6 (47)
13 Swivel & hose or fitting Ass’y 46.3 (21)
Upperstructure
1 Engine hood Ass’y 41.9 (19)
2 Hydraulic oil tank & filters Ass’y 97.0 (44)
3 Engine 330.8 (150)
4 Operator's seat & mount Ass’y 222.6 (101)
5 Counterweight & rear protector Ass’y 392.5 (178)
6 Turning frame Ass’y 789.4 (358)
7 Controls (4 cables) Ass’y 75.0 (34)
8 Battery Ass’y 27.6 (12.5)
9 Fuel tank & piping Ass’y 9.92 (4.5)
10 Canopy or cabin Ass’y 191.7 (87) 507.2 (230)
11 Covers, steps and panels 130.1 (59)
12 Swing motor Ass’y 70.6 (32)
13 Pump & mount and hoses Ass’y 76.1 (34.5) <72.8 (33)>
14 Control valve & fitting and hoses Ass’y 110.3 (50)
15 Boom swing cylinder Ass’y 61.7 (28)
2-3-1 4720103
2. TECHNICAL DATA

[Unit : lbs. (kg)]
ViO35-2 (US
Canopy Cabin
Equipment No. Part
Steel Rubber Steel Rubber
crawler crawler crawler crawler
Front implement
1 Bucket Ass’y 202.9 (92)
2 Bucket arm & link Ass’y 37.5 (17)
3 Bucket cylinder Ass’y 50.7 (23) <48.5 (22)>
4 Arm Ass’y 124.5 (56.5) <131.1 (59.5)>
5 Arm cylinder Ass’y 70.6 (32)
6 Boom Ass’y 297.7 (135)
7 Boom cylinder Ass’y 92.6 (42) 94.8 (43)
8 Boom bracket Ass’y 191.8 (87)
9 Quick coupler Ass’y 66.2 (30)
Undercarriage
46.3×2 49.6×2 46.3×2 49.6×2
1 Idler Ass’y
[(21)×2] [(22.5)×2] [(21)×2] [(22.5)×2]
5.51×2 5.51×2
2 Crawler guard Ass’y − −
[(2.5)×2] [(2.5)×2]
3 Crawler adjuster Ass’y 37.5 (17) × 2
4 Track roller Ass’y 17.1 (7.75) × 8
5 Sprocket Ass’y 16.5 (7.5) × 2
6 Carrier roller Ass’y 6.61 (3) × 2
7 Track frame Ass’y 674.7 (306)
379.3×2 291.1×2 379.3×2 291.1×2
8 Steel crawler & Rubber crawler Ass’y
[(172)×2] [(132)×2] [(172)×2] [(132)×2]
9 Blade cylinder Ass’y 41.9 (19)
10 Blade Ass’y 407.9 (185)
11 Travel motor Ass’y 77.2 (35) × 2
12 Swing bearing Ass’y 103.6 (47)
13 Swivel & hose or fitting Ass’y 46.3 (21)
Upperstructure
1 Engine hood Ass’y 41.9 (19)
2 Hydraulic oil tank & filters Ass’y 97.0 (44)
3 Engine 330.8 (150)
4 Operator's seat & mount Ass’y 222.6 (101)
5 Counterweight & rear protector Ass’y 888.6 (403)
6 Turning frame Ass’y 1230.4 (558)
7 Controls (4 cables) Ass’y 75.0 (34)
8 Battery Ass’y 27.6 (12.5)
9 Fuel tank & piping Ass’y 9.92 (4.5)
10 Canopy or cabin Ass’y 191.7 (87) 507.2 (230)
11 Covers, steps and panels 130.1 (59)
12 Swing motor Ass’y 86.0 (39)
13 Pump & mount and hoses Ass’y 73.9 (33.5) <70.6 (32)>
14 Control valve & fitting and hoses Ass’y 110.3 (50)
15 Boom swing cylinder Ass’y 68.4 (31)
2-3-2 4720103
2. TECHNICAL DATA
2-4 Lifting Capacity List
ViO27-2
With:
(" Cabin# Canopy) Type
(" Steel # Rubber) Crawler
Quick coupler
W/O Bucket
A : Reach from swing center line [in. (m)]

B : Load point height [in. (m)]
C : Lifting load [lbs. (kg)]
P : Load point
: Rating over front
: Rating over side or 180 degrees
Blade on ground Unit : lbs. (kg)

A [in. (m)] Max. 118.1 (3.0) 98.43 (2.5) 78.7 (2.0)
B [in. (m)]
* 1323 1047
118.1 (3.0) − − − − − −
(600) (475)
* 1301 827 * 1312 1058 * 1323 * 1246
98.4 (2.5) − −
(590) (375) (595) (480) (600) (565)
* 1400 750 * 1411 1147 * 1521 * 1521
78.7 (2.0) − −
(635) (340) (640) (520) (690) (690)
* 1422 684 * 1830 1025 * 2337 1356 * 2977 1687
39.4 (1.0)
(645) (310) (830) (465) (1060) (615) (1350) (765)
* 1521 750 * 2040 981 * 2635 1312 * 3594 1885
0 (0)
(690) (340) (925) (445) (1195) (595) (1630) (885)
* 1521 981 * 2205 1312 * 2955 1885
-39.4 (-1.0) − −
(690) (445) (1000) (595) (1340) (885)
* 1422 * 1422
-59.1 (-1.5) − − − − − −
(645) (645)
2-4-1 4720103
2. TECHNICAL DATA
Blade above ground Unit : lbs. (kg)

A [in. (m)] Max. 118.1 (3.0) 98.43 (2.5) 78.7 (2.0)
B [in. (m)]
1058 1047
118.1 (3.0) − − − − − −
(480) (475)
882 827 * 1323 1058 * 1213 * 1246
98.4 (2.5) − −
(400) (375) (600) (480) (550) (565)
816 750 1147 1114 * 1521 * 1521
78.7 (2.0) − −
(370) (340) (520) (505) (690) (690)
728 684 1091 1025 1455 1356 1819 1687
39.4 (1.0)
(330) (310) (495) (465) (660) (615) (825) (765)
783 750 1058 981 1389 1312 1985 1852
0 (0)
(355) (340) (480) (445) (630) (595) (900) (840)
1047 981 1411 1312 1985 1852
-39.4 (-1.0) − −
(475) (445) (640) (595) (900) (840)
* 1422 * 1422
-59.1 (-1.5) − − − − − −
(645) (645)
Note :
The lifting load with the asterisk (*) mark is limited by hydraulic lifting capacity rather than tipping. The lifting capacity
shown in the above list is based on the ISO Standard No. 10567 and represents either 87 % of hydraulic lifting
capacity or 75 % of tipping load, which is smaller.
2-4-2 4720103
2. TECHNICAL DATA
ViO35-2
With:
(" Cabin# Canopy) Type
(" Steel # Rubber) Crawler
Quick coupler
W/O Bucket
A : Reach from swing center line [in. (m)]

B : Load point height [in. (m)]
C : Lifting load [lbs. (kg)]
P : Load point
: Rating over front
: Rating over side or 180 degrees
Blade on ground Unit : lbs. (kg)

A [in. (m)] Max. 137.8 (3.5) 118.1 (3.0) 98.4 (2.5) 78.74 (2.0)
B [in. (m)]
* 1544 970 * 1532 1147 * 1532 * 1532
118.1 (3.0) − − − −
(700) (440) (695) (520) (695) (695)
* 1621 805 * 1819 1114 * 1985 1411 * 2370 1808
78.7 (2.0) − −
(735) (365) (825) (505) (900) (640) (1075) (820)
* 1720 739 * 2128 1047 * 2580 1312 * 3352 1709
39.4 (1.0) − −
(780) (335) (965) (475) (1170) (595) (1520) (775)
* 1742 805 * 2293 1036 * 2867 1301 * 3638 1643
0 (0) − −
(790) (365) (1040) (470) (1300) (590) (1650) (745)
* 1775 915 * 2062 981 * 2503 1246 * 3241 1632 * 3925 2260
-39.4 (-1.0)
(805) (415) (935) (445) (1135) (565) (1470) (740) (1780) (1025)
* 1720 1147 * 2106 1301 * 2569 1676 * 3296 2304
-59.1 (-1.5) − −
(780) (520) (955) (590) (1165) (760) (1495) (1045)
* 1643 * 1720
-78.7 (-2.0) − − − − − − − −
(745) (780)
2-4-3 4720103
2. TECHNICAL DATA
Blade above ground Unit : lbs. (kg)

A [in. (m)] Max. 137.8 (3.5) 118.1 (3.0) 98.4 (2.5) 78.74 (2.0)
B [in. (m)]
1114 981 1312 1147 * 1532 * 1532
118.1 (3.0) − − − −
(505) (445) (595) (520) (695) (695)
904 805 1279 1114 1632 1411 * 2293 1808
78.7 (2.0) − −
(410) (365) (580) (505) (740) (640) (1040) (820)
849 739 1235 1047 1499 1312 1996 1709
39.4 (1.0) − −
(385) (335) (560) (475) (680) (595) (905) (775)
904 783 1169 1036 1477 1279 1907 1643
0 (0) − −
(410) (355) (530) (470) (670) (580) (865) (745)
1080 915 1147 981 1466 1235 1896 1632 2734 2238
-39.4 (-1.0)
(490) (415) (520) (445) (665) (560) (860) (740) (1240) (1015)
1312 1147 1499 1301 1962 1676 2734 2304
-59.1 (-1.5) − −
(595) (520) (680) (590) (890) (760) (1240) (1045)
* 1643 1400
-78.7 (-2.0) − − − − − − − −
(745) (635)
Note :
The lifting load with the asterisk (*) mark is limited by hydraulic lifting capacity rather than tipping. The lifting capacity
shown in the above list is based on the ISO Standard No. 10567 and represents either 87 % of hydraulic lifting
capacity or 75 % of tipping load, which is smaller.
2-4-4 4720103
CHAPTER 3
SERVICE STANDARDS
3-1 Machine Performance.......................................................................... 3-1-1

3-2 Engine.................................................................................................. 3-2-1
3-3 Undercarriage ...................................................................................... 3-3-1
3-3-1 Rubber Crawler Specifications................................................... 3-3-1
3-3-2 Steel Crawler Specifications ...................................................... 3-3-2
3-3-3 Common Specifications of Steel & Rubber Crawlers................. 3-3-3
3-4 Controls ............................................................................................... 3-4-1
3-5 Hydraulic Equipment............................................................................ 3-5-1
3-5-1 Hydraulic Cylinders .................................................................... 3-5-1
3-6 Implement ............................................................................................ 3-6-1
3-6-1 Front Attachments...................................................................... 3-6-1
3-6-2 Blade Moving Device ................................................................. 3-6-3
3-6-3 Bucket Teeth.............................................................................. 3-6-3
3-7 List of Tightening Torque ..................................................................... 3-7-1
3-7-1 Machine ..................................................................................... 3-7-1
3-7-2 Engine........................................................................................ 3-7-4
3-7-3 Tightening Torque for General Bolts and Nuts .......................... 3-7-4
3. SERVICING STANDARDS
3. Service Standards
3-1 Machine Performance

Note : ( ) : Cabin type, < > : W/O Quick coupler type
Applicable model ViO27-2 (US
Item Measuring condition Unit Standard Allowance
Machine performance
Working speed
Boom speed Machine position
Max. cylinder extension Up 1.8 (1.8) 2.1 (2.1)
sec.
• Engine : rated speed

• Hydraulic oil temp. : 122 to 140 °F (50 to 60 °C) Down 2.3 (1.8) 2.6 (2.1)
Bucket teeth grounded • Site : Firm, flat ground
• Excluding cushion
Arm speed Machine position
Max. cylinder retraction Extend 2.1 2.4
sec.
• Engine : rated speed Retract 2.6 2.9

Max. cylinder extension • Hydraulic oil temp. : 122 to 140 °F (50 to 60 °C)
• Site : Firm, flat ground
Bucket speed Machine position
Max. cylinder retraction Dump 2.1 <1.8> 2.4 <2.1>
sec.
• Engine : rated speed Curl 3.1 <2.7> 3.4 <3.0>

Boom offset speed Machine position
Right swing 5.1 5.5

Max. cylinder retraction
sec.
• Hydraulic oil temp. : 122 to 140 °F (50 to 60 °C) Left swing 5.1 5.5
Max. cylinder extension • Full stroke
Blade speed Machine position
Max. cylinder retraction Up 1.3 1.6
sec.
• Engine : rated speed Down 1.3 1.6

Blade grounded • Hydraulic oil temp. : 122 to 140 °F (50 to 60 °C)
3-1-1 4720103

Machine performance
Machine position
High speed
16.0 (15.3) 18.4 (17.6)

sec./
Travel speed 787.4 in.
(20 m)

• Hydraulic oil temp. : 122 to 140 °F (50 to 60 °C) Low speed
• Traveling time for 787.4 in. (20 m) after an 27.7 (25.7) 31.9 (29.6)
approach run of 196.9 in. (5 m) or more.
Machine position
High speed
10.3 11.8

• Hydraulic oil temp. : 122 to 140 °F (50 to 60 °C) sec./
Track speed • Site : Firm, flat ground 3 rev.
• Travel lever : Full throttle
(Floating crawler side)
• Float one side of the crawler. Low speed
Make a mark on the crawler.
After turning the floating crawler side more 17.3 19.9
than once at full throttle, measure the time
needed for 3 turns of the crawler.
Machine position

in. (mm)/
• Hydraulic oil temp. : 122 to 140 °F (50 to 60 °C) 11.8 (300)
Track deviation 787.4 in. 14.2 (360)
• Site : Firm, flat ground or less
(20 m)
• Measure the deviation (χ) in a travel distance
of 787.4 in. (20 m) after an approach run of
196.9 in. (5 m) or more.
3-1-2 4720103

Machine performance
Machine position
in.
(mm) 4.72 (120)
Traveling drift 7.09 (180)
/ or less
5 min.
• Engine : stopped
• Hydraulic oil temp. : 122 to 140 °F (50 to 60 °C)
• Drift of the machine after 5 min. on a slope with
an inclination of 15 degrees.
Drift of cylinders
Machine position
Boom drift 0.39 (10) 0.59 (15)
(Cylinder rod retraction) or less
Arm drift 0.39 (10) 0.59 (15)

(Cylinder rod extension) in. or less
• Engine : stopped (mm)
• Hydraulic oil temp. : 122 to 140 °F (50 to 60 °C) /
Bucket drift • Site : Firm, flat ground 10 min.
0.24 (6) 0.35 (9)
(Cylinder rod extension) • Make the boom and bucket pins the same
or less
height.
• Measure the retraction or extension of each cyl-
inder rod after leaving the machine at the above
Blade drift position for 10 min. 0.24 (6) 0.35 (9)
(Cylinder rod extension) • Lift the blade to the highest position, and mea- or less
sure the cylinder rod extension after 10 min.
Machine position
in.
Boom offset drift (mm) 0.24 (6)
0.35 (9)
(Cylinder rod extension) / or less
10 min.
• Make the boom and bucket pins the same
height.
• Park the machine on a slope with an inclination
of 15 degrees and turn the upperstructure 90
degrees to the crawler and engage the swing
lock.
• Measure the cylinder rod extension after 10 min.
3-1-3 4720103

Machine performance
Machine position
in. 6.65 10.0

Swing drift at stopping (mm) or (169) or less, (254)
• Engine : rated speed degrees 30 or less 45
• Make the boom and bucket pins the same height.
• Make match marks on the outer race and the
inner race of the swing bearing (or the track
frame).
• Measure shifted distance between both marks
after making one turn with no load.
Machine position
sec. /
Swing time 32 37
5 turns

• Make one idling turn with no load, then mea-
sure the time necessary to make 5 turns.
Machine position
( at engine
stop ) 0
in.
Swing drift • Engine : stopped
(mm)
degrees to the crawler.
• Make match marks on the outer race and the ( at engine
operating ) !2.17 (55)
(!10 degrees)
frame).
• Measure shifted distance or angle between
both marks after 5 min.
3-1-4 4720103

Machine performance
Working speed
Boom speed Machine position
Max. cylinder extension Up 2.2 (1.9) 2.5 (2.2)
sec.

• Hydraulic oil temp. : 122 to 140 °F (50 to 60 °C) Down 2.5 (2.1) 2.8 (2.4)
Bucket teeth grounded • Site : Firm, flat ground
• Excluding cushion
Arm speed Machine position
Max. cylinder retraction Extend 1.7 2.0
sec.
• Engine : rated speed Retract 2.6 2.9

Bucket speed Machine position
Max. cylinder retraction Dump 2.1 <1.8> 2.4 <2.1>
sec.
• Engine : rated speed Curl 3.1 <2.6> 3.4 <2.9>

Boom offset speed Machine position
Right swing 5.4 5.8

Max. cylinder retraction
sec.
• Hydraulic oil temp. : 122 to 140 °F (50 to 60 °C) Left swing 5.7 6.1
Max. cylinder extension • Full stroke
Blade speed Machine position
Max. cylinder retraction Up 1.4 1.7
sec.
• Engine : rated speed Down 1.0 1.3

Blade grounded • Hydraulic oil temp. : 122 to 140 °F (50 to 60 °C)
3-1-5 4720103

Machine performance
Machine position
High speed
16.4 (15.7) 18.9 (18.1)

sec./
Travel speed 787.4 in.
(20 m)

• Hydraulic oil temp. : 122 to 140 °F (50 to 60 °C) Low speed
• Traveling time for 787.4 in. (20 m) after an 28.8 (26.7) 33.1 (30.7)
approach run of 196.9 in. (5 m) or more.
Machine position
High speed
10.4 12.0

• Hydraulic oil temp. : 122 to 140 °F (50 to 60 °C) sec./
Track speed • Site : Firm, flat ground 3 rev.
• Travel lever : Full throttle
(Floating crawler side)
• Float one side of the crawler. Low speed
Make a mark on the crawler.
After turning the floating crawler side more 17.5 20.1
than once at full throttle, measure the time
needed for 3 turns of the crawler.
Machine position

in. (mm)/
• Hydraulic oil temp. : 122 to 140 °F (50 to 60 °C) 11.8 (300)
Track deviation 787.4 in. 14.2 (360)
• Site : Firm, flat ground or less
(20 m)
• Measure the deviation (χ) in a travel distance
of 787.4 in. (20 m) after an approach run of
196.9 in. (5 m) or more.
3-1-6 4720103

Machine performance
Machine position
in.
(mm) 4.72 (120)
Traveling drift 7.09 (180)
/ or less
5 min.
• Drift of the machine after 5 min. on a slope with
an inclination of 15 degrees.
Drift of cylinders
Machine position
Boom drift 0.39 (10) 0.59 (15)
(Cylinder rod retraction) or less
Arm drift 0.39 (10) 0.59 (15)

(Cylinder rod extension) in. or less
• Engine : stopped (mm)
• Hydraulic oil temp. : 122 to 140 °F (50 to 60 °C) /
Bucket drift • Site : Firm, flat ground 10 min.
0.24 (6) 0.35 (9)
(Cylinder rod extension) • Make the boom and bucket pins the same
or less
height.
• Measure the retraction or extension of each cyl-
inder rod after leaving the machine at the above
Blade drift position for 10 min. 0.24 (6) 0.35 (9)
(Cylinder rod extension) • Lift the blade to the highest position, and mea- or less
sure the cylinder rod extension after 10 min.
Machine position
in.
Boom offset drift (mm) 0.24 (6)
0.35 (9)
(Cylinder rod extension) / or less
10 min.
• Make the boom and bucket pins the same
height.
degrees to the crawler and engage the swing
lock.
• Measure the cylinder rod extension after 10 min.
3-1-7 4720103

Machine performance
Machine position
in. 6.65 10.0

Swing drift at stopping (mm) or (169) or less, (254)
• Engine : rated speed degrees 30 or less 45
• Make match marks on the outer race and the
frame).
• Measure shifted distance between both marks
after making one turn with no load.
Machine position
sec. /
Swing time 29 34
5 turns

• Make one idling turn with no load, then mea-
sure the time necessary to make 5 turns.
Machine position
( at engine
stop ) 0
in.
Swing drift • Engine : stopped
(mm)
degrees to the crawler.
• Make match marks on the outer race and the ( at engine
operating ) !2.17 (55)
(!10 degrees)
frame).
• Measure shifted distance or angle between
both marks after 5 min.
3-1-8 4720103
3-2 Engine
1) Nominal and Allowable Values

ViO27-2
Applicable model 3TNE78A-EBV
Item Unit Standard Wear limit
Cylinder head
Cylinder head distortion in. (mm) 0.002 (0.05) or less 0.00591 (0.15)
Intake degrees 120 −
Valve seat angle
Exhaust (°) 90 −
0.054 to 0.06
Intake 0.078 (1.98)
(1.36 to 1.53)
Valve seat width in. (mm)
0.065 to 0.074
Exhaust 0.089 (2.27)
(1.66 to 1.87)
0.273 to 0.274
Stem outside dia. 0.272 (6.9)
(6.945 to 6.960)
0.27559 to 0.27618
Intake valve Guide inside dia. in. (mm) 0.279 (7.08)
(7.000 to 7.015)
0.0016 to 0.0028
Oil clearance 0.0071 (0.18)
(0.040 to 0.070)
0.2732 to 0.274
(6.940 to 6.955)
0.27559 to 0.27618
Exhaust valve Guide inside dia. in. (mm) 0.279 (7.08)
(7.000 to 7.015)
0.0017 to 0.003
(0.045 to 0.075)
Valve guide projection in. (mm) 0.472 (12) −
0.0117 to 0.0195
Intake
(0.296 to 0.496)
Valve sinkage in. (mm) 0.039 (1.0)
0.0118 to 0.0197
Exhaust
(0.3 to 0.5)
0.049 to 0.0569
Intake
Valve head (1.244 to 1.444)
in. (mm) 0.02 (0.50)
thickness 0.053 to 0.061
Exhaust
(1.35 to 1.55)
Intake valve Open b. TDC degrees 10 to 20 −
operating timing Close a. BDC (°) 40 to 50 −
Exhaust valve Open b. BDC degrees 51 to 61 −
operating timing Close a. TDC (°) 13 to 23 −
Free length in. (mm) 1.75 (44.4) −
Valve spring Inclination in. (mm) − 0.043 (1.1)
Tension [0.0394 in. (1 mm) compressed] lbs. (kg) 0.81 (0.368) (Irregular pitch) / 5.98 (2.71)
0.006 to 0.01
Intake / exhaust valve clearance in. (mm) −
(0.15 to 0.25)
Cylinder block
3.0709 to 3.0720
Cylinder bore dia.
(78.000 to 78.030)
3.0717 to 3.0720
L mark
(78.020 to 78.030)
3.0787 (78.20)
3.0713 to 3.0717
Cylinder bore dia. M mark in. (mm)
(78.010 to 78.020)
3.0709 to 3.0713
S mark
(78.000 to 78.010)
Roundness of cylinder sleeve bore 0 to 0.00039 (0 to 0.01) 0.00118 (0.03)
Cylindricity of cylinder sleeve bore 0 to 0.00039 (0 to 0.01) 0.00118 (0.03)
3-2-1 4720103

Valve
0.62858 to 0.62929
Shaft outside dia. 0.63 (15.95)
(15.966 to 15.984)
Intake / exhaust 0.62992 to 0.63071
Bush inside dia. 0.633 (16.09)
valve rocker arm (16.000 to 16.020)
0.00063 to 0.0021
(0.016 to 0.054)
Push rod bend in. (mm) 0.00118 (0.03) or less −
0.47146 to 0.47205
(11.975 to 11.990)
0.47244 to 0.47315
Tappet Guide hole inside dia. 0.474 (12.05)
(12.000 to 12.018)
0.00039 to 0.0017
(0.010 to 0.043)
Piston
3.0688 to 3.070
Piston outside dia.
(77.950 to 77.980)
3.0696 to 3.070
L mark
(77.970 to 77.980)
3.0694 to 3.0696
ML mark 3.066 (77.90)
(77.965 to 77.970)
Piston outside dia.
3.0692 to 3.0694
MS mark
(77.960 to 77.965)
3.0688 to 3.0692
S mark
(77.950 to 77.960)
in. (mm)
0.00138 to 0.00256
Minimum clearance between piston and cylinder −
(0.035 to 0.065)
0.025 to 0.03
Top clearance −
(0.630 to 0.750)
0.9051 to 0.9055
Outside dia. 0.9015 (22.90)
(22.991 to 23.000)
0.9055 to 0.9582
Piston pin Bush inside dia. 0.9063 (23.20)
(23.000 to 23.008)
0 to 0.00067
(0.000 to 0.017)
Piston ring
0.0801 to 0.0807
Ring groove width −
(2.035 to 2.050)
0.0763 to 0.0771
Ring width −
(1.940 to 1.960)
Top ring
0.0029 to 0.0043
Clearance between groove and ring −
(0.075 to 0.110)
0.00787 to 0.01575
End gap 0.059 (1.5)
(0.200 to 0.400)
in. (mm)
0.079 to 0.080
(2.025 to 2.040)
0.07776 to 0.07835
Ring width −
(1.975 to 1.990)
Second ring
0.00138 to 0.0256
(0.035 to 0.400)
0.00984 to 0.015
End gap 0.059 (1.5)
(0.250 to 0.400)
3-2-2 4720103

Piston ring
0.1187 to 0.119
(3.015 to 3.030)
0.1169 to 0.1177
Ring width −
(2.970 to 2.990)
Oil ring in. (mm)
0.00098 to 0.00236
(0.025 to 0.060)
0.00787 to 0.01575
End gap 0.059 (1.5)
(0.200 to 0.400)
Connecting rod
1.81102 to 1.81165
Crank pin metal inside dia. −
(46.000 to 46.016)
0.05854 to 0.05906
Crank pin metal thickness −
(1.487 to 1.500)
Crank pin side
1.69102 to 1.69141
Crank pin outside dia. 1.68937 (42.91)
(42.952 to 42.962)
0.0015 to 0.00354
(0.038 to 0.090)
in. (mm)
0.90649 to 0.9071
(23.025 to 23.038)
0.90516 to 0.90551
Piston pin side Piston pin outside dia. 0.90157 (22.90)
(22.991 to 23.000)
0.00098 to 0.00185
(0.025 to 0.047)
0.00118 (0.03) or less
Twist and parallelism 0.00315 (0.08)
for 3.937 (100)
Cam
1.7687 to 1.76968
Cam shaft outside dia. 1.76574 (44.85)
(44.925 to 44.950)
Gear side
0.00157 to 0.00512
Oil clearance −
(0.040 to 0.130)
1.76811 to 1.76909
(44.910 to 44.935)
Intermediate
0.00256 to 0.00453
Oil clearance −
(0.065 to 0.115)
in. (mm) 1.7687 to 1.76968
(44.925 to 44.950)
Flywheel side
0.00197 to 0.00394
Oil clearance −
(0.050 to 0.100)
Bend 0.00079 (0.02) or less 0.00197 (0.05)
1.521 to 1.526
Intake cam 1.512 (38.40)
(38.635 to 38.765)
Cam height
1.521 to 1.526
Exhaust cam 1.512 (38.40)
(38.635 to 38.765)
Crank shaft
1.8485 to 1.84889
Outside dia. 1.84685 (46.91)
(46.952 to 46.962)
0.07823 to 0.07874
Journal Main metal thickness −
in. (mm) (1.987 to 2.000)
0.0015 to 0.00366
(0.038 to 0.093)
Bend 0.00079 (0.02) or less −
3-2-3 4720103

0.00354 to 0.01067
Crank shaft −
(0.090 to 0.271)
0.00197 to 0.00984
Cam shaft −
(0.05 to 0.25)
Side gap in. (mm)
0.00787 to 0.01575
Connecting rod −
(0.20 to 0.40)
0.00394 to 0.01181
Idle gear −
(0.10 to 0.30)
Crank gear, cam gear, idle gear and fuel 0.00276 to 0.00591
−
injection pump drive gear (0.07 to 0.15)
Backlash in. (mm)
0.00433 to 0.00748
Lubricating oil pump gear −
(0.11 to 0.19)
Others
5.17 (19.6)
High speed −
Lube oil pump GPM at 3600 min-1 (rpm)
discharge volume (L/min) 1.16 (4.4)
Low speed −
at 800 min-1 (rpm)
PSI 42.66 to 56.88
Oil pressure regulating valve opening pressure −
(kPa) (294.2 to 392.2)
PSI 5.68 to 8.53
Oil pressure switch operating pressure −
(kPa) (39.2 to 58.8)
GPM 9.24 (35)
Cooling water pump discharge volume −
(L/min) at 3220 to 3280 rpm
157.1 to 162.5
Thermostat valve Temperature °F (°C) −
(69.5 to 72.5)
opening tempera-
0.177 (4.5) or more
ture Lift at opening in. (mm) −
at 185°F (85°C) or higher
Thermo-switch 224.6 to 235.4
ON −
operating tempera- °F (°C) (107 to 113)
ture OFF 212 (100) or more −
3-2-4 4720103
ViO35-2
Applicable model 3TNE82A-EBVB
Cylinder head
Cylinder head distortion in. (mm) 0.002 (0.05) or less 0.00591 (0.15)
Intake degrees 120 −
Valve seat angle
Exhaust (°) 90 −
0.054 to 0.06
Intake 0.078 (1.98)
(1.36 to 1.53)
Valve seat width in. (mm)
0.065 to 0.074
Exhaust 0.089 (2.27)
(1.66 to 1.87)
0.273 to 0.274
(6.945 to 6.960)
0.27559 to 0.27618
Intake valve Guide inside dia. in. (mm) 0.279 (7.08)
(7.000 to 7.015)
0.0016 to 0.0028
(0.040 to 0.070)
0.2732 to 0.274
(6.940 to 6.955)
0.27559 to 0.27618
Exhaust valve Guide inside dia. in. (mm) 0.279 (7.08)
(7.000 to 7.015)
0.0017 to 0.003
(0.045 to 0.075)
Valve guide projection in. (mm) 0.472 (12) −
0.0117 to 0.0195
Intake
(0.296 to 0.496)
Valve sinkage in. (mm) 0.039 (1.0)
0.0118 to 0.0197
Exhaust
(0.3 to 0.5)
0.049 to 0.0569
Intake
Valve head (1.244 to 1.444)
in. (mm) 0.02 (0.50)
thickness 0.053 to 0.061
Exhaust
(1.35 to 1.55)
Intake valve Open b. TDC degrees 10 to 20 −
operating timing Close a. BDC (°) 40 to 50 −
Exhaust valve Open b. BDC degrees 51 to 61 −
operating timing Close a. TDC (°) 13 to 23 −
Free length in. (mm) 1.75 (44.4) −
Valve spring Inclination in. (mm) − 0.043 (1.1)
Tension [0.0394 in. (1 mm) compressed] lbs. (kg) 0.81 (0.368) (Irregular pitch) / 5.98 (2.71)
0.006 to 0.01
Intake / exhaust valve clearance in. (mm) −
(0.15 to 0.25)
Cylinder block
3.22834 to 3.22952
Cylinder bore dia.
(82.000 to 82.030)
3.22913 to 3.22952
L mark
(82.020 to 82.030)
3.47243 (88.20)
3.22873 to 3.22913
Cylinder bore dia. M mark in. (mm)
(82.010 to 82.020)
3.22834 to 3.22873
S mark
(82.000 to 82.010)
Roundness of cylinder sleeve bore 0 to 0.00039 (0 to 0.01) 0.00118 (0.03)
Cylindricity of cylinder sleeve bore 0 to 0.00039 (0 to 0.01) 0.00118 (0.03)
3-2-5 4720103

Valve
0.62858 to 0.62929
Shaft outside dia. 0.63 (15.95)
(15.966 to 15.984)
Intake / exhaust 0.62992 to 0.63071
valve rocker arm (16.000 to 16.020)
0.00063 to 0.0021
(0.016 to 0.054)
Push rod bend in. (mm) 0.00118 (0.03) or less −
0.47146 to 0.47205
(11.975 to 11.990)
0.47244 to 0.47315
Tappet Guide hole inside dia. 0.474 (12.05)
(12.000 to 12.018)
0.00039 to 0.0017
(0.010 to 0.043)
Piston
3.22637 to 3.22755
Piston outside dia.
(81.950 to 81.980)
3.22716 to 3.22755
L mark
(81.970 to 81.980)
3.22696 to 3.2216
ML mark 3.224 (81.90)
(81.965 to 81.970)
Piston outside dia.
3.22677 to 3.22696
MS mark
(81.960 to 81.965)
3.22637 to 3.22677
S mark
(81.950 to 81.960)
in. (mm)
0.00138 to 0.00256
Minimum clearance between piston and cylinder −
(0.035 to 0.065)
0.025 to 0.03
Top clearance −
(0.630 to 0.750)
0.9051 to 0.9055
Outside dia. 0.9015 (22.90)
(22.991 to 23.000)
0.9055 to 0.9582
Piston pin Bush inside dia. 0.9133 (23.20)
(23.000 to 23.008)
0 to 0.00067
(0.000 to 0.017)
Piston ring
0.0813 to 0.08189
(2.065 to 2.080)
0.07756 to 0.07835
Ring width −
(1.970 to 1.990)
Top ring
0.0029 to 0.0043
(0.075 to 0.110)
0.00787 to 0.01575
End gap 0.059 (1.5)
(0.200 to 0.400)
in. (mm)
0.08012 to 0.08071
(2.035 to 2.050)
0.07756 to 0.07835
Ring width −
(1.970 to 1.990)
Second ring
0.00177 to 0.00315
(0.045 to 0.080)
0.00787 to 0.01575
End gap 0.059 (1.5)
(0.200 to 0.400)
3-2-6 4720103

Piston ring
0.15807 to 0.15866
(4.015 to 4.030)
0.01563 to 0.15709
Ring width −
(3.970 to 3.990)
Oil ring in. (mm)
0.00098 to 0.00236
(0.025 to 0.060)
0.00787 to 0.01575
End gap 0.059 (1.5)
(0.200 to 0.400)
Connecting rod
1.81102 to 1.81165
Crank pin metal inside dia. −
(46.000 to 46.016)
0.05854 to 0.05906
Crank pin metal thickness −
(1.487 to 1.500)
Crank pin side
1.69102 to 1.69141
Crank pin outside dia. 1.68937 (42.91)
(42.952 to 42.962)
0.0015 to 0.00354
(0.038 to 0.090)
in. (mm)
0.90649 to 0.9071
(23.025 to 23.038)
0.90516 to 0.90551
Piston pin side Piston pin outside dia. 0.90157 (22.90)
(22.991 to 23.000)
0.00098 to 0.00185
(0.025 to 0.047)
0.00118 (0.03) or less
Twist and parallelism 0.00315 (0.08)
for 3.937 (100)
Cam
1.7687 to 1.76968
(44.925 to 44.950)
Gear side
0.00157 to 0.00512
Oil clearance −
(0.040 to 0.130)
1.76811 to 1.76909
(44.910 to 44.935)
Intermediate in. (mm)
0.00256 to 0.00453
Oil clearance −
(0.065 to 0.115)
1.7687 to 1.76968
(44.925 to 44.950)
Flywheel side
0.00197 to 0.00394
Oil clearance −
(0.050 to 0.100)
Crank shaft
1.8485 to 1.84889
Outside dia. 1.84685 (46.91)
(46.952 to 46.962)
0.07823 to 0.07874
Journal Main metal thickness −
in. (mm) (1.987 to 2.000)
0.0015 to 0.00366
(0.038 to 0.093)
Bend 0.00079 (0.02) or less −
3-2-7 4720103

0.00354 to 0.01067
Crank shaft −
(0.090 to 0.271)
0.00197 to 0.00984
Cam shaft −
(0.05 to 0.25)
Side gap in. (mm)
0.00787 to 0.01575
Connecting rod −
(0.20 to 0.40)
0.00394 to 0.01181
Idle gear −
(0.10 to 0.30)
Crank gear, cam gear, idle gear and fuel 0.00276 to 0.00591
−
injection pump drive gear (0.07 to 0.15)
Backlash in. (mm)
0.00433 to 0.00748
Lubricating oil pump gear −
(0.11 to 0.19)
Others
5.17 (19.6)
High speed −
Lube oil pump GPM at 3600 min-1 (rpm)
discharge volume (L/min) 1.16 (4.4)
Low speed −
at 800 min-1 (rpm)
PSI 42.66 to 56.88
Oil pressure regulating valve opening pressure −
(kPa) (294.2 to 392.2)
PSI 5.68 to 8.53
Oil pressure switch operating pressure −
(kPa) (39.2 to 58.8)
GPM 9.24 (35)
Cooling water pump discharge volume −
(L/min) at 3220 to 3280 rpm
157.1 to 162.5
Thermostat valve Temperature °F (°C) −
(69.5 to 72.5)
opening tempera-
0.177 (4.5) or more
ture Lift at opening in. (mm) −
at 185°F (85°C) or higher
Thermo-switch 224.6 to 235.4
ON −
operating tempera- °F (°C) (107 to 113)
ture OFF 212 (100) or more −
3-2-8 4720103
3-3 Undercarriage
3-3-1 Rubber Crawler Specifications
[Unit : in. (mm)]
Applicable model ViO27-2, ViO35-2 (US

Measuring
Part Standard Wear limit
position
Rubber crawler specifications
(1) Rubber crawler
A 0.94 (24) 0.39 (10)
(2) Idler & shaft

A Ø1.38 (Ø35) −
B Ø1.38 (Ø35) −
C Ø1.54 (Ø39) −
D 1.26 (32) 0.94 (24)
E 2.76 (70) 2.56 (65)
F Ø11.6 (Ø295) Ø11.3 (Ø287)
3-3-1 4720103
3-3-2 Steel Crawler Specifications

[Unit : in. (mm)]

Measuring
position
Steel crawler specifications
(1) Crawler link (Triple grouser)
A 2.36 (60) 2.24 (57)
B 0.65 (16.5) 0.26 (6.5)
Note : C 4.00 (101.6) 4.06 (103)

For the link pitch, measure 5 links at three places and obtain the
average value.
(2) Master pin
A 3.80 (96.5) −
B Ø0.74 (Ø18.9) Ø0.67 (Ø16.9)
(3) Pin
A 3.64 (92.5) −
B Ø0.76 (Ø19.2) Ø0.68 (Ø17.2)
(4) Bush & master bush

A 2.05 (52) −
B Ø0.77 (Ø19.5) Ø0.8 (Ø20.4)
C Ø1.27 (Ø32.2) Ø1.19 (Ø30.2)
(5) Idler & shaft

A Ø1.38 (Ø35) −
B Ø1.38 (Ø35) −
C Ø1.54 (Ø39) −
D 1.10 (28) 0.79 (20)
E 2.76 (70) 2.56 (65)
F Ø11.0 (Ø280) Ø10.7 (Ø272)
3-3-2 4720103
3-3-3 Common Specifications of Steel & Rubber Crawlers

[Unit : in. (mm)]

Measuring
position
Common specifications of steel & rubber crawlers
(1) Sprocket
A 0.20 (5) 0.40 (10)
B 1.14 (29) 0.94 (24)
(2) Track roller & shaft

A Ø1.18 (Ø30) −
B Ø2.44 (Ø62) −
C Ø3.30 (Ø84) Ø3.11 (Ø79)
D 2.87 (73) 3.07 (78)
E Ø5.51 (Ø140) Ø5.31 (Ø135)
(3) Carrier roller & shaft

A Ø0.98 (Ø25) −
B Ø2.05 (Ø52) −
C Ø3.15 (Ø80) Ø2.99 (Ø76)
D 3.54 (90) −
3-3-3 4720103
3-4 Controls

Item Measuring conditions Unit Standard Allowable limit
Controls
Operating force
Right control lever • Engine : stopped
1.99 (0.9) 3.09 (1.4)
(Boom & Bucket) • Hydraulic oil temp. : 122 to 140 °F (50 to 60 °C)
• Lever operating force : Measure the force by
Left control lever
hanging the spring scale on the lever grip. 1.99 (0.9) 3.09 (1.4)
(Arm & Swing)
• Pedal operating force : Measure the force by
Blade lever applying load as shown below. 4.41 (2.0) 5.52 (2.5)
Forward Forward
lbs. (kg) 4.19 (1.9) 5.52 (2.5)
Travel levers
Reverse Reverse
4.19 (1.9) 5.52 (2.5)
Boom swing lever − −
Boom swing pedal 12.1 (5.5) 14.3 (6.5)
P.T.O. pedal 12.1 (5.5) 14.3 (6.5)
Play of control lever & pedal
Right control lever • Engine : stopped
0.00 (00) −
(Front & rear / left & right) • Hydraulic oil temp. : 122 to 140 °F (50 to 60 °C)
• Play of each control lever and pedal :
Left control lever
Measure the total play (front & rear and left & 0.00 (00) −
(Front & rear / left & right)
right) at the lever grip end or the pedal end.
0.59 (15)
Blade lever 0.98 (25)
in. (mm) or less
0.79 (20)
Travel levers 1.38 (35)
or less
Boom swing pedal 0.39 (10) 0.79 (20)
P.T.O. pedal − −
Control valve
Spool stroke
Boom
Bucket
Arm 0.28 (7.0)
in. (mm) −
Swing
Parallel-flow divider
Inlet 0.28 (7.0)
Right travel
Left travel
0.28 (7.0)
Blade in. (mm) −
Boom swing
Offset −
3-4-1 4720103
3-5 Hydraulic Equipment
3-5-1 Hydraulic Cylinders

ViO27-2
Unit : in. (mm)

No. 7-1 / 7-2 8
6-1 / Tightening
1 2 3 4 5 Nut size
6-2 Standard Allowable limit torque
(mm)
Cylinder ft•lbf (N•m)
Boom 34.65 21.65 2.95 Ø2.95 Ø1.57 Ø1.77(Ø45) / Ø1.79 (Ø45.5) / 542.5 to 614.9
G3/8 M27
(Cabin type) (880) (550) (75) (Ø75) (Ø40) Ø1.97(Ø50) Ø1.99 (Ø50.5) (735 to 833)
Boom 34.65 21.65 2.95 Ø2.95 Ø1.57 Ø1.77 (Ø45) / Ø1.79 (Ø45.5)/ 542.5 to 614.9
G3/8 M27
(Canopy type) (880) (550) (75) (Ø75) (Ø40) Ø1.97 (Ø50) Ø1.99 (Ø50.5) (736 to 834)
30.31 19.45 3.03 Ø2.95 Ø1.77 G3/8 / 759.5 to 831.9
Arm Ø1.57 (Ø40) Ø1.59 (Ø40.5) M33
(770) (494) (77) (Ø75) (Ø45) G1/2 (1030 to1130)
Bucket
31.31 20.16 3.82 Ø2.36 Ø1.38 361.7 to 434.0
(W/O Quick G3/8 Ø1.50 (Ø38) Ø1.52 (Ø38.5) M24
(795) (512) (97) (Ø60) (Ø35) (490 to 588)
coupler type)
Bucket
31.31 20.16 3.19 Ø2.60 Ø1.57 542.5 to 614.9
(Quick G3/8 Ø1.50 (Ø38) Ø1.52 (Ø38.5) M27
(795) (512) (81) (Ø65) (Ø40) (735 to 833)
coupler type)
5.71 3.03 1.50 Ø1.97 Ø0.98 Ø0.98 (Ø25) / Ø1.00 (Ø25.5)/ 68.7 to 79.6
Quick coupler G1/4 M14
(145) (77) (38) (Ø50) (Ø25) Ø1.18 (Ø30) Ø1.20 (Ø30.5) (93 to 108)
31.42 18.11 3.82 Ø3.15 Ø1.57 542.5 to 614.9
Boom swing G1/4 Ø1.57 (Ø40) Ø1.59 (Ø40.5) M27
(798) (460) (97) (Ø80) (Ø40) (735 to 833)
18.7 7.09 4.17 Ø2.95 Ø1.57 795.7 to 868.0
Blade R1/4 Ø1.57 (Ø40) Ø1.59 (Ø40.5) M30
(475) (180) (106) (Ø75) (Ø40) (1079 to 1177)
Nut for pipe
Symbol Name
G (PF) Straight pipe thread
R (PT) Taper pipe thread (male)
Rc (PT) Taper pipe thread (female)
3-5-1 4720103
ViO35-2
Unit : in. (mm)

No. 7-1 / 7-2 8
6-1 / Tightening
1 2 3 4 5 Nut size
6-2 Standard Allowable limit torque
Cylinder (mm)
ft•lbf (N•m)
Boom 38.9 24.5 3.3 Ø3.35 Ø1.77 759.5 to 831.9
G3/8 Ø1.97 (Ø50) Ø1.99 (Ø50.5) M33
(Cabin type) (989) (623) (84) (Ø85) (Ø45) (1030 to 1130)
Boom 38.9 24.5 3.3 Ø3.35 Ø1.77 759.5 to 831.9
G3/8 Ø1.97 (Ø50) Ø1.99 (Ø50.5) M33
(Canopy type) (989) (623) (84) (Ø85) (Ø45) (1030 to 1130)
33.6 20.3 3.5 Ø3.35 Ø1.97 G3/8 / 759.5 to 831.9
Arm Ø1.97 (Ø50) Ø1.99 (Ø50.5) M33
(854) (516) (89) (Ø85) (Ø50) G1/2 (1030 to 1130)
Bucket
31.31 20.16 3.19 Ø2.60 Ø1.57 542.5 to 614.9
(W/O Quick G3/8 Ø1.50 (Ø38) Ø1.52 (Ø38.5) M27
(795) (512) (81) (Ø65) (Ø40) (735 to 833)
coupler type)
Bucket
31.31 20.16 3.19 Ø2.76 Ø1.57 542.5 to 614.6
(Quick G3/8 Ø1.50 (Ø38) Ø1.52 (Ø38.5) M27
(795) (512) (81) (Ø70) (Ø40) (735 to 833)
coupler type)
5.71 3.03 1.50 Ø1.97 Ø0.98 Ø0.98 (Ø25) / Ø1.00 (Ø25.5) / 672.7 to 781.2
Quick coupler G1/4 M14
(145) (77) (38) (Ø50) (Ø25) Ø1.18 (Ø30) Ø1.20 (Ø30.5) (93 to 108)
31.42 18.11 3.82 Ø3.54 Ø1.57 542.5 to 614.6
Boom swing G1/4 Ø1.57 (Ø40) Ø1.60 (Ø40.5) M27
(798) (460) (97) (Ø90) (Ø40) (735 to 833)
18.7 7.09 4.17 Ø3.15 Ø1.57 795.7 to 868.0
Blade R1/4 Ø1.57 (Ø40) Ø1.60 (Ø40.5) M30
(475) (180) (106) (Ø80) (Ø40) (1079 to 1177)
Nut for pipe
Symbol Name
G (PF) Straight pipe thread
R (PT) Taper pipe thread (male)
Rc (PT) Taper pipe thread (female)
3-5-2 4720103
3-6 Implement
3-6-1 Front Attachments

ViO27-2
Unit : in. (mm)

Applicable model : ViO27-2 (US Wear limit
No. Standard
Measuring point Pin Bore of bush or hole
1 Boom swing fulcrum Ø2.36 (Ø60)
2 Boom fulcrum Ø2.36 (Ø60)
3 Boom swing cylinder, rod Ø1.57 (Ø40)
4 Boom swing cylinder, bottom Ø1.57 (Ø40)
5 Boom cylinder, bottom Ø1.97 (Ø50)
6 Boom cylinder, rod Ø1.77 (Ø45)
7 Arm fulcrum Ø1.97 (Ø50)
8 Arm cylinder, bottom Ø1.57 (Ø40)
9 Arm cylinder, rod Ø1.57 (Ø40) -0.02
+0.02 (+0.5)
10 Bucket cylinder, bottom Ø1.50 (Ø38) (-0.5)
11 Bucket cylinder, rod Ø1.50 (Ø38)
12 Link “A” arm Ø1.50 (Ø38)
13 Bucket fulcrum Ø1.50 (Ø38)
14 Bucket “link A” Ø1.50 (Ø38)
15 (14) Bucket link pin (Quick coupler) Ø1.50 (Ø38)
16 (13) Arm link pin (Quick coupler) Ø1.50 (Ø38)
17 Quick coupler cylinder, rod Ø0.98 (Ø25)
18 Quick coupler cylinder, bottom Ø1.18 (Ø30)
Note : Allowable clearance is 0.04 in. (1.0 mm).
3-6-1 4720103
ViO35-2
Unit : in. (mm)

Applicable model : ViO35-2 (US Wear limit
No. Standard
1 Boom swing fulcrum Ø2.76 (Ø70)
2 Boom fulcrum Ø2.36 (Ø60)
3 Boom swing cylinder, rod Ø1.57 (Ø40)
4 Boom swing cylinder, bottom Ø1.57 (Ø40)
5 Boom cylinder, bottom Ø1.97 (Ø50)
6 Boom cylinder, rod Ø1.97 (Ø50)
7 Arm fulcrum Ø1.97 (Ø50)
8 Arm cylinder, bottom Ø1.97 (Ø50)
9 Arm cylinder, rod Ø1.97 (Ø50) -0.02
+0.02 (+0.5)
10 Bucket cylinder, bottom Ø1.50 (Ø38) (-0.5)
11 Bucket cylinder, rod Ø1.50 (Ø38)
12 Link “A” arm Ø1.50 (Ø38)
13 Bucket fulcrum Ø1.50 (Ø38)
14 Bucket “link A” Ø1.50 (Ø38)
15 (14) Bucket link pin (Quick coupler) Ø1.50 (Ø38)
16 (13) Arm link pin (Quick coupler) Ø1.50 (Ø38)
17 Quick coupler cylinder, rod Ø0.98 (Ø25)
18 Quick coupler cylinder, bottom Ø1.18 (Ø30)
Note : Allowable clearance is 0.04 in. (1.0 mm).
3-6-2 4720103
3-6-2 Blade Moving Device
Unit : in. (mm)

Applicable model : ViO27-2, ViO35-2 (US Wear limit
No. Standard
1 Blade cylinder, rod Ø1.57 (Ø40)
2 Blade cylinder, bottom Ø1.57 (Ø40) -0.02 (-0.5) +0.02 (+0.5)
3 Blade fulcrum Ø1.50 (Ø38)
Note : Allowable clearance between pin and bore of bush or hole is 0.04 in. (1.0 mm).
3-6-3 Bucket Teeth
Unit : in. (mm)

Measuring point Standard Wear limit Measure
10.28 (261) 8.07 (205) Replace
3-6-3 4720103
3-7 List of Tightening Torque
3-7-1 Machine
Unit : ft•lbf (N•m)
Applicable model: ViO27-2, ViO35-2
Equipment
Thread size Tightening torque Adhesive
No. Tightening part
Engine / Electrical equipment
32.6 to 43.4
1 Engine mount vibroisolating rubber M12 4T torque
(44.1 to 58.8)
79.6 to 94.0
2 Engine × Engine mount (Radiator side) M12 (10.9T) Three Bond 1324
(107.9 to 127.5)
47.0 to 54.3
3 Engine × Engine mount (Flywheel side) M10 (10.9T) Three Bond 1324
(63.7 to 73.6)
32.6 to 43.4
4 Engine stopper × Engine mount M10 Three Bond 1324
(44.1 to 58.8)
79.6 to 94.0
5 Engine bracket × Turning frame (fan side) M12 (10.9T) Three Bond 1324
(107.9 to 127.5)
Engine bracket × Turning frame 57.9 to 72.3
6 M12 (10.9T) Three Bond 1324
(Flywheel side) (78.5 to 98.0)
1.63 to 1.85
7 Hose clip 48,70 (Intake hose installation) −
(2.2 to 2.5)
Lock nut
1.45 to 2.17
8 Battery holding rod Nut M6 3.62 to 4.34 ft•lbf
(1.96 to2.94)
(4.9 to 5.88 N•m)
0.89 to 1.11
9 Fuel gauge unit Pan head screw M5
(1.2 to 1.5)
0.74 to 1.11
10 Fuel gauge hose Hose clip 13
(1.0 to 1.5)
1.63 to 1.85
11 CW-T (A-B-C) Hose clip 41
(2.2 to 2.5)
2.17 to 2.89
12 Battery cable terminals Nut M6
(2.94 to 3.92)
14.5 to 16.6
13 Air cleaner M8
(19.6 to 22.6)
18.1 to 23.9 ft•lbf
1.85 to 2.15 (2.5 to 2.9)
14 Fuel tank band Nut M10 (24.5 to 32.4 N•m)
<Tank tighten side>
<Lock nut side>
2.17 to 5.06
15 Radiator cap M6
(2.94 to 6.86)
16 Sub tank M6 1.11 to 1.48 (1.5 to 2.0)
Lock nut M18 21.7 to 25.3
17 Safety starter switch (high-speed travel)
(Fine screw thread) (29.4 to 34.3)
Driving system
32.6 to 43.4
1 Sprocket (ViO27-2) M10 Three Bond 1324
(44.1 to 58.8)
57.9 to 72.3
2 Sprocket (ViO35-2) M12 Three Bond 1324
(78.5 to 98.1)
Travel device
6.51 to 7.23
1 Plugs (idler, adjust cylinder & carrier roller) PT 1/8 Loctite 572
(8.83 to 9.81)
32.6 to 43.4
2 Idler seal cover × Crawler spring M10 Three Bond 1324
(44.1 to 58.8)
151.9 to 180.8
3 Track roller tightening nut M16 Three Bond 1324
(205.9 to 245.2)
4 Nipple valve M16 36.2 (49.0)
3-7-1 4720103

Equipment
No. Tightening part
Controls
54.3 to 61.5
1 Levers (L, R) × Pilot valve Nut M14 Three Bond 1324
(73.6 to 83.4)
1.48 to 1.92
2 Knobs (L, R) × Levers (L, R) Binding head screw M4 Three Bond 1324
(2.0 to 2.6)
9.4 to 12.3
3 L-ball 8 × Link ball 8 Nut M8
(12.7 to 16.7)
5.79 to 7.23
4 L-ball 8 × Rod,Link ball 8 Nut M8
(7.84 to 9.8)
14.5 to 18.8
5 Valve mount × Turning frame Flange bolt M10 Three Bond 1324
(19.6 to 25.5)
2.89 to 3.62
6 Accelerator cable Nut M6
(3.92 to 4.9)
14.5 to 18.1
7 Blade cable Nut M12
(19.6 to 24.5)
Frame
1 Swing bearing × Lower frame M14 180.8 (245) Loctite 262
2 Swing bearing × Turning frame M14 180.8 (245) Loctite 262
354.4 to 441.3
3 Counter weight × Turning frame M24 Three Bond 1324
(480.5 to 598.2)
57.9 to 72.3
4 Crawler guard (steel crawler only) M12 Three Bond 1324
(78.5 to 98.1)
123.0 to 151.9
5 Bracket × Turning frame M16 Three Bond 1324
(166.7 to 205.9)
Hydraulic equipment
Hexagon socket 61.5 to 68.0
1 CF Coupling Three Bond 1324
head bolt M12 (83.4 to 92.2)
32.6 to 43.4
2 Swivel joint × Track frame M10 Three Bond 1324
(44.1 to 58.8)
86.8 to 108.5
3 Swing motor × Turning frame M14 Three Bond 1324
(117.7 to 147.1)
32.6 to 43.4
4 Travel motor × Track frame (ViO27-2) M10 Three Bond 1324
(44.1 to 58.8)
57.9 to 72.3
5 Travel motor × Track frame (ViO35-2) M12 Three Bond 1324
(78.5 to 98.1)
86.8 to 108.5
6 Hydraulic oil tank × Turning frame M14 Three Bond 1324
(117.7 to 147.1)
115.7 to 137.4
7 Drain plug 24 × Hydraulic oil tank M24
(156.9 to 186.3)
10.9 to 11.6
8 Oil level gauge × Hydraulic oil tank M10
(14.7 to 15.7)
9 Hose band 14 − 0.72 (0.98)
1.81 to 2.52
10 Hose clip 16 −
(2.45 to 3.4)
2.89 to 3.62
11 Hose clip 25 & 35 −
(3.92 to 4.9)
3.62 to 4.34
12 Hose clip 60 & 70 −
(4.9 to 5.88)
2.0 to 3.0
13 Breather cover (for hydraulic oil tank) Pan head screw M5
(2.7 to 4.1)
18.1 to 23.9
14 Flange (pump) M10
(24.5 to 32.4)
3-7-2 4720103

Equipment
No. Tightening part
Rigging
Canopy pole × Canopy mount 123.0 to 151.9
1 M16 (10.9T)
(canopy type) (166.7 to 205.9)
Turning frame × Canopy mount 123.0 to 151.9
2 M16
(canopy type) (166.7 to 205.9)
57.9 to 72.3
3 Under cover × Track frame M12 Three Bond 1324
(78.5 to 98.1)
123.0 to 151.9
4 Weight (side L, R × Bracket) M16 Three Bond 1324
(166.7 to 205.9)
123.0 to 151.9
5 Weight (side R × Bracket) M16 Three Bond 1324
(166.7 to 205.9)
Work implements
32.6 to 43.4
1 Lock plate (swing cyl. bottom pin) M10 Three Bond 1324
(44.1 to 58.8)
32.6 to 43.4
2 Lock plate (blade arm fulcrum pin) M10 Three Bond 1324
(44.1 to 58.8)
108.5 to 130.2
3 Bucket side cutter Nut M14 Loctite 262
(147.1 to 176.5)
57.9 to 72.3
4 Implement cylinder pin lock M12 Three Bond 1324
(78.5 to 98.1)
32.6 to 43.4
5 Slide cover M10 Three Bond 1324
(44.1 to 58.8)
Quick coupler type
Pin lock bolt
1 M6 0.7 to 0.9 (1.0 to 1.2) Three Bond 1324
(quick coupler cylinder × bracket pin)
Quick coupler cylinder × operate check
2 M6 0.7 to 0.9 (1.0 to 1.2) Three Bond 1324
valve
3-7-3 4720103
3-7-2 Engine
Tightening torque for major bolts and nuts

