Service Manual Cx350d

SERVICE MANUAL
CX350D CX350D
CX370D CX370D
Crawler Excavator Crawler Excavator
1/3 SERVICE MANUAL

Part number 47843027
Part number 47843027

English
May 2015
© 2015 CNH Industrial Italia S.p.A. All Rights Reserved.
SERVICE MANUAL
CX350D Crawler excavators LC version (TIER4 FINAL) - EU Market

CX350D Crawler excavators NLC version (TIER4 FINAL) - EU Market
47843027 21/05/2015
EN
Contents
INTRODUCTION
Engine....................................................................................... 10
[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
[10.102] Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
[10.106] Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
[10.101] Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
[10.105] Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
[10.103] Crankshaft and flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
[10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
[10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8
[10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9
[10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10
[10.250] Turbocharger and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11
[10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12
[10.500] Selective Catalytic Reduction (SCR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . 10.13
[10.501] Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust
treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14
[10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
[10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
[10.310] Aftercooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
[10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
Hydraulic systems....................................................................... 35
[35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1
[35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2
[35.106] Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3
[35.102] Pump control valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4
[35.304] Combination pump units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5
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[35.359] Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6
[35.357] Pilot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7
[35.355] Hydraulic hand control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.8
[35.356] Hydraulic foot control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.9
[35.352] Hydraulic swing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.10
[35.353] Hydraulic travel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.11
[35.354] Hydraulic central joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.12
[35.736] Boom hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.13
[35.737] Dipper hydraulic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.14
[35.738] Excavator and backhoe bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.15
[35.360] Hammer and rotating bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.16
Frames and ballasting ................................................................. 39

[39.140] Ballasts and supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1
Tracks and track suspension ........................................................ 48

[48.130] Track frame and driving wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.1
[48.100] Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.2
[48.134] Track tension units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.3
[48.138] Track rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.4
Cab climate control ..................................................................... 50

[50.100] Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1
[50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.2
Electrical systems ....................................................................... 55

[55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1
[55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2
[55.525] Cab engine controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3
[55.015] Engine control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4
[55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5
[55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6
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[55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7
[55.202] Cold start aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8
[55.011] Fuel tank system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9
[55.010] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.10
[55.014] Engine intake and exhaust system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.11
[55.988] Selective Catalytic Reduction (SCR) electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . 55.12
[55.989] Exhaust Gas Recirculation (EGR) electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.13
[55.012] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.14
[55.013] Engine oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.15
[55.640] Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.16
[55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.17
[55.036] Hydraulic system control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.18
[55.051] Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls. . . . . . . . . . . . . . . . . 55.19
[55.050] Heating, Ventilation, and Air-Conditioning (HVAC) control system. . . . . . . . . . . . . . . 55.20
[55.524] Cab controls (Lift arm, Boom, Dipper, Bucket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.21
[55.416] Swing control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.22
[55.417] Travel control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.23
[55.530] Camera. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.24
[55.518] Wiper and washer system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.25
[55.404] External lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.26
[55.514] Cab lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.27
[55.408] Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.28
[55.992] Anti-theft system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.29
[55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.30
Booms, dippers, and buckets ....................................................... 84

[84.910] Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.1
[84.912] Dipper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.2
[84.100] Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.3
Platform, cab, bodywork, and decals ............................................. 90

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[90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1
[90.156] Cab glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2
[90.118] Protections and footboards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3
[90.120] Mechanically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.4
[90.100] Engine hood and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.5
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INTRODUCTION
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1
Contents
INTRODUCTION
Foreword - Important notice regarding equipment servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety rules – General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety rules – Personal safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safety rules – ROPS judgment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Torque – Bolt and nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Torque – Special torque setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Basic instructions - Shop and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
General specification – Main equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Weight (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Weight (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Weight (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Weight (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Conversion factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Abbreviation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Product identification - Machine orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
(*) See content for specific models

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Foreword - Important notice regarding equipment servicing

All repair and maintenance work listed in this manual must be carried out only by qualified dealership personnel,
strictly complying with the instructions given, and using, whenever possible, the special tools.
Anyone who performs repair and maintenance operations without complying with the procedures provided herein
shall be responsible for any subsequent damages.
The manufacturer and all the organizations of its distribution chain, including - without limitation - national, regional, or
local dealers, reject any responsibility for damages caused by parts and/or components not approved by the manu-
facturer, including those used for the servicing or repair of the product manufactured or marketed by the manufacturer.
In any case, no warranty is given or attributed on the product manufactured or marketed by the manufacturer in case
of damages caused by parts and/or components not approved by the manufacturer.
The manufacturer reserves the right to make improvements in design and changes in specifications at any time without
notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and
illustrative material herein are as accurate as known at time of publication but are subject to change without notice.
In case of questions, refer to your CASE CONSTRUCTION Sales and Service Networks.
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Safety rules
Personal safety
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all
safety messages that follow this symbol to avoid possible death or injury.
Throughout this manual you will find the signal words DANGER, WARNING, and CAUTION followed by special in-
structions. These precautions are intended for the personal safety of you and those working with you.
Read and understand all the safety messages in this manual before you operate or service the machine.
DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.
WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury.
CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.
FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT

IN DEATH OR SERIOUS INJURY.
Machine safety
NOTICE: Notice indicates a situation that, if not avoided, could result in machine or property damage.
Throughout this manual you will find the signal word Notice followed by special instructions to prevent machine or
property damage. The word Notice is used to address practices not related to personal safety.
Information
NOTE: Note indicates additional information that clarifies steps, procedures, or other information in this manual.
Throughout this manual you will find the word Note followed by additional information about a step, procedure, or
other information in the manual. The word Note is not intended to address personal safety or property damage.
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Safety rules – General information

Cleaning
Clean the metal parts with cleaning solution that meets the standard and steam cleaning. (except for bearings)
After cleaning, dry well, and inject oil in all parts.
Also inject oil into the bearings after drying.
Inspection
When disassembling parts, check all the parts.
If there are any worn or damaged parts, replace them.
Inspect carefully to prevent initial breakdowns.
Bearing
Replace any loose bearings.
Air dry bearings before installing them.
Needle bearing
When inserting needle bearings, be very careful not to damage them.
Apply grease to the section where the needle bearing will be inserted.
Gear
Check that there is no wear and no damage.
Oil seal, O-ring, gasket

Always install new oil seals, O-rings, and gaskets.
Apply grease to sections where oil seals and O-rings will be inserted.
Shaft
Check that there is no wear and no damage.
Check the bearings and check for damaged oil seals on the shaft.
Service parts
Install CASE CONSTRUCTION genuine service parts.
When placing an order, check the parts catalog. It contains the CASE CONSTRUCTION genuine part numbers.
Any breakdowns arising from the installation of non-genuine parts are not covered by the warranty.
Lubricants (fuel, hydraulic oil)

Use the oil from the specified company or specified in the operator's manual or service Manual.
Any breakdowns arising from any fuel or hydraulic oil other than those specified are not covered by the warranty.
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Safety rules – Personal safety

WARNING:
This symbol indicates a precaution.
It gives information concerning the safety of the operator and those in the surroundings.
Read and understand these precautions thoroughly before performing the work.
Always comply with warnings and precautions so as to avoid any accidents.

This section covers information related to overall safety.
Check whether all warning labels are in place.
Additional labels can be ordered from Service Parts.
WARNING:
Read the operator's manual to gain a thorough understanding of machine control operations.
WARNING:
Perform any machine operations from the seating position.
Any other method may cause severe injuries.
WARNING:
Only the one operator is to ride on the machine. No one else is to ride on it.
WARNING:
Check the safety messages in the operator's manual before starting the engine.
Check all the warning labels on the machine.
Check that no one is within the machine’s operating range.
Check the operating methods in a safe location before starting the actual work.
Understand the machine operations well, then operate in compliance with all service-related laws and regulations.
The operator's manual can be purchased at your CASE CONSTRUCTION dealer.
WARNING:
Working with sloppy clothes or clothes with which safety cannot be ensured leads to damage to the machine
and injury to the operator.
Always wear clothes that ensures safety.
In order to work more safely, it is recommended to wear additional safety equipment.
Helmet, safety shoes, ear protection, goggles, work clothes, and gloves
WARNING:
Pay careful attention when working with the engine running.
WARNING:
Check hydraulic equipment.
Work according to the procedure.
Do not change the procedure.
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WARNING:
Check that there is no one in the surroundings before draining the pressure from hydraulic circuits during
machine hydraulic cylinder inspection.
WARNING:
Use gloves when handling high-temperature parts.
WARNING:
Bring the lower parts or attachments in contact with the ground before inspecting or repairing them.
WARNING:
Check that hoses and tubes are securely connected.
If there is any damage to a hose or tube, replace it.
Do not check for oil leaks by hand. Use cardboard or wood.
WARNING:
When removing an attachment pin or other hardened pin, use a hammer that has a soft head.
WARNING:
Wear eye protection when using a hammer to install a pin or when working with a grinder.
At this time, use goggles or eye protectors that meet standards.
WARNING:
Park the machine in a safe location when repairing or inspecting it.
WARNING:
Use work site protection when repairing the machine.
Check the oil, coolant, grease, and tools.
Recover materials and parts as necessary.
Pay enough attention to safety.
WARNING:
Some of the machine's parts are extremely heavy.
Use an appropriate lifting equipment for such parts.
For weights and procedures, see the Service Manual.
WARNING:
Exhaust gases are toxic.
Always provide good ventilation when working indoors or in any other enclosed space.
WARNING:
If the electrolytic battery solution freezes, it may explode.
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Safety rules – ROPS judgment

1. Purpose
Judge whether or not the model is compliant with ROPS by the ROPS criteria.
Compliance with ROPS is highly dependent on its deadweight and boom.
The model has passed the ROPS test for its deadweight with all selectable options installed (as of 2014).
However, the judgment is required because its deadweight or boom position may go beyond the assumption de-
pending on derivative or order conditions.
2. ROPS criteria
Weight
For each class, the following weight shall not be exceeded.
If the weight is exceeded, a cab may become damaged in case of a rollover, causing the operator to die or become
severely disabled.
It is not applicable beyond the criterion.
The ROPS-compliant model shall not exceed the weight shown in the table.
(The following weight is shown on the decal in the ROPS cab.)
Gross body weight Class

CX130D
20500 kg (45194.76 lb) or less CX160D
CX180D
CX210D
32000 kg (70547.92 lb) or less CX250D
CX300D
CX350D
40000 kg (88184.90 lb) or less
CX370D
Boom position
Warning
• If you make such modification as lowers the boom position, ROPS is not applicable.
• Consultation with us is required whenever it is assumed that the boom position is lowered by modification.
• The range of change in the boom position cannot be determined uniformly.
SMIL14CEX2001EA 1
(a) Ground point
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It is not applicable if the position overlapping with a cab on the side view (mark * in the figure) is lowered significantly
as compared with the standard model (standard arm), within the maximum digging radius with the bucket tip on the
surface of the ground.
Moreover, it cannot be said that the 24-ton model, close to the limit weight, with a cab that can bear up to 31-tons and
the 21-ton model with the same cab are the same in the degree of influence.
3. Prohibitions
• Such modification as reduces the strength of the platform where the ROPS cab is installed. (Such action or modi-
fication as reduces the function of the retaining anchor in the left rear of the cab)
• Such modification as affects the ROPS strength of the ROPS cab.
All changes (grinding, welding, drilling, removal, etc.)
Modification prohibited (Red components)
are prohibited.
Removal of components is prohibited.
Conditional modification permitted (Gray components) Welding and drilling of bars (limited to 20 mm (0.79 in)
or less in diameter) are allowed.
Cab (CX130D/CX160D/CX180D)
SMPH15CEX5805FA 2
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Cab (CX210D/CX250D/CX300D)
SMIL14CEX2002FA 3
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Cab (CX350D/CX370D)
The large-sized model (CX350D/CX370D) cab consists of the medium-sized model (CX210D/CX250D/CX300D) cab
in the figure plus seven reinforcements.
SMIL14CEX2003FA 4
The high cab is not supported basically. (Since it varies for each model, consultation with us is required in each case.)
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Torque – Bolt and nut

• Tighten alternating between left and right and top and bottom so that uniform tightening force is applied.
LPIL12CX00005EA 1
• If LOCTITE® was used on a removed bolt (there is something white sticking to the bolt when it is removed), clean the
old LOCTITE® off with cleaning fluid, dry the bolt, then apply 2 - 3 drops of LOCTITE® to the thread section of the bolt.
Torque table
Bolt nominal
M6 M8 M10 M12 M14 M16 M18 M20
diameter (size)
Wrench 10 mm 13 mm 17 mm 19 mm 22 mm 24 mm 27 mm 30 mm
Hexagon 6.9 N·m 19.6 N·m 39.2 N·m 58.8 N·m 98.1 N·m 156.9 N· 196.1 N· 294.2 N·
Tighten-
bolt (5.089 lb (14.456 lb (28.912 lb (43.369 lb (72.355 lb m (115.72 m (144.63 m (216.99
ing torque
ft) ft) ft) ft) ft) 3 lb ft) 6 lb ft) 1 lb ft)
Hexagon
8.8 N·m 21.6 N·m 42.1 N·m 78.5 N·m 117.7 N·m 176.5 N· 245.2 N· 343.2 N·
socket Tighten-
(6.491 lb (15.931 lb (31.051 lb (57.899 lb (86.811 lb m (130.18 m (180.85 m (253.13
head bolt ing torque
ft) ft) ft) ft) ft) 0 lb ft) 0 lb ft) 1 lb ft)
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Torque – Special torque setting

Nominal bolt
Code Retightening location Wrench Tightening torque
diameter
1* Travel motor M24 36 mm 900 - 1051 N·m (664 - 775 lb ft)
2* Drive sprocket M20 30 mm 521 - 608 N·m (384.27 - 448.44 lb ft)
3* Take-up roller M16 24 mm 267 - 312 N·m (196.93 - 230.12 lb ft)
4* Upper roller M20 30 mm 521 - 608 N·m (384.27 - 448.44 lb ft)
5* Lower roller M24 36 mm 902 - 1049 N·m (665 - 774 lb ft)
6* Track guard M24 36 mm 902 - 1049 N·m (665 - 774 lb ft)
7 Shoe M24 32 mm 1236 - 1510 N·m (912 - 1114 lb ft)
8 Counterweight M33 50 mm 1862 - 2058 N·m (1373.34 - 1517.90 lb ft)
9* Turntable bearing M24 36 mm 900 - 1050 N·m (664 - 774 lb ft)
10* Swing unit M24 36 mm 900 - 1050 N·m (664 - 774 lb ft)
11* Mount M20 30 mm 289 - 337 N·m (213 - 249 lb ft)
12* Engine Front bracket M10 17 mm 64 - 73 N·m (47 - 54 lb ft)
13* Rear bracket M12 19 mm 109 - 127 N·m (80 - 94 lb ft)
14* Radiator M16 24 mm 147 - 176 N·m (108 - 130 lb ft)
15* Flange M10 17 mm 64 - 73 N·m (47 - 54 lb ft)
Hydraulic 17 mm
pump hexagon
16* Pump M20 367 - 496 N·m (270.69 - 365.83 lb ft)
socket
head
17* Hydraulic oil tank M16 24 mm 233 - 276 N·m (172 - 204 lb ft)
18* Fuel tank M16 24 mm 233 - 276 N·m (172 - 204 lb ft)
19* Control valve M16 24 mm 267 - 312 N·m (196.93 - 230.12 lb ft)
20* Lock bar M16 24 mm 267 - 312 N·m (196.93 - 230.12 lb ft)
Center joint
21* Joint M12 19 mm 109 - 127 N·m (80.39 - 93.67 lb ft)
22 Cab M16 24 mm 149 - 173 N·m (109.90 - 127.60 lb ft)
23 Battery M10 17 mm 20 - 29 N·m (15 - 21 lb ft)
CAUTION:
• Make sure to apply LOCTITE® 262™ or equivalent to the locations with the * mark, and tighten according to the
specified torque.
• Tightening torque: N・m÷9.8 = kgf・m
Tighten bolts and nuts that are not specified in the above table, as follows:
Nominal bolt diameter (Size) M6 M8 M10 M12 M14 M16 M18 M20
Hexagon bolt Tightening 19.6 N· 39.2 N· 58.8 N· 98.1 N· 156.9 N· 196.1 294.2 N·
torque 6.9 N·m
m m m m m N·m m
Hexagon socket
Tightening 21.6 N· 42.1 N· 78.5 N· 117.7 N· 176.5 N· 245.2 343.2 N·
head bolt torque 8.8 N·m
m m m m m N·m m
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SMIL14CEX2929HB 1
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SMIL14CEX2930HB 2
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SMIL14CEX2931GB 3
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Basic instructions - Shop and assembly

Shimming
For each adjustment operation, select adjusting shims and measure the adjusting shims individually using a microm-
eter, then add up the recorded values. Do not rely on measuring the entire shimming set, which may be incorrect, or
the rated value shown on each shim.
Rotating shaft seals

For correct rotating shaft seal installation, proceed as follows:
1. Before assembly, allow the seal to soak in the oil it will be sealing for at least thirty minutes.
2. Thoroughly clean the shaft and check that the working surface on the shaft is not damaged.
3. Position the sealing lip facing the fluid.
NOTE: With hydrodynamic lips, take into consideration the shaft rotation direction and position the grooves so that
they will move the fluid towards the inner side of the seal.
4. Coat the sealing lip with a thin layer of lubricant (use oil rather than grease). Fill the gap between the sealing lip
and the dust lip on double lip seals with grease.
5. Insert the seal in its seat and press down using a flat punch or seal installation tool. Do not tap the seal with a
hammer or mallet.
6. While you insert the seal, check that the seal is perpendicular to the seat. When the seal settles, make sure that
the seal makes contact with the thrust element, if required.
7. To prevent damage to the seal lip on the shaft, position a protective guard during installation operations.
O-ring seals
Lubricate the O-ring seals before you insert them in the seats. This will prevent the O-ring seals from overturning and
twisting, which would jeopardize sealing efficiency.
Sealing compounds
Apply a sealing compound on the mating surfaces when specified by the procedure. Before you apply the sealing
compound, prepare the surfaces as directed by the product container.
Spare parts
Only use CNH Original Parts or CASE CONSTRUCTION Original Parts.
Only genuine spare parts guarantee the same quality, duration, and safety as original parts, as they are the same
parts that are assembled during standard production. Only CNH Original Parts or CASE CONSTRUCTION Original
Parts can offer this guarantee.
When ordering spare parts, always provide the following information:

• Machine model (commercial name) and Product Identification Number (PIN)
• Part number of the ordered part, which can be found in the parts catalog
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Protecting the electronic and/or electrical systems during charging and welding
To avoid damage to the electronic and/or electrical systems, always observe the following practices:
1. Never make or break any of the charging circuit connections when the engine is running, including the battery
connections.
2. Never short any of the charging components to ground.
3. Always disconnect the ground cable from the battery before arc welding on the machine or on any machine
attachment.
• Position the welder ground clamp as close to the welding area as possible.
• If you weld in close proximity to a computer module, then you should remove the module from the machine.
• Never allow welding cables to lie on, near, or across any electrical wiring or electronic component while you
weld.
4. Always disconnect the negative cable from the battery when charging the battery in the machine with a battery
charger.
NOTICE: If you must weld on the unit, you must disconnect the battery ground cable from the machine battery.
The electronic monitoring system and charging system will be damaged if this is not done.
5. Remove the battery ground cable. Reconnect the cable when you complete welding.
WARNING
Battery acid causes burns. Batteries contain sulfuric acid.
Avoid contact with skin, eyes or clothing. Antidote (external): Flush with water. Antidote (eyes): flush
with water for 15 minutes and seek medical attention immediately. Antidote (internal): Drink large
quantities of water or milk. Do not induce vomiting. Seek medical attention immediately.
Failure to comply could result in death or serious injury.
W0111A
Special tools
The special tools that CASE CONSTRUCTION suggests and illustrate in this manual have been specifically re-
searched and designed for use with CASE CONSTRUCTION machines. The special tools are essential for reliable
repair operations. The special tools are accurately built and rigorously tested to offer efficient and long-lasting oper-
ation.
By using these tools, repair personnel will benefit from:

• Operating in optimal technical conditions
• Obtaining the best results
• Saving time and effort
• Working in safe conditions
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General specification
CX350D Crawler excavators LC version (TIER4 FINAL) - EU Market WE
Engine
Water-cooled, 4-cycle diesel, 6-cylinder in line, High pressure common
Type rail system (electric control), Turbocharger with air cooled intercooler,
SCR system
Model ISUZU AQ-6HK1X
Rated flywheel horse power
ISO 9249 200 kW (272 Hp) at 1900 RPM
ISO 14396 210 kW (286 Hp) at 1900 RPM
Piston displacement 7790 cm³ (475 in³)
Maximum torque
ISO 9249 988 N·m (729 lb ft) at 1500 RPM
ISO 14396 1020 N·m (752 lb ft) at 1500 RPM
Bore and stroke 115 - 125 mm (4.53 - 4.92 in)
Voltage 24 V
Alternator 50 A
Starter 24 V 5.0 kW
Hydraulic system
Main pumps 2 variable displacement axial piston pumps with regulating system
2 × 300.0 L (79.3 US gal) at
Max. oil flow
1900 RPM
34.3 MPa (4975 psi)
Boom/Arm/Bucket 37.3 MPa (5410 psi) with auto
Working circuit pressure power up
Swing circuit 30.4 MPa (4410 psi)
Travel circuit 34.3 MPa (4975 psi)
Pilot pump 1 gear pump
Max. oil flow 28.5 L (7.5 US gal)
Working circuit pressure 3.9 MPa (566 psi)
Control valves With Boom/Arm holding valve
One 4-spool valve for Right track travel, Bucket, Boom and Arm
acceleration
One 5-spool valve for Left track travel, Auxiliary, Swing, Boom
acceleration and Arm
Swing device
Motor Fixed displacement axial piston motor
Brake Mechanical disc brake
Final drive Planetary gear reduction
Turn table bearing Ball bearing type with internal gear
Maximum swing speed 9.7 RPM
Swing torque 112.000 N·m (82.607 lb ft)
Cylinders NO. of cylinders – bore X Rod diameter X Stroke
Boom 2 x Ø 145 mm (5.709 in) - Ø 100 mm (3.937 in) - 1495 mm (58.858 in)
Arm 1 x Ø 170 mm (6.693 in) - Ø 120 mm (4.724 in) - 1748 mm (68.819 in)
Bucket 1 x Ø 150 mm (5.906 in) - Ø 105 mm (4.134 in) - 1210 mm (47.638 in)
Cooling system
Fan Ø 850 mm (33.5 in) with 6-blades
Radiator capacity 85.7 kW (73,700 kcal/h)
fin type Corrugated fin (wavy type)
fin space 1.75 mm (0.06890 in)
Long life coolant Coolant 55 % , Water 45 %
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Oil cooler capacity 52.9 kW (45,500 kcal/h)

Intercooler capacity 25.7 kW (22,100 kcal/h)
Fuel cooler capacity 1.7 kW (1,410 kcal/h)
Filters
Suction filter 105 μm
Return filter 6 μm
Pilot line filter 8 μm
Hydraulic controls
Boom/Arm/Bucket/Swing Pilot pressure control system (ISO control pattern)
Travel Pilot pressure control system
SP - mode
Work mode select H - mode
Auto - mode
Travel mode select 2-speed travel
Attachment cushion control
Hydraulic lock (gate lock, left side tilt console)
Electrical system
Engine control
Dial type throttle control
One touch idle / Auto deceleration / Auto idle
shutdown system
Emergency stop
Monitor system
Message display (Caution, condition, etc.)
Work mode display (SP, H, Auto)
Machine condition (Power boost, etc.)
Alarm display and buzzer
Water temperature
Hydraulic oil temperature
Fuel level
Diagnosis system
Rear view camera image
Urea water level
Wire harness
Waterproof type connector
Safety
Travel alarm
Double horn
Battery 2 X 12 V 128 A·h/5HR
Lights
Working light Upper 24 V 70 W X 1
Boom 24 V 70 W X 1
Cab 24 V 70 W X 2
Operator's cab room 24 V 70 W X 1
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Operator environment
Operator's cab
Smooth and round shape design cab, fabricated by press work
Safety glass for all windows
Shock-less cab suspension by 4-point fluid mounting
Sliding front window with auto lock
Built-in type full-color LCD monitor display
Membrane switch on monitor display
Windshield wiper & washer
Floor mat
Polycarbonate roof hatch & Sun shade
Auto air-conditioner
Rain deflector
Sun visor
Roll-over protective structure (ROPS)
Top guard OPG level 1 (in CAB structure)
Top guard OPG level 2 (additional guard)
Operator's seat
Low frequency air suspension with air springs and double acting hydraulic damper. (Achieves ISO7096
in category EM6)
With following features
Manual weight adjustment Backrest angle adjustment
Seat height adjustment Adjustable pivoting armrests linked to consoles
Adjustable headrest Retractable seat belt
Adjustable lumbar support Control consoles adjust independently of seat
Others
Rear view mirror (Cab side & Right side)
Rear view Camera
Undercarriage
Travel motor Variable displacement axial piston motor
Hydraulic service brake Brake valve
5.5 km/h (3.4 mph) (Automatic travel speed
High
Travel speeds shifting)
Low 3.3 km/h (2.1 mph)
Drawbar pull 273 kN (61373 lb)
Number of carrier rollers (each side) 2
Number of track rollers (each side) 8
Number of shoes (each side) 48
Type of shoe Triple grouser shoe
Link pitch 216 mm (8.504 in)
Width of shoe 600 mm (23.622 in) (S.T.D)
Grade-ability 70 % ( 35 ° )
Mass
Operating mass 35800 kg (78925.49 lb)
with 3.25 m (10.6627 ft) Arm, 1.4 m³ Bucket, 600 mm (23.622 in) grouser shoe, operator, lubricant,
coolant and full fuel tank
Shipping mass 34100 kg (75177.63 lb)
Operating mass - (operator mass [ 75 kg (165.35 lb)) + 90 % of fuel mass [ 440 kg (970.03 lb) ]+ bucket
mass [ 1180 kg (2601.45 lb) ]
Counter weight mass 6400 kg (14109.58 lb)
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Ground pressure 0.067 MPa (9.718 psi)

with 3.25 m (10.6627 ft) Arm, 1.4 m³ Bucket, 600 mm (23.622 in) grouser shoe
Digging force (with 1.4 m³ bucket) ( ISO 6015 )

3.25 m (10.6627 ft) 2.21 m (7.2507 ft) 2.63 m (8.6286 ft) 4.04 m (13.2546 ft)
Arm Arm Arm Arm
Arm digging force 164.5 kN (36981.1 lb) 225.3 kN (50649.5 lb) 194.7 kN (43770.3 lb) 140.0 kN (31473.3 lb)
With auto power up 178.8 kN (40195.8 lb) 245.0 kN (55078.2 lb) 211.7 kN (47592.1 lb) 152.2 kN (34215.9 lb)
Bucket digging force 229.7 kN (51638.6 lb) 229.7 kN (51638.6 lb) 229.7 kN (51638.6 lb) 229.7 kN (51638.6 lb)
Dimensions
3.25 m (10.6627 ft) 2.21 m (7.2507 ft) 2.63 m (8.6286 ft) 4.04 m (13.2546 ft)
Arm Arm Arm Arm
Overall length 6010 mm 6010 mm 6010 mm 6010 mm
(without attachment) (236.614 in) (236.614 in) (236.614 in) (236.614 in)
Overall length (with 11170 mm 11250 mm 11220 mm 11190 mm
attachment) (439.764 in) (442.913 in) (441.732 in) (440.551 in)
Overall height (to top 3470 mm 3620 mm 3630 mm 3620 mm
of boom) (136.614 in) (142.520 in) (142.913 in) (142.520 in)
of Cab) (128.346 in) (128.346 in) (128.346 in) (128.346 in)
of guardrail) (136.614 in) (136.614 in) (136.614 in) (136.614 in)
Upper structure 3030 mm 3030 mm 3030 mm 3030 mm
overall width (119.291 in) (119.291 in) (119.291 in) (119.291 in)
Swing (rear end) 3550 mm 3550 mm 3550 mm 3550 mm
radius (139.764 in) (139.764 in) (139.764 in) (139.764 in)
Clearance height
1210 mm (47.638 in) 1210 mm (47.638 in) 1210 mm (47.638 in) 1210 mm (47.638 in)
under upper structure
Minimum ground
clearance
Wheel base (Center 4040 mm 4040 mm 4040 mm 4040 mm
to center of wheels) (159.055 in) (159.055 in) (159.055 in) (159.055 in)
4980 mm 4980 mm 4980 mm 4980 mm
Crawler overall length
(196.063 in) (196.063 in) (196.063 in) (196.063 in)
2600 mm 2600 mm 2600 mm 2600 mm
Track gauge
(102.362 in) (102.362 in) (102.362 in) (102.362 in)
Undercarriage overall
3200 mm 3200 mm 3200 mm 3200 mm
width [with 600 mm
(125.984 in) (125.984 in) (125.984 in) (125.984 in)
(23.622 in) shoes]
Crawler tracks height 1090 mm (42.913 in) 1090 mm (42.913 in) 1090 mm (42.913 in) 1090 mm (42.913 in)
Working ranges
3.25 m (10.6627 ft) 2.21 m (7.2507 ft) 2.63 m (8.6286 ft) 4.04 m (13.2546 ft)
Arm Arm Arm Arm
6450 mm 6450 mm 6450 mm 6450 mm
Boom length
(253.937 in) (253.937 in) (253.937 in) (253.937 in)
Bucket radius 1680 mm (66.142 in) 1680 mm (66.142 in) 1680 mm (66.142 in) 1680 mm (66.142 in)
Bucket wrist action 173 ° 173 ° 173 ° 173 °
Maximum reach at 10980 mm 9970 mm 10450 mm 11710 mm
GRP (432.283 in) (392.520 in) (411.417 in) (461.024 in)
11170 mm 10180 mm 10650 mm 11900 mm
Maximum reach
(439.764 in) (400.787 in) (419.291 in) (468.504 in)
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INTRODUCTION
7340 mm 6300 mm 6720 mm 8140 mm

Max. digging depth
(288.976 in) (248.031 in) (264.567 in) (320.472 in)
10380 mm 9830 mm 10280 mm 10650 mm
Max. digging height
(408.661 in) (387.008 in) (404.724 in) (419.291 in)
7240 mm 6730 mm 7110 mm 7530 mm
Max. dumping height
(285.039 in) (264.961 in) (279.921 in) (296.457 in)
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INTRODUCTION
CX350D Crawler excavators NLC version (TIER4 FINAL) - EU Market WE
Engine
SCR system
ISO 9249 200 kW (272 Hp) at 1900 RPM
ISO 14396 210 kW (286 Hp) at 1900 RPM
Maximum torque
ISO 9249 988 N·m (729 lb ft) at 1500 RPM
ISO 14396 1020 N·m (752 lb ft) at 1500 RPM
Voltage 24 V
Alternator 50 A
Starter 24 V 5.0 kW
Hydraulic system
2 × 300.0 L (79.3 US gal) at
Max. oil flow
1900 RPM
34.3 MPa (4975 psi)
acceleration
Swing device
Cooling system
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INTRODUCTION

Filters
Return filter 6 μm
Hydraulic controls
SP - mode
Auto - mode
Electrical system
Engine control
shutdown system
Emergency stop
Monitor system
Water temperature
Fuel level
Diagnosis system
Urea water level
Wire harness
Safety
Travel alarm
Double horn
Lights
Boom 24 V 70 W X 1
Cab 24 V 70 W X 2
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INTRODUCTION
Operator's cab
Floor mat
Rain deflector
Sun visor
Operator's seat
in category EM6)
Others
Rear view Camera
Undercarriage
High
Mass
coolant, full fuel tank and top guard OPG level 2
mass [ 1180 kg (2601.45 lb) ]
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INTRODUCTION


3.25 m (10.6627 ft) 2.21 m (7.2507 ft) 2.63 m (8.6286 ft) 4.04 m (13.2546 ft)
Arm Arm Arm Arm
Arm digging force 164.5 kN (36981.1 lb) 225.3 kN (50649.5 lb) 194.7 kN (43770.3 lb) 140.0 kN (31473.3 lb)
Bucket digging force 229.7 kN (51638.6 lb) 229.7 kN (51638.6 lb) 229.7 kN (51638.6 lb) 229.7 kN (51638.6 lb)
Dimensions
3.25 m (10.6627 ft) 2.21 m (7.2507 ft) 2.63 m (8.6286 ft) 4.04 m (13.2546 ft)
Arm Arm Arm Arm
Overall length 6010 mm 6010 mm 6010 mm 6010 mm
(without attachment) (236.614 in) (236.614 in) (236.614 in) (236.614 in)
Overall length (with 11170 mm 11250 mm 11220 mm 11190 mm
attachment) (439.764 in) (442.913 in) (441.732 in) (440.551 in)
of boom) (136.614 in) (142.520 in) (142.913 in) (142.520 in)
of Cab) (128.346 in) (128.346 in) (128.346 in) (128.346 in)
of guardrail) (136.614 in) (136.614 in) (136.614 in) (136.614 in)
Upper structure 3030 mm 3030 mm 3030 mm 3030 mm
overall width (119.291 in) (119.291 in) (119.291 in) (119.291 in)
Swing (rear end) 3550 mm 3550 mm 3550 mm 3550 mm
radius (139.764 in) (139.764 in) (139.764 in) (139.764 in)
Clearance height
under upper structure
Minimum ground
clearance
Wheel base (Center 4040 mm 4040 mm 4040 mm 4040 mm
to center of wheels) (159.055 in) (159.055 in) (159.055 in) (159.055 in)
4980 mm 4980 mm 4980 mm 4980 mm
Crawler overall length
(196.063 in) (196.063 in) (196.063 in) (196.063 in)
Track gauge 2390 mm (94.094 in) 2390 mm (94.094 in) 2390 mm (94.094 in) 2390 mm (94.094 in)
Undercarriage overall
2990 mm 2990 mm 2990 mm 2990 mm
width [with 600 mm
(117.717 in) (117.717 in) (117.717 in) (117.717 in)
(23.622 in) shoes]
Crawler tracks height 1090 mm (42.913 in) 1090 mm (42.913 in) 1090 mm (42.913 in) 1090 mm (42.913 in)
Working ranges
3.25 m (10.6627 ft) 2.21 m (7.2507 ft) 2.63 m (8.6286 ft) 4.04 m (13.2546 ft)
Arm Arm Arm Arm
6450 mm 6450 mm 6450 mm 6450 mm
Boom length
(253.937 in) (253.937 in) (253.937 in) (253.937 in)
Bucket radius 1680 mm (66.142 in) 1680 mm (66.142 in) 1680 mm (66.142 in) 1680 mm (66.142 in)
Bucket wrist action 173 ° 173 ° 173 ° 173 °
Maximum reach at 10980 mm 9970 mm 10450 mm 11710 mm
GRP (432.283 in) (392.520 in) (411.417 in) (461.024 in)
11170 mm 10180 mm 10650 mm 11900 mm
Maximum reach
(439.764 in) (400.787 in) (419.291 in) (468.504 in)
7340 mm 6300 mm 6720 mm 8140 mm
Max. digging depth
(288.976 in) (248.031 in) (264.567 in) (320.472 in)
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INTRODUCTION
10380 mm 9830 mm 10280 mm 10650 mm

Max. digging height
(408.661 in) (387.008 in) (404.724 in) (419.291 in)
7240 mm 6730 mm 7110 mm 7530 mm
Max. dumping height
(285.039 in) (264.961 in) (279.921 in) (296.457 in)
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INTRODUCTION
Engine
SCR system
ISO 9249 200 kW (272 Hp) at 1900 RPM
ISO 14396 210 kW (286 Hp) at 1900 RPM
Maximum torque
ISO 9249 988 N·m (729 lb ft) at 1500 RPM
ISO 14396 1020 N·m (752 lb ft) at 1500 RPM
Voltage 24 V
Alternator 50 A
Starter 24 V 5.0 kW
Hydraulic system
2 × 300.0 L (79.3 US gal) at
Max. oil flow
1900 RPM
34.3 MPa (4975 psi)
acceleration
Swing device
Cooling system
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INTRODUCTION

Filters
Return filter 6 μm
Hydraulic controls
SP - mode
Auto - mode
Electrical system
Engine control
shutdown system
Emergency stop
Monitor system
Water temperature
Fuel level
Diagnosis system
Urea water level
Wire harness
Safety
Travel alarm
Double horn
Lights
Boom 24 V 70 W X 1
Cab 24 V 70 W X 2
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INTRODUCTION
Operator's cab
Floor mat
Rain deflector
Sun visor
Operator's seat
in category EM6)
Others
Rear view Camera
Undercarriage
High
Mass
coolant and full fuel tank
mass [ 1180 kg (2601.45 lb) ]
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INTRODUCTION


3.25 m (10.6627 ft) Arm 2.21 m (7.2507 ft) Arm 2.63 m (8.6286 ft) Arm
Arm digging force 164.5 kN (36981.1 lb) 225.3 kN (50649.5 lb) 194.7 kN (43770.3 lb)
With auto power up 178.8 kN (40195.8 lb) 245.0 kN (55078.2 lb) 211.7 kN (47592.1 lb)
Bucket digging force 229.7 kN (51638.6 lb) 229.7 kN (51638.6 lb) 229.7 kN (51638.6 lb)
Dimensions
Overall length (without
6010 mm (236.614 in) 6010 mm (236.614 in) 6010 mm (236.614 in)
attachment)
Overall length (with
11170 mm (439.764 in) 11250 mm (442.913 in) 11220 mm (441.732 in)
attachment)
Overall height (to top of
3470 mm (136.614 in) 3620 mm (142.520 in) 3630 mm (142.913 in)
boom)
3260 mm (128.346 in) 3260 mm (128.346 in) 3260 mm (128.346 in)
Cab)
3470 mm (136.614 in) 3470 mm (136.614 in) 3470 mm (136.614 in)
guardrail)
Upper structure overall
3030 mm (119.291 in) 3030 mm (119.291 in) 3030 mm (119.291 in)
width
Swing (rear end) radius 3550 mm (139.764 in) 3550 mm (139.764 in) 3550 mm (139.764 in)
Clearance height under
1210 mm (47.638 in) 1210 mm (47.638 in) 1210 mm (47.638 in)
upper structure
Minimum ground clearance 470 mm (18.504 in) 470 mm (18.504 in) 470 mm (18.504 in)
Wheel base (Center to
4040 mm (159.055 in) 4040 mm (159.055 in) 4040 mm (159.055 in)
center of wheels)
Crawler overall length 4980 mm (196.063 in) 4980 mm (196.063 in) 4980 mm (196.063 in)
Track gauge 2600 mm (102.362 in) 2600 mm (102.362 in) 2600 mm (102.362 in)
Undercarriage overall width
[with 600 mm (23.622 in) 3200 mm (125.984 in) 3200 mm (125.984 in) 3200 mm (125.984 in)
shoes]
Crawler tracks height 1090 mm (42.913 in) 1090 mm (42.913 in) 1090 mm (42.913 in)
Working ranges
Boom length 6450 mm (253.937 in) 6450 mm (253.937 in) 6450 mm (253.937 in)
Bucket radius 1680 mm (66.142 in) 1680 mm (66.142 in) 1680 mm (66.142 in)
Bucket wrist action 173 ° 173 ° 173 °
Maximum reach at GRP 10980 mm (432.283 in) 9970 mm (392.520 in) 10450 mm (411.417 in)
Maximum reach 11170 mm (439.764 in) 10180 mm (400.787 in) 10650 mm (419.291 in)
Max. digging depth 7340 mm (288.976 in) 6300 mm (248.031 in) 6720 mm (264.567 in)
Max. digging height 10380 mm (408.661 in) 9830 mm (387.008 in) 10280 mm (404.724 in)
Max. dumping height 7240 mm (285.039 in) 6730 mm (264.961 in) 7110 mm (279.921 in)
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INTRODUCTION
Engine
SCR system
ISO 9249 200 kW (272 Hp) at 1900 RPM
ISO 14396 210 kW (286 Hp) at 1900 RPM
Maximum torque
ISO 9249 988 N·m (729 lb ft) at 1500 RPM
ISO 14396 1020 N·m (752 lb ft) at 1500 RPM
Voltage 24 V
Alternator 50 A
Starter 24 V 5.0 kW
Hydraulic system
2 × 300.0 L (79.3 US gal) at
Max. oil flow
1900 RPM
34.3 MPa (4975 psi)
acceleration
Swing device
Cooling system
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INTRODUCTION

Filters
Return filter 6 μm
Hydraulic controls
SP - mode
Auto - mode
Electrical system
Engine control
shutdown system
Emergency stop
Monitor system
Water temperature
Fuel level
Diagnosis system
Urea water level
Wire harness
Safety
Travel alarm
Double horn
Lights
Boom 24 V 70 W X 1
Cab 24 V 70 W X 2
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INTRODUCTION
Operator's cab
Floor mat
Rain deflector
Sun visor
Operator's seat
in category EM6)
Others
Rear view Camera
Undercarriage
High
Mass
coolant, full fuel tank and top guard OPG level 2
mass [ 1180 kg (2601.45 lb) ]
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INTRODUCTION


Arm digging force 164.5 kN (36981.1 lb) 225.3 kN (50649.5 lb) 194.7 kN (43770.3 lb)
Bucket digging force 229.7 kN (51638.6 lb) 229.7 kN (51638.6 lb) 229.7 kN (51638.6 lb)
Dimensions
Overall length (without
6010 mm (236.614 in) 6010 mm (236.614 in) 6010 mm (236.614 in)
attachment)
Overall length (with
11170 mm (439.764 in) 11250 mm (442.913 in) 11220 mm (441.732 in)
attachment)
3470 mm (136.614 in) 3620 mm (142.520 in) 3630 mm (142.913 in)
boom)
3260 mm (128.346 in) 3260 mm (128.346 in) 3260 mm (128.346 in)
Cab)
3470 mm (136.614 in) 3470 mm (136.614 in) 3470 mm (136.614 in)
guardrail)
Upper structure overall
3030 mm (119.291 in) 3030 mm (119.291 in) 3030 mm (119.291 in)
width
Swing (rear end) radius 3550 mm (139.764 in) 3550 mm (139.764 in) 3550 mm (139.764 in)
Clearance height under
1210 mm (47.638 in) 1210 mm (47.638 in) 1210 mm (47.638 in)
upper structure
Minimum ground clearance 470 mm (18.504 in) 470 mm (18.504 in) 470 mm (18.504 in)
Wheel base (Center to
4040 mm (159.055 in) 4040 mm (159.055 in) 4040 mm (159.055 in)
center of wheels)
Crawler overall length 4980 mm (196.063 in) 4980 mm (196.063 in) 4980 mm (196.063 in)
Track gauge 2390 mm (94.094 in) 2390 mm (94.094 in) 2390 mm (94.094 in)
Undercarriage overall width
[with 600 mm (23.622 in) 2990 mm (117.717 in) 2990 mm (117.717 in) 2990 mm (117.717 in)
shoes]
Crawler tracks height 1090 mm (42.913 in) 1090 mm (42.913 in) 1090 mm (42.913 in)
Working ranges
Boom length 6450 mm (253.937 in) 6450 mm (253.937 in) 6450 mm (253.937 in)
Bucket radius 1680 mm (66.142 in) 1680 mm (66.142 in) 1680 mm (66.142 in)
Bucket wrist action 173 ° 173 ° 173 °
Maximum reach at GRP 10980 mm (432.283 in) 9970 mm (392.520 in) 10450 mm (411.417 in)
Maximum reach 11170 mm (439.764 in) 10180 mm (400.787 in) 10650 mm (419.291 in)
Max. digging depth 7340 mm (288.976 in) 6300 mm (248.031 in) 6720 mm (264.567 in)
Max. digging height 10380 mm (408.661 in) 9830 mm (387.008 in) 10280 mm (404.724 in)
Max. dumping height 7240 mm (285.039 in) 6730 mm (264.961 in) 7110 mm (279.921 in)
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INTRODUCTION
General specification – Main equipment

Lower component
Travel unit
Manufacturer KYB Corporation
Motor type Variable displacement piston motor
Automatic 2-speed switchover with parking brake
Absorption amount 181.3 - 106.7 cm³/rev (11.1 - 6.5 in³/rev)
Operating pressure 34.3 MPa (4975 psi)
Operating flow 292.5 l/min (292.500 US gpm)
Brake torque 41.285 N·m or more (reduction gear included)
Relief valve set pressure 35.3 MPa (5120 psi)
Automatic 2-speed switch over pressure 25 - 27 MPa (3597 - 3884 psi)
Reduction gear
Reduction gear type Planetary gear 2-stage reduction gear
Reduction ratio 65.783
Dry weight 394 kg (868.621 lb)
Take-up roller
Weight 168 kg (370.377 lb)
Upper roller
Weight 42 kg (92.594 lb)
Lower roller
Recoil spring
Item Weight Quantity
Yoke 78.6 kg (173.2833 lb) 1
Sems B M16 X 50 1.0 kg (2.205 lb) 4
Threaded rod 50.7 kg (111.7744 lb) 1
Deep groove nut M64 1.9 kg (4.1888 lb) 1
SP pin 10 x 100 0.1 kg (0.2205 lb) 1
Recoil spring 124.6 kg (274.6960 lb) 1
Grease cylinder assembly 41.1 kg (90.6100 lb) 1
Sems B M16 X 65 0.3 kg (0.6614 lb) 2
Assembly (total) 298 kg (656.9775 lb)
Mounting length of spring 781 mm (30.7480 in)
Shoes CX350D LC - CX370D LC - CX370D NLC

Weight or quantity
600 grouser (shoe) 2217 kg (4887.648 lb)
Link 1 pair
Shoes 48
Bolt 192
Nut 192
Link 1 pair
Shoes 48
Bolt 192
Nut 192
Link 1 pair
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INTRODUCTION
Weight or quantity
Shoe 48
Bolt 192
Nut 192
Shoes CX350D NLC

Weight or quantity
Link 1 pair
Shoes 48
Bolt 192
Nut 192
Link 1 pair
Shoes 48
Bolt 192
Nut 192
Link 1 pair
Shoe 48
Bolt 192
Nut 192
Link 1 pair
Shoe 48
Bolt 192
Nut 192
Link 1 pair
Shoe 48
Bolt 192
Nut 192
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INTRODUCTION
Upper component
Swing unit CX350D LC - CX350D NLC
Swing motor assembly
Swing motor
Manufacturer Kawasaki Precision Machinery Ltd.
Motor type Fixed displacement piston motor
With parking brake
Absorption amount 180.1 cm³/rev (10.99 in³/rev)
Operating pressure 30.4 MPa (4409.5 psi)
Operating flow 290 L/min (76.6099 US gpm)
Mechanical brake torque 1010.80 N·m (745.53 lb ft) or more
Brake off pressure 3.1 MPa (449.7 psi) or less
Relief valve set pressure 30.4 MPa (4409.5 psi)
Swing reduction gear
Turntable bearing
Number of teeth 92
Weight 541 kg (1192.701 lb)
Counterweight
Weight 6400 kg (14109.585 lb)
Swing unit CX370D LC - CX370D NLC

Swing motor assembly
Swing motor
Motor type Fixed displacement piston motor
With parking brake
Absorption amount 180.1 cm³/rev (10.99 in³/rev)
Operating flow 290 L/min (76.6099 US gpm)
Mechanical brake torque 1010.80 N·m (745.53 lb ft) or more
Brake off pressure 3.1 MPa (449.7 psi) or less
Relief valve set pressure 30.4 MPa (4409.5 psi)
Turntable bearing
Number of teeth 92
Weight 541 kg (1192.701 lb)
Counterweight
Weight 7402 kg (16318.617 lb)
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INTRODUCTION
Engine-related
Engine
Engine model name Isuzu 6HK1X diesel engine
4-cycle, water-cooled, overhead camshaft, vertical in-line, direct
Engine type
injection type (electronics control type)
Number of cylinders - diameter - stroke 6 - Æ115 mm (4.53 in) - 125 mm (4.92 in)
Total displacement 7.79 l (7.790 US gal)
Compression ratio 17.5
Rated output 198 kW (269.20 Hp) / 1900 RPM
Maximum torque 983 N·m (725.02 lb ft) / 1500 RPM
Fuel consumption ratio 231 g/kWh
Engine dry weight About 690 kg (1521.190 lb)
Engine dimension L 1388 mm (54.646 in) - W 1047 mm (41.220 in) - H 1194 mm
(47.008 in)
Cooling fan 850 mm (33.465 in) - suction type - 6 blades resin and steel
With bell mouth-type fan guide
Pulley ratio 0.8 (reduction)
Charging generator 24 V 50 A AC type
Starter motor 24 V 5 kW (6.8 Hp) reduction type
Coolant capacity 14.5 l (3.830 US gal)
Oil pan capacity Max: 46 L (12.152 US gal) 　Min: 36 L (9.510 US gal) KSH10440
Direction of rotation Right (viewed from fan side)
Compliant with JISD0006-2010
Air cleaner (double element)

Manufacturer Nippon Donaldson, Ltd.
Element (outer) Filtering area size 12.70 m² (136.70 ft²)
Element (inner) Filtering area size 1.74 m² (18.73 ft²)
Radiator
Manufacturer Tokyo Radiator MFG. Co.,Ltd.
Weight 44.7 kg (98.547 lb)
Oil cooler
Oil volume 16 L (4.227 US gal)
Weight 19.8 kg (43.652 lb)
Radiator
Coolant capacity 11.5 L (3.038 US gal)
Weight 18.1 kg (39.904 lb)
Air cooler
Capacity -
Weight 1.0 kg (2.205 lb) x 2
Fuel cooler
Capacity 0.3 L (0.079 US gal) x 2
Total weight 180 kg (396.832 lb)
SCR
Manufacturer Tokyo Radiator MFG. Co.,Ltd.
Urea capacity 164.5 L (43.456 US gal)
Weight 14.1 kg (31.085 lb)
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INTRODUCTION
Hydraulic device
Hydraulic pump
Main pump
Pump type Double variable displacement piston pump
Displacement 160 cm³/rev (9.764 in³/rev) x 2
Rated 34.3 MPa (4975 psi)
Operating pressure
Maximum 37.3 MPa (5410.4 psi)
Input revolution speed 1900 RPM
304 L/min (80.31 US gpm) x 2 (at Pd = 3 MPa (435 psi)
1900 RPM)
Maximum discharge flow
301 L/min (79.52 US gpm) x 2 (at Pd = 8 MPa (1160 psi)
1900 RPM)
Pilot pump
Pump type Gear pump
Displacement 15 cm³/rev (0.92 in³/rev)
Maximum discharge flow 28.5 L/min (7.53 US gpm) (at 1900 RPM)
Hydraulic simultaneous constant output control (as fail-safe)
Control method Electric negative control by external command milli-amp (on front
and rear sides)
SMIL14CEX2901FA 1
PQ Diagram
a. Discharge pressure: MPa (psi)

b. Discharge flow: L/min
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INTRODUCTION
Control-related
Control valve
STD (with 2nd option add-on valve)
Manufacturer KYB Corporation
Maximum flow 285 L/min (75.289 US gpm) (at 1900 RPM)
Overload set pressure 289 MPa (41919 psi), boom down
39.2 MPa (5686 psi) boom up, arm, bucket
22.6 MPa (3278 psi)
Main relief set pressure 34.3 MPa (4975 psi)
(Upon pressure 37.3 MPa (5410 psi)
boost)
Foot relief set pressure 2.55 MPa (370 psi)
Function Straight travel circuit
Boom-up and arm-out/in 2 pumps internal flow
Boom and arm load holding circuit
Boom-down and arm-in load holding circuit
Bucket-close regenerative circuit
Arm-in forced regenerative circuit
Pressure boost circuit
2 pumps flow (external flow)
Arm 1/arm 2 parallel variable spool
Neutral cut spool
Weight 266 kg (586.430 lb)
Solenoid valve (5 stack)

Manufacturer Yuken Kogyo Co., Ltd.
Valve specifications
Maximum flow SP: 30 L/min (7.925 US gpm), Others: 5.000 L/min (1.321 US gpm)
Rated pressure 4.5 MPa (652 psi)
G3/8 Port P0, P1, D1, D2
Port size
G1/4 Port C1, C3, C12
Solenoid specifications
Operating voltage 20 - 32 V DC
Power consumption 17 W or less
Remote control valve for Left/Right operations

Secondary pressure 0.64 - 2.45 MPa (92.8320 - 355 psi), primary pressure short type
port 1,3 19 °
Operating angle
port 2,4 25 °
Weight 1.9 kg (4.1888 lb)
Remote control valve for travel operation

Secondary pressure 0.64 - 2.45 MPa (92.8320 - 355 psi), primary pressure short type
Operating angle 12.4 °
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INTRODUCTION
Operation remote control valve control diagram
SMIL14CEX2902EB 2
1 Push rod stroke [mm (in)] 5 Secondary pressure

2 Operating angle [deg.] 6 Independent operating torque (Port 1)
3 Secondary pressure [MPa (psi)] 7 Independent operating torque (Port 3)
4 Operating torque [Nm]
SMIL14CEX2903EB 3
1 Push rod stroke [mm (in)] 4 Operating torque [Nm]

2 Operating angle [deg.] 5 Secondary pressure
3 Secondary pressure [MPa (psi)] 6 Independent operating torque
Travel remote control valve control diagram
SMIL14CEX2904EB 4
1 Push rod stroke [mm (in)] 4 Operating torque [Nm]

2 Operating angle [deg.] 5 Secondary pressure
3 Secondary pressure [MPa (psi)] 6 Independent operating torque
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INTRODUCTION
Cushion valve (heat circuit, with shuttle valve)

Manufacturer Yanagisawa Seiki MFG. Co., Ltd.
Port size G3/8 ( A - P port)
G1/4 ( Q - V port)
Weight 12.5 kg (27.5578 lb)
Selector valve (option)

2WAY
Manufacturer Nishina Industrial Co., Ltd.
Rated flow rate 25 l/min (6.604 US gpm)
Operating method ISO
Port size G3/8
Center joint
Operating pressure High-pressure passage (ABCD) 34.3 MPa (4975 psi)
Drain port (T) 1 MPa (145 psi)
Pilot port (P) 3.9 MPa (566 psi)
Flow rate High-pressure passage (ABCD) 360 L/min (95.102 US gpm)
Drain port (T) 40 L/min (10.567 US gpm)
Pilot port (P) 31 L/min (8.189 US gpm)
Port A Forward right G1
Port B Forward left G1
Port C Backward right G1
Port D Backward left G1
Port T Drain port G1/2
Port P Pilot port G1/4
Weight 55.5 kg (122.3566 lb)
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INTRODUCTION
Cylinder
Boom cylinder
Cylinder bore Æ145 mm (5.709 in)
Rod diameter Æ100 mm (3.937 in)
Maximum retracted length 2090 mm (82.283 in)
Stroke 1495 mm (58.858 in)
Weight 285 kg (628.317 lb)
Arm cylinder
Stroke 1748 mm (68.819 in)
Weight 510 kg (1124.358 lb)
Bucket cylinder
Stroke 1210 mm (47.638 in)
Weight 288 kg (634.931 lb)
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INTRODUCTION
Weight
Divided weight
SMIL14CEX2905GB 1
Code Part name Weight

1 Operating weight 35800 kg (78925.490 lb)
2 Upper component (including CW and TTB) 16200 kg (35714.886 lb)
3 Counterweight 6400 kg (14109.585 lb)
4 Lower component (with grouser shoe) 12500 kg (27557.783 lb)
5 Main unit weight 28700 kg (63272.669 lb)
6 Attachments 6980 kg (15388.266 lb)
7 Boom (including cylinder) 3220 kg (7098.885 lb)
8 Arm (including cylinder and linkage) 1880 kg (4144.691 lb)
NOTE: The weights shown here are approximate values.
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INTRODUCTION
Stand alone part weight

Part name Weight
1 Travel unit 1024 kg (2257.534 lb)
2 Take-up roller 335 kg (738.549 lb)
3 Upper roller 175 kg (385.809 lb)
4 Lower roller 993 kg (2189.190 lb)
5 Swing unit 474 kg (1044.991 lb)
6 Turntable bearing 593 kg (1307.341 lb)
7 Engine 905 kg (1995.183 lb)
8 Radiator 246 kg (542.337 lb)
9 Hydraulic pump 238 kg (524.700 lb)
10 Fuel tank 266 kg (586.430 lb)
11 Hydraulic oil tank 237 kg (522.496 lb)
12 Control valve 264 kg (582.020 lb)
13 Center joint 59 kg (130.073 lb)
14 Boom Standard 2561 kg (5646.039 lb)
Shoe weight (per side)

Part name Weight
1 600 mm (23.62 in) grouser shoe 2217 kg (4887.648 lb)
Arm weight
Part name Weight
1 Standard arm 1149 kg (2533.111 lb)
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INTRODUCTION
Bucket weight
Heavy Duty buckets
Capacity ISO 7451 (Heaped) Width Mass
0.91 m³ (1.19 yd³) 900 mm (35.4 in) 1213 kg (2674 lb)
1.19 m³ (1.56 yd³) 1100 mm (43.3 in) 1338 kg (2950 lb)
1.33 m³ (1.74 yd³) 1200 mm (47.2 in) 1439 kg (3172 lb)
1.54 m³ (2.01 yd³) 1350 mm (53.1 in) 1533 kg (3380 lb)
1.75 m³ (2.29 yd³) 1500 mm (59.1 in) 1666 kg (3673 lb)
2.03 m³ (2.66 yd³) 1700 mm (66.9 in) 1829 kg (4032 lb)
2.17 m³ (2.84 yd³) 1800 mm (70.9 in) 1894 kg (4176 lb)
Rock buckets
0.91 m³ (1.19 yd³) 900 mm (35.4 in) 1254 kg (2765 lb)
1.19 m³ (1.56 yd³) 1100 mm (43.3 in) 1382 kg (3047 lb)
1.33 m³ (1.74 yd³) 1200 mm (47.2 in) 1480 kg (3263 lb)
1.54 m³ (2.01 yd³) 1350 mm (53.1 in) 1576 kg (3474 lb)
1.75 m³ (2.29 yd³) 1500 mm (59.1 in) 1706 kg (3761 lb)
2.03 m³ (2.66 yd³) 1700 mm (66.9 in) 1872 kg (4127 lb)
2.17 m³ (2.84 yd³) 1800 mm (70.9 in) 1939 kg (4275 lb)
Ditch cleaning buckets

864 kg (1905 lb)
1.48 m³ (1.94 yd³) 2130 mm (84 in)
1050 kg (2315 lb) (*)
1077 kg (2374 lb)
1.66 m³ (2.17 yd³) 2440 mm (96 in)
1290 kg (2844 lb) (*)
NOTE: (*) with additional cutting edge.

