Volvo EW180 Wheeled Excavator Service Manual

Service Information
Document Title: Function Group: Information Type: Date:

General dimensions 030 Service Information 2014/5/11
Profile:
General dimensions
Mono Boom
Figure 1
Dimensions of machine (Mono boom)
Dimensions (Mono boom), whole machine
Item Symbol Unit Standard Option

Front digging unit Boom length - m (ft) 5.2 (17′ 1″)
Arm length - m (ft) 2.6 (8′ 6″) 3.1 (10′ 2″)
Overall height Cab A mm (ft) 3100 (10′ 2″)
Boom B mm (ft) 3840 (12′ 7″) 3750 (12′ 4″)
Wheelbase C mm (ft) 2800 (9′ 2″)
From slew center to front axle center D mm (ft) 1700 (5′ 7″)
From slew center to rear axle center E mm (ft) 1100 (3′ 7″)
Overall length F mm (ft) 8920 (29′ 3″) 8950 (29′ 4″)
Ground clearance Upper frame G mm (ft) 1250 (4′ 1″)
Axle H mm (ft) 320 (1′ 1″)
Superstructure Overall width I mm (ft) 2460 (8′ 1″)
Turning radius R mm (ft) 2600 (8′ 6″)
Tread J mm (ft) 1874 (6′ 2″)
Overall tire width K mm (ft) 2495 (8′ 2″)
2 Piece boom
Figure 2
Dimensions of machine (2 Piece boom)
Dimensions (2 Piece boom), whole machine
Item Symbol Unit Standard Option

Front digging unit Boom length - m (ft) 4.97 (16′ 4″) 5200 (17′ 1″)
Arm length - m (ft) 2.3 (7′ 7″) 2.6 (8′ 6″)
Overall height Cab A mm (ft) 3100 (10′ 2″)
Boom B mm (ft) 3995 (13′ 1″) 4100 (13′ 5″)
Wheelbase C mm (ft) 2800 (9′ 2″)
From slew center to front axle center D mm (ft) 1700 (5′ 7″)
From slew center to rear axle center E mm (ft) 1100 (3′ 7″)
Overall length F mm (ft) 6900 (22′ 8″)
Ground clearance Upper frame G mm (ft) 1250 (4′ 1″)
Axle H mm (ft) 320 (1′ 1″)
Superstructure Overall width I mm (ft) 2460 (8′ 1″)
Turning radius R mm (ft) 2600 (8′ 6″)
Tread J mm (ft) 1874 (6′ 2″)
Overall tire width K mm (ft) 2495 (8′ 2″)
Service Information

Location of components 030 Service Information 2014/5/11
Profile:
Location of components
Figure 1
1 Bucket 13 Slew motor and gearbox 25 Main control valve

2 Link 14 Battery 26 Center passage
3 Connecting rod 15 Fuel tank 27 Transfer gearbox and travel motor
4 Bucket cylinder 16 Engine 28 Air cleaner
5 Arm 17 Hydraulic tank 29 Front drive shaft
6 Boom 18 Muffler 30 Tool box
7 Arm cylinder 19 Cowl 31 Front axle
8 Boom cylinder 20 Counterweight 32 Cab
9 I-ECU 21 Hydraulic pump 33 Tire
10 Remote control valve (lever) 22 Rear axle 34 Axle locking cylinder
11 Operator seat 23 Radiator and oil cooler 35 Steering wheel
12 Slew gear 24 Rear drive shaft
Service Information

Measurement conversion 030 Service Information 2014/5/11
tables
Profile:
Measurement conversion tables

Length
Unit cm m km in ft yd mile
cm 1 0.01 0.00001 0.3937 0.03281 0.01094 0.000006
m 100 1 0.001 39.37 3.2808 1.0936 0.00062
km 100000 1000 1 39370.7 3280.8 1093.6 0.62137
in 2.54 0.0254 0.000025 1 0.08333 0.02777 0.000015
ft 30.48 0.3048 0.000304 12 1 0.3333 0.000189
yd 91.44 0.9144 0.000914 36 3 1 0.000568
mile 160930 1609.3 1.6093 63360 5280 1760 1
1 mm = 0.1 cm, 1 mm = 0.001 mm
Area
Unit cm2 m2 km2 a ft2 yd2 in2

cm2 1 0.0001 - 0.000001 0.001076 0.000012 0.155000
m2 10000 1 0.000001 0.01 10.764 1.1958 1550.000
km2 - 1000000 1 10000 1076400 1195800 -
a 0.01 100 0.0001 1 1076.4 119.58 -
ft2 - 0.092903 - 0.000929 1 0.1111 144.000
yd2 - 0.83613 - 0.008361 9 1 1296.00
in2 6.4516 0.000645 - - 0.006943 0.000771 1
1 ha = 100 a, 1 mile2 = 259 ha = 2.59 km2
Volume
Unit cm3 = cc m3 l in3 ft3 yd3

cm3 = m l 1 0.000001 0.001 0.061024 0.000035 0.000001
m3 1000000 1 1000 61024 35.315 1.30796
l 1000 0.001 1 61.024 0.035315 0.001308
in3 16.387 0.000016 0.01638 1 0.000578 0.000021
ft3 28316.8 0.028317 28.317 1728 1 0.03704
yd3 764529.8 0.76453 764.53 46656 27 1
1 gal (US) = 3785.41 cm3 = 231 in3 = 0.83267 gal (US)
Weight
Unit g kg t oz lb
g 1 0.001 0.000001 0.03527 0.0022
kg 1000 1 0.001 35.273 2.20459
t 1000000 1000 1 35273 2204.59
oz 28.3495 0.02835 0.000028 1 0.0625
lb 453.592 0.45359 0.000454 16 1
1 tonne (metric) = 1.1023 ton (US) = 0.9842 ton (UK)
Pressure
Unit kgf/cm2 bar Pa=N/m2 kPa lbf / in2 lbf / ft2

kgf / cm2 1 0.98067 98066.5 98.0665 14.2233 2048.16
bar 1.01972 1 100000 100 14.5037 2088.6
Pa=N / m2 0.00001 0.001 1 0.001 0.00015 0.02086
kPa 0.01020 0.01 1000 1 0.14504 20.886
lbf / in2 0.07032 0.0689 6894.76 6.89476 1 144
lbf / ft2 0.00047 0.00047 47.88028 0.04788 0.00694 1
kgf / cm2 = 735.56 Torr (mmHg) = 0.96784 atm
Approximately conversions
SI Conversion Non-SI Conversion SI

Unit Factor Unit Factor Unit
Torque
newton meter (N·m) x 10.2 = kgf·cm x 0.8664 = (lb·in)
newton meter (N·m) x 0.74 = lbf·ft x 1.36 = N·m
newton meter (N·m) x 0.102 = kgf·m x 7.22 = (lbf·ft)
Pressure (Pa = N / m2)
kilopascal (kPa) x 4.0 = in. H2O x 0.249 = kPa
kilopascal (kPa) x 0.30 = in. Hg x 3.38 = kPa
kilopascal (kPa) x 0.145 = psi x 6.89 = kPa
(bar) x 14.5 = psi x 0.069 = (bar)
(kgf / cm2) x 14.22 = psi x 0.070 = (kg / cm2)
(newton / mm2) x 145.04 = psi x 0.069 = (bar)
megapascal (MPa) x 145 = psi x 0.00689 = MPa
Power (W = J / s)
kilowatt (kW) x 1.36 = PS (cv) x 0.736 = kW
kilowatt (kW) x 1.34 = HP x 0.746 = kW
kilowatt (kW) x 0.948 = Btu / s x 1.055 = kW
watt (W) x 0.74 = ft·lb / s x 1.36 =W
Energy (J = N·m)
kilojoule (kJ) x 0.948 = Btu x 1.055 = kJ
joule (J) x 0.239 = calorie x 4.19 =J
Velocity and Acceleration
meter per sec2 (m / s2) x 3.28 = ft / s2 x 0.305 = m / s2
meter per sec (m / s) x 3.28 = ft / s x 0.305 = m/s
kilometer per hour (km / h) x 0.62 = mph x 1.61 = km / h
Horse Power / Torque
BHP x 5252 R.P.M. = TQ (lbf·ft) TQ x R.P.M. 5252 = B.H.P.
Temperature
ºC = (ºF - 32) /1.8 ºF = (ºC x 1.8) + 32
Flow Rate
liter / min (dm3 / min) x 0.264 = US gal / min x 3.785 = liter / min
Note : ( ) Non-Si Unit
Service Information

Specifications, general 030 Service Information 2014/5/11
Profile:
Specifications, general
Specifications
Item Unit Specification

Operating weight kg 18500
lb 40785
Minimum turning radius mm 10400
inch 409.4
Slew speed rpm 12.3
Maximum travel speed km / h 34
mph 21.1
Maximum digging force kg 10500 / 11540
(Normal / boost) lb 23272 / 25441
Maximum drawbar pull kg 10400
lb 22928
Gradeability % 62
degree 32
Brake stopping distance (at 32 km/h) m 10
ft 33
Service Information

Standard tightening torque 030 Service Information 2014/5/11
Profile:
Standard tightening torque

The following charts give the standard tightening torques of screws and nuts.
Exceptions are given in sections of “Disassembly and Assembly”
Tightening torque (meter)
Classification 4T, 5T 10T

Screw type
Screw size Tightening torque kgf·m (lbf·ft) Tightening torque kgf·m (lbf·ft)
M4 0.2 ± 0.02 (1.4 ± 0.1) 0.4 ± 0.04 (2.9 ± 0.3)
M5 0.3 ± 0.03 (2.2 ± 0.2) 0.8 ± 0.08 (5.8 ± 0.6)
M6 0.5 ± 0.05 (3.6 ± 0.4) 1.4 ± 0.14 (10.1 ± 1.0)
M8 1.2 ± 0.12 (8.7 ± 0.9) 3.3 ± 0.3 (23.8 ± 2.2)
M10 2.3 ± 0.23 (16.6 ± 1.7) 6.5 ± 0.7 (47 ± 5)
M12 4.0 ± 0.4 (29 ± 3) 11.3 ± 1.1 (82 ± 8)
<M14> 6.4 ± 0.6 (46 ± 4) 17.9 ± 1.8 (129 ± 13)
M16 9.5 ± 0.9 (69 ± 6) 26.7 ± 2.7 (193 ± 19)
<M18> 13.5 ± 1.4 (97 ± 10) 38.0 ± 3.8 (274 ± 27)
M20 18.6 ± 1.9 (134 ± 14) 52.2 ± 5.2 (377 ± 38)
<M22> 24.7 ± 2.5 (178 ± 18) 69.4 ± 6.9 (500 ± 50)
M24 32.1 ± 3.2 (232 ± 23) 90.2 ± 9.0 (650 ± 65)
M30 62.6 ± 6.3 (452 ± 45) 176.1 ± 17.6 (1270 ± 127)
M36 108.2 ± 10.8 (781 ± 78) 304.3 ± 30.4 (2200 ± 220)
M42 171.8 ± 17.2 (1240 ± 124) 483.2 ± 48.3 (3500 ± 350)
M45 211.3 ± 21.1 (1525 ± 152) 594.3 ± 50.4 (4300 ± 430)
Tightening torque (Inch)
Classification 4T, 5T 10T

Screw type
Screw size Tightening torque kgf·m (lbf·ft) Tightening torque kgf·m (lbf·ft)
1/4 0.6 ± 0.06 (4.3 ± 0.4) 1.7 ± 0.2 (12.2 ± 1.2)
5/16 1.2 ± 0.12 (8.7 ± 0.8) 3.0 ± 0.3 (21.7 ± 2.2)
3/8 2.0 ± 0.20 (14.4 ± 1.4) 5.6 ± 0.5 (40 ± 4)
7/16 3.2 ± 0.32 (23 ± 2) 8.9 ± 0.9 (64 ± 6)
1/2 4.7 ± 0.47 (34 ± 3) 13.4 ± 1.3 (97 ± 10)
9/16 6.8 ± 0.68 (50 ± 5) 19.0 ± 1.9 (137 ± 14)
5/8 9.3 ± 0.93 (67 ± 7) 26.1 ± 2.6 (190 ± 19)
3/4 16.0 ± 1.60 (115 ± 15) 45.1 ± 4.5 (325 ± 33)
7/8 25.5 ± 2.55 (185 ± 19) 71.6 ± 7.2 (520 ± 52)
1 38.0 ± 3.80 (275 ± 27) 106.9 ± 10.7 (770 ± 77)
1-1/8 54.1 ± 5.41 (390 ± 39) 152.2 ± 15.2 (1100 ± 110)
1-1/4 74.2 ± 7.42 (535 ± 54) 208.9 ± 20.9 (1510 ± 151)
1-3/4 98.8 ± 9.88 (710 ± 71) 277.8 ± 27.8 (2000 ± 200)
1-1/2 128.2 ± 12.82 (925 ± 93) 360.7 ± 36.1 (2600 ± 260)
This torque table does not apply to screws with nylon packings or where nonferrous metal washers are to be used, or which
require tightening to a different specified torque, or tightening procedure.
 N·m (Newton meter) : 1 N·m ≅ 0.1 kgf·m
Tightening torque of split flange screws

Use these torques for split flange screws.
Tightening torque (split flange screws)
Thread diameter Width across Tightening torque

of screw (mm) flats (mm) kgf·m (lbf·ft) N·m
10 12 16 14 17 22 6.7 ± 0.7 (48.4 ± 5) 11.5 ± 1 (83 ± 65.7 ± 6.8 112 ± 9.8
8) 28.5 ± 3 (206 ± 20) 279 ± 29
Tightening torque for hydraulic plugs with o-ring
Figure 1
Hydraulic plugs with o-ring
1. O-ring
2. Plug
PF thread
Tightening torque (hydraulic plugs)
Thread Plug part no. Tightening torque kgf·m (lbf·ft)

1/8 9415 - 11012 2.5 ± 0.2 (18 ± 1.4)
1/4 9415 - 11022 5.0 ± 0.5 (36.1 ± 3.6)
3/8 9415 - 11032 7.5 ± 0.5 (54 ± 3.6)
1/2 9415 - 11042 11.0 ± 1.0 (79.4 ± 7.2)
3/4 9415 - 11052 18.0 ± 1.0 (130 ± 7)
1 9415 - 11062 21.0 ± 2.0 (152 ± 14)
Tightening torque for swivel nut fitting with o-ring

Figure 2
Swivel nut fitting with o-ring
1. Connector
2. O-ring
3. Swivel nut
4. Hose
Tightening torque for swivel nut fitting
Tube outer Thread size (in) Tightening torque of hose nut

diameter(in) and fitting, kgf·m (lbf·ft)
1/2 UN 13 / 16 - 16 9.5 ± 0.95 (69 ± 7)
3/4 UN 1 3 / 16 - 12 18 ± 1.8 (130 ± 13)
1 UN 1 7 / 16 - 12 21 ± 2.1 (152 ± 15)
Service Information

Time Guide 070 Service Information 2014/5/11
Profile:
Time Guide
EW170/EW180
1 Standard parts, service
16 Lubricants, fuels and other liquids

16206 0.50 Engine, changing oil and filter
16234 0.75 Hydraulic oil tank, changing oil and filter excl. cleaning tank
16236 1.50 Hydraulic oil tank, changing oil and filter incl. cleaning tank.
16238 1.50 Transmission (gear box), change oil and filter
16259 1.00 Axles, changing oil
16271 0.75 Swing motor reduction gearbox, changing oil
17 Service
17101 0.75 Arrival inspection
17102 2.00 Delivery inspection
17202 3.50 Warranty service 100hours, according to service programme

17204 7.00 Warranty service 1000hours, according to service programme
17307 2.50 Maintenance service, every 250 hours

2 Standard parts, service
21 Engine
21001 6.00 Engine, remove
21002 6.00 Engine, install in test run
21004 17.00 Engine removed, general overhaul
21006 2.75 Compression test, engine at operating temperature
21102 5.00 Cylinder head, replace gasket

21168 2.00 Cylinder head removed, decarbonizing and grinding in valves
21171 1.25 Cylinder head removed, pressure testing
21251 6.00 Flywheel housing, changing

21310 10.00 Cylinder liner and piston, replace one
21318 12.00 Cylinder liners and pistons, replace all
21412 1.75 Valves, adjust

21421 0.50 Valve cover, replace gasket : each
21436 1.50 Valve cover all, replace gasket
21416 5.00 Intake valve, replace one
21418 7.00 Intake valve, replace all
21426 5.00 Exhaust valve, replace one
21428 7.00 Exhaust valve, replace all
21451 1.50 Rocker arm, replace one
21481 1.50 Push rod, replace one
21493 0.50 Rocker arm mechanism removed, reconditioning
21511 2.25 Timing gear cover, replace

21522 2.25 Timing gear cover, replace gasket in machine
21530 2.70 Timing gear, replace in machine
21532 2.75 Timing gear case, replace gasket in machine
21614 2.50 Crankshaft, replace front oil seal

21615 9.00 Crankshaft engine removed, replace
21618 5.00 Crankshaft, replace rear oil seal
21661 5.00 Flywheel, replace
21681 1.25 Vibration damper, replace
21711 2.25 Oil sump, replace

21722 2.50 Sump gasket, replace incl. cleaning oil strainer
21811 1.25 Engine mounting bracket, replace one
21821 0.75 Engine mounting rubber cushion, replace one
22 Lubricating system
22106 0.75 Oil pressure relief valve, replace
22114 2.75 Oil pump, replace
22306 2.25 Oil cooler, replace and test
23 Fuel system
23301 0.25 Fuel system, bleeding
23302 0.50 Feed pump, replace
23304 0.50 Feed pump, checking feed pressure
23314 0.50 Fuel filter all, replace
23315 0.25 Fuel filter extra, replace
23397 0.50 Feed pump removed, reconditioning
23410 2.00 Fuel tank, replace

23441 0.50 Fuel filler pump, replace
23491 0.50 Fuel heater assembly, replace
23601 0.50 Idling speed, checking and adjusting

23602 0.50 Stall speed, checking and adjusting
23630 0.75 Injection timing, checking and adjusting
23640 0.50 Injection timing, checking
23670 1.75 Injection pump, remove
23672 2.25 Injection pump, fitting incl. setting injection timing
23673 4.00 Injection pump, replace incl. setting injection timing
23702 1.75 Injectors, replace all

23704 1.00 Injector, replace one
23716 1.75 Injectors, replace copper washer in machine
23718 0.50 Delivery pipe, replace one
23774 2.75 Injectors all, testing and adjusting incl. remove and install
23780 2.00 Injectors removed, reconditioning all
23791 0.75 Injector return manifold, replace
25 Inlet system, exhaust system

25102 0.50 Induction manifold, replace gasket
25104 1.75 Exhaust manifold, replace gasket
25220 1.00 Muffler, replace
25221 0.75 Exhaust pipe, flexible tube, replace
25511 1.75 Turbo charger, replace

25512 0.75 Turbo charger, remove
25513 1.00 Turbo charger, install
25516 1.75 Turbo charger removed, reconditioning
25591 0.50 Turbo charge oil supply hose, replace
25592 0.50 Turbo charge oil drain tube, replace
25601 0.50 Air cleaner, cleaning filter, element

25602 0.25 Air cleaner, checking pressure drop indicator
25603 0.25 Air cleaner, primary filter replace
25604 0.25 Air cleaner, secondary filter replace
25606 1.25 Pre-heating coil, replace
25811 2.00 Charge air cooler, replace

25817 0.75 Charge air cooler plumbing, replace
25818 0.75 Charge air cooler connection, replace
26 Cooling System
26101 0.50 Radiator, pressure testing
26102 0.25 Coolant, checking antifreeze resistance
26104 0.50 Coolant, replace
26108 2.75 Radiator, replace
26112 0.50 Radiator hose upper, replace
26114 0.75 Radiator hose lower, replace
26116 1.50 Radiator hoses all, replace
26202 1.50 Coolant pump, replace

26271 1.50 Coolant pump removed, reconditioning
26298 1.25 Thermostat, replace incl. testing
26311 0.75 Fan, replace

26312 0.50 Fan belt and/or alternator belt, replace
26313 0.50 Fan belt, alternator belt, air con compressor belt, replace all belts
26314 0.75 Fan belt, alternator belt, air con compressor belt, checking and adjust
26341 0.75 Fan drive pulley and spacer, replace
26344 0.50 Fan drive belt tensioner, replace
27 Engine control
27911 0.50 Control linkage, replace (rod end, yoke, lever, damper)
27912 0.75 Cable, replace
27913 0.50 Cable bracket, replace
27921 0.75 Stepping motor (RPM control), replace
27922 0.50 Stepping motor relay, replace
3 Electrical system, warning system, information

system instruments
31 Battery
31101 0.50 Batterys, checking replace capacity
31102 0.75 Batterys, replace all
31103 0.50 Main switch, replace
31106 0.25 Earth lead to battery, replace
31108 0.50 Starter motor lead to battery, replace
32 Alternator, charge regulator

32102 1.00 Alternator, replace incl. function check
32135 0.75 Alternator, replace carbon brush kit in machine
32174 0.50 Charging test in machine (with measuring instrument)
32205 0.75 Charging regulator, replace
33 Starting system
33118 1.00 Starter motor, replace
33411 0.75 Starter switch (eng. start switch), replace
35 Lighting
35144 0.50 Control lamp on instrument board, replace
35224 0.25 Head lamp assembly, changing one incl. adjust

35316 0.25 Rear lamp, replace one
35656 0.25 Work lighting, replace one head lamp assembly

35661 0.50 Back-up alarm, replace
36 Other electrical equipment

36102 0.50 Flasher unit, replace relay
36110 0.75 Flasher switch, replace
36117 0.25 Flasher lamp, replace
36211 0.50 Horn, replace

36231 0.75 Horn switch, replace
36311 0.75 Windscreen wiper front, replace motor

36351 0.50 Windscreen flusher pump, replace
36381 0.50 Windscreen wiper, replace switch
36391 0.50 Windscreen wiper, replace controller
36450 0.50 Relay(general), replace

36452 0.50 Battery relay, replace
36456 0.75 Pre-heating relay, replace
36461 0.50 Switch, replace
36462 0.50 Limit switch (hyd. servo line safety), replace
36466 0.50 Brake light switch, replace
36691 0.75 Engine mode switch (engine rpm selector), replace

36692 1.00 Controller (hyd. - ECU), replace
37 Cable, fuse, relay

37111 6.00 Main wire harness, replace
37121 2.75 Instrument wire harness, replace
37141 0.75 Battery cable +, replace
37142 0.25 Battery cable -, replace
37220 0.25 Fuse(general), replace
37226 0.50 Slow blow fuse, replace
37311 2.50 Engine wire harness, replace
37911 0.50 Boom wire harness, replace
38 Instrument, sensor, warning and information system

38211 1.25 Engine temperature gauge, replace
38221 1.25 Fuel level gauge, replace
38291 1.25 Hour counter, replace
38611 0.50 Engine temperature sensor, replace

38612 0.50 Hydraulic tank oil temperature sensor, replace
38621 0.25 Fuel lever sender, replace
38641 0.50 Engine oil pressure sensor, replace
38642 0.50 Travel alam sensor, replace
38643 0.50 Travel speed sensor, replace
38644 0.50 Auto idling sensor, replace
38651 0.50 Engine speed sensor, replace
38711 1.00 Switch board (display unit), replace

38721 1.00 Cluster assembly, replace
39 Miscellaneous
39321 1.00 Radio (with tape player), replace
39521 0.50 Antenna, replace

39522 0.75 Antenna cable, replace
39531 0.50 Speaker, replace
39991 0.75 Converter (DC/DC-converter), replace
4 Power transmission
42 Transmission with hydraulic control

42310 0.50 Transmission (transfer gear box), check oil pressure
42311 2.25 Transmission, remove
42312 2.50 Transmission, install
42316 11.00 Transmission removed, reconditioning
42351 0.75 Gear shift valve, replace
42356 0.50 Gear shift valve removed, reconditioning
42359 0.75 Transmission lube. filter, replace
42381 3.25 Input shaft, replace seal
42382 0.75 Seal for front output shaft, replace
42383 0.75 Seal for rear output shaft, replace
43 Gearbox, mechanical
43121 3.25 Swing gearbox, replace
43126 0.75 Swing gearbox removed, replace seal
43131 5.00 Pump gearbox coupling assembly, replace
43134 5.00 Coupling cushion(element), replace
44 Hydrostatic drive
44110 0.50 Travel motor assembly, check oil pressure
44111 2.00 Travel motor assembly, replace
44112 0.50 Travel motor relief valve, replace
44113 4.00 Travel motor removed, reconditioning
44116 0.50 Travel motor removed, replace seal
44120 0.50 Swing motor, check oil pressure
44111 4.00 Travel motor assembly, replace one
44112 0.75 Travel motor relief valve, replace
44113 2.00 Travel motor removed, replace cylinder kit
44116 2.00 Travel motor removed, replace seal
44121 1.75 Swing motor, replace
44122 0.75 Swing motor relief valve, replace
44123 1.50 Swing motor removed, replacing reconditioning
44124 0.75 Swing motor, replace plate(brake)
44125 1.00 Swing motor, replace brake piston seal
44126 1.00 Swing motor removed, replace seal
44128 0.50 Swing motor brake valve, replace
44303 3.25 Turning joint (centre passage), replace
44304 2.75 Turning joint, replace hub
44306 2.75 Turning joint, replace seal kit
45 Propeller shaft
45104 0.75 Propeller shaft, rear replace
45110 0.75 Propeller shaft, front replace
46 Front axle. rear axle

46011 3.75 Rear axle, replace
46021 3.75 Front axle, replace
46511 2.25 Axle hub(rear), replace

46512 2.25 Axle hub(front), replace
46513 2.00 Hub(rear), replace seal one
46514 2.00 Hub(front), replace seal one
46517 2.50 Axle hub removed(rear), reconditioning
46518 2.75 Axle hub removed(front), reconditioning
46531 2.25 Differential(rear), replace
46532 6.00 Differential(front), replace
46611 1.50 Drive shaft(rear), replace one side

46612 2.50 Drive shaft(front), replace one side
46616 2.75 Drive shaft seal(front), replace one side
49 Miscellaneous
49221 18.00 Swing ring gear, replace
49231 0.75 Swing ring gear outer seal, replace
49232 16.00 Swing ring gear inner seal, replace
5 Brake
51 Wheel brake
51121 1.50 Front brake disc, replace on both side
51181 1.75 Front brake piston, replace seal
51211 1.50 Rear brake disc, replace on both side

51281 1.75 Rear brake piston, replace seal
52 Hydraulic brake system

52005 0.50 Brake system, check and adjusting pressure in circuit
52037 0.25 Brake system, bleeding
52508 1.00 Foot brake valve, replace
52509 0.75 Foot brake valve removed, reconditioning
52702 0.50 Accumulator, replace

52704 1.25 Hydraulic pump, replace
52911 0.50 Brake cut-off valve, replace
55 Parking brake
55141 0.50 Parking brake solenoid valve, replace
6 Steering
64 Steering
64121 1.00 Steering column, replace
64506 3.50 Steering cylinder, replace

64528 0.75 Steering system, checking and adjusting working pressure
64560 1.75 Steering cylinder, repacking in machine
64581 1.00 Steering valve(unit) removed, reconditioning
64582 1.25 Steering valve, replace
7 Frame, springs, damping, axle suspension

wheel/track unit
71 Frame
71611 2.00 Counterweight, replace
76 Axle locking
76111 0.50 Axle locking cylinder, replace one
76115 1.00 Axle locking cylinder, repacking
8 Machinery house, cab
81 Cab
81021 3.25 Operator cab, replace
82 Engine hood, Mud guard, Foot step

82101 0.50 Engine hood, replace
82102 0.25 Engine hood stay, replace
82103 0.25 Engine hood latch, replace
82222 2.75 Cowl frame, replace

82261 0.50 Side cover(door), replace
82262 0.25 Side cover(door) latch, replace
82263 0.25 Side cover(door) gas spring, replace
82264 0.25 Side cover(door) stay, replace
82266 1.25 Tool box assembly, replace
82267 0.50 Tool box step(door), replace
82268 0.25 Tool box stay, replace
82269 0.25 Tool box latch, replace
82301 3.50 Radiator guard(casing), replace
83 Doors, Hatch, Cover plate(all)

83111 0.50 Cab door, replace
83143 0.25 Cab door stripped, replace
83151 0.25 Cab door catch, replace
83411 0.25 Cab door lock, replace
83441 0.25 Cab door handle, replace
83611 0.50 Roof scuttle, replace

83612 0.25 Roof scuttle latch, replace
83701 0.25 Bottom cover, replace

83703 0.25 Main control valve cover, replace
83711 1.25 Cab bracket (viscous mounting), replace
84 Outside trim parts, glass, sealing mouldings

84161 0.25 Rear view mirror, replace (incl. stay)
84311 0.75 Windscreen glass, replace

84331 0.75 Rear window glass, replace
84351 0.75 Side window glass, replace
85 Seat
85211 0.75 Seat, replace
85216 1.00 Seat support, replace
87 Air conditioning unit

87101 5.00 Cooler and Heater assembly, replace
87202 1.00 Duct(foot), replace

87203 0.75 Duct(rear), replace (incl. grille)
87204 0.75 Defroster hose, replace
87241 0.75 Intake filter, replace
87304 3.75 Radiator, replace

87306 3.75 Fan motor, replace
87307 1.00 Heater hose, replace
87308 0.50 Heater valve, replace
87402 0.50 Refrigerant, draining
87403 1.25 Cooling unit, performance test
87405 0.75 Refrigerant, filling excl. vacuum pumping
87406 1.75 Thermostat, replace
87407 1.75 Shutter assembly, replace
87408 0.75 Valve actuator, replace
87409 0.75 Intake actuator, replace
87410 0.75 Mode actuator, replace
87411 0.75 Vent actuator, replace
87412 3.75 Power transistor, replace
87431 1.75 Compressor, replace (draining and filling)
87432 0.75 Compressor mounting bracket, replace
87433 0.50 Compressor belt, replace
87434 0.50 Compressor belt adjuster, replace
87451 3.75 Evaporator, replace
87456 3.25 Expansion valve, replace
87461 1.25 Condenser, replace
87471 1.25 Receiver dryer, replace
87481 1.25 Liquid hose, replace
87482 1.25 Discharge hose, replace
87483 1.25 Suction hose, replace
87491 0.75 Switch and controller, replace
88 Interior equipment
88101 1.75 Instrument panel, replace(right)
88103 2.00 Instrument panel, replace(left)
88106 0.50 Instrument panel safety catch, replace (incl. guard lever slide)
88107 0.50 Instrument panel gas spring, replace
88411 0.25 Seat safety belt, replace
9 Hydraulic system, digging equip.
91 Working hydraulic and servo system

91111 3.50 Hydraulic tank, replace
91113 0.50 Suction strainer, replace
91114 0.25 Breather, replace
91115 0.25 Oil level gauge, replace
91116 0.25 By-pass valve(filter), replace
91117 0.75 Suction cover, replace
91124 1.00 Pipe and hose (pump - valve), replace
91125 1.00 Pipe and hose (valve - cylinder), replace
91126 0.50 Pipe and hose (valve - swing motor), replace
91127 1.25 Pump suction hose and pipe, replace
91129 0.50 Connector (pipe and hose), replace
91130 2.25 Oil cooler, replace
91133 1.75 Oil cooler line bypass valve (check valve), replace
91136 1.75 Oil cooler line pipe and hose, replace
91137 1.25 Oil cooler line pipe coupling, replace
91141 0.50 Oil return element, replace
91142 0.25 Oil drain filter, replace
91143 0.25 Servo system filter, replace
91201 6.00 Main control valve, replace

91202 5.00 Main control valve removed, general overhaul
91203 3.50 Control valve block assembly(3-spool), replace
91204 3.75 Control valve block assembly(4-spool), replace
91205 4.00 Control valve block assembly(intermediate), replace
91211 1.00 Swing valve and travel valve, reconditioning
91212 1.00 Boom valve, reconditioning
91213 1.00 Bucket valve, reconditioning
91214 1.00 Dipper arm valve, reconditioning
91220 0.75 Main pressure relief valve, replace
91221 0.75 Overflow valve (port relief), replace
91224 0.75 Check valve. replace
91235 1.25 Rupture valve, replace (boom cylinder)
91236 1.25 Rupture valve, replace (dipper arm cylinder)
91241 1.00 Solenoid valve, replace
91291 0.50 Rupture valve hose, replace (boom cylinder)
91292 0.50 Rupture valve pipe, replace (boom cylinder)
91296 0.50 Rupture valve hose, replace (dipper arm cylinder)
91297 0.50 Rupture valve pipe, replace (dipper arm cylinder)
91301 5.00 Hydraulic pump, replace
91302 5.00 Pump removed, general overhaul
91303 7.25 Pump block seal, replace all
91304 5.50 Pump shaft seal, replace
91306 0.75 Pump regulator, replace
91307 1.75 Pump regulator, general overhaul
91431 0.75 Servo pump, replace

91436 1.25 Servo pump block seal, replace
91437 1.00 Servo pump shaft seal, replace
91441 0.75 Proportional solenoid valve (power shift), replace
91451 0.75 Accumulator, replace
91452 1.00 Accumulator block, replace
91471 0.50 Servo pipe and hose, replace
91481 1.50 Remote control valve(lever), replace
91482 0.75 Remote control valve(lever) removed, reconditioning
91484 1.25 Remote control valve(pedal), replace
91485 0.75 Remote control valve(pedal) removed, reconditioning
91486 0.75 Remote control valve hose, replace
91488 0.50 Remote control valve switch, replace
91491 0.75 Solenoid valve, replace
91492 0.75 Servo selector valve, replace
91643 1.00 Boom, replace pipe (boom cylinder)

91644 0.50 Boom, replace hose (boom cylinder)
91645 1.00 Boom, replace pipe (dipper arm cylinder)
91646 0.50 Boom, replace hose (dipper arm cylinder)
91647 1.00 Boom, replace pipe (bucket cylinder)
91648 0.50 Dipper arm, replace hose (bucket cylinder)
91649 0.75 Dipper arm, replace pipe (bucket cylinder)
91651 1.25 Hammer and shear system recondition
91691 0.75 Hammer and shear pipe, replace (for boom)
91692 0.50 Hammer and shear hose, replace (for boom)
91693 0.75 Hammer and shear pipe, replace (for dipper arm)
91694 0.50 Hammer and shear hose, replace (for dipper arm)
91695 0.75 Hammer and shear hose and pipe, replace (m.c.v - 3 way valve)
91696 0.75 Hammer and shear pedal valve(r.c.v), replace
91697 1.00 Hammer and shear 3-way valve, replace
91698 0.75 Hammer and shear pipe and hose, replace (for 2nd pump flow)
91699 0.50 Hammer and shear ball valve, replace
92 Mechanical equipment
92401 1.00 Quickfit pump (gear pump), replace
92402 0.75 Quickfif valve, replace
92403 0.75 Quickfit solenoid valve, replace
92404 0.75 Quickfif control switch, replace
92421 1.75 Quickfit hydraulic cylinder bracket(body), replace
92431 1.25 Quickfif hydraulic cylinder, replace
92441 0.50 Quickfit hydraulic hose, replace (for boom)
92442 0.50 Quickfit hydraulic pipe, replace (for boom)
92443 0.25 Quickfit hydraulic hose, replace (for dipper arm)
92444 0.50 Quickfit hydraulic pipe, replace (for dipper arm)
92445 0.75 Quickfit hydraulic cylinder hose, replace (cylinder-dipper arm)
92511 0.75 Bucket assembly, replace

92512 0.25 Bucket pin, replace
92581 0.50 Bucket tooth, replace all
92582 0.50 Bucket side cutting edge, replace
92791 1.75 Dozer blade, replace

92792 0.75 Dozer cylinder, replace one
92793 0.25 Dozer blade, replace link pin
92796 1.25 Dozer cylinder, repacking in machine
94212 1.00 Stabilizer cylinder, replace one

94216 1.50 Stabilizer cylinder, repacking in machine
94211 0.25 Stabilizer cylinder, replace body pin
97 Unit for digging

97411 6.00 Boom, removal
97412 6.00 Boom, installation
97416 0.75 Boom removed, replace two bushing
97417 0.50 Boom, replace one pin
97418 0.25 Boom grease pipe, replace
97419 0.25 Boom grease hose, replace
97431 1.25 Boom cylinder, replace
97432 1.50 Boom cylinder, repacking in machine
97433 1.25 Boom cylinder removed, repacking
97436 0.50 Boom cylinder removed, replace bushing
97437 0.25 Boom cylinder, replace one pin
97511 2.50 Dipper arm, removal

97512 3.00 Dipper arm, installation
97516 0.75 Dipper arm removed, replace two bushing
97517 0.25 Dipper arm, replace one pin
97518 0.25 Dipper arm grease pipe, replace
97519 0.25 Dipper arm grease hose, replace
97521 1.00 Arm connecting rod, replace
97526 0.75 Arm connecting rod removed, replace two bushing
97527 0.25 Arm connecting rod, replace one pin
97528 0.50 Connecting rod yoke, replace
97531 1.25 Dipper arm cylinder, replace
97532 1.50 Dipper arm cylinder, repacking in machine
97533 1.25 Dipper arm cylinder removed, repacking
97536 0.50 Dipper arm cylinder removed, replace one bushing
97537 0.25 Dipper arm cylinder, replace one pin
97551 1.00 Bucket cylinder, replace
97552 1.25 Bucket cylinder, repacking in machine
97553 1.25 Bucket cylinder removed, repacking
97556 0.50 Bucket cylinder removed, replace one bushing
97557 0.25 Bucket cylinder, replace one pin
Service Information

NET 8940-00170 Replace 080 Service Information 2014/5/11
tool for the hydraulic tank
and fuel tank
Profile:
NET 8940-00170 Replace tool for the hydraulic tank and fuel tank
Figure 1
Replace tool for the hydraulic tank and fuel tank
Item Quantity Name Remark

1 2 Lifting eye bolt SAE 4120
Service Information

tool for the remote control
valve joint
Profile:
NET 8940-00200 Replace tool for the remote control valve joint
Figure 1
Replace tool for the remote control valve joint

1 1 Socket SAE 4130 (QT)
2 1 Stop plate SAE 4130 (QT)
Service Information

NET 8940-00210 Inspection 080 Service Information 2014/5/11
tool for the engine speed
control switch
Profile:
NET 8940-00210 Inspection tool for the engine speed control switch
Figure 1
Inspection tool for the rotary switch

1 1 Connector SWP (3P - male)
2 1 Connector SWP (3P - female)
3 3 Wire 0.85 (R,G,B color)
4 1 Connector PAC (3P - male)
Service Information

NET 8940-00220 Inspection 080 Service Information 2014/5/11
tool for the power shift
valve
Profile:
NET 8940-00220 Inspection tool for the power shift valve
Figure 1
Inspection tool for the power shift valve

1 1 Connector SWP (2P - male)
2 1 Connector SWP (2P - female)
3 2 Wire 0.85 (RB,W color)
4 1 Connector PAC (3P - male)
Service Information

tool for the slew motor
guide pin
Profile:
NET 8940-00290 Replace tool for the slew motor guide pin
Figure 1
Replace tool for the slew motor guide pin

1 2 Guide bar SAE 4130 (25 ~ 35 HRC)
2 2 Screw M8 × 1.0 × 16L
Service Information

NET 8940-00390 Adjust 080 Service Information 2014/5/11
tool for the axle steering
rod end
Profile:
NET 8940-00390 Adjust tool for the axle steering rod end
Figure 1
Adjust tool for the axle steering rod end

1 1 Plate - 12t SAE 1045
2 1 Round bar - φ 50 SAE 1045
3 1 Plate - 7t SAE 1045
Service Information

tool for the hydraulic
return check valve
Profile:
NET 8940-00400 Replace tool for the hydraulic return check valve
Figure 1
Replace tool for the hydraulic return check valve

1 1 Round bar - φ 30 SAE 1045
Service Information

tool for the center passage
Profile:
NET 8940-00410 Replace tool for the center passage
Figure 1
Replace tool for the center passage

1 1 Ring SAE 4120 (QT)
2 1 Round bar φ26 SAE 4120 (QT)
3 1 Nut M24
Service Information

tool for the slew ring gear
Profile:
NET 8940-00420 Replace tool for the slew ring gear
Figure 1
Replace tool for the slew ring gear

1 2 Ring SAE 1045 (QT)
2 2 Round bar φ22 SAE 1045 (QT)
3 4 Nut M20
4 4 Washer φ22 × φ33 × 10 t
Service Information

tool for the travel motor
guide pin
Profile:
NET 8940-00430 Replace tool for the travel motor guide pin
Figure 1
Replace tool for the travel motor guide pin

1 2 Guide bar SAE 4130 (25 ~ 35 HRC)
2 2 Screw M8 × 1.0 × 16L
Many thanks for your purchase.
Happy every day.
file:///C|/Users/yeqiwen/Documents/QIWEN-YE-END.txt[2014/5/11 8:35:13]
Service Information

Lubrication 160 Service Information 2014/5/12
Profile:
Lubrication
Lubrication chart
Kind of fluid Specification Ambient temperature Capacity, liter (gal)

(Reservoir) °C °F Specified Refill
Engine oil SAE 30 0 ~ 50 32 ~ 120 26.2 (6.9) 24.0 (6.3)
(engine oil pan) SAE 10W -32 ~ 10 -22 ~ 50
SAE 10W - 30 -20 ~ 20 -4 ~ 68
* SAE 15W - 40 -15 ~ 40 5 ~ 104
SAE 40 25 ~ 50 77 ~ 120
**Hydraulic oil ISO VG 32 -20 ~ 15 -4 ~ 59 334 (88) 200 (53)
(hydraulic oil tank) * ISO VG 46 -10 ~ 30 14 ~ 86
ISO VG 68 0 ~ 40 32 ~ 118
Engine oil SAE 15W - 40 -32 ~ 50 -22 ~ 120 3.8 (1.0)
(transfer gearbox)
***Gear oil * SAE 90, API GL4 or GL5 -20 ~ 30 -4 ~ 86 Slew gearbox : 6.0 (1.6)
(slew gearbox and axle) SAE 140, API GL4 or GL5 10 ~ 50 50 ~ 120 Carrier : 8.5 (2.25)
Each hub : 3.0 (0.79)
SAE 80W - 90, API GL4 or GL5 -30 ~ 40 -22 ~ 104
SAE 85W - 140, API GL4 or GL5 0 ~ 50 32 ~ 120
Diesel fuel ASTM D975 No.1 -30 ~ -10 -22 ~ 14 295 (78)
(fuel tank) * ASTM D975 No.2 -10 ~ 50 14 ~ 120
Grease * Multi purpose #2 -30 ~ 50 -22 ~ 120 27 (7.1)
(slew ring gear)
Grease Multi purpose #2 -15 ~ 45 5 ~ 113 -
(pin and bushing) * Molybdenum disulphide NPGL 2 -15 ~ 45 5 ~ 113
Coolant Add antifreeze * (Water 50%, antifreeze 50%) 26.5 (7)
(cooling system)
NOTE!
* : Installed at factory.
NOTE!
** : Anti-wear hydraulic oil with high viscosity index 160 or more.
NOTE!
*** : With limited slip additive
ASTM : American Society of Testing and Material

SAE : Society of Automotive Engineers
ISO : International Standardization Organization
API : American Petroleum Institute
 Specified capacity : Total amount of oil including oil for components and oil in piping.
 Refill capacity : Amount of oil needed to refill reservoir during periodic inspection and maintenance.
 Installed at factory.
CAUTION
When fuel sulphur content is less than 0.5%, change engine oil at periodic maintenance hours described in this manual.
Change oil according to the following table if fuel sulphur content is above 0.5%.
Fuel sulphur content and change interval
Fuel sulphur content Change interval of oil in engine oil pan

0.5% to 1.0% 1/2 of regular interval
Above 1.0% 1/4 of regular interval
CAUTION
When starting the engine in an ambient temperature of lower than 0°C, be sure to use engine oil of SAE 10W, SAE 10W-30
and SAE 15W-40, even though the ambient temperature goes up to 10°C more or less in the day time.
CAUTION
Use API classification CF or CG as engine oil, and if API classification CD, reduce the engine oil change interval to half.
Service Information

Periodic maintenance table 173 Service Information 2014/5/12
Profile:
Periodic maintenance table

Recommended periodic maintenance must always be performed as stipulated to keep the machine in excellent operating
condition to ensure safe operation.
Improper lubrication, maintenance and operation of the machine can be dangerous and cause injury or death to you or
other persons on the job site.
CAUTION
See the operator's manual for detailed information on periodic maintenance.
Every 10 service hours (before starting)
 Visual inspection
 Check for loose screws/nuts.

 Check for coolant, fuel and oil leakage.
 Check electrical wiring.
 Coolant level
If coolant level is insufficient, the warning lamp lights. Check the coolant level through the radiator filter
port.
 Engine oil level
If engine oil level is insufficient, the warning lamp lights. Check the engine oil level with the dipstick and
supply oil if required.
 Fuel level
Fill the fuel tank after daily operation.
 Air cleaner element
Check and clean the element before operating. Replace the element if necessary.
 Water separator
Check the water separator, drain off water and sediment.
 Hydraulic tank breather
Check the breather assembly condition.
 Bucket teeth
Check the bucket teeth condition for excessive wear and cracks. Replace if necessary.
 Fan belt tension
Fan belt tension is automatically adjusted by auto-tensioner.

But periodically check the tensioner and fan belt.
 Brake system
Before starting apply service brake and check if operation is normal.
 Greasing
Apply grease to the following pins. Arm/bucket pin, arm/connecting rod pin, link/bucket cylinder rod end
pin, and bucket/link pin.
 Axle, transfer gearbox breather
Check axle and transfer gearbox breather. Waah if required.
Every 40 service hours
 Air conditioner belt (if mounted)
Check the air conditioner belt tension particularly in the hot weather. Adjust or replace the belt if
necessary.
Initial 100 service hours
 Replace transfer gearbox oil.
 Drain water or sediment from fuel tank.
 Change hydraulic oil return filter.
Use genuine parts. Bleed the air from the hydraulic tank before opening the filter cover. When assembling,
pay attention not to damage o-ring.
 Change servo hydraulic filter element.
Use genuine parts.

Inspect the removed filter carefully for small particles.
 Change drain filter cartridge.
Fill the new cartridge with the hydraulic oil and lubricate the o-ring before the assembly.
 Change slew ring/pinion gear grease.
Remove grease from slew ring/pinion compartment and fill with the specified amount of grease (27 liter).
Apply silicon when assembling the cover to prevent water seepage.
 Replace axle hub, differential gear oil.
 Greasing
King pins, axle shaft bearings, drive shaft, tie rods, front axle U-joint, axle oscillating pin, stabilizer
mounting pin/cylinder pin, dozer mounting pin/cylinder pin.
 Transfer gearbox oil level
Check and add oil if necessary.

 Axle, hub oil level
Check oil level and add oil if necessary.
 Change hydraulic oil filter
Use genuine parts.
 Check battery electrolyte and refill if necessary.
 Greasing the slew bearing
Apply grease to the slew bearing grease nipples (3 places) front of the machine.
 Slew gearbox oil level
Check oil level and add oil if necessary. If oil level is low, check oil seal for leakage. Repair if necessary.
 Change slew gearbox oil.
Drain and fill with the specified gear oil.
 Change engine oil and filter.
Drain and fill with the specified engine oil and use genuine parts.
CAUTION
If non genuine parts are used and a serious failure occurs it could affect machine warranty.
 Change fuel filter.
Change primary and secondary filters simultaneously. Use genuine parts.
 Check coolant freeze point.
Check the coolant freeze point and adjust as required. (Ratio of antifreeze solution and water is 50 : 50,
installed at factory.)
Use a low silicate, diesel engine type antifreeze mixed with the correct proportion of clean, quality water to
lower the coolant freezing point and raise the boiling point.
A quality product with the proper additives, mixed with water containing low levels of calcium, magnesium,
chloride and sulphur, can minimize corrosion, scaling and silicate gel problems.
To optimize the cooling system functions use a heavy duty antifreeze through the four seasons.
 Change hydraulic oil return filter.
Use genuine parts.
 Check and clean radiator, oil cooler and air conditioner condenser cooling fins.
Check the cooling fins for foreign material.

Clean the cooling fins with compressed air.
 Change drain filter.
Fill the new cartridge with the hydraulic oil and lubricate the o-ring before the assembly.
 Change slew gearbox oil.
Drain and fill with the specified oil.
 Clean hydraulic oil suction filter.
Bleed hydraulic oil tank and remove cover and clean suction filter.
 Change servo hydraulic filter.
Use genuine parts.
 Check and adjust the engine valve clearance.
Measure the engine inlet and exhaust valve clearance.

Adjust if necessary.
 Change hydraulic oil and clean suction filter.
 Clean cooling system and replace the coolant.
Clean the radiator and oil cooler fins and replace the coolant using a heavy duty, four season antifreeze.
 Change slew ring/pinion gear grease.
Remove grease from slew ring/pinion housing and fill with the specified amount of grease.
 Check engine functional parts.
Check starter motor, alternator, turbocharger impeller and engine vibration damper pulley. Repair or
replace if necessary.
 Replace transfer gearbox oil.
Drain and refill to specified level.
 Replace axle oil (hub, differential).
Drain and refill to specified level.

Service Information

Brake performance 1732 Service Information 2014/5/12
Profile:
Brake performance
Measuring condition
 Time lag when pressing the pedal: 0.5 sec.

 Oil pressure: 70 ~ 80 kgf/cm2 (996 ~ 1138 psi)
 Road surface: Flat, horizontal, straight, dry, paved surface
 Machine speed: Speed when applying brakes: 32 km/h (20 mph)
 Tire inflation pressure: Specified pressure
Specifications, unit : m (ft)
Item Standard value

Brake performance (Stopping distance) 10 (33) or less
Special tools
Part no. Part name Quantity

Commercially available Tape measure 1
Measuring procedure
 Start the engine and set the attachment in the travel posture.
 Place the speed control lever in the highest speed range and drive the machine.
 When the machine is travelling at 32 km/h, depress the brake pedal with 19 kg.
 Decide the run-up road, the point at which to apply the brakes, then apply the brakes when the braking point is
reached.
 Measure the distance from the braking point to the point where the machine stops.
 Carry out the test three times and take the average value.
Figure 1
Measurement, brake performance
1. Brake pedal depressed

2. Brake point
3. Stopping point
4. Stopping distance
5. Run-up load
Service Information

Coasting left and right slew 1732 Service Information 2014/5/12
Profile:
Coasting left and right slew

Preparation
 Full load in bucket.

 Arm cylinder is fully retracted.
 Bucket cylinder is fully extended.
 Mark the slew bearing and directly below mark the undercarriage. (2 point)
 Slew the superstructure so that the arm and boom is 180 degrees. (1 point)
Figure 1
Measurement condition, coasting slew
Figure 2
Checking amount of coasting
1. Amount of coasting
2. Marking on the undercarriage
3. Marking on the slew bearing
Measurement
 Operate the slew control lever at full stroke and slew 180°.
 When the marks align, return the lever to neutral position.
 Measure the distance between the mark on the slew bearing and the mark on the undercarriage.
Figure 3
Amount coasting
1. Slew start point

2. Slew end point
3. Amount coasting
Wear limits, unit : mm (in)
Standard Allowable value Max. limit

Amount of Less than 1465 (58) 1520 (60)
coasting 1332 (52)
Service Information

Creeping of hydraulic 1732 Service Information 2014/5/12
cylinder
Profile:
Creeping of hydraulic cylinder

Preparation

Figure 1
Measuring condition, creeping
 With a full load in the bucket (1170 kg), set the front-end digging unit as shown above.
Measurement
 Stop the engine.

 Wipe the oil off the cylinder rod, and mark the measuring start point with tape.
 Measure the amount of creep on the cylinder rod over a 5 minute period.
 After measuring, remove the tape and clean carefully.
Creeping value, unit : mm (in) / 5 min.

Boom cylinder Less than 10 (0.4) 15 (0.6) 20 (0.8)
Arm cylinder Less than 10 (0.4) 15 (0.6) 20 (0.8)
Bucket cylinder Less than 40 (1.6) 50 (2.0) 70 (2.8)
Service Information

Measuring condition 1732 Service Information 2014/5/12
Profile:
Measuring condition
The purpose of this chapter is to explain how to evaluate the various performances of Volvo Construction Equipment
hydraulic excavators.
The tolerances listed below are for new machines.
For the machine already in use a certain allowance is permitted according to field conditions.
Unless otherwise specified, measurements should be performed under the following conditions:
 Engine speed : High rpm, “H” mode

 Hydraulic oil temperature : 50 ± 5 °C (122 ± 41°F)
 Site : Firm, level ground
Cylinder speed
Preparation
Boom cylinder

Figure 1
Measuring condition, boom cylinder
A. Raise
B. Lower
Arm cylinder
 Arm cylinder is fully extended.
Figure 2
Measuring condition, arm cylinder
A. Roll out
B. Roll in
Bucket cylinder
 Bucket cylinder is fully retracted.
Figure 3
Measuring condition, bucket cylinder
A. Roll out
B. Roll in
Measurement
 Operate the remote control lever at full stroke.

 Measure the time, by stop watch, for the cylinder to fully stroke.
 Measure 3 times to take average value.
Cylinder speed, unit : sec
Item Operation Standard Allowable value Remarks

Boom cylinder Raise 2.6 ± 0.3 2.9 From the ground to full extension
Lower 3.2 ± 0.4 3.6 From full extension to the ground
Arm cylinder Roll–in 3.1 ± 0.4 3.5 From full retraction to full extension
Roll–out 2.4 ± 0.3 2.7 From full extension to full retraction
Bucket cylinder Roll–in 3.5 ± 0.4 3.9 From full retraction to full extension
Roll–out 2.3 ± 0.3 2.6 From full extension to full retraction
2nd Boom cylinder Raise 4.1 ± 0.5 4.6 From the ground to full extension
Lower 5.6 ± 0.6 6.2 From full extension to the ground
Service Information

Measuring of slew bearing 1732 Service Information 2014/5/12
clearance
Profile:
Measuring of slew bearing clearance

Specifications
Slew bearing clearance
Specification
Clearance of Removed condition Standard 0.05 ~ 0.2 mm (0.002″ ~ 0.008″)
bearing in axial Allowable 0.4 mm (0.016″)
direction clearance
Installed condition Standard 0.2 ~ 1.7 mm (0.008″ ~ 0.07″)
Allowable 2.5 mm (0.10″)
clearance
Tightening torque Outer screw kgf·m (lbf·ft) 52.2 ± 5.2 (377 ± 38)
Inner screw 75 ± 7.5 (542 ± 54)
Measurement
CAUTION
Prior to proceeding ensure that the mounting screws are properly tightened.
Removed condition
 Put the slew gear on a flat surface and then set 3 magnetic bases on the outer race at 120° intervals.
 Set 3 dial gauges on the inner race.
 Lifting the outer race vertically, axial clearance is the movement between bearing races.
 Read the values of dial gauges.
Figure 1
Measurement, bearing clearance (removed)
1. Dial gauge
2. Magnet base
3. Inner race
4. Outer race
5. Lifting direction
Installed condition
Clean the outer race of slew gear and the underside of undercarriage.
The slew gear wear is not uniform over the entire circumference.
To obtain the exact play, it is necessary to take two measurements and pivot the superstructure by 90°.
1st measurement
 Position superstructure on centerline of undercarriage.

 Bear the digging unit on the ground until the tracks are partially lifted off the ground.
 Place the magnetic base.
 Adjust the dial gauge to zero at the underside of undercarriage and outer race of slew gear.
 Gently lower the excavator onto the ground and raise the bucket to the level of the cab floor with arm extended.
Read the values shown by the needle on the dial gauge.
 Bear the digging unit on the ground once again to check that the dial gauge pointer properly returns zero.
Figure 2
Measurement, bearing clearance (installed)
1. Outer race
2. Superstructure
3. Inner race
4. Undercarriage
2nd measurement
 Position superstructure at 90° in relation to first measurement.

 Measure the clearance according to the method shown at 1st measurement.
Allowable clearance
Measure the clearance twice in each position and record it in the table below.
Clearance recording format
Clearance read at 1st position of Clearance read at 2nd position of

superstructure superstructure
A (1st measurement)
B (2nd measurement)
Total A+B A+B
Average clearance Total / 2 Total / 2
If there is a large difference between measurements A and B, there is likely a mistake, therefore, repeat the measurement
several times.
CAUTION
The most important factor of slew gear failure is concerned with the axial clearance. Therefore, lubricate the bearing and
slew gear teeth periodically.
Service Information

Operating force of steering 1732 Service Information 2014/5/12
wheel
Profile:
Operating force of steering wheel

Measuring condition
 Road surface: Flat, horizontal, dry, paved surface

 Coolant temperature: Within operating range
 Hydraulic oil temperature: 45 ~ 55°C (113 ~ 131°F)
 Engine speed: Low and high idle
Specifications, unit : kg (lb)
Item Standard value Allowable value

Force of steering wheel 1.5 ~ 2.0 (3.3 ~ 4.4) Max. 3.0 (6.6)
Special tools
Part name Quantity

Push-pull scale 1
Measuring procedure
 Hook push–pull scale (A) to the knob of the steering wheel.
 Hook push-pull scale (A) to the center of knob.
 Start the engine.
 After starting the engine, place all attachments in the travel position and release the brakes.
 Set push–pull scale at a tangent, and read the value when the steering wheel is moving smoothly.
 Do not read the value at the time the steering wheel starts to move.
Figure 1
Measurement, operating force of steering wheel
A. Push-pull scale
Service Information

Operating time of steering 1732 Service Information 2014/5/12
wheel
Profile:
Operating time of steering wheel

Measuring condition
 Road surface: Flat, horizontal, dry, paved surface

 Hydraulic oil temperature: 45 ~ 55°C (113 ~ 131°F)
 Engine speed: Low and high idle
Specifications, unit : sec.
Item Standard value Allowable value

Time of rotation of steering wheel Low idle 3.5 ~ 4.0 Max. 6.0
lock to lock High idle 2.8 ~ 3.2 Max. 5.0
Special tools
Part name Quantity

Stop watch 1
Measuring procedure
 Start the engine.
 After starting the engine, place all attachments in the travel position and release the brakes.
 Turn the steering wheel so that the wheels are fully articulated to the left or to the right.
 Measure the time taken for the steering wheel to be turned to the full lock position on the opposite side.
 Turn the steering wheel as fast as possible without forcing it.

 Measure at low idle and high idle, when turning to the right and to the left.
Figure 1
Measurement, operating time of steering wheel
1. To the left
2. To the right
Service Information

Parking brake performance 1732 Service Information 2014/5/12
Profile:
Parking brake performance

Measuring condition

 Road surface: Flat, dry, paved surface with required gradient.
 Machine: In operating condition
Specifications
Item Standard value

Parking brake performance 25% (14 °)
Figure 1
Measuring condition
Measuring procedure
 Start the engine and drive the machine straight up the gradient with the bucket unloaded.
 Depress the brake, place the F-R lever in neutral, then stop the engine.
 Engage the parking brake then slowly release the brake pedal and the machine must remain stopped.
 The measurement must be made with the machine facing either up or down the slope.
Figure 2
Measurement, parking brake performance
Service Information

Slew speed 1732 Service Information 2014/5/12
Profile:
Slew speed
Preparation

Figure 1
Measuring condition, slew speed
Measurement
 Operate the slew control lever at full stroke.

 Measure the time for the superstructure to make 3 full turns at constant speed. (Exclude first full turn)
 Measure right and left alternately.
Slew speed, unit : sec/3rev

Slew speed 14.0 ± 1.5 16.0 17.0
Service Information

Starting engine with 1763 Service Information 2014/5/12
booster cables
Profile:
Starting engine with booster cables

Before connecting the booster cables check the following:
 Size of booster cable and clip should be suitable for the battery size.
 Check cables and clips for breaks, corroded surfaces, etc.
 Make sure cables and clips for are firmly secured.
 Keep the starting switch in “off” position, (both machines).
 The battery of the running engine must be the same capacity as that of the engine to be boost started.
 When starting from another machine do not allow the machines to touch.
Connect the booster cables in the following manner :
 Connect clip (1) of booster cable (A) to the battery positive (+) terminal of the machine to be boost started.
 Connect clip (2) to the battery positive (+) terminal of the engine which is running.
 Connect clip (3) of booster cable (B) to the battery negative (–) terminal of the engine which is running.
 Connect clip (4) to the superstructure of the machine to be boost started.
CAUTION
Make sure the clips are firmly connected to battery terminals. Start the engine with the fully charged battery, then crank the
engine being boost started.
When connecting the cables, do not allow the positive (+) and negative (–) terminals to make contact.
Figure 1
Connection, booster cables
CAUTION
Make sure that the booster cable connections are correct. Connect the booster cable to the engine block as far as possible
from the battery.After the engine has started, the booster cables must be disconnected in the reverse order.
Starting engine
 Turn the key switch to “START” position and start the engine.
 Cranking time MAX. 30 seconds, wait MIN. 2 minutes between cranking attempts.
 After the engine has started, the booster cables must be disconnected in the reverse order.
Figure 2
Disconnection, booster cables
Disconnect the cables as follows :
 Disconnect clip (1) of booster cable (B) from the superstructure.

 Disconnect clip (2) from the battery negative (–) terminal of the running engine.
 Disconnect clip (3) of booster cable (A) from the battery positive (+) terminal of the running engine.
 Disconnect clip (4) from the battery positive (+) terminal of the machine which was boost started.
Happy every day.
Service Information

Engine characteristic curve 210 Service Information 2014/5/31
(Cummins B5.9-C)
Profile:
Engine characteristic curve (Cummins B5.9-C)

Engine characteristics
Item Specification
Rated output 145 PS/1900 rpm (143 HP/1900 rpm)
Max. torque (Net) 63 kgf·m/1500 rpm (455 lbf·ft/1500 rpm)
Min. fuel consumption 151g / PS·h
Rated fuel consumption 158g / PS·h
Figure 1
Engine, characteristic curve
T. Torque
F. Fuel consumption
O. Output
E. Engine speed
Service Information

Engine, description 210 Service Information 2014/5/31
(Cummins B5.9-C)
Profile:
Engine, description (Cummins B5.9-C)

 The engine is a 6-cylinder, 4-stroke, direct injected, turbocharged, aftercooled, water cooled assembly with a cast
iron block and cylinder head.
 Gears in the engine gear case are hardened helical type for strength and reduced noise, arranged to provide quiet,
smooth transmission of power.
 The cylinder block and head are designed with internal passages formed as sets for lubrication and cooling. The
water pump and oil cooler are integrally mounted.
 The fan belt is a poly type V-belt for improved performance and an auto tension adjuster maintains belt tension.
Figure 1
Engine, fuel filter side view
1. High pressure fuel line

2. Fuel injection pump
3. Engine data plate
4. Engine oil pressure sensor port (1/8″ NPTF)
5. Engine oil heater port (M22 × 1.5P)
6. Engine speed sensor port (3/4″-16 UNF)
7. Fuel feed pump
8. Water temperature sensor port (3/4″ NPTF)
9. Primary fuel filter/water separator
10. Secondary fuel filter
11. Dipstick
Figure 2
Engine, turbocharger side view
1. Exhaust gas discharge port

2. Valve cover
3. Starter
4. Engine block
5. Oil pan
6. Engine oil drain valve (M22 × 1.5P)
7. Engine oil cooler
8. Water temperature switch port (PT 1/2″)
9. Water inlet
10. Thermostat
11. Turbocharger
12. Block heater port
Figure 3
Engine, top view
1. Fuel shut-off solenoid

2. Engine oil refill plug
3. Fan drive and pulley
4. Fan spacer
5. Aftercooler
Figure 4
Engine, front view
1. Turbocharger
2. Automatic belt tensioner
3. Fan pulley
4. Alternator
5. Water pump
6. Water inlet
7. Vibration damper
8. Fan belt
9. Gear cover
10. Fuel injection pump gear cover
Figure 5
Engine, rear view
1. Engine lifting eye

2. Fuel filter head
3. Flywheel
4. Flywheel housing
5. Engine oil filter
6. Turbocharger
Service Information

Valve clearance adjustment 214 Service Information 2014/5/12
Profile:
Valve clearance adjustment

Cummins B5.9-C
Valves must be correctly adjusted for the engine to operate efficiently. Valve adjustment must be performed using the
specified values.
Adjust the valves at each 1000 hours or 1 year maintenance interval.
All the valve adjustments must be made when the engine is cold and stabilized coolant temperature is 60°C or below.
 Turn the valve adjustment screws in until touching the push rod sockets, and then loosen them one full turn. Use
1/2″ drive, Part No. 3377371 Engine Barring Tool.
Figure 1
Valve clearance adjustment condition
 Locate top dead center for cylinder No.1 by rotating the crankshaft slowly while pressing on the engine timing pin.
When the pin engages the hole in the camshaft gear, cylinder No.1 is at top dead center on the compression stroke.
Figure 2
Valve clearance
Inlet valve 0.25 mm 0.010 in

Exhaust valve 0.51 mm 0.020 in
Figure 3
Rotation, camshaft gear
1. Camshaft gear
2. Timing pin
3. Gear housing
A. Compression stroke
CAUTION
Disengage the timing pin. Engine components may be damaged if the engine is rotated with the timing pin engaged.
Figure 4
Removal, timing pin
Figure 5
Adjustment, clearance between the valve stem and rocker lever
Tools : 14 mm spanner, “-” screwdriver, feeler gauge.
 The clearance is correct when slight resistance is felt as the feeler gauge is moved between the valve stem and
rocker lever. At that point, tighten the lock nut. (Tightening torque : 24 N·m)
 Adjust the valves indicated (*) in the table below.
 After tightening the lock nut, check the valve clearance again. If the clearance is not correct, readjust.
Valves to be adjusted (*)
Cylinder 1 2 3 4 5 6
Inlet (I) * * *
Exhaust (E) * * *
Figure 6
Valves to be adjusted
CAUTION
Be sure the timing pin is disengaged.
NOTE!
Mark the crankpulley and cover.
NOTE!
Rotate the crankshaft 360°.
Figure 7
Marking, crankpulley
 Adjust the valves indicated (*) in the table below.

After tightening the lock nut, check the valve clearance again.
If the clearance is not correct, readjust.
Valves to be adjusted (*)
Cylinder 1 2 3 4 5 6
Inlet (I) * * *
Exhaust (E) * * *
Figure 8
Valves to be adjusted
 Assemble the gaskets, valve covers, o-rings and special screws.
Figure 9
Assembly, valve covers
Tools : 16 mm spanner
Tightening torque : 24 N·m (18 lbf·ft)
NOTE!
Check valve covers and o-rings. If damaged, replace with a new one.
Injection nozzles installation
 Assemble a sealing washer on each injection nozzle. Use only one sealing washer.
Figure 10
Assembly, injection nozzles
 Apply anti-seize compound to the threads of the injector hold-down nut and between the top of the nut and
injector body.
Figure 11
Apply, anti-seize compound
Figure 12
Installation, injection nozzle
Tools : 16 mm spanner, 24 mm Deep socket

NOTE!
Install the injection nozzle. The protrusion on the injector body fits into a notch in the cylinder head to position the injector.
Tighten the injection nozzle nuts.
Figure 13
Tightening, injection nozzle
NOTE!
Some sockets can damage the sealing surface of the fuel drain outlet.
Service Information

Engine mounting 218 Service Information 2014/5/12
Profile:
Engine mounting
Figure 1
Engine mounting, front-fan side view
Figure 2
Engine mounting, rear-flywheel side view
A. A-details (cushion)
NOTE!
Check the color markings for cushion installation.
Cushion (A-details)
Front (fan side) - Yellow and white
Rear (flywheel side) - Blue and white
Tightening torque, unit : kgf·m (lbf·ft)
No. Mounting position Tightening torque

1 Engine mounting bracket (front) M12 × 1.75 × 35L (4)
* Apply loctite # 243 M12 × 1.75 × 65L (2)
11 ~ 12 (80 ~ 87)
2 Engine mounting bracket (rear) M12 × 1.75 × 50L
* Apply loctite # 243 7.2 ~ 8.4 (52 ~ 61)
3 Engine mounting cushion M22 × 2.5 × 130L
69.4 ± 6.9 (501 ± 50)
Service Information

Lubricating system, 220 Service Information 2014/5/31
description
Profile:
Lubricating system, description

 Engine lubricating oil is supplied to the contact faces of rotating components such as turbocharger, crankshaft,
camshaft, piston, inlet/exhaust valve, rocker arm and timing gear by means of forced lubrication from the oil pump.
Lubricating oil flow diagram
Figure 1
Lubrication oil flow
1. Oil pump
2. Pressure regulating valve
3. Oil cooler
4. Filter bypass valve
5. Oil filter
6. Turbocharger oil supply
7. Turbocharger to oil pan
8. Piston cooling nozzle
9. Oil pump idler gear
Service Information

Fuel injection system 230 Service Information 2014/5/31
(Cummins B5.9-C)
Profile:
Fuel injection system (Cummins B5.9-C)

 Highly pressurized fuel compressed by the fuel pump is direct injected through the injection nozzle into the
combustion chamber.
 Remaining fuel after injection is returned to tank automatically.
 A water separator installed to protect the fuel system components provides a means to drain off the water and
contaminants collected from the system.
Fuel flow system diagram
Figure 1
Diagram, fuel system
1. Fuel feed pump

2. Fuel filter
2A. Filter bracket

2B. Secondary fuel filter
2C. Primary fuel filter/water separator
3. Bleed screw
4. Low pressure supply line
5. Fuel injection pump
6. Fuel drain line
7. High pressure fuel supply line
8. Fuel injection nozzle
Service Information

Fuel tank, description 2341 Service Information 2014/5/12
Profile:
Fuel tank, description
Figure 1
Structure, fuel tank
1 Tank 7 Screw
2 Cap 8 Plain washer
3 Screen filter 9 Spring washer
4 Drain cock 10 Shim
5 Plug 11 Level gauge
6 O-ring 12 Hydraulic tank
13 Tool box
 When mounting the tank, adjust the height by use of shim (10).
Tightening torque :
 Screw (7) : 52.2 ± 5.2 kgf·m (377 ± 38 lbf·ft)

Service Information

Fuel filler pump, 2344 Service Information 2014/5/12
description
Profile:
Fuel filler pump, description

 The pump outlet is plumbed directly to the fuel tank to reduce the risk of introducing contamination.
 The master switch must be in the ON position to operate the fuel filler pump.
CAUTION
The filter at the end of fuel filler pump inlet hose is a strainer, and will not filter impurities from the fuel. When filling use
CLEAN fuel only!
CAUTION
Do not operate the fuel filler pump without fuel or for extended periods of time.
CAUTION
Drain the fuel from the suction hose before putting it in the storage compartment.
CAUTION
In case the pump has been disassembled, assemble the pump so the that the sharp portion of the vane faces the
counterclockwise direction.
Figure 1
Structure, fuel filler pump
Service Information

Fuel warmer, description 2349 Service Information 2014/5/12
Profile:
Fuel warmer, description

 The fuel warmer function is to prevent filter and line blockage by melting the paraffin wax extracted from the diesel
fuel in severe cold weather.
 If the fuel warmer switch on the switch board is ON, the warning lamp on the monitor panel is activated.
CAUTION
After starting the engine, be sure to turn the fuel warmer switch to the OFF position.
 After removing the fuel secondary filter, install the fuel warmer assembly (K-1 ~ K-7).
 Assemble the wire K-2 to the connector EN28-F in the engine compartment.
Figure 1
Structure, fuel warmer
A. Filter head
B. Fuel filter
K-1. Fuel warmer

K-2. Wires
K-3. Gasket
K-4. Adapter
K-5. O-ring
K-6. Insulator
K-7. Center post
Component location
Figure 2
Component location, fuel warmer
Service Information

Fuel lines, description 235 Service Information 2014/5/12
Profile:
Fuel lines, description

The fuel level sensor is installed in the fuel tank.
When the fuel level gauge indicates EMPTY, there is still approximately 40 Liter remaining.
Fuel flow
Tank → Water separator → Fuel feed pump → 1st fuel filter → 2nd fuel filter → Fuel injection pump → Nozzle → Tank
Figure 1
Fuel line
1. Suction hose
2. Water separator
3. Suction hose
4. Return hose
A. Clamp tightening torque : 0.12 ~ 0.17 kgf·m (0.87 ~ 1.23 lbf·ft)

CAUTION
Never tighten clamp (A) exceeding specified torque. It may cause leakage.
Service Information

Inlet and exhaust system, 250 Service Information 2014/5/12
description
Profile:
Inlet and exhaust system, description

 The air required for combustion is filtered by the precleaner, air cleaner filter, and then supplied to the engine
combustion chamber through the turbocharger.
 For operator convenience the clogging of the inlet system is sensed and activates a warning lamp on the dash
board.
 The exhaust system is designed so that exhaust noise is remarkably reduced when the exhaust gas is passed
through the manifold and muffler.
Inlet
Figure 1
Inlet system
1. Air cleaner to turbocharger

2. Turbocharger to aftercooler
3. Aftercooler
4. Inlet manifold (Cylinder head)
5. Inlet valve
Exhaust
Figure 2
Exhaust system
1. Exhaust valve
2. Exhaust manifold
3. Turbocharger
4. Turbocharger to muffler
Service Information

Radiator, description 2611 Service Information 2014/5/12
Profile:
Radiator, description
 A water cooling system maintains the temperature of the cylinder wall and lubricant at an optimum level so that the
engine can be operated at maximum efficiency. Coolant is force circulated through the radiator, cylinder head and
cylinder block by the internally mounted water pump.
 Coolant will not circulate through the radiator until the engine reaches operating temperature. When the
thermostat reaches 83°C, it will open, allowing flow from the head to the radiator.
Coolant flow
Figure 1
Cylinder block
1. Coolant inlet
2. Water pump impeller
3. Coolant flow past oil cooler
4. Coolant flow past cylinders
5. Coolant to cylinder head
Figure 2
Cylinder head
1. Coolant flow from cylinder block

2. Coolant to thermostat housing
Figure 3
Thermostat
1. Coolant flow past injector

2. Thermostat
3. Coolant bypass passage open
4. Coolant flow to pump inlet
5. Bypass passage closed
6. Coolant flow back to radiator
Service Information

Coolant heater, description 2691 Service Information 2014/5/12
Profile:
Coolant heater, description

 The engine oil heater (oil pan) and coolant heater (engine block) are practical engine starting aids for severe cold
weather.
 The heater is designed for external power supply.(AC 120V, 240V)
Figure 1
Coolant heater
Coolant heater
Part no. Watt (W) Voltage (V)

2011 - 00490 750 240
2011 - 00500 750 120
(Supplied with wiring harness)
Components location
Figure 2
Components location
A. Engine oil heater

B. Coolant heater
Service Information

Engine oil heater, 2692 Service Information 2014/5/12
description
Profile:
Engine oil heater, description

See [Invalid linktarget]
Engine oil heater
Figure 1
Engine oil heater
A. Length “A”
B. 27 HEX
C. Adapter
D. M22
E. Element
Engine oil heater
Part no. Watt (W) Voltage (V) A

2011–00430 150 240 4 1 / 4″
2011–00440 150 120
2011–00450 300 240 6 1 / 4″
2011–00460 300 120
(Supplied with wiring harness)

Service Information

Engine control (Cummins 270 Service Information 2014/5/12
B5.9-C)
Profile:
Engine control (Cummins B5.9-C)

Engine control, specifications
Specifications
Low idle rpm High idle rpm Cable length, mm (inch)

800 ~ 900 2030 ~ 2110 3700 (145.7)
Normal condition (automatic position)

Engine rpm will be controlled by the engine speed control switch on the control panel.
Emergency case
 When the control system is defective, set the auto/manual switch to the MANUAL position.
 Pull the engine control cable to set speed, and fix by lock nut.
NOTE!
After repairing, set the switch to AUTOMATIC position. Release the lock nut of control cable.
Assembly
 Install locking screw (10) through stepping motor (9) lever to set initial position.
 Set throttle lever (2) against high idle stop.
 Adjust rod (3) to align with levers (2, 4).
 Remove locking screw (10) from the stepping motor (9).
 Set throttle lever (2) to low idle stop.
 Push knob (A) of cable (1) down completely.
 With pin (7) at the end of the slot in yoke (6) adjust rod end (5) to align with lever (8).
 Set engine speed control switch to H-mode and check no-load high rpm.
Figure 1
Adjustment, engine throttle lever
1 Cable 5 Adjust rod end 9 Stepping motor

2 Lever 6 Yoke 10 Locking screw
3 Adjust rod 7 Pin L Low
4 Lever 8 Lever H High
Service Information

Engine speed control 275 Service Information 2014/5/12
switch, description
Profile:
Engine speed control switch, description

 The operator can easily control the work mode, engine speed, and maximum working horsepower by turning the
engine speed control switch if the ACS controller is in the automatic operating position.
 The switch also controls the engine speed and maximum working horsepower according to the built-in program of
the controller for each mode.
 The engine speed control switch changes the voltage input to the controller according to the position (step)
selected.
Figure 1
Engine speed control switch
Engine speed control switch, specification
No. Wire specification Signal

1 0.85YL Power (B+)
2 0.85YB Output (SIG)
3 0.85GY Ground (GND)
Inspection:
 Measure with the connector in the connected position.
Figure 2
Voltage measurement
Voltage output of engine speed control switch

Engine speed control switch Mode Voltage (V)
step
1 I 0.5
5 F 2.5
9 H or P 4.5
Specifications
Engine speed control switch, specification
Item Specification
Power supply DC 24 V
Output voltage DC 0 ~ 5 V
Type Potentiometer
Consumption 0.5 W
Service Information

Stepping motor, 2751 Service Information 2014/5/31
description
Profile:
Stepping motor, description

 The stepping motor controls the engine speed by moving the injecting pump lever according to the signal received
from the controller (V-ECU).
 The rotating angle of motor is linear to the incoming impulse signal from the controller (V-ECU).
 The throttle position sensor built into the motor confirms the operating angle to the controller, which maintains the
engine rpm to the value selected at the engine speed control switch, by analysing the motor lever angle sensor and
the engine rpm sensor signals.
Figure 1
Structure, stepping motor
A. Angle sensor connector
Throttle position (angle) sensor connector
Figure 2
Connector configuration
Stepping motor, wire specification

1 LY Power (VCC)
2 GW Output (SIG)
3 WL Ground (GND)
Motor connector
Figure 3
Connector configuration
Connector, wire specification

1 BY Stepping motor A
2 W Stepping motor A'
3 RL Stepping motor B
4 LW Stepping motor B'
Inspection (throttle position sensor):
 After starting, measure with the connector in the connected position.
Figure 4
Voltage measurement
Change of voltage output
Engine speed control switch Throttle position sensor output voltage (V)
Step 1 As the number of step increases, the output voltage increases 0.1 V → 4.9 V
↓
Step 9
Happy every day.
Service Information

Electrical system, 300 Service Information 2014/5/12
description
Profile:
Electrical system, description

The electrical system consists of three major circuits: main power, monitor and control circuits.
 The main power circuit functions include: engine starting, battery charging, and lighting operations. The main
power circuit operates at 24 volts.
 The monitor circuit inputs information from various sensors and switches to the Advanced Control System (ACS)
controller (V-ECU) concerning the machine operating status.
 The control circuit transfers electrical signals from the ACS controller (V-ECU) to main component actuators that
control functions such as: auto engine warm-up, auto idling, auto travel speed selection, power boost, work mode
selection and pump flow control (option).
CAUTION
Do not disconnect electrical connectors while the engine is running. Damage to engine, V-ECU, I-ECU, D-ECU, sensors and
other components may result.
Other characteristics
 Wiring harness connectors are numbered to facilitate troubleshooting.

 Slow blow fuses protect electrical components of the main power circuit.
 The relay box and fuse box are readily accessible.
 Using the master switch all electric power of the machine can be disconnected.
Service Information

Precaution of connector 300 Service Information 2014/5/12
handling
Profile:
Precaution of connector handling

1. Our connector has a lock, always release the lock before separating the connector.
Figure 1
Connector precaution 1
1. When connecting, align this arrow and push in. Be sure to fit rubber cover tightly.
2. When removing, press this part and pull the connector out.
3. When connecting, align the guide inside the connector and push.
4. When removing, press in on both ends and pull the connector out.
2. Never pull the wire to separate the connector.
Figure 2
Connector precaution 2
3. If the connector is difficult to separate, do not try to pull it out. (If it is difficult to reach by hand, remove the clamp
and move the wiring harness.)
Figure 3
connector precaution 3
A. This must be removed.
Service Information

Trouble shooting, 300 Service Information 2014/5/12
electronic control system
Profile:
Trouble shooting, electronic control system

Precautions
 Although the D-ECU displays an error code, it is not a defect of the D-ECU.
 The error code does not disappear until the start switch is turned OFF and ON again even though the problem has
been repaired.
 Always read carefully the automatic control system section of the service manual.
 Diagnose the machine problem according to the procedure for the error code displayed. Then check the repair
through the controller input / output diagnosing procedure.
 Always readjust the throttle linkage assembly, after removal for engine maintenance.
 If there are unsolved problems after trying the above procedures, contact your dealer for further information or
service.
Troubleshooting procedure according to the controller input/output

Figure 1
Troubleshooting, V-ECU input/output 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Troubleshooting procedure according to the error codes of D-ECU
 The D-ECU displays ER11.

Figure 7
Troubleshooting, D-ECU displays ER11

Figure 8
Figure 9
 If the D-ECU displays ER20 as you turn on the start switch, the controller's protecting circuit operated automatically.
You can not control the engine speed because the protecting circuit cut off the motor driving current.
 If the D-ECU displays ER20 while you operate the machine, the controller's protecting circuit operated
automatically. Then the engine speed dropped to LOW IDLE suddenly and you can not control the engine speed
because the protecting circuit cut off the motor driving current.

Figure 10

Figure 11
Figure 12

Figure 13

Figure 14
 Always readjust the rod assembly of the engine throttle linkage, after they are reassembled for the purpose of
engine maintenance.
Troubleshooting procedure according to the fault phenomena.
 The engine speed does not change while rotating the engine speed control switch.
Figure 15
Engine speed does not change 1
Figure 16
Engine speed does not change 2
 Automatic idling function does not work after a lapse of 10 seconds in non-operating condition.
Figure 17
Auto idling function does not work
 Automatic idling function repeats ON and OFF while the machine is not operated.
Figure 18
Auto idling function repeat ON and OFF
 The engine speed does not increase after a certain speed is reached.
Figure 19
The engine speed does not increase
The procedure to adjust the engine throttle linkage

Figure 20
The procedure to adjust the engine throttle linkage
Service Information

Troubleshooting, 300 Service Information 2014/5/12
description
Profile:
Troubleshooting, description
Check before troubleshooting
 Electrical system malfunctions can be identified and isolated if you adhere to established troubleshooting
procedures. Get all the facts → Analyze the problem → Relate the symptoms to other systems → Consider any
recent repair → Use the logic charts → Look for the obvious causes first → Determine and eliminate the root cause.
Basic checking items
No. Item Standard value Remedy

1 Check battery voltage (engine stopped). 23 ~ 26 V Replace
2 Check level of battery electrolyte. – Add or replace
3 Check for abrasion, bare or burnt wiring, damaged or separated – Replace
connectors.
4 Check for missing wiring clamps, hanging wires, splices and wrong – Repair
gauge wire.
5 Check for water leaking into harnesses. (Check carefully water – Separate the connector,
leakage / damage at connectors and terminals). Corrosion seriously then remove corrosion
affects electronic components. and dry thoroughly.
6 Check alternator voltage (engine running at overhalf throttle). 27.5 ± 0.5 V Replace
7 Unusual sound when the battery relay is operated. (Turn start switch – Replace
ON / OFF).
8 Check the condition of the slow blow and standard fuses (Burnt or - – Replace
intermittent operation).
Diagnosing procedure
Troubleshooting today's complex electronic/electrical systems based on
Trial and Error component replacement and inadequate maintenance practices such as splicing into wiring harnesses,
piercing/removing wiring insulation for a test light probe or multimeter clips, is a Hit or Miss method that is time
consuming and costly in terms of parts, labour, and downtime.
It usually results in a Temporary Fix correcting a symptom without solving the root cause of the problem.
 Study the system: Read the service manual → review the master electrical schematic → understand the component
functions.
 Analyze the complaint: Ask the operator → when did the problem start → what is the abnormality → were any parts
replaced or repairs done recently → If so why?
 Inspect the machine: Check the battery, fuses terminal connections, harnesses, switches and etc., → Also check
other systems. i.e. No fuel!
 Operate the machine: Hear → See → Feel the effect of the phenomenon.
 Trace possible causes: Look for the obvious causes first → Avoid unnecessary replacement of parts → Use the
proper tools and the schematics to find the root cause.
 Objective: To identify and isolate the problem to specify a component(s).
Electrical system malfunctions, high resistance circuit
1. A high resistance circuit can result in dim lights, slow or non-operative components.
2. Faults:
 Loose, corroded, dirty, oily terminal connections.
 Poor ground connection.
 Incorrect size of wire.
 Strands broken inside the wire.
3. To locate fault:
 Measure the voltage of the circuit at various locations to find the section with a voltage drop. i.e. across a
wiring harness connector.
Electrical system malfunctions, open circuit
1. An open circuit will result in no components operating in a particular circuit.