Tightening torque
No. Item Thread size × Pitch Lubricating oil
1 Cylinder head bolt M9 × 1.25 49.2 to 52.1 (66.7 to 70.6) Yes
2 Connecting rod bolt (class 1) M8 × 1.0 27.5 to 30.4 (37.3 to 41.2) Yes
3 Flywheel mounting bolt M10 × 1.25 61.5 to 65.1 (83.4 to 88.3) Yes
4 Metal cap bolt M10 × 1.5 56.4 to 59.3 (76.5 to 80.4) Yes
5 Crankshaft pulley fastening bolt M14 × 1.5 83.2 to 90.4 (112.8 to 122.6) Yes
6 Fuel injection nozzle retainer clamp nut M6 × 1.0 5.06 to 6.51 (6.86 to 8.82) No
7 Timer fastening nut M12 × 1.75 43.4 to 50.6 (58.8 to 68.6) No
8 Governor weight support nut M12 × 1.25 32.6 to 36.2 (44.1 to 49.0) Yes
9 High pressure pipe nut M12 × 1.25 21.7 to 25.3 (29.4 to 34.3) No
3-7-3 Tightening Torque for General Bolts and Nuts

Tightening torque
Item Thread size × Pitch Remarks
[Unit : ft•lbf (N•m)]
7.23 to 8.68
M6 × 1
(9.8 to 11.8)
16.6 to 21.0
M8 × 1.25
(22.6 to 28.4)
32.6 to 43.4
M10 × 1.5
(44.1 to 58.8)
57.9 to 72.3
M12 × 1.75
Coarse (78.5 to 98.1)
1) Apply 80% of tightening torque
thread 86.8 to 108.5 when tightened to aluminum.
M14 × 2
Hexagon head bolt (7T) (117.7 to 147.1) 2) Apply 60% of tightening torque
Nut 123.0 to 151.9 for 4T bolts and lock nuts.
M16 × 2 3) Use fine screw threads for
(166.7 to 205.9)
engine only.
173.6 to 209.8
M18 × 2.5
(235.4 to 284.4)
238.7 to 296.6
M20 × 2.5
(323.6 to 402.1)
94.0 to 108.5
M14 × 1.5
Fine (127.5 to 147.1)
thread 155.5 to 177.2
M16 × 1.5
(210.9 to 240.3)
1/8 7.23 (9.8)
1/4 14.5 (19.6)
PT plug
3/8 21.7 (29.4)
1/2 43.4 (58.8)
M8 9.4 to 12.3 (12.7 to 16.7)
M12 18.1 to 25.3 (24.5 to 34.3)
Pipe joint bolt
M14 28.9 to 36.2 (39.2 to 49.0)
M16 36.2 to 43.4 (49.0 to 58.8)
3-7-4 4720103
CHAPTER 4
ENGINE
4-1 Measurement, Inspection and Adjustment .......................................... 4-1-1

4-1-1 Measuring the Compression Pressure....................................... 4-1-1
4-1-2 Adjusting the Valve Clearance................................................... 4-1-2
4-1-3 Checking the V-belt Tension...................................................... 4-1-3
4-1-4 Checking the Fuel Injection Valve.............................................. 4-1-3
4-1-5 Checking and adjusting the Fuel Injection Timing ..................... 4-1-6
4-1-6 Adjusting the Maximum (or Minimum) Idling Speed .................. 4-1-7
4-1-7 Checking the Cooling Water System and Radiator
for Water Leakage ..................................................................... 4-1-7
4-1-8 Checking the Sensors................................................................ 4-1-8
4-2 Measurement Procedure, Service Data and Corrective Action ........... 4-2-1
4-2-1 Cylinder Head ............................................................................ 4-2-1
4-2-2 Cylinder Block ............................................................................ 4-2-6
4-2-3 Valve Rocker Arm ...................................................................... 4-2-8
4-2-4 Piston and Piston Rings........................................................... 4-2-10
4-2-5 Connecting Rod ....................................................................... 4-2-13
4-2-6 Cam shaft................................................................................. 4-2-16
4-2-7 Crank shaft............................................................................... 4-2-17
4-2-8 Gears ....................................................................................... 4-2-20
4-2-9 Trochoid Pump......................................................................... 4-2-21
4-3 Precautions for Reassembly................................................................ 4-3-1
4-4 Fuel Injection System .......................................................................... 4-4-1
4-4-1 Fuel Injection Pump ................................................................... 4-4-1
4-4-2 Fuel Injection Valve.................................................................... 4-4-2
4-4-3 Governor Mechanism................................................................. 4-4-3
4-4-4 Specifications of Fuel Injection Pump ........................................ 4-4-5
4-5 Electrical Equipment ............................................................................ 4-5-1
4-5-1 Starter Motor .............................................................................. 4-5-1
4-5-2 Alternator ................................................................................... 4-5-3
4-5-3 Air Heater................................................................................... 4-5-4
4. ENGINE
4. Engine
4-1 Measurement, Inspection and Adjustment
4-1-1 Measuring the Compression Pressure
1) Measurement Procedure
(1) Warm up the engine. Remove the fuel injection pipe
and the fuel injection valve from the cylinder to be
measured.
(2) Crank the engine before attaching the compression
gauge adapter.
Note :
Crank the engine when the regulator handle has been
turned to "STOP" position (no injection state).
(3) Attach the compression gauge adapter and the
compression gauge to the cylinder to be measured.
Note :
Never fail to attach the gasket to the tip of the adapter.
(4) Crank the engine with the starter motor until the
reading of the compression gauge is stabilized,
according to the above step (2) and Note.
[Engine compression pressure (Reference values)]

Compression pressure at 300 rpm PSI (MPa) Variations of compression
pressure among cylinders
Standard Limit PSI (MPa)
426.6 to 455.0 (2.9 to 3.1) 341.3 to 369.7 (2.4 to 2.6) 28.4 to 42.7 (0.2 to 0.3)
2) Trouble Diagnosis Through Measurement of Compression Pressure

Reduction in the compression pressure of the cylinder is one of the major causes of the increase in blow-by gas
(which causes contamination and increased consumption of lubricating oil, and other trouble) and the engine start-
ing failure. The compression pressure is influenced by the following factors :
(1) Degree of the clearance between the piston and the cylinder ;
(2) Degree of the clearance around the intake / exhaust valve seats ; and
(3) Gas leak through the nozzle gasket or the cylinder head gasket.
This means that the compression pressure decreases as the engine parts are worn and lose durability through the
use of the engine over a long period of time.
In addition, the compression pressure is also decreased by scratches on the cylinder or the piston which are caused
by dust or other foreign matters drawn in through the soiled filter element of the air cleaner, and wear or breakage of
any piston rings. Therefore, the condition of the engine should be diagnosed by measuring the compression pres-
sure.
4-1-1 4720103
4. ENGINE
Causes and countermeasures to be taken when the compression pressure is less than the limit value.
No. Item Causes Countermeasures
• Filter element of air cleaner • Clogged filter element • Clean the filter element.
1 • Broken filter element • Replace the filter element.
• Defective filter element seal portion
• Valve clearance • Excessive or no valve clearance • Adjust the valve clearance.
2
(Refer to Section 4-1-2.)
• Valve timing • Improper valve timing • Adjust the valve clearance.
• Improper valve clearance (Refer to Section 4-1-2.)
3
• Inspect and adjust the valve rocker arm.
(Refer to Sections 4-2-3, 4-2-6 and 4-2-8.)
• Cylinder head gasket • Gas leak through the gasket • Replace the gasket.
• Nozzle gasket • Re-tighten the cylinder head and the nozzle at the
4
specified torque.
(Refer to Section 3-7-2 of Chapter 3.)
• Intake/exhaust valve • Gas leak due to worn valve seats or • Lap the valve seats.
5 • Valve seat trapped foreign matters (Refer to Section 4-2-1 2).)
• Sticking of valves • Replace the intake/exhaust valves.
• Piston • Gas leak due to scratches or wear of • Do the honing and use oversize parts.
6 • Piston ring the piston, piston ring or cylinder (Refer to Sections 4-2-2 3) and 4-2-4 8).)
• Cylinder
4-1-2 Adjusting the Valve Clearance
(1) Inspect and adjust the intake / exhaust valve clear-

ance while the engine is in the cold state.
(2) Set the piston in the cylinder to be measured to the
top dead center (TDC) of compression.
(3) Loosen the lock nut and the adjust screw. Check
that the valve cap is free from inclination or foreign
matter.
(4) Insert a thickness gauge between the rocker arm
and the valve cap. Tighten the adjust screw until the
clearance listed below is attained.
Intake / exhaust valve Refer to Section "3-2 1) Nominal

clearance and Allowable Values".
Notes :
1. If the valve cap is worn or otherwise damaged in the
head, replace it with a new one.
2. Check that the valve cap is fitted on the head of
intake/exhaust valve.
4-1-2 4720103
4. ENGINE
4-1-3 Checking the V-belt Tension
Push the center of the V-belt between the alternator

and the cooling water pump with a finger. If the slack
is 0.39 to 0.59 in. (10 to 15 mm), the V-belt tension is
proper. If not, adjust the V-belt tension using the
adjuster at the alternator.
4-1-4 Checking the Fuel Injection Valve
1) Measuring the Fuel Injection Pressure
Note :
Thoroughly remove carbon deposits from the injection
nozzle hole before the measurement.
(1) Connect the fuel injection valve to the high pressure

pipe of the nozzle tester.
(2) While pumping the lever of the nozzle tester slowly,
read the pressure gauge on the nozzle tester the
moment the nozzle starts fuel injection.
(For the fuel injection pressure, refer to Section "2-1
Specifications".)
(3) If the measured fuel injection pressure is lower than
the specified value, replace the pressure adjusting
shim with a thicker one.
Types of pressure adjusting shim thickness

Fuel injection pressure adjustment
[in. (mm)]
0.0051 (0.13) 0.0059 (0.15)
Increase the pressure adjusting shim thickness by 0.0039 in. (0.1 mm) to
0.0071 (0.18) 0.0158 (0.4)
increase the fuel injection pressure by about 270 PSI (1863 KPa).
0.0197 (0.5) 0.0315 (0.8)
4-1-3 4720103
4. ENGINE
[Reference : Structure of fuel injection valve]
2) Checking the Spray Pattern

While pumping the lever of the nozzle tester once or twice per second at the specified fuel injection pressure (Refer
to Section "2-1 Specifications".), check the spray pattern. If the spray pattern is not normal, clean or replace the noz-
zle.
(1) Check that the pattern is neither like a stream nor slivered.
(2) Check that fuel is sprayed conically around the nozzle center line and that the spray angle is 150 degrees.
(3) Spray fuel on a sheet of white paper placed about 11.8 in. (30 cm) below the nozzle. The injection spray should
form a perfect circle.
(4) No fuel should drip from the nozzle after injection.
(5) Fuel should not ooze from the nozzle hole when the fuel injection pressure rises to a value that is a little lower
than the specified value : 284 PSI (2.0 MPa).
(6) Test the injection with a nozzle tester ; retighten the nozzle holder and test it again if there is excessive fuel leak
from the overflow coupling. Replace the nozzle as a set if the fuel leak is still excessive.
4-1-4 4720103
4. ENGINE
3) Nozzle Valve Sliding Test

Thoroughly wash the nozzle valve using clean fuel. Hold the nozzle
body vertical, and put the nozzle valve approx. 1 / 3 of its length into
the body.
Check if the nozzle valve falls smoothly by self-weight when released.
If so, the nozzle valve is good. In case of a new nozzle, remove the
seal peel, and immerse it in clean light oil or the like to clean its inner
and outer surfaces and thoroughly remove rust-preventive oil before
using the nozzle. Note that a new nozzle is immersed in rust-preven-
tive oil and then is pasted with a seal peel to shut off the outside air.
4) Nozzle Body Identification Number
4-1-5 Checking and adjusting the Fuel Injection Timing
1) Replacing the Fuel Injection Pump

When the pump has become old and worn, replace the pump in
the following manner.
Note :
The fuel injection pump as the service part is the same as that
used in the standard engine (without coupling).
Procedure
a) Remove the current pump from the gear case. Loosen the
end nuts to remove the fuel pump. (Leave the FIP coupling
and driving gear in the gear case CMP.)
Note :
Do not separate the FIP coupling and driving gear.
Do not touch the attachment bolts (E mark : 4 bolts).
b) Align the fuel injection pump for service with the aligning
marks on the gear case and the pump to install on the gear
case.
c) Attach the FIP coupling and driving gear semi-assembly to
the pump.
• Tightening torque : 36.1 to 43.4 ft•lbf (58.8 to 68.8 N•m)
This completes the replacement of the fuel pump.
Check the fuel injection timing with the FID method.
4-1-5 4720103
4. ENGINE
2) Checking and Adjusting the Fuel Injection Timing

(1) Using the crankshaft pulley, turn the engine in the specified
direction. Check the injection timing with the delivery valve
spring holder of the fuel injection pump for the cylinder
No.1. (Cylinder are numbered from No.1 sequentially from
the flywheel side).
(2) When the crankshaft is turned in the specified direction, the

fuel level rises at the tip of the delivery valve spring holder.
At that time, stop turning the crankshaft.
(3) Check the timing mark imprinted on the flywheel through the
peep hole in the flywheel housing.
(For the fuel injection timing, refer to Section "2-1 Specifica-
tions".
(4) If the measured injection timing differs from the specified

timing, adjust the injection timing by turning down the fuel
injection pump toward the engine or to the opposite side
after loosening the lock nut of the fuel injection pump.
• If injection timing is late, turn down the fuel injection pump
away from the engine.
• If the injection timing too early, turn the injection pump down
toward the engine.
4-1-6 4720103
4. ENGINE
4-1-6 Adjusting the Maximum (or Minimum) Idling Speed
(1) First warm up the engine. Then, gradually increase the

engine speed up to the maximum idling speed. (Refer to
Section "2-1 Specifications".)
(2) If the maximum idling speed differs from the specified one,
adjust the maximum idling speed using the maximum
idling speed adjusting bolt.
(3) Set the minimum idling speed to the specified value,
(Refer to Section "2-1 Specifications".) by turning the mini-
mum idling speed adjusting bolt.
Note :
The illustration shows the partial perspective view of the gover-
nor for the direct injection system.
4-1-7 Checking the Cooling Water System and Radiator for Water Leakage
1) Checking the Cooling Water System for Water Leakage

Note :
The cooling water system can be checked effectively while the
engine is warm.
(1) Supply cooling water up to the normal water level in the

radiator. Attach the cap tester body to the radiator.
(2) Start operating the cooling water pump, and set the pres-
sure of the tester to 10.67 to 14.93 PSI (0.073 to 0.103
MPa). Any lower reading of the pressure gauge on the cap
tester indicates water leakage from the cooling water sys-
tem. Then, find out the portion of the cooling water system
from which cooling water leaks.
2) Checking the Radiator Cap

Attach the radiator cap to a cap tester. Set the pressure of the
tester to 10.67 to 14.93 PSI (0.073 to 0.103 MPa). Check if the
cap is opened at the set pressure. If not, replace the cap,
because it is defective.
4-1-7 4720103
4. ENGINE
4-1-8 Checking the Sensors
1) Checking the Thermostat and the Thermoswitch

(1) Thermostat
Put the thermostat into the water in a container. While
measuring the water temperature, heat the water. Check
that the thermostat functions at a temperature of 157.1
to 162.5 °F (69.5 to 72.5 °C).
(2) Thermoswitch
Put the thermoswitch into the antifreeze or oil in a con-
tainer. While measuring the liquid temperature, heat the
liquid. If the tester shows continuity at a temperature of
224.6 to 235.4 °F (107 to 113 °C), the thermoswitch is
normal.
2) Hydraulic Switch
Remove the connector from the hydraulic switch. While
running the engine, bring the tester probes into contact
with the switch terminal and the cylinder block. If the
tester shows continuity, the hydraulic switch is defective.
4-1-8 4720103
4. ENGINE
4-2 Measurement Procedure, Service Data and Corrective Action
For the maintenance of all parts, make measurements according to the following measurement procedure. If any
part is found to be defective or if any part is not within the allowable value, replace it with a new one. However, if it is
expected that any part within the allowable value will exceed the value before the next maintenance based on the
record of its use, be sure to replace such a part beforehand.
4-2-1 Cylinder Head
1) Checking the Combustion Surface for Distortion

(1) Remove the intake / exhaust valves and the fuel
injection valve from the engine. Clean the surface of
the cylinder head.
(2) Place a straight-edge along each of the four sides
and each diagonal of the cylinder head. Measure
the clearance between the straight-edge and the
combustion surface with a thickness gauge.
Cylinder head
combustion Standard Wear limit
surface distortion
Refer to Section "3-2 1) Nominal and Allowable Values".
(3) Visually check if the combustion surface is free from

discoloration, cracks, and crazing. In addition, use the color check kit for cracks and crazing.
2) Intake / Exhaust Valve Seat

(1) Valve sinkage
Over long periods of use and repeated lappings, combustion efficiency may drop. Measure the sinking depth and
replace the valve and valve seat if the valve sinking depth exceeds the standard value.
Standard. Wear limit
Intake
Valve valve Refer to Section "3-2 1) Nominal and
sinkage Exhaust Allowable Values".
valve
4-2-1 4720103
4. ENGINE
(2) Width and angle of the valve seat

Remove carbon deposits from the seat surface. Mea-
sure the seat width and angle using vernier calipers and
an angle gauge respectively.
Standard Wear limit
Valve Intake
seat
width Exhaust
Refer to Section "3-2 1) Nominal and
Valve Intake Allowable Values".
seat
Exhaust
angle
[Valve seat correction procedure]

(1) If the seat surface is worn or roughened slightly, lap
the seat surface to a smooth state with a valve com-
pound mixed with oil.
(2) If the seat surface is worn or roughened exces-
sively, correct the seat surface using a seat grinder
or a seat cutter, and finish it according to the above
step (1).
[Procedure for using seat grinder and seat cutter]

(1) Correct the roughened seat surface with a seat
grinder or a seat cutter.
Seat grindstone Angle θ (degrees)
Intake valve 30
Exhaust valve 45
(2) When the seat width is enlarged from the initial

value, correct it by grinding the seat surface with a
70 degrees seat grinder or a seat cutter. Then, grind
the seat surface with a 15 degrees grinder so that
the seat width should be the standard value.
Note :
When using a seat cutter, apply pressure evenly taking
care not to cut the seat surface unevenly.
(3) Knead a valve compound with oil and finish the valve seat by lapping with the compound.
Note :
If any valve requires correction, be sure to measure the oil clearance between the valve stem outside dia. and the
valve guide inside dia. If the oil clearance exceeds the wear limit, replace the valve or the valve guide before correct-
ing the valve seat surface. (For the oil clearance between the valve and the valve guide, refer to the subsection 3 in
this section.)
4-2-2 4720103
4. ENGINE
(4) Last, lap the valve using only oil.

Notes :
1. After correcting the valve seat, thoroughly clean the valve and the cylinder head using light oil or the like. Thor-
oughly remove the valve compound or the grindstone powder.
2. For slightly poor contact, take the steps (3) and (4) only.
3) Intake / Exhaust Valve

(1) Wear and bend of the valve stem
Replace the valve stem if bent or worn excessively. In this case, replace the valve guide together with the valve
stem.
(2) Valve stem and valve guide
Oil clearance is the difference between the valve guide inside diameter measured with a three-point micrometer or a
cylinder gauge and the stem outside diameter measured with a micrometer. If the oil clearance is near the wear limit,
replace both the intake / exhaust valve and the valve guide with new ones.
Note :
Three-point micrometer : Used for an inside diameter of 0.157 to 0.315 in. (4 to 8 mm).
Cylinder gauge : Used for an inside diameter of 0.236 in. (6 mm) or more.
Standard Wear limit
Stem
outside dia.
Intake
Guide
valve
inside dia.
Oil clearance Refer to Section "3-2 1) Nominal
Stem and Allowable Values".
outside dia.
Exhaust
Guide
valve
inside dia.
Oil clearance
(3) Thickness of valve head

Measure the thickness of the valve head with a micrometer.
If the measured value is near the wear limit, replace the
valve with a new one.
Standard Wear limit
Intake
Thickness valve Refer to Section "3-2 1) Nominal
of valve
Exhaust and Allowable Values".
head
valve
4-2-3 4720103
4. ENGINE
[Valve guide replacement procedure]

(1) Extract the valve guide from the cylinder head using a
valve guide extraction tool.
(2) Put the valve guide into a container containing liquid
nitrogen, ether or alcohol together with dry ice. Then, hit
the sufficiently cooled valve guide to fit it into the cylinder
head using a valve guide insertion tool.
(3) After inserting the valve guide, finish the inside of the
valve guide with a reamer.
(4) Check the projection of the valve guide.
Standard Wear limit
Refer to Section "3-2 1) Nominal

Valve guide projection
and Allowable Values".
4) Valve Stem Seal

[Time of replacement]
(1) When oil loss is found excessive.
(2) When the valve stem seal is removed.
(3) When the intake / exhaust valve is removed.
[Precautions on installation]
Before reinstalling the intake / exhaust valve, thoroughly
remove the burrs on the valve stem surface and then apply
sufficient lubricating oil to the valve stem.
4-2-4 4720103
4. ENGINE
5) Checking the Valve Spring

(1) Visually check if the valve spring is free from flaws
and corrosion.
(2) Measure the free length (length of the spring) and
inclination (squareness of the side of the coil).
Standard Wear limit
Free length
Inclination
Valve Tension Refer to Section "3-2 1) Nominal
spring [lbs. (kg)] and Allowable Values".
[0.0394 in.
(1 mm)
compressed]
6) Checking Valve Spring Holder and Cotter

Check the contact of the inner surface of the valve
spring holder with the outer surface of the cotter as well
as the contact of the inner surface of the cotter with the
notch in the head of the valve stem. If such contact is
uneven or if the cotter has sunk due to wear, replace the
cotter with a new one.
4-2-5 4720103
4. ENGINE
4-2-2 Cylinder Block
1) Checking the Cylinder Block

(1) Visually check if the cylinder block is free from water
leak, oil leak and cracks. If any portion of the cylin-
der block might be cracked, check the portion by
color check.
(2) Replace the cylinder block if badly damaged and
unreparable.
(3) Thoroughly clean each oil hole. Make sure that it is
not clogged.
2) Measuring the Cylinder Bore and the Distortion of the Cylinder

Measure each cylinder bore with a cylinder gauge. Mea-
sure the cylinder bore diameters at the point a, approx.
0.79 in. (20 mm) below the crest of the liner, and at the
points b and c at equal intervals.
Obtain the distortion of the cylinder (the roundness and
cylindricity of each cylinder) from the following measured
values :
• Roundness :
Difference between the max. and min. bore values on
the same cross section of each liner.
• Cylindricity :
Difference between the max. and min. bore values in
the same direction of each liner.
Apply honing (honing and boring) if any measured value
exceeds the allowable limit.
Note :
For oversized pistons and piston rings, refer to Section "4-
2-4 Piston and Piston Rings".
Standard Wear limit
Cylinder bore dia.

Roundness of cylinder
Cylindricity of cylinder
4-2-6 4720103
4. ENGINE
3) Honing
(1) Application of honing
Apply honing or boring to the cylinder if it is partially
worn, flawed, or otherwise damaged. If the partial wear,
flaw or other damage is minor, it can be repaired only by
honing with a Flex-Hone. However, if it is not minor,
apply honing after boring. In this case, taking the maxi-
mum wear into consideration, it is important to examine
whether the cylinder can attain perfect roundness after
honing and / or boring, and whether prepared oversized
pistons and piston rings can be used. (For the oversized
pistons and piston rings, refer to Section "4-2-4 Piston
and Piston Rings".)
(2) Procedure for using the Flex-Hone
It is common practice to use the Flex-Hone for honing.
The procedure for using it is described below. Any mate-
rial needs a honing allowance of approx. 0.00004 in. (1 /
1000 mm) for honing with the Flex-Hone.
[1] Items to be prepared
Flex-Hone, power drill, and honing liquid
Flex-Hone Applicable bore dia.
Yanmar code No. [in. (mm)]
129400-92420 2.99 to 3.5 (76 to 89)
[2] Handling procedure

Soak the Flex-Hone in the honing liquid. Insert the Flex-
Hone into the cylinder and move it up and down for about
30 seconds while turning it at a cross hatch angle of about
30 to 40 degrees. Then, extract the Flex-Hone while turn-
ing it.
Notes :
1. Use the Flex-Hone at a speed of 300 to 1200 rpm. Use
of the Flex-Hone at a higher speed may be hazardous.
2. Never insert into or extract from the cylinder the Flex-
Hone, with the power drill stopped.
4-2-7 4720103
4. ENGINE
4) Overhaul of Cylinder (Reference)
4-2-3 Valve Rocker Arm
1) Measuring the Rocker Arm Shaft Outside Diame-

ter and the Rocker Arm Bush Inside Diameter
Oil clearance is the difference between the rocker arm
bush inside diameter measured with a cylinder gauge
and the rocker arm shaft outside diameter measured
with a micrometer. If the oil clearance is near the wear
limit, replace the rocker arm shaft and the rocker arm
with new ones.
Standard Wear limit
Shaft
Intake / outside dia.
Refer to Section "3-2 1)
exhaust
Bush inside Nominal and Allowable Val-
valve rocker
dia. ues".
arm
Oil clearance
4-2-8 4720103
4. ENGINE
2) Checking the Push Rod Bend, Measuring the Tappet

Stem Outside Diameter and Checking the Tappet Con-
tact Surface
Put the push rod on the surface plate to check that there is no
clearance between the push rod and the surface plate. Mea-
sure the tappet stem outside diameter with a micrometer.
Standard Wear limit
Push rod bend

Stem outside
diameter Refer to Section "3-2 1)
Guide hole Nominal and Allowable Val-
Tappet ues".
inside
diameter
Oil clearance
3) Other Inspections
(1) Valve rocker arm shaft spring
Check if the rocker arm shaft spring is free from corro-
sion and wear. If not, replace it with a new one.
(2) Wear of intake/exhaust valve rocker arm and valve cap
Check the intake / exhaust valve rocker arm for the con-
tact surface with the valve cap. If any of them is exces-
sively worn or partially flaked, replace it.
(3) Check the portion where the valve clearance adjust
screw is in contact with the push rod. If the portion is
worn or flaked, replace the push rod or the adjust screw.
4-2-9 4720103
4. ENGINE
4-2-4 Piston and Piston Rings
1) Checking the Piston

(1) Remove carbon deposits from the head and com-
bustion surface of the piston while taking care not to
damage the piston. Check if there are any cracks or
damage.
(2) Check the outer surface and ring grooves of the pis-
ton, and replace it if worn or damaged.
2) Measuring the Piston Outside Diameter

To measure the piston outside diameter, measure the long
diameter of the oval hole in the vertical direction to the
piston pin bush hole at a position which is 0.87 to 0.98 in.
(22 to 25 mm) above from the lower end of the piston.
Standard Wear limit
Piston outside dia.

Minimum clearance Refer to Section "3-2 1) Nominal
between piston and Allowable Values".
and cylinder
3) Shapes of Piston Rings
Top ring
4-2-10 4720103
4. ENGINE
4) Measuring the Ring Groove Width, the Ring Width (B), and the End Gap
To measure the piston ring groove width, first measure the
width (B) of the piston ring. Then, fit the piston ring into
the ring groove after cleaning the groove carefully. Insert a
thickness gauge between the piston ring and the groove
to measure the clearance between them. Obtain the ring
groove width by adding the ring width to the measured
clearance.
To measure the end gap, push the piston ring into the
sleeve using the piston head, insert a thickness gauge
between both ends of the piston ring. If the sleeve is worn,
measure the end gap after pushing the piston ring into the
sleeve to the portion which is less worn (approx. 1.18 in.
(30 mm) from the lower end of the sleeve).
Standard Wear limit
Ring groove
width
Ring width (B)
Top
ring Clearance
between
groove and ring
End gap
Ring groove
width
Ring width (B)
Second Refer to Section "3-2 1) Nominal
ring Clearance and Allowable Values".
between
groove and ring
End gap
Ring groove
width
Ring width (B)
Oil ring Clearance
between
groove and ring
End gap
4-2-11 4720103
4. ENGINE
5) Installation of Piston Rings

(1) Using a piston ring replacer, fit the piston ring into
the ring groove, with the manufacturer's mark near
the end of the piston ring facing upward (to the com-
bustion chamber side). After fitting the piston ring,
check that the piston ring moves smoothly.
(2) After fitting all the piston rings, shift the end gaps of
them at 120 degrees intervals, so that they are not
aligned along the piston. Apply lubricating oil to the
piston pin before inserting it into the piston.
6) Measuring the Outside Diameter and Bush Hole

Inside Diameter of the Piston Pin
Measure the outside diameter and bush hole inside
diameter of the piston pin. Replace the piston pin if one
or both of the measured values exceed the wear limit.
Apply lubricating oil to the piston pin before inserting it
into the piston.
Standard Wear limit
Outside dia.
Piston Bush hole Refer to Section "3-2 1) Nomi-
pin inside dia. nal and Allowable Values".
Oil clearance
4-2-12 4720103
4. ENGINE
7) Top Clearance (Reference)
Top clearance
8) Oversized Piston and Piston Ring
(0.250S : Oversized by 0.0098 in. (0.25 mm))
Piston assembly code

Size classification Piston ring assembly code
(including piston ring assembly)
0.250S 119813-22900 129003-22950
4-2-5 Connecting Rod
1) Visual Inspection
Inspect the following portions for cracks, distortion and discoloration :
(1) Portions close to the boundaries between the chamfered parts of the large and small ends, and the I-beam sec-
tion of the connecting rod
(2) Portion around the oil hole in the bush at the small end
2) Measuring the Twist and Parallelism

Measure the twist and parallelism of the connecting rod with a connecting rod aligner.
Twist and parallelism
4-2-13 4720103
4. ENGINE
3) Measuring the Clearance Between the Crank Pin and Bush

To measure the oil clearance between the crank pin and
the crank pin metal, measure the inside diameter of the
crank pin metal and the outside diameter of the crank
pin, and calculate the difference between them.
If the measured oil clearance exceeds or near the wear
limit, replace the crank pin metal. If the crank pin is
excessively or partially worn, grind the crank pin, and
use an oversized crank pin metal.
Note :
To measure the inside diameter of the crank pin metal,
install the metal into the large end of the connecting rod
and tighten the rod bolts at a specified tightening torque,
making sure that each half of the metal is set in the cor-
rect way.
Rod bolt tightening torque Refer to Section "3-7-2
(Apply lubricating oil to Engine Tightening torque for
the rod bolt) major bolts and nuts".
Standard Wear limit
Crank
pin metal
inside dia.
Crank
Crank pin metal Refer to Section "3-2 1) Nomi-
pin side thickness nal and Allowable Values".
Crank
pin outside
dia.
Oil clearance
4) Measuring the Oil Clearance Between the Piston

Pin Bush and the Piston Pin
To measure the oil clearance between the piston pin
bush and the piston pin, measure the inside diameter of
the piston pin bush and the outside diameter of the pis-
ton pin, and calculate the difference between them.
Standard Wear limit
Bush
inside dia.
Piston Refer to Section "3-2 1) Nomi-
Piston pin
pin side. nal and Allowable Values".
outside dia
Oil clearance
4-2-14 4720103
4. ENGINE
5) Checking the Contact of the Crank Pin Metal

Apply a blue ink or a minium to the inside surface of the
crank pin metal. Instal the crank pin metal to the crank
shaft, and tighten the rod bolts at a specified tightening
torque (refer to the above 3 of this section) to check the
contact of the metal. If the contacted surface of the metal
occupies 75 % or more of the total surface, the crank pin
metal is good in terms of contact.
6) Installing the Piston and the Connecting Rod

Install the piston with the connecting rod, with the marks
at the large end of the connecting rod facing the fuel
injection pump. Also, install the piston so that the recess
of the combustion chamber is on the fuel injection pump
side as seen from the top.
7) Side Gap of the Connecting Rod

After installing the connecting rod to the crank shaft,
tighten the rod bolts at a specified tightening torque
(refer to the above 3 of this section). Measure the side
gap by inserting a thickness gauge between the con-
necting rod and the crank arm. If the measured value
exceeds the wear limit, replace the crank pin metal or
the connecting rod.
Side gap Nominal and Allowable Val-
ues".
8) Undersized Crank Pin Metal

Undersized by 0.0098 in. (0.25 mm)
Crank pin metal
Metal thickness in. (mm)
Part code No.
Standard
119810-23350 0.064 (1.625)
4-2-15 4720103
4. ENGINE
4-2-6 Cam shaft
1) Side Gap Around the Cam Shaft

Before extracting the cam shaft, contact a dial gauge
with the cam shaft gear to measure the side gap around
the cam shaft. If the measured value exceeds the wear
limit, replace the thrust metal with a new one.
ues".
2) Checking the Cam Shaft Appearance

Check the cam shaft for the contact surface of the cam
with the tappet, seizure and wear of the bearing, and
damage of the cam gear.
3) Measuring the Bend of the Cam Shaft

Support the cam shaft with V-blocks. Using a dial gauge,
measure the runout of the journal at the center of the
cam shaft while rotating the cam shaft.
Take 50 % of the measured runout as bend.
Standard Wear limit

Cam shaft bend
4) Measuring the Intake / Exhaust Cam Height
Standard Wear limit
Intake
Cam cam Refer to Section "3-2 1) Nominal and
height Exhaust Allowable Values".
cam
4-2-16 4720103
4. ENGINE
5) Measuring the Outside Diameters of the Cam Shaft

Measure the outside diameters of the cam shaft with a
micrometer. Calculate the oil clearance from the mea-
sured cam shaft outside diameter and the cam shaft
bush inside diameter measured with a cylinder gauge
after inserting the cam shaft bush into the cylinder block.
Standard Wear limit
Cam shaft
Gear outside dia.
side Oil
clearance
Cam shaft
Inter- outside dia. Refer to Section "3-2 1) Nominal and
medi-
Oil Allowable Values".
ate
clearance
Cam shaft
Fly- outside dia.
wheel
side Oil
clearance
6) Extracting the Cam Shaft Bush

Extract the bush with a cam shaft bush tool.
4-2-7 Crank shaft
1) Side Gap Around the Crank Shaft

Before extracting the crank shaft and when installing it,
contact a dial gauge with the end of the crank shaft.
Press the crank shaft to each of the right and left sides in
the axial direction to measure the side gap. Alternatively,
insert a thickness gauge directly into the clearance
between the thrust metal in the reference part and the
thrust face of crank shaft to measure the side gap. If the
measured value exceeds the wear limit, replace the
thrust metal with a new one.
ues".
4-2-17 4720103
4. ENGINE
2) Color Check of Crank Shaft

Clean the crank shaft and check it using a color check kit
or a magnetic inspector. Replace the crank shaft if it is
cracked or badly damaged. If the damage is minor, cor-
rect it by re-grinding.
3) Checking the Metals

Check the metals for flaking, melting, seizure, and the
state of the contact spur face. Replace any of the metals
if it is damaged.
4) Bend of the Crank Shaft

Support the journals of the crank shaft with V-blocks at
both ends. Measure the runout at the center journal with
a dial gauge while rotating the crank shaft to check the
bend of the crank shaft.
Bend Nominal and Allowable Val-
ues".
5) Measuring the of Crank Pin and Journal

Measure the outside diameters, roundness, taper angles
of the crank pin and journal. If the partial wear or the
roundness exceeds the wear limit but the measured out-
side diameter is within the limit, correct it by regrinding.
Replace the crank shaft with a new one, if it is unrepara-
ble. An under sized crank pin metal by 0.0098 in. (0.25
mm) is available. (Refer to Section 4-2-5, 4-2-8 in this
chapter.)
4-2-18 4720103
4. ENGINE
Standard Wear limit
Crank Crank pin

pin outside dia.
Outside
dia. Refer to Section "3-2 1) Nominal and
Crank Main metal Allowable Values".
journal thickness
Oil
clearance
6) Precautions for Installation of the Metal Caps

(1) The lower half of the metal on the cap side has no oil groove.
(2) The upper half of the metal on the cylinder block side has an oil groove.
(3) Check the cylinder block alignment No.
(4) Place the embossed mark "FW" of the cap on the flywheel side.
(5) Place the main metal as a reference one on the flywheel side.
7) Undersized Main Metal by 0.0098 in. (0.25 mm) and Oversized Thrust Metal by 0.0098 in. (0.25 mm)
Main metal Thrust metal
Metal thickness Metal thickness
Part code No. in. (mm) Part code No. in. (mm)
Standard Standard
119810-02870 0.084 (2.125) 119810-02940 0.084 (2.125)
4-2-19 4720103
4. ENGINE
4-2-8 Gears
1) Checking the Gears

Check the teeth surfaces of each gear and replace the gear if the teeth are damaged, worn, or flaked.
2) Measuring the Backlashes

Apply a dial gauge onto the pitch circle of the gear, and measure the backlash.
Standard Wear limit
Crank gear,
cam gear, idle
gear and fuel Refer to Section "3-2 1)
Backlash injection pump Nominal and Allowable Val-
drive gear ues".
Lubricating oil
pump gear
3) Checking and Measuring the Idle Gear Shaft and the Idle Gear
(1) Measure the idle gear bush inside diameter and the
idle gear shaft outside diameter, and replace the
bush or the idle gear shaft if the oil clearance
exceeds the wear limit.
(2) Check that the oil holes in the idle gear shaft and the
bush are aligned.
Standard Wear limit
Shaft
outside dia.
Refer to Section "3-2 1) Nomi-
Idle gear Bush
nal and Allowable Values".
inside dia.
Oil clearance
4-2-20 4720103
4. ENGINE
4) Gear Train
After installing all the gears, check that the matchmarkes A, B and C on the idle gear are aligned with those on the
crank gear the fuel injection pump drive gear and the cam gear respectively.
4-2-9 Trochoid Pump
1) Clearance Between Outer Rotor and Pump Body

Insert a thickness gauge between the outer rotor and the
pump body to measure the clearance.
Standard Wear limit
Clearance between
outer rotor and
pump body
4-2-21 4720103
4. ENGINE
2) Clearance Between Outer Rotor and Inner Rotor

Insert a thickness gauge between the top of the inner
rotor tooth and the top of the outer rotor tooth to mea-
sure the clearance.
Standard Wear limit
Clearance between
outer rotor and
inner rotor
3) Distortion Between Pump Body and Inner Rotor,

Outer Rotor
Place a straight edge on the end face of the pump body
and insert a thickness gauge between the straight edge
and the rotors to measure the distortion.
Standard Wear limit
Distortion between
the pump body and Refer to Section "3-2 1) Nominal and
the inner and outer Allowable Values".
rotors
4) Clearance Between Rotor Shaft and Side Cover

Shaft Hole
Measure the rotor shaft outside diameter and the side
cover shaft hole diameter, and calculate the difference
between the hole diameter and the outside diameter.
Standard Wear limit
Clearance between
Refer to Section "3-2 1) Nominal and
rotor shaft and
Allowable Values".
side cover shaft hole
5) Others
(1) Check for looseness of the engagement of the drive
gear and the rotor shaft, and replace the entire assembly if there is looseness or play.
(2) Push the oil pressure regulating valve piston from the drill hole side to check if the piston returns normally.
Replace the entire assembly if the piston does not return due to the broken spring or any other trouble.
(3) Check that the rotor shaft rotates smoothly when the drive gear is rotated.
4-2-22 4720103
4. ENGINE
4-3 Precautions for Reassembly
Reassemble the engine components in the reverse order of the disassembly procedure. Follow the precautions
below particularly before and during the reassembly.
1) Cleaning the Components

Clean the cylinder block, the cylinder head, the crank shaft, and the cam shaft carefully so that they are free from
chips, dust, sand, and other foreign matter.
2) Parts to be Replaced in Reassembly

Be sure to replace the following parts with new ones in reassembly.
(1) Valve stem seal
(2) Head gasket packing
(3) Nozzle protector of the fuel injection valve
(4) All of the copper packings, O-rings and gasket packings.
3) Measuring the Side Gap Around the Crank Shaft

Apply a dial gauge to the end of the crank shaft. Press the
crank shaft to each of the right and left sides in the axial
direction to measure the side gap. Alternatively, insert a
thickness gauge directly into the clearance between the ref-
erence thrust metal and the thrust surface of the crank shaft
to measure the side gap. If the measured value exceeds the
wear limit, replace the thrust metal with a new one.
Refer to Section "3-2 1) Nom-
Side gap
inal and Allowable Values".
4) Gear Train
After installing all the gears, check
that the match marks A, B and C on
the idle gear are aligned with those
on the crank gear, the fuel injection
pump drive gear and camshaft
gear respectively, as shown below.
4-3-1 4720103
4. ENGINE
5) Where to Use Liquid Packing

(1) Between the cylinder block and the gear case flange
(2) Between the gear case flange and the gear case cover
(3) Oil pan mounting surface
Notes :
1. Use Three Bond No. 005 (Yanmar part code : 97777-001212) as the liquid packing.
2. Apply the liquid packing so that there should no break halfway. Otherwise, oil leakage or other trouble may be
caused.
6) Applying Lubricating Oil to the Intake / Exhaust

Valve Stem
Apply lubricating oil to the valve stem so that the oil
spreads over the lower surface (hatched portion in the fig-
ure) of the valve guide, before reinstalling the valve stem.
7) Reinstalling the Piston Rings

(1) Fit the piston ring into the ring groove, with the manu-
facturer's mark near the end of the piston ring facing
upward (to the combustion chamber side), using a
piston ring replacer. After fitting the piston ring, check
that it moves smoothly.
(2) Install the piston their end gaps rings into their
respective ring grooves so that their end gaps are
shifted at 120 degrees intervals, making sure that
they are not aligned along the piston. Apply lubricat-
ing oil to the outside surface of the piston.
4-3-2 4720103
4. ENGINE
8) Applying Lubricating Oil to the Push Rod Adjust Screw Contact Portion
Apply lubricating oil to the hatched portion of the push rod as shown in the figure, before reassembly.
9) Installation Direction of the Piston and the Connecting Rod
Piston
Connecting
rod
10) Tightening Order and Tightening Torque of the Cylinder Head Bolts
Tighten the cylinder head bolts at a specified tightening torque in the numerical order as shown below.
Refer to Section "3-7-2

Tightening torque Engine Tightening torque for
major bolts and nuts".
11) After Completing the Reassembly, Carry Out a Verification Run of the Engine to Check That There is No
Water or Oil Leakage.
4-3-3 4720103
4. ENGINE
4-4 Fuel Injection System
4-4-1 Fuel Injection Pump
The fuel injection pump is a Yanmar YPES Bosch type. It

is an integrated inline pump equipped with a built-in gov-
ernor.
The cam shaft has a fuel feed pump drive cam and a
tappet drive cam for the plunger. A drive gear is mounted
on the drive side of the cam shaft, and a governor weight
is installed on the opposite side.
As the plunger rises, the fuel opens the delivery valve
and goes through the high pressure pipe to the fuel
injection valve.
When the control rack connected to the governor lever
moves, the pinion rotates the plunger. This changes the
positions of the plunger notch and the fuel hole, and in
turn controls the fuel injection quantity.
Note :
Pumps are numbered from No.1, No.2, No.3 ···from the
governor side to match them with the numbers of the cyl-
inders.
4-4-1 4720103
4. ENGINE
4-4-2 Fuel Injection Valve
1) ViO27-2
Applicable Model 3TNE78A-EBV
Nozzle type EB
Valve seat type 150P214HAO
Fuel injection pressure PSI (Mpa) 2844 (19.6)
Diameter nozzle hole ! number of nozzle holes in. (mm) ! pcs. 0.008 (0.21) ! 4
Part code number (Assembly) 719810-53100
2) ViO35-2
Applicable Model 3TNE82A-EBVB
Nozzle type DM
Valve seat type 150P224TGO
Fuel injection pressure PSI (Mpa) 2844 (19.6)
Diameter nozzle hole ! number of nozzle holes in. (mm) ! pcs. 0.009 (0.22) ! 4
Part code number (Assembly) 729609-53200
No. Part
1 Nozzle holder
2 Shim
3 Nozzle spring
4 Nozzle spring seat
5 Positioning pin
6 Valve stop spacer
7 Nozzle
8 Nozzle case nut
4-4-2 4720103
4. ENGINE
4-4-3 Governor Mechanism
The governor is a mechanical all speed type and installed in the YPES-CL type of fuel injection pump. For the struc-
ture of the governor works in the lower part of the tension lever with the centrifugal force of the governor weight
transmitted through the sleeve. An excess fuel spring for increasing the fuel injection quantity at the starting of the
engine is installed at the bottom end of the tension lever. The tension lever, which is supported by the bearing for the
governor lever shaft, has free vibration.
One end of the governor spring is hung to the upper right end of the tension lever, and the other end of the governor
spring is hung to the spring lever of the control lever shaft.
A governor lever, which can be rotated smoothly, is installed on the governor lever shaft. The bottom end of the gov-
ernor lever contacts with the shifter contacting with the sleeve and also contacts with the excess fuel spring contact-
ing with the lower part of the tension lever, and therefore, the governor lever vibrates in synchronism with the
vibration of the tension lever as the revolution of the pump increases or decreases.
The top end of the governor lever is connected to the control rack of the fuel injection pump via the governor link.
4-4-3 4720103
4. ENGINE
1) Adjusting the Maximum Idling Speed

(1) Set the governor control lever to the fuel increase position
end.
(2) Adjust the tightening volume of the maximum speed adjust-
ing bolt.
Increase the idling speed. Check that the maximum idling
speed is within the specified range.
Maximum idling speed
ViO27-2 Refer to Section
ViO35-2 "2-1 Specifications".
Note :
Adjustment after mounting the engine to the machine:
Refer to Section "7-3-10 Adjustment of Accelerator Lever".
2) Adjusting the Minimum Idling Speed

(Adjusting the Idling)
(1) Measure the idling speed while lowering the governor con-
trol lever to the idling position and adjust the position of the
control lever to the position where the specified minimum
idling speed is attained, with the idling adjusting bolt.
Maximum idling speed
ViO27-2 Refer to Section
ViO35-2 "2-1 Specifications".
Note :
Adjustment after mounting the engine to the machine:
Refer to Section "7-3-10 Adjustment of Accelerator Lever".
4-4-4 4720103
4. ENGINE
4-4-4 Specifications of Fuel Injection Pump
Applicable model
3TNE78A-EBV 3TNE82A-EBVB
(ViO27-2) (ViO35-2)
Item
(1)+(2)+(3) 719818-51460 719824-51480

Fuel injection pump assembly
code number
(1)+(2)+(3)+(4) - -
Assembly code number 119808-51001 129139-51001
Part code number 129108-51100 129108-51100
Plunger diameter Dp in. (mm) Ø0.30 (Ø7.5) Ø0.30 (Ø7.5)

Plunger barrel
assembly
Lead angle degrees 30 30
Fuel injection pump
Identification mark M-4 M-4

(1)
Part code number 129505-51300 129450-51300
cu. in. / St
Suck back volume QR 0.0014 (23.6) 0.0014 (23.6)
Delivery valve (cu. mm / St)
assembly
Angleich cut in. (mm) 0.006 (0.15) 0.0075 (0.19)
Identification mark T R
Cam shaft Part code number 119810-51040 119810-51040
Assembly code number 129423-61000 129423-61000
Governor weight Part code number 129486-61201 129486-61201
Part code number 129489-61700 129489-61700
lbs. / in.
Governor spring Spring constant 12.88 (0.23) 12.88 (0.23)
(kg / mm)
Item
Governor
Free length in. (mm) 1.54 (39.0) 1.54 (39.0)

(2)
Tension lever shape
in. (mm) 2.64 (67) 2.64 (67)
(Length between the supporting points)
Type Angleich Angleich

Torque rise device
Part code number 171353-61550 171353-61550
Built-in solenoid Built-in solenoid

Engine stop device
(119233-77931) (119233-77931)
Assembly code number

(3) Fuel feed pump
Type Magnetic type Magnetic type
4-4-5 4720103
4. ENGINE
4-5 Electrical Equipment
4-5-1 Starter Motor

To start the engine, the starter motor rotates the ring gear installed on the engine flywheel with the pinion gear
engaged with the ring gear so that the force generated by the rotation exceeds the resistance including the engine
compression pressure and all frictional force. The starter motor consists of the following major parts : a motor which
generates torque ; a pinion which transmits the torque to the engine ring gear ; a clutch ; and a magnetic switch
which pushes out the pinion and turns on and off the principal current.
1) Specifications and Service Data

Yanmar code 129698-77010
3TNE78A-EBV
Applicable model
3TNE82A-EBVB
Starter motor model S114-815
Nominal output kW 1.2 / 3.0
Rotation direction
Clockwise
(viewed from pinion side)
Engagement method Magnetic shift
Terminal voltage / Current V/A 11 / !90
No load
Speed rpm "2750
Terminal voltage / Current V/A 8.4 / 250
Load
characteris- ft•lbf
"52.08 (70.6)
tics Torque / speed (N•m)
/ "1200
/ rpm
Overrunning
Clutch type
clutch
Pinion coming out voltage V !8
Pinion DP or module
DP10/12
/ Number of pinion teeth
Standard spring force lbs. (kg) 35.7 (16.2)
Brush Standard height 0.61 (15.5)
in. (mm)
/ Wear limit / 0.37(9.5)
Magnetic
switch
Series coil / Shunt coil Ω 0.37 / 0.62
resistance at
68 °F (20 °C)
Outside Standard Ø1.14(29)
diameter / Wear limit / Ø1.10(28)
Differ-
ence
Correction limit 0.00197 (0.05)
Commutator between in. (mm)
/ Precision / 0.00039 (0.01)
max. and
min. dia.
Mica Correction limit 0.00787(0.2) / 0.02
undercut / Precision to 0.03 (0.5 to 0.8)
0.47027 to 0.47138
Brush Shaft diameter
(11.945 to 11.973) /
side / Bearing inside
0.47244 to 0.47350
bearing diameter
(12.0 to 12.027)
Interme- Shaft diameter
diate / Bearing inside -
bearing diameter
Standard
in. (mm) 0.48976 to 0.49031
diameters Pinion Shaft diameter
(12.44 to 12.454) /
sliding / Bearing inside
0.47362 to 0.47441
section diameter
(12.03 to 12.05)
0.48976 to 0.49031
Pinion Shaft diameter
(12.44 to 12.454) /
side / Bearing inside
0.49213 to 0.49319
bearing diameter
(12.5 to 12.527)
L dimension (Gap between pinion 0.01 to 0.1
in. (mm)
and pinion stopper) (0.3 to 2.5)
4-5-1 4720103
4. ENGINE
2) Construction of Starter Motor

No. Part No. Part
1 Armature 9 Pinion shaft
2 Yoke 10 Planetary gear
3 Brush holder 11 Washer stopper
4 Rear cover 12 Gear case
5 Center housing (P) 13 Shift lever
6 Internal gear 14 Magnetic switch
7 Center housing (A) 15 Dust cover
8 Pinion
4-5-2 4720103
4. ENGINE
4-5-2 Alternator
The alternator is a revolving-field type three-phase AC generator. The AC electricity generated by the alternator is
converted to DC through the full-wave rectification by the diode and is stored in the battery.
The alternator contains a regulator using an IC and can detect the battery voltage to adjust the generated voltage in
the alternator.
Specification
Nominal output voltage
V/A 12 / 40
(Full-wave rectification)
Alternator model LR140-721B
Yanmar code 119836-77201
Working speed rpm 1000-18000
Working speed rpm 18000
Nominal output current A/V 40 / 12 (5000 rpm)
Working ambient temperature °F (°C) -22 to 212 (-30 to 100)
Pulley diameter / V-belt size in. (mm) Ø2.9 (74) / A39
Ground polarity Negative
3TNE82A-EBVB
Applicable models
3TNE78A-EBV
No. Part
1 Rotor
2 Ball bearing
3 Rear bracket assembly
4 Front bracket
5 Pulley
6 Screw
4-5-3 4720103
4. ENGINE
4-5-3 Air Heater
The air heater installed on the intake manifold is a starting aid in cold weather, which serves to warm the air and
send it to the combustion chamber to start the engine easily at low ambient temperature.
The air heater is operated to warm the sucked air by setting the starter switch key to "AIR HEATER" position and
supplying electricity for about 10 to 15 seconds.
If electricity is supplied to the air heater for more than 15 seconds, this will cause breaking of the heater lead or bat-
tery trouble.
Specifications
Rated output 400 W
Rated current 33.3 A
Rated voltage DC12 V
Rated operating time 30 sec. max.
Ground polarity Negative
4-5-4 4720103
CHAPTER 5
HYDRAULIC SYSTEM
5-1 Outline ................................................................................................. 5-1-1

5-1-1 Control Valve Operation............................................................. 5-1-4
5-1-2 Additional Operation of Control Valve........................................ 5-1-6
5-2 Hydraulic Circuit Schematic................................................................. 5-2-1
5-2-1 Quick Coupler ............................................................................ 5-2-1
5-2-2 W/O Quick Coupler .................................................................... 5-2-3
5-3 Circuit Operation.................................................................................. 5-3-1
5-3-1 Boom.......................................................................................... 5-3-1
5-3-2 Arm ............................................................................................ 5-3-3
5-3-3 Bucket ........................................................................................ 5-3-5
5-3-4 Swing ......................................................................................... 5-3-7
5-3-5 Boom Swing............................................................................... 5-3-9
5-3-6 Blade........................................................................................ 5-3-11
5-3-7 Travel ....................................................................................... 5-3-13
5-3-8 Non-Deviation Travel
(with Boom, Arm, Bucket or Boom Swing Operation).............. 5-3-15
5-3-9 Simultaneous Operation of Boom Up and Arm Retract ........... 5-3-17
5-3-10 Simultaneous Operation of Boom Up and Bucket ................. 5-3-19
5-3-11 Simultaneous Operation of Arm and Bucket.......................... 5-3-21
5-3-12 Simultaneous Operation of Boom Up and Swing................... 5-3-23
5-3-13 Hydraulic P.T.O...................................................................... 5-3-25
5-3-14 Quick Coupler ........................................................................ 5-3-27
5-4 Pressure Adjustment ........................................................................... 5-4-1
5-4-1 Relief Valves .............................................................................. 5-4-1
5-4-2 Swing Brake Valve..................................................................... 5-4-3
5-4-3 Cut-Off Valve ............................................................................. 5-4-4
5. HYDRAULIC SYSTEM
5. Hydraulic System
5-1 Outline
The hydraulic system consists of an engine, variable displacement piston pumps, a gear pump, a control valve, a
boom cylinder, an arm cylinder, a bucket cylinder, a boom swing cylinder, a blade cylinder, a swing motor, a swivel
joint, two travel motors, 2 way valve and a hydraulic oil tank. The oil discharged from the variable displacement pis-
ton pumps and that from the gear pump flow to the actuators through the control valve.
The hydraulic pilot control system comprises a pilot pump, a cut-off valve mounted on the hydraulic pump and two
pilot valves. The oil discharged from the pilot pump flows into the pilot ports of the control valve through the cut-off
valve, the pilot valves and the 2 way valve to control the valve spool movement in proportion to the pressure at the
port.
5-1-1 4720103
5. HYDRAULIC SYSTEM
1) Hydraulic Pump
The variable displacement piston pumps, the gear pump
and the pilot pump are linked to the flywheel of the
engine through the coupling. The number of revolutions
of each hydraulic pump is identical to the engine speed.
Discharge volume of each pump

cu. in. (cu. cm) / rev
No. Pump ViO27-2 ViO35-2
Piston
1 P1 0.79 (13.0) 0.95 (15.5)
pump
Piston
2 P2 0.79 (13.0) 0.95 (15.5)
pump
3 Gear pump P3 0.49 (8.1) 0.58 (9.5)
4 Pilot pump P4 0.30 (4.9) 0.27 (4.5)
2) Oil Flow
(1) Piston pumps P1 and P2, and gear pump P3
The pumps take in oil through the suction filter from the
hydraulic oil tank and discharge it. The discharged oil
flows to the ports P1, P2 and P3 of the control valve and
returns from the ports T1 and T2 to the hydraulic oil tank
through the oil cooler and the return filter. This circula-
tion is repeated.
(2) Pilot pump P4
When the lock lever is set to the "UNLOCK" position, the
oil from the pilot pump P4 flows back to the hydraulic oil
tank through the ports B1 and B2 of the cut-off valve
integrated into the pump, the pilot valves and the return
filter.
The bypass valve in the return filter opens at a differen-

tial pressure of 21.3 PSI (0.147 MPa).
5-1-2 4720103
5. HYDRAULIC SYSTEM
5-1-3 4720103
5. HYDRAULIC SYSTEM
5-1-1 Control Valve Operation
1) Oil Flow from Hydraulic Pump

(1) Piston pump P1
The oil from the piston pump P1 is fed to the left travel
motor, the boom swing and arm cylinders and the P.T.O.
through the port P2 of the inlet section, the travel (L),
boom swing, arm and P.T.O. sections.
(2) Piston pump P2

The oil from the piston pump P2 is fed to the right travel
motor and the boom and bucket cylinders through the
port P1 of the inlet section, the travel (R), boom and
bucket sections.
(3) Gear pump P3

The oil from the gear pump P3 flows through the port P3
of the parallel-flow divider to the blade and swing sec-
tions, and also to the arm and P.T.O. sections to be com-
bined with the oil from the piston pump P1.
2) Simultaneous Operation of Boom and Bucket

The parallel passage to the bucket section has a throttle
to allow the oil to flow to the boom section more
smoothly than to the bucket section even when the
boom is given a heavy load, so that the boom and the
bucket can be operated simultaneously.
3) Anti-Drift Valve (Reduction of Boom Drifting)

The anti-drift valve is installed in the boom section to
reduce the boom drifting.
4) Track Drive Lock

When the lock lever is set to the "LOCK" position, the
spool of the inlet section is in the neutral position, so that
the oil from the piston pumps P1 and P2 flows back to
the hydraulic oil tank through the return passage. There-
fore, the implement does not operate and the machine
does not travel even when each control lever is oper-
ated.
5-1-4 4720103
5. HYDRAULIC SYSTEM
5-1-5 4720103
5. HYDRAULIC SYSTEM
5-1-2 Additional Operation of Control Valve
5-1-6 4720103
5. HYDRAULIC SYSTEM
5-2 Hydraulic Circuit Schematic
5-2-1 Quick Coupler
Applicable model : ViO27-2
5-2-1 4630010
5. HYDRAULIC SYSTEM
5-2-2 4630010
5. HYDRAULIC SYSTEM
5-2-2 W/O Quick Coupler
5-2-3 4630010
5. HYDRAULIC SYSTEM
5-2-4 4630010
5. HYDRAULIC SYSTEM
5-3 Circuit Operation
5-3-1 Boom
1) Boom “Up”
(1) Pilot oil flow
When the boom control lever is pulled back to raise the
boom, the oil from the pilot pump P4 flows through the
cut-off valve and the port 1 of the pilot valve (RH) to the
port a8' of the parallel-flow divider and the port a8 of the
boom section to move their spools.
(2) Oil flow from hydraulic pump

The oil discharged from the piston pump P2 flows to the
boom section through the port P1 of the inlet section,
while the oil discharged from the gear pump P3 flows to
the boom section through the port P3 of the parallel-flow
divider and the parallel passage, and combines with the
oil from the piston pump P2. Then the combined oil
opens the check valve of the anti-drift valve in the boom
section and flows through the port A9 to BU of the boom
cylinder to extend its cylinder rod, raising the boom. The
return oil from BD of the boom cylinder flows back to the
hydraulic oil tank through the port B8 of the boom sec-
tion, the ports T1 and T2 of the control valve and the oil
cooler.
2) Boom "Down"
(1) Pilot oil flow
When the boom control lever is pushed forward to lower
the boom, the oil from the pilot pump P4 flows to the pis-
ton of the anti-drift valve through the cut-off valve, the
port 3 of the pilot valve (RH) and the port b8' of the anti-
drift valve to open the check valve. The pilot oil also
flows to the port b8 of the boom section to move its
spool.