NOTE: Refer to the Operator’s Manual for direct fit buckets application as function of the arm.
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INTRODUCTION
Weight
Divided weight
SMIL14CEX2905GB 1

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INTRODUCTION

Part name Weight
5 Swing unit 474 kg (1044.991 lb)
7 Engine 905 kg (1995.183 lb)
10 Fuel tank 266 kg (586.430 lb)

Part name Weight
Arm weight
Part name Weight
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INTRODUCTION
Bucket weight
Heavy Duty buckets
0.91 m³ (1.19 yd³) 900 mm (35.4 in) 1213 kg (2674 lb)
1.19 m³ (1.56 yd³) 1100 mm (43.3 in) 1338 kg (2950 lb)
1.33 m³ (1.74 yd³) 1200 mm (47.2 in) 1439 kg (3172 lb)
1.54 m³ (2.01 yd³) 1350 mm (53.1 in) 1533 kg (3380 lb)
1.75 m³ (2.29 yd³) 1500 mm (59.1 in) 1666 kg (3673 lb)
2.03 m³ (2.66 yd³) 1700 mm (66.9 in) 1829 kg (4032 lb)
2.17 m³ (2.84 yd³) 1800 mm (70.9 in) 1894 kg (4176 lb)
Rock buckets
0.91 m³ (1.19 yd³) 900 mm (35.4 in) 1254 kg (2765 lb)
1.19 m³ (1.56 yd³) 1100 mm (43.3 in) 1382 kg (3047 lb)
1.33 m³ (1.74 yd³) 1200 mm (47.2 in) 1480 kg (3263 lb)
1.54 m³ (2.01 yd³) 1350 mm (53.1 in) 1576 kg (3474 lb)
1.75 m³ (2.29 yd³) 1500 mm (59.1 in) 1706 kg (3761 lb)
2.03 m³ (2.66 yd³) 1700 mm (66.9 in) 1872 kg (4127 lb)
2.17 m³ (2.84 yd³) 1800 mm (70.9 in) 1939 kg (4275 lb)

864 kg (1905 lb)
1.48 m³ (1.94 yd³) 2130 mm (84 in)
1050 kg (2315 lb) (*)
1077 kg (2374 lb)
1.66 m³ (2.17 yd³) 2440 mm (96 in)
1290 kg (2844 lb) (*)

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Weight
Divided weight
SMIL14CEX2905GB 1

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INTRODUCTION

Part name Weight
5 Swing unit 474 kg (1044.991 lb)
7 Engine 905 kg (1995.183 lb)
10 Fuel tank 266 kg (586.430 lb)

Part name Weight
Arm weight
Part name Weight
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INTRODUCTION
Bucket weight
Heavy Duty buckets
0.91 m³ (1.19 yd³) 900 mm (35.4 in) 1213 kg (2674 lb)
1.19 m³ (1.56 yd³) 1100 mm (43.3 in) 1338 kg (2950 lb)
1.33 m³ (1.74 yd³) 1200 mm (47.2 in) 1439 kg (3172 lb)
1.54 m³ (2.01 yd³) 1350 mm (53.1 in) 1533 kg (3380 lb)
1.75 m³ (2.29 yd³) 1500 mm (59.1 in) 1666 kg (3673 lb)
2.03 m³ (2.66 yd³) 1700 mm (66.9 in) 1829 kg (4032 lb)
2.17 m³ (2.84 yd³) 1800 mm (70.9 in) 1894 kg (4176 lb)
Rock buckets
0.91 m³ (1.19 yd³) 900 mm (35.4 in) 1254 kg (2765 lb)
1.19 m³ (1.56 yd³) 1100 mm (43.3 in) 1382 kg (3047 lb)
1.33 m³ (1.74 yd³) 1200 mm (47.2 in) 1480 kg (3263 lb)
1.54 m³ (2.01 yd³) 1350 mm (53.1 in) 1576 kg (3474 lb)
1.75 m³ (2.29 yd³) 1500 mm (59.1 in) 1706 kg (3761 lb)
2.03 m³ (2.66 yd³) 1700 mm (66.9 in) 1872 kg (4127 lb)
2.17 m³ (2.84 yd³) 1800 mm (70.9 in) 1939 kg (4275 lb)

864 kg (1905 lb)
1.48 m³ (1.94 yd³) 2130 mm (84 in)
1050 kg (2315 lb) (*)
1077 kg (2374 lb)
1.66 m³ (2.17 yd³) 2440 mm (96 in)
1290 kg (2844 lb) (*)

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Weight
Divided weight
SMIL14CEX2905GB 1

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INTRODUCTION

Part name Weight
5 Swing unit 474 kg (1044.991 lb)
7 Engine 905 kg (1995.183 lb)
10 Fuel tank 266 kg (586.430 lb)

Part name Weight
Arm weight
Part name Weight
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INTRODUCTION
Bucket weight
Heavy Duty buckets
0.91 m³ (1.19 yd³) 900 mm (35.4 in) 1213 kg (2674 lb)
1.19 m³ (1.56 yd³) 1100 mm (43.3 in) 1338 kg (2950 lb)
1.33 m³ (1.74 yd³) 1200 mm (47.2 in) 1439 kg (3172 lb)
1.54 m³ (2.01 yd³) 1350 mm (53.1 in) 1533 kg (3380 lb)
1.75 m³ (2.29 yd³) 1500 mm (59.1 in) 1666 kg (3673 lb)
2.03 m³ (2.66 yd³) 1700 mm (66.9 in) 1829 kg (4032 lb)
2.17 m³ (2.84 yd³) 1800 mm (70.9 in) 1894 kg (4176 lb)
Rock buckets
0.91 m³ (1.19 yd³) 900 mm (35.4 in) 1213 kg (2674 lb)
1.19 m³ (1.56 yd³) 1100 mm (43.3 in) 1338 kg (2950 lb)
1.33 m³ (1.74 yd³) 1200 mm (47.2 in) 1439 kg (3172 lb)
1.54 m³ (2.01 yd³) 1350 mm (53.1 in) 1533 kg (3380 lb)
1.75 m³ (2.29 yd³) 1500 mm (59.1 in) 1666 kg (3673 lb)
2.03 m³ (2.66 yd³) 1700 mm (66.9 in) 1829 kg (4032 lb)
2.17 m³ (2.84 yd³) 1800 mm (70.9 in) 1894 kg (4176 lb)

864 kg (1905 lb)
1.48 m³ (1.94 yd³) 2130 mm (84 in)
1050 kg (2315 lb) (*)
1077 kg (2374 lb)
1.66 m³ (2.17 yd³) 2440 mm (96 in)
1290 kg (2844 lb) (*)

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INTRODUCTION
Dimension
Standard arm [ 3.25 m (10.66 ft)]

NOTE: The values used in this document are subject to change without notice due to a design change or other rea-
sons.
The values indicated in the diagram include the shoe lug height (a) [ 36 mm (1.417 in) ].
SMPH15CEX0708GA 1
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INTRODUCTION
Short arm [ 2.63 m (8.63 ft)]

sons.
SMPH15CEX0709GA 2
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INTRODUCTION
Long arm [ 4.04 m (13.25 ft)]

sons.
SMPH15CEX0710GA 3
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INTRODUCTION
Ultra short arm [ 2.21 m (7.25 ft)]

sons.
SMPH15CEX0711GA 4
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INTRODUCTION
Dimension

sons.
SMPH15CEX0712GA 1
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INTRODUCTION
Short arm [ 2.63 m (8.63 ft)]

sons.
SMPH15CEX0713GA 2
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INTRODUCTION
Long arm [ 4.04 m (13.25 ft)]

sons.
SMPH15CEX0714GA 3
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INTRODUCTION

sons.
SMPH15CEX0715GA 4
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INTRODUCTION
Dimension

sons.
SMPH15CEX0708GA 1
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INTRODUCTION
Short arm [ 2.63 m (8.63 ft)]

sons.
SMPH15CEX0709GA 2
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INTRODUCTION

sons.
SMPH15CEX0711GA 3
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Dimension

sons.
SMPH15CEX0712GA 1
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INTRODUCTION
Short arm [ 2.63 m (8.63 ft)]

sons.
SMPH15CEX0713GA 2
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INTRODUCTION

sons.
SMPH15CEX0715GA 3
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INTRODUCTION
Conversion factors
Unit conversion rate
-x→
Gravitational unit SI unit
←÷-
kgf 9.807 N
lbf 4.448 N
kgf•cm 0.0981 N•m
lbf•ft 1.356 N•m
lbf•in 0.113 N•m
kgf/cm2 0.0981 MPa
atm 0.1013 MPa
lbf/in2 0.0069 MPa
mm Hg 133.3 Pa
in Hg 3386 Pa
kgf・m/s 0.00981 kW
lbf•ft/s 0.00136 kW
PS 0.7355 kW
HP 0.746 kW
kgf•m 9.807 J
kcal 4186 J
kgf•s/cm2 98067 Pa•s
cP 0.001 Pa•s
P 0.1 Pa•s
cSt 1 x 10-6 m2/s
St 0.0001 m2/s
Length
Millimeters to inches
mm In. mm In. mm In. mm In.
1 0.0394 26 1.0236 51 2.0079 76 2.9921
2 0.0787 27 1.0630 52 2.0472 77 3.0315
3 0.1181 28 1.1024 53 2.0866 78 3.0709
4 0.1575 29 1.1417 54 2.1260 79 3.1102
5 0.1969 30 1.1811 55 2.1654 80 3.1496
6 0.2362 31 1.2205 56 2.2047 81 3.1890
7 0.2756 32 1.2598 57 2.2441 82 3.2283
8 0.3150 33 1.2992 58 2.2835 83 3.2677
9 0.3543 34 1.3386 59 2.3228 84 3.3071
10 0.3937 35 1.3780 60 2.3622 85 3.3465
11 0.4331 36 1.4173 61 2.4016 86 3.3858
12 0.4724 37 1.4567 62 2.4409 87 3.4252
13 0.5118 38 1.4961 63 2.4803 88 3.4646
14 0.5512 39 1.5354 64 2.5197 89 3.5039
15 0.5906 40 1.5748 65 2.5591 90 3.5433
16 0.6299 41 1.6142 66 2.5984 91 3.5827
17 0.6693 42 1.6535 67 2.6378 92 3.6220
18 0.7087 43 1.6929 68 2.6772 93 3.6614
19 0.7480 44 1.7323 69 2.7165 94 3.7008
20 0.7874 45 1.7717 70 2.7559 95 3.7402
21 0.8268 46 1.8110 71 2.7953 96 3.7795
22 0.8661 47 1.8504 72 2.8346 97 3.8189
23 0.9055 48 1.8898 73 2.8740 98 3.8583
24 0.9449 49 1.9291 74 2.9134 99 3.8976
25 0.9843 50 1.9685 75 2.9528 100 3.9370
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Inches to millimeters
in. mm in. mm in. mm in. mm
1/64 0.3969 17/64 6.7469 33/64 13.0969 49/64 19.4469
1/32 0.7938 9/32 7.1438 17/32 13.4938 25/32 19.8438
3/64 1.1906 19/64 7.5406 35/64 13.8906 51/64 20.2406
1/16 1.5875 5/16 7.9375 9/16 14.2875 13/16 20.6375
5/64 1.9844 21/64 8.3344 37/64 14.6844 53/64 21.0344
3/32 2.3813 11/32 8.7313 19/32 15.0813 27/32 21.4313
7/64 2.7781 23/64 9.1281 39/64 15.4781 55/64 21.8281
1/8 3.1750 3/8 9.5250 5/8 15.8750 7/8 22.2250
9/64 3.5719 25/64 9.9218 41/64 16.2719 57/64 22.6219
5/32 3.9688 13/32 10.3188 21/32 16.6688 29/32 23.0188
11/64 4.3656 27/64 10.7156 43/64 17.0656 59/64 23.4156
3/16 4.7625 7/16 11.1125 11/16 17.4625 15/16 23.8125
13/64 5.1594 29/64 11.5094 45/64 17.8594 61/64 24.2094
7/32 5.5563 15/32 11.9063 23/32 18.2563 31/32 24.6063
15/64 5.9531 31/64 12.3031 47/64 18.6531 63/64 25.0031
1/4 6.3500 1/2 12.7000 3/4 19.0500 1 25.4000
Feet to meters
ft. 0 1 2 3 4 5 6 7 8 9 ft.
　 m m m m m m m m m m 　
---- 0.305 0.610 0.914 1.219 1.524 1.829 2.134 2.438 2.743 ----
10 3.048 3.353 3.658 3.962 4.267 4.572 4.877 5.182 5.486 5.791 10
20 6.096 6.401 6.706 7.010 7.315 7.620 7.925 8.230 8.534 8.839 20
30 9.144 9.449 9.754 10.058 10.363 10.668 10.973 11.278 11.582 11.887 30
40 12.192 12.497 12.802 13.106 13.411 13.716 14.021 14.326 14.630 14.935 40
50 15.24 15.545 15.850 16.154 16.459 16.764 17.069 17.374 17.678 17.983 50
60 18.288 18.593 18.898 19.202 19.507 19.812 20.117 20.422 20.726 21.031 60
70 21.336 21.641 21.946 22.250 22.555 22.860 23.165 23.470 23.774 24.079 70
80 24.384 24.689 24.994 25.298 25.603 25.908 26.213 26.518 26.822 27.127 80
90 27.432 27.737 28.042 28.346 28.651 28.956 29.261 29.566 29.870 30.175 90
100 30.480 30.785 31.090 31.394 31.699 32.004 32.309 32.614 32.918 33.223 100
Meters to feet
m 0 1 2 3 4 5 6 7 8 9 m
　 ft. ft. ft. ft. ft. ft. ft. ft. ft. ft. 　
---- 　 3.2808 6.5617 9.8425 13.1234 16.4042 19.685 22.9659 26.2467 29.5276 ----
10 32.8084 36.0892 39.3701 42.6509 45.9318 49.2126 52.4934 55.7743 59.0551 62.3360 10
20 65.6168 68.8976 72.1785 75.4593 78.7402 82.0210 85.3018 88.5827 91.8635 95.1444 20
101.706 104.986 108.267 114.829 121.391 124.671 127.952
30 98.4252 0 9 7 111.5486 4 118.1102 1 9 8 30
131.233 134.514 137.795 141.076 144.357 147.637 150.918 154.199 157.480 160.761
40 6 4 3 1 0 8 6 5 3 2 40
164.042 167.322 170.603 173.884 177.165 180.446 183.727 187.007 190.288 193.569
50 0 8 7 5 4 2 0 9 7 6 50
196.850 200.131 203.412 206.692 209.973 213.254 216.535 219.816 223.097 226.378
60 4 2 1 9 8 6 4 3 1 0 60
229.658 232.939 236.220 239.501 242.782 249.343 252.624 255.905 259.186
70 8 6 5 3 2 246.063 8 7 5 4 70
262.467 265.748 269.028 272.309 275.590 278.871 282.152 285.433 288.713 291.994
80 2 0 9 7 6 4 2 1 9 8 80
295.275 298.556 301.837 305.118 308.399 311.679 314.960 318.241 321.522 324.803
90 6 4 3 1 0 8 6 5 3 1 90
328.084 331.364 334.645 337.926 341.207 344.488 347.769 351.049 354.330 357.611
100 0 8 7 5 3 2 0 9 7 5 100
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Miles to kilometers
miles 0 1 2 3 4 5 6 7 8 9 miles
　 km km km km km km km km km km 　
---- 1.609 3.219 4.828 6.437 8.047 9.656 11.265 12.875 14.484 ----
10 16.093 17.703 19.312 20.921 22.531 24.140 25.750 27.359 28.968 30.578 10
20 32.187 33.796 35.406 37.015 38.624 40.234 41.843 43.452 45.062 46.671 20
30 48.280 49.890 51.499 53.108 54.718 56.327 57.936 59.546 61.155 62.764 30
40 64.374 65.983 67.592 69.202 70.811 72.420 74.030 75.639 77.249 78.858 40
50 80.467 82.077 83.686 85.295 86.905 88.514 90.123 91.733 93.342 94.951 50
60 96.561 98.170 99.779 101.39 102.998 104.607 106.217 107.826 109.435 111.045 60
70 112.654 114.263 115.873 117.482 119.091 120.701 122.310 123.919 125.529 127.138 70
80 128.748 130.357 131.966 133.576 135.185 136.794 138.404 140.013 141.622 143.232 80
90 144.841 146.450 148.060 149.669 151.278 152.888 154.497 156.106 157.716 159.325 90
100 160.934 162.544 164.153 165.762 167.372 168.981 170.590 172.200 173.809 175.418 100
Kilometers to miles
km 0 1 2 3 4 5 6 7 8 9 km
　 miles miles miles miles miles miles miles miles miles miles 　
---- 0.621 1.243 1.864 2.485 3.107 3.728 4.350 4.971 5.592 ----
10 6.214 6.835 7.456 8.078 8.699 9.321 9.942 10.563 11.185 11.806 10
20 12.427 13.049 13.670 14.292 14.913 15.534 16.156 16.777 17.398 18.020 20
30 18.641 19.263 19.884 20.505 21.127 21.748 22.369 22.991 23.612 24.233 30
40 24.855 25.476 26.098 26.719 27.340 27.962 28.583 29.204 29.826 30.447 40
50 31.069 31.690 32.311 32.933 33.554 34.175 34.797 35.418 36.040 36.661 50
60 37.282 37.904 38.525 39.146 39.768 40.389 41.010 41.632 42.253 42.875 60
70 43.496 44.117 44.739 45.360 45.981 46.603 47.224 47.846 48.467 49.088 70
80 49.710 50.331 50.952 51.574 52.195 52.817 53.438 54.059 54.681 55.302 80
90 55.923 56.545 57.166 57.788 58.409 59.03 59.652 60.273 60.894 61.516 90
100 62.137 62.758 63.380 64.001 64.623 65.244 65.865 66.487 67.108 67.729 100
Area
Square inches to square centimeters
in2 0 1 2 3 4 5 6 7 8 9 in2
　 cm2 cm2 cm2 cm2 cm2 cm2 cm2 cm2 cm2 cm2 　
---- 　 6.452 12.903 19.355 25.806 32.258 38.710 45.161 51.613 58.065 ----
10 64.516 70.968 77.419 83.871 90.323 96.774 103.226 109.677 116.129 122.581 10
20 129.032 135.484 141.935 148.387 154.839 161.290 167.742 174.194 180.645 187.097 20
30 193.548 200.000 206.452 212.903 219.355 225.806 232.258 238.710 245.161 251.613 30
40 258.065 264.516 270.968 277.419 283.871 290.323 296.774 303.226 309.677 316.129 40
50 322.581 329.032 335.484 341.935 348.387 354.839 361.290 367.742 374.194 380.645 50
60 387.097 393.548 400.000 406.452 412.903 419.355 425.806 432.258 438.710 445.161 60
70 451.613 458.065 464.516 470.968 477.419 483.871 490.323 496.774 503.226 509.677 70
80 516.129 522.581 529.032 535.484 541.935 548.387 554.839 561.290 567.742 574.194 80
90 580.645 587.097 593.548 600.000 606.452 612.903 619.355 625.806 632.258 638.710 90
100 645.161 651.613 658.065 664.516 670.968 677.419 683.871 690.323 696.774 703.226 100
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Square centimeters to square inches

cm2 0 1 2 3 4 5 6 7 8 9 cm2
　 in2 in2 in2 in2 in2 in2 in2 in2 in2 in2 　
---- 　 0.155 0.310 0.465 0.620 0.775 0.930 1.085 1.240 1.395 ----
10 1.550 1.705 1.860 2.015 2.170 2.325 2.480 2.635 2.790 2.945 10
20 3.100 3.255 3.410 3.565 3.720 3.875 4.030 4.185 4.340 4.495 20
30 4.650 4.805 4.960 5.115 5.270 5.425 5.580 5.735 5.890 6.045 30
40 6.200 6.355 6.510 6.665 6.820 6.975 7.130 7.285 7.440 7.595 40
50 7.750 7.905 8.060 8.215 8.370 8.525 8.680 8.835 8.990 9.145 50
60 9.300 9.455 9.610 9.765 9.920 10.075 10.230 10.385 10.540 10.695 60
70 10.850 11.005 11.160 11.315 11.470 11.625 11.780 11.935 12.090 12.245 70
80 12.400 12.555 12.710 12.865 13.020 13.175 13.330 13.485 13.640 13.795 80
90 13.950 14.105 14.260 14.415 14.570 14.725 14.880 15.035 15.190 15.345 90
100 15.500 15.655 15.810 15.965 16.120 16.275 16.430 16.585 16.740 16.895 100
Volume
Cubic inches to cubic centimeters
in3 0 1 2 3 4 5 6 7 8 9 in3
　 cm3 cm3 cm3 cm3 cm3 cm3 cm3 cm3 cm3 cm3 　
（ cc））（ cc））（ cc））（ cc））（ cc））（ cc））（ cc））（ cc））（ cc））（ cc））
---- 　 16.387 32.774 49.161 65.548 81.936 98.323 114.710 131.097 147.484 ----
10 163.871 180.258 196.645 213.032 229.419 245.807 262.194 278.581 294.968 311.355 10
20 327.742 344.129 360.516 376.903 393.290 409.678 426.065 442.452 458.839 475.226 20
30 491.613 508.000 524.387 540.774 557.161 573.549 589.936 606.323 622.710 639.097 30
40 655.484 671.871 688.258 704.645 721.033 737.420 753.807 770.194 786.581 802.968 40
50 819.355 835.742 852.129 868.516 884.904 901.291 917.678 934.065 950.452 966.839 50
1016.00 1032.38 1048.77 1065.16 1081.54 1097.93 1130.71
60 983.226 999.613 0 7 5 2 9 6 1114.323 0 60
1147.09 1163.48 1179.87 1196.25 1212.64 1229.03 1245.42 1261.80 1278.19 1294.58
70 7 4 1 8 6 3 0 7 4 1 70
1310.96 1327.35 1343.74 1360.13 1376.51 1392.90 1409.29 1425.67 1442.06 1458.45
80 8 5 2 0 7 4 1 8 5 2 80
1474.83 1491.22 1507.61 1524.00 1540.38 1556.77 1573.16 1589.54 1605.93 1622.32
90 9 6 3 1 8 5 2 9 6 3 90
1638.71 1655.09 1671.48 1687.87 1704.25 1720.64 1737.03 1753.42 1769.80 1786.19
100 0 7 4 2 9 6 3 0 7 4 100
Cubic centimeters to cubic inches

cm3 0 1 2 3 4 5 6 7 8 9 cm3
（ cc）））
（ cc）
　 in3 in3 in3 in3 in3 in3 in3 in3 in3 in3
---- 0.0610 0.1220 0.1831 0.2441 0.3051 0.3661 0.4272 0.4882 0.5492 ----
10 0.6102 0.6713 0.7323 0.7933 0.8543 0.9154 0.9764 1.0374 1.0984 1.1594 10
20 1.2205 1.2815 1.3425 1.4035 1.4646 1.5256 1.5866 1.6476 1.7087 1.7697 20
30 1.8307 1.8917 1.9528 2.0138 2.0748 2.1358 2.1968 2.2579 2.3189 2.3799 30
40 2.4409 2.5020 2.5630 2.6240 2.6850 2.7461 2.8071 2.8681 2.9291 2.9902 40
50 3.0512 3.1122 3.1732 3.2343 3.2953 3.3563 3.4173 3.4784 3.5394 3.6004 50
60 3.6614 3.7224 3.7835 3.8445 3.9055 3.9665 4.0276 4.0886 4.1496 4.2106 60
70 4.2717 4.3327 4.3937 4.4547 4.5157 4.5768 4.6378 4.6988 4.7598 4.8209 70
80 4.8819 4.9429 5.0039 5.0650 5.1260 5.1870 5.2480 5.3091 5.3701 5.4311 80
90 5.4921 5.5531 5.6142 5.6752 5.7362 5.7972 5.8583 5.9193 5.9803 6.0413 90
100 6.1024 6.1634 6.2244 6.2854 6.3465 6.4075 6.4685 6.5295 6.5905 6.6516 100
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INTRODUCTION
Gallons (U.S) to liters

U.S- 0 1 2 3 4 5 6 7 8 9 U.S-
.gal. .gal.
　 liters liters liters liters liters liters liters liters liters liters 　
---- 3.7853 7.5707 11.3560 15.1413 18.9266 22.7120 26.4973 30.2826 34.0680 ----
10 37.8533 41.6386 45.4239 49.2093 52.9946 56.7799 60.5653 64.3506 68.1359 71.9213 10
102.203 105.989 109.774
20 75.7066 79.4919 83.2772 87.0626 90.8479 94.6332 98.4186 9 2 5 20
113.559 117.345 121.130 124.915 128.701 132.486 136.271 140.057 143.842 147.627
30 9 2 5 9 2 5 8 2 5 8 30
151.413 155.198 158.983 162.769 166.554 170.339 174.125 177.910 181.695 185.481
40 2 5 8 1 5 8 1 5 8 1 40
189.266 193.051 196.837 200.622 204.407 208.193 211.978 215.763 219.549 223.334
50 5 8 1 4 8 1 4 8 1 4 50
227.119 230.905 234.690 238.475 242.261 246.046 249.831 253.617 257.402 261.187
60 7 1 4 7 1 4 7 0 4 7 60
264.973 268.758 272.543 276.329 280.114 283.899 287.685 291.470 295.255 299.041
70 0 4 7 0 3 7 0 3 7 0 70
302.826 306.611 310.397 314.182 317.967 321.753 325.538 329.323 333.109 336.894
80 3 6 0 3 6 0 3 6 0 3 80
340.679 344.464 348.250 352.035 355.820 359.606 363.391 367.176 370.962 374.747
90 6 9 3 6 9 3 6 9 2 6 90
378.532 382.318 386.103 389.888 393.674 397.459 401.244 405.030 408.815 412.600
100 9 2 6 9 2 5 9 2 5 9 100
Liters to gallons (U.S)

liters 0 1 2 3 4 5 6 7 8 9 liters
　 U.S.gal. U.S.gal. U.S.gal. U.S.gal. U.S.gal. U.S.gal. U.S.gal. U.S.gal. U.S.gal. U.S.gal. 　
---- 0.2642 0.5284 0.7925 1.0567 1.3209 1.5851 1.8492 2.1134 2.3776 ----
10 2.6418 2.9060 3.1701 3.4343 3.6985 3.9627 4.2268 4.4910 4.7552 5.0194 10
20 5.2836 5.5477 5.8119 6.0761 6.3403 6.6044 6.8686 7.1328 7.3970 7.6612 20
30 7.9253 8.1895 8.4537 8.7179 8.9820 9.2462 9.5104 9.7746 10.0388 10.3029 30
40 10.5671 10.8313 11.0955 11.3596 11.6238 11.8880 12.1522 12.4164 12.6805 12.9447 40
50 13.2089 13.4731 13.7372 14.0014 14.2656 14.5298 14.7940 15.0581 15.3223 15.5865 50
60 15.8507 16.1148 16.3790 16.6432 16.9074 17.1716 17.4357 17.6999 17.9641 18.2283 60
70 18.4924 18.7566 19.0208 19.2850 19.5492 19.8133 20.0775 20.3417 20.6059 20.8700 70
80 21.1342 21.3984 21.6626 21.9268 22.1909 22.4551 22.7193 22.9835 23.2476 23.5118 80
90 23.7760 24.0402 24.3044 24.5685 24.8327 25.0969 25.3611 25.6252 25.8894 26.1536 90
100 26.4178 26.6820 26.9461 27.2103 27.4745 27.7387 28.0028 28.2670 28.5312 28.7954 100
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INTRODUCTION
Gallons (Imp.) to liters

Im- 0 1 2 3 4 5 6 7 8 9 Imp-
p.g- .gal.
al.
　 liters liters liters liters liters liters liters liters liters liters 　
---- 　 4.5455 9.0909 13.6364 18.1818 22.7273 27.2727 31.8182 36.3636 40.9091 ----
10 45.4545 50.0000 54.5455 59.0909 63.6364 68.1818 72.7273 77.2727 81.8182 86.3636 10
100.000 104.545 109.090 113.636 118.181 122.727 127.272 131.818
20 90.9091 95.4545 0 5 9 4 8 3 7 2 20
136.363 140.909 145.454 150.000 154.545 159.090 163.636 168.181 172.727 177.272
30 6 1 5 0 5 9 4 8 3 7 30
181.818 186.363 190.909 195.454 200.000 204.545 209.090 213.636 218.181 222.727
40 2 6 1 5 0 5 9 4 8 3 40
227.272 231.818 236.363 240.909 245.454 250.000 254.545 259.090 263.636 268.181
50 7 2 6 1 5 0 5 9 4 8 50
272.727 277.272 281.818 286.363 290.909 295.454 300.000 304.545 309.090 313.636
60 3 7 2 6 1 5 0 5 9 4 60
318.181 322.727 327.272 331.818 336.363 340.909 345.454 350.000 354.545 359.090
70 8 3 7 2 6 1 5 0 5 9 70
363.636 368.181 372.727 377.272 381.818 386.363 390.909 395.454 400.000 404.545
80 4 8 3 7 2 6 1 5 0 5 80
409.090 413.636 418.181 422.727 427.272 431.818 436.363 440.909 445.454 450.000
90 9 4 8 3 7 2 6 1 5 0 90
454.545 459.090 463.636 468.181 472.727 477.272 481.818 486.363 490.909 495.454
100 5 9 4 8 3 7 2 6 1 5 100
Liters to gallons (Imp.)

liters 0 1 2 3 4 5 6 7 8 9 liters
　 Imp.g- Imp.g- Imp.g- Imp.g- Imp.g- Imp.g- Imp.g- Imp.g- Imp. Imp.g- 　
al. al. al. al. al. al. al. al. al.
---- 0.2200 0.4400 0.6600 0.8800 1.1000 1.3200 1.5400 1.7600 1.9800 ----
10 2.2000 2.4200 2.6400 2.8600 3.0800 3.3000 3.5200 3.7400 3.9600 4.1800 10
20 4.4000 4.6200 4.8400 5.0600 5.2800 5.5000 5.7200 5.9400 6.1600 6.3800 20
30 6.6000 6.8200 7.0400 7.2600 7.4800 7.7000 7.9200 8.1400 8.3600 8.5800 30
40 8.8000 9.0200 9.2400 9.4600 9.6800 9.9000 10.1200 10.3400 10.5600 10.7800 40
50 11.0000 11.2200 11.4400 11.6600 11.8800 12.1000 12.3200 12.5400 12.7600 12.9800 50
60 13.2000 13.4200 13.6400 13.8600 14.0800 14.3000 14.5200 14.7400 14.9600 15.1800 60
70 15.4000 15.6200 15.8400 16.0600 16.2800 16.5000 16.7200 16.9400 17.1600 17.3800 70
80 17.6000 17.8200 18.0400 18.2600 18.4800 18.7000 18.9200 19.1400 19.3600 19.5800 80
90 19.8000 20.0200 20.2400 20.4600 20.6800 20.9000 21.1200 21.3400 21.5600 21.7800 90
100 22.0000 22.2200 22.4400 22.6600 22.8800 23.1000 23.3200 23.5400 23.7600 23.9800 100
Weight
Pounds to kilograms
lbs. 0 1 2 3 4 5 6 7 8 9 lbs.
　 kg kg kg kg kg kg kg kg kg kg 　
---- 0.454 0.907 1.361 1.814 2.268 2.722 3.175 3.629 4.082 ----
10 4.536 4.989 5.443 5.897 6.350 6.804 7.257 7.711 8.165 8.618 10
20 9.072 9.525 9.979 10.433 10.886 11.340 11.793 12.247 12.701 13.154 20
30 13.608 14.061 14.515 14.968 15.422 15.876 16.329 16.783 17.236 17.690 30
40 18.144 18.597 19.051 19.504 19.958 20.412 20.865 21.319 21.772 22.226 40
50 22.680 23.133 23.587 24.040 24.494 24.947 25.401 25.855 26.308 26.762 50
60 27.215 27.669 28.123 28.576 29.030 29.483 29.937 30.391 30.844 31.298 60
70 31.751 32.205 32.658 33.112 33.566 34.019 34.473 34.926 35.380 35.834 70
80 36.287 36.741 37.194 37.648 38.102 38.555 39.009 39.462 39.916 40.370 80
90 40.823 41.277 41.730 42.184 42.637 43.091 43.545 43.998 44.452 44.905 90
100 45.359 45.813 46.266 46.720 47.173 47.627 48.081 48.534 48.988 49.441 100
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INTRODUCTION
Kilograms to pounds
kg 0 1 2 3 4 5 6 7 8 9 kg
　 lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. 　
---- 2.205 4.409 6.614 8.819 11.023 13.228 15.432 17.637 19.842 ----
10 22.046 24.251 26.456 28.660 30.865 33.069 35.274 37.479 39.683 41.888 10
20 44.093 46.297 48.502 50.707 52.911 55.116 57.320 59.525 61.730 63.934 20
30 66.139 68.344 70.548 72.753 74.958 77.162 79.367 81.571 83.776 85.981 30
40 88.185 90.39 92.595 94.799 97.004 99.209 101.413 103.618 105.822 108.027 40
50 110.232 112.436 114.641 116.846 119.050 121.255 123.460 125.664 127.869 130.073 50
60 132.278 134.483 136.687 138.892 141.097 143.301 145.506 147.710 149.915 152.120 60
70 154.324 156.529 158.734 160.938 163.143 165.348 167.552 169.757 171.961 174.166 70
80 176.371 178.575 180.780 182.985 185.189 187.394 189.599 191.803 194.008 196.212 80
90 198.417 200.622 202.826 205.031 207.236 209.440 211.645 213.850 216.054 218.259 90
100 220.463 222.668 224.873 227.077 229.282 231.487 233.691 235.896 238.100 240.305 100
Weight kilograms to newtons

kgf 0 1 2 3 4 5 6 7 8 9 kg
　 N N N N N N N N N N 　
---- 9.81 19.61 29.42 39.23 49.03 58.84 68.65 78.45 88.26 ----
10 98.07 107.87 117.68 127.49 137.29 147.10 156.91 166.71 176.52 186.33 10
20 196.13 205.94 215.75 225.55 235.36 245.17 254.97 264.78 274.59 284.39 20
30 294.20 304.01 313.81 323.62 333.43 343.23 353.04 362.85 372.65 382.46 30
40 392.27 402.07 411.88 421.69 431.49 441.30 451.11 460.91 470.72 480.53 40
50 490.33 500.14 509.95 519.75 529.56 539.37 549.17 558.98 568.79 578.59 50
60 588.40 598.21 608.01 617.82 627.63 637.43 647.24 657.05 666.85 676.66 60
70 686.47 696.27 706.08 715.89 725.69 735.50 745.31 755.11 764.92 774.73 70
80 784.53 794.34 804.15 813.95 823.76 833.57 843.37 853.18 862.99 872.79 80
90 882.60 892.41 902.21 912.02 921.83 931.63 941.44 951.25 961.05 970.86 90
100 980.67 990.47 1000.28 1010.08 1019.89 1029.70 1039.5 1049.31 1059.12 1068.92 100
Newtons to weight kilograms

N 0 1 2 3 4 5 6 7 8 9 N
　 kgf kgf kgf kgf kgf kgf kgf kgf kgf kgf 　
---- 0.1020 0.2039 0.3059 0.4079 0.5099 0.6118 0.7138 0.8158 0.9177 ----
10 1.0197 1.1217 1.2237 1.3256 1.4276 1.5296 1.6315 1.7335 1.8355 1.9375 10
20 2.0394 2.1414 2.2434 2.3453 2.4473 2.5493 2.6513 2.7532 2.8552 2.9572 20
30 3.0591 3.1611 3.2631 3.3651 3.4670 3.5690 3.6710 3.7729 3.8749 3.9769 30
40 4.0789 4.1808 4.2828 4.3848 4.4868 4.5887 4.6907 4.7927 4.8946 4.9966 40
50 5.0986 5.2006 5.3025 5.4045 5.5065 5.6084 5.7104 5.8124 5.9144 6.0163 50
60 6.1183 6.2203 6.3222 6.4242 6.5262 6.6282 6.7301 6.8321 6.9341 7.0360 60
70 7.1380 7.2400 7.3420 7.4439 7.5459 7.6479 7.7498 7.8518 7.9538 8.0558 70
80 8.1577 8.2597 8.3617 8.4636 8.5656 8.6676 8.7696 8.8715 8.9735 9.0755 80
90 9.1774 9.2794 9.3814 9.4834 9.5853 9.6873 9.7893 9.8912 9.9932 10.0952 90
100 10.1972 10.2991 10.4011 10.5031 10.6050 10.7070 10.8090 10.9110 11.0129 11.1149 100
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INTRODUCTION
Pressure
Weight pounds/square inch to weight kilograms/square centimeter
lbf/in2 0 1 2 3 4 5 6 7 8 9 lbf/in2
(psi) kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 (psi)
---- 　 0.0703 0.1406 0.2109 0.2812 0.3515 0.4218 0.4921 0.5624 0.6327 ----
10 0.7030 0.7733 0.8436 0.9139 0.9842 1.0545 1.1248 1.1951 1.2654 1.3357 10
20 1.4060 1.4763 1.5466 1.6169 1.6872 1.7575 1.8278 1.8981 1.9684 2.0387 20
30 2.1090 2.1793 2.2496 2.3199 2.3902 2.4605 2.5308 2.6011 2.6714 2.7417 30
40 2.8120 2.8823 2.9526 3.0229 3.0932 3.1635 3.2338 3.3041 3.3744 3.4447 40
50 3.5150 3.5853 3.6556 3.7259 3.7962 3.8665 3.9368 4.0071 4.0774 4.1477 50
60 4.2180 4.2883 4.3586 4.4289 4.4992 4.5695 4.6397 4.7100 4.7803 4.8506 60
70 4.9209 4.9912 5.0615 5.1318 5.2021 5.2724 5.3427 5.4130 5.4833 5.5536 70
80 5.6239 5.6942 5.7645 5.8348 5.9051 5.9754 6.0457 6.1160 6.1863 6.2566 80
90 6.3269 6.3972 6.4675 6.5378 6.6081 6.6784 6.7487 6.8190 6.8893 6.9596 90
100 7.0299 7.1002 7.1705 7.2408 7.3111 7.3814 7.4517 7.5220 7.5923 7.6626 100
Weight kilograms/square centimeter to weight pounds/square inch

kgf/cm2 0 1 2 3 4 5 6 7 8 9 kgf/cm2
　 lbf/ lbf/ lbf/ lbf/ lbf/ lbf/ lbf/ lbf/ lbf/ lbf/ 　
in2(psi) in2(psi) in2(psi) in2(psi) in2(psi) in2(psi) in2(psi) in2(psi) in2(psi) in2(psi)
---- 　 14.22 28.45 42.67 56.90 71.12 85.35 99.57 113.80 128.02 ----
10 142.25 156.47 170.70 184.92 199.15 213.37 227.60 241.82 256.05 270.27 10
20 284.50 298.72 312.95 327.17 341.40 355.62 369.85 384.07 398.30 412.52 20
30 426.75 440.97 455.20 469.42 483.65 497.87 512.10 526.32 540.55 554.77 30
40 569.00 583.22 597.45 611.67 625.90 640.12 654.35 668.57 682.80 697.02 40
50 711.25 725.47 739.70 753.92 768.14 782.37 796.59 810.82 825.04 839.27 50
60 853.49 867.72 881.94 896.17 910.39 924.62 938.84 953.07 967.29 981.52 60
70 995.74 1009.97 1024.19 1038.42 1052.64 1066.87 1081.09 1095.32 1109.54 1123.77 70
80 1137.99 1152.22 1166.44 1180.67 1194.89 1209.12 1223.34 1237.57 1251.79 1266.02 80
90 1280.24 1294.47 1308.69 1322.92 1337.14 1351.37 1365.59 1379.82 1394.04 1408.27 90
100 1422.49 1436.72 1450.94 1465.17 1479.39 1493.62 1507.84 1522.06 1536.29 1550.51 100
Weight kilograms/square centimeter to kilopascals

kgf/cm2 0 1 2 3 4 5 6 7 8 9 kgf/cm2
　 kpa kpa kpa kpa kpa kpa kpa kpa kpa kpa 　
---- 　 98.1 196.1 294.2 392.3 490.3 588.4 686.5 784.5 882.6 ----
10 980.7 1078.7 1176.8 1274.9 1372.9 1471.0 1569.1 1667.1 1765.2 1863.3 10
20 1961.3 2059.4 2157.5 2255.5 2353.6 2451.7 2549.7 2647.8 2745.9 2843.9 20
30 2942.0 3040.1 3138.1 3236.2 3334.3 3432.3 3530.4 3628.5 3726.5 3824.6 30
40 3922.7 4020.7 4118.8 4216.9 4314.9 4413.0 4511.1 4609.1 4707.2 4805.3 40
50 4903.3 5001.4 5099.5 5197.5 5295.6 5393.7 5491.7 5589.8 5687.9 5785.9 50
60 5884.0 5982.1 6080.1 6178.2 6276.3 6374.3 6472.4 6570.5 6668.5 6766.6 60
70 6864.7 6962.7 7060.8 7158.9 7256.9 7355.0 7453.1 7551.1 7649.2 7747.3 70
80 7845.3 7943.4 8041.5 8139.5 8237.6 8335.7 8433.7 8531.8 8629.9 8727.9 80
90 8826.0 8924.1 9022.1 9120.2 9218.3 9316.3 9414.4 9512.5 9610.5 9708.6 90
100 9806.7 9904.7 10002.8 10100.8 10198.9 10297 10395.0 10493.1 10591.2 10689.2 100
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Kilopascals to weight kilograms/square centimeter

kpa 0 100 200 300 400 500 600 700 800 900 kpa
　 kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 　
---- 　 1.020 2.039 3.059 4.079 5.099 6.118 7.138 8.158 9.177 ----
1000 10.197 11.217 12.237 13.256 14.276 15.296 16.315 17.335 18.355 19.375 1000
2000 20.394 21.414 22.434 23.453 24.473 25.493 26.513 27.532 28.552 29.572 2000
3000 30.591 31.611 32.631 33.651 34.670 35.690 36.710 37.729 38.749 39.769 3000
4000 40.789 41.808 42.828 43.848 44.868 45.887 46.907 47.927 48.946 49.966 4000
5000 50.986 52.006 53.025 54.045 55.065 56.084 57.104 58.124 59.144 60.163 5000
6000 61.183 62.203 63.222 64.242 65.262 66.282 67.301 68.321 69.341 70.360 6000
7000 71.380 72.400 73.420 74.439 75.459 76.479 77.498 78.518 79.538 80.558 7000
8000 81.577 82.597 83.617 84.636 85.656 86.676 87.696 88.715 89.735 90.755 8000
9000 91.774 92.794 93.814 94.834 95.853 96.873 97.893 98.912 99.932 100.952 9000
10000 101.972 102.991 104.011 105.031 106.050 107.070 108.090 109.110 110.129 111.149 10000
Torque
Feet weight pounds to weight kilogram meters
lbf.ft 0 1 2 3 4 5 6 7 8 9 lbf.ft
　 kgf·m kgf·m kgf·m kgf·m kgf·m kgf·m kgf·m kgf·m kgf·m kgf·m 　
---- 　 0.138 0.277 0.415 0.553 0.692 0.830 0.969 1.107 1.245 ----
10 1.384 1.522 1.660 1.799 1.937 2.075 2.214 2.352 2.490 2.629 10
20 2.767 2.906 3.044 3.182 3.321 3.459 3.597 3.736 3.874 4.012 20
30 4.151 4.289 4.428 4.566 4.704 4.843 4.981 5.119 5.258 5.396 30
40 5.534 5.673 5.811 5.949 6.088 6.226 6.365 6.503 6.641 6.780 40
50 6.918 7.056 7.195 7.333 7.471 7.610 7.748 7.887 8.025 8.163 50
60 8.302 8.440 8.578 8.717 8.855 8.993 9.132 9.270 9.409 9.547 60
70 9.685 9.824 9.962 10.100 10.239 10.377 10.515 10.654 10.792 10.930 70
80 11.069 11.207 11.346 11.484 11.622 11.761 11.899 12.037 12.176 12.314 80
90 12.452 12.591 12.729 12.868 13.006 13.144 13.283 13.421 13.559 13.698 90
100 13.836 13.974 14.113 14.251 14.389 14.528 14.666 14.805 14.943 15.081 100
Weight kilogram meters to feet weight pounds

kgf·m 0 1 2 3 4 5 6 7 8 9 kgf·m
　 lbf.ft lbf.ft lbf.ft lbf.ft lbf.ft lbf.ft lbf.ft lbf.ft lbf.ft lbf.ft 　
---- 7.228 14.455 21.683 28.910 36.138 43.365 50.593 57.820 65.048 ----
10 72.275 79.503 86.730 93.958 101.185 108.413 115.640 122.868 130.095 137.323 10
20 144.550 151.778 159.005 166.233 173.460 180.688 187.915 195.143 202.370 209.598 20
30 216.825 224.053 231.280 238.508 245.735 252.963 260.190 267.418 274.645 281.873 30
40 289.100 296.328 303.555 310.783 318.010 325.238 332.465 339.693 346.920 354.148 40
50 361.375 368.603 375.830 383.058 390.285 397.513 404.740 411.968 419.195 426.423 50
60 433.650 440.878 448.105 455.333 462.560 469.788 477.015 484.243 491.470 498.698 60
70 505.925 513.153 520.380 527.608 534.835 542.063 549.290 556.518 563.745 570.973 70
80 578.200 585.428 592.655 599.883 607.110 614.338 621.565 628.793 636.020 643.248 80
90 650.475 657.703 664.930 672.158 679.385 686.613 693.840 701.068 708.295 715.523 90
100 722.750 729.978 737.205 744.433 751.660 758.888 766.115 773.343 780.570 787.798 100
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Weight kilogram meters to Newton meters

kgf·m 0 1 2 3 4 5 6 7 8 9 kgf·m
　 N·m N·m N·m N·m N·m N·m N·m N·m N·m N·m 　
---- 9.81 19.61 29.42 39.23 49.03 58.84 68.65 78.45 88.26 ----
10 98.07 107.87 117.68 127.49 137.29 147.10 156.91 166.71 176.52 186.33 10
20 196.13 205.94 215.75 225.55 235.36 245.17 254.97 264.78 274.59 284.39 20
30 294.20 304.01 313.81 323.62 333.43 343.23 353.04 362.85 372.65 382.46 30
40 392.27 402.07 411.88 421.69 431.49 441.30 451.11 460.91 470.72 480.53 40
50 490.33 500.14 509.95 519.75 529.56 539.37 549.17 558.98 568.79 578.59 50
60 588.40 598.21 608.01 617.82 627.63 637.43 647.24 657.05 666.85 676.66 60
70 686.47 696.27 706.08 715.89 725.69 735.50 745.31 755.11 764.92 774.73 70
80 784.53 794.34 804.15 813.95 823.76 833.57 843.37 853.18 862.99 872.79 80
90 882.60 892.41 902.21 912.02 921.83 931.63 941.44 951.25 961.05 970.86 90
100 980.67 990.47 1000.28 1010.08 1019.89 1029.70 1039.5 1049.31 1059.12 1068.92 100
Newton meters to weight kilogram meters

N·m 0 10 20 30 40 50 60 70 80 90 N·m
　 kgf·m kgf·m kgf·m kgf·m kgf·m kgf·m kgf·m kgf·m kgf·m kgf·m 　
---- 1.020 2.039 3.059 4.079 5.099 6.118 7.138 8.158 9.177 ----
100 10.197 11.217 12.237 13.256 14.276 15.296 16.315 17.335 18.355 19.375 10
200 20.394 21.414 22.434 23.453 24.473 25.493 26.513 27.532 28.552 29.572 20
300 30.591 31.611 32.631 33.651 34.670 35.690 36.710 37.729 38.749 39.769 30
400 40.789 41.808 42.828 43.848 44.868 45.887 46.907 47.927 48.946 49.966 40
500 50.986 52.006 53.025 54.045 55.065 56.084 57.104 58.124 59.144 60.163 50
600 61.183 62.203 63.222 64.242 65.262 66.282 67.301 68.321 69.341 70.360 60
700 71.380 72.400 73.420 74.439 75.459 76.479 77.498 78.518 79.538 80.558 70
800 81.577 82.597 83.617 84.636 85.656 86.676 87.696 88.715 89.735 90.755 80
900 91.774 92.794 93.814 94.834 95.853 96.873 97.893 98.912 99.932 100.952 90
1000 101.972 102.991 104.011 105.031 106.050 107.070 108.090 109.110 110.129 111.149 100
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Temperature
Fahrenheit to centigrade
°F °C °F °C °F °C °F °C °F °C °F °C °F °C °F °C
-60 -51.1 2 -18.9 56 13.3 114 45.6 172 77.8 230 110 288 142.2 346 174.4
-58 -50 0 -17.8 58 14.4 116 46.7 174 78.9 232 111.1 290 143.3 348 175.6
-56 -48.9 2 -16.7 60 15.6 118 47.8 176 80.0 234 112.2 292 144.4 350 176.7
-54 -47.8 4 -15.6 62 16.7 120 48.9 178 81.1 236 113.3 294 145.6 352 177.8
-52 -46.7 6 -14.4 64 17.8 122 50.0 180 82.2 238 114.4 296 146.7 354 178.9
-50 -45.6 8 -13.3 66 18.9 124 51.1 182 83.3 240 115.6 298 147.8 356 180
-48 -44.4 10 -12.2 68 20 126 52.2 184 84.4 242 116.7 300 148.9 358 181.1
-46 -43.3 12 -11.1 70 21.1 128 53.3 186 85.6 244 117.8 302 150 360 182.2
-44 -42.2 14 -10 72 22.2 130 54.4 188 86.7 246 118.9 304 151.1 362 183.3
-42 -41.1 16 -8.9 74 23.3 132 55.6 190 87.8 248 120 306 152.2 364 184.4
-40 -40.0 18 -7.8 76 24.4 134 56.7 192 88.9 250 121.1 308 153.3 366 185.6
-38 -38.9 20 -6.7 78 25.6 136 57.8 194 90.0 252 122.2 310 154.4 368 186.7
-36 -37.8 22 -5.6 80 26.7 138 58.9 196 91.1 254 123.3 312 155.6 370 187.8
-34 -36.7 24 -4.4 82 27.8 140 60 198 92.2 256 124.4 314 156.7 372 188.9
-32 -35.6 26 -3.3 84 28.9 142 61.1 200 93.3 258 125.6 316 157.8 374 190.0
-30 -34.4 28 -2.2 86 30.0 144 62.2 202 94.4 260 126.7 318 158.9 376 191.1
-28 -33.3 30 -1.1 88 31.1 146 63.3 204 95.6 262 127.8 320 160 378 192.2
-26 -32.2 32 0.0 90 32.2 148 64.4 206 96.7 264 128.9 322 161.1 380 193.3
-24 -31.1 34 1.1 92 33.3 150 65.6 208 97.8 266 130.0 324 162.2 382 194.4
-22 -30.0 36 2.2 94 34.4 152 66.7 210 98.9 268 131.1 326 163.3 384 195.6
-20 -28.9 38 3.3 96 35.6 154 67.8 212 100.0 270 132.2 328 164.4 386 196.7
-18 -27.8 40 4.4 98 36.7 156 68.9 214 101.1 272 133.3 330 165.6 388 197.8
-16 -26.7 42 5.6 100 37.8 158 70.0 216 102.2 274 134.4 332 166.7 390 198.9
-14 -25.6 44 6.7 102 38.9 160 71.1 218 103.3 276 135.6 334 167.8 392 200
-12 -24.4 46 7.8 104 40.0 162 72.2 220 104.4 278 136.7 336 168.9 400 204.4
-10 -23.3 48 8.9 106 41.1 164 73.3 222 105.6 280 137.8 338 170.0 410 210.0
-8 -22.2 50 10.0 108 42.2 166 74.4 224 106.7 282 138.9 340 171.1 420 215.6
-6 -21.1 52 11.1 110 43.3 168 75.6 226 107.8 284 140.0 342 172.2 430 221.1
-4 -20.0 54 12.2 112 44.4 170 76.7 228 108.9 286 141.1 344 173.3 440 226.7
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Centigrade to fahrenheit
°C °F °C °F °C °F °C °F °C °F °C °F °C °F °C °F
-50 -58.0 -18 -0.4 14 57.2 46 114.8 78 172.4 110 230.0 142 287.6 174 345.2
-49 -56.2 -17 1.4 15 59.0 47 116.6 79 174.2 111 231.8 143 289.4 175 347.0
-48 -54.4 -16 3.2 16 60.8 48 118.4 80 176.0 112 233.6 144 291.2 176 348.8
-47 -52.6 -15 5.0 17 62.6 49 120.2 81 177.8 113 235.4 145 293.0 177 350.6
-46 -50.8 -14 6.8 18 64.4 50 122.0 82 179.6 114 237.2 146 294.8 178 352.4
-45 -49.0 -13 8.6 19 66.2 51 123.8 83 181.4 115 239.0 147 296.6 179 354.2
-44 -47.2 -12 10.4 20 68.0 52 125.6 84 183.2 116 240.8 148 298.4 180 356.0
-43 -45.4 -11 12.2 21 69.8 53 127.4 85 185.0 117 242.6 149 300.2 181 357.8
-42 -43.6 -10 14.0 22 71.6 54 129.2 86 186.8 118 244.4 150 302.0 182 359.6
-41 -41.8 -9 15.8 23 73.4 55 131.0 87 188.6 119 246.2 151 303.8 183 361.4
-40 -40.0 -8 17.6 24 75.2 56 132.8 88 190.4 120 248.0 152 305.6 184 363.2
-39 -38.2 -7 19.4 25 77.0 57 134.6 89 192.2 121 249.8 153 307.4 185 365.0
-38 -36.4 -6 21.2 26 78.8 58 136.4 90 194.0 122 251.6 154 309.2 186 366.8
-37 -34.6 -5 23.0 27 80.6 59 138.2 91 195.8 123 253.4 155 311.0 187 368.6
-36 -32.8 -4 24.8 28 82.4 60 140.0 92 197.6 124 255.2 156 312.8 188 370.4
-35 -31.0 -3 26.6 29 84.2 61 141.8 93 199.4 125 257.0 157 314.6 189 372.2
-34 -29.2 -2 28.4 30 86.0 62 143.6 94 201.2 126 258.8 158 316.4 190 374.0
-33 -27.4 -1 30.2 31 87.8 63 145.4 95 203.0 127 260.6 159 318.2 191 375.8
-32 -25.6 0 32.0 32 89.6 64 147.2 96 204.8 128 262.4 160 320.0 192 377.6
-31 -23.8 1 33.8 33 91.4 65 149.0 97 206.6 129 264.2 161 321.8 193 379.4
-30 -22.0 2 35.6 34 93.2 66 150.8 98 208.4 130 266.0 162 323.6 194 381.2
-29 -20.2 3 37.4 35 95.0 67 152.6 99 210.2 131 267.8 163 325.4 195 383.0
-28 -18.4 4 39.2 36 96.8 68 154.4 100 212.0 132 269.6 164 327.2 196 384.8
-27 -16.6 5 41.0 37 98.6 69 156.2 101 213.8 133 271.4 165 329.0 197 386.6
-26 -14.8 6 42.8 38 100.4 70 158.0 102 215.6 134 273.2 166 330.8 198 388.4
-25 -13.0 7 44.6 39 102.2 71 159.8 103 217.4 135 275.0 167 332.6 199 390.2
-24 -11.2 8 46.4 40 104.0 72 161.6 104 219.2 136 276.8 168 334.4 200 392.0
-23 -9.4 9 48.2 41 105.8 73 163.4 105 221.0 137 278.6 169 336.2 210 410.0
-22 -8 10 50.0 42 107.6 74 165.2 106 222.8 138 280.4 170 338.0 220 428.0
-21 -6 11 51.8 43 109.4 75 167.0 107 224.6 139 282.2 171 339.8 230 446.0
-20 -4 12 53.6 44 111.2 76 168.8 108 226.4 140 284.0 172 341.6 240 464.0
-19 -2 13 55.4 45 113.0 77 170.6 109 228.2 141 285.8 173 343.4 250 482.0
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INTRODUCTION
Consumables
By using appropriate lubricants the excavator can operate in ambient temperatures ranging from -20 °C (-4 °F) to
45 °C (113 °F). Refer to the list of lubricants contained in this manual.
NOTICE: When operating the machine in ambient temperatures outside the above mentioned range, consult your
CASE CONSTRUCTION Dealer for specific fluids to be used.
Hydraulic fluid
CASE AKCELA HYDRAULIC EXCAVATOR FLUID
MAT3509 ( ISO 6743 -L-HV 46 )
Biodegradable fluid:
CASE AKCELA HYDRAULIC EXCAVATOR FLUID BIO

MAT3509 ( ISO 6743 -L-HS 46 )
When changing over the hydraulic fluid in the system from mineral oil to biodegradable oil proceed as follows:
1. Drain the system completely.
2. Flush the system with biodegradable oil in order to minimize the contamination from residual mineral oil: guideline
provided in ISO 15380 target no more than 2 % of mineral oil remaining in the system after fluid changeover.
3. Replace the suction filter, the hydraulic return filter and the pilot line filter.
4. Make the final fill with biodegradable oil.
NOTICE: the hydraulic return filter and the pilot line filter shall be replaced 50 h after the change over to the biodegrad-
able hydraulic fluid.
Transmission component oil

CASE AKCELA GEAR 135 H EP 80W-90
MS 1316, SAE 80W/90, API GL-5
Grease
CASE AKCELA 251H EP MULTI-PURPOSE GREASE
NLGI 2
Engine oil
CASE AKCELA UNITEK 10W-40
MAT3521 ( SAE 10W40, ACEA E9, API CJ-4 )
Engine coolant
CASE AKCELA PREMIUM ANTI-FREEZE
MAT3620 (ASTM D 6210 Type 1-FF)
NOTICE: CASE AKCELA PREMIUM ANTI-FREEZE is concentrate and shall be mixed with water before filling the
cooling system. Refer to the following Antifreeze/water mixture chart.
Minimum ambient temperature -20 °C (-4 °F) -25 °C (-13 °F) -30 °C (-22 °F) -40 °C (-40 °F)
Antifreeze 40 % 45 % 50 % 60 %
Water 60 % 55 % 50 % 40 %
NOTICE: do not mix coolants of a different origin or brand. The same product must be used when topping up the
system.
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INTRODUCTION
Fuel
Use only Ultra-Low Sulphur Diesel (S10) that meets EN 590 specifications.
Using other types of fuel may lead to stalled engine output or deterioration in fuel economy.
NOTICE: The warranty shall be invalid if any serious defect is caused by usage of any other fuel. Using fuel other than
recommended may cause damage to the fuel injection pump, injector, DOC (Diesel Oxidation Catalist), and other fuel
supply system or the engine. CASE CONSTRUCTION may not be responsible to any of such damages.
If the temperature drops below the fuel cloud point, output deficiency or engine start problems may occur due to wax
crystals.
NOTICE: If operating in severe winter climate, consult the fuel supplier or the CASE CONSTRUCTION dealer for
specific diesel fuel according to the EN 590 to be used.
Conditions applicable to diesel fuel. The diesel fuel used must:

• be free from dust particles, even minute ones,
• have the proper viscosity,
• have a high cetane number,
• present great fluidity at low temperatures,
• have low sulphur content,
• have very little residual carbon.
Recommended conditions that can be applied to diesel fuel:

• JIS (Japanese Industrial Standard): No. 2
• DIN (Deutsche Industrie Normen): DIN 51601
• SAE (Society of Automotive Enginneers) based on SAE-J-313C : No. 2-D
• BS (British Standard) based on B-1S/2869-1970: Class A
• EN 590 (less than 10 ppm sulfur)
• Or fuel specified by the country using these standards and this machine.
It is recommended that the following safety information be considered in order to prevent damage to the engine
fuel supply system.
• Some fuel suppliers mix old engine oil and diesel fuel.
• Makers of larger engine permit the use of this kind of fuel.
• However, do not use diesel fuel contaminated with engine oil in customer's engines.
• Not only will this fuel damage the engine, it may also have a negative impact on the exhaust gas purification function.
• Before using diesel fuel, confirm with the supplier whether the fuel complies with the above specifications.
NOTICE: consult the supplier or the CASE CONSTRUCTION Dealer regarding appropriate use of fuel additives.
NOTICE: in order to prevent condensation during cold weather, fill the fuel tank to full after the completing the day's
work.
Fuel storage:
Long storage can lead to the accumulation of impurities and condensation in the fuel. Engine trouble can often be
traced to the presence of water in the fuel. The storage tank must be placed outside and the temperature of the fuel
should be kept as low as possible. Drain off water and impurities regularly.
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INTRODUCTION
Environment and ecology

Before carrying out any maintenance operation on this machine and before disposing of used fluids or lubricants,
always think of the environment. Never throw oil or fluid on the ground and never place it in leaking receptacles.
Consult your local ecological recycling center or your CASE CONSTRUCTION Dealer to obtain information on the
correct method of disposing of these lubricants.
The following are recommendations which may be of assistance:

• Become acquainted with and ensure that you understand the relative legislation applicable to your country.
• Where no legislation exists, obtain information from suppliers of oils, filters, batteries, fuels, antifreeze, cleaning
agents, etc., with regard to their effect on man and nature and how to safely store, use and dispose of these sub-
stances.
• Local Environmental Agency will, in many cases, be able to help you as well.
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INTRODUCTION
Capacities
Engine 48 L (12.7 US gal)
Cooling system 38 L (10.0 US gal)
Fuel tank 580 L (153.2 US gal)
DEF/AdBlue® tank 152 L (40.2 US gal)
Whole system: 350 L (92.5 US gal)
Hydraulic system
Tank: 175 L (46.2 US gal)
Travel reduction units 9.5 L (2.5 US gal) x2
5.0 L (1.3 US gal)
Swing unit
1.2 kg (2.6 lb) grease
Turntable teeth 21 kg (46.3 lb)
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INTRODUCTION
Abbreviation
Abbreviation Explanation
A/C Air-conditioner
A/D Analog/Digital
ABDC After bottom dead center
AC Alternating current
ACC Accessories
ACG Alternating current generator
ACT Actuator
API American Petroleum Institute
ASM Assembly
ATDC After top dead center
ATF Automatic transmission fluid
Drilled hole B Notch hole bolt
Eye B Eyebolt
Full threaded B Full threaded bolt
Hexagon socket head B Hexagon socket head bolt
High-strength B High-strength bolt
Reamer B Reamer bolt
B+ Battery positive
BAT Battery
BBDC Before bottom dead center
BKT Bracket
BRG Bearing
BTDC Before top dead center
C/B Circuit breaker
C/U Control unit
C. RAIL Common rail
CAL Calibration
CAN Type of control unit communication format (controller area network)
CCD Charged-coupled device
CCV Coolant control valve
CCW Counterclockwise
CFG Configuration
CHK Check
CKP Crankshaft position
CMP Camshaft position
CN. Connector
CO Carbon monoxide
CPU Central processing unit
CW Clockwise
DC Direct current
DCU Dosing control unit
DEF/AdBlue® Urea solution
DI Direct injection type
DIAG Diagnosis
DLC Data link connector
DMM Digital multi-meter
DOC Diesel oxidation catalyst
DPD Diesel particulate diffuser
DTC Diagnostic trouble code
ECM Engine controller module
ECT Engine coolant temperature
ECU Engine control unit
EEPROM Electrically erasable programmable read-only memory
EGR Exhaust gas recirculation
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INTRODUCTION
EMI Electromagnetic interference
EMPS Engine module programming system
ENG Engine
EPF Engine protection feature
EVRV Electric vacuum regulating valve
EXH Exhaust gas
F/B Feedback
F/C Fuel cut
F/L Fusible link
FLW Fusible link wire
FRP Fiber-reinforced plastic
FRT Front
FT Fuel temperature
FVM Field view monitor
FWD Forward
GEN Generator
GND Ground
GPS Global Positioning System
HBCV Hose burst check valve
HC Hydrocarbon
HO2S Heated O2 sensor
HR Hour
HRD High reach demolition model
HYD. Hydraulic mechanism
IAC Idle air control
IAT Intake air temperature
IC Integrated circuit
ID Plate Decal and ID plate
IMT Intake manifold temperature
INL Suction air
INJ Injection
ISO International Standardization Organization
ISP Intake shutter position
ITP Intake throttle position
J/C Joint connector
JIS Japanese Industrial Standards
KW Type of communication format (keyword)
LED Light-emitting diode
LH Left
LLC Long-life coolant
LM Lifting magnet
M/A Motor actuator
M/V Electromagnetic valve
MAF Mass air flow
MAP Manifold air pressure
Max Maximum
MCM Main control module
MIL Malfunction indicator lamp (diagnosis)
milli-amp Current
Min Minimum
MPU Micro-processing unit
High-strength N High-strength nut
NC Normally closed
NO Normally open
NOx Nitrogen oxide
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INTRODUCTION
N-TDC Speed at top dead center
O2S O2 sensor
OBD On-board diagnosis
OEM Original equipment manufacturing
OPT Option
OT Oil temperature
P/L Pilot lamp
P.C.D. Pitch diameter
PCV Pump control valve/positive crankcase ventilation
P-I Proportional - integral
PM Particulate matter
PTO Power take-off
PWM Pulse width modulated wave
QOS Quick preheat unit
QWS Quick warm up system
R/L Relay
RAM Random access memory
REF Reference
RH Right
ROM Read-only memory
ROPS Roll over protective structure
RP Rail pressure
Rr Rear
RWD Rearward
Flush head S Flush head Screw
Phillips pan head S Phillips pan head Screw
Screw tapping S Screw tapping Screw
S/A Subassembly
SAE Society of Automotive Engineers
SBF Slow blow fuse
SCR Selective Catalytic Reduction
SCV Suction control valve
SIG Signal
SLD Shield
SOL Solenoid
SP pin Special pin
ST Starter/start
STD Standard
SW Switch
TDC Top dead center
TEMP Temperature
TH. Throttle valve
TP Throttle position
UART Universal asynchronous receiver-transmitter
VB Battery voltage
VGS Turbo Variable geometry system turbo
High-strength W High-strength washer
Outer-tooth W Outer-tooth washer
W/H Wire, harness
W/L Warning light
W/S Welded splice
WOT Wide open throttle
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INTRODUCTION
Product identification
SMIL15CEX6240EA 1
SMIL15CEX6241EA 2
When ordering parts, obtaining information or assistance, always supply your CASE CONSTRUCTION Dealer with
the type and serial number of your machine or accessories. Write the following in the spaces below: the type, serial
number and year of manufacture of your machine, accessories and the serial numbers of the various hydraulic and
mechanical components.
Machine
(1) Designation/Model
Hydraulic Excavator CX350D
Hydraulic Excavator CX370D
(2) Product Identification Number (PIN)
(3) Year of Construction
(4) Model Year
(5) Maximum operating mass

(the weight shown on the manufacturer's plate is the value
SMIL15CEX3307AA 3
using the heaviest configuration and that it does not al-
ways correspond to the transport configuration)
(6) Engine power ISO 14396
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INTRODUCTION
Engine
Manufacturer and model: ISUZU AQ-6HK1X
Serial number:
SMIL14CEX6817AA 4
ID label
This is attached on the cylinder head cover.
SMIL14CEX4269AA 5
Emission decal
The emission decal is affixed on the cylinder head cover.
It describes important details for using the engine. Make
sure to read before using the engine. Also, the emission
decal describes details regarding the engine only.
SMIL14CEX1607AA 6
SCR (Selective Catalytic Reduction) serial

number
The number is stamped on top of the urea SCR.
1. Center DOC serial:

2. SCR serial:
SMIL14CEX4270AB 7
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INTRODUCTION
Structure protection (ROPS) (Roll Over Pro-

tective Structure)
Complies with ISO 12117-2
Identification number:
15UUEH-001 8
Cab protection (FOPS) (Falling Objects Pro-

tective Structure)
Complies with ISO 10262 level 2.
Product identification number:
E4E41FA0 9
Quick coupler (optional)

(1) Serial number:
(2) Weight:
(3) Working pressure:
(4) Type/Model:
(5) Part number:
(6) Year of manufacture:
(7) SWL (Safe Working Load): SMIL14CEX0110AB 10
Component serial numbers

Hydraulic pump:
Swing reduction gear:
Travel reduction gears:
Travel control valve:
Attachment control valve:
Swing control valve:
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Product identification - Machine orientation

The terms "Right-hand", "Left-hand", "Front" and "Rear"
are used in this manual to indicate the sides as they are
seen from the operator's seat when the cab is over the
idler wheels.
NOTE: the illustration shows the machine in normal travel
position. In normal travel position, the cab is over the
idler wheels. The travel reduction gears are at the rear
of the upperstructure. This manual uses the terms “right”,
“left”, “front” and “rear” to show the side viewed from the
operator's seat when the cab is located above the idler
wheel.
A. Front
B. Rear
C. Right side
D. Left side
E. Travel motor
F. Idler wheel
SMIL14CEX6815BB 1
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SERVICE MANUAL
Engine

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Contents
Engine - 10
[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
[10.102] Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
[10.106] Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
[10.101] Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
[10.105] Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
[10.103] Crankshaft and flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
[10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
[10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8
[10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9
[10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10
[10.250] Turbocharger and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11
[10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12
[10.500] Selective Catalytic Reduction (SCR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13
[10.501] Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust
treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14
[10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
[10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
[10.310] Aftercooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
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[10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
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Engine - 10
Engine and crankcase - 001

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Contents
Engine - 10
TECHNICAL DATA
Engine
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Engine
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SERVICE
Engine
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Check - Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Test - Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Compression test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Crankcase
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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Engine - Engine and crankcase
Engine - General specification

Engine main specifications
Item Engine model 6HK1
Diesel/4-cycle/water-cooled, inline 6 cylinder
Type
OHC
Shape of combustion chamber Direct injection type
Cylinder liner type Dry type
Cylinder bore x stroke 115 mm (4.53 in) x 125 mm (4.92 in)
Displacement 7.79 L (475.37 in³)
Compression ratio 16.3
Compression pressure 3 MPa (441 psi) 200 RPM
Idling speed 800 RPM
Intake 0.4 mm (0.016 in) While cool
Valve clearance
Exhaust 0.4 mm (0.016 in) While cool
Ignition method Compression ignition
Injection order 1, 5, 3, 6, 2, 4
Lubrication system
Lubrication type Compression type
Oil pump type Gear type
Lubrication oil amount 36 - 46 L (9.5 - 12.2 US gal)
Oil filter type Full-flow filter (Cartridge type)
Oil cooling type Built-in type, water cooling
Cooling system
Cooling type Water cooling
Radiator type Corrugated fin (Pressure type)
Water pump type Centrifugal type, belt type
Thermostat type 2-wax type unit
76 °C (170 °F) With jiggle valve
Type 1
Thermostat valve open valve 82 °C (180 °F) Without jiggle valve
temperature 85 °C (185 °F) With jiggle valve
Type 2
82 °C (180 °F) Without jiggle valve
Coolant capacity 16.0 L (4.2 US gal)
Fuel system
Injection pump type Electronic control common rail (fuel rail) type
Governor type Electronic type
Timer type Electronic type
Multi-hole type 7 holes, inner diameter Ø
Injection nozzle type
0.14 mm (0.0055 in)
Charging system
Generator type AC type
Output 24 - 90 V 50 A
Regulator type IC
Starter system
Starter type Reduction type
Output 24 V 5.0 kW
Preheat system type Glow plug
Glow plug standard voltage/current 23 V 3.5 A
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Cooling system main specifications

Item Specifications
Water pump Centrifugal impeller method
Type 1 0.80
Pulley ratio
Type 2 0.85
Thermostat Wax pellet type
Type 1
Full open temperature
Type 2
Electrical system main specifications

Generator
Item Specification
Manufacturer name Mitsubishi Electric Corporation
Isuzu parts number 1-81200-633-0 1-81200-603-2
Manufacturer type A009TU3782 A004TU6285
Nominal voltage 24 V
Output current 90 A 50 A
Rated rotation count 5000 RPM
Output current/voltage 114 A/ 27 V/ 5000 RPM 50 A/ 27 V/ 5000 RPM
No-load voltage 24 V/ 900 RPM
Rotational direction Clockwise direction
Polarity (-)
Pulley diameter (P.C.D) 90.0 mm (3.54 in) 80.0 mm (3.15 in)
Starter
Item Specification
Manufacturer Mitsubishi Electric Corporation
Isuzu parts number 181100-4140
Manufacturer code number M008T60971
Output 24 V/ 5.0 kW
Rating 30 s
York outer diameter 85.0 mm (3.35 in)
Rotational direction Right
Protection type Dust proof, drip proof
Low speed mechanism Inner contact gear
Module 3
Pressure angle 14.5
Pinion Number of teeth 11
Gear ratio{ring
12.8 {129/11}
gear/pinion gear}
Voltage 23 V
No load Current 85 A or less
Rotational speed 3300 RPM or more
Voltage 9V
Restraint Current 1,400 or less
Torque 88 N·m (65 lb ft) or more
Pinion/engaged voltage 16.0 V or less
Glow plug
Item Type
Preheat device model Glow plug
Glow plug rated voltage/current 23 V/ 3.5 A
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Engine - Identification
Engine number
SMIL14CEX3961GB 1
1. Engine number stamping
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Engine - External view

Engine structural diagram
SMIL14CEX3962FA 1
SMIL14CEX3963FA 2
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SMIL14CEX3964FA 3
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Engine - Static description

The control provided by the control unit applies to the range from injection to air intake and exhaust, including fuel
injection quantity, injection timing, air intake restriction, EGR, and idling speed.
Cylinder block
The cylinder block is made of cast iron, and it has an equal center distance for each bore and a high rigidity, and the
center of the crankshaft matches the center of the block. Tighten the bearing cap using the plastic region rotational
angle tightening method with the ladder frame structure.
Cylinder liner
A cylinder liner that matches with the cylinder block bore inner diameter is selected, and the identification number is
stamped on the left side of the cylinder.
Piston
The piston is a strut cast autothermatic piston made of aluminum alloy, and the combustion chamber is the round
re-entrant type.
Cylinder head
The cylinder head is made of cast iron and has four valves per cylinder. The angle tightening method has been
adopted for the cylinder head bolt to further improve its reliability and durability.
Crankshaft
The crankshaft uses tufftrided steel, and each of the journal diameter grades are marked on the No. 1 balance weight.
EGR system
The EGR system is controlled by the engine control module (ECM) according to various data, including the water
temperature, engine speed, and engine load, to recirculate the exhaust gas for purification. The primary components
are the EGR valve, EGR cooler, and various sensors.
Connecting rod cap bolt

The angle tightening method has been adopted for the connecting rod cap bolt to further improve its reliability and
durability.
Common rail (fuel rail) type electronic control injection system

The common rail (fuel rail) type electronic control injection system consists of the fuel supply pump that sets the target
pressure of the high pressure fuel to supply the fuel, the common rail (fuel rail) that measures the high-pressure fuel,
and the fuel injector that injects the fuel in the form of a fine mist. Each of these is controlled by the ECM based on
various signals that control the injection timing and injection quantity in accordance with driving conditions.
Fuel injector
The fuel injector has adopted the 7- hole nozzle, and adjusts the fuel injection quantity and injection timing by opening
or closing the electromagnetic valve on the injector head portion.
The ECM corrects variations in the fuel injection quantity between fuel injectors in accordance with the ID code data
in the memory. When adjusting the fuel injector, the ID code data must be recorded in the ECM.
Fuel filter with sedimenter

The fuel filter with sedimenter removes water by using the difference in the specific gravity of diesel oil and water, and
notifies the operator through the indicator when it becomes full of water.
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Preheat system
The preheat system consists of the ECM, glow relay, glow plug, and glow indicator light. The preheat system is
activated when the engine coolant temperature is low so as to help the engine start.
Lubricating system
An oil filter with a full-flow bypass is used, and the pistons are cooled down using the water-cooled oil cooler and the
oil jet.
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Engine - Prepare
WARNING
Escaping fluid!
Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or
other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or per-
forming work on the hydraulic system. Before applying pressure, make sure all connections are tight
and all components are in good condition. Never use your hand to check for suspected leaks under
pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your
doctor immediately.
W0178A
WARNING
Avoid injury!
Shut off the engine, remove the key, and make sure all motion is stopped before servicing the machine.
W1128A
WARNING
Crushing hazard!
The lifting systems must be operated by qualified personnel who are aware of the correct procedures
to follow. Make sure all lifting equipment is in good condition, and all hooks are equipped with safety
latches.
W0256A
WARNING
Heavy objects!
Lift and handle all heavy components using lifting equipment with adequate capacity. Always support
units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders.
W0398A
WARNING
Explosion hazard!
Batteries emit explosive gases. Always ventilate when using in an enclosed area or when charging.
Keep the battery away from sparks, open flames, and other ignition sources.
W0369A
NOTICE: Keep away from flames.