2. Faults:
 Blown fuse, broken wire, connector not making contact, disconnected terminal at a component or a
disconnected ground wire.
3. To locate fault:
 Visually check for blown fuses, loose or disconnected terminals and wires.
 Measure the voltage across the circuit to check for circuit continuity.
 If there is no continuity, check along the circuit until continuity is established.
Electrical system malfunctions, grounded circuit
1. A grounded circuit will result in a blown fuse and the replacement fuses blowing immediately.
2. Faults:
 A power wire contacting the frame, caused by worn off insulation exposing bare wire stands or a pinched
wire where the insulation has been cut.
3. To locate fault:
 Visually inspect the wiring harness for worn or pinched areas. Pay particular attention where the harness
passes through clamps, grommets or is located near hot areas such as the exhaust system or radiator.
 Remove the fuse and separate the harness connectors at several locations and check each section for
continuity to ground.
Electrical system malfunctions, shorted circuit
1. A shorted circuit will result in components of separate circuits operating when the switches of either circuit are
turned ON.
NOTE!
Components may also short to ground, however this usually blows the fuse.
2. Fault:
 Two harnesses rubbing together until the insulation is worn through allowing bare wires to make contact.
3. To locate fault:
 Disconnect the wire to the switch of the component that should not be ON.
 Disconnect the harness connectors in the circuit until the component stops operating. The short circuit will
be between the last two places the circuit was disconnected.
Service Information

Troubleshooting, electrical 300 Service Information 2014/5/12
system
Profile:
Troubleshooting, electrical system

Figure 1
Power is not supplied
Figure 2
Engine does not start
Figure 3
Electric power and engine does not stop
Figure 4
Charging lamp does not work
Figure 5
Preheat lamp does not work
Figure 6
Blower fan does not work
Figure 7
The compressor does not work
Figure 8
Air is not warm when heater is operated
Service Information

Battery, description 311 Service Information 2014/5/12
Profile:
Battery, description
 The two batteries (12 V each) connected in series supply 24 volts of electrical power.
 Batteries are used to start the engine, supply the current to the electrical components, and store the current from
the alternator.
Figure 1
Battery
B Battery
M Master switch
G Ground
WARNING
If a tool touches a cable connected between the positive terminal and the chassis, there is danger that it will cause
sparks.
WARNING
Battery post clamps must be tightly connected. If loosely connected, the terminal may be burnt or eroded by sparks
caused by defective contact.
WARNING
Battery acid can burn or blind you. If acid gets on your skin or in your eyes, immediately wash with soap and plenty
of clean water and consult a doctor immediately.
CAUTION
When removing the battery, first disconnect the cable with the black tube from the ground (normally, from the negative (–)
terminal).
CAUTION
Battery power may be lowered under severe cold weather.In this case, warm up the batteries and start the engine.
Service Information

Battery, specifications 311 Service Information 2014/5/12
Profile:
Battery, specifications
Specifications
Item Unit Specifications

Battery Type – PT
Capacity V–Ah 12–150
Quantity EA 2
Service Information

Master switch, description 311 Service Information 2014/5/12
Profile:
Master switch, description

 To disconnect the electrical system from the batteries for protection of electrical components when welding,
servicing of circuits and as a safety precaution when parking the machine.
 Mounted on the battery cover.
 If the master switch is turned to the ON position, the automatic greasing (option), fuel filler pump and room lamp
are available even when the start switch is in the OFF position.
Figure 1
Master switch
Service Information

Master switch, 311 Service Information 2014/5/12
specifications
Profile:
Master switch, specifications

 Operating voltage: DC 6 ~ 36 V
Service Information

Charging, description 320 Service Information 2014/5/12
Profile:
Charging, description
When the start motor is activated and the engine starts:
 The alternator generates current to activate all the electrical systems, and the extra current charges the battery.
 Alternator B+ terminal → Slow blow fuse (80A) →
1. Fuse box → Electrical systems

2. Battery relay → Battery
 Alternator R terminal → Preheating controller pin 3
 The current flows to the safety start relay to cut off the operation of start motor and prevent accidentally re-
engaging the start motor.
 Before starting the engine, flowing to battery → fuse box (F1, 10A) → alternator indicator → so, the current flows to
the alternator i terminal to turn off the alternator indicator because the current does not flow according as the
potential difference disappears after the start motor is activated and the engine starts.
 The current flows to the hour meter, which operates in the start switch ON position.
If the start switch is turned to the OFF position to stop the engine starting.
 The engine rotates by inertia for a while and the alternator generates current, although the stop relay and the
battery relay are shut off.
 When the connection with the batteries is cut off, the voltage peaks and puts a load on the electrical circuit
components.
 In order to prevent an overload the circuit shutdown is delayed as follows:
Alternator i terminal → diode (MA34-W2) → so, the current flows to the battery relay coil to keep the battery relay
engaged, and when the alternator stops generating current, the battery relay is completely shut off.
Service Information

Alternator, description 321 Service Information 2014/5/12
Profile:
Alternator, description
Figure 1
Alternator, terminals and performance
R Relay terminal, tightening torque 8.0 N·m (6.0 lbf·in) maximum

E Ground, tightening torque 68 N·m (50 lbf·in) maximum
I Warning lamp, tightening torque 8.0 N·m (6.0 lbf·in) maximum
B+ Battery terminal, tightening torque 12.0 N·m (9.0 lbf·in) maximum
CAUTION
Caution adjusting V–belt tension: Do not put the pry bar directly to stator or rear housing. (When using the pry bar, insert a
wooden block between the pry bar and alternator.
Figure 2
Alternator, side view
1. 5/8″ ~ 18 UNF (tightening torque : 70 ~ 80 Ibf·ft)
2. When ordering an alternator the pulley is not included.
Service Information

Alternator, specifications 321 Service Information 2014/5/12
Profile:
Alternator, specifications
Specifications
Item Specifications
Type Delco Remy 21 SI
Voltage 24 V
Output 50 A (70 A option)
Cooling method Air cooling
Temperature range –25 ~ 93 °C
Allowable maximum speed 10,000 rpm
Weight 8 kg (including fan and pully)
Service Information

Regulator, description 322 Service Information 2014/5/12
Profile:
Regulator, description
The figure below illustrates the circuitry between the alternator and the regulator.
The alternator incorporates a field coil (FC/ rotor coil), a stator coil (SC) and a diode (D). The regulator contains a transistor
(T), a diode (D), and a zener diode (ZD). The terminal DS of the alternator sends current from the alternator to the regulator
in this way :
DS → I → R1 → Base (B) of the transistor T1

DS → FC → F → Collector (C) of the transistor T1
By turning the key switch ON, current flows to the base (B) of the transistor T1, electrifying the collector (C) and the emitter
(E) of the transistor T1, and then the current passes to the field coil (FC).
In this condition, the rotation of the alternator generates voltage.
Power generation
Electrical power is generated as follows :
When the alternator starts rotation, the voltage between I–E is increased from the initial excitation level, increasing the flow
of current to the field coil. This further raises the voltage between R–E, which changes from battery excitation to self–
excitation, and begins charging the battery.
Figure 1
Power generation circuit
Voltage adjustment
The charging voltage is controlled by the regulator.
When the output of the alternator exceeds the set voltage of the zener diode, the transistor T1 turns off, stopping the flow
of current to the field coil. As a result, the stator coil stops generating voltage.
When the voltage V1 is applied between I-E, it is divided into V2 and V3 due to resistances R3 + R4 and R5.
When the voltage V3 has reached the zener voltage, the zener diode (ZD) is electrified, allowing the current to flow to B of
the transistor T2 opening the circuit from C to E.
The electrical conduction of the transistor T2 lowers the voltage between T2 C and E. As a result, the base current passing to
transistor T1 via R1 flows to E through T2, and turns off transistor T1.
This stops the current flowing to the field coil, and the output voltage is thus lowered.
When V3 lowers to below the set voltage, the base current flowing to T2 through the zener diode will be stopped. This
causes T2 to turn off, and T1 turns on again, increasing the output voltage. The output of the alternator is thus maintained at
a specified level through the repetition of the above operations.
Figure 2
Voltage adjustment circuit
Service Information

Battery relay, description 330 Service Information 2014/5/12
Profile:
Battery relay, description

 The relay turns the battery current ON or OFF, according to low power signals received from the start switch. Use of
the relay permits the start switch to control the power of the batteries with a small capacity wire.
CAUTION
Do not use a battery relay that is not a genuine part. The internal wiring connection and specification is different from the
genuine battery relay; though it seems similar in appearance, it may impede the safety features of the machine.
Figure 1
Battery relay
Service Information

Battery relay, specifications 330 Service Information 2014/5/12
Profile:
Battery relay, specifications

Specifications
Item Specifications
Rated voltage DC 24 V
Rated load 100 A (Continuous), 1000 A (30 seconds)
Excited current 0.5 A or less (at 24 V, 20 °C)
Open voltage DC 9 V or less (at 20 °C)
Minimum working voltage DC 20 V or more (at 20 °C)
Insulation resistance 1 MΩ or more (500 V megger meter)
Operating temperature -30 ∼ 80 °C
Service Information

Engine stop motor, 330 Service Information 2014/5/12
description
Profile:
Engine stop motor, description

Engine stop motor
 Engine stop system is composed of start switch, stop motor relay and engine stop motor and engine stop and stop
is controlled by the current from ACC terminal of start switch.
 The speed of stop motor is decelerated and changed circular motion the straight going and returning motion by
the inner warm gear and push or pull the engine stop lever.
 When turning the start switch to the ON position, the stop motor rotate 0° ~ 180° and stop automatically.
Figure 1
Engine stop motor drive circuit
1 Battery 4 Stop motor relay

2 Slow blow fuse 5 Engine stop motor
3 Start switch
 And then, turning the start switch to the OFF position, the stop motor rotate 180° ~ 360° to the engine STOP
position and stop.
Engine start
 When turning the start switch to the ON position, current flows

Battery (+) → Slow blow fuse → Start switch B, ACC → Engine stop motor relay 4, 2 → Ground.
 And then the engine stop motor relay terminals 1, 5 are connected. The current flows to Battery (+) → Slow blow
fuse → Engine stop motor B, P2 → Stop motor relay 1, 5 → Engine stop motor A → Engine stop motor E → Ground.
The engine stop motor rotate to clockwise.
Figure 2
Engine start circuit

3 Start switch
 When the engine stop motor rotate from 0° to 180° and stop.
Figure 3
Engine stop motor position (180° rotation)
Engine stop
 When turning the start switch to the OFF position, the current flowing to the stop motor relay terminal 4 is shut-off
and the terminals 5, 3 is connected.
 And then, the current flows to Battery (+) → Slow blow fuse → Engine stop motor B, P1 → Stop motor relay 3, 5 →
Engine stop motor A → Engine stop motor E → Ground. And engine stop motor rotate to clockwise once more.
Figure 4
Engine stop circuit

3 Start switch
 When the engine stop motor rotate from 180° to 360° and stop.
Figure 5
Engine stop motor position (360° rotation)
Figure 6
Engine stop motor
1 Lower case 5 Tightening torque 0.9 ∼ 1.5N·m (9 ∼15 kgf·cm)

2 Adhesive (EFLEX) 6 Blind plug
3 Cable assembly 7 Breather
4 Upper case 8 Label
Service Information

Engine stop motor, 330 Service Information 2014/5/12
specifications
Profile:
Engine stop motor, specifications

Specifications
Item Specifications
Operating voltage 20 ∼ 30 V
Operating temperature -30 ∼ 80 °C (-22 ~ 176 °F)
Operating time 1 second or less
Operating distance 35 mm (1.4 in)
Current No load 2.0 A or less
Load (5.5 kgf) 11.0 A or less
Revolution (No load) 60 rpm or more
Operating force 15 kgf (33 lbf) or more
Insulation resistance 1 MΩ or more
Minimum start voltage 1.6 V or less (No load)
Mass 1.1 Kg
Wire specifications
No. Wire specifications

A AVS 1.25 BL
E AVS 1.25 SB
B AVS 1.25 R/BL
P1 AVS 1.25 BL/Y
P2 AVS 1.25 BL/SB
Service Information

Safety start relay, 330 Service Information 2014/5/12
description
Profile:
Safety start relay, description

 When trying to restart the engine in the engine running condition, or if the start switch is in the START position
after the engine is activated, the relay cuts off the current to the start motor to protect it.
CAUTION
When measuring the contact resistance of the safety start relay, be sure to use a multi-tester to protect the internal
semiconductors and zener diode. (Do not use the 500V megger meter.)
Figure 1
Safety start relay
7 Tightening torque 2.94 ∼ 3.92 N·m (2.2 ∼ 2.9 lbf·ft)

8 KET SWP receptacle housing & terminal (4P)
Figure 2
Staring operation sequence
Service Information

Safety start relay, 330 Service Information 2014/5/12
specifications
Profile:
Safety start relay, specifications

Specifications
Item Specifications
Operating temperature –30 ~ 90 °C
Rated coil current 2 A or less
Contact point capacity Momentary 200 A, Continuous 150 A
Minimum operating voltage 18 V or less
Minimum holding voltage 12 V or more
Wire specifications
No. Wire specifications Signal

1 AVS 1.25 R/W Start switch C terminal
2 AVS 1.25 SB/W Relay
3 AVS 0.85 R/SB Start switch C terminal
4 AVS 0.85 Y/SB Alternator I terminal
5 AVS 0.85 SB/R Travel control lever F and R
6 AVS 0.85 SB Ground
Service Information

Start switch, description 330 Service Information 2014/5/12
Profile:
Start switch, description

 The switch selectively routes power supply to various electrical components of the engine start / stop, preheating
and accessory circuits.
Figure 1
Switch, start
Switch circuit
Figure 2
Start switch, terminals
1 START 3 OFF
2 ON 4 PRE
Figure 3
Connection of terminals
Service Information

Start switch, specifications 330 Service Information 2014/5/12
Profile:
Start switch, specifications

Specifications
Item Specifications
Maximum current B+–BR, B+–ACC : 30 A
B+–R1, B+–R2 : 60 A
B+–C : Momentary 75 A, Continuous 22 A
Insulation resistance 1 MΩ or more (500 V megger meter)
Wire specifications
NO. Wire specifications

2A B+, AVS 5.0 Y
3 BR, AVS 3.0 R/W
5 ACC, AVS 3.0 R
23 R2, AVS 5.0 W
7 C, AVS 3.0 R/SB
26 R1, AVS 3.0 R/GN
Inspection method
Figure 1
Start switch, inspection method
 Continuity test at each position by tester.

Service Information

Starting operation 330 Service Information 2014/5/12
Profile:
Starting operation
Power supply
 The negative terminal (–) of battery is grounded to the machine. When the master switch is in the off position, the
power supply is disconnected.
If the master switch is turned to the ON position and the start switch to the OFF position, current flows in the following
circuits.
 Battery (+) → Start motor terminal (B+) → Battery relay

 Battery (+) → Slow blow fuse (FU51, 60A) →
 Fuse (15A) → Fuel filler pump (option) switch

 Fuse (FU1, 15A) → Room lamp switch of switch assembly
 Fuse (FU2, 10A) → Brake & tail, license, instrument, switches lamps
 Fuse (FU3, 15A) → High beam lamp
 Fuse (FU6, 10A) → Hazard lamp
 Fuse (FU5, 10A) → Cassette & radio
 Battery (+) → Slow blow fuse (FU52, 60A) →
 Fuse box (FU30, 15A) → Start switch terminal (B+)
When the start switch is turned to the ON position, current flows in the following circuits.
 Start switch terminal (B+) → ACC terminal →
 Engine stop motor → Ground

 V-ECU
 Fuse box (FU8, 10A) → Charge warning lamp on the I-ECU → Alternator I terminal → Rotor coil → I.C
regulator → Ground. So the charge warning lamp comes ON and excites the alternator.
 Start switch terminal (B+) → BR terminal → Battery relay coil → Ground
When the battery relay is operated :
 Battery relay
 Air preheat relay

 Slow blow fuse (60A)
 Safety relay
 Alternator B+ terminal.
 So, the current flows to the fuse box, and all electrical systems can be used.
Engine starting
If the start switch is turned to the START position, the current flows in the following circuits.
 Start switch terminal (B+)
 R2 terminal → Preheating controller

 C terminal
 Safety start relay pin 1

 So, the current flows to the engine stop relay coil to activate the safety start relay and engine stop
relay.
When the engine stop relay is operated:
 Fuse box (F11, 30A) → Start switch (ACC) → Engine stop relay → So, the current flows to the engine stop motor and
the fuel is supplied to the engine.
When safety start relay is operated:
 Battery relay → Safety start relay → So, the current flows to the start motor S terminal to rotate the start motor and
the engine starts.
 When the travel control lever is at forward (F) or reverse (R) position, current flows to the safety start relay pin 3 to
prevent the safety start relay from energizing.
Starter safety lockout

If the start switch is in the START position continuously :
 Alternator I terminal → current flows to the safety start relay pin 2 and the safety start relay is cut off. Therefore, the
start motor stops.
 While the engine is running, the start motor can not engage even if the start switch is turned to the START position.
Stop
 If the start switch is released, it automatically returns to the ON position. When the start switch is turned to the OFF
position, the current to the engine stop motor from start switch ACC terminal is shut off. No electric current flows to
the engine stop motor, so the engine will stop.
The V-ECU holds on the battery power cut-off relay (RE12) of the relay box to release the PEAK load on the electrical
system when the engine stops.
 Alternator B+ terminal → Slow blow fuse (60A) → Fuse box (FU24, 10A) → Battery power cut-off relay (RE06) of the
relay box → Diode (Di03) → so, the electric current flows to the battery relay coil to temporarily activate the battery
relay. At this time, the V-ECU sets the stepping motor to the low idle condition to reduce the load, and then cuts off
the battery relay.
Service Information

Start motor, description 331 Service Information 2014/5/12
Profile:
Start motor, description

Solenoid switch
The solenoid switch provides positive engagement before cranking and safely handles maximum starting current. The
seamless, one-piece solenoid case is sealed to prevent entry of foreign material, and to increase contact life. The solenoid
switch contacts are made with special alloy material that prevents sticking. The solenoid contact rod moves inside a nylon
insert to resist cycling wear.
Frame
Utilizes tube stock to provide for improved sealing and uniform air gap tolerances.
Long life brushes
Four, wide, one piece brushes and positive spring retention design provide even brush wear, uniform pressure and better
cycle life.
High durability armature
Conductors are welded to the commutator for added strength and heat-resistance. The armature is epoxy impregnated and
glass banded for increased reliability.
Figure 1
Start motor inclusive solenoid
1 Oil wick 8 Bronze bearing

2 One piece brush 9 Heavy duty drive
3 Seamless, one piece solenoid case 10 Bronze bearing
4 Sealing boot 11 O-ring
5 Totally enclosed shift mechanism 12 Bronze bearing
6 Oil wick 13 Removable end cap
7 Shaft seal
Totally enclosed shift mechanism

Nodular iron drive housing, plus o-ring seal, completely encloses overruning drive and positive engagement mechanism for
protection from dirt and moisture. The two piece assembly allows rotation of mounting flange to provide 12 or 24 different
positions with respect to solenoid location.
Bearing lubrication and sealing
Three oil impregnated, sintered-bronze bearings support the armature shaft. The bearings are constantly lubricated by extra
large oil reservoirs and tangent wick oilers eliminate the need for regular maintenance. The shaft seal and special o-rings
prevent entry of oil, dirt or moisture into the motor. The sealing boot prevents entry of oil into the solenoid when used on
wet clutch applications.
Figure 2
Start motor, performance
A Speed (rpm x 1000) D Output (kW)

B Torque (Ibf · ft) E Amperes
C Volt (V)
Heavy duty drive

High durability drive reduces overspeed friction, increases operating life and prevents possible lock-up damage to shaft or
motor. The pinion indexes on helical splines, positively engaging ring gear before power switches on and does not become
disengaged with sporadic engine firing. During engine overspeed it automatically separates the driving saw tooth dentil
from driven member.
Service Information

Start motor, specifications 331 Service Information 2014/5/12
Profile:
Start motor, specifications

Specifications
Item Unit Specifications

Start Capacity 24 V – 7.46 kW
motor Rotation Clockwise or counterclockwise
Mounting S. A. E. # 3
No. of tooth/pinion blank EA 11 / 12
Pitch mm 6~8
Service Information

Air heater, description 333 Service Information 2014/5/12
Profile:
Air heater, description

 Air heater heat the air drawn into the inlet manifold.
CAUTION
When installing, position according to the air flow direction.
Figure 1
Air heater
Service Information

Air heater, specifications 333 Service Information 2014/5/12
Profile:
Air heater, specifications
Figure 1
Air heater specification curve.
1. Element surface temperature
Specifications
Item Specifications
Rated current 120 A ± 10%
Electric power 2.64 KW (800 °C, for 20 seconds)
Service Information

Preheating controller, 333 Service Information 2014/5/12
description
Profile:
Preheating controller, description

 The preheating controller receives electrical signals from various switches to control the preheating and
afterheating functions.
 Input signal :
 Start switch
 Thermo switch
 Alternator output signal (R terminal)
 Output signal :
 Lamp (I-ECU)
 Preheating relay
Figure 1
Preheating controller
Service Information

Preheating controller, 333 Service Information 2014/5/12
specifications
Profile:
Preheating controller, specifications

Specifications
Item Specifications
Operating voltage DC 16 ~ 32 V
Service Information

Preheating relay, 333 Service Information 2014/5/12
description
Profile:
Preheating relay, description

 The relay receives electrical signals from the preheating controller to operate the air heater.
Figure 1
Preheating relay
Service Information

Preheating relay, 333 Service Information 2014/5/12
specifications
Profile:
Preheating relay, specifications

Specifications
Item Specifications
Rated voltage DC 24V
Contact point capacity 200 A (maximum)
Rated coil current 2 A or less
Minimum operating voltage DC 18 V
Rated running time 60 seconds or less
Insulation resistance More than 1 MΩ (500 V megger meter)
Service Information

Preheating system, 333 Service Information 2014/5/12
description
Profile:
Preheating system, description

In cold weather engine starting is improved by the use of a preheating system.
It is operated only when the ambient temperature is lower than 15 °C.
Preheating
When the start switch is turned to the PRE position, the current flows in the following circuits A, B.
 A : Start switch B + terminal → R1 terminal → No. 8 pin of preheating controller

 B : Start switch B + terminal → ACC terminal → No. 1 pin of preheating controller
 When the ambient temperature is above 15°C, the thermo switch is operated and it sends a signal to the
preheating controller, so the preheating function is not operated.
When the ambient temperature is below 15 °C, the current flows in the following circuits.
 No. 5 pin of preheating controller → preheating relay coil, so the preheating controller operates the relay.
 Battery → battery relay → preheating relay → air heater, so the air heater warms the air in the inlet manifold.
After a lapse of about 19 seconds since the preheating started, the current flows in the following circuit.
 No. 7 pin of the preheating controller → preheating finished indicator on I-ECU, so the preheating finished indicator
lights.
 The air heater stops in about 5 seconds after the preheating finished indicator comes ON.
Starting
When the start switch is at the START position, current flows in the following circuit.
 Start switch B+ terminal → R2 terminal → No. 4 pin of preheating controller, so the preheating controller recognizes
that the engine is activated.
 If engine starting is activated, the preheating controller operates the preheating relay/heater to prevent engine
smoke. External cold air drawn into the inlet manifold is heated in the inlet manifold before it enters the
combustion chamber.
Afterheating
When the start switch is released from the START position to the ON position after starting the engine
 The current of 10 ± 2 V flows from the alternator R terminal to the No. 2 pin of preheating controller, which
recognizes that the engine is running.
 The preheating controller activates the preheating relay for about 15 seconds to operate the air heater and heat the
inlet air to prevent engine smoke.
Air heater operation
Position of Condition Output

start switch Thermo switch Alternator R Lamp Relay
output
Preheating PRE OFF ON, after OFF, after lamp lighting time:
19 ± 2 seconds 5 ± 2 seconds
ON Always ON Always OFF
Afterheating START OFF Always OFF Always ON
ON Always OFF
START OFF High Always OFF ON for 15 ± 2 seconds
→ ON and OFF
OFF Low Always OFF
ON Always OFF
Service Information

Thermo switch, description 333 Service Information 2014/5/12
Profile:
Thermo switch, description

 The thermo switch measures ambient temperature to activate or deactivate the preheating function.
 If the ambient temperature is above 15 °C (59 °F), the air heater is not operated even when the start switch is in the
PRE (preheating) position.
Figure 1
Thermo switch
1. AVO 5 R/Y
Service Information

Thermo switch, 333 Service Information 2014/5/12
specifications
Profile:
Thermo switch, specifications

Specifications
Item Specifications
Operating temperature ON : 15 +5.5/-1.2 °C, OFF : 9 +5.5/-1.2 °C
Internal resistance Maximum 0.5 Ω (at ON)

Insulation resistance 1 MΩ (Contact point OFF – 100 V insulation tester use)
Tightening torque 350 ± 50 kgf·cm (25 ± 3.6 lbf·ft)
Allowable current 0.5 A or less
Service Information

Combination lamp, 350 Service Information 2014/5/12
description
Profile:
Combination lamp, description
Figure 1
Combination lamp
1 Brake (21/25 W), AV 0.85 GN A Brake & Tail lamp

2 Stop, AV 0.85 SB B Turn signal lamp
3 Tail (5/10 W), AV 0.85 GN C Reverse travel lamp
4 Turn signal, AV 0.85 GN/Y
5 Ground, AV 0.85 SB
6 Reverse travel, AV 0.85 R/GN
7 Ground, AV 0.85 SB
Service Information

Combination lamp, 350 Service Information 2014/5/12
specifications
Profile:
Combination lamp, specifications

Specifications
Item Specifications
Rated voltage 24 V
Electric power consumed 21 W × 3 + 10 W
Service Information

Extra work lamp, 350 Service Information 2014/5/12
description
Profile:
Extra work lamp, description
Figure 1
Extra work lamps location
1. Cab front lamp

2. Cab rear lamp
3. Counterweight lamp
Figure 2
Extra work lamp
1. B+, AVSS 1.25 R/BL

2. Ground, AVSS 1.25 SB
3. KET SWP receptacle housing & terminal (2P)
4. Bulb (24 V, 70 W)
Service Information

Extra work lamp, 350 Service Information 2014/5/12
specifications
Profile:
Extra work lamp, specifications

Specifications
Item Specifications
Rated voltage 24 V
Electric power consumed 70 W / bulb
Bulb type Halogen (H3)
Service Information

Head lamp, description 350 Service Information 2014/5/12
Profile:
Head lamp, description
Figure 1
Head lamp
1. Position lamp, AVS 0.85 GN/W

2. Ground, AVS 0.85 SB
3. AMP MARK2 connector
4. Bulb-H4 (24 V, 70 W)
5. Bulb (24V, 4W)
Service Information

Head lamp, specifications 350 Service Information 2014/5/12
Profile:
Head lamp, specifications

Specifications
Item Specifications
Rated voltage 24 V
Electric power consumed 4: 70 W / bulb
5: 4W / bulb
Bulb type 4: Halogen (H4)

Quantity 4: 1 × 2
5: 1 × 2
Service Information

Lateral lamp, description 350 Service Information 2014/5/12
Profile:
Lateral lamp, description
Figure 1
Lateral lamp
1 AV 1.25 BN
2 AV 1.25 SB
3 KET SWP series plug housing & terminal (2P)
4 Bulb, R5W
5 Lens color – white
6 Lens color – white
Service Information

Lateral lamp, specifications 350 Service Information 2014/5/12
Profile:
Lateral lamp, specifications

Specifications
Item Specifications
Rated voltage 24 V
Electric power consumed 5W
Service Information

Side lamp, description 350 Service Information 2014/5/12
Profile:
Side lamp, description
Figure 1
Side lamp
1. Flasher (B+), AVS 0.85 GN

2. Ground, AVS 0.85 GSB
3. AMP MARK2 connector
4. Bulb (24 V, P21 W)
Flasher unit
Figure 2
Flasher unit
Service Information

Side lamp, specifications 350 Service Information 2014/5/12
Profile:
Side lamp, specifications

Side lamp, specifications
Item Specifications
Rated voltage 24 V
Electric power consumed 21 W / bulb (P21W)
Flasher unit, specifications
Item Specifications
Rated voltage 24 V
Operating temperature 25 ∼ 80 °C
Flashing interval 85 ± 20 cycle/minute
Electric power consumed (21 W + 21 W) × 2 + 3 W
Service Information

Work lamp, description 350 Service Information 2014/5/12
Profile:
Work lamp, description
Figure 1
Work lamp (boom)
1. B+, AVS 1.25 R/W

2. Ground, AVS 1.25 SB
3. KET SWP receptacle housing & terminal (2P)
4. Bulb (24 V, 70 W)
Service Information

Work lamp, specifications 350 Service Information 2014/5/12
Profile:
Work lamp, specifications

Specifications
Item Specifications
Rated voltage 24 V
Electric power consumed 70 W / bulb
Bulb type Halogen (H3)
Quantity 2×2
Service Information

Air horn, description 3621 Service Information 2014/5/12
Profile:
Air horn, description

 A horn switch is located in the center of the steering wheel, the edge of combination switch and on the top of left
control lever (if equipped 3 or 5 switches type control lever, one of the switches on the right control lever is used
for horn). Depressing one of the switches operate the electric motor for air compressor, which sounds the air horn.
Figure 1
Horn switches
Figure 2
Air horn
1 Trumpet (770 Hz)

2 Trumpet (650 Hz)
3 Compressor
Service Information

Air horn, specifications 3621 Service Information 2014/5/12
Profile:
Air horn, specifications

Specifications
Item Specifications
Sound pressure 108 ± 5 dB
Frequency 650 Hz ± 5%
770 Hz ± 5%
Operating voltage 20 ~ 28 V
Insulation resistance 1 MΩ (500 V megger meter)
Service Information

Travel alarm, description 3625 Service Information 2014/5/12
Profile:
Travel alarm, description

 The travel alarm is a safety device that sounds when the machine travel reverse, to warn workers of impending
danger.
 The alarm is connected to the travel control lever switch.
 The sound level is adjustable by the variable switch in the device.
Figure 1
Travel alarm
1 Relay, AVS 0.85 BL/R

2 Ground, AVS 0.85 SB
3 KET SWP receptacle housing * terminal (2P)
4 Sound volume switch
Service Information

Travel alarm, specifications 3625 Service Information 2014/5/12
Profile:
Travel alarm, specifications

Specifications
Item Specifications
Current 0.5 A
Sound pressure 0 ∼ 115 ± 5 dB (variable type)
Sound color 60 → 90 Hz (intermittent, expanding type)
Operating temperature -20 ∼ 50 °C
Service Information

Window limit switch, 3631 Service Information 2014/5/12
description
Profile:
Window limit switch, description

 If the front window is lifted up, the arm of the window limit switch is moved and cuts off the ground circuit of wiper
controller to stop the wiper motor.
Figure 1
Window limit switch
1. Apply loctite, tightening torque 0.2 ± 0.02 kgf·m (1.4 ± 0.1 lbf· ft)
Service Information

Window limit switch, 3631 Service Information 2014/5/12
specifications
Profile:
Window limit switch, specifications

Specifications
Item Specifications
Minimum connection angle 0 ~ 25° (Normally closed, NC)
26 ~ 70° (Normally opened, NO)
Operating voltage AC 14 ~ 30 V
Operating temperature –30 ~ 70 °C (–22 ~ 158 °F)
Inspection method
Figure 1
Window limit switch, inspection method
 test the continuity between the terminals at normally opened and normally closed position by tester.
Service Information

Windscreen wiper, 3631 Service Information 2014/5/12
components location
Profile:
Windscreen wiper, components location
Figure 1
Wiper motor, location
1 Washer nozzle 5 Wiper blade

2 Wiper motor link 6 Wiper arm
3 Wiper motor 7 Wiper park position
4 Window limit switch 8 Wiper operation sweep (70°)
Service Information

Windscreen wiper, 3631 Service Information 2014/5/12
descriptions
Profile:
Windscreen wiper, descriptions

 By the use of the wiper controller, the wiper motor provides various functions.
NOTE!
If the front window is lifted up, the limit switch is activated, so wiper motor does not work.
 If the wiper switch is the ON position, the wiper motor moves the arm/blade from the PARK position (on the front
edge of the cab) onto the front window, and sweeps the blade through 70°. When the wiper is switched to the OFF
position, the arm / blade completes the upward sweep and after about 1.5 seconds move to the vertical park
position on the cab. Parking the wiper arm/blade assembly off the front window improves visibility and eliminates
any interference with the front window operation.
 Pushing the washer switch sprays the washer solution onto the window, and after about 2 seconds, the wiper motor
engages. When the washer switch operation is stopped, the wiper blade wipes the window 3 more times, and then
returns to the park position.
 Lifting the front window while the wiper motor is running immediately stops the operation. However, lowering the
window will not automatically restart the wiper motor. The wiper switch must be turned OFF and then ON again to
activate the wiper function.
Service Information

Wiper controller, 3631 Service Information 2014/5/12
description
Profile:
Wiper controller, description

 The wiper controller receives information from the wiper switch, washer switch and window limit switch, to control
the wiper motor and washer pump operation.
 While the wiper motor and washer pump are operating, the wiper controller receives the operating information
from the wiper motor and shows the function selected.
Figure 1
Wiper controller
Service Information

Wiper motor, description 3631 Service Information 2014/5/12
Profile:
Wiper motor, description

 The wiper motor rotates alternately to both directions according to the output direction of wiper controller, and
works the intermittent operation or rotation by the position of wiper switch.
 When the motor rotates once, the wiper blade operates reciprocally up and down by the linkage.
 The cam plate in the motor outputs the signals to the controller in accordance with the motor position.
Figure 1
Wiper motor
1 P, AVS 0.85 BL/SB

2 R, AVS 0.85 BL/R
3 C, AVS 0.85 BL
4 F, AVS 0.85 SB/W
5 W, AVS 0.85 GN
Service Information

Wiper motor, specifications 3631 Service Information 2014/5/12
Profile:
Wiper motor, specifications

Specifications
Item Specifications
Motor type Ferrite magnet type
Nominal torque 180 kgf·cm (13 lbf·ft)
Speed (at 6 kgf·cm, loaded) 35 ± 4 rpm
Speed (at 30 kgf·cm, loaded) More than 20 rpm
Minimum operating voltage (no–load) Less than DC 16 V
Current (no–load) Less than 1.5 A
Current (loaded) Less than 15 A
Service Information

Auto/manual switch, 3641 Service Information 2014/5/12
description
Profile:
Auto/manual switch, description

 When the V-ECU is abnormal, the Auto/manual switch must be switched to MANU position.
 When the V-ECU is switched to the manual position, the resistor box changes the current to the proportional
solenoid valve so that the value corresponds to the 85% of the rated engine output power. In the MANU position
the engine speed is also controllable by the manual control cable in the right console.
Figure 1
Auto/manual switch
Service Information

Auto/manual switch, 3641 Service Information 2014/5/12
specifications
Profile:
Auto/manual switch, specifications

Wire specifications

1 AVS 0.85 W/SB V-ECU
2 AVS 0.85 W Proportional valve
3 AVS 0.85 W/Y Resister box
4 AVS 0.85 W/R V-ECU
5 AVS 0.85 SB/R Power supply (B+)
6 AVS 0.85 R/SB Proportional valve
Inspection method
 Continuity test between connector pins to be connected at ON/OFF. (At connection, the resistance is below 10mΩ)
Figure 1
Resistance measurement
Service Information

Combination switch, 3641 Service Information 2014/5/12
description
Profile:
Combination switch, description
Figure 1
Combination switch
1 Horn switch LH Left turn signal

2 Washer switch NEU Neutral
3 Wiper switch RH Right turn signal
4 Turn signal switch PA Head lamp flasher (passing)
5 SWP plug housing & terminal (12P) LO Low beam
HI High beam
Figure 2
Combination switch circuit
Horn switch
Activate air horn.
Washer switch
Activate front window shield washer.
Wiper switch
 J : Intermittent operation
 O : Wiper stop
 1st : Low speed
 2nd : High speed
Turn signal switch
 Push forward: flash left turn signal lamp

 Pull backward: flash right turn signal lamp
 Pull up: Head lamp high beam flasher (passing). It return to low beam when released.
 Push down: Head lamp high beam (fixed)
Wiring specifications
Connector Wiring number Signal

L 136, 1.25 GN left turn lamp, indicator
49a 132 1.25 W Flasher unit
R 143, 1.25 G/BN Right turn lamp
56 123, 1.25 W/Y Head lamp relay
56b 124, 1.25 Y Head lamps (low beam)
56a 123, 1.25 R/W Head lamps (high beam)
49a 132 1.25 W Flasher unit
15/1 121, 1.25 R/GN Power supply (FU3)
J 303 SB/BL Wiper motor controller
53 304, 0.75 W/Y Wiper motor controller
53b 304A, 0.75 W/Y Wiper motor controller
15(53a) 079, 0.75 SB Ground
53c 312, 0.75 R/SB Washer pump
H 505, 0.75 G Horn relay
Service Information

switch, description
Profile:
Engine speed control switch, description

 The operator can easily select the work mode, engine speed, and maximum working horsepower by turning the
engine speed control switch if the auto/manual switch is in the AUTO position.
 The output voltage range of the engine speed control switch is 0.5 ~ 4.5 V according to the selected step ( 9 steps).
 The V-ECU regulates the engine speed and maximum working horsepower according to the built-in program of the
V-ECU for each step.
Figure 1
Engine speed control switch
Inspection method
 Measure with the connector in the connected position.

 The output voltage is increased 0.5 V by step from step 1, 0.5 volts to step 9, 4.5 volts.
Figure 2
Voltage measurement
Engine speed control switch, voltage output
Switch step Mode Voltage (V)

1/2 I 0.5 / 1.0
3/4/5 F 1.5 / 2. 0 / 2.5
6/7/8 G 3.0 / 3.5 / 4.0
9 H, P 4.5
Service Information

switch, specifications
Profile:
Engine speed control switch, specifications

Wire specifications

1 0.85 R Power (B+)
2 0.85 GN Output (SIG)
3 0.85 SB Ground (GND)
Specifications
Item Specifications
Output voltage DC 0.5 ~ 4.5 V
Type Potentiometer
Consumption 0.5 W
Service Information

Head lamp switch, 3641 Service Information 2014/5/12
description
Profile:
Head lamp switch, description
Figure 1
Head lamp switch
 The head lamp switch is same in structure and specification with travel mode selection switch. So, the structure see
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1st position
The switch lights the tail lamps, license plate lamp, I-ECU and switch panels
2nd position
the switch operates head lamp on low beam

B+ 210, 0.85 R/GN Power supply
A – –
B 207, 0.85 GN/SB Head lamp relay
C 206, 0.85 GN/BL Work lamp, control lamps
Service Information

Left switch panel, 3641 Service Information 2014/5/12
description
Profile:
Left switch panel, description
Figure 1
Left switch panel
1 Room lamp switch

2 Overload warning switch (option)
3 Beacon switch (option)
4 Fuel heater switch (option)
5 Seat heater switch (option)
6 Blank, cover
7 Cassette mute switch (option)
8 Blank, cover
9 Blank, cover
Switch operating circuit
Figure 2
Operating circuit, switch 1, 2, 3, 4, 5 and 7
Room lamp switch

Figure 3
Room lamp switch
The switch lights the room lamp. The overhead lamp can be used only when this switch is in the ON position.
Overload warning switch (option)
Figure 4
overload warning switch
WARNING
When overload warning lamp is ON, stop the lifting operation and reduce the load. If not, it can cause serious
accidents, perhaps even fatal accidents.
When this switch is in A position, the overload warning lamp on the I-ECU is ON if overload happens.
Beacon switch (option)
Figure 5
Beacon switch
The switch is used to operate the lamp that show the status of machine working.
 ON : beacon lamp is activated.

 OFF : beacon lamp is OFF.
Seat heater switch (option)

Figure 6
Seat heater switch
The switch is used to warm the seat. Pressing the switch to the operating position lights the seat heater indicator on the I-
ECU.
When the seat is warmed, turn the switch to OFF position.
Fuel heater switch (option)
Figure 7
Fuel heater switch
The switch is used when it is difficult to start the engine because the fuel in winter is solidified. Pressing the switch to the
operating (ON) position lights the fuel heater indicator on the I-ECU.
CAUTION
After starting the engine, be sure to return the switch to the OFF position.
Cassette mute switch (option)
Figure 8
Cassette mute switch
This switch is used to mute the sound of speaker at a time.

Service Information

Right switch panel, 3641 Service Information 2014/5/12
description
Profile:
Right switch panel, description
Figure 1
Right switch panel
1 Hazard lamp switch 6 Axle locking switch

2 Extra lamp switch (option) 7 Quickfit switch 1 (option)
3 Boost/hammer selection switch 8 Work lamp switch
4 Auto idling switch 9 Quickfit switch 2 (option)
5 Dozer & stabilizer selection switch 10 Buzzer stop & confirm switch (option)
Switch operating circuit
Figure 2
Operating circuit, switch 1
Figure 3
Operating circuit, switch 2
Figure 4
Operating circuit, switch 3, 4, 5, 6 and 8
Figure 5
Operating circuit, switch 7, 9, 10
Hazard lamp switch
Figure 6
Hazard lamp switch
The switch is used for indicating an emergency to others during traveling, operating or emergency parking.
When pushing the switch to the ON position both the front and rear turn signals and indicators of I-ECU will flash.
Extra lamp switch (option)
Figure 7
Extra lamp switch
The switch lights the extra work lamps on the cab and counterweight.
 OFF: lights out.

 ON: extra work lamps ON.
Boost/hammer selection switch
Figure 8
Boost/hammer selection switch
PB Power boost operation

HM Hammer operation
The switch selects the one-touch power boost or hammer operation functions.
Pressing the boost/hammer switch on the right remote control valve (joystick) in the PB (power boost) position increases the
hydraulic working pressure for about 9 seconds.
Only with hammer equipped, pressing the switch to the HM (hammer) position, enables the boost/hammer switch to
operate the hammer.
Auto idling switch
Figure 9
Auto idling switch
When not operating the remote control valves (joysticks, travel pedal) and engine speed control switch for about 10 seconds
with the auto idling switch in the ON position, the engine speed decreases automatically to auto idle level for reducing fuel
consumption and noise.
If at least one is operated among the joysticks, travel pedal or engine speed control switch, the engine speed returns to the
set speed of the engine speed control switch.
Dozer blade/stabilizer selection switch
Figure 10
Dozer blade/stabilizer selection switch
DZ Dozer blade operation

ST Stabilizer operation
The switch selects the dozer blade or stabilizer operating function.
 DZ: the stabilizer operates.

 ST: when operating the dozer blade, operate this switch and then operate with the dozer blade, stabilizer lever.
Axle locking switch
Figure 11
Axle locking switch
The switch is used to lock or unlock front axle oscillation.
 ON: front axle can not oscillate.

 OFF: front axle oscillate according to ground conditions.
Quickfit switch (option)
Figure 12
Quickfit switch
The quickfit switches make operator perform to exchange a bucket electrically in cab.
When the switches are operated simultaneously to the OPEN position, quickfit unit is opened, the buzzer is activated, the
central warning lamp flash and quickfit indicator on the I-ECU is ON.
Pressing the buzzer stop & confirm switch to the STOP position, the buzzer will be silenced but the quickfit indicator is ON
and central warning lamp still flash.
After installing a bucket/tool, turn two switches to the LOCK position and press the buzzer stop & confirm switch to the
CONFIRM position, then the quickfit indicator and central warning lamp will be OFF.
Work lamp switch
Figure 13
Work lamp switch
The switch lights the work lamp when the head lamp switch is on the 1st or 2nd position.
Buzzer stop & confirm switch (option)
Figure 14
Buzzer stop & confirm switch
This switch is used to STOP buzzer sound when removing. a bucket/tool from the quickfit unit and CONFIRM the machine
condition after installing a bucket/tool to the quickfit unit.
Service Information

Travel control lever, 3641 Service Information 2014/5/12
description
Profile:
Travel control lever, description
Figure 1
Travel control lever
1. Transfer gearbox gear selection switch

2. Forward/reverse selection switch
3. Auto cruise switch (option)
4. KET SWP series housing & male terminal (6P)
Figure 2
Travel control lever circuit

F 703, 0.75 GN/SB Forward solenoid valve
R 705, 0.75 W/GN Reverse solenoid valve
15(49a) 701, 1.25 BL Power supply (FU21)
L 786, 0.75 W Gear shift solenoid valve
15(53a) 702, 1.25 BL Power supply (FU21)
KD 787, 0.75 BN Controller (V-ECU)
Service Information

Travel control lever, 3641 Service Information 2014/5/12
specifications
Profile:
Travel control lever, specifications

Specifications
Item Specifications
Step angle 15°
Output voltage ON: 24 V
OFF: 0 V
Type Rotary, push button
Maximum current 1 A (with 24 V)
Service Information

Travel mode selection 3641 Service Information 2014/5/12
switch, description
Profile:
Travel mode selection switch, description

 The operator can easily control the park mode (P), work & travel mode (W) and travel mode (T) by turning the travel
mode selection switch.
 The switch also controls the safety solenoid valve and parking brake solenoid valve in park mode (P), and the safety
solenoid valve in travel mode (T).
Travel mode (T)

If the travel mode selection switch is at travel position then the parking brake will be released.
At this position digging unit operation is not available.
Work mode (W)
If the travel mode selection switch is at work/travel position then the parking brake and safety function will be released.
At this position digging unit and travel operation is available.
Parking mode (P)
If the travel mode selection switch is at parking position then the parking brake will be activated.
At this position digging unit operation is not available.
Figure 1
Travel mode selection switch

B+ 690, 0.85 R/Y Power supply
A 70, 0.5 Y/SB Parking brake indicator (I–ECU)
B 692, 0.85 BL/SB Safety solenoid valve
Parking solenoid valve
C 658, 0.85 GN/Y Parking solenoid valve
Service Information

Travel mode selection 3641 Service Information 2014/5/12
Profile:
Travel mode selection switch, specifications

Specifications
Item Specifications
Power supply DC 24 V, 3 A
Step angle 45°
Output voltage ON: 24 V
OFF: 0 V
Type Rotary type
Service Information

Automatic control system, 366 Service Information 2014/5/12
components location
Profile:
Automatic control system, components location
Figure 1
Components location, automatic control system
1 D-ECU 6 Digging unit port pressure switch

2 Resistor box 7 V-ECU
3 Stepping motor 8 Travel pedal pressure switch
4 Auto/manual switch 9 engine speed control switch
5 Engine speed sensor
Service Information

Automatic control system, 366 Service Information 2014/5/12
description
Profile:
Automatic control system, description

The advanced control system (ACS) comprised of input components (sensors, switches), V-ECU, and output components
(actuators) continuously controls the machine performance to correspond to a built-in program.
The control system is manually controlled via an override switch so it can be operated on automatic (normal position) or
manual mode. MANUAL mode should only be used as an emergency when the machine is abnormality on automatic mode.
The functions of the automatic control system are as follows:
 Self diagnosing
 Machine status indication
 Mode selection: engine speed, work and travel mode
 Engine speed sensing power control
 Automatic idling
 Power boost
 Safety start / stop
 Automatic engine warm-up
CAUTION
The automatic control system is sensitive to contamination and must be protected from the penetration of moisture,
lubricants and dust. The ACS electronic components must also be protected from over-voltage, therefore it is imperative
that precautions concerning the charging system and welding procedures be strictly adhered to.
Figure 1
Automatic control system, block diagram
1 V-ECU
2 D-ECU
3 Start switch
4 Auto idling switch
5 Boost/hammer selection switch
6 Engine speed control switch
7 Boost/hammer switch
8 Travel control lever
9 Travel mode selection switch
10 Digging unit port pressure switch
11 Stop pressure switch
12 Brake pressure switch
13 Travel pedal pressure sensor
14 Coolant temperature sensor
16 Throttle position sensor
17 Stepping motor
18 Auto/manual switch
19 Resister box
20 Power shift proportional solenoid valve
21 Relay box
22 Hammer solenoid valve
23 Conflux cut-off solenoid valve
24 Safety solenoid valve
25 Power boost solenoid valve
26 Auto cruise solenoid valve
27 Battery relay
Service Information

Automatic engine warm- 366 Service Information 2014/5/12
up, description
Profile:
Automatic engine warm-up, description

 The V-ECU (1) controls engine warm-up in accordance with the engine coolant temperature (4) to prevent the wear
of engine components due to high engine speed at low temperature.
 The engine warm-up function will operate automatically and continue with the engine speed increasing gradually
until the operating temperature is almost normal.
Automatic engine warm-up
Warm–up condition Function

ON When the coolant temperature (4) is below 30 °C and the The speed is set to the step-4 value by the engine
engine speed control switch (3) is on the step-4 or lower speed control switch (3).
at engine start.
OFF When the coolant temperature (3) is above 30 °C or Automatic warm–up function is stopped.
warm-up function is activated for 10 minutes. or longer, The engine speed is controlled to the setting speed
or when operator selects H mode. with the engine speed control switch (3) or travel
pedal pressure sensor (8).
Figure 1
Components related Engine warm-up
1 V-ECU
2 Start switch
4 Engine coolant temperature sensor
5 Stepping motor
Service Information

Automatic idling, 366 Service Information 2014/5/12
description
Profile:
Automatic idling, description

 Automatic idling function is activated by pressing the auto idling switch (3).
 When this function is activated, the V-ECU (1) analyzes the operating status of the hydraulic circuits with the
feedback signals of the digging unit port pressure switch (7), travel pedal pressure sensor (8). If there is not any
operation for 10 seconds, the V-ECU reduces engine speed to the auto idle setting value.
 After the engine has decelerated, if the operator touches one of the remote control valves (joysticks, pedal) or turns
the engine speed control switch (2), the V-ECU increases the engine speed to the selected speed of the engine
speed control switch.
 Auto idling is working when the engine speed control switch is on the 3 ∼ 9 step.
 This function reduces fuel consumption and lowers noise levels, enhancing operator comfort and machine
profitability.
Figure 1
Components related to automatic idling
1 V-ECU
3 Auto idling switch
4 Stepping motor
Auto idling operation
Mode Switch Work status Auto idle ON Auto idle OFF

F - G - H - step 3-9 10 seconds lapse in work cycle Engine speed is decelerated to Engine speed remains at
P or relative auto idle speed (Step 2). the speed set by the
travel pedal engine speed control
stroke switch.
Work cycle restarted or Engine speed accelerates to the
change the step of the engine speed set by the engine speed
speed control switch control switch
I step 1or Work cycle started Engine speed remains at low idle. Engine speed remains at
relative travel low idle.
pedal stroke
step 2 or Work cycle started Engine speed remains at auto idle Engine speed remains at
relative travel speed. auto idle speed.
pedal stroke
Service Information

Machine status indication 366 Service Information 2014/5/12
Profile:
Machine status indication

 V-ECU continuously sends the signals of the current machine operating condition to the D-ECU.
 Indicating the operating condition facilitates troubleshooting and repairs.
 The D-ECU display the value that the V-ECU receives or outputs. Especially, for items based on the V-ECU output
value, the value may differ from the actual operating value of machine components. When the operating condition
of the equipment is abnormal, confirm by actually measuring the machine, then compare with the value displayed
on the D-ECU, and judge whether it is normal or abnormal.
D-ECU, indication contents
No. Item Status code Display Unit Remark

example
0 Engine speed – 1900 rpm Default
1 Mode – G1 I2/F3/G3/H
2 Engine speed control switch step SC SC 9 1∼9
3 Auto idling switch status A A ON ON/OFF
4 Boost/hammer switch status A. A.ON ON/OFF
5 Brake pressure switch status B B ON ON/ OFF
6 Travel mode selection switch status B. B. ON ON/ OFF
7 Power shift current D D 400 mA
8 Boost relay status E E ON ON/ OFF
9 Boom/arm conflux cut-off relay status E. E.ON ON/OFF
10 Auto cruise relay status F. F.ON ON/OFF
11 V-ECU power supply voltage G G26.5 V
12 Travel control lever status G. G.ON ON/OFF
13 Digging unit port pressure switch status H H. ON ON: forward/ reverse
OFF: neutral
14 Throttle position sensor value J J 4.2 V
15 Auto cruise switch status J. J. ON ON/OFF
16 Auto cruise status – CURZ
17 Travel pedal pressure sensor value RC RC30 kgf/cm2
18 Error code ER ER11
Service Information

Mode selection & 366 Service Information 2014/5/12
engine speed sensing
power control, description
Profile:
Mode selection & engine speed sensing power control, description

 The engine speed control switch (2) allows the operator to select the engine speed and work mode according to
the working condition and environment to optimize the machine performance and fuel efficiency.
 This is accomplished by turning the engine speed control switch to vary its output voltage to the V-ECU (1), 0.5 ~
+4.5V. The V-ECU then establishes an appropriate pulse signal value to rotate the stepping motor (5), to the correct
rotary angle, to position the fuel injection pump lever, to obtain the engine speed to match mode speed
requirement. the throttle position sensor (6, potentio meter) confirms the angle to the V-ECU for greater accuracy.
 The V-ECU continuously receives the current engine speed from engine speed sensor (7). It balances engine output
horsepower and hydraulic pump drive horsepower by changing the pump swash angle with driving the power shift
proportional solenoid valve (9) to keep pump torque below the engine torque developed at the selected engine
speed. this is called engine speed sensing power control (ESSPC) and working P, H and G modes.
Travel mode
The travel mode selection switch (3) allows the operator to select travel (T), work and travel (W) mode. When the switch is set
to parking (P) position, the operation of control levers and travel pedal is not available.
In T and W position if the travel pedal is operated, available engine speed and rated output horsepower will range from step
3 to step 9 according to travel pedal stroke.
However if a control lever is operated available engine speed and rated output horsepower will correspond to the higher
step selected by the engine speed control switch and travel pedal stroke.
H mode (Heavy duty operation)
H mode functions on step-9 of the engine speed control switch (2) and W position of the travel mode selection switch (3) to
increase the working capacity and working speed by utilizing 91% of the rated engine output horsepower.
If the travel mode selection switch (3) is set to T position the working capacity and speed is increased to 100% of the rated
engine output horsepower.
This mode is for heavy duty excavating operation or travel which require maximum digging and lifting force.
G mode (General duty operation)
G mode functions over a 3 step range as follows:
Step 6/7/8 utilize 90% of the rated engine output horsepower and is recommended for general duty operations that are
below the level which require maximum engine output.
These positions provide the most efficient, fuel saving, economical machine performance for general excavating and loading
operations.
F mode (Fine duty operation)
F mode functions over a 3 step range as follows:
Step 3/4/5 utilize 70% of the rated engine output horsepower, however at each step this mode outputs a constant current
to the power shift proportional solenoid valve (9) on the hydraulic pump to set and hold the swash plate angle for consistent
pump discharge.
At the same time, the V-ECU sends OFF signal to the boom and arm conflux cut-off solenoid valves (23, 24) and shut-off
summation of the two hydraulic pumps when operating the boom or arm.
Also, the V-ECU activates the boost solenoid valve (12). It provides fine controllability for precise smooth movements and
maximum lifting force at mid-range engine speeds.
This mode is recommended for finishing/levelling work and when fine precision control of the boom and arm is essential.
I mode (Idling operation)
I mode functions over a 2 step range as follows:
Both steps minimize the output of the pumps.
Step-1 is the low idle speed set at engine starting.
Step-2 is the auto idle speed and is available if the auto idling switch is in the ON position.
Figure 1
Components related to mode selection
1 V-ECU
3 Travel mode selection switch
5 Stepping motor
8 Auto/manual switch
9 Power shift proportional solenoid valve
10 Relay box
11 Boom/arm conflux cut-off solenoid valve
Service Information

Mode selection & 366 Service Information 2014/5/12
engine speed sensing
power control,
specification
Profile:
Mode selection & engine speed sensing power control, specification

Engine speed and work mode
Switc Mode Travel Engine Maximu Power Travel pedal Remarks

h mode speed m pump shift Travel Engine speed
steps (±40 rpm) torque current pedal (±40 rpm)
(unload / (±20 mA) pressure (unload)
load) (kgf/cm2)
9 Heavy H T 2070 / 100% 200 / 22.5 or more 2070 ESSPC

above 1900 variable
W 1800 / 91% 390 / 1800 ESSPC
above 1650 variable
8 Genera G1 T 1800 / 18.7 ∼ 22.5 1800 ∼ 2070 ESSPC
l W above 1650 1800
7 G2 T or W 1700 / 17.3 ∼ 18.7 1700 ∼ 1800

6 G3 above 1550
5 Fine F1 1600 / - 70% 510 16.0 ∼ 17.3 1600 ∼ 1700 Automatic power
4 F2 1500 / - 14.6 ∼ 16.0 1500 ∼ 1600 boost
Boom / arm conflux
3 F3 1400 / - 13.2 ∼ 14.6 1400 ∼ 1500
cut-off
2 Idle I1 1100 / - 60% 635 9.0 ∼ 13.2 1100 ∼ 1400 Auto idling
1 I2 850 / - 0.0 ∼ 9.0 850 ∼ 1100 Engine start
MANUAL condition Manual linkage cable 290
Service Information

Power boost, description 366 Service Information 2014/5/12
Profile:
Power boost, description

Automatic power boost
When high power is required like traveling in fixed speed or high pressure is needed for fine control (F-mode), working
pressure will be boosted automatically by the V-ECU to enhance machine performance.
One-touch power boost
If momentarily, additional excavating force or precise digging unit control is required, it can be obtained by pressing the
boost/hammer switch (4) of the right remote control valve (joystick). This will boost the pressure of main hydraulic relief
valve for approximate 9 seconds.
Although pressing continuously the switch (4) over 9 seconds, the power boost time is same to that of one-touch press.
This function is available only when the boost/hammer selection switch (6) is in the BOOST position.
If the hammer/boost selection switch (3) is in the HAMMER position, when a hammer is equipped the boost/hammer switch
(4) of right joystick is used as a hammer switch.
Power boost operation
Boost work condition Remark

Automatic - In F mode Boost solenoid valve (9) ON
boost
One–touch boost - Pressing boost/hammer switch (4) - Boost solenoid valve (9) ON
- Travel control lever (5) in neutral (N) - Working during pressing for about 9 seconds.
Figure 1
Components related to power boost
1 V-ECU
3 Boom/hammer selection switch
4 Boom/hammer switch (right joystick)
8 Relay box
Service Information

Safety start / stop, 366 Service Information 2014/5/12
description
Profile:
Safety start / stop, description

The engine and electrical systems are protected during start–up and shut–down of machine by safety features programmed
in the V-ECU (1).
These features include the automatic reduction of engine speed to auto idle value at start–up and shut–down, and electrical
surge protection at shut-down.
Start and stop operation
Item Condition Feature

Start-up Start switch (2) at START position. Battery power cut-off relay (6) ON.
Engine speed automatically set to the low idle
position regardless of the engine speed control
switch .
Shutdown Start switch (2) at OFF position. Battery power cut-off relay (6) and V-ECU (1) OFF
delayed approximate 2 seconds.
Engine speed automatically set to low idle position.
Figure 1
Components related to safety start and stop
1 V-ECU
2 Start switch
3 Stepping motor
6 Relay box (battery power cut-off relay)
7 Battery relay
Service Information

Self diagnosing 366 Service Information 2014/5/12
Profile:
Self diagnosing
 To analyze the data sent to the V-ECU, to determine if the variance indicate an abnormality, and then display the
appropriate fault code on the D-ECU to alert the operator of a possible malfunction.
CAUTION
When a fault code is displayed on the D-ECU, immediately stop running, check and repair the relevant mechanical parts and
electric / electronic parts. Only operate the machine that is in safe operating condition.
 The fault code continues to be displayed until the defect is repaired, the engine is restarted, and the self diagnosing
function again checks the ACS.
Fault codes of control system

Fault codes of control system
No. System check Fault cause Fault

code
1 V-ECU and communication ER 11
 Defects of V-ECU
 Communication wire short circuit or poor connections
between V-ECU and D-ECU
2 V-ECU power supply voltage ER 14

 Defects of input voltage (Excessively high or low voltage)
3 Stepping motor ER 20
 Defects of stepping motor
 Short circuit or poor connection of stepping motor
 Defect of stepping motor driving part of V-ECU
4 Engine speed sensor ER 21

 Defects of engine speed sensor
 Faulty of gap adjustment
 Input of abnormal speed
 Short circuit or poor connection of speed sensor
5 Power shift proportional solenoid ER 22

valve  Defects of proportional solenoid valve
 Short circuit or poor connection of proportional solenoid
valve
6 Engine coolant temperature sensor ER 25

 Defects of engine coolant temperature sensor
 Short circuit or poor connection of engine coolant
temperature
7 Throttle driving linkage ER 28
 Defects of throttle driving linkage
8 Travel pedal pressure switch ER 77

 Travel pedal pressure switch defects short circuit and poor
connection of pressure sensor
NOTE!
Before carrying out troubleshooting, check if all related connectors, battery voltage and alternator output are normal.
Service Information

Vehicle electronic control 366 Service Information 2014/5/12
unit (V-ECU), description
Profile:
Vehicle electronic control unit (V-ECU), description

The vehicle electronic control unit (V-ECU) receives information on the operating status from sensors installed in the
machine and then outputs signals to the appropriate actuators to control major component functions for optimum
performance.
Figure 1
V-ECU
V-ECU, connector pin specifications 1
Connector IN01 Connector IN03

No. Description No. Description
1 Sending (TX) 1 –
2 Receiving (RX) 2 –
3 Ground (AGND) 3 –
4 D-ECU power supply (+24 V) 4 Brake switch
5 Ground (AGND) 5 Travel mode selection switch
6 – 6 Automatic idling switch
7 Ground (DGND) 7 Boost/hammer selection switch
8 – 8 Start switch (ACC)
11 Battery ground (GND)
12 Battery power supply (+24 V)
V-ECU, connector pin specifications 2
Connector IN02 Connector IN04

1 Engine speed sensor output (SIG) 1 Stepping motor A
2 Engine speed sensor ground (GND) 2 Stepping motor A'
3 Coolant temperature sensor output (SIG) 3 Stepping motor B
4 Coolant temperature sensor power (VCC) 4 Stepping motor B'
5 Throttle position sensor power (VDD) 5 –
6 Throttle position sensor output (SIG) 6 –
7 Throttle position sensor ground (GND) 7 –
8 Travel pedal pressure sensor power (VDD) 8 –
9 Travel pedal pressure sensor output (SIG) 9 –
10 Travel pedal pressure sensor ground (GND) 10 –
11 Engine speed control switch power (24V) 11 –
12 Engine speed control switch output (SIG) 12 Power boost relay
13 Engine speed control switch ground (GND) 13 Boom/arm conflux cut-off relay
14 Power shift proportional solenoid valve output (SIG) 14 –
15 Power shift proportional solenoid valve ground (GND) 15 Battery power cut-off relay
16 – 16 –
17 – 17 Travel relay (24 V)
18 – 18 –
19 –
20 –
Service Information

Chassis connection 370 Service Information 2014/5/12
Profile:
Chassis connection
Chassis connection
Designation Function
31R1 Master switch
31R2 Start motor
MA04 Superstructure
MA32 Superstructure
31C1 Cab frame for beacon
31C2 Cab frame for horn switch in steering wheel
ENE01 Superstructure
ENE011 Engine body for engine oil pressure switch
ENE012 Engine body for thermo switch
ENE013 Engine body for air heater
Service Information

Connector, configuration 370 Service Information 2014/5/12
Profile:
Connector, configuration
Figure 1
Connectors, configuration 1
Figure 2
Figure 3
Figure 4
Service Information

Connectors, location 370 Service Information 2014/5/12
Profile:
Connectors, location
Instrument part connectors
Figure 1
Connectors location, instrument part
Connector Description Connector Description

RH01-Q10 Buzzer stop & confirm switch (option) IN28-M Left speaker
RH02-M Hammer/boost switch IN29-M Left speaker
RH02-L Hammer/boost switch IN33 Fuse box
RH03-N2 Start switch IN36-R3 Flasher unit
RH04-C4 Start switch IN37-H12 Wiper controller
RH05-H3 - IN38-J5 Quickfit relay #1
RH06-W4 Horn IN39-J5 Quickfit relay #2
IR01-W12 Connected to start switch, horn switch, IN41-W2 Diode (fuel heater)
boost/hammer switch wire harness
IR02-W8 Connected to buzzer stop switch wire IN43-J5 Emergency relay
harness
IS01-W15 Connected to right switch panel wire IN44-J5 Engine stop relay
harness
IS02-W15 Connected to right switch panel wire IN45-M6 Auto/manual switch
harness
IC01-W8 Connected to I-ECU wire harness IN60-J5 Safety operation relay
IC02-W16 Connected to I-ECU wire harness IM01-T24 Connected to IC03, IL01, IL02, IR01, V-ECU,
preheat controller, relay box, air conditioner
unit, IC02, fuse box wire harness
IC03-W15 Connected to I-ECU, extra work lamp, IM02-T24 Connected to IC02, V-ECU, IS02, IS01, IC03,
room lamp, beacon, antenna, wiper motor wiper controller, fuse box, auto/manual switch,
wire harness relay box wire harness
IN01-S8 V-ECU IM03-T24 Connected to fuse box, IS01, relay box, IC02, V-
ECU wire harness
IN02-S20 V-ECU IM04-T24 Connected to V-ECU, fuse box, IS01, IS02, IC01,
IL02, relay box, quickfit relay wire harness
IN03-S12 V-ECU IM05-T4 Connected to fuse box, work lamp relay, fuel
heater relay wire harness
IN04-S18 V-ECU IL01-W16 Connected to mute switch, head lamp switch,
travel mode switch, D-ECU wire harness
IN05-F4 Connected to Air conditioner unit IL02-W15 Connected to rotator switch, left switch panel
wire harness
IN06-W2 Diode (battery relay) LH01-H4 Safety limit switch
IN07-S14 Cassette & radio LH02-AA2 Seat heater (option)
IN08-M Right speaker LH03-AA2 Air suspension motor (option)
IN09-M Right speaker LH04-S8 D-ECU
IN10-J5 Battery power cut-off relay LH05-M Horn switch (left joystick)
IN11-J5 Horn relay LH05-L Horn switch (left joystick)
IN12-J5 Tail and control lamps relay LH06-W4 Rotator switch (left joystick, option)
IN13-J5 Head lamp relay LH07-Q8 Beacon switch (option)
IN14-J5 Work lamp relay LH08-Q8 overload warning switch (option)
IN15-J5 Turn signal lamp relay LH09-Q8 Room lamp switch
IN16-J5 Fuel heater relay (option) LH10-Q8 Fuel heater switch (option)
IN17-J5 Back-up alarm & lamp relay LH11-Q8 Seat heater switch (option)
IN18-J5 Cruise relay (option) LH13-Q8 Cassette mute switch (option)
IN19-J5 Boost relay LH15-H4 Head lamp switch
IN20-J5 Conflux cut-off relay LH16-H4 Travel mode selection switch
IN22-H6 DC-DC converter LH17-W2 Diode (parking solenoid valve)
IN23-A8 Preheat controller LH18-W2 Diode (parking solenoid valve)
IN25-H4 Checker (Excaliever)
IN26-H2 Buzzer
IN27-H2 Resister box
Cab and right switch panel parts connectors

Figure 2
Connectors location, cab and right switch panel part

CA01-S20 I-ECU SW04-Q10 Hammer/boost selection switch
CA02-A6 Wiper motor SW05-Q10 Auto idling switch
CA02-H2 Window limit switch SW06-Q10 Dozer/stabilizer selection switch
CA04-D Room lamp SW07-Q10 Axle locking switch
CA05-M Beacon lamp SW08-Q10 Quickfit switch 1 (option)
CA07-H Antenna SW09-Q10 Work lamp switch
CA08-M Extra work lamp, cab right (option) SW11-Q10 Quickfit switch 2 (option)
CA09-M Extra work lamp, cab right (option) SW12-L Cigarette lighter
CA10-M Extra work lamp, cab left (option) SW12-M Cigarette lighter
CA11-M Extra work lamp, cab left (option) IC01-W8 Connected to I-ECU wire harness
CA12-M Extra work lamp, cab rear (option) IC02-W16 Connected to I-ECU wire harness
CA13-M Extra work lamp, cab rear (option) IC03-W15 Connected to I-ECU, extra work lamp, room
lamp, beacon, antenna, wiper motor wire
harness
SW01-H3 Engine speed control switch IS01-W15 Connected to right switch panel wire harness
SW02-Q10 Hazard lamp switch IS02-W15 Connected to right switch panel wire harness
SW03-Q10 Extra lamp switch (option)
Main part connectors

Figure 3
Connectors location, main part

BM01-H2 Right boom lamp MA24-G2 Boost solenoid valve
BM02-H2 Left boom lamp MA25-G2 Conflux cut-off solenoid valve
EM01-W15 Connected to engine wire harness MA26-G2 Dozer/stabilizer solenoid valve
EM02-W15 Connected to engine wire harness MA27-G2 Safety solenoid valve
EM03-W16 Connected to engine wire harness MA28-G2 Axle locking solenoid valve
EM04-W4 Connected to engine wire harness MA29-M Air cleaner restriction switch
FT01-H3 Fuel sender MA30-M Air cleaner restriction switch
FT02-L Horn compressor MA31-G2 Brake fail pressure switch
FT03-L Horn compressor MA32 Body ground
FT04-P2 Fuel filler pump MA33-H2 Receiver dryer
IM01-T24 Connected to instrument wire harness MA38-W2 Diode (air heater)
IM02-T24 Connected to instrument wire harness MA39-H2 Air heater relay
IM03-T24 Connected to instrument wire harness MA40 Air heater relay
IM04-T24 Connected to instrument wire harness MA41 Air heater relay
IM05-T4 Connected to instrument wire harness MA42 Safety relay
MA01A-H2 Front combination lamp, right MA43 Safety relay
MA01B-H2 Front combination lamp, right MA44-H2 Safety relay
MA02-R3 Head lamp, right MA45 Battery relay
MA03 Slow blow fuse MA46 Battery relay
MA04 Body ground MA48 Battery relay
MA05-H2 Fuse holder MA49 Battery relay
MA06A-H2 Front combination lamp, left MA50-W2 Diode (battery relay)
MA06B-H2 Front combination lamp, left MA48 Battery relay
MA07-R3 Front combination lamp, left MA49 Battery relay
MA08-W2 Diode (reverse solenoid valve) MA50-W2 Diode (battery relay)
MA09-W2 Diode (forward solenoid valve) MA52-H2 Rear combination lamp, left
MA10-G2 Forward solenoid valve MA53 Rear combination lamp, left
MA11-G2 Reverse solenoid valve MA54 Rear combination lamp, left
MA12-W2 Diode (reverse solenoid valve) MA55 Overload pressure switch
MA13-G2 Stop pressure switch MA56 Lateral lamp
MA14-G2 Stop pressure switch MA57-G2 Transmission pressure switch
MA15-G2 Travel pedal pressure sensor MA58-G2 Rotator solenoid valve (option)
MA16-G2 Auto cruise solenoid valve MA60-G2 Rotator solenoid valve (option)
MA17-H2 Diode (forward solenoid valve) MB01-F2 Connected to boom lamps
MA18 Starter motor MC01-H12 Combination switch
MA19-G2 Digging unit pressure switch MF01-H6 Connected to Fuel sender, horn
compressor, fuel filler pump wire harness
MA20-W2 Diode (washer pump) MS01-H Horn (steering wheel)
MA21-G2 Washer pump MT01-H2 Travel control lever
MA23-G2 Hammer solenoid valve
Engine part connectors
Figure 4
Connectors location, engine part

ENE01 Engine body ground EN43-H2 Rear combination lamp, right
EN01 Alternator EN44-H3 Rear combination lamp, right
EN02 Alternator EN45-H2 Rear combination lamp, right
EN03 Alternator EN46-G2 Gear change solenoid valve
EN04 Alternator EN47-G2 Parking solenoid valve
EN05-P Thermo switch EN48-W2 Diode (engine stop motor)
EN24-H2 Power shift proportional solenoid valve EN49-G2 Extra work lamp, counterweight (option)
EN25-H4 Water temperature sensor EN50-G2 Beacon lamp (option)
EN26-02 Coolant temperature switch EN51-G2 Engine room lamp
EN27-P2 Engine speed sensor EN52-G2 Emergency pressure switch
EN28-F2 Fuel heater (option) EN53-Z2 Quickfit solenoid valve (option)
EN29-H4 Stepping motor EN54 Starter motor
EN30-H3 Stepping motor EN55-AF2 License lamp
EN31 Air heater EN56-AF2 License lamp
EN32-H6 Engine stop motor EM01-W15 Connected to main wire harness
EN33 Engine oil pressure switch EM02-W15 Connected to main wire harness
EN36-H2 Air compressor EM03-W16 Connected to main wire harness
EN39-W2 Diode (compressor) EM04-W2 Connected to main wire harness
EN40-H2 Back-up lamp
Air conditioner part connectors
Figure 5
Connectors location, air conditioner part

AC01-S Controller & switch panel AC10-H Cooling fan
AC02-E Controller & switch panel AC11-H Relay 1
AC03-S Controller & switch panel AC12-H Temperature sensor
AC04-H Connected to air conditioner wire harness AC13-H Inlet actuator
AC05-H Connected to air conditioner wire harness AC14-H Valve actuator
AC06-H Connected to air conditioner wire harness AC15-H Relay 2
AC07-H Connected to air conditioner wire harness AC16-H Relay 3
AC08-H Vent actuator AC17-H Relay 4
AC09-H Mode actuator AC18-H Relay 5
Service Information

Electrical components 370 Service Information 2014/5/12
Profile:
Electrical components
Motors
Designation Wiring diagram Circuit No. Function
MO201 3 2,010 Engine start
MO202 4 2,040 Engine stop motor)
MO203 4 2,060 Fuel filler pump (35 L, option))
MO204 6 2,170 Stepping motor (with position sensor)
MO801 14 8,020 Washer motor
MO802 14 8,030 Wiper motor
MO804 16 8,090 Air conditioner compressor (option)
MO805 16 8,090 Air conditioner motor 1 (option)
Solenoid valves
Designation Wiring diagram Circuit No. Type Function
MA401 11 4,010 Hydraulic valve Auto cruise
MA402 11 4,040 Hydraulic valve Forward travel
MA403 11 4,050 Hydraulic valve Reverse travel
MA404 11 4,060 Hydraulic valve Gear shifting
MA405 11 4,090 Hydraulic valve Axle locking
MA501 12 5,050 Hydraulic valve Parking brake
MA901 17 9,020 Proportional valve Pump power shift
MA902 17 9,030 Hydraulic valve Boom/arm conflux cut-off
MA903 17 9,040 Hydraulic valve Power boost
MA904 17 9,060 Hydraulic valve Hammer
MA905 18 9,070 Hydraulic valve Hydraulic safety
MA906 18 9,080 Hydraulic valve Dozer/stabilizer
MA907 18 9,090 Hydraulic valve Rotator, left (option)
MA908 18 9,100 Hydraulic valve Rotator, right (option)
MA909 18 9,120 Hydraulic valve Quickfit (option)
Sensor
Designation Wiring diagram Circuit No. Type of sensor Function
SE201 3 2,020 Temperature Ambient temperature
SE202 5 2,070 Temperature Engine coolant temperature
SE203 5 2,080 Level Fuel level
SE205 5 2,100 pressure Engine oil pressure
SE206 5 2,110 Pressure Air cleaner
SE207 6 2,140 Pressure DIgging unit port pressure
SE209 6 2,160 Frequency Engine speed
SE401 11 4,040 Pressure Travel pedal control pressure
SE402 11 4,040 Pressure Transmission oil pressure
SE501 12 5,010 Pressure Service brake
SE502 12 5,020 Pressure Service brake
SE503 12 5,030 Pressure Brake oil fail
SE601 13 6,010 Pressure Steering oil
SE801 14 8,060 Mechanical Window front
SE802 16 8,090 Temperature Air conditioner temperature (option)
SE901 18 9,070 Mechanical Safety bar
SE902 18 9,190 ∼ 9,120 Pressure Safety operation
SE903 18 9,130 Pressure Boom raise pressure
Lamps
LA301 8 3,190 Left tail lamp (front)
LA302 8 3,200 Left tail lamp (rear)
LA303 8 3,210 Right tail lamp (front)
LA304 8 3,220 Right tail lamp (rear)
LA305 8 3,230 Lateral lamp (option)
LA306 8 3,240 Left turn signal lamp (front)
LA307 8 3,250 Left turn signal lamp (rear)
LA308 8 3,270 Right turn signal lamp (front)
LA309 8 3,280 Right turn signal lamp (rear)
LA310 9 3,310 Left head lamp (high beam)
LA311 9 3,320 Right head lamp (high beam)
LA312 9 3,340 Left head lamp (high beam)
LA313 9 3,350 Right head lamp (high beam)
LA314 9 3,360 Left back-up lamp
LA315 9 3,370 Right back-up lamp
LA316 9 3,380 Work lamp (boom)
LA317 9 3,390 Work lamp (boom)
LA318 10 3,400 Room lamp
LA319 10 3,410 Beacon lamp (cab, option)
LA320 10 3,420 Beacon lamp (counterweight, option)
LA321 10 3,430 Engine room lamp
LA322 10 3,440 Extra work lamp (cab-front, option)
LA323 10 3,450 Extra work lamp (cab-front, option)
LA318 10 3,460 Extra work lamp (cab-rear, option)
LA324 10 3,470 Extra work lamp (counterweight, option)
Control lamps
LC01 1 1,100 Central warning indicator
LC02 1 1,100 Central warning indicator
LC03 1 1,100 Battery charge indicator
LC04 5 2,100 Engine oil pressure indicator
LC05 5 2,090 Coolant temperature indicator
LC06 5 2,110 Air cleaner indicator
LC07 12 5,030 Brake fail warning lamp
LC08 18 9,130 Overload warning lamp
LC09 3 2,020 Air heater indicator
LC10 4 2,050 Fuel heater switch (option)
LC11 18 9,120 Quickfit indicator (option)
LC12 12 5,040 Parking mode indicator
LC13 13 6,010 Emergency steering readiness indicator
LC14 13 6,020 Emergency steering operating indicator
LC15 9 3,330 High beam indicator
LC16 8 3,260 Left turn signal
LC17 8 3,290 Right turn signal
LC18 17 9,050 Power boost indicator
LC19 11 4,070 Axle locking indicator
LC20 7 3,010 I-ECU illumination
LC21 7 3,020 I-ECU illumination
LC22 7 3,120 D-ECU illumination
LC23 8 3,300 Hazard lamp switch
LC24 7 3,030 Extra work lamp switch (option)
LC25 7 3,040 Boost/hammer selection switch
LC26 7 3,050 Auto idling switch
LC27 7 3,060 Dozer/stabilizer selection switch
LC28 7 3,070 Axle locking switch
LC29 7 3,080 Quickfit switch 1 (option)
LC30 7 3,090 Quickfit switch 2 (option)
LC31 7 3,100 Work lamp switch
LC32 7 3,110 Buzzer stop & confirm switch (option)
LC33 7 9,130 Room lamp switch
LC34 7 1,140 Overload switch (option)
LC35 7 1,150 Beacon switch (option)
LC36 7 3,160 Fuel heater switch (option)
LC37 7 3,170 Seat heater switch (option)
LC38 7 3,180 Mute switch (option)
LC39 16 8,090 Air conditioner switch illumination
Switches
SW101 2 1,100 Start switch
SW102 2 1,100 Master switch
SW201 4 2,050 Fuel heater switch (option)
SW202 4 2,060 Fuel filler switch (option)
SW203 6 2,120 Engine speed control switch
SW204 6 2,130 Auto idling switch
SW301 7, 8 3,010 ∼ 3,230 Head lamp switch
SW302 8 3,240 ∼ 3,290 Turn signal switch (combination switch)
SW303 8 3,240 ∼ 3,290 Hazard lamp switch
SW304 9 3,310 ∼ 3,360 High beam switch (combination switch)
SW305 9 3,380 ∼ 3,390 Work lamp switch
SW306 10 3,400 Room lamp switch
SW307 10 3,410 ∼ 3,420 Extra work lamp switch (option)
SW308 10 3,440 ∼ 3,470 Beacon switch (option)
SW401 11 4,020 Travel mode selection switch
SW402 11 4,040 Auto cruise switch (travel control lever, option)
SW403 11 4,050 ∼ 4,060 Forward/reverse switch (travel control lever)
SW404 11 4,070 Gear shift switch (travel control lever)
SW405 11 4,080 ∼ 4,060 Axle locking switch
SW801 14 8,010 Cassette mute switch (option)
SW802 14 8,020 Washer
SW803 14 8,030 Wiper
SW804 15 8,040 Horn switch (left joystick)
SW805 15 8,040 Horn switch (right joystick, option)
SW806 15 8,040 Horn switch (steering wheel)
SW807 15 8,040 Horn switch (combination switch)
SW808 15 8,060 Buzzer stop & confirm switch (option)
SW809 15 8,070 Seat heater switch (option)
SW901 17 9,010 Auto/manual switch
SW902 17 9,040 ∼ 9,050 Boost/hammer switch (right control lever)
SW903 17 9,060 Boost/hammer selection switch
SW904 18 9,080 Dozer/stabilizer selection switch
SW905 18 9,090 Joystick switch, rotator left (option)
SW906 18 9,100 Joystick switch, rotator right (option)
SW907 18 9,110 ∼ 9,120 Quickfit switch 1 (option)
SW908 18 9,110 ∼ 9,120 Quickfit switch 2 (option)
SW909 18 9,130 Overload switch (option)
Relays
RE01 2 1,100 Battery relay
RE02 3 2,010 Safety relay
RE03 4 2,040 Engine stop motor
RE04 4 2,050 Fuel heater (option)
RE05 3 2,020 Air heater
RE06 3 2,030 Battery relay cut-off
RE07 7 3,010 ∼ 3,240 Brake & tail lamps, control lamps
RE08 9 3,310 ∼ 3,350 Head lamps
RE09 8 3,240 ∼ 3,290 Turn signal, & hazard lamps
RE10 9 3,600 ∼ 3,370 Back-up lamp, alarm
8,050
RE11 9 3,380 ∼ 3,390 Work lamps
RE12 11 4,010 Auto cruise solenoid valve
RE13 13 6,010 ∼ 6, 020 Emergency steering
RE14 15 8,040 Horn
RE15 16 8,090 Air conditioner relay 1 (option)
RE20 17 9,030 Conflux cut-off solenoid valve
RE21 17 9,040 Power boost solenoid valve
RE22 18 9,090 ∼ 6, 020 Safety operation (quickfit & rotator)
RE23 18 9,120 Quickfit solenoid valve
RE24 18 9,120 Quickfit solenoid valve
Fuses
Designation Feed AMP Wiring Circuit No. Circuits
diagram
FU1 50 15 10 3,350 ∼ 3,360 Feed room lamp, beacon lamp
FU2 30 10 4 3,010 ∼ 3,170 Feed brake & tail lamps, control lamps
FU3 50 15 9 3,030 ∼ 3,040 Feed head lamp (passing)
FU4 50 30 10 3,370 ∼ 3,400 Feed extra work lamps
FU5 30 10 142 8,0160 DC-DC converter
FU6 30 10 8 8,040 Feed hazard lamps
FU7 50 10 15 8,070 Seat heater
FU8 FU30 10 2, 13, 14, 15 1,200 / 8,010 Feed I-ECU, emergency steering
6,010 ∼ 6,020
8,040
FU9 50 10 10 3,210 / 3,220 –
FU10 50 30 4 2,050 Feed fuel heater
FU11 30 10 4 2,040 Engine stop motor
FU12 50 20 9 3,250 ∼ 3,290 Feed head lamp & high beam
FU13 50 20 9 3,330 ∼ 3,340 Feed work lamp
FU14 50 15 14 8,020 ∼ 8,030 Wiper & washer
FU15 50 10 5 8,040 feed horn
FU16 50 20 16 8,090 Air conditioner
FU17 50 10 15 8,080 Cigarette lighter
FU18 50 10 8 3,180 ∼ 3,230 Feed turn signal lamps
FU19 50 10 17, 18 9,060 Solenoid (hammer, rotator, quickfit)
9,090 ∼ 9,110
FU20 50 10 15 8,050 Back-up lamps & alarm
FU21 50 10 9, 11 3,300 ∼ 3,320 Solenoids (forward/reverse travel, gear shifting,
4,040 ∼ 4,080 axle locking)
FU22 50 10 12 5,010 ∼ 5,020 Stop lamps
FU23 50 10 12, 18 5,050 Solenoids (safety, parking, dozer/stabilizer)
9,070 ∼ 9,080
FU24 50 10 11, 17 4,010 Solenoids (auto cruise, power boost, conflux
9,030 ∼ 9,040 cut-off)
FU25 50 10 6, 17 2,060 / 9,020 V-ECU
FU26 50 10 11 8,020 Brake & tail lamp (left)
FU27 50 10 16 9,120 Brake & tail lamp (right)
FU28 50 15 16 9,130 ∼ 9,140 Head lamp (high beam)
FU29 50 15 16 9,130 ∼ 9,140 Head lamp (low beam)
FU30 50 15 1, 3, 4 1,100 Start switch
2,010 ∼ 2,040
FU50 Battery 40 1 1,100 Slow blow fuse
FU51 Battery 40 1 1,100 Slow blow fuse
FU52 RE01 80 1 1,100 Slow blow fuse
FU53 FU52 80 1 1,100 Slow blow fuse
Service Information

Explanations to wiring 370 Service Information 2014/5/12
diagrams
Profile:
Explanations to wiring diagrams
Figure 1
Wiring diagram (principle diagram)
Example of lead and component marking
1 50 Box with feed designation Positive feed (30,15, 15E, etc.)