The oil discharged from the piston pump P2 flows
through the port P1 of the inlet section to the boom sec-
tion. In this operation, the oil flows in the opposite direc-
tion to the oil flow in the Boom Up operation with regard
to the boom cylinder.
<OPT> pattern
The boom control lever and the arm control lever
changes mutually operation from standard pattern.
The oil from port 1 of the pilot valve (LH) flows to port C
of the 2 way valve to move the boom section spool in
boom up position.
The oil from port 3 of the pilot valve (LH) flows to port D
of the 2 way valve to move the boom section spool in
boom down position.
5-3-1 4720103
5. HYDRAULIC SYSTEM
5-3-2 4720103
5. HYDRAULIC SYSTEM
5-3-2 Arm
1) Arm “Retract”
(1) Pilot oil flow
When the arm control lever is pulled back to retract the
arm, the oil from the pilot pump P4 flows through the cut-
off valve and the port 1 of the pilot valve (LH) to be
divided into two oil flows. One of them flows to the port
b4' of the parallel-flow divider to move its spool.
The other flows to the port b4 of the arm section to move
its spool.

The oil from the piston pump P1 flows through the port
P2 of the inlet section to the arm section. The oil from
the gear pump P3 flows through the port P3 of the paral-
lel-flow divider and the parallel passage to the arm sec-
tion and combines with the oil from the port P2. The
combined oil flows through the port B4 of the control
valve to AI of the arm cylinder to extend its cylinder rod.
The return oil from AO of the arm cylinder flows back to
the hydraulic oil tank through the port A4 of the arm sec-
tion, the ports T1 and T2 of the control valve and the oil
cooler.
2) Arm "Extend"
(1) Pilot oil flow
When the arm control lever is pushed forward to extend
the arm, the oil from the pilot pump P4 flows through the
cut-off valve and the port 3 of the pilot valve (LH) to the
port a4 of the arm section to move its spool.

tion and combines with the oil from the port P2. The
combined oil flows in the opposite direction to the oil flow
in the arm retract operation with regard to the arm cylin-
der.
<OPT> pattern
The boom control lever and the arm control lever
changes mutually operation from standard pattern.
The oil from port 1 of the pilot valve (RH) flows to port B
of the 2 way valve to move the arm section spool in arm
retract position.
The oil from port 3 of the pilot valve (RH) flows to port A
of the 2 way valve to move the arm section spool in arm
extend position.
5-3-3 4720103
5. HYDRAULIC SYSTEM
5-3-4 4720103
5. HYDRAULIC SYSTEM
5-3-3 Bucket
1) Bucket “Curl”
(1) Pilot oil flow
When the bucket control lever is moved to the left to curl
the bucket, the oil from the pilot pump P4 flows through
the cut-off valve and the port 2 of the pilot valve (RH) to
the port a10 of the bucket section to move its spool.

P1 of the inlet section and the port A10 of the bucket
section to BKI of the bucket cylinder to extend its cylin-
der rod.
The return oil from BKO of the bucket cylinder flows
back to the hydraulic oil tank through the port B10 of the
bucket section, the ports T1 and T2 of the control valve
and the oil cooler.
2) Bucket "Dump"
(1) Pilot oil flow
When the bucket control lever is moved to the right to
dump the bucket, the oil from the pilot pump P4 flows
through the cut-off valve and the port 4 of the pilot valve
(RH) to the port b10 of the bucket section to move its
spool.

In this operation, the oil flows in the opposite direction to
the oil flow in the bucket curl operation with regard to the
bucket cylinder.
5-3-5 4720103
5. HYDRAULIC SYSTEM
5-3-6 4720103
5. HYDRAULIC SYSTEM
5-3-4 Swing
1) Right Swing
(1) Pilot oil flow
When the swing control lever is moved to the right, the
oil from the pilot pump P4 flows through the cut-off valve
and the port 4 of the pilot valve (LH) to the port a2 of the
swing section to move its spool.

of the parallel-flow divider, the parallel passage and the
port A2 of the swing section to the port A1 of the brake
valve, so that the swing motor can be rotated.
The return oil from the swing motor flows back to the
hydraulic oil tank through the port B1 of the brake valve,
the port B2 of the swing section, the ports T1 and T2 of
the control valve and the oil cooler.
2) Left Swing
(1) Pilot oil flow
When the swing control lever is moved to the left, the oil
from the pilot pump P4 flows through the cut-off valve
and the port 2 of the pilot valve (LH) to the port b2 of the
swing section to move its spool.

The oil flows in the opposite direction to the oil flow in the
right swing operation with regard to the swing motor.
3) Release and Operation of Swing Motor Mechani-

cal Brake
When the engine is started, the oil from the pilot pump
P4 flows to the port PB of the swing motor and presses
the piston (with a spring) of the swing motor mechanical
brake to release the brake.
When the engine is stopped, the oil from the pilot pump
P4 does not flow to the swing motor so that the spring
force causes the brake to be applied.
4) Swing Motor Hydraulic Brake Operation

When the swing control lever is released (i. e., returned
to the neutral position), the oil flow to the swing motor is
blocked and the pressures at the ports A1 and B1 of the
brake valve become equal and consequently the brake
is applied. However, the swing motor continues to rotate
in a short time due to its inertia. This causes the motor to
act like a pump and increases the circuit pressure on the
port B2 side. The increased pressure opens the relief
valve SR1 to let the oil on the lower pressure side
escape to the port A2, so that the circuit pressure is
absorbed and cavitation is prevented on the port A2
side.
The port M of the swing motor has the drain function and
a circuit which directly takes in the return oil flowing from
the port T1 to the hydraulic oil tank to prevent negative
pressure in the swing motor.
5-3-7 4720103
5. HYDRAULIC SYSTEM
5-3-8 4720103
5. HYDRAULIC SYSTEM
5-3-5 Boom Swing
The boom swing pedal is linked to the spool of the con-

trol valve through an L-ball and a rod.
1) Right Boom Swing

Oil Flow from Hydraulic Pump
When the boom swing pedal is moved on the right, the
spool is pressed forward. The oil from the piston pump
P1 flows through the port P2 of the inlet section and the
port B5 of the boom swing section to BSR of the boom
swing cylinder to retract its cylinder rod.
The return oil from BSL of the boom swing cylinder flows
back to the hydraulic oil tank through the port A5 of the
boom swing section, the ports T1 and T2 of the control
valve and the oil cooler.
2) Left Boom Swing

When the boom swing pedal is moved on the left, the
spool is pulled back. The oil flows in the opposite direc-
tion to the oil flow in the right boom swing operation with
regard to the boom swing cylinder.
5-3-9 4720103
5. HYDRAULIC SYSTEM
5-3-10 4720103
5. HYDRAULIC SYSTEM
5-3-6 Blade
The blade lever is linked to the spool of the control valve

through an L-ball and a blade cable.
1) Blade "Down"
When the blade lever is pushed forward to lower the
blade, the spool is pulled back. The oil from the gear
pump P3 flows through the port P3 of the parallel-flow
divider, the parallel passage, the port B1 of the blade
section and the port D of the swivel joint to BLD of the
blade cylinder to extend its cylinder rod, lowering the
blade.
The return oil from BLU of the blade cylinder flows back
to the hydraulic oil tank through the port C of the swivel
joint, the port A1 of the blade section, the ports T1 and
T2 of the control valve and the oil cooler.
2) Blade "Up"
When the blade lever is pulled back to raise the blade,
the spool is pressed forward. The oil flows in the oppo-
site direction to the oil flow in the blade down operation
with regard to the blade cylinder.
3) Circuit Relief Valve Installed in Blade Up Circuit

When the blade is raised while the machine is traveling,
the oil quantity control function of the hydraulic pump
operates to reduce its discharge volume, and the travel
speed is slowed down. To minimize such speed reduc-
tion, a circuit relief valve with the set pressure lower than
that of the system relief valve is installed in the blade cyl-
inder circuit for raising the blade.
5-3-11 4720103
5. HYDRAULIC SYSTEM
5-3-12 4720103
5. HYDRAULIC SYSTEM
5-3-7 Travel
Each travel lever is linked to the spool of the control
valve through an L-ball and a rod.
1) Forward Travel (Right)

When the right travel lever is pushed forward, the spool
of the right travel section is pressed forward.
P1 of the inlet section, the port B7 of the right travel sec-
tion and the port E of the swivel joint to the port P2 of the
right travel motor to rotate it. The return oil from the port
P1 of the right travel motor flows back to the hydraulic oil
tank through the port A of the swivel joint, the port A7 of
the right travel section, the ports T1 and T2 of the control
2) Forward Travel (Left)

P2 of the inlet section, the port B6 of the left travel sec-
tion and the port B of the swivel joint to the port P1 of the
left travel motor to rotate it. The return oil from the port
P2 of the left travel motor flows back to the hydraulic oil
tank through the port F of the swivel joint, the port A6 of
the left travel section, the ports T1 and T2 of the control
3) Reverse Travel (Right and Left)

When the right or left travel lever is pulled back, the
spool of the travel section is pulled back. The oil flows in
the opposite direction to the oil flow in the forward travel
operation with regard to the right or left travel motor.
4) High-Speed Function
When the high-speed pedal is moved, the signal is
transmitted from the safety switch to the solenoid valve
A to increase the travel speed.
(1) Pilot oil flow

When the high-speed pedal is moved, the signal is
transmitted from the safety switch to the cut-off valve
and the solenoid valve A is opened. The oil from the pilot
pump P4 flows through the port PA of the solenoid valve
A to the port G of the swivel joint and is divided into two
flows to ports G and H there to flow to the port PS of
each travel motor.
(2) Increase in output speed of travel motor

The pilot oil from the pilot pump P4 moves the swash
plate control piston to incline the swash plate to its mini-
mum angle, which shortens the piston stroke of the
travel motor and decreases the travel motor capacity to
increase its output speed. This increases the travel
speed.
Meanwhile, the travel driving force weakens as the out-
put torque of the travel motor becomes smaller due to
the shortened piston stroke.
5-3-13 4720103
5. HYDRAULIC SYSTEM
5-3-14 4720103
5. HYDRAULIC SYSTEM
5-3-8 Non-Deviation Travel (with Boom, Arm,

Bucket or Boom Swing Operation)

1) Travel Section
The oil from the piston pump P1 and that from the piston
pump P2 flow through the ports P2 and P1 of the inlet
section to the left and right travel sections, respectively.
The right and left travel sections are each connected in
series in their respective section groups and located the
most upstream in the circuits of the piston pumps P2 and
P1, respectively. Therefore, all of the oil from each pis-
ton pump flows to the travel motor when the travel lever
is operated.
2) Boom Section
The oil from the gear pump P3 flows through the paral-
lel-flow divider and the parallel passage to the boom
section. Therefore, the machine can travel with no devia-
tion even when the boom control lever is moved while
the machine is traveling.
3) Arm Section
The oil from the gear pump P3 flows through the blade
and swing sections, the parallel-flow divider and the par-
allel passage to the arm section. Therefore, the machine
can travel with no deviation even when the arm control
lever is moved while the machine is traveling.
4) Bucket Section
The oil from the gear pump P3 flows back to the hydrau-
lic oil tank through the port P3 of the parallel-flow divider,
the parallel passage and the return passage of the arm
section.
Therefore, the bucket does not operate as no oil is sup-
plied to the bucket section when the bucket control lever
is independently operated while the machine is traveling.
5) Boom Swing Section

All the oil in the circuit of the piston pump P1 is supplied
to the travel section in the most upstream for the pump
P1, and the boom swing section in the downstream is
supplied with no oil. No oil from the gear pump P3 is
supplied to the boom swing section, either, so that the
boom swing does not operate while the machine is trav-
eling.
5-3-15 4720103
5. HYDRAULIC SYSTEM
5-3-16 4720103
5. HYDRAULIC SYSTEM
5-3-9 Simultaneous Operation of Boom Up and

Arm Retract

1) Boom "Up"
The oil from the piston pump P2 flows to the boom sec-
tion through the port P1 of the inlet section. The oil from
section and combines with the oil from the piston pump
P2.
2) Arm "Retract"
The oil from piston pump P1 flows through the port P2 of
the inlet section to the arm section. The oil from the gear
pump P3 flows through the port P3 of the parallel-flow
divider and the parallel passage to the arm section and
combines with the oil from the piston pump P1.
3) Simultaneous Operation of "Boom Up" and "Arm

Retract"
If the arm control lever is pulled back to retract the arm
while the boom control lever is pulled back to raise the
boom, the parallel-flow divider receives the same pilot oil
pressure from the ports a8' and b4' to keep the spool in
the neutral position.
At that time, the oil from the gear pump P3 is combined
with the oil to the arm cylinder prior to the boom cylinder
to increase the speed of the arm retract operation.
Refer to Section "5-3-1 Boom" and Section "5-3-2 Arm"
for the oil flow with regard to the arm and boom cylin-
ders.
5-3-17 4720103
5. HYDRAULIC SYSTEM
5-3-18 4720103
5. HYDRAULIC SYSTEM
5-3-10 Simultaneous Operation of Boom Up

and Bucket

1) Boom "Up"
The oil from the piston pump P2 flows to the boom and
bucket sections through the port P1 of the inlet section.
of the parallel-flow divider and the parallel passage and
combines with the oil from the piston pump P2 before
the boom and bucket sections.
2) Simultaneous Operation of "Boom Up" and "Bucket"

A throttle is installed in the parallel passage to the bucket
section so that the oil can flow more smoothly to the
boom section when the bucket control lever is moved
while the boom with a heavy load is being raised. There-
fore the boom and the bucket can operate simulta-
neously.
Refer to Section "5-3-1 Boom" and Section "5-3-3
Bucket" for the oil flow with regard to the boom and
bucket cylinders.
5-3-19 4720103
5. HYDRAULIC SYSTEM
5-3-20 4720103
5. HYDRAULIC SYSTEM
5-3-11 Simultaneous Operation of Arm and

Bucket

1) "Arm" operation
tion and combines with the oil from the piston pump P1.
2) "Bucket" Operation
P1 of the inlet section to the bucket section.
3) Simultaneous Operation of "Arm" and "Bucket"

When the arm is given a heavy load, the horsepower
control shift of the gear pump P3 works to decrease the
discharge volume of the piston pump P2, so that the
bucket speed slows down. To make up for the bucket
speed reduction, the oil from the gear pump P3 flows
through the throttle of the parallel-flow divider and the
parallel passage to the bucket section and combines
with the oil from the piston pump P2.
Refer to Section "5-3-2 Arm" and Section "5-3-3 Bucket"
for the oil flow with regard to the arm and bucket cylin-
ders.
5-3-21 4720103
5. HYDRAULIC SYSTEM
5-3-22 4720103
5. HYDRAULIC SYSTEM
5-3-12 Simultaneous Operation of Boom Up

and Swing

1) "Boom Up" operation
The oil from the piston pump P2 flows to the boom sec-
tion through the port P1 of the inlet section. The oil from
section and combines with the oil from the piston pump
P2.
2) "Swing" Operation
The oil from the gear pump P3 flows to the swing section
through the port P3 of the parallel-flow divider.
3) Simultaneous Operation of Boom Up and Swing

The oil from the gear pump P3 flows to the port P3 of the
parallel-flow divider and is divided into two oil flows. One
of them flows to the swing section, and the other flows to
the boom section through the parallel passage to com-
bine with the oil from the piston pump P2. Throttles and
a check valve are installed in the swing section so as to
match the swing speed with the boom-up speed.
Refer to Section "5-3-1 Boom" and Section "5-3-4
Swing" for the oil flow with regard to the boom cylinder
and the swing motor.
5-3-23 4720103
5. HYDRAULIC SYSTEM
5-3-24 4720103
5. HYDRAULIC SYSTEM
5-3-13 Hydraulic P.T.O.
The P.T.O. pedal is linked to the spool of the P.T.O. sec-

tion through an L-ball and a rod.
When the lock lever is in the lock position, the P.T.O.
section is not supplied with any oil from the piston pump
P1 but with oil from the gear pump P3 only.

The selector valve is changed so that the single acting or
double acting of the P.T.O. can be selected.
Combined oil / Single acting

If the selector valve is opened and the P.T.O. pedal is
moved on the left side, the oil from the piston pump P1
and that from the piston pump P3 are combined in the
control valve. The combined oil flows from the port A3 of
the control valve to the port A of the P.T.O.
The majority of the return oil form the port B of the
P.T.O. flows through the selector valve and returns to
the hydraulic oil tank through the return filter. The
remaining oil flows through the ports B3 and T of the
control valve and returns to the hydraulic oil tank through
the return filter.
If the P.T.O. pedal is moved on the right side, the oil
from the piston pump P1 and that from the piston pump
P3 flow through the selector valve and directly return to
the hydraulic tank through the return filter. Therefore, no
pressure oil is fed to the P.T.O.
[Example of the P.T.O. : Breaker]

Discharge volume from port A : 13.4 GPM (50.6 L / min)
Combined oil / Double acting

If the selector valve is closed and the P.T.O. pedal is
moved on the left side, the oil from the piston pump P1
and that from the piston pump P3 are combined in the
control valve. The combined oil flows from the port A3 of
the control valve to the port A of the P.T.O.
The return oil from the port B of the P.T.O. flows through
the ports B3 and T of the control valve, and returns to
the hydraulic oil tank through the return filter.
If the P.T.O. pedal is moved on the right side, the oil
from the piston pump P1 and that from the piston pump
P3 are combined in the control valve. The combined oil
flows from the port B3 of the control valve to the port B of
the P.T.O.
The return oil from the port A of the P.T.O. flows through
the ports A3 and T of the control valve, and returns to
the hydraulic oil tank through the return filter.
[Example of the P.T.O. : Tilt bucket]

Discharge volume from port A and port B : 13.4 GPM
(50.6 L / min)
5-3-25 4720103
5. HYDRAULIC SYSTEM
5-3-26 4720103
5. HYDRAULIC SYSTEM
5-3-14 Quick Coupler
Operate the quick coupler by turning the control switch

to the mounting or dismounting position.

1) Control Switch in Mounting Position
The oil from the pilot pump P4 flows through the port C1
(the port C2 for ViO35-2) of the cut-off valve and the
operator check valve to the bottom side of the quick cou-
pler cylinder to extend its cylinder rod.
The return oil flows through the operator check valve
and the port C2 (the port C1 for ViO35-2) of the cut-off
valve to the suction circuit of the pilot pump P4.
2) Control Switch in Dismounting Position

The oil from the pilot pump P4 flows through the port C2
(the port C1 for ViO35-2) of the cut-off valve and opens
the check valve in the operator check valve to flow to the
rod side of the quick coupler cylinder, so that the cylinder
rod is retracted.
The return oil flows through the operator check valve
and the port C1 (the port C2 for ViO35-2) of the cut-off
valve to the suction circuit of the pilot pump P4.
5-3-27 4720103
5. HYDRAULIC SYSTEM
5-3-28 4720103
5. HYDRAULIC SYSTEM
5-4 Pressure Adjustment

5-4-1 Relief Valves
1) Conditions
(1) Engine : rated speed
(2) Hydraulic oil temperature : 122 to 140 °F (50 to 60 °C)
(3) Pressure gauge capacity : 4977.1 PSI (34.3 MPa)
2) Relief Valve Specifications

Set pressure
Valve Pump ViO27-2, ViO35-2
PSI (MPa) GPM (L/min)
R1 Piston pump P2 2986.2 (20.6)
at 7.92 (30)
System relief valve R2 Piston pump P1 2986.2 (20.6)
R3 Gear pump P3 2986.2 (20.6) at 5.02 (19)
Boom (rod end) Piston pump P2 3412.8 (23.5)
Boom (bottom end) Piston pump P2 3697.2 (25.5)
Arm (rod end) Piston pump P1 3697.2 (25.5)
Arm (bottom end) Piston pump P1 3412.8 (23.5) at 1.32 (5)
Circuit relief valve Bucket (rod end) Piston pump P2 3697.2 (25.5)
Bucket (bottom end) Piston pump P2 3697.2 (25.5)
Boom swing (rod end) Piston pump P1 3697.2 (25.5)
Boom swing (bottom end) Piston pump P1  
Blade (rod end) Gear pump P3 1422.0 (9.8) at 1.32 (5)
(1) Remove the floor mat and step 1.
(2) Remove the plugs (PT 1/8) 2 of the hose connectors connecting the pumps to the control valve and install the oil
pressure gauge.
5-4-1 4720103
5. HYDRAULIC SYSTEM
4) Adjustment Procedure
(1) To check the pressure of the system relief valve R1 (for the piston pump P2) of the control valve, retract the
bucket cylinder to its stroke end, hold the lever and read the gauge. Adjust the pressure if necessary.
(2) To check the pressure of the system relief valve R2 (for the piston pump P1), extend the boom swing cylinder to
its stroke end, hold the lever and read the gauge. Adjust the pressure if necessary.
(3) To check the pressure of the system relief valve R3 (for the gear pump P3), extend the blade cylinder to its
stroke end, hold the lever and read the gauge. Adjust the pressure if necessary.
(4) To adjust the pressure of each circuit relief valve, extend or retract the cylinder to its stroke end, hold the lever
and read the gauge. Whether the pressure of the circuit relief valve is lower than that of the system relief valve
can be read on the gauge.
Increase the pressure of the system relief valve and that of the circuit relief valve by turns, and lock the adjust
screw when the specified pressure of the circuit relief valve is obtained. Then lower the pressure of the system
relief valve to the specified pressure and lock the adjust screw.
5) Pressure Change by One Turn of Adjust Screw
Tightening torque
Pressure change Number of adjust
for lock nut
PSI (MPa) screw turns
ft·lbf (N·m)
System relief valve 1763.3 (12.2) 1/1
14.47(19.6)
Circuit relief valve 1763.3 (12.2) 1/1
5-4-2 4720103
5. HYDRAULIC SYSTEM
5-4-2 Swing Brake Valve
1) Conditions
(2) Hydraulic oil temperature : 122 to 140 °F (50 to 60
°C)
(3) Pressure gauge capacity : 4977.1 PSI (34.3 MPa)
(4) Set pressure : 2844.0 (19.6 MPa)
2) Measuring Procedure
(1) Remove the floor mat and step 1.
(2) Remove the plug (PT 1/8) 2 to install the pressure
gauge.
(3) Fix the upperstructure and move the swing lever to
the right and the left, hold the lever with relief pres-
sure applied and read the gauge.
3) Pressure Adjustment Procedure

(1) Loosen the lock nut 1 for the relief valve and adjust
the relief pressure with the adjust screw 2.
Pressure change by one turn of adjust screw
Pressure change Tightening torque for lock nut
21.7 to 28.9 ft·lbf

1422 PSI (9.8 MPa)
(29.4 to39.2 N·m)
Note :
Readjust the relief pressure only when necessary.
5-4-3 4720103
5. HYDRAULIC SYSTEM
5-4-3 Cut-Off Valve
1) Conditions
(2) Hydraulic oil temperature : 122 to 140 °F (50 to 60
°C)
(3) Pressure gauge capacity : 1422 PSI (9.8MPa)
(4) Set pressure : 426.6 PSI (2.9MPa)
(1) Remove the cover 1.
(2) Remove the plug (PT 1/8) 2 for the hose connector
and install the pressure gauge.
(3) Move the lock lever to the "LOCK" position, and
read the gauge.
5-4-4 4720103
5. HYDRAULIC SYSTEM
3) Pressure Adjustment Procedure

ViO27-2
(1) Remove the plug (with an O-ring) 1.
(2) Increase or decrease the number of shims to adjust
the pressure to the specified value.
Pressure change per shim
Pressure change Tightening torque for plug
28.4 to 35.6 PSI

21.7 ft·lbf (29.4 N·m)
(0.2 to 0.25 MPa)
ViO35-2
(1) Loosen the lock nut 1.
(2) Turn the adjust screw 2 to adjust the pressure to the
specified value.
(3) After adjustment, hold the adjust screw 2 and
tighten the lock nut 1.
Notes :
• Stop the engine before adjusting the pressure.
• Sufficiently loosen the lock nut to prevent the breakage
of the O-ring.
Pressure change by one turn of adjust screw
Pressure change Tightening torque for lock nut
19.5 to 23.9 ft·lbf

108.1 PSI (0.75MPa)
(26.5 to32.4 N·m)
5-4-5 4720103
CHAPTER 6
HYDRAULIC EQUIPMENT
6-1 Hydraulic Pump ................................................................................... 6-1-1

6-1-1 ViO27-2...................................................................................... 6-1-1
6-1-2 ViO35-2.................................................................................... 6-1-37
6-2 Control Valve ....................................................................................... 6-2-1
6-3 Pilot Valve............................................................................................ 6-3-1
6-4 Swing Motor ......................................................................................... 6-4-1
6-5 Travel Motor........................................................................................ 6-5-1
6-5-1 ViO27-2...................................................................................... 6-5-1
6-5-2 ViO35-2.................................................................................... 6-5-43
6-6 Pilot Check Valve (Quick Coupler Type) ............................................. 6-6-1
6. HYDRAULIC EQUIPMENT
6. Hydraulic Equipment
6-1 Hydraulic Pump
6-1-1 ViO27-2
1. Outline
1) Piston Pump
The piston pump consists of a drive shaft, a swash plate, a rotary group, a housing, a control spring, a control piston,
a pilot pump, a gear pump, a flange, a valve assembly, a relief valve, and other components. It is a variable displace-
ment piston pump that discharges two equivalent volumes by means of a rotary group.
One rotary group is divided into one intake port and two discharge ports.
The gear pump P3 and the pilot pump P4 are connected to the piston pump via the drive shaft and these pumps and
the piston pump share one intake port.
The control system is a simultaneous incline angle full horsepower control.
No. Part
1 Drive shaft
2 Swash plate
3 Rotary group
4 Housing
5 Control spring
6 Control piston
7 Pilot pump
8 Gear pump
9 Flange
10 Valve assembly
11 Relief valve
6-1-1 4720103
2) Oil Flows From Intake Port and Pilot Pump Discharge Port
The oil flows from the intake port S of this pump and the discharge port P4 of the pilot pump are as follows :
• The oil sucked in from the intake port S flows into the intake ports S1, S2, S3, and S4 of the piston pumps, the gear
pump and the pilot pump, as shown with arrows in the above figure, and the oil is discharged to their respective
circuits.
• The oil discharged from the discharge port P4 of the pilot pump flows to the valve assembly through the relief valve
installed in the housing, as shown with an arrow in the above figure.
6-1-2 4720103
2. Theory of Operation
1) Pump Functions
• The cylinder barrel, which is splined to the drive shaft, revolves with the shaft.
• The pistons installed into the cylinder barrel, following the swash plate, make a reciprocating motion, which causes
the volume of the cylinder to change, thereby enabling the intake and discharge pump operations.
• As the pistons move from the bottom dead center to the top dead center, thereby increasing the volume, oil flowing
from the intake port runs through the valve plate into the cylinder barrel. (Intake stroke)
• As the pistons move from the top dead center to the bottom dead center, thereby decreasing the volume, the oil in
the cylinder barrel is discharged to the discharge port. (Discharge stroke)
• By changing the inclination of the swash plate, the piston stroke is changed and thus the displacement of the pis-
ton can be changed.
• Oil taken in from the inner port of the cylinder barrel is discharged from the inner discharge port of the valve plate.
• Oil taken in from the outer port of the cylinder barrel is discharged from the outer discharge port of the valve plate.
• The oil discharged from the inner port (the outer port) of the valve plate is discharged from the port P1 (P2).
6-1-3 4720103
2) Horsepower Control
Control the discharge volume of the piston pumps so that the amount of load in the piston pumps P1 and P2, the tro-
choid pump and the gear pump does not exceed the set torque.
The oil pressure from the piston pumps P1 and P2 flows to the control pin (A) through the oil passage inside the port
block. The discharge pressure of the gear pump flows to the control pin (B) through the inner passage of the piston
pump body.
The oil pressure discharged from the piston pumps P1 and P2 and the gear pump rises and presses the respective
control pins, causing the inclination angle of the swash plate to decrease and the discharge volume of the pumps to
reduce.
The one side of the swash plate is held with springs. The spring force is adjusted according to the discharge pres-
sure of each pump. The amount of horsepower (torque) of the pumps is controlled by the springs not to exceed the
set torque.
6-1-4 4720103
3) Gear Pump
The gear pump is used as the pump for the swing motor and blade.
Two gears in the housing rotate engaging with each other to work as a pump by transferring the oil between the gear
tooth and the inner surface of the housing.
The special loading system, which adjusts the clearance between the side surface of the gear tooth and the inner
surface of the housing to the appropriate value reflecting the discharge pressure, is adopted to the gear pump so
that the high efficiency is maintained for a long time.
6-1-5 4720103
4) Pilot Pump
The main part of the pilot pump comprises a trochoid rotor, which consists of inner and outer rotors, and a loading
plate, which keeps appropriate side clearance of trochoid rotor.
The rotation center of the outer rotor is off the center of the shaft. The inner rotor is involved by the spline engaging
with the shaft. When the shaft rotates to revolve the inner rotor, the inner rotor drives the outer rotor.
At this time, the oil is continuously sucked into the intake port on the right side S and discharged from the discharge
port on the left side D in the figure below as the oil capacity inside the pilot pump changes due to the off-center rev-
olution.
The loading plate leads the oil pressure from the discharge side of the trochoid pump to the rear side to keep the
appropriate side clearance by the discharge pressure.
6-1-6 4720103
5) Function of Valve Assembly

This pump has a valve assembly, which switches the directions of the pressure oil flow from the pilot pump. Some
solenoid and check valves are installed in the valve assembly.
[1] The solenoid valve A supplies pressure oil to the port A when the solenoid is turned on. When the solenoid is
turned off, the solenoid valve A blocks the pilot oil pressure and allows the oil in the port A to escape to the
intake port through the housing of the piston pump.
[2] The pressure oil is supplied to the solenoid valve B through the check valve. The oil flowing from the check valve
toward the solenoid valve B is divided into two directions. One flows to the solenoid valve B and the other flows
to the port D through the orifice.
[3] The solenoid valve B supplies the pilot pressure oil to the ports B1 and B2 when the solenoid is turned on. When
the solenoid is turned off and no pilot oil is supplied from the pilot pump for some reason, the check valve works
to keep the pressure decrease of the ports B1 and B2 at a minimum.
When the solenoid is turned off, the solenoid valve B blocks the pilot pressure oil and allows the oil in the ports
B1 and B2 to escape to the intake port through the housing of the piston pump.
W/O Quick coupler
6-1-7 4720103
[4] The valve assembly with three solenoid valves has the solenoid valve C. When the solenoid is turned on, the
solenoid valve C supplies the pilot pressure oil to the port C2 and allows the oil in the port C1 to escape to the
intake port through the housing of the piston pump. When the solenoid is turned off, the solenoid valve C sup-
plies the pilot pressure oil to the port C1 and allows the oil in the port C2 to escape to the intake port through the
housing of the piston pump.
Quick coupler
6-1-8 4720103
3. Exploded View and Parts Comprised
1) Hydraulic Pump
6-1-9 4720103
No. Part Q'ty No. Part Q'ty No. Part Q'ty

1 Housing 1 28 Retainer holder 1 52 Plug 2
2 Needle bearing 1 29 Retainer plate 1 53 O-ring 3
3 Pin 1 30 Swash plate 1 60 Trochoid rotor assembly 1
4 Thrust washer 2 31 Holder 1 61 Bush 1
5 Shaft 1 32 Pin 1 62 Loading plate 1
6 Thrust washer 1 33 Orifice 1 63 O-ring 1
7 Gasket 1 34 Spring seat 1 64 O-ring 2
8 Pin 2 35 Spring 1 65 Steel ball 1
10 Flange 1 36 Spring 1 70 Poppet 1
11 Internal snap ring 1 37 Spring seat 1 71 Spring 1
12 Oil seal 1 39 Set screw 1 72 Shim 2
13 Needle bearing 1 40 Seal washer 1 73 O-ring 1
14 Bush 2 41 Nut 1 74 Plug 1
15 Screw 2 42 Pin 1 75 Pin 1
16 Stopper 1 43 Pin 1 80 Gear pump 1
20 Valve plate 1 44 Stopper 1 81 O-ring 1
21 Cylinder barrel 1 45 Stopper 1 82 O-ring 1
22 Internal snap ring 1 46 Disc spring 3 83 Pin 1
23 Collar 1 47 Washer 1 85 Socket head bolt 2
24 Spring 1 48 Plug 1 86 Washer 2
25 Collar 1 49 O-ring 1 87 Air bleeder assembly 1
26 Pin 3 50 Socket head bolt 4
27 Piston assembly 10 51 Plug 6
6-1-10 4720103
1) Valve Assembly
[1] W/O Quick coupler
No. Part No. Part No. Part No. Part

1 Body 7 O-ring 13 Poppet 20 O-ring
2 Spool 8 Spring 14 Spring 21 Socket head bolt
3  9 Plug 16 Plug 22 O-ring
4 Solenoid 10 O-ring 17 Socket head bolt
5 Solenoid 11 Plug 18 Clamp
6  12 O-ring 9 Plug
6-1-11 4720103
[2] Quick coupler

Valve assembly part
No. Part No. Part No. Part No. Part

1 Body 7 O-ring 13 Poppet 20 O-ring
2 Spool 8 Spring 14 Spring 21 Socket head bolt
3 Spool 9 Plug 16 Plug 22 O-ring
4 Solenoid 10 O-ring 17 Socket head bolt
5 Solenoid 11 Plug 18 Clamp
6 Solenoid 12 O-ring 9 Plug
6-1-12 4720103
4. Special Tools
(12) Oil seal installation jig
(13) Bearing installation jig
(12) Oil seal
(13) Bearing disassembly jig
6-1-13 4720103
5. Disassembly and Reassembly

1) Precautions for Disassembly and Reassembly
(1) Since the parts of this hydraulic system are precision-made for tight clearances, be sure to perform disassembly
and reassembly in a clean area that is free from dust.
(2) Prepare clean tools and cleaning oil and handle the parts carefully.
(3) First clean the external surface of the removed assemblies.
(4) Before beginning disassembly, review the drawings of the internal construction and prepare the required parts
according to the purpose and extent of the disassembly.
(5) Never disassemble or readjust the adjust screws unless required. If they are disassembled or readjusted, it may
cause the set horsepower to be changed and have a negative influence.
(6) In principle, the removed seals and rings must be replaced with new ones. As some replacement parts are avail-
able only in subassemblies, refer to the parts catalog to prepare the necessary subassemblies in advance.
(7) Handling of O-rings
[1] Lubricate the O-rings and the O-ring fitting seats with clean grease or hydraulic oil.
[2] The O-rings may not be damaged in handing or distorted by heat.
[3] Do not permanently deform the O-rings.
[4] Avoid rolling the O-rings when fitting them.
A distorted O-ring may not return to its original shape, and therefore may cause oil leak.
(8) Before beginning reassembly, check the mating surfaces of each section to be sure that there is no cleaning oil
or hydraulic oil on the outer surface of the O-ring grooves. If reassembly is performed without cleaning such oil,
it may be mistaken for oil leak.
(9) Use a torque wrench to tighten the bolts following the torque specification.
6-1-14 4720103
2) Tools for Disassembly and Reassembly

Tools Applicable part Form
Tightening torque : 4.35 ft·lbf (5.9 N·m) (15) Screw
Tightening torque : 37.6 ft·lbf (51.0 N·m) (48) Plug
Tightening torque : 78.8 ft·lbf (106.9 N·m) (50) Socket head bolt
Tightening torque : 21.7 ft·lbf (29.4 N·m) (52), (74) Plug
(21) Socket head bolt

Tightening torque : 9.33 ft·lbf (12.65 N·m)
Torque wrench (for valve assembly)

(41) Nut
Width across flats : 0.67 in. (17 mm)

Width across flats : 0.12 in. (3 mm) (15) Screw

Width across flats : 0.31 in. (8 mm) (48) Plug
Hexagon Width across flats : 0.39 in. (10 mm) (50) Socket head bolt
socket for Width across flats : 0.24 in. (6 mm) (52), (74) Plug
torque wrench
(for valve assembly)
Wrench Width across flats : 0.67 in. (17 mm) (41) Nut
Width across flats : 0.12 in. (3 mm) (15) Screw

Width across flats : 0.20 in. (5 mm) (39) Set screw
Width across flats : 0.31 in. (8 mm) (48) Plug
Hexagon bar
wrench Width across flats : 0.39 in. (10 mm) (50) Socket head bolt
Width across flats : 0.24 in. (6 mm) (52), (74) Plug
(for valve assembly)
Snap ring
For internal snap ring For internal snap ring
pliers
(1) Housing
Vice
(for holding housing)
(12) Oil seal
Hand press
(13) Bearing
6-1-15 4720103
3) Disassembly
Procedure
(1) Remove the socket head bolt to remove the solenoid
valve assembly.
(2) Fix the pump with the input shaft down.
(3) Remove the set screw 39, the nut 41, and the seal washer
40.
Note :
Do not disassemble when there
are no trouble around these
parts, such as oil leak. When dis-
assembly is done, it makes
horsepower control change.
Therefor, measure the dimension
of L before removal, and adjust it
to the same dimension when
reinstallation.
(4) Remove the socket head bolts 85 and the washers 86,
and then remove the gear pump 80.
6-1-16 4720103
Procedure
(5) Remove the O-rings 81 and 82, the pin 83 and the steel
ball 65.
(6) Remove the loading plate 62.
(7) Remove the trochoid rotor assembly 60.
(8) Fix the pump with the input shaft up, and remove the
socket head bolts 50.
6-1-17 4720103
Procedure
(9) Remove the flange 10.
(10) Remove the gasket 7 and the pins 8 from the flange 10
or the housing 1.
(11) Remove the internal snap ring 11 from the flange 10.
(12) Press the oil seal 12 and the needle bearing 13 with a
hand press to remove them from the flange 10.
6-1-18 4720103
Procedure
(13) Remove the screws 15 to remove the bushes 14.
(14) Remove the thrust washer 6 from the shaft 5.
(15) Remove the shaft 5.
(16) Remove the swash plate 30 and the holder 31.
Note :
When removing the swash plate, take care not to drop the
holder. It may damage the internal parts, such as pistons.
6-1-19 4720103
Procedure
(17) Remove the spring seat 34.
(18) Remove the springs 35 and 36 from the housing.
(19) Remove the cylinder barrel assembly 21 to 29.
Note :
Take care not to drop the valve plate 20, which may cling
under the cylinder barrel.
(20) Remove the valve plate 20.
6-1-20 4720103
Procedure
(21) Remove the pin 3.
(22) Remove the thrust washers 4.
(23) Remove the spring seat 37.
(24) Remove the plug 74.
Note :
Take care not to lose the shims 72, which may cling to the
backside of the plug. If the shim is lost, the relief set pressure
of the pilot pump decreases.
6-1-21 4720103
Procedure
(25) Remove the spring 71.
(26) Remove the poppet 70 and the pin 75.
Note :
The stopper 45, the disc springs 46 and the washer 47 cling to
the housing side of the plug. Take care not to drop and loose
them.
6-1-22 4720103
Procedure
(30) Remove the stopper 45, the disc springs 46, and the
washer 47 from the plug 48.
6-1-23 4720103
4) Reassembly
Procedure
(1) Apply grease to the pins 26 and install them into the cylin-
der barrel 21.
(2) Insert the retainer holder 28 into the cylinder barrel 21.
(3) Install the piston assembly 27 into the tapered bore in the
center of the retainer plate 29 from its small-diameter side
and insert them into the cylinder barrel.
Notes :
• Confirm that the tapered bore surface in the center of the
retainer plate 29 contacts with the side surface of the
retainer holder 28.
• When only the small-diameter side end surface of the
tapered bore in the center of the retainer plate 29 contacts
with the retainer holder 28, the retainer plate 29 has been
installed upside down. Remove and reinstall it in the correct
direction.
(4) Install the poppet 70 and the pin 75 into the housing 1.
Note :
Take care about the direction of the poppet.
6-1-24 4720103
Procedure
(5) Install the spring 71 into the housing 1.
(6) Install the O-ring 73 and the shims 72 onto the plug 74.
Note :
If the shim drops, the relief set pressure of the pilot pump
decreases. Therefor, apply the grease to the shims before
installing them to the plug to prevent them from dropping.
(7) Install the plug 74 in the housing.
Note :
When installing the plug, be careful not to drop the shims
installed on the plug.
(8) Install the O-ring 49, the washer 47, the disc springs 46
and the stopper 45 onto the plug.
Note :
Take care about the direction of disc springs.
6-1-25 4720103
Procedure
(9) Install the plug 48 in the housing 1.
Note :
When installing the plug, be careful not to drop the parts
installed on the plug.
(10) Fix the housing 1 with its larger opening side up.
Note :
When fixing the housing, take care not to damage the mount-
ing surfaces of the intake port and gear pump because oil leak
may be caused.
(11) Insert the pins 42 and 43 into the housing 1.
(12) Insert the spring seat 37 into the housing 1.
6-1-26 4720103
Procedure
(13) Install the pin 3 into the housing 1.
(14) Install the valve plate 20 with the copper alloy side up
into the housing.
(15) Install the two thrust washers 4 into the housing 1.
(16) Place the cylinder barrel assembly 21 to 29 onto the

valve plate 20.
Note :
Install it carefully not to make flaws and dent on the valve
plate and rotary parts, which can cause breakage.
6-1-27 4720103
Procedure
(17) Install the spring seats 35 and 36.
Note :
Install them carefully not to make flaws and dent on the valve
plate 20 and cylinder barrel assembly, which can cause
breakage.
(18) Place the spring seat 34 onto the spring 35.
Note :
Install it carefully not to make flaws and dent on the valve
plate 20 and cylinder barrel assembly, which can cause
breakage.
(19) Install the shaft so that the spline of the shaft 5 and bear-
ing 2 are engaged with that of the cylinder barrel 21 and
the retainer holder 28.
Note :
Install it carefully not to make flaws and dent on the pump
internal parts, which can cause breakage.
(20) Apply grease to the shaft of holder 31 and insert it into

the swash plate 30.
6-1-28 4720103
Procedure
(21) Install the swash plate 30 into housing 1.
Note :
Take care not to drop the holder when installing it. This can
damage the internal parts, such as pistons.
(22) Install the thrust washer 6 onto the shaft 5.
(23) Install the pins 8 into the housing 1.
(24) Install the gasket 7 into the housing 1 aligning with the
pins 8.
6-1-29 4720103
Procedure
(25) Install the internal snap ring 11 into the flange 10.
(26) Install the oil seal 12 into the flange 10 with a jig.
(27) Install the needle bearing 13 into the flange 10 with a jig.
Note :
Press-fit the needle bearing with the emboss side up.
(28) Fix the flange 10, and tighten the bushes 14 with screws
15.
6-1-30 4720103
Procedure
(29) Install the flange 10 into the housing 1.
(30) Fasten the flange 10 with the socket head bolts 50.
(31) Fix the pump with the input shaft down.
(32) Install the trochoid rotor assembly 60 into the housing 1.
6-1-31 4720103
Procedure
(33) Install the O-rings 63 and 64 into the loading plate 62
and install them into the housing 1.
(34) Install the steel ball 65 and the O-rings 81 and 82 into the
housing 1.
Note :
A steel ball is a minute part. Take care not to drop when
installing.
(35) Install the pin 83 into the housing 1.
(36) Align the spline of the trochoid rotor assembly 60 with

the internal spline of the shaft 5 and install the gear
pump 80.
6-1-32 4720103
Procedure
(37) Install the washer 86 into the socket head bolts 85 and
then fasten the gear pump 80.
(38) Install the set screw 39 and adjust the projection dimen-
sion of the set screw to the same as before disassem-
bling.
(39) Install the seal washer 40 and then tighten the nut 41.
Note :
When tightening the nut, hold the set screw 39 with hexagon
wrench not to move.
If the set screw moves, horsepower control characteristic
changes.
(40) Fasten the solenoid valve assembly with solenoid head

bolt.
Note :
Take care not to drop the O-ring installed into the solenoid
valve assembly. Dropping O-ring may cause oil leak.
6-1-33 4720103
Clean the parts to be checked and completely dry them.
Check the major parts carefully and replace any ones on which excessive wear or damage that may cause malfunc-
tion is found.
Replace deformed or damaged seals.
Procedure
(1) Piston assembly and cylinder barrel
• Perform visual inspections for any flaws, scuffing or exces-
sive wear (especially on the sliding parts).
• Check the clearance between the outside diameter of each
piston and the inside diameter of the cylinder barrel.
D−d = 0.00197 in. (0.05 mm)
(2) Piston shoes and pistons

• Check the axial play of each piston and shoe.
ε ! 0.00787 in. (0.2 mm)
(3) Shaft
• Check the oil seal installation area.
Wear ! 0.00098 in. (0.025 mm)
6-1-34 4720103
7. Troubleshooting
Trouble Cause Measure
(1) Wrong pump shaft direction. Reinstall in correct direction.
(2) Strainer or intake pipe is closed. Clean strainer. Open intake pipe.
1. Oil is not (3) Tip of intake pipe sticks out of oil surface in Raise oil surface in tank or put tip of intake pipe
discharged from tank. under oil surface.
pump.
(4) Damage of pump's main parts. Disassemble and replace damaged parts with
Malfunction of input shaft and coupling. new one. Clean all parts completely and then
reassemble.
(1) Pressure does not rise or specified volume of Check hydraulic equipment being in trouble.
oil does not flow due to hydraulic equipment If necessary, replace or repair it.
except for pump, such as hydraulic motor or
control valves.
(2) Large quantity of high-pressure oil leak due Disassemble the pump. If the sliding surface is
2. Isufficient
to wear on sliding area of pump. not smooth, repair with regrinding or wrapping.
volume of oil is dis-
If wear is beyond repair, replace parts. Clean all
charged from
parts completely and then reassemble them.
pump.
(3) Air sucked in from intake side of pump. Check and replace intake piping and packing, or
Circuit pressure check and retighten tightening area.
does not rise.
(4) Clogging of strainer or air sucked in due to Clean or replace strainer.
low oil level.
(5) Cavitation caused by excessive intake resis- Reduce intake resistance.
tance due to abnormal oil temperature and
hydraulic oil viscosity or other factors.
(1) Air sucked in due to low oil level in tank. Replenish hydraulic oil and perform air release
operation with no load.
(2) Pump's intake resistance is too large due to Reduce intake resistance.
improper thickness and length of intake pipe.
(3) Pump cavitation due to clogged strainer. Clean strainer.
When strainer is heavily clogged, flush circuit and
replace hydraulic oil.
3. Pump creates
abnormal sounds. (4) Short capacity of strainer. Select strainer whose capacity is two or three
times as much as the max. displacement.
(5) Too low oil temperature. Refer to the Operation and Maintenance Manual
Pump cavitation due too high viscosity of for selecting oil and oil temperature.
hydraulic oil.
(6) Defective coupling. Check for core deflection.
(7) Resonance with others. Check bolts for looseness.
(1) Too high set torque of horsepower-control. Readjust set screw.
4. Excessive engine
load. (2) Clogging of pilot oil passage and orifice Readjust set screw. If nothing improves, disas-
(Excessive drop of inside pump, and seizing and scuffing of semble and check pump.
engine speed or parts.
engine stall)
(3) Seizing and wear of internal parts of pump. Repair pump.
(1) Broken oil seal and oil leak due to increase in Replace with new oil seal.
drain oil volume and rise in internal pressure Take great care not to damage lip when inserting
5. Oil leak. of pump housing. oil seal.
(Capacity to resistant pressure of oil seal :
42.7 PSI. (0.3 MPa)
6-1-35 4720103

(1) Low set pressure of relief valve. Set specified value.
(2) Poppet of relief valve is clogged with dust. Dissemble and clean pump and valve.
Replace hydraulic oil.
6. Malfunction of (3) Damage or wear of relief valve poppet. Replace poppet.

valve. When damage is found on pump case side,
• Oil does not flow. replace pump with new one.
• Pressure has no (4) Valve does not switch due to no electric cur- Check electric current.
stability. rent flowing to solenoid.
(5) Spool of solenoid valve is clogged with dust. Dissemble and clean pump and valve.
(6) Damage or wear of solenoid valve spool. Replace valve assembly.
6-1-36 4720103
6-1-2 ViO35-2
1. Outline
1) Piston Pump
The piston pump consists of a drive shaft, a swash plate, a rotary group, body H, a control spring, a control rod, a
gear pump, a body S, a valve block assembly, a relief valve, and other components. It is a variable displacement pis-
ton pump that discharges two equivalent volumes by means of a rotary group.
One rotary group is divided into one intake port and two discharge ports.
The gear pump P3 and the pilot pump P4 are connected to the piston pump via the coupling and these pumps and
the piston pump share one intake port.
The control system is a simultaneous incline angle full horsepower control.
No. Part
1 Drive shaft
2 Swash plate
3 Rotary group
4 Body H
5 Control spring
6 Control rod
7 Gear pump
8 Body S
9 Valve block assembly
10 Relief valve
6-1-37 4720103
2) Valve Assembly and Relief Valve

1] W/O Quick coupler
No. Part
1 Relief valve
2 Check valve
3 Body
4 Solenoid valve A
5 Solenoid valve B
The valve assembly comprises a body, two solenoid valves A and B, a relief valve and a check valve. It has the fol-
lowing two functions and is installed on the body S of the piston pump
[1] Shifting between the high-low travel speeds utilizing the gear pump oil for pilot. (Solenoid valve A.)
[2] Turning on and off the pilot oil for hydraulic joy stick. (Solenoid valve B.)
6-1-38 4720103
2] Quick coupler
No. Part
1 Relief valve
2 Check valve
3 Body
4 Solenoid valve A
5 Solenoid valve B
6 Solenoid valve C
The valve assembly comprises a body, solenoid valves A, B and C, a relief valve and a check valve. It has the flow-
ing functions and is installed on the body H of the piston pump :
[1] Shifting between high-low travel speeds utilizing the gear pump oil for pilot (Solenoid valve A)
[2] Turning on and off the pilot oil for hydraulic joy stick (Solenoid valve B.)
6-1-39 4720103
1) Pump Function
• The cylinder barrel, which is splined to the drive shaft, revolves with the shaft.
• The pistons installed into the cylinder barrel, following the swash plate, make a reciprocating motion, which causes
the volume of the cylinder to change, thereby enabling the intake and discharge pump operations.
• As the pistons move from the bottom dead center to the top dead center, thereby increasing the volume, oil flowing
from the intake port runs through the valve plate into the cylinder barrel. (Intake stroke)
• As the pistons move from the top dead center to the bottom dead center, thereby decreasing the volume, the oil in
the cylinder barrel is discharged to the discharge port. (Discharge stroke)
• By changing the inclination of the swash plate, the piston stroke is changed and thus the displacement of the pis-
ton can be changed.
• Oil taken in from the inner port of the cylinder barrel is discharged from the inner discharge port of the valve plate.
• Oil taken in from the outer port of the cylinder barrel is discharged from the outer discharge port of the valve plate.
6-1-40 4720103
2) Control Function
• The discharge volume of the pump is regulated by the inclination of the swash plate angle. The swash plate angle
is controlled by a direct variable mechanism using a simple spring.
• The swash plate pivots on the ball behind it and the load F1 applied from the piston is in the direction as shown in
the below figure, which creates a clockwise moment with regard to the swash plate. To counteract this force, the
spring force F2 is applied in the opposite direction by the spring installed to set the horsepower at a constant level,
so that a specified load can be obtained.
• With increase in the pressure, the above clockwise moment increases, and when it overcomes the counterclock-
wise moment by the spring force, it compresses the spring to reduce the swash plate angle. Thus, the discharge
volume is decreased to maintain the horsepower at a constant level.
• When the pressure P3 acts on the rod, a clockwise moment proportional to the pressure is created on the swash
plate. This causes the P-Q characteristic curve to shift. Thus, the total horsepower, including the horsepower of the
gear pumps, can be maintained at a constant level. (Total horsepower control mechanism)
6-1-41 4720103
3) Function of Valve Block Assembly and Relief Valve

[1] W/O Quick coupler
The oil from the pilot pump P4 flows through the body H of the piston pump to the valve block and is supplied to the
solenoid valves after its pressure is regulated by the relief valve.
The solenoid valve A (SOL A) supplies the oil to the port PA when it is turned on, and causes the oil in the port PA to
escape into the housing of the piston pump when it is turned off.
The solenoid valve B (SOL B) supplies the oil to the ports PB (1 and 2) when it is turned on, and causes the oil in the
ports PB (1 and 2) to escape into the housing of the piston pump when it is turned off.
6-1-42 4720103
[2] Quick coupler

The oil from the pilot pump P4 flows through the body H of the piston pump to the valve block and is supplied to the
solenoid valves after its pressure is regulated by the relief valve.
The solenoid valve A (SOL A) supplies the oil to the port PA when it is turned on, and causes the oil in the port PA to
escape into the housing of the piston pump when it is turned off.
The solenoid valve B (SOL B) supplies the oil to the ports PB (1 and 2) when it is turned on, and causes the oil in the
ports PB (1 and 2) to escape into the housing of the piston pump when it is turned off.
The solenoid valve C (SOL C) supplies the oil to the port PC1 and cause the oil in the port PC2 to escape into the
housing the piston, when it is turned on. Also it causes the oil in the port PC1 to escape into the housing of the piston
pump and supplies the oil to the port PC2 when it is turned off.
6-1-43 4720103
3. Exploded View and Component Parts
6-1-44 4720103
No. Part Q'ty No. Part Q'ty

1 Body S 1 28 Coned disc spring 4
2 Body H 1 29 Internal snap ring 1
3 Drive shaft 1 30 Internal snap ring 1
4 Cylinder barrel 1 31 External snap ring 1
5 Valve plate 1 32 O-ring 1
6 Piston 10 33 O-ring 3
7 Shoe 10 34 Plug 1
8 Shoe holder 1 35 O-ring 1
9 Barrel holder 1 36 Hexagon socket head bolt 5
10 Swash plate 1 37 Hexagon socket head plug 5
11 Needle 3 38 Plug 1
12 Rocking pin 2 40 Spring pin 1
13 Packing 1 41 Hexagon socket head set screw 1
14 Spring C 1 42 Hexagon nut 1
15 Spring T1 1 43 Seal washer 1
16 Spring holder 1 44 Gear pump kit 1
17 Spring guide 1 45 Coupling 1
18 Pin 1 46 Collar 1
19 Rod C 1 47 Hexagon bolt 2
21 Retainer 2 48 O-ring 1
22 Stopper pin A 1 49 Washer 2
23 Stopper pin B 1 50 O-ring 1
24 Socket head pin 1 51 O-ring 2
25 Ball bearing 1 52 Valve assembly 1
26 Needle bearing 1 53 Hexagon socket head bolt 3
27 Oil seal 1 54 Spring washer 3
6-1-45 4720103
4. Special Tool
Oil seal installation jig
6-1-46 4720103

(1) Since the parts of this hydraulic system are precision-made for tight clearances, be sure to perform disassembly
and reassembly in a clean area that is free from dust.
(3) First clean the external surface of the removed assemblies.
(5) Never disassemble or readjust the adjust screws unless required. If they are disassembled or readjusted, it may
cause the set horsepower to be changed and have a negative influence.
(6) In principle, the removed seals and rings must be replaced with new ones. As some replacement parts are avail-
able only in subassemblies, refer to the parts catalog to prepare the necessary subassemblies in advance.
[2] The O-rings may not be damaged in handing or distorted by heat.
A distorted O-ring may not return to its original shape, and therefore may cause oil leak.
(8) Before beginning reassembly, check the mating surfaces of each section to be sure that there is no cleaning oil
or hydraulic oil on the outer surface of the O-ring grooves. If reassembly is performed without cleaning such oil,
it may be mistaken for oil leak.
(9) Use a torque wrench to tighten the bolts following the torque specification.