NOTICE: The air conditioner circuit is filled with high pressure gas, gas may spray out dangerously when loosening
lines.
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Items to prepare:
• Wrenches [ 7 mm, 8 mm, 10 mm, 13 mm, 17 mm,
19 mm, 36 mm ]
• Box wrench [ 30 mm]
• Shackle (with the required lifting capacity) x 2
• Wire rope (with the required breaking load)
• Lifting equipment (with the required lifting capacity)
• Marking pen
• Cap
• Plug
• Waste oil can
• Rag
• Cleaning fluid
• Wood plank, etc.
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Engine - Remove
1. Remove the cable connected to minus side of the bat-
tery or turn OFF the battery disconnect switch.
• Secure the terminal and harness in order to prevent
them from touching the frame or other parts when
they have been removed.
• Or protect them with a rubber cap or other cap to
prevent sparks.
2. Remove the 5 bolts (1) with a wrench ( 19 mm) to re-
move the under cover (2).
Bolt tightening torque: 63.7 - 73.5 N·m (47.0 -
54.2 lb ft)
SMIL14CEX0769AB 1
3. Drain engine oil.

4. Drain coolant of the radiator. (Refer to Radiator - Re-
move (10.400) for detail.)
5. Remove the engine hood. (Refer to Hood - Remove
(90.100) for detail.)
6. Remove the hydraulic pump. (Refer to Variable dis-
placement pump - Remove (35.106) for detail.)
7. Remove the radiator hose and fan shroud. (Refer to
Radiator - Remove (10.400) for detail.)
8. Remove lines from the compressor. (Refer to Air-con-
ditioning compressor - Remove (50.200) for detail.)
9. Remove wirings from the starter. (Refer to Engine
starter - Remove (55.201) for detail.)
10. Remove wirings from the alternator. (Refer to Alter-
nator - Remove (55.301) for detail.)
11. Remove the 2 bolts (1) with a wrench ( 13 mm) to
remove the box cover (2).
SMIL14CEX0770AB 2
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12. Disconnect the 5 connections (1) of the engine har-

ness and frame main wire harness in the box.
• Wrap the disconnected connectors with a vinyl after
bundle them so as to prevent invasion of water, dust
and dirt.
SMIL14CEX0771AB 3
13. Loosen the hose band (1) with a wrench ( 7 mm) to

remove the air cleaner (2).
Loosen the hose band (3) with a wrench ( 7 mm) to
remove the 2 intercooler hoses (4).
Remove the 4 nuts (5) to remove the exhaust pipe (6).
SMIL14CEX0772AB 4
14. Remove the hose band (1) to remove the 2 urea

coolant hoses (2).
Remove the hose band (3) to remove the 2 heater
hoses (4).
• Attach caps and plugs at the engine and the hoses
so as to prevent invasion of water, dust and dirt.
SMIL14CEX0773BB 5
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15. Remove the hose band (1) to remove the 2 fuel hoses
(2).
• Attach caps and plugs at the engine and the hoses
so as to prevent invasion of water, dust and dirt.
SMIL14CEX0774AB 6
16. Prepare a waste oil can and then remove the 2 engine
oil remote hoses ( (1) with a wrench ( 36 mm).
• Apply marking at each location of the engine and
the hoses so as to match connections at assem-
bling.
• Attach caps and plugs at each location of the en-
gine and the hoses so as to prevent invasion of wa-
ter, dust and dirt.
• Wash each location of the engine and the hoses by
blowing parts cleaner so as to prevent adhering dirt
at connections and not to damage them.
SMIL14CEX0775AB 7
17. Attach the 2 shackles (1) and then secure the engine
main unit with a wire rope (2) and a lifting equipment.
SMIL14CEX0776AB 8
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18. Remove the 4 bolts (1) with a box wrench ( 30 mm)

Bolt tightening torque: 289 - 337 N·m (213.16 -
248.56 lb ft)
SMIL14CEX0777BB 9
19. Lift the engine main unit with a wire rope (1) and a
lifting equipment.
Make sure that you have a safe site, and then settle the
engine on a wood plank or other block.
SMIL14CEX0778BB 10
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Engine - Install
1. Install the engine in the reversed order of the procedure
for removal.
Each bolt has to be tightened in the specified torque.
Refer to the Torque – Bolt and nut () for tightening
torque for bolts without instruction.
After installation, fill coolant, fill engine oil, bleed air
from the fuel line, wash and fill air conditioner gas.
Follow respective procedures and descriptions for de-
tail.
2. Make sure that there is no water leak or oil leak by
running the engine in idle speed with no load.
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Engine - Check - Engine oil

WARNING
Burn hazard!
Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that
exceed 49 °C (120 °F). Allow fluids to cool before proceeding.
W0330B
NOTICE: The engine should be in a horizontal position.

NOTICE: Wait at least 5 min before starting the engine and after stopping the engine.
Engine oil inspection

1. Remove the oil level gauge from the oil level gauge
guide tube.
NOTE: Wipe off the engine oil remaining on the oil level
gauge.
2. Install the oil level gauge to the oil level gauge guide
tube.
guide tube.
4. Inspect the engine oil.
NOTE: Check the engine oil remaining on the oil level
gauge to inspect the engine oil level.
1. Upper limit
2. Lower limit
NOTE: If the oil level is under the lower limit, add engine
oil. Replace the engine oil if engine oil is dirty.
SMIL14CEX3221AB 1
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Engine - Test - Engine oil

Sampling of engine oil
1. Open the side door (1).
At this time, make sure to apply the lock (2).
SMIL14CEX1174AB 1
2. Place a sampling container under the sampling port (1).

3. Open the valve (2) to drain a proper amount of oil.
4. Close the valve (2) to check that there is no leakage.
5. If necessary, add the same amount of oil as the drained
oil.
SMIL14CEX1175AB 2
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Engine - Compression test

NOTE: Warm up the engine.
1. Remove the glow plug from the cylinder head assem-
bly.
NOTE: Remove all the glow plugs.
2. Remove the injector harness connectors from the lower
cover.
SMIL14CEX3444AA 1
3. Install the special tool on the cylinder head assembly.

Special tool: Compression gauge adapter (Refer
to Cylinder head - Special tools (10.101))
SMIL14CEX3445AA 2
Special tool: Compression gauge (adapter) (Refer

to Cylinder head - Special tools (10.101))
SMIL14CEX3446AA 3
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4. Insert the compression gauge adapter (2) into the glow

plug installation hole to install the compression gauge
(1).
SMIL14CEX3447BB 4
5. To measure the compression pressure proceed as fol-

lows:
• Turn the starter and read the compression pressure
when the compression gauge indicator is stable at
about 200 RPM.
• Measure the compression pressure for all cylinders.
Standard value: 3240 kPa (470 psi).
Limit value: 2260 kPa (328 psi).
Difference between each cylinder: 294 kPa
(43 psi)
CAUTION: Be careful of the streaming air

blowing out from the glow plug hole while rotating.
NOTE: If the key switch is turned ON with the injector har-
ness connector removed, the ECM judges that it is a mal-
function and a diagnostic trouble code is set. Be sure to
clear DTCs after the inspection is complete.
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Crankcase - Remove
Battery ground cable disconnect
1. Disconnect the battery ground cable from the battery.
Coolant drain
1. Remove the radiator cap from the radiator.
CAUTION:
○ Do not loosen the radiator cap or sub-tank cap

when the coolant temperature is high.
○ Because steam and boiling water can burst out
from the radiator and possibly cause burns,
check that the engine has cooled.
2. Remove the drain plug from the radiator.

3. Drain coolant from the radiator.
SMIL14CEX2956AB 1
NOTE: If the EGR cooler has an air bleeding plug (1),
loosen the plug and remove it with the gasket (2).
With the pressurized reserve tank specification, it is not
necessary to bleed the air.
4. Remove the drain plug (1) from the cylinder block.
5. Discharge coolant from the engine.
6. Install the drain plug (1) to the cylinder block.
7. Install the drain plug to the radiator.
SMIL14CEX2973AB 2
Engine oil drain

1. Remove the drain plug from the oil pan.
2. Drain the engine oil from the oil pan.
3. Install the drain plug to the oil pan.
Tightening torque: 70 N·m (52 lb ft)
Engine harness disconnect

1. Disconnect the engine harness from the engine assem-
bly.
NOTE: Disconnect each connector.
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Cooling fan removal

1. Remove the cooling fan (1) from the adapter (2).
SMIL14CEX3121AB 3
Fan guide removal

1. Remove the fan guide (6) from the fan guide bracket.
1. Bolt
2. Washer
3. Rubber mount
4. Rubber mount
5. Guide tube
6. Fan guide
2. Remove the fan guide bracket from the engine assem-
bly.
SMIL14CEX3122AB 4
Cooling fan belt removal

1. Remove the cooling fan belt from the engine assembly.
1. Adjust bolt
2. Fixing bolt
3. Fixing bolt
SMIL14CEX3123AB 5
Crankshaft pulley removal

1. Remove the crankshaft pulley from the crankshaft.
2. Remove the crankshaft damper from the crankshaft
pulley.
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Crankshaft front oil seal removal

1. Remove the crankshaft front oil seal from the timing
gear case.
CAUTION: Be careful not to damage the oil

seal pressfitting surface of the timing gear case.
1. Felt
2. Slinger
3. Crankshaft front oil seal
SMIL14CEX3124AB 6
2. Remove the slinger from the crankshaft using the spe-

cial tool.
Special tool: Slinger puller (Refer to Crankshaft -
Special tools (10.103))
SMIL14CEX3125AA 7
CAUTION: When replacing the oil seal, re-

place the slinger.
SMIL14CEX3126AA 8
Water pump assembly removal

1. Remove the fan pulley from the water pump assembly.
SMIL14CEX3127AA 9
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2. Remove the water bypass hose from the water pump

assembly and the water duct.
1. Water bypass hose
3. Remove the water hose from the EGR cooler water
pipe and the water pump assembly.
4. Remove the water pump assembly from the front cover.
SMIL14CEX3128AB 10
Front cover removal

1. Remove the adjust plate from the front cover.
2. Remove the front cover from the cylinder block.
Turbocharger assembly removal

1. Remove the air cleaner duct from the air cleaner as-
sembly and the turbocharger assembly.
2. Remove the air intake hose from the turbocharger as-
sembly and the intercooler.
3. Remove the exhaust pipe from the turbocharger.
4. Disconnect the oil feed pipe (1) from the turbocharger
assembly.
NOTE: Remove the clip (2).
5. Remove the oil feed pipe (1) from the pipe bracket.
6. Disconnect the oil return pipe (3) from the turbocharger
assembly.
7. Remove the oil return pipe (3) from the cylinder block.
8. Disconnect the water return pipe (5) from the tur-
bocharger assembly. SMIL14CEX2955AB 11
9. Remove the water return pipe (5) from the cylinder

head assembly.
10. Disconnect the water feed pipe (4) from the tur-
bocharger assembly.
11. Remove the water feed pipe (4) from the cylinder
block.
12. Disconnect the harness connector from the tur-
bocharger assembly.
13. Remove the turbocharger assembly from the exhaust
manifold.
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EGR gas temperature sensor 1 removal

1. Disconnect the harness connector from EGR gas tem-
perature sensor 1 (1).
2. Remove the harness bracket from the fan guide stay.
3. Remove EGR gas temperature sensor 1 (1) from EGR
pipe A.
SMIL14CEX2980AB 12

2. Remove the harness bracket from EGR pipe B.
pipe B.
SMIL14CEX2981AB 13
EGR cooler removal

1. Disconnect the water rubber hose (1) from the EGR
cooler.
SMIL14CEX2959AB 14
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2. Remove the EGR pipe B (2) from the EGR valve (1)
and the EGR cooler C (3).
SMIL14CEX2983AB 15
3. Remove the EGR cooler C (1) from the EGR bracket C

(2).
4. Remove the EGR bracket C (2) from the EGR cooler B
(3).
5. Remove the EGR cooler B (3) from the EGR cooler
bracket A (4).
6. Remove the EGR cooler bracket A (4) from the EGR
cooler A.
SMIL14CEX2961AB 16
7. Remove the EGR heat protector (1) from the EGR pipe
A.
SMIL14CEX2980AB 17
8. Remove the EGR cooler A (1) from the EGR pipe A (2).
9. Remove the EGR pipe A (2) from the exhaust manifold.
(3).
SMIL14CEX2986AB 18
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EGR valve removal

1. Disconnect the harness connector from the EGR valve
(1).
2. Remove the EGR valve (1) from the inlet pipe.
SMIL14CEX2974AB 19
Oil separator bracket removal

1. Remove the clip (2) from the cylinder block.
2. Remove the ventilation hose from the air breather.
3. Remove the oil separator bracket (1) from the cylinder
head assembly.
SMIL14CEX2988AB 20
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EGR cooler water pipe removal

1. Remove the EGR cooler water pipe (1) from the engine
assembly.
SMIL14CEX2989GB 21
2. Disconnect the radiator upper hose from the water out-

let pipe.
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3. Remove the water bypass hose (1) from the water

pump assembly and the water duct.
SMIL14CEX2991AB 22
Oil level gauge guide tube removal

guide tube (1).
2. Disconnect the oil level gauge guide tube (1) from the
front engine hanger bracket.
3. Remove the oil level gauge guide tube (1) from the
cylinder block.
SMIL14CEX2992AB 23
Intake throttle valve removal

1. Remove the air duct from the intake throttle valve.
2. Disconnect the harness connector from the intake
throttle valve.
NOTE: Pull the lock operation portion to release the lock.
1. Lock operation section
2. Lock release
3. Lock
SMIL14CEX2993AB 24
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3. Remove the intake throttle valve (1) and the gasket (2)
from the inlet pipe (3).
SMIL14CEX2994AB 25
Inlet pipe removal

1. Disconnect the harness connector from the boost pres-
sure sensor/boost temperature sensor (1).
2. Disconnect the harness connector from the IMT sensor
(3).
3. Remove the harness clip (2) from the inlet pipe.
SMIL14CEX2995AB 26
4. Remove the inlet pipe (1) from the inlet cover.
SMIL14CEX2996AB 27
Glow plug removal

1. Remove the glow plug connector from the glow plug.
SMIL14CEX2997AA 28
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bly.
SMIL14CEX2998AA 29
Injection pipe removal

1. Remove the clip from the inlet pipe.
2. Remove the injection pipe from the injector and the
common rail assembly.
CAUTION:
○ Do not reuse the removed injection pipe.

○ Seal the common rail and injector to prevent
foreign material from entering.
1. No.1 injection pipe

SMIL14CEX2999AB 30
7. Fuel pipe
Fuel pipe removal

1. Remove the fuel pipe from the fuel supply pump and
the common rail assembly.
NOTE: Remove the clip.
CAUTION: Do not reuse the removed gasket.
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Fuel leak off pipe assembly removal

1. Disconnect the fuel leak-off pipe (1) from the cylinder
head.
2. Remove the fuel leak-off pipe (1) from the fuel supply
pump.
NOTE: Remove the eyebolt tightened together with the fuel
feed pipe.
3. Disconnect the fuel leak-off pipe (1) from the common
rail assembly.
4. Remove the fuel leak-off pipe (1) from the inlet pipe.
SMIL14CEX3000AB 31
Common rail assembly removal

1. Disconnect the harness connector from the fuel pres-
sure sensor.
2. Remove the common rail assembly (1) from the inlet
cover.
SMIL14CEX3001AB 32
Cylinder head cover removal

1. Disconnect the ventilation hose from the air breather
2. Remove the cylinder head cover (1) from the lower
cover (3).
3. Remove the head cover gasket (2) from the cylinder
head cover (1).
SMIL14CEX2970AB 33
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Injector harness removal

1. Remove the connector from the lower cover.
CAUTION: Do not pull the wire, or pry the

connector with a screwdriver.
SMIL14CEX3002AA 34
2. Disconnect the terminal nut (3) of the injector harness

(2) from the injector (1).
CAUTION: Be careful not to damage the in-

jector side stud bolts.
SMIL14CEX3003AB 35
3. Remove the injector harness from the cylinder head

assembly.
NOTE: Remove the bracket tightening bolts and then re-
move the injector harness together with the bracket.
1. Injector harness terminal
2. Injector harness bracket
SMIL14CEX3004AB 36
Injector removal
1. Remove the injector leak-off pipe from the injector.
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2. Remove the injector from the cylinder head assembly.

NOTE: When it is difficult to remove the injector, use a
special tool.
Special tool: Fuel injector remover (Refer to Fuel
injectors - Special tools (10.218))
SMIL14CEX3005AA 37
Special tool: Sliding hammer (Refer to Fuel injec-

tors - Special tools (10.218))
SMIL14CEX3006AA 38
1. Sliding hammer
2. Fuel injector remover
3. Injector
SMIL14CEX3007AB 39
CAUTION:
○ Confirm that the sleeve is not pulled out to-

gether when pulling out the injector using a spe-
cial tool.
○ Store each ID code plate on the injector head
with the cylinder number tag attached to avoid
a mix-up.
○ Be extremely careful not to damage the injector
nozzle.
SMIL14CEX3008AA 40
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Lower cover removal

1. Remove the lower cover from the cylinder head assem-
bly.
2. Remove the rubber plug from the cylinder head assem-
bly.
Rocker arm shaft removal

1. Loosen the adjust screw using a wrench.
NOTE: Loosen all valve clearance adjustment screws.
SMIL14CEX3009AA 41
2. Remove the rocker arm shaft from the cylinder head

assembly.
NOTE: Evenly loosen the rocker arm shaft bracket and
the rocker arm assembly bracket tightening bolts from both
ends and remove them.
CAUTION: Be careful not to remove the bolt

shown in the diagram.
SMIL14CEX3010AA 42
Camshaft removal
1. Remove the camshaft bearing cap from the cylinder
head assembly.
2. Remove the camshaft bearing from the camshaft bear-
ing cap.
3. Remove the camshaft from the cylinder head.
4. Remove the camshaft bearing from the cylinder head
assembly.
NOTE: Temporarily assemble the removed caps and bear-
ings in the original position to avoid a mixup after the bear-
ings have been inspected.
SMIL14CEX3011AA 43
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Bridge removal
1. Remove the bridge cap (1) from the bridge (2).
CAUTION: Be careful not to drop the bridge

cap into the engine.
2. Remove the bridge (2) from the bridge guide.
NOTE: After removing, organize to avoid a mix-up with
other installation locations.
SMIL14CEX3012AB 44
Cylinder head assembly removal

1. Remove the cylinder head assembly from the cylinder
block.
NOTE: Loosening order of the head bolts
SMIL14CEX3013EB 45
CAUTION: Since the idle gear C (1) protrudes

from the bottom surface of the cylinder head, be
careful not to damage the gear.
SMIL14CEX3014AB 46
2. Remove the cylinder head gasket from the cylinder

block.
CAUTION: Do not reuse the cylinder head

gasket.
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Fuel supply pump removal

1. Disconnect the harness connector from the fuel supply
pump.
2. Remove the fuel supply pump from the cylinder block.
NOTE: Remove together with the bracket.
1. Fuel supply pump
2. Bracket
3. Gear
4. Nut
5. Bolt
6. O-ring
7. O-ring
8. Nut SMIL14CEX3129AB 47
9. Bolt
10. Nut
Starter assembly removal

1. Disconnect the earth cable from the starter assembly.
2. Remove the starter assembly from the flywheel hous-
ing.
SMIL14CEX3130AA 48
CKP sensor removal

1. Disconnect the harness connector from the CKP sen-
sor (1).
2. Remove the CKP sensor (1) from the flywheel housing
(2).
CAUTION: Be careful not to subject the sen-

sor to shock.
SMIL14CEX3131AB 49
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Flywheel removal
1. Remove the flywheel from the crankshaft.
NOTE: Gradually loosen the flywheel installation bolts in
the order shown in the diagram.
CAUTION: Fix the flywheel firmly so that it will

not rotate.
SMIL14CEX3132AB 50
Crankshaft rear oil seal removal

1. Remove the crankshaft rear oil seal from the crankshaft
using the special tool.
SMIL14CEX3125AA 51
1. Felt
2. Slinger
3. Crankshaft rear oil seal
SMIL14CEX3124AB 52

seal pressfitting surface.
NOTE: Remove the slinger and oil seal together.
SMIL14CEX3133AA 53
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Oil pan removal

1. Disconnect the harness connector from the oil level
switch.
2. Remove the oil pan from the crankcase.
3. Remove the gasket from the oil pan.
Oil strainer removal

1. Remove the oil strainer from the crankcase.
2. Remove the O-ring from the oil strainer.
CAUTION: Do not reuse the O-ring.
SMIL14CEX3134AA 54
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Flywheel housing removal

1. Remove the PTO oil pipe (3) from the flywheel housing
and the cylinder block.
2. Remove the oil pipe (1) from the pipe bracket (2) and
the oil port cover.
SMIL14CEX3135AB 55
3. Remove the cover (2) and the O- ring (1) from the fly-
wheel housing.
SMIL14CEX3136AB 56
4. Remove the PTO idle gear from the flywheel housing.

5. Remove the flywheel housing from the cylinder block
and the crankcase.
CAUTION: Do not forget to remove the bolt

(1) shown in the diagram.
SMIL14CEX3137AB 57
Idle gear measurement

1. Align the dial gauge to the idle gear.
NOTE: Attach the dial gauge to the idle gear tooth to be
measured.
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2. Inspect the backlash.

NOTE: Gently move the gear right and left to read the in-
consistency on the dial gauge.
CAUTION: Measure the idle gear backlash

before removing the idle gear A.
Specified value: 0.1 - 0.1700 mm (0.0039 -

0.0067 in)
Limit: 0.3 mm (0.0118 in)
CAUTION: Replace the idle gear if the mea-

58
sured value exceeds the limit value. SMIL14CEX3138AA
3. Measure the clearance using the feeler gauge.

NOTE: Measure the clearance between the idle gear and
the thrust collar.
CAUTION: Measure the play of the idle gear

in the axis direction before removing the idle gear
B.

0.0061 in)
Limit: 0.20 mm (0.0079 in)
CAUTION: Replace the idle gear if the mea- SMIL14CEX3139AA 59
sured value exceeds the limit value.
Idle gear A removal

1. Remove the idle gear A from the idle gear A shaft.
2. Remove the idle gear A shaft from the cylinder block.
SMIL14CEX3140AA 60
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Oil pump assembly removal

1. Remove the oil pump assembly from the cylinder block.
SMIL14CEX3141AA 61
Idle gear B removal

1. Remove the idle gear B from the idle gear B shaft.
2. Remove the idle gear B shaft from the cylinder block.
SMIL14CEX3142AA 62
Piston removal
1. Clean the cylinder liner using the scraper.
NOTE: Remove carbon from the top of the cylinder liner
using a scraper
SMIL14CEX3143AA 63
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2. Remove the connecting rod bearing cap from the con-

necting rod.
NOTE: Set the piston of the cylinder to be removed to the
bottom dead center.
SMIL14CEX3144AA 64
3. Remove the connecting rod bearing from the connect-

ing rod bearing cap.
NOTE: Organize the removed bearings by the cylinders
using tags, etc.
4. Remove the piston from the cylinder block.
NOTE: Pull out the piston and connecting rod together to
the cylinder head side.

jet.
ing rod.
using tags, etc.
Crankshaft removal
NOTE: Measure the crankshaft clearance in the axis direc-
tion at the bearing section no.7.
0.0081 in)
CAUTION: Replace the thrust bearing if the

measured value is not within the range of the spec-
ified value.
SMIL14CEX3145AA 65
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2. Remove the crankcase from the cylinder block.

NOTE: Using the 4 replacer holes (1), remove the
crankcase.
SMIL14CEX3147AB 66
3. Remove the thrust bearing from the crankcase.

4. Remove the crankshaft bearing from the crankcase.
SMIL14CEX3148AA 67
5. Remove the crankshaft from the cylinder block.

6. Remove the thrust bearing from the cylinder block.
7. Remove the crankshaft bearing from the cylinder block.
Piston oil jet removal

1. Remove the piston oil jet from the cylinder block.
SMIL14CEX3149AA 68
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Cylinder liner removal

1. Remove the cylinder liner from the cylinder block.
CAUTION:
○ Because the cylinder liner is thin, handle it care-

fully.
○ Do not tilt the cylinder liner when storing.
SMIL14CEX3150AA 69
SMIL14CEX3151AA 70
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Crankcase - Inspect
CAUTION:
○ Clean the each part of the cylinder block before

inspecting.
○ Be careful not to damage the cylinder block
while cleaning.
1. Inspect the cylinder block.
CAUTION: Replace the cylinder block if dam-

age such as a crack has been found in the inspec-
tion.
2. Perform dye penetrant check.
NOTE: Check if there is a problem which cannot be de-
tected by visual inspection.

tion.
3. Inspect the water leak using the water pressure tester.
Specified pressure: 490 kPa (71 psi)
Specified time: 3 min

tion.
4. Measure the cylinder liner using the cylinder gauge.
Measurement position: 15.0 - 20.0 mm (0.5906 -
0.7874 in) From the cylinder block top surface
4.5295 in) Diameter
Limit： 115.20 mm (4.5354 in) Diameter
CAUTION: Replace the cylinder block if the

measured value exceeds the limit value.
5. Remove the cylinder liner from the cylinder block.
6. Align the simple straight ruler to the cylinder block.
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7. Measure the clearance using the feeler gauge (1).

NOTE: Flatness of the cylinder block top surface.
Measurement part: 6 section(s)
Limit: 0.20 mm (0.0079 in)
CAUTION: Replace the cylinder block if the

SMIL14CEX3212AB 1
8. Inspect the oil jet.

NOTE: Oil hole clogging.
The fuel pipe deformation.
Check valve operation.
160 kPa (23 psi) Open valve pressure of check
valve
SMIL14CEX3213AA 2
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Crankcase - Install
Cylinder liner preparation
CAUTION: When replacing the cylinder liner,
select the cylinder liner following the procedure
below.
1. Check marking of the cylinder block.
NOTE: A marking on a cylinder block indicates the cylinder
block bore grade.
1. Grade marking location
SMIL14CEX3152AB 1
2. Check the grade of the cylinder liner.

1. Grade confirmation location
SMIL14CEX3153AB 2
3. Select the cylinder liner.
Matching grades for cylinder block and liner outer diameter

Marking on the block 1 2 3
Liner outer diameter 1X 3X
Cylinder block inner diameter, liner outer diameter grade

Grade 1 1X 2 1X 3 3X
118.001 - 118.010 mm 118.011 - 118.020 mm 118.021 - 118.030 mm
Block inner diameter
(4.6457 - 4.6461 in) (4.6461 - 4.6465 in) (4.6465 - 4.6469 in)
118.001 - 118.010 mm
Liner outer diameter 117.991 - 118.000 mm (4.6453 - 4.6457 in)
(4.6457 - 4.6461 in)
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Cylinder liner installation

1. Clean the cylinder block using the air.
2. Clean the cylinder liner using the air.
3. Install the cylinder liner to the cylinder block.
NOTE: Install the cylinder liner on the cylinder block verti-
cally.
CAUTION: Do not tap or apply excessive force

when inserting the liner.
CAUTION: After replacing the cylinder liner,

be sure to measure the protrusion amount of the
cylinder liner.
SMIL14CEX3154AA 3
4. Measure the cylinder liner using the dial gauge.

0.0039 in) Protrusion amount of cylinder liner
Limit: under 0.03 mm (0.0012 in) less than
NOTE: The limit value indicates the difference in the pro-
trusion amounts with the adjacent cylinder liner.
SMIL14CEX3155AA 4
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Piston oil jet installation

1. Install the piston oil jet to the cylinder block.
CAUTION: Be careful not to deform or dam-

age the nozzle part of the piston oil jet.
SMIL14CEX3156AA 5
SMIL14CEX3157AA 6
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Crankshaft bearing preparation

CAUTION: When replacing the crankshaft
bearing, select the crankshaft bearing following
the procedure below.
1. Check marking of the crankcase.
NOTE: The marking on the crankcase indicates the inner
diameter grade of the cylinder block journal section.
Grade indications are lined up as No.1, 2, 3, 4, 5, 6, 7 from
the left when looking at the marking section from the front
side.
SMIL14CEX3158AA 7
NOTE: Check the marking on the crankshaft.

The marking on the crankshaft indicates the outer diameter
grade of the journal section.
side.
SMIL14CEX3159AA 8
1. Select the crankshaft bearing.

NOTE: Refer to the bearing selection table.
Bearing selection table

Grade combination Oil clearance
Cylinder block Crank journal Bearing
No.1, 2, 3, 5, 6, 7 No.4
grade grade identification color
0.065 - 0.092 mm 0.095 - 0.122 mm
1 1 Black
(0.0026 - 0.0036 in) (0.0037 - 0.0048 in)
0.063 - 0.089 mm 0.093 - 0.119 mm
1 2 Brown
(0.0025 - 0.0035 in) (0.0037 - 0.0047 in)
0.067 - 0.094 mm 0.097 - 0.124 mm
2 1 Blue
(0.0026 - 0.0037 in) (0.0038 - 0.0049 in)
0.065 - 0.091 mm 0.095 - 0.121 mm
2 2 Black
(0.0026 - 0.0036 in) (0.0037 - 0.0048 in)
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CAUTION: Be careful not to mistake the bear-

ing shape when installing the crankshaft bearing.
1. Upper bearing
2. Oil hole
3. Grade identification color
4. Oil groove
5. Lower bearing
SMIL14CEX3160AB 9
Crankshaft installation
1. Install the crankshaft bearing to the cylinder block.
NOTE: Install a bearing with an oil hole on the cylinder
block.
CAUTION: Make sure there is no grime or

oil on the cylinder block contact surface for the
crankshaft bearing.
2. Apply the grease to the thrust bearing.
NOTE: Apply a small amount of grease to the thrust bear-
ing to prevent falling.
3. Install the thrust bearing to the cylinder block.
NOTE: Install the thrust bearing on the No.7 journal so that
the oil groove faces the engine front.
SMIL14CEX3161AA 10
4. Apply the engine oil to the crankshaft bearing.

5. Apply the engine oil to the crankshaft.
6. Put the crankshaft on the cylinder block.
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the oil groove faces the engine rear.
SMIL14CEX3162AA 11
8. Install the crankshaft bearing to the crankcase.
CAUTION: Make sure there is no grime or oil

on the crankcase contact surface for the crank-
shaft bearing.
10. Install the thrust bearing to the crankcase.
SMIL14CEX3163AA 12

12. Apply the liquid gasket to the crankcase.
NOTE: Apply ThreeBond 1207B to the crankcase thor-
oughly so that there is no break in application of the bead.
Bead width: 3 - 4 mm (0.118 - 0.157 in).
Bead height: 3 - 4 mm (0.118 - 0.157 in)
CAUTION: After applying the liquid gasket,

install the crankcase within 5 min.
SMIL14CEX3164AA 13
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13. Put the crankcase on the cylinder block.
CAUTION: Be careful not to let the thrust bear-

ing fall.
SMIL14CEX3165AA 14
14. Apply the disulfide molybdenum grease to the bolt.

NOTE: Apply to the threaded portion and seat surface on
the M14 bolt for crankcase installation.
CAUTION: Do not apply grease to the M10.
NOTE: Tightening order
SMIL14CEX3146AB 15
15. Tighten the bolt using the torque wrench.

Tightening torque: 98 N·m (72 lb ft) M14 bolt.
17. Tighten the bolt using the special tool.
Tightening angle: 30 ° M14 bolt.
Special tool: Angle gauge (Refer to Cylinder
heads - Special tools (10.101))
SMIL14CEX3073AA 16

CAUTION: Confirm that the crankshaft turns

smoothly after tightening the bolts.
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Piston installation
1. Install the connecting rod bearing to the connecting rod.
2. Apply the engine oil to the connecting rod bearing.
CAUTION: Apply engine oil only to the internal

diameter of the connecting rod bearing.
3. Apply the engine oil to the piston ring.
4. Apply the engine oil to the piston.
• Thoroughly apply engine oil to the ring grooves and
piston side surface.
5. Adjust the piston ring.
• Shift each piston ring joint by the specified angle.
Specified angle: 90 °
6. Apply the engine oil to the cylinder liner in the applica-
tion area (1).
SMIL14CEX3166AB 17
7. Install the special tool to the piston.

Special tool: Piston setting tool (Refer to Piston -
SMIL14CEX3167AA 18
8. Align the piston to the cylinder block.

• Turn the piston so that the front mark faces the en-
gine front.
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9. Press the piston.
CAUTION:
○ To avoid damaging the oil jet, place the crank

pin on the cylinder on which the piston will be
installed at top dead center.
○ To avoid damaging the piston ring, firmly at-
tach the piston installer to the cylinder block and
push it.
○ Be careful not to damage the crank pin and
cylinder liner.
○ Attach a stopper so that the liner does not pro- SMIL14CEX3168AB 19
trude.
1. No.1 compression ring joint

3. Oil ring joint
4. Front mark
10. Install the connecting rod bearing to the connecting
rod bearing cap.

diameter of the connecting rod bearing
12. Align the connecting rod bearing cap to the connecting
rod.
NOTE: Confirm that the numbers on the connecting rod
bearing cap and the connecting rod are the same.
1. Front and back side discrimination boss
2. Grade mark of the large end hole diameter
3. Cylinder number
SMIL14CEX3169AB 20
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13. Install the connecting rod bearing cap to the connect-

ing rod.
NOTE: Precautions when tightening the connecting rod
bolt.
CAUTION: Set each cylinder to the bottom

dead center while working.
CAUTION:
○ Do not allow tightening tools to touch the oil jet.

○ Confirm that the crankshaft turns smoothly after SMIL14CEX3170AA 21
tightening the connecting rod bolt.
NOTE: Apply to the threaded portion and seat surface of
the bolts for the connecting rod installation.
Tightening angle: 60 °
SMIL14CEX3073AA 22

Tightening torque: 98 N·m (72 lb ft) Check the
tightening
SMIL14CEX3171AA 23
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Idle gear B installation

1. Install the idle gear B shaft to the cylinder block.
Tightening torque: 31 N·m (23 lb ft).
2. Apply the engine oil to the idle gear B shaft.
3. Apply the engine oil to the idle gear B.
4. Install the idle gear B to the cylinder block.
CAUTION: Confirm that the idle gear B turns

smoothly after installing.
Oil pump assembly installation

1. Clean the cylinder block using the scraper.
NOTE: Remove grime and oil from the oil pump installation
area.
2. Apply the engine oil to the cylinder block.
CAUTION: Do not allow engine oil to adhere

on the oil pump installation surface.
SMIL14CEX3172AA 24
3. Apply the liquid gasket to the oil pump.

NOTE: Referring to the diagram, apply ThreeBond 1141E
to the oil pump.
CAUTION:
○ Do not allow the liquid gasket to adhere to the

locations indicated by arrows in the diagram.
○ Install the oil pump within 5 min of applying liq-
uid gasket.
SMIL14CEX3173AA 25
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4. Install the oil pump to the cylinder block.

SMIL14CEX3174AA 26
Idle gear A installation

1. Align No.1 cylinder to the compression top dead center.
2. Apply the engine oil to the idle gear A shaft.
3. Apply the engine oil to the idle gear A.
4. Install the idle gear A shaft to the idle gear A.
5. Align the idle gear A to alignment mark.
NOTE: Align the L mark (1) on the crank gear with the O
mark (2) on the idle gear A.
SMIL14CEX3175AB 27
6. Install the idle gear A to the cylinder block.

1. Camshaft gear
2. Aligning position
3. Idle gear B
5. PTO gear
6. PTO idle gear
7. Crank gear
8. Oil pump gear
9. Supply pump gear
10. Idle gear A
11. Idle gear C
SMIL14CEX3176BB 28
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Flywheel housing installation

NOTE: Remove dust and oil from the flywheel housing in-
stallation area.
2. Apply the liquid gasket to the flywheel housing.
NOTE: Refer to the diagram and apply the ThreeBond
1201 to the flywheel housing.
CAUTION:
○ Do not apply liquid gasket to the location (1) in

the diagram.
○ After applying the liquid gasket, install the fly-
wheel housing within 5 min.
1. Liquid gasket application prohibited area

SMIL14CEX3177AB 29
3. Install the flywheel housing to the cylinder block.

NOTE: Install the flywheel housing after aligning with the
knock pin position of the cylinder block.
Tightening torque
No.1 bolt 96 N·m (71 lb ft)
4. Apply engine oil to the PTO idle gear shaft.

NOTE: Apply it to the sliding surface.
SMIL14CEX3178BB 30
5. Install the washer to the PTO idle gear shaft.
CAUTION: Install it with the oil groove of the

washer facing toward the gear side.
6. Apply engine oil to the washer.
NOTE: Apply it to the oil groove side of the washer.
7. Install the PTO idle gear to the PTO idle gear shaft.
CAUTION: Install it with the convex section of

the gear facing the front side.
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8. Apply engine oil to the PTO idle gear.


NOTE: Turn the gear shaft and adjust the oil.

10. Install the PTO idle gear to the flywheel housing.
CAUTION:
○ Install it with the oil groove of the washer facing

toward the gear side.
○ Orient the notch of the shaft facing upward for
oil lubrication and make sure to install the thrust
collar so that the paint portion is within the area
indicated by the diagram.
NOTE: Assemble the thrust collar to the mounting bolt and SMIL14CEX3179AB 31
install it after applying engine oil.
1. 30 °
2. Paint portion
3. Notch
4. PTO idle gear shaft
5. Thrust collar
1. Thrust collar
2. Washer
3. PTO idle gear
5. Oil groove
SMIL14CEX3180AB 32
11. Install the O-ring (1) to the cover (2).

12. Install the cover (2) to the flywheel housing.
SMIL14CEX3181AB 33
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13. Install the oil pipe (1) to the pipe bracket (2)and the oil
port cover.
Pipe bracket side
Oil port cover side
Clip
SMIL14CEX3135AB 34
14. Install the PTO oil pipe (3) to the flywheel housing and
the cylinder block.
Flywheel housing side
PTO side
Cylinder block side
Clip
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Oil strainer installation

1. Install the O-ring to the oil strainer.
CAUTION: Use new O-rings.

2. Install the oil strainer to the crankcase.
M8 bolt (1)
M10 bolt (2)
SMIL14CEX3182AB 35
Oil pan installation

1. Apply the liquid gasket to the crankcase (1).
NOTE: Apply ThreeBond 1207B to each joint of the
crankcase (1), flywheel housing (3) and timing gear case
(2).
Bead width: 3 mm (0.118 in)
Bead height: 2 mm (0.079 in)

install the oil pan within 5 min .
SMIL14CEX3183AB 36
2. Install the gasket to the oil pan.
CAUTION: Use new gasket.

3. Install the oil pan to the crankcase.
4 stud bolts
CAUTION: Note that one of the bolts has a

different length from others.
1. Short bolt installation area

2. Stud bolt installation area
SMIL14CEX3184AB 37
4. Connect the harness connector to the oil level switch.
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Crankshaft rear oil seal installation

1. Prepare the special tool.
NOTE: In order to install the crankshaft rear oil seal, use
the one(s) in the following table from among the parts in-
cluded in the kit.
Special tool: Oil seal installer kit (Refer to Crankshaft
- Special tools (10.103))
SMIL14CEX3185AA 38
Name Part number

1 Adapter 5-8840-2709-0
2 Adapter tightening bolt 5-8840-2714-0
3 Center bolt 5-8840-2713-0
4 Sleeve 5-8840-9063-0
5 Collar 5-8840-2710-0
6 Adapter ring 5-8840-2711-0
7 Crankshaft rear oil seal -
SMIL14CEX3186AB 39
2. Apply the engine oil to the crankshaft rear oil seal.
CAUTION: Apply only to the lip section of the

oil seal.
3. Install the crankshaft rear oil seal to the adapter.
4. Install the adapter to the crankshaft.
1. Collar
2. Adapter tightening bolts
3. Adapter
SMIL14CEX3187AB 40
5. Install the adapter ring (2) to the sleeve (1).
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6. Install the sleeve (1) to the adapter.
SMIL14CEX3188AB 41
7. Install the center bolt to the sleeve.

8. Tighten the center bolt using the wrench.
NOTE: Tighten the center bolt until the sleeve touches the
adapter.
SMIL14CEX3189AA 42
9. Inspect the crankshaft rear oil seal.

NOTE: Measure the distance between the crankshaft head
and the crankshaft rear oil seal.
Specified value: 7.2 - 7.8 mm (0.283 - 0.307 in).
1. Flywheel housing
3. Oil seal press-fitting measurement
4. Crankshaft
SMIL14CEX3190AB 43
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Flywheel installation
NOTE: Apply to the seat surface and threaded portion on
the flywheel installation bolts.
2. Install the flywheel to the crankshaft.
CAUTION: Pay attention to the knock pin po-

sition of the crankshaft.
SMIL14CEX3191AB 44

SMIL14CEX3073AA 45

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CKP sensor installation

1. Install the CKP sensor (1) to the flywheel housing (2).

sor to shock.
NOTE: Tighten together with the clip.

Tightening torque: 6 N·m (53 lb in).
2. Connect the harness connector to the CKP sensor (1).
SMIL14CEX3131AB 46
Starter assembly installation

1. Install the starter assembly to the flywheel housing.
2. Connect the earth cable to the starter assembly.
SMIL14CEX3192AA 47
Fuel supply pump installation

2. Align alignment mark to the bracket.
1. Supply pump bracket side slit
2. Supply pump gear side alignment mark
SMIL14CEX3193AB 48
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3. Align the fuel supply pump to the cylinder block.

1. Confirmation hole
2. Supply pump gear
SMIL14CEX3194AB 49
4. Install the fuel supply pump (1) to the cylinder block.

Bolt (5)
Nut (8)
Nut (10)
1. Fuel supply pump
2. Bracket
3. Gear
4. Nut
SMIL14CEX3195AB 50
5. Bolt
6. O-ring
7. O-ring
8. Nut
9. Bolt
10. Nut
5. Connect the harness connector to the fuel supply
pump.
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Cylinder head assembly installation

CAUTION:
○ Clean the aligning surface of the cylinder head

and cylinder block before installing the cylinder
head assembly.
○ Be careful not to damage the cylinder head and
cylinder block while cleaning.
1. Apply the liquid gasket to the cylinder block.
NOTE: Use ThreeBond 1207B.
CAUTION: After applying liquid gasket, install

the cylinder head within 5 min.
SMIL14CEX3196AA 51
2. Install the cylinder head gasket to the cylinder block.
CAUTION: Use a new cylinder head gasket.

3. Install the cylinder head assembly to the cylinder block.
CAUTION: Be careful not to damage the cylin-

der head gasket.
NOTE: Tightening order of the head bolts
SMIL14CEX3197AA 52
SMIL14CEX3198EB 53
NOTE: 1 to 26 in the diagram indicate the M14 bolts.

27 and 28 in the diagram indicate the M10 bolts.
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4. Prepare the head bolt.

NOTE: Apply molybdenum disulfide grease to the seat sur-
face and threaded portion of the M14 head bolts.
Apply engine oil to the seat surface and threaded portion
of the M10 head bolts.
5. Tighten the head bolt using the torque wrench.
M14 bolt
M14 bolt
7. Tighten the head bolt using the special tool.
Tightening angle: 30 - 60 ° M14 bolt
SMIL14CEX3073AA 54

M10 bolt
Check the tightening M14 bolt
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Front cover installation

1. Clean the cylinder block using a scraper.
2. Apply liquid gasket to the front cover.
Bead width: 1.5 - 5 mm (0.0591 - 0.1969 in)
Bead width: 0.3 - 1.5 mm (0.0118 - 0.0591 in)
3. Install the O-ring (1) to the front cover.
CAUTION: Install the front cover within 5 min

of applying liquid gasket.
SMIL14CEX3199AB 55
4. Install the front cover to the cylinder block.
CAUTION: Pay attention to the cylinder block

knock pin position.

Stud bolt
Location to tighten together with the adjust
1.
plate
2. Stud bolt
SMIL14CEX3200AB 56
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Water pump assembly installation

1. Install the water pump assembly to the front cover.
CAUTION: Use new gaskets.

Stud bolt
1. Nut
SMIL14CEX3201AB 57
2. Install the water hose to the EGR cooler water pipe and
the water pump assembly.
3. Install the water bypass hose (1) to the water pump
SMIL14CEX2991AB 58
4. Install the fan pulley to the water pump assembly.

SMIL14CEX3202AA 59
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Crankshaft front oil seal installation

NOTE: In order to install the front slinger, use the one(s) in
the following table from among the parts included in the kit.
Special tool: Oil seal setting tool kit (Refer to
Crankshaft - Special tools (10.103))
SMIL14CEX3203AA 60
Name Part number

1 Slinger -
2 Adapter 8-9439-6857-0
4 Sleeve 8-9702-0623-0
5 Center bolt 8-9702-0655-0
SMIL14CEX3204AB 61
2. Install the slinger to the adapter.

NOTE: There is a left handed quadruple-start screw cut at
the front slinger.
CAUTION: Be careful not to allow the assem-

bly direction of the slinger to be incorrect.
3. Install the adapter (1) to the crankshaft.
SMIL14CEX3205AB 62
4. Install the sleeve to the adapter.

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adapter.
SMIL14CEX3206AA 63
7. Inspect the slinger.

and the slinger.
0.7205 in)
1. Slinger press-fitting measurement
2. Slinger
3. Crankshaft
SMIL14CEX3207AB 64

NOTE: In order to install the crankshaft front oil seal, use
cluded in the kit.
Name Part number
1 Adapter 8-9439-6857-0
2 Oil seal -
4 Sleeve 8-9702-0625-1
5 Center bolt 8-9702-0655-0
SMIL14CEX3204AB 65
9. Apply the engine oil to the crankshaft front oil seal.

oil seal.
10. Install the crankshaft front oil seal to the adapter.
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adapter.
SMIL14CEX3206AA 66
14. Inspect the crankshaft front oil seal.

and the crankshaft front oil seal.
0.3406 in).
2. Timing gear case
4. Crankshaft
SMIL14CEX3208AB 67
Crankshaft pulley installation

1. Install the crankshaft damper to the crankshaft pulley.
NOTE: Tighten the bolts in a diagonal line order.
SMIL14CEX3209AA 68
2. Install the crankshaft pulley to the crankshaft.


Apply engine oil on the threaded area of bolt
SMIL14CEX3210AB 69
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Bridge installation
1. Apply the engine oil to the bridge.
2. Install the bridge to the bridge guide.
CAUTION: Confirm that the bridge moves

smoothly.
3. Apply the engine oil to the bridge cap.
4. Install the bridge cap to the bridge.

SMIL14CEX3074AA 70
Camshaft installation
SMIL14CEX3075AA 71
2. Apply the engine oil to the camshaft bearing.

NOTE: Apply engine oil to the sliding surface of the bear-
ing.
CAUTION: Apply engine oil after cleaning the

bearing installation sections of the camshaft bear-
ing and cylinder head.
3. Install the camshaft bearing to the cylinder head as-
sembly.
NOTE: To prevent the effect of spring force on the sub gear,
use a scissors gear spring wrench to rotate the sub gear
before installing the camshaft on the cylinder head.
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4. Align the sub gear to the camshaft gear using the spe-
cial tool.
Special tool: Scissors gear spring wrench (Refer to
Camshaft - Special tools (10.106))
SMIL14CEX3076AA 72
NOTE: Install the alignment pin (1) from the sub gear side
if the holes of the sub gear and the camshaft main gear are
aligned.
SMIL14CEX3077AB 73
5. Install the camshaft to the cylinder head assembly.

NOTE: Mesh together the idle gear C and the camshaft
gear so that the alignment mark on the camshaft gear
matches the top surface of the cylinder head, and gently
install the camshaft.
CAUTION: Align the alignment marks of the

sub gear side.
SMIL14CEX3078AA 74
6. Check alignment mark of the camshaft gear.
CAUTION:
○ Confirm that the alignment mark is not mis-

aligned before installing the camshaft bearing
cap.
○ If the alignment mark is not at the correct posi-
tion, reinstall the camshaft.
ing.

ing and camshaft bearing cap.
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8. Install the camshaft bearing to the camshaft bearing

cap.
9. Install the camshaft bearing cap to the cylinder head
assembly.
NOTE: Turn the camshaft bearing cap so that the arrow
mark on the top surface faces the engine front side, and
assemble in numerical order.
Engine oil application
SMIL14CEX3079AA 75
Rocker arm shaft installation

1. Apply the engine oil to the front side camshaft bracket
(1) and rear side camshaft bracket (3).
NOTE: Apply to each sliding surface.
2. Apply the engine oil to the rocker arm (2).
NOTE: Confirm that the adjust screw is fully loosened.
SMIL14CEX3080AB 76
3. Install the rocker arm shaft to the cylinder head assem-

bly.
NOTE: On the camshaft bearing assembly section only, ap-
ply oil to the threaded portion of the stud bolts and the seat
surface/threaded portion of the nuts, then tighten them.
Tightening order
Rocker arm shaft Tightening torque
Tightening
Parts
torque
Front side camshaft bearing
cap
28 N·m (21 lb ft)
Rear side camshaft bearing
SMIL14CEX3081AB 77
cap
Rocker arm bracket 56 N·m (41 lb ft)
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Rocker arm shaft adjustment

NOTE: Valve clearance adjustment
CAUTION:
○ Adjust the valve clearance while cool

○ Loosen all adjust screws before adjustment.
SMIL14CEX3082AA 78
SMIL14CEX3075AA 79
2. Prepare the feeler gauge.

Thickness: 0.4 mm (0.0157 in)
NOTE: Insert the thickness gauge between the rocker arm
and bridge cap.
3. Turn the adjust screw.
NOTE: When the movement of the thickness gauge be-
comes stiff, secure the adjust screw nut of the rocker arm.
SMIL14CEX3083AA 80
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5. With the thickness gauge inserted, lightly tighten the
adjust screw of the bridge.
6. Confirm that the leading end of the adjust screw and
valve shaft end have made contact and the movement
of the thickness gauge has become stiff.
7. Check if the valve shaft end on the opposite side is
floating or touching at an angle.
8. If it is floating or touching at an angle, slightly loosen
the bridge adjust screw and adjust the valve shaft ends
on both sides to touch properly.
SMIL14CEX3085AA 81
Clearance: less than 0.1 mm (0.0039 in)
Between valve and bridge
NOTE: To prevent turning, fix the bridge adjust screw with
a flathead screwdriver, and tighten the adjust screw nut.
Adjustment table
Cylinder No. 1 2 3 4 5 6
Valve IN EX IN EX IN EX IN EX IN EX IN EX
No.1 cylinder compression top dead
O O O O O O
center (O mark is an adjustable part)
center (O mark is an adjustable part) O O O O O O
　
Lower cover installation

1. Apply the liquid gasket (2) to the rubber plug (1).
NOTE: Apply ThreeBond 1207B.
SMIL14CEX3084AB 82
2. Install the rubber plug to the cylinder head.
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3. Apply the liquid gasket to the rubber plug in the appli-

cation area (1).
NOTE: Apply ThreeBond 1207B to the rubber plug and
cylinder head mating surfaces.

install the lower cover within 5 min .
SMIL14CEX3086AB 83
4. Install the gasket to the lower cover.

5. Install the lower cover to the cylinder head.
SMIL14CEX3087AB 84
Common rail assembly installation

1. Align the common rail assembly (1) to the inlet cover.
2. Temporarily tighten the bolt to the common rail assem-
bly (1).
3. Temporarily tighten the nut to the common rail assem-
bly (1).
4. Securely tighten the bolt to the common rail assembly
(1).
5. Securely tighten the nut to the common rail assembly
(1).
SMIL14CEX3088AB 85
6. Connect the harness connector to the fuel pressure
sensor.
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Fuel leak off pipe assembly installation

1. Temporarily tighten the fuel leak-off pipe (1) to the cylin-
der head assembly.
2. Temporarily tighten the fuel leak-off pipe (1) to the com-

mon rail assembly.
3. Temporarily tighten the fuel leak-off pipe (1) to the fuel
supply pump.
NOTE: Tighten the fuel feed pipe together. SMIL14CEX3089AB 86
4. Securely tighten the fuel leak-off pipe (1) to the cylinder

head assembly.
5. Securely tighten the fuel leak-off pipe (1) to the com-
mon rail assembly.
6. Securely tighten the fuel leak-off pipe (1) to the fuel
supply pump.
7. Install the clip to the fuel leak-off pipe (1).
Fuel pipe installation

1. Install the fuel pipe to the fuel supply pump and the

2. Install the clip to the bracket.
Tightening torque: 9 N·m (79.7 lb in)
Injector installation
CAUTION: When reusing an injector, do not
change the installation position.
1. Apply the engine oil to the bolt (2).
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2. Temporarily tighten the injector (1) to the cylinder head

assembly.
CAUTION: Be extremely careful not to dam-

age the injector nozzle.
SMIL14CEX3090AB 87
3. Temporarily tighten the injection pipe to the injector.
CAUTION: Use new injection pipes

4. Temporarily tighten the injection pipe to the common
rail assembly.
5. Securely tighten the injector to the cylinder head as-
sembly.
6. Install the injector leak-off pipe to the injector.
Injection pipe installation

1. Securely tighten the injection pipe to the injector.
7. Fuel pipe
SMIL14CEX3091AB 88
2. Securely tighten the injection pipe to the common rail

assembly.
3. Install the clip to the inlet cover.
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Glow plug installation

1. Install the glow plug to the cylinder head assembly.
Tightening torque: 20 N·m (14.8 lb ft)
CAUTION: Be careful not to exceed the spec-

ified torque when tightening.
SMIL14CEX3092AA 89
2. Install the glow plug connector to the glow plug.

CAUTION: Confirm that the glow plug connec-

tor does not interfere with the surrounding parts.
SMIL14CEX3093AA 90
Injector harness installation

1. Install the injector harness to the cylinder head assem-
bly.
NOTE: Tighten the bolts on the bracket and install the in-
jector harness together with the bracket.
SMIL14CEX3094AB 91
2. Connect the terminal nut (3) of the injector harness (2)

to the injector (1).

SMIL14CEX3095AB 92
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3. Install the connector to the lower cover.

Tightening torque: 2 N·m (18 lb in)
Cylinder head cover installation

1. Align the head cover gasket (2) to the cylinder head
cover (1).
2. Install the cylinder head cover (1) to the lower cover (3).
NOTE: Referring to the tightening order in the diagram,
temporarily tighten all bolts and then completely tighten
them.
SMIL14CEX2970AB 93
SMIL14CEX3096AB 94
3. Connect the ventilation hose (1) to the air breather.

4. Connect the water pipe bracket (2) to the cylinder head
cover.
5. Connect the clip (3).
SMIL14CEX2969AB 95
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Inlet pipe installation

1. Install the inlet pipe (1) to the inlet cover.
SMIL14CEX3097AB 96
2. Connect the harness connector to the boost pressure

sensor/boost temperature sensor (1).
3. Connect the harness connector to the IMT sensor (3).
4. Install the harness clip (2) to the inlet pipe.
SMIL14CEX3098AB 97
Intake throttle valve installation

1. Install the gasket (2) and intake throttle valve (1) to the
inlet pipe (3).
2. Install the air duct to the intake throttle valve (1).
SMIL14CEX3099AB 98
3. Connect the harness connector to the intake throttle

valve.
NOTE: After connecting the harness connector, press in
the lock operation portion to lock.
2. Lock release
3. Lock
SMIL14CEX2993AB 99
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EGR cooler water pipe installation

SMIL14CEX2991AB 100
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2. Install the EGR cooler water pipe (1) to the engine as-
sembly.
SMIL14CEX2989GB 101
NOTE: Tightening torque of bolt (1) in the diagram is dif-

ferent from others.
SMIL14CEX3100AB 102
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Oil separator bracket installation

1. Temporarily tighten the oil separator bracket (1) to the
cylinder head assembly.
NOTE: Tighten together with the clip (2).
2. Install the ventilation hose to the air breather.
3. Securely tighten the oil separator bracket (1) to the
CAUTION: Pay attention to the installation an-

gle of the hose.
SMIL14CEX3102AB 103
4. Install the clip (2) to the cylinder block.
EGR valve installation

4. Install the EGR valve (1) to the inlet pipe.
SMIL14CEX3103AB 104
EGR cooler installation

1. Temporarily tighten the EGR pipe A (2) to the exhaust
manifold (3).
2. Temporarily tighten the EGR cooler A (1) to the EGR
pipe A (2).
SMIL14CEX2986AB 105
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3. Temporarily tighten the EGR cooler bracket A (4) to the

EGR cooler A.
4. Temporarily tighten the EGR cooler B (3) to the EGR
cooler bracket A (4).
5. Temporarily tighten the EGR bracket cooler C (2) to the
EGR cooler B (3).
6. Temporarily tighten the EGR cooler C (1) to the EGR
cooler bracket C (2).
SMIL14CEX3104AB 106
7. Temporarily tighten the EGR pipe B (2) to the EGR

cooler C (3) and the EGR valve (1).
SMIL14CEX2983AB 107
8. Securely tighten the EGR pipe A to the exhaust mani-

fold.
9. Securely tighten the EGR cooler A to the EGR pipe A.
10. Securely tighten the EGR cooler B to the EGR cooler
A.
11. Securely tighten the EGR cooler bracket C to the EGR
cooler B.
12. Securely tighten the EGR cooler C to the EGR cooler
bracket C.
13. Securely tighten the EGR pipe B to the EGR cooler C.
14. Securely tighten the EGR pipe B to the EGR valve.
15. Securely tighten the EGR cooler bracket A to the EGR
cooler bracket C.
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cooler bracket B.
17. Securely tighten the EGR pipe B to the rear engine
hanger bracket.
18. Install the EGR heat protector (1) to the EGR pipe.
SMIL14CEX2985AB 108
19. Connect the water rubber hose (1) to the EGR cooler.
SMIL14CEX2982AB 109
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EGR gas temperature sensor 2 installation

CAUTION:
○ Check the EGR gas temperature sensor 2 con-

nector color, and take care not to assemble in-
correctly.
○ Because the connector color cannot be iden-
tified using the outer surface if the exterior is
painted, remove the connector and identify it
using the connector interior color.
○ If it is difficult to determine the color, remove
the connectors of EGR gas temperature sensor
2 and the IMT sensor, and determine the color
Sensor name Connector color

EGR gas temperature
Light gray
sensor 2
IMT sensor Gray
CAUTION:
○ Do not subject the tip of the sensor to impact

when installing the EGR gas temperature sen-
sor.
○ Do not reuse an EGR gas temperature sensor
that has been subjected to impact due to being
dropped, etc.
1. Apply anti-seize lubricant to EGR gas temperature sen-
sor 2.
NOTE: Apply High Temperature Stainless Never- Seez:
5-87411-039-0, manufactured by Bostik in the U.S., etc. to
the threaded portion of EGR gas temperature sensor 2.
2. Install EGR gas temperature sensor 2 to EGR pipe B.
Tightening torque: 19.6 N·m (14 lb ft)
3. Install the harness bracket to EGR pipe B.
4. Connect the harness connector to EGR gas tempera-
ture sensor 2.
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CAUTION:

sor.
dropped, etc.
sor 1.
Apply High Temperature Stainless Never- Seez:
5-87411-039-0, manufactured by Bostik in the U.S.,
etc. to the threaded portion of EGR gas temperature
sensor 1.
2. Install EGR gas temperature sensor 1 to EGR pipe A.
3. Install the harness bracket to the fan guide stay.
ture sensor 1.
Oil level gauge guide tube installation

1. Install the oil level gauge guide tube (1) to the cylinder
block.
2. Connect the oil level gauge guide tube (1) to the cylin-
der head assembly.
tube (1).
SMIL14CEX3105AB 110
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Turbocharger assembly installation

1. Replenish the turbocharger assembly with the engine
oil.
NOTE: Pour engine oil from the oil feed port and manually
rotate the shaft slightly.
CAUTION: Do not apply force to the turbine

blade and compressor.
2. Align the gasket to the turbocharger assembly.
3. Install the turbocharger assembly to the exhaust man-
ifold.
4. Install the water feed pipe to the cylinder block.
Clip
CAUTION: Use a new gasket.

5. Connect the water feed pipe to the turbocharger as-
sembly.

6. Install the water return pipe to the cylinder block.
Clip

7. Connect the water return pipe to the turbocharger as-
sembly.

8. Install the oil return pipe to the cylinder block.

9. Connect the oil return pipe to the turbocharger assem-
bly.
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10. Install the oil feed pipe to the pipe bracket.


11. Connect the oil feed pipe to the turbocharger assem-
bly.
1. Oil feed pipe

2. Clip
3. Oil return pipe
4. Water feed pipe
5. Water return pipe SMIL14CEX2954AB 111
12. Install the exhaust pipe to the turbocharger assembly.

13. Install the air intake hose to the turbocharger assem-
bly and the intercooler.
14. Install the air cleaner duct to the air cleaner assembly
and the turbocharger assembly.
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Cooling fan belt installation

1. Install the cooling fan belt to the engine assembly.
Cooling fan belt adjustment

1. Adjust the cooling fan belt.
NOTE: Measure the amount of cooling fan belt flex by
pressing on the point indicated by the arrow in the diagram
with the specified pressure.
Standard: 98 N (22 lb)
Pulley
Cooling Fan Belt Amount of flex
ratio
Type 1: Triple inte- 6 - 8 mm (0.236 -
0.80
grated belt 0.315 in)
0.85
SMIL14CEX3211AB 112
1. Crankshaft pulley
2. Generator
3. Fan pulley
2. Adjust the cooling fan belt to the specified value using
the adjust bolt.
NOTE: Loosen adjust-plate-side nut (2) and bracket side
bolt (3), shown in the diagram, and lightly tighten to the
position for seating.
Adjust the belt deflection amount to the specified value us-
ing adjust bolt (1).
NOTE: After adjustment, tighten the adjust-plate-side nut
and bracket-side bolt to the specified torque.
SMIL14CEX3123AB 113
Fan guide installation

1. Install the fan guide bracket to the engine assembly.
2. Install the fan guide (6) to the fan guide bracket.
1. Bolt
2. Washer
3. Rubber mount
4. Rubber mount
5. Guide tube
6. Fan guide
SMIL14CEX3122AB 114
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Cooling fan installation

1. Install the cooling fan to the adapter.
1. Cooling fan
2. Adapter
SMIL14CEX3121AB 115
Engine harness connect

1. Connect the engine harness to the engine assembly.
NOTE: Connect each connector.
Engine oil filling

1. Replenish the engine assembly with the engine oil.
NOTE: Add engine oil up to the MAX position of the oil level
gauge.
CAUTION: Check the tightening of the drain

plug before adding engine oil.
Battery ground cable connect

1. Connect the battery ground cable to the battery.
Coolant filling
CAUTION:
○ Work while taking care to prevent excess

coolant from splashing onto the exhaust sys-
tem parts.
○ Wipe off any excess coolant.
1. Remove the air bleeding plug (1) and the gasket (2)
from the EGR cooler.
NOTE: If the EGR cooler and water pipe have air bleeding
plugs, loosen the plugs and remove them.
SMIL14CEX2956AB 116
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2. Replenish the radiator with coolant.
CAUTION: Add slowly to prevent air from en-

tering the system.
3. Install the air bleeding plug to the EGR cooler.
NOTE: Check that the coolant has overflowed.
CAUTION: Do not reuse the gasket.

NOTE: While manually pressing the upper hose several
times to bleed the air in the hose, add an amount of coolant
equal to the difference between the remaining coolant level
and the radiator cap mouth.
Repeat until the coolant level no longer decreases.
5. Install the radiator cap to the radiator.
CAUTION: Securely attach the radiator cap.

6. Add coolant to the radiator reserve tank.
NOTE: Add up to the MAX line of the radiator reserve tank.
CAUTION: Wipe off any excess coolant.

7. Start the engine.
NOTE: Idle the engine for 5 min.
8. Stop the engine.
CAUTION:

NOTE: Add an amount of coolant equal to the difference
between the remaining coolant level and the radiator cap
mouth.
CAUTION: If the coolant amount is exces-

sively low, inspect for coolant leakage.
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NOTE: For models with heaters, the set temperature and
blower speed are set to the maximum, and warm up the
engine at approximately 1500 - 2000 RPM.
Touch the radiator upper hose, and confirm that it has be-
come warm.
CAUTION: If the upper hose is not warm, per-

form step 12 again.

13. Stop the engine.
CAUTION: Confirm that the engine has

cooled.
mouth.