2 SW301 SW = switch 3 = Function group 01 = Running
number
3 SCH08 Diagram number
4 3.010 3 = Function group 010 = Running number
5 102 Running number
6 201 Running number
7 IM04-W IM04 = connector number W = connector type
8 1 connector pin number
9 SCH12 Diagram number near arrow-shaped box is a
reference to another diagram
10 115 Reference number in arrow-shaped box which
can be found in arrow-shaped box in the
diagram which is being referred to
11 48 Box with designation for chassis connection Chassis connection (48 etc.)
Component marking
Components on the wiring diagrams are marked according to the division into function groups.
Component marking:
Component marked for example SW301, SW is a switch, 3 indicates function group, 01 is a running number.
NOTE!
Relays and fuses are not marked according the division into function groups.
Function group
1 feeds / chassis connections
2 Engine
3 Electrical system, lighting, etc.
4 Power transmission
5 Brakes
6 Steering
7 Miscellaneous
8 Cab
9 Hydraulics
Positive feed
Designation in the boxes (30, 50, etc.)
The direction of the current goes from a large box drawn with a thick line to a small box with a thin line.
Boxes with the same designation are connected to each other on the fuse box.
Chassis connection
Designation in the boxes (31, 48, etc.)
The direction of the current goes from a small box drawn with a thin line to a small box with a thick line.
Boxes with the same designation are connected to each other on the fuse box.
Colour marking of leads

Y =Yellow BN/W = Brown/White
GN = Green BL/W = Blue/White
BL = Blue VO = Violet
GR = Grey GN/W = Green/White
W = White BL/Y = Blue/Yellow
BN = Brown BL/R = Blue/Red
OR = Orange P = Pink
Y/W = Yellow/White SB = Black
GN/R = Green/Red
NOTE!
Further combinations of colour markings on leads may occur.
Color marking of leads, positive chassis connection
Feed = Red
Chassis connection = Black
Service Information

List of circuits 370 Service Information 2014/5/12
Profile:
List of circuits
List of circuits
Circuit No. Wiring Function
diagram
1,100 1 Positive feeds / chassis connections
1,200 2 Positive feeds / chassis connection, V-ECU / I-ECU
2,010 3 Start motor with starter inhibitor
2,020 3 Preheating element
2,030 3 key-turn OFF, battery relay hold
2,040 4 Engine shut down / key-turn engine stop
2,050 4 Fuel heater (option)
2,060 4 Fuel filler pump (option)
2,070 5 Engine coolant temperature gauge
2,080 5 Fuel level gauge
2,090 5 Engine coolant temperature warning lamp
2,100 5 Engine oil pressure indicator
2,110 5 Air cleaner restriction indicator
2,120 6 Engine speed control switch
2,130 6 Auto idling switch
2,140 6 Digging unit port pressure
2,150 6 Engine coolant temperature
2,160 6 Engine speed
2,170 6 Stepping motor
3,010 7 Illumination, I-ECU
3,020 7 Illumination, I-ECU
3,030 7 Control lamp, extra lamp switch (option)
3,040 7 Control lamp, boost/hammer selection switch
3,050 7 Control lamp, auto idling switch
3,060 7 Control lamp, dozer/stabilizer selection switch
3,070 7 Control lamp, axle locking switch
3,080 7 Control lamp, quickfit switch 1 (option)
3,090 7 Control lamp, quickfit switch 2 (option)
3,100 7 Control lamp, work lamp switch
3,110 7 Control lamp, buzzer stop & confirm switch (option)
3,120 7 Illumination, D-ECU
3,130 7 Control lamp, room lamp switch
3,140 7 Control lamp, overload switch (option)
3,150 7 Control lamp, beacon switch (option)
3,160 7 Control lamp, seat heater switch (option)
3,170 7 Control lamp, fuel heater switch (option)
3,180 8 Control lamp, mute switch (option)
3,190 8 Left tail lamp, front
3,200 8 Left tail lamp, rear
3,210 8 Right tail lamp, front
3,220 8 Right tail lamp, rear
3,230 8 Lateral lamp (option)
3,240 8 Left turn signal lamp, front
3,250 8 Left turn signal lamp, rear
3,260 8 Left turn signal indicator
3,270 8 Right turn signal lamp, front
3,280 8 Right turn signal lamp, rear
3,290 8 Right turn signal indicator
3,300 8 control lamp, hazard lamp switch
3,310 9 Left head lamp, low beam
3,320 9 Right head lamp, low beam
3,330 9 High beam indicator
3,340 9 Left head lamp, high beam
3,350 9 Right head lamp, high beam
3,360 9 Left back-up lamp
3,370 9 Right back-up lamp
3,380 9 Work lamp, boom
3,390 9 Work lamp, boom
3,400 10 Room lamp
3,410 10 Beacon lamp, cab (option)
3,420 10 Beacon lamp, counterweight (option)
3,430 10 Engine room lamp
3,440 10 Extra work lamp, cab-front (option)
3,450 10 Extra work lamp, cab-front (option)
3,460 10 Extra work lamp, cab-rear (option)
3,470 10 Extra work lamp, counterweight (option)
4,010 11 Auto cruise solenoid valve (option)
4,020 11 Travel mode switch
4,030 11 Travel pedal pressure switch
4,040 11 Auto cruise switch (option)
4,050 11 Forward travel solenoid valve
4,060 11 Reverse travel solenoid valve
4,070 11 Gear shift solenoid valve
4,080 11 Anti-oscillation indicator
4,090 11 Axle locking solenoid valve
5,010 12 Stop lamp
5,020 12 Stop lamp
5,030 12 Brake oil fail indicator
5,040 12 Parking mode indicator
5,050 12 Parking solenoid valve
6,010 13 Emergency steering readiness indicator
6,020 13 Emergency steering operating indicator
6,030 13 Steering pressure switch
8,010 14 Radio & cassette
8,020 14 Wiper
8,030 14 Washer
8,040 15 Horn
8,050 15 Back-up alarm
8,060 15 Buzzer
8,070 15 Seat heater (option)
8,080 15 Cigar lighter
8,090 16 Air conditioner (option)
9,010 17 Auto/manual selection
9,020 17 Pump power shift control
9,030 17 Boom/arm conflux cut-off
9,040 17 Power boost
9,050 17 Boost indicator
9,060 17 Hammer operation (option)
9,070 18 Hydraulic safe lock
9,080 18 Dozer/stabilizer selection
9,090 18 Rotator, left rotation (option)
9,100 18 Rotator, right rotation (option)
9,110 18 Quickfit operation (option)
9,120 18 Quickfit indicator (option)
9,130 18 Overload indicator (option)
19 Communication
Service Information

Positive feed 370 Service Information 2014/5/12
Profile:
Positive feed
Feed
Designation Function
50 50-Feed directly from battery
30 30-Feed for room lamp, radio & cassette, beacon, hazard lamp, engine stop motor, directly from
battery
45 45-Feed for fuel filler pump, directly from battery
27 Feed via RE01
700 700 feed for controller (V-ECU)
5A 5A feed for I-ECU, emergency steering signal
Service Information

Wiring diagram 1, main 370 Service Information 2014/5/12
diagram, positive feed /
chassis connection
Profile:
Wiring diagram 1, main diagram, positive feed / chassis connection
Figure 1
Wiring diagram 1, main diagram, positive feeds / chassis connections
Service Information

Wiring diagram 2, positive 370 Service Information 2014/5/12
feed / chassis connection,
control units
Profile:
Wiring diagram 2, positive feed / chassis connection, control units
Figure 1
Wiring diagram 2, positive feeds / chassis connections, control units
Service Information

Wiring diagram 3, function 370 Service Information 2014/5/12
group 2, engine
Profile:
Wiring diagram 3, function group 2, engine
Figure 1
Service Information

group 2, engine
Profile:
Figure 1
Service Information

group 2, engine
Profile:
Figure 1
Service Information

group 2, engine
Profile:
Figure 1
Service Information

group 3, electrical, lighting
etc.
Profile:
Wiring diagram 7, function group 3, electrical, lighting etc.
Figure 1
Wiring diagram 7, function group 3, electrical system, lighting etc.
Service Information

etc.
Profile:
Figure 1
Service Information

etc.
Profile:
Figure 1
Service Information

Wiring diagram 10, 370 Service Information 2014/5/12
function group 3, electrical,
lighting etc.
Profile:
Figure 1
Service Information

function group 4,
transmission
Profile:
Wiring diagram 11, function group 4, transmission
Figure 1
Wiring diagram 11, function group 4, transmission
Service Information

function group 5, brakes
Profile:
Wiring diagram 12, function group 5, brakes
Figure 1
Wiring diagram 12, function group 5, brakes
Service Information

function group 6, steering
Profile:
Wiring diagram 13, function group 6, steering
Figure 1
Wiring diagram 13, function group 6, steering
Service Information

function group 8, cab
Profile:
Wiring diagram 14, function group 8, cab
Figure 1
Service Information

Profile:
Figure 1
Service Information

Profile:
Figure 1
Service Information

function group 9,
hydraulics
Profile:
Wiring diagram 17, function group 9, hydraulics
Figure 1
Service Information

function group 9,
hydraulics
Profile:
Figure 1
Service Information

communication
Profile:
Wiring diagram 19, communication
Figure 1
Wiring diagram 19, communication, control units
Service Information

Fuse box, description 3721 Service Information 2014/5/12
Profile:
Fuse box, description

 To conveniently locate and identify the fuse capacity of protecting individual circuit from overload.
CAUTION
Always install a fuse of the same type with the correct amperage rating to prevent electrical system damage from overload.
Figure 1
Fuse box
Fuse box, continuity test

Fuse failure is often caused by a fine crack in the fuse, and this kind of crack is very hard to detect by visual inspection.
Checking fuse continuity with a tester is far superior to eye inspection.
Service Information

Fuse, specifications 3721 Service Information 2014/5/12
Profile:
Fuse, specifications
Fuse (blade-type) color codes
Amperage rating Color Amperage rating Color

1A Black 10 A Red
3A Violet 15 A Light blue
4A Pink 20 A Yellow
5A Tan 25 A Natural (White)
7.5 A Brown 30 A Light green
Specifications
No. Specification Load name No. Specification Load name

FU1 15 A Room lamp, beacon lamp FU16 20 A Air conditioner
FU2 10 A Brake & tail lamp FU17 10 A Cigar lighter
FU3 15 A High beam (passing) FU18 10 A Turn signal lamp
FU4 30 A Extra work lamp FU19 10 A Solenoid valve (hammer)
FU5 5A DC-DC converter F20 10 A Back up lamp and alarm
FU6 10 A Hazard lamp FU21 10 A Solenoid valves (low travel, axle
locking)
FU7 10 A Seat heater, emergency FU22 10 A Stop lamp
steering
FU8 10 A I-ECU FU23 10 A Solenoid valves (safety, parking)
FU9 10 A Spare FU24 10 A Solenoid valves (cruise, boost,
conflux cut-off)
FU10 30 A Fuel heater FU25 10 A Controller (V-ECU)
FU11 30 A Engine stop motor FU26 10 A Brake & tail lamp (left)
FU12 20 A Head lamp, high beam FU27 10 A Brake & tail lamp (right)
FU13 20 A Work lamp FU28 15 A Head lamp (high beam)
FU14 15 A Wiper and washer FU29 15 A Head lamp (low beam)
FU15 10 A Air horn FU30 15 A Start switch
Service Information

Slow blow fuse, description 3721 Service Information 2014/5/12
Profile:
Slow blow fuse, description

 When large-capacity current flows, the slow blow fuse protects components within short a time, and when small
capacity flows, it is fused slowly enough to solve the inconvenience of frequent fuse replacement.
Figure 1
Fuse unit
Fuse exchange procedure
 Release screw (9) fixing the fuse housing to the bracket (8).
 Open cover (2) by pushing cover (2) and lock (3) upward.
 Open side cover (6, 7) using a screwdriver.
CAUTION
Check the opening end.
 Remove fuse (1) by removing screw (4) from connector (5).

 Install new fuse.
 Assemble in the reverse order.
Figure 2
Slow flow fuse assembly
Service Information

Slow blow fuse, 3721 Service Information 2014/5/12
specifications
Profile:
Slow blow fuse, specifications

Specifications
Item Specifications
Rated voltage DC 32 V or less
Fusing ability Continuous Melting time
100 % More than 4 hours
200 % 5 ~ 100 seconds
300 % 0.5 ~ 15 seconds
500 % Within 1 seconds
Housing color codes
Amperage rating Color

20 A Light blue
30 A Pink
40 A Green
50 A Red
60 A Yellow
70 A Brown
80 A Black
100 A Blue
120 A Chestnut colored
Service Information

Relay box, description 3723 Service Information 2014/5/12
Profile:
Relay box, description
Figure 1
Relay box
Relay codes of relay boxes
Relay No. Components Type Wiring diagram

R1 Back-up horn and alarm Normally opened (NO) RE10
R2 Safety operation (quickfit, rotator) Normally opened (NO) RE22
R3 Battery relay shut-off Normally opened (NO) RE06
R4 Turn signal lamp Normally opened (NO) RE09
R5 Work lamp Normally opened (NO) RE11
R6 Head lamp Normally opened (NO) RE08
R7 Tail lamp, switch panel and I-ECU control Normally opened (NO) RE07
lamp
R8 Horn Normally opened (NO) RE14
R9 Quickfit solenoid valve Normally opened (NO) RE24
R10 Quickfit solenoid valve Normally opened (NO) RE23
R11 Engine stop motor Normally opened (NO) RE03
R12 Emergency steering Normally opened (NO) RE13
R13 Fuel heater Normally opened (NO) RE04
R14 Conflux cut-off solenoid valve Normally opened (NO) RE20
R15 Power boost solenoid valve Normally opened (NO) RE21
R16 Auto cruise solenoid valve Normally opened (NO) RE12
Service Information

Relay box, specifications 3723 Service Information 2014/5/12
Profile:
Relay box, specifications

Specifications
Item Specifications
Ambient temperature –30 ~ 90 °C
Maximum operating voltage 20 V (at 20 °C)
Coil resistance 315 Ω ± 10 %
Service Information

Resistor box, description 3723 Service Information 2014/5/12
Profile:
Resistor box, description

 The resistance of resistor box make the current correspond to the 85% of the rated engine output power for the
proportional solenoid valve when the V-ECU is in MANUAL status.
Figure 1
Resistor box
Service Information

Resistor box, specifications 3723 Service Information 2014/5/12
Profile:
Resistor box, specifications

Specifications
Item Specifications
Rated wattage 50 W
Rated resistance (at 25°C) 74 ± 2 Ω
Temperature -30 ~ 120 °C (-22 ~ 248 °F)
Insulation resistance 20 MΩ and more (500 V megger meter)
Wire specifications
NO. Wire specifications Signal

1 AVX 1.25 R Auto/manual switch
2 AVX 1.25 SB Ground
Service Information

Coolant temperature 3861 Service Information 2014/5/12
sensor, description
Profile:
Coolant temperature sensor, description

 The sensor is a dual sensor to simultaneously provide information necessary to the coolant temperature gauge on
the I-ECU and the automatic engine warm–up function of the V-ECU.
 The temperature sensor senses temperature by the resistance variation according to temperature changes with the
thermistor.
Figure 1
Coolant temperature sensor
Figure 2
Coolant temperature sensor circuits
Service Information

sensor, specifications
Profile:
Coolant temperature sensor, specifications

Wire specifications
No. Description Wire specifications

1 Thermistor A (+) AVX 1.25 Y/R
2 Thermistor A (GND) AVX 1.25 SB
3 Thermistor B (VCC) AVX 1.25 W/R
4 Thermistor B (VOUT) AVX 1.25 W
Thermistor A, specifications
Temperature Resistance (W) Current (mA)

(50 °C) 153.9 + 23/-20 33.5 ± 3.8
80 °C 51.9 + 4.9/-4.4 65.5 + 2.8/-2.9
100 °C 27.4 + 1.9/-1.2 85 + 1.2/-2.0
(120 °C) (16.1 ± 1.2) (98.5 ± 1.6)
( ): Specifications are reference only.
Thermistor B, specifications
Temperature Resistance (kW) Current (V out)

-10 20.5 0.38
0 13.3 0.56
10 8.84 0.80
20 6 1.09
30 4.2 1.43
50 2.14 2.20
80 0.83 3.35
100 0.53 3.80
Inspection method
Detach the temperature sensor, and then measure the resistance and temperature to compare the values.
Figure 1
Inspection method, thermistor A
Figure 2
Inspection method, thermistor B
Service Information

switch, description
Profile:
Coolant temperature switch, description

 The switch activates the output signal “ON” and “OFF” according to the temperature of coolant.
 If the measured temperature is higher than the setting temperature, the switch outputs the signal activating the
coolant temperature indicator and warning buzzer on the I-ECU and the sound alarm device (option).
Figure 1
Coolant temperature switch
1. AVX 0.5 SB
2. AVX 0.5 GN
3. PT3/8
Service Information

Profile:
Coolant temperature switch, specifications

Specifications
Item Specifications
Operating temperature ON : 105 ± 3 °C, OFF : 98 °C or less
Current capacity 0.5 A (at 24 V), 1 A (at 12 V)

Insulation resistance 10 MΩ and more (500 V megger meter)
Temperature 40 ~ 120 °C
Mounting torque 200 ~ 250 kgf·cm (14.5 ~ 18.0 lbf·ft)
Inspection method
Figure 1
Pin connection
 Put the switch measuring tip into coolant, raise the temperature, measure the continuity by tester and the
temperature, and compare with the specification.
 In the same method, cool the coolant, measure the disconnection and the temperature, and compare with the
specification.
Service Information

Fuel level sensor, 3862 Service Information 2014/5/12
description
Profile:
Fuel level sensor, description

 This unit sends and indicates the resistance according to the level of fuel in the fuel tank to the fuel gauge in the
monitor module.
CAUTION
If the post of the sender is bent at assembling, an accurate fuel amount can not be indicated by the float movement.
Figure 1
Fuel level sensor
Service Information

Fuel level sensor, 3862 Service Information 2014/5/12
specifications
Profile:
Fuel level sensor, specifications
Figure 1
Fuel level sensor, level position
Specifications
Item Specifications
Resistance (Ω) E 1/2 F
110 ± 7 (32.5) 3±2
Distance of float (mm) C B A
680 ± 5 383.5 ± 5 87 ± 5
Wire specifications

1 AVS 0.85 BL/GN Low level switch
2 AVS 0.85 Y/BL Sender
3 AVS 0.85 SB Ground (GND)
Inspection method
Detach the fuel sender, and then measure the resistance at the position of float in the full/empty condition.
Figure 2
Pin connection
Service Information

Safety limit switch, 3863 Service Information 2014/5/12
description
Profile:
Safety limit switch, description

 If the left control console is lifted up (locked position) the safety limit switch arm moves to the normally opened
position and deactivates the solenoid valve cutting off the servo hydraulic pressure flowing to the remote control
valves (joysticks, pedals) and hydraulic cylinders and motors become inoperable.
WARNING
The correct adjustment of the limit switch position is critical to safe machine operation. Failure to ensure correct
operation can result in unexpected control lever function causing injury or death!
Figure 1
Safety limit switch
1. Apply loctite
Service Information

Safety limit switch, 3863 Service Information 2014/5/12
specifications
Profile:
Safety limit switch, specifications

Specifications
Item Specifications
Minimum connection angle 0° ~ 25° (Normally closed, NC)
26° ~ 70° (Normally opened, NO)
Inspection method
 Continuity test between terminals (A–B, C–D) at normally opened and normally closed position by tester.
Service Information

Air cleaner restriction 3864 Service Information 2014/5/12
switch, description
Profile:
Air cleaner restriction switch, description

 The switch installed between the air cleaner and engine air inlet port, lights the air cleaner restriction indicator when
the air cleaner is clogged and the air inlet manifold vacuum reaches specified pressure and closes the switch.
 After cleaning or replacing the air cleaner, the switch returns automatically to the original condition.
Figure 1
Air cleaner restriction switch
1. 0.85 R
2. 0.85 SB
Service Information

Air cleaner restriction 3864 Service Information 2014/5/12
Profile:
Air cleaner restriction switch, specifications

Specifications
Item Specifications
Supply voltage 12 ~ 24 V
Switch type Normally opened (NO) type
Operating pressure 508±45 mm H2O
Operating temperature – 20 ~ 80 °C (– 20 ~ 176 °F)
Overload voltage 1 A 30 V (DC), 2 A 125 V (AC)
Withstand voltage 600 V (50 ∼ 60 Hz, 1 minute)
Inspection method
Figure 1
Pin connection
 Slowly restrict the air inlet to lower the pressure on the switch, and then conduct the continuity test.
Service Information

Brake pedal pressure 3864 Service Information 2014/5/12
switch, description
Profile:
Brake pedal pressure switch, description

 The switch turn on the brake lamp while the brake pedal is depressed
Figure 1
Brake pedal pressure switch
1. M12 × 15, torque: 60 N·m

2. Pressure switch
3. Connector
Service Information

Brake pedal pressure 3864 Service Information 2014/5/12
Profile:
Brake pedal pressure switch, specifications

Specifications
Item Specifications
Operating voltage 42 V (Maximum)
Switch type Normal open (NO) type
Operating pressure 3 ∼ 6 kgf/cm2 (43 ∼ 85 psi)
Operating temperature -30 ~ 100 °C (-220 ~ 212 °F)
Inspection method
Figure 1
Pin connection
 Remove connector and connect a tester.

 Depress brake pedal and check if connected.
Service Information

Engine oil pressure switch, 3864 Service Information 2014/5/12
description
Profile:
Engine oil pressure switch, description

 The switch is utilized to activate the engine oil pressure indicator of I-ECU and when the engine oil pressure is
below the set pressure, it turns off the output.
Figure 1
Engine oil pressure switch
Service Information

Engine oil pressure switch, 3864 Service Information 2014/5/12
specifications
Profile:
Engine oil pressure switch, specifications

Specifications
Item Specifications
Rated load 24 V, 5 W
Operating pressure 0.7 ± 0.2 kgf / cm2(10 ± 3 psi)
Contact point type Normally closed (NC) type
- Below the working pressure : ON
- Above the working pressure : OFF
Insulation resistance Above 1MΩ in the condition of twice the working pressure (500 V megger
meter.)
Inspection method
Disconnect the switch and apply pressure to the switch for continuity test.
Figure 1
Pin connection
Engine oil pressure switch, pressure condition
Condition Continuity
Pressure 0.7 ± 0.2 kgf / cm2 and less YES
Pressure 0.7 ± 0.2 kgf / cm2 and more NO
Service Information

Gear shifting control 3864 Service Information 2014/5/12
pressure switch,
description
Profile:
Gear shifting control pressure switch, description

 The switch detects the transmission clutch operating pressure and enable the engagement of the directional
solenoid valve.
 When the travel mode selection switch is in parking position (P), the direction solenoid valve can not be engaged.
Figure 1
Gear shifting control pressure switch
1 Cab 5 AMP ES plug housing & terminal (2P)

2 Rubber A AV 0.85 BL/W
3 Tie B AV 0.85 SB
4 Serial hose
Service Information

Gear shifting control 3864 Service Information 2014/5/12
pressure switch,
specifications
Profile:
Gear shifting control pressure switch, specifications

Specifications
Item Specifications
Switch type Normal open (NO) type
Operating pressure 26.5 ∼ 28.5 bar (384 ∼ 413 psi)
Inspection method
 Disconnect the harness and apply pressure to the switch by releasing the parking brake then conduct the continuity
test.
Figure 1
Pin connection
Engine oil pressure switch, pressure condition
Condition Continuity
Pressure 0.7 ± 0.2 kgf / cm2 and less YES
Pressure 0.7 ± 0.2 kgf / cm2 and more NO
Service Information

Hydraulic oil pressure 3864 Service Information 2014/5/12
switch, description
Profile:
Hydraulic oil pressure switch, description

 If the pressure of the hydraulic circuit in which the switch is installed is higher than the set pressure, the switch
operates to break off the electrical signal.
 The output signal is sent to the V-ECU and utilized as basic data for the V-ECU operating switchover. (Used as input
data for automatic idling, power boost, safety start, etc.)
Figure 1
Hydraulic pressure switch (20K)
1. M12 ×15, tightening torque: 60 N·m

2. Pressure switch
3. COnnector
Service Information

Hydraulic oil pressure 3864 Service Information 2014/5/12
Profile:
Hydraulic oil pressure switch, specifications

Specifications
Item Specifications
Type Normally closed (NC) type
Maximum operating pressure 196 kgf/cm2 (2900 psi)
Operating voltage 42 V (maximum)
Switch operating pressure 17 ± 1 kgf/cm2 (247 ± 14 psi)
Inspection method
Figure 1
Pin connection
 Remove connector.
 Install a tester.
 Move the digging unit and check simultaneously the operation of the digging unit port pressure switch. (Continuity
test: Before work–Connected, During–Disconnected)
Service Information

Travel pedal pressure 3864 Service Information 2014/5/12
sensor, description
Profile:
Travel pedal pressure sensor, description

 The sensor detects travel pedal pressure and sends it to the V-ECU for controlling the engine speed and main pump
flow.
 The operator can control engine speed and travel speed by depressing the travel pedal.
Figure 1
Travel pressure sensor
Service Information

Travel pedal pressure 3864 Service Information 2014/5/12
sensor, specifications
Profile:
Travel pedal pressure sensor, specifications

Specifications
Item Specifications
Operating pressure 0 ∼ 50 kgf/cm2 (0 ∼ 711 psi)
Maximum working pressure 750 kgf/cm2 (10,669 psi)
Operating voltage 1 ~ 5 V (maximum)
Resistance 10 Ω (minimum)
Inspection method
Figure 1
Pin connection
 After starting, measure with the connector in the connected position.

Service Information

Engine speed sensor, 3865 Service Information 2014/5/12
description
Profile:
Engine speed sensor, description

 The engine speed sensor is a frequency sensor which produces an AC signal in which the frequency (HZ) varies as
the condition changes.
 The sensor generates the AC signal from the passing flywheel ring gear teeth (1 pulse per tooth) and signals the V-
ECU which determines the engine speed.
 The V-ECU calculates the engine speed by analyzing the frequency received.
CAUTION
If the clearance to the flywheel is not accurate or there are lots of metallic particles on the surface of the sensor, the engine
speed sensor can not generate accurate voltage and frequency.
Figure 1
Engine speed sensor
1. 0.85 SB
2. 0.85 W
Service Information

Engine speed sensor, 3865 Service Information 2014/5/12
specifications
Profile:
Engine speed sensor, specifications

Specifications
Item Specifications
Output voltage AC 2 ~ 8 V
Output frequency 1 ~ 5 KHz
Coil resistance 300 Ω (maximum)
Coil inductance 142 H (maximum)
Leakage resistance 100 MΩ
Operating temperature –40 ~ +135 °C (–40 ~ 275 °F)
Assembly process
 Center the flywheel ring gear tooth in the engine speed sensor mounting hole.
 Slowly tighten the engine speed sensor until it contacts the ring gear tooth, then turn it to the opposite direction by
3/4 ~ 1 turn, and fasten the lock nut.
 At this time the clearance is approximate 1.0 ~ 1.2 mm (0.04 ″ ~ 0.05 ″).
Inspection method
Figure 1
Pin connection
 Start the engine, separate the connector and measure across the connector terminals attached to the sensor.
 Specification: AC 2 ~ 8 V.
Service Information

Alarm (Buzzer), description 3872 Service Information 2014/5/12
Profile:
Alarm (Buzzer), description

 When an abnormality occurs in the running condition of the machine, the buzzer activates warning the operator to
take immediate action.
WARNING
Do not ignore the alarm and continue to operate the machine!
Safely shut down the machine. Inspect and repair the fault. Failure to comply could result in injury or death!
 The reasons for alarming (at the same time with alarm indicator)
 Coolant high temperature

 Engine oil low pressure
 Quickfit operation (option)
 Overload warning (option)
Figure 1
Alarm
1. AVS 0.85 SB
2. AVS 0.85 R
Alarm (Buzzer), specifications

Specifications
Item Specifications
Rated voltage, current DC 28 V, 0.2 A or less
Sound pressure level 80 ± 10 dB (at DC 24 V, 1 m from machine)
Resistance 60 ± 2 Ω (20 °C)
Service Information

Display unit (D-ECU), 3872 Service Information 2014/5/12
description
Profile:
Display unit (D-ECU), description

 The display unit (D-ECU) displays the fault code after self diagnosing of the V-ECU.
 This is also can inquire selectively about the machine operating condition.
Figure 1
Display unit (D-ECU)
1. Unit indicator
2. Display window
3. Item on / off switch
4. Item selection switches
Connector specifications

1 Receiving (Rx) 5 Ground (AGND)
2 Sending (Tx) 6 Light ground
3 Ground (AGND) 7 Ground (DGND)
4 Power (+24 V) 8 Light power
Unit indicator
A. Fault LED (red) : BLINKS at the same time that the fault code is displayed on the display window.
B. Current LED (green) : ON at the same time that the current value of the power shift proportional solenoid valve or
the flow control proportional valve is displayed on the display window.
C. Voltage LED (green) : ON at the same time that the V-ECU power voltage and throttle position sensor value is
displayed on the display window.
D. Pressure LED (green) : ON at the same time that the pressure value is displayed on the display window.
E. Engine speed LED (green) : ON at the same time that the engine speed is displayed on the display window.
Display window
D-ECU displays the engine speed (rpm) in normal state, and if there is any abnormality, displays the fault code in engine
running state. detailed fault codes see [Invalid linktarget] .
By pressing the item on/off switch and item selection switch, It displays the operating condition of machine. detailed
contents see [Invalid linktarget] .
Item on/off switch

Pressing this switch indicates the items of equipment condition, and repressing it indicates the engine speed.
Item selection switch
After pressing the Item on/off switch, the operator can select by pressing the item selection switches. and then the D-ECU
display the machine condition items sequentially.
Service Information

Instrument panel (I-ECU), 3872 Service Information 2014/5/12
description
Profile:
Instrument panel (I-ECU), description

 The instrument panel (I-ECU) displays the information received from the sensors and switches of the machine to
alert the operator for any abnormality.
 The instrument is adjustable the operator viewing angle and is illuminated for night work.
 All light bulbs should be checked daily and replaced if burnt-out because the indicators alert the failure of the
machine.
 The panel contains a coolant temperature gauge, fuel gauge, hour meter and alert indicators to show machine
conditions.
 The I-ECU utilizes a plug-in printed circuit board (PCB) to facilitate replacement and troubleshooting. If a failure is
suspected always check the plug-in connection.
Figure 1
Instrument panel (I-ECU)
Connecter A, B : connect between Printed circuit board and wire harness of I-ECU
Connector C, D : connect between wire harness of I-ECU and INST. wire harness of machine
I-ECU, electrical circuit

Figure 2
Instrument panel (I-ECU), electrical circuit
IM1 Coolant temperature gauge LC9 Not used LC20 Overload warning
IM2 Fuel level gauge LC10 Coolant temperature LC21 Spare
HR Hour meter LC11 Power boost LC22 Quickfit
LC1 Central warning LC12 Air cleaner LC23 Spare
LC2 Central warning LC13 Not used LC24 AIr heater
LC3 Left turn LC14 Brake fail LC25 Fuel heater
LC4 High beam LC15 Not used LC26 Emergency steering
LC5 Right turn LC16 Parking mode LC27 Emergency steering
LC6 Charge LC17 Not used LC28 Illumination
LC7 Not used LC18 Not used LC29 Illumination
LC8 Engine oil pressure LC19 Not used
I-ECU, checking
Before engine starting
 Before starting the engine, if turn the start switch to the ON position all indicators is turned ON for 3 seconds. At
the same time the buzzer is operated 2 times with the cycle of 1.0 seconds ON and 1.0 seconds OFF.
 Check if all indicator lights come on, and if not, check for burnt-out light bulbs, and the plug–in connectors
(connector A, B) of the printed circuit board .
After engine starting
 Before start–up, the engine alternator indicator and oil pressure indicator lamps remain ON.
 Once the engine starts, the above indicators should go out.
 When the engine is run at very low speed, the alternator indicator may remain ON. If this happens, increase the
engine speed, and check if the light goes off. If it remains ON, it is necessary to check the charging system.
 If the engine oil pressure indicator remains ON for 2 ~ 3 seconds after the engine is running, stop the engine and
check the engine lubricating system.
Service Information

gauge and indicator
Profile:
Instrument panel (I-ECU), gauge and indicator

Coolant temperature gauge
Figure 1
Coolant temperature gauge
 In normal operating conditions, the pointer of this gauge is in the green range.
 Although the actual temperature does not appear on the gauge, see the following table.
Specifications
Temperature (°C) 50 70 110 120

Resistance (Ω) (156.4) 73.8 ± 5 21.5 ± 2 (15.5)
Fuel level gauge
Figure 2
Fuel level gauge
 Indicates the fuel level in the fuel tank.

 Indication characteristics.
Specifications
Position E 1/2 F
Resistance (Ω) 95 ± 3.75 (32.5) 7 ± 3.75
 Fill the fuel tank at the end of each day to prevent condensation from accumulating.
CAUTION
If operation is continued with the warning lamp ON, any water or sediment in the bottom of the fuel tank may be drawn into
the supply line, contaminating the injection pump system causing accelerated wear or possibly pump seizure due to a lack
of lubrication.
Hour meter
Figure 3
Hour meter
 Indicates the running time of the machine. The running time is an important criteria for machine maintenance. In
case of abnormality, immediately replace it, and record the previous running time.
 During normal operating, the green lamp flashes at about 6 seconds intervals.
Central warning indicator (Red)
Figure 4
Central warning indicator
 The central warning indicator is composed of 2 control lamps (LC 29, 30) and turns ON when one of the engine oil
pressure, coolant temperature, overload, charge, air cleaner and quickfit indicators turns ON.
 The indicator is flushed with the cycle of 0.5 seconds ON and 0.5 seconds OFF continuously.
Alternator indicator (red)
Figure 5
Alternator indicator
 It indicates an abnormality of the electrical charging system. If the bulb is burned out, the batteries is in discharge.
 Activates if the voltage from the alternator falls below the range of 17 volts to 23 volts.
 When the indicator turns ON,the alarm buzzer will sound.
Switch OFF all electrical devices and stop the engine.
Check the electrical charging system and make the necessary repairs.
CAUTION
If operations are continued without repair, the batteries will discharge and may damage the control system electronics.
Engine oil pressure indicator (red)
Figure 6
Engine oil pressure indicator
 Comes ON when the engine oil pressure falls below approximate 0.7 kgf/cm2 (10 psi).
 When the indicator turns ON,Take immediate action.
Lower the bucket onto the ground, put the machine in a safe position and stop the engine.
Check the engine oil lubricating system and make the necessary repairs.
Refill the engine with a specified oil, to the correct level.
CAUTION
If operations are continued it may lead to engine damage.
Coolant temperature indicator (red)
Figure 7
Coolant high temperature indicator
 Activates when the coolant temperature rises.

 The indicator comes ON when the coolant temperature is above approximate 105 °C and goes OFF below
approximate 98 °C.
 When the indicator turns ON, the alarm buzzer will sound.
Lower the engine speed, run at idling, cool the engine sufficiently, and then stop the engine.
Check the cooling system and make the necessary repairs.
The cooling system must be inspected in the following order : coolant level, clogged condition of radiator core,
damaged/slipping engine fan belt, faulty engine thermostat, or damaged water pump.
WARNING
Use the auxiliary tank for coolant refill. If the radiator cap is opened and the coolant is not cooled sufficiently, the
operator may be burnt.
Air cleaner restriction indicator (red)

Figure 8
Air cleaner restriction indicator
 Comes ON when the air cleaner filter is clogged with dust.

 When the indicator turns ON,
Stop the engine, and clean or replace the air cleaner filter.
CAUTION
If used without cleaning or replacing, the engine will loose power, black exhaust smoke may increase, and machine
performance will deteriorate.
Brake oil pressure warning indicator (red)
Figure 9
Brake oil pressure warning indicator
 The indicator comes ON when the brake accumulator pressure false below specified valve.
Immediately stop the engine, and check and repair the faulty component.
Parking brake indicator (red)
Figure 10
Parking brake indicator
 The indicator activates when the travel mode selection switch is set at the parking position (P).
The Digging unit and travel operation is not available.
Automatic lubrication indicator (red)–option
Figure 11
Automatic lubrication indicator
 This indicator will light when the grease tank is empty and flash when the feeding system is malfunctioning.
 Light ON: The grease tank is empty.
 Light flashing: Abnormality with pump system, manifolds or high pressure lines. Immediately stop operations, then
check and repair the faulty component.
CAUTION
If operations are continued with a system malfunction, the digging units running without grease will be damaged due to
premature wear of the pins and bushings.
Overload indicator (red)–option
Figure 12
Overload indicator
 The indicator will come ON at overload (when higher hydraulic pressure than the setting pressure of the pressure
sensor is detected.)
 When the indicator turns ON, lower the bucket onto the ground slowly.
WARNING
The overloading work may overturn the machine.
Preheating indicator (amber)
Figure 13
Preheating indicator
 This indicator comes ON when the preheating is finished provided the start switch is in the PREHEAT position.
(Activates when the coolant temperature is below 15 °C.)
Fuel heater indicator (green)–option
Figure 14
Fuel heater indicator
 Activates when pressing the fuel heater switch.
 5 ~ 10 minutes after the engine is started, turn OFF the switch.
Quickfit digging unit indicator (red) - option
Figure 15
Quickfit digging unit indicator
 When the two quickfit switches are pressed to the OPEN position at the same time, the alarm buzzer is activated,
the quickfit indicator os ON and central warning lamp is FLASHED.
If the buzzer stop/confirm switch is pressed to STOP position, the buzzer will be silenced.
 If the two quickfit switches are pressed to the LOCK position and the buzzer stop/confirm switch is pressed to
CONFIRM position, the quickfit indicator and central warning lamp will be OFF.
CAUTION
If operations are continued it may lead to engine damage.
Power boost indicator (Green)
Figure 16
Power boost indicator
 When the boost/hammer switch of right remote control valve (joystick) is pushed while the boost/hammer selection
switch is turned to the BOOST position, the power boost indicator ON for 9 seconds and digging power increase for
9 seconds.
 Also, while work mode is the F (fine) mode or travel pedal is operated, the power boost indicator ON.
High beam indicator (red)
Figure 17
High beam indicator
 The indicator comes ON when the brake accumulator pressure falls below specified valve.
Immediately stop the engine, and check and repair the faulty component.
Emergency steering readiness indicator (green)

Figure 18
Emergency steering readiness indicator
 This lamp indicates that emergency steering system is ready, at normal state this lamp is ON.
 If there is any problem in the steering system, the lamp will be OFF.
Emergency steering operating indicator (red)
Figure 19
Emergency steering operating indicator
 This lamp indicates that emergency steering system is operating.

Service Information

specifications
Profile:
Instrument panel (I-ECU), specifications

Wire specifications
No. Specifications No. Specifications

FROM TO FROM TO
A16 C1 AVSS 0.5 BL A10 D1 AVSS 0.5 BN
A13 C2 ACSS 0.5 GN/BL B8 D2 AVSS 0.5 BL/W
A11 C3 AVSS 0.5 R/W B15 D3 AVSS 0.5 W/SB
B16 C4 AVSS 0.5 Y/R B1 D4 AVSS 0.5 BL
B10 C5 AVSS 0.5 Y/BL A6 D5 AVSS 0.5 Y/SB
– C6 – A5 D6 AVSS 0.5 GN/W
B2 C7 AVSS 0.5 Y A4 D7 AVSS 0.5 GN
B4 C8 AVSS 0.5 BL/GN – D8 –
B11 C9 AVSS 0.5 BN/BL A2 D9 AVSS 0.5 BL/R
B3 C10 AVSS 0.5 Y/W A1 D10 AVSS 0.5 Y/GN
B8 C11 AVSS 0.5 BL/SB A20 D11 AVSS 0.5 BN/SB
B5 C12 AVSS 0.5 W/Y A19 D12 AVSS 0.5 W
A9 C13 AVSS 0.5 BN/W A8 D13 AVSS 0.5 BN/R
A7 C14 AVSS 0.5 R/BL A17 D14 AVSS 0.5 BN
A18 C15 AVSS 0.5 BL/W – D15 –
B12 C16 AVSS 0.5 Y/BN – D16 –
B7 C17 AVSS 0.5 GN A14 D17 AVSS 0.5 GN/SB
A15 C18 AVSS 0.5 B A13 D18 AVSS 0.5 BL/W
B13 C19 AVSS 0.5 Y/GN A12 D19 AVSS 0.5 BL/SB
B14 C20 AVSS 0.5 R/GN B9 D20 AVSS 0.5 SB
Indicator operating specifications
Category Item Operation Operating method

Indicator LC1/LC2 Buzzer
Dangerous Coolant temperature O (LC1) O O V-ECU is operated
Engine oil low pressure O (LC1) O O Pressure switch is operated
Overload O (LC1) O O Pressure switch is operated
Brake fail O (LC1) O O Pressure switch is operated
Quickfit attachment O (LC1) O O Operating switch is operated
 Buzzer stop function

 Confirm function
Caution Charge O (LC6) O X Charging system is failure

Air cleaner O (LC1) O X Exhaust switch is operated
Coolant level O (LC1) O X Not used
Tell-tails Air heater O (LC1) X X Start key and V-ECU are operated
Fuel heater O (LC1) X X V-ECU is operated
Parking mode O (LC1) X X Switch is sett to P mode
High beam O (LC1) X X Combination switch is operated
Left turn O (LC1) X X
Right turn O (LC1) X X
Emergency steering, readiness O (LC1) X X Pressure switch is operated
Emergency steering, operation O (LC1) X X
Auto grease O (LC1) X X Auto greasing controller is
operated
Multi function 1 O (LC1) X X Not used
Multi function 2 O (LC1) X X Not used
Power boost O (LC1) X X Operating switch is operated
Oscillation lock O (LC1) X X Not used
Hydraulic oil temperature O (LC1) X X Not used
Water separator O (LC1) X X Not used
Service Information

Radio, description 3932 Service Information 2014/5/12
Profile:
Radio, description
 A high quality AM, FM radio and cassette tape unit, powered through the start switch.
 If the cassette mute switch (option) is installed and turned to ON, the sounds through is cut off even when the
cassette power is ON.
 For the operating method, see the operator's manual.
 The cassette contains a battery, which memorizes the selected content up to 140 hours maximum.
Figure 1
Radio with cassette
Service Information

Radio, specifications 3932 Service Information 2014/5/12
Profile:
Radio, specifications
Specifications
Item Specifications
Rated voltage DC 13.2 V
Operating voltage DC10 ~ 16 V
Output 25 W × 2 EA
Frequency range AM 533 ~ 1602 KHZ / FM 87.5 ~ 108 MHZ
Safety capacity of antenna 80 PF ± 10 %
Pin connections
Pin number Description

1 Auto. antenna
2 Normally closed (NC)
3 Speaker front left ( - )
4 Speaker front right ( - )
6 Illumination ( - )
7 Ground (GND)
9 Speaker front left ( + )
10 Back up
11 ACC
12 Speaker front right ( + )
14 Illumination ( + )
Service Information

DC–DC converter, 3937 Service Information 2014/5/12
description
Profile:
DC–DC converter, description

 The converter lowers battery voltage of 24V to supply the working voltage for cassette.
Figure 1
DC-DC converter
1 AVS 0.85 W (24 V) 4 AVS 0.85 BL (ACC)

2 AVS 0.85 R (12 V) 5 AVS 0.85 GN (B/U)
3 AVS 0.85 SB (GND)
Inspection method
 Put the tester in the voltage measuring position, and measure the voltage across the output and ground terminals.
Figure 2
Pin connection
Service Information

DC–DC converter, 3937 Service Information 2014/5/12
specifications
Profile:
DC–DC converter, specifications

Specifications
Item Specifications
Input voltage DC 20 ~ 32 V
Output voltage DC 13 ± 1 V
Output current Maximum 4 A
Happy every day.
Service Information

Power train, description 400 Service Information 2014/5/12
Profile:
Power train, description

The power from engine (1) is transmitted via the flywheel to coupling (2). The coupling alleviates torsional vibration caused
by the variation of engine torque and transmits the power to main pump (3), and at the same time steering pump (4) is
driven by the engine through a PTO (power take-off).
By selecting the direction of drive via the forward / reverse shifter on the steering column, travel motor (6) rotates clockwise
or counterclockwise by the hydraulic power from main pump (3) through swivel joint (5) and drives the transfer gearbox.
When selecting the speed of travel using the speed selector lever on the steering column the hydraulic power from steering
pump (4) shifts the gearbox.
The motive force from the gearbox output shafts is sent to the front and rear axle.
The motive force transmitted to the axle is reduced by the pinion gear and ring gear of the differential. It then passes from
the differential to the axle shaft of the final drive.
The motive force of the sun gear is reduced by a planetary mechanism and is transmitted through the planetary hub to the
wheel.
Figure 1
Power train system
1 Engine 6 Travel motor 11 Front axle

2 Main pump 7 Remote control valve (pedal) 12 Rear axle
3 Steering pump 8 Forward/reverse select valve 13 Tire
4 Main control valve 9 Transfer gearbox
5 Center passage 10 Drive shaft
Service Information

Power train, hydraulic 400 Service Information 2014/5/12
circuit
Profile:
Power train, hydraulic circuit
Figure 1
Hydraulic circuit, power train
1 Transfer gearbox 11 Axle locking cylinder 21 Propeller shaft

2 Valve block 12 Pressure switch 22 Wheel rim
3 Wiring connector 13 Pressure switch 23 Tire
4 Pressure switch 14 Steering unit 24 Insert-antistone
5 Accumulator 15 Steering column 25 Priority valve
6 Gear pump 16 Steering wheel 26 Filter
7 Brake supply valve 17 Front axle 27 Service brake latch pedal
8 Service brake valve 18 Rear axle 28 Travel pressure sensor
9 Accumulator 19 Oscillating pin 29 Controller
10 Accumulator block 20 Propeller shaft
Service Information

Power train, lower piping 400 Service Information 2014/5/12
Profile:
Power train, lower piping

Center passage port
Port connection
Part name Components Size

A Travel gearbox low speed PF 1/2″
B Travel gearbox high speed PF 1/2″
C Travel gearbox leakage PF 3/8″
D Axle locking supply PF 1/4″
E Front axle brake PF 3/8″
F Rear axle brake PF 3/8″
G Axle locking drain PF 3/8″
K Steering cylinder (right) PF 1/2″
M Steering cylinder (left) PF 1/2″
Tightening torque
Part size Connector Hose / pipe

PT, PF 1/4″ 3 ~ 4 (22 ~ 29) 3 (22)
PT, PF 3/8″ 4 ~ 5 (29 ~ 36) 4.5 (32)
PT, PF 1/2″ 4.5 ~ 6 (32 ~ 43) 6 (43)
M 10 4.6 ± 0.5 (33 ± 4)
Figure 1
Power train, lower piping
Service Information

Power train, mechanism 400 Service Information 2014/5/12
Profile:
Power train, mechanism

The travel system is a 4 wheel drive power train driven by a hydraulic motor.
Figure 1
Power train, mechanism
Travel speed is controlled by the travel remote control valve (pedal) which controls engine speed and pump flow.
Set the travel mode switch at “T” position, the engine speed selection rotary switch to step 1 and depress the travel remote
control valve (pedal) to control travel speed.
Engine speed control mechanism
Figure 2
Engine speed control mechanism
Service Information

Power train, related 400 Service Information 2014/5/12
components
Profile:
Power train, related components
Figure 1
Power train, related components (1)
1 Transfer gearbox 5 Oscillating pin 9 Drain plug

2 Front axle 6 Axle locking cylinder 10 Brake port
3 Propeller shaft (front) 7 Air breather 11 Lubrication pressure check port
4 Rear axle 8 Oil fill and check plug 12 Transmission air breather
a. 17.9 ± 1.6 (129.2 ± 11.6)

b. 26.7 ± 2.7 (192.8 ± 19.5)
c. 32.1 ± 3.2 (231.8 ± 23.1)
d. 6.5 ± 0.7 (46.9 ± 5.1)
Figure 2
Power train, related components (2)
13 Oil filler port 18 Lubrication pressure connector 23 Intake filter (inside governor)
14 Oil level port 19 2nd pressure connector 24 Air breather (center)
15 Oil drain port 20 1st pressure connector 25 Drain port
16 Lubrication pressure check port 21 Oil fill and check plug 26 1st pressure check (M14 × 1.5)
17 Shift lock 22 Oil drain plug 27 2nd pressure check (M14 × 1.5)

e. 28.5 ~ 31.5 (205.8 ~ 227.4)
f. 90.2 ± 9.0 (651.2 ± 65)
g. 90.2 ± 9.0 (651.2 ± 65)
h. 44 ± 2 (317.7 ± 14.4)
k. 52.2 ± 5.2 (376.9 ± 37.5)
Service Information

Power train, schematic 400 Service Information 2014/5/12
diagram
Profile:
Power train, schematic diagram
Figure 1
Power train, schematic diagram
1 Engine 7 Center passage 13 Brake valve

2 Main pump 8 Travel motor 14 Steering unit
3 1st / 2nd solenoid valve 9 Transfer gearbox 15 Gear pump
4 Travel pedal 10 Rear axle 16 Brake pump
5 Forward / reverse solenoid valve 11 Front axle 17 Steering pump
6 Main control valve 12 Steering cylinder
Service Information

Power train, travel 400 Service Information 2014/5/12
interlock
Profile:
Power train, travel interlock

System diagram
Figure 1
Travel interlock, system diagram
1 Remote control valve (pedal) 6 Main pump 11 Power shift valve

2 Engine speed control switch 7 Axle 12 Forward / reverse solenoid valve
3 Controller 8 Transfer gearbox 13 Pressure sensor
4 Stepping motor 9 Travel motor
5 Engine 10 Main control valve
Mode selection and travel interlock

The controller compares related engine speed which are set by the engine speed control switch and travel remote control
valve (pedal), then selects the larger value to control engine speed and pump flow.
 If the remote control valve (pedal) is not actuated then engine speed and pump flow is controlled by the engine
speed control switch.
 If the engine rpm selected by remote control valve (pedal) is larger than rotary switch value engine speed and
pump flow is controlled by the remote control valve (pedal).
 If the engine speed selected by control switch is larger than remote control valve (pedal) value then the engine
speed and pump flow is controlled by the control switch.
 If the control switch is set at step 1 then engine speed and pump flow is totally controlled by the remote control
valve (pedal).
Service Information

Power train, 400 Service Information 2014/5/12
troubleshooting
Profile:
Power train, troubleshooting

Troubleshooting
System line Function Phenomenon Troubleshooting Remark

Control and related Travel Does not operate. Operate at manual mode. Manual mode
circuit interlock (Set auto/manual switch at manual Travel, work possible
mode and control engine speed with
throttle linkage).
Forward/reverse/ Forward/ Forward/reverse - Check forward/reverse solenoid valve
neutral select reverse function does not and related circuit.
related circuit operate. Replace faulty part.
Pressure sensor Travel Engine speed is not Replace sensor. Travel and work
faulty interlock controllable. Set travel mode at ″T″ and control possible
engine rpm with engine speed control
rotary switch.
Stepping motor and Travel Engine speed is not Check related circuit.
related circuit interlock controllable. Replace faulty part.
Operate at manual mode.
Service Information

Power train, upper piping 400 Service Information 2014/5/12
Profile:
Power train, upper piping

Port connection
Port connection
Part name Port Port Part name Remark

Gear pump 1 PL IN Filter Steering supply
2 PL P Supply valve Brake supply
Service brake valve 2.1 E Center passage Service brake (front)
2.2 F Service brake (rear)
5 T7 Tank Service brake return (front / rear)
Center passage C T3 Tank Travel gearbox leakage
Brake supply valve T R6 Main return pipe Supply valve return
AB 1.1 Service brake valve Service brake (front)
AC 1.2 Service brake (rear)
Control valve assembly P S1 Block - servo hydraulic Gear shift in
T - Pipe assembly Gear shift return
B A Center passage Gear shift low speed
A B Gear shift high speed
Center passage G R5 Main return pipe Axle locking return
D A3 Solenoid valve Axle locking supply
Main suction MS BS Gear pump Pump suction (brake)
Hydraulic tank - SS Pipe assembly Pump suction (steering)
Priority valve R K Center passage Steering (right)
L M Steering (left)
EF R4 Main return pipe -
T T8 Tank Steering return
P OUT Filter Steering supply
Figure 1
Power train, upper piping (1)
Figure 2
Power train, upper piping (2)
Service Information

Slew gearbox, assembly 4312 Service Information 2014/5/12
Profile:
Slew gearbox, assembly

Precaution
 When mounting the gearbox assembly to the superstructure, position it on the dowel pin located in the mounting
plate to ensure that the drain/fill ports are properly positioned.
 Mount the hydraulic motor on the gearbox assembly so that the oil level gauge and plumbing connections are
positioned as shown in the construction drawings.
 Use a torque wrench to tighten the mounting screws to the specified torque.
 Clean all parts with cleaning solvent and dry with compressed air.
 Rework damaged parts and before assembling, prepare all replacement parts.
 Coat the sliding parts, bearings and gears with clean gear oil.
 Replace the o-ring and oil seal.
 Use a torque wrench to tighten the screws and plugs to the specified torque.
Tightening torque
Item no. Description Thread Tightening torque

24 Screw M12 12 ~ 13 (87 ~ 94)
22 Screw M16 27 ~ 28 (195 ~ 202
15 Screw M10 6.5 ~ 7 (47 ~ 50)
44 Pipe PT 1/2″ 6.5 ~ 7 (47 ~ 50)
43 Plug PT 1/2″ 6.5 ~ 7 (47 ~ 50)
40 Pipe PT 3/4″ 10 ~ 11 (73 ~ 79)
Assembly, slew gearbox
Procedure Remark Tool

1 Shaft Bearing assembly
 Apply grease (NLGI 2) jig.
 Install o-ring (13) in collar (11), and then install it on onto o-ring (13). : See [Invalid
shaft (10).  Heat the spherical linktarget]
 Press spherical bearing (16) onto shaft (10). bearing in oil to 110°C
(212°F) prior to
installation.
2 Cover
- Press oil seal (14) into cover (12) using the seal Apply loctite (# 680) onto the - Oil seal
pressing jigs. outer diameter of the oil seal. assembly jig
Take care to get any loctite on the : See [Invalid
oil seal lip. linktarget]
- Oil seal
assembly guide
jig
: See [Invalid
linktarget]
3 Case Eye bolt (M8 ×

– Install shaft (10) assembly into case (19) using an eye bolt WARNING 1.25)
(M8 × 1.25).
The shaft is heavy, take
appropriate safety precautions
when handling.
4 Cover assembly. Spanner

 Coat the mating surface : 17 × 19 mm
 Install oil seal protector (A) onto the gear of shaft of cover (12) with liquid Torque wrench
(10). gasket, loctite # 5699.
 Install cover assembly (12) on case (19) and install  Apply grease (NLGI2) Oil seal assembly
screws (15). onto the oil seal lip. guide jig
 Apply loctite # 277 onto : See [Invalid
the threads of screws linktarget]
(15).
5 Bearing Press-fit both inner and outer race Bearing assembly

– Block case (19) as shown. simultaneously. jig
– Press-fit spherical bearing (17) into case (19). : See [Invalid
linktarget]
6 Retaining ring Check if casing (19) rotates Snap ring pliers

– Fully seat spherical bearing (17), and install retaining ring smoothly after assembling the (expansion φ 90)
(18) onto shaft (10). bearing and retaining ring.
7 2nd planetary gear assembly. Hammer

 Align the spring pin
 Insert thrust washers (8) and planetary gear (3) into holes in pin assembly (4)
carrier (2). and carrier (2).
 Insert pin (5) and bushing (6).  Apply a dab of grease to
 Tap spring pin (9) into the pin hole of carrier (2). hold thrust washers (8)
After inserting, stake both sides of spring pin (9). to gear (3).
 Install spring pin (9) with
the slit facing the end of
pin (5).
 Ensure that gears (3)
rotate smoothly.
8 1st planetary gear assembly. Check if planetary gears (30) Snap ring pliers
rotate smoothly. (expansion φ 30)
 Press–fit pins (31) into carrier (29) and install spring
pins (36). After inserting, stake both sides of spring
pins (36).
 Put thrust washer (27) on the surface of carrier (29).
 Onto pin (31) install thrust washer (33), gear (30)
including bearing (32), thrust washer (34) and
retaining ring (35).
9 Ring gear and 2nd planetary assembly. Hammer

WARNING
 Insert dowel pins (21) at four places on case (19).
The parts are heavy, take
 Install ring gear (20) onto case (19).
appropriate safety precautions.
 Insert 2nd planetary gear assembly (1) into ring
gear (20).
 Coat the mating surface
 Insert thrust ring (25) into 2nd planetary gear (1),
of case (19) with liquid
then install sun gear (26).
gasket loctite # 5699.
 Support case (19).
10 1st planetary gear assembly and 1st sun gear. Confirm that shaft (10) rotates
 Install 1st planetary gear assembly (28) into ring smoothly by turning the 1st sun
gear (20). gear.
 Install retaining ring (38) into sun gear (37), and
insert it into planetary (28).
11 Plate Allen wrench : 14

– Install plate (23) onto ring gear (20) then install screws (22).  Align the match marks mm (M16)
on casing (19) ring gear Torque wrench
(20) and plate (23).
 Coat the mating surface
of ring gear (20) with
liquid gasket loctite #
5699.
 Apply loctite # 277 onto
the threads of screw (22).
 Align the tap hole with
the drain pipe mounting
port.
A Tap hole
12 Motor Snap ring pliers

– Install the motor onto plate (23) then install screws (24).  Align the match marks of (expansion φ 35)
the motor and plate (23). Allen wrench :
 Coat the mating surface 10mm (M12)
of plate (23) with liquid Torque wrench
gasket loctite # 5699.
 Apply loctite # 277 onto
the threads of screws
(24).
13 Drain pipe and level gauge. Spanner 24 × 27

 Face the oil drain port of mm
 Tighten plug (40) to pipe (39) and pipe (39) to case pipe downward. Torque wrench
(11).  Coat with teflon tape or
 Install pipe (36) onto the motor, and insert level loctite # 577 on the pipe
gauge (35). and plug thread.
Service Information

Slew gearbox, description 4312 Service Information 2014/5/12
Profile:
Slew gearbox, description

Model code : RGS 100 / 16 00
Code Description
RGS Type No.
Example, S = Slew gearbox
100 Size No. (Theoretical output torque)
Example, 100 = 1000 kgf·m
16 Reduction ratio code
00 Serial No.
Slew gearbox consists of the driving shaft as a group including the 1st planetary gear assembly, the 2nd planetary gear
assembly and the 1st and 2nd sun gear pinions, the housing supporting the driving shaft, and the ring gear including the
planetary gear.
Slew gearbox, sectional view
Figure 1
Slew gearbox, sectional view
1 No.2 planetary gear assembly 17 Spherical bearing 32 Needle bearing

2 No.2 carrier 18 Retaining ring 33 Thrust washer
3 No.2 planetary gear 19 Case 34 Thrust washer
4 No.2 pin assembly 20 Ring gear 35 Retaining ring
5 No.2 pin 21 Dowel pin 36 Spring pin
6 Bushing 22 Screw 37 No.1 sun gear
8 Thrust washer 23 Plate 38 Retaining ring
9 Spring pin 24 Screw 39 Level gauge
10 Drive shaft 25 Thrust ring 40 Pipe
11 Collar 26 No.2 sun gear 41 Name plate
12 Cover 27 Thrust washer 42 Screw
13 O-ring 28 No.1 planetary gear assembly 43 Plug
14 Oil seal 29 No.1 carrier 44 Pipe
15 Screw 30 No.1 planetary gear
16 Spherical bearing 31 No.1 pin
Slew gearbox, exploded view
Figure 2
Slew gearbox, exploded view
Function
The 2-stage planetary gear reduction assembly converts the high speed/ low torque output of the hydraulic motor to low
speed/high torque output, which is transmitted via the reduction drive shaft pinion gear to the slew ring inner circumference
gear to rotate the superstructure.
Operation
Power supplied to the output shaft of the hydraulic motor is transmitted to the 2nd sun gear (26) through the splines of the
1st sun gear (37), the 1st planetary gear (30), the 1st pin (31) and the 1st carrier (29). In the same way, power is transmitted
to output shaft (10) through the splines of the 2nd planetary gear (3), the 2nd pin (5) and the 2nd carrier (2).
Figure 3
Slew gearbox
A. Torque flow
At this time, the reduction ratio of gearbox is as follows :
 1st reduction ratio

i1 = (Zr / ZS1) + 1
i1 = 1st reduction ratio
ZS1 = No. of gear teeth of the 1st sun gear
Zr = No. of tooth of ring gear
 2nd reduction ratio
i2 = (Zr / ZS2) + 1
i2 = 2nd reduction ratio
ZS2 = No. of gear teeth of the 2nd sun gear
Accordingly the total reduction ratio of gearbox is as follows :
i = i1 × i2
= (Zr / ZS1 + 1) × (Zr / ZS2 + 1)
i = Total reduction ratio
Service Information

Slew gearbox, disassembly 4312 Service Information 2014/5/12
Profile:
Slew gearbox, disassembly

General tools
General tools
No. Description Size Quantity

1 Spanner 17 × 19mm 1
24 × 27mm 1
2 Socket wrench - 1
3 Allen wrench 10mm 1
14mm 1
4 Torque wrench 400 ~ 1800 1
1200 ~ 4800 1
5 Snap ring pliers φ 35 1
φ 42
φ 90
6 Bearing puller -
7 Plastic hammer - 1
10 Eye bolt M8 2
M 12 2
M 16 2
M 18 2
11 (-) Drive 150 mm 1
Special tools
Special tools
No. Part no. Description Quantity

1 8920 - 00280 Bearing assembly jig 1
2 8932 - 00080 Bearing assembly jig 1
3 8920 - 00550 Oil seal assembly jig 1
4 8920 - 00570 Oil seal assembly guide jig 1
5 8920 - 00560 Oil seal assembly guide jig 1
Bearing assembly jig (unit : mm)

Figure 1
Jig for bearing assembly (1)
Bearing assembly jig (unit : mm)
Figure 2
Jig for bearing assembly (2)
Oil seal assembly jig (unit : mm)
Figure 3
Jig for oil seal assembly (3)
Oil seal assembly guide jig (unit : mm)

Figure 4
Jig for oil seal assembly guide (4)
Oil seal assembly guide jig (unit : mm)
Figure 5
Jig for oil seal assembly guide (5)
Precautions for disassembly
 Thoroughly clean the gearbox assembly prior to disassembly.

 Select a clean work area.
 Match mark attached components to indicate proper positioning during reassembly.
 Take care not to mix the parts of sub assemblies i.e. planetary bearings, gears and thrust washers.
 Thoroughly clean all parts and the inside of the casings.
 Inspect and analyze all failures. - Determine the root cause!
Disassembly, slew gearbox
Procedure Remark Tool

1 Removal of hydraulic motor. Allen wrench 10
 Make match marks on the mm (M12)
 Remove plug (43) and drain the gear oil. hydraulic motor casing,
 Remove screws (24). plate (23), ring gear (20),
 Lift the motor off the gearbox. and case (19).
 Make sure the match
marks are permanent and
clearly visible.
A Match marks
2 Removal of motor mount plate. Allen wrench 14
mm (M16)
 Remove screws (22).
 Remove plate (23).
3 1st sun gear.

– Remove 1st sun gear (37).
4 1st planetary gear assembly.

Snap ring pliers
 Remove 1st planetary gear assembly (28) from ring  Match mark gears (30), (expansion φ35)
gear (20). pins (31) and carrier (29).
 Disassemble the 1st planetary gear assembly in the  Do not mix the gears,
following order : bearings, thrust washers,
and pin assemblies.
1. Remove retaining ring (35), and then thrust washer  Do not remove pins (31) if
(34), planetary gear (30), needle bearing (32) and not worn or damaged.
thrust washer (33).  Do not reuse spring pins
2. Remove thrust washer (27). (36).
3. Remove spring pin (36) from carrier (29) to take out
pin (31).
5 Ring gear
– Remove ring gear (20) and dowel pin (21).
6 2nd sun gear.

– Remove 2nd sun gear (26) and thrust ring (25).
7 2nd planetary gear assembly
 Remove 2nd planetary gear assembly (1) from shaft  Match mark gears (3), pins
(10). (5), and carrier (2).
 Disassemble the 2nd planetary gear assembly in  Do not mix the gears,
the following order : thrust washers, bushings,
 Tap spring pin (9) into pin (5). and pin assemblies.
 Remove pin (5) and bushing (6) from carrier (2).  Do not reuse spring pins
 Remove planetary gear (3) thrust washers (8). (9).
 To remove spring pin (9),
tap it into pin (5).
 After removing pin (5),
remove the spring pin.
8 Retaining ring Snap ring pliers

– Remove retaining ring (18). (expansion φ90)
9 Cover and oil seal

– Remove screws (15). Do not reuse the oil seal. Spanner 17 × 19
– Remove cover (12). mm
– Remove oil seal (14). (-) Driver
10 Shaft
– Block the gearbox as shown.
– Press shaft (10) from case (19).
11 Press spherical bearing (16) and collar (11) from shaft (10). If it is difficult to remove spherical
bearing (16) as illustrated, use a
bearing puller.
CAUTION
Be careful not to damage collar (11)
by excessive force.
12 Remove o-ring (13) from collar (11). Do not reuse the o-ring.
13 Bearing Spherical bearing (17) can also be
– Remove the spherical bearing (17) from case (19) using removed using a bench press.
puller.
Service Information

Slew gearbox, lubrication 4312 Service Information 2014/5/12
Profile:
Slew gearbox, lubrication

CAUTION
Prior to operating the slew function, fill the gearbox with the specified oil to the correct level.
Precautions for lubrication
 Check the oil level prior to operating the slew function.

 Check for oil leakage on the motor and gearbox assembly.
 Check for loose mounting screws.
 Check for abnormal sound or vibration while rotating.
 Check for any abnormal temperature increase after operating for a short time.
 Check the slew performance against the operating specifications.
WARNING
The temperature of the case is high just after running. use a thermometer to measure. Do not touch directly by hand
to prevent a burn injury.
The temperature of the case must be lower than the ambient temperature + 60 °C, during continuous operation.
Gear oil specification
 Use a gear oil equivalent to API classification GL4 / GL5, SAE EP 90 or 140.
Gear oil replacement
 First (initial) oil replacement : 500 operating hours

 Subsequent oil replacement : 1000 operating hours
 After maintenance (initial) : 250 operating hours
CAUTION
Regardless of the operating hours the gear oil must be replaced at least once per year.
CAUTION
Do not mix different types, classifications or brands of oil.
Gear oil level
 Take out the level gauge, wipe it on a clean cloth, re-insert, take out, and then check if the oil is within the slanting
lines as shown.
Figure 1
Check, oil level
A. Level
* The level gauge also serves as an air breather for the gearbox.
Gear oil replacement
CAUTION
Drain the gear oil while it is still warm to flush out any contaminants.
 Remove the plug from the drain pipe and drain the oil into a suitable container.
 After completely draining, install the plug and torque to specification.
 Refill the gearbox through the oil level gauge stand pipe using a funnel that allows the pipe to breathe.
NOTE!
Oil capacity : 6 Liter (1.6 gal)
Figure 2
Refilling, gear oil
A. Level gauge
B. Fill
C. Plug
D. Drain
Service Information

Slew gearbox, maintenance 4312 Service Information 2014/5/12
standard
Profile:
Slew gearbox, maintenance standard

The parts are precision finished and must be handled carefully.
Keep the parts of the planetary carrier(s) together, do not mix the bushing, gears, pins and thrust washers.
Seals
Replace the oil seal and o-ring, although they appear not damaged.
Part replacement criteria
 Replace all parts that appear damaged or are not within the allowable value.
 Replace some parts in sets, i.e. gears, bushings and thrust washers.
Wear limit
Item Part name Condition Standard value Allowable value

No.
37 No.1 sun gear Pitting on gear teeth surface. Diameter : Within φ
26 No.2 sun gear 1 mm
30 No.1 planetary gear Area ratio :
3 No.2 planetary gear Within 5%
20 Ring gear
30 No.1 planetary gear Flaking on the needle bearing

31 No.1 pin sliding surface.
32 Needle bearing Partial wear
3 No.2 planetary gear Wear on outer diameter of bushing.
4 No.2 pin assembly
25 Thrust ring Wear on the shaft contact surface. Diameter clearance Diameter clearance
0.13 ~ 0.254 mm : Within 0.45 mm
38 Retaining ring Abnormal wear on the face area. Oil groove depth
35 Retaining ring : Within 0.5 mm
18 Retaining ring
8 Thrust washer Abnormal wear on the face area.
33 Thrust washer
34 Thrust washer
27 Thrust washer
17 Spherical bearing Pitting/flaking of the race or rollers.
Does not rotate smoothly by hand.
16 Spherical bearing
14 Oil seal Always replace.
Service Information

Slew gearbox, 4312 Service Information 2014/5/12
troubleshooting
Profile:
Slew gearbox, troubleshooting

Figure 1
Troubleshooting, slew gearbox
Service Information

Gearbox (traveling), 4314 Service Information 2014/5/12
assembly
Profile:
Gearbox (traveling), assembly

Precaution
 Clean all parts thoroughly before the assembly and clean the oil line using compressed air.
 Check for damaged or worn parts and prepare new parts.
 Replace the oil seals, o-ring, and bearings.
 Check the pressure in the hydraulic line after assembly.
 Follow the instruction in the operator's manual and service manual.
Install the lubrication oil suction pipe.
Figure 1
Assembly, suction pipe
Tools : Spanner 27mm, Socket 13mm
Install the pipe mounting screw (M8).
Figure 2
Assembly, pipe mounting screw
Install the bearing in the housing bore.

Rotate the gearbox 180° on the maintenance stand
Figure 3
Assembly, bearing
Insert baffle plate firmly against the shoulder.
CAUTION
Pay attention to the radial installation position!
Figure 4
Assembly, baffle plate
Press the ball bearing into the cover.
Figure 5
Press the ball bearing
Lock the bearing using the snap ring.

Figure 6
Locking, bearing
Tools : Snap ring pliers (compression)
Insert the o-ring into the o-ring groove of the bearing cover.
CAUTION
Apply grease when assembling.
Figure 7
Assembly, o-ring
Assemble the oil baffle, aligning the notch of baffle and the cover.
Figure 8
Assembly, oil baffle
Assemble the short side of output shaft with the bearing cover.
Figure 9
Assembly, short side of output shaft
Press fit the bearing cap on the output shaft.
CAUTION
To avoid damaging the ball bearing, fit the pressing sleeve on the bearing race!
Figure 10
Press fit the bearing cap
Insert two studs.
Figure 11
Assembly, studs
Tools : Studs (2)
Heat the assembled bearing in the gearbox using an air heat blower.
Figure 12
Heat the assembled bearing
Tools : Air heat blower
After heating assemble the cover.
Figure 13
Assembly, cover
After removing the two stud bolts install the cover screws.
Figure 14
Assembly, cover screws
Tools : Socket 19mm
Insert the shaft seal.

 Mount the seal lower than the surface of the cover (2+1mm)
 Apply grease between the seal lip and the dust lip.
 In case the seal outer side is made of rubber, apply alcohol solution (1 : 1) or use curil T.
Figure 15
Assembly, shaft seal
Use the jig when installing the seal.
Figure 16
Assembly, seal
Install the screws (8) and dust plate on the output flange.
CAUTION
Ensure that the seal contact area is not damaged or worn.
Figure 17
Assembly, screws and dust plate
Press fit the dust plate against the shoulder on the output flange.
Figure 18
Press fit the dust plate
Insert the output flange on the output shaft.
Figure 19
Assembly, output flange
Assemble the o-ring between the flange and the output shaft and install the washer.
CAUTION
Apply grease when assembling o-ring.
Figure 20
Assembly, o-ring
Install the two screws in the output shaft.

Figure 21
Assembly, screws
Tools : Socket 17mm, torque wrench
Lock the screws using the lock plate.
Figure 22
Locking, screws
Use the correct driver to press the lock plate on the heads of the flange mounting screws (2).
Rotate the gearbox 180°
Figure 23
Press the lock plate
Tools : Driver, hammer
Ensure that the ball bearing is seated properly.

Figure 24
Assembly, ball bearing
Install the seal.
 Mount the seal lower than the surface of the cover (2+1mm).
Figure 25
Assembly, seal
Use the jig when driving the seal into the housing bore.
Figure 26
Driving, seal
Install the screws and press fit the dust plate against the shoulder on the output flange.
Figure 27
Assembly, screws
Install the output flange on the output shaft.
Figure 28
Assembly, output flange
Assemble the o-ring and washer.
Figure 29
Assembly, o-ring and washer
Install the two screws in the shaft.

Figure 30
Assembly, screws
Tools : Socket 17mm, torque wrench
Lock the screws using the lock plate.
Figure 31
Locking, screws
Tools : Driver, hammer
Press the ball bearing over the collar of the helical gear until contact is obtained, then install the snap ring.
Press the ball bearing into the cover until it is firmly seated.
Figure 32
Install the snap ring.

Figure 33
Assembly, snap ring
Press the helical gear into the ball bearing cover assembly until firmly seated.
Figure 34
Assembly, helical gear
Tools : Press, support blocks
Assemble the shift dog.
Figure 35
Assembly, shift dog
Install the spacer and the shift dog.

Figure 36
Assembly, spacer and shift dog
Assemble the shim on the shift dog.
Figure 37
Assembly, shim
Fix the shim using the snap ring.
CAUTION
After assembly the max. clearance between the upper surface of the shift dog and the shim is 0.1 mm. Adjust it using various
shims (1.6, 1.8, 2.0, 2.2, 2.4, 2.6 mm)
Figure 38
Assembly, shim
Tools : Snap ring pliers (expansion), feeler gauge
Press the needle bearing firmly against the shoulder.

CAUTION
Pay attention to the installation position, designation showing upward.
Figure 39
Assembly, needle bearing
Install the helical gear subassembly into the gearbox housing.
Figure 40
Assembly, helical gear subassembly
Fix the bearing cover to the gearbox housing using the snap ring.
Figure 41
Fix the bearing cover
Components of the shift dog assembly.

Figure 42
Components, shift dog assembly
Squeeze in the circlip and install the o-ring.
Figure 43
Assembly, o-ring
Tools : Snap ring plier (expansion)
Install the sliding pads on the fork and assemble the sliding collar.
Figure 44
Assembly, sliding pads and collar
Insert the shift fork and the sliding collar.

Figure 45
Assembly, shift fork and sliding collar
Insert the shift lever shaft until full contact is obtained.
Figure 46
Assembly, shift lever shaft
Align the shift lever shaft radially and fix it by driving the roll pin in until it is flush.
Figure 47
Driving, roll pin
Tools : Hammer, punch
Assemble the parking brake emergency release lever.
 Adjustment for the operating distance will be done after assembling the planetary gear sub assembly.
 Put the lever in the release position.
Figure 48
Assembly, parking brake emergency lever
Install the plug.

NOTE!
Use a new o-ring
Figure 49
Assembly, plug
Tools : Allen wrench 10mm, toque wrench
Press fit the bearing inner race on the carrier shafts.
Figure 50
Assembly, bearing inner race
Tools : Press
Apply grease to the bearing race, then set the bearing needles.
Figure 51
Apply, grease
Install the planetary gears, collar shims and the circlips.
Figure 52
Assembly, planetary gears, collar, shims and circlips
Install the ball bearing firmly against the shoulder.
Figure 53
Fix with circlip.

Figure 54
Assembly, circlip
Heat the ball bearing and mount the planetary carrier until contact is obtained.
 Move the parking brake emergency release lever and check if it operates smoothly.
Figure 55
Assembly, planetary carrier
Fix the planetary carrier with the circlip.
Figure 56
Fix, planetary carrier
Loosen the screw clamping the lever to the shaft.

Figure 57
Loosen the screw
Tools : Allen wrench 6 mm
Fix the lever in “OFF” position by means of the lever locking screw.
Figure 58
Fix the lever in "OFF" position
Tools : Spanner 17mm
Rotate the shaft clockwise until it stops, then tighten the screw to clamp the lever to the shaft.
Figure 59
Tightening, screw
Fix the lever by means of the screw.

Figure 60
Fixing, lever
Tools : Allen wrench 6, 8mm
CAUTION
Check: With the lever in the “OFF” position, rotate the output shaft. The planetary carrier should not rotate. (Readjust the
shaft and lever positioning if necessary). After confirming the carrier does not rotate, move the lever to the “ON” position
and install the lever locking screw.
Figure 61
Checking, rotate the output shaft
Press the ball bearing firmly against the shoulder.
Figure 62
Fix the circlip.
Figure 63
Fixing, circlip
Tools : Snap ring pliers (expansion)
Squeeze in the two rectangular oil seal rings and engage them.
Figure 64
Assembly, oil seal
Install the shaft seal and fix the snap ring.
Figure 65
Assembly, shaft seal
Grease the two rectangular rings, align them centrically and press the drive shaft into guide sleeve until contact is obtained.
Figure 66
Assembly, drive shaft
Fix the sleeve by means of snap ring.
Figure 67
Assembly, sleeve
Squeeze in the circlip
Figure 68
Assembly, circlip
Install the backing plate with the offset plane surface facing upwards.
Figure 69
Assembly, backing plate
Determine adjustment value “B”
 To check “B” don't assemble the seal or the piston springs, also don't apply oil to the discs and plates.
 Adjustment value “B” with 10 disc pairs = 10.6 + 0.2mm
 Adjustment value “B” with 11 disc pairs = 7.8 + 0.2mm
Figure 70
Determine adjustment value "B"
Assemble the piston.
Figure 71
Assembly, piston
Assemble the disc carrier and tap it against the shoulder until contact is obtained.
Figure 72
Assembly, disc carrier
Mount the backing plate aligning the tab and notch.
Figure 73
Assemble alternating plate/disc pack, starting with one inner plate.
 Carry out corrections by means of the corresponding outer plates (S = 1.0, 1.2, 1.4 or 1.8 mm).
Figure 74
Assembly, alternating plate/disc pack
Determine the dimension “B” from the end face of the inner plate carrier to the outer plate.
Figure 75
Determine the dimension "B"
Tools : Calipers
Install the bearing.
Figure 76
Assembly, bearing
Install the sun gear.
Figure 77
Assembly, sun gear
Assemble shim (S = 3.0 ~ 3.9 mm).

Figure 78
Assembly, shim
Fix the shim by means of the circlip.
Figure 79
Fix, shim
Check the end play.

Max. end play allowed = 0.1mm. Adjust using a suitable shim.
Figure 80
Check, end play
Tools : Feeler gauge
After adjustment, squeeze out the circlip and remove the components, up to and including the piston.
Figure 81
Squeeze out circlip
Squeeze circlip into the ring groove with the sealing lip facing the pressure chamber (Facing up). Install o-ring into the
groove.
NOTE!
Apply grease
Figure 82
Assembly, o-ring
CAUTION
Stack cup springs as shown.
Figure 83
Stack, cup springs
Assemble the piston.

Figure 84
Assembly, piston
Install seal ring with the sealing lip facing the pressure chamber (Facing down).
NOTE!
Apply grease.
Figure 85
Assembly, seal ring
Insert the inner plate carrier against the shoulder, until contact is obtained.
Figure 86
Assembly, inner plate
Mount the backing plate.

Figure 87
Assemble alternating plate/disc pack, starting with one inner plate.

NOTE!
Oil the plates prior to installation.
Figure 88
Insert the ball bearing into the centering disc.
Figure 89
Fix the bearing by means of the circlip.

Figure 90
Fix, bearing
Insert the centering disc subassembly into the internal bore.
Figure 91
Assembly, centering disc subassembly
Fix the disc by means of the circlip.
Figure 92
Fix, disc
Align the outer plates radially.

Figure 93
Alignment, outer plates
Assemble the internal gear until all plates/discs are inserted and the gear is properly seated.
Figure 94
Assembly, internal gear
Assemble the sun gear.
CAUTION
Pay attention to the installation position. See photo (shoulder facing down).
Figure 95
Assembly, sun gear
Mount predetermined shim.

Figure 96
Assembly, shim
Preload the plate pack by means of assembly jig and squeeze in circlip
NOTE!
Use new circlip.
Figure 97
Preload the plate pack
Tools : jig
Assemble order of the sun gear, washer (shim) and circlip.
Figure 98
Assembly, sun gear, washer (shim) and circlip
Check oil tightness and the function of clutch assembly.

Install the hydraulic connector.
Figure 99
Check, function of clutch assembly
Tools : Socket
Connect the hand priming pump.

Operate the piston by filling the chamber several times.
Build a test pressure of 35bar and close the connection to the hand priming pump by means of the shut-off valve.
During a test of 3 minutes, no pressure drop is permitted.
Figure 100
Check, pressure drop
Remove the connector and the hand priming pump and install the throttle valve.
NOTE!
Install new o-ring.
Figure 101
Assembly, new o-ring
Install the pre-assembled clutch.
Figure 102
Assembly, clutch
Squeeze in circlip.
Figure 103
Assembly, circlip
Insert the backing plate.
Figure 104
Assemble alternating plate/disc pack, starting with one outer plate.

NOTE!
Lubricate the plates.
Figure 105
Insert the piston firmly against the shoulder.
Figure 106
Assembly, piston
Insert the two cup springs and align them centrically.
CAUTION
Pay attention to the installation position.
Figure 107
Assembly, two cup spring
Assemble the measuring cover and pull it evenly against the shoulder, using 4 screws.
Figure 108
Assembly, measuring cover
Tools : Socket 19mm, measuring cover
Determine dimension X from the plane surface of the housing to the plane surface of the piston.
Dimension X - e.g. 12.6 mm
Figure 109
Determine dimension X
A. Clutch disc
B. Disc
C. Piston
D. Cup spring
E. Clutch disc housing
Measure dimension Y from the contact face of the drive casing to the flange mount surface.
Adjustment value A = X - Y
 Specification = 1.4 + 0.2 mm

 Example (Y = 11.1 mm) Adjustment value is in the specification. A = X - Y = 12.6 - 11.1 = 1.5 mm
 Carry out any corrections by means of corresponding outer plate
(S = 2.8, 2.9, 3.0, 3.2, 3.3 and 3.5 mm)
Figure 110
Measuring, dimension X
Now, remove the measuring cover and the piston again.
Figure 111
Removal, cover and piston
Figure shows the installation position of the disc, piston and its sealing components.
Figure 112
Installation position of components
1 Drive casing 5 Snap ring 9 Back-up ring

2 Clutch disc housing 6 O-ring 10 Piston
3 Back-up ring 7 Disc 11 Cup springs
4 U-section ring 8 U-section ring 12 O-ring
Insert o-ring in the ring groove.
 Expand o-ring slightly prior to the assembly to ensure perfect contact in the recess.
Figure 113
Assembly, o-ring
Insert back-up ring and U-section ring in the ring groove. Oil both rings.
Figure 114
Assembly, back-up ring and U-section ring
Insert the disc to the installation position.
CAUTION
Figure 115
Assembly, disc
Fix disc by means of the snap ring.