Tools Q'ty Nominal size (Unit : mm)
Hexagon bar wrench 1 for each 4, 6 and 8
Offset wrench 1 13
Snap ring pliers 1 For internal snap ring
Plastic hammer 1
Hexagon socket head bolt 2 M10!65
Grease Little
6-1-47 4720103
3) Disassembly
Procedure
1. Removal of valve block assembly
Remove the three hexagon socket head bolts 53
(M8!75) to take off the valve block assembly 52.
Tool : Hexagon bar wrench 6
2. Removal of gear pump kit

Remove the two hexagon bolts 47 (M8!25) to take off the
gear pump kit 44, the collar 46 and the coupling 45.
Tool : Offset wrench 13
3. Removal of hexagon socket head set screw

Loosen the hexagon nut 42 sufficiently to remove the
hexagon socket head set screw 41.
Tools : Offset wrench 13 and hexagon bar wrench 4
Note :
Before removing the hexagon
socket head set screw, write
down the projection height a of it,
as shown in the right figure.
4. Separation of body S kit and body H kit

Remove the upper two of the five hexagon socket head
bolts 36 (M10!45).
Install and tighten two hexagon socket head bolts

(M10!65) for temporary installation by about 0.394 in.
(10 mm) in place of the two bolts to loosen the remaining
three hexagon socket head bolts 36.
Then, loosen the two bolts for temporary installation to
separate the body S and the body H.
6-1-48 4720103
Procedure
Tap the spring installation area of body H with a plastic ham-
mer for easy separation of the bodies.
5. Disassembly of body S kit

(1) Take the spring T1 15 and the spring holder 16 out of the
body S kit.
(2) Take the cylinder barrel kit out.
(3) Remove the swash plate 10 and the rocking pins 12.
6-1-49 4720103
Procedure
(4) Remove the stopper pin A 22, the two coned disc springs
28, the stopper pin B 23, the two coned disc springs 28,
and the rod 19.
(5) Remove the internal snap ring 29 on the drive shaft side
from body S.
(6) Tap the drive shaft 3 lightly with a plastic hammer to pull
the oil seal 27 and the drive shaft 3 with the ball bearing
25 out of body S.
6. Disassembly of body H kit

Take the spring guide 17 out of the body H.
6-1-50 4720103
Procedure
7. Disassembly of cylinder barrel kit
(1) Remove the shoe holder 8 with the assembly of pistons 6
and shoes 7 installed and the barrel holder 9 from the cyl-
inder barrel 4.
(2) Remove the needles 11.
(3) Remove the internal snap ring 30 and then take the
retainer 21, the spring C 14 and the retainer 21 in this
order out of the cylinder barrel 4.
6-1-51 4720103
4) Reassembly
Procedure
1. Installation of cylinder barrel kit
(1) Install the retainer 21, the spring C 14, the retainer 21 and
the internal snap ring 30 in this order into the shaft hole of
cylinder barrel 4.
(2) Install the needles 11 into the cylinder barrel 4.
(3) Install the barrel holder 9 and the shoe holder 8 with
assembly of pistons and shoes inserted, carefully into the
cylinder barrel 4.
Note :
Do not tap the pistons with a hammer or the like for installa-
tion.
2. Installation of stopper pins A and B kits

Install the two coned disc springs 28 onto the stopper pin
A 22 to assemble the stopper pin A kit.
In the same way, install the two coned disc springs 28
onto the stopper pin B 23 to assemble the stopper pin B
kit.
Note :
Take care not to install the coned disc springs 28 in the wrong
direction.
6-1-52 4720103
Procedure
3. Installation of body S kit
(1) Installation of oil seal and drive shaft
Install the drive shaft 3 with the ball bearing 25, the oil
seal 27 and the internal snap ring 29 in this order into the
body S 1.
Note :
Replace the removed oil seal with a new one in reassembly
Apply a small quantity of grease to the lip and outer side

face of the oil seal 27, and tap it lightly with a hammer
using a special installation jig to install it into the body S.
For easy installation, place the body S 1 on the body H 2
temporarily.
(2) Install the stopper pin A kit and the stopper pin B kit into
the body S 1.
(3) Install the rod C 19 into the body S 1.
6-1-53 4720103
Procedure
(4) Put the rocking pins 12 into the holes in the swash plate
10, and install it with the rocking pins fitted into the holes
in the body S 1.
(5) Install the cylinder barrel kit into the body S 1.
(6) Install the spring holder 16 on the spring T 1 15, and fit the
globular part of spring holder 16 into the hole in the swash
plate 10.
4. Installation of body H kit

(1) Install the spring guide 17 into the body H 2.
6-1-54 4720103
Procedure
(2) Place the valve plate 5 on the body H 2 quietly with the
spring pin 40 on body H 2 fitted into the thin groove of
valve plate 5.
Note :
Take care not to place the valve plate on the wrong side on
body H.
The thin-grooved side of the valve plate should be contacted
with the cylinder barrel.
5. Joining body S and body H

(1) Install the packing 13 on the mating surface of body S 1
using the socket head pin 24.
Note :
Replace the removed packing with a new one.
(2) To put the body S and the body H together, install and
softly tighten the two hexagon socket head bolts
(M10!65) for temporary installation in place of the upper
two hexagon socket head bolts 36 (M10!45).
When the clearance between the mating surfaces of body
S and body H gets narrow to 0.197 to 0.394 in. (5 to 10
mm), install and tighten the other three hexagon socket
head bolts 36 (M10!45).
Remove the hexagon socket head bolts for temporary
installation, and instead, install and tighten the two hexa-
gon socket head bolts 36 (M10!45).
6. Installation of hexagon socket head set screw

Fasten the hexagon socket head set screw 41 with the
hexagon nut 42 so that the set screw has the same pro-
jection height as that before disassembly.
Tools : Offset wrench 13 and hexagon bar wrench 4
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Procedure
7. Installation of gear pump kit
(1) Install the O-rings 50 and 51 on the mating surface of the
piston pump kit for the gear pump kit.
Note :
Replace the removed O-rings with new ones.
(2) Install the collar 46 and the coupling 45 in the area cou-
pled with the gear pump kit of the piston pump kit.
(3) Install the gear pump kit 44 onto the piston pump kit with
the two hexagon bolts 47 (M8!25) and washers 49.
Tool : Offset wrench 13
8. Installation of valve block assembly

(1) Install the O-rings 33 and 51 on the mating surface of the
piston pump kit for the valve block assembly.
Note :
Replace the removed O-rings with new ones.
6-1-56 4720103
Procedure
(2) Install the valve block assembly 52 onto the piston pump
kit with the three hexagon socket head bolts 53 (M8!75)
and the spring washers 54.
9. Operation check after reassembly

After the above reassembly, rotate the drive shaft by hand
to check the smooth operation of it.
6-1-57 4720103
Clean the parts to be checked and completely dry them.
Check the major parts carefully and replace any ones on which excessive wear or damage that may cause malfunc-
tion is found.
Replace deformed or damaged seals.
Procedure
(1) Piston assembly and cylinder barrel
• Perform visual inspections for any flaws, scuffing or exces-
sive wear (especially on the sliding parts).
• Check the clearance between the outside diameter of each
piston and the inside diameter of the cylinder barrel.
D−d = 0.00197 in. (0.05 mm)
(2) Piston shoes and pistons

• Check the axial play of each piston and shoe.
ε ! 0.00787 in. (0.2 mm)
(3) Shaft
• Check the oil seal installation area.
Wear ! 0.00098 in. (0.025 mm)
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7. Troubleshooting
(1) Wrong pump shaft direction. Reinstall in correct direction.
(2) Strainer or intake pipe is closed. Clean strainer. Open intake pipe.
1. Oil is not (3) Tip of intake pipe sticks out of oil surface in Raise oil surface in tank or put tip of intake pipe
discharged from tank. under oil surface.
pump.
(4) Damage of pump's main parts. Disassemble and replace damaged parts with
Malfunction of input shaft and coupling. new one. Clean all parts completely and then
reassemble.
(1) Pressure does not rise or specified volume of Check hydraulic equipment being in trouble.
oil does not flow due to hydraulic equipment If necessary, replace or repair it.
except for pump, such as hydraulic motor or
control valves.
(2) Large quantity of high-pressure oil leak due Disassemble the pump. If the sliding surface is
2. Isufficient
to wear on sliding area of pump. not smooth, repair with regrinding or wrapping.
volume of oil is dis-
If wear is beyond repair, replace parts. Clean all
charged from
parts completely and then reassemble them.
pump.
(3) Air sucked in from intake side of pump. Check and replace intake piping and packing, or
Circuit pressure check and retighten tightening area.
does not rise.
(4) Clogging of strainer or air sucked in due to Clean or replace strainer.
low oil level.
(5) Cavitation caused by excessive intake resis- Reduce intake resistance.
tance due to abnormal oil temperature and
hydraulic oil viscosity or other factors.
(1) Air sucked in due to low oil level in tank. Replenish hydraulic oil and perform air release
operation with no load.
(2) Pump's intake resistance is too large due to Reduce intake resistance.
improper thickness and length of intake pipe.
(3) Pump cavitation due to clogged strainer. Clean strainer.
When strainer is heavily clogged, flush circuit and
replace hydraulic oil.
3. Pump creates
abnormal sounds. (4) Short capacity of strainer. Select strainer whose capacity is two or three
times as much as the max. displacement.
(5) Too low oil temperature. Refer to the Operation and Maintenance Manual
Pump cavitation due too high viscosity of for selecting oil and oil temperature.
hydraulic oil.
(6) Defective coupling. Check for core deflection.
(7) Resonance with others. Check bolts for looseness.
(1) Too high set torque of horsepower-control. Readjust set screw.
4. Excessive engine
load. (2) Clogging of pilot oil passage and orifice Readjust set screw. If nothing improves, disas-
(Excessive drop of inside pump, and seizing and scuffing of semble and check pump.
engine speed or parts.
engine stall)
(3) Seizing and wear of internal parts of pump. Repair pump.
(1) Broken oil seal and oil leak due to increase in Replace with new oil seal.
drain oil volume and rise in internal pressure Take great care not to damage lip when inserting
5. Oil leak. of pump housing. oil seal.
(Capacity to resistant pressure of oil seal :
42.7 PSI. (0.3 MPa)
6-1-59 4720103

(1) Low set pressure of relief valve. Set specified value.
(2) Poppet of relief valve is clogged with dust. Dissemble and clean pump and valve.
6. Malfunction of (3) Damage or wear of relief valve poppet. Replace poppet.

valve. When damage is found on pump case side,
• Oil does not flow. replace pump with new one.
• Pressure has no (4) Valve does not switch due to no electric cur- Check electric current.
stability. rent flowing to solenoid.
(5) Spool of solenoid valve is clogged with dust. Dissemble and clean pump and valve.
(6) Damage or wear of solenoid valve spool. Replace valve assembly.
6-1-60 4720103
6-2 Control Valve
1. Outline
This control valve is a mono-block valve comprising eleven-series connected three-position directional control
valves which control the operation of the actuators by switching the circuit, system relief valves which control the cir-
cuit pressure, circuit relief valves, an anti-cavitation valve, load check valves, throttles and others.
1) Circuit Configuration
There are two pump ports at the inlet section and the parallel-flow divider. Oil from the port P1 flows to the right
travel, boom and bucket spool sections, which are connected via parallel passages. Oil from the port P3 also flows
to the boom and bucket sections through the spool of the parallel-flow divider.
The parallel passage allows simultaneous operation of more than one spool, however, they cannot always operate
in the same motion. Specifically, due to the differences in load and capacity between the actuators, pressures to be
generated vary and the spool with a smaller load pressure operates earlier.
To allow the simultaneous operation of the spools in the same motion as a single operation, the spool stroke of the
spool section with a heavier load needs to be adjusted to the full stroke while that of the spool section with a lighter
load needs to be adjusted to half a stroke or smaller.
Oil from the port P2 flows to the left travel, boom swing, arm and P.T.O. spool sections. Oil from the port P3 also
flows to the arm and P.T.O. sections through the spool of the parallel-flow divider.
Oil from the port P3 flows to the blade and swing spool sections, which are also connected via parallel passages.
6-2-1 4720103
2. Operation
1) Unloaded state (Port p1 with No Pilot Oil Supplied)
(1) Oil flow discharged from the pump P1
A part of oil discharged from the hydraulic pump P1 flows into the control valve through the port P2 and flows out
directly to the hydraulic oil tank through the spool of the inlet section. While the remainder of the oil flows through the
return passage of the left travel, boom swing, arm and P.T.O. spools to the hydraulic oil tank.
Thus, the oil discharged from the hydraulic pump is fed to the left travel, boom swing, arm and P.T.O. sections
through the return passage. However, the pressure in the return passage becomes equal to the pressure of the
hydraulic oil tank, so that the pressure does not rise even if the control levers for the left travel, boom swing, arm or
P.T.O. are operated.
A part of oil discharged from the hydraulic pump P2 flows into the control valve through the port P1 and flows out
directly to the hydraulic oil tank through the spool of the inlet section. While the remainder of the oil flows through the
return passage of the right travel, boom and bucket spools to the tank passage.
Thus, the oil discharged from the hydraulic pump is fed to the right travel, boom and bucket sections through the
return passage. However, the pressure in the return passage becomes equal to the pressure of the hydraulic oil
tank, so that the pressure does not rise even if the right travel, boom or bucket control lever is operated.
The oil discharged from the hydraulic pump P3 flows into the control valve through the port P3 and flows to the par-
allel passage of the blade and swing sections.
In the neutral state of the spools, the return passage is not blocked by any spool, so that the oil from the parallel pas-
sage flows to the hydraulic oil tank through the return passage of the blade and swing spools, the check valve in the
parallel-flow divider, the P2 parallel passage, the return passage of the arm spool and the return passage of the
P.T.O section.
Operation in unload state
6-2-2 4720103
2) Neutral State (Port p1 with Pilot Oil Supplied)

When the pilot oil is supplied to the port p1, the spool of the inlet section moves to block the passage, which has
directly opened to the tank passage. Therefore, the oil from port P2 flows to the left travel spool section through the
inlet spool land. In the neutral state of the spools, the return passage is not blocked by any spool, so that the oil
flows from the left travel spool section to the hydraulic oil tank through the return passage of the left travel, boom
swing and arm spools and the return passage of the P.T.O. spool.
When the pilot oil is supplied to the port p2, the spool of the inlet section moves to block the passage, which has
directly opened to the tank passage. Therefore, the oil from port P1 flows to the right travel spool section through the
inlet spool land. In the neutral state of the spools, the return passage is not blocked by any spool, so that the oil
flows from the right travel spool section to the hydraulic oil tank through the return passage of the right travel and
boom spools and the return passage of the bucket spool leading to the tank passage.
The oil discharged from the hydraulic pump flows into the control valve through the port P3 and flows to the parallel
passage of the blade and swing sections.
In the neutral state of the spools, the return passage is not blocked by any spool, so that the oil flows from the paral-
lel passage to the hydraulic oil tank through the return passage of the blade and swing spools, the check valve in the
parallel-flow divider, the P2 parallel passage, the return passage of the arm spool and the return passage of the
P.T.O section leading to the tank passage.
Operation in neutral state
6-2-3 4720103
3. Operation of Directional Control Valves

1) Travel Operation
(1) Travel forward operation
When the left [right] control lever is pushed forward, the spool is pressed forward. The oil from the port P2 [P1] flows
to the return passage of the left [right] travel spool through the inlet spool land.
The oil in the return passage of the left [right] travel spool flows to the port B6 [B7], which is opened as the spool has
been moved, and is fed to the travel motor.
Meanwhile, the return oil from the travel motor flows into the control valve through the port A6 [A7] and flows to the
tank passage, which is opened as the spool has been moved.
Note :
The words in brackets are for the right travel operation.
6-2-4 4720103
(2) Travel reverse operation

When the left [right] control lever is pulled back, the spool is pulled back. The oil from the port P2 [P1] flows to the
return passage of the left [right] travel spool through the inlet spool land.
The oil in the return passage of the left [right] travel spool flows to the port A6 [A7], which is opened as the spool has
been moved, and is fed to the travel motor.
Meanwhile, the return oil from the travel motor flows into the control valve through the port B6 [B7] and flows to the
tank passage, which is opened as the spool has been moved.
Note :
The words in brackets are for the right travel operation.
6-2-5 4720103
2) Operation of Boom
(1) Boom up operation
When the boom control lever is pulled back to raise the boom, the secondary pressure oil from the pilot valve flows
to the ports a8 and a8' to move each the spool of the boom section and that of parallel-flow divider, respectively.
Refer to 8) Operation of Parallel-flow Divider for the operation of the parallel-flow divider.
Therefore, the amount of oil from the pumps P2 and P3 is fed to the boom section when the boom control lever is
pulled back. (A part of oil flows to the tank passage through the P2 parallel passage.)
The return passage is blocked by the boom spool as the spool has been moved, so that the oil from the port P1
flows through the parallel passage via the check valve installed at the upper part of the return passage of the travel
spool to the parallel passage of the boom section.
The passage between the anti-drift valve and the bridge passage is opened as the spool has been moved. There-
fore, the oil in the parallel passage flows to the anti-drift valve through the load check valve in the boom section and
the bridge passage.
The oil in the anti-drift valve opens the anti-drift valve (in the state of free flow) to flow to the port A9 and the bottom
side of the boom cylinder.
Meanwhile, the return oil from the rod side of the boom cylinder flows to the tank passage through the port B8 and
the notch in the boom spool, which is opened to the tank passage as the spool has been moved.
Thus, the boom cylinder is extended to raise the boom.
6-2-6 4720103
(2) Boom down operation

When the boom control lever is pushed forward to lower the boom, the secondary pressure oil from the pilot valve
flows to the ports b8 to move the spool of the boom section.
The return passage is blocked by the boom spool as the spool has been moved, so that the oil from the port P1
flows through the parallel passage via the check valve installed at the upper part of the return passage of the travel
spool to the parallel passage of the boom section. (A part of oil flows to the tank passage through the notch in the
boom spool.)
The passage between the port B8 and the bridge passage is opened through the notch in the boom spool as the
spool has been moved. Therefore the oil in the parallel passage flows through the load check valve of the boom sec-
tion and the bridge passage to the port B8 and is fed to the rod side of the boom cylinder.
Meanwhile, the return oil from the bottom side of the boom cylinder flows to the tank passage through the port A9,
the anti-drift valve, which is opened by the pilot pressure from the port b8', and the notch in the boom spool, which is
opened to the tank passage as the spool has been moved.
Thus, the boom cylinder is retracted to lower the boom.
6-2-7 4720103
3) Anti-Drift Valve Operation

(1) Holding
In the neutral state of the spool of the boom section, the pilot piston chamber a is connected to the drain passage
through the pilot port b8' for anti-drift valve release. The piston chamber b is also connected to the drain passage
through the drain port Dr1.
This allows the piston A to stay in the state shown in the figure below.
The holding pressure of the boom cylinder works on the anti-drift valve chamber as shown in the figure, pressing the
needle valve on the needle valve seat and the anti-drift valve on the section body seat to prevent oil leak from the
bottom side of the boom cylinder and the boom cylinder from moving due to the oil leak.
6-2-8 4720103
(2) Releasing (boom down)

When the pilot oil flows to the pilot port b8' for release of the anti-drift valve, the pilot pressure moves the piston A to
the right, and the piston B presses the needle valve to open. At that time, the return oil from the boom cylinder flows
through the throttle of the anti-drift valve, the anti-drift valve chamber, the pilot piston chamber, and the drill hole and
pushes up the steel ball to flow through the throttle (drill hole) in the boom spool to the tank passage.
The pressure in the anti-drift valve chamber decreases as the needle valve has been opened, and the return oil from
the boom cylinder has opened the anti-drift valve so that the return oil from the boom cylinder flows to the tank pas-
sage through the notch in the boom spool.
6-2-9 4720103
4) Bucket Operation
(1) Bucket dump operation
When the bucket control lever is moved to the right to dump the bucket, the secondary pressure oil from the pilot
valve flows to the port b10 to move the spool of the bucket section.
The return passage is blocked by the bucket spool as the spool has been moved, so that the oil from the port P1
flows through the bypass valve of the anti-drift valve and the passage via the check valve to the parallel passage.
The passage between the port B10 and the bridge passage is opened as the bucket spool has been moved, so that
the oil flowed to the parallel passage flows through the load check valve and the bridge passage to the port B10, and
is fed to the rod side of the bucket cylinder.
The oil from the port P1 also flows through the P1 parallel passage and the throttle in the parallel passage of the
anti-drift valve to the parallel passage of the bucket section. (This throttle is installed to increase the pressure loss in
the parallel passage leading to the bucket section and supply the oil to the boom section prior to the bucket section
when the boom and bucket are simultaneously operated.)
Meanwhile, the return oil from the bottom side of the bucket cylinder flows through the port A10 to the tank passage,
which is opened as the bucket spool has been moved.
Thus, the bucket cylinder is retracted to dump the bucket.
6-2-10 4720103
(2) Bucket curl operation

When the bucket control lever is moved to the left to curl the bucket, the secondary pressure oil from the pilot valve
flows to the port a10 to move the spool of the bucket section.
The return passage is blocked by the bucket spool as the spool has been moved, so that the oil from the port P1
flows through the bypass valve of the anti-drift valve and the passage via the check valve to the parallel passage.
The passage between the port A10 and the bridge passage is opened as the bucket spool has been moved, so that
the oil flowed to the parallel passage flows through the load check valve and the bridge passage to the port A10, and
is fed to the head side of the bucket cylinder.
The oil from the port P1 also flows through the P1 parallel passage and the throttle in the parallel passage of the
anti-drift valve to the parallel passage of the bucket section. (This throttle is installed to increase the pressure loss in
the parallel passage leading to the bucket section and supply the oil to the boom section prior to the bucket section
when the boom and bucket are simultaneously operated.)
Meanwhile, the return oil from the rod side of the bucket cylinder flows to the tank passage through the port B10 and
the notch in the bucket spool, which is opened to the tank passage as the bucket spool has been moved.
Thus, the bucket cylinder is extended to curl the bucket.
6-2-11 4720103
5) Boom Swing Operation

(1) Right boom swing operation
When the boom swing pedal is moved on the right, the spool of the boom swing section is pressed forward. The
return passage is blocked by the boom swing spool as the spool has been moved, so that the oil from the port P2
flows to the parallel passage through the check valve installed at the upper part of the return passage of the left
travel spool. (A part of oil flows to the tank passage through the notch in the boom swing spool.)
The passage between the port B5 and the bridge passage is opened as the boom swing spool has been moved, so
that the oil flowed to the parallel passage flows through the load check valve and the bridge passage to the port B5
and is fed to the rod side of the boom swing cylinder.
Meanwhile, the return oil from the bottom side of the boom swing cylinder flows to the tank passage through the port
A5 and the notch in the boom swing spool, which is opened to the tank passage as the spool has been moved.
Thus, the boom swing cylinder is retracted to swing the boom to the right.
6-2-12 4720103
(2) Left boom swing operation

When the boom swing pedal is moved on the left, the spool of the boom swing section is pulled back. The return
passage is blocked by the boom swing spool as the spool has been moved, so that the oil from the port P2 flows to
the parallel passage through the check valve installed at the upper part of the return passage of the left travel spool.
(A part of oil flows to the tank passage through the notch in the boom swing spool.)
The passage between the port A5 and the bridge passage is opened as the boom swing spool has been moved, so
that the oil flowed to the parallel passage flows through the load check valve and the bridge passage to the port A5
and is fed to the bottom side of the boom swing cylinder.
Meanwhile, the return oil from the rod side of the boom swing cylinder flows to the tank passage through the port B5
and the notch in the boom swing spool, which is opened to the tank passage as the spool has been moved.
Thus, the boom swing cylinder is extended to swing the boom to the left.
6-2-13 4720103
6) Arm Operation
(1) Arm retract operation
When the arm control lever is pulled back to retract the arm, the secondary pressure oil from the pilot valve flows into
the port b4 of the arm section and the b4' of the parallel-flow divider to move the spool of the arm section and keep
the spool of the parallel-flow divider in the neutral position.
Refer to 8) Operation of Parallel-flow Divider for the operation of the parallel-flow divider.
The return passage is blocked by the arm spool as the spool has been moved, so that the oil from the port P2 flows
to the parallel passage of the arm section through the tandem passage installed between the boom swing valve
body and the arm valve body.
The P3 pump line is also blocked by the arm spool, the oil from the port P3 flows through the check valve installed in
the parallel-flow divider to the parallel passage of the arm section.
Therefore, the amount of oil from the ports P2 and P3 is fed to the arm section when the arm control lever is pulled
back.
The passage between the port B4 and the bridge passage is opened as the arm spool has been moved, so that the
oil flowed to the parallel passage flows through the load check valve and the bridge passage to the port B4 and is
fed to the bottom side of the arm cylinder.
Meanwhile, the return oil from the rod side of the arm cylinder flows to the tank passage through the port A4 and the
notch, which is opened to the tank passage as the arm spool has been moved.
Thus, the arm cylinder is extended to retract the arm.
6-2-14 4720103
(2) Arm extend operation

When the arm control lever is pushed forward to retract the arm, the secondary pressure oil from the pilot valve flows
into the port a4 of the arm section to move the spool of the arm section.
The return passage is blocked by the arm spool as the spool has been moved, so that the oil from the port P2 flows
to the parallel passage of the arm section through the tandem passage installed between the boom swing section
body and the arm section body.
The P3 pump line is also blocked by the arm spool, the oil from the port P3 flows through the check valve installed in
the parallel-flow divider to the parallel passage of the arm section.
Therefore, the amount of oil from the ports P2 and P3 is fed to the arm section when the arm control lever is pushed
forward.
The passage between the port A4 and the bridge passage is opened as the arm spool has been moved, so that the
oil flowed to the parallel passage flows through the load check valve and the bridge passage to the port A4 and is
fed to the rod side of the arm cylinder.
Meanwhile, the return oil from the bottom side of the arm cylinder flows through the port B4 to the tank passage,
which is opened as the arm spool has been moved.
Thus, the arm cylinder is retracted to extend the arm.
6-2-15 4720103
7) P.T.O. Operation
7-1) Shut-off valve in closed state
When the shut-off valve is in the opened state, the oil from the pump flows back to the tank. Therefore, make sure
that the shut-off valve is closed.
(1) Spool pull operation
The return passage is blocked by the P.T.O. spool as the spool has been moved, so that the oil from the port P2
flows through the tandem passage installed between the boom swing section body and the arm section body and
the parallel passage of the arm section to the parallel passage of the P.T.O. section.
The P3 pump line is also blocked by the P.T.O. spool, so that the oil from the port P3 flows through the check valve
in the parallel-flow divider to the parallel passage of the P.T.O. section.
Therefore, the combined oil from the ports P2 and P3 is supplied to the P.T.O. section when the P.T.O. is used.
The passage between the port A3 and the bridge passage is opened as the P.T.O. spool has been moved, so that
the oil flowed to the parallel passage flows through the load check valve and the bridge passage to the port A3 and
is fed to the attachment connected to the P.T.O. port.
Meanwhile, the return oil from the attachment connected to the P.T.O. port flows through the port B3 to the tank pas-
sage, which is opened as the P.T.O. spool has been moved.
6-2-16 4720103
(2) Spool press operation

The return passage is blocked by the P.T.O. spool as the spool has been moved, so that the oil from the port P2
flows through the tandem passage installed between the boom swing section body and the arm section body and
the parallel passage of the arm section to the parallel passage of the P.T.O. section.
The P3 pump line is also blocked by the P.T.O. spool, so that the oil from the port P3 flows through the check valve
in the parallel-flow divider to the parallel passage of the P.T.O. section.
Therefore, the combined oil from the ports P2 and P3 is supplied to the P.T.O. section when the P.T.O. is used.
The passage between the port B3 and the bridge passage is opened as the P.T.O. spool has been moved, so that
the oil flowed to the parallel passage flows through the load check valve and the bridge passage to the port B3 and
is fed to the attachment connected to the P.T.O. port.
Meanwhile, the return oil from the attachment connected to the P.T.O. port flows through the port A3 to the tank pas-
sage, which is opened as the P.T.O. spool has been moved.
6-2-17 4720103
8) Parallel-Flow Divider Operation

(1) In boom up operation
When the boom control lever is pulled back to raise the boom, the secondary pressure oil from the pilot valve flows
to the ports a8 and a8' to move the spool of the boom section and the spool of the parallel-flow divider, respectively.
Therefore, the oil from the pump P3 flows into the three ways as follows :
1. Flows to the boom section through the throttle, the passage A, the inside of the spool of the parallel-flow divider
and the combined oil passage for the boom.
2. Flows to the boom section through the spool land opening of the parallel-flow divider and the combined oil pas-
sage for the boom.
3. Partly flows to the tank passage through the notch in the parallel-flow divider and the P2 parallel passage.
Refer to 2) Boom Operation for the operation of the boom section in the boom up operation.
6-2-18 4720103
(2) In arm retract operation

When the arm control lever is pulled back to retract the arm, the secondary pressure oil from the pilot valve flows to
the ports b4 and b4' to move the spool of the arm section and keep the spool of the parallel-flow divider in the neutral
position, respectively. Therefore, the oil from the port P3 flows through the spool land opening of the parallel-flow
divider and the P2 parallel passage to the arm section.
Refer to 6) Arm Operation for the operation of the arm section in the arm retract operation.
6-2-19 4720103
(3) In simultaneous operation of boom up and arm retract

When the arm control lever is pulled back to retract the arm while the boom is raising, the secondary pressure oil
from the pilot valve flows to the ports a8 and b4 to move the boom spool and the arm spool respectively, and also
flows to the ports a8' and b4'. When the ports a8' and b4' are applied with the same oil pressure, the spool of the par-
allel-flow divider is kept in neutral position due to the return spring force of the spool of the parallel-flow divider.
Therefore, the oil from the port P3 flows into the two ways as follows :
1. Flows to the arm section through the spool land opening of the parallel-flow divider and the P2 parallel passage.
2. Flows to the boom section through the notch in the spool of the parallel-flow divider and the combined oil pas-
sage for the boom.
The oil flows to the arm section prior to the boom section as there are no notch to pass through before the arm sec-
tion.
(4) In other operations
The spool of the parallel-flow divider is kept in the neutral position. The oil flow from the port P3 is the same as that
in (3) Simultaneous operation of boom up and arm retract.
6-2-20 4720103
9) Blade Operation
(1) Blade up operation
When the blade lever is pulled back to raise the blade, the spool of the blade section is pressed forward. The oil from
the port P3 flows through the parallel passage to the return passage of the blade section and is blocked by the blade
spool as the spool has been moved.
The passage between the port A1 and the bridge passage is opened as the blade spool has been moved, the oil
flowed to the parallel passage flows through the load check valve and the bridge passage to the port A1 and is fed to
the rod side of the blade cylinder.
Meanwhile, the return oil from the bottom side of the blade cylinder flows through the port B1 to the tank passage,
which is opened as the blade spool has been moved.
Thus, the blade cylinder is retracted to raise the blade.
6-2-21 4720103
(2) Blade down operation

When the blade lever is pushed forward to lower the blade, the spool of the blade section is pulled back. The oil from
the port P3 flows through the parallel passage to the return passage of the blade section and is blocked by the blade
spool as the spool has been moved.
The passage between the port B1 and the bridge passage is opened as the blade spool has been moved, the oil
flowed to the parallel passage flows through the load check valve and the bridge passage to the port B1 and is fed to
the bottom side of the blade cylinder.
Meanwhile, the return oil from the rod side of the blade cylinder flows to the tank passage through the port A1 and
the notch in the blade spool, which is opened to the tank passage as the blade spool has been moved.
Thus, the blade cylinder is extended to lower the blade.
6-2-22 4720103
10) Swing Operation

(1) Right swing operation
When the swing control lever is moved to the right, the secondary pressure oil flows to the port a2 to move the spool
of the swing section.
The oil from the port P3 flows to the parallel passage and is blocked by the return passage of the swing section
closed as the swing spool has been moved. (A part of oil flows to the tank passage through the drill hole in the swing
spool.)
The passage between the port A2 and the bridge passage is opened as the swing spool has been moved, the oil
flowed to the parallel passage flows through the load check valve and the bridge passage to the port A2 and is fed to
the swing motor.
Meanwhile, the return oil from the swing motor flows to the tank passage through the port B2 and the notch in the
swing spool, which is opened to the tank passage as the swing spool has been moved.
6-2-23 4720103
(2) Left swing operation

When the swing control lever is moved to the left, the secondary pressure oil flows to the port b2 to move the spool
of the swing section.
The oil from the port P3 flows to the parallel passage and is blocked by the return passage of the swing section
closed as the swing spool has been moved. (A part of oil flows to the tank passage through the drill hole in the swing
spool.)
The passage between the port B2 and the bridge passage is opened as the swing spool has been moved, the oil
flowed to the parallel passage flows through the load check valve and the bridge passage to the port B2 and is fed to
the swing motor.
Meanwhile, the return oil from the swing motor flows to the tank passage through the port A2 and the notch in the
swing spool, which is opened to the tank passage as the swing spool has been moved.
6-2-24 4720103
11) System Relief Valves

(1) Relief operation
[1] Pressure oil flows through the inside of the piston installed in the pressure control valve (the parent valve) and
the throttle B to the inner chamber A, so that it is filled with oil. The pressure control valve and the socket are
securely seated, and so are the socket and the section body seat.
[2] When the oil pressure in the port P reaches the set pressure of the regulating valve spring, the pressure oil flows
through the piston to the regulating valve to open it.
At this time, the pressure oil passes through the inside of the piston, the throttle B, the inner chamber A, the ring-
shaped throttle C and the drill hole D in sequence, and flows outside the socket to the tank passage.
[3] When the regulating valve opens, the pressure in the inner chamber A is lowered, and consequently, the pres-
sure control valve is opened and the pressure oil in the port P flows directly to the tank passage through the drill
hole E.
[4] When the pressure in the port P lowers to less than the set pressure of the regulating valve spring, the regulating
valve is pressed on the seat with the force of the regulating valve spring and the pressure in the inner chamber A
becomes equal to that in the port P. Therefore, the pressure control valve is also pressed on the seat portion of
the socket and returned to the original state ([1]).
6-2-25 4720103
12) Circuit Relief Valves

The circuit relief valve is installed in the rod and bottom sides of the bucket, boom and arm cylinders and the rod side
of the boom swing and blade cylinders.
(1) Relief operation
[1] Pressure oil flows through the inside of the piston installed in the pressure control valve (the parent valve) and
the throttle B to the inner chamber A, so that it is filled with oil. The pressure control valve and the socket are
securely seated, and so are the socket and the section body seat.
[2] When the oil pressure in the port P reaches the set pressure of the regulating valve spring, the pressure oil flows
to the regulating valve to open it.
At this time, the pressure oil passes through the inside of the piston, the throttle B, the inner chamber A, the ring-
shaped throttle C and the drill hole D in sequence, and flows outside the socket to the tank passage.
[3] When the regulating valve opens, the pressure in the inner chamber A is lowered, and consequently, the pres-
sure control valve is opened and the pressure oil in the port P flows directly to the tank passage through the drill
hole E.
[4] When the pressure in the port P lowers to less than the set pressure of the regulating valve spring, the regulating
valve is pressed on the seat with the force of the regulating valve spring and the pressure in the inner chamber A
becomes equal to that in the port P. Therefore, the pressure control valve is also pressed on the seat portion of
the socket and returned to the original state ([1]).
6-2-26 4720103
(2) Suction operation

When negative pressure is generated in the port P, the port P is supplied with oil from the tank passage to prevent
negative pressure.
When the pressure in the tank passage exceeds that in the port P, upward force is applied to the socket. This cre-
ates an opening between the section body seat and the socket, and oil flows from the tank passage to the port P, so
that the space in the port P is filled with oil.
13) Anti-Cavitation Valve

The anti-cavitation valve is installed in the bottom side of the boom swing cylinder.
When negative pressure is generated in the port P, the port P is supplied with oil from the tank passage to prevent
negative pressure.
When the pressure in the tank passage exceeds that in the port P, upward force is applied to the valve. This creates
an opening between the section body seat and the valve, and oil flows from the tank passage to the port P, so that
the space in the port P is filled with oil.
6-2-27 4720103

(1) Precautions for disassembly
[1] Since the parts of the hydraulic equipment are generally precision-made for tight clearances, be sure to perform
disassembly and reassembly in a clean area that is free from dust.
[2] Prepare clean tools and treated oil, and handle them carefully.
[3] First clean the external surface of removed assemblies.
[4] Before beginning, review the drawings of the internal construction and prepare the required parts according to
the purpose and extent of the disassembly. After disassembly, replace the removed seals and O-rings with new
ones in principle. As some replacement parts are available only as subassemblies, see the parts catalogue to
prepare the necessary subassemblies in advance.
(2) Precautions for reassembly

[1] Handling the O-rings
1] Lubricate the O-rings and the O-ring fitting seats with clean grease or hydraulic oil.
2] The O-rings may not have any defects in molding, or be damaged in handling or distorted by heat.
3] Do not stretch any O-rings with such great force as to permanently deform them.
Prevent any O-ring from being damaged when it is set to the spool from its sharp end.
4] Avoid rolling the O-rings when fitting them.
A distorted O-ring may not return to its original shape; therefore it may cause oil leakage.
[2] Before beginning reassembly, check that there is no treated oil or hydraulic oil on the outer surface of the O-ring
groove in the mating face of each section. If reassembly is performed without cleaning such oil, it may be mis-
taken for oil leakage.
[3] Reassembly of control valve sections
Put the control valve sections with the actuator port down in the order shown in the figure below.
Note :
The symbol representing for each valve section is as follows and is carved on the upper surface (the actuator port
side) of each valve body.
Section ViO35-2 ViO27-2
Blade SG ←
Swing GE ←
Parallel-flow divider UF ←
P.T.O. TB ←
Arm FT ←
Boom swing FS ←
Travel (L) CH ←
Inlet AK ←
Travel (R) BC ←
Boom EF ←
Anti-drift valve KJ KI
Bucket VB ←
6-2-28 4720103
Tool Q'ty Size

Hexagon bar wrench (mm) 1 (for each) 4, 5, 6, 8
Wrench (mm) 1 (for each) 10, 13, 19, 21, 22, 26
Socket wrench (mm) 1 (for each) 13, 19, 21, 22, 26
Torque wrench [N·m (kgf·m)] 1 1.96 to 19.6 (0.2 to 2.0)
Torque wrench [N·m (kgf·m)] 1 19.6 to 98.1 (2.0 to 10.0)
Magnet 1
Player 1
Screwdriver 1
Tweezers 1
6-2-29 4720103
3) Disassembly
3)-1. Removal of spools
(1) Pilot operated type (swing, parallel-flow divider, and
arm sections)
Remove each spool as in example of the removal proce-
dure of the swing spool given below.
[1] Remove the two hexagon socket head bolt and SWP
washer assemblies 10 with a hexagon bar wrench (4
mm).
[2] Remove the pilot case A1 9.
[3] Slowly pull the spool assembly (2a-2e) out of the
valve holding the spool assembly by the spring part
in the level direction with the spool bore.
[4] The other pilot spools (for parallel-flow divider and
arm sections) are able to be removed in the same No. Part
procedure and the same direction. 1 Body (symbol GE)
Note : 2 Swing spool assembly
At this time, check the O-ring 7 is installed at the bottom a Valve rod (for swing)
of the flange for pilot case on the body side.
b Return spring holder
c Return spring (26 K)
d Return spring holder
e Valve rod edge
3 Check valve
4 Check valve spring
5 O-ring 1B P11
6 Check valve retainer
7 O-ring 1B S22
8 Pilot case B1
9 Pilot case A1
Hexagon socket head bolt M5!20 flows
10
washer assembly
6-2-30 4720103
(2) Pilot operated type (boom and bucket sections)

Remove each spool as in the example of the removal
procedure of boom spool given below.
[1] The removal procedure of the boom spool is the
same as that of the spools in (1) except the boom
spool is removed in opposite direction.
No. Part
1 Body (symbol EF)
2 Boom spool assembly
a Valve rod (for boom)
c Return spring (26K)
e Valve rod edge
3 Check valve
5 O-ring 1B P11
7 O-ring 1B S22
8 Pilot case B1
9 Pilot case A1
Hexagon socket head bolt M5!20 and
10
SWP washer assembly
6-2-31 4720103
(3) Hand operated type (blade section)

Remove the spool of the blade section following the pro-
cedure below.
[1] Remove the two hexagon socket head bolts 12 with
a hexagon bar wrench (4 mm).
[2] Remove the return spring case 10.
[3] Slowly pull the blade spool assembly (2a-2g) out of
the valve holding the blade spool assembly by the
spring part in the level direction with the spool bore.
Note :
Take care in pulling out of the spool assembly, otherwise
the spool seal [dust wiper (2c) and O-ring (2b)] can
move to the spool edge and the rip area can be dam-
aged.
No. Part
1 Body (symbol SG)
2 Blade spool assembly
a Valve rod (for blade)
b O-ring 1A P12
c Dust wiper
d Seal plate
e Return spring holder
f Return spring
g Valve rod edge
3 O-ring 1A P12
4 Dust wiper
5 Seal plate
6 Check valve
8 O-ring 1B P11
10 Return spring case
11 Hexagon socket head bolt M5!10
6-2-32 4720103
(4) Hand operated type

(P.T.O., boom swing, and travel sections)
Remove each spool as in example of the removal proce-
dure of the P.T.O. spool given below.
[1] The removal procedure of the P.T.O. spool is the
same as that of the spools in (3) except the P.T.O.
spool is removed in opposite direction.
(5) Precautions
When replacing the spool, never disassemble the spool. No. Part
Replace it with a new one as a spool assembly. 1 Body (symbol TB)
2 P.T.O. spool assembly
a Valve rod (for P.T.O.)
b O-ring 1A P12
c Dust wiper
d Seal plate
f Return spring
g Valve rod edge
3 O-ring 1A P12
4 Dust wiper
5 Seal plate
6 Check valve
8 O-ring 1B P11
6-2-33 4720103
(6) Inlet section

[1] Remove the two hexagon socket head bolt and
washer assemblies 8 with a hexagon bar wrench (4
mm).
[2] Remove the pilot case A2 6.
[3] Remove the return spring 4 and the return spring
holder 3.
[4] Slowly pull the inlet spool out of the valve holding the
spool by the spool edge in the level direction with the
spool bore.
Note :
At this time, check the O-ring 5 is installed at the bottom
of the flange for the pilot case on the body side No. Part
1 Body (symbol AK)
2 Valve rod (for inlet)
3 Return spring holder
4 Return spring
5 O-ring 1B S22
6 Pilot case A2
7 Pilot case B1
8
SWP washer assembly
6-2-34 4720103
3)-2. Disassembly of check valve (load check valve)

[1] Remove the check valve retainer 4 from the central
part of the upper surface of the valve with a wrench
or socket wrench (19 mm).
Note :
The check valve can difficult to loosen due to the O-ring
caught in the thread part. In that time, do not force it
loosen, but retighten and loosen it again.
[2] Remove the check valve spring 2 and the check

valve 1 in the bore, which the check valve retainer
has been removed from, with tweezers or a magnet.
[3] The parallel-flow divider, travel and anti-drift valve
sections can be disassembled in the same proce-
dure.
No. Part
1 Check valve
3 O-ring
6-2-35 4720103
3)-3. Disassembly of anti-drift valve

When the anti-drift valve malfunctions, replace it as an
anti-drift valve assembly. For reference, the disassembly
procedure for examination is shown below.
[1] Remove the two hexagon socket head bolts A with a
hexagon bar wrench (5 mm).
[2] Remove the anti-drift valve case B.
[3] Take care not to drop the two positioning pins C on
the anti-drift valve body side.
Note :
Take care not to lose and damage the pins.
[4] Remove the anti-drift valve 1 and the needle valve 9,

which are exposed.
Notes :
• Remove the needle valve 9 first and keep it as it is
easily removed.
• The anti-drift valve should not be disassembled but it
should be kept as an anti-drift valve assembly (1-7,
10).
[5] Hold the anti-drift valve case with a vice and remove
the bush 17 with a wrench or socket wrench (26 No. Part
mm). 1 Anti-drift valve
Note : 2 Cap seal 1 BE10
Set the vice on any side face other than the port side to 3 Filter
hold the anti-drift valve.
4 Spacer
5 Snap ring AR7
[6] Remove the piston B 15 and piston A1 14 in the
6 Anti-drift valve spring A
bore, which the bush has been removed from, with
7 Spring holder
tweezers or a magnet.
Notes : 8 O-ring AS 1B17
• Make marks on the piston B and the piston A1 so that 9 Needle valve
they can be reassembled in the same direction as it 10 Internal snap ring 9
was before. 11 O-ring 1A P6
• The piston guide 13 should not be disassembled, but it 12 O-ring 1B P8
should be kept together with the anti-drift valve case B. 13 Piston guide
14 Piston A1
[7] Remove the ball retainer 19 with a hexagon bar
15 Piston B
wrench (4 mm).
16 O-ring 1B P18
[8] Remove the steel ball 18 of Ø 0.28 in. (7 mm) from
17 Bush PF1/2!1/4
the bore, which the ball retainer has been removed
from, using a magnet. 18 Steel ball Ø0.28 in. (7 mm)
19 Ball retainer
6-2-36 4720103
4. Reassembly
4) -1. Reassembly of check valve (load check valve)
• Put each section on the work table with the actuator
port side up.
(1) Blade, swing, P.T.O., arm, boom swing, boom and
bucket sections (See Fig. 1)
[1] Install the check valve 1 into the bore in the center of
the valve section in the regular direction (with the
umbrella side down), and make sure that it is com-
pletely inserted into the central part.
[2] Install the check valve spring 2 to the check valve
guide.
[3] Tighten the check valve retainer 4 by hand so that
the check valve guide is installed in the guide of the
check valve retainer, and the check valve spring 2
into the guide of the check valve retainer.
Note :
Make sure the O-ring 3 is installed to the check valve
retainer 4.
[4] After tightening the check valve retainer to some

extent, tighten it with a wrench or socket wrench (19
mm) at the specified torque.
(2) Parallel-flow divider, travel, and anti-drift valve sec-

tions (See Fig. 2)
[1] Install the check valve 1 into the bore in the center of
the valve section in the regular direction (with the
umbrella side down), and make sure that it is com-
pletely inserted in the central part.
[2] Apply grease to the check valve spring 2 and install it
into the guide of the check valve retainer 4. No. Part
Note : 1 Check valve
Make sure the O-ring 3 is installed to the check valve 2 Check valve spring
retainer 4. 3 O-ring
[3] Check that the check valve spring 2 does not fall off
even if the check valve is turned upside down. Then,
tighten the check valve retainer 4 by hand so that the
guide of the check valve 1 installed in the valve sec-
tion body is put into the guide of the check valve
retainer 4.
[4] After tightening the check valve retainer to some
extent, tighten it with a wrench or socket wrench (19
mm) at the specified torque.

6-2-37 4720103
4)-2. Reassembly of spool assembly

(1) Pilot operated type
[1] Make sure that there is no dust or the like in any
spool assemblies and any spool bores in the valve
section bodies and that the O-ring 7 is securely
installed in the bottom of the flange on the front and
rear sides of each valve section body. Then, install
each spool assembly into the spool bore in the
respective valve section body taking care not to
install it in a wrong position and a wrong direction.
Notes :
Apply a little hydraulic oil to the spools before installing
them.
No. Part
[2] Slowly put in and out the spool several times by 1 Body (symbol GE)
hand to see if the spool moves lightly without a feel- 2 Swing spool assembly
ing of scratching. a Valve rod (for swing)
Note : b Return spring holder
If you feel something is wrong, replace the spool assem- c Return spring (26K)
bly and the valve section body as a set. d Return spring holder
e Valve rod edge
[3] Securely install the pilot case 9 to the flange of the
3 Check valve
valve section body from the spring side of the spool
assembly, and tighten the hexagon socket head bolt
5 O-ring 1B P11
and washer assemblies 10 with a hexagon bar
wrench (4 mm) at the specified torque.
7 O-ring 1B S22
Tightening torque : 4.3 to 5.1 ft·lbf
8 Pilot case B1
(5.9 to 6.9 N·m)
9 Pilot case A1
Hexagon socket head bolt M5!20 SWP
10
washer assembly
6-2-38 4720103
[4] Make sure that the O-ring 7 is installed to the flange

on the other side of the valve section body before
installing the pilot case 8 to the flange of the valve
section body. Tighten the hexagon socket head bolt
and washer assemblies 10 with a hexagon bar
wrench (4 mm) at the specified torque.

(5.9 to 6.9 N·m)
No. Part
1 Body (symbol EF)
2 Boom spool assembly
a Valve rod (for boom)
c Return spring (26K)
e Valve rod edge
3 Check valve
5 O-ring 1B P11
7 O-ring 1B S22
8 Pilot case B1
9 Pilot case A1
Hexagon socket head bolt M5!20 SWP
10
washer assembly
6-2-39 4720103
(2) Hand operated type

[1] Make sure that there is no dust or the like in any
spool assemblies and any spool bores in the valve
section bodies. Then, install each spool assembly
into the spool bore in the respective valve section
body taking care not to install it in a wrong position
and a wrong direction.
[2] Slowly put in and out the spool several times by
4
hand to see if the spool moves lightly without a feel-
ing of scratching.
[3] Install the return spring case 10 to the spring side of
the spool assembly, and tighten the hexagon socket
head bolts 12 with a hexagon bar wrench (4 mm) at
No. Part
the specified torque.
1 Body (symbol SG)
Tightening torque : 4.3 to 5.1 ft·lbf 2 Blade spool assembly
(5.9 to 6.9 N·m)
a Valve rod (for blade)
Note : b O-ring 1A P12
Do not tighten each bolt at a time, but alternatively c Dust wiper
tighten the two bolts little by little so that the return spring d Seal plate
case is installed evenly. e Return spring holder
f Return spring
g Valve rod edge
3 O-ring 1A P12
4 Dust wiper
5 Seal plate
6 Check valve
8 O-ring 1B P11
6-2-40 4720103
[4] Install the O-ring 3, the dust wiper 4 and the seal
plate 5 in this order to the spool projected on the
other side of the valve section body and tighten the
bolts 11 with a hexagon bar wrench (4 mm) at the
specified torque.