CAUTION: If the level of the radiator reserve

tank has fallen the next morning, add coolant up
to the MAX line.
Fuel air bleed

Refer to Fuel injection system - Bleed (10.218).
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Index
Engine - 10

Crankcase - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Crankcase - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Crankcase - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Engine - Check - Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Engine - Compression test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Engine - External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine - Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Engine - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engine - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Engine - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine - Test - Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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Engine - 10
Pan and covers - 102

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Contents
Engine - 10
SERVICE
Pan and covers

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine oil pan
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine block cover
Front - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Front - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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Engine - Pan and covers
Pan and covers - Remove

Oil pressure sensor
1. Disconnect the harness connector from the oil pressure
sensor (2).
2. Remove the oil pressure sensor from the oil port cover
(1).
SMIL14CEX3222AB 1
Oil port cover

1. Disconnect the oil feed pipe from the oil port cover.
2. Remove the oil port cover from the cylinder block.
3. Remove the O-ring (1) and the O-ring (2) from the oil
port cover.
SMIL14CEX3223AB 2
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Pan and covers - Install

Oil port cover
1. Install the O-ring (1) and the O-ring (2) to the oil port
cover.
SMIL14CEX3223AB 1
2. Install the oil port cover to the cylinder block.

1. Bolt - short
2. Bolt - long
SMIL14CEX3224AB 2
3. Connect the oil feed pipe to the oil port cover.

Tightening torque: 28 N·m (21 lb ft) eyebolt
Oil pressure sensor

1. Install the oil pressure sensor (2) to the oil port cover
(1).
2. Connect the harness connector to the oil pressure sen-

sor (2).
SMIL14CEX3222AB 3
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Engine oil pan - Remove

1. Disengage the battery ground cable from the battery.
Engine oil drain

Oil pan removal

1. Disengage the harness connector from the oil level
switch.
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Engine oil pan - Install

(2) .

install the oil pan within 5 min.

SMIL14CEX3214AB 1


SMIL14CEX3184AB 2
Engine oil filling

1. Replenish the engine oil with the engine assembly.


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Engine block cover Front - Remove

Coolant drain
CAUTION:

SMIL14CEX2956AB 1

6. Install the drain plug to the cylinder block.
SMIL14CEX3414AB 2
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Cooling fan removal

SMIL14CEX3121AB 3
Fan guide removal

1. Bolt
2. Washer
3. Rubber mount
4. Rubber mount
5. Guide tube
bly.
SMIL14CEX3122AB 4

1. Adjust bolt
2. Fixing bolt
3. Fixing bolt
SMIL14CEX3123AB 5

pulley.
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1. Remove the crankshaft front oil seal (3) from the timing
gear case.

1. Felt
2. Slinger
SMIL14CEX3124AB 6

cial tool.
SMIL14CEX3125AA 7

place the slinger.
SMIL14CEX3126AA 8

SMIL14CEX3127AA 9
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SMIL14CEX3128AB 10
Front cover removal

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Engine block cover Front - Install

Bead width: 1.5 - 5 mm (0.06 - 0.20 in)
Bead height: 0.3 - 1.5 mm (0.0118 - 0.0591 in)

SMIL14CEX3199AB 1
CAUTION: Pay attention to the cylinder block

knock pin position.

Tightening torque: 13 N·m (115 lb in) Stud bolt
1. Location to tighten together with the adjust plate
2. Stud bolt
SMIL14CEX3200AB 2

Tightening torque: 39 N·m (28.8 lb ft) Nut in the

diagram
1. Nut
SMIL14CEX3201AB 3
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SMIL14CEX3353AB 4

SMIL14CEX3202AA 5

SMIL14CEX3203AA 6
Name Part number

1 Slinger -
2 Adapter 8-9439-6857-0
Adapter tightening
3 8-9702-0656-0
bolt
4 Sleeve 8-9702-0623-0
5 Center bolt 8-9702-0655-0
SMIL14CEX3204AB 7
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the front slinger.

SMIL14CEX3205AB 8

adapter.
SMIL14CEX3206AA 9
7. Inspect the slinger

and the slinger.
0.7205 in)
2. Slinger
3. Crankshaft
SMIL14CEX3207AB 10
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cluded in the kit.
Legend Parts number
1 Adapter 8-9439-6857-0
2 Oil seal –
Adapter tightening
3 8-9702-0656-0
bolt
4 Sleeve 8-9702-0625-1
5 Center bolt 8-9702-0655-0
SMIL14CEX3204AB 11

adapter.
SMIL14CEX3396AA 12

and the crankshaft front oil seal.
0.3406 in)
2. Timing gear case
4. Crankshaft
SMIL14CEX3208AB 13

SMIL14CEX3209AA 14
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Tightening torque: 200 N·m (148 lb ft) Apply en-

gine oil on the threaded area of bolt
SMIL14CEX3210AB 15


Cooling fan belt Pulley ratio Amount of flex
0.80
0.85
1. Crankshaft pulley SMIL14CEX3211AB 16
2. Generator
3. Fan pulley
the adjust bolt.
NOTE: Loosen adjust-plate-side nut (2) and bracket side
and bracket-side bolt to the specified torque.
Tightening torque: 76 N·m (56.1 lb ft) Ad-
just-plate-side nut
Tightening torque: 127 N·m (93.7 lb ft) Bracket- SMIL14CEX3123AB 17
side bolt

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1. Bolt
2. Washer
3. Rubber mount
4. Rubber mount
5. Guide tube
6. Fan guide
SMIL14CEX3122AB 18

1. Install the cooling fan (1) to the adapter (2).
SMIL14CEX3121AB 19
Coolant filling
CAUTION:

tem parts.
SMIL14CEX3360AB 20

tering the system.
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Perform the urea SCR dosing module coolant piping air
bleeding process while referring to the owner's manual
from the machinery manufacturer.

NOTE: Idle the engine for 5 min
8. Stop the engine.
CAUTION:

mouth.

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engine at approximately 1500 - 2000 RPM
come warm.

form step 12 again.


cooled.
mouth.



to the MAX line.

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Index
Engine - 10

Engine block cover Front - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine block cover Front - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine oil pan - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine oil pan - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pan and covers - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Pan and covers - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - 10
Valve drive and gears - 106

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Contents
Engine - 10
TECHNICAL DATA
Camshaft
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Rocker shaft
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Idler gear
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Camshaft
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
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Engine - Valve drive and gears
Camshaft - Special tools

Isuzu reference 5-8840-2674-1
CASE CONSTRUCTION tool
Not needed
number
Description Scissors gear spring
wrench
SMIL14CEX3076AA 1
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Rocker shaft - Remove


1. Disconnect the water pipe bracket (2) from the cylinder
head cover.
2. Disconnect the ventilation hose (1) from the air
breather.
Disconnect the clip (3).
SMIL14CEX2969AB 1

cover (3).
head cover (1).
SMIL14CEX2970AB 2


SMIL14CEX3002AA 3
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jector (1) side stud bolts.
SMIL14CEX3003AB 4

assembly.
SMIL14CEX3004AB 5
Lower cover removal

bly.
bly.

SMIL14CEX3009AA 6
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assembly.

SMIL14CEX3010AA 7
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Rocker shaft - Disassemble

1. Remove the camshaft bearing cap (2) from the rocker
arm shaft.
NOTE: Hold the camshaft bearing cap (2) on the front and
remove the installation bolt (1).
2. Remove the rocker arm from the rocker arm shaft.
3. Remove the washer from the rocker arm shaft.
4. Remove the bracket from the rocker arm shaft.
NOTE: After disassembly, organize them according to the
installation order in order to avoid a mixup.
SMIL14CEX3399AB 1
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Rocker shaft - Inspect

1. Inspect the rocker arm.
NOTE: Confirm that the roller surface is not damaged.
SMIL14CEX3405AA 1
2. Measure the rocker arm using the vernier caliper.

NOTE: Measure the clearance between the outer diameter
of the roller pin and the inner diameter of the roller (1).
2. Dimension B
3. Calipers
4. Dimension A
5. Direction for pulling the string
6. Direction for pushing the roller
NOTE: Place a string between the rocker arm and roller to
measure dimension A.
SMIL14CEX3406AB 2
3. Calculate the clearance from the measured value.

NOTE: Calculate the clearance between the outer diame-
ter of the roller pin and inner diameter of the roller by sub-
tracting dimension B from A.
0.0039 in)
Limit: 0.2 mm (0.0079 in)
CAUTION: Replace the rocker arm if the clear-

ance exceeds the limit value.
Rocker arm shaft inspection

1. Inspect the camshaft bearing cap.
NOTE: Inspect the oil hole for clogging.
SMIL14CEX3407AA 3
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2. Inspect the rocker arm shaft.

NOTE: Inspect the oil hole for clogging.
SMIL14CEX3408AA 4
3. Put the rocker arm shaft on V-block.

4. Measure the rocker arm shaft using the dial gauge.
NOTE: Measure the bending of the rocker arm shaft.
Limit: 0.3 mm (0.0118 in)
NOTE: Replace the rocker arm shaft if the measured value
exceeds the limit value.
SMIL14CEX3409AA 5
5. Measure the rocker arm shaft using the micrometer.

NOTE: Measure the outer diameter of the rocker arm shaft.
Specified value: 22.00 mm (0.8661 in)
Limit: 21.85 mm (0.8602 in)
NOTE: Replace the rocker arm shaft if the measured value
is under the limit value.
Measure the rocker arm using a cylinder gauge.
6. Measure the rocker arm using a cylinder gauge.
NOTE: Measure the inner diameter of the rocker arm.
NOTE: Calculate the clearance by subtracting the inner
diameter of the rocker arm from the outer diameter of the
rocker arm shaft.
0.0022 in)
Limit: 0.2 mm (0.0079 in)
NOTE: Replace the rocker arm and the rocker arm shaft if
SMIL14CEX3410AA 6
the clearance is under the limit value.
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Rocker shaft - Assemble

1. Check the front mark (1) of the rocker arm shaft.
CAUTION: Assemble with the front mark of

the rocker arm shaft shown in the diagram facing
toward the front and top of the engine.
SMIL14CEX3400AB 1
2. Temporarily tighten the camshaft bearing cap to the

rocker arm shaft.
NOTE: Temporarily tighten the rear side camshaft bearing
cap (1).
Temporarily tighten while in the assembly and completely
tighten when installing the cylinder head.
SMIL14CEX3401AB 2
3. Apply the engine oil to the rocker arm.

NOTE: Apply to the roller (1) and bush inner diameter (2).
SMIL14CEX3402AB 3
4. Install the rocker arm to the rocker arm shaft.

5. Install the washer to the rocker arm shaft.
6. Install the bracket to the rocker arm shaft.
CAUTION: Confirm that the inlet rocker arm is

assembled to the front side.
1. Front mark
NOTE: Install on the same location as before the disas-
sembly.
SMIL14CEX3403AB 4
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7. Temporarily tighten the camshaft bearing cap to the

rocker arm shaft.
NOTE: Temporarily tighten the camshaft bearing cap on
the front.
Temporarily tighten while in the assembly and completely
tighten when installing the cylinder head.
SMIL14CEX3404AA 5
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Rocker shaft - Install

SMIL14CEX3080AB 1

bly.
Tightening order
Rocker arm shaft tightening torque
Parts Tightening torque
Front side camshaft bear-
28 N·m (21 lb ft)
ing cap
Rear side camshaft bear-
28 N·m (21 lb ft)
ing cap
SMIL14CEX3081AB 2

NOTE: Valve clearance adjustment 　
CAUTION:
○ Adjust the valve clearance while cool.

SMIL14CEX3082AA 3
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SMIL14CEX3075AA 4

Thickness： 0.4 mm (0.0157 in)
and bridge cap.
Tightening torque： 22 N·m (16 lb ft)
SMIL14CEX3083AA 5

SMIL14CEX3085AA 6
Clearance ： less than 0.1 mm (0.0039 in) be-
tween valve and bridge
Adjustment table
O O O O O O
　
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SMIL14CEX3084AB 7

3. Apply liquid gasket to the rubber plug in the application
area (1).

install the lower cover within 5 min
SMIL14CEX3386AB 8

Tightening torque： 13 N·m (115 lb in)
SMIL14CEX3087AB 9

bly.
SMIL14CEX3094AB 10
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SMIL14CEX3095AB 11

cover (1).
them.
SMIL14CEX2970AB 12
SMIL14CEX3096AB 13

cover.
SMIL14CEX2969AB 14
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Idler gear - Remove

Coolant drain
CAUTION:

SMIL14CEX2956AB 1

SMIL14CEX2973AB 2
Engine oil drain


bly.
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assembly.
NOTE: Remove the clip (2). SMIL14CEX2954AB 3

assembly.
bocharger assembly.
head assembly.
bocharger assembly.
block.
bocharger assembly.
manifold.

pipe A.
SMIL14CEX2980AB 4
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perature sensor 2.
pipe B.
SMIL14CEX2981AB 5
EGR cooler removal

cooler.
SMIL14CEX2982AB 6
SMIL14CEX2983AB 7

(2).
(3).
bracket A (4).
cooler A.
SMIL14CEX2984AB 8
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A.
SMIL14CEX2985AB 9
9. Remove the EGR pipe A (2) from the exhaust manifold
(3).
SMIL14CEX2986AB 10
EGR valve removal

(1).
SMIL14CEX2987AB 11

head assembly.
SMIL14CEX2988AB 12
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assembly.
SMIL14CEX2989GB 13
2. Remove the fan guide stay (2) from the fan guide (1)
and the fan guide bracket (3).
SMIL14CEX2990AB 14
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let pipe.
SMIL14CEX2991AB 15

guide tube (1).
cylinder block.
SMIL14CEX2992AB 16

throttle valve.
2. Lock release
3. Lock
SMIL14CEX2993AB 17
SMIL14CEX2994AB 18
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Inlet pipe removal

(3).
SMIL14CEX2995AB 19
SMIL14CEX2996AB 20
Glow plug removal

SMIL14CEX2997AA 21

bly.
SMIL14CEX2998AA 22
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CAUTION:


SMIL14CEX2999AB 23
7. Fuel pipe
Fuel pipe removal


head.
pump.
feed pipe.
rail assembly.
SMIL14CEX3000AB 24
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sure sensor.
cover.
SMIL14CEX3001AB 25

1. Disconnect the ventilation hose from the air breather.
cover (3).
head cover (1).
SMIL14CEX2970AB 26


SMIL14CEX3002AA 27
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SMIL14CEX3003AB 28

assembly.
SMIL14CEX3004AB 29
Injector removal
special tool.
SMIL14CEX3005AA 30

SMIL14CEX3006AA 31
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1. Sliding hammer
3. Injector
SMIL14CEX3007AB 32
CAUTION:

cial tool.
a mix-up.
nozzle.
SMIL14CEX3008AA 33
Lower cover removal

bly.
bly.

SMIL14CEX3009AA 34
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assembly.

SMIL14CEX3010AA 35
Camshaft removal
head assembly.
ing cap.
assembly.
SMIL14CEX3011AA 36
Bridge removal

cap (1) into the engine.

SMIL14CEX3012AB 37

block.
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SMIL14CEX3013EB 38

SMIL14CEX3014AB 39

block.

gasket.

pump (1).
2. Remove the fuel supply pump (1) from the cylinder
block.
NOTE: Remove together with the bracket (2).
3. Gear
4. Nut
5. Bolt
6. O-ring
7. O-ring
SMIL14CEX3129AB 40
8. Nut
9. Bolt
10. Nut
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ing.
SMIL14CEX3130AA 41
CKP sensor removal

sor (1).
(2).

gasket.
SMIL14CEX3131AB 42
Flywheel removal

not rotate.
SMIL14CEX3132AB 43
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1. Remove the crankshaft rear oil seal (3) from the crank-
shaft using the special tool.
SMIL14CEX3125AA 44
1. Felt
2. Slinger
SMIL14CEX3124AB 45

SMIL14CEX3133AA 46
Oil pan removal

switch.
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the oil port cover.
SMIL14CEX3135AB 47
3. Remove the cover (2) and the O-ring (1) from the fly-
wheel housing.
SMIL14CEX3136AB 48

and the crankcase.

SMIL14CEX3137AB 49
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measured.
CAUTION:
○ Measure the idle gear backlash before re-

moving the idle gear A.specified value: 0.10 -
0.17 mm (0.0039 - 0.0067 in) limit: 0.30 mm
(0.0118 in)
○ Replace the idle gear if the measured value ex-
ceeds the limit value.
SMIL14CEX3138AA 50

the thrust collar.
CAUTION:
○ Measure the play of the idle gear in the axis

direction before removing the idle gear B.
specified value: 0.080 - 0.155 mm (0.0031 -
0.0061 in) limit: 0.20 mm (0.0079 in)
○ Replace the idle gear if the measured value ex-
ceeds the limit value.
SMIL14CEX3139AA 51
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Idle gear A removal

SMIL14CEX3140AA 52

SMIL14CEX3141AA 53
Idle gear B removal

SMIL14CEX3142AA 54
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Idler gear - Inspect

1. Inspect the idle gear.
NOTE: Inspect the idle gears for tooth contact, peeling and
pitching.
2. Measure the idle gear shaft (1) using the micrometer.
1.1803 in) Outer diameter
SMIL14CEX3248AB 1
3. Measure the idle gear using the cylinder gauge.

NOTE: Measure the bush inner diameter of each idle gear.
0.0024 in)
NOTE: The difference between the inner diameter of the
idle gear bush and the outer diameter of the idle gear shaft
is the clearance.
SMIL14CEX3249AA 2
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Idler gear - Install



area.

SMIL14CEX3172AA 1

to the oil pump.
CAUTION:

uid gasket.
SMIL14CEX3173AA 2
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SMIL14CEX3174AA 3

SMIL14CEX3175AB 4
6. Install the idle gear A (10) to the cylinder block.

1. Camshaft gear
3. Idle gear B
5. PTO gear
6. PTO idle gear
7. Crank gear
8. Oil pump gear
9. Supply pump gear
10. Idle gear A
11. Idle gear C
SMIL14CEX3176BB 5
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stallation area.
CAUTION:

the diagram. SMIL14CEX3177AB 6

Tightening torque
No. 1 bolt: 96 N·m (71 lb ft)
SMIL14CEX3178BB 7
4. Apply engine oil to the PTO idle gear shaft (4).
SMIL14CEX3180AB 8
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5. Install the washer (2) to the PTO idle gear shaft (4).

6. Apply engine oil to the washer (2).

7. Install the PTO idle gear (3) to the PTO idle gear shaft
(4).

8. Apply engine oil to the PTO idle gear (3).

9. Install the washer (2) to the PTO idle gear shaft (4).
CAUTION: Install it with the oil groove (5) of

the washer facing toward the gear side.
10. Install the PTO idle gear (3) to the flywheel housing.
NOTE: Assemble the thrust collar (5) to the mounting bolt
and install it after applying engine oil.
CAUTION:
○ Install it with the oil groove of the thrust collar

(5) facing toward the gear side.
○ Orient the notch (3) of the shaft facing upward
for oil lubrication and make sure to install the
thrust collar (5) so that the paint portion (2) is
within the area indicated by the diagram.
1. 30 °
SMIL14CEX3179AB 9

SMIL14CEX3181AB 10
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13. Install the oil pipe (1) to the pipe bracket (2)and the oil
port cover.
Tightening torque: 34 N·m (25 lb ft) Pipe bracket
(2) side
Tightening torque: 28 N·m (21 lb ft) Oil port cover
side
Tightening torque: 24 N·m (18 lb ft) Clip
the cylinder block.
Tightening torque: 34 N·m (25 lb ft) Flywheel
housing side
SMIL14CEX3135AB 11
Tightening torque: 15 N·m (11 lb ft) PTO side
Tightening torque: 41 N·m (30 lb ft) Cylinder
block side

(2).

SMIL14CEX3183AB 12

Tightening torque: 11 N·m (8 lb ft) 4 stud bolts

SMIL14CEX3184AB 13
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Special tool: Oil seal installer kit (Refer to Crank-
shaft - Special tools (10.103))
SMIL14CEX3185AA 14
Name Part number

1 Adapter 5-8840-2709-0
3 Center bolt 5-8840-2713-0
4 Sleeve 5-8840-9063-0
5 Collar 5-8840-2710-0
6 Adapter ring 5-8840-2711-0

cluded in the kit.
SMIL14CEX3186AB 15

1. Collar

oil seal.

SMIL14CEX3187AB 16
5. Install the adapter ring to the sleeve.

adapter.
SMIL14CEX3189AA 17
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9. Inspect the crankshaft rear oil seal (2).

1. Flywheel housing
NOTE: Measure the distance between the crankshaft (4)
head and the crankshaft rear oil seal (2).
Specified value: 7.2 - 7.8 mm (0.283 - 0.307 in)
SMIL14CEX3190AB 18

SMIL14CEX3191AB 19

Tightening angle: 60°
Tightening angle: 60°
SMIL14CEX3073AA 20
tightening
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sor to shock.
NOTE: Tighten together with the clip. tightening torque:

6 N·m (4 lb ft)
SMIL14CEX3131AB 21

SMIL14CEX3192AA 22

1. Supply pump bracket side slit.
2. Supply pump gear side alignment mark.
SMIL14CEX3193AB 23
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NOTE: Confirm that the white paint can be seen through
the timing confirmation hole (1) on the top surface of the
flywheel housing.
4. Check alignment mark of the supply pump gear (2).
SMIL14CEX3194AB 24

Tightening torque: 75 N·m (55 lb ft) Bolt (5)
Tightening torque: 75 N·m (55 lb ft) Nut (8)
Tightening torque： 51 N·m (38 lb ft) Nut (10)
2. Bracket
3. Gear
4. Nut
5. Bolt
6. O-ring
7. O-ring SMIL14CEX3195AB 25
8. Nut
9. Bolt
10. Nut
pump.

CAUTION:

head assembly.
bead width: 3.0 mm (0.1181 in)
bead height: 2.0 mm (0.0787 in)

SMIL14CEX3196AA 26
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der head gasket
NOTE: Tightening order of the head bolts.
SMIL14CEX3197AA 27
SMIL14CEX3198EB 28

Tightening torque: 98 N·m (72 lb ft) M14 bolt
SMIL14CEX3073AA 29
tightening M14 bolt.
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Bridge installation

smoothly.


SMIL14CEX3074AA 30
SMIL14CEX3075AA 31

ing.
cluded in the kit.


SMIL14CEX3076AA 32
sembly.
cial tool.
Special tool: Scissors gear spring wrench (Refer
to Camshaft - Special tools (10.106))
aligned.
SMIL14CEX3077AB 33
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sub gear side.
SMIL14CEX3078AA 34
CAUTION:

cap.

ing.

cap.
assembly.
Tightening torque: 28 N·m (21 lb ft) Engine oil ap-
plication
SMIL14CEX3079AA 35
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SMIL14CEX3080AB 36

bly.
Tightening order
SMIL14CEX3081AB 37

Front side camshaft bearing cap 28 N·m (21 lb ft)
Rear side camshaft bearing cap 28 N·m (21 lb ft)

CAUTION:

SMIL14CEX3082AA 38
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SMIL14CEX3075AA 39

and bridge cap.
SMIL14CEX3083AA 40

on both sides to touch properly
SMIL14CEX3085AA 41
Clearance: less than 0.1 mm (0.0039 in) between
valve and bridge
Adjustment table
Value IN EX IN EX IN EX IN EX IN EX IN EX
No.1 cylinder
compression top dead
O O O O O O
center (O mark is an
adjustable part)
No.6 cylinder
compression top dead
O O O O O O
center (O mark is an
adjustable part)
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1. Apply the liquid gasket (2) to the rubber plug (1) .
SMIL14CEX3084AB 42

cation area (1).

install the lower cover within 5 min.
SMIL14CEX3086AB 43

SMIL14CEX3087AB 44
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bly (1).
bly (1).
(1).
(1).
Tightening torque: 25 N·m (18.4 lb ft) SMIL14CEX3088AB 45

sensor.

der head assembly.

mon rail assembly.

supply pump.

head assembly.
mon rail assembly.
supply pump.

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CAUTION: When reusing an injector (1), do
not change the installation position.
assembly.

SMIL14CEX3090AB 47
3. Temporarily tighten the injection pipe to the injector (1).
CAUTION: Use new injection pipes.

rail assembly.
5. Securely tighten the injector (1) to the cylinder head
assembly.
6. Install the injector leak-off pipe to the injector (1).

assembly.
3. No.3 injection pipe SMIL14CEX3091AB 48

7. Fuel pipe
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SMIL14CEX3092AA 49


SMIL14CEX3093AA 50

bly.
SMIL14CEX3094AB 51


jector (1) side stud bolts

SMIL14CEX3095AB 52
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cover (1).
them.
SMIL14CEX2970AB 53
SMIL14CEX3096AB 54

cover.
SMIL14CEX2969AB 55

SMIL14CEX3097AB 56
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SMIL14CEX2995AB 57

1. Install the intake throttle valve (1) with the gasket (2) to
the inlet pipe (3).
SMIL14CEX3099AB 58

valve.
2. Lock release
3. Lock
SMIL14CEX2993AB 59

SMIL14CEX2991AB 60
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sembly.
Clamp tightening torque: 20 N·m (15 lb ft)
SMIL14CEX2989GB 61
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ferent from others.
SMIL14CEX3100AB 62
3. Connect the radiator upper hose to the water outlet

pipe.
4. Install the fan guide stay (2) to the fan guide bracket
(3).
5. Install the fan guide stay (2) to the fan guide (1).
SMIL14CEX2990AB 63


gle of the hose.
SMIL14CEX2988AB 64
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SMIL14CEX2987AB 65

manifold (3).
pipe A (2).
SMIL14CEX2986AB 66

EGR cooler A.
5. Temporarily tighten the EGR cooler bracket C (2) to the
EGR cooler B (3).
SMIL14CEX3104AB 67

SMIL14CEX3247AB 68
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fold.
Tightening torque : 67 N·m (49 lb ft)
A.
cooler B.
bracket C.
cooler bracket C.
cooler bracket B.
hanger bracket.
SMIL14CEX2985AB 69
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SMIL14CEX2982AB 70

CAUTION:

correctly.

EGR gas temperature sensor 2 Light gray
IMT sensor Gray
CAUTION:

sor.
dropped, etc.
sor 2.
Tightening torque: 19.6 N·m (14.5 lb ft)
ture sensor 2.
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CAUTION:

sor.
dropped, etc.
sor 1.
ture sensor 1.

block.
der head assembly.
tube (1).
SMIL14CEX3105AB 71

oil.


ifold.
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4. Install the water feed pipe (4) to the cylinder block.

Tightening torque: 24 N·m (18 lb ft) Clip (2)
SMIL14CEX2954AB 72
5. Connect the water feed pipe (4) to the turbocharger

assembly.

6. Install the water return pipe (5) to the cylinder block.

7. Connect the water return pipe (5) to the turbocharger
assembly.

8. Install the oil return pipe (3) to the cylinder block.

9. Connect the oil return pipe (3) to the turbocharger as-
sembly.

10. Install the oil feed pipe (1) to the pipe bracket.

11. Connect the oil feed pipe (1) to the turbocharger as-
sembly.

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Engine oil filling

gauge.

Coolant filling
CAUTION:

tem parts.
plugs (1), loosen the plugs and remove them.
SMIL14CEX2956AB 73

tering the system.
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8. Stop the engine.
CAUTION:

mouth.


come warm.

form step 12 again.

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cooled.
mouth.



to the MAX line.

Fuel air bleed

Refer to Fuel injection system - Bleed (10.218).
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Camshaft - Remove

head cover.
breather.
SMIL14CEX3382AB 1

cover (3).
head cover.
SMIL14CEX2970AB 2


SMIL14CEX3002AA 3
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SMIL14CEX3003AB 4

assembly.
SMIL14CEX3004AB 5
Lower cover removal

bly.
bly.

SMIL14CEX3009AA 6
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assembly.

SMIL14CEX3010AA 7
Camshaft removal
head assembly.
ing cap.
assembly.
SMIL14CEX3011AA 8
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Camshaft - Disassemble
1. Fasten the camshaft to the vise.
CAUTION: Do not attach the camshaft directly

to the vise.
NOTE: Secure the hexagonal section of the camshaft with

a cap, such as an aluminum one.
2. Remove the snap ring (1) from the camshaft gear (5)
using the snap ring pliers.
3. Remove the sub gear (3) from the camshaft gear (5)
using the snap ring pliers.
CAUTION: Be careful not to damage the cam

or the journal section of the camshaft.
2. Disc spring
4. Spring
SMIL14CEX3383AA 1
SMIL14CEX3384AB 2
4. Remove the camshaft gear from the camshaft using the

puller.
NOTE: Use a piece of wood (1).
CAUTION: Do not apply a puller directly on

the cam gear.
5. Remove the knock pin from the camshaft.
SMIL14CEX3385AB 3
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Camshaft - Inspect
Camshaft gear inspection
1. Inspect the camshaft gear.
NOTE: Inspect gears for tooth contact, peeling and pitch-
ing, etc.
2. Measure the camshaft gear using the vernier caliper.
NOTE: Measure the distance between the camshaft thrust
surface and the camshaft gear.
1.1045 in)
SMIL14CEX3388AA 1
Camshaft inspection
1. Inspect the camshaft.
NOTE: Inspect the camshaft journal and cam sections for
worn and damage.
CAUTION: If any abnormality is found in the

inspection, replace the camshaft.
2. Put the camshaft on V-block.
NOTE: Hold the No.1 and No.7 journal sections using the
V blocks.
3. Measure the camshaft using the dial gauge.
NOTE: To measure the fluctuation, attach the dial gauge to
the No.4 journal section and gently turn the camshaft 360
degrees.
Limit: 0.05 mm (0.0020 in)
SMIL14CEX3389AA 2
4. Measure the camshaft using the micrometer.
SMIL14CEX3390AA 3
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Lift amount of the cam

Specified value 52.8 mm (2.0787 in)
Inlet
Limit value 51.8 mm (2.0394 in)
Specified value 54.5 mm (2.1457 in)
Exhaust
Limit value 53.5 mm (2.1063 in)
NOTE: Repair minor damage or worn using an oil stone.

5. Measure the camshaft journal using the micrometer.
Limit: 39.85 mm (1.5689 in)
SMIL14CEX3391AA 4
6. Measure the camshaft bearing using the gauge.
SMIL14CEX3392AA 5
7. Calculate the oil clearance from the measured value.

NOTE: The difference between the inner diameter of the
bearing and the outer diameter of the journal is the oil clear-
ance.
0.0034 in)
Limit: 0.15 mm (0.0059 in)
CAUTION: Replace the bearing if the oil clear-

ance exceeds the limit value.
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Camshaft - Assemble
1. Install the knock pin to the camshaft.
2. Align the camshaft gear to the knock pin.
NOTE: Turn the camshaft gear so that the projected part
of the center boss faces the camshaft.
3. Install the camshaft gear to the camshaft.
CAUTION: When tightening the gear, be care-

ful not to damage the cam and the journal section.
SMIL14CEX3387AA 1
4. Fasten the camshaft to the vise.
CAUTION: Do not attach the camshaft directly

to the vise.
NOTE: Secure the camshaft using an aluminum clasp, etc.

5. Install the sub gear to the camshaft gear.
NOTE: Attach the left end of the spring to the camshaft
main gear pin and assemble it so that a gap is created on
the right.
Assemble the sub gear so that the sub gear pin fits into the
gap between the right side of the camshaft main gear pin
and the right end of the spring.
6. Install the snap ring to the camshaft gear using the snap
ring pliers.
NOTE: Assemble the snap ring and disc spring firmly.
SMIL14CEX3383AA 2
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Camshaft - Install
ing.


sembly.
NOTE: To prevent the effect of spring force on the sub gear, SMIL14CEX3075AA 1
cial tool.
aligned.
SMIL14CEX3076AA 2
SMIL14CEX3077AB 3
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sub gear side.
SMIL14CEX3078AA 4
CAUTION:

cap.
ing.

cap.
assembly.

SMIL14CEX3079AA 5
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SMIL14CEX3080AB 6

bly.
Tightening order
Front side camshaft
bearing cap
28 N·m (21 lb ft)
Rear side camshaft
bearing cap
SMIL14CEX3081AB 7

CAUTION:

SMIL14CEX3082AA 8
SMIL14CEX3075AA 9
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and bridge cap.
SMIL14CEX3083AA 10

floating or touching at an angle
SMIL14CEX3085AA 11
valve and bridge
Adjustment table
O O O O O O
　

SMIL14CEX3084AB 12
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cation area (1).

SMIL14CEX3086AB 13

SMIL14CEX3087AB 14

bly.
SMIL14CEX3094AB 15



SMIL14CEX3095AB 16
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cover (1).
them.
SMIL14CEX2970AB 17
SMIL14CEX3096AB 18

cover.
SMIL14CEX2969AB 19

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Index
Engine - 10

Camshaft - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Camshaft - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Camshaft - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Camshaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Camshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Camshaft - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Idler gear - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Idler gear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Idler gear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Rocker shaft - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Rocker shaft - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Rocker shaft - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Rocker shaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Rocker shaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Engine - 10
Cylinder heads - 101

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Contents
Engine - 10
TECHNICAL DATA
Cylinder heads
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cylinder head
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Valves
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Valve guide
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SERVICE
Valve cover
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cylinder head
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Valves
Seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Spring - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Spring - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Spring - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
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Engine - Cylinder heads
Cylinder heads - Special tools

Head bolt
380300009
number
Description Angle gauge
SMIL14CEX2693AA 1
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Cylinder head - Special tools

Common tool
number
Description Sealing cup installer
SMIL14CEX2686AA 1

Common tool
number
Description Nozzle sleeve remover
SMIL14CEX2687AA 2

380001721
number
Description Nozzle sleeve installer
SMIL14CEX2688AA 3

Common tool
number
Description Bridge guide setting
tool
SMIL14CEX2689AA 4
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380300014
number
Description Valve guide replacer
SMIL14CEX2690AA 5

(5-8531-7002-0)
380002626
number
Description Compression gauge
(adapter)
SMIL14CEX2691AA 6

380300015
number
Description Compression gauge
adapter
SMIL14CEX2692AA 7

Common tool
number
Description Oil seal installer
SMIL14CEX3037AA 8
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Valves - Special tools

Valve spring
Common tool
number
Description Valve spring replacer
SMIL14CEX2699AA 1

Not needed
number
Description Pivot ASM
SMIL14CEX2700AA 2
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Valve guide - Special tools

380300013
number
Description Valve stem seal setting
tool
SMIL14CEX2685AA 1
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Valve cover - Remove

1. Disengage the water pipe bracket (2) from the cylinder
head cover.
2. Disengage the ventilation hose (1) from the air
breather.
Disengage the clip (3).
SMIL14CEX2969AB 1

cover (3).
head cover (1).
SMIL14CEX2970AB 2
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Valve cover - Install

cover (1).
Tightening torque: 13.0 N·m (115.1 lb in)
them.
SMIL14CEX2970AB 1
SMIL14CEX2971AB 2

cover.
SMIL14CEX2969AB 3
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Cylinder head - Remove

Coolant drain
CAUTION:

SMIL14CEX2972AB 1

SMIL14CEX2973AB 2

bly.
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assembly.
5. Remove the oil feed pipe from the pipe bracket.

assembly.
bocharger assembly.
head assembly.
bocharger assembly.
block.
bocharger assembly.
manifold.

pipe A.
SMIL14CEX2980AB 4
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pipe B.
SMIL14CEX2981AB 5
EGR cooler removal

cooler.
SMIL14CEX2982AB 6
SMIL14CEX2983AB 7
3. Remove the EGR cooler C (1) from the EGR bracket C.

4. Remove the EGR bracket C (2) from the EGR cooler B.
bracket A.
cooler A.
SMIL14CEX2984AB 8
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A.
SMIL14CEX2985AB 9
(3).
SMIL14CEX2986AB 10
EGR valve removal

(1).
SMIL14CEX2987AB 11

head assembly.
SMIL14CEX2988AB 12
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assembly.
SMIL14CEX2989GB 13
SMIL14CEX2990AB 14
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let pipe.
SMIL14CEX2991AB 15

guide tube (1).
cylinder block.
SMIL14CEX2992AB 16

throttle valve.
2. Lock release
3. Lock
SMIL14CEX2993AB 17
SMIL14CEX2994AB 18
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Inlet pipe removal

(3).
SMIL14CEX2995AB 19
SMIL14CEX2996AB 20
Glow plug removal

SMIL14CEX2997AA 21

bly.
SMIL14CEX2998AA 22
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CAUTION:


SMIL14CEX2999AB 23
7. Fuel pipe
Fuel pipe removal


head.
pump.
feed pipe.
rail assembly.
SMIL14CEX3000AB 24
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sure sensor.
cover.
SMIL14CEX3001AB 25

cover (3).
head cover (1).
SMIL14CEX2970AB 26


SMIL14CEX3002AA 27
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SMIL14CEX3003AB 28

assembly.
SMIL14CEX3004AB 29
Lower cover removal

bly.
bly.
Injector removal
1. Remove the injector leak-off pipe from the injector .
NOTE: When it is difficult to remove the injector , use a
special tool.
SMIL14CEX3005AA 30
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Special tool: sliding hammer (Refer to Fuel injec-

SMIL14CEX3006AA 31
1. Sliding hammer
3. Injector
SMIL14CEX3007AB 32
CAUTION:

cial tool.
a mix-up.
nozzle.
SMIL14CEX3008AA 33

SMIL14CEX3009AA 34
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assembly.

SMIL14CEX3010AA 35
Camshaft removal
head assembly.
ing cap.
assembly.
SMIL14CEX3011AA 36
Bridge removal


SMIL14CEX3012AB 37
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block.
NOTE: Loosening order of the head bolts.
SMIL14CEX3013EB 38

SMIL14CEX3014AB 39

block.

gasket.
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Cylinder head - Disassemble

Engine hanger bracket removal
1. Remove the front engine hanger bracket (2) from the
2. Remove the rear engine hanger bracket (4) from the
1. Front engine hanger
3. Rear engine hanger
SMIL14CEX3015CB 1
Inlet cover removal

1. Remove the inlet cover (2) and the gasket (1) from the
SMIL14CEX3016AB 2
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Exhaust manifold removal

1. Remove the exhaust manifold cover (2) from the ex-
haust manifold.
2. Remove the heat protector (1) from the exhaust mani-
fold.
SMIL14CEX3017AB 3
3. Remove the exhaust manifold (1) from the cylinder

head assembly.
NOTE: Mark the position of the distance nut (2).
SMIL14CEX3018AB 4
4. Disassemble the exhaust manifold.

1. Rear side exhaust manifold
2. Seal ring
3. Front side exhaust manifold
SMIL14CEX3019AB 5
Bracket removal
1. Remove the EGR cooler bracket B (1) from the cylinder
head assembly.
SMIL14CEX3020AB 6
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Thermostat removal
1. Remove the water outlet pipe (2) from the cylinder head
assembly.
1. Fan guide bracket
2. Remove the thermostat from the cylinder head assem-
bly.
3. Remove the gasket from the thermostat.
SMIL14CEX3021AB 7
Overheat switch removal

1. Remove the overheat switch (1) from the cylinder head
assembly.
SMIL14CEX3022AB 8
Engine coolant temperature sensor removal

1. Remove the engine coolant temperature sensor from
the cylinder head assembly.
1. Overheat switch
2. Water temperature sensor
SMIL14CEX3023AB 9
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CMP sensor removal

1. Disengage the harness connector from the CMP sen-
sor.
2. Remove the CMP sensor from the cylinder head as-
sembly.

sor to shock.
SMIL14CEX3024AA 10
Idle gear C removal

1. Press the idle gear C cover using the driver.
NOTE: Lightly tap the outer perimeter of the cover using a
screwdriver and tilt the cover.
2. Remove the idle gear C cover from the cylinder head
assembly using the pliers.
SMIL14CEX3025AA 11
3. Remove the screw and the idle gear shaft (2).

4. Remove the idle gear C (1) from the cylinder head as-
sembly.
SMIL14CEX3026AB 12
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Valve spring removal

1. Press the valve spring using the special tool.
Special tool: Valve spring replacer (Refer to
Valves - Special tools (10.101))
SMIL14CEX3027AA 13
Special tool: Pivot ASM (Refer to Valves - Special

tools (10.101))
SMIL14CEX3028AA 14
2. Remove the split collar from the spring seat.

3. Remove the special tool from the cylinder head assem-
bly.
4. Remove the valve spring seat from the valve spring.
5. Remove the valve spring from the cylinder head as-
sembly.
NOTE: Store the removed valve springs according to the
cylinders.
SMIL14CEX3029AA 15
Inlet valve removal

1. Remove the inlet valve from the cylinder head assem-
bly.
NOTE: Organize the removed valve according to the cylin-
ders.
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Exhaust valve removal

1. Remove the exhaust valve from the cylinder head as-
sembly.
NOTE: Organize the removed valve according to the cylin-
ders.
SMIL14CEX3030AA 16
Valve stem oil seal removal

1. Remove the valve stem oil seal from the valve guide
using the pliers.
CAUTION: Do not reuse the valve stem oil

seal.
2. Remove the valve spring seat from the cylinder head
assembly.
Valve guide removal

1. Remove the valve guide from the cylinder head assem-
bly using the special tool.
Special tool: Valve guide replacer (Refer to Cylin-
der head - Special tools (10.101))
SMIL14CEX3031AA 17
NOTE: Tap the valve guides out from the bottom surface
of the cylinder head.
SMIL14CEX3032AA 18
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Valve seat insert removal

1. Heat the valve seat insert with the gas burner.
Heating temperature: 700 - 800 °C (1292 -
1472 °F): 2 sections inner surface of the insert
Specified time: 5 min Natural cooling
NOTE: Cool the valve seat insert naturally after heating.
2. Remove the valve seat insert from the cylinder head
assembly using the driver.

der head.
Injector sleeve removal

1. Remove the injector sleeve (1) from the cylinder head
assembly using the special tool.
Special tool: Nozzle sleeve remover (Refer to
Cylinder head - Special tools (10.101))
SMIL14CEX3033AA 19
Tap the injector sleeve (1) out from the bottom surface
of the cylinder head.
CAUTION:
○ Be careful not to damage the bottom surface of

the cylinder head.
○ Do not reuse the removed injector sleeve.
SMIL14CEX3034AA 20
Bridge guide removal

1. Install the nut (1) to the bridge guide.
NOTE: Electrically weld the nut (1) to the top of the bridge
guide.
2. Remove the bridge guide from the cylinder head as-
sembly using the sliding hammer.
SMIL14CEX3035AB 21
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Oil seal removal

1. Remove the oil seal from the cylinder head assembly.
NOTE: Attach a rod from the inner surface of the cylinder
head, and tap it to remove it to the outer side.
SMIL14CEX3036AA 22
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Cylinder head - Assemble

Oil seal installation
1. Install the oil seal to the cylinder head (1) assembly.
Special tool: Oil seal installer (Refer to Cylinder
head - Special tools (10.101))
SMIL14CEX3037AA 1
CAUTION: Be careful not to damage the lip

section of the oil seal.
SMIL14CEX3036AA 2
1. Cylinder head
2. Oil seal installer
SMIL14CEX3038AB 3
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Bridge guide installation

1. Apply the engine oil to the bridge guide.
2. Install the bridge guide to the cylinder head assembly
Special tool: Oil seal installer (Refer to Cylinder
head - Special tools (10.101))
Specified length: 122.0 - 123.0 mm (4.8031 -
4.8425 in) 1 in the diagram
Specified length: 37.5 mm (1.4764 in) 2 in the di-
agram
SMIL14CEX3039AA 4
SMIL14CEX3040AA 5
Injector sleeve installation

1. Install the O-ring (2) to the injector sleeve.
2. Apply the engine oil to the O-ring.
3. Apply the cement to the injector sleeve.
NOTE: Apply LOCTITE® 620™ to the tapered section of the
injector sleeve.
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4. Apply the engine oil to the cylinder head assembly.

NOTE: Apply engine oil to the injector sleeve contact sur-
face.
1. O-ring with white paint
3. LOCTITE® 620™ application
4. Engine oil application
SMIL14CEX3041BB 6
5. Install the injector sleeve to the cylinder head assembly

Special tool: Nozzle sleeve installer (Refer to
Cylinder head - Special tools (10.101))
SMIL14CEX3042AA 7
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1. Punch bar
2. Ball
3. Guide sleeve
4. Sleeve
5. Clamp
6. Bolt
CAUTION: Allow the cylinder head to float so

that the ball comes out from the bottom surface.
SMIL14CEX3043BB 8
Valve seat insert installation

1. Prepare the dolly block (1).
NOTE: Prepare the one which has smaller outer diameter
than the valve seat insert.
2. Align the valve seat insert to the cylinder head.
3. Align the dolly block to the valve seat insert.
4. Install the valve seat insert (2) to the cylinder head as-
sembly using the press (3).
SMIL14CEX3044AB 9
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Valve guide installation

1. Apply the engine oil to the valve guide.
2. Install the valve guide to the cylinder head assembly
Special tool: Valve guide replacer (Refer to Cylin-
SMIL14CEX3045AA 10
NOTE: Tap the valve guides from the upper side of the
cylinder head.
SMIL14CEX3046AA 11
Specified length: 17.1 - 17.9 mm (0.6732 -

0.7047 in) From the upper surface of the cylinder
head to the edge surface of the valve guide
CAUTION: When replacing the valve guide,

replace it with the valve.
SMIL14CEX3047AA 12
Valve stem oil seal installation

1. Install the valve spring seat to the cylinder head assem-
bly.
NOTE: Apply engine oil to the outer circumference of the
valve guide.
CAUTION: Use a new valve stem oil seal.
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3. Install the valve stem oil seal to the valve guide using
the special tool.
Special tool: Valve stem seal setting tool (Refer to
Valve guide - Special tools (10.101))
CAUTION:
○ Inspect the valve stem oil seal for deformation

or cracks.
○ Confirm that the garter spring has not come
loose.
SMIL14CEX3048AA 13
SMIL14CEX3049AA 14
Exhaust valve installation

1. Apply the engine oil to the exhaust valve.
2. Install the exhaust valve to the cylinder head assembly.
NOTE: Confirm that there is an E-mark on the valve.
SMIL14CEX3050AA 15
Inlet valve installation

1. Apply the engine oil to the inlet valve.
2. Install the inlet valve to the cylinder head assembly.
NOTE: Confirm that there is an I-mark on the valve.
SMIL14CEX3050AA 16
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Valve spring installation

1. Check the identification paint (2) of the valve spring.
Valve spring identification paint
Inlet: Blue
Exhaust: White
1. Spring pitch (small)
SMIL14CEX3051AB 17
2. Install the valve spring to the cylinder head assembly.

NOTE: Turn the valve spring to face the identification paint
(2) application area towards the cylinder head assembly.
3. Install the spring seat to the valve spring.
SMIL14CEX3027AA 18
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tools (10.101))
SMIL14CEX3052AA 19
SMIL14CEX3053AA 20
5. Install the split collar to the spring seat.

NOTE: Lightly tap the valve stem head to stabilize the split
collar.
CAUTION: Confirm that the split collar is in the

valve stem groove.
Idle gear C installation

1. Apply the engine oil to the idle gear C (1).
NOTE: Apply to the sliding surface of the gear.
2. Apply the engine oil to the idle gear shaft (2).
idle gear shaft (2).
3. Temporarily tighten the idle gear C (1) to the cylinder
head assembly.
CAUTION: Confirm that the spigot of the idle

gear shaft (2) is firmly installed to the cylinder head
assembly.
SMIL14CEX3054AB 21
4. Securely tighten the idle gear C (1) to the cylinder head

assembly.
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5. Apply the cement to the idle gear C cover.

NOTE: Apply Loctite 962T to the outer circumference of
the idle gear C cover.
6. Install the idle gear C cover to the cylinder head assem-
bly using the special tool.
Special tool: Sealing cup installer (Refer to Cylin-
SMIL14CEX3055AA 22
1. Between the idle gear C cover end surface and

cylinder head chamfered edge section.
Specified length (1): 1.5 - 2.5 mm (0.0591 -
0.0984 in)
SMIL14CEX3056AA 23
CMP sensor installation

2. Install the CMP sensor to the cylinder head assembly.

sor to shock.

3. Connect the harness connector to the CMP sensor.
SMIL14CEX3057AA 24
Engine coolant temperature sensor installation

1. Install the engine coolant temperature sensor to the
NOTE: Apply LOCTITE® 572™ to the threaded portion.
1. Overheat switch
2. Water temperature sensor
SMIL14CEX3058AB 25
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Overheat switch installation

1. Install the overheat switch (1) to the cylinder head as-
sembly.
SMIL14CEX3059AB 26
Thermostat installation
1. Install the gasket to the thermostat.
2. Install the thermostat to the cylinder head assembly.

1. Jiggle valve position
CAUTION: Be careful not to mistake the as-

sembly position and direction.
SMIL14CEX3060AB 27
3. Install the water outlet pipe (2) to the cylinder head

assembly.
SMIL14CEX3061AB 28
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Bracket installation
1. Install the EGR cooler bracket B (1) to the cylinder head
assembly.
SMIL14CEX3062AB 29
Exhaust manifold installation

1. Install the gasket (2) to the cylinder head assembly.
NOTE: Install the gasket by turning the protruding section
downward.
CAUTION: Confirm that the gasket (2) is firmly

installed to the cylinder head.
SMIL14CEX3063AA 30
NOTE: It will ride on the casted surface (1) of the cylinder

head as shown in the diagram when installed incorrectly.
SMIL14CEX3064AB 31
2. Assemble the exhaust manifold.

NOTE: Assemble the seal ring (2) onto the rear side ex-
haust manifold (1) and adjust each seal ring joint to be 120
degrees apart.
SMIL14CEX3019AB 32
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3. Install the exhaust manifold (1) to the cylinder head

assembly.
NOTE: Assemble the distance nut (2) and washer referring
to the diagram.
SMIL14CEX3065AB 33
Tightening torque: 55 N·m (40.57 lb ft) Nut (2)

Tightening torque: 34 N·m (25.08 lb ft) Distance
nut (4)
1. Distance tube
2. Washer
SMIL14CEX3066AB 34
4. Install the heat protector (1) to the exhaust manifold.

1. Tightening torque: 20 N·m (14.75 lb ft) Bolt
2. Tightening torque: 41 N·m (30.24 lb ft) Nut
5. Install the exhaust manifold cover (2) to the exhaust
manifold.Install the exhaust manifold cover to the ex-
haust manifold.
SMIL14CEX3067AB 35
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Inlet cover installation

1. Install the gasket (1) to the inlet cover.
2. Install the inlet cover (2) to the cylinder head assembly.
NOTE: Refer to the diagram for the tightening order.
1 and 7 in the diagram indicate reamer bolts.
SMIL14CEX3068AB 36
SMIL14CEX3069AB 37
Engine hanger bracket installation

1. Install the front engine hanger bracket (2) to the cylinder
head assembly.
Tightening torque: 48 N·m (35.40 lb ft) Front en-
gine hanger bracket (2)
Tightening torque: 94 N·m (69.33 lb ft) Front en-
gine hanger (1)
2. Temporarily tighten the rear engine hanger bracket (4)
to the cylinder head assembly.
CAUTION: Completely tighten the rear engine

hanger bracket after installing the EGR cooler.
Tightening torque: 94 N·m (69.33 lb ft) Rear en-

gine hanger bracket (4)
Tightening torque: 48 N·m (35.40 lb ft) Rear en-
gine hanger (3)
SMIL14CEX3070AB 38
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Cylinder head - Install

CAUTION:

head assembly.

the cylinder head within 5 min
SMIL14CEX3071AA 1


der head gasket.
SMIL14CEX3072AA 2
SMIL14CEX3013EB 3

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SMIL14CEX3073AA 4

Bridge installation
SMIL14CEX3074AA 5

smoothly.


47843027 21/05/2015
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ing.


sembly.
cial tool.
aligned.
SMIL14CEX3076AA 7
SMIL14CEX3077AB 8
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sub gear side.
CAUTION:

cap.
SMIL14CEX3078AA 9
ing.


cap.
assembly.
SMIL14CEX3079AA 10

SMIL14CEX3080AB 11
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bly.
Tightening order
Front side
camshaft bear-
ing cap
28 N·m (21 lb ft)
Rear side
SMIL14CEX3081AB 12
camshaft bear-
ing cap
Rocker arm
56 N·m (41 lb ft)
bracket

CAUTION:

SMIL14CEX3082AA 13
SMIL14CEX3075AA 14
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and bridge cap.
Tightening torque: 22 mm (16 in)
SMIL14CEX3083AA 15

SMIL14CEX3085AA 16
valve and bridge
Adjustment table
O O O O O O
　

NOTE: Apply ThreeBond 1207B
SMIL14CEX3084AB 17
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cation area (1).

SMIL14CEX3086AB 18

SMIL14CEX3087AB 19

bly (1).
bly (1).
(1).
(1).
SMIL14CEX3088AB 20
sensor.
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der head assembly.

mon rail assembly.

supply pump.

head assembly.
mon rail assembly.
supply pump.


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assembly.


rail assembly. SMIL14CEX3090AB 22

assembly.

assembly.
7. Fuel pipe
SMIL14CEX3091AB 23
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SMIL14CEX3092AA 24


SMIL14CEX3093AA 25

bly.
SMIL14CEX3094AB 26
2. Connect the terminal nut (3) of the injector harness

(2)to the injector (1).


SMIL14CEX3095AB 27
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cover (1).
them.
3. Connect the ventilation hose to the air breather.
SMIL14CEX2970AB 28
SMIL14CEX3096AB 29

SMIL14CEX3097AB 30

SMIL14CEX3098AB 31
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1. Install the intake throttle valve (1) with the gasket (2) to
the inlet pipe (3).
SMIL14CEX3099AB 32

valve (1).
2. Lock release
3. Lock
SMIL14CEX2993AB 33

SMIL14CEX2991AB 34
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sembly.
Clamp Tightening torque: 20 N·m (14 lb ft)
SMIL14CEX2989GB 35

ferent from others.
pipe.
SMIL14CEX3100AB 36
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(3).
SMIL14CEX3101AB 37


gle of the hose.
SMIL14CEX3102AB 38

SMIL14CEX3103AB 39
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manifold (3).
pipe A.
SMIL14CEX2986AB 40

EGR cooler A.
4. Temporarily tighten the EGR cooler bracket B (3) to the
EGR cooler bracket A (4).
EGR cooler B (3).
SMIL14CEX3104AB 41

fold.
SMIL14CEX2983AB 42
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A.
cooler B.
bracket C.
cooler bracket C.
cooler bracket B.
hanger bracket.
SMIL14CEX2985AB 43
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SMIL14CEX2982AB 44

CAUTION:
○ check the EGR gas temperature sensor 2 con-

correctly.

EGR gas temperature
Light gray
sensor 2
IMT Sensor Gray
CAUTION:

sor.
dropped, etc.

sor 2.
ture sensor 2.
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CAUTION:

sor.
dropped, etc.

sor 1.
ture sensor 1.

block.
der head assembly.
tube (1).
SMIL14CEX3105AB 45

oil.

ifold.
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Clip (2)

assembly.
SMIL14CEX2955AB 46

Clip (2)

assembly.


sembly.


sembly.

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Coolant filling
CAUTION:

tem parts.
SMIL14CEX2956AB 47

tering the system.

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8. Stop the engine.
CAUTION:

mouth.


come warm.

form step 12 again.

CAUTION: Confirm that the engine has cooled
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mouth.


17. Add coolant to the radiator reserve tank

to the MAX line.
Fuel air bleed

Refer to the Fuel injection system - Bleed (10.218).
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Cylinder head - Inspect

Bridge cap inspection
1. Measure the bridge cap using the dial gauge.
NOTE: Measure the contact surface of the bridge cap and
rocker arm.
Limit: 0.1 mm (0.0039 in) Amount of wear on the
bridge cap
CAUTION:
○ Replace the bridge cap if the measured value

○ Replace the bridge cap if it has an abnormal
wear such as band-shaped wear. SMIL14CEX3108AA 1
Bridge inspection
1. Inspect the bridge (1).
NOTE: Confirm that the bridge moves smoothly on the
bridge guide (2).
2. Check the clearance of the bridge cap.
Standard value: 0.020 - 0.057 mm (0.0008 -
0.0022 in) Between the bridge (1) and bridge cap
Between the bridge (1) and bridge cap
SMIL14CEX3109AB 2
Idle gear C inspection

NOTE: Measure the clearance in the axis direction be-
tween the cylinder head and idle gear C (1).
Standard value: 0.090 - 0.145 mm (0.0035 -
0.0057 in)
Limit: 0.2 mm (0.0079 in)
2. Measure the idle gear shaft using the vernier caliper.
NOTE: Outer diameter of the idle gear shaft.
Specified value: 30 mm (1.1811 in) SMIL14CEX3110AB 3
Limit: 29.85 mm (1.1752 in)
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Inlet valve inspection

1. Measure the inlet valve using the micrometer.
NOTE: Outer diameter of the valve stem.
Measurement part: 3 section (s) normal text for-
matting
Specified value: 8.0 mm (0.3150 in) Diameter
Limit: 7.88 mm (3.102 in) Diameter
CAUTION: Replace the bridge cap if the mea-

SMIL14CEX3111AA 4
2. Install the inlet valve (1) to the valve guide (3).

3. Measure the valve guide (3) clearance using the dial
gauge in position (2) 10 mm (0.394 in) under the valve
guide head.
NOTE: Valve guide (3) clearance
0.0028 in)
Limit: 0.2 mm (0.0079 in)
CAUTION: Replace the exhaust valve and

valve guide if the measured value exceeds the
5
limit value. SMIL14CEX3112AB
4. Measure the inlet valve using the micrometer.

NOTE: Valve thickness
Limit: 1.30 mm (0.0512 in)

limit value.
SMIL14CEX3113AA 6
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5. Inspect the exhaust valve using the red lead primer.

NOTE: Inspect the contact surface of the exhaust valve
and valve seat.
Specified value: 2.7 mm (0.1063 in) Contact width
Limit: 3.0 mm (0.1181 in) Contact width
CAUTION:
○ If the measured value exceeds the limit value,

fix the contact surface of the valve seat using a
sheet cutter.
○ If the contact position is not in the center of the SMIL14CEX3114AA 7
valve seat, fix the contact surface of the valve
seat using a sheet cutter.
○ If the contact surface is not smooth, fix the con-
tact surface of the valve seat using a sheet cut-
ter.
6. Adjust the valve seat to standard value using the valve
seat cutter.
CAUTION: Use a seat cutter suitable for the

valve seat angle and valve stem diameter.
Valve seat angle: 30 °

External diameter of the valve stem: 8.0 mm
(0.3150 in) Diameter
SMIL14CEX3115AA 8
7. Apply the compound to the valve seat.

8. Install the inlet valve to the valve guide.
9. Adjust contact surface to standard value using the
valve lapper.
NOTE: Lightly tap the inlet valve on the valve seat while
turning it.
CAUTION: After fixing the valve, remove all

compounds.
SMIL14CEX3116AA 9
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10. Check the sinking amount of the inlet valve.

0.0406 in)
Limit: 2.3 mm (0.0906 in)
SMIL14CEX3117AA 10
Exhaust valve inspection

1. Measure the exhaust valve using the micrometer.
NOTE: Outer diameter of the valve stem.
Specified value: 8.0 mm (0.3150 in) Diameter
Limit: 7.88 mm (0.3102 in) Diameter

valve guide if the measured value is under the limit
value.
SMIL14CEX3118AA 11
2. Install the exhaust valve (1) to the valve guide (3).

3. Measure the valve guide (3) clearance using the dial
gauge in position (2) 10 mm (0.394 in) under the valve
guide head.
NOTE: Valve guide (3) clearance.
0.0038 in)
Limit: 0.25 mm (0.0098 in)

12
limit value. SMIL14CEX3112AB
4. Measure the exhaust valve using the micrometer.

NOTE: Valve thickness
Limit: 1.30 mm (0.0512 in)

limit value.
SMIL14CEX3113AA 13
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5. Inspect the exhaust valve using the red lead primer.

NOTE: Inspect the contact surface of the exhaust valve
and valve seat.
Specified value: 2.5 mm (0.0984 in) Contact width
Limit: 3.0 mm (0.1181 in) Contact width
CAUTION:
○ If the measured value exceeds the limit value,

fix the contact surface of the valve seat using a
sheet cutter.
○ If the contact position is not in the center of the SMIL14CEX3114AA 14
valve seat, fix the contact surface of the valve
seat using a sheet cutter.
○ If the contact surface is not smooth, fix the con-
tact surface of the valve seat using a sheet cut-
ter.
6. Adjust the valve seat to standard value using the valve
seat cutter.
CAUTION: Use a seat cutter suitable for the

valve seat angle and valve stem diameter.
Valve seat angle: 45 °

External diameter of the valve stem: 8.0 mm
(0.3150 in) Diameter
SMIL14CEX3115AA 15
7. Apply the compound to the valve seat

8. Install the exhaust valve to the valve guide.
9. Adjust contact surface to standard value using the
valve lapper.
NOTE: Tap the exhaust valve on the valve seat while turn-
ing it.
CAUTION: After fixing the valve, remove all

compounds.
SMIL14CEX3116AA 16
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10. Check the sinking amount of the exhaust valve

0.0579 in)
Limit: 2.8 mm (0.1102 in)
SMIL14CEX3117AA 17
Cylinder head assembly inspection

CAUTION:
○ Clean the each part of the cylinder head assem-

bly before inspecting.
○ Be careful not to damage the cylinder head
while cleaning the cylinder head assembly.
1. Inspect the cylinder head assembly.
NOTE:
• Installation surface of the cylinder head gasket
• Combustion chamber
• Exhaust port
• Valve seat
• Glow plug hole
CAUTION: Replace the cylinder head if dam-

tion. SMIL14CEX3119AA 18
NOTE: Fix it if it is possible.

3. Align the simple straight ruler to the cylinder head as-
sembly.
NOTE: Flatness of the bottom of the cylinder head.
Limit: 0.2 mm (0.0079 in)
5. Inspect the water leak using the water pressure tester. SMIL14CEX3120AB 19
Specified pressure: 490 kPa (71 psi)

NOTE: Perform a hydraulic test with the injector holder in-
stalled.
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Valves Seal - Remove


head cover.
breather.
SMIL14CEX3382AB 1

cover (3).
head cover (1).
SMIL14CEX2970AB 2


SMIL14CEX3002AA 3
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SMIL14CEX3003AB 4

assembly.
SMIL14CEX3004AB 5
Lower cover removal

bly.
bly.

SMIL14CEX3009AA 6
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assembly.

SMIL14CEX3010AA 7
Camshaft removal
head assembly.
ing cap.
assembly.
CAUTION: Temporarily assemble the re-

moved caps and bearings in the original position
to avoid a mixup after the bearings have been
inspected. SMIL14CEX3011AA 8
Bridge removal

SMIL14CEX3012AB 9

1. Secure the valve using air.
NOTE: Secure the valve on the closed position by blowing
the compressed air into the cylinder from the glow plug
hole.
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SMIL14CEX3027AA 10

tools (10.101))
SMIL14CEX3052AA 11

bly.
sembly
cylinders.
SMIL14CEX3053AA 12
Valve stem oil seal removal

1. Remove the valve stem oil seal from the valve guide
using the pliers.
CAUTION: Do not reuse the valve stem oil

seal.
2. Remove the valve spring seat from the cylinder head

assembly.
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Valves Seal - Install

1. Install the valve spring seat to the cylinder head assem-
bly.
valve guide.
CAUTION: Use a new valve stem oil seal.

3. Install the valve stem oil seal to the valve guide using
the special tool.
CAUTION:
○ Inspect the valve stem oil seal for deformation

or cracks.
○ Confirm that the garter spring has not come
loose.
SMIL14CEX3048AA 1
Special tool: Valve stem seal setting tool (Refer to

Valve guide - Special tools (10.101))
SMIL14CEX3049AA 2
Valve spring installation

Inlet Blue
Exhaust White

application area towards the cylinder head assembly.
4. Secure the valve using air. SMIL14CEX3051AB 3

hole.
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5. Press the valve spring using the special tool

SMIL14CEX3027AA 4

tools (10.101))
SMIL14CEX3052AA 5
SMIL14CEX3053AA 6

collar.

valve stem groove.
47843027 21/05/2015
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Bridge installation

smoothly.


SMIL14CEX3074AA 7
ing.

SMIL14CEX3075AA 8

sembly.
cial tool.
SMIL14CEX3076AA 9
47843027 21/05/2015
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aligned.
SMIL14CEX3077AB 10


sub gear side.
CAUTION:
SMIL14CEX3078AA 11
cap.
ing.

cap.
assembly.
Tightening torque ： 28 N·m (21 lb ft) Engine oil
application
SMIL14CEX3079AA 12
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SMIL14CEX3080AB 13

bly.
Tightening order
cap
28 N·m (21 lb ft)
cap
SMIL14CEX3081AB 14

CAUTION:

SMIL14CEX3082AA 15
SMIL14CEX3075AA 16
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and bridge cap.
SMIL14CEX3083AA 17
Clearance ： Less than 0.1 mm (0.0039 in) be-
SMIL14CEX3085AA 18
Adjustment table
O O O O O O
　
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SMIL14CEX3084AB 19

area (1).

SMIL14CEX3386AB 20

NOTE: Tightening order.
SMIL14CEX3087AB 21

bly.
SMIL14CEX3094AB 22
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SMIL14CEX3095AB 23

cover (1).
them.
SMIL14CEX2970AB 24
SMIL14CEX3096AB 25

cover.
SMIL14CEX3382AB 26
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Valves Spring - Remove


head cover.
breather.
SMIL14CEX3382AB 1
3. Remove the cylinder head cover from the lower cover

(3).
head cover (1).
SMIL14CEX2970AB 2


SMIL14CEX3002AA 3
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SMIL14CEX3003AB 4

assembly.
SMIL14CEX3004AB 5
Lower cover removal

bly.
bly.

SMIL14CEX3009AA 6
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assembly.

SMIL14CEX3010AA 7
Camshaft removal
head assembly.
ing cap.
assembly.
SMIL14CEX3011AA 8
Bridge removal

SMIL14CEX3012AB 9

hole.
47843027 21/05/2015
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SMIL14CEX3027AA 10

tools (10.101))
SMIL14CEX3052AA 11

bly.
sembly.
cylinders.
SMIL14CEX3053AA 12
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Valves Spring - Install

Inlet Blue
Exhaust White
SMIL14CEX3051AB 1

application area towards the cylinder head assembly.
hole.
SMIL14CEX3027AA 2

tools (10.101))
SMIL14CEX3052AA 3
47843027 21/05/2015
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collar.

valve stem groove.
SMIL14CEX3053AA 4
Bridge installation

smoothly.


SMIL14CEX3074AA 5
SMIL14CEX3075AA 6

ing.

sembly.
47843027 21/05/2015
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cial tool.
Special tool: Scissors gear spring wrench (Refer to
aligned.
SMIL14CEX3076AA 7
SMIL14CEX3077AB 8


sub gear side.
SMIL14CEX3078AA 9
CAUTION:

cap.
ing.