Figure 116
Fix, disc
Insert back-up ring and seal ring in the ring groove of the housing. Oil both rings.
CAUTION
Pay attention to the installation position of the seal ring (seal lip downward).
Figure 117
Assembly, back-up ring and seal ring
Assemble the piston and place it evenly against the shoulder, using the measuring cover as well as screws.
Now, remove the measuring cover.
Figure 118
Assembly, piston
Install the two cup springs and align them centrically.
CAUTION
Figure 119
Assembly, cup spring
Insert o-ring in the flange port countersinking. Insert two o-rings in the ring grooves of the guide sleeve.
NOTE!
Apply grease when assembling o-rings.
Figure 120
Assembly, o-rings
Insert o-ring into the ring groove of the drive casing and grease it.
Figure 121
Assembly, o-ring
Align guide bushing radially.

Assemble the drive casing.
CAUTION
Pay attention to the radial installation position.
Figure 122
Assembly, drive casing
Draw the drive casing evenly against the shoulder, using screw.
Figure 123
Assembly, drive casing
Tools : Allen wrench 10mm
Pull the drive shaft and guide bushing out of the housing bore, using the internal puller, until the snap ring can be engaged.
Figure 124
Pull the drive shaft and guide bushing
Tools : Internal puller
Fix the guide bushing radially by means of the screw plug.

NOTE!
Install a new circlip.
Figure 125
Fix, guide bushing
Insert gasket, composed of o-ring and turcon-ring in an oil bath prior to installation.
 Heat turcon-ring in an oil bath prior to installation.
CAUTION
Figure 126
Assembly, gasket
Insert pre-assembled piston and spring into the housing bore and install the screw plug.
Figure 127
Assembly, screw plug
Insert breather (1) and screw plug (2).
NOTE!
Use new o-ring for the screw plug.
Figure 128
Assembly, breather and screw plug
Install two screw plugs (1) and shear off plug (2).
Install the hydraulic connector (part no.: 8933 - 00170).
Figure 129
Assembly, screw plugs and shear off plug
Connect the hand priming pump.

Operate the piston by filling the chamber several times.
Figure 130
Operation, piston
Build a 35 bar test pressure and close connection to the hand priming pump by means of the shut off valve. During a test of
3 minutes, no pressure drop is permitted.
Figure 131
Check, pressure drop
Remove the connector and install the throttle valve.

NOTE!
Use new o-rings.
Figure 132
Assembly, throttle valve
Pre-assemble and mount the shift lock.
CAUTION
The following assembly procedure covers the installation of exchangeable components. Rotor set and valve body can not be
exchanged individually. If damage is noted in the area of the lubricating oil pump (rotor and valve body), the complete shift
lock has to be renewed. In doing so, only parts (rotor and valve body) of the same color marking may be mated.
Shift lock, assembly

Clean orifice and mounting position using compressed air.
Tap assembly into position.
NOTE!
Apply loctite # 242 prior to assembly.
Figure 133
Tap assembly
Assemble needle bearing lower than the surface (0.2 + 0.5 mm) using drift. To prevent needle bearing damage use jig and
press.
Figure 134
Assembly, needle bearing
Tools : Jig, press
Assemble o-ring into spool groove and assemble plastic ring into ring guide. Arrange spool end and the ring guide end and
insert plastic ring on o-ring.
Figure 135
Assembly, o-ring
Tools : Plastic ring guide
Measure plastic ring using measuring bushing.

Figure 136
Measurement, Plastic ring
Tools : Measuring bushing
Assemble each part at the correct position. When assembling check valve apply oil and be careful not to interchange parts.
After assembling check valve and relief valve, stake with a punch to prevent releasing.
Figure 137
Assembly, components
1 Check valve 10 N·m ZF - No. 4143 242 010 6 Screw plug 20 N·m
2 Spring 7 Check valve 10 N·m ZF - No. 4143 242 009
3 Spool 8 Check valve 10 N·m ZF - No. 4143 242 008
4 Screw plug 50 N·m o-ring (new part) 9 Relief valve 10 N·m
5 Seal ring
CAUTION
Use new o-ring for check valve and relief valve.
Figure 138
Use new o-ring
Assemble bearing and squeeze in the snap ring.

Assemble shaft into pump cover and squeeze the snap ring into cover groove.
Figure 139
Assembly, bearing and shaft
Assemble outer rotor in the cover.
CAUTION
Rotor should be replaced as a set.
Figure 140
Assembly, outer rotor
Apply grease on ball and assemble into ball groove on the shaft.
CAUTION
Assemble internal rotor to fit ball groove and the ball on the shaft.
Figure 141
Assembly, ball
Insert rotor pump into case and tighten the screw.

NOTE!
Apply oil on the rotor set when assembling.
Figure 142
Assembly, rotor pump
Apply grease and assemble o-ring into groove.
Figure 143
Assembly, o-ring
Assemble adapter connector.

NOTE!
Use new o-ring.
Figure 144
Assembly, adapter connector
Tightening torque : adapter 25 N·m (19 lbf·ft)
connector 35 N·m (26 lbf·ft)
Install 2 guide studs.

Assemble gasket, cover, screws and remove guide studs.
Figure 145
Assembly, gasket, cover and screws
Tools : Guide studs (M8) 5870 204 011
Tighten the cover screws.
Figure 146
Tightening, screws

Insert pump shaft into gearbox and fit to spline.
Figure 147
Assembly, pump shaft
Install 2 guide studs to gearbox and insert shift lock valve on the studs.
Install mounting screws and remove guide studs.
Figure 148
Assembly, guide studs
Tools : Guide studs (M8) 5870 204 011
Tighten mounting screws.
Figure 149
Tightening, screws
Assemble pipes and hoses at correct position.

CAUTION
Be careful not to interchange connecting ports.
Figure 150
Assembly, pipes and hoses
Install drain plug and fill gearbox to the correct level with specified engine oil.
Figure 151
Assembly, drain plug
Tightening torque (M26 × 1.5) : 80 N·m (60 lbf·ft)
Assemble the throttle valve.
Figure 152
Assembly, throttle valve
Install screw plugs.

NOTE!
Use new o-rings.
Figure 153
Assembly, screw plugs
Tools : Allen wrench : 6, 8, 10, 12 mm
Tightening torque (M10) : 25 N·m (19 lbf·ft)
(M14) : 35 N·m (26 lbf·ft)
(M18) : 50 N·m (37 lbf·ft)
CAUTION
Read operating inspection carefully before using the gearbox.
Figure 154
Inspection
Service Information

description
Profile:
Gearbox (traveling), description

Hydraulic diagram, schematic
Figure 1
Hydraulic diagram
No. Item Specification Function

1 Gear pump 10 cc/rev. To supply pressurized oil necessary for gear speed
(0.61 cu·in/rev) change and other lines.
2 Filter 10µ To filter the pressurized oil supply.
3 Relief valve 40 kgf/cm2 (569 psi) To control system pressure and protect the hydraulic
circuit components.
4 Control valve Reducing valve 32 +3/-2 kgf/cm2 To reduce system pressure to maintain required
(455 +42/-28 psi) gearbox inner or outer clutch pressure.
5 Check valve - To prevent back flow of pressurized oil.
6 Relief valve (Brake 14 ± 1.5 bar (200 ± 21 Controls clutch pressure drop to ensure smooth
valve) psi) application of both clutches when operating as
emergency brake.
7 Solenoid valve - For parking.
8 Solenoid valve - For gear shifting.
9 Accumulator 8 ~ 33 bar To protect the equipment from shock by supplying
(144 ~ 469 psi) pressurized oil exerting back pressure in gearbox in
case of gear shifting or emergency brake working.
10 Pressure check 32 +3/-2 kgf/cm2 Check port for gearbox inner or outer clutch
port (455 +42/-28 psi) pressure.
11 Pressure switch 26.5 ± 2.5 bar (377 ± Pressure switch for power of forward/reverse
35 psi) solenoid valve. (When pressure drops to 26.5 bar
forward/reverse solenoid power cuts off. The valve
goes to neutral position, Travel motor flow is cut and
the unit stops.)
12 Swivel joint - A rotary manifold transfers oil flow to/from the
upper/ lower structures.
P1 Pressure supply port - Connection port for outer clutch pressure supply line.
(Equipment speed: high speed travelling).
P2 Pressure supply port - Connection port for inner clutch pressure supply line.
(Equipment speed: low speed travelling).
J Pressure check port 32 +3/-2 kgf/cm2 Pressure check port for outer clutch (at oil
(455 +42/-28 psi) temperature 50°C) (Inner clutch pressure is 0.5 kgf/
cm2 or less at this time).
M Pressure check port 32 +3/-2 kgf/cm2 Pressure check port for inner clutch (at oil
(455 +42/-28 psi) temperature 50°C) (Outer clutch pressure is 0.5 kgf/
cm2 or less at this time).
L Pressure check port 2.8 ~ 3.5 kgf/cm2 Lubrication pressure check port. (At engine speed
(40 ~ 50 psi) ≥1500 rpm, gearbox oil temperature 50°C).
E Gearbox Leakage oil Max: 1.0 Liter/min. For 1st step (low speed travelling), oil supplied to P2
leakage port quantity (0.26 gpm) applies to inner clutch piston to disengage inner
Max. allowable 0.8kgf/cm2(11psi) clutch and some oil lubricates bearing parts by
pressure internal leakage of output side piston ring, before
returning to tank.
13 Throttle check valve - To make the clutch engage slowly, but release
quickly.
14 Accumulator 4.5 cc/rev. (0.27 cu·in/ Installed to reduce time in speed change since the
rev) application area of 1st speed clutch is larger than that
of 2nd speed.
15 1st speed clutch - Power shift device applied by cone type piston spring
16 1st speed cone type piston spring - and released by hydraulic pressure controlled by the
speed shift solenoid. To transmit power, and perform
17 2nd speed clutch -
parking and auxiliary brake function as well.
18 2nd speed cone type piston spring -
19 Lubrication line ø1.6mm Line for lubricating clutch parts.
20 Governor Pump 3.4 cc/rev (0.20 cu·in/ A rotor pump driven by the gearbox output shaft,
rev) supplies pressurized oil for lubrication and pilot valve
operation.
21 Non return - When downshift, if machine speed is higher than
changeover valve specification then this valve routes the oil for inner
clutch to outer clutch.
22 Relief valve 4.0 ± 0.5 kgf/cm2 To maintain oil pressure required for gearbox
lubrication and pilot valve working.
23 Shift piston - To perform gearshift and shift lock function
simultaneously.
24 Non return valve - At downshift, if the machine speed is above the
downshift point, the shift piston moving against the
spring force displaces oil. The oil volume is fed to P2
through the non return valve.
25 Leakage oil non - When the 1st gear is preselected, the leakage oil at
return valve the shift piston and from the non return valve is fed
from the pressure side P2 to the tank P1 through the
leakage oil non return valve. As a further function, the
valve blocks the control pressure to the inner and
outer clutch.
26 Travel mode - Parking brake control switch (Located in cab).
selection switch
27 Travel control - Gearbox control switch (Located in cab).
lever
28 Suction filter - To filter the pressurized oil supply.
Gearbox, external view
Figure 2
Gearbox, external view
1 Pressure line form the governor (shift lock) to the outer clutch
2 Bleeder-outer clutch
3 Travel motor mounting
4 Connection for inductive transmitter (option, M18 x 1.5)
5 Suction line for the rotor pump
6 Pressure line from the governor control valve (shift lock) to the inner clutch
7 Connenction leak oil control valve (shift lock) to the inner clutch
8 Gearbox mounting hole (M20)
9 Output flange
10 Pressure port-1st speed (M1.6 x 1.5): inner clutch
11 Pressure port-2nd speed (M1.6 x 1.5): outer clutch
12 Oil drain plug (M26 x 1.5) - for horizontal application
13 Oil drain plug (M26 x 1.5)
14 Name plate
15 Parking brake emergency release lever
16 Pressure measuring port - 1st speed
17 Pressure measuring port - 2nd speed
18 Governor control valve (shift lock valve)
19 Lubrication pressure check port
Gearbox, sectional view

Figure 3
Gearbox, sectional view
1 Gearbox input shaft 10 Cup spring for clutch

2 Accumulator to control pressure in the outer clutch 11 Throttle valve
3 Inner clutch 12 Drive shaft (Input)
4 Outer clutch 13 Drive (AN)
5 Planetary gear drive 14 Output (AB)
6 Emergency parking brake release device 15 Output (AB)
7 Governor control valve (Shift lock) 16 1st gear (low speed)
8 Rotor pump 17 2nd gear (high speed)
9 Helical gear drive 18 Parking (brake)
Function
The 2 HL100 is a 2 stage power shift gearbox consisting of a helical drive, planetary, dual counter shafts, an integrated multi-
disc brake and a multi-disc clutch. The power shift device consists of a planetary drive composed of the outer clutch (multi-
disc brake) which is splined to the gearbox housing, and the inner clutch multi-disc pack which is splined to the input shaft.
Both clutches are actuated by cup springs and released hydraulically. When both clutches are actuated the planetary can not
rotate and functions as an auxiliary and parking brake.
Parking brake emergency release device
A mechanically operated dog clutch is located between the planetary and helical gear output drive.
When the park brake emergency release lever is unlocked and shifted to the “OFF” position (dog clutch disengaged) the
power flow to the output shafts is disconnected. Since the gearbox input/output is mechanically disconnected the machine
can be towed without the gearbox restricting the towing speed.
WARNING
When the emergency parking release lever is in the “OFF” position the machine has no park brake function. Always
block the wheels prior to disconnecting the park brake!
CAUTION
Prior to towing, check the gearbox oil level. Do not exert excessive force when shifting the lever. After towing, return the
lever to the “ON” position (dog clutch engaged) and tighten the locking screw to specified torque.
Shift lock
The governor control valve operation delays downshifting from 2nd gear into 1st gear, if a danger of overspeeding exists
(vehicle speed of 1st gear above normal), until the gearbox has reached a predetermined rotating speed. This prevents
overspeed damage to the hydraulic travel motor and gearbox. (Gearbox output shaft speed approx. 800rpm).
CAUTION
Shift lock functions only when down shifting from 2nd to 1st speed.
Shift lock valve, sectional view

Figure 4
Shift lock valve, sectional view
1 Drain oil check valve P1 Shift oil for 2nd speed

2 Shuttle valve P2 Shift oil for 1st speed
3 Check valve B Inner clutch
4 Relief valve K Outer clutch
5 Filter R Planetary gear drive
6 Suction pipe
7 Pump
Shift lock valve, exploded view

Figure 5
Shift lock valve, exploded view
Operation, shift lock

Low speed (1st gear)
At gearbox stop, shift piston (5) is pushed up by piston spring (6) force. When 1st speed is selected oil flow from the
solenoid valve is supplied through P2 port. The oil flows through a passage under the shift piston and K port to release the
inner clutch while the outer clutch is engaged by spring force. The gearbox is at 1st speed state by the clutches. The rotor
pump oil is supplied to SH port according to machine speed, increasing but P2 port supply oil pressure holds the shift piston
so it does not move and the machine is at 1st speed state.
Figure 6
Operation, shift lock (low speed - 1st gear)
1 Throttle check valve 5 Outer clutch 9 Rotor pump 13 Shift piston

2 Outer clutch air breather 6 Parking release 10 Relief valve 14 Non return valve
3 Inner clutch 7 Output 11 Leakage oil non return valve
4 Travel motor 8 Output 12 Non return changeover valve
Low speed (2nd gear)

When 2nd speed is selected oil flow from the solenoid valve is supplied through P1 port. The oil flows through passage S of
the shift piston, check valve (2) and B port to release the outer clutch while the inner clutch is engaged by spring force. The
gearbox is at 2nd speed state by the clutches.
Figure 7
Operation, shift lock (low speed - 2nd gear)
HIgh speed (2nd gear)

The rotor pump oil is supplied to SH port according to the machine speed increasing. The supplied oil pressure pushes down
the shift piston against spring force and passage S of the shift piston is blocked, but oil supplied through check valve (2)
keeps the gearbox at 2nd speed state.
Figure 8
Operation, shift lock (high speed - 2nd gear)

3 Inner clutch 7 Output 11 Leakage oil non return valve 15 Accumulator
High speed (2nd to 1st gear)

At 2nd gear high speed the rotor pump oil is pushing the shift piston against spring force. At this time if 1st speed is
selected the solenoid valve cuts off oil to P1 port and supplies oil to P2 port. The oil flows through S1 passage, opens check
valve (2) and port B. Outer clutch is disengaged by the oil supplied through port B and the gearbox is at 2nd speed state.
According to machine speed (decreasing) rotor pump flow is decreased and the pressure against the spring force is
decreased. By the spring force the shift piston is pushed up, the oil flow supplied through B port is disconnected and P2 oil
flow through SL passage, K port and the gearbox is at 1st speed state.
Figure 9
Operation, shift lock (high speed - 2nd to 1st gear)

3 Inner clutch 7 Output 11 Leakage oil non return valve
Operation, clutch
Low speed (1st gear)
Shift control hydraulic pressure routed to the inner clutch piston compresses the cup springs releasing clutch (LK). Outer
clutch (LB) is spring applied and holds ring gear (A) stationary. The torque flow from the hydraulic motor is transmitted to
input shaft (AN) through sun gear (s) to planetary gear drive (PT) through gear (B) to gear drive (ST) and the output shafts
(AB) rotate.
Figure 10
Operation, clutch (low speed - 1st gear)
High speed (2nd gear)

Shift control hydraulic pressure routed to the outer clutch piston compresses the cup springs releasing clutch (LB). Inner
clutch (LK) is spring applied and locks ring gear (A) to input shaft (AN) through the clutch pack. The torque flow from the
hydraulic motor is transmitted to input shaft (AN) through clutch (LK) to ring drive (PT) and gear (B) to gear drive (ST) and
the output shafts (AB) rotate.
Figure 11
Operation, clutch (high speed - 2nd gear)
Inner clutch - throttle check valve / Outerclutch - throttle check valve

Figure 12
Throttle check valve
1 Fitting 5 Pin A Inner clutch - throttle check valve

2 Spring 6 Ball B Outer clutch - throttle check valve
3 O-ring 7 Orifice (0.8 mm)
4 Seat 8 Orifice (1.0 mm)
CAUTION
If the orifice is clogged 2nd speed will malfunction.(inner clutch)
If the orifice is clogged 1st speed will malfunction.(outer clutch)
Operation, gear shift complex valve

Travel control valve is composed of parking brake solenoid valve (1), 1st/ 2nd speed solenoid valve (2) and clutch pressure
reducing valve (3).
Parking brake solenoid valve
According to parking brake switch, the gearbox can be locked and unlocked. When the solenoid valve is not operating the
parking brake can be released by using T handle (5).
 Solenoid valve normal: Release T handle (5) to the end. (Full open)
 Solenoid valve abnormal: Tighten T handle (5) to the end. (Full closed)
1st / 2nd speed solenoid valve

According to 1st/2nd speed selection switch the solenoid valve supplies oil to disengage 1st/2nd speed clutch in gearbox.
Figure 13
Gear shift complex valve
1. Parking brake solenoid valve

2. 1st/ 2nd speed solenoid valve
3. Reducing valve
4. Relief valve
5. T handle
6. Pressure switch
Reducing valve
The reducing valve reduces gear pump output pressure (1st pressure) to secondary pressure which activates gearbox clutch.
Figure 14
Reducing valve
1 Cap 5 Seat
2 Adjustment screw 6 Valve
3 Body 7 Spool
4 Sealing 8 Spring
Service Information

disassembly
Profile:
Gearbox (traveling), disassembly

Instructions
1. Remove the travel motor from the gearbox.

2. Clean the gearbox thoroughly before the disassembly to prevent the possibility of dirt and foreign matter entering.
3. Use the special tools, see the manual.
4. Cleaning and inspection.
 Cleaning
Clean all parts thoroughly using solvent type cleaning fluid. It is recommended that parts be immersed in
cleaning fluid and moved up and down slowly until all old lubricant and foreign material is dissolved and
parts are thoroughly cleaned.
WARNING
Care should be exericsed to avoid skin rashes, fire hazards and inhalation of vapors when using
solvent cleaners.
 Bearings
Remove bearings from cleaning fluid and strike larger side of cone flat against a block of wood to
dislodge solidified particles of lubricant. Immerse again in cleaning fluid to flush out particles.
Repeat above operation until bearings are thoroughly clean. Dry bearings using moisture free
compressed air. Be careful to direct air stream across the bearings to avoid spinning. Do not spin
bearings when drying. Bearings may be rotated slowly by hand to facilitate drying process.
 Housings
Clean interior and exterior of housings, bearing caps, etc. thoroughly. Cast parts may be cleaned
in hot solution tanks with mild alkali solutions providing these parts do not have ground or
polished surfaces. Parts should remain in solution long enough to be thoroughly cleaned and
heated. This will aid the evaporation of the cleaning solution and rinse water. Parts cleaned in
solution tanks must be thoroughly rinsed with clean water to remove all traces of alkali. Cast parts
may also be cleaned with steam cleaner.
WARNING
Care should be exercised to avoid skin rashes and inhalation of vapors when using alkali cleaners.
All part cleaned must be thoroughly dried immediately by using moisture free compressed air or
soft lintless absorbent wiping rags free of abrasive materials such as metal filings, contaminated
oil or lapping compound.
 Inspection
The importance of careful and thorough inspection of all parts cannot be overstressed. Replacement of all
parts showing indication of wear or stress will eliminate costly and avoidable failures at a later date.
 Bearings
Carefully inspect all rollers, cages and cups for wear, chipping or nicks to determine fitness of
bearings for further use. Do not replace a bearing cone or cup individually without replacing the
mating cup or cone at the same time. After inspection, dip bearings in clean light oil and wrap in
clean lintless cloth or paper to protect them until installed.
 Oil seals, gaskets and retaining rings
Replacement of spring load oil seals, o-rings, metal sealing rings, gaskets and snap rings is more
economical when unit is disassembled than premature overhaul to replace these parts at a future
time. Further loss of lubricant through a worn seal may result in failure of other more expensive
parts of the assembly. Sealing members should be handled carefully, particularly when being
installed. Cutting, scratching, or curling under of lip of seal seriously impairs its efficiency. Apply a
thin coat of permatex No. 2 on the outer diameter of the oil seal to assure an oil tight fit into the
retainer. When assembling metal type sealing rings, lubricate with grease to stabilize rings in their
grooves for ease of assembly of mating members. Lubricate all o-rings and seals with
recommended type engine oil before assembly.
 Gears and shafts

If magna-flux process is available, use process to check parts. Examine teeth on all gears carefully
for wear, pitting, chipping, nicks, cracks or scores. If gear teeth show spots where case hardening
is worn through or cracked, replace with new gear. Small nicks may be removed with suitable
hone. Inspect shafts and quills to make certain they are not sprung, bent, or splines twisted, and
that shafts are true.
 Housing, covers, etc.

Inspect housings, covers and bearing caps to be certain they are thoroughly cleaned and that
mating surfaces, bearing bores, etc., are free from nicks or burrs. Check all parts carefully for
evidence of cracks or condition which would cause subsequent oil leaks or failures.
 Mounting
 Use standard quality (manufacturer furnished) o-ring when mounting hydraulic travel motor to
the gearbox casing.
 Control lines shall not be twisted. Use standard products for oil and fittings, etc.
 Whenever connecting hydraulic oil components (hose, fitting, pipe...), take extreme care to avoid
ingression of any contaminant. (To make absolutely sure, clean with compressed air.)
 Align the drive shaft yoke.
 When mounting gearbox torque requirement should be met. (52.3 ± 5.2 kgf·m, 377 ± 37 lbf·ft)
 Always use the recommended gearbox oil and fill with specified amount.
General tools
General tools
No. Description Size Quantity Remark

1 Allen wrench 3, 5, 6, 8, 10, 12 1
2 Spanner Set
3 Snap ring pliers
4 Air gun
5 Driver
6 Hammer
7 Torque wrench 100 N·m
8 Feeler gauge
9 Socket wrench Set
10 Eye bolt M12 1 Drive shaft gear
11 Punch 1 Shift lock valve
Special tools
Special tools
No. Part no. Description Quantity Size Remark

1 8933 - 00020 Adjustment screw (M12) 1 Set Shift lock valve
2 8933 - 00030 Offset screwdriver 1
3 8933 - 00040 Jig 1 Clutch
4 8933 - 00050 Internal puller 1 Planetary gear
8933 - 00060 Jig 1
5 - Puller 1 Planetary gear inner race
6 8933 - 00070 Pry bar set 1 Parking lever
7 8933 - 00080 Internal puller 1 Shaft needle bearing
8933 - 00090 1
8 8933 - 00100 Internal puller 1 Governor shuttle valve
8933 - 00110 Sliding hammer 1
9 8933 - 00120 Driver 1 Lock washer
10 8933 - 00130 Sleeve 1 Helical bearing
11 8933 - 00140 Driver 1 Needle bearing
12 8933 - 00150 Oil seal insert 1 Clutch shaft seal
13 8933 - 00160 Connector 1 Measure pressure
14 8933 - 00170 Connector 1
15 8933 - 00180 Hand priming pump 1
16 8933 - 00190 Measuring cover 1 Measuring outer clutch
17 8933 - 00200 Calipers 1 Measuring outer clutch
18 8933 - 00210 Inserter 1 Shift piston seal
19 8933 - 00220 Measuring sleeve 1
Precautions for disassembly
 Before disassembly clean the gearbox and prepare the required tools, manual and a bench for the parts.
CAUTION
Work safely!
Mount the gearbox on the maintenance stand vertically.
Figure 1
Mount the gearbox
Put an oil reservoir below the gearbox.

Remove the plug and drain the oil.
Figure 2
Removal, plug
Tools : Allen wrench (12mm)
Oil reservoir : 4 Liter
Remove all hoses and pipes.
Figure 3
Removal, hoses and pipes
Tools : Spanner (19, 27mm)
Remove the four screws and remove the shift lock valve.
Figure 4
Removal, screw and shift lock valve
Remove screws and remove cover with gasket.

Figure 5
Removal, screws and cover
Remove screws and pump cover out of housing.
Figure 6
Removal, screws and pump cover
Remove pump shaft.
Figure 7
Removal, pump shaft
Remove internal rotor out of pump shaft.

Figure 8
Removal, internal rotor
Disassemble control case and outer rotor from pump shaft and remove spring and ball from pump cover and remove ball
out of pump shaft.
CAUTION
When disassembling outer rotor, be careful spring against ball.
Figure 9
Removal, control case and outer rotor
Remove snap ring out of cover and remove shaft and bearing. Remove snap ring from shaft and remove bearing.
Figure 10
Removal, snap ring, shaft and bearing
Remove needle bearing out of case using puller.

Figure 11
Removal, needle bearing
Remove check valve, spool, spring out of valve body.
CAUTION
Mark assembly position of each valve.
Figure 12
Removal, check valve, spool and spring
Disassemble the accumulator valve from the housing.
Figure 13
Removal, accumulator valve
Remover circlip out of guide bushing.

Figure 14
Removal, circlip
Loosen the 10 screws evenly and than remove.
Figure 15
Loosen, screws
Tools : Allen wrench socket (10mm)
Install two adjusting screws and separate the drive casing from the gearbox.
Figure 16
Removal, drive casing
Tools : Setscrew 2 (M12)
spanner 24mm, pry bar
Remove the housing.

Figure 17
Removal, housing
Remove the cup spring.
Figure 18
Removal, cup spring
Close the supply line and press the piston out of the housing bore, using compressed air.
Figure 19
Close the supply line and press the piston
Remove the piston.

Figure 20
Removal, piston
Remove the breather and the plug.
Figure 21
Removal, breather and plug
Tools : Spanner (11mm)
Allen wrench (5mm)
Remove the seal ring and back-up ring from the ring groove of the housing.
Figure 22
Removal, seal ring and back-up ring
Squeeze out snap ring.

Figure 23
Squeeze out snap ring
Pull the gasket out of the housing bore, using offset screwdriver.
Figure 24
Pull out the gasket
Tools : Offset screwdriver
Remove o-ring from the housing.
Figure 25
Removal, o-ring
Remove the outer clutch pack.

Figure 26
Removal, outer clutch pack
Remove the backing plate.
Figure 27
Removal, backing plate
Squeeze out circlip.
Figure 28
Squeeze out circlip
Remove the inner clutch unit.

Figure 29
Removal, inner clutch unit
Fix the sun gear axially by means of an assembly jig.
Figure 30
Fix the sun gear
Remove circlip.
Figure 31
Removal, circlip
Remove the ring, washer and the sun gear.

Figure 32
Removal, ring, washer and sun gear
Separate the internal ring gear from the drive shaft.
Figure 33
Separate the internal ring gear
Figure 34
Squeeze out circlip
Remove center ring disc.

Figure 35
Removal, center ring disc
Remove the snap ring, press the ball bearing out of the centering disc.
Figure 36
Removal, snap ring
Ring, bearing, centering disc, ring gear (components).
Figure 37
Components
Remove the inner clutch discs and plates.

Figure 38
Removal, inner clutch disc and plates
Remove the backing plate.
Figure 39
Removal, backing plate
Pry the inner plate carrier out of the piston.
Figure 40
Removal, inner plate carrier
Tools : Screwdriver
Remove the seal from the carrier.

Figure 41
Removal, seal
Remove the piston from the drive shaft.
Figure 42
Removal, piston
Remove the cup springs.
Figure 43
Removal, cup springs
Remove o-ring and seal.

Figure 44
Removal, o-ring and seal
Remove support shim.
Figure 45
Removal, support shim
Figure 46
Squeeze out circlip
Remove the ring from the guide bushing.

Figure 47
Removal, ring
Tools : Snap ring pliers
Separate the guide bushing from the shaft.
Figure 48
Separate the guide bushing
Remove the seal from the guide bushing after squeezing out snap ring.
Figure 49
Removal, seal
Remove the snap ring.

Figure 50
Removal, snap ring
Remove the snap ring from the shaft to the bearing.
Figure 51
Removal, snap ring
Tools : Pliers
Press the bearing from the shaft.
Figure 52
Press the bearing
Remove the throttle valve from the center of the shaft.

Figure 53
Removal, throttle valve
Tools : Allen wrench (10mm)
Remove o-ring from throttle valve.
Figure 54
Removal, o-ring
Squeeze out circlip and remove the planetary drive assembly.
Figure 55
Removal, planetary drive assembly
Tilt the gearbox for 90°.

Separate and remove the planetary carrier from the helical gear using an internal puller.
Figure 56
Removal, planetary carrier
Squeeze out circlip from the planetary gear shaft.
Figure 57
Squeeze out circlip
Pry off the planetary gear using 2 offset screwdrivers.
Figure 58
Removal, planetary gear
Tools : Offset screwdriver
Remove the washer, planetary gear, and the bearing from the gear shaft.
Figure 59
Removal, washer, planetary gear and bearing
Pull off the bearing inner race of the planetary gear.
Figure 60
Pull off bearing inner race
Tools : Two-leg puller
Turn over the planetary drive and squeeze out the snap ring.
Figure 61
Turn over the planetary drive
Remove the bearing.

Figure 62
Removal, bearing
Remove the screw locking the park brake emergency release lever.
Figure 63
Removal, screw
Tools : Spanner (17mm)
Remove the dog clutch sliding collar.
Figure 64
Removal, dog clutch sliding collar
Remove the plug (10mm) from the housing.

Figure 65
Removal, plug
Tools : Allen wrench 10mm
Drive the roll pin from the plug hole.
Figure 66
Drive the roll pin
Tools : Punch, hammer
Pry the parking brake emergency release lever out of the housing bore.
Figure 67
Removal, parking brake emergency release lever
Tools : Pry bar
Remove the dog clutch shift fork and two sliding pads.
Figure 68
Removal, dog clutch shift fork
Remove the snap ring and o-ring.
Figure 69
Removal, snap ring and o-ring
Remove the snap ring fixing the helical gear.
Figure 70
Removal, snap ring
Remove helical gear from the housing.

Figure 71
Removal, helical gear
Tools : Plastic hammer
Remove the snap ring from the helical gear.
Figure 72
Removal, snap ring
Remove the snap ring, washer, and clutch dog.
Figure 73
Removal, snap ring, washer and clutch dog
Disassemble the needle bearing from the gear shaft using an internal puller.
Figure 74
Removal, needle bearing
Tools : Internal puller
Disassemble the helical gear and the bearing cap using a press.
Figure 75
Removal, helical gear and bearing cap
Tools : Plastic hammer
Squeeze out circlip from the bearing cap.
Figure 76
Removal, circlip
Remove the bearing.

Figure 77
Removal, bearing
Pry off the bearing from the helical gear.
Figure 78
Removal, bearing
Tools : Pry bar (2)
Rotate the gearbox so the travel motor mount flange faces downward. Remove the lock plate on the output flange for the
rear axle.
Figure 79
Removal, lock plate
Tools : Screwdriver, hammer
Remove the flange screws.

Figure 80
Removal, screws
Tools : Socket wrench 17mm
Remove the washer and o-ring.
Figure 81
Removal, washer and o-ring
Pry off the output flange.
Figure 82
Removal, output flange
Tools : Pry bar (2)
Pry the flange seal out of the housing bore.

Figure 83
Removal, flange seal
Remove the cover screws.
Figure 84
Removal, screws
Install two long screws to the cover.
Figure 85
Installation, two long screws
Reverse the mounting position.

Remove the lock plate on the output flange for front axle.
Figure 86
Removal, lock plate
Tools : Screwdriver, hammer
Remove the flange mounting screws.
Figure 87
Removal, screws
Remove the washer and o-ring.
Figure 88
Removal, washer and o-ring
Pry off the output flange.

Figure 89
Removal, output flange
Pry the flange seal out of the housing bore.
Figure 90
Removal, flange seal
Tools : Screwdriver
Using a brass drift, drive the shaft until the cover contacts the screw head.
Figure 91
Drive the shaft
Tools : Brass drift, hammer
Reverse the mounting position.

Remove the screws and install an eye bolt in the shaft.
Figure 92
Removal, screws
Using the eye bolt lift out the gear assembly.
Figure 93
Removal, gear assembly
Separate the cover from the drive gear.
Figure 94
Removal, cover
Separate the oil baffle from the drive gear.

Figure 95
Removal, oil baffle
Squeeze out circlip fixing the bearing to the cover.
Figure 96
Squeeze out circlip
Press ball bearing out of the cover.
Figure 97
Removal, ball bearing
Pull o-ring out of the ring groove.

Figure 98
Removal, o-ring
Pry off the cover and screws from the flange (front and rear). If there is no need to change screws or cover, do not
disassemble.
Figure 99
Removal, cover and screws
Tools : Pry bar
Remove the oil baffle from the housing.
Figure 100
Removal, oil baffle
Using a brass drift drive the ball bearing out of the housing.
Figure 101
Removal, ball bearing
Disassemble the mounting screw of the lubrication suction pipe.
Figure 102
Removal, screw
Remove the mounting nut from the lubrication oil pipe.
Figure 103
Removal, nut
Disassemble throttle valve and plugs.

Figure 104
Removal, throttle and plugs
Allen wrench 6, 8, 12mm
Put the disassembled parts in order and prepare the assembly.

Service Information

lubrication and
maintenance
Profile:
Gearbox (traveling), lubrication and maintenance

Oil specification: Engine oil API CD / CE / CF / SF / SG grade SAE 15W-40 Capacity: about 3.8 Liter (1.0 gal) Refill: Stop the
machine on even ground. Fill oil until it flows from the fill port and check oil level. Oil level check: Replace gearbox oil after
first 100 hour and after that every 2000 hour. (Change at least once a year)
 Operate gearbox until normal operating temperature.

 Stop the machine on even ground.
 Drain oil 5 minutes after engine shut-down.
 Fill oil until it flows from the fill port.
 Check oil level 5 minutes after and refill if required.
CAUTION
To lubricate gearbox components travel 2 minute at low speed.
CAUTION
If the ambient temperature is below -5°C travel at least 10 minute at low speed.
Service Information

Gearbox (travling), 4314 Service Information 2014/5/12
troubleshooting
Profile:
Gearbox (travling), troubleshooting

Transfer gearbox 1st / 2nd speed solenoid
Travel control lever 1st / 2nd solenoid Release clutch (supply Engaged clutch (cut- Travel speed
valve oil) off oil)
1st Power ON Inner clutch Outer clutch 1st (low)
2nd Power OFF Outer clutch Inner clutch 2nd (high)
Parking brake solenoid valve
Parking solenoid valve Clutch oil supply Engaged clutch Remarks

Power OFF None Inner clutch, outer clutch Parking
lever (Both cut-off) (By spring force)
Engine stop or control pressure low - Parking operation automatically
Rotary switch
Parking Safety lock Travel Work

T OFF ON Enable Disable
W OFF OFF Enable Enable
P ON ON Disable Disable
Transfer gearbox pressure, unit : kgf/cm2
Clutch Lubrication Drain Clutch back pressure

30 ~ 35 4.0 ± 0.5 0.8 0.5
Service Information

Travel motor, adjustment 4411 Service Information 2014/5/12
Profile:
Travel motor, adjustment

Condition
 Engine coolant temperature : Normal operating temperature.

 Hydraulic oil temperature : 50 ± 5°C (122 ± 10°F)
 Travel mode : T (travel)
Relief valve pressure
 Stop the machine on even ground and block the wheels of the front and rear axles.
 Thrust the attachment into the ground.
 Remove MB port plug and install a pressure gauge (600 kgf/cm2, 8530 psi).
 Apply service brakes fully, select 2nd speed gear and accelerate the engine.
 Adjust main relief pressure to higher than travel motor relief pressure specification.
 Release lock nut (2) and loosen (pressure decrease) or tighten (pressure increase) adjusting screw (1) to 370 kgf/
cm2(5263 psi). Hold adjusting screw (1) with allen wrench and tighten lock nut (2).
 Set reverse relief valve pressure the same way.
 Set the main relief pressure to specification.
 Adjust the relief valve pressure to correct value and pay attention to safety.
Figure 1
Adjustment, relief valve
1. Adjusting screw
2. Lock nut
Regulator pressure
CAUTION
Before adjusting check travel motor and system.
 Before adjusting ensure that main relief pressure and travel motor relief pressure are normal.
 Do not adjust regulator pressure for adjusting travel speed. Adjust the regulator pressure when the machine second
gear maximum speed is low, or starting and climbing force is low.
Figure 2
Regulator pressure, adjustment
1. Adjusting screw
2. Lock nut
Pressure measurement
 Stop the machine on level ground and set the bucket on undercarriage.
 Stop the engine, remove G1 and M1 port plug. Install pressure gauges (600 kgf/cm2, 8530 psi).
 Start the engine, select 2nd gear forward and slowly accelerate the engine.
 Observe the gauge readings at port G1 and M1.
 System pressure should register first at G1.
 When G1 pressure reaches the specified regulation start pressure, then M1 pressure should start to register.
 At this point both G1 and M1 pressure will rise to the specified maximum pressure.
 If the start of regulation pressure is not to specification, adjust as follows:
Pressure setting
 Mark the adjusting screw position.

 Release lock nut (2).
 If the start of regulation pressure is not to specification adjust as follows :
LOWER
Start of control point : Turn adjusting screw (1) clockwise.
RAISE
Start of control point : Turn adjusting screw (1) counterclockwise.
CAUTION
Do not adjust A,B for regulator setting. If the regulator pressure is higher than specification, starting force or maximum
speed at 2nd gear ratio will be low.
Regulator pressure
Unit Specification
Regulating pressure (start) kgf /cm2 (psi) 270 (3840)
Regulating pressure (end) 280 (3983)
Adjusting travel speed
 Minimum flow is adjusted by screw (B) and maximum flow is set by screw (A).
 The adjusting screws restrict adjustable swash plate angle.
 Set screws (A, B) are set at the factory do not adjust in the field.
Service Information

Travel motor, assembly 4411 Service Information 2014/5/12
Profile:
Travel motor, assembly

Rotary group assembly
Assemble rotary assembly.
Figure 1
Assemble, rotary group
Install sleeve on the drive shaft.
Figure 2
Assemble, sleeve
Heat housing to 80°C (176°F).

Figure 3
Heat housing
Insert the rotary assembly to the housing.
Figure 4
Insert, rotary assembly
Set Qmax screw to zero oil output.

Remove screw (1).
Assemble o-ring (2) to housing.
Figure 5
Remove screw and assemble o-ring
Set maximum cylinder swivel range with the screw.
Figure 6
Set, screw
* : Disc
Figure 7
Disc
Place centering disc.
Figure 8
Place centering disc
Install measuring tool.

Figure 9
Install measuring tool
Measure dimension X.
Figure 10
Measuring, dimension X
Port plate, assembly

Assemble the port plate and screw to specified torque.
Adjust Qmin screw height to the value recorded before disassembly.
Assemble plug and remove sleeve.
Figure 11
Assemble, port plate and screw
Control cover, assembly

Adjust screw height to the value recorded before disassembly.
Figure 12
Adjust, screw height
Assemble control cover.
Figure 13
Assemble, control cover
Press in shaft seal, disc and safety ring.
CAUTION
Pay attention to assemble depth.
Figure 14
Press, seal, disc and safety ring
Counterbalance valve, assembly

Figure 15
Assemble, counterbalance valve
Service Information

Travel motor, description 4411 Service Information 2014/5/12
Profile:
Travel motor, description

 The hydraulic motor is an axial piston, bent axis type motor. It is mounted directly to the transfer gearbox.
 The motor consists of: housing (6), the internal piston/rotary group and control housing (20).
 Housing (20) contains the control device and the pressure/return connection A and B. Oil from the pump is forced
into the motor through either A or B connection. Inside the motor, it pressurizes the pistons. The pistons are
located inside the barrel, where they slide back and forth. The resulting force turns output shaft (1) and creates
torque. Torque and rotational speed at output shaft (1) are inversely proportionate. This means, that higher speed
equals less torque, and vice versa. Both speed and torque are determined by the amount of oil flowing through the
motor. In turn, the amount of oil flow depends on the motor's displacement angle. The control device in housing
(20) regulates the displacement angle. The maximum swivel angle is 25°, the minimum swivel angle 7°.
 Motor performance can be summed up as follows:

Piston stroke at MIN. - Torque is MIN. - Output speed is MAX.
Piston stroke at MAX. - Torque is MAX. - Output speed is MIN.
Swivel angle and displacement affect output speed.
Swivel angle and operating pressure affect torque.
 The pump supplies oil to the hydraulic motor. The oil flows via connection A or B at control housing (20). From
there it flows through a kidney shaped hole in control lens (13) to cylinder barrel (8). Three bores in the barrel are
connected to the pressure side. Three others are connected to the return side. One bore is at dead center, which
means that the piston inside this bore is just changing direction.
 Inside the barrel bores, pistons (8) slide back and forth. Each one is sealed against the bore with two piston rings.
When three pistons are pressurized, a radial force is generated. This force then creates torque at output shaft (1).
 With the engine at idle or the machine just starting to move, spring force holds barrel (8) against control lens (13).
The springs are located behind center pin (25). When pressure increases, hydraulic force presses the barrel against
the control lens. The amount of this pressure is critical. A thin oil film must always remain between barrel (8) and
control lens (13). This keeps leak oil to a minimum.
 The leak oil that does develop lubricates the center pin, the pistons, and the output shaft bearing.
 Pressure oil from either connection A or B flows to regulator piston (b). The oil reaches the piston through check
valves (E) and internal passages in control housing (20). This holds the piston in a maximum displacement position,
which means maximum output torque. Pump pressure reaches the motor through spool (H) when it is moved by
control pressure at connections X1 or X2. Under certain conditions, the pressure flow may reverse direction, but the
motor still turns in the same direction as before. This can happen, for example, when suddenly releasing the travel
pedal at high speed. Such a reversal of pressure may adversely affect motor regulation.
 To prevent this, control pressure from one side (which side depends on travel direction) is applied to servo valve (a).
The pressure reaches the piston through valve spool (H). The spool shifts in response to control pressure changes.
 Through servo valve (a), control pressure acts on spring (18). When the engine speed increases, control pressure
increases. Now servo valve (a) exerts more and more force on spring(18). This allows high pressure to flow from
servo valve (a), through a passage, and to the larger surface of servo valve (b). Because pressure acts on its larger
surface, this regulator piston is now able to move barrel (8) towards minimum displacement, or angle. Because a
smaller angle means higher rotational speed, the machine travels faster. Minimum displacement (Qmin) - and
therefore maximum machine speed–is limited by adjustment screw (9).
 Regulation angle is also influenced by changes in operating pressure. This pressure acts on a differential surface on
servo valve (a). In this way, a definite pressure ratio is created. Operating pressure can thus influence regulation
angle : when operating pressure increases, the hydraulic motor regulation angle also increases.
 The motor regulation is set with adjustment screw (21). Exact adjustment will result in maximum machine
performance in terms of both speed and drawbar pull.
 Components
The motor assembly contains the following valves each having a specific function as described.
 Shuttle valve
The shuttle valve is actuated by supply oil pressure or negative oil pressure of the motor, and controls the
pressurized oil flow to the servo valve.
 Counterbalance valve
The counterbalance valve is used to enable smooth starting and stopping of the travel motor. It blocks or
throttles the circuit of the travel motor to control the motor speed according to the amount of oil
discharged by the pump.
 Servo valve
The servo valve routes the pressurized oil flow to the servo cylinder.
 Servo cylinder
The servo cylinder controls the angle of the valve plate to regulate the motor displacement. When the oil
pressure from the servo valve exceeds the specified pressure for start of motor regulation the cylinder
piston is moved to control the displacement from the minimum upper limit to the overall maximum limit.
Figure 1
Travel motor, port connection
Port connection
Port name Port size Description Port name Port size Description
A, B SAE 1 1/4 Oil supply (return) T M 26 × 1.5 Drain
G1 M 14 × 1.5 Regulator pressure S M 27 × 2.0 Plug
M1 M 14 × 1.5 Main pressure MA, MB M 18 × 1.5 Main pressure check
X M 14 × 1.5 Drain U M 22 × 1.5 Plug
Figure 2
Travel motor
1 Shaft 13 Control lens 25 Center pin

2 Seal 14 Throttle pin a Servo valve
3 Back-up ring 15 Counterbalance valve b Servo cylinder
4 Retaining ring 16 Return spring C Relief valve
5 Roller bearing 17 Adjusting screw D Orifice
6 Housing 18 Control spring E Check valve
7 Piston 19 Retaining ring F Orifice
8 Cylinder 20 Control housing G Check valve
9 Minimum flow adjusting screw 21 Regulator adjusting screw H Counterbalance spool
10 Seal 22 Maximum flow adjusting screw I Center pin
11 Cover 23 Steel seal ring
12 Control valve 24 Spring
Travel motor, circuit

Figure 3
Travel motor, circuit
1 Shuttle valve 5 Servo valve 9 Solenoid valve (forward / reverse)

2 Counterbalance valve 6 Shuttle valve 10 main pump
3 Relief valve 7 Main spool 11 Engine
4 Servo cylinder 8 Remote control valve (pedal)
Service Information

Travel motor, disassembly 4411 Service Information 2014/5/12
Profile:
Travel motor, disassembly

Precautions
 Thoroughly clean the gearbox assembly prior to disassembly.

 Match mark attached components to indicate proper positioning during reassembly.
 Take care not to mix parts of sub assemblies.
 Thoroughly clean all parts and the inside of the casings.
General repair instructions

Observe the following notices when carrying out repair work on hydraulic components.
Figure 1
Attention
Close all ports of the hydraulic components.
Figure 2
Hydraulic components
Replace all seals.
Figure 3
Seals
Check all seals and surfaces for wear.
CAUTION
Rework of sealing area with abrasive paper can damage the surface.
Figure 4
Sealing area
Fill up hydraulic components with hydraulic oil before start-up.
Figure 5
Filling, hydraulic oil
Seal kits and component groups

Drive shaft seal.
Figure 6
Seal
External seal kit.
Figure 7
Seal kit
Housing
Figure 8
Housing
Rotary group.
Figure 9
Rotary parts
Port plate with control piston.
Figure 10
Port plate parts
Sealing the drive shaft
Figure 11
Drive shaft seal
Remove retaining ring and shim form housing.
Figure 12
Removal, retaining ring
Install screw in the seal and pull out with pliers.
Figure 13
Removal, seal
Press shaft seal, shim and bushing using a jig.
CAUTION
Pay attention to pressing depth!
* Mark for pressing depth.

Assemble retaining ring.
Figure 14
Assembly, retaining ring
Counterbalance valve
Figure 15
Counterbalance
Relief valve/make-up check valve.
Figure 16
Relief valve parts
First measure and record setting height (h).

Replace seal nut.
Figure 17
Seal nut
When tightening, hold the setscrew, tighten the nut, then check setting height.
Figure 18
Tightening, nut
Control device
Figure 19
Control parts
Fix the servo valve assembly as shown for disassembly.

Disassemble cover (1).
Figure 20
Disassembly, cover
Mark each component position before disassembly.
Figure 21
Mark each component position
1. O-ring
2. Control oil inlet
3. Throttle pin
Figure 22
Mark each component position
1. Control oil inlet

2. Low pressure / high pressure
3. Low pressure / high pressure
4. Drain oil
5. Servo valve
Figure 23
Control parts
When disassembling pay attention to spring force.

Note adjusting screw height (x).
Remove 2 cover.
Figure 24
Removal, cover
Check o-ring.
Figure 25
Check, o-ring
Figure 26
O-rings
1. O-ring high pressure small servo valve side

2. O-ring control pressure
3. O-ring high pressure check valve
4. O-ring high pressure check valve
Remove relief valve.
Figure 27
Removal, relief valve
Check o-ring.
Figure 28
Check, o-ring
Remove counterbalance valve and check o-ring.
Figure 29
Removal, counterbalance valve
Figure 30
1 Housing 11 Spring 22 Screw

2 Plug 12 Cone 24 Thrust ring
3 Spring 13 Plug 25 Shuttle valve
4 Spring retainer 14 Torque element 26 Plug
5 Snap ring 15 Valve seat 30 Plug
6 Spool 16 Sleeve 31 Plug
7 Plug 18 O-ring 32 Screw
8 Spring 19 O-ring 40 Name plate
9 Cone 20 O-ring 41 Rivet
10 Ring 21 Screw 50 Brake release valve
Brake release valve
CAUTION
Replace valve as a unit.
Figure 31
Brake release valve
2 Guide 7 O-ring
3 Sleeve 8 O-ring
4 Spool 9 O-ring
5 Plug 10 Thrust ring
6 Spring
Shuttle valve
CAUTION
Replace valve as a unit.
Figure 32
Brake release valve
10 Valve seat
11 Valve seat
12 Ball
Port plate
Measure "X".
Figure 33
Measure length "X"
Remove Qmin screw. Set the rotary group at “O” position. Disassemble port plate at rotary group “O” position.
Figure 34
Remove Qmin screw
Mark the port plate and housing and remove screws.
Figure 35
Mark the port plate and housing
Check o-ring.
Replace o-ring with new one and apply grease.
Do not disassemble swivel rotary assembly to prevent wrong assembly of the pistons.
Figure 36
Check o-ring
Position piston
Figure 37
Position piston
Using allen wrench, remove screws.
Figure 38
Removal, screws
Remove piston ring from the piston.

Figure 39
Removal, piston ring
Remove clamping screw (fixed with loctite # 601) therefore heat control pin/control piston to approximately 120°C (248°F).
CAUTION
Replace the screw with a new one and apply loctite and tighten to specified torque.
Figure 40
Replace screw
Apply grease to control lens mating surface and put it on the port plate. Set the rotary assembly to perpendicular.
Figure 41
Apply grease
Rotary group disassembly
Figure 42
Rotary group
Assemble a screw to the center pin through the center hole and assemble washer and nut to prevent the piston disassembly
from the cylinder.
Screw (Unit: mm)
28 : M4 x 58
55 : M5 x 71
80 : M6 x 82
107 : M6 x 92
140 : M8 x 105
160 : M8 x 105
200 : M8 x 109
Figure 43
Assemble, screw, washer and nut
Press the shaft and pull out the rotary assembly.
CAUTION
Do not hit the shaft to prevent bearing damage.
Figure 44
Press the shaft
Rotary group disassembly

Rotary assembly
CAUTION
Replace as a set when required.
Figure 45
Rotary group
Rotary group
Adjust drive shaft with bearing.
Figure 46
Adjust, drive shaft
Remove the screw and cylinder.

Figure 47
Removal, screw and cylinder
Disassemble retaining plate.
CAUTION
The screws are fixed with loctite, therefore strike the screws sharply with a hammer and screwdriver before loosening.
Figure 48
Disassemble, retaining plate
Check if there is any damage on the spline or key groove.
Figure 49
Check, spline or key groove
Check if there are any scratches or pitting on the piston.
Figure 50
Check, piston
Check if there are any scratches or pitting on the center pin.
Figure 51
Check, center pin
Check if there is any wear on the retaining plate.
Figure 52
Check, retaining plate
Cylinder block, control lens

Check if there are any scratches or wear on the cylinder block bore.
Check if there are any scratches or cracks on the control lens surface.
Figure 53
Check, cylinder bore block and control lens surface
Control housing
Check if there are any scratches or wear on the mating surface and side guard.
Figure 54
Check mating surface and side guard
Housing
Check if there are any scratches or wear on the bearing mounting surface.
Figure 55
Check, bearing mounting surface
Service Information

Travel motor, maintenance 4411 Service Information 2014/5/12
standard
Profile:
Travel motor, maintenance standard

Leakage test
Measurement condition
 Coolant temperature : Within operating range

 Oil temperature: 50 ± 5°C (122 ± 10°F)
 Travel mode : T
 Transfer gearbox: 2nd gear
Measuring procedure
 Stall test:
 Disconnect the drain line from the travel motor and plug the end of the line.
 Connect a hose to the motor drain fitting and put the other end into a calibrated container.
 Park the excavator on level ground. Block the machine to keep it from moving.
Select 2nd gear and forward travel direction. Accelerate the engine to maximum speed to obtain
maximum system pressure.
 With a watch, measure the time it takes for a certain amount of oil to flow from the hose. Then calculate
the actual amount of leak oil per minute.
 Repeat the test for “Reverse” operation.
CAUTION
If the leakage is significantly greater in one direction than the other, a seal in the swivel joint may be leaking.
Figure 1
Calculate the amount of leak oil
Maximum permissible leak oil : 12 Liter/min (3.2 gpm)

Service Information

Slew brake, description 4412 Service Information 2014/5/12
Profile:
Slew brake, description

Sectional and exploded view
See [Invalid linktarget] .
Slew brake
The slew brake is spring applied and hydraulically released. Friction plates (742) are splined to and rotate with cylinder block
(111). Mating plates (743) are splined to motor casing (301). When the remote control valve servo hydraulic pressure to SH
port is blocked, the primary servo hydraulic oil pressure flow to brake piston (702) is cut off and the force of brake springs
(712) acting on piston (702) squeeze the mating and friction plates together, preventing output shaft (101) from rotating
thereby stopping the superstructure from slew.
When the primary servo hydraulic oil pressure reacts on the opposite side of brake piston (702) it overcomes the force of
springs (712) and moves the piston creating clearance between the friction and mating plates, thereby releasing the brake.
Figure 1
Slew brake
A. Oil pressure
B. Spring force
C. Oil pressure chamber
Service Information

Slew motor, adjustment 4412 Service Information 2014/5/12
Profile:
Slew motor, adjustment

Crossover relief valve
 Remove pressure port plug PA or PB.

 Install oil pressure gauge (600 kgf/cm2 : 8530 psi).
Tools : 6 mm Allen wrench
Fitting size of pressure checking port : PF 1/4″
 Secure the superstructure by putting the bucket against an immovable object or in a trench.
 Operate the slew lever in the appropriate direction and check the relief pressure.
 Loosen lock nut (1) and turn adjusting screw (2) as follows :
 To increase pressure, turn clockwise.

 To decrease pressure, turn counterclockwise.
 If the relief pressure can not be adjusted correctly, replace the relief valve assembly.
Pressure measuring port location
Figure 1
Position, pressure measuring
Service Information

Slew motor, assembly 4412 Service Information 2014/5/12
Profile:
Slew motor, assembly

Tightening torque
Tightening torque, unit : kgf·cm (lbf·in)
Description Item no. Thread Tightening torque

Screw 401 M 20 4400 (3800)
VP Plug 464 PF 1/4 370 (320)
Screw 171 M8 300 (260)
RO Plug 469 M 30 2250 (1950)
Plug 992 PT 1/2 660 (570)
Plug 994 PT 3/4 1000 (870)
Relief valve 051 M 33 1800 (1560)
Rebound damping valve 400 M 22 700 (610)
Preparation
 Rework damaged parts and before assembling, prepare all replacement parts.
 Coat the sliding parts and bearings with clean hydraulic oil.
 Replace the o-rings and oil seal.
 Use a torque wrench to tighten the screws and plugs, to the specified torque.
NOTE!
Assembly, slew motor
Procedure Remark
1 Place casing (301) on the work bench with the valve
casing side upward.
2-1 Heat the inner race of bearing (443) and press-fit to drive Pay attention to the direction of the inner race collar.
shaft (101).
A. Output shaft
2-2 Heat the inner race of bearing (444) and press-fit to drive
shaft (101).
3 Install snap ring (437) in casing (301) and seal cover (305). Pay attention the direction of oil seal. The seal lip must
Install oil seal (491) in casing (301) using the oil seal face toward casing (301). Coat the lip of the oil seal
driver. with grease.
4 Using a brass bar, tap the outer race of roller bearing

(443) until the bearing is fully seated in casing (301).
5 Install drive shaft (101) to casing (301). Be careful not to damage the lip of the oil seal. Apply
vinyl tape to the drive shaft spline.
6 Set the casing horizontally and assemble swash plate Insert it with the larger chamfered side of the swash
(124) casing side. plate toward the casing.
Coat lightly with grease.
A Casing side
7 Insert push rods (116) and spacer F (117) to cylinder (111) Be careful not to damage the sliding surface of the
and install spherical bushing (113) with the larger outer cylinder. Insert 2 push rods into each hole.
diameter toward the cylinder.
8 Fit piston sub assembly unit (121, 122) to retainer (123).
9 Assemble the retainer with the piston sub assembly unit

to the cylinder block and install it on drive shaft (101)
aligning the splines.
10 Set casing (301) with seal cover (305) downward and Align 4 tangs to the notches as shown.
assemble three mating plates (743) and four friction
plates (742) in sequence.
11 Mount o-ring (706, 707) to casing (301). Coat the o-rings with grease.
12 Assemble brake piston (702) to casing (301). Place 4 notches of the brake piston as shown below.
The piston is difficult to assemble because of the
restriction of the o-ring; screw two M8 screws into the
brake piston and tap them gently.
A. Brake piston
B. Screw hole
C. Mounting side
13 Assemble brake springs (712) into brake piston (702). Confirm the springs are fitted to the brake piston
completely.
14 Install the outer race of roller bearing (444) in valve Tap evenly on the outer diameter of the outer race
casing (303) while tapping it lightly. with a brass bar until it is fully seated.
15 Assemble valve plate (131) to valve casing (303) and fit o- Coat lightly with grease.
ring (472). Ensure dowel pins (451) are installed in the valve
casing.
16 Mount valve casing (303) to casing (301) and tighten Be careful to note the mounting direction of the valve
screw (401) to the specified torque. casing.
Be careful not to drop the valve plate or let the brake
springs pop out.
Tighten the screws evenly.
17 Insert spool (351) and spring (355) into the valve casing Confirm the smooth movement of the spool before
and install RO plug (469) with o-ring (488). installing the plug.
Tighten the plug to the specified torque.
18 Assemble relief valve (051) to valve casing (303).
19 Assemble rebound damping valve sub assembly (052) to Be sure to install all the o-rings.
valve casing (303).
20 Assemble plug (461) with o-ring (485) to casing (301).
1. Relief valve
Service Information

Slew motor, description 4412 Service Information 2014/5/12
Profile:
Slew motor, description

The oil supplied from main pump (1) passes through control valve (2) to rotate slew motor (3). The turning force of the
motor is transmitted through gearbox (4), pinion (5) and slew ring gear (6), making the superstructure revolve.
Figure 1
Slew motor
1. Main pump
2. Control valve
3. Slew motor
4. Gearbox
5. Pinion gear
6. Slew ring gear
Hydraulic motor
Rotary group consists of cylinder block (111) and 9 piston assemblies located in the cylinder. Both ends of cylinder block
(111) are supported by bearings (443) and (444). Piston assemblies are guided by return plate (123) and spring (122) so they
slide smoothly on the swash plate. Valve plate (131) is pressed against the cylinder block surface by the mechanical pressure
of spring (114) and hydraulic pressure working on the bushing.
Between the outer diameter of the cylinder block and housing a mechanical brake for parking is mounted.
The cover section has a relief valve for cushioning and an anti-cavitation valve to prevent cavitation.
Gearbox
Gearbox is composed of sun gear, planetary gear, pinion gear and housing. Power supplied to the output shaft of the slew
motor reduces the motor speed through the sun gear and planetary gear and the high torque is transmitted to the pinion
gear.
Slew ring gear
The slew ring gear is a single row sealed ball bearing that supports the superstructure on the undercarriage and allows the
superstructure to rotate smoothly.
The outer race is screwed to the superstructure and the inner race (with inner circumference gear) is screwed to the
undercarriage. The slew gearbox pinion meshes with the internal gear of the inner race and drives it to rotate the
superstructure.
Components of slew system
Figure 2
Slew system
Construction
Figure 3
Construction, slew motor
1. Relief valve
2. Rebound damping valve
3. Lifting screw
Rotational direction
lnlet Outlet View from shaft end

A B Clockwise
B A Counterclockwise
Port connection
Port Symbol Thread size Tightening torque kgf·m

(*1 : JIS B2351 ″O″ Size) (lbf·ft)
Main port A, B PF 3/4 - 20 *1 17 (123)
Anti-cavitation M PF 3/4 - 20 *2 17 (123)
Drain DB PF 3/8 - 15 *1 7.5 (54)
Brake releasing PG PF 1/4 - 12 *1 3.7 (27)
Brake servo hydraulic SH PF 1/4 - 12 *1 3.7 (27)
Pressure checking PA, PB 2-PF 1/4 - 15 *1 3.7 (27)
Gear oil filling port (oil level checking) Gl, L PT 3/4 - 19 10 (72)
Gear oil outlet GO PT 1/2 - 15 6.6 (48)
Sectional view
Figure 4
Slew motor, sectional view
Exploded View
Figure 5
Slew motor, exploded view
031 Delay valve 400 Rebound damping valve assembly

051 Relief valve 401 Screw
052 Rebound damping valve 437 Snap ring
100 Casing 438 Snap ring
101 Shaft 443 Roller bearing
111 Cylinder 444 Roller bearing
113 Bushing 451 Dowel pin
114 Cylinder spring 464 VP plug
116 Push rod 467 Plug
117 Spacer F 468 Plug
118 Spacer 469 RO Plug
121 Piston 472 O-ring
122 Shoe 485 O-ring
123 Thrust plate 487 O-ring
124 Shoe plate 488 O-ring
131 Valve plate 489 O-ring
151 Plug 491 Oil seal
161 O-ring 702 Brake piston
162 O-ring 706 O-ring
163 O-ring 707 O-ring
171 Screw 712 Brake spring
301 Casing 742 Friction plate
303 Valve casing 743 Mating plate
305 Seal cover 981 Plug
351 Spool 984 Plug
355 Spring 992 Plug
390 Name plate 994 Plug
391 Rivet
Service Information

Slew motor, disassembly 4412 Service Information 2014/5/12
Profile:
Slew motor, disassembly

General tools
General tools
Thread Description Size (mm) Item Tool

M 20 Screw 17 Allen wrench
PF 1/4 Plug 19 VP Plug Spanner, socket wrench
M8 Plug 13 Spanner, socket wrench
M 30 Plug 14 RO Plug Allen wrench
M6 Screw 10 Delay valve Spanner, socket wrench
M 33 41 Relief valve Spanner, socket wrench
PT 1/2 10 Plug Allen wrench
PT 3/4 14 Plug Allen wrench
Special tools
Special tools
Description Size
Snap ring plier φ 52, φ 60 (φ 2.05, φ 2.36)
Driver (–) Medium (2)
Pry bar 10 × 8 × 200 mm (0.4 × 0.3 × 7.9 in)
Hammer Plastic and steel hammers
Torque wrench Torque
100 ~ 450 kgf·cm (80 ~ 400 lbf·in)
400 ~ 1800 kgf·cm (80 ~ 1600 lbf·in)
1200 ~ 4800 kgf·cm (1000 ~ 4200 lbf·in)
Slide hammer bearing puller
Special tool for removing the brake piston See next illustration.
Brake piston tool

Figure 1
Brake piston tools (Part no.: 8932-00040)
NOTE!
Disassembly, slew motor
Procedure Remark
1 Lift the motor assembly with a wire rope and crane. Clean the motor thoroughly before separating from
Clean with cleaning solvent, and dry with compressed air. the gearbox.
2 Remove the drain plug (36) and drain the oil.
3 Before disassembling make a match mark on motor casing Select a clean place.
(301) and valve casing (303). Put a rubber sheet on the work bench to prevent
the parts from being damaged.
4 Remove screws and delay valve (031) from casing (301).
Remove screws (171, 172) and rebound damping valve (052)
from valve casing (303).
1. Relief valve
5 Remove relief valve (051) from valve casing (303). Replace o-ring and back-up ring.
6 Remove RO plug (469) and take out spring (355) and spool Be careful not to damage the spool seat.
(351) from the valve casing.
7 Remove screw (401) and valve casing (303) from casing (301). Be careful not to drop the valve plate from the
When loosening the screws casing (303) will be raised by valve casing. (Sometimes the valve plate is adhered
brake springs (712). to the cylinder).
Remove valve plate (131) from the valve casing.
8 Remove brake springs (712) from the brake piston.
9 Disassemble brake piston (702) from casing (301) by using the Lift it straight, using the screw holes in the brake
special tool. piston.
10 After placing the motor horizontally, take out cylinder (111) When taking out the cylinder, be careful not to pull
from drive shaft (101). out push rod (116).
Remove pistons (121), retainer (123), spherical bushing (113), Piston must be installed into the same bores
spacer (117) and swash plate (124). because of wear pattern.
Mark the pistons and respective cylinder bores.
11 Pull out friction plates (742) and mating plates (743) from
casing (301).
12 Remove drive shaft (101) and shoe plate (124). Tap drive shaft spline to prevent oil seal damage.
13 Do next step if required. Do not reuse the bearing race.

(1) Remove the inner race of roller bearing (443) from drive
shaft (101) with a press.
A. Press
B. Drive shaft
C. Support the inner race
(2) Remove snap ring (437) and pull out seal cover (305) from
casing (301).
Remove oil seal (491) from seal cover (305) using a seal driver.
(3) Use a slide hammer and a bearing puller or a press to Do not reuse the bearing.
remove the outer race of bearing (443) from casing (301).
(4) Pull out roller bearing (444) from valve casing (303) with a Do not reuse the bearing.
sliding hammer and a bearing puller.
NOTE!
Disassembling is finished. Check each component thoroughly.
Oil seal replacement (When replacing the oil seal only)

NOTE!
Procedure, oil seal replacement
Procedure Remark
1 Remove snap ring (437) and pull out seal cover (305) from
casing (301).
2 Remove oil seal (491) from seal cover (305) with a seal driver
(M4 × 0.7 screws).
3 Install new oil seal (491) to casing (301) and drive shaft (101) Coat the lip of the oil seal with grease.
after assembling two screws (M4 × 0.7) on the oil seal. Be careful not to damage the lip of the oil seal,
tape the shaft splines. The seal lip must face
toward casing (301).
4 Insert seal cover (305) and install snap ring (437) to casing (301).
Service Information

Slew motor, lubrication 4412 Service Information 2014/5/12
and air purging
Profile:
Slew motor, lubrication and air purging

 Following the repair or replacement of the slew motor assembly it is necessary to pre-lubricate the internal
components to prevent scoring/scuffing of the bearings and sliding parts.
Remove the upper case drain port plug and fill the casing with the specified hydraulic oil.
 Oil capacity : 900 cc
 Prior to start up purge the air from the circuit plumbing and motor.
Figure 1
Position, drain
A. Drain port
Precautions for lubrication
 Check that there is no contamination in the ports or plumbing before connecting to the motor.
 Check for oil leakage on the motor assembly.
 Check if the direction of rotation according to the control lever is correct.
 Check for abnormal sound or vibration while rotating.
 Check for any abnormal temperature increase after operating for a short time.
 Check if the hydraulic pressures are set to the specified values.
Service Information

Slew motor, measurement 4412 Service Information 2014/5/12
of wear
Profile:
Slew motor, measurement of wear

Standard for parts service and replacement
The following standards of the serviceability of parts can be determined from measurements made at disassembly. However,
they are general standards and when parts show excessive external damage or discoloration, top priority should be given to
the determination of the extent to which parts are to be replaced, according to the purpose of disassembly and the
remaining life expectancy of the parts.
Wear limits
Item Standard Recommended value for Remedy

dimension replacement mm (in)
mm (in)
Clearance between piston and 0.032 0.062 Replace cylinder.
cylinder bore (D–d) (0.0012) (0.0024)
Gap between piston and 0 0.3 Replace piston shoe

caulked part of shoe (α) (0.0118) assembly.
Thickness of shoe (t) 6 5.8 Replace piston shoe

(0.2360) (0.2280) assembly.
Assembled height of retainer 7 6.5 Replace spherical bushing

plate and spherical bushing (H-h) (0.2760) (0.2560) and retainer plate as a set.
Thickness of friction plate (t) 4 3.6 Replace

(0.1570) (0.1420)
Standard for correcting sliding surfaces

If the surface roughness of the sliding surface of a part exceeds the following standard, correct it or replace the part.
Sliding surface
Part Standard surface roughness Standard roughness requiring correction
Shoe 0.8–Z (Ra=0.2) 3–Z (Ra=0.8)
(lapping)
Swash plate 0.4–Z (Ra=0.1) 3–Z (Ra=0.8)
(lapping)
Cylinder 1.6–Z (Ra=0.4) 12.5–Z (Ra=3.2)
(lapping)
Valve plate 0.8–Z (Ra=0.2) 6.3–Z (Ra=1.6)
(lapping)
 Lap each sliding surface to a standard roughness level or finer.

 If the sliding surface of the cylinder block, valve plate, retaining plate or spherical bushing is roughened, replace the
parts as sub assemblies.
Service Information

Slew motor, principle of 4412 Service Information 2014/5/12
operation
Profile:
Slew motor, principle of operation

Hydraulic motor
When high pressure oil from the hydraulic pump delivered via the main control valve, enters port (a) of valve plate (1), it
flows to half of the 9 pistons spaced equidistance in cylinder block (4) and pushes the pistons out of the bores against the
inclined swash plate, generating force F in an axial direction.
Force F vector divides into components of radial force F1, F2, and is transmitted sequentially via pistons (5) to cylinder block
(4), generating a rotational torque causing the cylinder block splined to output drive shaft (6) to rotate.
The top dead center port (A) is the starting point of the high pressure rotational cycle : for 180° the pistons move out of the
bores as they slide along the swash plate toward bottom dead center port (B), then they begin moving into the bores
discharging low pressure oil to the return circuit. If the supply port and return port are interchanged, the slew motor rotates
in the opposite direction.
The theoretical output torque T is calculated by the following formula.
T=p×θ/2×π
p : Effective differential pressure, kgf/cm2
q : Capacity per one rotation, cc/rev
Figure 1
Operation, slew motor
1 Valve plate L Low pressure oil

2 Shoe H High pressure oil
3 Swash plate O Outlet port
4 Cylinder block I Inlet port
5 Piston
6 Drive shaft
Valve casing, anti-cavitation check valve

The motor can be rotated faster than supplied oil flow because there is no counterbalancing valve to prevent overspeed. In
order to prevent cavitation of the motor, oil compensating insufficient flow is drawn through the anti-cavitation check valve.
Figure 2
Anti–cavitation check valve
Valve casing, relief valve (Type: KRD21EK10)
1. Closed
When the oil pressure at port (P) is less than the force of spring (321) on spool (301), the spool remains seated as
shown.
Spring (321) forces spool (301) against the seat closing the path to port (R) and at the same time pushes against
sleeve (201). Oil pressure at port (P) enters orifice (M) and flows through spool (301) to chamber (G), however the
pressure is insufficient to move piston (303).
2. Opening
When the oil pressure at port (P) is greater than the force of spring (321), spool (301) is pushed off its seat allowing
the pressure to relieve through port (R).
At the same time the pressure increases through orifice (M) to chamber (G), acts on piston (303) overcomes the
force of spring (322) and the piston moves to the right.
At this time pressure Pg1 in chamber (G) remains constant.
The relief pressure (P1) is calculated by the following formula.
P1 x A1 = Fsp1 + Pg1 x A2
Fsp1: Spring (321) load
3. As piston (303) moves right the oil in chamber (h) is drained to port (R) via the slot in the piston.
Since the piston slot is throttled (tapered), the return flow is restricted which slows movement of piston (303) and
allows the pressure in chamber (G) to slowly increase thereby cushioning the pressure spike as the relief valve
opens.
4. When piston (303) reaches the end of its stroke, the pressure in chamber (G) is the same as that at port (P). The
relief pressure (Ps) is calculated by the following formula.
PS = Fsp1 / (A1 - A2)
See the figure. (Pressure vs Time) In accordance with the above procedure, the relief pressure changes as shown in
the graph.
5. Closing
As the oil pressure at port (P) decreases, the force of spring (321) pushing against spool (301) also decreases as it
moves the spool toward the seat. At the same time the oil pressure through orifice (M) to chamber (G) decreases
and the force of spring (322) moves piston (303) to the left. The pressurized oil at port (R) flows through the large
passage in piston (303), opens the check ball valve and quickly fills chamber (H) assisting spring (322) to rapidly
move the piston left to its initial position.
Figure 3
Operation, relief valve
1 Area A1 303 Piston

2 Area A2 321 Spring
3 Area A3 322 Spring
4 Check ball G Chamber
5 Spring seat H Chamber
6 Seat M Orifice
201 Sleeve T Time
301 Spool P Relief pressure
Valve casing, rebound damping valve

Figure (1) shows the relationship between the neutral condition of the rebound damping valve and the hydraulic circuit.
 Explains the braking condition causing the brake pressure at the AM port.
 When the pressure is applied to the AM port, it enters chamber (n) from the orifice in seat (313) and passage (m) of
spool (311) via passage (l).
When the pressure (p) is more than the set value (ps) of spring (321), spool (311) moves left, compressing spring
(321). The spool (311) moves off seat (313) to the left compressing the weak spring (322). (Figure (2) condition)
 When the movement of inertia load stops (Y point in Figure(4)), the brake pressure will be lowered. When P < PS,
spool (311) moves right by the force of spring (321). The seat (313) also wants to move right by spring (322), but
the seat return causes the time to be delayed for the spool return because chamber (p) has the damping function
via narrow passage (g). Accordingly seat (t) is opened and the connecting passage is connected between port AM
and BM, both side motors of hydraulic motor by l → t → r → k. Thereby AM port pressure and BM port pressure are
to be same rapidly and then the Z point condition in figure (4) to prevent the hydraulic motor from the reaction.
(Figure (3) condition).
Figure 4
Operation, rebound damping valve
A Rebound damping valve

T Time
P Pressure
Service Information

Slew motor, 4412 Service Information 2014/5/12
troubleshooting
Profile:
Slew motor, troubleshooting

Given below are actions to be taken when you have found any abnormality with the hydraulic motor during operation.
Identify possible causes
Before proceeding to work, try to determine the nature of the fault, check all related systems and discuss the malfunction
with the operator. Finally recheck the most likely causes of the malfunction again before dismantling the motor.
Beware of dirt
Many faults result from dirt. Therefore take adequate measures prior to disassembly and during assembly to prevent entry of
any contamination.
Handling parts
Parts are precision finished and sufficient care should be taken in handling so as not to damage them.
CAUTION
It is recommended during assembly to replace o-rings and oil seals with new ones.
Fault finding of motor

It is extremely difficult to trace trouble in the hydraulic circuits. Inspect the following items and investigate whether or not
the fault is caused by the motor.
Inspecting the oil in casing
Remove the drain plug and inspect the hydraulic oil in the casing. If a large amount of metallic particles drain out with the
oil, you should suspect a failure of internal parts.
Presence of abnormal sound
Check whether the motor emits an abnormal sound.
Pressure measurement of various points
Measure pressures at various points and check for faults, instead of disassembling parts at random.
Measuring the motor case drain flow
 Put the bucket in a trench to prevent the superstructure from rotating.

Operate the slew lever to fully load the slew motor. The normal drain oil flow in stall condition is below
approximately 23 l pm (6 gpm) (Pressure 270 kgf/cm2 : temperature 100°C).
 The drain oil flow during the normal slew is below 0.6 l pm (0.16 gpm).
Gearbox does not rotate.

Troubleshooting
Condition Cause Correction

The circuit pressure is abnormal.
1. Rebound damping valve/crossover  Reset to specified value.
relief valve set pressure is incorrect.  Repair or replace the valve.
2. Rebound damping valve/crossover  Measure the case drain
relief valve operation is faulty. volume, replace the worn
3. Internal leakage of the motor. parts of the motor.
4. Internal parts of the motor  Repair or replace the
damaged. motor.
5. Internal parts of the gearbox are  Repair or replace the
worn or damaged. gearbox.
The circuit pressure is normal.

1. The machine is overloaded.  Reduce the load.
2. The slew brake does not release.  Check the brake release
hydraulic circuit.
 Check the brake delay
valve operation.
 Repair or replace the brake
assembly.
The rotating direction is reversed.

Troubleshooting

Slew direction vs
lever direction is reversed. 1. Valve casing to motor casing is  Reposition the valve
incorrectly assembled. casing.
2. Inlet/outlet hoses are interchanged.  Interchange the hoses.
3. Joystick servo hydraulic hoses are
interchanged.  Check joystick/main
control valve hoses and
change accordingly.
Rotation does not reach the specified value.

Troubleshooting

Slew rotation is slow.
1. Rebound damping valve/  Reset to specified value, if
crossover relief valve set too faulty repair or replace the
low or faulty operation. valve.
2. Insufficient flow to the motor.  Check pump output and
3. Internal leakage of the motor. plumbing for damage.
 Measure the case drain
volume, replace the worn
parts of the motor.
Brake torque is insufficient.

Troubleshooting

Slew drift is excessive.
1. The brake release pressure is  Check the brake delay valve and
not cut off. the hydraulic circuit.
2. The friction/mating plates are  Replace the friction/mating plates
worn or damaged. as a set.
3. The brake piston is sticking.  Replace the piston, and the motor
casing if damaged.
4. The brake springs are weak or  Replace the springs and
broken. determine if the damage is caused
by overheating.
Abnormal operating temperature.

Troubleshooting

Slew start-up under load is slow and the
motor/gearbox overheats. 1. Excessive internal leakage of  Measure the case drain
the motor. volume, replace the worn
2. Rebound damping valve/ parts of the motor.
crossover relief valve set too  Reset to specified value, if
low or faulty operation. faulty repair or replace the
3. Gearbox oil level is low. valve.
4. Gearbox bearings damaged.  Check the oil for
5. Brake assembly is dragging. contamination, and refill to
6. The brake piston is seized or the proper level.
the friction/mating plates are  Repair or replace the
deformed and jamming. gearbox assembly.
 Repair or replace the motor
assembly.
Oil leakage from output shaft seal

Troubleshooting

Oil leakage from the motor or gear
reduction output shaft. 1. Wear or damage of the oil  Replace the oil seal.
seal lip.  Replace the shaft and seal.
2. Wear or damage of the shaft  Measure the case drain
at seal contact area. volume, repair or replace
3. Internal pressure of the motor the motor.
is abnormal.  check if the case drain line
is plugged.
Oil leakage from mating surfaces.

Troubleshooting

Leakage from mating joint surface
1. O-ring is twisted.  Insert correctly.
2. O-ring is damaged.  Replace the o-ring.
3. The seal surface is damaged.  Disassemble and correct.
4. Screws are loose or damaged.  Tighten to the proper
torque specification. Use
loctite if required.
Service Information

Flexible coupling 442 Service Information 2014/5/12
Profile:
Flexible coupling
Figure 1
Structure, flexible coupling
Figure 2
Flexible coupling, sectional view A - A
1. Insert A
2. Element
3. Insert B
4. Hub
5. Screw (M16 x 2.0 x 60L)
6. Screw (M16 x 2.0 x 50L)
7. Clamping screw (M16 x 2.0 x 20L)
8. Spring pin

No. Tightening torque
5 21 ~ 23 (152 ~ 166)
6 21 ~ 23 (152 ~ 166)
7 10 ~ 12 (72 ~ 87)
Service Information

Center passage, description 4431 Service Information 2014/5/12
Profile:
Center passage, description

The center passage consists of hub (2), shaft (1), seal (4), cover (3), plugs (11, 12, 16), spacer (5) and screws (14).
The hub contains oil grooves to route the flow of oil. The shaft has passages to supply oil into the hub. The seal prevents oil
leakage between shaft and hub. The cover prevents external oil leakage and with screws (14), fix spacer (5), hub (2) and shaft
(1) together.
High pressure oil from the main control valve is delivered to the center passage, and flows through ports A ~ P to the travel
motor, steering cylinder, brakes, blade and axle cylinders.
Each port is used for supply or return drain (3 ~ 350 kgf/cm2)
Shaft assembly (1) is fixed to the under structure and hub (2) rotates freely on the shaft with the superstructure. The oil flows
through circumferential grooves in the hub, therefore oil flow is not obstructed by slew.
Sectional view
Figure 1
Structure, sectional view
Port connection
Port connection
Port Port size Connection Port Port size Connection

A PF 1/2 - 14 To gearbox (1st) I Plug Dozer/stabilizer (raise)
B PF 1/2 - 14 To gearbox (2nd) J PF 1/2 - 14 Travel motor (forward)
C PF 3/8 - 19 Gearbox drain K 1″ Flange Steering cylinder - right
D PF 1/4 - 19 Axle locking supply L PF 1/2 - 14 Stabilizer (lower)
E PF 3/8 - 19 Service brake (front) M PF 1/2 - 14 Steering cylinder - left
F PF 3/8 - 19 Service brake (rear) N PF 1/2 - 14 Dozer blade (lower)
G PF 3/8 - 19 Axle locking drain P PF 1/2 - 14 Travel motor drain
H 1″ Flange Travel motor (reverse)
Exploded view
Figure 2
Structure, exploded view
1 Shaft 9 O-ring
2 Hub 10 Back-up ring
3 Cover 11 O-ring
4 Seal 12 Screw
5 Spacer 13 Spring washer
6 Retaining ring 14 Plug - PT
7 Shim 15 Plug - PT
8 O-ring 16 Plug - PT
Service Information

Center passage, 4431 Service Information 2014/5/12
disassembly and assembly
Profile:
Center passage, disassembly and assembly

General tools
General tools
Symbol Tool Used for Remark

a Hammer Disassembly 1. Steel hammer
Assembly 2. Wooden or plastic hammer
b Rubber mat Not less than 500 mm (20 in) square
c Wrench 1. Allen wrench
2. Double ended and singe ended wrench
3. Extension pipe
d Torque wrench Assembly 100 kgf·m (700 ft·lbs)
e Pin Disassembly
A. Grind the tip of a ∀nail∀ to shape as a

screwdriver.
f Spatula Disassembly
Assembly
A. Made from a hack-saw blade.