(5.9 to 6.9 N·m)
Notes :
• Take care with the direction of the dust wiper. (Install it
with the rip side out.)
• Do not tighten each bolt to the specified torque at a
time, but alternatively tighten the two bolts little by little
so that the seal plate is installed evenly.
No. Part
1 Body (symbol TB)
2 P.T.O. spool assembly
a Valve rod (for P.T.O.)
b O-ring 1A P12
c Dust wiper
d Seal plate
f Return spring
g Valve rod edge
3 O-ring 1A P12
4 Dust wiper
5 Seal plate
6 Check valve
8 O-ring 1B P11
13 Check valve retainer (SC3A)
14 O-ring 1B P14
6-2-41 4720103
(3) Inlet section

[1] Make sure that there is no dust or the like in the inlet
spool and the spool bore in the inlet section body
and that the O-ring 5 is securely installed in the bot-
tom of the flange on the front and rear sides of P1
and P2 inlet section body. Then, install the inlet
spool assembly into the spool bore in the inlet sec-
tion body taking care not to install it in a wrong direc-
tion.
Note :
Apply a little hydraulic oil to the spool before installing it.
[2] Install the return spring holder 3 and the return No. Part
spring 4. 1 Body (symbol AK)
[3] Securely install the pilot case 6 to the flange of the 2 Valve rod (for inlet)
inlet section body and tighten the hexagon socket 3 Return spring holder
head bolt and washer assembly 8 with a hexagon
4 Return spring
bar wrench (4 mm) at the specified torque. 5 O-ring 1B S22
Tightening torque : 4.3 to 5.1 ft·lbf 6 Pilot case A2
(5.9 to 6.9 N·m)
7 Pilot case B1
8
SWP washer assembly
6-2-42 4720103
4)-3 Reassembly of anti-drift valve

When the anti-drift valve malfunctions, replace it as an
anti-drift valve assembly. For reference, the reassembly
procedure after disassembled for examination is shown
below.
[1] Hold the anti-drift valve case B by any side face
other than the port side with a vice.
[2] After holding the anti-drift valve case, insert the pis-
ton A1 14 into the bore in the piston guide 13 in the
correct direction.
[3] Insert the piston B 15 into the bore in the anti-drift
valve case B in the correct direction, and then
tighten the bush 17 with a wrench or socket wrench
(26 mm) at the specified torque.
(58.8 to 68.6 N·m)
Notes :
• Be sure to check the bush 17 for the O-ring 16.
• Slowly put in and out the pistons 14 and 15 several
times by hand to see if the pistons move lightly without
a feeling of scratching. If you feel something is wrong,
replace the pistons 14 and 15 and the anti-drift valve
as a set.
[4] Gently set the steel ball 18 Ø 0.28 in. (7 mm) on the
steel ball seat on the upper surface of the anti-drift No. Part
valve case and tighten the ball retainer 19 with a
1 Anti-drift valve
hexagon bar wrench (4 mm) at the specified torque.
2 Cap seal 1 BE10
Tightening torque : 5.8 to 7.2 ft·lbf 3 Filter
(7.8 to 9.8 N·m)
4 Spacer
Note :
Be sure to check the ball retainer for the O-ring 12. 5 Snap ring AR7
6 Anti-drift valve spring A
[5] Check the side face of the valve section body on the
anti-drift valve side for the O-ring. Then, assemble 7 Spring holder
the anti-drift valve assembly (1-7, 10) and the needle 8 O-ring AS 1B17
valve 9 and insert them into the bore for the anti-drift
9 Needle valve
valve.
[6] Align the two positioning pins C on the anti-drift valve 10 Internal snap ring 9
body side to the positioning holes in the anti-drift 11 O-ring 1A P6
valve case and slowly push the anti-drift valve case
12 O-ring 1B P8
until it contacts with the anti-drift valve section body.
Note : 13 Piston guide
Make sure that the needle valve 9 is put into the seat 14 Piston A1
section inside the anti-drift valve case.
15 Piston B
[7] Tighten the hexagon socket head bolts A with a 16 O-ring 1B P18
hexagon bar wrench (5 mm) at the specified torque. 17 Bush PF1/2!1/4
Tightening torque : 7.2 to 8.0 ft·lbf 18 Steel ball Ø0.28 in. (7 mm)
(9.8 to 10.8 N·m) 19 Ball retainer
Note :
Do not tighten each bolt to the specified torque at a time,
but alternatively tighten the two bolts little by little so that
the anti-drift valve case is installed evenly.
6-2-43 4720103
5. Disassembly and Reassembly of Relief Valves

1) Disassembly and Reassembly
Any of the relief valve must be replaced as an assembly in principle. However, only in an emergency case, the relief
valve may be disassembled and reassembled.
(1) Cleaning and Inspection
Clean all the parts using clean treated oil (mineral oil), dry them using compressed air and inspect all of them.
[1] No defect must be found on the seat surface of the poppet. The contact surface must be uniform.
[2] No scratch must be found on the outer surface of the sliding part of the poppet tip.
[3] No damage, distortion or wear must be found on the spring.
[4] No distortion or wear must be found on the O-ring and the backup ring.
If any defect is found in the above inspection, replace the whole relief valve assembly. However, a defective O-
ring can only be replaced with a new one.
(2) Precautions for reassembly
When installing the parts of a relief valve assembly, observe the following precautions for handling O-rings.
[1] Lubricate O-rings with clean grease or hydraulic oil.
[2] O-rings may not have any defects in molding, or be damaged in handling or distorted by heat.
[3] Do not stretch any O-rings with such great force as to permanently deform them.
[4] Avoid rolling the O-rings when fitting them. A distorted O-ring may not return to its original shape, and therefore,
may cause oil leak.
6-2-44 4720103
2) Disassembly and Reassembly of System Relief

Valves
(1) Disassembly
[1] Lightly hold the body 5 by the hexagonal part of the
width across flats 22 with a vice stand.
[2] Remove the nut M14 8 with a wrench (19 mm).
[3] Remove the adjust screw 7 with a hexagon bar
wrench (4 mm).
[4] Remove the spring 9 and the poppet 6 using twee-
zers or the like.
[5] Remove the plug 4 with a wrench (19 mm), and the
other parts can be removed at this time.
[6] Remove the socket 1, the piston 3, the spring 10 and
the poppet 2 in this order.
(2) Reassembly
[1] Install the poppet 6 and the spring 9 into the plug 4
and tighten the adjust screw lightly. At this time, also
tighten the nut M14 8 lightly.
[2] Install the spring 10 and the piston 3 into the poppet
2, and install them into the socket 1.
[3] Make sure that the piston 3 is put into the hole in the
tip of the plug 4 and screw the plug 4 to the body 5 at No. Part
the specified torque. 1 Socket

2 Poppet
3 Piston
[4] Adjust the pressure with adjust screw 7 using a
4 Plug
hexagon bar wrench (4 mm) and tighten the nut M14
5 Body
8 at the specified torque.
6 Poppet
7 Adjust screw
8 Nut 14
9 Spring
10 Spring
11 O-ring 1B P15
12 O-ring 1B S10
13 O-ring 1A P7
14 Backup ring
15 O-ring 1B P14
6-2-45 4720103
3) Disassembly and Reassembly of Circuit Relief

Valves
(1) Disassembly
width across flats 22 with a vice stand.
[2] Remove the nut M14 8 with a wrench (19 mm).
[3] Remove the adjust screw 7 with a hexagon bar
wrench (4mm).
[4] Remove the spring 9, the poppet 6 and the spring
guide using tweezers or the like.
[5] Remove the plug 4 with a wrench (19 mm), and the
other parts can be removed at this time.
[6] Remove the socket 1, the piston 3, the spring 10 and
the poppet 2 in this order.
(2) Reassembly
[1] Install the spring guide 16 to the adjust screw 7 and
install the spring 9.
[2] Install the poppet 6 into the plug 4 and lightly tighten
the adjust screw 7 (with the spring guide 16 and the No. Part
spring 9 installed). At this time, also tighten the nut 1 Socket
M14 8 lightly. 2 Poppet
[3] Install the spring 10 and the piston 3 into the poppet 3 Piston
2, and install them into the socket 1.
4 Plug
[4] Make sure that the piston 3 is put into the hole in the
5 Body
tip of the plug 4 and screw the plug 4 to the body 5 at
6 Poppet
the specified torque.
7 Adjust screw
Tightening torque : 43.4 ft·lbf (58.8 N·m) 8 Nut 14
[5] Adjust the pressure with adjust screw 7 using a 9 Spring
hexagon bar wrench (4 mm) and tighten the nut M14 10 Spring
8 at the specified torque. 11 O-ring 1B P15
Tightening torque : 14.5 ft·lbf (19.6 N·m) 12 O-ring 1B S10
13 O-ring 1A P7
14 Backup ring
15 O-ring 1B P14
16
6-2-46 4720103
4) Disassembly and Reassembly of Anti-cavitation

Valve
(1) Disassembly
width across flats 22 with a vise stand.
[2] Remove the plug 3 with a hexagon bar wrench (8
mm).
[3] Remove the spring 4, and then push the anti-cavita-
tion valve on the seat side taking care not to damage
the seat portion. Pull the O-ring 6 and the backup
ring 5 out of the body on the side of the removed
plug 3 taking care not to damage them by the inter-
nal thread of the body 2.
(2) Reassembly No. Part

[1] Install the anti-cavitation valve 1 into the body 2 and 1 Anti-cavitation valve
put the spring 4 into them. 2 Body
[2] Tighten the plug 3 at the specified torque. 3 Plug
Tightening torque : 43.4 ft·lbf (58.8 N·m) 4 Spring

5 Backup ring
6 O-ring 1AP10A
7 O-ring 1BP14
8 O-ring 1BP15
6-2-47 4720103
6. Service Standard
Inspection of parts
Part Inspection Item Inspection Standard and Measure
1. Section body (1) Check section body for scratches, (1) Replace if following parts are damaged.
rust and corrosion. • Sliding surface with spool, especially spool land
applied with retention pressure
• Seal pockets around spool installation area or flange
• Seal portion of port in contact with O-ring
• Each relief and circuit relief valve seat portions
• Other damages which may lose normal functions
2. Spool (1) Check spool for scratches, scuffing, (1) Replace spool if scratches are found on the exter-
rust and corrosion. nal sliding surface.
(2) Insert spool into bore in section (2) Repair or replace if spool does not operate
body and stroke it while making it smoothly.
rotate.
3. Check valve (1) Check check valve and check valve (1) Repair or replace if seat portion is damaged or
(Load check valve) spring for damages. dented.
(2) Insert check valve into the check (2) Check valve is normal if it moves smoothly. If not,
valve retainer and operate it. replace it.
4. Spring and relative (1) Check spring, return spring holder, (1) Replace if operation is not smooth or damages are
parts plug and cover for rust, corrosion, serious enough to decrease durability.
distortion and breakage.
5. Seal of spool and rela- (1) Check O-ring for hardening, distor- (1) Replace
tive parts tion and damages.
(2) Check dust wiper for distortion and (2) Replace

damages.
(3) Check seal plate for rust, corrosion (3) Repair or replace
and distortion.
6. Relief valve (1) Check appearance for rust. (1) Replace
(2) Check contact surface of valve seat (2) Replace if damaged or dented.
for damages and dent.
(3) Check spring for abnormality. (3) Replace
(4) O-ring and backup ring (4) Replace all in principle
6-2-48 4720103
7. Troubleshooting
1) Control Valve
1. Attachment does not (1) Malfunction of relief valve (1) Measurement of relief valve pressure
operate, operates • *Dust caught between poppet and • *Replace as assembly
slowly, or at low pres- seat. • *Replace as assembly
sure • *Dust caught between poppet and • *Replace as assembly
Time lag when operat- seat. • *Replace as assembly
ing attachment.
• *Sticking of poppet • Readjust adjust screw and tighten lock nut at speci-
• *Breakage or permanent set of spring fied torque.
• Loose adjust screw • Disassembly and cleaning
(2) Dust caught between body and • Replace body and spool if seriously damaged.
spool, or sticking of spool.
2. Drifting of cylinder is (1) Too large clearance between sec- (1) Replace spool.
large when spool is in tion body and spool
neutral position.
(2) Spool does not return to the neutral (2) Measurement of secondary pilot pressure
position completely. • Disassembly and cleaning.
• Dust caught between section body Replace section body together with spool in case of
and spool, or sticking of spool sticking.
• Breakage or permanent set of spring • Replace spring.
(3) Malfunction of circuit relief valve (3) Measurement of circuit relief valve pressure
Refer to causes with * above Refer to measures with * above
(4) Malfunction of anti-drift valve (4) Replace anti-drift valve section assembly (includ-
• Dust caught between anti-drift valve ing anti-drift valve)
and needle valve seat
• Sticking of anti-drift valve or needle
valve
• Clogged throttle of anti-drift valve
3. Cylinder is retracted in (1) Malfunction of load check valve (1)

extend operation and • Dust caught between load check • Disassembly and cleaning
at start of operation. valve and section body Replace body and spool if seriously damaged.
• Sticking of load check valve • Replace spring.
• Breakage or permanent set of spring
In case of malfunctions marked with*, be sure to replace the relier valve as a relief valve assembly.
6-2-49 4720103
2) Relief Valve
1. Pressure does not rise Relief valve is left open due to sticking • Check engagement part of valve for no foreign sub-
at all. of poppet or piston, or dust is caught in stances caught.
valve seat portion. • Check each part moves free from sticking.
• Completely clean all parts.
2. Relief pressure is Poppet of relief valve is damaged. • Replace damaged part.

unstable. Piston is stuck on adjust pressure con- • Completely clean all parts.
trol valve. • Remove flows on outer surface.
3. Relief pressure is out of (1) Wear due to dust (1) Disassembly and cleaning
range of set values.
(2) Loose lock nut and adjust screw (2) Pressure adjustment
• Breakage or permanent set of spring • Replace spring
(3) Malfunction of system and circuit (3) Measurement of system and circuit relief valve
relief valves pressures
4. Oil leakage (1) Damaged seat portion (1) Replace damaged or worn parts.
Wear of O-ring Check each part for smooth operation and reas-
semble.
(2) Sticking of part due to dust (2) Check for no scratches, cuts or foreign substances
and reassemble.
6-2-50 4720103
6-3 Pilot Valve
Pilot valve unit for arm rest installation

Type 4TH5
Maintenance Instructions
1. Introduction
1) Foreword
This manual deals with the instructions relative to servicing and maintenance operations for the hydraulic pilot con-
trol unit 4TH5 for the inspections and servicing operations associated with the hydraulic system of the machine to
which they are connected. Please consult the maintenance manual supplied by the equipment manufacture.
It is recommended that only qualified personnel perform the installation, connection and maintenance of this device,
and that all operations shall be carried out in compliance with the technical standards in force and the cleanliness
regulations specific to this type of installation.
To ensure maximum performance and safety during maintenance operations we advise you to
Read this manual thoroughly
All information, illustrations, instructions and characteristics contained in this document are based on the latest prod-
uct information available at the time of publication. In its attempts to maintain a high-quality product, MANNESMANN
REXROTH reserves the right to make design or technical modifications at any time and without prior notification.
2) Safety Instructions
Please pay a special attention to the signals of safety alerts and special instructions in this manual. They are indi-
cated in the following manner:
Indicates information or instructions which must be followed to guarantee your safety during opera-
tions.
CAUTION :
Warning against possible equipment damage.
Note :
Useful information.
6-3-1 4720103
2. Troubleshooting
CAUTION :
Before starting any procedures of troubleshooting or removing the hydraulic pilot control unit, inspect the global
machine's hydraulic system to eliminate all possible malfunctions not related to the pilot control unit.
Abnormal operation of equipment connected to the hydraulic pilot unit

Malfunction Probable case Additional checks Remedy
No machine movement (for (1) Leak See <Visual defects>
hydraulic signal receivers
(2) Control valve seized or Replace pilot unit
only)
blocked
Lack of speed of one or sev- (1) Poor pressure signal Replace pilot unit
eral machine movement(s)
(2) Leak See <Visual defects>
(for hydraulic signal receivers
only)
No machine movement (for (1) Electric function failure Replace handle
electric signal receivers only)
(2) Handle poorly connect Check the connection
Abnormal hydraulic pilot unit operation

Handle does not automati-
cally return to neutral posi-
tion:
(1) Manual return with fric- (1) Faulty cardan Replace cardan
tion
Handle does not automati-
cally return to neutral posi-
tion:
(2) Manual return without (1) Lip seal too hard inside Replace guides + plungers
friction guide
(2) Regulation unit setting Remove the regulation unit Replace pilot control unit
spring broken for visual inspection
(3) Regulation unit plater
broken
Handle turns (1) Handle parts loose Tighten all handle parts
Visual defects
Handle push buttons worn Replace push buttons
out
Rubber boot damaged Replace boot
Leak on arm rest originating Leak between guide and Lift the boot to perform a Replace guides + plungers
from under the boot push buttons visual inspection
Seepage on body Porous body Replace the pilot unit
6-3-2 4720103
3. Fundamental Rules
1) General Information Concerning Pilot Control Unit Connection
When removing the pilot control unit, all openings must be plugged immediately to prevent any contamination of the
hydraulic system.
When replacing the pilot control unit, remove the plastic plugs from the openings and lines just before making the
connections.
Do not tighten connectors to a torque greater than that specified in the assembly instructions.
Check the hydraulic installation's oil quality and filtration capacity during all servicing/maintenance operations.
The use of teflon tape, hemp and joint filler is prohibited.
Hydraulic lines and connections must not be under any strain whatsoever.
4. Removal / Installation of the Pilot Control Unit Connection

1) General Recommendations
CAUTION :
Before removing the pilot control unit from the machine, the block and its surroundings must be thoroughly cleaned
with a high-pressure cleaner.
No impurities must enter the hydraulic system. Plastic plugs are to be fitted on lines and orifices immediately follow-
ing their removal.
Wear protective clothing and use suitable equipment to prevent accidents, particularly concerning
the hydraulic fluid.
Set all actuators connected to the machine in neutral position (on the ground, at lower limit...) to
avoid accidents which could result from uncontrolled movements of the equipment when the
hydraulic system is disconnected.
With the machine off, release the pressure remaining in the system by manipulating all of the distri-
bution spools. This is performed by moving the handle in all directions.
2) Pilot Control Unit Removal

Immediately after disconnecting the lines from the control device, fit the sealing plugs. Make sure to collect any pos-
sible oil leakage in a suitable receptacle.
Unscrew the mounting screws and remove the control device.
3) Installation of the Hydraulic Pilot Control Unit

Contact faces must be perfectly clean.
Check the evenness of the support area on the machine (tolerance : 0.5 mm).
Check the condition of the line connector seals.
Clean the pilot control unit if it has been in storage for a long period of time.
Correctly place and secure the pilot control unit onto the machine with the mounting screw (maxi torque : 10 N·m).
Connect the lines to the control unit as per the connecting diagram and tighten to the torque specification (maxi
torque : 30 N·m).
Ensure that the hoses are not twisted or rubbed.
Once correctly installed, the unit can be placed into operation.
6-3-3 4720103
5. Pilot Control Unit Repair Procedures

1) Push Button Replacement
Procedure
Note :
The pilot control unit does not need to be removed from the
machine to perform this operation.
Machine off :
- place all of the machine's equipment connected
to the pilot control unit in neutral position,
- release stored pressure by operating all of the
pilot unit's control valves by moving the handle
in all directions.
Remove worn out push button(s) using a small screwdriver.
The installation of new elements is performed without any

special tools ; the parts are simply pressed into place.
6-3-4 4720103
2) Boot or Handle Replacement

Procedure
Preliminary operations
Remove the pilot control unit from the machine's arm rest of
free the unit by unscrewing the 4 screws fixing the plate in
order to release the electrical cable.
Hold the pilot control unit using a vice or a vice-grip wrench
(clamp onto the body above the arm rest, 65 opening).
Note :
The pilot control unit does not need to be removed from the
machine to release the cable. However, it is recommended to
lift the control unit by undoing the 4 fixing screws on the arm
rest.
It is unnecessary to remove the units without electrical func-
tions.
Machine off :
- place all of the machine's equipment connected
to the pilot control unit in neutral position,
- release stored pressure by operating all of the
pilot unit's control valves by moving the handle
in all directions.
Handle removal
Lift and turn the boot inside out.
Remove the grommet from its emplacement to free the cable.
Loosen the handle mounting nut (19 mm open-end wrench).
Reassembly : torque : 30±3 N·m
Unscrew and remove the handle.
Boot replacement
Remove the faulty boot and replace it with a new boot.
Replace the handle following the disassembly instructions in
reverse order.
6-3-5 4720103
Procedure
Handle replacement
Clamp the threaded section of the bent lever in a vice fitting
with V-shaped vice clamps.
Remove the pin (5 mm pin driver)
Remove : - pin,
- bent lever,
- handle.
Replace the bent lever onto the new handle and secure it with
the pin (5 mm pin driver)
Note :
Respect the position of the bent lever to ensure that the han-
dle is correctly oriented as indicated by the machine's techni-
cal specifications.
Replace the nut on the threaded section and replace the boot.
Screw the handle onto the pilot control unit and tighten the nut
(19 mm open-end wrench).
Connect the new handle's electrical wiring to the machine's
electric system.
Fit the grommet into its emplacement while leaving enough
cable length so as to enable the correct handle operation.
Secure the cable to the grommet with a cable clamp.

Fold down the boot.
6-3-6 4720103
3) Cardan Replacement
Procedure
Remove the pilot control unit from the machine's arm rest.
Secure the pilot control unit in a vice (clamp onto the body).
Remove the handle.
Note :
It is recommended to remove the pilot control unit from the
machine. Nevertheless, the servicing on machine is possible
by securing the unit into a vice-grip wrench (65 opening). This
is performed by extracting the body from the arm rest so as to
clamp the vice-grip wrench onto the body in order to hold it
above the arm rest.
Removal of the cardan

Fit an Allen wrench into the assembly screw and unscrew it (8
mm Allen wrench).
Reassembly : torque : 45±4 N·m

Remove : - the cardan,
- the shim(s)
Reassembly : Adjust the pre-depression of the cardan by

selecting the shims necessary to obtain play-free contact
between the switch-plate and the plungers. In neutral position,
the depression of the plungers must not exceed 0.2 mm. In
order to check this value, observe the displacement of the
plunger located opposite to the one being pressed.
Note :
The pre-depression may be difficult to achieve on site. Could
be necessary to readjust it after reassembly and system work-
ing control.
6-3-7 4720103
4) Guide / Plunger and Regulation Unit Replacement

Procedure
Remove the pilot control unit from the machine's arm rest.
Remove the handle.
Remove the cardan.
Note :
It is recommended to remove the pilot control unit from the
machine. Nevertheless, the servicing on machine is possible
by securing the unit into a vice-grip wrench (65 opening). This
is performed by extracting the body from the arm rest so as to
clamp the vice-grip wrench onto the body in order to hold it
above the arm rest.
Removal
Secure the pilot control unit to a vice.
Remove the retaining plate.
Reassembly : Line up the notches for the grommet in both the
plate and the body.
Insert the end of a thin screwdriver between the guide and the
body, carefully lift the guide to remove it from the body.
Note :
Hold the guide with the other hand during the extraction oper-
ation to limit the effect of the return spring.
Remove the guide / plunger assembly.

Repeat the operation for the other 3 sub-assemblies.
Reassembly : Use the retaining plate to insert the 4 guides
into the body simultaneously and perpendicularly.
Reassemble in reverse order.
Regulation unit verification

Extract the regulation units from the body (using flat nose pli-
ers).
Visually check that the guides / plungers are in good condi-

tion. If defects are present, replace the 4 sub-assemblies.
Inspect the regulation units and particularly their spring. If
defects are detected, replace the 4 units.
6-3-8 4720103
6-3-9 4720103
Item Description Reference N° Dimensions

1 Handle TT 07 213 322
3 Lever kit 07 213 213
4 Rubber boot 07 259 959
7 Retaining plate 07 261 225
8 Cardan kit composed of : 1 cardan + shims 07 213 399
10 Plunger kit composed of : 07 213 396
4 plunger guides a
4 plain plungers b
4 spring rings c
Item Description Reference N° Dimensions

1 Handle ST with cable socket AMP 08 200 133
2 Push button kit 07 213 314
3 Lever kit 07 213 213
4 Rubber boot 07 259 959
7 Retaining plate 07 261 225
8 Cardan kit composed of : 1 cardan + shims 07 213 399
10 Plunger kit composed of : 07 213 396
4 plunger guides a
4 plain plungers b
4 spring rings c
6-3-10 4720103
6-4 Swing Motor
1. Structure and Functions

The swing motor consists of a swash plate type axial piston motor, a relief valve, a make-up valve, a mechanical
brake, a planetary reduction gear and other parts.
The rotary group of the piston motor consists of a cylinder barrel integrated with a drive shaft and nine pistons
located in the cylinder barrel. The cylinder barrel is supported by bearings at both ends.
The piston is guided by a shoe holder and a barrel holder, which ensures that the piston slides smoothly along the
swash plate.
There are housed a relief valve for relieving excessive pressure (cushion relief) and a make-up valve for preventing
cavitation in the housing.
The mechanical brake, which consists of disc plates and steel plates, is installed between the cylinder barrel and the
housing as a parking brake.
6-4-1 4720103
1) Hydraulic Motor
Hydraulic oil supplied from the pump through the control valve is fed to the valve plate 5 through the relief valve.
When the hydraulic oil is supplied to the port A, the oil flows into the actuator ports of the cylinder barrel 4 which cor-
respond to the port A, and presses the piston 6. The pressing force the piston receives from the hydraulic oil is con-
verted into rotating force through the swash plate 7 and transmitted to the output shaft 3 splined to the cylinder barrel
4.
The return oil from the actuator ports flows out of the port B of the valve plate 5. In the opposite rotation to the above,
the hydraulic oil flows into from the port B and the return oil flows out of the port A.
6-4-2 4720103
2) Mechanical Brake
The mechanical brake serves to mechanically lock the output shaft of the swing motor while the motor is stopped.
When the brake release pressure is in the OFF state, the brake piston fixed to the housing with a pin is kept pressed
by the spring, against the disc plate splined to the cylinder barrel. Consequently, the frictional force disables the rota-
tion of the cylinder barrel, and therefore, the output shaft of the swing motor is locked. (See Fig. A.)
When the brake release pressure is turned ON, the hydraulic oil is led to the brake release port and the oil pressure
which exceeds the force of the spring moves the brake piston in the arrowed direction in Fig. B. Consequently, the
disc plate is disengaged and the frictional force between them is lost, and therefore, the cylinder barrel can be
rotated. (See Fig. B.)
6-4-3 4720103
3) Make-Up Valve
(1) Make-up valve has two functions.
Make-up valve prevents cavitation caused by the overrun of the piston motor and the drifting of swing.
Even when the pump stops supplying the oil, the motor still continues to rotate due to the inertia force of the upper-
structure, so that the motor acts like a pump. At that time, the extra oil from the port T is supplied to the main circuit
of the motor through the make-up valve to prevent a vacuum inside the circuit.
(2) When a closed circuit is formed between the control valve and the motor in braking or other states, the extra oil
as much as the drain oil from the motor and the oil leakage from the valve is supplied to the circuit through the make-
up valve to prevent a vacuum inside the circuit and apply the brakes in the same state as for a normal circuit.
6-4-4 4720103
4) Relief Valves
(1) Working principle of relief valves
The relief valves decides the driving and braking force for swinging. It is installed on each main line for the ports A
and B and comprises a circuit where the oil from the relief valve on one side flows to the low pressure line on the
other side.
(2) Relief valve operation

Relief valve pressure depends on the balance of the pressure force applied to the differential area of S1 and S2 (S1-
S2) and the spring force.
Screws had been set before shipping. Do not readjust the screws. Readjusting the screws may not only cause their
primary performance to lose, but also damage equipment and result in a serious accident.
6-4-5 4720103
5) Reduction Gear
(1) Planetary single reduction gear (for ViO27-2 type)
The motor shaft 1 is splined to the drive gear 2. The drive gear 2 engages with the planetary gears 3. The planetary
gears 3 engage with the ring gear of reduction gear housing 4. The planetary gears 3 are held by the holder 5. The
holder 5 and pinion shaft 6 are splined with each other.
The driving force of the hydraulic motor is outputted from the motor shaft 1, and then transmitted to the pinion shaft
6 through the drive gear 2, the planetary gears 3 and the holder 5.
6-4-6 4720103
(2) Planetary double reduction gear (for ViO35-2 type)

The motor shaft 1 is splined to the drive gear 2. The driving force of the hydraulic motor is transmitted to the plane-
tary gears 3 engaging with drive gear 2. The planetary gears 3 are engaging with the ring gear of the reduction gear
housing 4. Therefore, the planetary gears 3 revolve along the ring gear, as they rotate on their own axis. The plane-
tary gears 3 are held by the holder 5 through the bearing, and the holder 5 transmits the revolution movement of the
planetary gears 3 to the sun gear 6 splined to the holder. The sun gear 6 engages with the planetary gears 7and the
rotation movement is transmitted to the planetary gears 3 as in the first gear. The planetary gears 7 engages with the
ring gear of the reduction gear housing 4, so that the planetary gears 7 revolve along the ring gear, as they rotate on
their own axis. The planetary gears 7 are held by the holder 8 through the bearing. Therefore, the holder 8 transmits
the revolution movement of the planetary gears 7 to the pinion shaft 9 splined to the holder 8.
6-4-7 4720103
51
A
6-4-8 4720103
Q'ty Q'ty
No. Part No. Part
ViO27-2 ViO35-2 ViO27-2 ViO35-2
1 Pinion shaft 1 39 Washer 1
2 Collar 1 40 Snap ring 1
3 Plate 1 41 Disc plate 1
4 Taper-roller bearing 1 42 O-ring 1
5 Housing 1 43 O-ring 1
6 Plug 1 44 Brake piston 1
7 O-ring 1 45 Spring seat 2
8 Oil seal 1 46 Disc spring assembly 1
9 Taper-roller bearing 1 47 O-ring 1
10 Plate 2 48 Valve plate 1
11 Collar 1 49 Pin 1
12 Holder B 1 50 Ball bearing 1
13 Thrust washer 3 4 51 Pin 2
14 Inner race 3 4 52 Cover 1
15 Needle bearing 3 4 53 O-ring 2
16 Planetary gear B 3 4 54 Plug 2
17 Thrust plate 1 55 O-ring 2
18 Screw  4 56 Socket head bolt 5
19A Drive gear 1  57 Socket head bolt 2
19B Sun gear B  1 58 Plug 1
20 Holder  1 59 O-ring 1
21 Thrust washer  4 60 Orifice 1
22 Inner race  4 61 Check valve 2
23 Needle bearing  4 62 Spring 2
24 Planetary gear  4 63 O-ring 2
25 Thrust plate  1 64 Plug 2
26 Drive gear  1 65 Back up ring 2
27 O-ring 1 66 O-ring 1
28 Housing 1 67 Poppet sheet 1
29 Ball bearing 1 68 Poppet 1
30 Shaft 1 69 Relief housing 1
31 Thrust plate 1 70 Spring seat 1
32 Piston 9 71 Spring 1
33 Retainer plate 1 72 O-ring 1
34 Retainer holder 1 73 Plug 1
35 Pin 3 74 O-ring 1
36 Cylinder barrel 1 75 Adjuster 1
37 Collar 1 76 Washer 1
38 Spring 1 77 Nut 1
6-4-9 4720103
4. Disassembly
[1] Hydraulic motor
Procedure
(1) Loosen two socket head bolts 57 to remove the hydraulic
motor assembly from the reduction gear body.
57
(2) Remove the valve plate 48 and the pin 49.
Note :
The valve plate 48 could be left on the motor side.
(3) Remove the valve plate 48 and the pin 49.
Note :
The valve plate 48 could be left on the motor side.
6-4-10 4720103
Procedure
(4) Remove the ball bearing 50 and the O-rings 53.
(5) Remove the plugs 64, the springs 62 and the check
valves 61.
(6) Loosen plug 73 to remove relief valve assembly.
Notes :
• Do not move the adjuster kit 75, or the set pressure
changes.
• The relief valve assembly should not be disassembled.
(7) Remove the pins 51 and the O-ring 47 from the housing
28.
6-4-11 4720103
Procedure
(8) Remove the disc spring assembly 46 and the spring
seats 45, and then remove the parking brake piston 44
using the gauge port of the housing 28.
(A plug is installed on the gauge port.)
Notes :
• Brake piston can be pulled out by gradual air blow from
gauge port.
• Blow air gradually to prevent break piston from jumping out
suddenly.
(9) Remove cylinder barrel assembly.
(10) Remove the retainer plate 33 and the piston assemblies

32 from the cylinder barrel assembly.
6-4-12 4720103
Procedure
(11) Remove the pins 35 and the retainer holder 34.
(12) Remove the snap ring 40 pressing the washer 39.
(13) Remove the washer 39, the spring 38 and the collar 37.
(14) Remove the disc plate 41 and the thrust plate 31.
6-4-13 4720103
Procedure
(15) Tap an end of the shaft 30 with a plastic hammer, and
then remove shaft 30.
(16) Disassemble the ball bearing 29 and the shaft 30.
Note :
Replace the removed bearing with a new one.
6-4-14 4720103
[2] Reduction gear

Procedure
(17) Remove the O-ring 27, the drive gear 19A, the thrust
plate 17, the planetary gears 16, the needle bearings 15,
the inner races 14, the thrust washers 13 and the holder
B 12.
Note :
ViO27-2 only.
(18) Remove the O-ring 27, the thrust plate 25, the drive gear
26, the planetary gears 24, the needle bearings 23, the
inner races 22, the thrust washers 21 and the holder 20.
Note :
ViO35-2 only.
(19) Remove the sun gear 19B.
Note :
ViO35-2 only.
6-4-15 4720103
Procedure
(20) Remove the holder B 12 assembly.
Note :
ViO35-2 only.
(21) Hold the holder 12 with a vise, and then loosen the
screws 18 to remove the thrust plate 17.
Notes :
• The screws may be hard to remove due to the loctite
applied when installed. In this case, warm the screw part up
by a drier, and the screws can be removed easily.
• ViO35-2 only.
(22) Remove the planetary gears B 16, the needle bearings

15, the inner races 14 and the thrust washers 13.
Note :
ViO35-2 only.
(23) Remove the collar 11 and the plates 10.
Note :
When replacing the taper-roller bearings 4 and 9 and the col-
lar 2, replace them as the housing assembly.
6-4-16 4720103
Procedure
(24) Remove the pinion shaft 1 (with the inner case of taper-
roller bearing 4, the plate 3, and the collar 2).
Note :
Take care not to drop them when removing the pinion shaft.
When the pinion shaft cannot be pulled out easily, tap it out
with a plastic hammer.
(25) Remove the inner race from the taper-roller bearing 9.
(26) Remove the oil seal 8.
Notes :
• Do not use the removed oil seal again.
• Take care not to damage the outer races of taper-roller
bearings 4 and 9.
(27) Remove the outer races of taper-roller bearings 4 and 9

and the plug 6.
6-4-17 4720103
5. Disassembly
[1] Hydraulic motor
Procedure
(1) Install the relief valve assembly.
(2) Install the check valves 61 and the springs 62.
(3) Install the plugs 64 (with O-ring).
(4) Install the collar 37, the spring 38 and the washer 39 into
the cylinder barrel 36.
Note :
Be careful with the installation direction of collar 37.
6-4-18 4720103
Procedure
(5) Install the snap ring 40 pressing the washer 39.
(6) Apply grease to the pins 35, and then install them into the
cylinder barrel 36.
(7) Install the retainer holder 34.
(8) Set the piston assemblies 32 into the retainer plate 33,
and install them into the cylinder 36.
Note :
Apply sufficient grease to the sliding parts before installing.
(9) Press-fit ball the bearing 29 onto the shaft 30.
Note :
Install the ball bearing 29 with the snap ring set to the direc-
tion shown in the right figure.
6-4-19 4720103
Procedure
(10) Press-fit the shaft 30 and the ball bearing 29 onto the
housing 28.
(11) Apply grease on the rear surface of the thrust plate 31.
Note :
The thrust plate has direction.
(12) Install the cylinder barrel assembly.
Note :
Take care the pins 35 do not come off when installing.
(13) Apply grease to the O-rings 42 and 43, and install them
into the brake piston 44.
6-4-20 4720103
Procedure
(14) Install the brake piston 44 into the housing 28 positioning
the holes for the pins 51.
Install the two spring seats 45 and the disc spring
assembly 46 in a right direction.
(15) Apply grease to the O-ring 47 and install it the housing

28.
Notes :
• Conform whether the pins 51 can be installed into the holes
in the brake piston 44 and housing 28. If not, remove the
brake piston 44 to readjust the positions.
• Install the pins 51 in the cover 52 before assembling.
(16) Apply grease to the two O-rings 53 and the two pins 51,
and install them into the cover 52.
(17) Press-fit the ball bearing 50 to the cover 52.
(18) Install the pin 49 and the valve plate 48.
Note :
Apply grease to the rear surface of the valve plate to prevent it
from dropping.
6-4-21 4720103
Procedure
(19) Install the cover 52 assembly into the housing 28 posi-
tioning the pins 51.
Note :
Take care not to drop the pins 51 and the valve plate 48.
(20) Tighten five socket head bolts 56 temporarily, and then

retighten them with a torque wrench at the specified
torque.
6-4-22 4720103
[2] Reduction gear

Procedure
(21) Press-fit the oil seal 8 into the housing 5.
Note :
Apply grease to the installation part and the outer surface of
the oil seal 8 before press-fitting.
• Dimension of oil seal after press-fitting

ViO27-2 : 0.177 in. (4.5 mm)
ViO35-2 : 0.157 in. (4.0 mm)
(22) Press-fit the outer races of the taper-roller bearings 4

and 8, and install the plug 6.
(23) Apply grease to the inner race of the taper-roller bearing

4 (with the plate 3 and the collar 2) installed into pinion
shaft 1.
(24) Install the pinion shaft 1 into the housing 5.
Note :
Apply grease to the rip of the oil seal 8 before installing the
pinion shaft 1.
(25) Install the inner race of the taper-roller bearing 9.
6-4-23 4720103
Procedure
(26) Install the collar 11 and the plates 10.
(27) Install the thrust washers 13, the inner races 14, the nee-
dle bearings 15, the planetary gears 16, the thrust plate
17 and the drive gear 19A into the holder B 12.
(28) Apply grease to the O-ring 27 and install it into the hous-
ing 5.
Note :
The thrust plate has direction..
Note :
ViO27-2 only.
dle bearings 15 and the planetary gears 16 into the
holder B 12.
Note :
ViO35-2 only.
6-4-24 4720103
Procedure
(30) Install the thrust plate 17 and the screws 18 into the
holder B 12.
Note :
Apply adhesive to the screws before installing.
Note :
ViO35-2 only.
(31) Install the holder B 12 assembly.
Note :
ViO35-2 only.
(32) Install the sun gear 19B
Note :
ViO35-2 only.
(33) Install the holder 20.
Note :
ViO35-2 only.
6-4-25 4720103
Procedure
dle bearings 23, the planetary gears 24, the drive gear
26, the thrust plate 25 and the O-ring 27.
Note :
ViO35-2 only.
(35) Put the motor assembly onto the reduction gear assem-
bly, and then temporarily tighten two socket head bolts
57 and retighten them at the specified torque.
6-4-26 4720103
6. Service Standard
Clean the removed parts with wash oil, dry them with compressed air and repair or replace them, if necessary,
according to the following service standards :
1) Motor
No. Part Service standard
1 Piston 32 assembly • Deep flaws on sliding parts or rough sliding surface.
• Too large clearance between piston and cylinder barrel bore.
• Maximum diameter clearance : 0.00157 in. (0.04 mm).
• Too large looseness in shoe ball part.
• Maximum play (travel limit) 0.0157 in. (0.4 mm).
2 Thrust plate 31 • Deep flaws on sliding parts or rough sliding surface.
Retainer holder 34
Retainer plate 33
Valve plate 48
Brake piston 44
3 Cylinder barrel 36 • Deep flaws on sliding parts and rough sliding surface.
• Excessive wear or damage on engaged surface.
4 Disc 41 • Deep flaws or flaking on disc (friction material).
• Excessive wear or damage on engaged surface.
5 Ball bearing 29, 50 • Flaking or break away on rolling contact surface.
• Dents on rolling contact surface.
• Abnormal rotation of bearing (with noise and no smoothness).
6 Spring 38 • Damage or excessive deformation.
7 O-ring 42, 43, 47, 53, 54, 59, 63 • Flaws causing oil leak or loss of seal characteristic, or permanent set.
2) Reduction Gear
1 Pinion shaft 1 • Excessive flaws, wear or flaking on gear tooth surface.
2 Plate 2 • Excessive flaws or wear.
3 Taper-roller bearing 4, 9 • Excessive flaws, dent or flaking in race parts of roller.
• Rotation with noise and no smoothness.
• When replacing housing 5, do it as housing assembly.
4 Oil seal 8 • Flaws, deformation or excessive wear on lip part.
• Stiffened lip part.
5 Housing 5 • Excessive flaws, wear or flaking on gear tooth surface.
Holder 12, 20 • When replacing housing 5, do it as housing assembly.
Drive gear 26
Sun gear 19B
Drive gear 19A
6 Inner race 14, 22 • Excessive flaws, wear and flaking on rolling contact surface with nee-
dle bearing.
7 Needle bearing 15, 22 • Excessive flaws, wear and flaking on surface of needle bearing.
8 Planetary gear B 16, 24 • Excessive flaws, wear and flaking on surface of gear tooth.
• Excessive flaws, wear and flaking on rolling contact surface with nee-
dle bearing.
9 Thrust plate 17, 25 • Excessive flaws, wear and seizing on sliding surface.
6-4-27 4720103
3) Valve
1 Spring 62 • Deep damage or large distortion.
2 Plug 64, 73 • Flaws causing oil leak or loss seal characteristic.
Check valve 61 • Permanent set.
O-ring 63, 66, 72, 74
Backup ring 65
4) Others
1 Others plugs, O-rings • Flaws causing oil leak or loss of seal characteristic.
• Permanent set.
6-4-28 4720103
7. Troubleshooting
1) Motor
1. Motor does not rotate. (1) Malfunction of equipment other than Check whether the specified volume of hydraulic oil
piston motor, valve (built-in motor) is fed to the motor suction side. Then, check and
and reduction gear. repair each part.
(2) Escape of pressure oil due to exces- Replace any excessively worn parts.
sive wear of motor's sliding parts. Repair any flaws or burr on the surfaces, clean all
the parts and reassemble them.
(3) Malfunction due to breakage of Disassemble the motor replace any broken parts.
motor's main parts. Clean all the parts and reassemble them.
(In this case, motor makes an
abnormal sound.)
(4) Malfunction due to breakage of main Disassemble the motor replace any broken parts.
parts of reduction gear. Clean all the parts and reassemble them.
(In this case, reduction gear makes
an abnormal sound.)
(5) Operation of relief valve due to too Check the load and regulate it to the value corre-
much load applied to motor. sponding to the set relief pressure.
2. Motor speed is low. (1) Specified volume of oil is not sup- Check whether the specified volume of hydraulic oil
plied to motor due to failure of is fed to the motor suction side. Then, check and
hydraulic pump, system relief valve, repair each part.
etc.
(2) Specified speed is not obtained due After disassembling the motor, check them for
to drop of motor's displacement. excessive wear of the sliding parts. Repair or
replace any worn parts.
3. Large fluctuation in motor (1) A large volume of high pressure oil After disassembling the motor, check the parts and
revolutions. leaks and flows out of drain port due replace any worn parts.
to wear of motor's sliding parts, Clean all the parts and reassemble them.
causing excessive drop and fluctua-
tion in motor revolutions.
The fluctuation is also caused due to
worn bearing.
4. Oil leak. (1) Breakage of oil seals or O-rings. Replace any broken oil seal and O-ring. Take care
not to damage the lip of the oil seal.
Maximum temperature of safety use of O-ring is
176 °F (80 °C). When hydraulic oil temperature
rises more than 176 °F (80 °C), some measures
are necessary, such as oil cooler into hydraulic cir-
cuit.
(2) Due to the reason of [1-(2)] and [3- Repair motor according to procedure of [1-(2)] and
(1)] oil pressure is applied to inside [3-(1)], and then replace oil seal with new one.
of motor housing, causing oil seal Take care not to damage lip part when oil seal
breakage and oil leak. inserting.
$ Oil seal
Capacity to resist pressure
42.7 PSI (0.3 MPa)
(Maximum momentary)
Common ! 14.2 PSI (0.1 MPa)
6-4-29 4720103
4. Oil leak. (3) Due to foreign material inside drain Clean clogged drain pipe. Check drain system to
pipe and long thin pipe, back pres- reduce line resistance. After taking these measures
sure rises, causing oil seal breakage so that oil pressure which is less than 42.7 PSI (0.3
and oil leak. MPa) is not applied to oil seal, replace oil seal with
$ Oil seal new one.
Capacity to resist pressure Take care not to damage lip part when inserting oil
42.7 PSI (0.3 MPa) seal.
(Maximum momentary)
Common ! 14.2 PSI (0.1MPa)
5. Excessive abnormal (1) Increase in drain amount due to According to 2-(2) and 3-(1), take measures and
sound and fluctuation in decreased motor efficiency. remedies.
rotation and pressure due
(2) Malfunction of make-up valve. According to 1-(3), take measures and remedy.
to cavitation.
(3) Short supply of pressure and oil Check supply pressure and oil amount of make-up
amount to make-up valve. valve, and set specified value if necessary.
6-4-30 4720103
2) Valve
1. Motor does not rotate, or (1) Malfunction of equipment other than Check whether the specified volume of hydraulic oil
rotate at a low speed. piston motor, valve (built-in motor) is fed to suction side of valve. Then, check and
and reduction gear. repair each part.
(2) Increasing inner leaking due to Replace O-ring and backup ring with new one.
breakage of relief valve, O-ring or
seal.
(3) Defective seat of make-up valve. • Remove all foreign substances, repair any dam-
[1] Foreign substances caught inside. aged area, clean parts and reassemble them.
If damage is serious and too much oil leaks,
replace make-up valve seat.
[2] Rough and damaged sliding surface • Repair sliding surface, or replace check valve
of check valve. with new one.
[3] Broken spring. • Replace spring. Remove all foreign substances,
repair any damaged area, clean parts and reas-
semble them. Replace if seriously damaged and
too much oil leaks.
(4) Defective seat of relief valve. • Remove all the foreign substances, repair any
[1] Foreign substances caught inside. damaged area, clean the parts and reassemble
them.
Replace if the damage is serious and too much
oil leaks.
[2] Broken spring. • Replace relief valve assembly.
(5) Too low cracking pressure of relief

valve.
[1] Permanent set of spring. Replace relief valve assembly.
[2] Clogged poppet orifice. Clean part with wash oil and reinstall it.
2. Motor does not stop or is (1) Defective seat of make up valve. • Remove all foreign substances, repair any dam-
slow to stop. [1] Foreign substances caught inside. aged area, clean parts and reassemble them.
[2] Rough and damaged sliding surface • Repair sliding surface, or replace check valve
of check valve. with new one.
too much oil leaks.
(2) Defective seat of relief valve. • Remove all the foreign substances, repair any
[1] Foreign substances caught inside. damaged area, clean the parts and reassemble
them.
Replace if the damage is serious and too much
oil leaks.
[2] Broken spring. • Replace relief valve assembly.
(3) Too low cracking pressure of relief

valve.
[1] Permanent set of spring. • Replace relief valve assembly.
[2] Clogged poppet orifice. • Clean part with wash oil and reinstall it.
6-4-31 4720103
2. Motor does not stop or is (4) Increasing leaking.

slow to stop. [1] Increasing inner leaking due to • According to 1-(2), and 1-(3), take measures and
breakage of O-ring seal. remedies.
3. Abnormal sound. (1) Defective seat of make up valve. • Remove all foreign substances, repair any dam-
[1] Foreign substances caught inside. aged area, clean parts and reassemble them.
too much oil leaks.
(2) Short supply of pressure and oil Check supply pressure and oil amount of make-up
amount to make up valve. valve, and set specified value if necessary.
(3) Resonance with other relief valves Readjust set pressure of relief valve.
due to change of relief set pressure.
4. Large shock in stopping (1) Malfunction of shock reduction sys- • Remove all the foreign substances, repair any
swinging. tem. damaged area, clean parts and reassemble
[1] Foreign substances caught inside. them.
Replace if damage is serious and too much oil
leaks.
[2] Pressure oil is not supplied to piston • Clean relief assembly to remove foreign sub-
chamber. stances clogged in orifice.
[3] Increasing leaking due to worn slid- • Repair any damage area, or replace with new
ing surface of piston. one.
(2) Increasing relief set pressure. Readjust set pressure of relief valve.
(1) Malfunction of relief valve. • Remove all foreign substances, repair any dam-
[1] Foreign substances caught in sliding aged area, clean parts and reassemble them.
parts. Replace if damage is serious and too much oil
leaks.
6-4-32 4720103
3) Parking Brake
1. Motor does not rotate. (1) No release pressure is generated, Adjust "PB" pressure to specified pressure.
Parking brake is not or supply pressure is too low (less
released. than specified value). Therefore,
brake piston does not operate.
(2) Valve does not operate due to high Measure motor drain pressure, and check for
motor drain pressure. clogged drain circuit and repair it if necessary.
If amount of motor drain is excessively large, check
motor and repair it if necessary.
(3) Brake piston does not operate. • Replace O-ring with new one.
[1] Pressure oil leak due to abnormal • Check parts and repair flaws.
wear or breakage of O-ring of brake If sliding part is seriously damaged, replace pis-
piston. ton with new one.
[2] Malfunction of piston due to wear • Clean sliding parts to remove foreign sub-
and flows of brake piston sliding stances.
parts.
[3] Malfunction due to foreign sub-
stances caught in piston sliding
parts.
2. Parking brake force is (1) Worn disc. • Replace disc with new one.
low.
(2) Permanent set of spring in piston • Replace spring with new one.
Brake force is not gener-
parts.
ated.
[4] Defective sliding part of brake pis- • Repair sliding. Replace with new one if seriously
ton, or deteriorated friction surface damaged. However, surface of friction material of
of disc. disc cannot be repaired.
[5] Pressure inside cylinder chamber is • Clean filter and orifice, or replace them with new
not relieved due to clogged of orifice ones.
and filter.
3. Parking brake cannot be (1) Brake piston is touching on disc due • Adjust "PB" pressure to specified pressure.
released, creating noise, to low release pressure "PB".
vibration, shock, and
(2) Decrease in pressure inside cylinder • Replace O-ring with new one.
abnormality and generat-
chamber due to excessive wear and
ing heat.
breakage of O-ring in brake piston.
6-4-33 4720103
6-5 Travel Motor
6-5-1 ViO27-2
1. Structure
The travel motor consists of a swash plate type axial piston motor, a counter balance valve, a crossover relief valve,
a 2-speed switching mechanism and a reduction gear.
The swash plate type axial piston motor has 9 pistons and a 2-speed (low and high) switching mechanism.
The counter balance valve and the crossover relief valve are integrated with the piston motor which is housed in the
reduction gear.
The reduction gear reduces the output revolutions of the piston motor through the planetary double-reduction mech-
anism and increases the output torque to transmit it to the sprocket.
6-5-1 4720103
1) Motor
When the travel control valve is switched to "Travel", the hydraulic oil flows through the counter balance valve to the
port A of the valve plate.
When the pressure at the port A rises, the hydraulic oil flows into the bores corresponding to the port A in the cylin-
der barrel.
When the hydraulic oil flows into the bores, the pistons are pressed against the sliding surface of the swash plate,
and the shoes fitted on the pistons slide on the sliding surface of the swash plate towards the circumference. That
motion of more than one piston on the high pressure side is converted into the rotational motion of the cylinder bar-
rel.
The output shaft splined to this cylinder barrel also starts to rotate together with the rotation of the cylinder barrel.
When the pistons move to the low pressure side, the pistons are pushed into the bores and discharge hydraulic oil
from them. The hydraulic oil discharged from the cylinder barrel flows through the port B of the valve plate to the
return passage.
When the travel control valve is switched to the opposite side, the pressure at the port B becomes high and the pres-
sure at the port A becomes low, so that the rotation of the output shaft is reversed.
6-5-2 4720103
2) Counter Balance Valve

The counter balance valve works to reduce the shock caused when the piston motor stops and to prevent it from
overrunning a specified speed due to external loading.
When the control valve is moved to the neutral position, the hydraulic oil flow to the ports P1 and P2 is blocked. This
causes the pressures in the chambers R and L to fall to nearly zero, and the spool is returned to the neutral position
by the force of the springs on both sides. When the spool is returned to the neutral position, the ports M1 and M2 of
the piston motor are blocked by the plunger and the check valve, and the motor is stopped rotating.
6-5-3 4720103
(1) Counter Balance Function

When the hydraulic oil discharged from the hydraulic pump is led to the port P1 of the counter balance valve through
the control valve, the hydraulic oil flows through the check valve L and the port M1 to the piston motor to rotate the
piston motor.
The return oil from the piston motor flows to the counter balance valve through the port M2, but the flow is blocked
by the check valve R. This causes the pump’s discharge pressure rise.
The hydraulic oil with its pressure rise at the port P1 passes through the orifice L and flows into the chamber L.
When the pressure in the chamber L reaches a specified pressure, the plunger starts moving to the right. Then, the
hydraulic oil at the port M2 flows through the notch on the circumference of the plunger to the port P2, while causing
back pressure on the port M2 side, and returns to the hydraulic oil tank through the control valve.
While the plunger is moving, the hydraulic oil in the chamber R is pressured by the plunger and flows through the ori-
fice R to the port P2. The volume of the hydraulic oil flowing out from the chamber R is kept below a specified vol-
ume by this orifice and the moving speed of the plunger does not exceed a specified speed.
When the discharge pressure of the pump rises, the opening of the plunger notch becomes large and the back pres-
sure at the port M2 is reduced.
Thus, the piston motor revolves at a speed which corresponds to the pressure at the port P1, i.e., the oil volume
flowing from the port P1.
6-5-4 4720103
(2) Brake Function

When the control valve is returned to the neutral position, the flow of pressure oil from the pump is blocked and the
pressures at the ports P1 and P2 become equal. Consequently, the plunger starts returning to the neutral position
through the force of the spring R. When the plunger moves, the opening of the plunger notch becomes small, and
since the piston motor still continues to rotate through the inertial force (the pumping of the motor), the pressure at
the port M2 rises. The relief valve R2 is activated by this pressure and lets the oil escape to the port M1 so that the
shock due to the inertial force at the port M2 is absorbed, and at the same time, the cavitation at the port M1 is pre-
vented.
6-5-5 4720103
3) Relief valve
The relief valve decides the driving and braking force for traveling. It is installed on the cross line and has the shock-
less function for reducing the shock caused at the start of acceleration and speed reduction. The relief valve consists
of :
(a) Area difference type relief valve, and
(b) Free piston.
The relief valve works in the following two stages :
(1) First Stage (Shock Absorbing Operation)

When the travel control valve is switched to "Travel", the pressure oil from the pump flows to the passage P1 (P2),
while the oil flows to the spring and piston chambers through the respective orifices for them.
The pressure oil causes the piston to start moving to the left. While the piston is moving, the pressure in the spring
chamber is not increased and is kept at a low level. Therefore, the pressure receiving area S1 of the poppet is much
larger than the regular pressure receiving area (S1-S2) and the poppet opens at about 1/3 of the regular set pres-
sure to let the pressure oil escape to the passage P2 (P1), so that a sudden shock is absorbed. (Low pressure relief)
6-5-6 4720103
(2) Second Stage (Relief Operation)

When the free piston reaches its stroke end, the pressure in the spring chamber rises and the pressures before and
after the poppet become equal. The pressure receiving area of the poppet becomes (S1-S2) and the relief valve
works at the regular set pressure. Thus, the pressure rise is kept below the set pressure and the shock at the start-
ing is reduced. (high pressure relief)
When the motor is started and gains inertia, the pressure in the passage P1 (P2) falls. When the pressure falls below
the set pressure of the relief valve, the poppet closes and all the pressure oil flows to the motor to rotate it at full
speed.
The 2-stage pressure mechanism (shockless mechanism) reduces the shock caused at the start of acceleration and
speed reduction. This mechanism is also instrumental in enhancing the reliability of the equipment and in preventing
cavitation caused in the early stage of speed reduction.
The pressure waveforms of the conventional type and shockless type relief valves are as follows :
6-5-7 4720103
4) 2-Speed Switching Mechanism

1) 1st Speed (Low Speed)
The swash plate has three surfaces a, b and c, as shown in the left figure, and is installed on the flange holder with
two steel balls so that it can move. When the control valve is in the low speed position, since the spool is located in
the position as shown in the left figure by the force of the spring and oil passage is connected to the port T via Pi 1
and Pi 2, the low pressure of the return passage only works on the swash plate control piston. In this condition, the
swash plate control piston does not push up the swash plate. Accordingly, the surface a at the rear of the swash
plate is pressed against the vertical surface by the thrust force of the motor and the force of the spring with the steel
balls as the inclination axis. The inclination angle of the swash plate is "α" as shown in the figure.
6-5-8 4720103
2) 2nd Speed (High Speed)

When the control valve is switched to the high speed position, the pressure oil from the pump is led to the end face
of the spool and the spool is shifted to the position as shown in the left figure. This causes the ports M1 and M2 to
open and the hydraulic oil from the port A (high pressure) in the valve plate of the motor is supplied to the swash
plate control piston though the valve port M1. This pressure oil pushes up the swash plate control piston, which over-
comes the motor thrust force and the spring force, and the surface a of the swash plate is detached from the vertical
surface to cause the surface b to be contacted with the vertical surface tightly. When the surface b contacts with the
vertical surface, the inclination angle of the surface c, which is the sliding surface of the swash plate, is reduced to
"β". Accordingly, the stroke of the piston is reduced to lower the motor displacement. The motor with smaller dis-
placement rotates faster (high speed).
When the motor revolves in reverse, the same action as the above occurs, except that the high and low pressure
ports are reversed.
When the engine is stopped, since no pumps work, no pressure oil is supplied to the end face of the spool and the
spool returns to the 1st speed position by the spring force. Accordingly, no force is applied to the swash plate control
piston to press the swash plate, and the swash plate maintains its low inclination angle "α" through the spring force.
Thus, the low speed condition is always maintained at starting.
6-5-9 4720103
5) Reduction Gear
The reduction gear comprises a planetary double-reduction mechanism.
The drive gear 1 engages with the 1st-stage planetary gear 2 and the 2nd-stage sun gear 4 engages with the 2nd-
stage planetary gear 5. The 2nd-stage planetary carrier 6 is fastened to the machine body. The planetary gears 2
and 5 engage with the ring gear (housing) 7.
The driving force from the piston motor is transmitted to the drive gear 1 and reduced by the gears. The reduced
driving force is then transmitted to the ring gear 7 though the planetary gear 5 of the 2nd-stage planetary carrier 6
fastened to the machine body. (Driving force is also transmitted from the 1st-stage planetary gear 2.) The input and
output revolutions are opposite to each other.
6-5-10 4720103
6-5-11 4720103
No. Part Q'ty No. Part Q'ty No. Part Q'ty

1 Flange holder 1 32 Shaft 1 62 Plug 2
2 Floating seal 1 33 Steel ball 2 63 Spring seat 2
3 Angular bearing 1 34 Spring 2 64 Spring 2
4 Ring nut 1 35 Piston assembly 2 65 O-ring 1B P24 2
5 Plug 2 36 Swash plate 1 66 Cap 2
6 Housing 1 37 Piston assembly 9 67 Spool 1
7 Steel ball 109 38 Retainer plate 1 68 Spring 1
8 Plug PT 1/8 2 39 Retainer holder 1 69 O-ring 1B P11 1
9 Thrust washer 4 40 Cylinder barrel 1 70 Plug 1
10 Collar 4 41 Pin 3 71 Hexagon socket head bolt 6
11 Cage & roller 4 42 Collar 1 72 Valve body 1
12 Planetary gear B 4 43 Spring 1 73 O-ring 1B P10 2
13 Thrust plate 1 44 Washer 1 74 O-ring 1B P7 3
14 Screw 4 45 Internal snap ring 1 75 O-ring 2
15 Sun gear 1 46 Valve plate 1 76 Backup ring 4
16 External snap ring 1 47 Ball bearing 1 77 O-ring 1B P12 2
17 Drive gear 1 48 O-ring 1B P7 2 78 Poppet seat 2
18 Holder 1 49 Pin 1 79 Poppet 2
19 Inner race 3 50 Pin 2 80 Relief housing 2
20 Cage & roller 3 51 O-ring 1B P11 2 81 Orifice 2
21 Planetary gear A 3 52 Plug 2 82 Spring seat 2
22 Thrust plate 1 53 Base plate 1 83 Spring 2
24 Wire 1 54 Orifice 4 84 Shim 2
25 O-ring 1B P130 1 55 Plug 2 85 Free piston 2
26 Cover 1 56 O-ring 1B P11 1 86 Backup ring 4
27 Plug PF1/4 2 57 Plug 1 87 O-ring 1B P15 2
28 O-ring 1BP11 2 58 Plunger 1 88 O-ring 1B P24 2
29 O-ring 1A (AS 568-245) 1 59 Check valve 2 89 Plug 2
30 Oil seal 1 60 Spring 2 90 Hexagon socket head bolt 4
31 Ball bearing 1 61 O-ring S8 A1 2 93 Orifice 2
6-5-12 4720103
4. Special Tools
Unit : in. (mm)
S-2 : Eye bolt S-5 : Housing disassembly jig
S-6 : Ring nut tightening jig
S-8 : Ball bearing disassembly jig S-10 : Angular bearing press-fitting jig
6-5-13 4720103
Unit : in. (mm)

S-9 : Floating seal assembly jig
S-11 : Housing press-fitting jig
S-13 : Oil seal press-fitting jig
6-5-14 4720103
Unit : in. (mm)

S-14 : Ball bearing press-fitting jig S-15 : Shaft S/A press-fitting jig
S-16 : Snap ring assembly jig S-17 : Ball bearing press-fitting jig
S-1 : Pin Ø0.138 (Ø3.5) !1.18 (30)

S-7 : Round rod Ø0.394 (Ø10) !5.9 (150)
S-3 : Round rod Ø0.787 (Ø20) !39.4 (1000)
S-4 : Piano wire Ø0.00787 (Ø0.2) !27.6 (700)
6-5-15 4720103

(1) Since the parts of the hydraulic equipment are precision-made for tight clearances, be sure to perform disassem-
bly and reassembly in a clean area that is free from dust.
(3) First clean the external surfaces of the removed assemblies.
(5) After disassembly, replace the removed seals and O-rings with new ones in principle. As some replacement
parts are available only as subassemblies, see the parts catalog to prepare the necessary subassemblies in
advance.
(6) Handling O-rings
[2] The O-rings may not be damaged in handling or distorted by heat.
A distorted O-ring may not return to its original shape, and therefore, may cause oil leak.
(7) Before beginning reassembly, check the mating surface of each section to be sure that there is no cleaning oil or
hydraulic oil on the surface of the outer side from the O-ring groove. If reassembly is performed without cleaning
such oil, it may be mistaken for oil leak.Tools for disassembly and reassembly
2) Tool for Disassembly and Reassembly