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cap.
assembly.
SMIL14CEX3079AA 10

SMIL14CEX3080AB 11

bly.
Tightening order
SMIL14CEX3081AB 12

Front side camshaft bearing cap
28 N·m (20 lb ft)
Rear side camshaft bearing cap
47843027 21/05/2015
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CAUTION:

SMIL14CEX3082AA 13
SMIL14CEX3075AA 14

and bridge cap.
SMIL14CEX3083AA 15
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SMIL14CEX3085AA 16
Clearance ： Less than 0.1 mm (0.0039 in) be-
Adjustment table
O O O O O O
　

SMIL14CEX3084AB 17

cation area (1).

SMIL14CEX3386AB 18
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SMIL14CEX3087AB 19

bly.
SMIL14CEX3094AB 20



SMIL14CEX3095AB 21
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cover.
them.
SMIL14CEX2970AB 22
SMIL14CEX3096AB 23

cover.
SMIL14CEX3382AB 24

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Valves Spring - Inspect

CAUTION: If a damage or worn is found in
visual inspection, replace the valve spring.
1. Measure the perpendicularity using the right-angle
gauge.
Limit: 3.4 mm (0.1339 in)
SMIL14CEX3411AA 1
2. Measure the free length using the vernier caliper.

Free length of valve spring
Inlet Specified value 59.88 mm (2.3575 in)
Exhaust Specified value 67.00 mm (2.6378 in)
SMIL14CEX3412AA 2
3. Measure the load using a load tester.

NOTE: Compress the valve spring to the specified value
and measure the load.
Valve spring length for installation
Inlet 47.00 mm (1.8504 in)
Exhaust 46.00 mm (1.8110 in)
Load when installing the valve spring

Inlet Specified value 333 N (75 lb)
Exhaust Specified value 383 N (86 lb)
CAUTION: Replace the valve spring if the SMIL14CEX3413AA 3
measured value is under the limit value.
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Index
Engine - 10

Cylinder head - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Cylinder head - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Cylinder head - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Cylinder head - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Cylinder head - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cylinder head - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cylinder heads - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Valve cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Valve cover - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Valve guide - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Valves - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Valves Seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Valves Seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Valves Spring - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Valves Spring - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Valves Spring - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
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Engine - 10
Connecting rods and pistons - 105

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Contents
Engine - 10
TECHNICAL DATA
Piston
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Piston
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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Engine - Connecting rods and pistons
Piston - Special tools

380300022
number
Description Piston setting tool
SMIL14CEX2670AA 1

380300005
number
Description Piston ring setting tool
SMIL14CEX2673AA 2
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Piston - Remove
Coolant drain
CAUTION:

NOTE: If the EGR cooler has an air bleeding plug (1) ,
SMIL14CEX2956AB 1

SMIL14CEX2973AB 2

bly.
Engine oil drain

tightening torque： 70 N·m (52 lb ft)
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Oil pan removal

switch.

2. Remove the O-ring from the oil strainer
SMIL14CEX3134AA 3
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assembly.

assembly.
bocharger assembly.
head assembly.
bocharger assembly.
block.
bocharger assembly.
manifold.

pipe A.
SMIL14CEX2980AB 5
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pipe B.
SMIL14CEX2981AB 6
EGR cooler removal

cooler.
SMIL14CEX2982AB 7
SMIL14CEX2983AB 8

(2).
(3).
bracket A (4).
cooler A.
SMIL14CEX2984AB 9
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A.
SMIL14CEX2985AB 10
(3).
SMIL14CEX2986AB 11
EGR valve removal

(1).
SMIL14CEX2987AB 12

head assembly.
SMIL14CEX2988AB 13
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assembly.
SMIL14CEX2989GB 14
SMIL14CEX2990AB 15
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let pipe.
SMIL14CEX2991AB 16

guide tube (1).
cylinder block.
SMIL14CEX2992AB 17

throttle valve.
2. Lock release
3. Lock
SMIL14CEX2993AB 18
SMIL14CEX2994AB 19
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Inlet pipe removal

(3).
SMIL14CEX2995AB 20
SMIL14CEX2996AB 21
Glow plug removal

SMIL14CEX2997AA 22

bly.
SMIL14CEX2998AA 23
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CAUTION:


SMIL14CEX2999AB 24
7. Fuel pipe
Fuel pipe removal


head.
pump.
feed pipe.
rail assembly.
SMIL14CEX3000AB 25
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sure sensor.
cover.
SMIL14CEX3001AB 26

cover (3).
head cover (1).
SMIL14CEX2970AB 27


SMIL14CEX3002AA 28
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SMIL14CEX3003AB 29

assembly.
SMIL14CEX3004AB 30
Injector removal
special tool.
SMIL14CEX3005AA 31

SMIL14CEX3006AA 32
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1. Sliding hammer
3. Injector
SMIL14CEX3007AB 33
CAUTION:

cial tool.
a mix-up.
nozzle.
SMIL14CEX3008AA 34
Lower cover removal

bly.
bly.

SMIL14CEX3009AA 35
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assembly.

SMIL14CEX3010AA 36
Camshaft removal
head assembly.
ing cap.
assembly.
SMIL14CEX3011AA 37
Bridge removal


SMIL14CEX3012AB 38

block.
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SMIL14CEX3013EB 39

SMIL14CEX3014AB 40

block.

gasket.
Piston removal
using a scraper.
SMIL14CEX3143AA 41
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necting rod.
bottom dead center.
SMIL14CEX3144AA 42

using tags, etc.

jet.
ing rod.
using tags, etc.
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Piston - Install
Piston installation

NOTE: Thoroughly apply engine oil to the ring grooves and
NOTE: Shift each piston ring joint by the specified angle.
6. Apply the engine oil to the cylinder liner in the applica-
tion area (1).
SMIL14CEX3166AB 1

Special tool: piston setting tool (refer to Piston - Spe-
cial tools (10.105))
SMIL14CEX3167AA 2

NOTE: Turn the piston so that the front mark faces the
engine front.
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CAUTION:

installed at top dead center
○ To avoid damaging the piston ring, firmly at-
push it.
cylinder liner.
○ Attach a stopper so that the liner does not pro-
trude.
SMIL14CEX3168AB 3

3. Oil ring joint
4. Front mark
rod bearing cap.

rod.
3. Cylinder number
SMIL14CEX3169AB 4

ing rod.
bolt
CAUTION: Set each cylinder to the bottom

dead center while working.
CAUTION:
○ Do not allow tightening tools to touch the oil jet

○ Confirm that the crankshaft turns smoothly after SMIL14CEX3170AA 5
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Tightening torque: 39 N·m .
Special tool: Angle gauge (Refer to Cylinder heads -
SMIL14CEX3073AA 6

Check the tightening
SMIL14CEX3171AA 7

CAUTION:

head assembly.
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SMIL14CEX3071AA 8


der head gasket.
SMIL14CEX3072AA 9
SMIL14CEX3013EB 10

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SMIL14CEX3073AA 11

Bridge installation
SMIL14CEX3074AA 12

smoothly.


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ing.


sembly.
cial tool.
Special tool: scissors gear spring wrench (Refer to
aligned.
install the camshaft. SMIL14CEX3076AA 14
SMIL14CEX3077AB 15
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sub gear side.
CAUTION:

cap.
SMIL14CEX3078AA 16
ing.


cap.
assembly.

SMIL14CEX3079AA 17

SMIL14CEX3080AB 18
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bly.
Tightening order
Front side
camshaft bear-
ing cap
28 N·m (21 lb ft)
Rear side
SMIL14CEX3081AB 19
camshaft bear-
ing cap
Rocker arm
56 N·m (41 lb ft)
bracket

CAUTION:

SMIL14CEX3082AA 20
SMIL14CEX3075AA 21
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and bridge cap.
SMIL14CEX3083AA 22

SMIL14CEX3085AA 23
Clearance: Less than 0.1 mm (0.0039 in) between
valve and bridge
Adjustment table
No.1 cylinder
compression
top dead center O O O O O O
(O mark is an
adjustable part)
No.6 cylinder O O O O O O
compression
top dead center
(O mark is an
adjustable part)
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NOTE: Apply ThreeBond 1207B
SMIL14CEX3084AB 24

cation area (1).
CAUTION: After applying the liquid gasket (2),

SMIL14CEX3086AB 25

SMIL14CEX3087AB 26
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bly (1).
bly (1).
(1).
(1).
SMIL14CEX3088AB 27
sensor.

der head assembly.

mon rail assembly.
3. Temporarily tighten the fuel leak-off pipe to (1) the fuel

supply pump.

head assembly.
mon rail assembly.
supply pump.
7. Install the clip to the fuel leak-off pipe.
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1. Apply the engine oil to the bolt (2)
assembly.



assembly.

assembly.
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7. Fuel pipe
SMIL14CEX3091AB 30


SMIL14CEX3092AA 31


SMIL14CEX3093AA 32

bly.
SMIL14CEX3094AB 33
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SMIL14CEX3095AB 34

cover (1).
them.
3. Connect the ventilation hose to the air breather.
SMIL14CEX2970AB 35
SMIL14CEX3096AB 36

SMIL14CEX3097AB 37
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SMIL14CEX3098AB 38

1. Install the gasket (2) and the intake throttle valve (1) to
the inlet pipe (3).
SMIL14CEX3099AB 39

valve (1).
2. Lock release
3. Lock
SMIL14CEX2993AB 40

SMIL14CEX2991AB 41
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sembly.
SMIL14CEX2989GB 42

ferent from others.
pipe.
SMIL14CEX3100AB 43
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(3).
SMIL14CEX3101AB 44


gle of the hose.
SMIL14CEX3102AB 45

SMIL14CEX3103AB 46
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manifold (3).
pipe A (2).
SMIL14CEX2986AB 47

EGR cooler A.
EGR cooler B (3).
SMIL14CEX3104AB 48

fold.
SMIL14CEX2983AB 49

A.
cooler B.
bracket C.
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cooler bracket C.
cooler bracket B.
hanger bracket.
SMIL14CEX2985AB 50
SMIL14CEX2982AB 51
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CAUTION:
• Check the EGR gas temperature sensor 2 connector color, and take care not to assemble incorrectly.
• Because the connector color cannot be identified using the outer surface if the exterior is painted, remove the
connector and identify it using the connector interior color.
• If it is difficult to determine the color, remove the connectors of EGR gas temperature sensor 2 and the IMT
sensor, and determine the color using the connector interior color.

IMT Sensor Gray
CAUTION:
• Do not subject the tip of the sensor to impact when installing the EGR gas temperature sensor.
• Do not reuse an EGR gas temperature sensor that has been subjected to impact due to being dropped, etc.

sor 2.
ture sensor 2.
CAUTION:

sor 1.
ture sensor 1.
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block.
der head assembly.
tube (1).
SMIL14CEX3105AB 52

oil.

ifold.
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Clip (2)

assembly.

SMIL14CEX2955AB 53


assembly.


sembly.


sembly.

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Oil strainer installation.


Tightening torque： 24 N·m (18 lb ft) M8 bolt (2)
Tightening torque： 48 N·m (35 lb ft) M10 bolt (1)
SMIL14CEX3182AB 54
Oil pan installation.

1. Apply the liquid gasket to the crankcase. (1)
crankcase (1) , flywheel housing (3) and gear case.
bead width： 3 mm (0.118 in)
bead height： 2 mm (0.079 in)
2. Timing gear case

SMIL14CEX3183AB 55

Tightening torque： 11 N·m (97 lb in) 4 stud bolts


SMIL14CEX3184AB 56
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Engine oil filling

gauge.


Coolant filling
CAUTION:

tem parts.
SMIL14CEX2956AB 57

tering the system.
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8. Stop the engine.
CAUTION:

mouth.


come warm.

form step 12 again.

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CAUTION: Confirm that the engine has cooled

mouth.



to the MAX line.
Fuel air bleed

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Piston - Disassemble
1. Remove the piston ring from the piston using the spe-
cial tool (1).
Special tool: Piston ring setting tool (Refer to Pis-
ton - Special tools (10.105))
SMIL14CEX3362AA 1
NOTE: Organize the removed piston rings according to the

cylinders.
SMIL14CEX3363AB 2
2. Remove the snap ring from the piston.

3. Remove the piston pin (1) from the piston.
SMIL14CEX3364AB 3
4. Remove the connecting rod from the piston.

NOTE: Organize the removed piston rings according to the
cylinders.
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Piston - Assemble
1. Install the snap ring to the piston using the snap ring
pliers.
NOTE: Install the snap ring on only one side.
2. Align the connecting rod assembly to the piston.
NOTE: Turn the direction of the protrusion mark (2) of the
connecting rod and front mark (1) of the piston in the op-
posite direction.
SMIL14CEX3365AB 1
3. Apply the engine oil to the piston pin.

4. Install the piston pin to the piston.
5. Install the snap ring to the piston using the snap ring
pliers.
CAUTION:
○ Confirm that the snap ring is securely installed

in the ring groove.
○ Confirm that the connecting rod moves
smoothly after installing the snap ring.
SMIL14CEX3366AA 2
6. Install the oil ring to the piston.

NOTE: Assemble the coil expander ring on the piston, and
then assemble the oil ring.
CAUTION:
○ Assemble the oil ring joint so that the coil ex-

pander joint is on the direct opposite.
○ Check that there is no gap at the position of
the arrow in the diagram when the oil ring coil
expander is installed.
SMIL14CEX3367AA 3
7. Install the third ring to the piston using the special tool.
NOTE: Make the N mark point upward.
SMIL14CEX3362AA 4
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8. Install the second ring to the piston using the special

tool.
SMIL14CEX3362AA 5
9. Install the top ring to the piston using the special tool.
SMIL14CEX3362AA 6

11. Inspect the piston ring.
NOTE: Confirm that the piston rings rotate smoothly.
1. Top ring
2. Second ring
3. Third ring
4. Oil ring
SMIL14CEX3368AB 7
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Piston - Inspect
Piston ring inspection
CAUTION: Clean the inspection target section
thoroughly before starting inspection.
NOTE: Clearance inspection of the piston ring joint

1. Press the piston ring using the piston.
NOTE: Press the piston ring into the bottom end of the
cylinder block.
SMIL14CEX3369AA 1

Piston ring join
Parts Standard value Limit value
Top ring 0.1800 - 0.2800 mm
(0.0071 - 0.0110 in)
Second 0.35 - 0.50 mm (0.0138
ring - 0.0197 in) 1.2 mm
Third 0.35 - 0.50 mm (0.0138 (0.0472 in)
ring - 0.0197 in)
Oil ring 0.15 - 0.35 mm (0.006 -
0.014 in)
SMIL14CEX3370AA 2
CAUTION: Replace the piston ring if the mea-
3. Measure the clearance using the feeler gauge:
• Measurement of the clearance between the piston
ring groove and the piston ring.
Clearance between the piston ring groove
and the piston ring
Top ring 0.057 - 0.097 mm
(0.0022 - 0.0038 in)
Second 0.085 - 0.120 mm
ring (0.0033 - 0.0047 in) 0.2 mm
Third 0.085 - 0.120 mm (0.0079 in)
ring (0.0033 - 0.0047 in)
SMIL14CEX3371AA 3
Oil ring 0.020 - 0.060 mm
(0.0008 - 0.0024 in)
CAUTION: Replace the piston and the piston

ring if the measured value exceeds the limit value.
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NOTE: Measurement of the tension of the piston ring.

4. Measure the tension using the tension meter.
NOTE: Measure the oil ring with the coil expander ring in-
stalled.
Tension – when the piston ring clearance is secured

Top ring 23 - 31 N (5 - 7 lb) 11.8 N (3 lb)
Second ring 13.7 - 22.6 N (3 - 5 lb) 5.9 N (1 lb)
Third ring 20.8 - 28.2 N (5 - 6 lb) 4.9 N (1 lb)
Oil ring 43 - 58.1 N (10 - 13 lb) 41.2 N (9 lb)
CAUTION: Replace the piston and the piston

ring if the measured value exceeds the limit value.
Piston inspection
CAUTION: Clean the piston before starting
inspection.
1. Inspect the piston.

• Confirm that the piston is not damaged.
• Check if there is a problem which cannot be detected
by visual inspection.
3. Measure the piston using the micrometer.
Measurement position: 82 mm (3.2283 in) From top
surface of the piston
4.5271 in) Diameter
SMIL14CEX3372AA 4
4. Use the cylinder gauge for measure the inner diameter

of the cylinder liner indicated in the diagram to the thrust
direction and radial direction together.
Measurement part: 6 section (s)
1. 20 mm from the top surface of the cylinder block
SMIL14CEX3373AA 5
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5. Calculate the average value from the measured value.

4.5295 in) Diameter
• The difference between the inner diameter of the
cylinder liner and outer diameter of the piston is the
clearance.
0.0063 in) Diameter
CAUTION: Replace the piston or the cylinder

liner if the measured value is above the specified
value.
7. Install the piston pin to the piston.
NOTE: Confirm that there is a certain degree of resistance
so that it can be lightly pushed in when inserting at room
temperature.
CAUTION: If there is looseness, measure the

clearance between the piston pin and piston.
SMIL14CEX3374AA 6
8. Measure the piston pin using the micrometer.

Measurement part: 6 section (s)
Specified value: 40 mm (1.5748 in)
Limit: 39.95 mm (1.5728 in)
CAUTION: Replace the piston pin if the mea-

9. Use the gauge for measure the inner diameter of the

connecting rod bush small end section.
10. Use the gauge for measure the piston pin installation
section. SMIL14CEX3375AA 7

• Clearance between the piston pin and connecting
rod bush
0.0011 in) Diameter
Limit: 0.05 mm (0.0020 in)
• Clearance between the piston and piston pin
0.0007 in) Diameter
Limit: 0.04 mm (0.0016 in)
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Connecting rod assembly inspection

1. Measure the connecting rod assembly using the con-
necting rod aligner.
NOTE: Connecting rod alignment for 100 mm.
Distortion and parallelism
Limit: 0.2 mm (0.0079 in) Distortion and paral-
lelism
CAUTION: Replace the connecting rod as-

sembly if the measured value exceeds the limit
value.
SMIL14CEX3376AA 8

necting rod.
NOTE: Clean the connecting rod bearing and crankshaft.
3. Inspect the connecting rod bearing.
NOTE: Inspect the connecting rod bearing for damage.

inspection, replace the connecting rod bearing.


6. Install the connecting rod bearing to the connecting rod

bearing cap.

rod.
3. Cylinder number
NOTE: The following is the measurement method for the
connecting rod bearing clearance using a plasti-gauge.
SMIL14CEX3169AB 9
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9. Put the plasti-gauge on the crankshaft.
CAUTION: Do not rotate the crankshaft.

ing rod.
SMIL14CEX3377AA 10

SMIL14CEX3073AA 11

necting rod.
SMIL14CEX3171AA 12
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16. Use the gauge for measure the maximum width of the
plasti – gauge.
0.0030 in)
Limit: 0.1 mm (0.0039 in)
CAUTION: Replace the connecting rod bear-

ing if the measured value exceeds the limit value.

connecting rod bearing oil clearance using the measured
difference between the outer diameter of the crankshaft pin
and the inner diameter of the connecting rod. SMIL14CEX3378AA 13

ing rod.
heads - Special tools (10.101) )
SMIL14CEX3073AA 14

heads - Special tools (10.101) )
SMIL14CEX3171AA 15
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22. Use the cylinder gauge for measure the connecting

rod bearing inner diameter at 4 points.
1. Measurement part
2. Measurement part
3. Measurement part
4. Measurement part
SMIL14CEX3379AA 16
23. Use the micrometer for measure the crank pin outer
diameter of the crankshaft at 4 points.
1. Measurement part
2. Measurement part
3. Measurement part
4. Measurement part
NOTE: The difference between the connecting rod bearing
inner diameter and crank pin outer diameter is the connect-
ing rod oil clearance.
SMIL14CEX3380AB 17
0.0030 in)
Limit: 0.1 mm (0.0039 in)
CAUTION: Replace the connecting rod bear-

ing if the measured value exceeds the limit value.
NOTE: Selection of the connecting rod bearing
CAUTION: Select the grade of the connecting

rod bearing when replacing the connecting rod or
connecting rod bearing.
25. Check marking of the connecting rod.
NOTE: Check the large end hole diameter grade marking
on the connecting rod.
3. Cylinder number
SMIL14CEX3169AB 18
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26. Select the connecting rod bearing.

Large end
hole diameter Bearing
grade of the identification oil clearance
connecting color (1)
rod
A Green 0.0370 -
0.0760 mm
B Yellow (0.0015 -
0.0030 in)
SMIL14CEX3381AB 19
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Index
Engine - 10

Piston - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Piston - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Piston - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Piston - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Piston - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Piston - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - 10
Crankshaft and flywheel - 103

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Contents
Engine - 10
TECHNICAL DATA
Crankshaft
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Engine flywheel
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Crankshaft oil seal
Front seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Front seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Rear seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Crankshaft
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
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Engine - Crankshaft and flywheel
Crankshaft - Special tools

CASE CON-
Isuzu reference STRUCTION tool Description
number
5-8840-2360-0 380002574 Slinger puller
SMIL14CEX2694AA 1
CASE CON-
number
Oil seal setting
8-9439-6856-0 380001712
tool kit
SMIL14CEX3203AA 2
CASE CON-
number
5-8840-9061-0 380002611 Oil seal installer
SMIL14CEX2695AA 3
Item Isuzu reference Description

1 5–8840–2709–0 Adapter
Adapter
2 5–8840–2714–0
tightening bolts
3 5–8840–2713–0 Center bolt
4 5–8840–9063–0 Sleeve
5 5–8840–2710–0 Collar
6 5–8840–2711–0 Adapter ring
Crankshaft rear
7 —
oil seal
SMIL14CEX2696AA 4
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Code ISUZU reference Description

1 – Slinger
2 8-9439-6857-0 Adapter
Center boltAdapter
3 8-9702-0656-0
tightening bolt
4 8-9702-0623-0 Sleeve
5 8-9702-0655-0 Center bolt
SMIL14CEX3204AB 5
CASE CON-
number
Crankshaft gear
8-9439-6818-0 Common tool
puller
SMIL14CEX2697AA 6
CASE CON-
number
Crankshaft gear
8-9439-6819-0 380002613
installer
SMIL14CEX2698AA 7
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Engine flywheel - Remove


ing.
SMIL14CEX3130AA 1
CKP sensor removal

sor (1).
2. Remove the CKP sensor from the flywheel housing (2).

sor to shock.
SMIL14CEX3131AB 2
Flywheel removal

not rotate.
SMIL14CEX3132AB 3
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Ring gear removal

1. Inspect the ring gear.
NOTE: If no damage has been found in the inspection, do
not remove the ring gear.
2. Remove the ring gear from the flywheel.
NOTE: Attach a rod to the edge of the ring gear and remove
it by tapping evenly.
CAUTION: To prevent damaging, place

pieces of wood under the flywheel.
SMIL14CEX3393AA 4
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Engine flywheel - Install

Ring gear installation
1. Heat the ring gear with the gas burner.
NOTE: Evenly heat the inside of the ring gear.
Heating temperature: less than 200 °C (392 °F)
2. Install the ring gear to the flywheel.
CAUTION:
○ Turn the ring gear so that the chamfered surface

faces the flywheel and install.
○ After shrink-fitting, check that the ring gear is
airtight against the flywheel.
SMIL14CEX3394AA 1

SMIL14CEX3191AB 2

SMIL14CEX3073AA 3

tightening
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sor to shock.

SMIL14CEX3131AB 4

SMIL14CEX3130AA 5

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Engine flywheel - Inspect

1. Inspect the flywheel.
NOTE: Inspect the flywheel friction surface for damage
such as cracks.
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Crankshaft oil seal Front seal - Remove

Cooling fan removal
SMIL14CEX3395AB 1
Fan guide removal

1. Bolt
2. Washer
3. Rubber mount
4. Rubber mount
5. Guide tube
bly.
SMIL14CEX3122AB 2

1. Adjust bolt
2. Fixing bolt
3. Fixing bolt
SMIL14CEX3123AB 3

pulley.
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gear case.

1. Felt
2. Slinger
SMIL14CEX3124AB 4

cial tool.

place the slinger.
SMIL14CEX3125AA 5
SMIL14CEX3126AA 6
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Crankshaft oil seal Front seal - Install

SMIL14CEX3203AA 1

Name Part number
1 Slinger -
2 Adapter 8-9439-6857-0
4 Sleeve 8-9702-0623-0
5 Center bolt 8-9702-0655-0
SMIL14CEX3204AB 2

the front slinger.

SMIL14CEX3205AB 3
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adapter.
SMIL14CEX3206AA 4
7. Inspect the slinger (2).

head and the slinger.
Specified value ： 17.7 - 18.3 mm (0.6969 -
0.7205 in)
SMIL14CEX3207AB 5

cluded in the kit.
Name Part number
1 Adapter 8-9439-6857-0
2 Oil seal -
4 Sleeve 8-9702-0625-1
5 Center bolt 8-9702-0655-0
SMIL14CEX3204AB 6

oil seal.
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adapter.
SMIL14CEX3396AA 7

head and the crankshaft front oil seal (3).
0.3406 in)
2. Timing gear case
SMIL14CEX3208AB 8

SMIL14CEX3209AA 9
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SMIL14CEX3210AB 10


Standard： 98 N (22 lb)
Pulley
Cooling fan belt Amount of flex
ratio
Type 1: Triple 6.0 - 8.0 mm
integrated belt 0.80
(0.236 - 0.315 in)
integrated belt 0.85
(0.236 - 0.315 in)
SMIL14CEX3211AB 11
2. Generator
3. Fan pulley
the adjust bolt (1).
NOTE: Loosen adjust-plate-side nut (2) and bracket-side
(2) and bracket-side bolt (3) to the specified torque.
just-plate-side nut (2)
side bolt (3)
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just-plate-side nut
just-plate-side nut
1. Bolt
2. Washer
3. Rubber mount
4. Rubber mount SMIL14CEX3122AB 13
5. Guide tube

just-plate-side nut
SMIL14CEX3121AB 14
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Crankshaft oil seal Rear seal - Remove


ing.
SMIL14CEX3130AA 1
CKP sensor removal

sor (1).
(2).

sor to shock.
SMIL14CEX3131AB 2
Flywheel removal

not rotate.
SMIL14CEX3132AB 3
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SMIL14CEX3397AA 4
1. Felt
2. Slinger
SMIL14CEX3398AB 5


If the slinger of the remover is easy to come off, the outer
circumference of the jig can be tightened using a clip band
to improve the workability.
SMIL14CEX3133AA 6
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Crankshaft oil seal Rear seal - Install

Special tool: Oil seal installer kit (Refer to Crank-
shaft - Special tools (10.103))
SMIL14CEX3185AA 1

cluded in the kit.
Name Part number
1 Adapter 5-8840-2709-0
2 Adapter tightening bolt 8840-2714-0
3 Center bolt 8840-2713-0
4 Sleeve 8840-9063-0
5 Collar 8840-2710-0
6 Adapter ring 8840-2711-0
SMIL14CEX3186AB 2

oil seal.
3. Install the crankshaft rear oil seal to the adapter (3).
1. Collar
SMIL14CEX3187AB 3
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5. Install the adapter ring (2) to the sleeve.

SMIL14CEX3188AB 4

adapter.
SMIL14CEX3189AA 5

and the crankshaft rear oil seal (2).
1. Flywheel housing
4. Crankshaft
SMIL14CEX3190AB 6

SMIL14CEX3191AB 7
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Tightening angle: 60 ° SMIL14CEX3073AA 8

tightening


sor to shock.

SMIL14CEX3131AB 9

SMIL14CEX3130AA 10

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Crankshaft - Remove
Battery ground
Coolant drain
CAUTION:


SMIL14CEX2956AB 1
SMIL14CEX2973AB 2
Engine oil drain


bly.
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Cooling fan removal

SMIL14CEX3121AB 3
Fan guide removal

1. Bolt
2. Washer
3. Rubber mount
4. Rubber mount
5. Guide tube
6. Fan guide
SMIL14CEX3122AB 4

bly.

1. Adjust bolt
2. Fixing bolt
3. Fixing bolt
SMIL14CEX3123AB 5

pulley.
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gear case.

seal press-fitting surface of the timing gear case.
1. Felt
2. Slinger
SMIL14CEX3124AB 6

cial tool.
Special tools (10.103) )
SMIL14CEX3125AA 7

place the slinger.
SMIL14CEX3126AA 8
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SMIL14CEX3127AA 9

SMIL14CEX3128AB 10

Front cover removal

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assembly.

assembly.
bocharger assembly.
head assembly.
bocharger assembly.
block.
bocharger assembly.
manifold.

pipe A.
SMIL14CEX2980AB 12
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pipe B.
SMIL14CEX2981AB 13
EGR cooler removal

cooler.
SMIL14CEX2982AB 14
SMIL14CEX3247AB 15

(2).
(3).
bracket A (4).
cooler A.
SMIL14CEX2984AB 16
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A.
SMIL14CEX2985AB 17
(3).
SMIL14CEX2986AB 18
EGR valve removal

(1).
SMIL14CEX2987AB 19

head assembly.
SMIL14CEX2988AB 20
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assembly.
SMIL14CEX2989GB 21

let pipe.
SMIL14CEX3353AB 22
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guide tube (1).
cylinder block.
SMIL14CEX2992AB 23

throttle valve.
2. Lock release
3. Lock
SMIL14CEX2993AB 24
3. Remove the intake throttle valve (1) and the gasket (2),
SMIL14CEX2994AB 25
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Inlet pipe removal

(3).
SMIL14CEX2995AB 26
SMIL14CEX2996AB 27
Glow plug removal

SMIL14CEX2997AA 28

bly.
SMIL14CEX2998AA 29
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7. Fuel pipe
common rail assembly. SMIL14CEX2999AB 30
CAUTION:

Fuel pipe removal


head.
2. Remove the fuel leak-off pipe (1)from the fuel supply
pump.
feed pipe.
rail assembly.
SMIL14CEX3000AB 31
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sure sensor.
cover.
SMIL14CEX3001AB 32

cover (3).
head cover.
SMIL14CEX2970AB 33


SMIL14CEX3002AA 34
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SMIL14CEX3003AB 35

assembly.
SMIL14CEX3004AB 36
Injector removal
special tool.
SMIL14CEX3005AA 37

SMIL14CEX3006AA 38
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1. Sliding hammer
3. Injector
SMIL14CEX3007AB 39
CAUTION:

cial tool.
a mix-up.
nozzle.
SMIL14CEX3008AA 40
Lower cover removal

bly.
bly.

SMIL14CEX3009AA 41
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assembly.

SMIL14CEX3010AA 42
Camshaft removal
head assembly.
ing cap.
assembly.
ings in the original position to avoid a mix-up after the bear-
SMIL14CEX3011AA 43
Bridge removal


SMIL14CEX3012AB 44

block.
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SMIL14CEX3013EB 45


block.

gasket.
SMIL14CEX3014AB 46

pump.
1. Fuel supply pump
2. Bracket
3. Gear
4. Nut
5. Bolt
6. O-ring
7. O-ring
8. Nut
SMIL14CEX3129AB 47
9. Bolt
10. Nut
2. Remove the fuel supply pump from the cylinder block.
NOTE: Remove together with the bracket.
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ing.
SMIL14CEX3130AA 48
CKP sensor removal

sor (1).
(2).

sor to shock.
SMIL14CEX3131AB 49
Flywheel removal

not rotate.
SMIL14CEX3132AB 50
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SMIL14CEX3125AA 51
1. Felt
2. Slinger

SMIL14CEX3124AB 52
SMIL14CEX3133AA 53
Oil pan removal

switch.
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2. Remove the O-ring from the oil strainer.
SMIL14CEX3134AA 54

the oil port cover.
SMIL14CEX3135AB 55
wheel housing.
SMIL14CEX3136AB 56

and the crankcase.

SMIL14CEX3137AB 57
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measured.

0.0067 in)
Limit: 0.30 mm (0.0118 in) SMIL14CEX3138AA 58

the thrust collar.

B.
0.0061 in)
Limit: 0.20 mm (0.0079 in)

sured value exceeds the limit value. SMIL14CEX3139AA 59
Idle gear A removal

SMIL14CEX3140AA 60
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SMIL14CEX3141AA 61
Idle gear B removal

SMIL14CEX3142AA 62
Piston removal
using a scraper.
SMIL14CEX3143AA 63
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necting rod.
bottom dead center.
SMIL14CEX3144AA 64

using tags, etc.

jet.
ing rod.
using tags, etc.
Crankshaft removal
NOTE: Measure the crankshaft clearance in the axis direc-
tion at the bearing section no.7.
Specified value ： 0.104 - 0.205 mm (0.0041 - 0.0081 in)
CAUTION: Replace the thrust bearing if the

measured value is not within the range of the spec-
ified value.
SMIL14CEX3145AA 65
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NOTE: Loosening order
SMIL14CEX3146AB 66
NOTE: Using the 4 replacer holes (1), remove the

crankcase.
SMIL14CEX3147AB 67
3. Remove the thrust bearing from the crankcase.

4. Remove the crankshaft bearing from the crankcase.
5. Remove the crankshaft from the cylinder block.
6. Remove the thrust bearing from the cylinder block.
7. Remove the crankshaft bearing from the cylinder block.
SMIL14CEX3148AA 68
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Crankshaft - Install
Crankshaft bearing preparation
CAUTION: When replacing the crankshaft
bearing, select the crankshaft bearing following
the procedure below.
1. Check marking of the crankcase.
NOTE: The marking on the crankcase indicates the inner
diameter grade of the cylinder block journal section.
side.
SMIL14CEX3158AA 1
NOTE: Check the marking on the crankshaft.

The marking on the crankshaft indicates the outer diameter
grade of the journal section.
side.
SMIL14CEX3159AA 2
2. Select the crankshaft bearing.

NOTE: Refer to the bearing selection table.

Grade combination Oil clearance
Cylinder Crank Bearing
block journal identification No.1, 2, 3, 5, 6, 7 No.4
grade grade color
0.065 - 0.092 mm (0.0026 - 0.095 - 0.122 mm (0.0037 -
1 1 Black
0.0036 in) 0.0048 in)
0.063 - 0.089 mm (0.0025 - 0.093 - 0.119 mm (0.0037 -
1 2 Brown
0.0035 in) 0.0047 in)
0.067 - 0.094 mm (0.0026 - 0.097 - 0.124 mm (0.0038 -
2 1 Blue
0.0037 in) 0.0049 in)
0.065 - 0.091 mm (0.0026 - 0.095 - 0.121 mm (0.0037 -
2 2 Black
0.0036 in) 0.0048 in)
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CAUTION: Be careful not to mistake the bear-

ing shape when installing the crankshaft bearing.
1. Upper bearing
2. Oil hole
4. Oil groove
5. Lower bearing
SMIL14CEX3160AB 3
Crankshaft installation
NOTE: Install a bearing with an oil hole on the cylinder
block.
CAUTION: Make sure there is no grime or

oil on the cylinder block contact surface for the
crankshaft bearing.
the oil groove faces the engine front.
SMIL14CEX3161AA 4

5. Apply the engine oil to the crankshaft.
6. Put the crankshaft on the cylinder block.
SMIL14CEX3162AA 5
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CAUTION: Make sure there is no grime or oil

on the crankcase contact surface for the crank-
shaft bearing.

10. Install the thrust bearing to the crankcase.
the oil groove faces the engine rear. SMIL14CEX3163AA 6

Bead width: 3 - 4 mm (0.118 - 0.157 in)
Bead height: 3 - 4 mm (0.118 - 0.157 in)
NOTE: Apply ThreeBond 1207B to the crankcase thor-
oughly so that there is no break in application of the bead.

install the crankcase within 5 min.
SMIL14CEX3164AA 7
13. Put the crankcase on the cylinder block.
CAUTION: Be careful not to let the thrust bear-

ing fall.
SMIL14CEX3165AA 8

CAUTION: Do not apply grease to the M10

bolt.
SMIL14CEX3250AB 9
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Tightening angle: 30 ° M14 bolt
Tightening torque: 37 N·m (27 lb ft) M10 bolt SMIL14CEX3073AA 10

tightening M14 bolt
CAUTION: Confirm that the crankshaft turns

smoothly after tightening the bolts.
Piston installation

NOTE: Thoroughly apply engine oil to the ring grooves and
NOTE: Shift each piston ring joint by the specified angle.
6. Apply the engine oil, in the application area (1), to the
cylinder liner.
SMIL14CEX3166AB 11
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Special tool: Piston setting tool (Refer to Piston -
Special tools (10.105) )
SMIL14CEX3167AA 12

NOTE: Turn the piston so that the front mark faces the
engine front.
3. Oil ring joint
4. Front mark
CAUTION:

installed at top dead center.
○ To avoid damaging the piston ring, firmly at- SMIL14CEX3168AB 13

push it.
cylinder liner.
○ Attach a stopper so that the liner does not pro-
trude.
rod bearing cap.

rod.
3. Cylinder number
SMIL14CEX3169AB 14
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ing rod.
bolt.
CAUTION:
○ Set each cylinder to the bottom dead center

while working.
○ Do not allow tightening tools to touch the oil jet.
○ Confirm that the crankshaft turns smoothly after
SMIL14CEX3170AA 15

SMIL14CEX3073AA 16

Check the tightening
SMIL14CEX3171AA 17


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area.

SMIL14CEX3172AA 18

to the oil pump.
CAUTION:

uid gasket.
SMIL14CEX3173AA 19

SMIL14CEX3174AA 20

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SMIL14CEX3175AB 21

1. Camshaft gear
3. Idle gear B
5. PTO gear
6. PTO idle gear
7. Crank gear
8. Oil pump gear
9. Supply pump gear
10. Idle gear A
11. Idle gear C
SMIL14CEX3176BB 22

stallation area.
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CAUTION:

the diagram.

SMIL14CEX3177AB 23

Tightening torque
No.1 bolt : 96 N·m (71 lb ft)
SMIL14CEX3178BB 24



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NOTE: Assemble the thrust collar to the mounting bolt and
1. 30 °
2. Paint portion
3. Notch
5. Thrust collar
SMIL14CEX3179AB 25
1. Thrust collar
2. Washer
3. PTO idle gear
5. Oil groove
CAUTION:

facing toward the gear side.
oil lubrication and make sure to install the thrust SMIL14CEX3180AB 26

12. Install the cover to the flywheel housing.
SMIL14CEX3181AB 27
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13. Install the oil pipe (1) to the pipe bracket (2) and the
oil port cover.
side
side
the cylinder block.
housing side
SMIL14CEX3135AB 28
block side
Oil strainer installation


Tightening torque: 24 N·m (18 lb ft) M8 bolt (2)
Tightening torque: 48 N·m (35 lb ft) M10 bolt (1)
SMIL14CEX3182AB 29

crankcase, flywheel housing and gear case.
1. Crankcase
2. Timing gear case
3. Flywheel housing

install the oil pan within 5 min. SMIL14CEX3183AB 30
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Tightening torque: 11 N·m (97 lb in) 4 stud bolts


SMIL14CEX3184AB 31

1. Special tool: Oil seal installer kit (Refer to Crank-
shaft - Special tools (10.103)).
SMIL14CEX3185AA 32
Name Part number

1 Adapter 5-8840-2709-0
3 Center bolt 5-8840-2713-0
4 Sleeve 5-8840-9063-0
5 Collar 5-8840-2710-0
6 Adapter ring 5-8840-2711-0

cluded in the kit.
SMIL14CEX3186AB 33

3. Install the crankshaft rear oil seal to the adapter (3).
1. Collar
SMIL14CEX3187AB 34
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SMIL14CEX3188AB 35

adapter.
SMIL14CEX3189AA 36

and the crankshaft rear oil seal (2).
1. Flywheel housing
4. Crankshaft
SMIL14CEX3190AB 37
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SMIL14CEX3191AB 38

SMIL14CEX3073AA 39
tightening


sor to shock.
SMIL14CEX3131AB 40
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SMIL14CEX3130AA 41

SMIL14CEX3193AB 42

2. Supply pump gear
SMIL14CEX3194AB 43
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4. Install the fuel supply pump to the cylinder block.

1. Fuel supply pump
2. Bracket
3. Gear
4. Nut
5. Bolt
SMIL14CEX3195AB 44
6. O-ring
7. O-ring
8. Nut
9. Bolt
10. Nut
pump.

CAUTION:

head assembly.
Bead width: 3.0 mm (0.1181 in)
Bead height: 2.0 mm (0.0787 in)


SMIL14CEX3196AA 45
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1 to 26 in the diagram indicate the M14 bolts.

der head gasket.
SMIL14CEX3197AA 46
SMIL14CEX3198EB 47

Special tool: angle gauge (Refer to Cylinder

tightening M14 bolt

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1. Bead width: 1.5 - 5.0 mm (0.0591 - 0.1969 in)

2. Bead height: 0.3 - 1.5 mm (0.0118 - 0.0591 in)

SMIL14CEX3199AB 49

Tightening torque: 13 N·m (115 lb in) Stud bolt (2)
1. Location to tighten together with the adjust plate
SMIL14CEX3200AB 50

Tightening torque: 39 N·m (28.8 lb ft) Nut (1)
SMIL14CEX3201AB 51
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SMIL14CEX3100AB 52

SMIL14CEX3202AA 53

SMIL14CEX3203AA 54
Name Part number

1 Slinger -
2 Adapter 8-9439-6857-0
4 Sleeve 8-9702-0623-0
5 Center bolt 8-9702-0655-0

SMIL14CEX3204AB 55
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the front slinger.

SMIL14CEX3205AB 56

adapter.
SMIL14CEX3206AA 57
7. Inspect the slinger (2).

0.7205 in)
and the slinger (2).
3. Crankshaft
SMIL14CEX3207AB 58
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cluded in the kit.
Legend Part number
1 Adapter 8-9439-6857-0
2 Oil seal -
4 Sleeve 8-9702-0625-1
5 Center bolt 8-9702-0655-0 SMIL14CEX3204AB 59

oil seal.

adapter.
SMIL14CEX3206AA 60
14. Inspect the crankshaft front oil seal (3).

0.3406 in)
(4) and the crankshaft front oil seal (3).
2. Timing gear case
SMIL14CEX3208AB 61

SMIL14CEX3209AA 62
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SMIL14CEX3210AB 63
Bridge installation

smoothly.

ing.


sembly.
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cial tool.
aligned.
SMIL14CEX3076AA 65
SMIL14CEX3077AB 66


sub gear side.
SMIL14CEX3078AA 67
CAUTION:

cap.
ing.

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cap.
assembly.
SMIL14CEX3079AA 68

SMIL14CEX3080AB 69

bly.
Tightening order.
Front side camshaft bear-
ing cap
28 N·m (21 lb ft)
cap
SMIL14CEX3081AB 70
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NOTE: Valve clearance adjustment.
CAUTION:

SMIL14CEX3082AA 71
SMIL14CEX3075AA 72

and bridge cap.
SMIL14CEX3083AA 73
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valve and bridge
NOTE: With the thickness gauge inserted, lightly tighten
the adjust screw of the bridge.
Confirm that the leading end of the adjust screw and valve
shaft end have made contact and the movement of the
thickness gauge has become stiff.
Check if the valve shaft end on the opposite side is floating
or touching at an angle.
If it is floating or touching at an angle, slightly loosen the
SMIL14CEX3085AA 74
bridge adjust screw and adjust the valve shaft ends on both
sides to touch properly.
To prevent turning, fix the bridge adjust screw with a flat-
head screwdriver, and tighten the adjust screw nut.
Adjustment table
O O O O O O
　

SMIL14CEX3084AB 75

cation area (1).

SMIL14CEX3086AB 76
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SMIL14CEX3087AB 77

bly (1).
bly (1).
(1).
(1).

sensor.
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der head assembly.

mon rail assembly.

supply pump.

head assembly.
mon rail assembly.
supply pump.

assembly.

SMIL14CEX3090AB 80
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rail assembly.
sembly.

assembly.
7. Fuel pipe
SMIL14CEX3091AB 81


SMIL14CEX3092AA 82
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SMIL14CEX3093AA 83

bly.
SMIL14CEX3094AB 84



SMIL14CEX3095AB 85

cover (1).
SMIL14CEX2970AB 86
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them
SMIL14CEX3096AB 87

cover.
SMIL14CEX2969AB 88

SMIL14CEX3097AB 89

SMIL14CEX2995AB 90
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the inlet pipe (3).
SMIL14CEX2994AB 91
2. Install the air duct to the intake throttle valve.

valve.
2. Lock release
3. Lock
SMIL14CEX2993AB 92

SMIL14CEX3100AB 93
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sembly.
SMIL14CEX2989GB 94

pipe.
ferent from others.
SMIL14CEX3100AB 95
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gle of the hose.
SMIL14CEX3102AB 96

SMIL14CEX3103AB 97

manifold (3).
pipe A (2).
SMIL14CEX2986AB 98
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EGR cooler A.
EGR cooler B (3).
cooler bracket C (2) .
SMIL14CEX3104AB 99

SMIL14CEX3247AB 100

fold.
A.
cooler B.
bracket C.
cooler bracket C.
cooler bracket B.
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hanger bracket.
SMIL14CEX2985AB 101
SMIL14CEX2982AB 102
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CAUTION:

correctly.

EGR gas temperature sen-
Light gray
sor 2
IMT sensor Gray
CAUTION:

sor.
dropped, etc.
sor 2.
ture sensor 2.

CAUTION:

sor.
dropped, etc.
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sor 1.
ture sensor 1.

block.
der head assembly.
tube (1).
SMIL14CEX3105AB 103
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oil.


ifold.
Tightening torque: 52 N·m (38 lb ft) SMIL14CEX2954AB 104


assembly.


assembly.


sembly.

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sembly.



2. Generator
3. Fan pulley
Cooling fan Pulley ratio Amount of flex
belt
Type 1: Triple 0.80 6.0 - 8.0 mm SMIL14CEX3211AB 105
integrated belt (0.236 -
0.315 in)
Type 2: Triple 0.85 6.0 - 8.0 mm
integrated belt (0.236 -
0.315 in)
2. Adjust the cooling ban belt to the specified value using
Tightening torque: 127 N·m (93.7 lb ft) Bracket-
side bolt (3)
NOTE: After adjustment, tighten the adjust-plate-side nut SMIL14CEX3123AB 106
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1. Bolt
2. Washer
3. Rubber mount
4. Rubber mount
5. Guide tube
SMIL14CEX3122AB 107

SMIL14CEX3121AB 108

Engine oil filling

gauge.

Coolant filling
CAUTION:

tem parts.
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SMIL14CEX2956AB 109

tering the system.



8. Stop the engine.
CAUTION:

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mouth.


come warm.

form step 12 again.


cooled.
mouth.



to the MAX line.

Fuel air bleed

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Crankshaft - Disassemble
1. Remove the crank gear from the crankshaft using the
special tool.
Special tool: Crankshaft gear puller (Refer to
SMIL14CEX3251AB 1
SMIL14CEX3252AA 2
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Crankshaft - Assemble
1. Heat the crank gear with the oil heater.
Heating temperature: 170 - 180 °C (338 - 356 °F)
2. Install the crank gear to the crankshaft using the special
tool.
Special tool: Crankshaft gear installer (Refer to
NOTE: Turn the crank gear so that the alignment mark
faces outward and install.
SMIL14CEX3253AA 1
SMIL14CEX3254AA 2
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Crankshaft - Inspect
1. Inspect the crankshaft.
CAUTION: Replace the crankshaft if damage

such as a crack has been found in the inspection.
2. Put the crankshaft on V-block.

NOTE: Hold the No.1 and No.7 journal sections.
3. Prepare the dial gauge.
4. Turn the crankshaft.
• 1 rotations
SMIL14CEX3255AA 1
CAUTION: Rotate the crankshaft slowly.
5. Measure the fluctuation using the dial gauge.
Specified value: less than 0.06 mm {less than
0.0024 in} or less
Limit: 0.45 mm { 0.0177 in}
CAUTION: Replace the crankshaft if the mea-

SMIL14CEX3256AA 2
6. Measure the crankshaft using the micrometer.

Outer diameter of the crankshaft journal
3.2233 in) No. 4 journal
3.2244 in) No. 4 journal
Outer diameter of the crankshaft pin
3.1493 in)
SMIL14CEX3257AA 3
CAUTION: Clean the crankshaft bearing and

the bearing installation surface.
crankshaft bearing oil clearance using the measured differ-
ence between the outer diameter of the crankshaft journal
and the inner diameter of the crankshaft bearing.
CAUTION: Clean the crankshaft bearing and

the bearing installation surface.
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9. Install the crankcase to the cylinder block.


bolt.

SMIL14CEX3258AB 4
SMIL14CEX3073AA 5
15. Measure the inner diameter using the cylinder gauge.

NOTE: Measure the inner diameter when the crankshaft
bearing is installed.
NOTE: The difference between the outer diameter of
crankshaft journal and the inner diameter of the crankshaft
bearing is the oil clearance.
Crankshaft bearing oil clearance
0.093 -
0.124 mm
Specified value
No. 4 journal (0.0037 -
SMIL14CEX3259AA 6
section 0.0049 in)
0.14 mm
Limit value
(0.0055 in)
0.063 -
0.094 mm
Other than No. Specified value (0.0025 -
4 journal sec- 0.0037 in)
tion
0.14 mm
Limit value
(0.0055 in)
crankshaft bearing clearance using a plasti-gauge.
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17. Put the plasti-gauge on the crankshaft.
CAUTION: Do not rotate the crankshaft.
SMIL14CEX3260AA 7
18. Install the crankcase to the cylinder block.

Tightening order

bolt.
SMIL14CEX3258AB 8


25. Measure the plasti-gauge using the gauge.
NOTE: Measure the maximum width of the plasti-gauge.
Crankshaft bearing oil clearance
0.093 -
0.124 mm
Specified value
No. 4 journal (0.0037 -
section 0.0049 in)
0.14 mm
Limit value
(0.0055 in)
0.063 -
0.094 mm SMIL14CEX3261AA 10
Other than No. Specified value (0.0025 -
4 journal sec- 0.0037 in)
tion
0.14 mm
Limit value
(0.0055 in)
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NOTE: The following is the inspection method for the

TUFFTRIDE layer on the crankshaft.
WARNING: If the inspection solution for the

TUFFTRIDE layer inspection gets into your eyes,
wash them immediately with large volumes of
clear water and seek medical treatment.
CAUTION: The inspection solution is highly

corrosive, so when the inspection is finished, im-
mediately wipe it away and clean with water or
steam.
26. Clean the crankshaft using the organic solvent. Clean
the crankshaft using the organic solvent.
27. Prepare the inspection solution.
Provision concentration: 5 - 10 %
NOTE: Dilute copper chloride ammonium solution to the
specified concentration with distilled water and make in-
spection solution.
28. Inspect the crankshaft using the inspection solution.
NOTE: Drop inspection solution on the crankshaft using a
dropper.
Wait time for results: 40 s
1. Drip prohibited area
2. Inspection solution application area
3. Pin or journal sliding surface
CAUTION: Replace the crankshaft if the color

of the inspection solution application area has
changed to bronze after the specified time has SMIL14CEX3262AB 11
passed.
29. Inspect the crank gear.
NOTE: Inspect the crank gear for tooth contact, peeling
and wear.
SMIL14CEX3263AA 12
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30. Inspect the crankshaft damper.

NOTE: Inspect the crankshaft damper for cracks and peel-
ing.
CAUTION:
○ Make sure to replace the crankshaft damper

if any abnormality has been found otherwise
cracking may occur.
○ Inspect the bolts for the crankshaft and flywheel
if any abnormality has been found in the crank-
shaft damper.
SMIL14CEX3264AA 13
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Index
Engine - 10

Crankshaft - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Crankshaft - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Crankshaft - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Crankshaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Crankshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Crankshaft - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Crankshaft oil seal Front seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Crankshaft oil seal Front seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Crankshaft oil seal Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Crankshaft oil seal Rear seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Engine flywheel - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Engine flywheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine flywheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Engine - 10
Fuel tanks - 216

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Contents
Engine - 10
Fuel tanks - 216
SERVICE
Fuel tank
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fuel cooler
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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Engine - Fuel tanks
Fuel tank - Prepare

WARNING
Chemical hazard!
When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.
Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect
fluids in proper containers. Obey all local and environmental regulations when disposing of chemi-
cals.
W0371A
WARNING
Avoid injury!
W1128A
WARNING
Escaping fluid!
doctor immediately.
W0178A
WARNING
Crushing hazard!
latches.
W0256A
WARNING
Heavy objects!
W0398A
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Engine - Fuel tanks
Items to prepare:
• Wrenches [ 19 mm, 24 mm]
• Eyebolts ( M12 x 4)
• Cap
• Plug
• Drum can (for draining fuel)
• Rag
• Cleaning fluid
• Wood planks, etc.
• Marking pen
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Engine - Fuel tanks
Fuel tank - Remove

1. Remove the cap (1) and the filter (2).
SMIL14CEX1007AB 1
2. Drain all fuel inside the fuel tank to a drum can or other
container.
SMIL14CEX1008AA 2
3. Remove the 6 bolts (1) to remove the cover (2).
SMIL14CEX1009AB 3
4. Remove the 4 bolts (1) to remove the stay (2).

Remove the 2 bolts (3).
SMIL14CEX1010AB 4
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Engine - Fuel tanks
SMIL14CEX1011AB 5
6. Remove the 2 bolts (1) to remove the 2 connectors (2).
SMIL14CEX1012AB 6
SMIL14CEX1013AB 7
8. Remove the bolt (1) and the 2 nuts (2) to remove the
stay (3).
SMIL14CEX1014AB 8
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Engine - Fuel tanks
9. Loosen the 3 hose bands (1) to disconnect the 3 hoses

(2).
Disconnect the connector (3).
• Apply marking at each location of the fuel tank and
the hose so as to match connections at assembling.
• Attach caps and plugs at each location of the fuel
tank and hose so as to prevent invasion of water,
dust and dirt.
SMIL14CEX1015AB 9
SMIL14CEX1016AB 10
11. Loosen the hose band (1) to disconnect the hose (2).
Remove the 2 hose clamps (3).
• Apply marking at each location of the fuel tank and
the hose so as to match connections at assembling.
tank and hose so as to prevent invasion of water,
dust and dirt.
SMIL14CEX1017AB 11
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Engine - Fuel tanks
12. Remove the 6 bolts (1) and the 6 spacers (2) at bottom
of the fuel tank with a wrench [ 24 mm].
• Do not lose a shim which may be inserted between
the reservoir and the frame in order to adjust height
depending on system.
• Also, note inserted section and quantity.
• Bolt tightening torque: 234.4 - 276.0 N·m (172.9 -
203.6 lb ft)
SMIL14CEX1018BB 12
13. Remove the 2 bolts (1) at bottom of the side cover.
SMIL14CEX1019AB 13
14. Remove the 3 bolts (1) to remove the side cover (2).
SMIL14CEX1020AB 14
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Engine - Fuel tanks
15. Attach the 2 eyebolts ( M12) (1) on top of the fuel tank.
• Tighten up the eyebolt all the way and then loosen it
for a half turn.
SMIL14CEX1021BB 15
16. Attach the 2 shackles (1) to the eyebolt and then lift it
with a wire rope (2) and a lifting equipment.
Make sure that you have a safe site, and then settle the
fuel tank on a wood plank or other block.
Make sure to secure the fuel tank so as to prevent it
from falling.
SMIL14CEX1022BB 16
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Engine - Fuel tanks
Fuel tank - Install

To install, perform the reverse of the removal proce-
dure.
When installing the bolts, tighten them to the specified
torque.
If the torque is not specified, see the Torque – Bolt and
nut ().
Finally, carefully check for any fuel leaks.
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Engine - Fuel tanks
Fuel cooler - Prepare

WARNING
Chemical hazard!
cals.
W0371A
WARNING
Avoid injury!
W1128A
WARNING
Escaping fluid!
doctor immediately.
W0178A
Items to prepare:
• Wrench [ 13 mm]
• Screwdriver
• Pliers
• Marking pen
• Cap
• Plug
• Rag
• Cleaning fluid
• Catching pan
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Engine - Fuel tanks
Fuel cooler - Remove

1. Apply marking at each location of the fuel cooler and
the hoses (1), (2) so as to match connections at as-
sembling.
• Remove the 4 hose bands (3) with pliers or other tool
and then pull out the hoses.
• Prepare a catching pan right underneath it to catch
spilling fuel.
cooler and hose so as to prevent invasion of water,
dust and dirt.
SMIL14CEX0779AB 1
2. Remove the 8 bolts (1) with a wrench [ 13 mm] to re-

move the fuel cooler (2).
SMIL14CEX0780AB 2
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Engine - Fuel tanks
Fuel cooler - Install

To installation, perform the reverse of the removal pro-
cedure.
After connecting the hoses, carefully check for any fuel
leaks.
Tighten bolts being installed to the specified torque.
For bolts for which the torque is not specified, see
Torque – Bolt and nut ().
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Index
Engine - 10
Fuel tanks - 216

Fuel cooler - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fuel cooler - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Fuel cooler - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Fuel tank - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fuel tank - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel tank - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Engine - 10
Fuel filters - 206

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Contents
Engine - 10
Fuel filters - 206
TECHNICAL DATA
Fuel filters
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Fuel filters
Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Fuel filters
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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Engine - Fuel filters
Fuel filters - Special tools

CASE CONSTRUC-
Item Description
TION tool number
1 380002630 Filter wrench
SMIL14CEX2951AB 1
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Fuel filters - Component identification

1. Priming pump
2. Air bleeding plug
3. Case
4. Drain plug
SMIL14CEX3970BB 1
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Fuel filters - Remove

Filter assembly
1. Disconnect the harness connector from the fuel filter
pressure sensor.
2. Remove the fuel feed hose from the fuel filter.
CAUTION: To prevent the fuel leaking, attach

a plug on the removed hose.
3. Remove the fuel return hose from the fuel filter.
CAUTION: To prevent the fuel leaking, attach

a plug on the removed hose.
4. Remove the fuel filter from the machine.
NOTE: Element replaceable specification
1. Priming pump
3. Drain plug
4. Case
5. Fuel filter element
SMIL14CEX3106AB 1
NOTE: Cartridge-type specification

2. Cartridge-type element
SMIL14CEX3107AB 2
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Fuel filter element

CAUTION: Be careful not to allow foreign mat-
ter to get inside the filter during work.
NOTE: The following applies to the element replaceable

specification.
1. Loosen the air bleeding plug using a wrench.
2. Prepare the pan.
3. Loosen the drain plug using the wrench.
4. Drain the fuel from the case.
5. Tighten the drain plug using the wrench.
6. Remove the case from the fuel filter body using the
special tool.
Special tool: Filter wrench (Refer to Fuel filters -
Special tools (10.206) ) SMIL14CEX3486AA 3
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7. Remove the fuel filter element (3) from the fuel filter
body (2).
8. Remove the O-ring (5) from the case (6).
9. Inspect the case.
NOTE: Clean if the inside of the case is dirty.
2. Fuel filter body
4. Float
7. Gasket
8. Drain plug
SMIL14CEX3487CB 4
10. Prepare a pan.

NOTE: The following applies to the cartridge-type specifi-
cation.
11. Remove the fuel filter element from the fuel filter body
using a wrench.
CAUTION: Do not reuse the cartridge-type el-

ement.
SMIL14CEX3488AB 5
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Fuel filters - Install

Fuel filter element
CAUTION: Be careful not to allow foreign mat-
ter to get inside the filter during work.
NOTE: The following applies to the element replaceable

specification.
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1. Install the fuel filter element (3) to the case (6).
CAUTION: Do not forget to install the float (4).
2. Install the O-ring (5) to the case (6).
CAUTION: Use new O-rings (5).
3. Apply the engine oil to the O-ring (5).

4. Temporarily tighten the case (6) to the fuel filter.
NOTE: Use your hands to tighten, do not use tools.
5. Tighten the case (6) using the special tool. SMIL14CEX3486AA 1
Special tool: Filter wrench (Refer to Engine oil

filter - Special tools (10.304) )
2. Fuel filter body
7. Gasket
8. Drain plug
SMIL14CEX3487CB 2
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6. Apply engine oil to the gasket.

NOTE: Lightly apply to the gasket of the fuel filter element.
The following applies to the cartridge specification.
CAUTION: Use a new fuel filter element.

7. Install the fuel filter element to the fuel filter body.
NOTE: Tighten by approximately 2/3 of a turn or to the
specified torque after the gasket comes in contact with the
seal surface.
Filter assembly
1. Install the fuel filter to the machine.
2. Install the fuel return hose to the fuel filter.
3. Install the fuel feed hose to the fuel filter.
4. Connect the harness connector to the fuel filter pres-
sure sensor.
NOTE: Element replaceable specification
1. Priming pump
3. Drain plug
4. Case
SMIL14CEX3106AB 3
NOTE: Cartridge-type specification

SMIL14CEX3107AB 4
Fuel air bleed

Refer to the Fuel injectors - Special tools (10.218).
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Index
Engine - 10
Fuel filters - 206

Fuel filters - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel filters - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fuel filters - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuel filters - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - 10
Fuel injection system - 218

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Contents
Engine - 10
TECHNICAL DATA
Fuel injectors
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Fuel injection system

Common rail
Fuel injectors
High pressure pump
SERVICE
Fuel injection system

Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Common rail
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Fuel injectors
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
High pressure pump
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Remove - Relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Install - Relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
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Engine - Fuel injection system
Fuel injectors - Special tools

CASE CON-
Isuzu
Item STRUCTION Description
reference
tool number
Sliding
1 5-8840-0019-0 380002602
hammer
Injector
2 5-8840-2826 380002601
remover
SMIL14CEX2679AB 1
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Fuel injection system - Component identification
SMIL14CEX3965FB 1
1. Solenoid pump 5. Fuel return pipe

2. Fuel filter 6. Fuel tank
3. Common rail 7. Supply pump
4. Fuel injector 8. Pre-fuel filter
CAUTION: Since the high-precision fuel system has been adopted, take care to prevent any foreign matter
from entering the fuel system.
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Common rail - Component identification
SMIL14CEX3966FB 1
1. Flow damper 3. Fuel inlet

2. Pressure limiter 4. Pressure sensor
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Fuel injectors - Component identification

1. ID plate
2. Terminal stud
3. Injector drive section
4. Injector
5. Gasket
6. O-ring
7. Leak-off pipe installation section
SMIL14CEX3969BB 1
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High pressure pump - Component identification
SMIL14CEX3967GB 1
1. Fuel temperature sensor 4. Camshaft nut

2. Suction control valve 5. Union
3. High pressure pipe 6. Joint bolt
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1. Union
2. Gauze filter
3. Supply pump
4. Strainer
5. Joint bolt
CAUTION: There is a gauze filter assembled inside

the union of the fuel supply pump, but the union should
not be removed to prevent any foreign matter from
entering.
SMIL14CEX3968AB 2
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Fuel injection system - Bleed

Fuel air bleed (with element replaceable specification)
CAUTION: To prevent engine failure, be sure
to perform air removal after the installation or re-
moval of fuel system parts.
1. Priming pump
3. Drain plug
4. Case
SMIL14CEX3106AB 1
1. Prepare the pan.

2. Turn ON the ignition switch.
3. Loosen the air bleeding plug (2) using a wrench.
4. Operate the priming pump (1).
NOTE: Operate the priming pump (1) until fuel comes out
from around the plug (2).
5. Tighten the air bleeding plug (2) using a wrench.
Number of times: 10 count(s) or more
NOTE: Wait for approximately 1 min after operating the
priming pump (1).
NOTE: Remove the air in the fuel filter element (5).
Repeat steps 3 to 7 until air no longer bleeds from the air
bleeding plug (2).
CAUTION: Perform at least 3 times.

CAUTION: Remove the fuel around the air

bleeding plug (2) thoroughly after tightening.
NOTE: Idle the engine for 5 s.
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CAUTION:
○ Do not change the engine speed when the en-

gine is started.
○ If the engine does not start, repeat the process
from step 2.
NOTE: Slowly increase the engine speed, and maintain it

for 3 min.
Accelerate the engine speed to maximum.
Fuel air bleed (with cartridge-type specification)

SMIL14CEX3107AB 2
1. Prepare a pan.
NOTE: Check that fuel comes out from around the air
bleeding plug (1).
CAUTION: Fully remove any fuel in the area

after tightening the air bleeding plug (1).
NOTE: Idle the engine for 5 s.
CAUTION:
○ Do not change the engine speed when the en-

gine is started.
○ If the engine does not start, repeat the process
from step 12.
NOTE: Slowly increase the engine speed, and maintain it

for 3 min.
Increase the engine speed to the maximum speed.
6. Stop the engine.
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Fuel air bleed (with an electromagnetic pump)

CAUTION: To prevent engine failure, be sure
to perform air removal after the installation or re-
moval of fuel system parts.
1. Priming pump
3. Drain plug
4. Case
SMIL14CEX3106AB 3
1. Prepare the pan.

2. Turn ON the starter switch.
3. Loosen the plug (2) using a wrench.
NOTE: Confirm that fuel comes out from around the plug
(2).
5. Tighten the plug using a wrench.
priming pump (1).
8. Tighten the plug (2) using a wrench.
NOTE: Wait for the specified time after operating the prim-
ing pump (1).
priming pump (1).
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CAUTION: Remove the fuel around the plug

(2) thoroughly after tightening.
Number of times: 10 count(s)
Specified time: 5 s
NOTE: Do not accelerate the engine revolution right after
staring.
Accelerate the engine revolution gradually.
Accelerate the engine revolution to maximum.
Lower the rotation.
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Fuel injection system - Inspect

The fuel system consists of the fuel tank, fuel filter, sup-
ply pump, common rail and injector, and all of these are
connected by fuel pipes.
Fuel system inspection

Inspection performed when there is a possibility that
there is an abnormality in the fuel system
1. Inspect the fuel quality.
Appropriate fuel must be used.
2. Check the fuel quantity.
An adequate amount must be filled.
3. Perform the supply pump fuel discharge inspection.
The fuel discharge must be normal and air must not be
mixed in.
4. Check whether a filter other than a genuine fuel filter,
pre-filter, or charge fuel pump has been added to the
machine fuel line.
NOTE: The DTC P0093 may be detected due to the fuel
resistance becoming larger because of the added filter.
5. If a filter has been added, remove it.
6. Inspect the main fuel filter, pre-fuel filter, and charge
fuel pump filter.
• There must be no excessive dirt or clogging.
• Air must not be mixed in.
7. If a problem is found, clean or replace.
8. Inspect the fuel pipe.
• There must be no damage, clogging, or improper
connection.
9. If a problem is found, perform repair or replacement.
10. Inspect the fuel tank.
• There must be no dirt or other debris entered in the
fuel tank.
• There must be no disconnected or damaged fuel
supply pipe.
• There must be no crushed or damaged tank.
• There must be no incorrectly connected fuel pipe.
• There must be no clogging of the feed port.
• There must be no water in the tank.
11. If a problem is found, repair or replace the fuel tank.
12. Perform air bleeding.
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Common rail - Remove

Coolant drain
CAUTION:

loosen the plug and remove it with the gasket (2) .
SMIL14CEX2956AB 1

SMIL14CEX2973AB 2

bly.
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head assembly.
SMIL14CEX2988AB 3

throttle valve.
2. Lock release
3. Lock
SMIL14CEX2993AB 4
SMIL14CEX2994AB 5
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3. Remove EGR gas temperature sensor 1 from EGR
pipe A.
SMIL14CEX2980AB 6

pipe B.
SMIL14CEX2981AB 7
EGR cooler removal

cooler.
SMIL14CEX2982AB 8
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SMIL14CEX2983AB 9

(2).
(3).
bracket A (4).
cooler A.
SMIL14CEX2984AB 10
A.
SMIL14CEX2985AB 11
(3).
SMIL14CEX2986AB 12
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EGR valve removal

(1).
SMIL14CEX2987AB 13
Inlet pipe removal

(3).
SMIL14CEX2995AB 14
SMIL14CEX2996AB 15
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7. Fuel pipe SMIL14CEX2999AB 16
CAUTION:

Fuel pipe removal


head.
pump.
feed pipe.
rail assembly.
SMIL14CEX3000AB 17
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sure sensor.
cover.
SMIL14CEX3001AB 18
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Common rail - Install

bly (1).
bly (1).
(1).
(1).

sensor.

der head assembly.

mon rail assembly.

supply pump.

head assembly.
mon rail assembly.
supply pump.