B. Approximately 120 mm(4.7 in)
C. Vinyl tape
D. Remove the edge completely
g Vise Disassembly assembly Vise adjustable over 150 mm (5.9 in)

h Locking fluid Three-bond 1360K (Loctite # 242)
i Lubricating oil Hydraulic oil or vaseline
j Cleaning oil
Apparatus
Hoist or crane
The lifting device should be capable of lifting the center passage assembly.
Work bench
The work bench should have an area of 1.2 m × 1.5 m (4 ft × 5 ft).
Others
Also prepare clean cloth, wooden block and oil pan.
Tightening torque
Thread size Tightening torque Thread size Tightening torque

PT 1/4 4 ± 0.5 (29 ± 3.6) PF 1/4 3 ~ 4 (22 ~ 29)
PT 3/8 8 ± 0.8 (58 ± 5.8) PF 3/8 4 ~ 5 (29 ~ 36)
PT 1/2 4.5 ~ 6 (32 ~ 43) PF 1/2 4.5 ~ 6 (32 ~ 43)
PT 3/4 19 ± 1.0 (137 ± 7.2)
Disassembly
Cleaning outside
NOTE!
Clean the outside of the center passage with hot water or steam.
NOTE!
Clean center passage with the ports plugged.
Removal
 Mark each hose assembly to identify its location on the center passage.
 Mark shaft (2) and hub (1) to aid in reassembly.
1. Detach the bottom plate in the middle of undercarriage.
WARNING
The plate is heavy, take appropriate safety precautions.
2. Remove hydraulic lines connected to the center passage hub, and plug each hose and oil port.
3. Remove hydraulic lines connected to the upper side of center passage shaft, and plug each hose and oil port.
4. Remove the center passage shaft clamping screw.
5. Screw an eye bolt in the middle of the center passage shaft, attach a sling to the lifting equipment. (To prevent the
center passage from dropping when removing the mounting screws.)
6. Unscrew the four sling mounting screws from the bottom.
7. Lower the sling slowly and take the center passage out through the bottom.
8. Dip the center passage into a cleaning solution to thoroughly clean the assembly.
9. Install on a work bench, and disassemble.
Disassembly procedure
 Fix the center passage on a work bench.
Figure 1
Fixing, center passage
 Remove screws (14), spring washer (15) and cover (3) from the center passage.
Figure 2
Removal, cover
 Pull out o-ring (8) and remove shim (7), retaining ring (6) and spacer (5).
Figure 3
Removal, shim, retaining ring and spacer
 Remove shaft (1) and hub (2).
Figure 4
Removal, shaft and hub
 Remove o-ring (9) and back-up ring from hub (2).
Figure 5
Removal, o-ring and back-up ring
 Remove seals (4) assembled in the hub (2) using a sharp pin.
CAUTION
Take care not to damage the seal grooves of hub (2).
Figure 6
Removal, seals
 Inspect each part, and repair or replace the defective or worn parts.
 Do not reuse o-ring or seals. Be sure to replace with new ones.
Assembly
Preparations
1. Prepare the required parts and clean all parts thoroughly.

2. Especially, take care that dust and foreign materials do not enter the seal grooves of the hub or oil ports of the
shaft.
3. Apply a dab of grease on the surface of o-rings and install ensuring they are not twisted or damaged.
4. Align the marks on hub and shaft.
5. Mount the assembly to machine referring to “assembly” section.
6. Sling the center passage with the shaft section upward.
7. Take care to align the match marks of shaft and hub.
8. Install the four mounting screws, the clamping screw and tighten to specified torque.
9. Connect each hydraulic line to the pre-marked location.
10. Check for operating condition and leakage, and track motor functions.
Assembly procedure
 Wash all parts thoroughly with a cleaning solvent and clear the passages using compressed air.
 Polish minor scratches with fine emery or crocus cloth.
Figure 7
Cleaning with solvent and compressed air
1. Shaft
2. Hub
3. Cover
 Before installing the seals, coat the seal grooves with hydraulic oil (2 ~ 3 times).
 Take care not to twist or damage the seals.
 Check the seal mounting condition.
Assemble 8 seals (4).
Assemble o-ring (11).
Figure 8
Assembly, seals and o-ring
4. Seal
11.O-ring
 Ensure the seals are not damaged or twisted, then by hand rubbing seat the seals inside of assembly section as
close as possible to a cylindrical condition.
Figure 9
Seal assembled in rear
4. Seal
 Coat the shaft (1) with hydraulic oil.

 Fix hub (2) to the stopper (3), and then operate the press (X) slowly and insert the shaft (1).
 Press–fit shaft (1). Before the horizontal support (4) interferes, remove it.
CAUTION
Hub (2) and shaft (1) must be parallel (horizontal) and when press-fitting, take care not to damage the seal.
Figure 10
Assembly, hub and shaft
1 Shaft 4 Horizontal support

2 Hub 5 Plate
3 Stopper X Press
 Assemble the plug.
 Coat the plug with a sealant.

After tightening plug 1/3 and applying loctite # 572, tighten completely.
Tightening torque :
 P/T 3/8 : 8 ± 0.8 kgf·m (58 ± 6 lbf·ft)

 P/F 3/4 : 19 ± 1.0 kgf·m (137 ± 7 lbf·ft)
Figure 11
Assembly, plug
1. Plug (PT 1/4)

2. Plug (PT 3/8)
3. Plug (PT 3/4)
 Assemble spacer (5) and retaining ring (6).

Assemble o-ring (8) and shim (7).
Figure 12
Assembly, spacer, retaining ring, o-ring and shim
5 Spacer 7 Shim
6 Retaining ring 8 O-ring
 Mount cover (3) and align cover screws (14) hole and hub screw hole and assemble screw with spring washer (15).
Tightening torque : 11.3 ± 1.1 kgf·m (82.8 ± 8 lbf·ft)
Figure 13
Assembly, cover
3 Cover 15 Spring washer

14 Screw
 After the completion of assembly, check the hub, shaft and rotating torque.
Starting torque : 30 kgf·m (218 lbf·ft)
Rotating torque : 20 kgf·m (144 lbf·ft)
 Connect adapter to each port for internal/external leakage test.
Each port pressure : 350 kgf/cm2 (4980 psi)
Figure 14
Check of rotating torque and pressure
1 Shaft fixing jig 3 Test checking adapter

2 Hub fixing jig X Rotating torque
 Plug each port.

 Assemble fitting by port if necessary.
After washing the fitting and plug with a solvent and drying, apply teflon tape and loctite # 542 on the entire
threaded section, and assemble.
See “Table of tightening torque”.
Operate the machine at least 3 ~ 6 hours later.
Figure 15
Assembly, fittings
 Assembly is completed.
Figure 16
Assembled center passage
Service Information

Center passage, inspection 4431 Service Information 2014/5/12
and troubleshooting
Profile:
Center passage, inspection and troubleshooting

Maintenance standard
Inspection method
Interval Check item Checking procedure Remedy

2,000 hours. Seal for oil leakage. Check oil leakage at cover, Replace o-ring, if any oil leakage is
top end and fittings. found.
4,000 hours. All sealing parts. Replace all sealing parts such as slipper
In principle, disassemble seal with square seal and o-rings.
and check regardless of All wearing parts. Check abnormal wear, Repair or replace referring to their limit
apparent condition. scoring or corrosion caused of serviceability.
by contamination or
burning.
When disassembled for All parts. Check shaft and hub Repair or replace referring to their limit
repair. grooves / lands for scoring. of serviceability.
o-rings and seals must be replaced.
Wear limits
Part Normal Allowable Replace

Hub Internal seal contact area and the If the wear of seal contact area is The wear of seal contact area is
stepped part have no visible wear. within 0.1 mm (0.004 in) as more than 0.1 mm deep.
measuring by finger nail (when the
dimension can"t be measured in
this way, visually check), it is
allowable.
However, oil leakage will occur, if it
is used continuously in this A. More than 0.1 mm
condition. (0.004″)
Shaft There is no damage or wear of New shaft external surface is The depth of damage is more
external surface. finished as 1.5s. If the pitting of the than 0.1mm.
shaft is slight, it is allowable.
A. More than 0.1 mm

(0.004″)
Replace with a new assembly, as

soon as possible, or replate.
Thrust There is no surface scuffing and no Replace when scoring is
washer visible wear. considerable, even if the wear of
the spacer thickness is slight.
A. 0.3 mm (0.012 inch)

B. 0.5 mm (0.020 inch) or less
O-ring Replace o-rings whenever Never fail to replace the o-rings

disassembling. and seals.
Inspection after assembly

After assembling, check for leakage and pressure test as shown in figure.
High pressure port
Install a changeover valve and pressure gauge to the shaft port and hub port respectively, and while watching the pressure
gauge (for high pressure) installed on the hub and also by regulating high pressure relief valve (7), gradually increase the
pressure and when the pressure has reached 1.5 times the maximum working pressure, close stop valve (3) to trap the
hydraulic oil in the center passage. Keep stop valve (6) on the low pressure relief valve side closed at this time.
Figure 1
Checking, high pressure port
A. Connect to body side

B. Connect to stem side
Low pressure port

(Drain port, return port, etc.)
Similar to the high pressure port, install a changeover valve and pressure gauge on each port of the shaft and hub.
Open stop valve (6) on the side of low pressure relief valve (5) and while watching the pressure gauge (for low pressure)
connected to the hub and also by regulating low relief valve (5), gradually increase the pressure and check for leakage with a
pressure of 10 kgf/cm2 (142 psi).
Checking, low pressure port
Item Description Remarks

1 Pressure gauge High and low pressures are required
2 Center passage
3 Stop valve
5 Relief valve for low pressure Setting pressure : 10 kgf/cm2 (142 psi)
6 Stop valve
7 Relief valve for high pressure Setting pressure : working pressure × 1.5
8 Changeover valve
9 Piping, etc.
Troubleshooting
Troubleshooting
Trouble Cause Remedy

External / internal leakage, machine (1) When the pressure between pump (1) Check the circuit between pump
does not travel straight on level ground and valve drops. and valve, and repair or replace.
or a slope, even if the travel motor and - The circuit for valve is defective. Check pump, valve, and center
pump are normal. passage by pressure gauge in that
sequence.
(2) When the pressure between pump (2) Check for leakage between center
and center passage drops. passage and valve.
- The circuit for center passage is If it is normal, separate center
defective. passage and test the pressure by
gauge.
If the pressure drops, disassemble
and check the o-ring, etc. visually.
When noise comes from the center Check the center passage plumbing for If the center passage is defective,
passage. vibration or abnormal heating by hand. disassemble to check the shaft and
seals. Repair or replace a worn shaft.
Service Information

Propeller shaft, description 450 Service Information 2014/5/12
Profile:
Propeller shaft, description

Function
The drive shaft is a connection between gearbox and differential. The drive shaft is composed of flange, journal, yoke and
shaft.
Figure 1
Propeller shaft, construction
1 Flange 3 Slide out york 5 Tube

2 Journal 4 Shaft slider inner 6 Grease nipple
Operation
Figure 2
Propeller shaft, operation
1. Gearbox
2. Spline
3. Differential
Vertical angle
Vertical angle
Front 3.7 °
Rear 3.0 °
Phasing
CAUTION
Pay attention to phasing when assembly.
Figure 3
Phasing
Service Information

Differential, description 4612 Service Information 2014/5/12
Profile:
Differential, description
Figure 1
Structure, differential
1 Carrier assembly 13 Taper roller bearing 25 Plane washer

2 Carrier 14 Shim 26 Side gear
3 Cap 15 Spacer 27 Pinion (differential)
4 Screw 16 Shim 28 Spider
5 Flange assembly 17 Bevel 29 Thrust washer
6 Flange 18 Bevel pinion 30 Thrust washer
7 Dust cover 19 Bevel ring gear 31 Adjusting screw
8 Holder 20 Screw 32 Taper roller bearing
9 Pinion nut 21 Differential assembly 33 Spring pin
10 Oil seal 22 Housing (left) 34 Screw
11 Seal (dust) 23 Housing (right)
12 Taper roller bearing 24 Screw
Service Information

Axle, disassembly and 4613 Service Information 2014/5/12
assembly
Profile:
Axle, disassembly and assembly

Mount the axle assembly securely on a maintenance stand.
Remove fill plug (1) and drain plug (2). Drain the oil from the axle housing into a suitable container.
Figure 1
Removal, fill plug and drain plug
1. Filling plug
2. Drain plug
Remove plug (1) from each final drive and drain the oil into a suitable container. Ensure the plug is positioned on the vertical
axis to completely drain the oil.
Figure 2
Removal, plug
1. Drain plug
Lubrication grease points, replace any damaged fittings. After reassembly lubricate until grease is forced out.
Figure 3
Lubricating, grease points
Remove the two countersunk screws holding the drum to the wheel hub.
Figure 4
Removal, countersunk screws
Install two screws (M10) into the threaded holes, tighten alternately to remove the drum.
Figure 5
Removal, drum
Remove the snap ring holding the planetary gear to the shaft. Remove the gear and bearing using a proper puller.
Figure 6
Removal, snap ring, gear and bearing
To reinstall the gear, strike the inner bearing race to drive the assembly on the shaft.
CAUTION
The pronounced bevel of the bearing must face toward the pin weld radius. Replace the four gears as a set.
Figure 7
Striking, inner bearing race
Remove and replace the o-ring on the wheel hub.
Figure 8
Removal, o-ring
Remove the snap ring from the ring gear.

Figure 9
Removal, snap ring
 Tools : snap ring plier (expansion)
Pull out the brake reaction disc.
Figure 10
Removal, brake reaction disc
Extract the inner and outer brake discs. Note the position of the discs. First and last discs are friction discs.
Figure 11
Removal, inner and outer brake discs
Remove the retaining ring from the axle shaft.

Figure 12
Pull out the disc carrier hub. Remove the thrust washer.
Figure 13
Removal, disc carrier hub and thrust washer
Remove the two screws and lock plates for the ring nut.
Figure 14
Removal, screws and lock plates
Remove the ring nut from the wheel hub spindle.

Figure 15
Removal, ring nut
Support the wheel hub and remove the ring gear assembly.
Figure 16
Removal, ring gear assembly
Extract the six push rods from the carrier gear.
Figure 17
Removal, push rods
Remove the retaining ring from the ring gear. Separate the carrier gear from the ring gear.
Figure 18
Remove the return springs retaining ring from the pressure plate by unhooking each return spring.
Separate the carrier gear from the pressure plate.
Replace the outer roller bearing if necessary.
Figure 19
Reinstall the pressure plate to the carrier gear.
Figure 20
Assembly, pressure plate
Insert the three return springs into the carrier gear.

Install the retaining ring on the pressure plate, push the springs through and hook them on the retaining ring.
Figure 21
Assembly, return spring and retaining ring
Install the carrier gear assembly into the ring gear.

Install the ring gear retaining ring.
Figure 22
Assembly, carrier gear assembly and ring gear retaining ring
Insert the six push rods.
Figure 23
Assembly, push rods
Extract brake piston (if required use compressed air) from the wheel hub spindle.
Figure 24
Removal, brake piston
Remove and replace the brake piston o-rings.
Figure 25
Removal and replacement, brake piston o-rings
Remove the wheel hub from the spindle.
Figure 26
Removal, wheel hub
Remove the seal.

Figure 27
Removal, seal
Remove the wheel hub outer bearing race if necessary.

Always replace the bearing as a complete assembly.
Figure 28
Removal, wheel hub outer bearing
Remove spindle screws (M14) and slide the spindle over the axle shaft.
Figure 29
Removal, spindle screws
Remove the seal and axle shaft inner bushing.

Figure 30
Removal, seal and axle shaft inner bushing
Install a new bushing and seal with properly sized drivers.
Figure 31
Assembly, new bushing and seal
Loosen the locking nut and unscrew the retaining dowel fixing the axle shaft bushing and bearing assembly to the axle
housing.
Figure 32
Loosen the locking nut
Pull the axle shaft assembly from the axle housing.

Figure 33
Removal, axle shaft assembly
Remove the bushing retaining snap ring and spacer ring from the axle.
Figure 34
Removal, bushing retaining snap ring and spacer ring
Slide the bushing off the axle. (Tap lightly with a nylon hammer.)
Figure 35
Removal, bushing
Remove the snap ring and extract the bearing from the bushing. Pry out the seal, and remove the outer o-ring.
Reassemble with new parts.
Figure 36
Removal, snap ring and bearing
Ensure the bearing retaining snap ring is firmly seated.
Figure 37
Assembly, snap ring
Install the bushing assembly on the axle shaft, slide the spacer ring into position and install the snap ring.
Figure 38
Assembly, bushing and snap ring
Remove the screws, cover and washer on steering connecting link.

Figure 39
Removal, screws
Remove the snap ring from the ball joint pin.
Figure 40
Removal, snap ring
Remove the snap ring and pin from the steering cylinder rod and connecting link.
Figure 41
Removal, snap ring and pin
Drive the connecting link and ball joint off the fixed pin.
Figure 42
Removal, connecting link
Remove the screws from the steering knuckle upper cap.
Figure 43
Removal, screws
Remove the cap and adjusting shims.
Figure 44
Removal, cap and adjusting shims
Remove the screws from the steering knuckle lower cap.

Figure 45
Removal, screws
Install the threaded puller screw in the knuckle pin.
Figure 46
Assembly, threaded puller screw
Install the puller base and extract the knuckle pin.
Figure 47
Removal, knuckle pin
Remove the steering knuckle.

Figure 48
Removal, steering knuckle
Straighten the safety plate crimping, loosen the lock nut and remove the ball joint end.
Figure 49
Removal, ball joint end
Remove the steering cylinder coupling flange.
Figure 50
Removal, steering cylinder coupling flange
Remove the cylinder base screws and extract the steering cylinder from the support.
Figure 51
Removal, steering cylinder
Extract the rod and base from the cylinder barrel.
Figure 52
Removal, rod and base
Remove the flange and replace the inner and outer o-rings/seals.
Figure 53
Removal, flange
Remove and replace the piston packing.

Figure 54
Removal and replacement, piston packing
Remove the screws retaining the differential unit, then extract it from the axle housing.
Figure 55
Removal, screws
Remove ring nut lock plates and loosen both ring nuts.
Figure 56
Removal, ring nut lock plates
Mark the caps so as not to exchange their position at reassembly.

Figure 57
Marking, reassembly position
Remove the caps and both ring nuts.
Figure 58
Removal, caps and ring nuts
Extract the differential unit from the carrier.
Figure 59
Removal, differential unit
Straighten the flange nut lock plate crimping, install the flange bar tool, remove the flange nut and flange.
Figure 60
Removal, flange nut and flange
Pry the pinion seal out of the carrier.
Figure 61
Removal, pinion seal
Remove the bevel pinion from the differential carrier. Drive the pinion shank with a plastic or rubber mallet; do not damage
the threads.
Figure 62
Removal, bevel pinion
Remove the pinion bearing races from the differential carrier.

Use a brass drift.
Figure 63
Removal, pinion bearing races
Remove shims, spacer and pinion underhead bearing.
Figure 64
Removal, shims, spacer and pinion
Mark the differential half-cases for reference at assembly.

Remove the screws and separate the half-cases.
Figure 65
Marking, differential half-cases
Do a visual check for wear on the pinion gears, side gears, thrust washers and spider.
Figure 66
Checking, components
If the bevel pinion crown gear or pinion gear are damaged or worn they must be replaced as a set. Always torque the crown
gear screws evenly in several stages using a criss-cross pattern.
Figure 67
Tightening, screws
Reinstall the crown gear on the half-case, install the two dowel pins, and tighten the screws.
 Replace the screws each time they are removed.

 The two lock washers are used on the screws beside each dowel pin.
Figure 68
Assembly, crown gear
Tightening torque : 132 ~ 146 N·m (97 ~ 107 lbf·ft)
Position the differential components in their relevant seats, then join the half-cases (matching reference marks), install and
tighten the screws.
Figure 69
Positioning, differential components
Prior to reassembling the differential the following measurements must be taken.

Note dimension “A” from the crown bevel gear axis, to the pinion underhead bearing seat.
To dimension “A” add 62.5 mm.
Figure 70
Measurement, dimension "A"
Stamped on the pinion gear is a number proceeded by (+) or (-) symbol.

This number expressed in 0.1 mm, indicates any deviation from the theoretical measurement of dimension “A”.
Therefore dimension “A” (±) deviation value = “B”.
If the symbol is (+), subtract the value from dimension “A”.
If the symbol is (-), add the value to dimension “A”.
Figure 71
Stamping, pinion gear
Determine pinion head thickness, dimension “C”.

Figure 72
Measuring, dimension "C"
Press the bearing on the pinion shaft. Place the outer race on the bearing.
 Determine bearing thickness, dimension “D”.

 Measure total thickness of pinion head and bearing.
 Dimension “D” = Total thickness - dimension “C”.
Figure 73
Measurement, dimension "D"
Determine adjusting shim “S” for correct axial positioning of the pinion gear.
 S = A - (B + D)
 Add 0.5 mm to dimension “S” to compensate for bearing preload.
Figure 74
Measurement, dimension "S"
Position adjusting shim and install the outer bearing race. Also install the bearing race for the pinion tail bearing.
Figure 75
Assembly, outer bearing race
Recheck pinion position by measuring dimension “E”.
 B - (45 + C) = “E”.
 Dimension “E” must be lower than dimension “B” by 0.05 mm.
 If necessary adjust the shim thickness.
Figure 76
Rechecking, pinion position
Insert the pinion gear into the differential carrier.

Install the spacer, shims and bearing on the pinion shaft.
NOTE!
Do not install the flange oil seal.
Figure 77
Assembly, pinion gear
Install flange, lock plate, flange nut and flange bar tool.
Tighten flange nut.
Figure 78
Assembly, flange, lock plate and flange nut
Measure the pinion axial clearance with a dial gauge.

Remove the flange and adjust the shim pack to obtain “0” clearance.
Reinstall the flange assembly, tighten the nut to specified torque and check the pinion rolling torque.
Figure 79
Checking, pinion rolling torque
Rolling torque : 20 ~ 40 N·m (15 ~ 30 lbf·ft)
Remove the flange assembly, install the oil seal, reinstall the flange, plate and nut. Torque the nut as specified and crimp the
lock plate.
If your model does not use a lock plate, stake the top edge of the flange nut.
Figure 80
Assembly, oil seal
Install the differential on the carrier, insert the ring nuts and adjust bevel crown gear to pinion clearance. (approximately)
Figure 81
Assembly, differential
Install the differential caps and screws.

Tighten to specified torque.
Ensure the caps match the reference marks.
Figure 82
Assembly, differential caps and screws
Measure differential axial clearance with a dial gauge.

Tighten one ring nut to align the lock plate notch.
Tighten the opposite nut to eliminate the axial clearance.
Preload the bearings by tightening the ring nut one additional notch.
Figure 83
Measurement, differential axial clearance
Position a dial gauge perpendicular to a crown gear tooth and measure the crown to pinion clearance (backlash).
 Backlash : 0.2 ~ 0.28 mm (0.008 ~ 0.011 in)

Figure 84
Measurement, backlash
Install the spring pin (1).
Figure 85
Assembly, spring pin
Brush a small amount of prussian bluing on 3 or 4 adjacent teeth of the crown bevel gear.
Rotate the pinion several revolutions in each direction until tooth contact marks are visible.
To change the contact pattern, adjust the pinion underhead bearing shim pack.
Figure 86
Brushing, small amount of prussian bluing
If the contact pattern is as shown remove the bluing from the gears.
A change to the gear backlash will change the gear tooth contact.
A change to the gear tooth contact will change the gear backlash.
Figure 87
Checking, contact pattern
If your model does not use a flange nut lock plate, stake the flange nut top edge in two places.
Figure 88
Staking, flange nut
Clean the contact surfaces thoroughly, apply silicone gasket material and install the differential assembly on the axle
housing.
Figure 89
Installation, differential assembly
Install differential screws and tighten in a criss-cross pattern.

Figure 90
Tightening, screws
Position the steering knuckle on the axle housing.
Figure 91
Positioning, steering knuckle
Install the upper and lower pins.

Cool with liquid nitrogen or drive with a hammer.
Figure 92
Assembly, upper and lower pins
Install the inner ball ring on the knuckle pin.

Figure 93
Assembly, inner ball bearing
Install the knuckle pin seal using a seal driver.
Figure 94
Assembly, knuckle pin seal
Install the outer ball ring in the knuckle housing.
Figure 95
Assembly, outer ball bearing
Install cover and shim on the lower knuckle side.

Install screws and tighten to specified torque.
Figure 96
Assembly, screws
Install the cover on the upper side, position 3 screws 120° apart and tighten until axial play is eliminated.
Ensure the knuckle rotates freely and measure the gap between cover and steering knuckle.
Figure 97
Measurement, gap between cover and steering knuckle
Remove the cover, install the adjusting shims, reinstall cover and screws.
Figure 98
Assembly, adjusting shims and cover
After torquing ensure that the knuckle rotates freely.

Axial clearance should be 0 ~ 0.1 mm.
Repeat operation 91 ~ 99 for the opposite side.
Figure 99
Tightening
Insert piston and rod into the cylinder barrel, then install the base on the rod.
Figure 100
Assembly, piston and rod
Install the steering cylinder in the support.

Ensure that the right-hand threaded hole in the rod end is on the right-hand side of the axle.
Figure 101
Assembly, steering cylinder
Install the cylinder base screws and tighten to specified torque.

Figure 102
Assembly, screws
Install the coupling base on the right-hand side and tighten the screws to specified torque.
Figure 103
Assembly, coupling base and screws
Thread the ball joint ends into the steering cylinder rod.
Figure 104
Threaded the ball joint ends
Ensure that the ball joint ends protrude an equal distance.

Figure 105
Ensure that the ball joint ends protrude an equal distance
CAUTION
When installing a new ball joint, remove the seal from the upper side to allow for proper lubrication.
Figure 106
When installing a new ball joint, remove the seal from the upper side to allow for proper lubrication.
Install the spacer on the steering link fixed pin.
Figure 107
Assembly, spacer
Install the steering connecting link. Use a driver on the inner ball ring.
Figure 108
Assembly, steering connecting link
Attach the connecting link to the steering cylinder ball joint end.
Ensure that the snap ring is properly seated.
Figure 109
Attachment, connecting link
Install the ball joint snap ring, washer and cover.
Figure 110
Assembly, ball joint snap ring, washer and cover
Install the screws, lock washers and tighten to specified torque.

Figure 111
Assembly, screws and lock washers
Insert the axle shaft together with the bushing/ball bearing assembly. Align the bushing groove with the retaining dowel
threaded hole in the axle housing.
Figure 112
Assembly, axle shaft
Install the retaining dowel, tighten it against the bushing, and lock with the self-locking nut.
Apply loctite # 242 to the dowel prior to installation.
Figure 113
Assembly, retaining dowel
Install the spindle with the bleeder screw facing upward.

Apply a silicone gasket material to the contact surface prior to installation
Figure 114
Assembly, spindle
Install the screws and tighten to specified torque.

Apply loctite # 262 to the screws prior to installation.
Figure 115
Assembly, screws
Install the wheel hub and the inner wheel bearing.

Adequately support the wheel hub to avoid damaging the oil seal.
Figure 116
Assembly, wheel hub
Insert the brake piston assembly.

Figure 117
Installation, brake piston assembly
Install the ring gear assembly.

Install the ring nut and tighten to eliminate any axial play.
Figure 118
Installation, ring gear assembly
Tighten the ring nut to preload the bearings.

Rotate the wheel several times then check the rolling torque.
Figure 119
Checking, rolling torque
Rolling torque : 15 ~ 30 N·m (11 ~ 22 lbf·ft)
Position the ring nut, install the lock plates and screws.
Apply loctite # 242 to the screws prior to installation.
Figure 120
Applying, loctite
Install the thrust washer and the disc carrier hub.
Figure 121
Assembly, thrust washer and disc carrier hub
Install the hub retaining ring on the axle shaft. Slew the steering knuckle several times to ensure that the retaining ring is
properly seated.
Figure 122
Assembly, hub retaining ring
Install the brake disc pack.

Start with a friction disc and alternate steel and friction discs until the correct number of discs are installed. The last disc is a
friction disc.
Free play between brake disc pack and the brake reaction disc is 3.6 ~ 4 mm (0.141 ~ 0.157 in). Steel discs are available in
various thickness.
Figure 123
Assembly, brake disc pack
Insert the brake reaction disc and install the retaining snap ring.
Figure 124
Assembly, retaining snap ring
Install the o-ring on the wheel hub.
Figure 125
Assembly, o-ring
Install the drum and planetary assembly.

Figure 126
Installation, drum and planetary assembly
Center the steering cylinder rod. Use calipers to check that the rod extends equally on both sides of the cylinder. Also ensure
that the ball joint ends extend equally from the rod.
Figure 127
Checking, rod extended dimension
Attach a straight edge to each wheel hub flange.

Check the parallelism by measuring the distance from the left flange to the right flange on both the front side and the rear
side of the axle.
Each measurement must be taken at the same distance from the center line on the straight edge.
Figure 128
Checking, parallelism
Adjust parallelism by tightening or loosening the ball joint ends.

Figure 129
Adjustment, parallelism
Tighten the ball joint lock nut to specified torque.

Bend the safety lock plate.
Figure 130
Bending, safety lock plate
Adjust the steering angle as follows:
 Screw the stop screw into the arm completely.

 Slew the steering knuckle so the arm is a close as possible to the axle housing.
 Back out the screw until it contacts the stop block.
 Turn the screw out an additional 6 revolutions and tighten the lock nut.
NOTE!
Apply loctite # 242 to the stop screw.
Figure 131
Adjustment, steering angle
Rear axle
Variations in assembling the planetary drives. Apply a silicone gasket material to the contact surface prior to installation of
the spindle.
Figure 132
Applying, silicone gasket material
To check the axial clearance of the axle shaft determine the following dimensions.
 Measure the distance from the drum flange to the axle striker plate.
Dimension “A”.
Figure 133
Measurement, dimension "A"
Measure the distance from the end of the axle shaft to the wheel hub flange.
Dimension “B”.
Clearance A - B = 0.2 ~ 0.4 mm (0.008 ~ 0.015 in)
Figure 134
Measurement, dimension "B"
If the clearance is not as specified, remove the axle shaft striker plate and adjust the thickness of shims as required.
Figure 135
Adjust the thickness of shims as required
Service Information

Axle, special tools 4613 Service Information 2014/5/12
Profile:
Axle, special tools

Special tools
No. Part name (part no.) Quantity No. Part name (part no.) Quantit
y
1 Planetary gear jig (8934 - 00250) 1 5 Shaft support jig (8934 - 00280) 1
2 Spindle nut jig (8920 - 00470) 2 6 Dry bearing jig (8934 - 00290) 1
3-1 Wheel bearing cup jig (8934 - 00260) 1 7 Spindle seal jig (8920 - 00490) 1
3-2 Hub seal jig (8920 - 00480) 1 9 Dust seal jig (8920 - 00500) 1
4 Dry bearing jig (8934 - 00270) 1 10 Flange support jig (8934 - 00300) 1
11 Bearing corn jig (8934 - 00310) 1 15 Differential seal jig (8920 - 00520) 1
12-1 Bearing cup jig (8934 - 00320) 1 16-1 Knuckle seal jig (8920 - 00530) 1
12-2 Bearing cup jig (8934 - 00330) 1 16-2 Knuckle seal jig (8920 - 00540) 1
13 Bearing corn jig (8934 - 00340) 1 17 Knuckle bearing jig (8934 - 00110) 1
14 Differential seal jig (8920 - 00510) 1 18 Ball joint jig (8934 - 00360) 1
Service Information

Hub reduction, description 4613 Service Information 2014/5/12
Profile:
Hub reduction, description

Front hub, sectional view
Figure 1
Front hub, sectional view
1 Support assembly 17 Spindle assembly (right) 33 Ring gear 49 Retaining ring

2 Support 18 Spindle (right) 34 Retaining ring 50 O-ring
3 Dry bearing 19 Dry bearing 35 Push rod 51 Hub assembly
(drum)
4 Oil seal 20 Oil seal 36 Pressure plate 52 Drum (hub)
5 Retaining ring 21 Seal (spindle) 37 Spring cover 53 Planetary gear
6 O-ring 22 Breather 38 Return spring 54 Needle bearing
7 Screw 23 Screw 39 Adjusting screw 55 Retaining ring
8 Nut 24 Wheel hub 40 Lock plate 56 Plate
9 Knuckle 25 Stud (wheel) 41 Retaining ring 57 Shim (0.1, 0.3, 0.5)
10 King pin 26 Oil seal 42 Thrust washer 58 Screw
11 Seal (king pin) 27 Taper roller bearing 43 Front drum 59 Magnetic plug
12 Taper roller bearing 28 Brake piston 44 Sun gear 60 O-ring
13 Screw 29 O-ring 45 Retaining ring 61 Grease nipple
14 Cover 30 O-ring 46 Counter disc (3.5, 4.0, 4.5) 62 Wheel nut
15 Shim (0.1, 0.3, 0.5, 1.0) 31 Taper roller bearing 47 Brake disc
16 Front shaft 32 Support 48 Brake plate
Rear hub, sectional view
Figure 2
Rear hub, sectional view
1 Spindle assembly (right) 12 O-ring 23 Retaining ring 34 Planetary gear

2 Spindle (right) 13 Taper roller bearing 24 Thrust washer 35 Needle bearing
3 Seal (spindle) 14 Support 25 Drum (rear) 36 Retaining ring
4 Breather 15 Ring gear 26 Shaft (rear) 37 Plate
5 Screw 16 Retaining ring 27 Counter disc 38 Shim
6 Hub 17 Push rod 28 Brake disc 39 Screw
7 Stud 18 Pressure plate 29 Brake plate 40 Magnetic plug
8 Oil seal 19 Spring cover 30 Retaining ring 41 O-ring
9 Taper roller bearing 20 Return spring 31 O-ring 42 Wheel nut
10 Brake piston 21 Adjusting nut 32 Drum assembly (hub)
11 O-ring 22 Lock plate 33 Drum (hub)
Service Information

Slew ring gear 490 Service Information 2014/5/31
Profile:
Slew ring gear

Slew ring gear
Slew ring gear, removal/installation
1. Remove superstructure.
WARNING
Confirm the weight of slew ring gear, and take appropriate safety measures.
2. Connect slew bearing to a hoist using lifting brackets (C).
Figure 1
Lifting, slew ring gear
3. Remove screws and lock washers and slew ring bearing (D).
4. Replace upper and lower seals as necessary.
5. Clean mating surfaces of slew bearing, superstructure, and under carriage.
CAUTION
The tooth marked with the letter “S” (A) is the starting and stopping point for the surface hardening process. The
tooth and the bearing loading plug must be installed on the right side of the machine so the wearing of slew
bearing is minimized.
Figure 2
Marks of starting and stopping
6. Install slew bearing on undercarriage so the tooth marked “S” or equivalent and bearing loading plug is the right
side of machine as shown.
7. Install screws and lock washers. Tighten screws to specified torque.
8. Apply Alvania EP #2 grease to slew bearing teeth and pinion gear.
A. Tooth
B. Loading plug
C. Lifting bracket (3 points)
D. Slew ring bearing assembly
E. Positioning hole (3 points)
NOTE!
Tightening torque : 52.2 ± 5.2 kgf·m (377 ± 38 lbf·ft)
Figure 3
Applying, grease
1. Front
2. Grease port
3. Plug position (outer race)
4. Inner race marked as “S” soft zone
Service Information

Slew ring gear seals, 490 Service Information 2014/5/31
installation
Profile:
Slew ring gear seals, installation

1. Remove oil seal (A).
Figure 1
Removal, oil seal
2. Scrape old adhesive from seal groove (B). Thoroughly clean seal groove and new seal using aerosol solvent.
3. Apply instant gel adhesive to seal groove.
4. Install seal with seal lip against outer race (A). Start about 76 mm (3 in) from end of seal using a blunt instrument to
force seal into groove. Push seal in direction of portion already installed to avoid stretching.
5. Before bringing ends of seal together, cut off excess length.
6. Apply adhesive to both ends of seal. Push ends into seal groove making sure they come together.
CAUTION
To avoid pulling seal out of groove, adhesive must cure for at least 24 hours before using slew function.
Figure 2
Applying, adhesive
Happy every day.
Service Information

Brake system diagram, 520 Service Information 2014/5/31
description
Profile:
Brake system diagram, description

The machine is equipped with a fully hydraulic brake system utilizing separate circuits to simultaneously apply the front axle
and rear axle multiple wet disc service brakes.
The principle of actuation is as follows:
 Hydraulic tank oil is sent by hydraulic pump (1) to brake supply valve (2) to accumulators (3).
 When the accumulators reach the maximum set pressure of the cut-off valve the oil flow from pump (1) is returned
to tank.
 When the accumulators drop below the minimum set pressure of the cut–off valve the oil flow from the pump is
directed to the accumulators.
 Depressing service brake pedal (9) permits pressurized oil flow from both accumulators for the service brakes to
flow through the brake valve, where the pressure is reduced, to the front and rear axle service brake assemblies.
The pressurized oil pushes the axle brake pistons, applying the multiple wet disc brakes with a pressure
proportional to the foot pedal stroke.
Figure 1
Brake system diagram
1 Gear pump 4 Pressure switch (for brake failure) 7 Front axle

2 Brake supply valve 5 Service brake valve 8 Rear axle
3 Accumulator 6 Pressure switch (for brake failure) 9 Service brake pedal
Service Information

Brake system, maintenance 520 Service Information 2014/5/31
Profile:
Brake system, maintenance

Specifications
Item Testing condition Measuring value Unit Standard value Tolerance

Brake pedal Engine speed: Low idle Operating force kg 19 less
degree ° 20 -
Brake supply Engine: Max. ~ Min. Cut-in bar 120 +5
valve Oil temperature : 50 ± 5°C Cut-out 150 -5
Normal brake system
Service brake Operating pressure 75 ±5
(Min.)
Accumulator Operating pressure 150 -5
(Max.)
Brake pump Displacement cc/rev 7.6 -
Brake warning ON pressure kgf/cm2 96 less
lamp OFF pressure 100 more
Brake oil Testing pressure: 75 bar Pressure drop bar Max. 5 less
pressure drop
Wear of brake Engine stop Front axle mm Max. 4.5 less
disc Activate brake Rear axle
Measure disc gap
Brake Road: Level, straight, paved Brake stopping m (ft) 10 (33) less
performance Speed: 32 km/h (20 mph) distance
Pedal operating time: 0.5 sec.
Pedal operating force: 19 kgf
Tire pressure: Specification
Measuring brake pressure

Measuring condition
Brake supply valve

Specifications, unit : bar (psi)
Item Standard value

Cut-in pressure 120 ~ 125 (1740 ~ 1812)
Cut-out pressure 145 ~ 150 (2103 ~ 2175)
Brake pressure switch

Specifications, unit : kgf/cm2 (psi)
Item Standard value

Brake stop light ON 100 (1422) or less
Brake stop light OFF 100 (1422) or more
Accumulator
Specifications, unit : bar (psi)
Item Standard value

Maximum pressure 180 (2610)
Working pressure range 120 ~ 150 (1740 ~ 2175)
Special tools
 Oil pressure gauge: 0 ~ 300 kgf/cm2 (0 ~ 4500 psi)

 Tee connector
NOTE!
When measuring, only use glycerine filled pressure gauges with a reading accuracy of ±1%.
Measuring set pressure of brake supply valve

Measuring
 Measure the pressure at which, the brake supply valve is actuated and the pressure building cycle cuts out.
 With the engine at low idle, use the brake pedal to lower the brake system pressure.
Measure the pressure at which, the brake supply valve is actuated and the pressure building cycle cuts in.
Adjusting
 The cut-out pressure can be adjusted by turning adjusting screw (3) on the brake supply valve.
Turn the adjusting screw as follows:
 To DECREASE set pressure, LOOSEN screw.

 To INCREASE set pressure, TIGHTEN screw.
Figure 1
Adjustment, brake supply valve
1. Body
2. Lock nut
3. Adjusting screw
4. Cap
Measuring warning lamp ON/OFF pressure
 Run the engine at low idle. Use the brake pedal to lower the accumulator pressure, and measure the pressure at
which the lamp comes ON.
 Run the engine at high idle to build up the accumulator pressure and measure the pressure at which the lamp goes
OFF.
 If the pressure is not standard value, check the switch.
If necessary, replace the switch.
 After replacing the switch, measure the pressure again.
Measuring accumulator pressure

 Start the engine and run it until the cut-out pressure of the brake system is reached.
 Stop the engine and measure the maximum outlet pressure of both service brake accumulators.
 Actuate the service brake pedal 15 times, the accumulator pressure for both circuits should not drop below 60 bar.
 If brake is available less than 15 times, check brake disc wear and check each accumulator for defects.
Measuring pressure of axle service brake
 Start the engine and raise the accumulator pressure until the cut-off valve is actuated and the pressure building
cycle cuts out.
 Depress the brake valve foot pedal completely and measure the brake circuit pressure between the brake valve and
the axle brakes.
Adjusting
 The brake pressure can be adjusted by adjustment screw (9) on the service brake valve which limits pedal stroke.
Turn the adjustment screw as follows :
 To DECREASE set pressure, RAISE the screw.

 To INCREASE set pressure, LOWER the screw.
Location of test point
 Test point A (PSD): Service brake/front axle.

Test point B (PSA): Service brake/rear axle.
Test point G1: Shift pressure on pressure switch.
To check the cut-in and cut-off pressure, the accumulator pressure on accumulators and the shifting pressure of
the warning lamp pressure switch.
 Test points on front and rear axle.

To check the service brake pressure for each brake circuit.
Figure 2
Position, brake pressure check
Air bleeding from brake system
WARNING
Block the tires securely. Set the travel mode switch at park position.
Order of operation
 Remove the bleeder screw cap, push a vinyl hose onto the screw and put the other end in a container.
 Start the engine and run on low idle.
 Depress the brake pedal, loosen the bleeder screw and bleed the air. Then tighten the bleeder screw and slowly
release the brake pedal.
 Two workers are needed for this operation: one depresses the pedal and the other bleeds the air from the
bleeder screw.
 Repeat this operation until the flow of brake oil is free of air bubbles. Then depress the pedal fully and tighten the
bleeder screw while oil is flowing out.
 Follow the same procedure to bleed the air from each wheel end brake assembly.
 To bleed the air completely, bleed the air first from the brake assembly farthest from the brake valve.
Figure 3
Bleeder screw, brake system air bleeding
Checking brake system leakage

Measuring condition

 Test pressure: 75 bar (1087 psi)
 Hydraulic pressure: Within operating range
Item Standard value, unit : bar (psi)

Drop in pressure Max. 5.0 (72)
Accumulator outlet pressure Max. 150 (2175)
Special tools
Part name Quantity

Brake test kit 1
WARNING
Block the tires securely.
Measuring procedure
 Remove bleeder screw, then install elbow and hydraulic pressure gauge in bleeder screw mount.
 Start the engine and bleed the air.
 Bleed air from plug.
 Depress the brake pedal. When the gauge reading is 75 bar (1087 psi), leave for 5 minutes and check how much the
pressure drops.
 After measuring, stop the engine, and loosen the bleeder screw.
 After completing operation, bleed the air from the brake circuit again.
 If the test results are not within specification, the axle brake assemblies, accumulators and the brake valves
should be isolated and tested individually to determine which component is causing the pressure drop.
Brake switch
The brake switches sense brake system pressure and turn on and off the brake warning lamp and stop light.
Brake stop light switch
Figure 4
Brake stop light switch
1. Brake stop light switch, break contact (low pressure)

2. Brake stop light switch, make contact (high pressure)
Brake warning lamp switch

The brake warning lamp switch assembled in the accumulator block activates the indicator in the cluster when the brake
system (accumulator) pressure is low.
Figure 5
Brake warning lamp switch
1. Normal (high pressure) - No contact

2. Abnormal (low pressure) - Contact
Testing
 High pressure `C' → Check continuity between A and B.
Continuity → Abnormal
Open circuit → Normal
 Low pressure `C' → Check continuity between A and B.
Continuity → Normal
Open → Abnormal
Figure 6
Testing, brake stop light switch
Service Information

Brake system, 520 Service Information 2014/5/31
troubleshooting
Profile:
Brake system, troubleshooting

Brake system pressure does not rise to the specified range.
1. Ask the operator the following questions.
 Did the pressure suddenly cease to rise?

→ Damage in hydraulic circuit or components.
 Was the brake oil pressure difficult to raise for some time?
→ Brake oil leakage, performance drop in brake components.
2. Check before troubleshooting
 Damaged hose or piping, external damage to components associated with brake system.
3. Fault check
 Check the brake oil pressure by gauge.

 If the warning lamp on the instrument panel remains “ON” despite confirming that the accumulator is pressurized,
the pressure switch is faulty.
The following symbols are used to indicate the action to be taken when a cause of failure is located.
 x : Replace
 D : Repair
 A : Adjust
 C : Clean
Cause Blockage Faulty Faulty Incorre Faulty Faulty Incorrect Faulty cut-
on hydra cut-off ctly accumulator brake ly off valve
suction ulic valve. adjuste - axle brakes. valve. adjusted accumulat
side of pump. d cut- brake or.
hydraulic off valve
pump / valve. pedal
aeration stroke.
of
hydraulic
oil.
a b c d e f g h
N Reme D D D A A
o. Problem dy x x x x x
1 No flow/low flow discharged o o
from pump with engine
running.
2 Hydraulic pressure builds o o
when cut-off valve is -
disconnected from the circuit.
3 Pressure does not rise when o
cut-off valve is disconnected
from the circuit.
4 Hydraulic pressure at cut-off o
valve OK, but pressure at
brake valve not to
specification.
5 Pressure from accumulator OK o o
but pressure to brake piston
not to spec.
6 Hydraulic pressure fluctuates o o o o
erratically.
7 Hydraulic pump noisy. o o
Brake is ineffective or not very effective

 Did the pressure suddenly cease to be effective?

→ Damage in hydraulic or components.
 Did brake gradually deteriorate?
→ Deterioration of seal or packing, wear of discs.
2. Check before troubleshooting
 Is oil pressure and brake oil quantity satisfactory?

 Is there any leakage of brake oil when the brake is operated?
 Is there any external damage to brake piping or components?
 Check residual thickness of brake discs.
 Check the inflation pressure and tire tread.
 Measure the pressure in the brake circuit.
3. Fault check
 Check against the performance test to see whether or not braking performance is abnormal.
 The left and right brakes at both front and rear axles.
 x : Replace
 D : Repair
 A : Adjust
 C : Clean
Cause Faulty Faulty Faulty Brake Faulty Faulty Air Fault

brake hydra operatio discs accumulator. cut–off ingression y
piston ulic n of worn/ valve. into brake brak
seals. pump. brake damaged/ circuit. e
piston/ metal to line.
pressure metal
plate. contact.
a b c d e f g h
N Reme D D D A A
o. Problem dy x x x x x
1 Braking action is abnormal o o
through one brake valve
section, but normal through
the other.
2 Max. brake pressure is normal, o o o
but braking action is not
effective.
3 Braking action on one axle o o o o
normal but abnormal on the
other axle.
4 Braking action fades when o o o o o
brake valves pedal is fully
depressed.
5 When brake is applied, an o o
abnormal noise is heard in the
axle.
6 Leakage of brake oil into axle o
housing.
7 Excessive disc/metal particles o
in axle oil.
8 Number of brake applications o
with engine shut down are not
to specification.
Brake drags or does not release

 Does brake pedal return completely?

 Is parking brake completely released?
2. Fault check
 Abnormal heat generation in brake.

 Inertia travel on flat ground.
 x : Replace
 D : Repair
 A : Adjust
 C : Clean
Cause Faulty brake Faulty lock Faulty disc Faulty brake

valve (pedal, check valve on lining. piston
piston sticking, brake line. operation.
return port
blockage).
a b c d
No. Remedy D D D
Problem x x x x
1 The brake pedal is released, oil flow from brake o o
valve stopped, but brakes do not disengage.
2 Hydraulic pressure falls off but brake releases o
only if oil is bled from the brake assembly
bleeder screw.
3 One brake assembly releases only partially, all o o
hydraulic pressure released.
Service Information

Brake supply valve 525 Service Information 2014/5/12
Profile:
Brake supply valve

Structure
Figure 1
Structure, brake supply valve
1 Valve assembly 10 O-ring 20 Jet

2 Check valve 11 Back-up ring 21 Piston assembly
3 Spool 12 Check valve cap 23 O-ring
4 Flow regulator cap 13 Check spring 24 Back-up ring
5 Piston assembly 14 O-ring 25 Plug
6 Spring 15 Steel ball 26 O-ring
7 O-ring 17 Unload valve
8 O-ring 18 Plug
9 Back-up ring 19 Plug
Specifications
Code Name Specification Tightening torque, unit : N·m (kgf·m)
CT1 Flow regulator 20 lpm (5.3 gpm) 68 (50)
CT3 Check valve IE45 - 60 (44)
CT4 Check valve 1.5 kgf/cm2 (21 psi) 60 (44)
CT5 Check valve 1.5 kgf/cm2 (21psi) 60 (44)
CT6 Unload valve IN : 120 kgf/cm2 (1707 psi) 45 (33)
OUT : 150 kgf/cm2 (2134 psi)
Port connection
Port Specification
P1, T, ACCA, ACCB PF 1/2″
AB, AC PF 3/8″
G1 PF 1/4″
(GP and PSA - plugged)
Unload valve (CT6)

This valve adjusts cut-in and cut-out pressure.
Figure 2
Unload valve (CT6)
Check valve (CT4, CT5)

This valve prevents pressure drop due to reverse flow.
Figure 3
Check valve (CT4, CT5)
Flow regulator (CT1)

This regulator regulates flow to brake system.
Figure 4
Flow regulator
Charging cycle
When the brake pressure drops to cut-in pressure due to depressing service brake pedal, unload valve (CT6) closes. Then
pump flow is supplied to the accumulators and brake system through flow regulator (CT1) until the cut-off pressure in the
brake system is reached.
After charging
When the brake pressure reaches cut-off pressure, unload valve (CT6) opens directing pump flow to tank port, thereby
preventing an excessive pressure increase.
Check valves (CT4, CT5) separate the brake circuits (Front, Rear) and protect each brake circuit against a drop in pressure
should the opposite brake circuit fail.
Valve operation
On initial start up flow/pressure is fed through the check valve and orifice (A) and (B).
Pressure between A and B is sent to chamber “C” and keeps the unloader spool in the closed position.
Due to the pilot pin diameter being 15% larger than the poppet seat diameter, a 15% differential is achieved.
Increasing pressure in the ACC line acts on the back end of the pilot pin and eventually overcomes the spring force in the
unloading cartridge and unseats the main poppet.
As orifice (A) is smaller than orifice (B) the unloader spool of chamber “C” is now open and unloads the pump pressure to
tank.
As the pressure at ACC falls to 15% of the unload pressure. The spring force overcomes the force being exerted on the pilot
pin and the main poppet reseats.
Pressure is now refed to chamber “C” and closes the unloader spool. Pump pressure now increases to charge the
accumulators.
Figure 5
Operation
1 Unload valve 4 Chamber "C" 7 Pilot pin

2 Main poppet 5 Unload spool
3 Orifice 6 Check valve (CT3)
Brake complex valve
Figure 6
Brake complex valve
1. Brake supply valve

2. Pressure switch
3. Accumulator
Service Information

Brake valve (pedal), 525 Service Information 2014/5/12
structure
Profile:
Brake valve (pedal), structure

The brake valve installed at the bottom of the operator's compartment is a dual circuit valve.
When the pedal is depressed, oil from upper valve activates the front axle brakes and the lower valve actuates the rear axle
brakes.
Figure 1
Structure, brake pedal (pedal)
A Accumulator 1 Valve piston (top)

B Accumulator 2 Valve piston (bottom)
C Front brake 3 Spring
D Rear brake 4 Spring
E Tank 5 Regulating spring
F Tank 6 Regulating spring
G Brake switch (front) 7 Regulating spring
H Brake switch (rear) 8 Foot pedal
9 Stop and adjusting screw
10 Spool
11 Seal
Service brake-locking feature

Use service brake locking feature for a while when working in W mode.
WARNING
For safety and protection of brake system, lower the dozer blade and stabilizer to the ground and support the
machine before working.
Figure 2
Service brake-locking feature
A Service brake 1 Latch pedal

B Brake release 2 Pedal
C Brake lock (using service brake) 3 Valve
4 Release position
5 Lock position
WARNING
Do not use service brake locking feature as a parking brake. Releasing of brake due to brake pressure drop may
cause a serious accident.
Position when traveling

Travel under the latch pedal is lowered down to prevent the accident from the unexpected lock of service brake.
To use the brake locking function, depress position A.
Figure 3
Position, pedal (traveling)
Service Information

Brake valve, description 525 Service Information 2014/5/12
Profile:
Brake valve, description

Brake actuated
Upper part
When foot pedal (8) is depressed, the operating force passes through spool (10), regulating springs (5, 6) and is transmitted
to piston (1). When piston (1) moves down tank port (E) closes and at the same time accumulator port (A) is connected to
brake port (C) and pressurized oil actuates the front axle brakes.
Lower part
When foot pedal (8) is depressed, the operating force passes through spool (10), springs (5, 6) and mechanically moves
upper piston (1) down, the lower piston (2) is then hydraulically moved down and tank port (F) closes while at the same time
accumulator port (B) is connected to brake port (D) and pressurized oil actuates the rear axle brakes.
Operation of brake when lower valve or upper valve fails
Since this brake valve arrangement utilizes separate accumulator circuits, brake circuits, and drain circuit ; if either the upper
or lower valve section fails, the non-affected section will operate normally thereby providing braking action to one axle.
Operating in balance
The brake pressure applied through the brake valve is proportional to the foot pedal stroke.
The regulating springs (5, 6) in the brake valve are designed in such a way that they are very sensitive to any change in
applied force caused by variations of the pedal stroke, and therefore the brake pressure changes infinitely according to the
angle of the pedal. This allows, especially in the lower pressure range, for a very responsive, controllable braking action of
the machine.
When the braking action is started the upper piston (1) is mechanically controlled by the regulating springs and the lower
piston (2) is hydraulically controlled. The downward moving pistons close via the control edge, tank ports (E, F) and connect
accumulator ports (A, B) with brake ports (C, D).
The force on the pedal controls the brake pressure, through the balance between the pressure on the top and the bottom of
pistons (1, 2). The brake valve upper and lower pistons are held in this regulating position by the foot pedal force on top of
the pistons and the hydraulic pressure below the pistons. When the desired brake pressure is achieved, the pistons are in a
partial brake position, closing accumulator ports (A, B) and tank ports (E, F), but keeping pressure on brake ports (C, D).
If the pedal is completely depressed the pistons move to the end of their stroke and the brakes are applied fully.
Brake release
Upper part
When foot pedal (8) is released and the operating pressure is removed from the top of the piston, hydraulic pressure at the
bottom of the piston and return spring (3) move piston (1) up connecting brake port (C) with tank port (E) and closing
accumulator port (A).
Lower part
When foot pedal (8) is released and the operating pressure is removed from the top of the piston, hydraulic pressure at the
bottom of the piston and return spring (4) move piston (2) up connecting brake port (D) with tank port (F) and closing
accumulator port (B).
WARNING
For safety the pressure of the accumulators must be completely depleted by repeatedly depressing the service brake
pedal before performing any maintenance on the brake system.
Service Information

Brake pump, description 5271 Service Information 2014/5/12
Profile:
Brake pump, description

Structure
Figure 1
Structure, brake pump
1. Gear shaft
2. Shaft seal
3. Dowel pin
4. Housing
5. Coupling
6. Thrust plate
7. Seal
8. Gear
9. Brake pump
10. Steering pump
Service Information

Brake pump, specifications 5271 Service Information 2014/5/12
Profile:
Brake pump, specifications

Specifications

Displacement cc/rev 7.6
cc·in/rev 0.46
Rated pressure kgf/cm2 (psi) 210 (2987)
Max. rpm rpm 3000
Max. back pressure in·Hg 0.2 ~ 0.3
Max. operating temperature °C (°F) 93 (200)
Tightening torque kgf·m 19.6 ± 1, ISO : 17 ± 0.5
lbf·ft 142 ± 7, ISO : 122 ± 3
NOTE!
Specification is for brake pump only.
Service Information

Brake accumulator, 5272 Service Information 2014/5/12
description
Profile:
Brake accumulator, description

Operation
The hydraulic accumulator is used to store energy in the form of pressurized oil supplied by the hydraulic pump.
The accumulator consists of a fluid section and a gas section. The fluid section which is connected to the hydraulic circuit,
causes the diaphragm to compress the gas volume as the hydraulic pressure rises.
The accumulator is used as an emergency energy source in case of engine shut down, circuit malfunction or pump failure. It
can also be used as a compensator for oil loss through system leakage and as an oscillation damper.
When the hydraulic pressure falls, the compressed gas volume will expand and displace the accumulated pressurized oil into
the circuit.
The diaphragm contains a valve disc which closes the hydraulic oil inlet / outlet when the accumulator is empty, to prevent
damage to the diaphragm.
The compressible gas used in the accumulator is NITROGEN.
Figure 1
Accumulator
Function
The hydraulic pump oil flow is divided by the accumulator charging valve (cut-off valve) into two brake circuits with
accumulators (A, B) for the front and rear axle brakes.
Accumulator (C) directly connected to the cut-off valve makes additional oil available to the brake system. Without this
accumulator a loss in pressure would occur at the smallest leakage in the cut-off valve control spool, keeping the valve at
the cut-in pressure cycle. Therefore this accumulator acts to balance out the cut-in, cut-out cycle. The brake system low
pressure warning lamp is connected to this accumulator.
In the event of engine shut-down or pump failure, the accumulators if fully charged will supply about 15 full brake
applications.
WARNING
For safety the pressure of accumulators must be completely depleted by repeatedly depressing the service brake
pedal before performing any maintenance on the brake system.
Service Information

Track brake, description 530 Service Information 2014/5/12
Profile:
Track brake, description
Figure 1
Wheel brake
1. Axle shaft
2. Brake piston
3. Push rod
4. Return spring
5. Pressure plate
6. Brake disc
7. Brake plate
8. Reaction disc
9. Bleeder
Operation
When the brake pedal is depressed, pressurized oil from the accumulators is routed through the brake valve to the wheel
end brake chamber.
Brake piston (2) moves to the left push rods (3) against pressure plate (5) compressing discs (6) and plates (7) against brake
reaction disc (8). Since discs (6) rotate with the wheel, when they are held, the rotation is stopped.
Release
When the brake pedal is released the hydraulic pressure acting on brake piston (2), compressing the discs/plates, is released.
The brake return springs (4) retract pressure plate (5) moving rod (3) and piston (2) to the right, releasing the brake.
Service Information

Parking brake diagram, 550 Service Information 2014/5/12
schematic
Profile:
Parking brake diagram, schematic

Parking brake function operates by the engagement of both clutch packs due to oil supply cut-off. The travel mode switch is
at “P” position, working and travelling are not available due to safety solenoid valve (5) and parking solenoid valve (3) cuts
off the gear pump oil flow.
WARNING
When parking always block the wheels and thrust the attachment into the ground.
Figure 1
Diagram, parking brake
1 Gear pump 4 1st/2nd speed solenoid valve

2 Travel mode switch 5 Solenoid valve
3 Parking solenoid valve 6 Gearbox
Service Information

Parking brake emergency 550 Service Information 2014/5/12
release
Profile:
Parking brake emergency release

A mechanically operated dog clutch is located between the planetary and helical gear output drive.
Prior to towing this machine the park brake must be released by disconnecting the dog clutch between the gearbox
planetary and output shafts.
Figure 1
Dog clutch
Normal position
During normal brake operation the lever (1) should be locked at normal position as illustrated.
Figure 2
Lever position, normal
Release position (emergency)

To release the parking brake remove screw (2), turn the lever to release position and re-install screw (2) as illustrated.
Figure 3
Lever position, release (emergency)
CAUTION
After the purpose of releasing the parking brake is achieved (towing is completed), turn it to original position by operating
in reverse order above sequence.
WARNING
Prior to releasing the parking brake, block the wheels to prevent accidental machine movement.
Service Information

Parking brake, description 550 Service Information 2014/5/12
Profile:
Parking brake, description

Parking brake
No shift control hydraulic pressure is routed to clutch packs (LB, LK) therefore both clutches are spring applied.
Ring gear (A) is held stationary by clutch (LB) and input shaft (AN) is locked to ring gear (A) by clutch (LK). Since the input
shaft (AN) is locked through clutches (LK, LB) to the gearbox housing, the planetary gear drive (PT) can not rotate.
This action prevents the rotation of output shafts (AS) by torque flow from the hydraulic motor or inertia through the
wheels.
Engine shut down, parking control switch lock or shift control hydraulic pressure drop will cause parking automatically.
Figure 1
Operation, clutch (parking brake)
Service Information

Parking brake, 550 Service Information 2014/5/12
maintenance
Profile:
Parking brake, maintenance

Air bleeding
After initial assembly of equipment or reassembly of high, low speed pressure line (from pump to gearbox) bleed the air
completely through air breather of gearbox prior to initial running of vehicle.
Bleeding procedure
 Depress service brake 1 ~ 2 times and lock.

 Thrust the attachment into ground.
 Block the wheels.
 Release gearbox air breather (outer clutch) until air does not bleed out.
 Then repeat low and high speed continuously until air does not bleed out.(Use care not to damage air breather).
 Tighten the air breather.
CAUTION
If there is air in the clutch line machine instantly stop when gear shifting.
CAUTION
If the air venting from transfer gearbox is not performed, the clutch within the gearbox may be seriously damaged.
Happy every day.
Service Information

Steering system, 640 Service Information 2014/5/31
description
Profile:
Steering system, description

Normal steering
When the steering wheel (5) is turned, the pressurized oil from the gear pump (1) is supplied to the steering unit (2) and
rotates the metering pump (2-1) and (2-2).
The oil sent from the metering pump (2-1), (2-2) flows into steering cylinder (8) then the motive force for steering is
obtained.
Emergency steering
When the engine or the hydraulic power source failure are occured, it is possible to use the emergency steering by steering
unit.
When the pump pressure is less than 7bar, change over valve (A) is actuated by a spring.
So that only oil flow from one of the gear wheel sets is available for the emergency steering.
Figure 1
Steering system diagram
1 Gear pump 3 Steering relief valve 7 Priority valve

2 Steering unit (Orbitrol) 4 Overload relief valve 8 Steering cylinder
2-1 Gerotor metering mechanism 5 Steering wheel 9 Tank
2-2 Gerotor metering mechanism 6 Steering column X Other working line
Service Information

maintenance standard
Profile:
Steering system, maintenance standard

Maintenance standard
Item Measuring condition Testing and Unit Standard Allowable

measuring value value
Operating time - Road surface: Low idle sec. 2.5 ~ 4.0 Max. 6.0
Flat, horizontal, dry, paved surface
- Coolant temperature:
Inside operating range High idle 1.5 ~ 3.2 Max. 5.0
- Hydraulic oil temperature:

45 ~ 55°C (113 ~ 131°F)
Operating force Low and high kg 1.5 ~ 2.0 Max. 3.0

- Tire inflation pressure:
idle
Specified pressure
- Engine speed:
Low and high idle
Oil pressure - Hydraulic oil temperature: Main relief kgf/cm2 150 (2130) Max. 155
45 ~ 55°C (113 ~ 131°F) (psi) (2200)
- Engine speed: High idle
Steering oil pressure

Measuring condition
 Hydraulic oil temperature : 45 ~ 55°C (113 ~ 131°F)

 Engine speed : high idle
Unit Standard value Permissible value

Steering oil pressure kgf/cm2 (psi) 145 +5/-0 Max. 150 (2130)
(2062 +71/-0)
Special tools
Tool Quantity
Pressure gauge 1
400 kgf/cm2 (5690 psi)
Procedure for measuring main relief pressure
WARNING
Loosen the oil filler cap (the breather cap) slowly to release the pressure inside the hydraulic tank, then operate the
steering wheel several times to release the remaining pressure in the hydraulic circuit.
1. Engage the parking brake and block the rear wheels.

2. Remove fitting (18) and install a tee fitting for measuring the right turn steering circuit.
3. Install hydraulic pressure gauge.
4. Start the engine and run at high idle.
Turn the steering wheel to the right and measure the pressure when the relief valve is actuated.
5. Adjustment
 Remove plug (1) using an Allen wrench.

 Adjust screw (2) using an Allen wrench.
6. Repeat the above procedure for the left turn steering circuit; primarily to check internal leakage.
 Fitting size of pressure union; M18 x 15, PF 1/2″
CAUTION
Do not try to adjust the pressure without reason. To gain access to the relief valve, removal of the steering unit from the
steering column is required.
Figure 1
Measurement, main relief pressure
Service Information

troubleshooting
Profile:
Steering system, troubleshooting

Troubleshooting
Fault Possible cause Remedy

Steering wheel is heavy to turn.
 Insufficient oil pressure.  Check the oil pressure.
 (1) Pump drive  (1) Replace pump

defective. drive.
 (2) Pump is worn out.  (2) Replace pump.
 Pressure relief valve is stuck in  Repair or clean pressure

open position or setting relief valve. Adjust the valve
pressure is too low. to the correct pressure.
 Too much friction in the  Grease/repair axle knuckle
mechanical parts of the steering pins, steering cylinder pins,
system. steering column bearings.
Check the hydraulic cylinder
for malfunction.
Constant steering is necessary for

straight travel. (“Snake-like driving”)  Leaf springs without spring  Replace leaf springs.
force or broken.
 Spring in relief valve broken.  Replace relief valve.
 Gerotor assembly worn.  Replace gerotor assembly.
 Cylinder scored or piston seals  Replace defective parts.
worn.
Neutral position of steering wheel

cannot be obtained, i.e. there is a  Steering column and steering  Align the steering column
tendency towards “motoring” unit out of alignment. with steering unit.
 Too little or no end play  Adjust the end play and if
between steering column and necessary, shorten the
steering unit input shaft. splined shaft.
 Pinching between inner and  Dismantle the steering unit
outer spools. and repair as required.
“Motoring” effect.
The steering wheel can turn on its own.  Leaf springs are stuck or broken  Replace leaf springs.
and therefore have reduced
spring force.
 Inner and outer spools sticking  Dismantle the steering unit
possibly due to dirt. and clean/repair as required.
Backlash
 Cardan shaft fork worn or  Replace cardan shaft.
broken.
 Leaf springs without spring  Replace leaf springs.
force or broken.
 Worn splines on the steering  Replace steering column/
column. shaft.
Shimmy–abnormal vibration of steering

wheel.  Air in the steering cylinder.  Bleed steering system,
remedy cause of air
 Worn axle knuckles or steering ingression.
cylinder pins.  Replace worn parts.
 Leaking dual relief valves and
anti-cavitation valves or broken  Repair/replace relief valve,
valve springs. anti-cavitation valves.
Replace the springs.
Steering wheel can be turned

continuously without articulating the  Oil is needed in the tank.  Fill with clean oil and bleed
front axle wheels. the system.
 Steering cylinder worn.  Replace or repair cylinder.
 Gerotor set worn.  Replace gerotor set.
 Spacer across cardan shaft  Install spacer.
missing.
Steering wheel can be turned slowly in

one or both direction without  One or both anti-cavitation  Clean or replace defective
articulating the front axle wheels. valves are leaking. valves.
 One or both relief valves are  Clean or replace defective
leaking. valve.
Steering is too slow and heavy when

trying to turn quickly.  Insufficient oil supply to  Replace pump.
steering unit, pump defective.
 Relief valve setting too low.  Adjust valve to correct
setting.
 Relief valve sticking owing to  Clean the valve.
dirt.
 Check valve in emergency  Clean or replace the check
steering unit stuck open valve.
allowing pressure to return to
tank.
Heavy kick-back in steering wheel in

both directions.  Incorrect setting of cardan shaft  Correct setting as shown in
and gerotor set. service manual.
Turning the steering wheel articulates

the axle wheels in the opposite  Hydraulic hoses for the steering  Reverse the hoses.
direction. cylinder have been
interchanged.
 Incorrect assembly of cardan  Reassemble correctly.
shaft and gerotor.
Hard point when starting to turn the
steering wheel.  Pump output low.  Check pump flow.
 Relief valve set pressure to low.  Inspect relief valve and
adjust.
 Crossover relief valve set Replace the valves if
pressure to low. (If equipped). defective.
 Oil is too thick (cold).
 Let motor run until oil is

warm.
Leakage at either input shaft, end cover,

gerotor set, housing or ports.  Shaft defective.  Replace shaft seal, see
 Screws loose. service manual.
 Washers or o-rings defective.  Tighten screws (3 ± 0.3
kgf·m).
 Replace washers or o-rings.
Service Information

Steering wheel, description 641 Service Information 2014/5/12
Profile:
Steering wheel, description

The steering wheel is adjustable for the operator's comfort. The height is adjustable maximum 40 mm by pulling up
adjusting lever (2). And the steering wheel is tiltable (push 24°, pull 8°) by pushing down adjusting lever (2).
Structure
Figure 1
Steering wheel
1. Steering column
2. Adjusting lever
3. Steering wheel
Service Information

Control valve (steering 6457 Service Information 2014/5/12
unit), assembly
Profile:
Control valve (steering unit), assembly

Cleaning
 Clean all parts carefully with solvent, blow dry or use paper towels.
 Do not use shop cloths since the lint may cause a malfunction.
Inspection and replacement
 Replace all seals and washers. Check all parts carefully for abrasion, burrs or scores and make repairs and
replacements as required.
Lubrication
 Before assembly lubricate all parts with hydraulic oil.
Mount the diameter 3/16″ ball for the check valve in LS port.
Figure 1
Assembly, ball
Mount the threaded bushing using an allen key span of jaws 2.

Figure 2
Assembly, bushing
Tightening torque : 10 ± 1 kgf·cm (8.7 ± 0.9 lbf·in)
Mount the ø3/6″ ball in the bore, and use an Allen key (span of jaws 4) to mount the threaded bushing.
Figure 3
Assembly, ball and bushing
Mount the ø3/6″ ball in the bore, and use an Allen key (span of jaws 4) to mount the threaded bushing.
Figure 4
Mount the ø5/8 mm ball in the bore, and mount the threaded bushing.
Figure 5
Mount the guide pin.
Figure 6
Assembly, guide pin
Mount the distributor plate.
Figure 7
Assembly, distributor plate
Mount the cardan shaft.
Figure 8
Assembly, cardan shaft
Mount the o-ring fitted gearwheel set.
Figure 9
Assembly, gearwheel set
Mount cardan shaft and distributor plate.
Figure 10
Assembly, cardan shaft and distributor plate
Mount the o-ring fitted gearwheel set.
Figure 11
Assembly, gearwheel set
Mount the distributor plate.

Figure 12
Assembly, distributor plate
Mount valve housing with o-rings.
Figure 13
Assembly, valve housing
Mount the guide pin.
Figure 14
Assembly, guide pin
Mount the spring.

Figure 15
Assembly, spring
Mount the shift valve.
CAUTION
Ensure that the shift valve is correctly positioned in relation to the guide pin.
Figure 16
Assembly, shift valve
Mount the cover take care not to change the position of the shift valve. Upon the first tightening, use a finger to press down
the cover.
Figure 17
Assembly, cover
Tightening torque : 3 ± 0.6 kgf·cm (22 ± 4 lbf·in)

Service Information

unit), description
Profile:
Control valve (steering unit), description

The steering unit device consists of a rotary valve bank spool (5), sleeve (6) and gerotor set (8), (9) flanged to main housing
(3).
The steering column (1) drives spool (5); inside sleeve (6) and these two parts turn at ± 8° in relation to each other.
These parts are positioned at an angle by means of Neutral position springs (2). When the steering wheel is not turned
(Neutral position), the springs return the sleeve to a neutral position in relation to the spool.
The cardan shaft (7) is intergral with sleeve (6) by pin (10) with stator (8) and rotor (9).
Steering check valve (4) enables the steering cylinder return flow to be reinjected direct for power supplying the device
(closed circuit).
During normal operation the valve is closed.
Figure 1
1 Steering column 4 Check valve 7 Cardan shaft 10 Pin
2 Neutral spring 5 Spool 8 Stator
3 Housing 6 Sleeve 9 Rotor
Exploded view
Figure 2
Control valve (steering unit), exploded view
1 Dust seal ring 13 Cardan shaft 30 Relief valve 51 Cardan shaft

2 Housing, spool and sleeve 15 O-ring 31 Spring for relief valve 52 Distributor plate
3 Ball ø8.5 mm 16 Distributor plate 32 Complete shock valve 53 Distributor plate
4 Thread bushing 17 Gearwheel set 33 Ball 54 Valve and valve
housing
5 Shaft seal 18 O-ring 34 Pin for suction valve 55 Spring
7 Bearing 19 End cover 35 LS check valve, screw 56 Guide pin
10 Ring 20 Washer 36 LS check valve, ball
11 Cross pin 23 Special screw 37 Check valve
12 Set of springs 24 Name plate 50 Mounting pin
Operation
Rotary valve bank
 Three positions:
 Neutral position
 Right hand feed position
 Left hand feed position
 In neutral position it has the following function
 Lock steering cylinder power supply (no reaction)

 Lock steering unit set power supply
 In feed position (right or left hand)
 It directs the oil from the pump to the gerotor set.

 It directs the oil from gerotor set towards the steering cylinder and the cylinder return flow towards the
tank.
Gerotor set
 Delivers an oil flow proportional to steering wheel turning motion.

 Ensure steering hydraulic servo-assistance.
 Functions as a hand pump when the pump has no flow (safety), however steering wheel operating force is very
heavy.
Operation of the rotary valve bank is connected to the gerotor set by the cardan shaft. Each of these components
fulfils specific functions which are put into motion by turning the steering wheel.
Right hand turning

When the steering wheel is turned, selector spool (5) turns in relation to feed sleeve (6); pin (10) which is tightly secured in
sleeve (6), goes through spool (5) via a hole with a diameter larger than that of the pin. This enables the spool to rotate on
either side by 8°. As a result of this, the cylinder feed lines open progressively, the return ports to the tank close and the oil is
directed towards the gerotor set (11) which directs the oil towards the steering cylinder. The volume of fluid discharged is in
direct proportion to the angular movement of the steering wheel. As from 8° the spool and sleeve turn at the same speed
and constitute a follow-up system.
If the steering is no longer activated, the centering springs push feed sleeve (6) to a neutral position. The oil from the pump
is once again channelled towards the tank and the cylinder chambers are locked.
Figure 3
Operation, right hand turning
Neutral position
The spool and sleeve are centered in relation to each other by the springs. Aligned ports channel the oil from the pump to
the tank (open center). The cylinder ports are closed (no reaction), so if the carrier frame strikes an obstacle, no
repercussions are felt at the steering wheel.
Figure 4
Operation, neutral position
Manual position
As soon as an operating fault arises upstream of the device (engine shut-down during travel -damage to component- burst
pipe), the gerotor set is automatically converted to a manual emergency pump which ensures closed circuit power-supply of
the steering cylinder.
When the steering wheel is turned, the selector spool turns too. When it reaches 8°, the pin drives the feed sleeve and the
gerotor set by means of the cardan shaft. Under these conditions, the steering unit operates as a manual pump and
discharges the oil towards the steering cylinder. Pressure depends on the torque exerted by the operator on the steering
wheel.
Manual steering pressure: 20 kgf/cm2 (284 psi)
Figure 5
Operation, manual position
Timing gerotor assembly
 Before disassembling for checking, mark the position of the various components.
 When reassembling:
 Position feed ports facing you.

 Assemble rotor (1), stator (2) and cardan shaft (3) so that the cardan shaft slot aligns with the valleys
between the rotor teeth as shown.
 Now rotate the assembly slightly to engage centering pin (5).
If this timing is not observed, steering tends to turn automatically in the reverse direction to that of the steering wheel.
(operates as a motor)
Figure 6
Timing gerotor assembly
Service Information

unit), disassembly
Profile:
Control valve (steering unit), disassembly

Special tools
No. Part name Remark

1 Seal assembly jig
2 Holding jig
3 Special pliers
Precautions
 Prior to removal from the machine ensure that the steering unit, the area around it and the connecting lines are
free of dirt and contamination.
 Before disassembling plug all ports, then clean all paint and surface contamination from the steering unit at points
of separation.
Using soft material jaw liners lightly, clamp the steering unit in a vise with gerotor end up.
Place the steering unit in the holding tool and remove the seven screws.
Figure 1
Removal, screws
Take out shaft valve.
Figure 2
Removal, shaft valve
Remove the spring.
Figure 3
Removal, spring
Remove the guide pin.

Figure 4
Removal, guide pin
Lift off the valve housing.
Figure 5
Removal, valve housing
Lift off the distributor plate.
Figure 6
Removal, distributor plate
Lift off the gearwheel set.

Figure 7
Removal, gearwheel set
Remove the cardan shaft.
Figure 8
Removal, cardan shaft
Figure 9
Remove the gearwheel set.

Figure 10
Removal, gearwheel set
Remove the cardan shaft.
Figure 11
Removal, cardan shaft
Figure 12
Remove the two assembly screws.

Figure 13
Removal, screws
Unscrew the threaded bushing.
Figure 14
Removal, bushing
Unscrew the threaded bushing.
Figure 15
Removal, bushing
Use a 2 mm Allen wrench to unscrew the bushing.

Service Information

Steering cylinder, assembly 6451 Service Information 2014/5/31
Profile:
Steering cylinder, assembly

Replace all the damaged parts and grind any sharp edges to prevent seal damage.
1. Replace all seals with new ones. Clean all parts and blow dry with compressed air. Assemble piston packing (2) and
wear ring (3). Apply hydraulic oil to packing and wear ring before assembly.
Figure 1
Assembly, piston packing and wear ring
2. Assemble rod packing (5), dust seal (6) and retaining ring (7).
Apply hydraulic oil to packing before assembly.
Figure 2
Assembly, rod packing, dust seal and retaining ring
3. Assemble cylinder tube to differential housing.
Figure 3
Assembly, cylinder tube
4. Assemble piston rod assembly (2) into the cylinder tube (1).
Figure 4
Assembly, piston rod assembly
5. Assemble cylinder gland (4) to housing and tighten screw (5) with spring washer (6). Assemble nut (12), lock washer
(13) to end screw (10) and to piston rod.
Figure 5
Assembly, cylinder gland
6. Align and assemble cylinder rod end, ball joint (8) and pin plate (9). Assemble plate (10). Align retainer (11) pin hole
and plate (9) pin hole. Assemble spring pin (12). Assemble steering lines and check if normal.
Figure 6
Assembly, Ball joint, pin plate and plate etc.
Service Information

Steering cylinder, 6451 Service Information 2014/5/31
description
Profile:
Steering cylinder, description
Figure 1
Steering cylinder, structure
1 Cylinder tube 10 Back-up ring 19 Rod end assembly (right) 28 Retaining ring
2 Rod assembly 11 Dust wiper 20 Rod end (right) 29 Anchor pin
3 Rod 12 O-ring 21 Nut 30 Cover
4 Piston 13 Backing ring 22 Nut 31 Screw
5 Piston packing 14 Retaining ring 23 Lock plate 32 Spring washer
6 Wear ring 15 Screw 24 Anchor pin 33 Grease nipple
7 Flange 16 Rod end assembly (left) 25 Spacer 34 Stop screw
8 Buffering ring 17 Rod end (left) 26 Lever 35 Nut
9 Rod packing 18 Ball joint 27 Retaining ring 36 Plug (plastic)
Service Information

Steering cylinder, 6451 Service Information 2014/5/31
disassembly
Profile:
Steering cylinder, disassembly

Tightening torque
A B C D E
3.3 ± 0.3 (24 ± 2) 67 ± 3 (484 ± 22) 19.5 ± 1 (141 ± 7) 67 ± 3 (484 ± 22) 23.5 ± 1.2 (170 ± 9)
Tools
Tools
Item Specification Remark

Socket wrench 19.22 mm T Handle Gland screw
Hammer Medium size Pin, tube
Punch φ 6mm, length 20cm Spring pin
Screwdriver (-) Medium size Seal plate
Spanner 46mm Nut
Gimlet - For remove seal
Before disassembly
 Stop the machine on even ground and block each wheel and thrust attachment into the ground.
 Oil drum
1. Using punch remove spring pin (12), remove retainer (11) and plate (10). Remove pin plate (9). Check ball joint (8)
and replace if required. Remove end screw.
Figure 1
Removal, spring pin, retainer and plate etc.
2. Remove screw (6) and gland (5) (both ends). Remove cylinder (4) from differential housing.
Figure 2
Removal, screw, gland and cylinder etc.
3. Remove retaining ring (7), dust seal (6) and rod packing from cylinder gland (4). Remove o-ring (8) and back-up
ring (9).
CAUTION
Replace all the seals.
Figure 3
Removal, retaining ring, dust seal and cylinder gland etc.
4. Remove piston packing (2), wear ring (3) out of piston packing.
CAUTION
Do not disassemble piston in the field. When piston is moved or disassembled at rod, replace rod and piston as an
assembly.
Figure 4
Removal, piston packing and wear ring
Service Information

Steering pump, description 6453 Service Information 2014/5/31
Profile:
Steering pump, description

Structure
Figure 1
Structure, steering pump
1. Gear shaft
2. Shaft seal
3. Dowel pin
4. Housing
5. Coupling
6. Thrust plate
7. Seal
8. Gear
9. Brake pump
10. Steering pump
Figure 16
Removal, bushing
Shake out the balls.
Figure 17
Removal, balls
Happy every day.
Service Information

Superstructure, installation 710 Service Information 2014/5/12
Profile:
Superstructure, installation
1. Bundle the hoses attached to the center passage together and place them upright.
2. Coat the screws and threaded holes of the slew ring with "Three bond 1215" (Loctite # 515).
3. Lift the superstructure and install it to the slew ring.
NOTE!
Lower the superstructure so that the slew pinion and the slew ring are engaged.
NOTE!
For tightening torque, see the torque chart.
NOTE!
Tighten diagonally opposite screws in sequence.
Figure 1
Installing the superstructure
4. Connect the hoses, center passage clamping screw and seal cover disconnected for removal.
Service Information

Superstructure, removal 710 Service Information 2014/5/12
Profile:
Superstructure, removal
WARNING
The superstructure weigh approximately 4 ~ 7 tons (excluding counterweight and digging units). Pay attention to
safe footing and the area around the crane before proceeding to remove or install the superstructure
1. Remove the digging unit.

2. Disconnect center passage clamping screw, seal cover, hydraulic oil hoses, drain hose, and one servo hydraulic oil
hose from center passage.
NOTE!
Bundle the hoses. Blind plug each disconnected hose and pipe.
3. Remove screws (A) fixing the outer race of the slew ring.
Figure 1
Slew ring installed
B. Confirm alignment of match-marks
4. Dismantle the cab, counterweight and guard. Place a wire rope on the superstructure and lift it with a crane to an
extent that the wire rope is not slack.
Figure 2
Lifting the superstructure
5. Lift the superstructure just a little, and after confirming safety all around, lift it up and out.
Service Information

Additional counterweight 716 Service Information 2014/5/12
& digging unit
Profile:
Additional counterweight & digging unit

When special digging units (such as : scrap handling clam, log loader etc.,) are installed on the excavators, an additional
counterweight is required for stability.
In these cases, check the digging unit specification and compare it carefully to the excavator load lifting capacity chart.
And if in doubt, contact your local dealer for advice.
Additional counterweight can be installed according to special digging units, however we are not responsible for any failure
of the excavator or breakage of digging units due to such application.
For reference, an excavator is basically designed only for excavating and is not designed to be used as a crane.
Service Information

Counterweight, installation 716 Service Information 2014/5/12
Profile:
Counterweight, installation
WARNING
Lift the counterweight just a little, and after confirming safety all around, proceed to install it.
1. Attach hook and shackle (A) to the lifting eyes of counterweight, and lift to the desired position.
Figure 1
Position, lifting and mounting
2. Match the screw hole (B). Insert the lock plate (2) and the spacer (4), and tighten screw (3).
 Lower the counterweight to the mounting face at the rear of the superstructure.
Item Tightening torque

Mounting screw (3) 135 ± 3 (975 ± 36)
NOTE!
Screw thread : Apply loctite # 601.
Service Information

Counterweight, removal 716 Service Information 2014/5/12
Profile:
Counterweight, removal
WARNING
The counterweight weighs 2900 kgs. Take care in performing removal. To lift the counterweight, use certified wire
ropes in good condition, of adequate load rating and length.
1. Attach wire slings to the lifting eyes at the top surface of the counterweight and lift until there is no slack in the
wire ropes.
2. Remove screw (3), using socket wrench or power wrench.
3. Lift the counterweight just a little, and after confirming safety all around, lift it up and out.
Figure 1
Removing the counterweight
1 Counterweight 6 Screw
2 Lock nut plate 7 Plain washer
3 Screw X Keep clearance (up / down) equal.(10 ± 3 mm)
4 Spacer Y Keep clearance (left / right) equal.(10 ± 3 mm)
5 Cover
Service Information

Pendulum locking cylinder, 7631 Service Information 2014/5/31
assembly
Profile:
Pendulum locking cylinder, assembly

 Remove sharp edges before assembly, clean with solvent and blow dry with compressed air.
Figure 1
Pendulum locking cylinder
 Apply hydraulic oil to buffer ring (14) and assemble it.
 Apply hydraulic oil to rod packing (12) and back-up ring (13) then assemble it (pay attention to direction).
Figure 2
Assembly, rod packing and back-up ring
 Press dry bearing (6) to cylinder tube using jig (A).
Figure 3
Press dry bearing
 Assemble retaining ring (5).
 Assemble dust wiper (11) and retaining ring (4).
Figure 4
Assembly, retaining ring and dust wiper
 Insert cylinder rod (2) to tube (1).
Figure 5
Assembly, cylinder rod
 Apply oil to shaft (10) and assemble it to cylinder tube (1). Assemble valve (9).
CAUTION
When assembling valve (9) replace the o-ring (seal).
Figure 6
Assembly, valve
 Insert steel ball to air breathing hole and assemble plug.
 Assemble grease nipple (15) and plug oil port.
Figure 7
Assembly, grease nipple and plug
A. Air breather
B. Steel ball
Service Information

description
Profile:
Pendulum locking cylinder, description
Figure 1
Pendulum locking cylinder (sectional view)
1 Tube 6 Dry bearing 11 Dust wiper

2 Rod 7 Steel ball 12 Rod packing
3 Bushing 8 Air breather 13 Back-up ring
4 Retaining ring 9 Valve 14 Step seal (Buffer ring)
5 Retaining ring 10 Shaft 15 Grease nipple
Service Information

disassembly
Profile:
Pendulum locking cylinder, disassembly

Before disassembly, clean cylinder unit thoroughly.
 Remove air breather plug.