No. Tool name Position of use
1 Socket torque wrench 230 Plug 5, 8, 61, Screw 14
2 (Preset type) 450 Socket head bolt 89, Plug 27, 52
3 (kgf·cm) 1800 Ring nut 4 Socket head bolt 70, Plug 57, 70
4 2800 Cup 66
Open end torque wrench
5 450 Plug 62
(kgf·cm)
6 Hexagon bit for torque wrench 4 Screw 14
7 (Width across flats) 5 Plug 8
8 (mm) 6 Plug 5, Socket head bolt 89
9 8 Plug 27, 70, Socket head bolt 71
10 10 Housing 6
11 Socket for torque wrench 19 Plug 52
12 (Width across flats) 22 Plug 57
13 (mm) 26 Plug 88
14 36 Cap 66
15 Open end wrench for torque wrench 12 Plug 62
(Width across flat)
(mm)
16 Screw drive Floating seal 2, Wire 24, Base plate 53
17 Hammer Angular bearing 3, Plug 5, Steel ball 7
18 Plastic hammer Shaft 32, Pin 49
19 Pliers Wire 24
20 Snap ring pliers Snap ring 45
21 Punch Plug 5, Pin 49
6-5-16 4720103
3) Disassembly
Procedure
(1) Fasten the motor by vise. Remove the socket head bolt 90
and the valve body S/A.
Tools :
• Torque wrench (2)
• Hexagon bit (7) for above
(2) If there is no abnormality in the valve body S/A, it need not

be disassembled.
Fasten the valve body 72 by vise. Remove the plug 89
and the relief valve S/A. Remove the relief housing 80 left
inside by clamping the outer circumference with pliers.
Apply cloth or other padding for removing.
Tools :
• Socket (13) for above
• Pliers (19)
(3) Remove the plug 52 and the cap 66.
Tools : 66
• Torque wrench (2), (4)
• Sockets (11), (14) for above
(4) Remove the spring 64 and the spring seat 63.
6-5-17 4720103
Procedure
(5) Turn slowly the plunger S/A 58 to remove. Take care no to
damage the outside circumference of the plunger.
(6) If there is no abnormality in the plunger S/A, it needs not

be disassembled. Insert the pin (Ø5!30) into the through
hole Ø6 of the plunger S/A and fasten it by vise. Remove 62
the plunger by using the head of the plug 62.
Tools :
• Hexagon wrench (15) for above
• Pin (S-1) 58
(7) Remove the spring 60, and the check valve 59. Keep the
left and right check valves of the plunger separate to facil-
itate reassembly.
(8) Remove the plugs 70, 57.
Tools :
6-5-18 4720103
Procedure
(9) Remove the spring 68 and the spool 67. Take care not to
damage the outside circumference of the spool.
(10) Remove the socket head bolt 71.
Tool :
(11) Remove the base plate 53. Take care not to pull out the
cylinder block as well. Lightly knock out the base plate
with a plastic hammer when it is hard to remove. If it is
still hard to remove, pry it up lightly with a screwdriver.
Tools :
• Plastic hammer (18)
• Screw driver (16)
(12) Remove the valve plate 46, O-ring 29 and pin 49.
6-5-19 4720103
Procedure
(13) Remove the cylinder block S/A, pin 41 retainer holder 39,
retainer plate 38 and piston S/A 37.
38 37 41 39
Take care not to damage the moving surface of the cylin-
der block.
(14) Remove the snap ring 45. Take care not to damage the
moving surface of the cylinder block.
Tool :
• Snap ring pliers (20)
(15) Remove the washer 44, spring 43 and collar 42.
45 43
44 42 40
(16) Remove the swash plate 36, steel ball 33, piston S/A 35
and spring 34.
6-5-20 4720103
Procedure
(17) Remove the plugs 8, 27.
Tools :
• Torque wrench (1), (2)
• Hexagon bit (6), (7) for above 27
(18) Fit the eye bolts (PT 1/4) to the screw holes of the plug
27 and put a round rod (approx. 1 m) through the eye
bolt holes. Turn the cover 26 until the wire 24 is visible
through the screw hole of the plug 8.
Tools :
• Eye bolt S-2
• Round rod S-3
(19) When the end of the wire 24 is visible, draw the wire out- 26
side the hole with a screw driver.
Tool :
(20) Turn the cover 26 while pulling the end of the wire with
24 pliers.
Tool :
• Pliers (19)
(21) Hang the hook to the eye bolt and remove the cover 26
(or remove the cover using the round rod).
Tools :
• Eye bolt S-2
• Round rod S-3
6-5-21 4720103
Procedure
(22) When the cover 26 is rusted and is hard to remove, dis-
assemble as follows :
Remove the plug 8.
Tools :
(23) Pull out the steel ball 7 from the screw hole of the plug 8.
Remove oil and grease (with thinner, white gasoline,
etc.). and blow compressed air to remove the steel ball.
When it is hard to remove, knock around the outside cir-
cumference of the housing 6.
Insert the piano wire into the screw hole to check that all
steel balls were pulled out.
Tools :
• Hammer (17)
• Piano wire S-4
(24) Fit a metal plate or the jig between the flange holder 1
and the housing 6, and tighten three M14 bolt evenly
from the housing side.
Tools :
• Metal plate or housing disassembly jig S-5
(25) Remove the housing 6.
6-5-22 4720103
Procedure
(26) Remove the sun gear S/A 15, holder S/A 18, planetary
gear A 21, cage & roller 20, drive gear 17 and thrust
plate 22.
(27) Hold the end of the wire 24 with pliers and pull it out.
Then, remove the cover 26.
Tool :
• Pliers (19)
(28) Remove the thrust plate 13 and the screw 14.
Tools :
(29) Remove the planetary gear B 12, cage & roller 11, collar
10 and thrust washer 9.
Take care not to damage the gear tooth surface and the
rolling contact surface of the collar.
6-5-23 4720103
Procedure
Tools :
(31) Remove the ring nut 4.
Tools :
• Ring nut tightening jig S-6
(32) Place the round rod on the groove of the steel ball 7 and
lightly knock on the part with a hammer to remove the
angular bearing 3.
Tools :
• Hammer (17)
• Round rod S-7
(33) Remove the floating seal 2 and the angular bearing 3.
6-5-24 4720103
Procedure
(34) Remove the other floating seal 2 with using two screw
drivers.
Tools :
(35) Place the round rod on the spline hole of the shaft 32 and
knock lightly on the rod with the hammer to remove the
shaft 32.
Tools :
• Hammer (16)
• Round rod S-7
(36) Remove the oil seal 30.
Tools :
• Hammer (17)
• Driver (16)
(37) Remove the ball bearing 31 from the shaft 32.
Tool :
• Ball bearing disassembly jig S-8
This is the end of disassembly.
6-5-25 4720103
4) Reassembly
Procedure
(1) Apply grease to the floating seal 2 and assemble it to the
flange holder 1.
Tool :
• Floating seal assembly jig (S-9)
(2) Press-fit the angular bearing 3 into the housing 6.
Tool :
• Angular bearing press-fitting jig S-10
(3) Apply grease to the other floating seal 2 and fit it on the
concentric circle.
Tool :
• Floating seal assembly jig S-7
(4) Press-fit the flange holder 1 into the housing 6.
Tool :
• Flange holder press-fitting jig S-7
6-5-26 4720103
Procedure
(5) Tighten the ring nut 4.
After turning the bearing several times, measure the start-
ing load (when the ring nut is tightened and there is no
clearance between it and the angular bearing) at the
housing installation bolt position. Assume the measured
load is "F". Tighten the ring nut to adjust the starting load
to F+3.75 to 5.51 lbs. (1.7 to 2.5kgf).
Tools :
• Ring nut tightening jig S-6
• Spring scale S-12
(6) Tighten the plug 5. Do not wind the seal tape around this
plug.
Tools :
(7) Calk the plug with the punch at two positions to prevent it
from loosening.
Tools :
• Hammer (17)
• Punch (21)
(8) Insert the steel balls 7 (109 pcs.).
6-5-27 4720103
Procedure
(9) Wind the seal tape around the plug 8 and tighten the plug.
Tools :
(10) Assemble the thrust washer 9, collar 10, cage & roller 11
and planetary gear B 12.
(11) Fit the thrust plate 13 on the trunnion of the flange

holder, apply Loctite #262 to the screw 14 and tighten it.
(Before applying Loctite remove oil and grease com-
pletely from the part, and use hardening agent.)
Tools :
(12) Assemble the sun gear 15 fitted with the snap ring 16,
the holder 18 fitted with the inner race 19 and the spring
pin 23, the planetary gear A 21, the cage & roller 20, and
the drive gear 17.
6-5-28 4720103
Procedure
(13) Assemble the thrust plate 22.
(14) Apply grease to the O-ring 25 and assemble it to the

cover 26.
Assemble the cover to the housing 6 aligning the U-

groove to the screw hole position of the plug 8.
(15) Bend the end of the wire 24 by about 8 mm to 90

degrees and insert it into the screw hole of the housing.
Turn the cover to draw in the wire.
Tools :
• Eye bolt (S-2)
• Round rod (S-3)
(16) Wind the seal tape around the plug 8 and tighten it.
Tools :
(17) Press-fit the oil seal 30 into the flange holder 1.
Tool :
• Oil seal press-fitting jig (S-13)
6-5-29 4720103
Procedure
(18) Press-fit the ball bearing 31 into the shaft 32.
Tool :
• Ball bearing press-fitting jig (S-14)
(19) Press-fit the shaft S/A into the flange holder 1.
Tool :
• Shaft S/A press-fitting jig (S-15)
(20) Assemble the steel ball 33, spring 34, piston S/A 35 and
swash plate 36 to the flange holder 1.
(Apply hydraulic oil to the moving sur-

face of the swash plate in advance.)
(21) Assemble the collar 42, spring 43, washer 44, and snap
ring 45 to the cylinder block 40.
Tools :
• Snap ring assembly jig (S-16)
6-5-30 4720103
Procedure
(22) Apply grease to the pin 41 and assemble the pins to the
holes at three positions in the cylinder block 40.
(23) Assemble the retainer holder 39, retainer plate 38 and

position S/A 37. Apply hydraulic oil to the 9 holes in the
cylinder block. 37
(24) Place the motor on its side and assemble the cylinder
block S/A with the shaft's spline as the guide.
(25) Press the cylinder block 40 by hand and check that there
is a spring force.
(26) Apply hydraulic oil to the moving part of the cylinder

block.
6-5-31 4720103
Procedure
(27) Assemble the O-ring 29 and pin 50 to the flange holder
1. Apply a small amount of grease to the O-ring.
(28) Press-fit the ball bearing 47 to the base plate 53.
Tool :
• Ball bearing press-fit jig (S-17)
(29) Assemble the pin 49 and calk it at two positions.
Tools :
• Hammer (17)
• Punch (21)
(30) Apply grease to the rear of the valve plate 49 and

assemble it to the base plate 53.
(31) Assemble the O-ring 48 to the base plate. Apply a small

amount of grease to the O-ring in advance.
6-5-32 4720103
Procedure
(32) Assemble the base plate 53.
(33) Tighten the socket head bolt 71.
Tools :
(34) Assemble the spool 67 and spring 68. Assemble the

spool by turning it. Apply hydraulic oil to the spool in
advance.
(35) Assemble the O-ring 69 and tighten the plugs 70, 57.
Tools :
6-5-33 4720103
Procedure
(36) Assemble the check valve 59, spring 60 and plug 62 fit-
ted with O-ring 61 to the plunger 58. Tighten the plug.
Apply a small amount of grease to the O-ring.
58
Tools :
• Wrench (15) for above
(37) Assemble the plunger S/A to the base plate 53. Turn the
plunger while assembling it. Apply hydraulic oil to the
plunger S/A in advance.
(38) Assemble the spring seat 63 and the spring 64.

64
63
(39) Tighten the cap 66 fitted with the O-ring 65. Apply small
amount of grease to the O-ring.
Tools :
6-5-34 4720103
Procedure
(40) Assemble the relief valve S/A to the valve body 72.
(41) Tighten the plug 88.
Tools :
(42) Assemble the O-rings 74, 73 to the valve body, and

assemble the valve body S/A 72 to the base plate 53.
Tools :
(43) Tighten the plug 52 fitted with the O-ring 51.
Tools :
(44) Pour gear oil (approx. 500 cc) into the screw hole of the
plug 27.
(45) Wind the seal tape around the plug 27 and tighten it.
Tools :
6-5-35 4720103
Procedure
(46) This completes the reassembly.
5) Performance Checks
(1) Air-leak test of the reduction gear
Remove one of the plugs 27 of the reduction gear, and apply compressed air (0.3 kgf/cm2) through the screw
hole in the water for 2 minutes. Check that no air bubbles appear.
(2) Air-leak test of the motor
Seal all but one of the piping ports of the motor with covers and apply compressed air (3 kgf/cm2) through the
open port for 2 minutes under. Check that no air bubbles appear.
(3) After confirming (1) and (2) above, fill the motor case with hydraulic oil and operate the motor for two minutes
each clockwise and counterclockwise, supplying 20 / min. of hydraulic oil.
Check that there is no abnormal heat, vibration or noise.
6-5-36 4720103
Clean the disassembled parts, dry them with compressed air and either replace or replace parts according the fol-
lowing service standards :
Standard value
No. Part name Check points (Value replacement recom- Measure
mended)
1 Floating seal 2 Moving surface. No abnormal flaws, wear or Replace.

seizure.
2 Angular bearing 3 Moving surface. No abnormal flaws, wear or Replace.

flaking in the ball or race.
3 Housing 6 Gear teeth surface. No abnormal flaws, wear or Replace.

flaking on tooth surface.
(More than 10% pitching in
the working area of a tooth
surface).
4 Planetary gear B, A 12, Gear teeth surface. Same as No.3. Replace.

21 Rolling contact surface of No abnormal flaws, wear or
cage and roller. flaking in the rolling contact
surface.
5 Cage & roller 11, 20 Cage and roller surface. No abnormal flaws, wear or Replace.
flaking.
6 Collar 10 Collar surface. No abnormal flaws, wear or Replace.

flaking.
7 Thrust waster 9 Moving surface. No abnormal flaws, wear or Replace.

seizure.
8 Thrust plate 13, 22 Moving surface. No abnormal flaws, wear or Replace.

seizure.
9 Sun gear 15 Gear teeth surface. Same as No.3. Replace.
10 Inner race 19 Cage and roller surface. No abnormal flaws, wear or Replace.
flaking.
11 Drive gear 17 Gear teeth surface. Same as No.3. Replace.
12 O-ring 25, 29, 48, 61, 65, Surface condition, hardness. No flaws or distortion. Rubber seals degenerate
69, 87, 77, 85, 74, 73, 75, Not hardened. with the lapse of time.
51 Replacement with new
seals as far as possible is
recommended on reas-
sembly.
13 Shaft 32 Oil seal surface. No flaws nor abnormal wear. Replace.
14 Ball bearing 31, 47 Same as No.2. Same as No.2. Replace.
15 Oil seal 30 Lip surface, hardness. No flaws, distortion or abnor- Replace.

mal wear.
Not hardened.
16 Swash plate 36 Friction surface for piston S/ No abnormal flaw (Over 0.02 When the firction surface
A, surface roughness. mm) wear or seizure 0.4 a is rough, repair by lapping
(0.8 a). (#1000).
Replace if the damage is
large.
6-5-37 4720103
Standard value
No. Part name Check points (Value replacement recom- Measure
mended)
17 Cylinder block 40 Clearance to piston S/A. 0.02 mm (0.04 mm). Replace cylinder block
Friction surface to valve No abnormal flaw (Over 0.02 and piston S/A together.
plate, surface roughness. mm), wear or seizure 0.4 a When the friction surface
(0.8 a). is rough, repair by lapping
(#1000).
If the damage is beyond
repair, replace the cylin-
der block and piston S/A
together.
18 Spring 43, 34, 60, 64, 68, Breakage or distortion. Replace.

82
19 Piston S/A 37 Clearance to the cylinder Same as No.17. Same as No.17.

block. Same as No.16. Same as No.16.
Friction surface to the swash 0.15 mm (0.4 mm). Replace.
plate, surface roughness.
Play in the piston and shoe.
20 Piston S/A 35 Clearance to the flange Same as No.17. Same as No.17.

holder. Same as No.16. Same as No.16.
Friction surface to the swash
plate, surface roughness.
21 Valve plate 46 Friction surface to the cylin- Same as No.17. Name as No.17.
der block, surface roughness. 4.8 mm. Replace.
Thickness : 5 mm.
22 Base plate 53 Friction surface to the No abnormal flaws, wear or Replace base plate and
plunger. seizure. plunger together.
Friction surface to the spool. No abnormal flaws, wear or Replace base plate and
seizure. spool together.
23 Plunger 58 Friction surface to the base No abnormal flaws, wear or Replace base plate and
plate. seizure. plunger together.
Friction surface to the check No abnormal flaws, wear or Replace plunger and
valve. seizure. check valve together.
24 Check valve 59 Friction surface to the No abnormal flaws, wear or Replace plunger and
plunger. seizure. check valve together.
Seat surface to the plunger. Seat should contact the Replace plunger and
whole area. check valve together.
25 Spool 67 Friction surface to the base No abnormal flaws, wear or Replace base plate and
plate. seizure. spool together.
26 Free piston 84 Friction surface to the valve No abnormal flaws, wear or Replace valve body and
body. seizure. free piston together.
6-5-38 4720103
7. Troubleshooting
1) Motor
1. Motor does not turn. 1) Malfunctioning of equipment other Check that the hydraulic oil is fed as specified to
than motor, counter-balance valve the motor inlet. Then check and repair each part.
and reduction gear.
2) Escape of pressurized oil due to Replace the parts with abnormal wear. Re- move
abnormal wear of motor's moving flaws or burrs on the part surface, clean all parts
parts. and reassemble.
3) Malfunctioning due to breakage of Disassemble and replace the broken parts.

motor's major parts. Clean all parts and reassemble. Take care not to
allow the entry of foreign substances.
2. Motor rev. speed is low. 1) Specified volume of oil not being sup- Check whether the specified volume of hydraulic oil
plied to the motor due to failure of the is fed to the motor suction side.
hydraulic pump, system relief valve, Then, check and repair each part.
etc.
2) Specified speed not obtained due to Disassemble. Check for the abnormal wear of the
drop of motor's capacity efficiency. moving parts. Repair or replace the parts.
3. Large fluctuation of 1) A large volume of high pressure oil Disassemble. Replace the parts with abnormal
motor revolutions. leaks and flows out from the drain port wear. Clean all parts and reassemble.
due to wear of motor's moving parts, Take care not to allow the entry of foreign sub-
causing excessive rev. drop and fluc- stances.
tuation. Rev. fluctuation is also caused
by the wear of bearing.
4. Oil leakage 1) Breakage of oil seals and O-rings. Replace broken oil seal and O-ring. Take care not
to damage the lip of the oil seal.
Apply a small amount of grease to O-rings before
assembly.
6-5-39 4720103

1. Motor does not turn or 1) Plunger cannot be moved.

low rev. speed. (1) No supply of pressurized oil Check for the breakage of the piping.
(2) Foreign substance caught between Remove all foreign substances completely, repair
plunger and base plate. the damage, clean and reassemble.
If the flaw is deep and there's large leakage,
replace the part.
(3) Orifice clogged. Clean with cleaning oil and reassemble.
2. Motor does not stop or is 1) Plunger doesn't return.

slow to stop. (1) Foreign substance caught between Remove all foreign substances completely, repair
plunger and base plate. the damage, clean and reassemble.
(2) Spring not assembled. If the flaw is deep and there's large leakage,
replace the part.
(3) Spring broken. Assemble the spring at the correct position.

Replace the spring. Remove foreign substance
completely, repair the damage, clean and reassem-
ble.
3. Large shocks on 1) Plunger is slow to return. Assemble the spring seat at the correct position.
stopping traveling. Spring seat not assembled.
4. Abnormal noise 1) Plunger does not return.

(1) Foreign substance caught between Remove foreign substance completely, repair the
plunger and base plate. damage, clean and reassemble. If the flaw is deep
and there's large leakage, replace the part.
(2) Spring broken. Replace the spring. Remove foreign substance

ble.
6-5-40 4720103
3) Relief Valve
1. Motor does not turn or 1) Seat of relief valve is defective.

low rev. speed. (1) Entry of foreign substance. Remove foreign substance completely, repair the
damage, clean and reassemble. If the flaw is deep
and there is large leakage, replace the part.
(2) Spring is broken. Replace the spring. Remove foreign substance

ble.
2) Cracking pressure of relief valve

dropped.
(1) Spring is worn. Replace the relief valve S/A.
2. Motor does not stop or 1) Seat of relief valve is defective.

slow to stop. (1) Entry of foreign substance. Remove all foreign substances completely, repair
the damage, clean and reassemble.
If the flaw is deep and there is large leakage,
replace the part.
(2) Spring is broken. Replace the spring. Remove foreign substance

ble.
2) Cracking pressure of relief valve low-

ered.
(1) Spring is worn. Replace the relief valve S/A.
3. Large shocks on stop- 1) Failure of 'Shockless' function

ping traveling. (1) Entry of foreign substance in free pis- Remove all foreign substances completely, repair
ton the damage, clean and reassemble.
replace the part.
(2) Spring is broken.
Replace the spring. Remove all foreign sub-
stances completely, repair the damage, clean and
reassemble.
(3) Relief set pressure raised. Replace the relief valve S/A.
6-5-41 4720103
4) Two-Speed Control
1. Cannot travel straight. 1) Plunger does not move.

(1) Foreign substance caught between Remove all foreign substances completely, repair
the spool and the valve body. the damage, clean and reassemble.
replace the part.
(2) Spring not assembled. Assemble the spring at the correct position.
(3) Spring in broken. Replace the sprig. Remove all foreign substance
ble.
2) Pressurized oil leaking due to abnor- Replace the 2-speed control piston. Remove all
mal wear of 2-speed control piston. foreign substances completely, repair the damage,
clean and reassemble.
3) 2-speed control piston not assembled. Assemble the 2-speed piston at correct position.
4) Abnormal wear of steel ball. Replace the steel ball. Remove all foreign sub-
stances completely, repair the damage, clean and
reassemble.
6-5-42 4720103
6-5-2 ViO35-2
1. Structure
The travel motor consists of a swash plate type axial piston motor, a counter balance valve, an anti-cavitation valve,
a 2-speed switching mechanism and a reduction gear.
The swash plate type axial piston motor has 9 pistons and a 2-speed (slow and fast) switching mechanism.
The counter balance valve and the anti-cavitation valve are integrated with the piston motor which is housed in the
reduction gear.
The reduction gear reduces the output revolutions of the piston motor through the planetary double-reduction mech-
anism and increases the output torque to transmit it to the sprocket.
6-5-43 4720103
1) Motor
When the travel control valve is switched to "Travel", the hydraulic oil flows through the counter balance valve to the
port A of the valve plate.
When the pressure at the port A rises, the hydraulic oil flows into the bores corresponding to the port A in the cylin-
der barrel.
When the hydraulic oil flows into the bores, the pistons are pressed against the sliding surface of the swash plate,
and the shoes fitted on the pistons slide on the sliding surface of the swash plate towards the circumference. That
motion of more than one piston on the high pressure side is converted into the rotational motion of the cylinder bar-
rel.
The output shaft splined to this cylinder barrel also starts to rotate together with the rotation of the cylinder barrel.
When the pistons move to the low pressure side, the pistons are pushed into the bores and discharge hydraulic oil
from them. The hydraulic oil discharged from the cylinder barrel flows through the port B of the valve plate to the
return passage.
When the travel control valve is switched to the opposite side, the pressure at the port B becomes high and the pres-
sure at the port A becomes low, so that the rotation of the output shaft is reversed.
6-5-44 4720103

The counter balance valve works to reduce the shock caused when the piston motor stops and to prevent it from
overrunning a specified speed due to external loading.
When the control valve is moved to the neutral position, the hydraulic oil flow to the ports P1 and P2 is blocked. This
causes the pressures in the chambers R and L to fall to nearly zero, and the spool is returned to the neutral position
by the force of the springs on both sides. When the spool is returned to the neutral position, the ports M1 and M2 of
the piston motor are blocked by the plunger and the check valve, and the motor is stopped rotating.
6-5-45 4720103
(1) Counter Balance Function

When the hydraulic oil discharged from the hydraulic pump is led to the port P1 of the counter balance valve through
the control valve, the hydraulic oil flows through the check valve L and the port M1 to the piston motor to rotate the
piston motor.
The return oil from the piston motor flows to the counter balance valve through the port M2, but the flow is blocked
by the check valve R. This causes the pump’s discharge pressure rise.
The hydraulic oil with its pressure rise at the port P1 passes through the orifice L and flows into the chamber L.
When the pressure in the chamber L reaches a specified pressure, the plunger starts moving to the right. Then, the
hydraulic oil at the port M2 flows through the notch on the circumference of the plunger to the port P2, while causing
back pressure on the port M2 side, and returns to the hydraulic oil tank through the control valve.
While the plunger is moving, the hydraulic oil in the chamber R is pressured by the plunger and flows through the ori-
fice R to the port P2. The volume of the hydraulic oil flowing out from the chamber R is kept below a specified vol-
ume by this orifice and the moving speed of the plunger does not exceed a specified speed.
When the discharge pressure of the pump rises, the opening of the plunger notch becomes large and the back pres-
sure at the port M2 is reduced.
Thus, the piston motor revolves at a speed which corresponds to the pressure at the port P1, i.e., the oil volume
flowing from the port P1.
6-5-46 4720103
(2) Brake Function

When the control valve is returned to the neutral position, the flow of pressure oil from the pump is blocked and the
pressures at the ports P1 and P2 become equal. Consequently, the plunger starts returning to the neutral position
through the force of the spring R. When the plunger moves, the opening of the plunger notch becomes small, and
since the piston motor still continues to rotate through the inertial force (the pumping of the motor), the pressure at
the port M2 rises. The relief valve R2 is activated by this pressure and lets the oil escape to the port M1 so that the
shock due to the inertial force at the port M2 is absorbed, and at the same time, the cavitation at the port M1 is pre-
vented.
6-5-47 4720103
This anti-cavitation mechanism works together with the counter balance valve.
Compared with conventional counter valance mechanism, this mechanism has oil passages A, B and C and check
valves B and C in addition.
6-5-48 4720103
(1) Engine Stop → Start

When the oil pressure force is applied to the port P1, the counter balance valve spool exceeds the force of the spring
and moves to the right. This causes the hydraulic oil in the port P1 to flow thorough the oil passage C to the hydraulic
motor and rotate it. (normal counter balance operation) Although the high pressure oil flows to the oil passage A at
the same time of this, the pressure oil does not leak to the low pressure side (the oil passage C side) due to the
operation of the check valve C.
(2) In Regular Rotation of Motor

Although the high pressure also flows to the oil passage A while the motor is rotating regularly, the pressure oil does
not leak to the low pressure side due to the operation of the check valve C. Therefore, the anti-cavitation has no
effect on the motor operation.
6-5-49 4720103
(3) Regular Rotation of Motor → In Speed Reduction

When reducing the motor speed, the hydraulic oil flows through the oil passage M2 out of the port P2 while the
counter balance valve is open although the motor still keeps rotating with the inertia force. Then the cavitation occurs
on the oil passage M1 side due to the shortage of oil supply from the port P1.
However, with this anti-cavitation mechanism, the hydraulic oil passes through the oil passage M2, the counter bal-
ance valve throttle C, the oil passage C, the check valve C, the oil passage A, the port P1, and the oil passage M1,
and returns to the motor to reduce the cavitation while the counter balance valve spool is returning to the neutral
position.
(4) In Motor Speed Reduction → Stop

The anti-cavitation mechanism works until the oil flow from the passage A to the P1 port is blocked at the point
shown in the figure below.
6-5-50 4720103

(1) 1st Speed (Low Speed)
The swash plate has three surfaces a, b and c, as shown in the figure, and is installed on the flange holder with two
steel balls so that it can move. When the control valve is in the low speed position, since the spool is located in the
position as shown in the left figure by the force of the spring and oil passage is connected to the port T via Pi 1 and
Pi 2, the low pressure of the return passage only works on the swash plate control piston. In this condition, the
swash plate control piston does not push up the swash plate. Accordingly, the surface a at the rear of the swash
plate is pressed against the vertical surface by the thrust force of the motor and the force of the spring with the steel
balls as the inclination axis. The inclination angle of the swash plate is "α" as shown in the figure.
6-5-51 4720103
(2) 2nd Speed (High Speed)

When the control valve is switched to the high speed position, the pressure oil from the pump is led to the end face
of the spool and the spool is shifted to the position as shown in the left figure. This causes the ports M1 and M2 to
open and the hydraulic oil from the port A (high pressure) in the valve plate of the motor is supplied to the swash
plate control piston though the valve port M1. This pressure oil pushes up the swash plate control piston, which over-
comes the motor thrust force and the spring force, and the surface a of the swash plate is detached from the vertical
surface to cause the surface b to be contacted with the vertical surface tightly. When the surface b contacts with the
vertical surface, the inclination angle of the surface c, which is the sliding surface of the swash plate, is reduced to
"β". Accordingly, the stroke of the piston is reduced to lower the motor displacement. The motor with smaller dis-
placement rotates faster (high speed).
When the motor revolves in reverse, the same action as the above occurs, except that the high and low pressure
ports are reversed.
When the engine is stopped, since no pumps work, no pressure oil is supplied to the end face of the spool and the
spool returns to the 1st speed position by the spring force. Accordingly, no force is applied to the swash plate control
piston to press the swash plate, and the swash plate maintains its 1st low inclination angle "α" through the spring
force. Thus, the low speed condition is always maintained at starting.
6-5-52 4720103
5) Reduction Gear
The reduction gear comprises a planetary double-reduction mechanism.
The drive gear 1 engages with the 1st-stage planetary gear 2 and the 2nd-stage sun gear 4 engages with the 2nd-
stage planetary gear 5. The 2nd-stage planetary carrier 6 is fastened to the machine body. The planetary gears 2
and 5 engage with the ring gear (housing) 7.
The driving force from the piston motor is transmitted to the drive gear 1 and reduced by the gears. The reduced
driving force is then transmitted to the ring gear 7 though the planetary gear 5 of the 2nd-stage planetary carrier 6
fastened to the machine body. (Driving force is also transmitted from the 1st-stage planetary gear 2.) The input and
output revolutions are opposite to each other.
6-5-53 4720103
6-5-54 4720103
No. Part Q'ty No. Part Q'ty

1 Flange holder 1 42 Spring seat 1
2 Floating seal 2 43 Spring 1
3 Angular bearing 1 44 Washer 1
4 Ring nut 1 45 Internal snap ring 1
5 Plug PT 1/4 2 46 Valve plate 1
6 Housing 1 47 Ball bearing 1
7 Steel Ball 132 48 O-ring 1B P7 3
8 Plug PT1/8 2 49 Pin 1
9 Thrust washer 4 50 Pin 2
10 Collar 4 51 O-ring 1B P11 2
11 Cage & roller 4 52 Plug 2
12 Planetary gear B 4 53 Base plate 1
13 Thrust plate 1 54 Orifice 4
14 Screw 4 55 Plug 2
15 Sun gear 1 56 Orifice 2
16 External snap ring 1 57 Plunger 1
17 Holder 1 58 Check valve 2
18 Planetary gear A 3 59 Spring 2
19 Cage & roller 3 60 O-ring 1B P10 2
20 Inner race 3 61 Plug 2
22 Drive gear 1 62 Spring seat 2
23 Thrust plate (t = 1.8, 2.3, 2.8) 1 63 Spring 2
24 Cover 1 64 O-ring 1B P29 2
25 O-ring 1 65 Cap 2
26 Wire 1 66 Spool 1
27 Plug PF1/4 2 67 Spring 1
28 O-ring 2 68 O-ring 1B P14 1
29 O-ring 1A G120 1 69 Plug 1
30 Oil seal 1 70 Hexagon socket head bolt 6
31 Ball bearing 1 71 Plug PT 1/4 1
32 Shaft 1 72 O-ring 1B P8 2
33 Steel ball 2 73 Plug PT1/8 2
34 Piston assembly 2 74 Valve body 1
35 Spring 2 75 O-ring 1B P12 2
36 Swash plate 1 76 Hexagon socket head bolt 3
37 Piston assembly 9 77 Check valve 2
38 Retainer plate 1 78 Spring 2
39 Retainer holder 1 79 O-ring 1B P14 2
40 Cylinder barrel 1 80 Plug PT3/8 2
41 Pin 3
6-5-55 4720103
4. Special Tools
Unit : in. (mm)
S-2 : Eye bolt S-5 : Housing disassembly jig
S-6 : Ring nut tightening jig
S-8 : Ball bearing disassembly jig S-10 : Angular bearing press-fitting jig
6-5-56 4720103
Unit : in. (mm)

S-9 : Floating seal assembly jig
S-12 : Flange holder press-fitting jig
S-13 : Oil seal press-fitting jig
6-5-57 4720103
Unit : in. (mm)

S-14 : Ball bearing press-fitting jig S-15 : Shaft S/A press-fitting jig
S-16 : Snap ring assembly jig S-17 : Ball bearing press-fitting jig
S-1 : Pin Ø0.197 (Ø5) !1.18 (30)

S-7 : Round rod Ø0.394 (Ø10) !5.9 (150)
S-3 : Round rod Ø0.787 (Ø20) !39.4 (1000)
S-4 : Piano wire Ø0.00787 (Ø0.2) !27.6 (700)
6-5-58 4720103

(1) Since the parts of the hydraulic equipment are precision-made for tight clearances, be sure to perform disassem-
bly and reassembly in a clean area that is free from dust.
(3) First clean the external surfaces of the removed assemblies.
(5) After disassembly, replace the removed seals and O-rings with new ones in principle. As some replacement
parts are available only as subassemblies, see the parts catalog to prepare the necessary subassemblies in
advance.
(6) Handling O-rings
[2] The O-rings may not be damaged in handling or distorted by heat.
A distorted O-ring may not return to its original shape, and therefore, may cause oil leak.
(7) Before beginning reassembly, check the mating surface of each section to be sure that there is no cleaning oil or
hydraulic oil on the surface of the outer side from the O-ring groove. If reassembly is performed without cleaning
such oil, it may be mistaken for oil leak.Tools for disassembly and reassembly
2) Tool for Disassembly and Reassembly

No. Tool Nominal size Applicable part
1 Torque wrench 230 Plug 5, 8, 61Screw 14
(Preset type)
2 450 Plug 27, 52 Socket head bolt 76
3 (kgf·cm) 1800 Ring nut 4 Socket head bolt 70, Plug 69, 80
4 2800 Cup 65
5 Hexagon bit for torque wrench 4 Screw 14
(Width across flats)
6 5 Plug 8
7 (mm) 6 Plug 5, 27, 52, 61 Socket head bolt 76
8 8 Plug 27, 69, 80 Socket head bolt 70
9 10 Housing 6
10 Socket for torque wrench 22 Plug 69
(Width across flats)
11 36 Cup 65
(mm)
12 Screwdriver
13 Hammer
14 Plastic hammer
15 Pliers
16 Snap ring pliers
17 Punch
6-5-59 4720103
3) Disassembly
Procedure
(1) Hold the motor with a vice to remove three hexagon socket
head bolts 76 and then valve body assembly.
Tools :
• Hexagon bit (7)
(2) Valve body assembly does not have to be disassembled

unless necessary.
Notes :
• Hold the valve body 74 with a vise.
• Remove the plug 80 to remove the spring 78 and the check
valve 77.
Tools :
• Hexagon bit (8)
(3) Remove plug 52 (with O-ring 51) and cap 65 (with O-ring
64).
Tools :
• Torque wrenchs (2) and (4)
• Socket (7)
• Socket (11)
(4) Remove spring 63 and spring seat 62.
6-5-60 4720103
Procedure
(5) Turn plunger assembly slowly to remove it.
Note :
Take care not to damage or dent the outside of plunger 57.
(6) Insert a pin Ø0.2!1.18 in. (Ø5!30 mm) into the through
hole (Ø0.24 in. (Ø6 mm)) in the plunger assembly. Hold it
with a vice to remove plug 61.
Note :
Disassemble the plunger assembly only when required.
Tools :
• Hexagon bit (7)
• Pin Ø0.2!1.18 in. (Ø5!30 mm) (S-13)
(7) Remove spring 59 and check valve 58.
Note :
Keep the right check valve and the left one separately to iden-
tify them with regard to the plunger for correct reassembly.
(8) Remove plugs 69 (with O-ring 68).
Tools :
• Hexagon bit (8)
6-5-61 4720103
Procedure
(9) Remove spring 67 and spool 66.
Note :
Take care not to damage or dent the outside of the spool.
(10) Remove eight hexagon socket head bolts 70.
Tool :
• Hexagon bit (8)
(11) Remove base plate 53.
Notes :
• When the base plate cannot be removed easily, tap it in the
pulling-out direction with a plastic hammer. If it is still not be
removed, pry it up lightly with a screwdriver.
• Take care that the cylinder barrel is not pulled out.
Tools :
• Screwdriver (12)
(12) Remove valve plate 46, O-rings 29 and 48, and pin 50.
6-5-62 4720103
Procedure
(13) Remove cylinder barrel assembly, pins 41, retainer
holder 39, retainer plate 38 and piston assemblies 37.
Note :
Take care not to damage the sliding surface of the cylinder
barrel.
(14) Remove internal snap ring 45 from cylinder barrel 40.
Note :
Take care not to damage the sliding surface of the cylinder
barrel.
Tools :
(15) Remove washer 44, spring 43 and spring seat 42.
(16) Remove swash plate 36, steel balls 33, piston assem-
blies 34 and springs 35.
6-5-63 4720103
Procedure
(17)Remove plugs 8 and 27.
Tools :
• Torque wrenches (1) and (2)
• Hexagon bit (6) and (7)
(18) Fit eye bolts (PF 1/4) into the tapped holes for plugs 27
and put a round rod [approx. 39.37 in. (1 m) in length]
through the eye bolt holes. Turn cover 24 until wire 26
can be seen from the tapped hole for plug 8.
Tools :
• Eye bolt (S-2)
• Round rod (S-3)
(19) When the end of wire 26 can be seen, draw the wire out-
side the hole with a screwdriver.
Tools :
(20) Turn cover 24 while pulling the end of wire 26 with pliers
to draw the wire out.
Tools :
• Pliers (15)
(21) Put a hook through the eye bolt holes to hang up and
remove cover 24 (or remove the cover using a round
rod).
Tools :
• Eye bolt (S-2)
• Round rod (S-3)
6-5-64 4720103
Procedure
(22) When the cover 24 has rusted and is hard to remove, fol-
low the disassembly procedure below:
Remove plug 8.
Tools :
• Hexagon bit (6)
(23) Pull all steel balls 7 out of the tapped hole for plug 8.
Notes:
• After removing oil and grease with thinner, white gasoline or
the like, blow compressed air over the steel balls to remove
them.
• It is hard to remove them, tap the outside of housing 6 with
a hammer.
• Insert a piano wire from the tapped hole for the plug to
make sure that all the steel balls have been removed.
Tools :
• Hammer (13)
• Piano wire (S-4)
(24) Put a metal plate or a jig between flange holder 1 and

housing 6, and tighten three M14 bolts evenly from the
housing side.
Tools :
• Hexagon bit (9)
• Metal plate or housing disassembly jig (S-5)
(25) Remove housing 6.
6-5-65 4720103
Procedure
(26) Hold the end of wire 26 with pliers and pull it out.
Then, remove cover 24.
Tool :
• Pliers (15)
(27) Remove sun gear 15, holder 17, planetary gears A 18,
cage & rollers 19, drive gear 22 and thrust plate 23.
(28) Remove thrust plate 13 and four screws 14.
Tools :
• Hexagon bit (5)
(29) Remove thrust washers 9, planetary gears B 12, collars

10, and cage & rollers 11.
Note :
Take care not to damage the gear tooth surface and the roll-
ing contact surfaces of the collars.
6-5-66 4720103
Procedure
(30) Remove two plugs 5.
Tools :
• Hexagon bit (7)
(31) Remove ring nut 4.
Tools :
• Ring nut tightening jig (S-6)
(32) Place a round rod on the groove for steel balls 7 and tap
it lightly with a hammer to remove angular bearing 3.
Tools :
• Hammer (13)
• Round rod (S-7)
(33) Remove one floating seal 2 and angular bearing 3.
6-5-67 4720103
Procedure
(34) Remove the other floating seal 2 using two screwdrivers.
Tools :
• Screwdrivers (12)
(35) Place a round rod on the hole for shaft 32 and tap the rod
lightly with a hammer to remove the shaft.
Tools :
• Hammer (13)
• Round rod (S-7)
(36) Remove oil seal 30.
Tools :
• Hammer (13)
(37) Remove ball bearing 31 from shaft 32.
Tool :
• Ball bearing disassembly jig (S-8)
6-5-68 4720103
4) Reassembly
Procedure
(1) Apply grease to one floating seal 2 and install it onto flange
holder 1.
Tool :
• Floating seal installation jig (S-9)
(2) Apply grease to the other floating seal 2 and fit it on the
concentric circle.
(3) Press-fit angular bearing 3 onto flange holder 1.
Tool :
• Angular bearing press-fitting jig (S-10)
(4) Tighten ring nut 4 so that there is no clearance between

the ring nut and angular bearing 3.
Tools :
6-5-69 4720103
Procedure
(5) Press-fit housing 3 onto angular bearing 1.
Tool :
• Housing press-fitting jig (S-12)
(6) Tighten ring nut 4.

Tighten the ring nut so that there is no clearance between
the housing and the angular bearing. Turn the housing
several times and then, measure the starting load.
Assume the measured load is "F" ft·lbf (N·m). Tighten the
ring nut to adjust the starting load to F + (12.3 to 18.0)
ft·lbf <16.7 to 24.5 N·m>
Tools :
• Spring scale (S-17)
(7) Tighten plugs 5.
Note :
Do not wind a seal tape around these plugs.
Tools :
• Hexagon bit (7)
(8) Caulk each plug 5 at two places with a punch to prevent it

from loosening.
Tools :
• Hammer (13)
• Punch (17)
6-5-70 4720103
Procedure
(9) Insert steel balls 7 (132 pcs.).
(10) Wind a seal tape around plug 8 and tighten it.
Tools :
• Hexagon bit (6)
(11) Install thrust washers 9, collars 10, cage & rollers 11 and
planetary gears B 12.
(12) Fit thrust plate 13 on the trunnion of the flange holder,

apply adhesive (Loctite #262 or its equivalent) to four
screws 14 and tighten them.
Note :
Before applying adhesive, remove oil and grease completely
from the screws, and use hardening accelerator.
Tools :
• Hexagon bit (5)
6-5-71 4720103
Procedure
(13) Install sun gear 15 fitted with external snap ring 16,
holder 17 fitted with inner races 20 and spring pins 21,
the planetary gears A 18, cage & rollers 19, and drive
gear 22.
(14) Install thrust plate 23.
(15) Apply grease to O-ring 25 and install it to cover 24.

Install the cover on housing 6 with the U-groove aligned
with the tapped hole for plug 8 in housing 6.
(16) Bend the end of wire 26 by about 0.24 in. (6 mm) at an

angle of 90 degrees and insert it into the tapped hole in
housing 6. Turn cover 24 to draw in wire 26.
Tools :
• Eye bolt (S-2)
• Round rod (S-3)
Tools :
• Hexagon bit (6)
6-5-72 4720103
Procedure
(18) Press-fit oil seal 30 into flange holder 1.
Tool :
• Oil seal press-fitting jig (S-13)
(19) Press-fit ball bearing 31 into shaft 32.
Tool :
(20) Press-fit the shaft assembly into flange holder 1.
Tool :
• Shaft assembly press-fitting jig (S-15)
(21) Install steel balls 33, springs 35, piston assemblies 34

and swash plate 36 into flange holder 1.
Note :
Apply hydraulic oil to the sliding surface of
the swash plate before installation.
6-5-73 4720103
Procedure
(22) Install spring seat 42, spring 43, washer 44 and internal
snap ring 45 into cylinder barrel 40.
Tools :
• Snap ring installation jig (S-16)
(23) Apply grease to pins 41 and install them into the three
holes in the splined area of cylinder barrel 40.
(24) Install retainer holder 39, retainer plate 38 and piston

assemblies 37.
Notes :
• Apply hydraulic oil to the 9 bores in the cylinder barrel.
• Do not hit the shoes of the piston assemblies to install them.
(25) Place the motor on its side and install the cylinder barrel
assembly using the shaft's spline as a guide.
6-5-74 4720103
Procedure
(26) Press cylinder barrel 40 by hand to check that spring
force works normally.
(27) Apply hydraulic oil to the sliding area of the cylinder bar-
rel.
(28) Install O-ring 29 and pins 50 into flange holder 1.
Note :
(29) Press-fit ball bearing 47 into base plate 53.
Tool :
(30) Install pin 49 and caulk it at two places.
Tools :
• Hammer (13)
• Punch (17)
6-5-75 4720103
Procedure
(31) Apply grease to the rear of valve plate 46 and install it
onto base plate 53.
(32) Install O-rings 48 onto base plate 53.
Note :
Apply a small amount of grease to O-rings 48 before installa-
tion.
(33) Install base plate 53 onto flange holder 1.
(34) Tighten eight hexagon socket head bolts 70.
Tools :
• Hexagon bit (8)
(35) Install spool 66 and spring 67.
Notes :
• Install the spool straight while turning it.
• Apply hydraulic oil to the spool before installation.
6-5-76 4720103
Procedure
(36) Install plug 69 fitted with O-ring 68.
Tools :
• Hexagon bit (8)
(37) Install check valve 58, spring 59, O-ring 60, and plug 61
to plunger 57. Tighten the plug.
Note :
Tools :
• Hexagon bit (7)
(38) Install the plunger assembly to base plate 53.
Notes :
• Apply hydraulic oil to the plunger assembly before installa-
tion.
• Install the plunger assembly straight while turning it.
(39) Install spring seats 62 and springs 63.
6-5-77 4720103
Procedure
(40) Tighten cap 65 fitted with O-ring 64.
Note :
Tools :
• Socket (11)
(41) Install check valves 77 and springs 78 into valve body

74.
(42) Tighten plug 80.
Tools :
• Hexagon (7)
(43) Install O-rings 75 onto valve body 74, and fasten the
valve body assembly to base plate 53.
Tools :
• Hexagon bit (7)
(44) Tighten plug 69 fitted with O-ring 68.
Tools :
• Hexagon bit (8)
6-5-78 4720103
Procedure
(45) Put gear oil (approx. (0.53 Qts <500 cc>) from the
tapped hole for plug 27.
Tools :
• Hexagon bit (7)
(47) This completes the reassembly.
6-5-79 4720103
Clean and dry all disassembled parts, and correct them by repairing or replacing parts (kit parts) according to the fol-
lowing standards :
Standard value
No. Parts Inspection item (recommended value for Measure
replacement
1 Floating seal 2 Sliding surface. No excessive flaws, wear or Replace.

seizure.
2 Angular bearing 2 Moving surface. No excessive flaws, wear or Replace.

flaking in ball or race.
3 Housing 6 Gear tooth surface. No excessive flaws, wear or Replace.

flaking on tooth surface.
(More than 10 % pitting in the
engaged area of a tooth sur-
face).
4 Planetary gears B 12 and Gear tooth surface. Same as No. 3. Replace.

A 18 Rolling contact surface of No excessive flaws, wear or
cage & roller. flaking on the rolling contact
surface.
5 Cage & roller 11, 19 Cage & roller surface. No excessive flaws, wear or Replace.
seizure.
6 Collar 10 Collar surface. No excessive flaws, wear or Replace.

seizure.
7 Thrust washer 9 Sliding surface. No excessive flaws, wear or Replace.

seizure.
8 Thrust plates 13 and 23 Sliding surface. No excessive flaws, wear or Replace.

seizure.
9 Sun gear 15 Gear tooth surface. Same as No. 3. Replace.
10 Inner races 20 Cage & roller (needle bear- No excessive flaws, wear or Replace.
ing) surface. flaking.
11 Drive gear 22 Gear tooth surface. Same as No. 3. Replace.
12 O-ring 25, 29, 48, 51, 60, Surface condition and hard- No flaws or distortion. Rubber seal members
64, 68, 72, 75, 79 ness. Not hardened. deteriorate with the lapse
of time.
Replacement with new
seals is recommended
every time they are reas-
sembled.
13 Shaft 32 Oil seal surface. No flaws or excessive wear. Replace.
14 Ball bearings 31 and 47 Moving surface. Same as No. 2. Replace.
15 Oil seal 30 Lip surface and hardness. No flaws, distortion or exces- Replace.
sive wear.
Not hardened.
16 Swash plate 36 Sliding surface against piston No excessive flaws (over When sliding surface has
assembly. 0.02 mm), wear or seizure roughened, repair it by
Surface roughness. 0.4 Ra (0.8 Ra). lapping (#1000).
Replace it if the damage
is beyond repair.
6-5-80 4720103
Standard value
No. Parts Inspection item (recommended value for Measure
replacement
17 CYlinder barrel 40 Clearance between it and 0.00079 in. (0.02 mm) Replace cylinder barrel
piston assembly. (0.00157 in. (0.04 mm)). and piston assembly
together.
Sliding surface against valve No excessive flaws (over When sliding surface has
plate. 0.02 mm), wear or seizure. roughened, repair it by
Surface roughness. 0.4 Ra (0.8 Ra). lapping (#1000).
If the damage is beyond
repair, replace the cylin-
der barrel and piston
assembly together.
18 Springs 35, 43, 59, 63, 67 Breakage or distortion. Replace.

and 78
19 Piston assembly 37 Clearance between it and cyl- Same as No. 17. Same as No. 17.
inder barrel.
Sliding surface against Same as No. 16. Same as No. 16.
swash plate and surface
roughness.
Play between pistons and 0.00591 in. (0.15 mm) Replace.
shoes. (0.0158 in. (0.4 mm).
20 Piston assembly 34 Clearance between it and Same as No. 17. Same as No. 17.
flange holder.
Sliding surface against Same as No. 16. Same as No. 16.
swash plate and surface
roughness.
21 Valve plate 46 Sliding surface against cylin- Same as No. 17. Same as No. 17.
der barrel and surface rough-
ness.
Thickness : 0.197 in. (5 mm). 0.189 in. (4.8 mm). Replace.
22 Base plate 53 Sliding surface against No. excessive flaws, wear or Replace base plate and
plunger. seizure. plunger together.
Sliding surface against spool. No excessive flaws, wear or Replace base plate and
seizure. spool together.
23 Plunger 57 Sliding surface against base No excessive flaws, wear or Replace base plate and
plate. seizure. plunger together.
Sliding surface against check No excessive flaws, wear or Replace plunger and
valve. seizure. check valve together.
24 Check valve 58 Sliding surface against No excessive flaws, wear or Replace plunger and
plunger. seizure. check valve together.
Seat surface against plunger. The plunger is seated com- Replace plunger and
pletely. check valve together.
25 Spool 66 Sliding surface against base No excessive flaws, wear or Replace base plate and
plate. seizure. spool together.
6-5-81 4720103
7. Troubleshooting
1) Motor
1. Motor does not rotate. 1) Malfunction of equipment other than Check whether the specified volume of hydraulic oil
motor, counter balance valve and is fed to the motor suction side.
reduction gear. Then, check and repair each part.
2) Escape of pressure oil due to exces- Replace any excessively worn parts.
sive wear of motor’s sliding parts. Repair any flaw or burr on the surfaces, clean all
the parts and reassemble them.
3) Malfunction due to breakage of Disassemble the motor and replace any broken
motor’s sliding parts. parts.
(In this case, motor makes an abnor- Clean all the parts and reassemble them.
mal sound).
4) Relief valve operates due to too much Check the load and regulate it to the value corre-
load applied to motor. sponding to the set relief pressure.
2. Motor speed is low. 1) Specified volume of oil is not being Check whether the specified volume of hydraulic oil
supplied to motor due to failure of is fed to the motor suction side.
hydraulic pump, system relief valve, Then, check and repair each part.
etc.
2) Specified speed is not obtained due to After disassembling the motor, check them for
drop of motor’s displacement. excessive wear of the sliding parts. Repair or
replace any worn parts.
3. Large fluctuation in 1) A large volume of high pressure oil After disassembling the motor, check the parts and
motor revolutions leaks and flows out from drain port replace any worn parts.
due to wear of motor’s parts, causing Clean all the parts and reassemble them.
a large drop and fluctuation in motor
revolutions.
The fluctuation is also caused by worn
bearing.
4. Oil leak 1) Breakage of oil seals or O-rings. Replace any broken oil seal and O-ring. Take care
not to damage the lip of the oil seal.
Apply a small amount of grease to O-rings before
assembly.
6-5-82 4720103

1. Motor does not turn or 1) Plunger is not moved.

motor speed is low. (1) No pilot pressure oil supplied. Check the piping for breakage.
(2) Foreign substances caught Remove all the foreign substances, repair any
between plunger and base plate. damaged area, clean and reassemble the parts.
If the damage is serious and oil leak is bad, replace
the part.
(3) Clogged orifice. Clean the part with cleaning oil and reinstall it.
2. Motor does not stop or is 1) Plunger does not return.

slow to stop. (1) Foreign substances caught Remove all the foreign substances, repair any
between plunger and base plate. damaged area, clean and reassemble the parts.
the part.
(2) Broken spring. Replace the spring. Then, remove all the foreign
substances, repair any damaged area, clean and
reassemble the parts.
(3) Spring is not installed. Install a spring in the correct position.
(4) Clogged orifice. Clean the part with cleaning oil and reinstall it.
3. Fluctuation in motor rev- 1) Plunger does not move smoothly.

olutions. (1) Foreign substances caught inside. Remove all the foreign substances and repair any
damaged area. Then, clean the parts and reas-
semble them.
the part.
(2) Clogged orifice. Clean the part and reinstall it.
4. Large shock on stopping 1) Plunger is slow to return.

traveling. (1) Spring seat is not installed. Install a spring seat in the correct position.
5. Abnormal sound. 1) Plunger does not return.

(1) Foreign substances caught inside. Remove al the foreign substances, repair any dam-
aged area, clean the parts and reassemble them.
the part.
(2) Broken spring. Replace the spring. Remove all the foreign sub-
stances, repair any damaged area, clean the parts
and reassemble them.
(3) Clogged orifice. Clean the part with cleaning oil and reassemble it.
6-5-83 4720103
1. Motor does not turn or 1) Seat of check valve is defective.

motor speed is low. (1) Foreign substances caught inside. Remove all the foreign substances, repair any
damaged area, clean the parts and reassemble
them.
If the damages is serious and oil leak is bad,
replace the part.
(2) Broken spring. Replace the spring. Remove all the foreign sub-
stances, repair any damaged area, clean the parts
and reassemble them.
2. Large cavitation sound 1) Sticking of check valve

on traveling. (1) Foreign substances caught between Remove all the foreign substances, repair any
check valve and valve body. damaged area, clean the parts and reassemble
them.
the part.
6-5-84 4720103

1. Deviation in travel. 1) Plunger does not move.

(1) Foreign substances caught between Remove all the foreign substances and repair any
spool and valve body. damaged area. Clean the parts and reassemble
them.
the part.
(2) Spring is not installed. Install a spring in the correct position.
(3) Broken spring. Replace the spring.

Remove all the foreign substances, repair any
them.
2) Oil leak due to excessive wear of two Replace the two speed control piston.
speed control piston. Remove all the foreign substances, clean the part
and reinstall it.
3) Two speed control piston is not Install a two speed control piston in the correct
installed. position.
4) Excessive wear of steel ball. Replace the steel ball.

them.
5) Incorrect orifice in oil passage of two Cleaning the orifice, then reinstall it.
speed piston chamber.
6) Clogged orifice in oil passage of two Cleaning the orifice, then reinstall it.
7) Plunger installed in the wrong direc- Check the direction of the plunger and install it in
tion. the correct direction.
2. Dose not travel at high 1) Plunger does not move due to foreign Remove all the foreign substances and repair any
speed. substances caught between plunger damaged area. Clean the parts and reassemble
and body. them.
the parts.
2) Oil leak due to excessive wear of two Replace the two speed control piston.
speed control piston. Remove all the foreign substances, clean the part
and reinstall it.
3) Two speed control piston is not Install a two speed control piston in the correct
installed. position.
4) Clogged orifice in oil passage of two Cleaning the orifice, then reinstall it.
3. Does not travel at low 1) Spring is not installed. Install a spring in the correct position.
speed.
2) Broken spring. Replace the spring.
them.
6-5-85 4720103
6-6 Pilot Check Valve (Quick Coupler Type)
1. Outline
The pilot check valve provides the oil flow in the hydraulic circuit with directionality.
This is opened at the specified pressure (cracking pressure) in one direction and completely blocks the oil flow in the
reverse direction. It, however, has the pilot function which enables oil flow in the reverse direction on certain condi-
tion.
The oil provided from the port A1 is blocked by the poppet. When the pressure exceeds the specified pressure
(cracking pressure), the poppet opens and the oil flows into the port A2.
The oil provided to the port A2 cannot flow out because the poppet is pressed on the valve body seat.
When the pressure (pilot pressure) in the ports B1and B2 rises, the spool presses and opens the poppet. This allows
oil to flow from the port A2 to the port A1.
6-6-1 4720103

No. Part Q'ty.
1 Valve body 1
2 Poppet 1
3 Spool 1
4 Plug 1
5 O-ring 2
6 Plug 1
7 Spring 1

1) Precaution for Disassembly and Reassembly
(1) Since the parts of this equipment are generally precision-made for tight clearances, be sure to perform disas-
sembly and reassembly in a clean place that is free from dust.
(2) Prepare clean tools and treated oil.
(3) First, clean the external surface of the removed valve body.
(4) Before beginning disassembly, review the drawings of the internal structure and prepare the required parts
(5) In principle, replace the removed O-rings with new ones.
[2] The O-rings may not be damaged in handing or distorted by heat
[3] Do not extend any O-rings with such great force as to permanently deform them.
[4] O-ring should be installed to the plug with a jig.