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rail assembly.
assembly.

7. Fuel pipe

SMIL14CEX2996AB 4
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SMIL14CEX2995AB 5

2. Connect the harness connector to the EGR valve (1).
SMIL14CEX2987AB 6

manifold (3).
pipe A (2).
SMIL14CEX2986AB 7

EGR cooler A.
EGR cooler B (3).
SMIL14CEX2984AB 8
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SMIL14CEX2983AB 9

fold.
A.
cooler B.
bracket C.
cooler bracket C.
cooler bracket B.
hanger bracket.
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SMIL14CEX2985AB 10
SMIL14CEX2982AB 11

CAUTION:

correctly.

IMT sensor Gray
CAUTION:

sor.
dropped, etc.
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sor 2.
ture sensor 2.

CAUTION:

sor.
dropped, etc.
sor 1.
ture sensor 1.

the inlet pipe (3).
SMIL14CEX2994AB 12
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valve.
2. Lock release
3. Lock
SMIL14CEX2993AB 13


gle of the hose.
SMIL14CEX2988AB 14
4. Install the clip to the cylinder block.


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Coolant filling
CAUTION:

tem parts.
SMIL14CEX2956AB 15

tering the system.
3. Install the gasket (2) and the air bleeding plug (1) to the
EGR cooler.



8. Stop the engine
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CAUTION:

mouth.


come warm.

form step 12 again.


cooled.
mouth.



to the MAX line.
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Fuel air bleed

Refer to the Fuel injection system - Bleed (10.218)
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Fuel injectors - Remove


1. Disengage the engine harness from the engine assem-
bly.

1. Disengage the water pipe bracket (2) from the cylinder
head cover.
2. Disengage the ventilation hose (1) from the air
breather.
Disengage the clip (3).
SMIL14CEX2969AB 1

cover (3).
head cover (1).
SMIL14CEX2970AB 2


SMIL14CEX3002AA 3
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2. Disengage the terminal nut (3) of the injector harness


SMIL14CEX3003AB 4

assembly.
SMIL14CEX3244AB 5
Lower cover removal

bly.
bly.

CAUTION:


SMIL14CEX2999AB 6
7. Fuel pipe
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Injector removal
special tool.
Special tool: Fuel injector remover (Refer to Fuel in-
jectors - Special tools (10.218))
SMIL14CEX3005AA 7
Special tool: Sliding hammer (Refer to Fuel injectors

SMIL14CEX3006AA 8
1. Sliding hammer
3. Injector
SMIL14CEX3007AB 9
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CAUTION:

cial tool.
a mix-up.
nozzle.
SMIL14CEX3008AA 10
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Fuel injectors - Install

assembly.



sembly.

assembly.
3. Install the clip to the inlet cover
1. No. 1 injection pipe
3. No. 3 injection pipe SMIL14CEX2999AB 2

7. Fuel pipe
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• Apply ThreeBond 1207B.
CAUTION: After applying the liquid gasket (2),

2. Install the rubber plug (1) to the cylinder head assem-

bly.
SMIL14CEX3084AB 3

4. Install the lower cover to the cylinder head assembly.
SMIL14CEX3087AB 4

bly.
SMIL14CEX3244AB 5



SMIL14CEX3095AB 6
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cover (1).
SMIL14CEX2970AB 7

them.
SMIL14CEX3096AB 8

cover.
SMIL14CEX2969AB 9


Fuel air bleed

Refer to the Fuel injection system - Bleed (10.218)
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High pressure pump - Remove


bly.
Fuel pipe removal


head.
pump.
feed pipe.
3. Remove the eyebolt tightened together with the fuel
feed pipe.
SMIL14CEX3241AB 1

pump (1).
block.
1. Fuel supply pump
2. Bracket
3. Gear
4. Nut
5. Bolt
SMIL14CEX3129AB 2
6. O-ring
7. O-ring
8. Nut
9. Bolt
10. Nut
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High pressure pump - Install

1. Align 1st cylinder to the compression top dead center.
SMIL14CEX3242AB 1

Check alignment mark of the supply pump gear (2).
the timing confirmation hole (1) on the top surface of the
flywheel housing.
SMIL14CEX3243AB 2

1. Fuel supply pump
2. Bracket
3. Gear
4. Nut
5. Bolt
7. O-ring
8. Nut
9. Bolt
10. Nut
pump.
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Fuel leak off pipe assembly Installation

der head assembly.

mon rail assembly.

supply pump.

head assembly.
mon rail assembly.
1. Tightening torque: 20 N·m (14.8 lb ft)
supply pump.
1. Tightening torque: 10.0 N·m (88.5 lb in)
1. Tightening torque: 9.0 N·m (79.7 lb in)
Fuel pipe Installation

CAUTION: Use new fuel pipes.



Fuel air bleed

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High pressure pump - Remove - Relief valve

1. Remove the relief valve from the fuel supply pump.
1. Relief valve
2. Union
3. Fuel temperature sensor
4. Suction control valve
SMIL14CEX3482AB 1
1. Relief valve
2. Union
3. Gauze filter
4. Fuel supply pump
5. Strainer
CAUTION:
○ Do not remove the strainer in the relief valve.

○ Do not remove the union.
SMIL14CEX3485AB 2
2. Inspect the relief valve.
CAUTION: Replace the relief valve if there is

grime or clogging on the strainer in the valve.
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High pressure pump - Install - Relief valve

1. Install the relief valve to the fuel supply pump.

1. Relief valve
2. Union
SMIL14CEX3482AB 1
1. Relief valve
2. Union
3. Gauze filter
4. Fuel supply pump
5. Strainer
SMIL14CEX3485AB 2
Fuel air bleed

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Index
Engine - 10

Common rail - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Common rail - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Common rail - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Fuel injection system - Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fuel injection system - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel injection system - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fuel injectors - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fuel injectors - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Fuel injectors - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Fuel injectors - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
High pressure pump - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
High pressure pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
High pressure pump - Install - Relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
High pressure pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
High pressure pump - Remove - Relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
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Engine - 10
Air cleaners and lines - 202

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Contents
Engine - 10
SERVICE
Air cleaner
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - Air cleaners and lines
Air cleaner - Inspect

1. Inspect the air cleaner element.
NOTE: Inspect the air cleaner element for a damage and
thinned portion.
Refer to the service manual from the machinery manufac-
turer.
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Index
Engine - 10

Air cleaner - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - 10
Turbocharger and lines - 250

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Contents
Engine - 10
FUNCTIONAL DATA
Turbocharger
SERVICE
Turbocharger
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Engine - Turbocharger and lines
Turbocharger - Component identification
SMIL14CEX3886FA 1
1. Turbine housing 6. Seal plate

2. Heat protector 7. Compressor impeller
3. Floating metal 8. Seal ring
4. Oil thrower 9. Seal ring
5. Compressor housing 10. Turbine shaft
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Turbocharger - Prepare
WARNING
Avoid injury!
W1128A
WARNING
Hot surface possible!
Wait for all components to cool before performing any operation.
W0251A
Items to prepare:
• Wrenches [ 8 mm, 10 mm, 13 mm, 17 mm]
• Cap
• Plug
• Rag
• Cleaning fluid
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Turbocharger - Remove
Disconnecting the battery ground cable
Draining the coolant

1. Drain the coolant from the radiator.
CAUTION: After draining the coolant, be sure

to tighten the drain plug.
Removing the turbocharger assembly

sembly and turbocharger assembly.
sembly and intercooler.
assembly.
NOTE: Remove the clips (2).
assembly.
SMIL14CEX2954AB 1
bocharger assembly.
bocharger assembly.
NOTE: Remove the clips (2).
bocharger assembly.
manifold.
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Turbocharger - Inspect
1. Inspect the turbocharger.
CAUTION: Note that a small amount of oil

content may adhere to the inner walls of the com-
pressor due to blow-by gas, but this is not a mal-
function.
NOTE: Inspect each part for cracks, interference, damage,

deformation, oil leaks, and gas leaks from the seal section,
etc.
Check that the turbine shaft turns smoothly.
2. Measure the clearance using the dial gauge.
0.0037 in)
NOTE: Set the dial gauge in the axis direction of the turbine
shaft, and adjust the gauge to 0.
Move the turbine shaft back and forth, and measure the
clearance in the axis direction.
SMIL14CEX2957AA 1
NOTE: Set a dial gauge with an offset pin on the turbine

shaft, and adjust the gauge to 0.
Move the turbine shaft up and down, and measure the
clearance in the radial direction.
CAUTION: Replace the turbocharger assem-

bly if the measured value of the turbine shaft is not
within the range of the specified value.
SMIL14CEX2958AA 2
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Turbocharger - Install
Installing the turbocharger assembly
1. Refill the turbocharger assembly with engine oil.
2. Align the gasket with the turbocharger assembly.
3. Install the turbocharger assembly on the exhaust man-
ifold.
assembly.

assembly.
6. Connect the oil return pipe (3) to the turbocharger as- SMIL14CEX2955AB 1
sembly.

sembly.
Tightening torque: 24 N·m (17.70 lb ft) Clip (2)
8. Install the exhaust pipe on the turbocharger assembly.

9. Install the air intake hose on the turbocharger assembly
and intercooler.
10. Install the air cleaner duct on the air cleaner assembly
and turbocharger assembly.
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Filling the coolant

1. Use a wrench to loosen the valve (1).
2. Fill the radiator with coolant.
CAUTION:
○ Make sure that no coolant overflows onto any

exhaust system part.
○ Wipe off any spilled coolant.
3. Use a wrench to tighten the valve (1).

SMIL14CEX2956AB 2
CAUTION: Use a new gasket (2).
Connecting the battery ground cable

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Index
Engine - 10

Turbocharger - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Turbocharger - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Turbocharger - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Turbocharger - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Turbocharger - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Engine - 10
Intake and exhaust manifolds and muffler - 254

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Contents
Engine - 10
SERVICE
Intake and exhaust manifolds and muffler

Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Intake manifold
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Exhaust manifold
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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Engine - Intake and exhaust manifolds and muffler
Intake and exhaust manifolds and muffler - Inspect

Suction air system
The suction air system consists of an air cleaner, suc-
tion air line, and turbocharger or the like.
Suction air enters the engine through the air cleaner
and intake manifold.
there is an abnormality in the suction air system
1. Inspect the air cleaner.
• There must be no excessive dirt or clogging.
2. If a problem is found, clean or replace.
3. Inspect the suction air line.
• There must be no crushing, breakage, or air leaks.
• There must be no inappropriate pipes or curves that
would lead to increased suction air resistance.
• There must be no lead valve breakage.
5. Inspect the turbocharger.
• There must be no abnormal rattling of the turbine
shaft.
• There must be no oil leakage.
Exhaust system
The exhaust system consists of an exhaust pipe and
tail pipe.
there is an abnormality in the exhaust system.
1. Inspect the exhaust pipe and tail pipe.
There must be no crushing, breakage, or exhaust
leaks.
2. If a problem is found, perform repair or replace-
ment.
3. Repair the machine.
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Intake manifold - Remove

Coolant drain
CAUTION:

SMIL14CEX2956AB 1

SMIL14CEX2973AB 2
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head assembly.
SMIL14CEX2988AB 3

throttle valve.
2. Lock release
3. Lock
SMIL14CEX2993AB 4
SMIL14CEX2994AB 5
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pipe A.
SMIL14CEX2980AB 6

pipe B.
SMIL14CEX2981AB 7
EGR cooler removal

cooler.
SMIL14CEX2982AB 8
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SMIL14CEX3247AB 9

(2).
(3).
bracket A (4).
cooler A.
SMIL14CEX2984AB 10
A.
SMIL14CEX2985AB 11
(3).
SMIL14CEX2986AB 12
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EGR valve removal

(1).
SMIL14CEX2987AB 13
Inlet pipe removal

(3).
SMIL14CEX2995AB 14
SMIL14CEX2996AB 15
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CAUTION:


SMIL14CEX2999AB 16
7. Fuel pipe
Fuel pipe removal


head.
pump.
feed pipe.
rail assembly.
SMIL14CEX3000AB 17
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sure sensor.
cover.
SMIL14CEX3001AB 18
Inlet cover removal

1. Remove the inlet cover (2) and the gasket (1) from the
SMIL14CEX3016AB 19
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Intake manifold - Install

Inlet cover installation
1. Install the gasket (1) to the inlet cover (2).
2. Install the inlet cover (2) to the cylinder head assembly.
NOTE: Refer to the diagram for the tightening order.
1 and 7 in the diagram indicate reamer bolts.
SMIL14CEX3016AB 1
SMIL14CEX3069AB 2

bly (1).
bly (1).
(1).
(1).

sensor.
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der head assembly.

mon rail assembly.

supply pump.

head assembly.
mon rail assembly.
supply pump.




rail assembly.
assembly.
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7. Fuel pipe
SMIL14CEX2999AB 5

SMIL14CEX2996AB 6

SMIL14CEX2995AB 7

SMIL14CEX2987AB 8
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manifold (3).
pipe A (2).
SMIL14CEX2986AB 9

EGR cooler A (1).
EGR cooler B (3).
SMIL14CEX2984AB 10

SMIL14CEX3247AB 11
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fold.
A.
cooler B.
bracket C.
cooler bracket C.
cooler bracket B.
hanger bracket.
SMIL14CEX2985AB 12
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SMIL14CEX2982AB 13

CAUTION:

correctly.

IMT sensor Gray
CAUTION:

sor.
dropped, etc.
sor 2.
ture sensor 2.
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CAUTION:

sor.
dropped, etc.
sor 1.
ture sensor 1.

the inlet pipe (3).
SMIL14CEX2994AB 14

2. Lock release
3. Lock
valve.
SMIL14CEX2993AB 15
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gle of the hose.
SMIL14CEX2988AB 16

Coolant filling
CAUTION:

tem parts.
SMIL14CEX2956AB 17

tering the system.
EGR cooler.
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8. Stop the engine.
CAUTION:

mouth.


come warm.

form step 12 again.

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cooled.
mouth.



to the MAX line.
Fuel air bleed

1. Remove the air in the fuel filter. (Refer to Fuel injection
system - Bleed (10.218)).
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Exhaust manifold - Remove

Coolant drain
• Do not loosen the radiator cap or sub-tank cap when
the coolant temperature is high.
• Because steam and boiling water can burst out from
the radiator and possibly cause burns, check that the
engine has cooled.
SMIL14CEX2956AB 1

SMIL14CEX2973AB 2
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assembly.

assembly.
bocharger assembly.
head assembly.
bocharger assembly.
block.
bocharger assembly.
manifold.

guide tube (1).
cylinder block.
SMIL14CEX2992AB 4
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pipe A.
SMIL14CEX2980AB 5

pipe B.
SMIL14CEX2981AB 6
EGR cooler removal

cooler.
SMIL14CEX2982AB 7
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SMIL14CEX2983AB 8

(2).
(3).
bracket A (4).
cooler A.
SMIL14CEX2984AB 9
A.
SMIL14CEX2985AB 10
(3).
SMIL14CEX2986AB 11
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Exhaust manifold removal

1. Remove the exhaust manifold cover (2) from the ex-
haust manifold.
2. Remove the heat protector (1) from the exhaust mani-
fold.
SMIL14CEX3238AB 12
3. Remove the exhaust manifold (1) from the cylinder

head assembly.
NOTE: Mark the position of the distance nut (2).
SMIL14CEX3018AB 13
4. Disassemble the exhaust manifold.

1. Rear side exhaust manifold
2. Seal ring
SMIL14CEX3019AB 14
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Exhaust manifold - Inspect

1. Inspect the exhaust manifold.
NOTE: Inspect the exhaust manifold for cracks.
2. Align the simple straight ruler to the cylinder head as-
sembly.
NOTE: Flatness of the exhaust manifold
Limit: 0.5 mm (0.0197 in)
CAUTION: Replace the exhaust manifold if

flatness is above the limit value.
SMIL14CEX3240AA 1
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Exhaust manifold - Install

Exhaust manifold installation
1. Install the gasket to the cylinder head assembly.
NOTE: Install the gasket by turning the protruding section
downward.
SMIL14CEX3239AA 1
CAUTION: Confirm that the gasket (2) is firmly

installed to the cylinder head.
NOTE: It will ride on the casted surface (1) of the cylinder

head as shown in the diagram when installed incorrectly.
SMIL14CEX3064AB 2
2. Assemble the exhaust manifold.

NOTE: Assemble the seal ring onto the rear side exhaust
manifold (1) and adjust each seal ring (2) joint to be 120
degrees apart.
SMIL14CEX3019AB 3
3. Install the exhaust manifold (1) to the cylinder head

assembly.
NOTE: The position of the distance nut (2) must be as rep-
resented in the diagram.
SMIL14CEX3018AB 4
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Tightening torque: 34 N·m (25 lb ft) Distance nut
(4)
1. Distance tube
2. Nut
3. Washer
4. Distance nut
SMIL14CEX3066AB 5
4. Install the heat protector (1) to the exhaust manifold.

Tightening torque: 20 N·m (15 lb ft) Bolt
Tightening torque: 41 N·m (30 lb ft) Nut
5. Install the exhaust manifold cover (2) to the exhaust
manifold.
SMIL14CEX3238AB 6

manifold (3).
pipe A (2).
SMIL14CEX2986AB 7

EGR cooler A.
cooler bracket A (4) .
EGR cooler B (3).
SMIL14CEX3104AB 8
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SMIL14CEX2983AB 9

fold.
A.
cooler B.
bracket C.
cooler bracket C.
cooler bracket B.
hanger bracket.
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SMIL14CEX2985AB 10
SMIL14CEX2982AB 11
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CAUTION:

correctly.

EGR gas temperature Light gray
sensor 2
IMT sensor Gray
CAUTION:

sor.
dropped, etc.
sor 2.
ture sensor 2.
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CAUTION:

sor.
dropped, etc.
sor 1.
ture sensor 1.

block.
der head assembly.
tube (1).
SMIL14CEX3105AB 12
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oil.


ifold.


assembly.


assembly.


sembly.

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sembly.


Coolant filling
CAUTION:

tem parts.
SMIL14CEX2956AB 14

tering the system.

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8. Stop the engine.
CAUTION:

mouth.


come warm.

form step 12 again.

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cooled.
mouth.



to the MAX line.
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Index
Engine - 10

Exhaust manifold - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Exhaust manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Exhaust manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Intake and exhaust manifolds and muffler - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Intake manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Intake manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Engine - 10
Selective Catalytic Reduction (SCR) exhaust treatment - 500

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Contents
Engine - 10
FUNCTIONAL DATA
Selective Catalytic Reduction (SCR) exhaust treatment

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Selective Catalytic Reduction (SCR) muffler and catalyst

Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Diesel Exhaust Fluid (DEF)/AdBlue® tank
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Coolant control valve
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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Engine - Selective Catalytic Reduction (SCR) exhaust treatment
Selective Catalytic Reduction (SCR) exhaust treatment - Overview

Purpose
This is a system that adds (injects) DEF/ADBLUE® (urea solution) to (into) the SCR catalyst. It breaks down NOx (ni-
trogen oxidation) in the exhaust gas into water and nitrogen and thereby reduces NOx to meet the emission regulation
and improve fuel economy.
Configuration
SMIL14CEX1023GB 1
1. Engine 9. Urea solution tank

2. Exhaust temperature sensor (FNT) 10. Dosing control unit
3. ECM 11. Dosing module
4. Exhaust temperature sensor (CNT) 12. SCR temperature sensor
5. NOx sensor 13. Coolant
6. Coolant control valve 14. Electrical wiring
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7. Supply module 15. Urea solution

8. Urea sensor
Operation
• The dosing control unit is controlling the injection quantity of DEF/ADBLUE® (urea solution) on the basis of the
information from each sensor and ECM. It also transmits failure information to the ECM via CAN communication.
• DEF/ADBLUE® (urea solution) is sucked up from the urea solution tank by the electric pump in the supply module,
and is conveyed to the dosing module. The supply module is controlling DEF/ADBLUE® (urea solution) within the
constant pressure range.
• DEF/ADBLUE® (urea solution) is injected into exhaust gas by the dosing module, and it is broken down into am-
monia (NH3) and carbon dioxide by the heat of the exhaust gas. Then, this ammonia is resolved into water and
nitrogen by chemical reaction with nitrogen oxide in the SCR.
• The coolant heat from the engine is used to prevent DEF/ADBLUE® (urea solution) in the dosing module and the
urea solution tank from freezing. Coolant flow to the urea solution tank is controlled by the coolant control valve.
• When DEF/ADBLUE® (urea solution) is injected, some products will be accumulated in the SCR catalyst etc.
In order to remove them, SCR regeneration (purge control) is carried out, which increases the exhaust temperature
temporarily at regular intervals to restore the original function of the catalyst.
• In order to prevent deterioration in exhaust gas or a failure in the engine, the engine output is limited (inducement)
in the following cases.
If DEF/ADBLUE® (urea solution) is not added in spite of warning display on the monitor
If any abnormalities, such as degradation in DEF/ADBLUE® (urea solution), addition of the discrepant one, and
dilution, are found.
If harness disconnection in the SCR-related electrical parts or clogging in the urea solution line has occurred.
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Selective Catalytic Reduction (SCR) exhaust treatment - Component

identification
The urea SCR system is installed to the rear of the oxidation catalyst. The urea SCR system is a system that cleans
exhaust gases by purifying NOx inside the exhaust gases processed by the catalyst though a reaction with urea fluid.
SMIL14CEX3887FA 1
1. Front chamber 4. Mixing chamber

2. SCR catalyst 5. Oxidation catalyst 2
3. Silencer 6. Oxidation catalyst 1
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Selective Catalytic Reduction (SCR) muffler and catalyst - Prepare

WARNING
Avoid injury!
W1128A
WARNING
Hot surface possible!
Wait for all components to cool before performing any operation.
W0251A
NOTICE: The engine is very hot immediately after stopping it. Start working after it is sufficiently cooled down.
Items to prepare:
• Cap
• Rag
• Cleaning fluid
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Selective Catalytic Reduction (SCR) muffler and catalyst - Remove

1. Remove the 6 harnesses (1) and the 2 coolant hoses
(2).
Remove the urea hose (3).
SMIL14CEX1004AB 1
2. Remove the U-bolt (2) from the exhaust pipe (1) with a
wrench ( 17 mm).
Remove the 4 bolts (3) with a wrench ( 17 mm) to sep-
arate the exhaust pipe (1) from the SCR (4).
• Attach caps at the line so as to prevent invasion of
water, dust and dirt.
SMIL14CEX1005AB 2

remove the SCR (2).
SMIL14CEX1006AB 3
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Selective Catalytic Reduction (SCR) muffler and catalyst -

Disassemble
1. Remove the silencer (1) from the SCR catalyst (3) and
rear bracket (7).
NOTE: Remove the rear hanger and bracket (2) .
2. Remove the SCR catalyst (3) from the front chamber
(5) and front bracket (6).
NOTE: Remove the front hanger and bracket (4) .
3. Disconnect the front chamber from the mixing chamber.
4. Remove the mixing chamber from the oxidation cata-
lyst assembly and bracket.
SMIL14CEX2968AB 1
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Selective Catalytic Reduction (SCR) muffler and catalyst - Inspect

1. Inspect the SCR catalyst.
NOTE: Inspect the connecting section for looseness, dam-
age, or leaking exhaust gas.
Inspect the clamp and rubber for degradation, cracks, or
damage.
Inspect the SCR catalyst for erosion, breakage, or clog-
ging.
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Selective Catalytic Reduction (SCR) muffler and catalyst - Assemble

1. Install the mixing chamber to the oxidation catalyst as-
sembly and bracket.
Tightening torque: 25 N·m (18 lb ft) M8
Tightening torque: 64 N·m (47 lb ft) M10
2. Connect the front chamber to the mixing chamber.
3. Install the SCR catalyst (3) to the front chamber (5) and
front bracket (6).
NOTE: Install the front hanger and bracket (4) .
4. Install the silencer (1) to the SCR catalyst (3) and rear
bracket (7).
NOTE: Install the rear hanger and bracket (2).
CAUTION: Do not reuse gaskets, nuts, or

bolts once they have been removed.
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Selective Catalytic Reduction (SCR) muffler and catalyst - Install

Install the SCR in the reversed order of the procedure
for removal.
After installation, check for leakage, chatter, etc.
For tightening torque for bolts that are not specified,
refer to Torque – Bolt and nut ().
New gaskets should be used.
NOTICE: After installation of the urea SCR dosing module, the coolant piping of coolant control valve piping needs to
be bled of air. For air bleeding for the coolant piping of coolant control valve piping, refer to Coolant control valve
- Install (10.500).
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Diesel Exhaust Fluid (DEF)/AdBlue® tank - Prepare

WARNING
Avoid injury!
W1128A
WARNING
Escaping fluid!
doctor immediately.
W0178A
Items to prepare:
• Wrenches [ 13 mm, 17 mm, 19 mm]
• Hexagon wrench [ 5 mm]
• Marking pen
• Cap
• Plug
• Waste oil can
• Rag
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Diesel Exhaust Fluid (DEF)/AdBlue® tank - Remove

1. Remove the urea pump. (Refer to the Diesel Exhaust
Fluid (DEF)/AdBlue® supply module - Remove
(55.988) for detail).
2. Remove the connector (1).
Remove the 2 coolant hoses (2).
Remove the 3 bolts (3) with a wrench [ 13 mm] to re-
move the coolant control valve (4).
SMIL14CEX1913AB 1
3. Remove the 2 urea hoses (2), the 2 coolant hoses (3)

and the breather hose (4) from the urea solution tank
(1).
Remove the 2 bolts (5) with a wrench [ 13 mm].
27.44 lb ft)
SMIL14CEX1914AB 2

Remove the 4 hexagon bolts (2) with a hexagon wrench
[ 5 mm] to remove the special sensor (3).
• Do not separate it from the urea solution tank (4).
SMIL14CEX1915AB 3
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move the cover (2).
SMIL14CEX1916BB 4
6. Remove the urea solution tank (1).
SMIL14CEX1917BB 5
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Diesel Exhaust Fluid (DEF)/AdBlue® tank - Install

Install the urea solution tank in the reversed order of the
procedure for removal.
After installation, add coolant and refill urea solution.
For details, follow their respective procedures and de-
scriptions.
NOTICE: After installation of the urea solution tank, the coolant piping of coolant control valve piping needs to be bled
of air. For air bleeding for the coolant piping of coolant control valve piping, refer to Coolant control valve - Install
(10.500).
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Coolant control valve - Remove

Coolant drain
CAUTION:

SMIL14CEX2956AB 1

SMIL14CEX2973AB 2
Coolant control valve removal

1. Disconnect the harness connector from the coolant
control valve.
2. Disconnect the coolant piping from the coolant control
valve.
3. Remove the coolant control valve from the machine.
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Coolant control valve - Install

Coolant control valve installation
1. Install the coolant control valve to the machine.
2. Connect the coolant piping to the coolant control valve.
3. Connect the harness connector to the coolant control
valve.
Coolant filling
CAUTION:

tem parts.
SMIL14CEX2956AB 1

tering the system.

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In order to bleed the urea SCR dosing module coolant
piping of air, choose the CCV (coolant control valve)
operation test in the device test from the service sup-
port screen.
NOTE: Repeat the operation test several times. Idle the
engine for 5 min.
8. Stop the engine.
CAUTION:

mouth.


In order to bleed the urea SCR dosing module coolant
piping of air, choose the CCV (coolant control valve)
operation test in the device test from the service sup-
port screen.
NOTE: Repeat the operation test several times.
For models with heaters, the set temperature and blower
speed are set to the maximum, and warm up the engine at
approximately 1500 - 2000 RPM.
come warm.

form step 12 again.

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cooled.
mouth.



to the MAX line.
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Index
Engine - 10

Coolant control valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Coolant control valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Diesel Exhaust Fluid (DEF)/AdBlue® tank - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Diesel Exhaust Fluid (DEF)/AdBlue® tank - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Diesel Exhaust Fluid (DEF)/AdBlue® tank - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Selective Catalytic Reduction (SCR) exhaust treatment - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Selective Catalytic Reduction (SCR) exhaust treatment - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Selective Catalytic Reduction (SCR) muffler and catalyst - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Selective Catalytic Reduction (SCR) muffler and catalyst - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Selective Catalytic Reduction (SCR) muffler and catalyst - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Selective Catalytic Reduction (SCR) muffler and catalyst - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Selective Catalytic Reduction (SCR) muffler and catalyst - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Selective Catalytic Reduction (SCR) muffler and catalyst - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Engine - 10
Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF)

exhaust treatment - 501

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Contents
Engine - 10
Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust

treatment - 501
FUNCTIONAL DATA
Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment
SERVICE
Exhaust Gas Recirculation (EGR) valve

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Diesel Oxidation Catalyst (DOC)
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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Engine - Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment
Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF)

exhaust treatment - Component identification
EGR
Part of the exhaust gas back into the intake manifold, which results in reduced nitrogen oxide emissions. Higher
operability and emission reduction are both realized by controlling the EGR system. A control current from the ECM
operates a solenoid to control the lift amount of the EGR valve. In addition, the EGR position sensor is used for
detection of the actual valve lift amount and for precision control of the EGR amount.
The EGR is activated when the specified conditions of engine speed, engine coolant temperature, intake air temper-
ature, and barometric pressure are met. Then, the valve opening position is calculated based on engine speed and
the desired fuel injection quantity. The motor drive duty is determined from this valve opening position, and the valve
is driven according to the motor drive duty. The intake throttle valve closes when the EGR is activated in order to
maintain an appropriate pressure in the intake manifold.
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SMIL14CEX3888GA 1
1. EGR position sensor 8. EGR gas temperature sensor 1

2. EGR valve 9. IMT sensor
3. Intake throttle position sensor 10. Intake throttle valve
4. EGR gas temperature sensor 2 11. Boost pressure sensor/boost temperature sensor
5. Coolant outlet 12. MAF/IAT sensor
6. Coolant inlet 13. Engine speed
7. EGR cooler 14. Engine load
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Exhaust Gas Recirculation (EGR) valve - Remove

Draining the coolant

1. Drain the coolant from the radiator.
CAUTION: After draining the coolant, be sure

to tighten the drain plug.
Removing the EGR cooler

1. Disconnect the rubber water hose (1) from the EGR
cooler.
SMIL14CEX2959AB 1
2. Remove EGR pipe B (2) from EGR valve (1) and EGR
cooler C (3).
SMIL14CEX2960AB 2
3. Remove EGR cooler C (1) from EGR bracket C (2).

4. Remove EGR bracket C (2) from EGR cooler B (3).
5. Remove EGR cooler B (3) from EGR cooler bracket A
(4).
6. Remove EGR cooler bracket A (4) from EGR cooler A.
SMIL14CEX2961AB 3
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7. Remove the EGR heat protector (1) from EGR pipe A.
SMIL14CEX2962AB 4
8. Remove EGR cooler A (1) from EGR pipe A (2).

9. Remove EGR pipe A (2) from the exhaust manifold (3).
SMIL14CEX2963AB 5
Removing the EGR valve

(1).
SMIL14CEX2964AB 6
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Exhaust Gas Recirculation (EGR) valve - Install

1. Install the EGR valve (1) on the inlet pipe.
SMIL14CEX2974AB 1
Installing the EGR cooler

1. Temporarily tighten EGR pipe A (2) to the exhaust man-
ifold (3).
2. Temporarily tighten EGR cooler A (1) to EGR pipe A
(2).
SMIL14CEX2975AB 2
3. Temporarily tighten EGR cooler bracket A (4) to EGR

cooler A .
4. Temporarily tighten EGR cooler B (3) to EGR cooler
bracket A (4).
EGR cooler B (3).
SMIL14CEX2976AB 3
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7. Temporarily tighten EGR pipe B (2) to EGR cooler C (3)

and EGR valve (1).
8. Fully tighten EGR pipe A to the exhaust manifold.
9. Fully tighten EGR cooler A to EGR pipe A.
10. Fully tighten EGR cooler B to EGR cooler A.
11. Fully tighten EGR cooler bracket C to EGR cooler B.
12. Fully tighten EGR cooler C to EGR cooler bracket C.

13. Fully tighten EGR pipe B to EGR cooler C.
14. Fully tighten EGR pipe B to the EGR valve.
15. Fully tighten EGR cooler bracket A to EGR cooler
bracket C.
16. Fully tighten EGR cooler bracket C to EGR cooler
bracket B.
17. Fully tighten EGR pipe B to the rear engine hanger
bracket.
18. Install the EGR heat protector (1) on the EGR pipe.
SMIL14CEX2978AB 5
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19. Connect the rubber water hose (1) to the EGR cooler.
SMIL14CEX2979AB 6
Filling the coolant

1. Use a wrench to loosen the valve (1) .
CAUTION:
○ Make sure that no coolant overflows onto any

exhaust system part.
○ Wipe off any spilled coolant.
3. Use a wrench to tighten the valve (1).

SMIL14CEX3360AB 7
CAUTION: Use a new gasket (2).

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Exhaust Gas Recirculation (EGR) valve - Inspect

1. Inspect the EGR valve.
specified time: 4500 h every
NOTE: Clean if there are carbon deposits.
Replace the EGR valve if it is damaged.
EGR cooler inspection

1. Inspect the EGR cooler.
Specified time: 4500 h every
NOTE: Inspect the inside of the EGR cooler, and clean it if
there are carbon deposits.
Inspect the inside of the EGR cooler, and replace the EGR
cooler if damage is found.
EGR cooler cleaning

1. Prepare the cleaning fluid.
NOTE: Use Oil-Clean for the cleaning fluid.
2. Prepare the container.
NOTE: Pour the Oil-Clean into the container.
3. Clean the EGR cooler using the cleaning fluid.
NOTE: Soak the EGR cooler in Oil-Clean and wait for the
specified time.
NOTE: Remove the Oil-Clean from the EGR cooler using
a cleaner after the specified time has passed.
CAUTION: Before installing the EGR cooler,

dry it completely.
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Diesel Oxidation Catalyst (DOC) - Remove

Exhaust gas temperature sensor removal

1. Disconnect the harness connector from the exhaust
gas temperature sensor.
NOTE: To prevent incorrect assembling, make an align-
ment mark on the connector before disconnecting.
Remove EGT sensor 1 and 2 together.
2. Remove the EGT sensor from the oxidation catalyst
assembly.
Oxidation catalyst assembly removal

1. Remove oxidation catalyst 1 from oxidation catalyst 2.
SMIL14CEX3232AA 1
2. Remove oxidation catalyst 2 from the mixing chamber.
SMIL14CEX3233AA 2
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Diesel Oxidation Catalyst (DOC) - Install

Oxidation catalyst assembly installation
1. Install oxidation catalyst 2 to the mixing chamber.
SMIL14CEX3233AA 1
2. Install oxidation catalyst 1 to oxidation catalyst 2.

Tightening torque: 25 N·m (18.4 lb ft) M8
Tightening torque: 64 N·m (47.2 lb ft) M10
SMIL14CEX3232AA 2
Exhaust gas temperature sensor installation

CAUTION:
○ Clean the old anti-seize lubricant on the sleeve

nut, and apply new anti-seize lubricant to the
threaded portion of the sleeve nut.
○ Do not subject the tip of the exhaust gas tem-
perature sensor to shock when installing.
○ Replace the oxidation catalyst assembly if dam-
age has been found in the sensor installation
section of the oxidation catalyst assembly.
1. Apply anti-seize lubricant to the EGT sensor.
the threaded portion of the EGT sensor.
2. Temporarily tighten the EGT sensor to the oxidation
catalyst assembly.
CAUTION: To prevent damage to the sensor

installation area caused by incorrect sensor as-
sembly, temporarily tighten manually.
NOTE: Exhaust gas temperature sensor identification
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Sensor type Screw size Connector color

Exhaust gas temperature sensor 2 M12X1.75 Dark gray
Exhaust gas temperature sensor 1 M12 X 1.25 Light gray
3. Final tighten the EGT sensor to the oxidation catalyst

assembly.
4. Connect the harness connector to the exhaust gas tem-
perature sensor.
CAUTION: Be careful not to twist the harness.
NOTE: Start the engine after assembling each part, and

check for gas leaks from each joint and for vibration.

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Index
Engine - 10
Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust

treatment - 501
Diesel Oxidation Catalyst (DOC) - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Diesel Oxidation Catalyst (DOC) - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment - Component identification 3
Exhaust Gas Recirculation (EGR) valve - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Exhaust Gas Recirculation (EGR) valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Exhaust Gas Recirculation (EGR) valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Engine - 10
Engine cooling system - 400

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Contents
Engine - 10
FUNCTIONAL DATA
Engine cooling system

Water pump
Coolant thermostat
SERVICE

Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Radiator
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Water pump
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Coolant thermostat
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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Engine - Engine cooling system
Engine cooling system - Component identification

The coolant system is the forced circulation system, and its main components are the water pump, thermostat and
radiator.
SMIL14CEX3881FA 1
1. Water jacket 8. Radiator cap

2. Drain plug 9. Radiator reserve tank
3. Oil cooler 10. Water outlet pipe
4. Water pump 11. Thermostat, 2 units
5. Drain cock 12. Engine coolant temperature sensor
6. Radiator 13. Bypass route
7. Cooling fan 14. EGR cooler
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Water pump - Component identification

The water pump is a centrifugal impeller type pump and is driven by the engine fan belt.
SMIL14CEX3882FA 1
1. Fan guide 3. Impeller

2. Bearing 4. Seal unit
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Coolant thermostat - Component identification

The thermostat is a wax pellet type, and consists of 2 units. One is a bottom bypass type while the other is an inline
type. They are installed inside the thermostat housing unit and allow for specific temperature adjustments.
SMIL14CEX3883FA 1
1. Jiggle valve 4. Gasket

2. Stamp mark (initial valve opening temperature) 5. Piston
3. Valve
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Engine cooling system - Inspect

WARNING
Hazardous chemicals!
Coolant can be toxic. Avoid contact with skin, eyes, and clothing. Antidotes:
EXTERNAL - Rinse thoroughly with water. Remove soiled clothing.
INTERNAL - Rinse the mouth with water. DO NOT induce vomiting. Seek immediate medical attention.
EYES - Flush with water. Seek immediate medical attention.
W0282A
WARNING
Burn hazard!
Hot coolant can spray and scald if you remove the radiator or deaeration tank cap while the system
is hot. To remove the cap: allow the system to cool, turn the cap to the first notch, and wait for all
pressure to release. Remove the cap only after all pressure has released.
W0367A
Coolant inspection
NOTICE: If the coolant temperature is high, do not perform the inspection.
NOTICE: Be sure to use long life coolant which is specified or recommended. Using at an unspecified concentration
may result in freezing due to decreased anti-freezing performance. Use a coolant concentration appropriate for the
usage environment.
NOTE: Before using, dilute the specified long life coolant to the specified concentration with soft tap water.
Area where the equipment is used LLC concentration

General area; Area where the lowest temperature is higher
30 %
than -12 °
Cold area; Area where the lowest temperature is -30 ° 50 %
Area where temperature drop to -30 ° 55 %
1. Inspect the radiator reverse tank.

Volume of coolant: 16.0 L (4.2 US gal)
NOTE: If coolant level is MIN or less, add it until it reaches
MAX.
NOTICE: When adding coolant, use coolant appropriate
for the usage environment.
2. Inspect the water leak using the radiator cap tester.
Inspection pressure: 200 kPa (29 psi)
Inspection locations:
• Radiator assembly
• Water pump assembly
• Radiator hose
• Heater hose
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3. Measure the specific gravity using the hydrometer (2).

Engine coolant temperature: 0 - 50 °C (32 - 122 °F)
while in inspection
NOTE: Use a container that is deeper than the length of
the hydrometer.
1. Radiator
2. Hydrometer
SMIL14CEX3230AB 1
4. Measure the temperature using the thermometer.

Engine coolant temperature: 0 - 50 °C (32 - 122 °F)
while in inspection
5. Calculate the concentration from the measured value.
1. Specific gravity
2. Temperature °C (°F)
NOTE: Measuring the coolant concentration using a
coolant scope is also possible.
SMIL14CEX3231BA 2
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Engine cooling system - Drain fluid

Coolant drain
CAUTION:

SMIL14CEX2972AB 1

SMIL14CEX2973AB 2
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Coolant cleaning
1. Add tap water to the radiator.
NOTE: Add up to the radiator mouth.
NOTICE: Securely instal the radiator cap.
3. Add tap water to the radiator reserve tank.
4. Install the cap to the radiator reserve tank.
NOTE: Perform only if the EGR cooler has an air bleeding
plug.
7. Stop the engine.
NOTICE: Confirm that the engine has cooled sufficiently.
10. Discharge tap water from the radiator
SMIL14CEX2956AB 3
12. Discharge tap water from the engine.
13. Install the drain plug to the cylinder block.
SMIL14CEX2973AB 4
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Engine cooling system - Filling

Coolant filling
CAUTION:
• Work while taking care to prevent excess coolant from splashing onto the exhaust system parts.
• Wipe off any excess coolant.
NOTE: If the EGR cooler has an air bleeding plug, loosen
the plug and remove it.
SMIL14CEX2956AB 1

NOTICE: Add slowly to prevent air from entering the sys-
tem.
EGR cooler.
NOTICE: Do not reuse the gasket.
NOTICE: Securely attach the radiator cap.
NOTICE: Wipe off any excess coolant.
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7. A. Start the engine.

B. In order to bleed the urea SCR dosing module
coolant piping of air, choose the CCV (coolant con-
trol valve) operation test in the device test from the
service support screen.
Idle the engine for 5 min.
8. Stop the engine
CAUTION:
• Do not loosen the radiator cap or sub-tank cap when the coolant temperature is high.
• Because steam and boiling water can burst out from the radiator and possibly cause burns, check that the
engine has cooled.

mouth.
NOTICE: If the coolant amount is excessively low, inspect
for coolant leakage.
12. A. Start the engine.
B. In order to bleed the urea SCR dosing module
coolant piping of air, choose the CCV (coolant
control valve) operation test in the device test
from the service support screen.
For models with heaters, the set temperature and blower
speed are set to the maximum, and warm up the engine at
approximately 1500 - 2000 RPM.
come warm.
NOTICE: If the upper hose is not warm, perform step 12
again.
NOTICE: Confirm that the engine has cooled.
mouth.
NOTICE: If the coolant amount is excessively low, inspect
for coolant leakage.
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NOTICE: If the level of the radiator reserve tank has fallen
the next morning, add coolant up to the MAX line.
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Radiator - Prepare
WARNING
Burn hazard!
Hot coolant can spray and scald if you remove the radiator or deaeration tank cap while the system
is hot. To remove the cap: allow the system to cool, turn the cap to the first notch, and wait for all
pressure to release. Remove the cap only after all pressure has released.
W0367A
WARNING
Escaping fluid!
doctor immediately.
W0178A
WARNING
Avoid injury!
W1128A
WARNING
Crushing hazard!
latches.
W0256A
WARNING
Heavy objects!
W0398A
Items to prepare:
• Pliers
• Shackle (that fulfills slinging capacity) x 2
• Wire rope (that fulfills breaking load)
• Lifting equipment (that fulfills slinging capacity)
• Cap
• Plug
• Reservoir for drainage
• Hose for drainage
• Rag
• Cleaning fluid
• Wood plank
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Radiator - Remove
1. Remove the engine hood. (Refer to the Hood - Re-
move (90.100)).
SMIL14CEX0783AB 1
3. Mount the hose (1) for drainage and then prepare the
reservoir (2) for drainage.
SMIL14CEX0784AB 2
4. Remove the radiator cap (1) for easy draining of

coolant.
SMIL14CEX0785AB 3
5. Loosen the drain plug (1) to drain coolant.
SMIL14CEX0786AB 4
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move the 2 covers (2).
Loosen the hose band (3) with a wrench ( 7 mm) to
remove the upper hose (4).
• Remove the lower hose with the same procedure as
well.
Loosen the hose band (5) to remove the reserve tank
hose (6).
SMIL14CEX0787AB 5
SMIL14CEX0788AB 6

Remove the 3 bolts (3) to remove the stay (4).
SMIL14CEX0789BB 7
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move the bracket (2).
SMIL14CEX0790BB 8

remove the bracket (2).
SMIL14CEX0791BB 9
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11. Remove the 8 bolts (1) and the 2 nuts (2) with a
wrench ( 13 mm) to remove the fan shroud (3).
SMIL14CEX0792BB 10
12. Remove the 4 bolts (1) with a wrench ( 13 mm).
SMIL14CEX0793AB 11
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13. Attach the 2 shackles (1) on top of the radiator and

then lift it with a wire rope (2) and a lifting equipment.
SMIL14CEX0794BB 12
14. Lift it together with the radiator cover (2) until the se-
cure bracket (1) at bottom of the radiator is disen-
gaged.
SMIL14CEX0795AB 13
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15. Make sure that you have a safe site, and then settle
the radiator on a wood plank. Make sure not to bend
or crash the secure bracket (1) at bottom when it is
laid down.
SMIL14CEX0796BB 14
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Radiator - Inspect
1. Inspect the radiator.
• Inspect the radiator fins for collapsing.
• Remove dust and other foreign materials.
• Repair the radiator fins if they are deformed as it can
lead to a decrease in heat dissipation effect, causing
overheating.
NOTICE: When repairing the fins, take sufficient care not
to damage the base of the fins.
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Radiator - Cleaning
NOTICE: Before cleaning, seal the hose connecting sections using caps, cloth tapes, etc.
1. Clean the radiator (1) using tap water.
• For foulings that can be removed by splashing tap
water, thoroughly wash them off.
NOTICE: At this time, do not use a high pressure washer
or brush.
2. Apply detergent to the radiator (1).
• Apply a type of mild detergent which contains ap-
proximate 8 % of surface acting agent, and leave for
10 min.
NOTICE: Do not use other materials than mild detergent,
because using other materials cause corrosion. SMIL14CEX4125AB 1
3. Clean the radiator (1) using a high pressure washer.

• When dirt is not washed off sufficiently, repeat the
cleaning work.
NOTICE: High pressure water should be applied perpen-
dicular to the fins from the engine side of the radiator.
NOTICE: Sufficiently rinse off the detergent ingredient to
prevent it from remaining on the core and the resin portions.
5. Clean the connecting section using tap water.
• Remove the seal, and clean the hose connecting
section.
• Wash the coolant passage inside the radiator with
water to remove scales and rusts completely.
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Radiator - Install
To install, follow the removal procedure in reverse.
torque.
If the torque is not specified, see the Torque – Bolt and
nut ().
Fill the radiator with the suitable coolant.
Coolant capacity is 35.40 L (9.35 US gal).
Finally, check that the level of coolant is correct.
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Water pump - Remove

Coolant drain
CAUTION:

SMIL14CEX2956AB 1

SMIL14CEX2973AB 2
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Cooling fan removal

SMIL14CEX3121AB 3
Fan guide removal

1. Bolt
2. Washer
3. Rubber mount
4. Rubber mount
5. Guide tube
bly.
SMIL14CEX3122AB 4

1. Adjust bolt
2. Fixing bolt
3. Fixing bolt
SMIL14CEX3123AB 5
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SMIL14CEX3127AA 6

SMIL14CEX3128AB 7
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Water pump - Inspect

1. Inspect the water pump assembly for:
• Cracks and damage on the water pump body
• Cracks and corrosion on the impeller
• Water leak from the seal unit

inspection, replace the water pump assembly.
2. Inspect the bearing unit.
• Rotate the fan while pushing the fan center to the ra-
dius direction and inspect for any significant loose-
ness or abnormal sounds.

inspection, replace the water pump assembly.
SMIL14CEX3226AA 1
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Water pump - Install

Tightening torque: 39 N·m (28.8 lb ft) Nut (1) in the

diagram
Tightening torque: 20 N·m (14.8 lb ft).
SMIL14CEX3225AB 1
SMIL14CEX3128AB 2

Tightening torque: 52 N·m (38.4 lb ft).
SMIL14CEX3127AA 3

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0.80 (0.236 -
integrated belt 0.315 in)
0.85 (0.236 -
integrated belt 0.315 in)
SMIL14CEX3211AB 4
2. Generator
3. Fan pulley
the adjust bolt (1) .
side bolt (3)

1. Bolt
2. Washer
3. Rubber mount
4. Rubber mount
5. Guide tube
6. Fan guide SMIL14CEX3122AB 6
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SMIL14CEX3121AB 7

Coolant filling
CAUTION:

tem parts.

tering the system.
SMIL14CEX2956AB 8
EGR cooler.

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8. Stop the engine.
CAUTION:

mouth.


come warm.

form step 12 again.
NOTE: Idle the engine for 5 min


cooled.
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mouth.



to the MAX line.
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Coolant thermostat - Remove

Coolant drain
CAUTION:


SMIL14CEX2956AB 1
SMIL14CEX2973AB 2
Thermostat removal
SMIL14CEX2990AB 3
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let pipe (2).
3. Remove the water outlet pipe (2) from the cylinder head
assembly.
4. Remove the thermostat from the cylinder head assem-
bly.
5. Remove the gasket from the thermostat.
SMIL14CEX3021AB 4
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Coolant thermostat - Inspect

1. Inspect the thermostat.
NOTE: Inspect the pellet, spring, shaft, jiggle valve (1), and
crimped sections for damage.
SMIL14CEX3228AB 1
2. Prepare the container.

NOTE: Put water and the thermostat into a heatable con-
tainer.
3. Raise the water temperature.
NOTE: In order to equalize the water temperature in the
container, stir well with the stirring rod (2).
CAUTION: Do not heat the thermostat directly.
4. Measure the water temperature using the thermometer.

NOTE: Measure open valve temperature of the thermostat. SMIL14CEX3229AB 2
1. Piece of wood
2. Stirring rod
Thermostat Open valve temperature Lift amount

With jiggle valve 76.5 - 90 °C (170 - 194 °F) 8.0 mm (0.315 in)
Type 1
Without jiggle valve 82 - 95 °C (180 - 203 °F) 8.0 mm (0.315 in)
With jiggle valve 85 - 100 °C (185 - 212 °F) 8.0 mm (0.315 in)
Type 2
Without jiggle valve 82 - 95 °C (180 - 203 °F) 8.0 mm (0.315 in)
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Coolant thermostat - Install

1. Install the gasket to the thermostat.

2. Install the thermostat to the cylinder head assembly.
1. Jiggle valve position
CAUTION: Be careful not to mistake the as-

sembly position and direction.
SMIL14CEX3227AB 1
3. Install the water outlet pipe (2) to the cylinder head

assembly.
pipe.
SMIL14CEX3021AB 2
(3).
SMIL14CEX2990AB 3

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Coolant filling
CAUTION:

tem parts.

tering the system.
SMIL14CEX2956AB 4
EGR cooler.



8. Stop the engine.
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CAUTION:

mouth.

11. Install the radiator cap to the radiator

come warm.

form step 12 again.

13. Stop the engine

cooled.
mouth.



to the MAX line.
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Index
Engine - 10

Coolant thermostat - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Coolant thermostat - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Coolant thermostat - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Coolant thermostat - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Engine cooling system - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine cooling system - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine cooling system - Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engine cooling system - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Radiator - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Radiator - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Radiator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Radiator - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Radiator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Water pump - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Water pump - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Water pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Water pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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Engine - 10
Fan and drive - 414

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Contents
Engine - 10
Fan and drive - 414
SERVICE
Belt
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - Fan and drive
Belt - Inspect
Cooling fan belt inspection
1. Inspect the cooling fan belt.
NOTE: Inspect for worn or damage.


Type 1: Triple integrated belt 0.80 6.0 - 8.0 mm (0.236 - 0.315 in)
Type 2: Triple integrated belt 0.85 6.0 - 8.0 mm (0.236 - 0.315 in)
2. Generator
3. Fan pulley
SMIL14CEX3211AB 1

just-plate-side nut (2).
side bolt (3).
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Index
Engine - 10
Fan and drive - 414

Belt - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - 10
Aftercooler - 310

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Contents
Engine - 10
Aftercooler - 310
SERVICE
Aftercooler
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Engine - Aftercooler
Aftercooler - Prepare
WARNING
Fuel vapors are explosive and flammable.
Do not smoke while handling fuel. Keep fuel away from flames or sparks. Shut off engine and remove
key before servicing. Always work in a well-ventilated area. Clean up spilled fuel immediately.
W0904A
Items to prepare:
• Screwdriver
• Wire cutters
• Cap
• Rag
• Cleaning fluid
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Aftercooler - Remove
1. Open the backward left door and the engine hood.
move the house frame (2).
SMIL14CEX0781AB 1
2. Remove the 2 hose clamps (1) to remove the 2 inter-

cooler hoses (2).
Remove the 4 nuts (3) with a wrench [ 13 mm] to re-
move the intercooler (4).
• Attach caps at intercooler and each location so as to
prevent invasion of water, dust and dirt.
SMIL14CEX0782AB 2
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Aftercooler - Inspect
1. Inspect the intercooler.
• Inspect the fins for collapsing. Remove dust and
other foreign materials.
NOTICE: When repairing the fins, take sufficient care not
to damage the base of the fins. Inspect the inside of the
intercooler, and if it is significantly dirty, clean it. When the
fins are clogged, clean them.
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Aftercooler - Cleaning
NOTICE: Before cleaning, seal the hose connecting sections using caps, cloth tapes, etc.
1. Clean the intercooler using tap water.
• For foulings that can be removed by splashing tap
water, thoroughly wash them off.
NOTICE: At this time, do not use a high pressure washer
or brush.
2. Apply detergent to the intercooler.
• Apply a type of mild detergent which contains ap-
proximate 8 % of surface acting agent, and leave for
10 min.
NOTICE: Do not use other materials than mild detergent,
because using other materials cause corrosion.
3. Clean the intercooler using a high pressure washer.
• When dirt is not washed off sufficiently, repeat the
cleaning work.
NOTICE: High pressure water should be applied perpen-
dicular to the fins from the engine side of the intercooler.
4. Clean the intercooler using tap water.
NOTICE: Sufficiently rinse off the detergent ingredient to
prevent it from remaining on the core and the resin portions.
5. Clean the connecting section using tap water.
• Remove the seal, and clean the hose connecting
section.
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Aftercooler - Install
dure.
Check for any air leaks.
Torque ().
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Index
Engine - 10
Aftercooler - 310
Aftercooler - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Aftercooler - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Aftercooler - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Aftercooler - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Aftercooler - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Engine - 10
Engine lubrication system - 304

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Contents
Engine - 10
TECHNICAL DATA
Engine oil filter

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Engine lubrication system

Engine oil pump
SERVICE
Engine lubrication system

Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine oil pump
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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Engine - Engine lubrication system
Engine oil filter - Special tools

CASE CONSTRUC-
Item Description
TION tool number
1 380002630 Filter wrench
SMPH14CEX6331AB 1
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Engine lubrication system - Component identification

A full-flow bypass integrated filter element, water cooling oil cooler, and piston coolant oil jet are adopted for the
lubrication system.
SMIL14CEX3884FB 1
*1. Delivery valve *13. Crankshaft bearing

*2. Oil port *14. Crank valve
*3. Full-flow oil filter *15. Relief valve
*4. Oil pressure switch *16. Gear train
*5. Oil pressure indicator lamp *17. Connecting rod bearing
*6. Fuse *18. Oil jet
*7. Starter switch *19. Oil pump
*8. Battery *20. Strainer
*9. Oil cooler *21. Flywheel PTO
*10. Thermo valve *22. Turbocharger
*11. Oil gallery *23. Engine oil pan
*12. Valve structure
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Engine oil pump - Component identification
SMIL14CEX3885FB 1
1. Driven gear assembly 3. Drive gear assembly

2. Oil pump body 4. Oil pump drive gear
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Engine lubrication system - Inspect

1. Inspect whether the engine oil is dirty, or contains water,
etc.
NOTE: If oil is dirty or contains water, change the oil after
investigating the causes and taking appropriate measures.
2. Inspect the engine oil level.
NOTE: When the oil level is low, replenish it.
3. Remove the oil pressure switch.
4. Install the oil pressure gauge.
NOTE: Isuzu reference: 5-8840-2843-0.
NOTE: Warm-up the engine.
6. Measure and confirm that the oil pressure is 550 kPa
(80 psi) or higher at 2000 RPM.
7. Turn OFF the ignition switch.
8. Remove the oil pressure gauge.
9. Install the oil pressure switch.
SMIL14CEX3448AA 1
11. Check for oil leakage.
12. Check for engine oil leakage
13. Inspect for oil leaks from the cylinder head cover and
oil pan, etc. while the vehicle is lifted up.
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Engine oil pump - Remove

Coolant drain
1. Remove the radiator cap from the radiator
CAUTION:


loosen the plug and remove it with the gasket (2). SMIL14CEX2956AB 1
4. Remove the drain plug (1) from the cylinder block
SMIL14CEX2973AB 2
Engine oil drain


bly.
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assembly.

assembly.
bocharger assembly.
head assembly.
bocharger assembly.
block.
bocharger assembly.
manifold.

pipe A.
SMIL14CEX2980AB 4
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perature sensor 2.
pipe B.
SMIL14CEX2981AB 5
EGR cooler removal

cooler.
SMIL14CEX2982AB 6
SMIL14CEX2983AB 7

(2).
(3).
bracket A (4).
cooler A.
SMIL14CEX2984AB 8
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A.
SMIL14CEX2985AB 9
(3).
SMIL14CEX2986AB 10
EGR valve removal

(1).
SMIL14CEX2987AB 11

head assembly.
SMIL14CEX2988AB 12
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assembly.
SMIL14CEX2989GB 13
SMIL14CEX2990AB 14
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let pipe.
SMIL14CEX2991AB 15

guide tube (1).
cylinder block.
SMIL14CEX2992AB 16

throttle valve.
2. Lock release
3. Lock
SMIL14CEX2993AB 17
SMIL14CEX2994AB 18
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Inlet pipe removal

(3).
SMIL14CEX2995AB 19
SMIL14CEX2996AB 20
Glow plug removal

SMIL14CEX2997AA 21

bly.
SMIL14CEX2998AA 22
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CAUTION:


SMIL14CEX2999AB 23
7. Fuel pipe
Fuel pipe removal


head.
pump.
feed pipe.
rail assembly.
SMIL14CEX3000AB 24
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sure sensor.
cover.
SMIL14CEX3001AB 25

cover (3).
head cover (1).
SMIL14CEX2970AB 26


SMIL14CEX3002AA 27
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SMIL14CEX3003AB 28

assembly.
SMIL14CEX3004AB 29
Injector removal
NOTE: When it is difficult to remove the injector use a spe-
cial tool.
SMIL14CEX3005AA 30

SMIL14CEX3006AA 31
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1. Sliding hammer
3. Injector
SMIL14CEX3007AB 32
CAUTION:

cial tool.
a mix-up.
nozzle.
SMIL14CEX3008AA 33
Lower cover removal

bly.
bly.

SMIL14CEX3009AA 34

assembly.

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Camshaft removal
head assembly.
ing cap.
assembly.
SMIL14CEX3011AA 35
Bridge removal


SMIL14CEX3012AB 36

block.
NOTE: Loosening order of the head bolts.
SMIL14CEX3013EB 37
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SMIL14CEX3014AB 38

block.

gasket.

pump (1).
block.
3. Gear
4. Nut
5. Bolt
6. O-ring
7. O-ring
SMIL14CEX3129AB 39
8. Nut
9. Bolt
10. Nut

ing.
SMIL14CEX3130AA 40
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CKP sensor removal

sor (1).
(2).

sor to shock.
SMIL14CEX3131AB 41
Flywheel removal

not rotate.
SMIL14CEX3132AB 42

1. Felt
2. Slinger
SMIL14CEX3124AB 43
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Special tool: Slinger Puller (refer to Crankshaft -

SMIL14CEX3125AA 44

SMIL14CEX3133AA 45
Oil pan removal

switch.

the oil port cover.
SMIL14CEX3135AB 46
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wheel housing.
SMIL14CEX3136AB 47

and the crankcase.

SMIL14CEX3137AB 48

measured.


0.0067 in) SMIL14CEX3138AA 49
Limit： 0.30 mm (0.0118 in)

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the thrust collar.

B.

0.0061 in)
Limit: 0.20 mm (0.0079 in)
CAUTION: Replace the idle gear if the mea- SMIL14CEX3139AA 50
Idle gear A removal

SMIL14CEX3140AA 51

SMIL14CEX3141AA 52
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Engine oil pump - Disassemble

1. Remove the driven gear from the oil pump body.
SMIL14CEX3216AA 1
2. Remove the cotter pin (1) from the oil pump body.
3. Remove the spring from the oil pump body.
4. Remove the ball from the oil pump body.
SMIL14CEX3217AB 2
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Engine oil pump - Inspect

0.0087 in)
Limit: 0.30 mm (0.0118 in)
NOTE: The clearance between the inner wall of the body
and each gear tooth tip.
CAUTION: Replace the gear if the measured

value exceeds the limit value.
SMIL14CEX3218AA 1
2. Measure the shaft using the micrometer.

0.6299 in)
Limit: 15.900 mm (0.6260 in)
NOTE: Driven gear shaft outer diameter.
3. Measure the body using the gauge.
NOTE: Measure the bush inner diameter of the body.
SMIL14CEX3219AA 2
4. Measure the cylinder block using the gauge.

NOTE: Measure the bush inner diameter of the cylinder
block.
SMIL14CEX4066AA 3
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0.0028 in)
Limit: 0.20 mm (0.0079 in)
NOTE: The difference between the shaft outer diameter
and the bush inner diameter is the clearance.
CAUTION: Replace the gear if the clearance

6. Inspect the ball (1).
7. Inspect the spring (2).
SMIL14CEX3220AB 4
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Engine oil pump - Assemble

1. Install the ball to the oil pump body.
2. Install the spring to the oil pump body.
3. Install the cotter pin (1) to the oil pump body.
SMIL14CEX3217AB 1
4. Apply the engine oil to the driven gear.

5. Install the driven gear to the oil pump body.
SMIL14CEX3216AA 2
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Engine oil pump - Install

area.

SMIL14CEX3172AA 1

to the oil pump.
CAUTION:

uid gasket.
SMIL14CEX3173AA 2

SMIL14CEX3174AA 3
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SMIL14CEX3175AB 4

1. Camshaft gear
3. Idle gear B
5. PTO gear
6. PTO idle gear
7. Crank gear
8. Oil pump gear
9. Supply pump gear
10. Idle gear A
11. Idle gear C
SMIL14CEX3176BB 5
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stallation area.
CAUTION:
○ Do not apply liquid gasket to the location indi-

cated in (1) in the diagram. SMIL14CEX3177AB 6

Tightening torque
SMIL14CEX3178BB 7


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NOTE: Assemble the thrust collar to the mounting bolt and
CAUTION:

facing toward the gear side.
oil lubrication and make sure to install the thrust
1. 30 °
2. Paint portion
3. Notch SMIL14CEX3179AB 8
5. Thrust collar

thrust collar facing toward the gear side.
1. Thrust collar
2. Washer
3. PTO idle gear
5. Oil groove
SMIL14CEX3180AB 9
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SMIL14CEX3181AB 10
13. Install the oil pipe (1) to the pipe bracket (2) and the
oil port cover.
side
side
the cylinder block.
housing side
SMIL14CEX3135AB 11
block side

bead width: 3 mm (0.118 in)
bead height: 2 mm (0.079 in)
(2).

SMIL14CEX3183AB 12

Tightening torque: 11 N·m (97 lb in) 4 stud bolts
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SMIL14CEX3184AB 13

Special tool: Oil seal installer kit (Refer to Crankshaft
SMIL14CEX3185AA 14

cluded in the kit.
Name Part number
1 Adapter 5-8840-2709-0
3 Center bolt 5-8840-2713-0
4 Sleeve 5-8840-9063-0
5 Collar 5-8840-2710-0
6 Adapter ring 5-8840-2711-0
SMIL14CEX3186AB 15

oil seal.

4. Install the adapter to the crankshaft.
SMIL14CEX3188AB 16
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adapter.
SMIL14CEX3189AA 17

head and the crankshaft rear oil seal (2).
1. Flywheel housing
SMIL14CEX3190AB 18


SMIL14CEX3073AA 19
tightening
Tightening angle : 60 °
tightening
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sor to shock.
SMIL14CEX3131AB 20

SMIL14CEX3130AA 21

SMIL14CEX3193AB 22
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2. Supply pump gear
the timing confirmation hole on the top surface of the fly-
wheel housing.
SMIL14CEX3194AB 23
4. Install the fuel supply pump to the cylinder block.

Tightening torque: 51 N·m (38 lb ft) Nut (10).
1. Fuel supply pump
2. Bracket
3. Gear
4. Nut
5. Bolt
7. O-ring
8. Nut
9. Bolt
10. Nut
pump.

CAUTION:

head assembly.
bead width: 3.0 mm (0.1181 in)
bead height: 2.0 mm (0.0787 in)

SMIL14CEX3196AA 25
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der head gasket.

SMIL14CEX3197AA 26
SMIL14CEX3198EB 27

Tightening angle: 30 - 60 ° (30 - 60 °) M14 bolt
SMIL14CEX3073AA 28
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tightening M14 bolt
Bridge installation

smoothly.