NOTE!
Pay attention to steel ball inside of the plug.
 Disassemble valve assembly.

 Fix cylinder tube and remove cylinder rod.
 Using gimlet remove retaining ring (4).
 Remove dust wiper (11) and retaining ring (5).
 Using gimlet remove dry bearing (6).
CAUTION
When disassembling dry bearing pay attention not to damage cylinder tube bore.
 Remove rod packing (12), back-up ring (13) and buffer ring (14).
Figure 1
Removal, cylinder rod, retaining ring and dry bearing etc.
Service Information

Handling the tire 771 Service Information 2014/5/12
Profile:
Handling the tire

Removing tires
 Raise the chassis with the stabilizer or blade so that the tires are raised above the ground.
Then, place wooden blocks under the front and rear axles.
 Loosen wheel nuts with a wheel wrench. (Wheel nuts on both the left and right wheel tires have right thread.)
Installing tires
 Coat wheel stud and thread areas of nuts with grease.

 When installing new tires, tighten lightly as the tires lifted and retighten the tires to the specified torque in the
order shown in the figure, after placing the tires on the ground.
Tightening torque : 58 ~ 62 kgf·m (419 ~ 448 lbf·ft)
Figure 1
Installation, tires
Tire pressure
 Use correct specification rim.

 Use correct specification valve, core, cap.
 Use new valve, core, cap for new tire.
 Check tires for air pressure and damage every 10 hour to prevent burst.
 Repair tire for not serious damage.
Figure 2
Tire pressure
A. High pressure
B. Normal pressure
C. Low pressure
Rotating tires
 The wear differently depending on their positions. Consquently, tires should be rotated periodically as shown in the
figure.
Figure 3
Rotating tires
Service Information

Tire, description 771 Service Information 2014/5/12
Profile:
Tire, description
The tire absorve shock from the ground and transmit drive force and brake force to ground.
Figure 1
Tire (construction)
1 Rim 7 Valve 13 Sectional width

2 Bead 8 Flap 14 Rim width
3 Side wall 9 Bead wire 15 Thread width
4 Sholder 10 Tube 16 Tire height
5 Thread 11 Belt 17 Tire outer radius
6 Rubber 12 Casing
Service Information

Tire, structure 771 Service Information 2014/5/12
Profile:
Tire, structure
Figure 1
Tire, structure
1 Tire 4 Wheel rim 7 Screw

2 Tube 5 Wheel rim 8 Washer
3 Flange 6 Inser-antistone 9 Wheel nut
Service Information

Tire, troubleshooting 771 Service Information 2014/5/12
Profile:
Tire, troubleshooting
Troubleshooting
Defect Cause
Low High Overload Over Slip Instantly Chemical to Quality Action
pressure pressure speed brake tire problem
Thread o o o o o Repair
burst Replace
Thread fan o o o o o Repair
off
Thread o o o o o o Repair
crack Replace
Thread o o o o o o Repair
easily wear
Side wall o o o Repair
crack
Thread and o o o Repair
casing Replace
separated
Casing o o o Replace
separated
Bead o o o o o o Replace
broken
Put off by o o o o Repair
shock Replace
Internally o o Replace
cut
Tire wearing shape and cause
Wearing Shape Cause

Bias wear Bad tow-in, chamber
Intersection
Shoulder wear Bad chamber
Intersection
Feather wear Bad tow-in
Intersection
Poligon wear - Eccentric or banded tire or wheel.
- Eccentric or banded hubor spirdle.
- Loosen bearing, king pin.
- Unballence in rotating parts.
Side of tire
Eccentric wear - Eccentric or banded tire or wheel.
- Eccentric or banded hubor spirdle.
- Unballence in rotating parts.
Side of tire
Sectional wear - Excessive brake force at a section of brake drum.
- Loosen wheel, joint.
- Bended axle or eccentric tire wheel.
Side of tire
CAUTION
Complex wearing can be happen.
Wearing Shape Cause

Shoulder wear Low pressure, overload, front wheel
Center wear Excessively high pressure, driving wheel
Triangle wear Low pressure, overload
Rail wear Low pressure, overload
Rib punch Low pressure, overload
NOTE!
Tire usage
1. Tire arrangement and rotation,

2. Use at profitable pressure and load.
3. Do not instant start, brake and turning.
Happy every day.
Service Information

Cab, installation 810 Service Information 2014/5/31
Profile:
Cab, installation
 Attach wire ropes to the lifting hooks of the cab, and lower the cab to the mounting position.
 Tighten the 7 mounting screws (2, 5, 6).
 Connect the main wiring connectors.
CAUTION
Take care that the cab frame does not hit the control board when removing or installing the cab.
Figure 1
Cab
1 Cab 5 Screw 9 Screw Tightening torque :

2 Screw 6 Screw 10 Plain washer – 2, 5, 6 Screw: 20 ± 2 kgf·m (144 ± 14 lbf·ft)
3 Plain washer 7 Mirror support 11 Spring washer – 9 Screw: 0.8 ± 0.1 kgf·m (5.8 ± 0.7 lbf·ft)
4 Spring washer 8 Rear view mirror
Service Information

Cab, removal 810 Service Information 2014/5/31
Profile:
Cab, removal
 Attach wire ropes to the lifting hooks of the cab, and lift the cab until there is no slack in the wire ropes.
 Remove the 7 mounting screws (2, 5, 6) located at the bottom plate of the cab.
 Disconnect the main wiring connectors, air duct and storage box.
 Lift the cab just a little, and after confirming safety all around, lift up and out.
NOTE!
Cab weight : about 275 kg (605 lb)
Service Information

Cab, specifications 810 Service Information 2014/5/31
Profile:
Cab, specifications
Specifications

Length mm (in) 1870 (73.6)
Height External mm (in) 1670 (65,7)
Internal mm (in) 1600 (63) - (With front window closed)
1570 (61.8) - (With front window opened)
Width External mm (in) 975 (38.4)
Internal mm (in) 921 (36.3)
Height from Seat index position to mm (in) 1100 (43.3) - (With front window closed)
roof 1070 (42.1) - (With front window opened)
Side distance from Seat index position mm (in) Left : 453 (17.8), Right : 445 (17.5)
Window Front Upper - Fully-open, laminated safety glass
Front Lower - Channel type detachable laminated safety glass
Side - Left : Sliding opened, tempered safety glass
Right : FIxed, tempered safety glass
Rear - Fixed, tempered safety glass
Seat Type - Adjustable suspension, reclinable with headrest and armrest (From
vertical position)
Reclining - Front : 20°, Rear : 70° (with foldable mechanism)
Adjust - Horizontal :
Forward 80 mm (3.2″), Rearward 70 mm (2.8″)
Vertical : ± 30 mm (1.2″)
Suspension load : 50 ~ 120 kg (110 ~ 265 lb)
Service Information

Viscose mount, description 810 Service Information 2014/5/31
Profile:
Viscose mount, description

 The bottom plate where cab is assembled is mounted on 5 viscose mounts, and then assembled to the upper deck.
 Viscose mounts is designed to absorb vibration generated when operating the machine.
 Silicon oil and gas inside the viscose mounts absorbs extreme shock impact.
CAUTION
If the viscose mount is dropped or impacted, silicon oil may leaked and lower the performance.
CAUTION
The exterior of viscose mount is natural rubber with low oil resistance. Avoid contact with grease and oil.
Installation position
Figure 1
Installation position
1 Bottom plate 6 Nut

2 Floor mat 7 Spring washer
3 Viscose mount 8 Screw
4 Plain washer A Viscose mount
5 Spring washer U Upper deck
Service Information

Viscose mount, installation 810 Service Information 2014/5/31
Profile:
Viscose mount, installation

1. Install the viscose mount on upper deck by tightening screw (8).
2. Check for deformation and debris on mounting surface.
CAUTION
The difference of height for viscose mount installed (5 pieces) must be within 1mm.
3. Tighten the lock nut (6) with specified torque.

4. Cover the floor mat.

NOTE!
If the ambient temperature is less than 0 °C, the viscosity of silicon oil inside the viscose mount is high, and the ride
is some what rough. After operating a few minutes, the viscosity will be lowered by heating due to vibration and
the ride will be much smoother.
Service Information

Viscose mount, removal 810 Service Information 2014/5/31
Profile:
Viscose mount, removal

1. Remove the cab.
2. Remove floor mat (2), and remove the bottom plate by loosening nut (6) tightened to bottom plate (1).
3. Remove the viscose mount by loosening screw tightened to upper deck.
Service Information

Air conditioning unit, 870 Service Information 2014/5/31
description
Profile:
Air conditioning unit, description

The advanced integrated air conditioning system with the heating and the cooling system installed in a single unit is
designed to provide a comfortable indoor environment in all seasons.
The integrated system is ergonomically designed for the most efficient air flow distribution. The easy to use control panel
provides a selection of cooling/heating and indoor/outdoor air through 8 levels and 4 fan speeds.
Characteristics of an integrated air conditioning system
 This system provides a comfortable indoor environment with powerful cooling and heating capacity in all weather
conditions.
 The thermistor installed in the integrated air conditioner protects the evaporator and cooling system from freezing.
 The cooling and heating system can be operated simultaneously to control humidity and indoor temperature.
 According to the indoor and outdoor air condition, indoor or outdoor air circulation can be selected. All fresh air is
drawn through the air filter installed between the duct and the cab vent.
Structure of integrated air conditioning system
Figure 1
Structure, air conditioning system
1 Engine A Indoor air

2 Compressor B Outdoor air
3 Condenser C Face
4 Evaporator D Foot
5 Heater core E Defroster
System structure
Figure 2
Number of parts, air conditioning system
Air conditioning system's parts
No. Item Quantity

A C H
1 Compressor 1 1
2 Receiver dryer & condenser 1 1
3 Air conditioner & heater 1
Air conditioner 1
Heater 1
4 Supply hose A 1 1
5 Supply pipe B 1 1
6 Supply hose C 1 1
7 Hose 1 1
8 Inlet hose A 1 1
9 Inlet pipe B 1 1
10 Inlet hose C 1 1
11 Belt tensioner 1 1
12 V-belt 1 1
13 Compressor bracket 1 1
14 O-ring 2 2
15 Drain hose 2 2
16 O-ring 4 4
17 O-ring 4 4
A : Air conditioner and heater mounted

C : Only air conditioner mounted
H : Only heater mounted
Body structure
Figure 3
Structure, air conditioning unit body
1 Blower case 8 Intake upper case 15 Relay

2 Evaporator upper case 9 Intake lower case 16 Heater valve
3 Evaporator lower case 10 Heater valve motor 17 Power transistor
4 Blower motor and fan 11 Evaporator 18 Temperature sensor
5 Air flow control motor 12 Heater 19 Heater valve assembly
6 Air direction control motor 13 Indoor / Outdoor selection motor
7 Shutter 14 Indoor filter
Service Information

maintenance
Profile:
Air conditioning unit, maintenance

Periodic inspection
 If the cooling or heating system are not used for a long time, see the periodic maintenance table and perform the
required inspections.
 During the off-season operate the air conditioner 2 ~ 3 times per month for 5 ~ 10 minutes to lubricate the
compressor components.
 In the summer season close the valve installed in the engine block to cut off the flow of coolant to the heater.
Check item
Proper refrigerant handling
Worldwide environmental protection regulations prohibit the discharge of any refrigerant into the atmosphere, and require
that refrigerant be recovered using the approved recovery equipment.
CAUTION
Use correct refrigerant recovery, recycling and charging stations, DO NOT use refrigerant, hoses, fittings, components or
refrigerant oils intended for use with other refrigerants.
Recovery, recycling and charging stations for R134a and other refrigerants MUST NOT be interchanged. Systems containing
other refrigerants use a different oil than systems using R134a. Certain seals are not compatible with both types of
refrigerants.
R12 and R134a refrigerant precautions
WARNING
Do not allow liquid refrigerant to contact eyes or skin. Liquid refrigerant will freeze eyes or skin on contact. Wear
goggles, gloves and protective clothing.
Repair and refilling of the refrigerant system must only be done by trained personnel. Contact your authorised
Volvo Construction Equipment workshop. If liquid refrigerant contacts eyes or skin, do not rub the area. Splash large
amounts of cool water on affected area, Go to a physician or hospital immediately for treatment. DO NOT allow
refrigerant to contact open flames or very hot surfaces such as electric welding arc, electric heating element and
lighted smoking materials.
DO NOT heat refrigerant over 52 °C (125 °F) in a closed container. Heated refrigerant will develop high pressure
which can burst the container. Keep refrigerant containers away from heat sources. Store refrigerant in a cool place.
do not handle a damp refrigerant container with your bare hands. Skin may freeze to the container. Wear gloves. If
skin freezes to the container, pour cool water over container to free the skin. Go to a physician or hospital
immediately for treatment.
Periodic maintenance table

Periodic maintenance items
Component Check item Check period

Compressor Operating condition 12 month
Condenser Condenser Contamination 6 month
Motor Operating condition 6 month
Evaporator Contamination 12 month
Refrigerant (R–134a) Charging capacity 6 month
Idler pulley Operating condition 12 month
V–belt Looseness, damage, aging 6 month
Tube Hose Aging 12 month
Tube connection Damage 6 month
Attached parts Leakage, looseness, contacting damage 6 month
Heater core Contamination 12 month
Blower motor Operating condition 12 month
Heater valve Leakage, operating condition 12 month
Outdoor filter Contamination 6 month
Check method
Check for gas leakage on refrigerant hose joint.
 When oil is found on the pipe joint, gas leakage could be occurring.
 Check the union and tighten to the proper torque.
Check the tension of V-belt for driving compressor.
 Check the belt for looseness by pressing with your fingers. When a force of approximately 10 kg is applied to the
belt center, allowable limit is 8 ~ 10 mm. After about 40 hours, recheck the belt tension.
Figure 1
Check, belt looseness
A. Compressor
B. Crank pulley
Check the compressor.
 After operating air conditioner for 5 ~ 10 minutes, check the high-pressure pipe and low pressure pipe by hand. In
normal condition the high pressure pipe is hot and low pressure is cold.
Check the condenser.
 When the condenser is contaminated, the radiating efficiency is lowered significantly. Clean the condenser to
improve cooling.
CAUTION
DO NOT use steam to clean the condenser core. The refrigerant can overheat! When cleaning with water, protect the
electrical components.
Check the refrigerant capacity
 Check the sight glass of the receiver/dryer. (Measuring port is located on the compressor connecting hose union.)
CAUTION
Note that bubble condition and discharging pressure are severely affected according to outdoor temperature, condenser
ambient temperature, wind speed and weather condition.
Operating condition
Checking method
Preparation
1. Start and run the engine at 1500 rpm.
2. Set the control lever to indoor and blower to high.
3. Operate the air conditioner at least 5 minutes and keep the indoor temperature
at 25 ~ 30 °C.
Checking method 4. Turn off the air conditioner for 40 ~ 50 seconds.

5. Turn on the air conditioner for 40 ~ 50 seconds.
6. Turn off the air conditioner for 40 ~ 50 seconds.
7. Turn on the air conditioner for 40 ~ 50 seconds.
Judgement criteria
Checking, amount of refrigerant
Performance Charge of Refrigerant

Condition Normal Low Very low Too much
Temperature of the High pressure side is High pressure side is There is almost no Abnormal
high / low pressure hot and low pressure warm and low-pressure temperature difference overheating at high
hoses. side is cold. side is slightly cool. between the high/low pressure hose.
Temperature difference Temperature difference pressure hoses.
is significant. is slight.
Refrigerant condition Almost transparent and Bubbles all the time Milky white fog No bubbles.
by sight glass. a few bubbles. and flow in white is is visible. If air is mixed,
New refrigerant visible. very large bubbles
HFC–134a: Imme- are visible.
diately changed at re-
operation.
Pipe joint Normal A little contaminated Excessively Good
with oil. contaminated with oil.
Air conditioner Refrigerant charge is Leakage is found. Most refrigerant is used Refrigerant is
sufficient and normal. Cooling efficiency is up. excessive.
Normal operating lowered. Cooling efficiency is Cooling efficiency is
system. extremely low. lowered.
Pressure High pressure : High / Low pressure are High / Low pressure are High/Low pressure
11 ~ 18 kgf / cm2 low. low. are very high.
Low pressure :
1.5 ~ 3 kgf/cm2
Repair None Fill with refrigerant. Check leakage. Stop the compressor.
Fill with refrigerant. Drain the refrigerant.
 An overcharged system (Too much refrigerant) can result in the pressure switch circuit de-energizing the
compressor magnetic clutch.
Service Information

refrigerant check and
recharging
Profile:
Air conditioning unit, refrigerant check and recharging

WARNING
DO NOT disassemble the compressor relief valve. The refrigerant in the circuit is rapidly ejected and may cause
injury.
Special tools
Figure 1
Tools for refrigerant charging
1. Quick coupler
2. Low pressure hose
3. Gauge manifold
4. High pressure hose
5. Quick coupler
6. Center filler hose
Quick coupler connecting method
 Remove the filler valve cap.

 Insert the quick coupler onto the filler valve, and press firmly sleeve (A) until a click sound is heard.
Figure 2
Quick coupling, connection
CAUTION
When connecting, take care not to bend the pipes.
Quick coupler disconnecting method

Hold body (A) of quick coupler and lift sleeve (B).
After removing the quick coupler, install the filler valve cap.
Figure 3
Quick coupling, disconnection
Pressure check procedure
 Close both the low and high pressure valves on the gauge manifold.
 Connect the appropriate quick coupler of the gauge set to the low (suction) pressure and high (discharge) pressure
side of the compressor.
 Connect the center filler hose to the refrigerant canister.
 Open (1/2 turn) and close each pressure valve to release the air from the hoses and gauge set.
 Start the engine and idle at approx. 1500 rpm for about 10 minutes to stabilize the system.
 Turn on the air–con switch and select the temperature selection switch to maximum cooling at maximum fan speed.
 Open all system vents for maximum air distribution.
 After 5 minutes, read the gauge dial.
 After checking, stop the engine, and then remove the gauge set.
Troubleshooting by gauge measured value

Operating condition
 Vents : Open all duct vents.

 Indoor, outdoor selection : Indoor circulating
 Fan speed : The highest speed
 Temperature : Maximum cooling
 Ambient temperature at air-con intake port : 30 ~ 35 °C
CAUTION
The pressure value may change according to the ambient temperature.
Troubleshooting (for ambient temperature 30 ~ 35 °C at air con intake port)

Troubleshooting
Refrigerant Pressure Phenomenon Cause Check, Repair

Mpa (kgf / cm2)
Low High
Normal 0.15 ~ 0.25 1.37 ~ 1.57 - - -
(1.5 ~ 2.5) (14 ~ 16)
Low 0.05 ~ 0.1 0.69 ~ 0.98 High/Low pressure are low. Refrigerant is low Check and repair the
(0.5 ~ 1.0) (7 ~ 10) Bubbles pass continuously in and has leaked. refrigerant leak.
sight glass. Fill with refrigerant.
Air conditioner outlet air is not
cold.
Refrigerant is 0 ~ (-) 0.5 ~ 0.6 If clogged completely, low Air conditioner Check and replace
not (5 ~ 6) pressure is indicated refrigerant circuit is receiver/dryer and
circulated. immediately to (-). clogged. expansion valve, etc.
If clogged a little, low pressure
is indicated slowly to (-).
Moisture is 0 ~ (-) 0.69 ~ 0.98 Start up operation is normal, Expansion valve is Check expansion
mixed into (7 ~ 10) and after a while, low pressure frozen moisture valve.
refrigerant drops to (-). mixed. Replace receiver /
circuit. dryer.
Low 0.4 ~ 0.6 0.69 ~ 0.98 Low pressure is higher than Faulty compressor Check and replace
compression (4 ~ 6) (7 ~ 10) normal. compressor.
of If air conditioner is turned off, (When compression
compressor. immediately High/Low pressure is poor, the outside
are the same. is not hot to touch).
Excessive 0.25 ~ 0.35 1.96 ~ 2.45 High / Low pressure are high, Excessive Check the amount of
refrigerant. (2.5 ~ 3.5) (20 ~ 25) simultaneously. refrigerant. refrigerant.
Engine rpm is lowered, but Poor cooling of Check and correct
bubbles on sight glass are not condenser. the cooling fin of
visible. condenser.
Air is mixed 0.25 ~ 0.3 1.96 ~ 2.45 High/Low pressure are high, Air is mixed. Refill with
into circuit. (2.5 ~ 3.0) (20 ~ 25) simultaneously. refrigerant.
High/Low pressure pipes are
warm.
A lot of bubbles in sight glass
are visible.
Excessive 0.3 ~ 0.4 1.96 ~ 2.45 High/Low pressure are high, Faulty expansion Check expansion
opening of (3 ~ 4) (20 ~ 25) simultaneously. valve. valve.
expansion Frost on low pressure pipe is Check the mounting
valve. visible. of heat sensing tube
and bulb.
Replace
expansion valve.
Refrigerant fill procedure
CAUTION
Use only refrigerant (R134a). DO NOT use any other refrigerant. Use the correct refrigerant pressure measuring gauge set.
DO NOT use any other refrigerant pressure gauges.
Special tools
Gauge set, vacuum pump, refrigerant.
Figure 4
Tools for refrigerant filling
1. Quick coupler
2. Vacuum pump
3. Filler hose
4. Refrigerant service canisters
Refrigerant draining
 To drain the refrigerant, connect the gauge set with the valves closed to the compressor lines and the center filler
hose to the service canisters.
 Open the valve at the service canister, then open the manifold valve for the low pressure side, and if the high
pressure side gauge reads below 3 kgf /cm2, open the high pressure side valve to drain both circuits
simultaneously.
 When the manifold gauges read 0 kgf /cm2 pressure, close both manifold valves and the service canister valve.
Evacuating
 Connect the center filler hose to the vacuum pump.

 Open both high/low manifold valves and start the vacuum pump.
 Evacuate the system until the low pressure side reads 710 mmHg vacuum, then close both manifold valves and stop
the vacuum pump.
 If the vacuum decreases more than 25 mmHg in 5 minutes, there is a leak in the system. Repair the leak and re-
evacuate the system.
 If there is no change in the vacuum reading, restart the vacuum pump and continue evacuating until the gauge
registers 760 mmHg.
 Close both the high/low manifold valves and stop the vacuum pump.
Refrigerant filling
 After removing the vacuum pump, connect the center filler hose to the service canister.
 First open the high pressure side valve, and the refrigerant will automatically fill to the pipes.
 If the filling rate is slow, close the high pressure side valve and leave for 5 ~ 10 minutes, and check for possible gas
leakage. After repairs continue the recharging cycle.
 Add refrigerant until the system is charged with the correct amount and close the manifold high pressure valve.
 Start the engine, and idle at 1000 ~ 1500 rpm.
 Turn ON the air conditioner and run at minimum temperature and maximum fan speed, and observe the refrigerant
flow in the sight glass.
WARNING
Do not open the high pressure side valve during the air conditioner running. At this time, reverse flow phenomenon
of refrigerant may occur.
 Open the low pressure side valve to fully fill the refrigerant system.
 If the refrigerant is fully filled, close the low pressure side valve.
 Observe the refrigerant flow in the sight glass, check the pressure and inspect for leakage.
 Stop the engine and remove the gauge set from the compressor.
 Install with the filler valve cap.
Service Information

related components
Profile:
Air conditioning unit, related components

Figure 1
1 Charging hose 6 Belt tensioner 11 Intake hose

2 Intake hose 7 Compressor 12 Drain hose
3 Heater valve 8 V-belt 13 Charging hose
4 Heater valve 9 Body 14 Condenser
5 Compressor bracket 10 Refrigerant hose 15 Receiver dryer
Tightening torque :
Refrigerant hose 1.5 ~ 1.8 kgf·m

Charging hose 2.0 ~ 2.5 kgf·m
Intake hose 3.0 ~ 3.5 kgf·m
Heater hose clamp 2.5 ~ 3.0 kgf·m
Refrigerant circuit
Figure 2
Circuit, refrigerant
1 Receiver dryer A Outside air

2 Compressor B High temperature and high pressure gas
3 Condenser C Low temperature and low pressure gas
4 Evaporator D Cool air
5 Blower E Low pressure liquid
6 Expansion F Inside air
G High pressure liquid
Switch and controller, description
Figure 3
Switch, air conditioning system
1. Air flow control switch
2. Air conditioner switch
3. Fan speed control switch
4. Indoor/outdoor selection switch
5. Cool and heat temperature control switch
NOTE!
The controller is integrated with switch.
Air flow control switch and air conditioner switch
Figure 4
Switch, air flow control
1. Upper
2. Lower
3. Lower/defrost
4. Defrost
5. Air conditioner switch
 Pressing the air flow control switch, the upper LED lights and the air direction is selected.
 When the air con switch is pressed, the upper LED lights. But the cooling system operates only when the fan speed
control switch is operated.
 Upper direction switch does not operate under heating condition to prevent the operator from becoming sleepy.
Fan speed control switch
Figure 5
Switch, fan speed control
 Pressing the fan speed control switch, the upper LED lights.
 Heating and cooling system operate only when the fan speed control switch is operated.
 The air conditioning system stops when the OFF switch is pressed.
 If heating is operated and air con switch is turned ON cooling and heating system work simultaneously. At this time,
the temperature control switch operation conforms to step 3.
 Any switch from step 1 - 4 can be selected. When any switch but step 1 is selected, a 2 second interval is required
between steps.
Temperature control switch

Figure 6
Switch, temperature control
A. Cool
B. Hot
 Cooling and heating operations are composed of 4 steps respectively.

 By pressing the right or left switch, temperature control moves by 1 step. Two LEDs light to indicate the current
position.
 Cooling operation : Composed of 4 steps, air temperature is controlled by the intermittent operation of the
compressor.
 Heating operation : Composed of 4 steps, air temperature is controlled by heater valve coolant flow.
 Room temperature operation : Air is circulated without air conditioner or heater.
Indoor or outdoor air selection switch
Figure 7
Switch, air selection
 Indoor or outdoor air can be selected.

 Indoor air : 100% of indoor air
 Outdoor air : 40% of outdoor air + 60% of indoor air
Method of operation
Operation, air conditioning system
Function Air direction Temperature Indoor or outdoor air Fan Compressor

control
Quick cooling Cool 4 step High ON
speed
Cooling Cool 4 step medium ON

speed
Defrost in Cool 4 step High or ON

the summer medium
Defrost in the Heat 2 ~ 3 step medium ON

spring & fall speed
Quick heating Heat 4 step High speed OFF

Heating Heat 2 ~ 3 step medium OFF
speed
Ventilation Neutral Low or OFF

medium
NOTE!
The above chart represents the normal method of operation. Choose the air selection mode according to the ambient
condition.
Service Information

specifications
Profile:
Air conditioning unit, specifications

Specifications
Item Specification
Air conditioner Evaporator Type Laminate
Cooling capacity 4000 Kcal / h
Condenser Type Parallel flow
Heat rejection 8,500 Kcal / h
Compressor Type Wobble plate
Model V-5
Displacement 148 cc / rev
Receiver dryer Capacity 420 cc
Safety device Dual High OFF 32 ± 2 kgf / cm2 (455 ± 28 psi)
(Dual pressure switch) Pressure pressure ON 26 ± 3 kgf / cm2 (370 ± 43 psi)
Low OFF 2.0 ± 0.2 kgf / cm2 (28 ± 3 psi)
pressure ON 2.1 ± 0.3 kgf / cm2 (30 ± 4 psi)
Refrigerant R 134 a, 750 ± 50 g (1.65 ± 0.1 lbs)
Heating Heating capacity 4,000 Kcal / h
system Core Cu-corrugated
Regular voltage DC 24 V
Consumption electric power 360 W
Air flow 420 m3/ h (549 yd3/ h)
Service Information

Heating control valve, 8735 Service Information 2014/5/12
description
Profile:
Heating control valve, description

Heating control valve
 The valve regulates the flow of engine coolant in accordance with the set position of the heating temperature
regulating switch. If setting the heating temperature high, the valve is opened to maximum coolant flow to the
heater. If set to the cooling position, the flow of coolant is cut off.
 In case hot air is blowing when the heater is set to off position, a faulty heater valve will allow coolant to flow
through the heater core. In this case, cooling efficiency will be significantly deteriorated.
 In summer, close the valve installed in the engine block to cut off the flow of coolant to the heater.
Service Information

Evaporator, description 8745 Service Information 2014/5/12
Profile:
Evaporator, description
Expansion valve
 The expansion valve regulates refrigerant flow from the receiver/dryer to the evaporator.
 As the high temperature / high pressure liquid passes through the valve it is restricted and sprayed into the
evaporator side where it changes state and becomes a gas.
 The rapid expansion of the refrigerant can cause moisture to freeze in the valve outlet port.
Figure 1
Structure, expansion valve
1 Spring 6 Evaporator
2 Ball 7 Outside uniform pressure tube
3 Valve rod 8 Heat reducing canister
4 Diaphragm A Refrigerant inlet (liquid)
5 Capillary tube B To compressor
Figure 2
Structure, expansion valve (side view)
1 Needle valve (Throttle valve) 6 Uniform pressure tube

2 Diaphragm 7 Pressure spring
3 Diaphragm compartment 8 Adjustment screw
4 Capillary tube A Refrigerant inlet (liquid)
5 Heat reducing canister B Refrigerant outlet
Evaporator
 The refrigerant passing through the expansion valve is converted to a low pressure liquid as it is sprayed into the
evaporator.
 The mist flowing through the core tubing evaporates as it absorbs heat from the indoor / outdoor air passing over
the evaporator fins. This process cools and dehumidifies the air, any moisture contained in the air is converted to
water which collects on the fins and is then drained from the evaporator housing.
Figure 3
Evaporator
1. Lower tank
2. Cooling fin
3. Upper tank
4. Plate
Service Information

Condenser, description 8746 Service Information 2014/5/12
Profile:
Condenser, description
Condenser
 The condenser mounted in front of the oil cooler and consists of tubes, refrigerant passing through, and cooling
fins, radiating heat rapidly.
 The condenser will condense the refrigerant gas which is under high pressure, high temperature condition into a
high pressure liquid, by cooling it with the air flow from the oil cooler fan.
 Insufficient cooling of the condenser retards the conversion of the high pressure gas into a high pressure liquid, this
causes the circuit pressure to rise which increases the system load and reduces the cooling capacity.
Figure 1
Structure, condenser
No. Wire specification

A. Receiver Dryer 1 AVX 0.85BG
B. Condenser
2 AVX 0.85BW
Service Information

Compressor, description 8743 Service Information 2014/5/31
Profile:
Compressor, description
Compressor
 The compressor is driven by the engine via a belt and the power is connected / disconnected by the magnetic
clutch. The basic principle of the V–5 compressor is to control proper flow in accordance with the cooling load by
changing the piston stroke (changing the angle of wobble plate).
 With the engine running and the compressor magnetic clutch engaged, the compressor draws low pressure
refrigerant in a gaseous state from the evaporator and compresses it into a high pressure, high temperature gas.
Increasing the pressure of refrigerant causes its boiling point to rise to a temperature higher than the outside air
temperature. As the high pressure gas flows through the condenser, the condenser fans draw air through the
condenser core which cools the refrigerant.
 The oil flowing with the refrigerant activates cooling and lubricating of the compressor.
Figure 1
Structure, compressor
A. Discharge
B. Suction
C. “A” Groove
Service Information

Compressor, specifications 8743 Service Information 2014/5/31
(V-5, R134a)
Profile:
Compressor, specifications (V-5, R134a)

Specifications
Type Wobble plate

Displacement 148 cc (8.3 cu·in) / rev.
Capacity (2000 rpm) 7,415 (20,300 BT/hr)
Number of cylinder 5
Speed Max. Continuous 6500 rpm
Transient 8000 rpm
Refrigerant R 134a
Lubricant 265 ml (ND–oil 8)
Direction of rotation Clockwise
Clutch coil voltage DC 24V
Service Information

Drying filter, description 8747 Service Information 2014/5/31
Profile:
Drying filter, description

Receiver dryer
 The dryer installed between the condenser outlet and evaporator inlet, consists of the body, desiccant, strainer,
filter, sight glass, safety plug and pressure switch.
 The receiver/dryer is a reservoir to store excess liquid refrigerant in the system. Excess refrigerant is required for two
reasons : Outside air temperature and humidity have an effect on the minimum quantity of refrigerant required in
the system for the air conditioner to operate at maximum efficiency. The higher the temperature and humidity, the
more refrigerant required in the system. More refrigerant is required due to the expansion valve opening farther
allowing more refrigerant into the low pressure side of the system.
 The strainer and filter remove particles caused by component failure, or corrosion due to acids and moisture in the
system.
 The desiccant is used to absorb moisture from the refrigerant. Moisture combined with refrigerant oil forms a
sludge which prevents adequate lubrication. Moisture combined with refrigerant creates hydrofluoric and
hydrochloric acids which are very corrosive to metal surfaces.
NOTE!
Evacuating the system will not remove the moisture from the desiccant. The receiver/dryer must be replaced.
 The safety plug is designed to protect the system from excessive pressure and temperature. It will release above
105 °C (221°F) or 35 kgf /cm2 (498 psi).
 A sight glass is installed so the condition of the flow of refrigerant can be checked.
Figure 1
Drying filter
1 Desiccant 5 Pressure switch

2 Strainer 6 Sight glass
3 Filter 7 Refrigerant inlet
4 Refrigerant outlet 8 Plug
Happy every day.
Service Information

Hydraulic tank, description 9111 Service Information 2014/5/31
Profile:
Hydraulic tank, description
Figure 1
Structure, hydraulic oil tank
1 Hydraulic oil tank assembly 9 Shim 17 Breather

2 Strainer assembly 10 Element 18 O-ring
3 Drain plug 11 Bypass valve 19 Strainer
4 O-ring 12 Spring 20 Screen filter
5 Level gauge 13 Screw 21 Plug
6 Screw 14 Spring washer 22 O-ring
7 Spring washer 15 O-ring
8 Plain washer 16 Screw
No. Tightening torque

6 52.2 ± 5.2 (377 ± 38)
13 6.5 ± 0.7 (47 ± 5)
16 0.3 ~ 0.5 (2.2 ~ 3.6)
 To check the oil level, park on a level surface, retract the arm cylinder, extend the bucket cylinder, lower the bucket
to the ground and stop the engine.
 Operate each control lever (for digging unit and travel) to its full stroke to release the residual pressure.
 The center line of the sight gauge is normal. Add oil when required. – Bypass valve set pressure: 1.5 ± 0.3 kgf/cm2
(21 ± 4 psi) – Air breather : 1) Relief set pressure : 0.5 kgf/cm2 (7 psi) 2) Suction set pressure : 0.05 kgf/cm2 (0.7 psi)
Figure 2
Oil level sight gauge
 When mounting the tank, make the bottom level with frame by use of shim (9).
 Maintain the clearance (front, rear, left and right) within 10 mm.
Oil filter bypass valve

When the filter is clogged
Bypass valve (1) is opened and the oil returns directly to the tank without passing through the filter.
NOTE!
Bypass valve set pressure : 1.5 ± 0.3 kgf/cm2 (21 ± 4.3 psi)
Figure 3
Oil flow, when the filter is clogged
1. Bypass valve
A. From main control valve
Air breather
Preventing negative pressure inside the tank
The tank is a pressurized sealed type, so negative pressure is formed inside the hydraulic tank when the oil level drops
during operations. When this happens, the difference in pressure between the tank and the outside atmospheric pressure
opens the poppet in the breather, and air from the outside is let into the tank to prevent negative pressure.
At that time filter (2) prevents contamination from entering the tank.
Preventing excessive pressure inside the tank
When the hydraulic actuators are operated, the oil level in the hydraulic system increases as temperature rises. If the
hydraulic pressure rises exceeding the set pressure, the breather is actuated to release the hydraulic pressure inside the tank.
Figure 4
Air breather
1 Body 3 Cap
2 Filter 4 Valve
Hydraulic tank pressurizing

The hydraulic tank is pressurized to create a positive pressure at the hydraulic pump inlet to prevent cavitation.
If the tank cap assembly does not function or seal properly, the hydraulic pump could be damaged.
To pressurize the tank, raise the boom to maximum height, extend the arm and bucket cylinders, then lower the boom to
the ground.
To prevent hydraulic oil ejection due to the tank internal pressure while hydraulic system maintenance and press the inner
button several times to release the pressure until the air is all out.
Service Information

Hydraulic circuits, arm in / 910 Service Information 2014/5/12
boom raise
Profile:
Hydraulic circuits, arm in / boom raise
Figure 1
Arm in/boom raise
 When the joysticks are operated to “ARM IN” and “BOOM RAISE” secondary servo hydraulic oil flows to ports (al3,
Al3, 4Pi, Al2, a) and to ports (br1, Ps, BU1, b) for the arm and boom respectively.
 When arm in and boom raise are operated simultaneously, operation speed depends on the lever control angle.
Each circuit is explained according to the priority function.
 Arm lever and boom lever at full stroke:
 When the arm lever is fully stroked, maximum secondary servo hydraulic pressure applied to port (Al2) on
servo hydraulic selector valve (37) pushes the spool to the right, blocking (BU1) flow and draining servo
hydraulic signal (pb) so the spool of logic valve (48) moves to the left.
 Since P1 pump flow is blocked by the arm spool the pressure rises, and flows through the check valve,
spool valve, to the logic valve upper side holding it closed, preventing P1 flow from merging with P2 flow
for boom raising (boom conflux).
 When the boom lever is fully stroked, maximum secondary servo hydraulic pressure applied to port (Ps) on
arm conflux valve (47) pushes the spool to the left, blocking port (Po), preventing P2 flow from merging
with P1 flow for arm in (arm conflux).
 Therefore P2 flow is dedicated to boom raise and P1 flow is dedicated to arm in.
 Boom raise priority (Arm fine control)

Boom lever at full stroke and Arm lever at half stroke :
 Since secondary pressure applied to port (Ps) is high (boom lever full stroke) the arm conflux flow is cut off
and P2 flow is dedicated to boom raise.
 However secondary pressure applied to port (Al2) is low (arm lever 1/2 stroke) so the spool of servo
hydraulic selector valve (37) is partially stroked and (BU1) oil flows to (pb) line moving the spool of logic
valve (48) partially to the right, reducing P2 flow to the upper side of logic valve (48).
Now P1 pump flow (PL) at the lower side opens the logic valve and merges with P1 pump flow to the
boom cylinders (boom conflux), to increase boom raise speed.
 Port (b) is also pressurized, closing center bypass valve (55), blocking P1 flow so it is routed through the
boom conflux valve.
 Therefore confluent flow is regulated according to the pressure applied to port (Al2) via the lever control
angle.
 Arm in priority (Boom fine control)

Arm lever at full stroke and boom lever at half stroke :
 Since secondary pressure applied to port (Al2) is high (arm lever full stroke) the spool of servo hydraulic
selector valve (37) is fully stroked, blocking (BU1) oil flow and draining servo hydraulic signal (pb) at the
spool valve of logic valve (48). Then P2 pump oil flows through the check valve and spool valve to the
logic valve upper side, closing the valve so P2 flow is dedicated to arm in.
 However secondary pressure applied to port (Ps) is low (boom lever 1/2 stroke) so the spool of arm
conflux valve (47) is partially stroked and some P2 pump flow (PR) is routed through port (PO) to merge
with P1 pump flow to the arm cylinder to increase arm in speed.
 Port (a) is also pressurized, closing center bypass valve (53), blocking P1 flow so it is routed through the
arm conflux valve.
 Therefore confluent flow is regulated according to the pressure applied to port (Ps) via the lever control
angle.
Service Information

Hydraulic circuits, arm in 910 Service Information 2014/5/12
conflux
Profile:
Hydraulic circuits, arm in conflux
Figure 1
Arm in conflux
 When joystick (13) is operated to “ARM IN” secondary pilot oil from the remote control valve flows to ports (al3,
Al3, Al2, a, 4Pi).
 (al3) oil flows to the main control valve moving the arm spool to the right, routing P1 pump flow to the arm
cylinder piston side, moving the arm in.
 (Al3) oil flows through shuttle valve (33) shifting the brake valve spool, routing primary pilot oil (PG) to release the
slew brake.
 (Al2) oil flows to pilot selector valve (37) shifting the spool, draining pilot signal (pb) at the spool valve of logic valve
(48). Then P1 (PL) pump oil flows through the check valve and spool valve to the logic valve upper side. Due to the
surface area differential valve (48) is held closed.
 (AM) oil flows to A3 solenoid valve in block (12) and is routed to port (Por) at center bypass valve (53) moving the
spool, block P1 pump flow to tank and the negative flow signal (Fr) ; therefore P2 pump flow increases and is
routed through arm conflux valve (47) via port (Po) to merge with P1 pump flow in the main control valve, and is
routed to the cylinder piston side moving the arm in (confluent flow).
 (4Pi) oil flows to the arm holding spool valve, shifting the spool, draining the oil from the upper side of arm holding
valve (52). This enables return oil from the cylinder rod side to open the holding valve (52) and flow through the
main control valve, hydraulic filter and oil cooler to tank.
 When supply flow is sufficient, regenerating valve is pushed to the right and the return circuit is unrestricted.
 When the engine rotates at low rpm or the supply flow is not sufficient due to combined operation, the pressure
will drop. In this case, regenerating valve is pushed to the left and the return circuit is restricted. Arm regenerating
check valve in the center of the arm spool is opened and some return oil is merged with supply flow, to the arm
cylinder.
This prevents cavitation and any sudden change of cylinder speed.
Service Information

Hydraulic circuits, arm out 910 Service Information 2014/5/12
Profile:
Hydraulic circuits, arm out
Figure 1
Arm out
 When joystick (13) is operated to “ARM OUT” secondary pilot oil from the remote control valve flows to ports (bl3,
a).
 (bl3) oil flows to the main control valve moving the arm spool to the left, routing P1 pump flow (PL) to the arm
cylinder rod side, retracting the rod moving the arm out.
 (a) oil flows to A3 solenoid valve in block (12) and is routed to port (Por) at center bypass valve (53) moving the
spool, blocking P1 pump flow to tank and the negative flow signal (Fr) ; therefore P2 pump flow (PR) increases and
is routed through arm conflux valve (47) via port (Po) to merge with P2 pump flow in the main control valve. The
confluent oil flow opens arm holding valve (52) and is routed to the cylinder rod side moving the arm out.
 Oil from the piston side returns through the main control valve to the hydraulic filter and oil cooler, then is drained
to tank.
Service Information

Hydraulic circuits, boom 910 Service Information 2014/5/12
lower
Profile:
Hydraulic circuits, boom lower
Figure 1
Boom lower
 While the boom joystick is in neutral (Pg2) oil is blocked by a pilot valve and prevents boom drift by boom holding
valve and poppet.
 When joystick (14) is operated to “BOOM LOWER” secondary pilot pressure is supplied to (ar1) and (3Pi).
 (3Pi) oil flow opens spool to allow (Pg2) flow to the poppet. (Pg2) oil opens the poppet and allows the boom
holding valve (43) to open.
 (ar1) oil pressure pushes the boom spool to the left and routes P2 (PR) pump oil to the rod side of the cylinders.
 The oil from the cylinder piston side returns through boom spool, opening back pressure check valve (44) and is
routed to the hydraulic filter and oil cooler, then is drained to tank.
 At the same time the return oil pressure opens the check valve at the center of the boom spool (boom
regeneration) and some of the return oil flow is merged with the supply oil to the rod side (confluent flow).
 Since center bypass valve (55) is open, P1 pump flow (PL) returns to tank. Flow sensing valve (56) restricts the return
flow, raising the pressure in passage (Fl) and the servo piston of P1 pump moves left decreasing the pump
discharge.
Service Information

Hydraulic circuits, boom 910 Service Information 2014/5/12
raise conflux (internal)
Profile:
Hydraulic circuits, boom raise conflux (internal)
Figure 1
Boom raise conflux
 When joystick (14) is operated to “BOOM RAISE”, secondary pilot pressure oil from the remote control valve (BU1)
flows to port (br1, Ps, b) and (pb) through pilot selector valve (37).
 (br1) flows to the main control valve pilot port (br1), moving the boom spool to the right, routing P2 pump flow
(PR) to the piston side of the cylinders extending the rods raising the boom.
 (Ps) flows to arm conflux valve (47) pilot port (Ps), controlling the valve blocking P2 pump flow (PR) to the arm
cylinder. (Refer Arm in/Boom raise)
 (b) flows to center bypass valve (55) and (BU1) flows to (Pb) through pilot selector valve (37).
 (pb) moves logic valve (48) spool to the right blocking (P1) oil to the logic valve, allowing the logic valve poppet to
open.
 (b) moves center bypass valve (55) to the left, blocking (P1) oil to tank and opens logic valve poppet (48). P1
combines with P2 flow in the main control valve, then is routed to the piston side of the cylinders raising the boom.
 The oil from the rod side flows to the hydraulic filter and oil cooler, then is drained to tank.
Negative signal (Fr) of P2 pump is disconnected by the boom spool and negative signal (Fl) of P1 pump is
disconnected by the spool of center bypass valve (55). So P1, P2 pump discharge is increased.
Service Information

Hydraulic circuits, bucket 910 Service Information 2014/5/12
Profile:
Hydraulic circuits, bucket
Figure 1
Bucket
Bucket curl (Depicted in schematic)
 When joystick (14) is operated to “ BUCKET CURL” secondary servo hydraulic oil from the remote control valve flows
to port (ar2) on the main control valve moving the bucket spool to the left, routing P2 pump flow (P ) to the
cylinder piston side extending the rod, curling the bucket.
 Since center bypass valve (55) is open, P1 pump flow (P ) returns to tank.
Flow sensing valve (56) restricts the return flow, raising the oil pressure in passage (Fl) shifting the servo piston of
P1 pump decreasing pump delivery.
Bucket dump
 When joystick (14) is operated to “ BUCKET DUMP” secondary servo hydraulic oil from the remote control valve
flows to port (br2) on the main control valve moving the bucket spool to the right, routing P2 pump flow (P ) to the
cylinder rod side retracting the rod, dumping the bucket.
 As the bucket spool shifts it blocks the negative flow signal (Fr) and P2 pump flow (P ) increases.
 Since center bypass valve (55) is open, P1 pump flow (P ) returns to tank.
Flow sensing valve (56) restricts the return flow, raising the oil pressure in passage (Fl) shifting the servo piston of
 Return oil from the piston side flows through the main control valve to the hydraulic filter and oil cooler, then is
drained to tank.
Service Information

Hydraulic circuits, neutral 910 Service Information 2014/5/12
Profile:
Hydraulic circuits, neutral

Servo hydraulic circuit (safety lever in unlocked position)
Servo hydraulic pressure circuit
Oil discharged by the gear pump passes through the relief valve and servo hydraulic filter (8) and enters the following
components, completing the servo hydraulic pressure circuit :
 Remote control valve for operating digging units (13, 14)

 Remote control valve for travel (15)
 Dozer blade remote control valve
 Slew brake valve (PG)
 Power shift valve (for pump control)
 Auto idle circuit (Pg1)
 Solenoid valve for main pressure boost, safety, axle locking, breaker, boom and arm conflux
 Travel 1st/2nd speed clutch release circuit, cruise solenoid valve circuit
Negative control signal circuit

The advantage of this circuit is minimizing pump discharge under no–load, thereby eliminating wasteful energy
consumption (for energy conservation), and reducing fuel costs.
The operating principle is the negative control type in which the increase in main return oil pressure (Fl, Fr) reduces the
discharge from the pump.
Negative control pressure (Fl, Fr) rises when in neutral because all the oil discharged from the pump is directed through the
throttle of the flow sensing valve (54), increasing the flow through it.
In the negative control circuit for the P1 pump, oil from port Fl of the control valve passes and enters port Pi1 (Fl) of the
pump.
In the negative control circuit for the P2 pump, oil from port Fr of the control valve passes and enters port Pi2 (Fr) of the
pump.
Main circuit
Hydraulic oil cleaned by tank strainer (22) is drawn in by the variable displacement pumps.
This oil is then discharged by P1, P2 pump and enters control valve.
When the flow sensing valve in the control valve is actuated, the oil drains through tank port (R).
The returning oil passes through the oil cooler and return filter (25) where any contaminates are removed as it is drained to
tank.
Service Information

Hydraulic circuits, ports 910 Service Information 2014/5/12
Profile:
Hydraulic circuits, ports

Hydraulic ports
Part Port Description

Pump P ,P Discharge port
Dd (T1) Drain port (Dr1 ~ Dr5, Dd1)
Pi1(Fl), Pi2(Fr) Negative control signal port
G1, 2 Gauge port
Control valve P Pump P1 port
P Pump P2 port
AR1 Boom lower port
BR1 Boom raise port
AR2 Bucket dump port (Cylinder retract)
BR2 Bucket curl port (Cylinder extend)
AR3 Blade raise port
BR3 Blade lower port
AL1 Reverse travel port
BL1 Forward travel port
AL2 Slew port (Right)
BL2 Slew port (Left)
AL3 Arm in port
BL3 Arm out port
AL4, BL4 Option port
ar1 Boom lower servo hydraulic port
br1 Boom raise servo hydraulic port
ar2 Bucket dump servo hydraulic port
br2 Bucket curl servo hydraulic port
ar3 Dozer blade servo hydraulic port (Raise)
br3 Dozer blade servo hydraulic port (Lower)
al1 Travel servo hydraulic port (Reverse)
bl1 Travel servo hydraulic port (Forward)
al2 Slew servo hydraulic port (Right)
bl2 Slew servo hydraulic port (Left)
al3 Arm in servo hydraulic port (Cylinder extend)
bl3 Arm out servo hydraulic port (Cylinder retract)
al4, bl4 Option servo hydraulic port
a Arm in/out conflux signal port
b Boom raise conflux signal port
Al2 Slew priority signal port (Boom conflux cut-off)
3Pi Boom lower holding valve port (Release)
Pg2 Boom holding 1st pressure (Release)
4Pi Arm in holding valve port (Release)
Pb Boom raise conflux signal port
RS1 Main return port
RS2 Boom raise, slew motor booster port
Ps Boom raise priority servo hydraulic port
pa Slew priority valve signal port
Py Pressure boost servo hydraulic port (Main)
Po Arm conflux port
Px Auto deceleration sensor port (Digging unit)
Pg1 Auto deceleration pressure source (Digging unit)
PG Slew brake release pressure source
Others Al3, SH, SW Slew brake release signal port
P2, P3, P5 Remote control valve servo hydraulic 1st pressure port
Bu1, BU Remote control valve servo hydraulic 2nd pressure
Control valve P Gear shift complex valve pressure source
T1 ~ T6 Tank return
Por Stabilizer, dozer blade select signal port
Pg3 Conflux release port
Pg4 Travel remote control valve 1st servo hydraulic pressure source
Service Information

Hydraulic circuits, slew 910 Service Information 2014/5/12
(left)
Profile:
Hydraulic circuits, slew (left)
Figure 1
Slew (left)
 When joystick (13) is operated to “ SLEW LEFT ” secondary pilot oil from the remote control valve flows to ports
(bl2, SW, pa).
 (bl2) oil flows to the main control valve moving the slew spool to the left, routing P1 pump flow (PL) to slew motor
port (B) to rotate the superstructure in a right hand direction.
 (SW) oil flows through shuttle valve (33) shifting the brake valve spool, routing primary pilot oil (PG) to release the
slew brake.
 (pa) oil flows to regenerating valve moving the spool to the left restricting the arm return flow; thereby maintaining
slew priority during slew/arm simultaneous operation.
 Since center bypass valve (53) is open, P2 pump flow (PR) returns to tank.
Flow sensing valve (54) restricts the return flow, raising the oil pressure in passage (Fr) shifting the servo piston of
Slew rebound damping valve
Just before slew is stopped completely, rebound phenomenon by too much clearance between ring gear and
pinion is prevented as the slew rebound damping valve interlocks ports A and B.
Service Information

Hydraulic circuits, slew 910 Service Information 2014/5/12
priority (slew right / arm
in)
Profile:
Hydraulic circuits, slew priority (slew right / arm in)
Figure 1
Slew priority (slew right / arm in)
 When joystick (13) is operated to “SLEW RIGHT” and “ARM IN” secondary pilot oil from the remote control valve
flows to ports (al2, SW, pa), and to ports (al3, Al3, Al2, a, 4Pi) respectively.
 During the combined operation some P1 pump flow (PL) is supplied to the arm cylinder through orifice (46),
however sharing the pump flow reduces the slew speed. To prevent this (pa) oil at the regenerating valve moves the
spool to the left restricting the retrun flow from the arm cylinder rod side. This raises the return circuit pressure, and
opens the regenerating check valve in the center of the arm spool, allowing some return oil to merge with the
supply flow to the arm cylinder. Therefore more P1 pump flow is directed to the slew function to maintain slew
priority.
 All of P2 pump flow (PR) and some of P1 pump flow (PL) is confluently supplied to the arm cylinder. As the supply
flow pressure to the cylinder piston side increases the regenerating valve spool is pushed to the right by the high
pressure signal, and the regenerating check valve closes.
 If the bucket is operated in conjuction with the arm and slew operation, P1 pump flow is divided between the arm
and bucket function. Due to a rapid decrease of flow to the arm cylinder (pressure drop in high pressure signal to
regenerating valve spool) and (pa) pressure applied to regenerating valve, the spool is pushed to the left
reactivating the arm regeneration cycle to maintain arm speed.
 Negative lines Fr and Fl are cut off, and the oil delivery rate of P1/P2 pumps is increased.
Service Information

Hydraulic circuits, standard 910 Service Information 2014/5/12
Profile:
Hydraulic circuits, standard
Figure 1
Hydraulic circuit, standard
1 Pump
2 Control valve
3 Slew motor
4 Travel motor
5 Boom cylinder
6 Arm cylinder
7 Bucket cylinder
8 Center passage
9 Axle locking cylinder
10 Dozer blade cylinder
11 Dozer blade servo hydraulic check valve
12 Solenoid valve
13 Remote control valve (lever) - Left
14 Remote control valve (lever) - Right
15 Remote control valve (pedal) - Travel
16 Remote control valve (lever) - Dozer blade
17 Check valve
18 Check valve
19 Solenoid valve
20 Drain filter
21 Hydraulic oil cooler
22 Suction strainer
23 Servo hydraulic filter
24 Stabilizer cylinder
25 Return filter
26 Bypass valve
27 Air breather
28 Hydraulic oil tank
29 Accumulator
30 Servo hydraulic block
31 Stabilizer servo hydraulic check valve
32 Block
33 Shuttle valve
34 Block
35 Block
36 Pressure switch
37 Servo hydraulic selector valve
38 Dozer/stabilizer selector valve
39 Shuttle connector
40 Bypass strainer
41 Double check valve
42 Gear pump
43 Boom holding valve
44 Check valve
45 Orifice
46 Orifice
47 Arm parallel conflux valve
48 Logic valve (Boom couflux)
49 Main relief valve
50 Port relief valve
51 Slew priority valve
52 Arm holding valve
53 Center bypass valve - 3 series
54 Flow sensing valve
55 Center bypass valve - 4 series
Service Information

Hydraulic circuits, travel 910 Service Information 2014/5/12
Profile:
Hydraulic circuits, travel
Figure 1
Travel
 When the travel pedal is operated secondary pilot pressure from remote control valve (15) flows to (bl1) according
to forward/reverse solenoid valve control (19). And pilot pressure from pilot pump flows to parking solenoid valve,
1st/2nd speed clutch in the transfer gearbox.
 (bl1) flows to the main control valve pilot port (bl1), moving the travel spool to the left, routing P1 pump flow (PL)
to port (B) of travel motor (4).
 The boom conflux logic valve (48) blocks P1 pump oil (PL) from merging with P2 pump oil (PR).
 The P2 pump oil (PR) flows through the center bypass valve (53) and returns to tank. Flow sensing valve (54)
restricts the return flow, raising the oil pressure in passage (Fr) shifting the servo piston of P2 pump decreasing
pump delivery.
 Travel mode select switch has 3 steps.
(P: Park, W : Work, T: Travel)
 Auto-decel function is not available while in travel mode.
 When the machine starts, the travel motor swash plate angle is increased to achieve enough torque to start moving
the machine.
Service Information

Hydraulic circuits, with 910 Service Information 2014/5/12
option parts
Profile:
Hydraulic circuits, with option parts
Figure 1
Hydraulic circuit with option parts (1)
1 Pump 46 Orifice
2 Control valve 47 Arm parallel conflux valve
3 Slew motor 48 Logic valve (Boom couflux)
4 Travel motor 49 Main relief valve
5 Boom cylinder 50 Port relief valve
6 Arm cylinder 51 Slew priority valve
7 Bucket cylinder 52 Arm holding valve
8 Center passage 53 Center bypass valve - 3 series
9 Axle locking cylinder 54 Flow sensing valve
10 Dozer blade cylinder 55 Center bypass valve - 4 series
11 Dozer blade servo hydraulic check valve 56 Flow sensing valve
12 Solenoid valve 57 Line rupture valve
13 Remote control valve (lever) - Left 58 Pressure switch
14 Remote control valve (lever) - Right 59 Line rupture valve
15 Remote control valve (pedal) - Travel 60 Single pedal
16 Remote control valve (lever) - Dozer blade 61 2nd boom valve
17 Check valve 62 2nd boom cylinder
18 Check valve 63 Single pedal
19 Solenoid valve 64 Reducing valve
20 Drain filter 65 3-way valve
21 Hydraulic oil cooler 66 3-way valve
22 Suction strainer 67 Stop valve
23 Servo hydraulic filter 68 Ball valve
24 Stabilizer cylinder 69 3-way valve
25 Return filter 70 Gear pump
26 Bypass valve 71 Demand valve
27 Air breather 72 Solenoid valve
28 Hydraulic oil tank 73 Rotator valve
29 Accumulator 74 Quickfit valve
30 Servo hydraulic block 75 Quickfit cylinder
31 Stabilizer servo hydraulic check valve
32 Block
33 Shuttle valve
34 Block
35 Block
36 Pressure switch
37 Servo hydraulic selector valve
38 Dozer/stabilizer selector valve
39 Shuttle connector
40 Bypass strainer
41 Double check valve
42 Gear pump
44 Check valve
45 Orifice
Figure 2
Hydraulic circuit with option parts (2)
Service Information

Hydraulic components, 910 Service Information 2014/5/12
description
Profile:
Hydraulic components, description

This machine incorporates the features and functions described below in its hydraulic circuit in order to provide easier
operation, greater safety, higher productivity, and better fuel economy.
Function of components
Purpose Component Function Feature

Ease of Travel
operation and  Controlled by servo hydraulic  Parking, travel & work function by
safety pressure travel mode select switch.
 Controlled by travel mode
select switch
Slew
 Slew priority circuit (during  Easier digging due to the use of
simultaneous slew and arm in) simultaneous slew and arm in.
 Automatic slew parking brake
 Rebound damping function  Delayed slew parking brake application
during slew to allow for inertia.
 Damping by rebound damping valve.
Digging units
 Controlled by servo hydraulic  Fine operation.
pressure
 Boom, arm regenerating circuit  Changing the balance between boom,
 Holding valve (boom, arm lock) arm and bucket functions.
 Heavy lift and heavy duty  Decreasing the amount of boom drift.
digging
 Increasing the working pressure by
increasing the pressure of main relief
valve.
Others
 Closed and semi-automatically  Contamination of hydraulic oil
pressurized hydraulic tank prevented, suction ability of pump
 Suction strainer improved.
 Return line : filter and drain  Damage of hydraulic components

filter prevented.
 Servo hydraulic circuit : line  Contamination of hydraulic oil
filter prevented.
 Hydraulic oil cooled by oil  Servo hydraulic operated circuit failure
cooler prevented.
 Emergency circuit  Deterioration of hydraulic oil
prevented.
 If engine stopped, movable by weight
of digging units.
Productivity Pump
increased  Full horsepower control  Effective use of engine horsepower
though action of two variable
displacement pumps.
Travel
 2-speed by power shift 2-  Low speed/high propel torque.
speed transfer gearbox control  High speed/low propel torque.
switch
Digging units
 Conflux for boom raising  Faster boom raising.
 Regeneration for boom  Positive bucket motion during
lowering simultaneous boom lowering and
bucket operation.
 Conflux circuit for arm in under  Faster arm in under heavy load.
heavy load
 Regeneration circuit for arm in  Faster arm in under light load.
under light load
 Conflux circuit for arm out  Faster arm out.
 Pressure increasing circuit for  Improved digging, lifting under heavy
heavy load load.
Fuel economy Pump

 Negative flow control  Flow minimized when in neutral
Controller
 Mode select switch changeover  Selecting an effective engine rpm
suited for the amount of work, fuel
 Auto idling consumption and fine control.
 Engine speed decelerated during
waiting periods for reduced fuel cost
and less noise.
Service Information

Hydraulic diagram, 910 Service Information 2014/5/12
schematic
Profile:
Hydraulic diagram, schematic
Figure 1
Hydraulic diagram
1 Gear pump 6 Arm cylinder 11 Main control valve E Arm

2 Main pump 7 Bucket cylinder A Dozer blade F Slew
3 Engine 8 Center passage B Bucket G Travel
4 Dozer blade cylinder 9 Slew motor C Boom
5 Boom cylinder 10 Travel motor D Option
The mechanical power from the engine is converted to hydraulic power by the main pumps. Hydraulic power from the main
pumps goes to the travel motor, slew motor and hydraulic cylinders via the control valve, where it is converted back to
mechanical power, which actuates the travel action, slew action and digging units.
Service Information

Operation, axle locking 910 Service Information 2014/5/12
Profile:
Operation, axle locking
Figure 1
Operation, axle locking
Axle locking
When the axle locking switch is at “LOCK” the axle locking solenoid valve spool (3) moves up to cut off the gear pump oil to
check valves (4). The check valves block oil flow from/to the axle locking cylinders. Therefore the oscillating axle is locked
and the machine is stable during slew operation or working on soft ground.
Axle floating (release)
When the axle locking switch is at “release” the axle locking solenoid valve spool moves down routing gear pump oil to the
check valves. The check valves (4) connect the axle locking cylinders to the tank return line (R5). The oil in the axle locking
cylinders is pressurized by check valve (6) and flows from / to the return line according to the force applied to the axle
locking cylinder pistons. Therefore the axle is floating and the machine can travel smoothly over rough road conditions.
Service Information

Operation, dozer blade / 910 Service Information 2014/5/12
stabilizer
Profile:
Operation, dozer blade / stabilizer
Figure 1
Operation, dozer blade / stabilizer
1. Main control valve

2. Selector valve
3. Center passage
4. Dozer blade cylinder
5. Stabilizer cylinder
6. Solenoid valve
* Servo hydraulic check valve opening pressure
A. 100 kgf / cm2 (1422 psi)

B. 50 ~ 60 kgf / cm2 (711 ~ 853 psi)
DOZER/STABILIZER SELECT SWITCH
 Switch lamp ON: Stabilizer operating.

 Switch lamp OFF: Dozer blade operating.
Dozer blade
Lower
When the dozer/stabilizer select switch is off, solenoid valve is energized and pushing down the spool, routing the gear
pump oil to port (Por), (Por) flows to the selector valve, moving the valve spool to up. When remote control valve (lever) is
operated to “LOWER” secondary servo hydraulic oil from the remote control valve flows to port (ar3), moving the dozer
blade/stabilizer spool down, P2 pump oil (PR) flows to the dozer blade cylinder rod side retracting the rods.
Oil in the dozer blade cylinder piston side, returns to tank through the selector valve while oil in stabilizer cylinder piston
side is blocked by the selector valve. Therefore only the dozer blade only operates.
Raise
When the lever is operated to “RAISE” secondary servo hydraulic oil from remote control valve (16) flows to port (br3),
moving the dozer blade/stabilizer spool up. P2 pump oil (PR) flows to the dozer blade cylinder piston side extending the
rods.
Stabilizer
Lower
When the dozer/stabilizer select switch is ON, solenoid valve is de–energized and the spool is moved up by spring force,
blocking the gear pump oil to (Por). The selector valve spool is moved down by spring force. When remote control valve
(lever) is operated to “LOWER” secondary servo hydraulic oil from the remote control valve flows to (ar3), moving the dozer/
stabilizer spool down, then P2 pump oil (PR) flows to the stabilizer cylinder rod side retracting the rods.
Raise
When remote control valve (lever) is operated to “RAISE” secondary servo hydraulic oil from the remote control valve flows
to (br3), moving the dozer/stabilizer spool up. P2 pump oil (PR) flows to the stabilizer cylinder piston side extending the
rods.
Service Information

Check valve, description 9112 Service Information 2014/5/12
Profile:
Check valve, description
Figure 1
Structure, check valve
1 Screw 4 Spring 7 Split pin

2 Valve cover 5 Spring seat 8 Thread
3 Valve 6 Nut A Hydraulic oil flow
Operating pressure
3.0 kgf/cm2 (42 psi) (Main control valve → Oil cooler → Oil tank)
4.5 kgf/cm2 (64 psi) (Main control valve → Oil tank)
 Creates a back pressure to prevent reverse flow in the return circuit.
CAUTION
When replacing and reassembling, the check valve must be installed to open in the direction of the flow.
CAUTION
If installed in the reverse direction, excessive back pressure will build in the return circuit.
Check valve mounting position

Figure 2
Check valve mounting position
A Check valve (4.5 kgf/cm2)

B Check valve (3.0 kgf/cm2)
C Hydraulic tank
D Main control valve mounting section
E Hydraulic oil cooler
Detaching & mounting
1. Unscrew clamp (18) and detach pipe (3) from main control valve.
2. Remove the check valve (4.5 kgf/cm2) directly assembled on the threaded section in pipe A.
3. Remove the check valve (3.0 kgf/cm2) directly assembled on the threaded section in pipe B.
4. When assembling the check valve, take care not to interchange the valves.
Hydraulic tank side : 4.5 kgf/cm2, oil cooler side : 3.0 kgf/cm2.
5. Pay attention to the assembling position and direction of check valve.
6. Assemble pipe and tighten the clamp.
CAUTION
Check (A, B) valves are threaded into the pipe.
Service Information

Lower line 9112 Service Information 2014/5/12
Profile:
Lower line
Figure 1
Port connection (lower line)
Port connection
Part Port Part Port Remarks

Center passage H Block B Reverse
J Travel motor A Forward
P T Transmission drain
N Pipe Q2 Dozer blade lower
I Q1 Dozer blade raise
Block P1 Stabilizer raise
L P2 Stabilizer lower
Block C4 Servo hydraulic check valve B1 (right) Stabilizer raise
C3 A1 (right) Stabilizer lower
C2 Servo hydraulic check valve A1 (left) Stabilizer lower
C1 B1 (left) Stabilizer raise
Pipe F1 Servo hydraulic check valve B1 (left) Dozer blade raise
F2 A1 (left) Dozer blade lower
F3 Servo hydraulic check valve A1 (right) Dozer blade lower
F4 B1 (right) Dozer blade raise
Service Information

Main line 9112 Service Information 2014/5/12
Profile:
Main line
Figure 1
Port connection (main line)
Main control valve Selector Center passage

AL1 Travel (reverse) AR1 Boom lower A Main control valve I Main control valve
BL1 Travel (forward) BR1 Boom raise B Center passage AR3 Dozer blade/stabilizer raise
AL2 Slew (right) AR2 Bucket dump C Center passage
BL2 Slew (left) BR2 Bucket curl BR3 Dozer blade/ stabilizer
lower
AL3 Arm in AR3 Dozer blade/ N Steering (right)
stabilizer raise Dozer blade lower
BL3 Arm out BR3 Dozer blade lower L Stabilizer lower
Service Information

Return and pump line 9112 Service Information 2014/5/12
Profile:
Return and pump line
Figure 1
Return and pump line
1. Main pump
2. Drain filter
3. Bypass valve (Main control valve → hydraulic oil tank) : 4.5 kgf/cm2 (64 psi)
Tightening torque : 2.0 ~ 2.5 kgf·m (14 ~ 18 lbf·ft)
4. Bypass valve (Main control valve → hydraulic oil tank) : 3.0 kgf/cm2 (42 psi)
5. Coupling
6. Main control valve
7. Hydraulic oil cooler
NOTE!
Bypass valves (3, 4) must not be switched.
NOTE!
Keep the pipe clearance to 18 ± 4mm
Service Information

Servo hydraulic line 9112 Service Information 2014/5/12
Profile:
Servo hydraulic line

Servo hydraulic line
Part Port Part Port Remark

Remote control lever 1 Main control valve ar2 Bucket curl
(right) 2 ar1 Boom lower
3 br2 Bucket dump
4 Servo hydraulic selector P (Boom raise)
P Block (2) P3
T T3
Remote control lever (left) 1 Block (1) A Slew (left)
2 Block (3) AO1 (Arm out)
3 Block (1) A Slew (right)
4 Block (3) Al1 (Arm in)
P Block (2) P5
T T5
Dozer blade control valve 1 Main control valve br3 Blade lower
2 ar3 Blade raise
P Block (2) P2
T T2
Remote control valve P Solenoid valve PG
(pedal) A Forward/reverse solenoid valve P
T Forward/reverse solenoid valve T
Forward/reverse solenoid A Main control valve bl1 Forward
valve B al1 Reverse
T Block (2) T4
Main pump Dr Drain filter IN Drain filter
Pi1 Main control valve Fl Negative
Pi2 Fr Negative
Psv Main pump S4
A3 Servo hydraulic filter IN
B3 Suction pipe IN
Main control valve Po Main control valve Pi
ar1 3Pi
al2 Block (1) A
bl2 Block (1) A
b Main control valve Ps
dr4 Hydraulic tank T2
Main control valve dr5
Selector valve T
Pa Block (1) B
Accumulator block PS Servo hydraulic filter OUT
AC Accumulator -
S1 (Control valve P)
S5 Main control valve Pg1
T Hydraulic tank T8
Solenoid valve (1) p1 Accumulator block Ps1
p2 S3
A1 Block (2) P1 Safety
A2 Main control valve Py Boost
A3 - Axle locking
T Hydraulic tank T6
Solenoid valve (2) p1 Solenoid valve (1) A1
p2 Block (3) p2
A1 - - Plug (breaker)
A2 Main control valve - Conflux cut-off
A3 Selector valve Dozer/stabilizer
T Solenoid valve (1) T
Slew motor SH Block (1) C
PG Solenoid valve (2) p2
MU Main control valve RS2
Dr Drain filter IN
Center passage P Slew motor Dr
Servo hydraulic selector P Main control valve br1
valve A pb
T Hydraulic tank T5
Block (2) T1 Hydraulic tank T4
P6 Main control valve Pg2
T6 Plug
Block (3) AL1 Main control valve al3 Arm in
AM a
AL2 Slew motor SH
AO1 Main control valve bl3 Arm out
Al3 Main control valve 4Pi
Servo hydraulic selector Pi
Main control valve br1 Main control valve Ps
Servo hydraulic pipe lines

Figure 1
Servo hydraulic pipe lines (1)
Figure 2
Servo hydraulic pipe lines (2)
Service Information

Arm holding valve, 9121 Service Information 2014/5/31
description
Profile:
Arm holding valve, description

Spool in neutral
4pi servo hydraulic signal : OFF
Spool A is positioned as shown, and chamber (1) and drain (Dr2) are isolated. As chamber (1) is connected to chamber (2)
through orifice (4), the pressure in chamber (1) will be Pc. As area d1 > d2, poppet B won"t move, and chamber (2) and
chamber (3) are isolated to hold the arm in position.
Figure 1
Arm holding valve
A. Spool
B. Poppet
C. Arm spool
D. Servo hydraulic signal port
R. Arm rod
H. High pressure oil supply passage
T. Tank passage
Spool operating
Arm out [Pv > Pc] (4pi servo hydraulic signal : OFF)
As chamber (1) is connected to chamber (2) through orifice (4), the pressure will be Pc and poppet B will open. The oil (Pv) in
high pressure supply passage is supplied to cylinder rod side through chamber (3).
Figure 2
Arm out
A. Spool
B. Poppet
R. Arm rod
T. Tank passage
Arm in [Pc > Pv] (4pi servo hydraulic signal : ON)

When servo hydraulic pressure (4pi) is applied, spool A moves left. As the oil is drained when chamber (1) and drain (Dr2) is
connected, the pressure in chamber (2) becomes low. When the pressure Pc is applied by (d1 area - d2 area), poppet B will
open and the oil returned from the cylinder, rod side, flows to tank passage.
Figure 3
Arm in
A. Spool
B. Poppet
R. Arm rod
T. Tank passage
Service Information

Arm regenerating valve, 9121 Service Information 2014/5/31
description
Profile:
Arm regenerating valve, description

Servo hydraulic pressure (al3) pushes the arm spool right (arm in) blocking the center bypass passage, and pressurized oil
from the pump opens the load check valve and flows through the U-shaped path, the circular notch of the spool, and port
AL3 to the cylinder, piston side.
Figure 1
Arm regenerating valve
A Check valve G Check valve for conflux

B Piston H High pressure supply passage
C Spool P Center bypass passage
D Spring R Reserve passage
E Arm holding valve T Tank passage
F Arm regenerating valve
Pressure on rod side is high [PB > PA]

The return oil flows from port BL3, to the circular notch of the spool, to restricted passage (1) and (2) where the pressure
rises, moving spool C and opening a narrow path to check valve A. When the check valve opens the oil flows via the passage
in the spool to merge with the flow through port AL3 to the cylinder, piston side.This process prevents cylinder cavitation
during arm in operation.
Figure 2
When pressure on rod side is high
A. Check valve
C. Spool
H. High pressure supply passage
T. Tank passage
Pressure on piston is high [PA > PB]

When the pressure at AL3 is greater than BL3, check valve A closes. The pressurized oil acts against piston B, and if it exceeds
the force of spring D, piston B and spool C move right and passage (2) is opened wide. The return oil now flows through
unrestricted passage (1) and (2) to tank. If servo hydraulic pressure is applied to port (pa) the force of the servo hydraulic
pressure multiplied by the piston area is added to the spring force and moves spool C, closing passage (2). As the return oil
pressure rises the regeneration process starts.
Figure 3
When pressure on piston is high
A Check valve G Check valve for conflux

B Piston H High pressure supply passage
C Spool P Center bypass passage
D Spring R Reserve passage
E Arm holding valve T Tank passage
F Arm regenerating valve
Service Information

Boom holding valve, 9121 Service Information 2014/5/31
description
Profile:
Boom holding valve, description

Spool in neutral
3pi servo hydraulic signal : OFF
The position of piston A is as illustrated and servo hydraulic pressure (Pg2) is isolated from chamber Y. Therefore, the
positions of piston B and poppet C become as shown, and passage (5) and (6) will be isolated from poppet C. As chamber
(1) is connected to chamber (2) through orifice (4), pressure Pc is obtained. As poppet E is closed because section area d1 >
d2, chamber (2) and (3) are completely isolated.
Figure 1
Structure, boom holding valve
A Piston F Boom spool

B Piston P Boom cylinder head side
C Poppet H High pressure supply passage
D Check valve T Tank passage
E Poppet
Spool operating
Boom raising [Pv > Pc] (3pi servo hydraulic signal : OFF)
As chamber (1) is connected to chamber (2) through orifice (4), pressure (Pc) is obtained and poppet E will open. The oil in
high pressure supply passage flows to cylinder, piston side.
Figure 2
Boom raising
B. Boom cylinder piston side
E. Poppet
P. Servo hydraulic pressure
T. Tank passage
Boom lowering [Pc > Pv] (3pi servo hydraulic signal : ON)
When servo hydraulic pressure (3pi) is applied, piston A moves up and servo hydraulic pressure (Pg2) flows to chamber Y.
Piston B and poppet C move to the right, so passage (5) and (6) are connected.
As chamber (3) is connected to the tank passage (by spool moving to left), the oil in chamber (1) opens check valve D
through passage (5) and (6), and then flows to tank passage through passage (7). Therefore, pressure Pc is applied to (d1
area – d2 area). Poppet E is opened and the oil returned from the cylinder, piston side, now flows to tank passage.
Figure 3
Boom lowering
A Piston F Boom cylinder piston side

B Piston G Drain port
C Poppet P Servo hydraulic pressure port
D Check valve T Tank passage
E Poppet
Service Information

Boom regenerating valve, 9121 Service Information 2014/5/31
description
Profile:
Boom regenerating valve, description

Servo hydraulic pressure (ar1) pushes the boom spool left (boom lowering) and pressurized oil from the pump opens the
load check valve and flows through the U-shaped path, the circular notch of the spool, and port AR1 to the cylinder, rod
side.
The return oil flows from port BR1, to the circular notch of the spool, where it passes through the path inside the spool to
check valve A. As the oil pressure rises it overcomes the spring force, opens the check valve and merges with the flow
through port AR1 to the cylinder, rod side.
This process prevents cylinder cavitation during boom lowering.
Figure 1
Structure, boom regenerating valve
A. Check valve
B. Spring
C. Back pressure check valve
H. Boom holding valve
P. Center bypass passage
T. Tank passage
Service Information

Control valve, 9121 Service Information 2014/5/31
troubleshooting
Profile:
Control valve, troubleshooting

 If an abnormal condition is noticed, check to see if the problem is in the control valve itself, one of the main pumps,
the servo hydraulic pump, or a circuit. To this end, you will need to measure servo hydraulic pressure, pump
delivery pressure, load pressure, etc. If any part of the system is to be disassembled for inspection, follow the
disassembly and reassembly procedures in this manual.
 Dirt is the enemy of hydraulic components.
Pay strict attention to protection from dirt. If any part of the system is to be disassembled, take preventative
measures beforehand.
 Moving parts must be handled with care. If they are damaged smooth the nicks or scratches with #2000 sand
paper.
 Take care not to damage the sealing face of o-ring. A damaged sealing face will certainly cause oil leaks.
Troubleshooting
Phenomenon Cause Remark

Travel does not occur. Malfunctioning travel relief valve. Measure travel relief valve pressure.
Slow to start up
(sluggish).  Contamination between main poppet  Disassemble and clean.
Slow response. valve and seat. If damaged heavily, replace the
assembly as a unit.
 Sticking main poppet.  Smooth sticking poppet with crocus
cloth.
 Broken or deformed spring.  Replace spring.
 Clogged main poppet orifice.  Remove contamination.
 Loosened adjusting screw.  Readjust and tighten lock nut to the
specified torque.
Clogged orifice in servo hydraulic circuit. Remove contamination.

Excessive drift of Excessive clearance between casing and spool. Replace control valve section.
cylinder in neutral Spool is not completely in neutral position. Measure primary, secondary servo hydraulic
position. pressure.
 Contamination between casing and spool,  Disassemble, clean, and smooth

or sticking spool. sticking part with crocus cloth.
 Broken or fatigued spring.  Replace spring.
 Clogged servo hydraulic circuit.  Remove contamination.
Malfunctioning port relief valve. Measure port relief valve pressure.

Malfunctioning anti-cavitation check valve.
 Contamination between poppet and  Disassemble and clean.

casing.
When extending Malfunctioning load check valve.

cylinder, at first it
retracts.  Contamination between poppet and  Disassemble and clean. If damaged,
casing. replace.
 Sticking poppet.  Smooth sticking poppet with crocus
cloth.
Bucket, boom or arm Malfunctioning main spool. Measure primary, secondary servo hydraulic
alone does not pressure.
operate.
Slow to start up  Excessive clearance between casing and  Replace control valve section.
(sluggish). spool.
Slow response.  Contamination between casing and spool.  Disassemble and clean.
 Sticking spool.
 Broken or fatigued return spring.  Smooth sticking spool with crocus
 Clogged servo hydraulic circuit. cloth.
 Replace spring.
 Remove contamination.
Malfunctioning main relief valve. Measure main relief valve pressure.

Malfunctioning port relief valve. Measure port relief valve pressure.
Malfunctioning servo hydraulic valve. Measure servo hydraulic pressure.
Clogged screen filter of joystick lever. Clean filter screen.
Slew priority function Loosened port relief valve. Measure and adjust port relief pressure.
does not occur. Clogged orifice in servo hydraulic circuit (Pa). Remove contamination.
Slew does not occur. Malfunctioning center bypass valve. Smooth sticking spool with crocus cloth or
remove contamination.
Despite lever being in Malfunctioning flow sensing valve. Measure flow sensing valve pressure.
neutral, negative
control does not  Contamination between poppet and seat.  Disassemble and clean. If damaged,
occur, and fails to replace the assembly as a unit.
minimize flow.  Broken or fatigued spring.  Replace spring.
 Clogged poppet orifice.  Disassemble and clean. Remove
contamination.
 Clogged filter.  Disassemble and clean. Replace filter
screen.
Service Information

Flow sensing valve, 9121 Service Information 2014/5/31
description
Profile:
Flow sensing valve, description

Oil in the center bypass passage flows to tank passage through orifice C of poppet A. Pump delivery volume can be
controlled as pressure (fp) balanced with passing flow at orifice C is fed back to the pump regulator.
Figure 1
Flow sensing valve
A Poppet P From center bypass passage

B Spring T Tank passage
C Orifice N Pressure signal to pump
When pressure (fp) reaches set pressure of spring B as a large amount of oil flows due to response delay of pump, poppet A
will open and the hydraulic oil flows to tank. Therefore, it acts as a relief valve.
Figure 2
Act as a relief valve
Service Information

General, inspection 9121 Service Information 2014/5/31
Profile:
General, inspection
Inspection methods
No. Part Remark

1 Housing
 Check for flaws, cracks and corrosion, and check for  If there are score marks, rust and corrosion,
hidden cracks by use of various detection methods. correct with #2000 sand paper and crocus
i.e. magnetic flux or penetration. cloth.
 If there is damage that can"t be repaired,
replace with a new component.
 Valve housing is a non-serviceable part. If there is  Housing bore : Spool and sliding parts.
damage, replace the control valve assembly. Especially around the pressure holding
areas as applied to : Seat : Seat of check
valve. Port seal : o-ring contact surface.
Seal : Main relief, port relief bore contact
surface.
2 Spool
 Check for nicks, scratches, rust, and corrosion on the  If there are nicks, scratches, rust and
outer diameter. corrosion, correct with #2000 sand paper
and crocus cloth.
 If a flaw is found on the outer diameter, check the  The spool is a non-serviceable part. If
relevant housing bore. damaged replace the control valve
assembly.
 Insert the spool into its bore and operate forward/  If it binds slightly try polishing the spool
reverse while rotating. with crocus cloth.
 Check if there is a flaw on the check valve seat and  If there is a flaw or a partial contact trace on
the check valve, inside the spool. the seal face seat, replace the valve.
 Insert the check valve into the spool, and operate it  If it sticks, replace it.
forward/reverse.
 Check the spring.  If there is damage or heat discoloration

replace it.
Return spring, rear side.