Tool Nominal Size
Wench (mm) 22
Hexagon socket screw key (mm) 8
6-6-2 4720103
3) Disassembly
Procedure
1. Check valve section
Remove the hexagon plug 4 from the valve body 1 to
remove the spring 7 and the poppet 2.
Tool :
• Wrench (22)
2. Pilot section
Remove the hexagon socket head plug 6 from the valve
body 1 to remove the spool 3.
Tool :
• Hexagon socket screw key (8)
6-6-3 4720103
4) Reassembly
Procedure
1. Installing poppet
Install the poppet 2 into the valve body 1.
Notes :
• No foreign substances adhering
• Lubricate the external surface of the poppet with lube oil.
2. Installing spring
Install the spring 7 into the poppet 2.
Note :
No dirt adhesion.
3. Installing hexagon plug

Screw the hexagon plug 4 in the valve body 1.
Tool :
• Wrench (22)
Notes :
• Make sure that the poppet 2 and the spring 7 have been
installed.
4. Installing spool
Install the spool 3 into the valve body 1.
Notes :
• Lubricate the external surface of the poppet with lube oil.
6-6-4 4720103
Procedure
5. Installing hexagon socket head plug
Install the hexagon socket head plug 6 into the valve body
1.
Tool :
• Hexagon socket screw key (8)
Notes :
• Make sure that the spool 3 has been installed.
6-6-5 4720103
5) Service Standard
Procedure
(1) Check valve
Measure the clearance between body 1 and poppet 2.
Clearance = ØD-Ød
Standard : max 0.00189 in. (0.048 mm)
(2) Pilot section

Measure the clearance between body 1 and spool 3.
Clearance = ØD-Ød
Standard : max 0.00177 in. (0.045 mm)
(3) Spring
Measure the full length of spring 7.
Standard : 0.579 to 0.602 (14.7 to 15.3 mm)
(4) Checking cracking pressure

Apply pressure on the port A1.
Measure the pressure when poppet opens.
Standard value : 58.3 PSI (0.4 MPa)
6-6-6 4720103
Procedure
(5) Checking leakage
[1] Apply pressure on the port A2 to measure the oil quantity
flowing out of the port A1.
Standard value : Less than 0.000132 GPM (0.0005 L/min)
at 14.2 PSI (0.1 MPa)
[2] Apply pressure on the port A1 to measure the oil quantity

flowing out of the port B1.
Standard vale : Less than 0.053 GPM (0.2 L/min) at 44.1
PSI (0.3 MPa)
(6) O-ring
Check the surface of O-ring 5 visually for flaws.
6-6-7 4720103
6) Troubleshooting
Malfunction of [1] Flaws in seat portion [1] Replace poppet
operate check [2] Dust caught in seat portion [2] Disassemble and clean, and replace hydraulic
valve [3] Permanent set of spring oil.
[3] Replace spring
External leakage [1] Damaged O-ring [1] Replace O-ring
[2] Damaged surface of installation area [2] Replace valve body
6-6-8 4720103
CHAPTER 7
ADJUSTMENT AND REPAIR
7-1 Electrical Equipment of Machine and Engine ...................................... 7-1-1

7-1-1 Parts Layout of Electrical Equipment ......................................... 7-1-1
7-1-2 Monitor and Alarm Systems....................................................... 7-1-3
7-1-3 Wiring Diagram .......................................................................... 7-1-6
7-1-4 Circuit Description of Engine Start and Stop, and Battery Charging .... 7-1-7
7-1-5 Removal and Reinstallation of Engine ....................................... 7-1-9
7-1-6 Removal and Reassembly of Starter Motor ............................. 7-1-16
7-1-7 Removal and Reinstallation of Fuel Injection Pump ................ 7-1-17
7-2 Undercarriage ...................................................................................... 7-2-1
7-2-1 Outline........................................................................................ 7-2-1
7-2-2 Major Parts................................................................................. 7-2-1
7-2-3 Points of Reassembly (Rubber Crawler Models) ....................... 7-2-2
7-2-4 Points of Reassembly (Steel Crawler Models)........................... 7-2-3
7-2-5 Removal and Reinstallation of Crawler...................................... 7-2-5
7-2-6 Removal and Reinstallation of Travel Motor .............................. 7-2-7
7-2-7 Disassembly and Reassembly of Idler....................................... 7-2-9
7-2-8 Disassembly and Reassembly of Track Roller ........................ 7-2-12
7-2-9 Disassembly and Reassembly of Carrier Roller ...................... 7-2-15
7-2-10 Installation of Floating Seal.................................................... 7-2-17
7-2-11 Drawings of Jigs..................................................................... 7-2-18
7-3 Controls ............................................................................................... 7-3-1
7-3-1 Control Train .............................................................................. 7-3-1
7-3-2 Mechanical Control Linkage....................................................... 7-3-2
7-3-3 Adjustment of Travel Levers ...................................................... 7-3-4
7-3-4 Adjustment of Boom Swing Pedal.............................................. 7-3-5
7-3-5 Adjustment of Blade Control Lever ............................................ 7-3-5
7-3-6 Adjustment of Lock Lever .......................................................... 7-3-6
7-3-7 Adjustment Procedure of Travel Alarm Switch .......................... 7-3-7
7-3-8 Adjustment Procedure of P.T.O. Pedal...................................... 7-3-8
7-3-9 Adjustment Procedure of P.T.O. Pedal Lock ............................. 7-3-8
7-3-10 Adjustment of Accelerator Lever.............................................. 7-3-9
7-4 Swing Bearing...................................................................................... 7-4-1
7-5 Hydraulic Equipment............................................................................ 7-5-1
7-5-1 Removal and Reinstallation of Hydraulic Pump......................... 7-5-1
7-5-2 Removal and Reinstallation of Control Valve............................. 7-5-3
7-5-3 Removal and Reinstallation of Swing Motor .............................. 7-5-6
7-5-4 Removal and Reinstallation of Swivel Joint ............................... 7-5-8
7-5-5 Disassembly and Reassembly of Swivel Joint......................... 7-5-11
7-5-6 Disassembly and Reassembly of Hydraulic Cylinders............. 7-5-14
7-5-7 Hydraulic Oil Tank.................................................................... 7-5-18
7-5-8 Piping Layout ........................................................................... 7-5-25
7-6 Work Implements ................................................................................. 7-6-1
7-6-1 Removal and Reinstallation of Work Implements ...................... 7-6-1
7-6-2 Quick Coupler ............................................................................ 7-6-8
7-7 Cabin ................................................................................................... 7-7-1
7-7-1 Cabin.......................................................................................... 7-7-1
7-8 New Cabin ........................................................................................... 7-8-1
7-8-1 Cabin.......................................................................................... 7-8-1
7. ADJUSTMENT AND REPAIR
7. Adjustment and Repair

7-1 Electrical Equipment of Machine and Engine
7-1-1 Parts Layout of Electrical Equipment
1) Electric Wiring and Equipment
No. Part No. Part No. Part

1 Safety switch 11 Lamp 150!95 21 Timer (1SEC)
2 Fuse box 12 Bulb (12V55W) 22 Safety relay (SN2206)
3 Safety switch 13 Working lamp 23 Diode (1.5-2P)
4 Horn 14 Bulb (12V55W) 24 Harness B
5 Diode (1.5-2P) 15 Harness (for boom light) 25 Engine ground cable
6 Harness A 16 Starter motor 26 Harness (headlight)
7 Battery cable (negative) 17 Indicator box 27 Slow blow fuse (50A)
8 Battery (130E41R) 18 Starter switch 28 Travel alarm
9 Battery cable (positive) 19 Safety relay 29 Travel alarm switch
10 Switch box (for quick coupler) 20 Glow relay
7-1-1 4720103
Cabin
No. Part No. Part

1 Harness A (CAB) 6 Wiper arm
2 Harness B (CAB) 7 Wiper blade
3 Curl cord 8 Room lamp
4 Wiper motor 9 Valve (12V 5W)
5 Headlight 10 Washer tank
7-1-2 4720103
7-1-2 Monitor and Alarm Systems
For safer machine operation, the operator needs to have a clear understanding of the machine’s condition. However,
it is difficult for the operator to keep an eye on every aspect of the machine he/she operating.
Therefore, gauges and alarms are installed to warn the operator of any trouble of the machine at the early stage.
Note :
The monitors do not give a full assurance of the machine’s condition. The indications shown on them should be used
as a guide for daily check and periodic maintenance according to the operation and maintenance manual.
1) Part Name
2) Function of Alarm Sensor

• All the lamps should go on for a few second when the starter switch is turned on.
• All the lamps should go off when the engine is running.
• The engine oil pressure and battery charge alarm lamps should go on when the engine is stopped.
• The buzzer should sound when a lamp goes on while the engine is running.
3) Alarm Sensor Operation

(1) Lube oil pressure drop monitoring (engine oil pressure switch)
When the engine oil pressure falls, the lamp goes on and the buzzer sounds.
The switch monitors the lube oil pressure drop of the engine and
causes the engine oil pressure alarm lamp to go on and the alarm
buzzer to sound.
Working pressure : 5.69 to 8.53 PSI (0.04 to 0.06 MPa)
Installation position : Engine block
7-1-3 4720103
When the alarm buzzer sounds, check the following items.

[1] Degeneration of engine oil
[2] Clogging of oil filter element
[3] Malfunction of engine oil pressure switch
Refer to Section "4-1-8 Checking the Sensors" for the checking procedure of the engine oil pressure switch.
[4] Malfunction of pressure control valve
[5] Wear or breakage of engine oil pressure pump
(2) Overheating sensor (water temperature switch)

The water temp. meter indicates the engine cooling water temperature.
The pointer should be within the white range while the engine is running.
If the pointer goes up to the red range, the engine is overheating.
Turned on : Cooling water temp. : 224.6 to 235.4°F (107 to 113°C)

Turned off : Cooling water temp. : 212°F (100°C) or less
Installation position : Cooling water pump on engine

[1] Refer to Section "4-1-7 Checking the Cooling Water System and Radiator for Water Leakage" and "10. Trouble-
shooting".
(3) Battery charge

When there is caused a potential difference between the output voltage of the alternator and the voltage of the bat-
tery, the lamp goes on and the buzzer sounds.
Lamp
ON

[1] Degeneration or malfunction of battery.
[2] Refer to Section "7-1-4 Circuit Description of Engine Start and Stop, and Battery Charging".
7-1-4 4720103
(4) Fuel gauge

When the starter switch is turned on, the fuel gauge starts to work to
indicate the oil level in the fuel tank.
• It is normal for the fuel gauge to take some time to indicate the cor-
rect level after the starter switch is turned on.
• The remaining oil level indication can change depending on the incli-
nation of the machine body.
Fuel gauge unit
Float position Resistance (Ω)

FULL 9.5 to 11.0
1/2 29 to 35
EMPTY 82 to 92
(5) Hour meter

When the starter switch is turned on, the hour meter starts to work.
7-1-5 4720103
7-1-3 Wiring Diagram
1) Standard Specifications
7-1-6 47201023
7-1-4 Circuit Description of Engine Start and Stop, and Battery Charging
1. Start Engine
The starter switch 30 is always supplied with electric current from
Turn on the starter switch.
the battery. (Battery -Slow blow fuse-Starter switch 30)
↓
Starter switch 30, AC-Lead wire RW-Fuse 15 A-Lead wire YR-
The timer is supplied with electric current.
Timer R (Lead wire)
↓
The relay is supplied with electric current Timer RW-Relay 2, Relay 1-Timer Y
from the timer, and the 1 and 2 are con-
nected.
↓
The relay operates, and the 3 and 4 are The relay 4 is always supplied with electric current from the battery
connected. through the slow blow fuse.
↓
The engine stop solenoid P (pull) is sup- The engine stop solenoid H (hold) is supplied with electric current
plied with electric current from the relay 3 when the starter switch is turned on.
to press the engine control lever.
↓
The engine stop solenoid P is stopped In about one second after the starter switch is turned on, the timer
being supplied with electric current. operates to stop electric current from flowing to the engine stop
solenoid P.
However, the engine stop solenoid H is still supplied with electric
↓ current when the starter switch is on, so that the control lever stays
pushed.
Turn the starter switch to "START" position. The starter motor B is always supplied with electric current from the
battery. The slow blow fuse lead wire RL and the safety relay B are
↓ supplied with electric current from the battery when the starter
switch is turned to "START" position.
The electric current is supplied from the The magnet switch of the starter motor operates to allow the pinion
starter switch 50 to the safety relay, and to jump out. At the same time, the crankshaft of the engine rotates
from safety relay S to the starter motor S to and the engine starts to run.
rotate the starter motor.
↓
The safety relay operates. When the engine speed reaches the rated speed, the alternator P
and safety relay P are connected.
Therefore, the alternator and safety relay are supplied with electric
current.
The signal from the alternator flows to the safety relay and cuts off
the connection between the safety relay S and the starter motor S,
which causes the pinion to be pulled back and the engine to be pre-
vented from overrunning.
2. Stop Engine
Turn off the starter switch.
↓
The engine stop solenoid H is stopped The control lever blocks a flow of fuel oil to stop the engine.
being supplied with the electric current to
pull back the control lever.
7-1-7 47201023
3. Charge Battery
The electric current generated by the alter- The electric current flows from the alternator B to the battery
nator flows to the battery to be charged. through the starter motor B to charge the battery.
↓
When the voltage generated by the alternator is low, the circuit in
the alternator is turned on, and the electric current flows from the
When the battery charge alarm lamp goes
battery charge alarm lamp in the indicator box to the alternator to
on, the battery charges poorly. light the alarm lamp.
(Indicator box→Lead wire WG→Alternator L)
7-1-8 47201023
7-1-5 Removal and Reinstallation of Engine
1) Removal
Procedure
(1) Remove the plate G 1.
(2) Swing the upperstructure so that the drain plug 7 of the

hydraulic oil tank 6 and the drain plug 9 for the cooling
water are halfway between the right and left crawlers.
Then, lower the bucket to the ground and stop the engine.
(3) Open the engine hood B 2 to pull out the pin 3 from the
cable, and then remove the battery cable 5 (negative)
from the battery 4.
(4) Remove the drain plug 7 from the hydraulic oil tank 6 to
drain hydraulic oil.
Type : YAMMAR SUPER HYDRO OIL

(VG 46 class) or its equivalent
Q'ty : 9.24 Gals. (35 L)
Remove the oil supply port cap, and draining the oil will be
smoother.
(5) Remove the drain plug 9 from the two-way cock for cool-
ing water to drain cooling water.
Q'ty : 3.28 Qts. (3.1 L)
At this time, removing the radiator cap 10 allows the cool-

ing water to drain more smoothly.
7-1-9 4720103
Procedure
(6) Remove the engine hoods A 11 and R 12.
(7) Remove the engine hood L 13 and the pipe 14.
(8) Remove the weights L 15 and R 16.
(9) Remove the canopy 18. (Remove the working lamp har-
ness 19.)
(10) Remove the floor step 20, the cover 21 and the grille 22.
(11) Disconnect the accelerator cable 23 on the engine side.
(12) Remove the control lever L assembly 24 (with hoses).
(13) After removing the cover, disconnect the connectors for

power relay 25, glow relay 26, timer 27 and fuse box 28.
(14) Remove the installation bolts 30 and the safety relay 29.
7-1-10 4720103
Procedure
(15) Remove the plate 31 (with the operator's seat) and the
control lever R assembly 32 (together with pilot hose,
blade and lock levers and instrument panel).
(16) Remove the handrail 33 and the side cover 34.
(17) Remove the operator's seat mount 35.
Notes :
• Remove the clamp fixed on the operator's seat mount to
remove the wire harness when lifting up the seat.
• Put rope to the operator's seat mount and use a lifting
device to lift it up.
(18) Remove the hydraulic hoses from the hydraulic pump.

1. Standard type
[1] ViO27-2
a : Suction hose
b : Hose P1
c : Hose P2
d : Hose P3
e : Hose PB1
f : Hose PB2
g : Hose PA
h : Hose PP
7-1-11 4720103
Procedure
[2] ViO35-2
a : Suction hose
b : Hose P1
c : Hose P2
d : Hose P3
e : Hose PB1
f : Hose PA
g : Hose PB2
h : Hose PB
Note :
Mark the removed hoses for the identification of the respec-
tive positions.
2. Quick coupler type (for ViO27-2 and ViO35-2)

Remove the hoses a to h, and then remove the following
hoses.
i : Hose PC1
j : Hose PC2
7-1-12 4720103
Procedure
(19) Remove the water supply port 36, the sub tank 37 and
the bracket B 38 (with bracket A and feed pump).
(20) Loosen the hose bands of the intake hoses B 40 and A

39.
(21) Remove the radiator mount 41, and then remove the
canopy mount 42 (with air cleaner).
(22) Remove the counter weight 43.
Note :
Put rope to the canopy mount 42 and the counter weight 43
and lift them up using a lifting device.
(23) ViO27-2
Remove the duct R A, the duct L B and the duct LOW C.
(24) ViO35-2
Remove the duct R A and the duct L B.
(25) Remove the tail pipe 45 from the muffler 44.
7-1-13 4720103
Procedure
(26) Remove the upper hose 47, the lower hose 48 and the
hose 49 (for cooling water supply) from the radiator 46.
(27) Remove the wire net 51 and the drain hose 52 for cool-
ing water from the shroud 50 to remove the radiator 46.
(28) Remove the return hoses 54 (between the control valve

and the oil cooler 53), and 55 (between the oil cooler and
the hydraulic oil tank).
(29) Remove the bolt 57 from the water separator 56.
(30) Remove the bolt 59 from the fuel filter 58.
(31) Remove the harnesses of the starter motor 61, alternator

62 and water temperature switch 63.
(32) Remove the engine oil pressure switch 64, the air heater
65 and the engine ground cable 66.
(33) Remove the engine stopper 67, and then remove the nut
69 from the vibroisolating rubber 68.
Note :
Loosen the nut of the lower vibroisolating rubber 70 to remove
the engine more smoothly.
7-1-14 4720103
Procedure
(34) Remove the engine by lifting.
Notes :
• Put rope on the hydraulic pump side and on the radiator
side and lift the engine up keeping its balance.
• Lift it up carefully so that it is not caught on the bolt of
vibroisolating rubber.
2) Reinstallation
Reinstall the engine in the reverse order of the removal procedure.
Adhesive and tightening torque
No. Parts Size Adhesive Tightening torque
115.7 to 137.4 ft·lbf
7 Drain plug (hydraulic oil tank) M24 
(156.9 to 186.3N·m)
M24!85 Apply Three Bond or its 354.4 to 441.3 ft·lbf
43 Counter weight
M24!140 equivalent (480.5 to 598.2 N·m)
Apply Three Bond or its 123.0 to 151.9 ft·lbf
15, 16 Weight L, R M16!75
equivalent (166.7 to 205.9 N·m)
123.0 to 151.9 ft·lbf
18 Canopy pole M16!40 
(166.7 to 205.9 N·m)
123.0 to 151.9 ft·lbf
42 Canopy mount M16!65 
(166.7 to 205.9 N·m)
32.6 to 43.4 ft·lbf
69, 70 Vibroisolating rubber M12 Nut 
(44.1 to 58.8 N·m)
Apply Three Bond or its 32.6 to 43.4 ft·lbf
67 Engine stopper 10!25
equivalent (44.1 to 58.8 N·m)
1.09 to 1.45 ft·lbf
37 Sub tank 6!20 
(1.47 to 1.96 N·m)
2.17 to 5.06 ft·lbf
36 Water supply port 6!16 
(2.94 to 6.86 N·m)
1.45 to 2.17 ft·lbf
39, 40 Hose clip 70, 48 
(1.96 to 2.94 N·m)
0.59 to 0.79 in.
 Clearance between fan and shroud  
(15 to 20 mm)
14.5 to 16.6 ft·lbf
 Air cleaner mount 8!16 
(19.6 to 22.6 N·m)
7-1-15 4720103
7-1-6 Removal and Reassembly of Starter Motor
1) Removal
Procedure
(1) Lower the bucket to the ground, and stop the engine.
(2) Open the engine hood B to disconnect the battery cable 2

(negative) from the battery C.
(3) Remove the grille 3 and the floor step 4.
(4) Remove the wire harness 6 connected to the starter motor

5.
(5) Remove the installation bolts 7 and the starter motor 5.
2) Reinstallation
Install the starter motor in the reverse order of the removal procedure.
Starter motor installation bolt (M10)
7-1-16 4720103
7-1-7 Removal and Reinstallation of Fuel Injection Pump
1) Removal
Procedure
(2) Swing the upperstructure so that the drain plug 7 of the

hydraulic oil tank 6 and the drain plug 9 for the cooling
water are halfway between the right and left crawlers.
Then, lower the bucket to the ground and stop the engine.
(3) Remove the drain plug 3 from the hydraulic oil tank 2 to
drain hydraulic oil.
Type : YAMMAR SUPER HYDRO OIL

(VG 46 class) or its equivalent
Q'ty : 9.24 Gals. (35 L)
Remove the oil supply port cap, and draining the oil will be
smoother.
(4) Remove the drain plug 5 from the two-way cock for cool-
ing water to drain cooling water.
Q'ty : 3.28 Qts. (3.1 L)
At this time, removing the radiator cap 6 allows the cool-

ing water to drain more smoothly.

7 10
(6) Remove the pin 9 to remove the fuel oil filter.
7-1-17 4720103
Procedure
(7) Remove the radiator mount 12.
(8) Remove the intake hose 14 from duct R 13 and then

remove the duct R 13 and duct L 15.
(9) Remove the upper hose 17, the lower hose 18, the hose
17-1 and the wire net 19 from the radiator 16.
(10) Remove the drain hose 20 and then remove the oil
cooler hose 21 and radiator 16.
(11) Remove the high pressure tube 22 from the fuel injection
pump and then remove the fitting bolt 23 and the check
valve 24.
(12) Remove the fitting bolt 25 to remove the LO pipe 26.
(13) Remove the cover 27 from the gear case.
7-1-18 4720103
Procedure
(14) Loosen the end nut 29 to remove the fuel injection pump.
Note :
• Never loosen the bolts 31 (4 bolts with E marked)
• Do not separate the FIP coupling and FIP driving gear.
(15) Remove the nut 33 and then remove the fuel injection
pump 32 (FIP coupling 30 and FIP driving gear stays in
the gear case.)
Note :
Confirm the graduation of fuel injection timing before removal
of the fuel injection pump.
2) Reinstallation
Install the fuel injection pump in the reverse order of the removal procedure.
Note :
• Do not use the FIP coupling mounted on the new fuel injection pump.
• Check the injection timing with FID method.
End nut
Apply the lubrication oil
7-1-19 4720103
7-2 Undercarriage
7-2-1 Outline
Hydraulic oil fed through the control valve and the swivel joint from the hydraulic pump causes the counter balance
valve installed in the travel motor to open. When the counter balance valve is opened, the motor starts rotating. Its
rotation is reduced by the reduction gear to increase the revolving torque, which is transmitted to the crawler via the
sprocket. When the oil flow is blocked, the counter balance valve is closed and the brake is automatically applied.
7-2-2 Major Parts Interchangeability of major parts

Spec. Steel crawler Rubber crawler
The maximum interchangeability is introduced between the steel Parts
and rubber crawler spec. models. Travel motor % %
For the interchangeability of the major parts, see the right table. Sprocket % %
Idler ! !
Track roller % %
Carrier roller % %
Crawler guard ! 
Note :
Special part : No interchange ability
7-2-1 4720103
7-2-3 Points of Reassembly (Rubber Crawler Models)
7-2-2 4720103
7-2-4 Points of Reassembly (Steel Crawler Models)
7-2-3 4720103
• How to bend cotter pins (For steel crawler)
7-2-4 4720103
7-2-5 Removal and Reinstallation of Crawler
When loosening or removing the nipple valve 1, the inside high-pressure grease can splash or cause the nip-
ple valve to fly out, which is hazardous. Do not bring your face close to the nipple valve 1.
1) Removal of Rubber Crawler
Handle the rubber crawlers with great care, as they are heavy.
ViO27-2 : 242.6 lbs. (110 kg) / for each crawler
Procedure
(1) Lower the implement to the ground, and remove the nip-
ple valve 1 to loosen the rubber crawler tension.
Note :
Move the machine back and forth if the grease does not come
out smoothly.
(2) Turn the implement to the direction opposite to the blade,

and raise the machine with the implement.
(3) Insert round bars between the track frame and the rubber
crawler 2, as shown in the right figure, and turn the
sprocket in the reverse direction. Slide the rubber crawler
off when the rubber crawler is separated from the idler by
the round bars.
2) Reinstallation of Rubber Crawler

Install the rubber crawler in the reverse order of the removal procedure.
7-2-5 4720103
3) Removal of Steel Crawler
Do not put your fingers between the shoes.
Handle the steel crawlers with great care, as they are heavy.
Procedure
(1) Stop the machine so that master pin 1 should be in the
lower middle position between the idler 2 and the sprocket
3.
(2) Remove the cotter pin 4.
(3) Lower the implement to the ground, and remove the nip-
ple valve 5 to loosen the steel crawler tension.
Note :
Move the machine back and forth if the grease does not come
out smoothly.
(4) Turn the track shoe 6 until the master pin 1 is positioned in
front of the idler 2.
(5) Set the block 7.
(6) Put a jig on the master pin 1 and remove it by patting with
a hammer.
Note :
When using a hammer to remove the master pin, take care
not to give a permanent set on the top of the master pin.
4) Reinstallation of Steel Crawler

Install the steel crawler in the reverse order of the removal procedure.
Note :
For how to bend cotter pin 4, refer to Section "7-2-4 Points of Reassembly (Steel Crawler Models)".
7-2-6 4720103
7-2-6 Removal and Reinstallation of Travel Motor
1) Removal
Procedure
(1) Remove the plate G 1 and the cover (pump) 2.
(2) Swing the upperstructure so that the drain plug 3 of

hydraulic oil tank is positioned halfway between the right
and left crawlers.
Lower the bucket to ground and stop the engine.
(3) Remove the drain plug 3 of hydraulic oil tank 4 to drain

hydraulic oil.
Alternatively, a compression vacuum, which is installed
to the breather hose of the hydraulic oil tank, can be
used if a stable air pressure (air from a compressor) can
be ensured.
Type : YAMMARE SUPER HYDRO OIL

(VG 46 or its equivalent)
Q'ty : 9.24 Gals. (35 L)
(4) Remove the crawler (rubber or steel) of removal side of

the travel motor (Refer to Section "7-2-5 Removal and
Reinstallation of Crawler".
(5) Remove the cover 5.
(6) Remove the hoses 6 (!4).
Note :
Mark the removed hoses not to reinstall them in the wrong
positions.
(7) Loosen the bolts to remove the sprocket 7.
7-2-7 4720103
Procedure
(8) Loosen the bolts to remove the travel motor 6.
2) Reinstallation
Install the travel motor in the revere order of the removal procedure.
Note :
Apply Three Bond 1324 or its equivalent to the installation bolts of travel motor and sprocket.
Model ViO27-2 ViO35-2

32.6 to 43.5 ft·lbf 57.9 to 72.3 ft·lbf
Tightening torque
(44.1 to 58.9 N·m) (78.5 to 98.0 N·m)
7-2-8 4720103
7-2-7 Disassembly and Reassembly of Idler
1) How to Distinguish Steel Crawler from Rubber Crawler

The procedures for disassembling and reassembling the idler for the steel crawler and that for the rubber crawler are
the same, though the two idlers are different in their external dimension.
2) Structure
No. Part Q’ty No. Part Q’ty

1 Idler 1 7 Floating seal 1
2 Screw plug PT 1/8 1 8 O-ring 1AG30 1
3 Floating seal 1 9 Idler seal cover (B) 1
4 Floating seal 1 10 External snap ring C (30) 1
5 Idler shaft CMP 1 11 Bush 2
6 Floating seal 1
7-2-9 4720103
3) Disassembly
Procedure
(1) Remove the idler assembly from the track frame and
remove the crawler adjusting spring.
(2) Remove the screw plug 2 from the idler 1 to drain lube oil.
Q'ty : 0.074 Qts. (0.07 L)
(3) Remove the snap ring C 10 from the idler 1.
Note :
Use a jig to remove the snap ring C.
(Refer to Section "7-2-11 Drawings of Jigs".)
(4) Remove the idler seal cover (B) 9.
(5) Remove the floating seal 7 from the idler seal cover (B) 9.
(6) Pull out the idler shaft CMP 5.
(7) Remove the floating seal 4 and the O-ring 4 from the idler
shaft CMP 5.
(8) Remove the floating seals 3 and 6 from the idler 1.
Note :
Do not mix the floating seals.
(9) Pull out the bush 11 from the idler 1.
Note :
Check the bush for wear, flaws or other abnormalities and dis-
assemble it only when necessary.
7-2-10 4720103
4) Reassembly
Procedure
(1) Clean all the parts, and check if the idler is worn or dam-
aged.
(2) When the seat surface of floating seal is rusted or flawed,

replace it with a new one.
(3) Press-fit a new bush 11 into the idler 1 with a jig.
(4) Insert the floating seals 3 and 6 into the idler 1.
Notes :
• Use an insertion jig.
(Refer to Section "7-2-11 Drawings of Jigs".)
• O-ring should not be twisted.
• Check the parallel accuracy of the seal surface to the face
A.
• Apply engine oil SAE 30 to the seat surfaces of the O-ring
and the floating seal.
(5) Install the O-ring 8 into the idler shaft CMP, and then
install the floating seal 4.
(6) Insert the idler shaft CMP into the idler 1.
(7) Install the floating seal 7 into the seal cover (B) 9 and then
insert them into the idler shaft CMP 5.
(8) Install the snap ring C 10 onto the idler shaft CMP 5.
(9) Supply lube oil from the plug hole of the idler 1, and then
install the plug 2.
Type : Engine oil SAE 30

Q'ty : 0.074 Qts. (0.07 L)
7-2-11 4720103
7-2-8 Disassembly and Reassembly of Track Roller
1) Structure

1 Roller 1 7 Bearing 6206YR8 1
2 Internal snap ring C (75) 1 8 Internal snap ring C (62) 1
3 Spacer (75!2.6) 1 9 Seal QLF 306212218 1
4 Seal QLF 306212218 1 10 Spacer (75!2.6) 1
5 Internal snap ring C (62) 1 11 Internal snap ring C (75) 1
6 Bearing 6206YR8 1 12 Shaft 1
7-2-12 4720103
2) Disassembly
Procedure
(1) Remove the track roller assembly from the track frame.
(2) Remove the snap ring C 2 and the spacer 3 to remove the
seal 4, and then drain lube oil.
Q'ty : 0.063 Qts. (0.06 L)
(3) Remove the snap ring C 5 from the track roller to remove
the bearing 6 together with the shaft 12.
Note :
Pull out the shaft with a press.
(4) Remove the snap ring C 11, the spacer 10, the seal 9 and
the snap ring C 8 to remove bearing 7.
7-2-13 4720103
3) Reassembly
Procedure
(1) Clean all the parts and check if the roller is worn or dam-
aged and the bearing has any looseness.
(2) Replace the seal with a new one.
(3) Install the snap ring C 5 into the track roller 1, and then set
the bearing 6 with the shaft 12. Press-fit it into the roller.
(4) Install the bearing 7 and the snap ring C 8 into the track
roller 1, and press-fit the seal 9.
Notes :
• Press-fit the bearing, the seal, and the shaft with a press.
• Apply multipurpose grease to the seal.
(5) Install the spacer 10 and the snap ring 11 into the track
roller.
(6) Turn over the track roller to supply lube oil.
Type : Engine oil SAE 30

Q'ty : 0.063 Qts. (0.06 L)
(7) Install the seal 4 into the track roller 1.
Note :
To release air from the roller, separate the seal and the
sleeve, and then, press-fit the sleeve after installing the seal
to the roller.
(8) Install the spacer 3 and the snap ring 2 into the track
roller.
7-2-14 4720103
7-2-9 Disassembly and Reassembly of Carrier Roller
1) Structure

1 Carrier roller 1 6 Bearing (6205) 1
2 Screw plug PT 1/8 1 7 Bearing (6205) 1
3 Internal snap ring C (52) 1 8 Seal QLF (30621218) 1
4 Cover 1 9 Shaft 1
5 External snap ring C (25) 1 10 Thrust collar (25!34!2) 2
2) Disassembly
Procedure
(1) Remove the carrier roller assembly from the track frame.
(2) Remove the snap ring 3 from the carrier roller 1 to remove
the cover 4.
(3) Remove the snap ring C 5, and then remove the thrust
collar 10 and the shaft 9.
Note :
Pull out the shaft with a press.
7-2-15 4720103
Procedure
(4) Remove the seal 8, the bearings 6 and 7 and the screw
plug 2 from the carrier roller 1.
3) Reassembly
Reassemble the carrier roller in the reverse order of the disassembly procedure.
(1) Clean all the parts and check if the roller is worn or damaged and the bearing has any looseness.
(2) Replace the seal and the cover with new ones.
(3) Install the screw plug last to release air from the roller.
Notes :
• Apply multipurpose grease to the seal.
• Fill up the clearance between the bearing and the roller with grease.
Type : ALBANIA EP-2 or its equivalent

Q'ty : 0.021 Qts. (0.02 L)
Tightening torque
6.51 to 7.23 ft·lbf (8.8 to 9.8 N·m)
(screw plug PT1/8)
7-2-16 4720103
7-2-10 Installation of Floating Seal
1. Inspection for Damage

(1) Check for flaws or breakages on the sliding surface of the floating seal.
(2) Check for flaws, breakages or distortion on the O-ring.
(3) Check for fins or burrs on the collar and roller bush.
Note :
The fins or burrs will cause damage to the O-ring. Remove any fin or burr with sand paper or the like.
2. Use of Jigs
(1) Clean the collar, roller, roller bush, etc. with oil or compressed air.
(2) Do not use a waste cloth to wipe the sliding surface of the floating seal. Use a paper cleaner instead.
(3) Installation using jigs :
(4) Check that there is no inclination of the sliding surface and no distortion in the O-ring.
(5) Clean the sliding surface completely and apply oil thinly.
(6) Assemble the roller assembly. Avoid placing heavy stress on the sliding surface.
3. Inspection after Installation

(1) After putting oil into the roller, seal it. Then, turn the roller manually 2 to 3 times to from an oil film on the sliding
surface.
(2) Turn the roller manually to check that the torque is not excessively high.
(3) Check that there is no oil leak.
7-2-17 4720103
7-2-11 Drawings of Jigs
7-2-18 4720103
7-3 Controls
7-3-1 Control Train
1) Control Lever (R)

Control Lever (L) 2) Travel Levers 3) Boom Swing Pedal
4) Blade Lever 5) High-Speed Pedal 6) Lock Lever
7) P.T.O. Pedal
7-3-1 4720103
7-3-2 Mechanical Control Linkage
1) Points of Assembly
(1) Use a jig to install the bush into the linkage.
(2) Set the crevices of the control valve spools horizontally.

(3) However, the crevice of the travel valve spools L and R should be set vertically.
(4) Apply grease to the linkages, and take care not to damage O-rings A when installing the linkages.
(5) Supply grease to the nipples B after installation.
7-3-2 4720103
2) Tightening Torque for Rod Joints and Control Valve Mount
7-3-3 4720103
7-3-3 Adjustment of Travel Levers
1) Position of Travel Lever Grips

(1) The difference in side level between the right
and left lever grips : Within 0.12 in. (3 mm)
(2) Adjustment
[1] Difference in side level
• Loosen the nut 1 of the L-ball and rotate the
rod 2 to adjust the positions of the lever grips
to 9.33 in. (237 mm) from the frame front end.
• After adjusting the difference in side level
between the both levers to within 0.12 in. (3
mm), tighten the nut 1.
[2] Difference in height
• Loosen lock nuts 4 of grips 3 and adjust the
height of both grips.
• After adjusting the difference in height
between the both levers to within 0.079 in. (2
mm), tighten the nut 4.
2) Adjustment of Stopper Bolts

(Forward and Reverse Travel)
(1) Loosen the lock nuts 5 of the stopper bolts
6.
(2) Screw in stopper bolts 6 until they have no
contact with travel lever.
(3) Move the travel lever to its stroke ends, and
loosen stopper bolts 6 until they contact with
the travel lever.
(4) Move the travel lever to the neutral position,
loosen the stopper bolts 6 half a turn further
and tighten lock nuts 5 to fix them.
7-3-4 4720103
7-3-4 Adjustment of Boom Swing Pedal
1) Setting Pedal Level

(1) Loosen the nut 2 of L-ball 1.
(2) Adjust the boom swing pedal with rod 3 so that the pedal
is level.
(3) Tighten the nut 2 of L-ball 1.
2) Adjustment of Stopper Bolts (Right and Left Boom

Swing)
(1) Loosen the lock nuts 4 and screw in the stopper bolts 5
until they have no contact with boom swing pedal.
(2) Move the boom swing pedal to its stroke ends, and
loosen the stopper bolts 5 until their heads contact with
the pedal.
(3) Loosen the stopper bolts 5 one more turn and tighten the
lock nuts 4 to fix them.
7-3-5 Adjustment of Blade Control Lever
(1) Loosen the nut 1 and adjust the blade control lever so
that it is vertical in neutral position.
(2) Adjustment of stopper bolts (blade up and down)
[1] Loosen the lock nuts 2 and screw in the stopper bolts 3
until they have no contact with the blade lever.
[2] Move the blade lever to its stroke ends, and loosen the
stopper bolts 3 until they contact with the blade lever.
[3] Loosen the stopper bolts 3 one more turn and tighten the
lock nuts 2 to fix them.
7-3-5 4720103
7-3-6 Adjustment of Lock Lever
1) Operation of Lock Lever

(1) The operating force for moving the lock lever from P
to N should be less than 13.23 lbs. (6 kg).
(2) The lock lever switch 4 should not allow the imple-
ments to operate when the lock lever is in N position.
2) Adjustment of Lock Lever

(1) Loose the bolts 1 (2 pcs.) and fasten the lock guide 2
temporarily.
(2) Adjust the lock guide 2 so that the rod 3 moves
smoothly when moving the lock lever and tighten the
bolts 1.
(3) After adjustment, check if the operating force is less
than 13.23 lbs. (6 kg).
3) Adjustment of Lock Lever Switch

(1) Move the lock lever to the position P.
(2) Loosen the bolt 5 of the bracket and adjust the switch
with it completely pressed in to 0.18 to 0.22 in. (4.5 to
5.5 mm) in the dimension.
Lock lever switch operation
Lever Switch Switch Cut-off Imple-
position condition circuit valve ment
operation operation
Pushed
P ON Operate Operate
Normal
Can not
N OFF Stop
operate
7-3-6 4720103
7-3-7 Adjustment Procedure of Travel Alarm

Switch
(1) Set the travel lever 1 to the neutral position.

(2) Loosen bolt 5 (4 pcs.) of bracket 3, 4 of travel alarm
switch 2.
(3) Adjust the distance between the travel lever arm 6
and the travel alarm switch 2 to 0.02 in. (0.5 mm) or
less.
Note :
Make the clearances A and B equal.
7-3-7 4720103
7-3-8 Adjustment Procedure of P.T.O. Pedal
1. Adjustment of P.T.O. pedal in neutral position

(1) Adjust the distance A to 3.63 to 3.70 in. (92 to 94 mm) with the rod 2.
2. Adjustment of P.T.O. pedal

(1) Tighten the stopper bolt 3 so that it does not contact with the P.T.O. pedal 1 when moving the P.T.O. pedal to its
stroke end.
(2) Move the P.T.O. pedal 1 on the right side to its stroke end.
(3) Loosen the stopper bolt 3 until the bolt head contacts with the P.T.O. pedal 1 at its full stroke.
(4) Loosen the stopper bolt 4 half more turn and tighten the lock nut 4.
(5) Adjust the left side by the same way as the right side.
7-3-9 Adjustment Procedure of P.T.O. Pedal Lock
Adjust the P.T.O. pedal lock after adjusting the P.T.O. pedal.
(1) Loosen the lock nut 7.
(2) Move the P.T.O. pedal 1 on the left side until the P.T.O. pedal 1 contacts with the stopper bolt 3.
(3) Move the P.T.O. pedal lock to the lock position.
(4) Adjust the distance H to 0.079 in. (2 mm) or less with the bolt 6.
(5) Tighten the lock nut 7.
7-3-8 4720103
7-3-10 Adjustment of Accelerator Lever
1) Adjustment of Minimum Idling Speed

(1) Adjust the length of the stopper bolt 1 to 1.06 in.
(27 mm), as shown in the drawing. Loosen the
stopper bolt 2 and keep it loosened.
(2) Move the accelerator lever forward to its stroke
end (the minimum idling speed position).
(3) Adjust the accelerator cable 5 in the part A so
that the regulator handle 3 on the engine side
contacts with the adjusting bolt 4 for the mini-
mum idling speed.
(4) Check if the minimum idling speed is 1025 to
1075 rpm. If not, make readjustment with the
accelerator cable 5 in the part A or the adjust-
ing bolt 4.
2) Adjustment of Maximum Idling Speed

(1) Move the accelerator lever back to its stroke
end until the regulator handle 3 on the engine
side contacts with the adjusting bolt 6 for the
maximum idling speed.
(2) Check if the maximum idling speed is 2545 to
2595 rpm for ViO27-2 and 2590 to 2650 rpm for
ViO35-2. If not, make readjustment with the
adjusting bolt 6 for the maximum idling speed.
(3) While keeping this condition, tighten the stop-
per bolt 2 until it contacts with the lever link and
then, tighten the lock nut 7.
7-3-9 4720103
7-4 Swing Bearing
1) Structure
The swing bearing is a single row ball bearing
and the internal gear is induction hardened.
The steel balls roll on the smooth surfaces of the
inner and outer races.
A soft zone is made at the starting point of the
hardening on the race, on which the steel balls
roll, and the "S" mark is indicated on the upper
surface of the inner race. In order to decrease
the load on this soft zone, place the "S" mark on
the right side of the track frame, as shown in the
right figure.
The outer race also has a soft zone at the steel
ball insertion port. Install this port on the right
side of the track frame, as shown in the right fig-
ure.
2) Part
No. Part
1 Swing bearing
2 Seal kit
3 Dowel pin 13!36
4 Bolt M14!65
3) Details of Swing Bearing

No. Part Q'ty
1 Steel ball 79
2 Seal A 1
3 Seal B 1
4 Support 79
5 Outer race 1
6 Inner race 1
7 Taper pin 1
8 Plug 1
4) Inspection
(1) Check the gear tooth surfaces for the nicks, flaws, cracks, wear and breakage. Replace if the damage is exces-
sive.
(2) Check for abnormal sound. Clean, grease or replace if necessary.
7-4-1 4720103
(3) Check for the play in the inner and outer races and rotation fluctuation. Refer to the service standards for repair
or replacement.
(4) Check for the grease leak from the swing bearing seal. Replace if the leakage is excessive.
5) Service Standards
Standard Wear limit
0.00394 to 0.00787 in. 0.01772 in.

(0.10 to 0.20 mm) (0.45 mm)
0.00354 to 0.00827 in. 0.01693 in.

(0.09 to 0.21 mm) (0.43 mm)
Ø0.8752 in.
Steel ball dia. 
(Ø22.23 mm)
Upperstructure!outer race Apply Loctite 262
Tightening torque M14!65 180.8 ft·lbf (245.2 N·m)
Undercarriage!inner race or its equivalent.
Note :
Supply multi-purpose grease to the swing bearing.
7-4-2 4720103
7-5 Hydraulic Equipment
7-5-1 Removal and Reinstallation of Hydraulic Pump

1) Removal
Procedure
(1) Remove the plate G 1 and the cover (pump) 2.

hydraulic oil tank is positioned halfway between the right
and left crawlers.

hydraulic oil.
Alternatively, a compression vacuum, which is installed to
the breather hose of the hydraulic oil tank, can be used if
a stable air pressure (air from a compressor) can be
ensured.

Q'ty : 9.24 Gals. (35 L)
(4) Open the engine hood A 5, and remove the engine hood L
6 and the weight L 7 to remove the multipurpose cover 8.
(5) Remove the tail pipe 9 from the muffler.
(6) Remove the hydraulic hoses from the hydraulic pump.
1. Standard specifications model

[1] ViO27-2
a : Suction hose
b : Hose P 1
c : Hose P 2
d : Hose P 3
e : Hose PB 1
f : Hose PB 2
g : Hose PA
h : Hose PP
7-5-1 4720103
Procedure
[2] ViO35-2
A : Suction hose
E : Hose PB 1
B : Hose P 1
F : Hose PA 2
C : Hose P 2
G : Hose PB 2
D : Hose P 3
H : Hose PB
Note :
Mark the removed hoses not to reinstall them in the wrong
positions.
2. Quick coupler type (ViO27-2, ViO35-2)
Remove the parts A to H, besides, the following hoses.

I : Hose PC1
J : Hose PC2
(7) Remove the wiring coupler of the cut-off valve 10, the
high-speed travel 11, and the quick coupler 12.
(8) Remove installation bolts 14 from the flywheel cover 13 to

remove the hydraulic pump.
Note :
Put the rope to the hydraulic pump to remove it using a lifting
device.
2) Reinstallation
Reassemble the hydraulic pump in the reverse order of
the removal procedure.
Note :
Apply heavy-duty grease to the spline shaft of the
hydraulic pump.
Hydraulic pump installation bolt M12
• Release the air from the pump after reinstallation (refer
to Section "1-10 Air Release of Hydraulic Equipment".)
7-5-2 4720103
7-5-2 Removal and Reinstallation of Control Valve
1) Removal
Procedure
(1) Remove the plate G 1 and the cover (valve) 2.

hydraulic oil tank 3 is positioned halfway between the right
and left crawlers.

hydraulic oil.
ensured.

Q'ty : 9.24 Gals. (35 L)
(4) Remove the floor step 5 and the cover (frame) 6.
(5) Remove the hydraulic hose from the control valve 7.
Notes :
• Remove all the hydraulic hoses from blade section in order.
• Mark the removed hoses not to reinstall them in the wrong
positions.
• Protect the hose and connector not to adhere dust.
7-5-3 4720103
Procedure
(6) Remove two L-balls 8, 9, and 10 connecting to the travel
R and L, and boom swing section spools of the control
valve 7.
(7) Remove the blade wire connection 11 from the blade sec-
tion.
(8) Remove the bolt 12 (M10) to remove the control valve 7.
7-5-4 4720103
2) Reinstallation
Reinstall the control valve in the reverse order of the removal procedure.
Notes :
• Install the hoses with no contact with other hoses.
• Raise the hydraulic oil temperature to 122 to 140 °F (50 to 60 °C) after reinstallation.
And apply load to all the sections to check for oil leak.
7-5-5 4720103
7-5-3 Removal and Reinstallation of Swing Motor
1) Removal
Procedure

hydraulic oil tank 2 is positioned halfway between the left
and right crawlers.
Lower the bucket to the ground and stop the engine.

hydraulic oil.
ensured.

Q'ty : 9.24 Gals. (35 L)
(4) Remove the floor step 4.
(5) Remove the hydraulic hoses from the swing motor 6.
a : Hose PB (hydraulic pump to swing motor)

b : Drain hose (swing motor to oil cooler)
c : Hose (control valve to swing motor)
d : Drain hose (swing motor to joint CMP)
e : Drain hose (control valve to swing motor)
(6) Remove the swing motor installation bolt (M14) 5 to

remove the motor.
Note :
Install the eye bolt M8, and then put a rope to the eye bolt to
remove the swing motor using a lifting device.
7-5-6 4720103
2) Reinstallation
Reassemble the swing motor in the reverse order of the removal procedure.
Swing motor installation bolt M14
Adhesive Apply three bond 1324
7-5-7 4720103
7-5-4 Removal and Reinstallation of Swivel Joint
1) Removal
Procedure
(1) Operate the implement and the blade to raise the
machine.
(2) After raising the machine, put crossties under it.
Note :
To prevent the machine from dropping, be sure to put
crossties.

and right crawlers.
Lower the bucket to the ground and stop the engine.
(5) Remove the drain plug 3 of the hydraulic oil tank 2 to drain
hydraulic oil.
ensured.

Q'ty : 9.24 Gals. (35 L)
(6) Remove the under cover (lower frame) 4.
7-5-8 4720103
Procedure
(7) Remove the hydraulic hoses of the lower frame side from
the swivel joint.
G : High-speed (R)
H: High-speed (L)
E : Travel motor (R)
B : Travel motor (L)
h : Drain (R)
i : Drain (L)
C : Blade cylinder
D : Blade cylinder
A : Travel motor (R)
Notes :
• Remove the hydraulic hoses in order from the lowest one of
the swivel joint.
• Mark the removed hoses not to reinstall them in the wrong
positions.
(8) Remove the swing motor.

<Refer to Section "7-5-3 Removal and Reinstallation of
Swing Motor".>
(9) Remove the hydraulic hoses on the upper frame side of

the swivel joint.
G : High-speed pilot (R)
C : Blade
A : Travel motor (R)
B : Travel motor (L)
D : Blade
E : Travel motor (R)
F : Travel motor (L)
h, i : Drain
(10) Remove the installation bolt 5 of the swivel joint. Then,

remove the swivel joint by lifting it up.
Note :
Mark the lower frame and the swivel joint to reinstall them in
the correct direction.
7-5-9 4720103
2) Reinstallation
Reassemble the swivel joint in the reverse order of the removal procedure.
Swivel joint installation bolt M10
Adhesive Apply Three Bond 1324
7-5-10 4720103
7-5-5 Disassembly and Reassembly of Swivel Joint
1) Swivel Joint
The swivel joint is used to prevent the hydraulic piping from twisting when the upperstructure swings. The swivel
joint consists of the shaft, hub and seal kit. The shaft and hub have holes and grooves, and the oil supplied from the
port of the shaft, passing through the hub groove, is fed to the actuators of the undercarriage.

1 Swivel joint assembly 1 8 Seal (O-ring 55.76!5.7) 7
2 Swivel shaft 1 9 Back-up ring 1
Swivel flange 10 O-ring 1A P 75.0 1
3 4
(with spring washer 10!40) 11 O-ring 1A G 70.0 1
4 Swivel hub 1 12 External snap ring 1
5 Swivel spacer 1 13 Screw plug PT 1/4 7
6 Seal kit 1 14 Bolt M 10 3
7 O-ring 55.76!5.7 1 15 Bolt M 10 4
7-5-11 4720103
2) Disassembly and Reassembly of Swivel Joint
• Disassembly
(1) Remove the bolts 14.
(2) Remove the swivel flange 5 and the O-ring 11.
(3) Remove the external snap ring C 12 and the swivel
spacer 5 from the swivel shaft 2.
(4) Pull the swivel shaft 2 out of the swivel hub 4 and
remove O-ring 10.
(5) Remove the swivel seals 8, O-ring 7 and back-up
ring 9 from the swivel hub 4.
• Reassembly
(1) Install swivel seals 8, O-ring 7 and back-up ring 9
into swivel hub 4.
(2) Apply multi-purpose grease to the inner surface of
swivel hub 4.
(3) Install the O-ring 10 on the swivel shaft 2 and
insert the shaft into the swivel hub 4 slowly.
• Use a jig E-004
• Apply multi-purpose grease to the outer surface of
the shaft.
(4) Install the swivel spacer 5 and the external snap
ring 12 to the swivel shaft 2.
(5) Install the swivel flange 3 with O-ring 11, on the
swivel hub 4 in this order and tighten bolts 14.
7-5-12 4720103
3) Cautions for Handling and Storing Seals

(1) O-rings are packed in the package that is suitable for storage.
(2) Do not leave the O-rings outside the package.
(3) For storing, put the O-rings in the packages and place them in a dark and cool place (in a parts box or cardboard
box) under 104°F (40°C) to avoid direct sunlight. If the stored condition is proper, it can be stored for four or five
years.
(4) Do not put anything on the O-rings, or they may be distorted.
4) How to Fit O-rings (for Inner Side)

• Fitting
(1) Use lithium soap group multi-purpose grease.
(2) For fitting a seal ring, make it heart-shaped as shown in the
right figures and press one end of it into the groove. Then, fit
the whole seal ring while pressing it with your finger (Figs. 1
and 2).
(3) When using jigs for fitting seal rings, use the jigs with round
edges to avoid damaging the seal rings. (Fig. 3)
(4) If the seal ring is distorted after fitting, correct the distortion
with the jig before assembly. (Fig. 4)
5) Repair and Replacement of Parts

(1) Disassemble and reassemble at a place free from dust.
(2) Completely remove the contamination, foreign matter
(sludge), etc. from the disassembled parts.
(3) Check for flaws or nicks on the seal surface of the shaft.
Repair or replace the part when necessary.
(4) Replace the shaft if it is worn.
(5) Replace all seals in reassembly.
7-5-13 4720103
7-5-6 Disassembly and Reassembly of Hydraulic Cylinders
1) Sectional View and Parts
No. Part Boom Arm Bucket Boom swing Blade Quick coupler
1 Spring ring % % % % % 
2 DKB seal % % % % % 
3 Lock washer % % % % % 
4 O-ring % % % % % %
5 Head % % % % % %
6 O-ring % % % % % %
7 ISI packing % % % % % %
8 Back-up ring %     
9 O-ring %     
10 Cylinder tube % % % % % %
11 Cushion collar %     
12 Cushion plunger %     
13 SPGTI seal % % % % % SPGW
14 Wearing ring % % % % % %
15 Piston % % % % % %
16 U nut % % % % % %
17 Rod % % % % % %
18 Spacer  %    
19 O-ring  %    
20 Cushion plunger  %    
21 Cushion collar  %    
22 Stopper  %    
23 Cover (stopper)  %    
24 External snap ring C (26)  %    
25 Pilot check valve      %
26 O-ring P8      %
27 O-ring P14      %
28 Screw plug 1/16      %
7-5-14 4720103
2) Cautions for Disassembly and Reassembly

(1) Parts are produced so accurately. Be careful not to damage any parts by dropping them or knocking them
together.
(2) When there are any burrs on the surface of seal installation part or O-ring groove, remove them.
(3) Never use the lock washer removed once.
(4) Replace once removed seal and O-ring with new ones.
(5) Clean all the parts and dry them by air blow.
3) Disassembly
Procedure
(1) Drain the oil from the hydraulic cylinder.
(2) Hold the cylinder in the bottom end or the pin hole on the
bottom side, and put the rod side of the cylinder on the
crosstie.
(3) Raise the pawl of the lock washer 3 on the head 5 and
loosen the head 5.
Note :
Loosen the head 5 with a hook wrench or a jig.
(4) Pull out the rod assembly 17 from the cylinder tube 10,
and then hold the cylinder rod assembly in the rod end or
the pin hole on the rod side.
(5) Disassembly of boom cylinder

Remove the U nut 16, and then the piston 15, the cushion
plunger 12, the cushion collar 11, and the head 5 in order.
7-5-15 4720103
Procedure
(6) Disassembly of arm cylinder
• Remove the snap ring C 24 to remove the cover 23 (stop-
per), the stopper 22, the cushion collar 21, and the spacer
18 in order.
• Remove the U nut, and then the piston 15 and the head 5 in
order.
(7) Disassembly of bucket, boom swing, blade and quick cou-

pler cylinders
Remove the U nut 16, and then the piston 15 and the
head 5 in order.
(8) Remove the O-rings 4, 6, 9 and 19 and the DKB seal 2,

the ISI packing 7 and the SPGTI seal 13.
Note :
Use a sharp tool to raise each O-ring or SPGTI seal, and then
insert a spatula to remove it.
7-5-16 4720103
4) Reassembly
Reassemble the hydraulic cylinder in the reverse order
of the disassembly procedure.
Notes :
• Take care not to install the cushion collar 2 and the
cushion plunger 12 in the wrong direction.
• Replace O-rings, packings and seals with new ones.
Tightening torque
Boom
No Item Boom Arm Bucket Blade Quick coupler
Swing
1 U nut size M33 ← M27 ← M30 M14
U nut tightening 759.5 to 831.9 ft·lbf 542.5 to 614.9 ft·lbf 798.3 to 870.8 ft·lbf 68.7 to 79.6 ft·lbf
2 ← ←
torque (1030 to 1130 N·m) (735.5 to 833.6 N·m) (1078.8 to 1176.8 N·m) (93 to 108 N·m)
Adhesive Three bond 1324 or
3 ← ← ← ← ←
its equivalent
7-5-17 4720103
7-5-7 Hydraulic Oil Tank
1. Structure
No. Part Q’ty No. Part Q’ty No. Part Q’ty

1 Bolt 8!20 3 11 Suction flange 1 20 Hexagon head bolt 2
2 Tank cap 1 12 Bolt 8!16 4 21 O-ring 4
3 O-ring 1A G105 1 13 O-ring 1A G105 1 22 Oil gauge 1
4 Side clutch spring 1 14 Suction filter 1 23 Hose (breather) 1
5 By-pass valve 1 15 Bolt 14!40 4 (2) 24 Hose clip (12) 1
6 Return filter 1 2 25 Oil supply port cap 1
16 Bolt 14!45
7 Bolt 5!10 3 (ViO35-2) 26 O-ring 1A P38 1
8 Plate 1 17 Drain plug 24 1
9 Packing 1 18 O-ring 1A S30 1
10 Element (breather) 1 19 Hydraulic oil tank 1
Note :
( ) for ViO35-2
7-5-18 4720103
2. Removal and Reinstallation of Hydraulic Oil Tank

1) Removal
Procedure

and right crawlers.

hydraulic oil.
ensured.

(VG46 or its equivalent)
Q'ty : 9.24 Gals. (35 L)
(4) Remove the engine hood B 5 and the battery 6.
7-5-19 4720103
Procedure
(5) Remove the weight R 7 and the engine hood R 8.
(6) Remove the engine hood A 9, the engine hood L 10 and

the pipe 11.
(7) Remove the canopy 13.