SMIL14CEX3074AA 29
SMIL14CEX3075AA 30
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ing.


sembly.
SMIL14CEX3076AA 31
cial tool.
aligned.
SMIL14CEX3077AB 32


sub gear side.
SMIL14CEX3078AA 33
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CAUTION:

cap.

ing. SMIL14CEX3079AA 34


cap.
assembly.
Tightening torque: 28 N·m (21 lb ft) Engine oil ap-
plication

SMIL14CEX3080AB 35

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bly.
Tightening order.
cap
28 N·m (21 lb ft)
cap
SMIL14CEX3081AB 36

NOTE: Valve clearance adjustment.
SMIL14CEX3082AA 37
SMIL14CEX3075AA 38

and bridge cap.
SMIL14CEX3083AA 39
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valve and bridge
NOTE: With the thickness gauge inserted, lightly tighten
the adjust screw of the bridge.
Confirm that the leading end of the adjust screw and valve
shaft end have made contact and the movement of the
thickness gauge has become stiff.
Check if the valve shaft end on the opposite side is floating
or touching at an angle.
If it is floating or touching at an angle, slightly loosen the
bridge adjust screw and adjust the valve shaft ends on both
sides to touch properly.
Adjustment table
Value IN EX IN EX IN EX IN EX IN EX IN EX
O O O O O O
O O O O O O

1. Apply the liquid gasket (2) to the rubber plug (1) .
SMIL14CEX3084AB 40

area (1).

SMIL14CEX3086AB 41
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SMIL14CEX3087AB 42

bly (1).
bly (1).
(1).
(1).

sensor.
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der head assembly.

mon rail assembly.

supply pump.

head assembly.
mon rail assembly.
supply pump.


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Temporarily tighten the injector (1) to the cylinder head
assembly.

SMIL14CEX3090AB 45

rail assembly.
sembly.

assembly.

7. Fuel pipe
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SMIL14CEX3092AA 47


SMIL14CEX3093AA 48

bly.
SMIL14CEX3094AB 49



SMIL14CEX3095AB 50
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cover (1).
them.
SMIL14CEX2970AB 51
SMIL14CEX3096AB 52

cover.
SMIL14CEX2969AB 53

1. Install the gasket (2) and inlet pipe (1) to the inlet cover.
SMIL14CEX3097AB 54
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SMIL14CEX2995AB 55

1. Install the gasket (2) and intake throttle valve (1) to the
inlet pipe (3).
SMIL14CEX3099AB 56

valve.
2. Lock release
3. Lock
SMIL14CEX2993AB 57

SMIL14CEX2991AB 58
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sembly.
SMIL14CEX2989GB 59

ferent from others.
SMIL14CEX3100AB 60
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pipe.
(3).
SMIL14CEX2990AB 61


gle of the hose.
SMIL14CEX2988AB 62

SMIL14CEX2987AB 63
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CAUTION:

correctly.

IMT sensor Gray
CAUTION:

sor.
dropped, etc.
sor 2.
ture sensor 2.
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CAUTION:

sor.
dropped, etc.
sor 1.
ture sensor 1.

manifold (3).
pipe A (2).
SMIL14CEX2986AB 64

EGR cooler A.
EGR cooler B (3).
cooler bracket C (2)
SMIL14CEX3104AB 65
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SMIL14CEX2983AB 66

fold.
A.
cooler B.
bracket C.
cooler bracket C.
cooler bracket B.
hanger bracket.
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SMIL14CEX2985AB 67
SMIL14CEX2982AB 68

block.
der head assembly.
tube (1).
SMIL14CEX3105AB 69
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oil.
ifold.
CAUTION: Use a new gasket. SMIL14CEX2954AB 70

assembly.


assembly.


sembly.


sembly.
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Engine oil filling

gauge.



Coolant filling
CAUTION:

tem parts.
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plugs loosen the plugs and remove them.

tering the system.
SMIL14CEX2956AB 71
EGR cooler.



8. Stop the engine.
CAUTION:

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mouth.


come warm.

form step 12 again.


cooled.
mouth.



to the MAX line.
Fuel air bleed

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Index
Engine - 10

Engine lubrication system - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine lubrication system - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine oil filter - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine oil pump - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Engine oil pump - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine oil pump - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Engine oil pump - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Engine oil pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Engine oil pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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CNH Industrial Italia S.p.A. viale delle Nazioni, 55 Modena Italy 41122
SERVICE - Technical Publications & Tools
© 2015 CNH Industrial Italia S.p.A.
All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CASE CONSTRUCTION policy is one of continuous improvement and the right to change prices, specification
or equipment at any time without notices is reserved.
All data given in this publication is subject to production variations. Dimensions and weight are approximate only
and the illustrations do not necessarily show products in standard condition. For exact information about any
particular product, please consult your CASE CONSTRUCTION Dealer.
47843027 21/05/2015
EN
SERVICE MANUAL
Hydraulic systems

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Contents
Hydraulic systems - 35
[35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1
[35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2
[35.106] Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3
[35.102] Pump control valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4
[35.304] Combination pump units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5
[35.359] Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6
[35.357] Pilot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7
[35.355] Hydraulic hand control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.8
[35.356] Hydraulic foot control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.9
[35.352] Hydraulic swing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.10
[35.353] Hydraulic travel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.11
[35.354] Hydraulic central joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.12
[35.736] Boom hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.13
[35.737] Dipper hydraulic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.14
[35.738] Excavator and backhoe bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.15
[35.360] Hammer and rotating bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.16
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Contents
FUNCTIONAL DATA
Hydraulic systems
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic systems
Hydraulic schema – Travel circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Hydraulic schema – Swing circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Hydraulic schema – Boom circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Hydraulic schema – Arm circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Hydraulic schema – Bucket Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Hydraulic schema – Negative control circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Hydraulic schema – Other circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Hydraulic schema – Option circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
SERVICE
Hydraulic systems
Service instruction Table of standards (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Service instruction Table of standards (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Service instruction Measurement method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Pressure setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Flow test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
DIAGNOSTIC
Hydraulic systems
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
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Hydraulic systems - Hydraulic systems
Hydraulic systems - Overview
SMIL14CEX1169HB 1
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1. Left side housing 4. Hydraulic oil tank

2. Swing body center section 5. Fuel tank
3. Pump chamber
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Pump chamber hydraulic equipment layout
SMIL14CEX4068HB 2
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1. Hydraulic pump 6. P1 pressure sensor

2. Accumulator 7. Pilot pump
3. Pilot filter 8. Hydraulic oil temperature sensor
4. 5 stack solenoid valve 9. P1 flow control proportional valve
5. P2 pressure sensor 10. P2 flow control proportional valve
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Swing body center section hydraulic equipment layout
SMIL14CEX4069HB 3
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1. Swing motor 4. N2 pressure sensor

2. Center joint 5. N1 pressure sensor
3. Control valve
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Housing left side hydraulic equipment layout
SMIL14CEX1172HB 4
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1. Cushion valve 6. Swing pressure sensor

2. Arm (out) pressure sensor 7. Boom (down) pressure sensor
3. Arm (in) pressure sensor 8. Bucket (open) pressure sensor
4. Boom (up) pressure sensor 9. Oil cooler
5. Bucket (close) pressure sensor
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Layout of hydraulic equipment in cab
SMIL14CEX1173GB 5
1. Travel remote control valve 2. Upper operation remote control valve
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Hydraulic systems - Hydraulic schema – Travel circuit

TRAVEL LOW-SPEED CIRCUIT
As an example, this section explains the forward travel operation.
The travel motor 2-stage tilting angle is a large tilting side. Even if the travel switch is set to the high-speed side,
switching the key switch OFF and then ON again always returns the system to this state.
By operating the travel remote control valve to the forward side, the pilot pressure oil is fed to the control valve pa1
port and switches the left travel spool to the forward side.
At the same time, the oil is also fed to the pa6 port to switch the right travel spool to the forward side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port and the discharge oil from hydraulic pump
A2 enters the control valve P2 port.
Each flows to the travel motor and causes forward travel through the left and right travel spools being switched.
The return oil from the travel motor goes through the left and right travel spools and returns to the hydraulic tank.
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Pressure line Pilot tank line

Tank line Electric line
Pilot pressure line
1. Travel motor 10. Console lever lock switch

2. Travel high-speed select switch 11. Hydraulic pump
3. Main computer 12. Travel remote control valve
4. Control valve 13. Check valve
5. Travel (left) 14. Oil cooler
6. Travel (right) 15. Backward left
7. Travel high speed 16. Forward left
8. Lever lock 17. Forward right
9. 5 stack solenoid valve 18. Backward right
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SMIL14CEX4125JB 1
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TRAVEL HIGH SPEED CIRCUIT

As an example, this section explains the forward travel operation.
Sets the travel motor 2-stage tilting angle to a small angle to set high speed.
At the same time, the oil is also fed to the pa6 port to switch the right travel spool to the forward side.
The return oil from the travel motor goes through the left and right travel spools and returns to the hydraulic tank.
Electrical signals are sent to the main computer by operation of the travel high-speed select switch and the main
computer sends electrical signals to the travel high-speed solenoid valve.
Due to the switching of the travel high-speed solenoid valve, the pilot pressure [ 3.9 MPa (565.695 psi)] from the C1
port enters the left and right travel motor Ps port through the center joint and sets the travel motor tilting angle to a
small angle to raise the speed.
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Pilot pressure line
1. Travel motor 10. Console lever lock switch

2. Travel high-speed select switch 11. Hydraulic pump
3. Main computer 12. Travel remote control valve
5. Travel (left) 14. Oil cooler
6. Travel (right) 15. Backward left
7. Travel high speed 16. Forward left
8. Lever lock 17. Forward right
9. 5 stack solenoid valve 18. Backward right
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SMIL14CEX4126JB 2
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STRAIGHT TRAVEL CIRCUIT (WITH HBCV)

As an example, this section explains the case in which forward travel and boom-up operations are carried out simul-
taneously.
In the same way, the oil is also fed to the pa6 port to switch the right travel spool to the forward side.
If a boom-up operation is carried out during travel, the pilot pressure oil is fed via the cushion valve to the control valve
pa4 port and switches the boom (1) (2) spools to the up side.
When a compound operation (it is a boom-up operation this time and a travel left/right operation) are detected by the
sensor, the pilot pressure oil is fed from the proportional valve to the straight travel valve and switches the straight
travel spool.
The amount of switching of the straight travel spool varies with the upper pilot pressure. (Because the pilot pressure
is low for slight upper operation, the amount of switching of the straight travel spool is slight to prevent sharp reduction
in the travel speed.)
Through the straight travel valve being switched, it is possible for the control valve P1 pressure oil to drive the left and
right travel motors and for the control valve P2 pressure oil to drive the boom.
Because the left and right motors are driven by 1 pump, the left and right motors have the same pressure and straight
travel is possible.
Furthermore, the P2 excess pressurized oil is fed to the travel side via the check valve with travel merge orifice to
minimize the drop in speed.
The same operations are carried out when travel and an upper actuator other than for the boom are operated simul-
taneously.
When the circuit has an HBCV, switching the spool lets the oil flow through the HBCV check valve and into the boom
cylinder bottom side and the boom-up operation is carried out.
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Pilot pressure line
1. Travel motor 15. Lever lock

2. Boom (up) 16. 5 stack solenoid valve
3. Boom (down) 17. Console lever lock switch
4. Cushion valve 18. Hydraulic pump
5. Remote control valve (boom, bucket) 19. Boom cylinder
6. Control valve 20. Travel remote control valve
7. Travel (left) 21. Check valve
8. Travel (right) 22. Oil cooler
9. Straight travel valve 23. Backward left
10. Straight travel signal (right) 24. Forward left
11. Straight travel signal (left) 25. Forward right
12. Travel high-speed select switch 26. Backward right
13. Main computer 27. 6 stack electromagnetic proportional valve
14. Travel high speed
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SMIL14CEX4127JB 3
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Hydraulic systems - Hydraulic schema – Swing circuit

SWING SPEED LIMIT CONTROL CIRCUIT
This control is for suppressing increases in the swing speed accompanying increased pump flow. (Only in H and SP
modes)
For independent swing operation, due to the swing pilot pressure sensor input electric signal, the main computer
outputs a signal to the P1 flow control proportional valve.
The discharge oil from the hydraulic pump A3 is fed to the P1 flow control proportional valve.
The output signal from the main computer to the P1 flow control proportional valve reduces the hydraulic pump A1
side discharge flow.
The control is canceled when a compound operation is performed.
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Pilot pressure line
1. Swing motor 10. Lever lock

2. Swing 11. Swing brake
3. Cushion valve 12. 5 stack solenoid valve
4. Right swing 13. Console lever lock switch
5. Left swing 14. P1 pressure sensor
6. Swing pilot pressure sensor 15. P1 flow control proportional valve
7. Remote control valve (arm, swing) 16. Hydraulic pump
9. Main computer 18. Oil cooler
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SMIL14CEX4128JB 1
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SWING RELIEF CUT CONTROL CIRCUIT

This control aims for an energy-saving effect by controlling the pump in such a way as to minimize the excess oil
drained from the swing motor relief valve for the starting pressure boost during an independent sharp swing operation.
When a swing operation starts, due to the swing pilot pressure sensor and P1 pressure sensor input electrical signals,
the main computer outputs a signal to the P1 flow control proportional valve.
The discharge oil from the hydraulic pump A3 is fed to the P1 flow control proportional valve.
The output signal from the main computer to the P1 flow control proportional valve controls the pilot pressure to reduce
the hydraulic pump A1 side discharge flow.
The output signal from the main computer to the P1 flow control proportional valve controls the pilot pressure to reduce
the hydraulic pump A1 side discharge flow.
The control is canceled when a compound operation is performed.
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Pilot pressure line

5. Left swing 14. P1 pressure sensor
6. Swing pilot pressure sensor 15. P1 flow control proportional valve
9. Main computer 18. Oil cooler
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SMIL14CEX4128JB 2
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SWING BRAKE CIRCUIT

As an example, this section explains the brake circuit operation after the end of a right swing operation.
When the remote control valve is returned to neutral from a right swing operation, the pilot pressure oil is cut off and
the control valve swing spool returns to neutral.
The flow of the pressure oil fed to the swing motor A port from the control valve A3 port is cut.
At the same time, the destination location is eliminated for the pressure oil flowing from the swing motor B port to the
control valve B3 port, so the pressure rises to the swing motor relief valve set pressure.
The pressure generated here becomes a brake force and stops the motor.
When the swing is stopped, the swing motor continues to rotate for a while due to inertial force. In order to make
up the shortfall in the oil volume, oil is supplied from the make-up line connected to the swing motor M port from the
control valve T3 port to open the make-up check valve and oil is suctioned in to prevent cavitation.
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Pilot pressure line

3. Right swing 11. 5 stack solenoid valve
4. Left swing 12. Console lever lock switch
5. Swing pilot pressure sensor 13. Main computer
6. Remote control valve (arm, swing) 14. Control valve
7. Hydraulic pump 15. Oil cooler
8. Control valve
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SMIL14CEX4129JB 3
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SWING PARKING CIRCUIT (LEVER IN NEUTRAL)

When the key is switched ON, the swing brake solenoid valve is switched by the electrical signal from the main com-
puter.
The swing motor PR port oil goes from the 5 stack solenoid valve C2 port through the swing brake solenoid, and
returns to the hydraulic tank to hold the swing parking brake.
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2. Cushion valve 10. Swing brake
7. Check valve 15. Hydraulic pump
8. Oil cooler 16. Key switch
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SMIL14CEX4130JB 4
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SWING PARKING CIRCUIT (BRAKE RELEASE)

When the engine is started and the swing lever is in neutral, the swing brake solenoid valve comes ON ( 24 V input),
the pressure to the swing motor PR port is cut, and the swing parking brake works.
When the lever operation raises the reading to the specified pressure value or higher at the pressure sensor in the
swing pilot line, the output from the main computer to the swing brake solenoid valve goes OFF, the swing motor PR
port pressure rises, the swing parking brake is released, and swing becomes possible. As an example, this section
explains the right swing operation.
By carrying out the right swing operation on the remote control valve, the pilot pressure oil is fed to the control valve
pa3 port via the cushion valve and switches the swing spool to the right swing side.
At the same time, the main computer detects the swing pilot pressure sensor signal, judges that there is a swing
operation, the electrical signal output from the main computer goes OFF, and switches the swing brake solenoid
valve. The pilot pressure oil is fed to the swing motor PR port from the swing brake solenoid valve C2 port to release
the swing parking brake.
The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the parallel oil path to the
swing spool.
Switching the spool lets the oil flow into the swing motor A port and the right swing operation is carried out. The
pressure oil from the swing motor B port goes through the swing spool and returns to the hydraulic tank. When this
is followed by an attachment operation, the pilot pressure is detected by respective pressure sensors and the swing
parking brake continues to be released.
After the swing operation ends, if about 5 s. pass with no upper operation, the swing brake solenoid valve output from
the main computer comes ON and the swing parking brake works again.
After the swing ends, if this is followed by an upper operation, when about 1 s. passes after the end of the upper
operation, the swing parking brake works again.
For upper independent operation, the swing parking brake is also released. When about 1 s. passes after the end of
the upper operation, the swing parking brake works again.
Key switch Swing pilot pressure Upper pilot pressure Swing brake Swing motor
sensor sensor solenoid valve mechanical brake
OFF OFF OFF OFF ON
ON OFF OFF ON ON
Higher than specified
ON OFF OFF OFF
pressure
Higher than specified
ON OFF OFF OFF
pressure
Higher than specified Higher than specified
ON OFF OFF
pressure pressure
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1. Swing motor 9. Main computer

4. Left swing 12. Main computer
5. Swing pilot pressure sensor 13. Control valve
7. Swing 15. Check valve
8. Lever lock 16. Oil cooler
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SMIL14CEX4131JB 5
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SWING PARKING CIRCUIT (MACHINE STOP)

When the machine is stopped (the key is switched OFF), the swing motor PR port oil goes from the 5 stack solenoid
valve C2 port through the swing brake solenoid, and returns to the hydraulic tank to hold the swing parking brake.
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2. Cushion valve 10. Swing brake
8. Oil cooler
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SMIL14CEX4132JB 6
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Hydraulic systems - Hydraulic schema – Boom circuit

BOOM-UP CIRCUIT (INDEPENDENT OPERATION) (WITH HBCV)
By moving the remote control valve to the boom-up side, the pilot pressure oil is fed via the cushion valve to the control
valve pa4 and pa8 ports and switches the boom (1) and (2) spools.
By moving the remote control valve to the boom-up side, the pilot pressure oil is fed via the cushion valve to the control
valve pa4 and pa8 ports and switches the boom (1) and (2) spools.
The discharge oil from hydraulic pump A2 is fed to the boom (1) spool via the parallel oil path, merges with the dis-
charge oil from boom (2), pushes open the boom load holding valve check valve (flows through boom cylinder HBCV
check valve when the circuit has an HBCV) and flows into the bottom side, and the boom-up operation is carried out.
The boom cylinder rod side return oil goes through the boom (1) spool and returns to the hydraulic tank.
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Pilot pressure line
1. Cushion valve 12. Attachment pressure sensor

2. Boom (up) 13. Console lever lock switch
3. Boom (down) 14. Monitor display
4. Boom (2) 15. Main computer
5. Remote control valve (boom, bucket) 16. P1 pressure sensor
6. Lever lock 17. P2 pressure sensor
7. Boost pressure relief 18. Hydraulic pump
8. 5 stack solenoid valve 19. Check valve
9. Control valve 20. Oil cooler
10. Boom load holding valve check valve 21. Boom HBCV
11. Boom cylinder
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SMIL14CEX4133JB 1
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BOOM-UP SPOOL STROKE CONTROL CIRCUIT (COMPOUND BOOM-UP + ARM-IN) (WITH

HBCV)
As an example, this section explains the boom-up + arm-in compound operation (leveling work).
The purpose is to increase the oil amount fed to the arm by pushing back the boom (2) spool during digging operation.
By operating the remote control valve to the boom-up side and arm-in side, the pilot pressure oil is fed via the cushion
valve to the control valve pa4, pa8 ports and pb5, pb9 ports and switches the boom (1) (2) and arm (1) (2) spools.
boom (2) and arm (1) spools.
The oil goes through the arm (1) spool and flows into the arm cylinder bottom side.
At this time, the boom (2) spool is pushed back by the boom regeneration proportional valve, making arm-in operation
movement smooth.
The arm cylinder rod side return oil goes through the load holding valve check valve and the arm (1) spool, and returns
to the hydraulic tank.
boom (1)spool.
Switching the spool lets the oil flow through the boom load holding valve check valve and into the boom cylinder
bottom side and the boom-up operation is carried out.
The boom cylinder rod side return oil goes through the boom (1) spool and returns to the hydraulic tank.
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1. Arm cylinder 17. Swing priority variable orifice

2. Arm (in) 18. Arm (2)
3. Arm (out) 19. Boom load holding valve check valve
4. Boom (up) 20. Boom cylinder
5. Boom (down) 21. Attachment pilot pressure sensors
6. Cushion valve 22. Console lever lock switch
7. Remote control valve (boom, bucket) 23. Monitor display
8. Remote control valve (arm, swing) 24. Main computer
10. Boost pressure relief 26. P2 pressure sensor
11. 5 stack solenoid valve 27. Hydraulic pump
12. Arm (1) 28. Check valve
13. Boom (2) 29. Oil cooler
14. Arm load holding valve spool 30. HBCV check valve
15. Load holding valve check valve 31. 6 stack proportional pressure reducing valve
16. Control valve 32. Boom spool stroke control
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SMIL14CEX4134JB 2
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BOOM-DOWN REGENERATIVE CIRCUIT (WITH HBCV)

By operating the remote control valve to the boom-down side and arm-out side, the pilot pressure oil is fed via the
cushion valve to the control valve pb8 port and pa9, pa5 ports and switches the boom (1) and arm (1) (2) spools.
boom (1) and arm (2) spools.
Switching the spool lets the oil flow into the boom cylinder rod side and the boom-down operation is carried out.
At the same time, switching the arm spool lets the oil flow into the arm cylinder rod side, and the arm-out operation
is carried out.
At this time, the boom (2) spool is moved to the boom-down side by the boom regeneration proportional valve. The
pilot pressure oil from the pb8 port separated in the internal path is fed to the load holding valve spool and moves the
spool to the left.
In this way, the load holding valve check valve spring chamber oil is connected to the tank line through the load holding
valve spool, the spring chamber pressure drops, and the load holding valve check valve is opened.
The boom cylinder bottom side pressure oil goes through the load holding valve check valve and is metered by the
boom (1) spool regeneration orifice.
The lower the cylinder rod side load pressure, the greater the volume of regeneration.
When the cylinder rod side load pressure becomes high, the check valve is closed and the cylinder bottom return oil
goes through the boom spool (1) without regeneration and returns to the hydraulic tank.
The boom bottom side return oil goes through the load holding valve check valve and is metered by the boom (2)
spool regeneration orifice.
Through this, the return oil pushes open the check valve in the spool and is regenerated on the cylinder rod side.
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Pilot pressure line
1. Arm HBCV check valve 18. 5 stack solenoid valve

2. Arm cylinder 19. Console lever lock switch
3. Control valve 20. Monitor display
4. 6 stack proportional pressure reducing valve 21. Main computer
5. Boom spool stroke control 22. Boom cylinder
6. Arm (1) 23. Boom HBCV check valve
7. Boom (2) 24. Arm (2)
8. Remote control valve (arm, swing) 25. Boom (1)
9. Remote control valve (boom, bucket) 26. Boom load holding valve check valve
10. Arm (in) 27. Check valve
11. Arm (out) 28. Orifice
12. Boom (down) 29. Bleed-off
13. Boom (up) 30. P1 pressure sensor
14. Cushion valve 31. P2 pressure sensor
15. Attachment pilot pressure sensor 32. Hydraulic pump
16. Boost pressure relief 33. Check valve
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SMIL14CEX4135JB 3
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BOOM-DOWN TILTING PREVENTION CIRCUIT (WITH HBCV)

Even if the boom spool goes its full stroke, negative control pressure is generated by the center bypass bleed-off oil
path.
Therefore, the circuit becomes such that the hydraulic pump does not discharge full flow. By operating the remote
control valve all the way to the boom-down side at once, the generation of high pressure is restrained and main unit
tilt is reduced.
Since the shortfall in the oil volume is compensated by the regenerative circuit, the engine output can be used effec-
tively.
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Pilot pressure line
1. Load holding valve check valve 13. P2 pressure sensor

3. Oil cooler 15. Boom cylinder
4. Bleed-off 16. Boom (1)
5. Cushion valve 17. Boom-down pilot pressure sensor
8. Remote control valve (boom, bucket) 20. Main computer
10. Boost pressure relief 22. Boom HBCV check valve
11. 5 stack solenoid valve 23. Orifice
12. Control valve 24. Negative control sensor
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SMIL14CEX4136JB 4
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BOOM-DOWN LOAD HOLDING VALVE CIRCUIT (with HBCV)

When the remote control valve boom operation lever is in neutral, the oil at the boom cylinder bottom side is sealed
by the load holding valve check valve, reducing internal leakage from the main spool and reducing the natural drop
of the boom.
By moving the remote control valve to the boom-down side, the pilot pressure oil is fed via the cushion valve to the
control valve pb8 port and switches the boom spool to the down side.
boom (1).
Switching the spool lets the oil flow into the boom cylinder rod side, and the boom-down operation is carried out.
The pilot pressure oil from the pb8 port separated in the internal path is fed to the load holding valve spool and moves
the spool to the left.
When the circuit has an HBCV, the separated pilot pressure oil operates on the HBCV PL port and switches the spool.
This opens the HBCV check valve.
The boom cylinder bottom side pressure oil goes through the HBCV check valve, load holding valve check valve, and
the boom (1) spool, and then returns to the hydraulic tank.
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Pilot pressure line
1. Load holding valve check valve 13. Boom cylinder

2. Load holding valve spool 14. Boom (1)
3. Cushion valve 15. Boom-down pilot pressure sensor
10. Control valve 22. Boom HBCV check valve
11. Check valve 23. Orifice
12. Oil cooler 24. Bleed-off
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SMIL14CEX4137JB 5
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Hydraulic systems - Hydraulic schema – Arm circuit

ARM-OUT CIRCUIT (WITH HBCV)
By moving the remote control valve to the arm-out side, the pilot pressure oil is fed via the cushion valve to the control
valve pa5 port and pa9 port and switches the arm (1) and (2) spools to the out side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the center bypass oil path
to the arm (1) spool.
The oil flows from the arm (2) spool through the arm oil merging path and merges downstream of the arm (1) spool.
Switching the arm spool lets the oil flow through the load holding valve check valve and into the arm cylinder rod side,
carrying out the arm-out operation.
When the circuit has an HBCV, switching the arm spool lets the oil flow through the load holding valve check valve,
push open the arm cylinder HBCV check valve, and flow into the rod side, then the arm-out operation is carried out.
The arm cylinder bottom side return oil goes through the arm (1) (2) spools and returns to the hydraulic tank.
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Pilot pressure line
1. Arm cylinder 13. Arm-out pilot pressure sensor

2. Arm (in) 14. Console lever lock switch
3. Arm (out) 15. Monitor display
4. Cushion valve 16. Main computer
5. Remote control valve (arm, swing) 17. P1 pressure sensor
7. Boost pressure relief 19. Hydraulic pump
9. Control valve 21. Oil cooler
10. Load holding valve check valve 22. Arm HBCV check valve
11. Arm (1) 23. Arm HBCV
12. Arm (2)
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SMIL14CEX4138JB 1
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ARM SEMI-PARALLEL 1 CIRCUIT

Purpose
Reduces the pressure drops while the oil flows into the arm via P1 parallel path (mainly during a compound operation).
Secures the swing pressure during an arm + swing compound operation and improves leveling operability.
Independent operation
By moving the remote control valve to the arm-out or arm-in side, the pilot pressure oil is fed via the cushion valve to
the control valve pa5 (pa9) or pb5 (pb9) port and switches the arm (1) and (2) spools to the out or in side.
The discharge oil from the hydraulic pump A2 enters the control valve P2 port, flows from the center bypass oil path
and through the arm oil merging path before the arm (2) spool, and merges downstream of the arm (1) spool.
The arm 1 parallel spool operates according to the pilot pressure for an arm open/close operation.
• The opening is changed by increasing or decreasing the pilot pressure.
The pressure oil that passes through the parallel path flows through the arm 1 parallel spool, then to the arm 1 spool.
carrying out the arm-out operation. (for opening)
Switching the arm spool lets the oil flow into the arm cylinder bottom side and the arm-in operation is carried out. (for
closing)
The arm cylinder bottom side return oil goes through the arm (1) and (2) spools and returns to the hydraulic tank.
The arm cylinder rod side return oil goes through the arm (1) spool and returns to the hydraulic tank. Compound
operation (+ swing operation)
By moving the remote control valve to the swing side at the same time, the pilot pressure oil is fed via the cushion
valve to the control valve pa3 or pb3 port and switches the swing spool. The discharge oil from the hydraulic pump
A1 enters the control valve P1 port and is fed from the center bypass oil path to the swing spool.
The pressure oil that passes through the parallel circuit flows through the arm 1 parallel spool and is fed to the arm
(1) spool.
and through the arm oil merging path before the arm (2) spool, and merges downstream of the arm (1) spool. If a
swing operation is performed during an arm open/close operation (during a compound operation), the arm 1 parallel
spool operates according to the pilot pressure.
• The opening is changed by increasing or decreasing the pilot pressure. When the swing pilot pressure increases,
the opening of the arm 1 parallel spool narrows to secure the pressure for swing operations.
Secures the swing acceleration pressure during an arm + swing compound operation (same for swing press digging).
closing)
The swing operation is carried out by switching the swing spool. Compound operation (arm in + boom up)
By moving the remote control valve to the arm-in side, the pilot pressure oil is fed via the cushion valve to the control
valve pb5 (pb9) port and switches the arm (1) and (2) spools to the in side.
By moving the remote control valve to the boom-up side at the same time, the pilot pressure oil is fed via the cushion
valve to the control valve pa4 port and switches the boom (1) and (2) spools.
The discharge oil from the hydraulic pump A1 enters the control valve P1 port and is fed from the center bypass oil
path to the boom (2) spool.
(1) spool.
to the boom (1) spool.
(2) spool.
The oil passes through the arm oil merging path before the arm (2) spool and merges downstream of the arm (1)
spool.
During an arm digging operation, the opening of the arm 1 parallel spool opens.
• The opening is changed by increasing or decreasing the pilot pressure. The opening of the arm 1 parallel spool is
closed when the arm digging operation is completed and boom-up operation is carried out.
This is to secure the boom-up responsiveness in the latter half of the digging operation.
Switching the arm spool lets the oil flow into the arm cylinder bottom side and the arm-in operation is carried out.
Switching the boom spool lets the oil flow into the boom cylinder rod side and the boom-up operation is carried out.
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Continuous arm operations (skeleton operation)

When judging the skeleton operation, the opening of the arm 1 parallel spool opens.
• The continuous arm open/close operations prevent hunting of the arm 1 parallel spool.
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Pilot pressure line
1. Hydraulic pump 11. Lever lock

2. 5 stack solenoid valve 12. Arm out
3. Remote control valve (arm, swing) 13. Arm in
4. Cushion valve 14. Arm (1)
5. Control valve 15. Arm (2)
6. 6 stack proportional pressure reducing valve 16. Load holding valve check valve
7. Main computer 17. Load holding valve spool
8. Arm cylinder 18. Arm semi-parallel 1
9. HBCV 19. Arm semi-parallel 2
10. Control lever lock switch
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SMIL14CEX4139JB 2
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ARM SEMI-PARALLEL 2 CIRCUIT

Purpose
Reduces the pressure drops while the oil flows into the arm via P2 parallel path (mainly during a compound operation).
Secures the pressure during an arm + boom compound operation and improves leveling operability.
The arm 2 parallel spool operates according to the pilot pressure for an arm open/close operation.
• The opening is changed by increasing or decreasing the pilot pressure.
The pressure oil that passes through the parallel path flows through the arm 2 parallel spool, then to the arm 2 spool.
closing)
The arm cylinder bottom side return oil goes through the arm (1) and (2) spools and returns to the hydraulic tank.
The arm cylinder rod side return oil goes through the arm (1) spool and returns to the hydraulic tank. Compound
operation (arm in + boom up)
valve pb5 (pb9) port and switches the arm (1) and (2) spools to the out or in side.
By moving the remote control valve to the bside at the same time, the pilot pressure oil is fed via the cushion valve to
the control valve pa3 or pb3 port and switches the swing spool. The discharge oil from the hydraulic pump A1 enters
the control valve P1 port and is fed from the center bypass oil path to the swing spool.
(1) spool.
oThe discharge oil from the hydraulic pump A2 enters the control valve P2 port, flows from the center bypass oil path
If a swing operation is performed during an arm open/close operation (during a compound operation), the arm 2
parallel spool operates according to the pilot pressure.
• The opening is changed by increasing or decreasing the pilot pressure. When the swing pilot pressure increases,
the opening of the arm 2 parallel spool narrows to secure the pressure for swing operations.
Secures the swing acceleration pressure during an arm + swing compound operation (same for swing press digging).
closing)
The swing operation is carried out by switching the swing spool. Compound operation (arm in + boom up)
valve pb5 (pb9) port and switches the arm (1) and (2) spools to the in side.
valve to the control valve pa4 (pa8) port and switches the boom (1) and (2) spools.
(1) spool.
to the boom (1) spool.
(2) spool.
The oil passes through the arm oil merging path before the arm (2) spool and merges downstream of the arm (1)
spool.
During an arm digging operation, the opening of the arm 2 parallel spool opens.
• The opening is changed by increasing or decreasing the pilot pressure. The opening of the arm 2 parallel spool is
closed when the arm digging operation is completed and boom-up operation is carried out.
This is to secure the boom-up responsiveness in the latter half of the digging operation.
Continuous arm operations (skeleton operation)
When judging the skeleton operation, the opening of the arm 2 parallel spool opens.
• The continuous arm open/close operations prevent hunting of the arm 2 parallel spool.
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Pilot pressure line
1. Hydraulic pump 13. Arm out

2. 5 stack solenoid valve 14. Arm in
3. Remote control valve (arm, swing) 15. Arm (1)
4. Remote control valve (boom, bucket) 16. Arm (2)
5. Cushion valve 17. Load holding valve check valve
6. Control valve 18. Load holding valve spool
7. 6 stack proportional pressure reducing valve 19. Arm semi-parallel 1
8. Main computer 20. Arm semi-parallel 2Lever lock
9. Arm cylinder 21. Boom (1)
10. HBCV 22. Boom (2)
11. Control lever lock switch 23. Boom (right)
12. Lever lock 24. Boom (left)
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SMIL14CEX4140JB 3
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ARM-IN REGENERATIVE CIRCUIT (WITH HBCV)

valve pb5 port and pb9 port and switches the arm (1) and (2) spools to the in side.
The discharge oil from hydraulic pump A2 enters the control valve P2 port, flows from the center bypass oil path and
through the arm (2) spool.
The oil flows from the arm (2) spool through the arm oil merging path and merges downstream of the arm (1) spool.
The pilot pressure oil from the pb5 port separated in the internal path is fed to the load holding valve spool and moves
the spool to the right.
The arm cylinder rod side pressure oil goes through the load holding valve check valve and the arm (1) spool and is
metered by the arm regeneration release valve. Through this, the return oil pushes open the check valve in the arm
(1) spool and is regenerated on the cylinder bottom side, securing the arm speed for leveling work etc.
When the circuit has an HBCV, the arm cylinder rod side pressure oil goes through the HBCV check valve. When the
cylinder bottom load pressure becomes high, the oil flows from the arm regeneration proportional valve of the 6 stack
proportional pressure reducing valves and the arm regeneration release valve is switched to the large orifice diameter
side and the return opening becomes larger.
Through this, the check valve in the spool is closed and the cylinder rod side return oil goes through the arm spool
(1) and the forced regeneration release valve without regeneration and returns to the hydraulic tank.
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Pilot pressure line
1. Load holding valve spool 16. Arm cylinder

2. Load holding valve check valve 17. Arm (1)
3. Oil cooler 18. Arm (2)
4. Regeneration check valve 19. Arm-in pilot pressure sensor
5. Metering large 20. Console lever lock switch
6. Metering small 21. Monitor display
7. Arm regeneration release valve 22. Main computer
8. Arm (in) 23. P1 pressure sensor
9. Arm (out) 24. P2 pressure sensor
11. Remote control valve (arm, swing) 26. Check valve
12. Lever lock 27. Arm HBCV check valve
13. Boost pressure relief 28. Arm HBCV
14. 5 stack solenoid valve 29. 6 stack proportional pressure reducing valve
15. Control valve 30. Arm regeneration proportional valve
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SMIL14CEX4141JB 4
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ARM-IN LOAD HOLDING VALVE CIRCUIT (WITH HBCV)

When the remote control valve arm operation lever is in neutral, the oil at the arm cylinder rod side is sealed by the
load hold valve check valve, reducing internal leakage from the main spool and reducing the natural drop of the arm.
valve Pb5 port and Pb9 port and switches the arm (1) and (2) spools to the in side.
to the arm (1) spool. The discharge oil from hydraulic pump A2 enters the control valve P2 port, flows from the center
bypass oil path and through the arm (2) spool front arm merge oil path and merges upstream of the arm (1) spool.
Switching the arm spool lets the oil flow into the arm cylinder bottom side and carries out the arm-in operation.
The pilot pressure oil from the Pb5 port separated in the internal path flows into the HBCV PL port and switches the
spool.
This opens the HBCV check valve.
The pilot pressure oil from the Pb5 port separated in the internal path is fed to the load hold valve spool and moves
the spool to the right. In this way, the load hold valve check valve spring chamber oil is connected to the tank line
through the load hold valve spool, the spring chamber pressure drops, and the load hold valve check valve is opened.
The arm cylinder rod side pressurized oil goes through the HBCV check valve, load hold valve check valve and the
arm (1) spool and returns to the hydraulic oil tank.
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Pilot pressure line
1. Load holding valve spool 14. Arm (2)

2. Load holding valve check valve 15. Arm-in pilot pressure sensor
3. Oil cooler 16. Console lever lock switch
4. Arm (in) 17. Monitor display
5. Arm (out) 18. Main computer
6. Cushion valve 19. P1 pressure sensor
7. Remote control valve (arm, swing) 20. P2 pressure sensor
8. Lever lock 21. Hydraulic pump
10. 5 stack solenoid valve 23. Arm HBCV check valve
11. Control valve 24. Arm HBCV
12. Arm cylinder 25. 6 stack proportional pressure reducing valve
13. Arm (1) 26. Arm regeneration proportional valve
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SMIL14CEX4142JB 5
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Hydraulic systems - Hydraulic schema – Bucket Circuit

BUCKET-OPEN CIRCUIT
By moving the remote control valve to the bucket-open side, the pilot pressure oil is fed via the cushion valve to the
control valve pa7 port and switches the bucket spool to the open side.
bucket spool.
Switching the spool lets the oil flow into the bucket cylinder rod side and the bucket-open operation is carried out.
The bucket cylinder bottom side pressurized oil goes through the bucket spool and returns to the hydraulic oil tank.
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Pilot pressure line
1. Cushion valve 11. Bucket-open pilot pressure sensor

2. Bucket (close) 12. Console lever lock switch
3. Bucket (open) 13. Monitor display
9. Bucket 19. Oil cooler
10. Bucket cylinder
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SMIL14CEX4143JB 1
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BUCKET-CLOSE REGENERATIVE CIRCUIT

By moving the remote control valve to the bucket-close side, the pilot pressure oil is fed via the cushion valve to the
control valve pb7 port and switches the bucket spool to the close side.
bucket spool. Switching the spool lets the oil flow into the bucket cylinder bottom and the bucket-close operation is
carried out.
The bucket cylinder rod side pressurized oil is metered by the bucket spool regeneration orifice.
Through this, the return oil pushes open the check valve in the spool and is regenerated on the cylinder bottom side.
The lower the cylinder rod side load pressure, the greater the volume of regeneration.
When the cylinder bottom side load pressure becomes high, the check valve is closed and the cylinder rod side return
oil goes through the bucket spool without regeneration and returns to the hydraulic tank.
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Pilot pressure line
1. Regeneration check valve 13. Bucket cylinder

2. Oil cooler 14. Bucket-close pilot pressure sensor
3. Orifice 15. Console lever lock switch
4. Cushion valve 16. Monitor display
5. Bucket (close) 17. Main computer
6. Bucket (open) 18. P1 pressure sensor
7. Remote control valve (boom, bucket) 19. P2 pressure sensor
10. 5 stack solenoid valve 22. 6 stack proportional pressure reducing valve
11. Control valve 23. Bucket spool stroke control
12. Bucket
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SMIL14CEX4144JB 2
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BUCKET-CLOSE SPOOL STROKE CONTROL CIRCUIT

Purpose
Reduces back pressure while digging.
During a non-digging operation or compound operation, controls the system to secure pressure required for a com-
pound operation.
electromagnetic inversely proportional valve.
The oil is fed from the electromagnetic inversely proportional valve to the control valve pb7 port and switches the
bucket spool to the close side.
The electromagnetic inversely proportional valve on the bucket operates according to the digging operation conditions.
• The opening of the bucket spool changes according to the digging operation conditions.
The discharge oil from the hydraulic pump A2 enters the control valve P2 port and flows from the parallel oil path to
the bucket spool.
Switching the bucket spool lets the oil flow into the bucket cylinder bottom side and the bucket-close operation is
carried out.
The bucket cylinder rod side return oil goes through the bucket spool and returns to the hydraulic tank. Compound
operation (bucket close + boom up)
electromagnetic inversely proportional valve.
The oil is fed from the electromagnetic inversely proportional valve to the control valve pb7 port and switches the
bucket spool to the close side.
valve to the control valve pa4 (pa8) port and switches the boom (1) and (2) spools.
The discharge oil from the hydraulic pump A1 enters the control valve P1 port and is fed from the center bypass oil
path to the boom (2) spool.
bucket spool.
The pressure oil that passes through the parallel circuit is fed to the boom (1) spool. The oil passes through the boom
oil merging path before the boom (1) spool and merges downstream of the boom (2) spool.
During a digging operation (compound operation), the electromagnetic inversely proportional valve on the bucket
operates.
• The opening of the bucket spool changes according to the digging operation conditions.
Switching the bucket spool lets the oil flow into the bucket cylinder bottom side and the bucket-close operation is
carried out.
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Pilot pressure line
1. Hydraulic pump 11 Lever lock

2. 5 stack solenoid valve 12. Bucket close
3. Remote control valve (arm, swing) 13. Boom up
4. Cushion valve 14. Boom (1)
5. Control valve 15. Boom (2)
6. 6 stack proportional pressure reducing valve 16. Bucket
7. Main computer 17. Boom (right)
8. Bucket cylinder 18. Boom (left)
9. HBCV 19. Bucket spool stroke control
10. Control lever lock switch
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Hydraulic systems - Hydraulic schema – Negative control circuit

NEGATIVE CONTROL CIRCUIT
When the remote control valve operation lever is set to neutral, the discharge oil from hydraulic pumps A1 and A2
goes from the control valve P1 and P2 ports through the center bypass oil path, and through the negative control relief
valve, and returns to the hydraulic tank.
The negative control pressure oil separated from the center bypass oil path is fed from Ps1 and Ps2 ports to the
negative control pressure sensor.
The electromagnetic proportional pressure reducing valve on the pump operates and the oil flows into the regulator
and moves the pump tilting to the low flow side, and reduces the pump discharge flow.
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Pilot pressure line Negative control line
1. P1 negative control relief valve 9. P2 pressure sensor

2. P2 negative control relief valve 10. N1 negative control pressure sensor
3. Control valve 11. N2 negative control pressure sensor
4. Main computer 12. P1 electromagnetic proportional pressure reducing
valve
5. Console lever lock switch 13 P2 electromagnetic proportional pressure reducing
valve
8. P1 pressure sensor 16. Oil cooler
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SMIL14CEX4146JB 1
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Hydraulic systems - Hydraulic schema – Other circuits

As examples, this section explains the cases when an arm-out operation is carried out, when an arm-out operation is
stopped, and when an arm-out operation is followed by an arm-in operation.
CUSHION CIRCUIT (ARM-OUT OPERATION)

When a remote control valve arm-out operation is carried out, the pilot pressure oil enters from the remote control
valve 4 port into the cushion valve, pushes up the internal check valve, and is fed to the control valve pa5 and pa9
ports.
At the same time, the cushion valve cushion spool is switched to the left.
The arm-in side oil pushed out from the control valve pb9 and pb5 ports passes from the cushion valve B port through
the cushion spool switched to the left and returns to the hydraulic oil tank.
At this time, the warmed oil from the return line enters the remote control valve through the cushion spool from the
cushion valve R port and returns to the hydraulic oil tank, so heat performance is improved.
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Pilot pressure line
1. Arm (in) 9. 5 stack solenoid valve

2. Arm (out) 10. Control valve
3. Cushion spool 11. Arm (1)
4. Orifice 12. Arm (2)
5. Check valve 13. Console lever lock switch
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SMIL14CEX4147JB 1
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CUSHION CIRCUIT (WHEN ARM-OUT OPERATION STOPPED)

When the remote control valve arm-out operation is returned to neutral, the oil pushed out from the control valve pa5
and pa9 ports flows to the cushion valve D port through the cushion orifice and returns from the remote control valve
to the hydraulic oil tank.
Through this orifice, the arm spool moves to the neutral position without returning sharply, so the cushioning is im-
proved.
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Pilot pressure line
1. Arm (in) 9. Control valve

2. Arm (out) 10. Arm (1)
8. 5 stack solenoid valve
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SMIL14CEX4148JB 2
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CUSHION CIRCUIT (ARM-OUT → ARM-IN OPERATION)

When the lever is operating all at once from an arm-out operation to an arm-in operation (arm rattling operation), the
pilot pressure oil is fed from the remote control valve 2 port into the cushion valve A port, pushes up the internal check
valve, and reaches the control valve pb5 port and pb9 port.
At the same time, the cushion valve cushion spool is switched to the right.
At this time, the oil pushed out from the pa5 and pa9 ports does not pass through the cushion orifice, but passes
through the cushion spool that has been switched to the right and returns to the hydraulic oil tank, so response is
improved.
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Pilot pressure line

2. Arm (out) 10. Arm (1)
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SMIL14CEX4149JB 3
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HEAT CIRCUIT (LEVER IN NEUTRAL)

The pilot line is equipped with a heat circuit to prevent response delay at low temperatures.
When the remote control valve operation lever is set to neutral, the discharge oil from hydraulic pumps A1 and A2
goes from the control valve P1 and P2 ports through the center bypass oil path, and returns to the hydraulic oil tank.
The pressurized oil from the control valve T8 port is fed to the cushion valve R port and returns through the cushion
spool to the hydraulic oil tank.
By circulating the oil inside the cushion spool, the temperature of the oil in the cushion valve is raised to improve heat
performance.
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Pilot pressure line

2. Arm (out) 8. Console lever lock switch
3. Cushion spool 9. Hydraulic pump
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SMIL14CEX4150JB 4
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AUTO PRESSURE BOOST CIRCUIT (ARM IN)

When an attachment is operated, this circuit boosts the control valve main relief set pressure from 34.3 - 37.3 MPa
(4975.215 - 5410.365 psi) according to the engine load ratio and hydraulic load pressure, then ends the pressure
boost after 8 s.
As an example, this section explains arm-in operations.
valve pb5 and pb9 ports and switches the arm (1) and (2) spools to the in side.
At the same time, the output signal from the arm-in pilot pressure sensor that detected the pressure oil separated
from the pilot internal oil path is input to the main computer, which judges that there is an arm-in operation.
Furthermore, the main computer judges that there is a boost in the main pump P1 and P2 pressure, outputs the ON
( 24 V) signal to the boost relief solenoid, and switches the valve.
The pilot pressure oil is fed to the control valve main relief valve PH port to hold the boost relief set pressure for 8 s.
There is no boost during travel operation or for the option circuit.
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Pilot pressure line
1. Cushion valve 11. Arm-in pilot pressure sensor

2. Arm (in) 12. Console lever lock switch
3. Arm (out) 13. Monitor display
4. Remote control valve (arm, swing) 14. Main computer
9. Arm 19. Oil cooler
10. Arm cylinder
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SMIL14CEX4151JB 5
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Hydraulic systems - Hydraulic schema – Option circuits

BREAKER CIRCUIT (INDEPENDENT OPERATION)
By operating the option remote control valve to the breaker side, the pilot pressure oil is fed to the control valve pa2
port and switches the option spool.
The discharge oil from hydraulic pump A1 is fed from the control valve P1 port through the parallel oil path and fed to
the option spool.
Switching the spool lets the oil flow from the relief valve A port through the B port and into the breaker. The breaker
set pressure is set by this relief valve.
At this time, the option pilot pressure sensor signal is detected, the pump P1 flow control proportional valve is con-
trolled by the output signals from the main computer to adjust the discharge flow.
The return oil from the breaker goes through the manifold and returns to the hydraulic tank.
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Pilot pressure line
1. Control valve 11. Lever lock

2. Manifold 12. 5 stack solenoid valve
3. Relief valve 13. P1 pressure sensor
4. Breaker 14. P2 pressure sensor
5. Main computer 15. P2 flow control proportional valve
6. Monitor display 16. P1 flow control proportional valve
7. ATT select switch 17. Hydraulic pump
8. Option remote control valve 18. Check valve
9. Option pilot pressure sensor 19. Oil cooler
10. Console lever lock switch
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SMIL14CEX4152JB 1
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DOUBLE-ACTING CIRCUIT (HYDRAULIC FORK)

As an example, this section explains the case in which the hydraulic fork attachment is used.
By operating the option remote control valve to the fork close side, the pilot pressure oil is fed to the control valve pa2
port and switches the option spool to the close side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port, is fed from the parallel oil path to the option
spool, flows into the hydraulic fork because of the option spool switching and operates to the close side.
At this time, the option pilot pressure sensor signal is detected, the pump P1 flow control proportional valve is con-
trolled by the output signals from the main computer to adjust the discharge flow.
The return oil from the hydraulic fork goes through the option spool and returns to the hydraulic tank.
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Pilot pressure line
1. Control valve 8. Hydraulic pump

2. Hydraulic fork 9. Option remote control valve
3. Monitor display 10. Option pilot pressure sensor
4. Main computer 11. Check valve
6. 5 stack solenoid valve 13. ATT select switch
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SMIL14CEX4153JB 2
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MULTI-PURPOSE CIRCUIT (BREAKER Q CONTROL)

When the breaker mode is selected by pressing the ATT select switch on the monitor, the ON signal ( 24 V) is output
from the main computer to the option switchover solenoid valve and switches the valve.
The pilot pressure oil flows from the option switchover solenoid valve P port to the A port and is fed to the 3- direction
valve PP port and shut-off valve PP port and switches each valve.
By operating the breaker with the lever switch, the pilot pressure oil is fed to the control valve pa2 port and switches
the option spool.
the option spool.
Switching the spool lets the oil flow from the shut-off valve A port through the B port and into the breaker.
The breaker set pressure is set by the relief valve built into the shut-off valve. At this time, the lever switch signal is
detected, and the pump P1 flow control proportional valve is controlled by the output signal from the main computer
to adjust the discharge flow.
The return oil from the breaker goes from the 3-direction valve A port through the T1 port and returns to the hydraulic
tank.
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Pilot pressure line

2. 3-direction valve 12. 5 stack solenoid valve
3. Shut-off valve 13. P1 pressure sensor
4. Breaker 14. P2 pressure sensor
5. Lever switch 15. P2 flow control proportional valve
6. ATT select switch 16. P1 flow control proportional valve
7. Main computer 17. Hydraulic pump
8. Monitor display 18. Check valve
9. Option switchover solenoid valve 19. Oil cooler
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SMIL14CEX4154JB 3
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MULTI-PURPOSE CIRCUIT (2 PUMPS FLOW CRUSHER)

When the crusher mode is selected by pressing the ATT select switch on the monitor display, if the flow is set to 2
pumps flow, the ON signal ( 24 V) is output from the main computer to the neutral solenoid valve to switch the valve.
Also, at this time, a signal from the main computer to the option switchover solenoid valve is not output and the valve
is not switched.
At this time, the pilot signal does not go to the 3-direction valve or to the shut-off valve and the 3-direction valve forms
the A Û B circuit.
By carrying out the crusher-close operation with the lever switch, the pilot pressure oil is fed to the control valve pa2
port and switches the option spool.
At the same time, the pilot pressure oil flows into the neutral cut solenoid valve and is fed to the control valve pcc port
and switches the control valve neutral cut valve.
The discharge oil from hydraulic pump A2 enters the control valve P2 port and passes through the center bypass oil
path.
Because the port to the tank is closed by the neutral cut valve, the discharge oil goes from the P3 port through the
P4 port and merges upstream of the option spool.
the option spool.
Switching the spool lets the oil flow from the shut-off valve A port through the B port and into the crusher.
At this time, the lever switch signal is detected, and the pump P1 flow control proportional valve is controlled by the
output signal from the main computer to adjust the discharge flow.
The return oil from the crusher goes from the 3-direction valve A port through the B port and the option spool and
returns to the hydraulic tank.
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Pilot pressure line
1. 3-direction valve 11. Lever lock

2. Shut-off valve 12. 5 stack solenoid valve
3. Crusher 13. Neutral cut solenoid valve
4. Lever switch 14. P1 pressure sensor
5. Control valve 15. P2 pressure sensor
6. ATT select switch 16. P2 flow control proportional valve
7. Main computer 17. P1 flow control proportional valve
8. Monitor display 18. Hydraulic pump
9. Option switchover solenoid valve 19. Check valve
10. Console lever lock switch 20. Oil cooler
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SMIL14CEX4155JB 4
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2ND OPTION CIRCUIT (HYDRAULIC ROTATION FORK)

As an example, this section explains the case in which the hydraulic rotation fork attachment is used.
By carrying out the right swing operation with the lever switch, the pilot pressure oil is fed to the control valve Par1
port.
The 4th hydraulic pump OUT discharge oil is fed to the control valve Pr port, goes through the 2nd option spool and
flows to the hydraulic rotation fork to carry out a right swing operation.
The return oil from the hydraulic rotation fork goes through the 2nd option spool and returns to the hydraulic tank.
The oil in the 2nd option drain line returns to the hydraulic tank without going through the control valve.
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Pilot pressure line

2. 2nd option solenoid valve 9. 5 stack solenoid valve
3. 2nd option lever switch 10. Hydraulic pump
4. Main computer 11. 4th pump
5. Monitor display 12. Check valve
6. Hydraulic rotation fork 13. Oil cooler
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Hydraulic systems - Service instruction Table of standards

Mode SP mode, with bucket

Lower specifications LC
Boom specifications Standard
Arm specifications Standard
Arm length Standard / Short / Long
Bucket size, specifications 1.2 / 1.4 / 1.6 / 1.8 standard
Item Standard value

32.8 - 36.8 MPa (4757.6 -
Normal use
5337.8 psi)
Main relief
35.8 - 39.8 MPa (5192.8 -
Pressure boost
5773.0 psi)
18.6 - 22.6 MPa (2697.9 -
Fourth pump relief Second option
3278.1 psi)
38.0 - 44.0 MPa (5511.9 -
Up
6382.2 psi)
Boom
29.0 - 35.0 MPa (4206.5 -
Down
5076.8 psi)
38.5 - 44.5 MPa (5584.4 -
Close
6454.7 psi)
Dipper
38.5 - 44.5 MPa (5584.4 -
Open
6454.7 psi)
38.5 - 44.5 MPa (5584.4 -
Open
6454.7 psi)
Bucket
39.5 - 45.5 MPa (5729.5 -
Close
6599.8 psi)
28.4 - 32.4 MPa (4119.4 -
Swing Both right and left
4699.6 psi)
Pressure measurement Breaker spec first speed -
Reciprocal spec Crusher
mode second speed (P1, -
P2)
Combined spec Breaker
-
mode first speed (P1)
Combined spec Crusher
Option P2)
Combined (electromagnetic
relief) spec Breaker mode -
first speed (P1)
relief) spec Crusher mode -
second speed (P1, P2)
Both right and left, and both 39.0 - 43.0 MPa (5657.0 -
Travel
forward and backward 6237.2 psi)
2.9 - 4.9 MPa (420.6 -
Pilot pump For pilot
710.7 psi)
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Item Standard value

SP mode 1890 - 1910 RPM
H mode 1690 - 1710 RPM
Engine speed (At no load)
A mode 1590 - 1610 RPM
Engine speed Low idle 890 - 910 RPM
measurement SP mode 1890 - 1910 RPM
H mode 1690 - 1710 RPM
Engine speed (At 2 relief)
A mode 1590 - 1610 RPM
Low idle 890 - 910 RPM
SP mode -10 - 10 %
Displacement
H mode -10 - 10 %
(At no load)
A mode -10 - 10 %
Displacement on P2 side SP mode 82 - 102 %
Pump Command (At 1 relief) H mode 82 - 102 %
Displacement Bucket open 69 - 89 %
At normal pressure A mode
Displacement (At 2 relief) SP mode 37 - 57 %
Boom up H mode 37 - 57 %
At normal pressure A mode 30 - 50 %
At no load Displacement for Boom cylinder 10.0 mm (0.394 in)
Attachment free-fall 10 min Dipper cylinder 15.0 mm (0.591 in)
amount measurement Each cylinder displacement Bucket cylinder 20.0 mm (0.787 in)
is a reference value. Tip (fall amount) 250.0 mm (9.843 in)
Up {stroke: 878 mm 2.6 - 3.6 s
(34.567 in)}
Boom
Down {stroke: 878 mm 1.7 - 2.9 s
Attachment speed (34.567 in)}
measurement Open 3.1 - 4.1 s
Dipper
Close 3.0 - 4.2 s
Open 2.4 - 3.4 s
Bucket
Close 3.5 - 4.7 s
5.6 - 6.6 s
Swing speed measurement Right/Left swing (every revolution)
9.2 - 10.4 RPM
Swing brake angle 180 ° Minimum operating radius
Swing brake performance 50 ° or less
swing at no load
3.4 - 4.4 s
High speed [every 6 m
4.9 - 6.3 km/h (3.0 -
(19.69 ft) ]
3.9 mph)
Travel speed measurement Forward/Backward
5.5 - 7.3 s
Low speed [every 6 m
3.0 - 3.8 km/h (1.9 -
(19.69 ft) ]
2.4 mph)
Zigzag amount while High speed 1000 mm (39.37 in) or less
Zigzag amount
traveling 20 m (65.62 ft)
measurement Low speed 1000 mm (39.37 in) or less
Forward/Backward
Measured with one side
340 - 360 mm (13.39 -
Shoe tension condition frame raised (both right and Iron
14.17 in)
left)
Forward/Backward (10 High speed 12.6 - 16.6 s
Sprocket rotation rotations)
Low speed 22.3 - 26.3 s
SP mode
Travel Motor
15 L/min (3.96 US gpm)
Very slow during a stall
Drain amount (MAX)
Swing motor
Ball race movement Up/Down 2.0 mm (0.079 in)
amount Right/Left 6.5 mm (0.256 in)
Bucket tip movement
Right/Left 110 mm (4.331 in)
amount
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Item Standard value

When compressed 781 mm (30.748 in)
Recoil spring
When freed 916 mm (36.063 in)
Travel second speed About 40 Ω
Pressure boost About 40 Ω
Solenoid Coil resistance 20 °C (68 °F)
Swing brake About 40 Ω
Lever lock About 40 Ω
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Hydraulic systems - Service instruction Table of standards

Mode SP mode, with bucket

Lower specifications STD / LC / NLC
Boom specifications HD
Arm specifications HD
Arm length Standard / Short / S-Short
Bucket size, specifications 1.4 / 1.6 / 1.8 / 2.0 HD
Item Standard value

32.8 - 36.8 MPa (4757.6 -
Normal use
5337.8 psi)
Main relief
35.8 - 39.8 MPa (5192.8 -
Pressure boost
5773.0 psi)
18.6 - 22.6 MPa (2697.9 -
Fourth pump relief Second option
3278.1 psi)
38.0 - 44.0 MPa (5511.9 -
Up
6382.2 psi)
Boom
29.0 - 35.0 MPa (4206.5 -
Down
5076.8 psi)
38.0 - 44.0 MPa (5511.9 -
Close
6382.2 psi)
Dipper
38.0 - 44.0 MPa (5511.9 -
Open
6382.2 psi)
38.5 - 44.5 MPa (5584.4 -
Open
6454.7 psi)
Bucket
39.5 - 45.5 MPa (5729.5 -
Close
6599.8 psi)
28.4 - 32.4 MPa (4119.4 -
Swing Both right and left
4699.6 psi)
Pressure measurement Breaker spec first speed -
Reciprocal spec Crusher
P2)
Combined spec Breaker
-
mode first speed (P1)
Combined spec Crusher
Option P2)
relief) spec Breaker mode -
first speed (P1)
relief) spec Crusher mode -
second speed (P1, P2)
Both right and left, and both 39.0 - 43.0 MPa (5657.0 -
Travel
forward and backward 6237.2 psi)
2.9 - 4.9 MPa (420.6 -
Pilot pump For pilot
710.7 psi)
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Item Standard value

SP mode 1890 - 1910 RPM
H mode 1690 - 1710 RPM
Engine speed (At no load)
A mode 1590 - 1610 RPM
Engine speed Low idle 890 - 910 RPM
measurement SP mode 1890 - 1910 RPM
H mode 1690 - 1710 RPM
Engine speed (At 2 relief)
A mode 1590 - 1610 RPM
Low idle 890 - 910 RPM
SP mode -10 - 10 %
Displacement
H mode -10 - 10 %
(At no load)
A mode -10 - 10 %
Displacement on P2 side SP mode 82 - 102 %
Pump Command (At 1 relief) H mode 82 - 102 %
Displacement Bucket open 69 - 89 %
At normal pressure A mode
Displacement (At 2 relief) SP mode 37 - 57 %
Boom up H mode 37 - 57 %
At normal pressure A mode 30 - 50 %
At no load Displacement for Boom cylinder 10.0 mm (0.394 in)
Attachment free-fall 10 min Dipper cylinder 15.0 mm (0.591 in)
amount measurement Each cylinder displacement Bucket cylinder 20.0 mm (0.787 in)
is a reference value. Tip (fall amount) 250.0 mm (9.843 in)
Up {stroke: 878 mm 3.1 - 4.1 s
(34.567 in)}
Boom
Down {stroke: 878 mm 1.9 - 3.1 s
Attachment speed (34.567 in)}
measurement Open 2.4 - 3.4 s
Dipper
Close 3.0 - 4.2 s
Open 2.4 - 3.4 s
Bucket
Close 3.5 - 4.7 s
5.6 - 6.6 s
Swing speed measurement Right/Left swing (every revolution)
9.2 - 10.4 RPM
Swing brake angle 180 ° Minimum operating radius
Swing brake performance 50 ° or less
swing at no load
3.4 - 4.4 s
High speed [every 6 m
4.8 - 6.2 km/h (3.0 -
(19.69 ft) ]
3.9 mph)
Travel speed measurement Forward/Backward
5.6 - 7.4 s
Low speed [every 6 m
2.9 - 3.7 km/h (1.8 -
(19.69 ft) ]
2.3 mph)
Zigzag amount while High speed 1000 mm (39.37 in) or less
Zigzag amount
traveling 20 m (65.62 ft)
measurement Low speed 1000 mm (39.37 in) or less
Forward/Backward
Measured with one side
340 - 360 mm (13.39 -
Shoe tension condition frame raised (both right and Iron
14.17 in)
left)
Forward/Backward (10 High speed 12.8 - 16.8 s
Sprocket rotation rotations)
Low speed 22.8 - 26.8 s
SP mode
Travel Motor
Drain amount (MAX)
Swing motor
Ball race movement Up/Down 2.0 mm (0.079 in)
amount Right/Left 6.5 mm (0.256 in)
Bucket tip movement
Right/Left 110 mm (4.331 in)
amount
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Item Standard value

When compressed 781 mm (30.748 in)
Recoil spring
When freed 916 mm (36.063 in)
Travel second speed About 40 Ω
Pressure boost About 40 Ω
Solenoid Coil resistance 20 °C (68 °F)
Swing brake About 40 Ω
Lever lock About 40 Ω
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Hydraulic systems - Service instruction Measurement method

ENGINE SPEED
Measurement method
1. No load operation mode at high idle: SP mode, H
mode and A mode speed.
2. Operation mode at low idle: SP mode speed.
NOTE: Bucket on ground.
SMIL14CEX6641AA 1
PRESSURE AT EACH PART
Measurement method
1. Engine at high idle.
2. Oil temperature is at 45 - 55 °C (113 - 131 °F).
3. Measure at the area between the counter balance
and the motor in the case of the travel and swing.
4. Before measuring the overload pressure, you must
measure the main relief pressure prior to an adjust-
ment and raise the main pressure to the overload
pressure or above. After the measurement, restore
the main pressure back to the specified pressure.
NOTE: Operate the attachment, etc. with the travel pos-
ture.
SMIL14CEX6642AA 2
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PUMP COMMAND DISPLACEMENT
Measurement method
1. Check the values of "PUMP1 FLOW RATE" and
"PUMP2 FLOW RATE" on the service screen.
How to display the service screen

1. Hold down the travel speed select switch and at-
tachment select switch on the monitor for 3 sec-
onds.
2. Display "CHECK" → "MACHINE STATUS" (1/9).
SMIL14CEX6643AA 3
CYLINDER DOWN AMOUNT
Measurement method
1. Circulate the oil to each cylinder before measur-
ing the oil temperature at 45 - 55 °C (113 - 131 °F).
(Record the oil temperature before and after mea-
surement).
2. Set the boom foot pin and bucket pin at the same
height.
Put the arm cylinder at its retraction end and the
bucket cylinder at its open end.
3. Stop the engine.
4. Measure the rod extension or retraction amount of
the boom, arm and bucket cylinder after 10 min.
5. Measure the displacement of the tip after 10 min SMIL14CEX6644AA 4
along with each cylinder movement amount.
(a) same height
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ATTACHMENT SPEED
Measurement method
3. No load.
Boom cylinder
With the arm-out end and bucket-open end, from
the boom cylinder up end (position) to the surface
of the ground; and from the surface of the ground to
the boom cylinder up end (position).
NOTE: Do not make any direct contact (hit) to the concrete
ground upon a boom-down operation. (Place tires on the
ground).
SMIL14CEX6645AA 5
Arm cylinder
Arm horizontal with the arm cylinder at its out end;
and the arm cylinder full stroke with the bucket cylin-
der at its open end.
SMIL14CEX6646AA 6
Bucket cylinder
Full stroke with the maximum radius.
SMIL14CEX6647AA 7
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SWING SPEED
Measurement method
3. No load.
4. Time needed to complete 1 rotation following the
previous 1 rotation.
SMIL14CEX6648AA 8
SWING 180 ° brake angle
Measurement method
1. Engine high idle.
3. No load.
4. Swing 180 ° and measure the flow angle after neu-
tral braking.
NOTE: same posture of the swing speed measurement.
TRAVEL SPEED
Measurement method
1. Oil temperature is at 45 - 55 °C (113 - 131 °F) with
the engine at high idle with no load.
2. After 4 - 5 m (13.12 - 16.40 ft) approach, measure
the time required to travel 6 m (19.69 ft).
However, if the meandering amount is 1 m (3.28 ft)
or more, correct the meandering amount and re-
measure as a reference.
3. Travel on the concrete surface.
4. Perform both the high-speed mode and low-speed
mode.
SMIL14CEX6649EA 9
(a) 4 - 5 m (13.12 - 16.40 ft) approach
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(b) 6 m (19.69 ft) travel
OFF TRAVEL AMOUNT
Measurement method
1. Engine high idle and oil temperature is 45 - 55 °C
(113 - 131 °F) with no load.
2. Measure the required time to travel 20 m (65.62 ft)
after a 4 - 5 m (13.12 - 16.40 ft) running start.
3. Shoe tension amount should be standard for right
and left.
4. Measure for both forward and backward traveling.
5. Measure for both high-speed and low speed trav-
eling.
(a) Off travel amount
(b) Reference line SMIL14CEX6650BA 10
NOTE: Same posture of the travel speed measurement.
TRAVEL SPROCKET SPEED
Measurement method
3. Raise the shoe and wait until the steady rotation
speed is reached, measure the time needed to
complete 10 rotations of the sprocket for both for-
ward travel and backward travel.
4. Measure for both the high-speed mode and low-
speed mode.
NOTE: Swing by 90 ° to raise the shoe.
SMIL14CEX6651BA 11
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SHOE TENSION AMOUNT
Measurement method
1. Raise the shoe, and at the central position of the
track, measure the gap between the underside of
the lower side frame and the topside of the shoe
plate.
2. Measure for both the left and right sides.
(a) Topside of shoe plate
(b) Underside of lower side frame
SMIL14CEX6652BA 12
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SWING BALL RACE BEARING MOVEMENT AMOUNT AND BUCKET TIP MOVEMENT
AMOUNT
Measurement method in a vertical direction

1. Measure the vertical movement amount at the front
and back of the ball race (two locations).
2. With the arm cylinder out and the bucket cylinder
closed, raise the bucket bottom 30 cm (11.81 in)
off the ground and perform 0-point adjustment with
the dial gauge attached at the lowering part as
shown in the following figure.
3. Jack up the main unit and measure the movement
amount on the dial gauge.
* Jack up the main unit until oscillation of the dial
gauge becomes stable.
(a) Front
(b) Rear
(*1) Lowering
SMIL14CEX6653CB 13
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Measurement method in a horizontal direction

1. Measure the movement amount at the right and left
of the ball race front and bucket tip.
2. With the arm cylinder out and bucket cylinder open,
push one side (right or left) with a force of 30 -
40 kgf and perform 0-point adjustment at the state.
3. Push the other side (right or left) with a force of
30 - 40 kgf and measure the horizontal movement
amount.
(a) Make the dial gauge contact the ball race instal-
lation bolt and measure the movement amount.
(*1) Bearing
SMIL14CEX6654BA 14
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Hydraulic systems - Pressure test

PROCEDURES FOR PRESSURE MEASUREMENT FROM THE MONITOR DISPLAY
Monitor and switch panel
SMIL14CEX2068EB 1
1. Liquid crystal monitor 3. Cover

2. Switch panel 4. Diffuser
Pressure measurement method

The P1, P2, N1, and N2 pressure can be measured
from the monitor display. (The pilot pressure cannot be
measured.)
Operating method
1. When both the travel speed select switch and the
attachment select switch on the switch panel are held
down, the display switches to the service support
screen.
2. Select CHECK on the service support screen.
3. Select MACHINE STATUS on the service support
screen.
4. In the field of “P1” ( P1 pump main pressure), “P2” (
P2 pump main pressure), ”N1" ( N1 negative control
pressure) and " N2 PRESS" ( N2 negative control pres-
sure), the pressure corresponding to each field will be
displayed.
*When a password is set to the service support screen,
you will not be taken to this screen unless entering the
password.
*Press the menu switch several times to return to the
normal screen.
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SMIL15CEX0738EA 2
a. Normal screen b. Service support screen
PROCEDURES FOR MEASURING HYDRAULIC OIL TEMPERATURE FROM THE MONITOR

DISPLAY
Hydraulic oil temperature measurement method

The hydraulic oil temperature can be measured from
the monitor display.
Operating method
1. When both the travel speed select switch and the
attachment select switch on the switch panel are held
down, the display switches to the service support
screen.
2. Select CHECK on the service support screen.
3. Select MACHINE STATUS on the service support
screen.
4. The hydraulic oil temperature will be displayed in the
“HYD.OIL TEMP” field.
SMIL14CEX2070EA 3
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PROCEDURES FOR PRESSURE MEASUREMENT BY INSTALLING PRESSURE GAUGE
Preparations
Role (worker 1: work supervisor, pressure adjustment)
Workers 2
Role (worker 2: operator)
Items to prepare
SMIL14CEX2071FB 4
1. Pressure gauge [ 10 MPa (1450 psi) -1] 6. Recording sheet

2. Pressure gauge [ 60 MPa (8703 psi) -2] 7. Pen
3. Hexagon wrench [ 8 mm, 6 mm] 8. Cleaning fluid
Wrench [ 17 mm, 24 mm, 27 mm x 2, 32 mm,
4. 9. Joint
36 mm x 2]
5. Rag
PRESSURE MEASURING PORTS

There are the following 3 ports for pressure measure-
ment.
• Main pressure: Pressure ports ( P1, P2)
(Attach the joint between the main pressure sensor
and the hydraulic pump, and attach the pressure
gauge.)
• Negative control pressure: Pressure ports ( N1, N2)
(Attach the joint between the negative control pres-
sure sensor and the control valve, and attach the
pressure gauge.)
• Pilot pressure: Pressure port (P3)
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SMIL14CEX2072HB 5
1. Hydraulic pump 4. Pressure port: P3 7. Pressure port: N2

2. Pressure port: P2 5. Control valve
3. Pressure port: P1 6. Pressure port: N1
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CONTROL VALVE
Location of relief valves

Tool Adjusting
Set pressure screw Per Measuring
Part Adjusting
Lock nut MPa (psi) revolution port
screw
MPa (psi)
Hexagon Hexagon
Main (normal 34.3 MPa 21.3 MPa
a diameter diameter Monitor P1
use) (4975.2 psi) (3089.6 psi)
27 mm (1.1 in) 27 mm (1.1 in)
1 Hexagon
Hexagon
Main (pressure diameter 37.3 MPa 28.4 MPa
b diameter Monitor P1
boost) 27.0 mm (5410 psi) (4119 psi)
32 mm (1.3 in)
(1.1 in)
27.4 MPa 21.2 MPa
2 boom up Monitor P2
(3974 psi) (3075 psi)
39.2 MPa 21.2 MPa
3 boom down Monitor P2
(5686 psi) (3075 psi)
39.2 MPa 21.2 MPa
4 arm in Hexagon Monitor P1
(5686.0 psi) (3075.1 psi)
diameter
Hexagon 39.2 MPa 21.2 MPa
5 arm out 17 mm (0.7 in) Monitor P1
diameter (5686 psi) (3075 psi)
6 mm (0.2 in) 39.2 MPa 21.2 MPa
6 Bucket close Monitor P2
(5686.0 psi) (3075.1 psi)
39.2 MPa 21.2 MPa
7 Bucket open Monitor P2
(5686 psi) (3075 psi)
Hexagon
3.92 MPa 2 MPa
8 pilot diameter
(568 psi) (290 psi)
24 mm (0.9 in)
SMIL14CEX2073FB 6
Detailed diagram of main relief valve adjustment locations
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*1. pressure boost lock nut *3. standard pressure adjusting screw
*2. pressure boost adjusting screw *4. standard lock nut
PRESSURE MEASUREMENT PREPARATIONS

1. Items to prepare
For 10 MPa (1450 psi)(for pilot/
Pres-
negative control measurement)
1. sure
For 60 MPa (8703 psi)(for main
gauge
measurement)
Wrench (box-end wrench), 17 mm
2. Tools
Hexagon wrench, 6 mm
Rag
Cleaning fluid
3. Other
Joint (for pilot/negative control
pressure measurement)
SMIL14CEX2074AA 7
2. Monitor check
Check the no-load engine maximum speed, by the ser-
vice check.
Engine MAX
1900 RPM
SMIL14CEX2075AA 8
3. Placement of main unit

Place the main unit on a flat, hard ground, put the
bucket cylinder at its open stroke end and the arm cylin-
der at its out stroke end, lower the boom and put the
arm tip on the ground.
SMIL14CEX2076AA 9
4. Ignition key
Turn the ignition key (1) OFF. Confirm that the engine
is stopped and then turn the ignition key ON again. (Do
not start the engine.)
SMIL14CEX2077AB 10
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5. Oil temperature check

Check the hydraulic oil temperature by the service
check.
Oil temperature: 45 - 55 °C (113.0 - 131.0 °F)
If the oil temperature is low, raise the oil temperature
according to the procedures for warm-up operation in
the operator's manual.
SMIL14CEX2075AA 11
6. Release of pressure inside circuit

Pull down the gate lock lever (1) forward and rotate the
upper operation lever (2) about 10 times to release the
pressure.
3. Gate lever
SMIL14CEX2078AB 12
Move the travel lever (1) back and forth about 5 times
to release the pressure.
SMIL14CEX2079AB 13
7. Release of pressure inside hydraulic reservoir.