3
 Check the spring, spring guide, spool cap and cover  If there is wear or damage, replace the part.
for rust, corrosion, wear, and damage.
4 Load check valve.
 Check the seat of check valve.  If there is a flaw or partial contact trace on
the seat, replace the part.
 Check the spring.  If there is damage replace it.
5 Orifice
 Check if the flow sensing valve orifice is clogged.  If clogged, bore with wire.
CAUTION
Do not distort or change the orifice size.
6 Boom holding valve, servo hydraulic logic valve
 Check the poppet seat for flaws.  If there is a flaw or partial contact trace on
the seat, replace the part.
 Insert the poppet, and operate it forward/reverse.  If it sticks, replace it.
7 Main relief, port relief valve.
 Check the seat for flaws.  If there is a flaw or partial contact trace on
the seat, replace it.
 Check if the orifice is clogged.  If clogged, bore with wire.
 Insert the poppet, and move it forward/reverse.  If it sticks replace it.
 Check the spring.  If there is damage or heat discoloration,

replace it.
 It is difficult to judge the relief valve for damage

visually, therefore check the operating condition
carefully.
Service Information

General, tools 9121 Service Information 2014/5/31
Profile:
General, tools
Before disassembling or assembling the valve, prepare the following tools :
Tools
No. Tool Size Quantity

1 Vise 1
2 Socket 27 mm 1
3 32 mm 1
4 41 mm 1
5 46 mm 1
6 Allen wrench 4 mm 1
7 5 mm 1
8 6 mm 1
9 8 mm 1
10 10 mm 1
11 12 mm 1
12 14 mm 1
13 17 mm 1
14 19 mm 1
15 Torque wrench 75 ~ 4000 kgf·cm (5 ~ 300 ft·lbs) Various
16 Loctite # 262 1
Prepare the following tools, also:
 M6 screw. (To remove cut-off valve, conflux flow valve, travel priority valve)
 Magnet bar. (To remove shuttle valve ball, flow control valve)
 Holder for main spool. (To protect the spool when clamped in the vise)
Holder (Material : Brass)

Figure 1
Holder
A. Hexagon holder (2 pieces)

B. Screw (M5 × 60L)
Holder usages, unit : mm
φD Hexagon Application part

28.2 41 Main spool
15.9 32 Center bypass spool, arm parallel conflux spool
Service Information

Hydraulic pressure, 9121 Service Information 2014/5/31
measuring and adjusting
Profile:
Hydraulic pressure, measuring and adjusting

Measuring condition
1. Engine speed : high idle

2. Working mode : “H” mode
3. Oil temperature when measuring : 50 ~ 60°C (122 ~ 140°F)
WARNING
Lower the digging units to the ground and stop the engine. Operate the control levers several times to release the
remaining pressure in the hydraulic piping. Pull the left control console safety lock lever backward into lock
position. Then release the pressure inside the hydraulic tank prior to removing any hoses or port plugs.
Measurement
 Connect two oil pressure gauges (600 kgf/cm2, 8530 psi) to the P1/P2 gauge ports.
 Start the engine, set to “H” mode, and measure the main pressure.
 Condition of digging unit to be measured.
 For the working equipment, set each cylinder to the end of its stroke.
 For slew, put the bucket against an immovable object or put it in a trench.
 For travel, apply the service brakes and block the wheels securely.
 Operate the switch on the upper part of operating lever (right) to measure the boost pressure.
Hydraulic pressure
Primary pump supply to each actuator and test port location.
Port connection
Plug Pump Actuator (test port)

(1) P1 (PL) pump
 Travel motor
 Slew motor
 Arm cylinder
 Option digging unit
 2nd boom cylinder
(2) P2 (PR) pump

 Boom cylinder
 Bucket cylinder
 Dozer blade
 Stabilizer cylinder
Figure 1
Pressure measuring port of hydraulic pump
1. Quick coupler ( PF 1/4)

2. Proportional valve
Adjustment of the pump displacement
CAUTION
For the correct setting of the limiting pressure of the valve, connect the hoses and do the procedures for adjusting the pump
displacement.
Figure 2
Adjustment, displacement
1 Jumper hose 6 Main pump
2 In 7 Plug
3 Plug 8 Jumper hose
4 Main control valve (4 spool) 9 Out
5 Main control valve (3 spool) 10 Servo hydraulic pump
 Disconnect the hose connected to the power shift valve from the gear pump.
 Mount a tee (PF 1/4″) to the gear pump.
 Connect the hoses to the tee as follows :
 Connect the power shift valve hose to one tee port.

 Disconnect the hose at the negative port (Pi1) and plug it.
 Install a jumper hose between negative port (Pi1) and the other tee port.
 Check the port relief pressure related to P1 pump.

 Repeat above procedure for P2 pump.
 Reconnect the servo hydraulic hoses to their original position upon completion of checking and adjusting
pressures.
Service Information

Logic valve, description 9121 Service Information 2014/5/31
Profile:
Logic valve, description

In neutral and boom lowering
Servo hydraulic signal : OFF
Piston A and B are positioned as shown by the force of the springs.
Pressure Pa at (a) port flows to chamber Z through passage (1) and (2) when check valve C opens.
Pressure Pb‚ at (b) port flows to chamber Z from orifice E of poppet D.
In case of Pa > Pb
As area d1 > d2, poppet D remains in position and the passage between (a) and (b) is cut-off. (when the boom is lowered,
some oil is leaked through orifice E).
In case of Pa < Pb
The pressure in chamber Z becomes Pb‚ through orifice E of poppet D, so check valve C is closed. Poppet D is positioned in
place due to area difference between d1 and d2, and the passage between (b) and (a) is cut-off.
Figure 1
Logic valve, in neutral and boom lowering
A Piston F From PL pump (Pa)

B Piston G Boom raise servo hydraulic oil
C Check valve H High pressure supply passage for
D Poppet 3-spool side boom (Pb)
E Orifice
Boom raising
Servo hydraulic signal : ON
When the boom is raised, servo hydraulic pressure is applied to Pb port. Piston A and B move left, and passage (1) and (2)
are cut-off.
In case of Pa > Pb
The pressure in chamber Z becomes Pb through orifice E of poppet D, so poppet D is opened and oil flows from (a) to (b).
In case of Pa < Pb
The pressure in chamber Z becomes Pb through orifice E of poppet D. Poppet D is positioned and passage between (a) and
(b) is cut-off.
Figure 2
Logic valve, boom raising
A Piston F From PL pump (Pa)

B Piston G Boom raise servo hydraulic oil
C Check valve H High pressure supply passage for
D Poppet 3-spool side boom (Pb)
E Orifice
Service Information

Main control valve, 9121 Service Information 2014/5/31
description
Profile:
Main control valve, description
Figure 1
Main control valve (construction)
1. Boom
2. Bucket
3. Dozer/stabilizer
4. Travel
5. Slew
6. Arm
7. Option
 Tightening torque (A) : 15 kgf·m (103 lbf·ft)

Main control valve, sectional view
Figure 2
Main control valve (sectional view)
1 Main spool
2 Main relief valve
3 Orifice
4 Logic valve
5 Check valve
6 Arm holding valve
7 Arm regenerating valve (arm conflux check valve)
8 Arm parallel conflux check valve
9 Center bypass valve
11 Load check valve
12 Load check valve (bucket, dozer)
13 Cap (travel)
14 Boom back pressure check valve
15 Port relief valve
17 Boom holding valve/selector valve
18 Arm parallel conflux valve
Main control valve, exploded view
Figure 3
Main control valve (exploded view)
1 O-ring 48 Spring 94 Spring guide

2 Back-up ring 49 Cap 95 Spring
3 O-ring 50 Spring 96 Spool
4 Cap 51 Spool 97 Spool
5 Check 53 Screw 98 Spool
6 Spring 54 Spring washer 99 Spool
7 Plug 55 Spool 100 Spool
8 O-ring 57 Screw 101 Spool
9 Check 58 Flange cover 102 Spool
10 Spring 59 O-ring 103 Spring
11 Cap 60 Cap 104 Spool cap
12 O-ring 61 Back-up ring 105 Spring guide
13 Cover assembly 62 O-ring 106 Check
14 O-ring 63 Check 107 Spring
15 Spring 64 Spring 108 O-ring
16 Poppet 65 Orifice 109 Cap
17 Cap 66 O-ring 110 Spring guide
18 Cap 67 Cap 111 Stopper
19 Cap 68 Back-up ring 112 Manifold
20 Housing 69 O-ring 113 Spool
24 Cover 70 Poppet 114 Spring guide
25 Screw 71 Spring 115 Screw
26 O-ring 72 Sleeve 119 Check
27 O-ring 73 Cap 120 Spring
28 Retainer 74 Piston 121 Spring
29 O-ring 75 Cap 122 O-ring
30 O-ring 76 Back-up ring 123 Sleeve
31 Housing 77 Check 130 Flow sensing valve
35 Chip (Nylon) 80 Cap 131 O-ring
36 Spring 81 O-ring 132 Main relief valve
37 Check 82 Piston 133 O-ring
38 Check 83 Cap 134 Relief valve
39 Cap 84 Spring 135 O-ring
40 O-ring 85 Spool 136 Back-up ring
41 Back-up ring 86 Sleeve 137 O-ring
43 Poppet 87 Piston 138 Relief valve
45 O-ring 91 Manifold 139 Relief valve
46 Cap 92 Cover assembly
47 Poppet 93 Screw
Service Information

Main relief valve, 9121 Service Information 2014/5/31
adjustment
Profile:
Main relief valve, adjustment

Adjustment of the limiting pressure
CAUTION
Adjustment temperature should be kept within 50 ~ 60°C (122 ~ 140°F), as unnecessary relief (valve loading) causes rapid
temperature rise.
NOTE!
Operate the bucket cylinder to the end of its stroke to check the low / high relief pressures.
Figure 1
Main relief valve
1 Adjusting screw (low pressure) 4 Cartridge

2 Lock nut 5 Adjusting screw (high pressure)
3 Lock nut
Figure 2
Adjusting points
A. Main relief valve pressure adjusting points
Low pressure adjustment : 320 kgf/cm2 (4550psi)
 Remove the servo hydraulic hose connected to the relief valve, and plug the hose end.
 Loosen lock nut (2), and turn adjusting screw (1) as follows :
To increase pressure, turn clockwise.
To decrease pressure, turn counterclockwise.
 Hold adjusting screw (1) securely and tighten lock nut (2).
 Reinstall the relief valve servo hydraulic hose.
CAUTION
Reconfirm the low pressure setting, then check the high pressure setting using the power boost function. Do not try to
adjust the high pressure setting without proper gauges.
High pressure adjustment : 350 kgf/cm2 (4980 psi)
 Remove the servo hydraulic hose connected to the relief valve, and plug the hose end.
 Loosen lock nut (2), and turn adjusting screw (1) clockwise until fully seated.
 Readjust the low pressure setting to specification.
 Reconfirm the high/low pressure settings.
Service Information

description
Profile:
Main relief valve, description

Normal pressure (320 kgf/cm2)
Py servo hydraulic signal : OFF
Hydraulic oil supplied from the pump flows to chamber (3) through orifice (2) of main poppet A.
As section area d1> d2, main poppet A will not move.
Figure 1
Main relief valve
A Main poppet E Servo hydraulic signal : OFF

B Servo hydraulic poppet P Port from pump
C Spring T Port to tank
D Piston
If the pressure reaches set value of spring C, servo hydraulic poppet B will open so that the oil flows to tank passage through
hole (4). The pressure in chamber (3) will be lowered.
Figure 2
When the pressure reaches set value
The oil supplied when servo hydraulic poppet B is opened (the pressure of chamber (3) is low) creates a pressure differential
between front and rear of orifice (2), so the “pressure of chamber (1) × d2” becomes larger than “pressure of chamber (3) ×
d1”. The circuit pressure is controlled to constant level as main poppet A opens to allow hydraulic oil flow to tank passage.
Figure 3
Hydraulic oil flow to tank passage
Pressurized (350 kgf/cm2)

Py servo hydraulic signal : ON
Servo hydraulic pressure moves piston D and the set pressure of spring C is increased, so pressure setting is raised.
Figure 4
Pressure setting is raised
E. Servo hydraulic signal : ON

Service Information

Port (overload) relief valve, 9121 Service Information 2014/5/31
adjustment
Profile:
Port (overload) relief valve, adjustment

(For boom, arm, bucket and option)
CAUTION
Do not adjust the port relief valve unnecessarily.
 Symptoms of faulty port relief valve :
 Main relief valve high/low pressures can not be adjusted.

 Digging unit hoses rupture repeatedly.
CAUTION
Adjustment temperature should be kept within 50 ~ 60 °C (122 ~ 140°F), unnecessary relief valve loading causes rapid
temperature rise.
CAUTION
If pump displacement is not decreased, the port relief valve will open at lower than specified pressure.
NOTE!
Operate the hydraulic cylinder of the circuit to be measured to the end of its stroke.
 Increase the main relief valve pressure to exceed 360 kgf/cm2 (5120 psi), approximately 1/2 turn.
 Decrease the displacement of the pump.
 After completion of adjustment, reset the main relief valve high/low pressures to specification.
Figure 1
Adjustment, port relief valve
Figure 2
Port location
Port connection
Port Digging unit Port Digging unit Port Digging unit Port Digging unit
br1 Boom raise ar1 Boom lower al1 Travel (Reverse) bl1 Travel (Forward)
br2 Bucket curl ar2 Bucket dump al2 Slew (Right) bl2 Slew (Left)
br3 Dozer/stabilizer lower ar3 Dozer/stabilizer raise al3 Arm in bl3 Arm out
al4 Option bl4 Option
Service Information

Port relief valve, 9121 Service Information 2014/5/31
description
Profile:
Port relief valve, description

Overload operation
Hydraulic oil from the cylinder port (P) flows through orifice of piston A to chamber (2). As section area d1 > d2, main
poppet B will not move.
Figure 1
Normal condition
If the pressure reaches set value of spring C, servo hydraulic poppet D will open so that the oil flows to tank through the
lateral hole and circular passage, so the pressure in chamber (2) will be lowered.
Figure 2
Pressure reaches at set value
The oil supplied when servo hydraulic poppet D is opened (the pressure of chamber (2) is low) creates a pressure differential
between front and rear of orifice in piston A (chamber (1) and (2)), so piston A moves to the left side and stops at the end of
servo hydraulic poppet D.
The oil in chamber (1) flows to tank passage through the orifice of piston A, through the lateral hole and circular passage.
Figure 3
Oil creates pressure differential
As the pressure is lowered front and rear of the orifice in servo hydraulic poppet D, “pressure of chamber (1) × d2” will be
higher than “pressure of chamber(2)×d1”. Therefore, poppet B opens and hydraulic oil from the cylinder port flows directly
to tank passage.
Figure 4
Oil flows to tank passage
Anti–cavitation operation
Section area of poppet B is larger than d1, and since pressure in the cylinder port is usually higher than pressure in the tank
port, the valve is closed. However if the pressure in the cylinder port decreases lower than the tank port (near to negative
pressure), poppet B is opened by tank pressure by as much as the area difference of d1 and d2. Then the tank passage
return oil will flow to the cylinder port to prevent cavitation.
Figure 5
Preventing the cavitation
Service Information

Pressure relief valve, 9121 Service Information 2014/5/31
troubleshooting
Profile:
Pressure relief valve, troubleshooting

Troubleshooting

Pressure does not rise. Main poppet of relief valve is sticking and valve
is open, or there is contamination on the poppet  Check for contamination on the
or seat. poppet.
 Confirm that each component slides
smoothly.
 Clean all components thoroughly.
Unstable relief pressure. Damaged poppet seat of relief valve.

Main poppet sticking.  Replace damaged component.
 Clean all components thoroughly.
 Smooth surface damage.
Relief pressure is Wear due to foreign matter.

incorrect. Loosened lock nut or adjusting screw.  Disassemble and clean.
 Adjust pressure.
Oil leak Damaged seat.

Worn o-ring.  Replace damaged or worn
Sticking component due to foreign matter. component. Confirm that each
component operates smoothly
before reassembling.
 Confirm that there are no scratches,
nicks, or contamination present
before reassembling.
Service Information

Disassembly and assembly, 9123 Service Information 2014/5/12
general
Profile:
Disassembly and assembly, general

General, precautions
 Thoroughly clean the valves prior to removal from the machine.

 Cap all hoses and plug all ports to prevent contamination from entering.
Disassembly, precautions
 Do not use excessive force, sharp or high hardness tools to disassemble the valves.
 Handle the components carefully, protect the highly polished precision finish. If the surface is damaged it will cause
internal oil leakage and malfunction.
 Match mark the parts to indicate original location and position during reassembly.
Assembly, precautions
 Rework damaged parts, polish minor burrs, nicks, score marks or sharp edges with fine emery and crocus cloth.
Prepare all replacement parts.
 Coat the sliding parts with clean hydraulic oil.
 Replace the seals, o-rings and back-up rings.
Service Information

Line rupture valve (2 piece 9123 Service Information 2014/5/12
boom), general
Profile:
Line rupture valve (2 piece boom), general
Figure 1
Line rupture valve (2 piece boom), piping (1)
Figure 2
Line rupture valve (2 piece boom), piping (2)
1 Plate 48 O-ring 100 U-bolt 148 Clamp

2 Pipe 49 O-ring 101 Hose 149 Hose
3 Pipe 50 O-ring 102 Hose 150 Elbow - 90°
4 Pipe 51 O-ring 103 Hose 151 Connector
5 Pipe 52 O-ring 104 Hose 152 Hose
6 Screw 53 O-ring 105 Elbow - 90° 153 O-ring
7 Screw 54 Clamp 106 Elbow - 90° 154 O-ring
8 Nut 55 Clamp 107 Plug 155 O-ring
9 Spring washer 61 Clamp 108 Elbow 156 O-ring
10 Spring washer 62 Clamp 109 Hose 157 Nut
11 U-bolt 63 Clamp 110 Hose 158 Connector
12 Clamp 64 Plate 111 Hose 159 Valve
13 Hose 65 Line rupture valve 112 O-ring 160 Pedal lock
14 O-ring 66 Pipe 113 O-ring 161 Plate
15 O-ring 67 Pipe 114 O-ring 162 Plate
16 Wire harness - switch 68 Pipe 115 O-ring 163 Bracket
17 Cover 69 Clamp 116 O-ring 164 Screw
18 Pressure switch 70 Block 117 O-ring 165 Screw
19 Line rupture valve 71 Block 118 O-ring 166 Screw
20 Bracket 72 Bracket 119 Clamp 167 Screw
21 Pipe 73 Pipe 120 Nut 168 Spring washer
22 Block 74 Block 121 Plate 169 Spring washer
23 Block 75 Plate 122 Nut 170 Clip
24 Screw 76 Clamp 123 Tee 171 Connector
25 Screw 77 Clamp 124 Tee 172 Tee
26 Screw 78 Clamp 125 Connector 173 Tee
27 Screw 79 Screw 126 Connector 174 Connector
28 Spring washer 80 Screw 127 Hose 175 Connector
31 Tee 83 Screw 131 Clamp 178 Connector
32 Tee 84 Screw 132 Valve 179 Connector
33 Tee 85 Screw 133 Plate 180 Hose
34 Connector 86 Screw 134 Pipe 181 Hose
35 Connector 87 Screw 135 Flange 182 Hose
36 Elbow - 90° 88 Screw 136 Pipe 183 Hose
37 Elbow - 90° 89 Screw 137 Pipe 184 Hose
38 Elbow - 90° 90 Nut 138 Pipe 185 Hose
39 Elbow 91 Flat washer 139 Screw 186 Hose
40 Cu-washer 92 Flat washer 140 Screw 187 Hose
41 Hose 93 Spring washer 141 Screw 188 O-ring
42 Hose 94 Spring washer 142 Screw 189 O-ring
43 Hose 95 Spring washer 143 Screw 190 Steel ball
44 Hose 96 Spring washer 144 Flat washer 191 Clamp
45 Hose 97 Clip 145 Spring washer 192 Clamp
46 Hose 98 Clamp 146 Spring washer
47 O-ring 99 Bar 147 Spring washer
Service Information

Line rupture valve (arm), 9123 Service Information 2014/5/12
assembly
Profile:
Line rupture valve (arm), assembly

Tightening torque
No. Screw size Tightening torque

1 M 22 × 1.0 6 (43.3)
4 M 27 × 1.5 7 (50.5)
13 M 33 × 1.5 22 (158.8)
18 G (PF) 1/8 1 (7.2)
29, 30 M 8 × 1.25 4 (28.9)
31 NPTF 1/16 1 (7.2)
Assembly
1. Assemble plug (35) with seal tape to the valve body. (6 places)
Tools : L wrench 4 mm
2. Assemble spool (25) to the valve body.

NOTE!
Ensure that the spool moves smoothly.
3. Assemble cover (17) with o-ring (26) to the valve body. Install screws (34).
4. Assemble plug (18) with o-ring (19) to the valve body.

5. Assemble spring holder (23), spacer (22) and springs (20, 21) to the valve body in this order, and assemble cover
(32) with o-ring (33).
Install screws (31).
6. Assemble check valve (16), spring (15) and plug (13) with o-ring (14).
Tools : Socket wrench 41 mm
NOTE!
If you replace check valve (16) with a new one, press-fit with a driveer and hammer.
7. Assemble logic valve (27), spring (28) and plug (30) with o-ring (29).
NOTE!
If you replace logic valve (27) with a new one, press-fit with a driver and hammer.
8. Assemble relief valve (4).

Service Information

description
Profile:
Line rupture valve (arm), description
Figure 1
Line rupture valve (arm)
1 Cap 13 Plug 25 Spool

2 Adjusting screw 14 O-ring 26 O-ring
3 Gasket 15 Spring 27 Logic valve
4 Relief valve assembly 16 Check valve 28 Spring
5 Spring 17 Cover 29 O-ring
6 O-ring 18 Plug 30 Plug
7 Poppet 19 O-ring 31 Screw
8 Back-up ring 20 Spring 32 Cover
9 O-ring 21 Spring 33 O-ring
10 Seat 22 Spacer 34 Screw
11 Plug 23 Spring holder 35 Plug
12 Filter 24 Body
The arm line rupture valve (anti-drop valve) connected between the arm cylinder and the main control valve consists of: a
servo hydraulic valve, logic valve, check valve, pressure relief valve and a housing.
The line rupture valve function is to prevent an accident caused by a sudden dropping of the boom when a pipe or hose
ruptures. It also prevents boom cylinder creep caused by internal leakage of the main control valve.
Neutral position
When the remote control valve is in neutral position, spring (15) pushes the poppet of check valve (16) forward blocking the
passage to port P1. The oil flow from P4 & P5 normally connected through orifice (a) is blocked by servo hydraulic valve
spool (25) at position (b). The spring force combined with the oil pressure acting on the sectional area difference between f
& e of logic valve (27) pushes the poppet forward blocking passage P3.
With the arm in crowd position / attachment off the ground, the weight pressurizes the oil on the arm cylinder piston side,
the flow connected via passage P2 is blocked by the poppet of check valve (16) and logic valve (27), trapping the oil in the
hydraulic cylinder preventing the arm from dropping.
Figure 2
Line rupture valve (arm), neutral position
Arm out (P1 → P2)

when operating the remote control valve joystick to arm out, servo hydraulic valve spool (25) and logic valve (27) are in the
neutral position. Pressurized oil from the main control valve is routed through P1 port, pushes open check valve (16), then
flows via P2 to the rod side of the hydraulic cylinder moving the arm out.
When the arm is out and the joystick is returned to neutral position (P1 = P2), as described previously check valve (16)
poppet blocks the passage and the pressurized oil on the arm rod side is trapped in the cylinder preventing the arm from
dropping.
When a pipe or hose ruptures during arm out, pressurized oil flow will be cut off to passage P1. As a result the pressure in
passage P1 drops quickly and the poppet of check valve (16) will be pushed forward by its spring blocking passage P1, and
pressurized oil flow from the rod side of the arm cylinder is blocked.
Figure 3
Line rupture valve (arm), arm out
Arm in (P2 → P1)

When operating the remote control valve joystick to arm in (lower the arm), servo hydraulic oil is supplied to passage (4Pi)
and pushes servo hydraulic valve spool (25) to the left against springs (20, 21).
As spool (25) moves, passage T3 aligns with position b, and the oil in the spring chamber of logic valve (27) drains to the
hydraulic tank through passage P4 and P5.
The pressure difference of area e and f causes logic valve (27) to open and the oil from P2 flows past the poppet of logic
valve (27) to servo spool (25).
The return oil from the rod side of the arm cylinder will flow from passage P2 → P3 → P1 →main control valve → tank.
The oil passage opening from P3 to P1 will be varied because of the area of notch (C), which controls the return oil flow rate
(speed) from the arm cylinder.
When a pipe or hose ruptures during arm lowering, the pressure at port P1 will be lower than passage P3, P2, so the poppet
of logic valve (27) will be pushed forward by its spring blocking passage P3, and return oil flow from the arm cylinder is
blocked.
When the joystick is released to neutral position, servo hydraulic pressure at (4Pi) is cut off, and springs (20, 21) move spool
(25) to the right blocking passage P3.
Figure 4
Line rupture valve (arm), arm in
Overload relief valve

Service Information

disassembly
Profile:
Line rupture valve (arm), disassembly

Tools
1. L wrench : 4, 5, 6 mm
2. Spanner : 32, 41 mm
3. Torque wrench : 1 ~ 22 kgf·m (7.2 ~ 158.8 lbf·ft)
4. Hexagonal wrench : 4, 5 and 6 mm
5. Socket wrench : 32, 41 mm
6. Hammer
7. Rod : φ15, 100 mm
Disassembly
1. Remove relief valve (4) from the line rupture valve.

Tools : Spanner 32 mm
CAUTION
Do not disassemble the pressure adjusting part.
2. Remove plug (30) of the logic valve, and pull out o-ring (29), spring (28) and logic valve (27).
3. Remove plug (13) of the check valve, and pull out the o-ring (14), spring (15) and check valve (16).
4. Remove screws (31), cover (32), o-ring (33), springs (20, 21), spacer (22) and spring holder (23).
5. Remove plug (18), and pull out o-ring (19).

6. Remove screws (34), cover (17) and o-ring (26).

7. Remove spool (25).
8. Remove plugs (35).

Service Information

specifications
Profile:
Line rupture valve (arm), specifications

Specifications

Oil temperature °C (°F) -20 ~ +95 (68 ~ 203)
Relief valve pressure kgf/cm2 (psi) 355 +5/0 (5049 +71/0) at 30 Liter/min.
Spool operating pressure kgf/cm2 (psi) 2 ~ 22.5 (29 ~ 320)
Signal operating pressure kgf/cm2 (psi)
P2 → T 5.5 (78)
P2 → P1 6.9 (98)
Max. leakage -
Pi → P1 20 cc/min. at 40 kgf/cm2 (569 psi)
P2 → P1+T 4 cc/min. at 100 kgf/cm2 (1422 psi)
Service Information

Line rupture valve (boom), 9123 Service Information 2014/5/12
assembly
Profile:
Line rupture valve (boom), assembly

Tightening torque
No. Screw size Tightening torque

1 M 22 × 2.0 6 (43.3)
5 M 39 × 3.0 28 (202.2)
14 G (PF) 1/2 8 (57.8)
15 M 27 × 1.5 7 (50.5)
28 G (PF) 3/4 22 (158.8)
34 G (PF) 1/4 2 (14.4)
35 NPTF 1/16 1 (7.2)
37 G (PF) 3/8 52 (36.1)
Assembly
1. Assemble plug (35) with seal tape to the valve body. (6 places)
2. Assemble plug (32) with o-ring (31) to the valve body. (2 places)
3. Assemble plug (37) with o-ring (36) to the valve body. (2 places)
4. Assemble the servo hydraulic valve parts.
 Assemble plug (14) with o-ring (13) to the valve body.

 Assemble spool (11) to the valve body.
NOTE!
Ensure that the spool moves smoothly.
 Assemble spring holder (10), spacer (9) and springs (6, 8) to the valve body in this order, and assemble
plug (28) with o-ring (27).
5. Assemble check valve (30), spring (29) and plug (26) with o-ring (27).
NOTE!
If you replace check valve (30) with a new one, press-fit with a driver and hammer.
6. Assemble logic valve (23), spring (24) and plug (26) with o-ring (25).
NOTE!
If you change logic valve (23) with a new one, press-fit with a driver and hammer.
7. Assemble relief valve (3).
Service Information

description
Profile:
Line rupture valve (boom), description
Figure 1
Line rupture valve (boom)
1 Cap 14 Plug 27 O-ring

2 Adjusting screw 15 Sleeve 28 Plug
3 Relief valve assembly 16 Spring 29 Spring
4 Gasket 17 Poppet 30 Check valve
5 Cap 18 O-ring 31 O-ring
6 Spring 19 Back-up ring 32 Plug
7 O-ring 20 O-ring 33 O-ring
8 Spring 21 Plug 34 Plug
9 Spacer 22 Filter 35 Plug
10 Spring holder 23 Logic valve 36 O-ring
11 Spool 24 Spring 37 Plug
12 Body assembly 25 O-ring
13 O-ring 26 Plug
The boom line rupture valve (anti-drop valve) connected between the boom cylinder and the main control valve consists of:
a servo hydraulic valve, logic valve, check valve, pressure relief valve and a housing.
The line rupture valve function is to prevent an accident caused by a sudden dropping of the boom when a pipe or hose
ruptures. It also prevents boom cylinder creep caused by internal leakage of the main control valve.
Neutral position
When the remote control valve is in neutral position, spring (29) pushes the poppet of check valve (30) forward blocking the
passage to port P1. The oil flow from P4 & P5 normally connected through orifice (a) is blocked by servo hydraulic valve
spool (11) at position (b). The spring force combined with the oil pressure acting on the sectional area difference between f
& e of logic valve (23) pushes the poppet forward blocking passage P3.
With the boom / attachment off the ground the weight pressurizes the oil on the boom cylinder piston side, the flow
connected via passage P2 is blocked by the poppet of check valve (30) and logic valve (23), trapping the oil in the hydraulic
cylinder preventing the boom from dropping.
Figure 2
Line rupture valve (boom), neutral position
Boom raising (P1 → P2)

When operating the remote control valve joystick to raise the boom, servo hydraulic valve spool (11) and logic valve (23) are
in the neutral position. Pressurized oil from the main control valve is routed through P1 port, pushes open check valve (30),
then flows via P2 to the piston side of the hydraulic cylinder raising the boom.
When the boom is raised and the joystick is returned to neutral position (P1 = P2), as described above check valve (30)
poppet blocks the passage and the pressurized oil on the boom piston side is trapped in the cylinder preventing the boom
from dropping.
When a pipe or hose ruptures during boom raising, pressurized oil flow will be cut off to passage P1. As a result the pressure
in passage P1 drops quickly and the poppet of check valve (30) will be pushed forward by its spring blocking passage P1,
and pressurized oil flow from the piston side of the boom cylinder is blocked.
Figure 3
Line rupture valve (boom), boom raising
Boom lowering (P2 → P1)

When operating the remote control valve joystick to lower the boom, servo hydraulic oil is supplied to passage (ar1) and
pushes servo hydraulic valve spool (11) upward against springs(6, 8).
As spool (11) moves, passage T3 aligns with position b, and the oil in the spring chamber of logic valve (23) drains to the
hydraulic tank through passage P4 and P5.
The pressure difference of area e and f causes logic valve (23) to open and the oil from P2 flows past the poppet of logic
valve (23) to servo spool (11).
The return oil from the piston side of the boom cylinder will flow from passage P2 → P3 → P1 → main control valve → tank.
The oil passage opening from P3 to P1 will be varied because of the area of notch (C), which controls the return oil flow rate
(speed) from the boom cylinder.
When a pipe or hose ruptures during boom lowering, the pressure at port P1 will be lower than passage P3, P2, so the
poppet of logic valve (23) will be pushed forward by its spring blocking passage P3, and return oil flow from the boom
cylinder is blocked.
When the joystick is released to neutral position, servo hydraulic pressure at (ar1) is cut off, and springs (6, 8) move spool
(11) downward blocking passage P3.
Figure 4
Line rupture valve (boom), boom lowering
Overload relief valve

Normally the hydraulic oil from port P2 flows through g, d → h.
If the pressure of the boom cylinder reaches the set value, the pressure in the chamber h will open the poppet (17) and the
oil from port P2 flows to T2 through g. So the pressure in the boom cylinder will be lowered.
Figure 5
Line rupture valve (boom), overload relief valve
Service Information

disassembly
Profile:
Line rupture valve (boom), disassembly

Tools
1. L wrench : 4, 6, 8, 10 and 12 mm
2. Spanner : 32 and 46 mm
3. Torque wrench : 1 ~ 28 kgf·m (7.2 ~ 202.2 lbf·ft)
4. Hexagonal wrench : 4, 6, 8, 10 and 12 mm
5. Socket wrench : 32, 46 mm
6. Hammer
7. Rod : φ 10, 100 mm
Disassembly
1. Remove relief valve (3) from the line rupture valve.

CAUTION
Do not disassemble the pressure adjusting part.
2. Remove plug (26) of the logic valve, and pull out o-ring (25), spring (24) and logic valve(23).
3. Remove plug (28) of the check valve, and pull the o-ring (27), spring (29) and check valve(30).

5. Pull out springs (6, 8), spacer (9) and spring holder (10).

7. Remove spool (11).
8. Remove plugs (35).



Service Information

specifications
Profile:
Line rupture valve (boom), specifications

Specifications

Oil temperature °C (°F) -20 ~ +95 (68 ~ 203)
Relief valve pressure kgf/cm2 (psi) 355 +5/0 (5049 +71/0) at 30 Liter/min.
Spool operating pressure kgf/cm2 (psi) 2 ~ 22.5 (29 ~ 320)
Signal operating pressure kgf/cm2 (psi)
P2 → T 5.5 (78)
P2 → P1 7.9 (112)
Max. leakage -
Pi → P1 20 cc/min. at 40 kgf/cm2 (569 psi)
P2 → P1+T 4 cc/min. at 100 kgf/cm2 (1422 psi)
Service Information

troubleshooting
Profile:
Line rupture valve (boom), troubleshooting

Line rupture valve, troubleshooting

1 Excessive oil leakage in the passage
P2 → P1.  Contamination between the  Disassemble and clean.
check valve and seat. If damaged, replace.
 Contamination between the
logic valve and seat.
 Oil leakage of the servo
hydraulic valve.
 Oil leakage of the relief valve.
2 Boom lowering (or arm in) does not

occur.  Sticking spool of the servo  Disassemble and clean.
hydraulic valve. If damaged, replace.
3 External oil leakage.

 Damaged seals.  Replace damaged or worn
component.
4 Slow response in boom lowering (or

arm in).  Clogged orifice in the logic  Disassemble and clean.
valve. If damaged, replace.
 Clogged port T in the servo
hydraulic valve.
Service Information

Line rupture valve (mono 9123 Service Information 2014/5/12
boom), general
Profile:
Line rupture valve (mono boom), general
Figure 1
Line rupture valve (mono boom), piping
1 U-bolt 46 Hose 96 Hose
2 Plate 47 Hose 97 O-ring
3 Pipe 48 Hose 98 O-ring
4 Pipe 49 Hose 99 O-ring
5 Pipe 50 Hose 101 Plate
6 Pipe 51 Hose 102 Line rupture valve
7 Screw 52 O-ring 103 Block
8 Screw 53 O-ring 104 Pipe
9 Nut 54 O-ring 105 Screw
10 Spring washer 55 O-ring 106 Screw
11 Spring washer 56 O-ring 107 Nut
12 Clamp 57 O-ring 108 Flat washer
13 Hose 58 O-ring 109 Spring washer
14 O-ring 59 Clamp 110 Spring washer
15 O-ring 60 Clamp 111 Clip
21 Wire harness - switch 71 Pipe 112 U-bolt
22 Cover 72 Pipe 113 Elbow - 90°
23 Pressure switch 73 Pipe 114 Elbow - 90°
24 Line rupture valve 74 Clamp 115 Plug
25 Bracket 75 Clamp 116 Elbow
26 Pipe 76 Clamp 117 Hose
27 Block 77 Pipe 118 Hose
28 Block 78 Pipe 119 Hose
29 Screw 79 Pipe 120 O-ring
30 Screw 80 Pipe 121 O-ring
31 Screw 81 Screw 122 O-ring
32 Screw 82 Screw 123 O-ring
33 Spring washer 83 Screw 124 O-ring
34 Spring washer 84 Screw 125 O-ring
35 Spring washer 85 Screw 126 Clamp
36 Tee 86 Screw 127 Nut
37 Tee 87 Flat washer 128 Plate
38 Tee 88 Spring washer 129 Nut
39 Connector 89 Spring washer 130 Tee
40 Connector 90 Clamp 131 Tee
41 Elbow - 90° 91 Clamp 132 Connector
42 Elbow - 90° 92 Clamp 133 Connector
43 Elbow - 90° 93 Hose 134 Hose
44 Elbow 94 Hose 135 Hose
45 Cu-washer 95 Hose 136 Hose
Service Information

Pump, assembly 9131 Service Information 2014/5/31
Profile:
Pump, assembly
Preparation
 Rework damaged parts before assembling, and prepare all replacement parts.
 Coat the sliding parts, bearing, etc. with clean hydraulic oil.
 Replace the o-ring and oil seals.
 Take care not to mix the parts of the front pump with the parts of the rear pump.
 Align the match marks of the pump casing parts and the regulators.
Assembly, pump
No. Procedure Remark

1 Fit swash plate support (251) to pump casing (271), tapping it Fit servo piston, tilting pin, stopper (L) (534) and
lightly with a hammer. stopper (S) (535) to the pump casing in advance of
assembling the swash plate support.
In tightening servo piston and tilting pin, use a jig to

prevent the tilting pin head and feedback pin from
being damaged.
In addition, apply loctite (medium strength) to their
threaded sections.
2 Place pump casing on its regulator fitting surface, fit tilting Confirm with fingers of both hands that the swash
bushing of swash plate to tilting pin (531), and fit swash plate plate can be moved smoothly.
(212) to swash plate support (251).
Apply grease to the sliding plate and swash plate
support, so the drive shaft can be fitted easily.
3 Fit drive shaft (111) with bearing (123), bearing spacer (127) Do not tap the drive shaft with a hammer.
and snap ring (824) to swash plate support (251). Assemble the parts into support (251) by tapping
the outer bearing race lightly with a plastic hammer.
Fit them fully using a brass drift.
4 Assemble seal cover (F) (261) to pump casing (271) and install Apply grease lightly to the oil seal in seal lip cover
screws (406). (F).
Assemble oil seal, taking care not to damage it.
For tandem type pump, fit rear cover (262) and seal
cover (261) similarly.
5 Assemble piston cylinder block [cylinder (141), piston Match the splines of spherical bushing (156) and
subassembly (151, 152), set plate (153), spherical bushing cylinder block (141).
(156), spacer (158) and cylinder spring (157)]. Then, insert the Then match to the splines of drive shaft (111).
cylinder block assembly into the pump casing. NOTE!
Ensure that the pistons are installed in their original
bores.
6 Fit valve plate (313, 314) to valve block (312), inserting pin into Take care not to mistake suction/delivery ports of
pin hole. the valve plate.
Suction port is the long crescent slot.
Apply grease to the valve plate fitting face to hold it

to the valve block.
7 Fit valve block (312) to pump casing (271) and tighten screw Assemble (312) to the rear pump first.
(401).
Take care not to mistake the direction of valve block
(312).
 Clockwise rotation (viewed from input shaft

side). Fit block with regulator up and with
delivery flange left, viewed from the front
side.
8 Fit feedback pin of tilting pin (531) to feedback lever of Take care not to interchange the front and rear
regulator. Install regulator and tighten screws (412, 413). pump regulators.
Align the match marks made prior to disassembly.
9 Fit drain port plug (468). This is the end of reassembling After assembling, fill with hydraulic oil to prevent
procedures. corrosion.
When mounting to a machine, fill with hydraulic oil
and bleed the air from the pump circuit.
Service Information

Pump, description 9131 Service Information 2014/5/31
Profile:
Pump, description
Model code
Symbol Description
K3V K3V series
112 Size (Displacement : cc/rev)
DT S : Single
DT : Tandem type double pump
P PTO attached type
10E Design series number
R Shaft rotation viewed from shaft end
R : Clockwise
L : Counterclockwise
9N34 Regulator type :
For more details, see the section for the regulator.
Structure, main pump

Figure 1
Structure, main pump
1. Set screw minimum flow

2. Eye bolt
3. Set screw maximum flow
Port connection
Port Port name Port size

A1, 2 Delivery SAE 6000 … 3/4″
B1 Suction SAE 2500 … 2 1/2″
Dr Drain PF 3/4″ - 20
Pi1, 2 Servo hydraulic PF 1/4″ - 15
Pm1, 2 Control PF 1/4″ - 15
Psv Servo assist PF 1/4″ - 16
A3 Gear pump delivery PF 1/2″ - 16
B3 Gear pump suction PF 3/4″ - 17
a1, 2, 3 Gauge PF 1/4″ - 15
Pump, sectional view
Figure 2
Main pump (sectional view)
05 PTO assembly 263 Seal cover (rear) 702 O-ring

111 Driving shaft (front) 271 Pump casing 710 O-ring
113 Driving shaft (rear) 312 Valve block 717 O-ring
116 Gear 313 Valve plate (right) 725 O-ring
123 Roller bearing 314 Valve plate (left) 728 O-ring
124 Needle bearing 401 Screw 732 O-ring
127 Bearing spacer 406 Screw 774 Oil seal
141 Cylinder block 466 Vp plug 789 Back-up ring
151 Piston 468 Vp plug 792 Back-up ring
152 Shoe 490 Plug 808 Lock nut
153 Set plate 531 Tilting pin 809 Lock nut
156 Spherical bushing 532 Servo piston 824 Snap ring
157 Cylinder spring 534 Stopper (L) 885 Valve plate pin
158 Spacer 535 Stopper (S) 886 Spring pin
211 Shoe plate 541 Seat 901 Eye bolt
212 Swash Plate 543 Stopper 953 Adjusting screw
214 Tilting bushing 544 Stopper 954 Adjusting screw
251 Swash plate support 545 Steel ball 981 Name plate
261 Seal cover (front) 548 Feedback pin 983 Pin
PTO, structure
Figure 3
PTO structure
115 Shaft 414 Screw

117 2nd gear 466 Plug
118 3rd gear 725 O-ring
125 Ball bearing 825 Retaining ring
126 Roller bearing 826 Retaining ring
128 Bearing spacer 827 Retaining ring
326 Gear case 886 Pin
Pump, principle of operation
 This pump assembly consists of two pumps connected by spline coupling (114). The two pumps are driven
simultaneously as the engine rotation is transmitted to the front drive shaft (111).
The suction and delivery ports are integrated at the connecting section of the two pumps, in valve block (312) : The
common suction port serves both the front and rear pumps.
Structure and operating principle of front and rear pump is the same so front pump only will be explained. The
pump consists of rotary group, swash plate group and valve block group.
 The rotary group consists of front drive shaft (111), cylinder block (141), piston and shoe (151, 152), set plate (153),
spherical bushing (156), spacer (158), and cylinder spring (157). The drive shaft is supported by bearings (123, 124).
The shoe is caulked to the piston to form a spherical coupling. It has a pocket to relieve thrust force generated by
loading pressures and create a hydraulic balance so that it slides lightly over shoe plate (211).
The sub group composed of a piston and a shoe is pressed against the shoe plate by the action of the cylinder
spring through the set plate and spherical bushing. Similarly, the cylinder block is pressed against valve plate (313)
by the action of the cylinder spring.
 The swash plate group consists of swash plate (212), shoe plate (211), swash plate support (251), tilting bushing
(214), tilting pin (531) and servo piston (532). The swash plate is supported by a cylindrical part on the opposite side
of its sliding surface and swash plate support (251).
The servo piston moves to the right and the left as hydraulic oil controlled by the regulator flows to a hydraulic
chamber located on both sides of the servo piston. The force exerted on the tilting pin by the servo piston causes
the swash plate to slide on support (251) to change the tilting angle (α).
 The valve block group consists of valve block (312), valve plate (313) and valve plate pin (885). The valve plate which
has two crescent ports is attached to the valve block to feed oil to and collect oil from the cylinder block. The oil
discharged via the valve plate is routed to an external pipe line by way of the valve block.
 The pump shaft driven by the engine, rotates the cylinder block via the splined bore. If the swash plate is tilted the
pistons arranged in the cylinder block make a reciprocating motion with respect to the cylinder block, while they
revolve with the cylinder block.
A single piston will perform a 180° motion away from the valve plate (oil suction stroke) and then make another
180° motion towards the valve plate (oil discharging stroke) as the cylinder block rotates. When the swash plate
tilting angle is zero, the piston does not stroke or discharge oil.
Figure 4
Moving, swash plate
1. Servo piston
2. Tilting pin
Adjustment of maximum flow

Adjust it by loosening hexagon nut (809) and by tightening (or loosening) adjusting screw (954).
Only the maximum flow is adjusted without changing other control characteristics.
 For the location of adjusting screw and nut, See [Invalid linktarget] .
Figure 5
Adjustment of maximum flow
X. Servo hydraulic pressure Pi
Y. Delivery flow, Q
Adjustment of minimum flow

Adjust it by loosening hexagon nut (808) and by tightening (or loosening) adjusting screw (953).
Similar to the adjustment of the maximum flow, other characteristics are not changed. However, if tightened too much, the
required horsepower for the maximum delivery pressure (or for relief) may increase.
Figure 6
Adjustment of minimum flow
Y. Delivery flow, Q
Service Information

Pump, disassembly 9131 Service Information 2014/5/31
Profile:
Pump, disassembly
Tools
The tools necessary to disassemble/reassemble the K3V pump are shown in the following list. The sizes of the screws and
plugs depend on the pump type.
Tools
Tool Size Necessary tool Description

(Marked with *)
Pump type
Name B mm K3V 63 K3V K3V K3V Screw PT plug (PT PO plug (PF Set screw
112 140 180 thread) thread)
Allen wrench 2 M4
2.5 M5
3 M6
4 * * * * M5 BP-1/16 M8
5 * * * * M6 BP-1/8 M10
6 * * * * M8 BP-1/4 PO-1/4 M12 M14
8 * * * * M10 BP-3/8 PO-3/8 M16 M18
10 M12 BP-1/2 PO-1/2 M20
12 M14
14 * M16 M18 BP-3/4 PO-3/4
17 * * * M20 M22 BP-1 PO-1, 1 1/4, 1
1/2
19 M24 M27
21
22 M30 PO-2
Box end spanner 19 * * * * M12 N12 VP-1/4
Hexagon socket 22 VP-3/8
Open end spanner
24 * * * M16 M16
27 * * * M18 M18 VP-1/2
30 * * * M20 M20
36 * * * VP-3/4
41 VP-1
50 VP-11/4
55 VP-11/2
Adjustable wrench * * * * Medium size.
Screwdriver * * * * Blade type screwdriver, medium size, 2 sets.
Hammer * * * * Plastic hammer.
Pliers * * * * For snap ring, TSR-160
Brass bar * * * * Approximately 10 x 8 x 200 mm
Torque wrench * * * * Capable of tightening to the specified torque.
Precautions
 Thoroughly clean the pump assembly prior to disassembly.

 Match mark the pump casing parts and the regulators to indicate proper positioning during reassembly.
 Take care not to mix the parts of the front pump with the parts of the rear pump.
 Thoroughly clean all parts and the inside of the casing.
 Inspect and analyze all failures. Determine the root cause!
Disassembly
Disassembly, pump

1 Select a place suitable for disassembly. Spread a rubber sheet or cloth on the workbench to
prevent parts from being damaged.
2 Remove dust, rust, etc., from pump surfaces with cleaning
solvent.
3 Remove drain port plug (468) and drain oil from the pump For tandem type pump, remove plugs from the front
casing and the rear pumps.
4 Remove screws (412, 413) and remove the regulator. See regulator section for disassembly.
NOTE!
Mark each regulator to match the pump.
5 Remove screws (401) which hold swash plate support (251), If a gear pump is fitted to the rear face of the pump,
pump casing (271) remove it before starting this work.
and valve block (312).
6 Place the pump horizontally on a workbench with regulator- Spread a rubber sheet on the workbench to prevent
fitting surface facing down, and separate pump casing (271) this surface from being damaged.
from valve block (312).
7 Pull cylinder (141) out of pump casing (271) straight over drive Take care not to damage sliding surfaces of the
shaft (111). Pull out piston (151), set plate (153), spherical cylinder, spherical bushing, shoes and swash plate,
bushing (156) and cylinder springs (157) simultaneously. etc.
NOTE!
Mark the pistons and respective cylinder bores.
Pistons must be installed into the same bores
because of wear pattern.
8 Remove screws (406) and front seal cover (261). Fit screws into pull-out tapped holes (M6) of seal
cover (F), so it can be removed easily.
Since an oil seal is fitted to the seal cover, take care

not to damage it during disassembly.
9 Remove screws (408) and rear seal cover (262).

10 Tap lightly the flange section of swash plate support (251) on
the pump casing side to separate swash plate support from
pump casing (271).
11 Remove shoe plate (211) and swash plate (212) from pump
casing (271).
12 Tap lightly the ends of drive shafts (111, 113) with a plastic
hammer to remove them from the swash plate supports.
13 Remove valve plates (313, 314) from valve block (312). These may be removed in step 6.
14 If necessary, remove stopper (L) (534), stopper (S) (535), servo When removing the tilting pin, use a jig to prevent
piston (532) and tilting pin (531) from pump casing (271), and the pin head from being damaged.
needle bearing (124) and splined coupling (114) from valve
block (312). Since loctite is applied to fitting areas of tilting pin
and servo piston, take care not to damage the servo
piston.
Do not remove the needle bearing except when it is

to be replaced.
CAUTION
Do not loosen hexagon nuts (808) and set screws
(953, 954). If loosened, the flow setting will be
changed.
Disassemble the hydraulic pump PTO assembly as follows :

Disassembly, hydraulic pump PTO assembly

2 Remove dust, rust, etc., from pump surfaces with cleaning
solvent.
3 Remove drain port plug (468) and drain oil from pump casing. For tandem type pump, remove plugs from the front
and the rear pumps.
4 Remove screws and remove the gear pump.
5 Remove screws(414) and remove the PTO assembly.
6 Remove retaining ring (827), idle shaft (115) and 2nd speed Do not remove roller bearing (126) from 2nd speed
gear (117), roller bearing, bearing spacer (128). gear (117).
7 Remove retaining ring (825), 3rd speed gear (118) and ball Do not remove roller bearing (125) from 3rd speed
bearing (125). gear.
NOTE!
Bearing is press fitted.
8 Assembly procedure is reverse of disassembly.

Service Information

Pump, installation 9131 Service Information 2014/5/31
Profile:
Pump, installation
Precautions, start-up
 Fill the pump casing with hydraulic oil.

 Vent the air from the pump circuit.
 Check that all hoses and pipes are properly connected.
 After starting the engine, operate at low idle for a while to completely vent the air from the circuit.
CAUTION
If there is air in the hydraulic system, sliding parts may be damaged.
Precautions, installation
 Keep the pump shaft horizontal during installation to the pump coupling.
 Ensure that there is neither a radial nor thrust load on the end of the pump shaft.
 When centering the pump shaft and the coupling, keep the alignment within ± 0.03mm.
 Use a torque wrench to tighten all screws and fittings to the specified torque.
Figure 1
Installation, pump
Precautions, tightening torque

Symbol Description Tightening torque Remark

A M18 × 2.5 × 60L 31 ~ 33 (224 ~ 238) Apply loctite # 277
B M18 × 2.5 × 55L
C M20 (10.9 and more, JIS) 37.4 ∼ 50.6 (270 ∼ 365)
D M16 × 2.0 × 16L 10 ~ 12 (72 ~ 87)
E M10 × 35L 3.4 (25)
F M15 × 35L 4 ~ 4.5 (29 ~ 33) Retighten
Service Information

Pump, maintenance 9131 Service Information 2014/5/31
standard
Profile:
Pump, maintenance standard

Precautions for usage
Precautions
Item Description
• Long term storage
 Long term storage of more than 1 year is not recommended.
 If installed in a machine, operate it occasionally.
 If in stock inventory, rotate the pump shaft occasionally.
 If in storage more than 1 year consider overhaul.
• Rotating direction
 Rotating direction of pump is depicted on the name plate.
Lubrication and air purging

Precautions
Item Cautions
• Lubrication
 Fill the pump casing through P1, P2 delivery ports with the specified hydraulic oil.
 Following repair or replacement of the pump it is necessary to prelubricate the
internal components to prevent scoring, scuffing, seizure of the bearing and
sliding parts.
• Air purging
 Following hydraulic system repairs, purge the air from the pump circuit by
loosening the upper plug in the pump casing.
Start-up
 Check that there is no contamination in the ports or plumbing before connecting to the pump.
 Check the direction of rotation and the suction/delivery direction.
 Check the oil level in the hydraulic tank.
 At initial start-up run the engine at idle to purge the air in the circuit.
 Check for oil leakage on the pump assembly.
 Check for abnormal sound or vibration.
 Check for any abnormal temperature increase after running for a short time.
General precautions
 Determine the nature of the abnormality, before disassembling. Especially, check if the problem is in the circuit, or
caused by the regulator, auxiliary valves, defective pump, or motor.
 Read the maintenance manual thoroughly before disassembling, and then follow the procedures carefully.
 When any section is to be disassembled, pay attention not to allow contamination into the pump.
 Since the parts are precision finished, handle them carefully to prevent damage.
Check of pump for abnormalities
The pump is usually fitted with a regulator, auxiliary valves or an auxiliary pump, so it may be difficult to find the cause of
failure. Check the following principal items, to identify the abnormality.
Check of filter and drain oil
Check the filter elements for abnormal impurities. As the shoes and cylinder wear, a small quantity of metal particles may be
detected. However, if a considerable amount of metal particles are found, the shoes may be damaged. Similarly, check the
drain oil in the pump casing.
Check of abnormal sound or vibration
Check the pump for abnormal sound and vibration. If any, check if it is a noise of regular frequency, such as hunting of the
regulator or the relief valve. If it is an abnormal vibration or sound, it may result from cavitation or damage inside the pump.
Check of circuit where two pumps are used
For the circuit with two single pumps or a tandem double pump, exchange the piping of one pump with that of the other
one. With the results of this exchange, it will be determined if the trouble is with the pump or a component downstream of
the pump.
Pressure measurement at various points
If the failure is a problem in control, do not overhaul the pump needlessly, but measure pressures at various points in the
circuit.
Standard for parts service and replacement
When a part exceeds any of the following criteria, replace or readjust it. However, when a part is damaged seriously in
appearance, replace it without fail.
Standard wear limit, unit: mm (inch)
Part name and Standard dimension/Recommended replacement value Remedy

inspection Pump type
item
K3V63 K3V112 K3V140 K3V180
Clearance 0.028/0.056 0.039/0.067 0.043/0.070 0.0375/0.078 Replace
between piston (0.0011/0.0022) (0.0015/0.0026) (0.0017/0.0027) (0.0015/0.0031) piston
and cylinder or cylinder.
bore (D-d)
Play between 0.1/0.3 0.1/0.3 0.1/0.3 0.1/0.35 Replace
piston and shoe (0.004/0.012) (0.004/0.012) (0.004/0.012) (0.004/0.014) piston and
caulking shoe
section(d) assembly.
Thickness of 3.9/3.7 4.9/4.7 5.4/5.0 5.4/5.0 Replace
shoe(t) (0.153/0.146) (0.192/0.185) (0.212/0.197) (0.212/0.197) piston and
shoe
assembly.
Free height of 31.3/30.5 41.1/40.3 47.9/47.1 40.9/40.1 Replace
cylinder (1.232/1.200) (1.618/1.586) (1.886/1.854) (1.610/1.578) cylinder
spring(L) spring.
Assembled 10.5/9.8 12.0/11.0 13.5/12.5 13.5/12.5 Replace
height of set plate (0.413/0.386) (0.47/0.43) (0.531/0.492) (0.531/0.492) set plate or
and spherical spherical
bushing (H-h) bushing.
Figure 1
Wear limit of parts
Repair standards for cylinder, valve plate and swash plate

Repair standards
Surface roughness of cylinder, Surface roughness requiring 3Z

valve plate and swash plate correction
Standard surface roughness 0.4Z max.(lapping)
(correction value)
CAUTION
Lap the cylinder and valve plate together to correct the surface roughness.
Tightening torque
Tightening torque
Description Size Tightening torque B Tool

kgf·m (lbf·ft) (mm)
Screw (Material : M5 0.7 (5.1) 4 Allen wrench
SCM 435) M6 1.2 (8.7) 5
M8 3.0 (22) 6
M10 5.8 (42) 8
M12 10 (72) 10
M14 17 (120) 12
M16 24 (170) 14
M18 34 (250) 14
M20 44 (320) 17
PT plug PT 1/16 0.7 (5.1) 4 Allen wrench
(Material : S45C) PT 1/8 1.05 (7.6) 5
PT 1/4 1.75 (13) 6
CAUTION PT 3/8 3.5 (25) 8
PT 1/2 5.0 (36) 10
Apply loctite # 577
PO plug PF 1/4 3.0 (22) 6 Allen wrench

(Material : S45C) PF 1/2 10 (72) 10
PF 3/4 15 (110) 14
PF 1 19 (140) 17
PF 1 1/4 27 (190) 17
PF 1 1/2 28 (200) 17
Service Information

Pump, troubleshooting 9131 Service Information 2014/5/31
Profile:
Pump, troubleshooting
Troubleshooting, overload of engine
Cause Remedy Remark

Revolution and pressure are higher than Set to specification.
set values.
Regulator torque is set higher than Readjust regulator. See regulator section.
normal.
Regulator is operating abnormally. Replace faulty parts.
Pump internal parts are seized or Replace faulty parts. Check filter and drain oil to see if
broken. abnormal wear particles are present.
Troubleshooting, pump oil flow is extremely low and discharge pressure is not raised
Cause Remedy Remark

Regulator is faulty. Repair regulator. See regulator section.
Pump internal parts are seized or Replace damaged parts. Check filters and drain oil.
broken.
Auxiliary pump is faulty. Replace auxiliary pump. Remove auxiliary pump and check
shaft coupling.
Servo hydraulic relief valve is faulty. Check servo hydraulic relief valve. See servo hydraulic relief valve
Particularly poppet, seat and spring. section.
Troubleshooting, abnormal noises and abnormal vibrations
Cause Remedy Remark

Cavitation Prevent cavitation.
Check if hydraulic oil is cloudy.  Hydraulic oil is insufficient.
 Auxiliary pump is damaged.
 Suction pipe is drawing air.
 Suction ports are blocked.
Caulked part of shoe is broken. Replace piston assembly and shoe plate.
Cylinder is cracked. Replace cylinder.
Pump is installed improperly. Correct installation.
Regulator is hunting. Repair regulator. See regulator section.
Servo hydraulic relief valve is hunting. Repair/replace valve. See servo hydraulic relief valve
section.
Service Information

Change of value by 9139 Service Information 2014/5/31
adjusting regulator
Profile:
Change of value by adjusting regulator

Change of value by adjusting regulator
Item Specification
Hydraulic pump rotating speed rpm 2100
Maximum flow Turn of adjusting screw (954) +1/4
Flow, lpm (U.S.gpm) - 6 (- 1.6)
Minimum flow Turn of adjusting screw (953) - 1/4
Flow, lpm (U.S.gpm) + 5 (+ 1.3)
Input horsepower Adjusting of outer Turn of adjusting screw (628) + 1/4
spring Pressure at compensating control start, delta P + 19 (+270)
kgf/cm2 (psi)
Input torque, delta T kgf·m (lbf·ft) + 5 (+ 36)
A 1.9
Adjusting of inner Turn of adjusting screw (QI, 628) + 1/4
spring Flow, lpm (U.S.gpm) + 18 (+4.8)
Input torque, delta T kgf·m (lbf·ft) +8 (+ 58)
Flow control characteristic Turn of adjusting screw (924) + 1/4
Pressure at flow control start, kgf/cm2 (psi) + 1.9 (+27)
Flow, lpm (U.S.gpm) + 13 (+3.4)
Service Information

Pump control curves 9139 Service Information 2014/5/31
Profile:
Pump control curves
Figure 1
Pump control curve
Service Information

Regulator, assembly 9139 Service Information 2014/5/31
Profile:
Regulator, assembly
Preparation
NOTE!
The parts are small and light weight. Take care not to lose them.
 Rework scored parts before assembling, and prepare all replacement parts.
 Replace the o-rings and seals.
 Align the match marks of the regulator to the pump casing.
Assembly, regulator

1 Put compensating rod (623) into compensating hole of casing
(601).
2 Put lever (1) (612) force-fitted pin into the compensating rod
groove, then fit lever (1) to the pin in the casing.
3 Fit spool (652) and sleeve (651) into the casing spool hole. Confirm that spool and sleeve slide smoothly in
casing without binding.
NOTE!
Pay attention to orientation of the spool.
1. Spool
2. Feedback lever
4 Fit feedback lever (611), matching its pin hole with the hole in Insert pin into feedback lever a little to ease -
the spool. Then insert pin (874). operation.
NOTE!
Take care not to mistake direction of feedback lever.
1. Lever (1) side

2. Lever (2) side
(Fulcrum plug of adjusting plug side)
5 Put servo hydraulic piston (643) into negative control hole of Confirm that servo hydraulic piston slides smoothly
casing. without binding.
6 Put the pin force-fitted in lever (2) (613) into the groove of the
servo hydraulic piston. Then fix lever (2).
7 Fit fulcrum plug (614) so that the pin force-fitted in fulcrum

plug (614) can be put into the pin hole of lever (2). Then fix
locking ring (858).
8 Insert adjusting plug (615) and fit locking ring. NOTE!

Take care not to mistake inserting holes for fulcrum
plug and adjusting plug.
At this point move feedback lever to confirm that it

has no excess play and is free from binding.
9 Fit return spring (654) and spring seat (653) into the spool Pay attention to the orientation of the spring seat.
hole and attach snap ring (814).
10 Fit set spring (655) to spool hole and put compensating piston
(621) and piston case (622) into compensating bore.
Fit servo hydraulic cover (641) and tighten it with screws (436,
438).
11 Put spring seat (644), servo hydraulic spring (646) and NOTE!
adjusting ring (Q) (645) into the servo hydraulic hole. Pay attention to the orientation of the spring seat.
Then fix spring seat (624), inner spring (626) and outer spring
(625) into the compensating hole.
12 Install cover (C) (629) fitted with adjusting screws (628) (925),
adjusting ring (C) (627), lock nut (630), hexagon nut (801) and
adjusting screw (924).
Then install screws (438).
Service Information

Regulator, description 9139 Service Information 2014/5/31
Profile:
Regulator, description
Model code (KR3G-9N34)
Symbol Description Remark

KR3 Regulator for K3V series pump
G Size
6 : K3V63
G : K3V112
H : K3V140, K3V180
9 Type of horsepower control
1 : Rated horsepower control
2 : Total cumulative horsepower control
3 : Pressure cut-off control
5 : Rated horsepower control + Pressure cut-off control
6 : Total cumulative horsepower control + Pressure cut-off control
9 : Total cumulative horsepower control + Power shift control
N Type of flow control
O : No of control
N : Negative flow control
P : Positive flow control
M : Manual flow control
E : Electric flow control
C : Negative flow control (Maximum flow cut control)
D : Positive flow control (Flow cut control attached)
34 Regulator design series number
Regulator, Sectional view

Figure 1
Sectional view, regulator
412 Screw 628 Screw (C) 730 O-ring

413 Screw 629 Cover (C) 732 O-ring
436 Screw 630 Lock nut 733 O-ring
438 Screw 631 Sleeve 734 O-ring
496 Plug 641 Servo hydraulic cover 735 O-ring
531 Tilting pin 643 Servo hydraulic piston 755 O-ring
548 Feedback pin 644 Spring seat (Q) 756 O-ring
601 Casing 645 Adjusting ring (Q) 763 O-ring
611 Feedback lever 646 Servo hydraulic spring 801 Nut
612 Lever (1) 651 Sleeve 814 Snap ring
613 Lever (2) 652 Spool 836 Snap ring
614 Plug 653 Spring seat 858 Snap ring
615 Plug 654 Return spring 874 Pin
621 Piston 655 Adjusting spring 875 Pin
622 Piston case 656 Cover 887 Pin
623 Rod 708 O-ring 897 Pin
624 Spring seat (C) 722 O-ring 898 Pin
625 Outer spring 724 O-ring 924 Adjusting screw
626 Inner spring 725 O-ring 925 Adjusting screw
627 Ring (C) 728 O-ring
Port connection
Port Port name Port size

Pi Negative servo hydraulic pressure signal port PF 1/4
P2 Companion pump servo hydraulic pressure port PF 1/4
Pf Secondary servo hydraulic pressure port on proportional solenoid valve PF 1/4
Tightening torque
Item Size Tightening torque

N·m kgf·cm lbf·ft
412, 413 M8 29.4 300 21.6
436, 438 M6 11.8 120 8.6
496 NPTF 1/16 8.8 90 6.5
630 M30 x 1.5 156.8 1600 115.0
801 M8 15.7 160 11.5
Regulator, principle of operation

Schematic
In-line type axial piston pump regulator consists of following controllers.
Horsepower control
As the delivery pressure of the pump P1 and mate pump P2 are raised, the delivery flow rate will be reduced automatically,
so the input torque will be regulated to a certain value.
(When the rpm is constant, the input horsepower will become constant also.)
The regulator is the total cumulative horsepower type, that operates by the sum of load pressures of the two pumps in the
tandem double pump system. Therefore the engine can be automatically prevented from being overloaded regardless of the
loading conditions on the two pumps.
Power shift control
The horsepower setting will be changed by changing the instruction current of the proportional solenoid valve attached to
the regulator. Only one proportional solenoid valve is provided. However, secondary pressure Pf (power shift pressure) flows
into the horsepower control portion of each pump regulator through the pump inner passage, and shifts it to same
horsepower setting, respectively.
Delivery flow rate of the pump can be changed, so the proper power level suitable for the work conditions can be acquired.
Negative flow control
Delivery rate of the pump can be controlled by varying the servo hydraulic pressure Pi.
This regulator is the negative flow control type which reduces delivery rate Q according to the increase of servo hydraulic
pressure Pi. If the servo hydraulic pressure corresponding to the flow required for the work is designated, the pump will
deliver only the required oil so unnecessary power consumption will be prevented.
This regulator has 3 control functions as above, however when different control functions act at the same time, low oil flow
instruction will have priority by the mechanical operation.
Figure 2
Structure, regulator
X Large end part 625 Outer spring

Y Small end part 626 Inner spring
531 Tilting pin 646 Servo hydraulic spring
548 Feedback pin 651 Sleeve
611 Feedback lever 652 Spool
612 Lever-1 654 Return spring
613 Lever-2 875 Pin
621 Compensating piston 897 Pin
623 Compensating rod 898 Pin
Regulator, negative flow control

According to the change of the servo hydraulic pressure Pi, the delivery flow is regulated, as shown.
The regulator is negative flow control type, so the delivery flow Q decreases as the servo hydraulic pressure Pi increases.
When the servo hydraulic pressure corresponding to the flow required for the work is commanded, the pump discharges the
required flow only, so it does not consume power needlessly.
Figure 3
Negative flow control chart
X. Servo hydraulic pressure, Pi
Y. Delivery flow. Q
Flow reducing function

As the servo hydraulic pressure Pi rises, servo hydraulic piston (643) moves right to a position where the force of servo
hydraulic spring (646) is balanced with the hydraulic force.
Groove “A” in the servo hydraulic piston is fitted with pin (875) that is fixed to lever 2 (613).
Therefore, when the servo hydraulic piston moves, lever 2 rotates around the fulcrum of point “B” [Fixed by fulcrum plug
(614) and pin (875)].
Since the large hole section “C” of lever 2 contains protruding pin (897) fixed to feedback lever (611), pin (897) moves to the
right as lever 2 rotates. Since the opposed flat section “D” of the feedback lever is fitted with pin (548) fixed by the tilting pin
(531) that slews the swash plate, the feedback lever rotates around the fulcrum of point “D”, as pin (897) moves.
Since the feedback lever is connected with spool (652) through pin (874), the spool moves to the right. The movement of the
spool causes the delivery pressure P1 to flow to port (Cl) through the spool and be admitted to the large-diameter section
of the servo piston.
The delivery pressure P1 that is constantly admitted to the small diameter section of servo piston moves the servo piston
right due to the area difference, resulting in a decrease of the tilting angle.
When the servo piston moves to the right, point “D” also moves right. The spool is fitted with return spring (654) and is
tensioned to the left at all times, so pin (897) is pressed against the large hole section “C” of lever 2.
Therefore, as point “D” moves, the feedback lever rotates around the fulcrum of point “C”, and the spool is shifted to the left.
This causes the opening between sleeve (651) and spool (652) to close slowly, and the servo piston stops when it is closed -
completely.
Flow increasing function
As the servo hydraulic pressure Pi decreases, servo hydraulic piston (643) is moved to the left by the action of servo
hydraulic spring (646), and lever 2 (613) is rotated around the fulcrum of point “B”. Since pin (897) is pressed against the
large hole section “C” of lever 2 by the action of the return spring (654) through spool (652), pin (874), and feedback lever
(611), the feedback lever rotates around the fulcrum of point “D” as lever 2 rotates, and shifts the spool to the left.
As the spool moves, port (Cl) opens a path to the tank port. This cuts off the pressure to the large diameter section of the
piston, and the servo piston shifts left due to delivery pressure P1 on the small diameter section, resulting in an increase of
the flow rate.
As the servo piston moves, point “D” also moves to the left, the feedback lever rotates around the fulcrum of point “C”, and
the spool moves right until the opening between the spool and sleeve is closed.
Regulator, total horsepower control
The regulator decreases the swash plate tilting angle (delivery flow) when the load pressure is increased to prevent engine
overload.
Since this regulator is the total cumulative horsepower type, it controls the tilting angles (displacement volumes) of the two
pumps to the same value as represented by the following equation:
Tin = P1 x Q/2π + P2 x Q/2π = (P1 + P2) x Q/2π
The horsepower control function is the same as the flow control function and is summarized as follows:
(For details of respective parts, see the section on flow control.)
Figure 4
Total horsepower control chart
X. Delivery pressure, (P1 + P2)

Y. Delivery flow, Q
Overload preventive function

When the pump delivery pressure P1 or the mate pump delivery pressure P2 rises, it acts on the stepped part of
compensating piston (621). It presses compensating rod (623) to the right till the force of outer spring (625) and inner spring
(626) is balanced with the hydraulic force.
The movement of the compensating rod is transmitted to lever 1 through pin (875), and lever 1 rotates around pin (875) “E”
fixed to casing (601). Since the large hole section “E” of lever 1 contains protruding pin (897) fixed to feedback lever (611),
the feedback lever rotates around the fulcrum of point “D” as lever 1 rotates, and spool (652) is shifted to the right.
As the spool moves, delivery pressure P1 flows to the large-diameter section of the servo piston through port (Cl), the servo
piston is moved to the right, the pump delivery flow rate is reduced, and the engine is prevented from being overloaded.
The movement of the servo piston is transmitted to the feedback lever through point “D”.
Then the feedback lever rotates around the fulcrum of point “F” and the spool moves to the left until the opening between
the spool and sleeve (651) is closed completely.
Flow reset function
As the pump delivery pressure P1 or the mate pump delivery pressure P2 decreases, compensating rod (623) is pushed back
by the action of springs (625, 626) and lever 1 is rotated around the fulcrum of point “E”.
Rotating of lever 1 causes the feedback lever to rotate around the fulcrum of point “D” and the spool moves to the left. As a
result, port (Cl) opens a path to the tank port, and the servo piston moves left as the pressure to the large diameter section
is released, resulting in an increase of the pump delivery rate.
The movement of the servo piston is transmitted to the spool by the action of the feedback mechanism till the opening
between the spool and sleeve is closed.
Regulator, low tilting angle (low flow) command priority function
As mentioned, the tilting angle commands of flow control and horsepower control are transmitted to the feedback lever and
the spool through the large hole sections “C”, “E” of levers 1 and 2, respectively. However, since sections “C” and “E” have the
pins (ø 4) protruding from the large hole (ø 8), the lever contacts pin (897) only when the tilting angle is lessened. If the
tilting angle command is larger, it is free without contacting pin (897) in the large hole (ø 8). Such a mechanical selection
method permits priority of the low tilting angle command of flow control and horsepower control.
Regulator, power shift control
The power shift pressure Pf controls the set horsepower of the pump to a desired level, as shown in the figure.
As the power shift pressure Pf rises, compensating rod (623) moves right through pin (898) and compensating piston (621).
This decreases the pump tilting angle and the set horsepower in the same way as explained in the overload preventive
function of the horsepower control.
On the contrary, the set horsepower rises as power shift pressure Pf falls.
Figure 5
Power shift control chart
X. Delivery pressure, (P1 + P2)
Y. Delivery flow, Q
Service Information

Regulator, disassembly 9139 Service Information 2014/5/31
Profile:
Regulator, disassembly
Precautions
 Thoroughly clean the pump prior to removing the regulators.

 Match mark the regulators to the pump casing.
 Take care not to mix the parts of the front regulator with the parts of the rear regulator.
 It is not necessary to loosen or remove the adjusting screws for cleaning.
 Replacement of the regulator as an assembly is recommended, since it consists of small precision finished parts and
overhaul is rather complicated.
Tools
Tools
Description Size
Allen wrench 4, 5, 6 mm (B)
Socket wrench, double ended (single ended) Compact (maximum 36 mm)
Adjustable wrench
Screwdriver-blade type
Plastic hammer
Torque wrench
Pliers snap ring
Pry bar Less than ø 4, L = 100
Tweezers
Screw M4, L = approximately 50 mm
Tightening torque
Tightening torque, unit : kgf·cm (lbf·in)
Description Size Tightening torque B (mm) Tool

Screw M5 70 (60) 4 Allen wrench
(Material : SCM 435) M6 120 (105) 5
M8 300 (260) 6
M10 580 (500) 8
M12 1000 (870) 10
M14 1600 (1390) 12
M16 2400 (2080) 14
M18 3400 (2945) 14
M20 4400 (3810) 17
PT plug (Material : S45C) Apply loctite PT 1/16 70 (60) 4 Allen wrench
# 577 PT 1/8 105 (90) 5
PT 1/4 175 (150) 6
PT 3/8 350 (260) 8
PT 1/2 500 (430) 10
PO plug (Material : S35C) PF 1/4 300 (260) 6 Allen wrench
PF 1/2 1000 (870) 10
PF 3/4 1500 (1300) 14
PF 1 1900 (1650) 17
PF 1 1/4 2700 (2340) 17
PF 1 1/2 2800 (2420) 17
Regulator, disassembly
Disassembly, regulator

2 Remove dust, rust, etc. from regulator surfaces with cleaning
solvent.
3 Remove screws (412, 413), and remove the regulator. NOTE!
Take care not to lose the o-ring.
4 Remove screws (438), and remove cover (C) (629). Cover (C) is fitted with adjusting screws (C), (C1)
(628, 925), adjusting ring (C) (627), lock nut (630),
hexagon nut (801) and adjusting screw (924).
CAUTION
Do not loosen these screws and nuts. If they are
loosened, adjusted pressure-flow setting will be
changed.
CAUTION
To adjust the pressure and flow, inspection and
adjustment on a test bench will be necessary.
5 After removing cover (C) (629) subassembly, take out outer Adjusting ring (Q) (645) can be easily drawn out with
spring (625), inner spring (626) and spring seat (C) (624) from a M4 screw.
compensating section. Then draw out adjusting ring (Q) (645),
servo hydraulic spring (646) and spring seat (644) from servo
hydraulic section.
6 Remove screws (436, 438), and remove servo hydraulic cover
(641).
After removing servo hydraulic cover, take out set spring (655)
from the servo hydraulic section.
7 Remove snap ring (814), and take out spring seat (653), return Sleeve (651) is fitted with snap ring (836).
spring (654) and sleeve (651).
CAUTION
When removing snap ring (814), return spring (654)
may pop out. Take care not to lose it.
8 Remove snap ring (858), and take out fulcrum plug (614) and Fulcrum plug (614) and adjusting plug (615) can be
adjusting plug (615). easily taken out with a M6 screw.
9 Remove lever (2) (613). Work will be promoted by using long needle nose -
NOTE! pliers.
Do not draw out pin (875).
10 Draw out pin (874), and remove feedback lever (611). Push out pin (874) (4 mm in diameter) with a slender
steel bar so that it does not interfere with lever (1)
(612).
Note the direction of the feedback lever.
11 Remove lever (1) (612).

NOTE!
Do not draw out pin (875).
12 Draw out servo hydraulic piston (643) and spool (652).

13 Draw out piston case (622), compensating piston (621) and Piston case (622) can be taken out by pushing
compensating rod (623). compensating rod (623) on opposite side of piston
This completes the operation. case.
NOTE!
Since component parts are small, take care not to lose them.
Service Information

Regulator, maintenance 9139 Service Information 2014/5/31
Profile:
Regulator, maintenance
Fault and remedies
In case a functional fault probably resulting from the regulator occurs, disassemble and inspect it, referring to the section of
disassembly and assembly.
Engine is overloaded
Determine which is faulty, front pump or rear pump, by loading each pump independently.
When both pumps are found faulty, investigate the following (1) and (2). Begin investigation with (3), when only one pump is
found faulty.
1. Check the power shift signal current.

2. Power shift pressure is low.
 Check the amplifier dither.

 Replace the proportional solenoid valve.
3. The compensating piston and rod are stuck.
 Disassemble and clean.
4. Pin (898) is stuck.
 Disassemble and clean.
Maximum flow is not available
1. Check that the servo hydraulic pressure Pi is normal.

2. Servo hydraulic piston (643) is stuck..... Disassemble and clean the regulator.
3. Spool (652) is stuck....... Disassemble and clean the regulator.
4. Piston (621) is stuck in piston case (622)...... Disassemble and clean the regulator.
 Replace faulty parts that are deeply scored.

 (1) and (2) are only for cases of the servo hydraulic control.
 (4) is only for cases of the max. flow control.
Regulator, inspection and adjustment

Maximum/minimum flow, horsepower control characteristics and flow control characteristics of this regulator can be
adjusted by the adjusting screw.
(See the specified value for the regulator adjustment)
CAUTION
The adjustment of main pump regulator should be performed by qualified personnel with a proper flow meter and pressure
gauge. Before adjusting, mark the adjusting screw and lock nut. The performance of 628, 924, 925 adjusting screws are
considerably changed, so qualified personnel shall perform adjustment.
Adjustment of input horsepower

Since the regulator is the total cumulative horsepower type, adjust the adjusting screws of both front and rear pumps, when
changing the horsepower set values. The pressure change values are based on two pumps pressurized at the same time.
Adjustment of outer spring
Adjust it by loosening hexagon nut (630) and by tightening (or loosening) adjusting screw C(628).
Tightening the screw shifts the control chart to the right and increases the input horsepower as shown in the figure.
Since turning adjusting screw C(628) by N turns changes the setting of inner spring, back-off adjusting screw C1 (925) by N
× A turns.
Figure 1
Adjustment of input horsepower
X. Delivery pressure, (P1+P2)
Y. Delivery flow, Q
Adjustment of inner spring

Adjust it by loosening hexagon nut (801) and by tightening (or loosening) adjusting screw C1 (925).
Tightening the screw increases the flow and the input horsepower as shown in the figure.
Figure 2
Change of input horsepower
X. Delivery pressure, (P1+P2)
Y. Delivery flow, Q
Adjustment of flow control characteristic

Loosen hexagon nut (801), and tighten (or loosening) adjusting screw (924).
If the adjusting screw is tightened, the control curve will move to right as shown in the figure.
Figure 3
Change of control curve
Y. Delivery flow, Q
Service Information

Servo pump, adjustment 9143 Service Information 2014/5/31
Profile:
Servo pump, adjustment

 Engine speed : high idle
 Oil temperature when measuring: 50 ~ 60 °C (120 ~ 140 °F)
Measurement
Install a pressure gauge 100 kgf/cm2 (1422 psi) to the accumulator block gauge port (G).
CAUTION
The material of the pump housing is aluminium. If tightened excessively, the threads can be damaged.
Adjustment
 Loosen nut (312) and turn screw (311) to adjust.

 Adjust the screw as follows.
 To increase pressure, turn clockwise.

 To decrease pressure, turn counterclockwise.
Figure 1
Adjustment, servo hydraulic pump pressure
1. Engine
2. Relief valve
3. Control valve pressure
G. Pressure check port
O. Outlet
S. Suction
Service Information

Servo pump, description 9143 Service Information 2014/5/31
Profile:
Servo pump, description
Figure 1
Structure, servo pump
1. Discharge port
2. Suction port
3. Rotational direction
Precautions
 Repair of this pump is not recommended.

 Replace o-ring (710) when installing a new pump.
 Check that there is no contamination in the ports or plumbing before connecting to the pump.
 Use a torque wrench to tighten the screws, fittings and plugs to the specified torque.
 Check and adjust the relief valve pressure setting.
 If the pump was dismantled coat the gears, shafts, and sealing surfaces with clean hydraulic oil prior to assembling.
 Output shaft rotating torque 1.0 kgf·m (7 lbf·ft).
Service Information

Proportional solenoid 9144 Service Information 2014/5/31
valve, description
Profile:
Proportional solenoid valve, description

Model code (KDRDE 5 K - 20 / 40 C **)
Symbol Description Remark

KDRDE Electric proportional pressure reducing valve
5 Nominal designation
K Cartridge type
20 Serial number
40 Maximum setting secondary pressure (40 kgf/cm2, 469 psi)
C Solenoid specification C : 24Ω * 0.7A
** Electrical connection
The proportional solenoid valve regulates secondary pressure (pressure in port A) to be proportional to the current applied
to the solenoid coil.
If the solenoid (801) is energized, spool (311) is pushed to the right, and oil flows from P to A. The pressure in port A affects
the spring of spool (311). If the pressure reaches the set value of the solenoid, the spool moves left and reduces the flow
from P to A.
 When selecting a mode by turning the engine speed control switch, the controller outputs a current value adequate
for the pertinent mode to the proportional solenoid valve to regulate the servo hydraulic pressure to the hydraulic
pump regulator.
 The valve regulates the secondary servo hydraulic pressure to the hydraulic pump regulators to control the swash
plate angle and allowable pump output.
 The secondary servo hydraulic pressure varies in proportion to the current value to the proportional solenoid valve.
 The proportional solenoid valve spool vibrates continuously to maintain the secondary servo hydraulic pressure,
and is very sensitive to contamination due to the close tolerances of the spool/valve body. In the event of a
malfunction, always inspect the valve for contamination before replacing it.
Notes on operation
Solenoid wiring
Solenoid has no polarity.
Input current
Never add more than 0.7A to the solenoid coil.
Adjusting screw
Factory adjusted at shipment.
Port A pressure increases when the adjusting screw is turned clockwise.
Figure 1
Proportional solenoid valve
450. Tools : spanner 32 mm

Tightening torque : 450 kgf·cm
725. Proportional solenoid valve secondary pressure measuring port
Tightening torque
Tightening torque, unit : kgf·cm
No. Item Thread size Tightening torque

079 Proportional valve M22 × 1 450 ± 50
311 Spool
312 Sleeve M14 × 1 300 ± 30
324 Spring
325 Valve case
351 Orifice M3 6 ± 1 (Loctite # 24)
361 O-ring
362 O-ring
363 O-ring
407 Screw M6 120
466 Plug PF 1/4 370
490 Plug NPTF 1/16 90
725 O-ring
732 O-ring
801 Solenoid valve M22 × 1 450 ± 50
802 Seal nut M6 75 ± 5
901 Name plate
Inspection method
 Connect the adapter cable for testing between proportional solenoid valve connectors as shown.
 Start engine and measure the current value.
Figure 2
Connection, proportional solenoid valve
A. Black with red stripe (BR)

B. White
C. Tester
D. Red
E. Black
Service Information

Proportional solenoid 9144 Service Information 2014/5/31
valve, measuring and
adjustment
Profile:
Proportional solenoid valve, measuring and adjustment

Measuring condition
 Engine speed: Corresponds to working mode

 Working mode: Select “H”, “G”, “F”, “I” mode in sequence.
 Oil temperature when measuring: 50 ~ 60 °C (120 ~ 140 °F)
Measurement
 Connect an oil pressure gauge (60 kgf/cm2, 850psi) to the pressure checking port to measure servo hydraulic
secondary pressure.
Adjustment
Loosen lock nut (2) and turn screw (1) to adjust by using a blade screwdriver.
 To increase pressure, turn clockwise.