In this step, disconnect the harness 14 of canopy light.
(8) Remove the floor step 15, the multipurpose cover 16 and
the grille 17.
(9) Disconnect the accelerator cable 18 on the engine side.
(10) Remove the control lever L assembly (with pilot hose)

19.
(11) Remove the cover, and then remove the connectors of

power relay 20, glow relay 21, timer 22 and fuse box 23.
(12) Remove the installation bolt 24 and the safety relay 25.
7-5-20 4720103
Procedure
(13) Remove the plate (with operator’s seat) 26 and the con-
trol lever R assembly (with pilot hose, blade & lock levers
and instrument panel) 27.
(15) Remove the operator’s seat mount 30.
Notes :
• Remove the clamp held on the seat mount and remove the
wire harness when lifting the seat mount up.
• Put rope to the seat mount to remove it using a lifting device
(16) Remove the installation bolts 33 for the duct R 31 and

the duct L 32 to remove the radiator mount 34.
7-5-21 4720103
Procedure
(17) Remove the suction hose 35, and the return hoses 36
and 37.
(18) Remove the return hose 38 connecting the oil cooler and
the hydraulic oil tank.
(19) Remove the installation bolts 39 nd the hydraulic oil tank.
Note :
Put rope to the hydraulic oil tank to remove it using a lifting
device.
7-5-22 4720103
2) Reinstallation
(1) Reassemble the hydraulic oil tank in the reverse order
of the removal procedure.
Notes :
[1] Completely drain the oil from the hydraulic oil tank and
wipe the impurities off the bottom of the tank.
[2] Replace the return filter 6 with a new one.
[3] Clean the suction filter 14. Replace it if the wire gauze
is damaged.
[4] Replace the oil when it reaches the replacement time
or it has been deteriorated. If reusing the oil, maintain
the oil quality so that it has no impurities.
[5] Check the packing 21 of the oil gauge 22 for oil leak,
and replace any defective packing or other parts if
necessary.
[6] Replace the element for breather 10 if it is dirty.
Note :
The size of the tank installation bolts 15 and 16 depends
on the model.
• ViO27-2 M14!40!4
• ViO35-2 M14!40!2
M14!45!2
Hydraulic oil tank installation bolt M14
Adhesive Apply Three Bond 1324 or its equivalent
7-5-23 4720103
3) Oil Level Check

(1) Place the machine on a firm and flat ground when
checking the hydraulic oil level.
(2) Check the hydraulic oil level with the oil level gauge
when the oil temperature is 32 to 86°F (0 to 30°C).
(3) The proper oil level is 0.394 in. (10 mm) above the mid-
dle of the oil level gauge. The hydraulic oil level
increases or decreases depending on the hydraulic oil
temperature due to its nature; therefore, check it when
the oil is cooled.
4) Machine Position in Oil Level Check

(1) Retract the bucket and arm cylinder rods completely to
lower the bucket to the ground.
(2) Lower the blade to the ground.
7-5-24 4720103
7-5-8 Piping Layout

1) Upperstructure
(Hydraulic oil tank → Hydraulic pump → Control valve)
7-5-25 4720103
2) Upperstructure
(Hydraulic oil tank → Hydraulic pump → Quick coupler)
7-5-26 4720103
3) Upperstructure
(Control valve ←→ Swing motor)
(Control valve ←→ Implement cylinders)
7-5-27 4720103
4) Upperstructure
(Control valve ←→ Swivel joint)
(Hydraulic pump → Swivel joint)
7-5-28 4720103
5) Upperstructure
(Control valve → Hydraulic oil tank)
(Hydraulic pump → Swing motor → Control valve)
7-5-29 4720103
6) Pilot Control for Implements

(Control valve → Pilot valve)
(Hydraulic pump → Pilot valve)
7-5-30 4720103
7) Undercarriage
(Swivel joint ←→ Travel motor)
(Swivel joint ←→ Blade cylinder)
7-5-31 4720103
7-6 Work Implements
7-6-1 Removal and Reinstallation of Work Implements
Notes :
• When removing the pins, check the number of shims installed and their positions.
• When removing the hose, put a plug on the hose connection port to stop the oil from flowing out.
1) Removal of Bucket
Procedure
(1) Lower the bucket to the ground with its back side down.
(2) Remove the bolt 2 (M10) to remove the pin 3.
(3) Remove the bucket 1.
7-6-1 4720103
2) Removal of Arm
Procedure
(1) Remove the bucket.
(2) Remove the bolt 1 (M10) and pull out the pin 2 to remove
the bucket link 3 and the bucket arm 4.
(3) Lightly place the top end of the arm 5 on the ground per-
pendicularly to the ground.
(4) Remove the hydraulic hose from the bucket cylinder 6

and the bolt 7 (M10) to pull out the pin 8, and then remove
the bucket cylinder 6.
Note :
Put rope to the bucket cylinder to remove it using a lifting
device.
(5) After putting rope to the arm 5, remove the bolt 10 (M10)
and remove the pin 12 from the arm cylinder 11 (on the
rod side).
Note :
Put a block under the arm cylinder.
(6) Remove the bolt 13 (M10) to pull out the arm pin 14 and
remove the arm 5.
7-6-2 4720103
3) Removal of Boom
Procedure
(1) After raising the boom 15 to the maximum, remove the
slide cover 2 from the boom cylinder 1.
(2) Place the top end of the boom 15 on the ground.
Note :
Install an expansion plug to the joint of removed hydraulic
hose and start the engine.
(3) After putting rope to the arm cylinder 3, remove the

hydraulic hose from the arm cylinder.
(4) Remove the bolt 4 (M10) to pull out the pin 5, and remove
the arm cylinder 3.
Note :
Put rope to the arm cylinder to remove it using a lifting device.
(5) After putting rope to the boom cylinder 1, remove the

hydraulic hose from the boom cylinder.
(6) Remove the bolt 6 (M10) to pull out the pin 7, and remove
the arm cylinder 1.
Note :
Put rope to the boom cylinder to remove it using lifting device.
(7) Remove the cover 8 to separate the joint sections 9 of

hydraulic hoses to the bucket cylinder.
(8) Remove the boom light wiring at connector part 10.
7-6-3 4720103
Procedure
(9) After putting rope to the boom 11, remove the bolt 12
(M10) to pull out the pin 13 and remove the boom 11.
Notes :
• Put rope to the boom to remove it using a lifting device.
• Take care that each hose is not caught in the hose protect
pipe 14.
4) Removal of Blade
Procedure
(1) Turn the implement to the blade side, lower the bucket
and the blade 1 to the ground and stop the engine.
(2) Remove the blade cover 2 to remove the hydraulic hose.
(3) After putting rope to the blade cylinder 5, remove the bolt
3 (M10) to pull out the pin 4 and remove the cylinder 5.
(4) After putting rope to the blade 1, remove the bolt 6 (M10)
to pull out the pin 7 and remove the blade.
Note :
Put rope to the blade cylinder or the blade to remove it using a
lifting device.
7-6-4 4720103
5) Removal of Boom Bracket

Procedure
(1) Remove the bucket 1.
<Refer to Section "7-6 1) Removal of Bucket".>
(2) Remove the arm 2.

<Refer to Section "7-6 2) Removal of Arm".>
(3) Remove the boom 3.

<Refer to Section "7-6 3) Removal of Boom".>
(4) Remove the bolt 4 (M10) to pull out the pin 5 (for the
boom swing cylinder).
(5) Remove the bolt 6 (M14) and the snap ring C 7 to pull out
the pin 8 and then remove boom bracket.
Note :
Put rope to the boom bracket to remove it using a lifting
device.
7-6-5 4720103
6) Removal of Boom Swing Cylinder

Procedure
(1) Swing the upperstructure so that the engine comes oppo-
site the blade. Then lower the bucket to the ground and
stop the engine.
In this case, stop the upperstructure halfway between
both crawlers to pull out the pin 1 on the bottom side of
the boom swing cylinder.
(2) Remove the boom swing cover 2 to remove the bolt 3

(M10), and then pull out the pin 4 (on the side).
(3) Remove the hydraulic hose.
(4) Remove the weight R 6, the hydraulic hose and the bolt 8
(M10), and then pull out the pin 9.
Note :
Use the bolt 10 (M12) to pull out the pin.
(5) Remove the boom swing cylinder 11.
7-6-6 4720103
7) Reinstallation
Reinstall the implement in the reverse order of the removal procedure.
Tightening torque and Adhesive

No. Size Tightening torque Adhesive
1 M12 57.9 to 72.3 ft·lbf (78.5 to 98.1 N·m) Apply Three bond 1324 or its equivalent.
2 M12 ↑ ↑
3 M12 ↑ ↑
4 M12 ↑ ↑
5 M12 ↑ ↑
6 M12 ↑ ↑
7 M12 ↑ ↑
8 M10 32.6 to 43.4 ft·lbf (44.1 to 58.8 N·m) ↑
9 M10 ↑ ↑
7-6-7 4720103
7-6-2 Quick Coupler
1) Structure

1 Bolt (M10!80) 1 11 O-ring (35!2.3) 1 21 Quick coupler cylinder 1
2 Pin (38!242) 1 12 O-ring 71 2 22 Pin (25!86) 2
3 Bolt (M12!30) 1 13 Bracket A 1 23 Internal snap ring C (25) 2
4 Pin (38!237) 1 14 Bolt (M8!20!20) 2 24 Hexagon socket head bolt 3
5 Snap ring E6 1 15 Collar (9!4) 2 25 Pin (30!37) 2
6 Plain washer 8 1 16 Plate (rubber) 1 26 Internal snap ring C (30) 2
7 Lock pin 1 17 Plate CMP 1 27 Ring (1AP47) 2
8 Lock plate 1 18 Bolt (M10!20) 2 28 Elbow PF1/4 2
9 External snap ring C (35) 1 19 Guard CMP 1 29 Pilot check valve 1
10 Shim (35!2.3) 1 20 Bracket B 1 30 Grease nipple 2
7-6-8 4720103
2) Disassembly
Procedure
(1) Remove the attachment (the bucket etc).
(2) Lower the boom until the quick coupler reaches 0.394 to
1.181 in. (10 to 30 mm) above the ground.
(3) Remove the snap ring C 9 and the shim 10, and then
remove the lock pin 7 and the lock plate 8.
(4) Remove the hydraulic hose A.
(5) Remove the bolt 3 (M10) to pull out the pin 4 to separate
the quick coupler from the bucket link.
(6) Remove the bolt 1 (M10) to pull out the pin 2, and then
remove quick coupler and the O-ring 12 from the arm.
(7) Remove s the nap rings 23 and 26, and the hexagon
socket head bolt 24, and then pull out the pins 22 and 25
to remove quick coupler cylinder.
Note :
Pull out the pin 25 with Jig. For the details of the jig, refer to
Section "3) Pin Puller Jig" below.
7-6-9 4720103
Procedure
(8) Remove the guard 19, the plate (rubber) 16 and the plate
17.
3) Pin Puller Jig
4) Reassembly
Reassemble the quick coupler in the reverse order of the disassembly procedure.
(1) Tightening torque
Bolt M12
Adhesive Apply Three Bond 1324 or its equivalent.
57.9 to 72.3 ft·lbf (78.5 to 98.1 N·m)
Hexagon socket head bolt

Adhesive Apply Three Bond 1324 or its equivalent.
7.23 to 8.68 ft·lbf (9.81 to 11.8 N·m)
(2) Applying grease

Apply multi-purpose grease to O-ring 11 (27.6!5.7).
7-6-10 4720103
7-7 Cabin
7-7-1 Cabin
• Structure and component parts

1 Lock CMP 1 17 Packing 4 33 Seal rubber A assembly 1
2 F lock release plate 1 18 Pipe 12 34 Hinge CMP (door) 2
3 Bolt 8!20 1 19 Tube 12 35 Seal rubber B assembly 1
4 Nut (with spring washer 8) 1 20 Cap nut 10 12 36 Hinge cover 2
5 Handle (outer) 1 21 Snap pin 2 37 Glass R (door) 1
6 Door hook 1 22 Polished washer 8 2 38 Frame CMP (door rear) 1
7 Nut (BC 10) 4 23 Stopper guide 1 39 Glass FL (door) 1
8 Bolt (with spring washer 6!10) 3 24 Plate CMP (stopper) 1 40 Pan headed screw 4
9 Pin 1 25 Flanged bolt (Black M8!16) 2 41 Striker CMP 1
10 Spring 1 26 Nut 10 2 42 HD washer 8.5!1.8 2
11 Rod (R handle CMP) 1 27 Bolt (10!30) 1 43 Button bolt 2
12 Pan headed screw 2 28 Packing 8 44 Catch 1
13 Cover 1 29 Cylinder CMP 1 45 Stopper rubber 1
14 Handle CMP 1 30 Lock plate 1 46 Trim 1
15 Bolt 6!16 3 31 Glass FU (door) 1
16 Latch cover 1 32 Frame CMP (door F) 1
7-7-1 4720103
1. Removal and Reinstallation of Cabin

1) Removal
Procedure
(1) Lower the bucket to the ground, and then stop the engine.
(2) Remove the floor mats A 1, B 2, and C 3.
(3) Remove the engine hood L 4 and the cover 5 (for the H
hose CMP).
(4) Remove the coupler of the harness 6 (for the cabin), and
then release the fixation of clamp 7.
(5) Remove the cover 8 (for the heater).
7-7-2 4720103
Procedure
(6) Remove the grip 9 and the grille 10, and then remove the
tree clip 11.
(7) Remove the nine clips, and then remove the cover 12 (for
the duct).
For the quick coupler type, remove the switch box 13.
(8) Remove the hoses (for the heater 14 and the defroster
15) on the heater unit side.
(9) Remove the heater frame (with the heater unit), and then
put it onto the operator's seat.
Note :
Protect the seat from damage with waste etc.
(10) Remove thirteen installation bolts from the cabin.
7-7-3 4720103
Procedure
(11) Put rope to the hooks on the top of cabin to lift it.
Notes :
• When lifting up the cabin, keep it horizontal.
• Operate carefully not to interfere with any other objects.
2) Reinstallation
(1) Reinstall the cabin in the reverse order of the
removal procedure.
(2) Install the seal rubber in the specified position.

Tightening torque
Installation bolt for cabin (10.9T!M12)
79.6 to 94.0 ft·lbf (107.9 to 127.5 N·m)
7-7-4 4720103
2. Removal and Reinstallation of Cabin Door

1) Removal
Procedure
(1) Remove the cap nuts 20 to remove the cabin door.
7-7-5 4720103
2) Reinstallation
(1) Reinstall the cabin door in the reverse order of the removal procedure.
(2) Adjustment of cabin door
[1] Adjustment of clearance between the cabin door and the cabin body.
After adjusting the clearances A, B, C, and D to the respective specified values tighten the cap nuts 20.
[2] Adjustment of striker
• Fully tighten the bolt 27 (for the stopper) in the lower part of the front door.
• Adjust the striker 41 in the front or back direction, and then set the operating force for closing the cabin door at
110.25 lbs. (50 kg) or less.
• Loosen the bolt 27 until it touches the stopper with the cabin door closed, and then lock it with the nut 26.
7-7-6 4720103
[3] Adjustment of door catch

1. Hold the cabin door to the door catch 44, and then adjust the door catch with the lock CMP so that the hook 6 can
be caught smoothly.
2. Adjust the door catch with the lock CMP so that the hook 6 can be released smoothly when operating the release
lever.
[4] Adjustment of stopper rubber
1. Fully tighten the stopper rubber 45 and hold the cabin door to the door catch 44. Loosen the stopper rubber 45
until it contacts with the cabin door.
2. Loosen the stopper rubber two more turns and fix it with the lock nut.
Note :
The stopper rubber should be adjusted within three turns after contacting with the cabin door.
Cap nut M10

Adhesive Apply loctite or its equivalent
7-7-7 4720103
3. Replacement of Cabin Door Glass

1) Removal of Glass
Procedure
(1) Remove the cabin door from the cabin.
<Refer to Section "2. Removal and Reinstallation of Cabin
Door".>
(2) Remove the cap nuts 20 to take off the frame CMP 32 (of
the door F) and 38 (of the door rear).
(3) Remove the seal rubbers A 33 and B 35.
(4) Cut the adhesive on the glasses FU 31 and FL 39 of the

frame CMP 32 (for the door F) and then remove the glass.
(5) Cut the adhesive on the glass R 37 of the frame CMP 38

(of the door rear), and then remove the glass.
Note :
For the procedure for cutting the adhesive, refer to the
removal procedure of the front windshield.
2) Replacement of Glass
(1) Clean the primer areas not to leave any old adhesive.
(2) Use adhesive for glass.
Note :
Use the proper primer and cleaner for adhesive.
Type of adhesive
Sika. AG : Sika Tack-Ultrafast or its equivalent
(3) Apply the adhesive at a width of 0.315 in. (8 mm) or more.
Note :
Wipe any excessive adhesive away.
7-7-8 4720103
Procedure
(4) Glue the dams (for the front door 380) and the dam (for
the front door 390) onto the frame CMP 32 (of the door F).
(5) Put adhesive around the frame CMP 32 (of the door F),
and then press the glass FU 31 and the glass FL 39
against the frame.
Notes :
• Glue the glass so that the edge of the glass FL 39 and the
frame are in a straight line.
• Install both edges of the trim 46 so that they are put into the
weather strip of the seal rubber A 33.
(6) Put adhesive around the frame CMP 38 (of the door rear),
and then press the glass R 37 against the frame.
(7) Install the seal rubbers A 33 and B 35.
7-7-9 4720103
4. Removal and Reinstallation of Front Window

1) Structure and Component Parts

1 Windshield UP (front W) 1 11 Link L CMP 1 21 Lever CMP (F/W) 2
2 Frame CMP (front W) 1 12 Link R CMP 1 22 Spring pin 3.0A !12 2
3 Grip 2 13 Stopper rubber 2 23 Roller shaft L CMP 1
4 Latch L CMP 1 14 Gas damper 2 24 Roller shaft R CMP 1
5 Latch R CMP 1 15 F/W holder 2 25 Torques M10!20 4
6 Bolt 8!16 8 16 Torques 4 26 Stopper rubber (door) 1
7 Dam seal 750 (F/W) 3 17 Handle R CMP 1 27 Torques M10!20 1
8 Roller 19.5!18 2 18 Handle L CMP 1 28 Plate CMP 1
9 Polished washer 6 2 19 Spring 2 29 Nut 10 1
Hexagon socket head bolt
10 2 20 Latch pin 2 30 Seal rubber (F/W) 1
(6!10)
7-7-10 4720103
2) Removal
Procedure
(1) Remove the coupler from the curl cable (for wiper wiring).
(2) Remove the installation bolts of handle CMP L 4 and R 5

with the frame CMP 2 (of the front window) closed.
(3) Un lock the lever CMP 20 (for the front window), and then
turn the grip 3 to the ceiling side.
Note :
When the grip 3 is turned up after removing the installation
bolt for the handle CMP, the frame CMP 2 leans this side.
(4) Remove the frame CMP 2 from the cabin by taking the
roller 8 out of the groove in the cabin frame while inclining
the upper part of the frame CMP 2 to the inside of the
cabin and moving the whole frame crosswise.
7-7-11 4720103
3) Reinstallation
Reinstall the front windshield in the reverse order of the removal procedure.
(1) When moving the front window to and from the storage space under the ceiling, check that the rollers move on
the rail smoothly.
(2) Check that the slide latch returns automatically.
(3) When the front window is stored under the ceiling, check that the play is 0.079 in. (2 mm) or less.
Handle CMP installation bolt (M8)
Adhesive Three bond 1344 or its equivalent
4) Adjustment of Stopper Rubber

Procedure
(1) Loosen the nut 29 of the stopper rubber 26, and then fully
tighten the stopper rubber 26.
(2) Raise the frame CMP 2 and lock it under the ceiling.
(3) Loosen the stopper rubber 26 until it contacts with the

frame CMP 2.
(4) Lower the frame CMP 2, and then loosen the stopper rub-
ber 26 two more turns (approximately 0.118 in. [3 mm])
and tighten the nut 29.
7-7-12 4720103
5) Adjustment of Frame CMP Lock

Procedure
(1) Store the frame CMP 2 under the ceiling.
(2) Loosen the installation bolt 6 for the lever CMP 21, and
then adjust and tighten the installation bolt 6 so that the
latch pins 22 can be installed into the holes in the links L
11 and R 12 smoothly.
(3) Loosen the installation bolt 16 for the front window holder
15 and lower the frame CMP 2. Then, adjust and tighten
the installation bolt 16 so that the latch pin can be installed
into the hole in the holder 15 smoothly.
7-7-13 4720103
6) Removal of Front Windshield

Procedure
(1) Cut the adhesive between the front windshield 1 and the
frame CMP 2 along the cut line with a metal spatula or a
cutter.
7) Replacement of Front Windshield

(1) Clean the primer not to leave any old adhesives.
(2) Use adhesive for glass.
Type of adhesive
Note :
Use the proper primer and cleaner for the adhesive.
(3) Apply adhesive at a width of 0.315 in. (8 mm) or more.
Note :
Wipe any excessive adhesive away.
Procedure
(1) Clean the surface of the frame CMP with a cleaner
(Cleaner No.1 manufactured by Sika or its equivalent).
(2) After the cleaner dries up, glue the three dam seals 7 to
the frame CMP 2.
(3) Put adhesive (Sika Tack-Ultrafast or its equivalent) around

the windshield 1 and press it against the frame CMP 2.
Notes :
• Pressing height is 0.197 in. (5 mm).
• The coating width is 0.315 in. (8 mm) or more.
• After gluing the windshield, do not move the frame CMP 2
at least about 40 minutes.
7-7-14 4720103
5. Cabin Glass
1) Structure and Component Parts

Dam
1 Seal rubber 3300 (F/W) 1 8 Sash assembly 1 15 1
(rear 36.0 in. [915 mm[)
2 Seal rubber 800 (F/W) 1 9 Seal rubber (roof) 1 16 Trim (glass) 1
Dam
3 Glass LOW (F/W) 1 10 1 17 Glass (L) 1
(sun roof 73.2 in. [1860 mm])
Dam
4 Stopper rubber 2 11 Sun roof 1 18 1
(L17.7 in. [450 mm[)
5 Glass run 270 2 12 Spacer (upper) 6 19 Spacer (lower) 6
6 Glass (LOW R) 1 13 Trim 1000 (curved glass) 1
7 Spacer 2 14 Glass (rear) 1
7-7-15 4720103
0.12 in. (3 mm) (between dam and frame)
7-7-16 4720103
7-8 New Cabin
7-8-1 Cabin
1. Removal and Reinstallation of Cabin

1) Removal
Procedure
(1) Lower the bucket to the ground, and then stop the engine.
(2) Remove the floor mats A 1, B 2 and C 3.
(3) Remove the engine hood L 4 and the cover 5 (for the 4
heater hose CMP).
3
5
2 1
(4) Remove the connector of the cabin harness 6.
(5) Remove the heater cover 7.
7-8-1 4720103
Procedure
(6) Remove the grip 8 and the grilles 9, and then remove the
clips 10.
8
(7) Remove all the clips, and then remove the duct cover 11.
For quick coupler types, remove the switch box 12.
10 12
11
9
(8) Remove the hoses 13 and 14 from the heater unit 15.
14
15
13
(9) Remove the heater support 16 (with the heater unit 15),
and then place it on the operator's seat.
16
Note :
Protect the operator's seat from damage with waste cloth or
the like.
(10) Remove the thirteen mounting bolts from the cabin.
7-8-2 4720103
Procedure
(11) Put rope to the shackles on the top of the cabin and lift it
up. a
Notes :
• When lifting up the cabin, keep it horizontal.
• Perform the lifting operation carefully so that the cabin does
not interfere with any other objects. b
Rope
<The way of lift for cabin>
[1] Remove the bolt a (M16!40) from A. B
[2] Remove the bolt b (M16!30) from B.
[3] Install the eyebolts to A and B. Install the eyebolts
[4] Install the shackles to the eyebolts.
A and shackles
Tightening torque of the bolt a & b :

123.0 to 151.9 ft lbf (166.6 to 205.8 N m)
2) Reinstallation
(1) Reinstall the cabin in the reverse order of the
removal procedure.
(2) Install the rubber seal in the specified position.

Tightening torque
Cabin mounting bolts (10.9T!M12)
Seal rubber
7-8-3 4720103
2. Removal and Reinstallation of Side Door

1) Removal
Procedure
(1) Remove the two caps 1 and the two cap nuts 2, and then
remove the side door 3. 1
2
7-8-4 4720103
2) Reinstallation
(1) Reinstall the side door in the reverse order of the removal procedure.
(2) Adjustment of side door
[1] Adjustment of clearance between side door and cabin body
Adjust the clearances A, B, C and D to the respective specified values, and then tighten the cap nuts 2.
[2] Adjustment of door catch
Adjust the door catch 4 by moving it in the right or left direction, and then set the operating force for closing the
side door at 110.25 lbs. (50 kg) or below.
D 2 0.236 in. (6 mm)
0.295 in.
(7.5 mm)
0.311 in.
(7.9 mm)
B
in.
0.295 m)
(7.5 m
7-8-5 4720103
[3] Adjustment of rubber stopper

1. Fully tighten the rubber stopper 5. Open the side door and hold the door to the door catch 6. Loosen the rubber
stopper 5 until it touches the counter weight.
2. Loosen the rubber stopper 5 two more turns and fix it with the lock nut 7.
Lock CMP
Release lever
Cover (reset)
7
5
Lock nut M10

Adhesive Apply loctite or its equivalent
7-8-6 4720103
3. Replacement of Side Door Glass

1) Removal of Glass
Procedure
(1) Remove the side door from the cabin.
<Refer to Section "2. Removal and Reinstallation of Side 2
Door".>
(2) Cut the adhesive between the front frame CMP 1 and the 1
glasses F TOP 2 and F BOTTOM 3, and then remove the
glasses.
4
(3) Cut the adhesive between the rear frame CMP 4 and the
glasses R TOP 5 and R BOTTOM 6, and then remove the
glasses.
Note :
For the procedure for cutting the adhesive, refer to the 5
removal procedure for the upper windshield.
6
3
• Use adhesive for glass.
Type of adhesive
Note :
Use proper primer and cleaner for adhesive.
• The width of adhesive applied to the frame is to be 0.315 in. (8 mm) or more.
Note :
Wipe any excess adhesive away.
7-8-7 4720103
Procedure
(1) Clean the primer areas of the front frame CMP 1 and the
rear frame CMP 4 so as not to leave any old adhesive.
2
(2) Apply adhesive to all the sides of the front frame CMP 1,
and then install and press the glasses F TOP 2 and F
BOTTOM 3 against the frame. 1
Note : 4
Glue the glass so that the edge of the glass F BOTTOM 3 and
the door frame are parallel.
(3) Apply adhesive to all the sides of the rear frame CMP 4,
and then install and press the glasses R TOP 5 and R
BOTTOM 6 against the frame. 5
6
3
7-8-8 4720103
4. Removal and Reinstallation of Upper Front Window

1) Removal
Procedure
(1) Remove the screw 1 on each side with a screwdriver.
1
(2) Pry the right side of the link 2 to the cabin frame side
using a screwdriver or the like, as shown in the photo at
the right.
Repeat this for the left side of the link 2.
(3) While pushing the window lock button 3 on the right side,
pry the link 2 to the outside using a screwdriver or the like,
and pull the right side of the window inside the cabin to 2
unlock it.
Repeat this for the left side of the window.
Note :
Be aware that when the left side of the window is unlocked, it
3
will fall inside.
4
(4) Hold the grips 4 on both sides and pull the window inside.
Then, raise the right side of the window and remove the
roller 5 from the rail.
(5) Remove the roller on the left side from the rail, and
remove the upper front window from the cabin.
7-8-9 4720103
2) Reinstallation
Reinstall the upper front window in the reverse order of the removal procedure.
(1) When moving the upper front window to and from the storage position under the ceiling, check that the rollers
move on the rails smoothly.
(2) Check that the lock works automatically.
3) Removal of Upper Windshield

Procedure
(1) Cut the adhesive between the upper windshield 6 and the
frame CMP 7 along the cut line with a metal spatula or a 7
cutter. 7
6
6
Cut line
4) Replacement of Upper Windshield

• Use adhesive for glass.
Type of adhesive
Notes :
• Use proper primer and cleaner for the adhesive.
• Wipe any excess adhesive away.
Procedure
(1) Clean the surface of the frame CMP 7 with a cleaner
(Cleaner No. 1 manufactured by Sika or its equivalent).
Glass 0.315 in.
(8 mm)
(2) After the cleaner dries up, glue the dam seals 8 to the
frame CMP 7.
Approx. 0.59 in.
(15 mm)
(3) Apply adhesive (SikaTack-Untlafast or its equivalent) to 8
the upper windshield 6 along its edge, and install and 0.197 in. (5 mm)
press it against the frame CMP 7.
Notes :
6 7
• The thickness of adhesive after pressed is to be 0.197 in. (5
mm).
• The width of adhesive applied is to be 0.315 in. (8 mm) or
more.
• After gluing the windshield, do not move the frame CMP 7
at least about 40 minutes.
0.197 in. 8
(5 mm)
0.315 in. (8 mm)
7-8-10 4720103
5. Cabin Glass
Gluing
m)
0. 0.08 in. (2 m
12
0.16 in. (4 mm)

in Gluing
.(
3
m
m
) E E
0.16 in. (4 mm)
D D Gluing
m)
0.08 in. (2 m m)
0.16 in. (4 m
0.24 in. Gluing
(6 mm)
0.08 in
.
0.16 in.
(4 mm)
(2 mm)
n.
0.08 in. (2 mm)

2i
0.1 mm) A
(3
Gluing
C C
n. ) Gluing
1i
0.1 8 mm
0.16 in.
(2.
A (4 mm)
Mount trim in the way it can cling to
Gluing glass adhesive evenly.
Mount trim in the way it can cling to glass

adhesive evenly. A
Adjust the positioning of rear glass and C
side glass L by clearance of trim section.
B
Gluing
Dam D
Gluing
Gluing
(4.55 mm)
Gluing 0.21 in. (5.3 mm)

0.18 in.
Dam
7-8-11 4720103
6. Structure and component

1) TIM cabin (body)
2 3 13
33
4 5 34
1 31 32 35
5
10 5
36
37
40, 41
CABIN SERIAL No.
9 IS STAMPED INTO
THIS LOCATION.
38
11
19
8
20
18
36 11 24 23
7 25
12 28
27
6
30
14 29
15
16 21 26
17 22 39
No. Name Q’ty No. Name Q’ty No. Name Q’ty

1 Cabin assy 1 15 Washer 12!30!2 1 29 Spring 1.5!10!50 1
2 Cabine body assy 1 16 Protector L 1 30 Screw 8!20 1
3 Bolt 16!30 1 17 Plate L 1 31 Scal 360 1
4 Washer 16!30!2.5 2 18 Dor catch 1 32 Support door 1
5 Washer 15!30!2 3 19 Bolt 6!35 4 33 Bolt 1
6 Cushion rubber 4 20 Washer 6 4 34 Nut M8 1
7 Seal 820 1 21 Rever door lock 1 35 Cap, nut M8 1
8 Seal 3300 1 22 Knob lever 1 36 Washer 11!38!5 2
9 Nut M5 2 23 Lock bar 1 37 Stopper, door 1
10 Cabine base assy 1 24 Shaft 1 38 Screw M6 2
11 Stopper, door 2 25 U-nut M6 1 39 Clamp 90 1
12 Plug 2 26 Washer 1 40 Label FOPS/ROPS 1
13 Bolt 16!40 1 27 Nylon collar 1 41 Rivet 3.2!8 2
14 Door catch 1 28 Screw, link 1
7-8-12 4720103
2) TIM cabin (accessory)

18 11
22
15
28 14
29
12
23 13
34 30
33
35
27 19
26
24 32 1
31
25 6 5
4
16
17
2
10
9
20
3
8 21
7
1 Glass rear 1 13 Nut M6 4 25 Bolt M8!16 1
2 Glass side L 1 14 Cover radio 1 26 Washer 8 1
3 Glass side R 1 15 Screw M6x16 2 27 Nut M8 1
4 Sash assy 1 16 Support, wiper arm 1 28 Bolt 16!40 2
5 Glass skylight 1 17 Screw M5!8 2 29 Washer 16!30!2.5 2
6 Joint seal 300 2 18 Inner roof 1 30 Washer 15!30!2 2
7 Holder, front window 2 19 Clip 10 31 Bolt 16!25 2
8 Screw M6!16 4 20 Heater hose 2 32 Washer 16!30!2.5 2
9 Cover lock 1 21 Rubber stopper 1 33 Bolt M10!20 2
10 Screw M6!16 4 22 Grill assy 1 34 Washer 10.5!30!2.5 2
11 Support rador 1 23 Grill assy 1 35 Cap 2
12 Washer 6 4 24 Work lamp 1
7-8-13 4720103
3) TIM cabin (electric part & wiper)
14
16
15
33
34 17
10
5
6
11
7 35
8
13
18
19
2
6
9
3
4
12
31
30
29 1 32
27
25 21
20
22
24
28
23
26

1 Wire harness cabin 1 13 Grommet 16!22!3 2 25 Arm, wiper 1
2 Grommet 1 14 Room lamp 1 26 Blade, wiper 1
3 Band 4 15 Screw 3.5!12.7 2 27 Hose, washer Lg:600 1
4 Antenna, radio 1 16 Bulb 1 28 Nozzle, washer 1
5 Bolt 6!30 2 17 Washer tank 1 29 Clamp 2
6 Washer 7!16!3 4 18 Washer 6!18!1 2 30 Elbow, washer 1
7 Washer 6!18!1 2 19 Screw M6!12 2 31 Hose 3500 1
8 Nut, seal M6 2 20 Wiper motor 1 32 Wire antenna 1
9 Nut, brass M6 2 21 Cover motor 1 33 Check valve, washer 1
10 Cap 2 22 Support motor 1 34 Grommet 20/28/4 2
11 Clamp, wire harness 7 23 Clap M5 2 35 Washer 6 2
12 Spring 1 24 Screw 5!12 2
7-8-14 4720103
4) TIM cabin (heater & duct cover)

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

1 Defroster 3 9 Clip 10 17 Nut M6 5
2 Screw 3.9!19 6 10 Ash tray 1 18 Screw M6!16 2
3 Cover heater 1 11 Clip 1 19 Clamp 2
4 Screw M6!16 6 12 Heater 1 20 Band 3
5 Hose 1400 defroster 1 13 Scal 720 1 21 Washer 6.5!17!1 6
6 Hose 700 defroster 1 14 Support heater 1 22 Handle 1
7 Clamp 2 15 Bolt M6!15 5 23 Screw M5!20 2
8 Cover duct 1 16 Washer 6 5 24 Washer 5.25!10!1 2
7-8-15 4720103
5) TIM cabin (front glass)
16
21
18 20
1
23
18 19
2
22
16
17
4 23
1110
3 9
15
12
6
29 (7) 8
30 13
34 14
28
28
25 33 26
26 31 27
(32) 24

1 Front glass assy 1 13 Bush, nyron 2 25 Guide R 1
2 Front glass up assy 1 14 Plug 1 26 Nyron seal Lg:440 2
3 Front glass assy 1 15 Seal 780 2 27 Screw M6!16 4
4 Flame front glass 1 16 Bush, nyron 3 28 Cushion 2
5 Front glass 1 17 Screw, link 2 29 Glass assy under 1
6 Lock L, upper window 1 18 Washer 4 30 Glass under 1
7 Lock R, upper window 1 19 Link 1 31 Lock L, lower window 1
8 Bolt M8!40 4 20 Collar 1 32 Lock R, lower window 1
9 Washer 8 4 21 Screw, link 2 33 Bolt M5!25 4
10 Nut M8 4 22 Gas spring 2 34 Seal 790 1
11 Cap, nut M8 4 23 Clip 4
12 Grip 2 24 Guide L 1
7-8-16 4720103
6) TIM cabin door (body)
20
19
18
16
15
17
3
11
13
14 12
8
10
17
6
7
21
22
5 23

1 Side door assy 1 9 Grass R top 1 17 Bolt 12!16 2
2 Door assy 1 10 Gress F bottom 1 18 Washer 12!22.5!2.5 2
3 Frame front 1 11 Grass F top 1 19 Nut 12 2
4 Frame rear 1 12 Hinge 1 20 Cap 12 2
5 Damper frame 2 13 Nut M6 4 21 Adapter 1
6 Bolt 5!15 4 14 Washer 6 4 22 Nut 1
7 Washer 5 4 15 Sleeve 2 23 Rubber stopper 1
8 Grass R bottom 1 16 Seal 4270 1
7-8-17 4720103
7) TIM cabin door (accessory)
19
18
17
20
16
15
13
14 23
6 12
5 1110
2 9 24
7 25
26
8 22
1 21
6
5 3
4

1 Knob 1 10 Washer 1 19 Cap, nut M6 6
2 Plate top 1 11 Washer 1 20 Rivet 3.2!8 2
3 Plate bottom 1 12 Lock plate 1 21 Catch 1
4 Nylon ring 1 13 Lever, door lock R 1 22 Spacer 1
5 Washer 8!19!1.5 3 14 Bolt M8!40 2 23 Mount 1
6 Screw M6!20 3 15 Cover front 1 24 Washer 8.4!16!1.6 2
7 Cap 6/10 1 16 Cover rear 1 25 Bolt M8!25 2
8 Lock, key 1 17 Washer 6 6 26 Cap, nut M8 2
9 Washer 1 18 Nut M6 6
7-8-18 4720103
CHAPTER 8
PERIODIC INSPECTION AND SERVICING
8-1 List of Periodic Inspection and Servicing .................................................8-1

8. PERIODIC INSPECTION AND SERVICING
8. Periodic Inspection and Servicing
8-1 List of Periodic Inspection and Servicing
& : Check $ : Supply ' : Replace " : Adjust (clean) # : Oil & grease
Every Every Every Every Every
Check & service items Daily
50 100 250 500 1000 hrs
Check falling off, breakage of parts &
Check loosened bolts & nuts, retighten &
General
Check engine condition &
Clean "
Check, resupply $
*Swing gear case oil
Replace ' 1st time '
Check, resupply $
Travel reduction gear oil
Lube oil
Check, resupply &
*Transmission oil
Check, resupply &
*Differential gear oil
Check, resupply &
Hydraulic oil
Replace '
Hydraulic Clean suction filter " 1st time "
system '
Replace return filter '
1st time
Check for abnormality of hydraulic pump &
Check grease-up positions, grease #
Greasing the swing gears and the swing bearings #
Grease
Greasing the track gauge change cylinder and the #
link fulcrum
Undercar- Check, adjust track tension &
riage *Check air pressure, wear, flaw in tyres &
*Check performance, play of steering lever &
Check performance, play of travel lever &
*Check performance of speed change lever &
*Check performance of forward/reverse pedal &
Steering *Check performance, play of steering wheel &
equipment Stroke &
*Brake pedal
Performance &
Stroke &
*Parking brake
Performance &
Check performance of accel. level &
Check front & work lights, horn &
Check hourmeter function &
Check function of change, oil and pilot lamps &
Electric Check wire breakage, short-circuits, loosened &
equipment terminals, retighten
Check, resupply battery fluid &
Check specific gravity of electrolyte " As required
Check function of OK monitor &
8-1 4720103
8. PERIODIC INSPECTION AND SERVICING
& : Check $ : Supply ' : Replace " : Adjust (clean) # : Oil & grease
Every Every Every Every Every
Check & service items Daily
50 200 400 1000 2000 hrs
Check & supply of oil to the tank &
Drain the fuel tank "
Fuel oil
Clean the oil/water separator "
Replace the fuel filter element '
Check the quantity of engine oil &
'
Replace the engine oil '
Lube oil 1st time
'
Replace the engine oil filter element '
1st time
Check & supply of cooling water &
Clean radiator fins "
Cooling &
Check the fan-belt tension
water 1st time
Replace the cooling water '
Clean & check the cooling water system ' within one year
Rubber hose Check & replace fuel oil pipe, cooling water pipe
Operation Check & adjust governor lever, accelerator & "
system
Intake Clean air cleaner & replace element " '
system *Check turbocharger, adjust "
Cylinder Adjust the intake and exhaust valve clearance "
head Lapping the intake and exhaust valve "
Check fuel valve nozzle, clean "
Fuel pump &
Check & adjustment of fuel injection pressure &
injection "
atomizing condition
valve
Check fuel pump, adjust "
*Applicable to models with the relevant equipment
Note :
• When machine is used at dusty worksites clean and replace filter element twice or more frequently than specified
in the table.
• Execution of periodic inspection and servicing is indispensable to conform the EPA emission control regulations.
Keep a record of the results.
8-2 4720103
CHAPTER 9
FUEL, LUBE OIL AND GREASE RECOMMENDED
9. Fuel, Lube Oil and Grease Recommended ...............................................9-1

9. REFERENCE DATA
9. Fuel, Lube Oil and Grease Recommended
Item Type
Engine oil Engine oil SAE 10W30, CD class
Travel reduction gear SAE 90 (GL-4)
Hydraulic oil YANMAR SUPER HYDRO. OIL (ISO VG46)
Fuel Diesel light oil
Engine cooling water YANMAR genuine long-life coolant (LLC) 51 % added
Idler
SAE 30
Track roller
Carrier roller Grease
Recommendations withe regard to temperature ranges Prescribed Amount of oil

Part be refilled Oil type
°C -20 -10 0 10 20 30 amount of oil to be changed
SAE 10WCD
Engine oil pan Engine oil SAE 10W-30CD 4.2 Qts. (4.0 L) 4.2 Qts. (4.0 L)
SAE 15W-40CD
0.53 Qts. (0.5 L) 0.53 Qts. (0.5 L)

Travel reduction gear Gear oil SAE 90 (GL-4)
(For right and left each) (For right and left each)
In the tank 9.24 Gals. (35 L)

Hydraulic oil system Hydraulic oil ISO VG46 Other parts 1.8 Gals. (7 L)
9.24 Gals. (35 L)
No.2-D
Fuel tank Light oil No.3-D 9.8 Gals. (37 L) 
No.3-D (S)
Radiator 3.3 Qts. (3.1 L)

Cooling system Water YANMAR genuine long-life coolant (LLC) added 
Subtank 0.4 Qts. (0.4 L)
°F 23 -14 5 -4 -13 -22 -31 -40

Lowest temperature
°C (-5) (-10) (-15) (-20) (-25) (-30) (-35) (-40)
Qts. 0.53 0.95 1.16 1.37 1.47 1.68 1.89 2.00
Amout of anti-freeze
(L) (0.5) (0.9) (1.1) (1.3) (1.4) (1.6) (1.8) (1.9)
Qts. 3.15 2.73 2.52 2.31 2.21 2.00 1.79 1.68
Amout of water
(L) (3.0) (2.6) (2.4) (2.2) (2.1) (1.9) (1.7) (1.6)
9-1 4720103
CHAPTER 10
TROUBLESHOOTING
10-1 Non-Breakdowns ............................................................................. 10-1-1

10-1-1 Natural Release of Bucket ..................................................... 10-1-1
10-1-2 Discontinuous Arm Movement ............................................... 10-1-1
10-1-3 Drifting of Upperstructure on Quick Travel Operation............ 10-1-2
10-1-4 Thermal Shock of Travel Motor.............................................. 10-1-3
10-1-5 Elongation of Boom Swing Cylinder on
75 degrees Swing .................................................................. 10-1-4
10-1-6 Telescopic Motion of Boom Swing Cylinder
with Lock Lever Set to Lock Position ..................................... 10-1-5
10-1-7 Time Lag on Travel Speed Switching .................................... 10-1-6
10-1-8 Fluctuation in Oil Level of Hydraulic Oil Tank Due
to Temperature Change......................................................... 10-1-7
10-1-9 Operation of Quick Coupler Cylinder
(for Quick Coupler Type)........................................................ 10-1-8
10-2 Troubleshooting ............................................................................... 10-2-1
10-2-1 Machine and Engine .............................................................. 10-2-1
10-2-2 Electrical Equipment on Panel ............................................. 10-2-23
10. TROUBLESHOOTING
10. Troubleshooting
10-1 Non-Breakdowns
10-1-1 Natural Release of Bucket
Phenomenon
When the arm is extended while scooping with the
bucket, the scooping side of the bucket is restricted by
the arm and causes back pressure because oil cannot
be supplied to the bucket cylinder in time.
When the boom is raised immediately in this condition,
the bucket is released naturally because of the back
pressure in the piston side of the cylinder
Operation
This problem can be solved by using a sequence of
three actions of bucket scooping, arm extension and
boom raising.
(For the models that cannot make the triple sequence
actions, extend the arm after raising the boom.)
10-1-2 Discontinuous Arm Movement
When scooping with the arm, the arm tends to move

slower as it draws near to the perpendicular and it may
stop momentarily.
Reason
This may happen because the oil supply cannot catch
up with the cylinder extension speed. This is a charac-
teristic of hydraulic equipment.
Specifically, this phenomenon appears when the engine

speed is in the low to medium speed range.
Advise your users fully that this will happen in hydraulic
equipment and that this is not a breakdown.
10-1-1 4720103
10. TROUBLESHOOTING
10-1-3 Drifting of Upperstructure on Quick Travel Operation
Phenomenon
The upperstructure drifts on quick travel operation (especially, on spin-or pivot-turning).
Drift
Reason
Inertial force is given to the upperstructure through the quick operation of the undercarriage, and high pressure is
applied to the swing motor. The relief valve is activated to turn the swing motor.
(The mechanical brake is released when the engine is running.)
10-1-2 4720103
10. TROUBLESHOOTING
10-1-4 Thermal Shock of Travel Motor
Phenomenon
When the travelling operation is made for pivot turning in cold temperatures after raising the hydraulic oil to more
than 140°F (60°C) higher than the ambient temp. through relief valve operation, etc., without travelling after starting
the engine, the machine may travel straight instead of making a pivot turn.
Reason
When the hot hydraulic oil is suddenly fed to the cold brake valve and motor, the spool in the brake valve sticks
momentarily due to thermal expansion, canceling the braking force.
Evaluation
Since the phenomenon disappears in 20 to 30 seconds and this situation is generally rare, this phenomenon pre-
sents no problem.
10-1-3 4720103
10. TROUBLESHOOTING
10-1-5 Elongation of Boom Swing Cylinder on 75 degrees Swing
Phenomenon
The boom swing cylinder elongates in digging operation at a 75 degrees swing.
Reason
When an outside sideways force is applied to the bucket, the force extends (retracts) the boom swing cylinder. At the
75 degrees swing position, however, the cylinder’s internal pressure is higher than in other positions due to the link
ratio. This activates the circuit relief valve and elongates the boom swing cylinder.
10-1-4 4720103
10. TROUBLESHOOTING
10-1-6 Telescopic Motion of Boom Swing Cylinder with Lock Lever Set to Lock Position
Phenomenon
When the boom swing pedal is moved with the lock lever set to the Lock position, the boom swings at very low
speed.
Reason
When the lock lever is in the Lock position, the oil flowing through the passage A of the control valve from the
hydraulic pump is unloaded into the hydraulic oil tank through the passage B. However, a very small pressure is gen-
erated by the resistance in the piping to the hydraulic oil tank. Therefore, when the boom swing pedal is moved, the
very small pressure is applied to the boom swing cylinder and the boom swings at very low speed.
10-1-5 4720103
10. TROUBLESHOOTING
10-1-7 Time Lag on Travel Speed Switching
Phenomenon
At cold temperatures, there is a time lag in switching from the high-speed to low-speed (with the high-speed pedal
released).
Reason
The shock caused during switching from the high-speed to low-speed is lightened by the throttles of A. At cold tem-
peratures, however, the passage resistance of the throttles becomes larger and it takes more time for the swash
plate of the travel motor to return to the low-speed.
10-1-6 4720103
10. TROUBLESHOOTING
10-1-8 Fluctuation in Oil Level of Hydraulic Oil Tank Due to Temperature Change
Phenomenon
The oil level of the hydraulic oil tank varies between before operation (the machine is cool) and after operation (the
machine is warm).
Reason
The oil level changes because the thermal expansion factor of oil is far larger (about 20 times) than that of steel.
1. Liner thermal expansion factor of steel : 11.7×10 -6

2. Cubical thermal expansion factor of steel : 3.51×10 -5
3. Cubical thermal expansion factor of hydraulic oil : 7.7×10 -4
(Example)
10-1-7 4720103
10. TROUBLESHOOTING
10-1-9 Operation of Quick Coupler Cylinder (for Quick Coupler Type)
Phenomena
(1) When the control switch of the quick coupler is in the removal mode, stop the engine and then restart it, and the
hook of the quick coupler open.
(2) The speed of hook slows down when mounting or dismounting operation is performed at a cold temperature.
Reasons
(1) The quick coupler cylinder has a circuit, where oil is provided at all times. Therefore, the oil is fed to the quick
coupler cylinder to move the hook as soon as the engine starts.
(2) The oil viscosity becomes higher at low temperatures, and it increases the passage resistance of the hoses, pre-
venting oil from flowing smoothly.
*Pressure oil from the port P4 is constantly supplied to the quick coupler cylinder through the SOL C.
10-1-8 4720103
10. TROUBLESHOOTING
10-2 Troubleshooting
10-2-1 Machine and Engine
(How to use the charts)
10-2-1 4720103
10. TROUBLESHOOTING
10-2-2 4720103
10. TROUBLESHOOTING
10-2-3 4720103
10. TROUBLESHOOTING
10-2-4 4720103
10. TROUBLESHOOTING
Inspection procedures
When the starter motor cannot be started by turning the starter switch on, check it as follows.
(Battery, starter switch and wiring assumed to be normal.)
(1) Safety relay & starter motor magnetic switch
Connect the S-and B-terminals of the starter motor directly.
[1] When the starter motor turns : The safety relay is faulty.
[2] When the starter motor does not turn : Either the starter motor magnetic switch or the starter motor is faulty.
(2) Starter motor
Connect the B-and M-terminals of the starter motor directly.
[1] When the starter motor turns : Magnetic switch is faulty.
[2] When the starter motor does not turn : Starter motor is faulty.
10-2-5 4720103
10. TROUBLESHOOTING
10-2-6 4720103
10. TROUBLESHOOTING
10-2-7 4720103
10. TROUBLESHOOTING
Work Implements
Inspection procedure
Switch the hose with the hose of the other circuit using the control valve.
[1] No descent : Control valve is faulty.
[2] Descent : Cylinder is faulty.
10-2-8 4720103
10. TROUBLESHOOTING
10-2-9 4720103
10. TROUBLESHOOTING
Inspection procedure
Switch the hose with the hose of the other circuit using the control valve.
[1] No boom swing drifting : Control valve is faulty.
[2] Boom swing drifting : Hydraulic cylinder is faulty.
10-2-10 4720103
10. TROUBLESHOOTING
10-2-11 4720103
10. TROUBLESHOOTING
10-2-12 4720103
10. TROUBLESHOOTING
10-2-13 4720103
10. TROUBLESHOOTING
10-2-14 4720103
10. TROUBLESHOOTING
Travel Equipment
10-2-15 4720103
10. TROUBLESHOOTING
10-2-16 4720103
10. TROUBLESHOOTING
1. When the hydraulic tester is not used :
(1) Reverse the hoses of the hydraulic pumps P1 and P2.
Phenomenon : Reversed ...................Replace the hydraulic pump.
(2) Reverse the hoses between the control valve and the swivel joint.
Phenomenon : Reversed ...........................................Overhaul or replace the control valve.
(3) Reverse the hoses between the swivel joint and the brake valve (or counter balance valve).
Phenomenon : Reversed ...................Overhaul or replace the swivel joint.
(4) Reverse the left and right hydraulic motors.
Phenomenon : Reversed ...........................................Replace the counter balance valve (or counter balance
valve) or the motor.
2. When the hydraulic tester is used :

(1) Flow volume at no load (Check the difference between the right and left motors.)
(2) Flow volume when loaded (Check the difference between the right and left motors.)
Conditions :
10-2-17 4720103
10. TROUBLESHOOTING
10-2-18 4720103
10. TROUBLESHOOTING
Check the drift with the machine placed on a slope with an inclination angle below 15 degrees.
[1] Continuous drift : Brake valve (or counter balance valve) is faulty.
[2] Discontinuous drift : Hydraulic motor is faulty.
10-2-19 4720103
10. TROUBLESHOOTING
Note :
When the oil temp. is still very low, switching to high-speed may not be made immediately when treading on the
high-speed pedal. This problem disappears as the oil temperature rises.
(Refer to Section "10-1-7 Time Lag on Travel Speed Switching".)
10-2-20 4720103
10. TROUBLESHOOTING
10-2-21 4720103
10. TROUBLESHOOTING
Quick Coupler Type
10-2-22 4720103
10. TROUBLESHOOTING
10-2-2 Electrical Equipment on Panel
(1) How to read the chart
(2) Refer to the wiring diagram for the number of the connector terminal and lead wire color.
(3) Color marks of leads

W (White) B(Black) R (Red) Y (Yellow)
G (Green) L (Blue) Br (Brown) Lg (Light green)
O (Orange) Gr (Grey)
Combination of colors
10-2-23 4720103
10. TROUBLESHOOTING
Monitor Lamps
10-2-24 4720103
10. TROUBLESHOOTING
Hourmeter
10-2-25 4720103
10. TROUBLESHOOTING
Water Temp. Alarm Lamp
10-2-26 4720103
10. TROUBLESHOOTING
Battery Charge Alarm Lamp
10-2-27 4720103
10. TROUBLESHOOTING
Engine Oil Pressure Alarm Lamp
10-2-28 4720103
10. TROUBLESHOOTING
Warning Buzzer
10-2-29 4720103
10. TROUBLESHOOTING
Fuel Level Gauge
10-2-30 4720103
10. TROUBLESHOOTING
Water Temperature
10-2-31 4720103
CHAPTER 11
REFERENCE DATA
11-1 Specifications for Attachment ..............................................................11-1

11. REFERENCE DATA
11. Reference Data
11-1 Specifications for Attachment
Unit : in. (mm)

Model
ViO27-2 ViO35-2
Item
Specifications for bucket installation
A (Distance between bucket pins) 8.38 (213)
B (Distance between bucket and bucket arm pivot pins) 8.64 (219.5)
C (Distance between bucket arm pins) 11.81 (300)
D (Distance between bucket link pins) 11.81 (300)
E (External width of arm-stick end boss) 5.51 (140)
E' (Internal width of bucket pin boss) 5.55 (141)
F (External width of bucket pin boss) 7.99 (203)
G / G' (Outer diameter of bucket pin) Ø1.5 / Ø1.5 (Ø38 / Ø38)
J (Cylinder length when it is fully retracted) 31.30 (795)
K (Cylinder length when it is fully extended) 51.45 (1307)
M (Bucket arm pin height from arm-stick and bucket pivot pins) 0.57 (14.5)
Oil pressure specifications
Hydraulic pump discharge volume GPM (L / min) P1 8.24 (31.2) 10.24 (38.8)
P2 8.24 (31.2) 10.24 (38.8)
P3 5.12 (19.4) 6.28 (23.8)
Set pressure of system relief valve PSI (MPa) P1 2986 (20.6)
P2 2986 (20.6)
P3 2986 (20.6)
Set pressure of bucket circuit relief valve PSI (MPa) 3697 (25.5)
11-1 4720103

Vio27 35-2 (Us) (New Cabin) SVM

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Proposition 65 Warning Proposition 65 Warning

GENERAL CAUTIONS FOR MAINTENANCE WORK

1-1 Correct Work............................................................................................1-1

1. General Cautions for Maintenance Work

1-1 Correct Work

1-2 Safety Precautions

1-4 Cautions for Disassembly and Reassembly

(1) Clean the machine before disassembly.

1-5 Cautions for Removal and Installation of Hydraulic Equipment

(1) Check that the hydraulic oil temperature is low enough.

1-6 Cautions for Removal and Installation of Hydraulic Piping

(1) Installation of hydraulic hose

1-7 Cautions for Handling Seals

(1) Clean out grooves of O-rings. Remove burrs or dust if any.

1-8 Correct Installation of Hydraulic Hose

(6) Use an elbow to prevent excessive twisting or bending of the hose.

1-9 Specifications of Hydraulic Hose

(1) Yanmar Standard Type

1) Type of Hose (Hose Dia. & Recommended Working Pressure)

2) Total Length of Hose [Unit : in. (cm)]

3) Hose Dia. (Unit : inch)

02....1/4'' 05....5/8'' 12....1 1/4''

Fitting 60 degrees bent type.

90 degrees bent type.

List of pipe threads

(2) Special Parts

The example hose, P 2 06 AB 075 W stands for :

Fitting type Code Fitting type Code

90 degrees bent type.

Straight pipe thread G 60 degrees bent type.

90 degrees bent type.

60 degrees bent type. UNF, thread with O-ring

90 degrees bent O-ring

Straight pipe thread with

30 30 degrees bent type.

1-10 Air Release of Hydraulic Equipment

1. Air Release of Variable Displacement Piston Pumps

Bleeder valve Width across flats : 0.40 in. (10 mm)

2. Air Release of Each Hydraulic Component

3. Air Release of Hydraulic Cylinders

2-1 Specifications....................................................................................... 2-1-1

Note : < > : W/O Quick coupler type

Note : < > : W/O Quick coupler type

Note : < > : W/O Quick coupler type

Note : < > : W/O Quick coupler type

Track roller Quantity (One side) pcs. 4

Crawler tension adjustment Grease adjuster

Note : < > : W/O Quick coupler type

Note : < > : W/O Quick coupler type

Note : < > : W/O Quick coupler type

Note : < > : W/O Quick coupler type

Note : < > : W/O Quick coupler type

Note : < > : W/O Quick coupler type

Note : < > : W/O Quick coupler type

Track roller Quantity (One side) pcs. 4

Crawler tension adjustment Grease adjuster

Note : < > : W/O Quick coupler type

Note : < > : W/O Quick coupler type

2-2 Outline Drawing and Working Area

2-2-1 Canopy type

2-2-2 Cabin type