 To decrease pressure, turn counterclockwise.
Figure 1
Pressure checking
1. Adjusting screw
2. Lock nut
3. Pressure checking port (a)
Service Information

Troubleshooting 9144 Service Information 2014/5/31
Profile:
Troubleshooting
Troubleshooting
Phenomenon Cause Remedy

Pressure does not rise Error in wiring. Correct wiring.
or vary. Damage of solenoid. Replace the solenoid.
Stuck piston or spool. Remove, clean and polish.
Damage of amplifier. Repair or replace the controller.
Pressure does not vary Incorrect dither adjustment. Readjust.
smoothly.
 Dither frequency is high.
 Dither amplitude is low.
Stuck piston or spool. Remove, clean and polish.

Pressure is unstable. Incorrect dither adjustment. Readjust.
 Dither frequency is low.

 Dither amplitude is high.
Slow response Servo hydraulic primary pressure is low. Readjust.

Service Information

Pressure accumulator, 9145 Service Information 2014/5/31
description
Profile:
Pressure accumulator, description

 The accumulator is installed with a check valve between the gear pump and solenoid valve, to prevent the back flow
of oil charged in the accumulator.
 The nitrogen gas in the accumulator is compressed by the oil discharged from the gear pump. When the hydraulic
pressure falls, the compressed gas volume will expand and displace the accumulated pressurized oil into the circuit.
 When the boom is left in the raised position, and the control lever is operated with the engine stopped, the
pressure of the compressed nitrogen gas inside the accumulator sends servo hydraulic pressure to the control valve
to actuate it and allow the digging unit to come down under its own weight.
NOTE!
The servo hydraulic pressure accumulated in the accumulator can be utilized only when start switch is ON and the
safety lever is released by the left control console being lowered.
CAUTION
Removal of residual pressure from the circuit must be done prior to any maintenance.
Circuit
Figure 1
Circuit, accumulator
1. Check valve
2. Accumulator
3. Solenoid
4. Control lever
Structure
Figure 2
Structure, accumulator
1 Screw plug 4 Closure button

2 Sealing ring 5 Housing
3 Diaphragm
Accumulator block
Figure 3
Accumulator block, sectional view
1. Block
2. Port relief valve
3. Plug
4. Plug
Service Information

Remote control valve 9148 Service Information 2014/5/31
(Joystick), assembly
Profile:
Remote control valve (Joystick), assembly

Preparation
 Prepare the workbench, tools and parts. Assemble the valve in a clean area.
General precautions
 See the general precautions during disassembling.

 Remove all contamination from the parts and check that parts are free from burrs, nicks scratches, etc.
 Replace o-rings and back up rings with new ones.
 In fitting o-rings and back up rings, pay attention not to damage them.
 Apply grease to the parts to hold them in place during assembly.
 Tighten screws to specified torques shown in the tightening torque table.
 After assembling, cover all ports to prevent contamination from entering the valve.
Assembly
1. Install bushing (131) into casing (101).
Figure 1
Bushing, assembly
2. Install o-ring (122) into casing (101).
Figure 2
O-ring, assembly
3. Install port plate to casing (101) with screws (125) and seal washers (121).
NOTE!
Position the port plate so spring pin (126) can enter into the casing hole. Replace washers (121) with new ones.
Figure 3
Install port plate
Figure 4
Fixing with screw and seal washer
4. Tighten screws (125) to the specified torque.
CAUTION
Tighten two screws alternately and evenly.
Figure 5
Screw in, screws
5. Assemble washer (217), secondary pressure spring (241) and spring seat (216) onto spool (201) in this order.
CAUTION
Do not push down spring seat more than 6 mm.
Figure 6
Assembly, washer, secondary pressure spring and spring seat
6. To assemble the reducing valve section, push down secondary pressure spring (241) and install the spring (241)
through large hole of the spool (201).
Figure 7
Reducing valve, assembly
7. Install return spring (221) into the casing.
Install reducing valve subassembly into the casing (101).
NOTE!
Install them to their original positions.
Figure 8
Spring, assembly
8. Assemble o-ring (214) onto plug (211).
Figure 9
O-ring, assembly
9. Assemble seal (213) to plug (211).
NOTE!
Assemble seal lip direction as shown below.
Figure 10
Seals, assembly
10. Assemble push rod (212) to plug (211).
CAUTION
Apply oil on push rod surface.
Figure 11
Push rod, assembly
Figure 12
Apply oil on push rod surface
1 Seal 3 Plug
2 Push rod 4 Apply hydraulic oil
11. Assemble plug subassembly to casing(101).

(When return spring is relaxed, subassembly stops due to resistance of o-ring.)
Figure 13
Plug subassembly, assembly
12. When return spring is compressed, assemble 4 sets at the same time, utilizing plate (151), and tighten joint (301)
temporarily.
CAUTION
The plug subassembly and plate (151) may fly out due to return spring (221) force. Pay attention to this.
Figure 14
4 sets of plug, assembly
13. Fit plate (151).
Special tool part no.: 8932–00590
Figure 15
Plate, fit
14. Tighten joint (301) to the specified torque to casing, utilizing jig.
Figure 16
Joint, tightening
15. Assemble disc (302) to joint (301).
CAUTION
Screw it to a position that it contacts the 4 push rods evenly.(Do not screw it past this position.)
Figure 17
Disc, assembly
16. Assemble adjusting nut (312). Tighten adjusting nut to the specified torque.
CAUTION
During tightening, do not change position of disc.
CAUTION
Hold disc (302) with a spanner when tightening the lock nut.
Figure 18
Adjusting nut, assembly
17. Place the switches and bracket at the original position, and tighten screw.
Figure 19
Switch bracket, assembly
18. Place the handle cover, and tighten screw (431).
Figure 20
Handle cover, assembly
19. Fix top of the bellows into the groove in the lower end of handling grip (402).
Figure 21
Bellows, assembly
20. Assemble adjusting nut (312) to the handle assembly and place it to the joint (301).
Figure 22
Handle and joint, assembly
21. Determine handle direction, and tighten lock nut (315) to specified torque.
Figure 23
Lock nut, assembly
22. Apply grease to rotating section of joint and contacting faces of disc and push rod.
CAUTION
Molybdenum based CSE 115B paste type grease is recommended, but commonly used spray type grease is also
acceptable.
Grease should be applied every six months.
Figure 24
Applying, grease
23. Install the lower end of bellows (501) onto casing (101).
Figure 25
Bellows, assembly
24. Inject volatile rust preventives through all ports and then put blind plugs in the ports.
Service Information

(Joystick), description
Profile:
Remote control valve (Joystick), description

The servo hydraulic valve PV48K is a remote control valve of the reducing valve type and has four reducing valves controlling
the secondary pressure in one valve casing. Its secondary pressure is controlled by adjusting the tilting angle of the handle.
The casing has vertical bores in which the reducing valves are assembled.
The pressure reducing section is composed of the spool (201), spring (241) for setting secondary pressure, return spring
(221), washer 1 (215), spring seat (216) and washer 2 (217). The spring for setting the secondary pressure has been preset so
that the secondary pressure is 5 to 10 kg/cm2 (71 ~ 142 psi) (depending on the type).
The spool is pushed against the push rod (212) by the return spring (241).
Model code (PV48K C 1 001 A)
Symbol Description
PV48K PV48K series servo hydraulic valve
C C : Built in with high pressure selection valve
Blank : Valve is not included
1 Operation type
1 : One-handle operation
2 : Two-handle operation
001 Rotation number
A Revision mark for rotation number : A, B …
Piping
For good responsiveness, piping of about 8 mm (0.31 inch) in inner diameter and 3 m (9.84 ft) in length is appropriate. To
avoid a back pressure effect, return the oil directly to the tank.
Fundamental functions
The servo hydraulic valve controls the main control valve spool stroke and direction. This function is carried out by providing
a spring at one end of the main control valve spool and applying the output pressure (secondary pressure) of the servo
hydraulic valve to the other end.
To accomplish this function, the servo hydraulic valve consists of the following :
 Inlet port (P), receives oil from the servo hydraulic system hydraulic pump.
 Output ports (1, 2, 3, 4) supply oil pressure to the inlet port of the control valve spool end.
 Tank port (T) controls the above output pressure.
 Spools to connect output port to main control valve inlet port, or tank port.
 Mechanism including springs applied to the above spools to control output pressure.
Functions of major sections

Spool (201) connects the oil passages that route (P) port oil from the hydraulic pump to outlet ports 1, 2, 3, 4 or to tank port
(T). Secondary pressure setting spring (241) works on this spool to determine the output pressure.
To change the force of this spring, push rod (212) slides in plug (211) reacting on the spring.
For the purpose of changing the displacement of the push rod, disc (302) and adjusting nut (312) are provided; the handle
can be tilted in any direction around the fulcrum of the universal joint (301). Spring (221) works on casing (101) and spring
seat (216) and tries to return push rod (212) to the zero displacement position irrespective of the output pressure. This
ensures its resetting to the center position.
This also has the effect of a reaction spring to give an accurate sense of control to the operator. The output pressure in
relation to the secondary pressure is directly proportional to the inclination of the remote control valve control handle.
External view
Figure 1
Remote control valve (Joystick)
A. Neutral adjusting position mark white paint on edge

B. Double operating angle (ports 2 - 4)
C. Tilting angle of handle
D. Single operating angle (ports 1 - 3)
E. Tilted direction of handle (No. 3 push rod direction)
F. PF 1/4
Tightening torque : 29.4 ± 2.0 N·m (300 ± 20 kgf·cm, 22 ± 2 lbf·ft)
G. 5 - PF 3/8
Tightening torque : 49 ± 4.9 N·m (500 ± 50 kgf·cm, 36 ± 3.6 lbf·ft)
Switch
ON : When depressing
OFF : When releasing
Figure 2
Remote control valve (sectional view)
101 Casing 211 Plug 302 Disc 454 Rubber tube

111 Plate 212 Push rod 312 Adjust nut 455 Switch
121 Washer (seal) 213 Seal 315 Lock nut 456 Wire
122 O-ring 214 O-ring 323 Handle bar 457 Bushing
125 Screw 216 Spring seat 402 Grip (handle) 458 Tube
126 Spring pin 217 Washer 2 403 Insert 459 Terminal
131 Bushing 221 Spring 404 Tube 460 Terminal
151 Plate 241 Spring 431 Screw 461 Terminal
201 Spool 301 Joint 432 Screw 501 Bellows
When the push rod is pushed down by tilting the handle, the spring seat moves down simultaneously and changes the
setting of the secondary pressure spring.
The casing has the oil inlet (primary pressure), port (P), and the oil outlet (tank), port (T). In addition the secondary pressure
is routed through ports 1, 2, 3 and 4 provided at the bottom face. An electric switch is fitted to each control valve and switch
(455) is built into the top of the handle grip. When the center of handle grip (402) at the handle head is pushed, the switch
will function. Wire lead (456) connected to the switch, is led through the handle section and casing to the outside.
Joystick patterns
The patterns in the left and right columns are applied to the left and right control levers.
Arm out (1) - Move the lever here to move the arm out.
Slew right (2) - Move the lever here to slew the superstructure to the right.
Arm in (3) - Move the lever here to move the arm in.
Slew left (4) - Move the lever here to slew the superstructure to the left.
Boom lower (5) - Move the lever here to lower the boom.
Bucket dump (6) - Move the lever here to dump the bucket.
Boom raise (7) - Move the lever here to raise the boom.
Bucket curl (8) - Move the lever here to curl the bucket.
Figure 3
Operation, remote control valve (Joystick)
A SAE system (Volvo CE Korea system)

B MHI system
C KOB system
D Standard backhoe loader system
E SCM system
Hold (9) - When the lever is released from any position, the lever will return to HOLD. Slew, arm, bucket or boom movement
will stop.
Two functions may be performed at the same time by moving the lever diagonally.
(If equipped with a hydraulic hammer,) Hammer Raise (6)-Move the lever here to raise the hammer.
Hammer lower (8) - Move the lever here to lower the hammer.
 Servo hydraulic line ports of Volvo CE Korea system (SAE system). – See the hydraulic circuit drawing.
(1) - bl3
(2) - al2
(3) - al3
(4) - bl2
(5) - ar1
(6) - ar2
(7) - br1
(8) - br2
WARNING
The remote control valve joystick pattern decal must conform with machine control pattern. Failure to comply could
result in injury or death.
NOTE!
The remote control valve joystick pattern can be changed at the connector block.
Operation
The operation of the servo hydraulic valve is described on the basis of the hydraulic circuit diagram and sectional view which
is a typical application example of the servo hydraulic valve.
Figure 4
Diagram, remote control valve (Joystick)
1 Remote control valve 4 Main control valve

2 Servo hydraulic pump 5 Hydraulic motor
3 Main pump 6 Hydraulic cylinder
Handle is in neutral position

The force of spring (241) determines that the output pressure of the servo hydraulic valve is not applied to spool (201).
Therefore, the spool is pushed up by spring (221) to the position of port 3. Then since the output is connected to tank port
(T) only, the output port pressure becomes equal to tank pressure.
Figure 5
Operation, handle is in neutral position
Handle is in operating position

When push rod (212) is stroked, spool (201) moves downward.
Then port (P) is connected with port 1, and the oil supplied from the servo hydraulic pump flows through port 1 to generate
the pressure.
When the pressure at port 1 increases to the value corresponding to the spring force set by tilting the handle, the hydraulic
pressure force balances with the spring force. If the pressure at port 1 increases higher than the set pressure, port (P) is
disconnected from port 1 and port (T) is connected with port 1. If it decreases lower than the set pressure, port (P) is
connected with port 1 and port (T) is disconnected from port 1.
In this manner the secondary pressure is kept at a constant value. In some valves, when the handle is tilted more than a
certain angle, the upper end of the spool contacts the inside bottom of the push rod and the output pressure is connected
with port (P).
Figure 6
Operation, handle is in operating position
Operating pressure
Figure 7
Operating pressure chart
Service Information

(Joystick), disassembly
Profile:
Remote control valve (Joystick), disassembly

Tools and tightening torques
Tools
Tool Size Part no. Part Thread Tightening torque

size kgf·cm (lbs·ft)
Allen wrench 6 (mm) 125 Screw M8 300 ± 30
(22 ± 2)
Spanner 22 (mm) 312 Adjusting nut M14 700 ± 50
(50 ± 4)
315 Lock nut M14 500 ± 35
(36 ± 2)
27 (mm) 302 Disc M14 700 ± 50
(50 ± 4)
Philips screwdriver About 15 cm 431 Tap screw 2 M4 5 ± 0.5
(4 ± 0.5 lbs·in)
432 Tap screw 3 M5 18~22
(16~19 lbs·in)
Blade screwdriver About 4~5 mm 211 Bushing M1
wide
Special tool 301 Joint M14 480 ± 30
(35 ± 2)
Torque wrench 100~1000 kgf·cm
(0~900 lbs·in)
(0~150 lbs·ft)
Other :
 Rust inhibitor  Cleaning solvent
 High temperature grease
(spray type recommended)
 Loctite #241 (special #261)  Sandpaper (#1000, #2000)

 Oilstone  Vise
Preparation
 Thoroughly clean the exterior of the valve prior to disassembly. Dismantle in a clean environment.
 Prepare the tools and materials.
General precautions
 All parts are precision fitted to very close tolerances therefore utmost care must be taken not to damage them
during the dismantling and assembling procedure.
 Do not strike or force any parts that may be partially seized.
 Protect the parts from rusting prior to assembling, and check all surfaces for scratches, nicks and wear. Replace any
damaged part.
Disassembly
1. Clean servo hydraulic valve with cleaning solvent.
CAUTION
Use plugs to cover all ports.
2. Fix servo hydraulic valve in a vise with copper (or lead) sheets.
Figure 1
Fixing with the vise
3. Lift the end of bellows (501) and provide enough wire to ensure the proper operation of disassembly.
Figure 2
Provide enough wire
CAUTION
Pay attention not to damage the bellows.
4. Loosen the adjusting nut; use a spanner on each nut.

Figure 3
Loosen the adjusting nut
5. Remove the handle assembly.
Figure 4
Handle assembly, removal
6. Rotate the disc (302) counterclockwise and remove it.
Figure 5
Disc, removal
7. Turn the joint counterclockwise to loosen it, utilizing jig (special tool).
NOTE!
[Photo] shows how to fit jig.
CAUTION
Take care when loosening the joint. Plate (151), plug (211) and push rod (212) may fly out due to compressed
return spring (221).
Figure 6
Using special tool
Figure 7
Joint, removal
8. Remove plate (151).
Figure 8
Plate, removal
9. When return spring (221) is released plug (211) stays in the casing because of the sliding resistance of the o-ring.
Take it out with a screwdriver.
CAUTION
Take it out, utilizing the external periphery groove of the plug and pay attention not to damage it by partial
loading. During removal, the plug may fly out due to return spring (211) force. Pay attention to this.
Figure 9
Spring, removal
10. Remove push rod (212), plug (211), reducing valve subassembly and return springs (221) from the casing.
NOTE!
Record relative position of reducing valve subassembly and return springs.
Figure 10
Reducing valve subassembly, removal
11. Fix pilot valve in a vise upward port plate (111). Loosen screws with hexagon socket key.
Figure 11
Loosening, screws
12. Remove port plate (111) and o-ring (122) from the casing (101).
Figure 12
O-ring, removal
13. Remove bushing (131) from the casing (101).
Figure 13
Bushing, removal
14. To disassemble the reducing valve section, push down secondary pressure spring (241) and remove the spring
(241) through large hole of the spool (201).
CAUTION
Pay attention not to damage spool surface. Do not push down spring seat more than 6mm.
Figure 14
Reducing valve, removal
15. Separate spool (201), spring seat (216), secondary pressure spring (241) and washer 2 (217).
Figure 15
Spring, spool and spring seat etc, removal
16. Remove push rod (212) from plug (211).
Figure 16
Push rod, removal
17. Remove o-ring (214) from plug (211)
Figure 17
O-ring, removal
18. Remove seal (213) from plug (211) using a small screwdriver.
Figure 18
Seal, removal
19. Remove bellows (501) by pulling the top from its groove in the grip.
Figure 19
Bellows, removal
20. Remove handle (402) cover.
Remove screw (431), and take off grip (402) cover.
Figure 20
Screws, removal
21. Remove the switch bracket.
Figure 21
Switch bracket, removal
22. Remove switches (455).
Figure 22
Switch, removal
CAUTION
Record the location relationship between the color of wire and the position at the handle.
23. Cleaning of parts :
 Initially wash the remote control valve assembly with clean solvent to remove the heavy accumulation of
dirt.
CAUTION
Allow the parts to soak in the solvent to soften the dirt. Do not wash the internal parts with contaminated
solvent. Ensure that all parts are thoroughly cleaned prior to reassembly.
 In the final stage, wash all passages, chambers, grooves with clean solvent, to ensure the utmost
cleanliness.
 Wipe off the parts with a clean cloth.
CAUTION
Do not dry parts with compressed air, since they may be damaged and/or rust may develop due to
moisture in the air.
24. Rust prevention of parts :

Apply rust inhibitor to all parts.
CAUTION
If left untreated after being cleaned, they will rust and will not function properly after being reassembled.
Service Information

(Joystick), maintenance
standard
Profile:
Remote control valve (Joystick), maintenance standard

Wear limit
Maintenance check Criteria Remark

item
Leakage The valve is to be replaced when the leakage becomes more Conditions : Primary press. 30 kgf/
than 1000 cc/min. at neutral handle position, or more than cm2 (426 psi) Oil viscosity 23 cSt
2000 cc/min. during operation.
Spool This is to be replaced when the sliding surface has worn The leakage is estimated to be nearly
more than 10 µm, compared with the non-sliding surface. equal to the above leakage.
Push rod
A. Worn more than 1mm
This is to be replaced when the top end has worn more than
1mm (0.004″).
Play at operating The pin, shaft, and joint of the operating section are to be When the play is due to loose parts /
section replaced when the play becomes more than screws, tighten to specification.
2 mm (0.008″)
Operation stability When abnormal noises, hunting, primary pressure drop, etc.
are generated during operation, and these cannot be
remedied, see causes of troubles and countermeasures,
replace the related parts.
NOTE!
In principle, replace seals and o-rings during reassembly.
NOTE!
When loosening the screws (125), replace the seal washers (121) without fail.
Service Information

(Joystick), troubleshooting
Profile:
Remote control valve (Joystick), troubleshooting

It isn't always easy to trace a malfunction. Some general phenomenon to be considered are listed in following table. See
cause and remedy.
However, the trouble is not always caused by one faulty part only, but by its relation to other parts.
So remedies other than listed in the table may be necessary.
Troubleshooting
Phenomenon Cause Remedy

Secondary pressure will not
rise.  Primary pressure is low.  Adjust primary pressure.
 Spring (241) breaks or yields.  Replace it with new one.
 Clearance between spool and casing  Replace spool subassembly and
is excessive. casing.
 There is play at handle section.  Disassemble and repair handle
section or replace it.
Secondary pressure is
unstable.  Sliding part is sticking.  Repair/replace parts.
 Tank line press fluctuates.  Return oil directly to tank.
 Air in hydraulic circuit.  Carry out operation several times
to bleed air from the system.
Secondary pressure is too

high.  Tank line pressure is too high.  Return oil directly to tank.
 Sliding part is stuck.  Repair/replace defective parts.
Service Information

(pedal), adjustment
Profile:
Remote control valve (pedal), adjustment

Without depressing the pedal and push rod (8), tighten nut (15).
Push rod stroke
To Decrease secondary servo hydraulic pressure Raise screw (21).
To Increase secondary servo hydraulic pressure Lower screw (21).
Figure 1
Adjustment, secondary servo hydraulic pressure
Service Information

(pedal), assembly
Profile:
Remote control valve (pedal), assembly

1. Assemble spacer (12), seal (11) and o-ring (10) into plug (9). Apply grease to o-ring. Apply grease to push rod (8)
and insert into plug.
NOTE!
Pay attention to seal direction.
Figure 1
Assembly, spacer, seal and o-ring
2. Hold spool (2) with brass plate and clamp. Assemble spring spacer (3), spring (4) and spring seat (6) and tighten
screw (7).
NOTE!
Apply loctite to screw.
Figure 2
Assembly, spring spacer, spring and spring seat
Tools : Allen wrench
Tightening torque : 0.35 kgf·m (30 lbf·in)
3. Insert return spring (5) and spool assembly (A). Apply oil to valve body (1) inside.
Figure 3
Assembly, return spring and spool assembly
4. Press and tighten the plug assembly. Assemble dry bearing (22). Assemble four plugs (18).
Figure 4
Assembly, dry bearing and plugs
A. Press push rod and tighten plug

B. Plug assembly
Tightening torque : 4 kgf·m (29 lbf·ft)
5. Assemble plug (9) and bellows. Apply grease to push rod. Assemble pedal (13) to valve body (1) with shaft (14) and
assemble retaining ring (23). Assemble screw (17) and capscerw (21).
Figure 5
Assembly, plug and bellows etc.
Service Information

(pedal), description
Profile:
Remote control valve (pedal), description

Structure
Figure 1
Structure, remote control valve (pedal)
1 Remote control valve (pedal) 9 Plug 17 Set screw

2 Spool 10 O-ring 18 Plug
3 Spacer 11 Seal 19 Plug (plastic)
4 Spring 12 Spacer 20 Bellows
5 Return spring 13 Pedal 21 Screw
6 Spring seat 14 Shaft 22 Dry bearing
7 Screw 15 Lock nut 23 Retaining ring
8 Push rod 16 Nut
Function
Figure 2
Diagram, remote control valve (pedal)
1. Neutral
2. Operating
3. Full stroke
Neutral (1)
At neutral position, hydraulic oil flows P (pump) to T (tank).
Valve spool (S) is at neutral position therefore moveable distance “A” is 6mm.
Operating
When the travel pedal is depressed valve spool (S) moves downward and allows oil flow to operate main control valve spool.
Operating (2)
According to depressing the pedal (P) port pressure rises to equal the force of the secondary pressure setting, created by
depressing the pedal, the oil pressure and spring pressure will be balanced. At this time servo hydraulic pressure (A1) pushes
the valve spool upward connecting (P) port to tank. Therefore the output pressure can be maintained to a constant valve
according to pedal stroke. According to the graph distance `A' is between 0.5 mm and 5 mm.
Full stroke (3)
At full stroke (A is less than 0.5 mm), spool (S) shifts downward and port (P) is connected to port (C). Therefore the pressure
of port (C) is controlled by servo hydraulic relief valve.
Service Information

(pedal), disassembly
Profile:
Remote control valve (pedal), disassembly

1. Disassemble bellows (20) from lock nut (15). Remove retaining ring (23) and pull out shaft (14). Remove pedal
assembly (13), record the height of screw (21) and remove the screw (21).
Figure 1
Removal, retaining ring, shaft and pedal assembly
2. Remove bellows (20) from plug (9). Remove plug (9) using spanner (32 mm). Pay attention that return spring (5) is
against plug (9). Remove spool assembly (A) and return spring (5).
Figure 2
Removal, plug, spool assembly and return spring
3. Remove four plugs (18) from valve (1). Check dry bearing (23) and replace with new one when required. Clean with
solvent and dry with compressed air.
Figure 3
Removal, four plugs
4. Hold spool (2) with brass plate and clamp, then remove screw (7). Remove spring seat (6), spring (4), spring spacer
(3) and spool. Inspect disassembled parts carefully and replace damaged parts.
NOTE!
If spool is damaged replace valve assembly.
Figure 4
Removal, screw, spring seat and spring etc.
5. Remove push rod (8). Remove spacer (12), seal (11) and o-ring (10). Check plug (9) and push rod (10). Replace as a
set if required. Replace o-ring (10), seal (11) and spacer.
Figure 5
Removal, push rod, spacer and o-ring etc.
6. Remove lock nut (15), screw (17) and nut (16). Measure the height of screw (17) before disassembly.
NOTE!
Remove screw (17) only when it is required.
Figure 6
Removal, lock nut, screw and nut
Service Information

(stabilizer/dozer blade),
description
Profile:
Remote control valve (stabilizer/dozer blade), description

Structure
Figure 1
Structure, remote control valve (stabilizer/dozer blade)
1 Lever 4 Return spring 7 Operating plate

2 Control spool 5 Spool 8 Drilling port
3 Control spring 6 Housing 9 Bellows
Function
Servo hydraulic control devices type - 2TH6 are direct operated pressure reducing valves. They consist basically of operating
element (1), valve insert consisting of control spool (2), control spring (3), return spring (4), spool (5) and housing (6). Servo
hydraulic control devices type - 2TH6 offer pressure dependent, sensitive control of valves, pumps and motors. In the start
position, the operating element is held in neutral by return spring (4) and the control chamber (servo hydraulic ports A, B) is
vented to tank through drilling (8). As lever (1) is operated, spool (5) is pushed by operating plate (7) against return spring
(4). At the same time, control spool (2) is moved by means of control spring (3). The spool first blocks off the tank orifice
from the control chamber (overlap function) before starting its control stroke. The gradual opening of port P causes pressure
to build up in the control chamber (A, B) proportional to the angle of shift of the lever. This pressure can be applied to the
adjustment devices of the valves, pumps or motors to be controlled (proportional hydraulic adjustment). The control of
these devices is carried out dependent upon lever movement and the control spring characteristics. A special feature of
servo hydraulic device - 2TH6 is the spreading of the fine control range when operating high pressure mobile control blocks
and sandwich type mobile control blocks. Easily recognizable reference points may be sensed at the end of the fine control
stage. When used with a servo hydraulic oil supply system, remote pressure control is possible without the need for a
separate servo hydraulic oil pump. Because of the oil stored in the accumulator, this system also offers emergency operation
even when the machine engine is stopped. A rubber gaiter (9) protects the mechanism against dirt and ensures that these
servo hydraulic control devices are suitable even for the most arduous applications.
Service Information

Solenoid valve, description 9149 Service Information 2014/5/31
Profile:
Solenoid valve, description

 Solenoid coil : An electronic coil to apply a force on the spool.
 Body : A main body with the flow passage and the port.
 Spool : Moved by solenoid coil and spring, and limits the flow passage of each port.
When power is supplied to a solenoid coil, an electro-magnetic force is formed and the spool in the guide is activated, which
pushes the spool and converts the oil flow passage while compressing the spring.
By the spool movements, the flow passage to each port is connected or disconnected, and if power is turned off, the spool is
returned by the spring force and each port also returns to the original condition.
These solenoid valves perform the following functions when activated.
Block 1 :
1. Safety switch (limit switch) (A1)

2. Main pressure boost (A2)
3. Axle locking selection (A3)
Block 2 :
1. Option selecting device (A1)

2. Boom/arm conflux shut-off (A2)
3. Dozer/stabilizer selection (A3)
Solenoid valve, structure

Block 1, 2
Figure 1
Structure, solenoid valve block 1, 2
1 Casing 5 Detent washer 9 Coil case 13 O-ring
2 Spool 6 Guide kit 10 O-ring 14 Name plate
3 Spring 7 Solenoid coil 11 Nut
4 Spring guide 8 Coil yoke 12 O-ring
Coil case (9) : Tightening torque 400 ~ 500 kgf·cm (30 ~ 36 lbf·ft)
Safety lever lock (A1)
Servo hydraulic safety lever lock function : when the left hand control console safety lever is moved to the operate position,
the switch is turned ON, directing the primary servo hydraulic pressure at port P1 to A1, and then to the remote control
valve. When the lever is moved to the lever lock position the switch is turned OFF, and the spring force moves the solenoid
valve spool, making it impossible to operate all the implement levers and travel system levers.
Main relief valve pressure boost (A2)
When the digging unit boost pressure switch is pressed, solenoid valve A2 is activated and port P2 is opened to port A2. The
servo hydraulic pressure from port A2 raises the relief pressure of the main relief valve.
Boom/arm conflux shut-off valve (A2) (Fine operation mode)
Activating the switch shut-off the oil flow P2 is connected to the boom and arm conflux circuit.
Axle locking selection (A3)
When the axle locking switch is pressed to OFF, solenoid valve A3 is activated routing primary servo hydraulic pressure at
port P2 to A3, shifting to the axle locking valve to release position.
Dozer/stabilizer selection (A3)
Activating the switch the oil flow P2 is connected to A3 and shift dozer/stabilizer selection spool to stabilizer operation.
Service Information

Solenoid valve, disassembly 9149 Service Information 2014/5/31
and assembly
Profile:
Solenoid valve, disassembly and assembly

Tools and tightening torque
Tightening torque, unit : kgf·cm (in·lb)
Part name Tools Tightening torque

Spring guide (4) (5) 26 mm 1900 ± 50 (1649 ± 43)
Guide kit (6) (7) 5 mm 70 ± 5 (61 ± 4)
Nut (11) (12) 27 mm 55 ± 5 (48 ± 4)
Disassembly
Precautions
 Thoroughly clean the exterior of the valve prior to disassembly. Dismantle in a clean environment.
 All parts are precision fitted to very close tolerances therefore utmost care must be taken not to damage them
during the dismantling and assembling procedure.
 Do not strike or force any parts that may be partially seized.
 Protect the parts from rusting prior to assembling, and check all surfaces for scratches, nicks and wear. Replace any
damaged part.
 Remove the spring guide and spring from the valve casing.
 Unscrew the coil case nut and extract the solenoid coil.
 Remove the guide kit, retainer and the spool.
 Extract the spool slowly to avoid binding the spool lands in the valve casing.
Assembly
Precautions
 Follow the same precautions as disassembly.

 Minor scratches, nicks, and sharp edges may be polished with very fine emery or crocus cloth.
 Replace all o-rings.
 Lightly coat the o-rings with grease to hold them in place during assembly.
 Lubricate the spool prior to assembly.
 Upon completion of assembly, plug all ports to prevent contamination intruding into the valve.
Assembly procedure
 Insert the spool and retainer.

 Install the o-ring and guide kit.
 Assemble the solenoid coil, o-ring and coil case.
 Tighten the coil case nut to specified torque.
 Install the spring and spring guide with a new o-ring.
 Tighten the spring guide to specified torque.
Troubleshooting
For minor problems, see the following causes and corrective actions.
Troubleshooting
No. Problem Cause Remedy
1 Spool does not move. Solenoid voltage is low. Check the electric wiring.
Test the solenoid coil.
Solenoid coil is burnt. Replace the coil.
Spool spring is broken. Replace the spring.
Contamination in the casing. Check the circuit and hydraulic oil for
contamination, clean as required.
2 Leakage from coil case or O-rings are damaged. Replace the o-rings.
spring guide. Coil case nut, spring guide are loose. Tighten to specified torque.
Service Information

Solenoid valve, inspection 9149 Service Information 2014/5/31
Profile:
Solenoid valve, inspection

 Use a sensory organ : By the sense of hearing or touch, check the solenoid valves for operating at switch ON.
 Coil continuity test : Check for coil damage by tester.
Figure 1
Inspection method
 Spool malfunction : In the event that the solenoid valve malfunctions and there is no electrical abnormality, the
spool may be stuck in the valve. Press the spool on the solenoid to check for spool sticking. Disassemble and clean
thoroughly, if damaged it must be replaced.
NOTE!
For hydraulic operation related information, see the hydraulic system.
Service Information

Servo hydraulic selector 9163 Service Information 2014/5/31
valve, description
Profile:
Servo hydraulic selector valve, description
Figure 1
Structure, servo hydraulic selector valve
1 Casing 4 O-ring 7 Screw (M6 x 55)

2 Servo hydraulic cap 5 Spool 8 Spring (S)
3 Return cap 6 Screw (M6 x 20) 9 Spring (L)
Port connection
Figure 2
Port connection
P BU1
T Dd (tank)
Pi Al2
A Pb
Function
Conflux when boom raising
When operating the boom, secondary servo hydraulic pressure is not supplied to Pi.
If the servo hydraulic secondary pressure oil flows to P → A and pushes the boom conflux valve piston, the boom conflux
valve is opened and the oil of P1 pump is combined with P2 pump oil.
Operating when arm in
When Pi oil is applied and the selector valve position is switched during arm in operation, servo hydraulic secondary
pressure oil does not flow to port P, the boom conflux valve is closed, and the conflux flow of P1 pump oil is blocked.
Service Information

Arm holding valve, 9121 Service Information 2014/5/12
Profile:
Arm holding valve, disassembly and assembly

(For assembly, reverse disassembly procedure)
When disassembling, mark each part to make assembling easier.
Figure 1
Disassembly, arm holding valve
A. Arm port relief valve
1. Remove screw (1) and remove cover (2).

CAUTION
When assembling, make sure that the o-ring is installed on manifold inlet before assembling.
2. Pull out spring seat (3), spring (4) and poppet (5).
Figure 2
Removal, spring etc.
3. Cover assembly
Remove cap (6) and pull out spring (7) and spool (8).
Figure 3
Removal, spool

Service Information

Arm parallel conflux check 9121 Service Information 2014/5/12
valve, disassembly and
assembly
Profile:
Arm parallel conflux check valve, disassembly and assembly

1. Remove cap (1) and pull out check valve (2) and spring (3).
Figure 1
Disassembly, arm parallel conflux check valve
Tools : Socket wrench, spanner 30 mm

Service Information

Arm parallel conflux valve, 9121 Service Information 2014/5/12
Profile:
Arm parallel conflux valve, disassembly and assembly

Figure 1
Arm parallel conflux valve
1. Remove cap (1) and pull out spring (2), spring seat (3) and spool (4).
Figure 2
Removal, spool etc.
2. Remove screw (5) and remove manifold.

Service Information

Arm regenerating and arm 9121 Service Information 2014/5/12
conflux check valve,
Profile:
Arm regenerating and arm conflux check valve, disassembly and

assembly
Figure 1
Arm regenerating and arm conflux check valve
1. Remove cap (1) and pull out spring (2) and spool (3).
2. Remove sleeve (4) and pull out piston (5), spring (6) and check valve (7).
3. Remove cap (8) and pull out piston (9).
Figure 2
Removal, arm regenerating and arm conflux check valve
Service Information

Boom back pressure check 9121 Service Information 2014/5/12
valve, disassembly and
assembly
Profile:
Boom back pressure check valve, disassembly and assembly

Figure 1
Boom back pressure check valve
1. Remove cap (1) and pull out spring (2) and poppet (3).
Service Information

Boom holding valve, 9121 Service Information 2014/5/12
Profile:
Boom holding valve, disassembly and assembly

Figure 1
Boom holding valve
Main body check valve

1. Remove screw (1) and remove cover assembly (2).
2. Pull out spring (3) and poppet (4).
Figure 2
Main body check valve
CAUTION
When reassembling, make sure that the o-ring is installed on housing inlet before assembling the cover.
Selector valve
1. Remove cap (5) and pull out piston (6) and spring (7).
Figure 3
Selector valve
Cover assembly
Figure 4
Cover assembly
1. Remove cap (8) and pull out spring (9) and check poppet (10)
Figure 5
2. Remove cap (11) and pull out piston (12).
Figure 6
Removal, piston
3. Remove cap (16) and pull out spring (15) and poppet (14).
Figure 7
Removal, poppet
4. Pull out sleeve (13) by tapping the left side of cover lightly.
CAUTION
Take care not to damage the surface edge (φ5) of sleeve.
Service Information

Center bypass valve, 9121 Service Information 2014/5/12
Profile:
Center bypass valve, disassembly and assembly

Figure 1
Center bypass valve
1. Remove cap (1) and pull out spring (2) and spool (3).
Figure 2
Removal, spring
CAUTION
Note that the spool notches in 3-series and 4-series side are different.
Service Information

Flow sensing valve (Foot 9121 Service Information 2014/5/12
relief valve), disassembly
and assembly
Profile:
Flow sensing valve (Foot relief valve), disassembly and assembly

Figure 1
Disassembly, flow sensing valve (Foot relief valve)
1. Remove cap (1) and pull out poppet (2).
Figure 2
Removal, cap etc.
2. Remove cap (3) and pull out shim (4) and spring (5).
CAUTION
If shims for adjusting pressure are installed, confirm the quantity.
Service Information

General, precautions 9121 Service Information 2014/5/12
Profile:
Removal
 Thoroughly clean the control valve prior to removal from the machine.
 Tag all hoses prior to disconnecting from the control valve.
 Use eye bolts to lift the control valve. Do not sling on the relief valves or spool caps.
WARNING
The control valve is heavy. Take appropriate safety precautions when handling.
Disassembly
 Do not use excessive force, sharp or high hardness tools to disassemble the control valve.
 Take care not to mix the parts of the various check valves and flow valves.
Assembly
 Take care not to interchange the spools.
Service Information

Load check valve - single, 9121 Service Information 2014/5/12
Profile:
Load check valve - single, disassembly and assembly

Figure 1
Load check valve
1. Remove cap (1) and pull out spring (2) and check valve (3).
Figure 2
Removal, check valve etc.

Service Information

Load check valve, 9121 Service Information 2014/5/12
Profile:
Load check valve, disassembly and assembly

Figure 1
Load check valve
A. Boom (single)
B. Slew, arm, travel, bucket, dozer/stabilizer, option (double)
1. Remove cap (1) and pull out spring (2), poppet (3) and check valve (4).
Figure 2
Removal, spool etc.

Service Information

Logic valve, disassembly 9121 Service Information 2014/5/12
and assembly
Profile:
Logic valve, disassembly and assembly

Figure 1
Logic valve
1. Remove cap (1) and pull out pistons (2, 3) and spring (4).
Figure 2
2. Pull out sleeve (5) by using the horizontal hole and pull out spring (6) and check valve (7).
Figure 3
3. Insert the round bar with threaded screw (M5 × 0.8) in one end into sleeve (8) and pull out sleeve (8).
Figure 4
Removal, sleeve etc.
4. Pull out spring (9) and poppet (10).
Figure 5
Removal, poppet and spring
Service Information

Profile:
Main relief valve, disassembly and assembly

1. Hold adjusting screw (1) and loosen lock nut (2).
2. Hold cap (4) and loosen lock nut (3).
3. Remove cap (4) and remove cartridge.
Figure 1
Main relief valve
4. Remove sleeve (6) and pull out piston (7), spring (8) and orifice (9).
Figure 2
Removal, piston etc.
CAUTION
Do not remove servo hydraulic seat, because it is press fitted.
5. Loosen each screw and nut.

Item Dimension Tightening torque

1 Adjusting screw 22 mm -
2 Lock nut 30 mm 6 (43)
3 Lock nut 30 mm 6 (43)
4 Cap 30 mm 10 (72)
5 Sleeve 27 mm -
Service Information

Main spool, disassembly 9121 Service Information 2014/5/12
and assembly
Profile:
Main spool, disassembly and assembly

(For assembly, reverse disassembly procedures)
When disassembling, mark each part to indicate original location and position during assembly.
Figure 1
Main spool
1. Remove screw (1), and remove cover (2).

CAUTION
When assembling, make sure that the o-ring is installed before assembling the cover.
2. Pull out the spool subassembly.
Figure 2
Removal, spool
CAUTION
Pull out the spool slowly confirming the housing condition.
3. Hold spool with holder (4) and vise, and loosen spool cap (3).
 Spool
Figure 3
Disassembly, spool
NOTE!
Remove oil from spool and holder.
NOTE!
When assembling, take care spring guide direction.
4. Remove spool cap (3) and remove spring guide (4), (7) and spring (5) and spacer (6).
Figure 4
5. Only for the arm and the boom spool, remove cap (8) and pull out spring (9) and check valve (10).
Figure 5

Service Information

Port relief valve, 9121 Service Information 2014/5/12
Profile:
Port relief valve, disassembly and assembly

CAUTION
Do not disassemble pressure adjusting part.
1. Remove sleeve (1) and remove cartridge.
Figure 1
Removal, sleeve
CAUTION
Set pressure is different according to position. Be sure to assemble it to its original position.
2. Remove cap (2) and pull out spring (3) and servo hydraulic poppet (4).
Figure 2
Tools : Socket, spanner 27 mm

3. Remove servo hydraulic seat (5) and pull out spring (6), (7), piston (8) and main poppet (9).
Figure 3
Removal, main poppet etc.
Service Information

Hydraulic quickfit, 924 Service Information 2014/5/12
description
Profile:
Hydraulic quickfit, description

The quickfit attachment consists of a flat assembly plate, which is fitted to the arm end and bucket link. There are two hooks
(6) on the plate, for the front shafts (2) on the bucket.
There is a lifting hook (3) on the quickfit attachment. With the bucket removed, the permitted load increases and the
operator's field of vision is improved.
The quickfit attachment is equipped which a double acting hydraulic cylinder. The quickfit lock wedge (4) is fitted to its
piston rod. Servo pressure acts on the piston side of the lock cylinder, locking the bucket in place against the rear hook (5).
This means that the lock wedge adjust itself and provides gap-free locking.
When the lock wedge (4) is released, the servo pressure is transferred to the piston rod side. If necessary, the release
pressure can be increased by loading the bucket cylinder in its end position.
There is a red marker (1) on the left side of the quickfit attachment, which is folded in when the lock wedge is in the locked
position and folded in when the lock wedge is in the locked position and folded out when the lock wedge is released.
Figure 1
Hydraulic quickfit, install
1. The red marker

2. Bucket shaft
3. Lifting hook
4. Locking wedge
5. Bucket rear hook
6. Tool attachment hook
Figure 2
Quickfit, structure (1)
1 Quickfit assembly 9 Nut

2 Quickfit bucket assembly (0.63, 0.78 m3) 10 Nut
3 Pin with locking 11 Shim (0.5 T)
4 Cord ring 12 Shim (1.0 T)
5 Spacer 13 Shim (0.5 T)
6 Special screw 14 Shim (1.0 T)
7 Screw 15 Shim (2.0 T)
8 Screw
Figure 3
Quickfit, structure (2)
1 Quickfit weld assembly 12 Copper gasket

2 Hydraulic cylinder 13 Copper gasket
3 Lock wedge 14 Hose assembly
4 Pin 15 Hose assembly
5 Split pin 16 Elbow
6 Stay 17 Elbow
7 Screw 18 Nut
8 Hexagon nut 19 Nut
9 Plain washer 20 Quickfit cover
10 Connector 21 Screw
11 Connector 22 Spring washer
Figure 4
Location, quickfit switch
1. Remove the blank switch and install

2. Remove the blank switch and install
Quickfit, piping
Figure 5
Quickfit, piping (1)
1 Nut 10 Tee 19 Connector

2 Quickfit valve 11 Tee 20 Copper gasket
3 Plate 12 Tee 21 Copper gasket
4 Plate 13 Connector 22 Hose
5 Nut 14 Connector 23 Hose
6 Screw 15 Connector 24 Hose
7 Screw 16 Connector 25 Hose
8 Spring washer 17 Connector 26 Hose
9 Spring washer 18 Connector 27 Hose
Figure 6
1 Nut 6 Flat washer 11 Hose

2 Plate 7 Clip 12 Hose
3 Plate 8 U-bolt 13 Clamp
4 Nut 9 Connector 14 Clip
5 Nut 10 Connector
Figure 7
1 Clamp 9 Screw 17 Hose

2 Block 10 Screw 18 Hose
3 Clamp 11 Screw 19 Hose
4 Plate 12 Spring washer 20 Hose
5 Plate 13 Spring washer 21 O-ring
6 Plate 14 Clip 22 O-ring
7 Screw 15 Connector
8 Screw 16 Connector
Figure 8
Quickfit valve
1. Servo hydraulic valve

2. Check valve
3. Shuttle valve
4. Solenoid valve
Service Information

Tool attachment, 924 Service Information 2014/5/12
adjustment
Profile:
Tool attachment, adjustment

Remove any shims between the screw holder and mating plates.
Hook the bucket on and lock it in accordance with the instructions for installing a bucket or tool.
Figure 1
Tool attachment, adjustment
1. Bucket/tool
2. Screw holder
3. Spacer
4. Tool attachment
Check the lock wedge position and the way the attachment butts up against the mating plates. Then calculate any
adjustment to the plate shims follows;
Put in thicker shims if the locking wedge goes too far into the hook.
Put in thinner shims if the locking wedge does not go far enough into the hook.
Figure 2
Adjustment using shims
1. Shims
2. Bucket hook
3. Lock wedge
Remove the bucket or tool in accordance with the instructions for removing a bucket or tool.
Fit the requisite number of shims beneath the mating plates, then re-install the bucket or tool.
Check that the locking wedge position is in accordance with the specified tolerances.
Measure or offer up and install the requisite number of shims between the screw holder and the mating plates. Tension the
mating plates with the requisite number of fastening screws.
CAUTION
All mating plates and adjustment screws must be adjusted to give a good fit.
Service Information

Dozer blade cylinder, 9275 Service Information 2014/5/31
description
Profile:
Dozer blade cylinder, description
Figure 1
Dozer blade cylinder (sectional view)
1 Tube 8 Retaining ring 15 Step seal (Buffer ring) 22 Dust seal

2 Rod 9 Lock washer 16 O-ring 23 Grease nipple
3 Bushing 10 Lock nut 17 Back-up ring
4 Gland 11 Screw 18 O-ring
5 Piston 12 Dust wiper 19 Contami seal
6 Retaining ring 13 Rod packing 20 Piston packing
7 Bearing 14 Back-up ring 21 Wear ring
Service Information

Cylinder, description 970 Service Information 2014/5/12
Profile:
Cylinder, description
Figure 1
Arm cylinder (sectional view)
Figure 2
Arm cylinder (exploded view)
1 Tube 8 Retaining ring 15 Dust seal 22 O-ring

2 Bushing 9 Cushion ring 16 Back-up ring 23 Piston packing
3 Rod 10 Piston 17 Rod packing 24 Wear ring
4 Bushing 11 Lock washer 18 Step seal 25 Contami seal
5 Gland 12 Lock nut 19 Back-up ring 26 Dust seal
6 Bearing 13 Screw 20 O-ring 27 Spring pin
7 Retaining ring 14 Grease nipple 21 Back-up ring 28 Cushion spool
NOTE!
Coat the screws of the gland with "Three bond 1360K" (or equivalent).
By construction the hydraulic cylinder consists largely of cylinder tube (1), piston (10) that reciprocates in it, piston rod (3)
that takes the movement of the piston, and gland (5) that serves as a head/guide. The cylinder tube (1) and the piston rod
(3) has a clevis, a trunnion or a flange to mount the cylinder assembly.
Packings, seals and bushing are used in the moving part or on the mounting part between piston (10) and cylinder tube (1),
between piston rod (3) and gland (5) and between cylinder tube (1) and gland (5).
Figure 3
Structure, cylinder
1 Cylinder tube
3 Piston rod
5 Gland
10 Piston
Operation of cylinder with cushion

If pressurized oil is fed alternatively to the oil inlet and outlet provided in the cylinder, force acts on the piston which in turn
causes piston rod (3) to extend and retract.
Cushion on rod side
If moving piston (10) strikes gland (5) without deceleration, impact results. A cushioning mechanism is provided to prevent
it, as shown in following figure.
When the piston is in its intermediate stroke with the head side under pressure, the oil in chamber “A” passes through path
“B” at a constant velocity and returns to the tank. Then if cushion ring (7) plunges into path “B” before the stroke end, the oil
in chamber “A” goes through clearance “D”.
As a result the oil flow returning to the tank decreases sharply which in turn reduces the moving speed of the piston.
Figure 4
Cushion action on rod side
A Chamber T Tank
C Cushion ring 5 Gland
D Clearance 7 Cushion ring
S Stroke
Cushion on piston side

In the same way as the construction of the rod side cushion, the oil passes through path “B” at a constant velocity and goes
back to the tank when the piston is at its intermediate stroke with the rod side under pressure.
Next, if cushion spool (9) plunges into path “B” before the stroke end, the oil goes only through clearance (A) between pass
“B” and cushion spool (9). As a result the oil flow returning to the tank decreases sharply which in turn reduces the speed of
the piston.
Figure 5
Cushion action on piston side
Service Information

Digging unit (mono boom), 970 Service Information 2014/5/12
description
Profile:
Digging unit (mono boom), description
Figure 1
Structure, digging unit
1 Boom 11 Pin 21 Screw 31 Shim

2 Arm 12 Lock pin 22 Screw 32 Shim
3 Bucket 13 Lock pin 23 Screw 33 Shim
4 Connecting rod 14 Lock pin 24 Screw 34 Shim
5 Yoke (left) 15 Pin 25 Nut 35 Shim
6 Yoke (right) 16 Plate 26 Spring washer 36 Shim
7 Pin 17 Nipple 27 Flat washer 37 Shim
8 Pin 18 Lock pin 28 Flat washer 38 Screw
9 Lock pin 19 Bucket cover 29 Code ring 39 Spring washer
10 Pin 20 Bucket bushing 30 Bucket shim 40 Shim
Gap and shims
Items Gap Necessary shims for maximum gap

Position Minimum Maximum Shim part no.(1t) Quantity Shim part no.(0.5 t) Quantity
GAP1 +0.25 +3.5 1173–00200 3 - -
GAP2 +1.0 +2.5 1173–01210 1 1173–01330 1
GAP3 0.0 +3.0 1173–00180 2 - -
GAP4 +0.2 +0.5 - - - -
GAP5 0.0 +1.0 - - - -
GAP6 +1.0 +2.5 1173–00600 1 1173–00590 1
GAP7 0.0 +1.0 - - - -
GAP8 0.0 +2.5 - - - -
GAP9 +0.5 +2.5 - - 1173–00590 2
GAP10 +0.5 +2.5 - - 1173–00190 2
GAP11 +0.5 +2.5 1173–01210 1 1173–01330 1
NOTE!
GAP 1 : Maximum 0.5 mm
NOTE!
Others : Maximum 1.0 mm
Initial lubricating table (unit : g)
Position Initial grease amount Position Initial grease amount

GR1 55 × 2 GR7 11
GR2 120 GR8 10
GR3 90 × 2 GR9 10 × 2
GR4 15 × 2 GR10 10 × 2
GR5 18 × 2 GR11 750
GR6 14 GR12 1500
NOTE!
Grease hose/bearing inner space included.
Hydraulic line connections (mono boom)

Figure 2
Mono boom, piping
1 Pipe 18 Spring washer 34 O-ring

2 Pipe 19 Spring washer 41 U-bolt
3 Pipe 20 Clamp 42 Plate
4 Clamp 21 Clamp 43 Pipe
5 Clamp 22 Clamp 44 Pipe
6 Clamp 23 Hose 45 Pipe
7 Pipe 24 Hose 46 Pipe
8 Pipe 25 Hose 47 Screw
9 Pipe 26 Hose 48 Screw
10 Pipe 27 O-ring 49 Nut
11 Screw 28 O-ring 50 Spring washer
12 Screw 29 O-ring 51 Spring washer
13 Screw 30 Pipe 52 Clamp
14 Screw 31 Screw 53 Hose
15 Screw 32 Spring washer 54 O-ring
16 Screw 33 O-ring 55 O-ring
17 Flat washer 34 Bracket
Service Information

Digging unit, maintenance 970 Service Information 2014/5/12
Profile:
Digging unit, maintenance

Clearance between pins and bushing
Figure 1
Position, clearance checking
Wear limits (unit : mm)
Check item Standard Pin diameter Bushing bore Remedy

Recommende Limit of Recommended Limit of
d service limit use service limit use
A Boom mounting pin 90 89 88.5 91 91.5 Replace
B Boom cylinder mounting pin 80 79 78.5 81 81.5 Replace
C Boom cylinder rod end pin 80 79 78.5 81 81.5 Replace
D Arm cylinder mounting pin 80 79 78.5 81 81.5 Replace
E Boom - arm coupling pin 80 79 78.5 81 81.5 Replace
F Arm cylinder rod end pin 80 79 78.5 81 81.5 Replace
G Bucket cylinder mounting pin 70 69 68.5 71 71.5 Replace
H Arm - link coupling pin 70 69 68.5 71 71.5 Replace
I Bucket - arm coupling pin 70 69 68.5 71 71.5 Replace
J Bucket cylinder rod end pin 70 69 68.5 71 71.5 Replace
K Bucket - link coupling pin 70 69 68.5 71 71.5 Replace
Greasing
Lubricating point (mono boom)
Figure 2
Lubricating position
1 Boom cylinder mounting pin (2EA) 7 Bucket cylinder mounting pin (1EA)
2 Boom mounting pin (2EA) 8 Arm and bucket joint pin (1EA)
3 Boom cylinder rod end pin (2EA) 9 Arm and link joint pin (1EA)
4 Arm cylinder mounting pin (1EA) 10 Connecting rod and link joint pin (1EA)
5 Boom and arm joint pin (2EA) 11 Bucket cylinder rod end pin (1EA)
6 Arm cylinder rod end pin (1EA) 12 Bucket and connecting rod joint pin (2EA)
Lubricating period
Lubricating period
Standard Auto lubrication unit (Option)

Every 10 hours (A, B, C, D) Lubricate point A same as standard.
(No auto-lubrication)
NOTE!
For auto lubricating unit, see operator's manual.
CAUTION
In swamp working condition, oil film may be destroyed due to submersion. Shorten the lubrication hours by 1/5.
NOTE!
Lubricating period is affected by the external working environment. Lubricate pin and bushing with grease as soon as
possible when abnormal noise occurs.
NOTE!
Failure to do this may damage bushing and pin.
Service Information

Stabilizer cylinder, 9722 Service Information 2014/5/31
description
Profile:
Stabilizer cylinder, description
Figure 1
Stabilizer cylinder (sectional view)
1 Tube 8 Retaining ring 15 Step seal (Buffer ring) 22 Dust seal

2 Rod 9 Lock washer 16 O-ring 23 Grease nipple
3 Bushing 10 Lock nut 17 Back-up ring
4 Gland 11 Screw 18 O-ring
5 Piston 12 Dust wiper 19 Contami seal
6 Retaining ring 13 Rod packing 20 Piston packing
7 Bearing 14 Back-up ring 21 Wear ring
Service Information

Boom, installation 9741 Service Information 2014/5/31
Profile:
Boom, installation
 Align superstructure hole with boom pin hole using hoist, and insert boom pin (34) a little.
 Install with hammer, and tighten lock screw (26).
*Adjust shims. After adjusting, make it less than 0.5 mm. (0.02 in)
 Insert o-rings (35) to 4 arm and bucket cylinder connecting hoses (25), and tighten.
 Connect the working lamp connector.
Figure 1
Installation, boom
Service Information

Boom, removal 9741 Service Information 2014/5/31
Profile:
Boom, removal
 Retract boom cylinder, and lower boom to ground.
 Disconnect 4 boom connecting hoses (25), and plug the hoses.
 Remove boom connecting pin lock screw (26).
Figure 1
Removal, boom connecting pin lock screw
 Hold boom cylinder with hoist (27), remove lock screw (28) and cylinder rod pin lock collar (29). Disconnect
lubrication hose (30), and remove pin (31).
 Start the engine and retract boom cylinder rod completely. Stop the engine, and release residual pressure
by operating control lever while start switch is “ON” position.
Figure 2
Removal, pin etc.
 Put boom cylinder on block (A), and disconnect connecting hose (32). Then, plug the hose and cylinder
port.
 Remove lock plate, cylinder pin (33) and the boom cylinder.
Figure 3
Removal, cylinder pin etc.
 Disconnect working lamp connector.

 Hold boom with hoist, and remove boom pin (34) with tool (A). Raise the boom, travel machine backward, and
lower boom safely.
Figure 4
Removal, boom pin
Service Information

Boom lifting cylinder, 9743 Service Information 2014/5/31
Profile:
Boom lifting cylinder, disassembly and assembly

Precautions
General tools
Special tools
Tightening torque
Figure 1
Tightening torque
Cylinder A B C
Piston nut, to tighten Lock nut, to tighten turn Screw
turn clockwise counterclockwise
Boom M 64 M 60 M 16
1st, 2nd boom (TÜV) 35 ± 5 (253 ± 36) 35 ± 5 (253 ± 36) 26.7 ± 2.7 (193 ± 19)
NOTE!
Apply "Three bond 1360K" or "Loctite # 242" to the rod and screw thread before tightening.
Volume of oil leakage

Oil leakage
Cylinder Volume of internal oil leakage

Boom 5.6 cc (0.34 cu·in) or less / 10 min.
Inspection after disassembly

Limit of serviceability
Preparation before disassembly
Disassembly
Assembly
Service Information

Boom lifting cylinder, 9743 Service Information 2014/5/31
installation
Profile:
Boom lifting cylinder, installation

 Move boom cylinder (29) with hoist, and align the hole. Insert pin (33), and tighten lock plate screws.
Figure 1
Assembly, boom cylinder
 Connect cylinder hose (32).
 After starting the engine, align boom cylinder rod eye to the pin.
 If it is aligned, push pin (31) in a little from the opposite side of the boom and install with hammer. Install lock collar
(31) and screw (28). Tighten the lock screw securely, and tighten lock screw (28).
 Connect lubrication hose (30).
Figure 2
Tightening lock screw etc.
Service Information

Dipper arm, installation 9751 Service Information 2014/5/12
Profile:
Dipper arm, installation

 Move arm (15) in to position, and put a block at point (A).
Figure 1
Assembly, dipper arm
 Align boom and arm pin hole. Insert pin (20), and install lock plate (19).
 Extend arm cylinder (18) to align with rod pin hole.
 Insert pin (17), and install lock plate (16).
Service Information

Dipper arm, removal 9751 Service Information 2014/5/12
Profile:
Dipper arm, removal

 Roll in arm (15) completely, and put blocks at points (A).
 Remove arm cylinder lock plate (16), and pin (17).
Figure 1
Removal, arm cylinder lock plate
 After starting the engine, retract arm cylinder (18) rod.
 Remove lock screw (19) and boom - arm connecting pin (20).
 Start the engine and slowly raise the boom.
CAUTION
Ensure the arm is securely blocked. Take appropriate safety measures.
Figure 2
Removal, boom - arm connecting pin
Service Information

Link, installation 9752 Service Information 2014/5/12
Profile:
Link, installation
 Lower arm end to ground, and extend bucket cylinder rod.
 Align connecting rod (9) with arm hole, insert lock pin (10), and tighten lock screw.
Figure 1
Assembly, link
 Align connecting rod hole with bucket cylinder rod hole and link (8) hole. Insert pin (7), and tighten lock screw.
Service Information

Link, removal 9752 Service Information 2014/5/12
Profile:
Link, removal
 Lower arm end to ground.
 Retract bucket cylinder rod completely, and remove pin (7) lock screw.
Figure 1
Removal, connecting rods
 Remove pin (7), and link (8).
CAUTION
Hold the link with a sling so it can not drop.
 Remove pin (10) lock screw connected to arm.

 Remove pin (10) and connecting rods (9).
Service Information

Dipper arm cylinder, 9753 Service Information 2014/5/31
description
Profile:
Dipper arm cylinder, description
Figure 1
Dipper arm cylinder (sectional view)
Figure 2
Dipper arm cylinder (exploded view)
1 Tube 8 Retaining ring 15 Dust seal 22 O–ring

4 Bushing 11 Lock washer 18 Buffer ring 25 Contami seal
6 Bearing 13 Screw 20 O–ring 27 Spring pin
7 Retaining ring 14 Grease nipple 21 Back-up ring 28 Cushion spool
NOTE!
Service Information

Profile:
Dipper arm cylinder, disassembly and assembly

Precautions
General tools
Special tools
Tightening torque
Figure 1
Tightening torque
Cylinder A B C
Arm M 68 M 65 M 16
35 ± 5 (253 ± 36) 35 ± 5 (253 ±36) 26.7 ± 2.7 (193 ± 19)
Oil leakage

Arm 6.0 cc (0.37 cu·in) or less / 10 minutes

Disassembly
Assembly
Service Information

installation
Profile:
Dipper arm cylinder, installation

 Move arm cylinder (18) to installing position.
 Align hole, and mount pin (23).
Figure 1
Assembly, pin
 Install lock plate.
Arm cylinder hose
 Connect arm cylinder hoses (22).
Figure 2
Assembly, cylinder hoses
Service Information

removal
Profile:
Dipper arm cylinder, removal

 Retract boom cylinder, and lower boom to ground.
 Tie the rod to the cylinder with wire.
 Hold arm cylinder with hoist (21).
Figure 1
Holding, arm cylinder
 Disconnect arm cylinder hose (22).
 Remove lock plate, and cylinder pin (23).
 Remove arm cylinder.
 When disconnecting hose (22), cap the hose, then plug cylinder port (24) and tie the hose to the pipe.
Figure 2
Disconnection, arm cylinder hose
Service Information

Bucket cylinder, description 9755 Service Information 2014/5/12
Profile:
Bucket cylinder, description
Figure 1
Bucket cylinder (sectional view)
Figure 2
Bucket cylinder (exploded view)
1 Tube 8 Retaining ring 15 Dust seal 22 O-ring

4 Bushing 11 Lock washer 18 Buffer ring 25 Contami seal
6 Bearing 13 Screw 20 O–ring
7 Retaining ring 14 Grease nipple 21 Back-up ring
NOTE!
Service Information

Bucket cylinder, 9755 Service Information 2014/5/12
Profile:
Bucket cylinder, disassembly and assembly

Precautions
General tools
Special tools
Tightening torque
Figure 1
Tightening torque
Item A B C
Bucket M 64 M 60 M 16
35 ± 5 (253 ± 36) 35 ± 5 (253 ± 36) 26.7 ± 2.7 (193 ± 19)
Oil leakage

Bucket 5.6 cc (0.34 cu·in) or less / 10 minutes

Disassembly
Assembly
Service Information

Bucket cylinder, installation 9755 Service Information 2014/5/12
Profile:
Bucket cylinder, installation

 Move bucket cylinder (12) with hoist, and align with pin hole. Insert pin (14), and install lock plate.
Figure 1
Assembly, bucket cylinder
Connection of hose
 Connect bucket cylinder hose (11).

 Extend bucket cylinder rod.
Service Information

Bucket cylinder, removal 9755 Service Information 2014/5/12
Profile:
Bucket cylinder, removal

WARNING
When the engine is running, the hydraulic line is under high pressure. Stop the engine, and release the residual
pressure by operating the control lever.
 Tie the rod to the cylinder with wire.

 Disconnect bucket cylinder hose (11).
Figure 1
Holding, bucket cylinder with hoist
 Hold bucket cylinder with hoist (12), and remove lock plate (13).
 Remove cylinder pin (14) and bucket cylinder.
 When disconnecting hose (11), cap the hose and tie it to the pipe to prevent oil leakage from the main circuit.
Service Information

Bucket cylinder, 9755 Service Information 2014/5/12
specifications
Profile:
Bucket cylinder, specifications

Specifications

Bucket cylinder Quantity EA 1
Bore × rod × stroke mm (in) φ115 × φ 75 × 990 (φ 4.53 × φ 2.95 × 39.0)
Center to center - Full retracted (A) mm (in) 1500 (59.1)

distance of pins Full extended (B) mm (in) 2940 (115.7)
Cushion - One side (extended - boom curl)
Figure 1
Cylinder length
A. Retracted length
B. Extended length
Service Information

Examples, hydraulic system 990 Service Information 2014/5/12
Profile:
Examples, hydraulic system

Unusual noise comes from the pump connection
Figure 1
Troubleshooting, unusual noise comes from the pump connection
Hydraulic oil is cloudy

Figure 2
Troubleshooting, hydraulic oil is cloudy
Hydraulic oil overheated

Figure 3
Troubleshooting, hydraulic oil overheated
Pump cavitation
Figure 4
Troubleshooting, pump cavitation
Hydraulic oil contaminated
Figure 5
Troubleshooting, hydraulic oil contaminated
Systems do not operate when remote control valve (lever) are operated.
Figure 6
Troubleshooting, systems do not operate when control levers are operated
Actuator moves when remote control valve (lever) is in the neutral position
Figure 7
Troubleshooting, actuator moves when control pressure valve is in the neutral position
The digging unit moves slowly

Figure 8
Troubleshooting, digging unit moves slowly (1)
Figure 9
Troubleshooting, digging unit moves slowly (2)
No cylinders move when control levers are operated.

Figure 10
Troubleshooting, no cylinders move when control levers are operated
Boom raising speed is slow.

Figure 11
Troubleshooting, boom raising speed is slow
No digging power
Figure 12
Troubleshooting, no digging power
Service Information

Examples, power 990 Service Information 2014/5/12
transmission
Profile:
Examples, power transmission

Slew is not smooth
Figure 1
Troubleshooting, slew is not smooth
Abnormal noise in slew motion

Figure 2
Troubleshooting, abnormal noise in slew motion
No slew motion
Figure 3
Troubleshooting, no slew motion
Slow/weak slew power

Figure 4
Troubleshooting, slow/weak slew power
Travel speed is slow

Figure 5
Troubleshooting, travel speed is slow
Left and/or right travel motor does not work.(one direction forward/reverse)
Figure 6
Troubleshooting, left and/or right travel motor does not work (1)
Figure 7
Troubleshooting, left and/or right travel motor does not work (2)
NOTE!
Overload : Track or rollers jammed, or the track is bogged down in mud, swamp etc.
Actuator drops noticeably when control lever is placed in neutral.
Figure 8
Troubleshooting, actuator drops noticeably when control lever is placed in neutral
Actuator drops briefly when starting operation.

Figure 9
Troubleshooting, actuator drops briefly when starting operation
Service Information

Troubleshooting, 990 Service Information 2014/5/12
diagnosing procedure
Profile:
Troubleshooting, diagnosing procedure

If a minor fault is left intact and operation is continued, a failure may be caused, entailing considerable expense and long
hours of restoration. Therefore when a minor defect occurs, do not rely only on your intuition and experience, but look for
the cause based on the troubleshooting principle and perform maintenance and adjustments to prevent a major failure from
occurring. Keep in mind that a failure results from a combination of different causes.
These five basic steps are essential for effective troubleshooting :
1. Study the system.

2. Ask the operator.
3. Inspect the machine.
4. Operate the machine yourself.
5. Trace possible causes.
Study the system

Study the machine"s technical manuals.
Know what the system is composed of, how it works, and the construction, functions and specifications of the system
components.
 Solve the problem by using the trouble shooting charts and hydraulic schematics!
Figure 1
Study the machine"s technical manuals
Ask the operator

Before inspecting, get the full story of the malfunctions from the operator.
Figure 2
Ask the operator
 How is the machine being used? (Find out if the machine is being operated correctly).
 When was the trouble noticed, and what type of work was the machine doing at that time?
 What are the details of the trouble? Is the trouble getting worse, or did it appear suddenly for the first time?
 Did the machine have any other troubles previously? If so, which parts were repaired or replaced before?
 Get all the facts concerning the complaint!
Inspect the machine

Before starting the troubleshooting procedure, check the machine"s daily maintenance points, as shown in the operator"s
manual.
Figure 3
Check the machine"s daily maintenance points
Also, check the electrical system, including the batteries, as troubles in the electrical system such as low battery voltage,
loose connections and blown fuses will result in malfunctions causing an operational failure of the machine.
 Analyze the problem thoroughly!
Operate the machine yourself

Try to identify the trouble by operating the machine yourself.
If the trouble cannot be confirmed, stop the engine and obtain further details of the malfunction from the operator.
 After repairs are completed, operate the machine to ensure that the root cause of the problem has been corrected!
Figure 4
Operate the machine yourself
Trace possible causes

Before reaching a conclusion, check the most likely causes again. Try to identify the actual cause of the trouble.
Based on your conclusion, make a plan for appropriate repairs to avoid consequent malfunctions.
 Do the easiest things first and double check before beginning any disassembly!
Figure 5
Trace all possible causes
Service Information

2 piece boom and cylinder, 996 Service Information 2014/5/31
description
Profile:
2 piece boom and cylinder, description
Figure 1
2nd cylinder
Unit Specification
A mm (in) 1310 (4′ 4″)
B mm (in) 2120 (6′ 11″)
Weight kg (lb) 180 (397)
Figure 2
1st boom
Unit Specification
A mm (in) 1677 (5′ 6″)
Figure 3
2nd boom
Unit Specification
A mm (in) 3700 (12′ 2″)
B mm (in) 793.2 (2′ 7″)
Service Information

2 piece boom valve, 996 Service Information 2014/5/31
description
Profile:
2 piece boom valve, description
Figure 1
2 piece boom valve, structure
1 Shuttle valve 7 Cover

2 Check valve 8 Housing
3 Boom holding check valve 9 Poppet B
4 Cover 10 Poppet A
5 Spool 11 Poppet D
6 Relief valve 12 Check valve C
Spool in neutral position

NOTE!
pi (servo hydraulic signal) : OFF
The position of piston A and poppet B become as shown in the following figure, and passage (5) and (6) will be isolated by
poppet B. As chamber (1) is connected to chamber (2) through orifice (4), pressure Pc is obtained. As poppet D is closed
because section area d1 > d2, chamber (2) and (3) are completely isolated.
Figure 2
2 piece boom, valve spool in neutral position
A. Piston A
B. Poppet B
C. Check valve C
D. Poppet D
E. Servo hydraulic signal port
F. Tank port
G. From port P
Spool operating, boom raising (Pv > Pc)

NOTE!
pi (servo hydraulic signal) : OFF
Main control valve spool moves to the right, the oil from the pump flows to chamber (3). As chamber (1) is connected to
chamber (2) through orifice (4), pressure (Pc) is obtained and poppet D will be opened. The oil high pressure is supplied to
the cylinder piston side.
Figure 3
2 piece boom, valve boom raising
A. Piston A
B. Poppet B
C. Check valve C
D. Poppet D
F. Tank port
G. From port P
Spool operating, boom lowering (Pc < Pv)

NOTE!
pi (servo hydraulic signal) : ON
As chamber (3) is connected to the tank passage by the main control valve spool moving to the left, servo hydraulic pressure
(pi) applied at signal port E, moves piston A upward and the oil opens poppet (B). The oil flows to chamber (3) through
passage (5), (6) and check valve C.
Therefore, pressure Pc is applied to the area difference (d1 - d2) and opens poppet D. The oil from the cylinder piston side
flows to the tank passage.
Figure 4
2 piece boom, valve boom lowering
A. Piston A
B. Poppet B
C. Check valve C
D. Poppet D
F. Tank port
G. From port P
Service Information

2 piece boom, description 996 Service Information 2014/5/31
Profile:
2 piece boom, description

Structure
Figure 1
Structure, digging unit (2 piece boom)
1 1st boom 13 Lock pin 25 Screw 37 Shim

2 2nd boom 14 Lock pin 26 Nut 38 Shim
3 Bucket 15 Lock pin 27 Spring washer 39 Shim
4 Arm 16 Pin 28 Flat washer 40 Screw
5 Connecting rod 17 Plate 29 Flat washer 41 Spring washer
6 Yoke (left) 18 Shim 30 Code ring 42 Pin
7 Yoke (right) 19 Lock pin 31 Shim 43 Pin
8 Pin 20 Bucket cover 32 Shim 44 Shim
9 Pin 21 Bucket bushing 33 Shim 45 Nipple
10 Lock pin 22 Screw 34 Shim 46 Plug
11 Pin 23 Screw 35 Shim
12 Pin 24 Screw 36 Shim
Gap and shims
Items Gap Necessary shims for maximum gap

Position Minimum Maximum Shim part no.(1t) Quantity Shim part no.(0.5 t) Quantity
GAP1 +0.25 +3.5 1173 - 00200 3 - -
GAP2 +1.0 +2.5 1173 - 01210 1 1173 - 01330 1
GAP3 0.0 +3.0 1173 - 00180 2 - -
GAP4 +0.2 +0.5 - - - -
GAP5 0.0 +1.0 - - - -
GAP6 +1.0 +2.5 1173 - 00600 1 1173 - 00590 1
GAP7 0.0 +1.0 - - - -
GAP8 0.0 +2.5 - - - -
GAP9 +0.5 +2.5 1173 - 00600 1 1173 - 00590 1
GAP10 +0.5 +2.5 1173 - 00180 1 1173 - 00190 1
GAP11 +0.5 +2.5 1173–01210 1 1173 - 01330 1
GAP12 +0.5 +2.5 1173 - 01630 1 1173 - 01390 1
GAP13 +0.5 +2.5 1173 - 01630 1 1173 - 01390 1
NOTE!
GAP 1 : Maximum 0.5 mm
NOTE!
Others : Maximum 1.0 mm
Initial lubricating table (unit : g)
Position Initial grease amount Position Initial grease amount Position Initial grease amount
GR1 38 GR7 52 GR13 11
GR2 38 GR8 29 GR14 10
GR3 50 GR9 62 GR15 10 × 2
GR4 44 GR10 15 × 2 GR16 10 × 2
GR5 63 GR11 18 × 2 GR17 750
GR6 35 GR12 14 GR18 1500
NOTE!
Grease hose/bearing inner space included.
Hydraulic line connections (2 piece boom)

Figure 2
2 piece boom, piping
1 Pipe 23 Pipe 45 Pipe

2 Pipe 24 Pipe 46 Pipe
3 O-ring 25 O-ring 47 Pipe
4 Screw 26 Πλατε 48 Screw
5 Spring washer 27 Clamp 49 Screw
6 Bar 28 Clamp 50 U-bolt
7 Plate 29 Screw 51 Nut
8 Plate 30 Clamp 52 Plate
9 Screw 31 Pipe 53 Clamp
10 Screw 32 Pipe 54 Screw
11 Spring washer 33 Screw 55 Hose
12 Flat washer 34 Screw 56 Pipe
13 Nut 35 Screw 57 Pipe
14 Clamp 36 Clamp 58 U-bolt
15 Screw 37 Clamp 59 Plate
16 Hose 38 Clamp 60 Plate
17 Hose 39 Bracket 61 Clamp
18 Hose 40 Pipe 62 Screw
19 Block 41 Pipe 63 Spring washer
20 Block 42 Hose 64 Spring washer
21 O-ring 43 Hose
22 O-ring 44 Pipe
Service Information

2 piece boom, maintenance 996 Service Information 2014/5/31
Profile:
2 piece boom, maintenance

Clearance between pins and bushing
Figure 1
Position, clearance checking
Wear limits (unit : mm)
Check item Standard Pin diameter Bushing bore Remed

Recommende Limit of Recommended Limit y
d service limit use service limit of use
A′ Boom cylinder mounting pin 80 79 78.5 81 81.5 Replace
B′ Boom mounting pin 90 89 88.5 91 91.5 Replace
C′ 2nd boom cylinder mounting pin 90 89 88.5 91 91.5 Replace
D′ 2nd boom cylinder rod end pin 90 89 88.5 91 91.5 Replace
E′ 1st boom cylinder rod end pin 80 79 78.5 81 81.5 Replace
F′ Arm cylinder mounting pin 80 79 78.5 81 81.5 Replace
G′ Arm cylinder rod end pin 80 79 78.5 81 81.5 Replace
H′ Boom - arm coupling pin 80 79 78.5 81 81.5 Replace
I′ Bucket cylinder mounting pin 70 69 68.5 71 71.5 Replace
J′ Arm - link coupling pin 70 69 68.5 71 71.5 Replace
K′ Bucket cylinder rod end pin 70 69 68.5 71 71.5 Replace
L′ Bucket - link coupling pin 70 69 68.5 71 71.5 Replace
M′ Bucket - arm coupling pin 70 69 68.5 71 71.5 Replace
Greasing
Lubricating point
Figure 2
Lubricating position
1 Boom cylinder mounting pin (2EA) 9 Arm cylinder rod end pin (1EA)
2 Boom mounting pin (2EA) 10 Bucket cylinder mounting pin (1EA)
3 1st boom cylinder rod end pin (2EA) 11 Arm and bucket joint pin (1EA)
4 2nd boom cylinder mounting pin (1EA) 12 Arm and link joint pin (1EA)
5 1st boom and 2nd boom joint pin (2EA) 13 Connecting rod and link joint pin (2EA)
6 2nd boom cylinder rod end pin (1EA) 14 Bucket cylinder rod end pin (1EA)
7 Arm cylinder mounting pin (1EA) 15 Bucket and connecting rod joint pin (2EA)
8 Boom and arm joint pin (2EA)
Lubricating period
Lubricating period
Standard Auto lubrication unit (Option)

Every 10 hours (A, B, C, D) Lubricate point A same as standard.
(No auto-lubrication)
NOTE!
For auto lubricating unit, see operator's manual.
CAUTION
In swamp working condition, oil film may be destroyed due to submersion. Shorten the lubrication hours by 1/5.
NOTE!
Lubricating period is affected by the external working environment. Lubricate pin and bushing with grease as soon as
possible when abnormal noise occurs.
NOTE!
Failure to do this may damage bushing and pin.
Service Information

2 piece boom, 996 Service Information 2014/5/31
specifications
Profile:
2 piece boom, specifications
Figure 1
Boom (2 piece)
Dimension, boom (2 piece)
Unit Specification
Boom A mm (ft) 4970 (16′ 4″)
B 5010 (16′ 5″)
C 1350 (4′ 5″)
Width 564 (1′ 10″)
Weight kg (lb) 1630 (3593)
Service Information

2 piece boom, valve 996 Service Information 2014/5/31
disassembly
Profile:
2 piece boom, valve disassembly

Tools, 2 piece boom valve holder
NOTE!
Material : Brass
Figure 1
Valve holder
Disassembly, main spool

NOTE!
For assembly, reverse the disassembly procedures.
NOTE!
1. Remove screw (1), and remove cover (2).
CAUTION
When reassembling, make sure that the o-ring is installed before assembling the cover.
 Allen wrench 8 mm
 Tightening torque : 5 kgf·m (36 lbf·ft)
Figure 2
Removal, cover
2. Pull out the spool sub assembly.
NOTE!
Pull out the spool slowly confirming the housing condition.
Figure 3
Removal, spool
3. Hold the spool with the holder and vise, and loosen spool cap (3).
NOTE!
Remove the oil from the spool and the holder.
 Allen wrench 8 mm
Figure 4
Loosen the spool cap
Figure 5
Spool cap
4. Remove spool cap (3), spring guide (4), spring (5) and spacer (6).
Figure 6
Disassembly, relief valve

NOTE!
NOTE!
1. Loosen sleeve (1) and remove the cartridge.
 Tools : spanner 32 mm
Figure 7
Removal, cartridge
2. Remove cap (2) and pull out spring (3) and servo hydraulic poppet (4).
Figure 8
Removal, servo hydraulic poppet
Figure 9
Disassembly, servo hydraulic poppet
3. Remove servo hydraulic seat (5) and pull out spring (6, 7), piston (8) and main poppet (9).
Figure 10
Removal, main poppet (1)
Figure 11
Removal, main poppet (2)
Disassembly, boom holding valve

NOTE!
NOTE!
1. Main body poppet
A. Remove screw (1) and valve assembly.
CAUTION
When reassembling, make sure that the o-ring is installed on the housing inlet before assembling the
valve.
Figure 12
Removal, valve assembly
B. Remove cap (2) and pull out spring (3) and poppet (4).
Figure 13
Removal, poppet
2. Selector valve
 Remove cap (5) and pull out spring (6) and poppet (7).
Figure 14
Removal, poppet
 Remove cap (8) and pull out spring (9).
 Tools : Allen wrench 10 mm

Figure 15
Removal, spring
 Pull out sleeve (13) by tapping the right side of the housing lightly.
3. Check valve
A. Remove cap (10) and pull out spring (11) and check valve (12).
 Tools : allen wrench 5 mm

Figure 16
Removal, check valve
Disassembly, shuttle valve

NOTE!
NOTE!
1. Remove screw (A) and cover (B).
CAUTION
When reassembling, make sure that the o-ring is installed on the housing inlet before assembling the cover.

Figure 17
Removal, cover
2. Remove cap (1) and pull out shuttle seat (2) and steel ball (3).

Figure 18
Shuttle valve
Figure 19
Removal, steel ball
Disassembly, check valve

NOTE!
NOTE!
1. Remove cap (1) and pull out spring (2) and check valve (3).
 Tools : Spanner 32 mm
Figure 20
Check valve
Figure 21
Removal, spring
Service Information

Disassembly and assembly 996 Service Information 2014/5/31
Profile:
Disassembly and assembly

 Thoroughly clean the valves prior to removal from the machine.

Disassembly, precautions
 Do not use excessive force, sharp or high hardness tools to disassemble the valves.
Assembly, precautions
Happy every day.

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Service Information

Document Title: Function Group: Information Type: Date:

Dimensions (Mono boom), whole machine

Item Symbol Unit Standard Option

Dimensions (2 Piece boom), whole machine

Item Symbol Unit Standard Option

Document Title: Function Group: Information Type: Date:

1 Bucket 13 Slew motor and gearbox 25 Main control valve

Document Title: Function Group: Information Type: Date:

Measurement conversion tables

Unit cm2 m2 km2 a ft2 yd2 in2

Unit cm3 = cc m3 l in3 ft3 yd3

Unit kgf/cm2 bar Pa=N/m2 kPa lbf / in2 lbf / ft2

SI Conversion Non-SI Conversion SI

Document Title: Function Group: Information Type: Date:

Item Unit Specification

Document Title: Function Group: Information Type: Date:

Standard tightening torque

Classification 4T, 5T 10T

Tightening torque (Inch)

Classification 4T, 5T 10T

 N·m (Newton meter) : 1 N·m ≅ 0.1 kgf·m

Tightening torque of split flange screws

Thread diameter Width across Tightening torque

Tightening torque for hydraulic plugs with o-ring

Thread Plug part no. Tightening torque kgf·m (lbf·ft)

Tightening torque for swivel nut fitting with o-ring

Tightening torque for swivel nut fitting

Tube outer Thread size (in) Tightening torque of hose nut

Document Title: Function Group: Information Type: Date:

1 Standard parts, service

16 Lubricants, fuels and other liquids

17202 3.50 Warranty service 100hours, according to service programme

17307 2.50 Maintenance service, every 250 hours

2 Standard parts, service

21102 5.00 Cylinder head, replace gasket

21251 6.00 Flywheel housing, changing

21412 1.75 Valves, adjust

21511 2.25 Timing gear cover, replace

21614 2.50 Crankshaft, replace front oil seal

21711 2.25 Oil sump, replace

22306 2.25 Oil cooler, replace and test

23410 2.00 Fuel tank, replace

23601 0.50 Idling speed, checking and adjusting

23702 1.75 Injectors, replace all

25 Inlet system, exhaust system

25511 1.75 Turbo charger, replace

25601 0.50 Air cleaner, cleaning filter, element

25811 2.00 Charge air cooler, replace

26202 1.50 Coolant pump, replace

26311 0.75 Fan, replace

3 Electrical system, warning system, information

32 Alternator, charge regulator

32205 0.75 Charging regulator, replace

35224 0.25 Head lamp assembly, changing one incl. adjust

35656 0.25 Work lighting, replace one head lamp assembly

36 Other electrical equipment

36211 0.50 Horn, replace