Push the air breather button (1) on top of the hydraulic
reservoir to release the pressure inside the tank.
SMIL14CEX2080AB 14
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8. Open/close of side door

Open the side door (1).
At this time, be sure to check that the lock (2) is applied.
SMIL14CEX2081AB 15
PRESSURE MEASUREMENT
Main pressure measurement

1. Pressure Gauge Installation
Detach the pressure sensors (a1) and (a2) from the
hydraulic pump (1), attach the pressure gauge joint (2),
and then attach the removed sensors.
(a1) : Items that can be (a2) : Items that can be
measured measured
Travel, left Travel, right
OptionSwing Bucket
Swing
Arm 1 pump flow Arm 2 pumps flow
Boom 2 pumps flow Boom 1 pump flow
SMIL14CEX2082AB 16
Attach the adapter (2) to the pressure gauge joint (1).
SMIL14CEX2083AB 17
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Install the pressure gauge (2) to the adapter (1) and fix
them.
Pressure gauge Port size: G1/4 for 60 MPa
(8703 psi)
SMIL14CEX2084AA 18
SMIL14CEX2085AB 19
A. Attachment pressure measurement

Example: Arm-out pressure measurement
Perform measurement according to the following oper-
ation.
Engine speed 1900 RPM

Work mode SP mode
Lever operation arm-out relief
Oil temperature 45 - 55 °C (113 - 131 °F)
1 pumps: P1 port
Measuring port
2 pump: P2 port
Pressure boost: 37.3 MPa (5410 psi)
Set pressure
Standard: 34.3 MPa (5410 psi)
SMIL14CEX2086EA 20
a. Arm-out relief
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During attachment operation, you can check the pres-

sure resulting from the pressure boost setting for 8 s
because the auto pressure boost works.
In 8 s or more, you can check the standard set pres-
sure.
For also arm out/in, bucket open/close, and boom up,
relieve each cylinder to make measurements.
Lever
Arm out Arm in Bucket open Bucket close Boom up Boom down
operation
Work mode SP mode
Oil temperature 45 - 55 °C (113 - 131 °F)
1 pump flow
P1 P1 P2 P2 P2 P2
measuring port
2 pumps flow
P2 P2 None None P1 None
measuring port
27.4 MPa
Pressure boost 37.3 MPa (5410 psi)
(3974 psi)
Standard 27.4 MPa
34.3 MPa (5410 psi)
pressure (3974 psi)
Boom-down pressure measurement

For pressure measurement with the boom down, put
the arm cylinder at its out stroke end, open the bucket,
put the bucket tip on the ground, carry out the boom-
down operation, and measure.
a. Boom-down relief
SMIL14CEX2087AA 21
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B. Travel pressure measurement

1. Install the stopper (1) on the crawler sprocket section
(2) and lock the travel motor.
2. Measure with the following operations.
Work mode SP mode (1st speed)
Lever operation Travel relief
45 - 55 °C (113.0 -
Oil temperature
131.0 °F)
Left travel: P1 port
Measuring port
Right travel: P2 port
Set pressure 34.3 MPa (5410 psi)
SMIL14CEX2088BB 22
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C. Swing pressure measurement

1. Do not let the bucket move even if swing pressure is
relieved with a swing operation such as digging a hole.
2. Measure with the following operations.
Work mode SP mode
Lever operation Swing relief
45 - 55 °C (113.0 -
Oil temperature
131.0 °F)
Measuring port P1 port
Set pressure 30 MPa (4352 psi)
SMIL14CEX2089BA 23
D. Option line pressure measurement

1. Close the stop valve (1) of the option line.
SMIL14CEX2090AB 24
2. Change the attachment select switch on the monitor to

the option line to be measured. (Breaker/crusher)
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3. Perform measurement according to the following oper-

ation.
Work mode SP mode
Lever operation Option relief
45 - 55 °C (113.0 -
Oil temperature
131.0 °F)
1 pumps: P1 port
Measuring port
2 pump: P2 port
SMIL14CEX2091AA 25
*Adjust the set pressure according to the specification

of the attachment used.
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PILOT PRESSURE MEASUREMENT
Pressure gauge installation

Remove the plug using the wrench (1) in order to install
a pressure gauge to the pressure measuring port (P3)
of the pump.
SMIL14CEX2092AB 26
Install the adapter (1).
SMIL14CEX2093AB 27
Install the pressure gauge (1) to measure the pressure.

Work mode SP mode
45 - 55 °C (113.0 -
Oil temperature
131.0 °F)
Set pressure 3.92 MPa (568.60 psi)
Pressure gauge port G1/4 for 10 MPa

size (1450 psi)
SMIL14CEX2094AA 28
SMIL14CEX2095AB 29
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NEGATIVE CONTROL PRESSURE MEASUREMENT
Pressure gauge installation

Disconnect the connector (3) from the N1 pressure sen-
sor (1) or N2 pressure sensor (2) of the pump, and re-
move the pressure sensor. ( N1, N2 : Pressure port)
(The pressure sensor location is used as the measur-
ing port.)
SMIL14CEX2096BB 30
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Attach the pressure gauge joint (1) to the port from

which the N1 pressure sensor or the N2 pressure sen-
sor is removed, attach the removed pressure sensor
and adapter (1) to the joint, and attach the pressure
gauge (3) . Measure the negative control pressure upon
each operation.
Pressure gauge port G1/4 for 10 MPa
size (1450 psi)

Work mode SP mode
45 - 55 °C (113.0 -
Oil temperature
131.0 °F)
P1 pump side: N1 port
Measuring port
P2 pump side: N2 port
3.8 MPa (551.19 psi)
Set pressure Maximum: 10 MPa
(1450.50 psi)
SMIL14CEX2097BB 31
SMIL14CEX2098AA 32
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Hydraulic systems - Pressure setting

MAIN PRESSURE ADJUSTMENT
Pressure measurement and adjustment preparations
Pressure adjustment is carried out with the control

valve.
To perform the adjustment with the control valve, the
following preparations are required.
Open/Close of engine hood

Open the engine hood (1).
SMIL14CEX2099AB 1
Removal of cover
Remove the 9 bolts (1) to remove the covers (2) and
(3).
SMIL14CEX2100AB 2
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For pressure boost

1. Loosen the standard lock nut [ 27 mm ] (1), and tighten
the adjusting screw [ 27 mm] (2).
At this time, fix the pressure boost adjusting screw with
a wrench [ 27 mm] so that it may not turn.
SMIL14CEX2101AB 3
2. After tightening the adjusting screw as far as it will turn,

and tighten the standard lock nut (1).
SMIL14CEX2102AB 4
3. Set the engine to the maximum speed.

4. Set the arm lever to the in position to bring about and
keep a relief state.
5. Loosen the pressure boost lock nut [ 32 mm (1.260 in)]
(1), and obtain the set pressure with the adjusting
screw [ 27 mm (1.063 in)] (2).
• Tighten it if pressure is lower than the set pressure.
• If pressure is higher than the set pressure, reduce it
below the set pressure, and then adjust it by tighten-
ing the screw.
SMIL14CEX2103AB 5
6. After the adjustment, fix the adjusting screw with a

wrench [ 27 mm], and tighten the lock nut.
7. After locking it, check the pressure on the pressure
boost side.
Repeat steps 1 to 7 until the set pressure is obtained
correctly.
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For standard
1. Loosen the standard lock nut [ 27 mm (1.063 in)] (1).
SMIL14CEX2104AB 6
2. Loosen the adjusting screw (1) to reduce pressure be-

low the set pressure, and then adjust it by tightening
the screw.
SMIL14CEX2105AB 7
3. After the adjustment, tighten the lock nut while fixing

the adjusting screw (1) with a wrench (2).
SMIL14CEX2106AB 8
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4. After locking it, check the pressure. Repeat steps 1 , 2

and 3 until the set pressure is obtained correctly. Stop
the engine.
Main relief pressure adjustment
Work mode SP mode
Lever operation Arm-in relief
45 - 55 °C (113.0 -
Oil temperature
131.0 °F)
Pressure boost:
37.3 MPa (5410.4 psi)
Measured pressure
Standard: 34.3 MPa
(4975 psi)
Pressure boost:
28.4 MPa (4119 psi) /
Pressure per revolution
revolution
of adjusting screw
Standard: 21.3 MPa
(3089 psi) /revolution
Disconnect the pilot hose for the pressure boost signal

(2) from the main relief valve (1), and attach the plug
(3) to the hose side. The procedure is different between
that for pressure boost and that for standard.
4. Control valve
5. Wrench [ 19 mm]
SMIL14CEX2107CB 9
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Overload relief pressure adjustment

Work mode SP mode
45 - 55 °C (113.0 -
Oil temperature
131.0 °F)
Measuring port P1/ P2 port
Boom down: 27.4 MPa
(3974 psi)
Measured pressure
Others: 39.2 MPa
(5686 psi)
Pressure per revolution 21.2 MPa (3075 psi) /
of adjusting screw revolution
Since the overload relief pressure is set higher than the

main relief pressure, the main relief pressure needs to
tentatively be set highly than the overload relief pres-
sure. (Except in the case of boom down)
1. Control valve
2. Arm in
3. Bucket close
4. Boom down
5. Arm out
6. Boom up
7. Bucket open
SMIL14CEX2108CB 10
Tentative adjustment of main relief pressure

Refer to the main pressure adjustment procedure to
tentatively set the pressure boost and the standard
pressure to 39 MPa (5686 psi) or more pressure.
• For the case of boom down (1), since the overload
set pressure is lower than the main relief set pres-
sure, the main relief pressure needs no tentative set-
ting.
SMIL14CEX4127AB-01 11
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Pressure adjustment
Example: Boom up (1) overload relief adjustment
1. Loosen the lock nut (1) with a wrench (2), and turn the
adjusting screw (3) with a hexagon wrench (4) to adjust
it.
• Tighten it if pressure is lower than the set pressure.
• If pressure is higher than the set pressure, loosen
the screw until it becomes below the set pressure,
and then adjust it by tightening the screw.
SMIL14CEX4129BB-01 13
2. After the adjustment, lock the lock nut (1).
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3. After the overload relief pressure adjustment, refer to

the main pressure adjustment procedure to adjust the
pressure boost and the standard pressure to normal
pressure.
• For each overload relief position, refer to Hydraulic
systems - Pressure test (35.000).
Swing Relief Pressure Adjustment

Work mode SP mode
45 - 55 °C (113.0 -
Oil temperature
131.0 °F)
Boom down: 30.4 MPa
Measurement pressure
(4409.5 psi)
Pressure per rotation of
11.6 MPa (1682.6 psi)
adjusting screw
1. Using the swing pressure measurement procedure for
reference, lock the swing, and check the swing pres-
sure.
2. Loosen the lock nut (2) with the wrench (1) and adjust
by turning the adjusting screw (3).
• If the pressure is below the set pressure, tighten.
• When higher than the set pressure, first loosen to
a pressure lower than the set pressure, and then
adjust on the tightening side.
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3. After adjustment, lock the lock nut (1).
PILOT PRESSURE ADJUSTMENT

1. Attach the pressure gauge (1). Loosen the lock nut
(4) with a wrench [ 24 mm] (2), and turn the adjusting
screw (5) with a hexagon wrench [ 6 mm] (3) to adjust
it.
2. After the adjustment, lock the lock nut (4).
Lever operation Neutral
Measuring port P3
Set pressure 3.92 MPa (568.60 psi)
SMIL14CEX4130BB 17
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Hydraulic systems - Flow test

Preparations
Workers 3 Role (worker 1: work supervisor, pressure adjustment)
Role (worker 2: operator)
Role (worker 3: flow, pressure measurement, recording)
Items to prepare
SMIL14CEX2109GB 1
1 Vacuum pump and power supply 8 Adapter (flange type)

2 Flow meter 9 Hydraulic hose (for flow measurement)
3 Pressure gauge ( 60 MPa x 2) 10 Recording sheet
4 Hexagon wrenches ( 6 mm, 10 mm) 11 Pen
Wrenches ( 17 mm, 19 mm, 24 mm, 27 mm x 2,
5 12 Cleaning fluid
32 mm, 36 mmx 2)
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6 Extension cable 13 Rag

7 Hydraulic tank lid (for vacuum pump)
Work preparations
1. Check that the main unit is in a work posture (vertical
placement of the arm).
2. Release the pressure. (Refer to the release of pressure
in the Hydraulic systems - Pressure test (35.000)).
* Check for the swing prevention.
SMIL14CEX2110AA 2
3. Remove the feed port cover (1) using the wrench (

17 mm).
SMIL14CEX2111AB 3
4. Install the hydraulic reservoir lid (for vacuum pump) (1)

using the bolts that have been removed in 3.
SMIL14CEX2112AB 4
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5. Install the vacuum pump (1) to the hydraulic reservoir

lid.
SMIL14CEX2113AB 5
6. Set the vacuum pump (1) as shown in the figure, and

then turn ON the power. (Use the extension cable if the
cable length is short).
SMIL14CEX2114AB 6
7. Remove the bolts (4), the split flange (2) and the hy-
draulic hose (3) using the hexagon wrench ( 10 mm)
(1). (The flow measurement on the P2 pump side is
explained here.)
SMIL14CEX2115AB 7
8. Install the adapter (flange type) (3) using the split flange
(2) to the tip of the hydraulic hose (1) that has been
removed in 7.
4. Hydraulic hose
SMIL14CEX2116AB 8
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9. Install the adapter (1) to the location where the hy-

draulic hose was removed. Install the "elbow adapter"
(3) to the (prepared) hydraulic hose (2) that will be con-
nected to the IN side of the flow meter, if necessary,
and connect to the adapter (1).
SMIL14CEX2117AB 9
10. Install the hydraulic hose (3) to the IN side (2) of the
flow meter (1) and fix it using the wrench.
Install the (prepared) hydraulic hose (5) to the OUT side
(4) of the flow meter (1) and fix it using the wrench.
Install the adapter (6) that was attached in 8 to the op-
posite side.
* Make sure to check the connection position when con-
necting.
* Make sure to open the throttle valve (7) fully.
Remove the vacuum pump and install the hydraulic
reservoir back in position.
Install the pressure gauges to P1 and P2. (Refer to the
Hydraulic systems - Pressure test (35.000)).
Open the engine hood. (Refer to the Hydraulic sys-
tems - Pressure setting (35.000)).
SMIL14CEX2118BB 10
11. Remove the cover.

12. Remove the pilot hose for the pressure boost signal
and plug into the hose side. (Refer to the Hydraulic
systems - Pressure setting (35.000)).
This completes the preparation for flow measurement.
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Flow Measurement
1. Perform a flow measurement. When performing a flow
measurement, position workers as shown in the figure.
(Worker 1 (1) : Work instructor, in charge of pressure
adjustment)
(Worker 2 (2): Operator)
(Worker 3 (3): In charge of measurement and recording
of flow and pressure)
SMIL14CEX2119AB 11
2. The operator starts the engine following the work in-

structor's signal.
3. Check the hydraulic fluid temperature ( 50 °C (122 °F))
on the monitor.
Check whether the engine speed and the pump current
are normal values.
4. The operator instructs the worker 1 to perform relief
operation with the arm out.
1. Ignition key
SMIL14CEX2120AB 12
5. The worker 2 reduces the arm-out port relief. (Min:

24 MPa (3481 psi) P1 + P2)
6. Start a flow measurement.
7. Perform relief operation with the arm out.
8. Measure data in increments of 2 MPa (290 psi) ( P1 +
P2).
* Perform the measurement up to 24 - 76 MPa (3481
- 11024 psi), and finish it when the highest pressure is
reached.
9. Remove the flow meter.
* This is because the maximum pressure gauge of
the flow meter exceeds the tolerance from 40 MPa
(5802 psi).
10. Set the arm-in port relief valve to normal pressure
again.
(For details of the adjustment, refer to Hydraulic sys-
tems - Pressure setting (35.000)).
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11. Remove the pressure gauge etc., and put them into a
normal state to finish the work.
1. Lock nut, 17 mm (0.669 in)
2. Hexagon wrench, 6 mm (0.236 in)
SMIL14CEX2121AB 13
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Hydraulic systems - Bleed

WARNING
Escaping fluid!
doctor immediately.
W0178A
Air bleed procedure mode (when bleeding, follow the procedure below.)
Hydraulic pump Cylinder air Swing motor air Travel motor air Check
air bleeding bleeding bleeding bleeding
Hydraulic oil or
hydraulic pump
replacement
Cylinder
replacement
Swing motor
replacement
Travel motor
replacement
NOTE: Failure to completely bleed off all the air can reduce the service life of hydraulic equipment and lead to damage.
Hydraulic pump
1. Loosen the air bleed plug (1) and check that oil oozes
from the air bleed port (2). If oil does not ooze out,
remove the air bleed plug (1), and fill hydraulic oil (3)
from the air bleed port (2) into the pump (4) case.
Temporarily tighten the air bleed plug (1).
Run the engine at low idle, slightly loosen the air bleed
plug (1), and run until oil oozes from the air bleed port
(2) section. Completely tighten the air bleed plug (1).
SMIL14CEX2132BB 1
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Travel motor
1. Remove the bolts (2), then remove the cover (1).
SMIL14CEX2123AB 2
2. Remove the drain port hose (1) and the hose adapter
(2).
SMIL14CEX2133BB 3
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3. Pour in hydraulic oil (1) from the air bleed port.

4. When the motor is filled with the hydraulic fluid (1), at-
tach the hose adapter and the hose.
5. Start the engine and execute a slow travel operation.
6. Repeatedly traveling forward and backward bleeds off
the air.
SMIL14CEX2134BB 4
Swing motor
1. Run the engine at low idle, loosen the tee (1) of drain
hose (3) , and check that oil oozes from the air bleed
port section (2).
NOTE: Do not execute a swing operation.
SMIL14CEX2135AB 5
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2. If oil does not ooze out, stop the engine for now, remove
the tee (1) and fill hydraulic oil (2) into the motor case.
SMIL14CEX2136BB 6
3. Temporarily tighten the tee (1) of drain hose (3).

Run the engine at low idle, slightly loosen the tee (1) of
drain hose, and run until oil oozes from the port section
(2).
Completely tighten the tee (1) of drain hose.
SMIL14CEX2135AB 7
4. With the engine at low idle, slowly swing evenly left and
right at least 2 rotations.
NOTE: After the air bleeding is complete, stop the engine
for at least 5 min to allow any air bubbles in the hydraulic
oil tank to dissipate.
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HBCV
CAUTION:
○ The HBCV air bleeding work requires 2 work-

ers: an operator and an air bleed worker.
○ Decide the signals beforehand and work safely.
○ Set the main unit so that the arm HBCV is at the
highest position.
Boom cylinder HBCV

1. Start the engine and lower the boom without jacking up
the main unit.
2. In the above state, loosen the hose mouthpiece (1) at
the position in the figure.
Foaming hydraulic oil comes out from the hose mouth-
piece section.
When foaming hydraulic oil stops coming out, tighten
the hose mouthpiece (1).
2. HBCV
SMIL14CEX2137BB 8
3. Execute steps 2. for the opposite side boom cylinder

too.
4. Check boom operations, If there is a delay in the oper-
ation response, bleed the air again with the same pro-
cedure.
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Arm cylinder HBCV

For arm-in operations, bleed the air from the arm cylin-
der HBCV (1) using the same procedure as for boom
cylinder HBCV air bleeding.
2. Hose mouthpiece
SMIL14CEX2138BB 9
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Hydraulic systems - Test

Sampling of hydraulic fluid
1. Open the side door (1).
At this time, make sure to apply the lock (2).
SMIL14CEX1174AB 1
2. Place a sampling container under the sampling port (1).

3. Open the valve (2) to drain a proper amount of oil.
4. Close the valve (2) to check that there is no leakage.
5. If necessary, add the same amount of oil as the drained
oil.
SMIL14CEX1176AB 2
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Hydraulic systems - Troubleshooting

Problem Possible Cause Correction
Hydraulic system faulty Malfunction of pump Check pressure or replace pump
operation or no operation
at all
Malfunction of relief valve Replace relief valve
Malfunction of cylinders Repair or replace
Too much pump load pressure Check circuit pressure
Crack on valve Replace as a valve assembly
No stroke of spool Check movement on spool
Too low tank oil level Add hydraulic fluid
Clogged filter in circuit Clean or replace filter
Flow reduction in circuit piping Check piping
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Index

Hydraulic systems - Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Hydraulic systems - Flow test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Hydraulic systems - Hydraulic schema – Arm circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Hydraulic systems - Hydraulic schema – Boom circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Hydraulic systems - Hydraulic schema – Bucket Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Hydraulic systems - Hydraulic schema – Negative control circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Hydraulic systems - Hydraulic schema – Option circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Hydraulic systems - Hydraulic schema – Other circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Hydraulic systems - Hydraulic schema – Swing circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Hydraulic systems - Hydraulic schema – Travel circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Hydraulic systems - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic systems - Pressure setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Hydraulic systems - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Hydraulic systems - Service instruction Measurement method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Hydraulic systems - Service instruction Table of standards (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Hydraulic systems - Service instruction Table of standards (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Hydraulic systems - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Hydraulic systems - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
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Reservoir, cooler, and filters - 300

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Contents
FUNCTIONAL DATA
Oil reservoir
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Oil reservoir
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Oil cooler/Heat exchanger
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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Hydraulic systems - Reservoir, cooler, and filters
Oil reservoir - Overview

Port diagram
SMIL14CEX3582FA 1
Port Port size Port Port size

D1 G3/8 D11 G1/4
D3 G3/8 D24 G3/8
D5 G1/4 T G1/2
D6 G1/4 T1 G3/8
D8 G1/4
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Oil reservoir - Prepare

WARNING
Chemical hazard!
cals.
W0371A
WARNING
Escaping fluid!
doctor immediately.
W0178A
WARNING
Avoid injury!
W1128A
WARNING
Burn hazard!
Before performing any service on the hydraulic system, you must allow it to cool. Hydraulic fluid
temperature should not exceed 40 °C (104 °F).
W0241A
WARNING
Crushing hazard!
latches.
W0256A
WARNING
Heavy objects!
W0398A
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Items to prepare:
• Wrenches [ 7 mm, 10 mm, 13 mm, 17 mm, 19 mm,
24 mm, 27 mm, 36 mm ]
• Eyebolt ( M12 x 2)
• Shackle (that fulfills slinging capacity) x 2
• Wire rope (that fulfills breaking load)
• Marking pen
• Cap
• Plug
• Waste oil can
• Rag
• Cleaning fluid
• Wood plank
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Oil reservoir - Remove

54.063 lb ft).
SMIL14CEX1177AB 1
2. Prepare a waste oil can (1) underneath the hydraulic

reservoir.
SMIL14CEX1178AB 2
3. Remove the plug (1) with a wrench [ 36 mm] to drain

hydraulic fluid.
• Attach the plug (1) after completing draining hy-
draulic fluid.
SMIL14CEX1179AB 3
4. Open the engine hood.

5. Remove the 10 bolts (1) with a wrench [ 19 mm] to
remove the cover (2) and (3).
SMIL14CEX1180AB 4
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6. Remove the 4 hexagon bolts (1) with a hexagon wrench

[ 10 mm] to remove the pipe (2).
Loosen the 2 hose clamps (3) with a wrench [ 7 mm] to
remove the hydraulic hose (4).
• Apply marking at each location of the hydraulic reser-
voir and the hose so as to match connections at as-
sembling.
• Attach caps and plugs at each location of the hy-
draulic reservoir and hose so as to prevent invasion
of water, dust and dirt.
• Wash each location of the hydraulic reservoir and the
hoses by blowing parts cleaner so as to prevent ad-
5
hering dirt at connections and not to damage them. SMIL14CEX1181AB
7. Remove the hydraulic hose (1) with a wrench [ 27 mm].

move the manifold (3).
sembling.
hering dirt at connections and not to damage them.
SMIL14CEX1182AB 6
8. Remove the 2 hydraulic hoses (1) with a wrench [

36 mm].
Remove the 2 bolts (2) with a wrench [ 13 mm] to dis-
connect the connector (3).
sembling.
7
hering dirt at connections and not to damage them. SMIL14CEX1183AB
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move the stay (2).
move the stay (4).

remove the cover (2).
SMIL14CEX1185AB 9
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11. Remove the 6 bolts (1) and the 6 spacers (2) at bottom
of the hydraulic reservoir with a wrench [ 24 mm].
• Do not lose a shim which may be inserted between
the reservoir and the frame in order to adjust height
depending on system.
• Also, note inserted section and quantity.
203.57 lb ft).
Loosen the 2 hose clamps (3) with a wrench [ 7 mm]
to remove the hydraulic hose (4).
SMIL14CEX1186BB 10
12. Remove the side cover (1). (Refer to the Fuel tank -
Remove (10.216) for detail.)
13. Attach the 2 eyebolts ( M12) (1) on top of the hydraulic
reservoir.
• Tighten up the eyebolt all the way and then loosen
it for a half turn.
• Make sure not to interfere the level gauge with any-
thing around while lifting.
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14. Attach the 2 shackles (1) to the eyebolt and then lift it
with a wire rope (2) and a lifting equipment.
Make sure that you have a safe site, and then settle
the fuel tank on a wood plank or other block.
Make sure to secure the hydraulic reservoir so as to
prevent it from falling.
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Oil reservoir - Install

dure.
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Oil cooler/Heat exchanger - Prepare

WARNING
Avoid injury!
W1128A
WARNING
Burn hazard!
Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that
exceed 49 °C (120 °F). Allow fluids to cool before proceeding.
W0330B
WARNING
Crushing hazard!
latches.
W0256A
WARNING
Heavy objects!
W0398A
NOTICE: Keep away from flames.

Items to prepare:
• Pliers
• Screwdriver
• Cap
• Waste oil can
• Rag
• Cleaning fluid
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Oil cooler/Heat exchanger - Remove

1. Drain hydraulic fluid from the hydraulic reservoir.
SMIL14CEX0783AB 1
3. Prepare a waste oil can (1).
SMIL14CEX0797AB 2
4. Remove the 2 hexagon bolts (1) on top side and the 2

bolts (1) on bottom side with a hexagon wrench 10 mm
to remove the line (2) and (3).
• Attach caps at each location of the oil cooler and the
line so as to prevent invasion of water, dust and dirt.
SMIL14CEX0798BB 3
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5. Remove the fan shroud. (Refer to the Radiator - Re-

move (10.400)).
6. Attach the 2 eyebolts ( M12) (1) on top of the oil cooler.
• Tighten up the eyebolt all the way and then loosen it
for a half turn.
• Remove the 6 oil cooler fixation bolts.
SMIL14CEX0799AB 4
7. Attach the 2 shackles (1) to the eyebolt and then lift

the oil cooler main unit with a wire rope (2) and a lifting
equipment.
SMIL14CEX0800BB 5
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8. Make sure that you have a safe site, and then settle the
oil cooler on a wood plank or other block.
SMIL14CEX1001BA 6
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Oil cooler/Heat exchanger - Install

dure.
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Index

Oil cooler/Heat exchanger - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Oil cooler/Heat exchanger - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Oil cooler/Heat exchanger - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Oil reservoir - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Oil reservoir - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Oil reservoir - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Oil reservoir - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Variable displacement pump - 106

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Contents
FUNCTIONAL DATA
Pump
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE
Pump
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Tool description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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Hydraulic systems - Variable displacement pump
Pump - Overview
Port diagram
SMIL14CEX3564GB 1
Standard model
(*1) Discharge port
Port Port name Port size

A1, A2 Discharge port *SAE6000psi 1
B1 Suction port *SAE2000psi 3
Dr1 Drain port G3/4-23
P1 Proportional valve primary pressure port G1/4-13
Psv Servo assist port G1/4-15
Pi1, Pi2 Negative control port G1/4-13
a1, a2, a4, a5, a6 Gauge port G1/4-15
A3 Gear pump discharge port G1/2-19
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B3 Gear pump suction port G3/4-20.5
a3 Gauge port G1/4-14
Dr3 Drain port (gear pump) G3/8-15
A4 Gear pump discharge port G1/2-16
B4 Gear pump suction pump G1-21
NOTE: The port size with * indicates the flange size.
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Pump - Sectional view

Overall view
SMIL14CEX3921FA 1
A. Drive shaft front side B. Drive shaft rear side
Drive shaft – Front side
SMIL14CEX3922FA 2
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Drive shaft – Rear side
SMIL14CEX3923HB 3
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Parts table
Adhesive (No. 130SN manufactured by ThreeBond
a. d. Valve plate for left rotation
Co., Ltd.) application
Outer regions of oil seal Lubricant (SEALUB L101) Tightening torque Flange socket ( 4-M10 x 1.5)
b. e.
application 33 N·m (24.34 lb ft)
Tightening torque Hexagon bolt ( 3-M6 x 1.0)
c. Valve plate for right rotation f.
12 N·m (24.34 lb ft)
Code Part name Component number (quantity) or type

4. Gear Pump (Quantity 1 set) ZX15LHRZ2-07A-V
11. Piston subassembly (Quantity 2 sets) 151 (9PC), 152 (9PC)
13. Cylinder subassembly (F) (Quantity 1 set) 141 (1PC), 313 (1PC)
14. Cylinder subassembly (R) (Quantity 1 set) 141 (1PC), 314 (1PC)
30. Swash plate subassembly (Quantity 2 sets) 212 (1PC), 214 (1PC)
41. Check valve 1 subassembly (Quantity 2 sets) 541 (1PC), 543 (1PC), 545 (1PC)
530. Tilting pin subassembly (Quantity 2 sets) 531 (1PC), 548 (1PC)
111. Drive shaft (F) (Quantity 1) 492. Mounted valve (Quantity 12)
113. Drive shaft (R) (Quantity 1) 531. Tilting pin (Quantity 2)
114. 1st gear (Quantity 1) 532. Servo piston (Quantity 2)
123. Cylinder roller bearing (Quantity 2) 534. Stopper (L) (Quantity 2)
124. Needle pin roller bearing (Quantity 2) 535. Stopper (S) (Quantity 2)
127. Bearing spacer (Quantity 3) 542. Spacer (Quantity 2)
141. Cylinder block (Quantity 2) 544. Spacer 1 (Quantity 2)
151. Piston (Quantity 18) 548. Feedback pin (Quantity 2)
152. Shoe (Quantity 18) 702. O-ring (Quantity 1) (Quantity 2)
153. Holder plate (Quantity 2) 710. O-ring (Quantity 1)
156. Spherical bushing (Quantity 2) 714. O-ring (Quantity 1)
157. Cylinder spring (Quantity 18) 717. O-ring (Quantity 2)
211. Shoe plate (Quantity 2) 719. O-ring (Quantity 2)
212. Swash plate (Quantity 2) 724. O-ring (Quantity 16)
214. Tilting bushing (Quantity 2) 725. O-ring (Quantity 9)
251. Swash plate support board (Quantity 2) 726. O-ring (Quantity 2)
261. Seal cover (F) (Quantity 1) 728. O-ring (Quantity 4)
271. Pump casing (Quantity 2) 732. O-ring (Quantity 2)
312. Valve block (Quantity 1) 774. Oil seal (Quantity 1)
313. Valve plate (F) (Quantity 1) 789. Backup ring (Quantity 2)
314. Valve plate (R) (Quantity 1) 792. Backup ring (Quantity 2)
325. Cover (Quantity 1) 808. Hexagon nut (Quantity 4)
326. Cover (Quantity 1) 824. Stop ring (Quantity 2)
401. Hexagon socket head bolt (Quantity 8) 885. Valve plate pin (Quantity 2)
406. Hexagon socket head bolt (Quantity 4) 886. Spring pin (Quantity 4)
407. Hexagon socket head bolt (Quantity 3) 901. Eyebolt (Quantity 2)
414. Hexagon socket head bolt (Quantity 4) 953. Hexagon socket head retaining screw (Quantity 2)
466. VP plug (Quantity 2) 954. Retaining screw (Quantity 2)
468. VP plug (Quantity 4) 981. Decal (Quantity 1)
490. Mounted valve (Quantity 27) 983. Rivet (Quantity 2)
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Pump - Static description

This pump has a structure in which 2 pumps are coupled by the 1st gear (116) and the 2 pumps can be driven at the
same time through the rotation of the power source being transmitted to the drive shaft F (111) on the front side.
The oil suction and discharge port are located in the connection section of the 2 pumps (specifically, the valve block
(312)), and the suction port is used in common by the front pump and rear pump.
Pump structure and operation principles are the same for the front and rear pumps. The front pump is explained
below.
The pump can be roughly divided into the rotary group, which is the main part of the pump that performs rotation, the
swash plate group, which changes the discharge flow, and the valve cover group, which switches between oil suction
and discharge.
The rotary group is made up of the drive shaft F (111), cylinder block (141), piston shoes (151) (152), holder plate
(153), spherical bushing (156), and cylinder spring (157).
The drive shaft is supported at both ends with bearings (123) and (124).
Along with being caulked to the piston to form a spherical joint, the shoe has a pocket section for balancing the
hydraulic pressure in order to reduce the thrust force generated by the load pressure and allow the shoe to slide
lightly on the shoe plate (211).
The piston shoe sub-group is pressed against the shoe plate by the cylinder spring via the holder plate and spherical
bushing so that it can slide smoothly on the shoe plate.
Also, in the same way the cylinder block is pressed against the valve plate (313) by the cylinder spring.
The swash plate group comprises the swash plate (212), shoe plate (211), swash plate support board (251), tilting
bushing (214), tilting pin (531), and servo piston (532).
The swash plate is supported by the swash plate support board at the cylindrically shaped section formed by the
opposite side of the shoe sliding surface.
By leading the hydraulic pressure force controlled by the regulator into the hydraulic pressure chambers on both sides
of the servo piston, the servo piston moves left and right. This moves the swash plate on the swash plate support
board via the tilting pin spherical section and changes the tilting angle (α).
The valve cover group comprises the valve block (312), valve plates (313) (314), and valve plate pin (885).
The valve plate, which has 2 oval-shaped ports, is installed on the valve block. Its function is to feed oil to the cylinder
block and recover it from the cylinder block.
The oil switched by the valve plate is discharged through the valve block to the outside lines.
Now when the drive shaft is driven by the power source (motor, engine, etc.), the cylinder block is also rotated at the
same time via the spline coupling.
When the swash plate tilts, the piston located at the center of the cylinder block moves reciprocally relative to the
cylinder while turning with the cylinder block.
Therefore, if just 1 piston is looked at, during one cylinder block rotation the piston moves away from the valve plate
(oil intake stroke) for 180 ° and then moves toward the valve plate (oil discharge stroke) for the remaining 180 °.
When the swash plate tilting angle is 0 °, the piston does not move through a stroke and oil is not discharged.
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Pump - Prepare
WARNING
Escaping fluid!
doctor immediately.
W0178A
WARNING
Avoid injury!
W1128A
WARNING
Crushing hazard!
latches.
W0256A
WARNING
Heavy objects!
W0398A
Items to prepare:
• Wrenches [ 13 mm, 17 mm, 19 mm, 27 mm,
36 mm]
• Hexagon wrench [ 10 mm, 14 mm]
• Nylon sling (that fulfills breaking load)
• Marking pen
• Cap
• Plug
• Rag
• Cleaning fluid
• Wood plank
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Pump - Remove
Pay attention to the followings when removing the hy-
draulic hose.
• Apply marking to the pump and the hoses so as to
match connections at assembling.
• Attach caps and plugs at each location of the pump
and hoses so as to prevent invasion of water, dust
and dirt.
• Wash each location of the pump and the hoses by
1. Remove the engine hood. (Refer to the Hood - Re-
move (90.100) for detail.)
2. Remove the muffler.
3. Remove the bolt (1) with a wrench [ 13 mm].
move the stay (3).
SMIL14CEX1314AB 1

move the cover (2).
move the cover (4).
move the cover (6).
SMIL14CEX1315AB 2

move the stay (2).
move the stay (4).
SMIL14CEX1316AB 3
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move the cover (2).
SMIL14CEX1317AB 4

move the 2 connectors (2).
Remove the 3 hydraulic hoses (3) with a wrench [
19 mm].
SMIL14CEX1318AB 5

27 mm].
Remove the hydraulic hose (2) with a wrench [ 36 mm].
SMIL14CEX1319AB 6
9. Remove the 2 connectors (1).

[ 10 mm] to remove the 2 hydraulic hoses (3).
SMIL14CEX1320AB 7
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10. Remove the 4 hexagon bolts (1) with a hexagon

wrench [ 14 mm] to remove the suction pipe (2).
SMIL14CEX1321AB 8
11. Secure the pump with a lifting equipment and nylon

sling (1) so as to prevent dropping the pump during
removal and installation work.
SMIL14CEX1322BB 9
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12. Remove the 12 bolts (1) of the pump with a wrench [

17 mm].
54.285 lb ft).
SMIL14CEX1323BB 10
13. Pull out the pump outward in axial direction with a

lifting equipment and nylon sling (1) and then lift the
pump.
SMIL14CEX1324BB 11
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the pump on a wood plank (1) or other block.
• Make sure to secure the pump so as to prevent it
from falling.
SMIL14CEX1325AB 12
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Pump - Tool description

The table below shows the tools required for assembly
and disassembly of the K3V/K5V pump.
The bolts and plugs may vary by pump type.
Tool name Tool dimensions

4 mm, 5 mm, 6 mm, 8 mm, 14 mm, 17 mm [B
Hexagon wrench
dimension ]
Socket wrench, doubleheader (single-head) wrench 19 mm, 27 mm
Monkey wrench Medium size
Screwdriver Flathead screwdriver (medium size) x 2
Plastic hammer
Torque wrench With adjustable specified torque tightening
Snap ring pliers For stop ring, TSR-160
Steel rod Key material steel rod, 10 x 8 x 200
Tweezers
Bolt M8, L = about 50
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Pump - Disassemble
When disassembling the pump, read the disassembly
procedures all the way to the end before disassembling
according to the sequence below.
The numbers in the parentheses after the part names
indicate part numbers in the pump structural diagram.
This manual lists the disassembly procedures for the
tandem pump. Perform disassembly using the type col-
umn as reference.
Also, be careful that parts from the front pump and rear
pump do not get mixed together.
1. Select a site to disassemble the pump.
• Find a clean location.
• Place a rubber plate or cloth on the work platform so
as not to damage the parts.
2. Use cleaning oil to remove any dirt or rust from the
surface of the pump.
3. Remove the drain port plug (468) and drain the oil from
the pump casing
• Remove the plugs from both the front and rear
pumps and drain the oil.
4. Remove the hexagon socket head bolts (412), (413),
and remove the regulator.
• See Pump control valve - Disassemble (35.102)
to disassemble the regulator.
SMIL14CEX1556AA 1
5. Loosen the hexagon socket head bolts (401) that fasten

together the swash plate support board (251), pump
casing (271), and valve block (312).
• When a gear pump, etc. is attached to the pump
rear surface, remove the gear pump, etc. first before
performing work.
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6. Face down the pump regulator installation surface hor-

izontally on the work platform, and separate the pump
casing (271) and valve block (312).
• When placing the regulator installation surface face-
down, be sure to place a rubber plate or similar ma-
terial on the work platform so as not to damage the
regulator installation surface.
• When separating the pump casing and valve block,
remove the 1st gear at the same time.
SMIL14CEX1555AA 2
7. Remove the cylinder block (141) out from the pump

casing (271) in a straight line in relation to the drive
shaft (111), and remove the piston (151), holder plate
(153), spherical bushing (156), and cylinder spring
(157) at the same time.
• Be careful not to damage the sliding surfaces of the
cylinder, spherical bushing, shoe, and swash plate.
SMIL14CEX1557AA 3
8. Remove the hexagon socket head bolt (406) and re-

move the seal cover (F) (261).
• Removal can be performed easily by inserting a bolt
into the hole on the seal cover (F) and then pulling
the bolt out.
• The seal cover (F) has an oil seal, so be careful not
to damage the oil seal when removing the seal cover.
SMIL14CEX1558AA 4
9. Tap the installation flange section of the swash plate

support board (251) on the pump casing side, and sep-
arate the swash plate support board and the pump cas-
ing.
SMIL14CEX1559AA 5
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10. Remove the shoe plate (211) and the swash plate
(212) from the pump casing (271).
SMIL14CEX1560AA 6
11. Lightly strike the shaft end sections of the drive shafts
(111), (113) with a plastic hammer, etc. to remove the
drive shafts from the swash plate support board.
SMIL14CEX1561AA 7
12. Remove the valve plates (313), (314) from the valve
block (312).
• These can also be removed in 2.
SMIL14CEX1562AA 8
13. If necessary, remove the stopper (L) (534), stopper (S)

(535) , servo piston (532), and tilting pin (531) from the
pump casing (271), and remove the needle bearing
(124) and 1st gear (116) rom the valve block (312).
• To avoid damaging the head of the tilting pin, use a
jig when removing it.
• Loctite has been applied to the section where the
tilting pin and the servo piston are bonded, so be
careful not to damage the servo piston.
• Try to avoid removing the needle bearing unless it
is at the end of its service life.
• Do not loosen the hexagon nuts of the valve block
or swash plate support board.
This changes the flow setting.
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Pump - Assemble
The assembly procedure is the reverse of the disas-
sembly procedure. However, follow the precautions be-
low.
1. Be sure to repair any parts damaged during disassem-
bly, and prepare replacement parts in advance.
2. Thoroughly clean all parts with cleaning oil and air blow
them before assembly.
3. Be sure to apply clean hydraulic oil to sliding parts and
bearings before assembly.
4. As a rule, replace all O-rings, oil seals, and other seal
parts with new parts.
5. Use a torque wrench to tighten all installation bolts and
plugs to the torque specified in Torque – Bolt and nut
().
SMIL14CEX1565AA 1
6. Be careful not to mix up the pump parts for the front
and rear.
7. Install the swash plate support board (251) on the pump
casing (271) by lightly striking it with a hammer.
• If the servo pistons, tilting pin, stoppers (L), and stop-
pers (S) have been removed, install these parts on
the pump casing in advance.
• To avoid damaging the heads of the tilting pins and
the feedback pins, use a jig when tightening the
servo pistons and tilting pins.
Also be sure to apply LOCTITE® (moderate strength)
to the threaded sections.
8. Face down the regulator installation surface of the
pump casing, insert the tilting bushing of the swash
plate onto the tilting pin (531), and correctly mount the
swash plate (212) on the swash plate support board
(251).
• Use the fingertips of both hands to check that the
swash plate moves smoothly.
• Coat the swash plates, swash plate support boards,
and all sliding sections with grease for easier instal-
lation of the drive shaft.
SMIL14CEX1563AA 2
9. Install the drive shaft (111) with a bearing (123), bear-

ing spacers (127), and stop ring (824) attached on the
swash plate support board (251).
• Do not strike the drive shaft with a hammer, etc.
• Lightly strike the outside ring of the bearing with a
plastic hammer to install it, and use a steel rod, etc.
to tightly insert it all the way in.
SMIL14CEX1564AA 3
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10. Install the seal cover (F) (261) to the pump casing
(271), and secure with the hexagon socket head bolts
(406).
• Apply a thin layer of grease to the oil seal inside the
seal cover (F).
• Be careful not to damage the oil seal when installing
it.
SMIL14CEX1566AA 4
11. Assemble the piston cylinder subassembly [cylinders

(141), pistons (151) and (152), holder plates (153),
spherical bushings (156), spacers (158), cylinder
springs (157)], and then insert it into the pump casing
in alignment with the phase of the splines of the
spherical bushings and cylinder blocks.
SMIL14CEX1567AA 5
12. Install the valve plate (313) on the valve block (312)
while aligning it with the pin (885).
• Be careful not to mistake the suction and discharge
directions of the valve plates.
SMIL14CEX1568AA 6
13. Install the valve block (312) on the pump casing (271),
and then tighten it with the hexagon socket head bolts
(401).
• Assembly is easier when starting with the rear side
pump.
• Install the valve block in the correct direction. (In-
stall the valve block so that the regulator faces up
and the suction flange faces right when looking at
the valve block from the front.)
• Insert the 1st gear into the valve block beforehand
and couple it with the drive shaft joint section spline.
SMIL14CEX1569AA 7
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14. Insert the feedback pins of the tilting pins into the
feedback lever of the regulators, install the regulators,
and tighten the hexagon socket head bolts (412) and
(413).
• Install the regulator, making sure not to mistake the
front and the rear of the regulator.
15. Install the drain port plug (468) to finish assembly.
SMIL14CEX1570AA 8
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Pump - Install
dure.
Refer to the Torque – Bolt and nut () for bolts without
instruction.
Fill it up with hydraulic fluid via the drain port so as not
to leave any air in the pump case.
If the 2nd option gear pump is installed, remove air via
the air bleed port on top of the power take-off case.
After installation, perform calibration. When the hy-
draulic pump is replaced, it is necessary to perform a
calibration setup in order to adjust the individual differ-
ence (tolerance) of the machine (component) after re-
placement of the component. For calibration setup pro-
cedure, refer to Instrument cluster - Overview - CAL-
IBRATE screen list (55.512).
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Index

Pump - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Pump - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pump - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pump - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pump - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Pump - Tool description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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Pump control valves - 102

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Contents
FUNCTIONAL DATA
Pump control valve

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SERVICE
Pump control valve

Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Tool description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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Hydraulic systems - Pump control valves
Pump control valve - Exploded view
SMIL14CEX2005HB 1
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SMIL14CEX2006HB 2
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Component table
*1. In normal times *3. Model
*2. At start-up and at redundant *4. Serial no.
- Regulator subassembly (Quantity 1) 651. Sleeve (Quantity 1)

412. Hexagon socket head bolt (Quantity 2) 652. Spool (Quantity 1)
413. Hexagon socket head bolt (Quantity 2) 653. Spring seat (Quantity 1)
418. Hexagon socket head bolt (Quantity 2) 654. Return spring (Quantity 1)
438. Hexagon socket head bolt (Quantity 6) 655. Set spring (Quantity 1)
439. Hexagon socket head bolt (Quantity 5) 656. Cover (Quantity 1)
466. VP plug (Quantity 3) 662. Spring (Quantity 1)
496. Filler plug (Quantity 14) 708. O-ring (Quantity 1)
497. MH plug (Quantity 4) 722. O-ring (Quantity 3)
541. Seal (Quantity 2) 724. Square ring (Quantity 4)
543. Stopper G (Quantity 2) 725. O-ring (Quantity 1)
545. Steel ball (Quantity 2) 728. O-ring (Quantity 1)
601. Casing (Quantity 1) 730. O-ring (Quantity 1)
611. Feedback lever (Quantity 1) 732. O-ring (Quantity 1)
612. Lever (1) (Quantity 1) 733. O-ring (Quantity 1)
613. Lever (2) (Quantity 1) 734. O-ring (Quantity 1)
614. Fulcrum plug (Quantity 1) 753. O-ring (Quantity 1)
615. Adjusting plug (Quantity 1) 755. O-ring (Quantity 7)
621. Compensation piston (Quantity 1) 756. O-ring (Quantity 1)
622. Piston case (Quantity 1) 757. O-ring (Quantity 1)
623. Compensation rod (Quantity 1) 763. O-ring (Quantity 1)
624. Spring seat C (Quantity 1) 801. Hexagon nut (Quantity 1)
625. Outer spring (Quantity 1) 802. Hexagon nut (Quantity 1)
626. Inner spring (Quantity 1) 814. Stop ring (Quantity 2)
627. Regulating ring C (Quantity 1) 836. Retaining ring (Quantity 1)
628. Adjusting screw C (Quantity 1) 858. Locking ring (Quantity 2)
629. Cover C (Quantity 1) 874. Pin (Quantity 1)
630. Lock nut (Quantity 1) 875. Pin (Quantity 2)
641. Pilot cover (Quantity 1) 876. Pin (Quantity 2)
642. Spool (Quantity 1) 887. Pin (Quantity 1)
643. Pilot piston (Quantity 1) 897. Pin (Quantity 1)
644. Spring seat Q (Quantity 1) 898. Pin (Quantity 1)
Hexagon socket head retaining screw (Quantity
645. Regulating ring Q (Quantity 1) 924.
1)
646. Pilot spring (Quantity 1)
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Pump control valve - Sectional view
SMIL14CEX3924FB 1
A. Port C1 (connected with servo piston large-diameter chamber)
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SMIL14CEX3925FA 2
Hydraulic circuit diagram
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SMIL14CEX3926HB 3
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SMIL14CEX3927HB 4
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Pump control valve - Dynamic description

Regulator operation explanation
Operation explanation (Refer to Pump control valve - Sectional view (35.102)).
Flow control
The command current I freely controls pump discharge flow as shown in the following figure.
SMIL14CEX0596AA 1
1. Discharge flow Q 2. Command current I
Actuation by flow decrease

When the command current I increases, the pilot piston (643) will move right, and come to a standstill at the position
where the force of the pilot spring (646) and the hydraulic pressure balance out. Since the grouped groove section
of the pilot piston (643) is engaged with the pin (875) fixed on the lever (2) (613), movement of the pilot piston (643)
makes the lever (2) rotate on the section B (fix by the fulcrum plug (614) and the pin (876)) as a fulcrum. Since the pin
(879) fixed on the feedback lever 611 has projected to the large opening C in the lever (2) (613), the pin (897) moves
right as the lever (2) (613) rotates. Since the bolt width section D of the feedback lever (611) is engaged with the pin
(548) fixed on the tilting pin (531) that sways the swash plate (212), movement of the pin (897) makes the feedback
lever (611) rotate on the section D as a fulcrum. Since the feedback lever (611) is interlocked with the spool (652)
through the pin (874), the spool (652)moves right.
When the spool (652) moves, although the discharge pressure P1 is always led to the servo piston small-diameter
section, the servo piston (532) will move right because of the area difference to reduce the tilting angle.
When the servo piston (532) moves right, the section D will also move right. Since the spool (652) is equipped with the
return spring (654) to pull the spool to the left at all times, the pin (897) is pressed against the large opening section
C of the lever (2) (613). Therefore, with movement of the section D, the feedback lever (611) rotates with the section
C as a fulcrum, and the spool (652) moves left. The opening sections of the sleeve (651) and the spool (652) start
closing gradually by this movement, and the servo piston (532) comes to a standstill at the position where they totally
close.
Actuation by flow increase

When the command current I decreases, the force of the pilot spring (646) will make the pilot piston (643) move left
and the lever (2) (613) rotate on the section B as a fulcrum. The pin (897) is pressed against the large opening section
C of the lever (2) (613) by the return spring (654) through the spool (652), the pin (874), and the feedback lever (611).
Therefore, with rotation of the lever (2) (613), the feedback lever (611) rotates on the section D as a fulcrum, and the
spool (652) moves left.
When the spool (652) moves, the port C1 will open to the tank port. Therefore, the servo piston large-diameter cham-
ber is bled of pressure, and the discharge pressure P 1 at the small-diameter section makes the servo piston (532)
move left to increase the flow.
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With movement of the servo piston (532), the section D also moves left, the feedback lever (611) rotates with the
section C as a fulcrum, and the spool (652) moves right. Actuation continues until the opening sections of the spool
(652) and the sleeve (651) are closed, and stops at the position where they are closed.
Horsepower control (at redundancy)

It prevents overload of the motor by decreasing the pump tilting angle when the load pressure increases as shown in
the following figure.
Actuation by horsepower control, which is briefly described below, is the same as that by flow control.
SMIL14CEX0597AA 2
1. Discharge flow Q 2. Discharge pressure P1 + P2
Overload prevention start-up

When the discharge pressure ( P1 + P2) rises, it will act on the stepped section of the compensation piston (621) .
Therefore, the compensation rod (623) is pushed to the right, and moved to the position where the force of the outer
spring (625) and that of the inner spring (626) balance out. The motion of the compensation rod is transmitted to the
lever (1) (612) through the pin (875), and it rotates on E as a fulcrum in the direction of H. Furthermore, the motion
of the lever (1) is transmitted to the feedback lever (611) through the pin (897), and it rotates on D as a fulcrum in
the direction of G. With that motion, the spool (652) interlocked with the feedback lever moves right. When the spool
moves right, the discharge pressure P1 will be led to the servo piston large-diameter chamber via the spool and the
port C1.
The discharge pressure P1 is always led to the servo piston small-diameter chamber section. As a result, the servo
piston moves right because of the area difference to reduce the tilting angle and the flow. Since the feedback lever
is interlocked with the servo piston and the spool, when the servo piston moves right, the feedback lever will rotate
on F as a fulcrum to move the spool to its original position. The opening sections of the sleeve and the spool close
gradually by this movement, and the servo piston comes to a standstill at the position where they totally close.
Flow recovery start-up

When the discharge pressure ( P1 + P2) decreases, the compensation rod (623) will be pushed to the left by the outer
spring (625) and the inner spring (626), and moved to the position where the force of the outer spring and that of the
inner spring balance out. The motion of the compensation rod is transmitted to the lever (1) (612) through the pin
(875), and it rotates on E as a fulcrum in the direction of G. Furthermore, the motion of the lever (1) is transmitted to
the feedback lever (611) through the pin (897), and it rotates on D as a fulcrum in the direction of H. With that motion,
the spool (625) interlocked with the feedback lever moves left. When the spool moves left, the port C1 will open
to the tank port. Therefore, the servo piston large-diameter chamber section is bled of pressure, and the discharge
pressure P1 at the small-diameter chamber section makes the servo piston (532) move left to increase the flow. Since
the feedback lever is interlocked with the servo piston and the spool, when the servo piston moves left, the feedback
lever will rotate on F as a fulcrum to move the spool to its original position. The opening sections of the sleeve and the
spool close gradually by this movement, and the servo piston comes to a standstill at the position where they totally
close.
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Low tilting (low flow) command override system

As explained, the tilting command of the flow control is transmitted to the feedback lever (611) and the spool (652)
through the large opening in the lever (2) (613), and that of the horsepower control is transmitted to them through the
large opening in the lever (1) (612). However, since the pin (j5) has projected to the large opening (j9), the lever for
smaller tilting command is in contact with the pin (897), and the (j9) hole in the lever for larger tilting command is free
without being in contact with the pin (897). By this mechanical selection, the lower tilting command within commands
of flow control and horse power control is prioritized.
Power shift control (reducing horsepower control)

The power shift pressure Pf freely controls pump setting horsepower as shown in the following figure.
When the power shift pressure Pf increases, the compensation rod (623) will move right through the pin (898) and the
compensation piston (621). Therefore, the pump tilting angle decreases and the horsepower set decreases, as de-
scribed in the overload prevention start-up of the horsepower control. On the contrary, the horsepower set increases
when the power shift pressure Pf decreases.
With this pump, the power shift pressure Pf becomes 0 MPa in normal mode; in redundant mode, however, the power
shift pressure Pf becomes 3.9 MPa
When the command current of the electromagnetic proportional pressure reducing valve decreases to about 200 mA
or less, this regulator judges it as an electrical system failure by the spool (642) incorporated in the pilot cover (641). At
that time, the regulator leads the pilot primary pressure to the Pf piston chamber, and the horsepower control function
activates.
SMIL14CEX0598AA 3
1. Discharge flow Q 2. Discharge pressure P1 + P2
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Pump control valve - Adjust

The adjusting screws (953), (954) at the pump main
unit side adjust the maximum and the minimum flows.
The adjusting screw (C) (628) of the regulator and the
adjusting ring (C) (627) adjust the horsepower control
feature, and the hexagon socket head bolt (924) adjusts
the flow control feature. ("Appendix table 1. List of
Regulator Adjustment Amounts" indicates adjustment
amounts and variation amounts.)
1. Maximum flow adjustment (pump main unit side)
1. Discharge flow Q
2. Command current I
SMIL14CEX2192EB 1
Loosen the hexagonal nut (808) and adjust by tight-

ening (or loosing) the retaining screw (954). Only the
maximum flow changes, other control features do not
change.
2. Minimum flow adjustment (pump main unit side)
1. Discharge flow Q
SMIL14CEX2193EB 2

ening (or loosing) the hexagon socket head retaining
screw (953).
As with adjustment of the maximum flow, other control
features do not change. However, the required power
at the time of the maximum discharge pressure may
increase when the screw is tightened too much.
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3. Input horsepower adjustment

A. Outer spring adjustment
1. Discharge flow Q
2. Discharge pressure ( P1 + P2)
SMIL14CEX2194EB 3
Loosen the hexagonal nut (630) and adjust by tighten-

ing (or loosing) the adjusting screw (C) (628).
The control diagram shifts right and the input horse-
power increases when the adjusting screw (C) is tight-
ened as shown in the foregoing figure.
The inner spring (626) set changes when the adjusting
screw (C) is turned for N times. Turn the adjusting ring
(C) (627) inversely for N x A times. (For the value A,
refer to Appendix table 1. List of Regulator Adjustment
Amounts.)
B. Inner spring adjustment
1. Discharge flow Q
2. Discharge pressure ( P1 + P2)
SMIL14CEX2195EB 4
Loosen the hexagonal nut (802) and adjust by tighten-

ing (or loosing) the adjusting ring (C) (627).
The flow increases and the input horsepower increases
when the adjusting ring (C) is tightened as shown in the
foregoing figure.
4. Flow control feature adjustment
1. Discharge flow Q
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SMIL14CEX2196EB 5

ening (or loosing) the hexagon socket head retaining
screw (924).
The control diagram shifts right when the hexagon
socket head retaining screw is tightened as shown in
the foregoing figure.
Appendix table 1. List of regulator adjustment amounts

Number of rotation 1900 RPM
Adjusting screw (954) tightening amount
+1/4
Maximum flow adjustment (rotation)
Flow change amount -5.80 L/min (-1.53 US gpm)
+1/4
Minimum flow adjustment (rotation)
Flow change amount -5.80 L/min (-1.53 US gpm)
+1/4
(rotation)
Outer spring Compensation control start pressure
+1.88 MPa (272.69 psi)
adjustment change amount
Input horsepower Input torque change amount 70.40 N·m (51.92 lb ft)
adjustment A 1.59
+1/4
Inner spring (rotation)
adjustment Flow change amount +15.00 L/min (3.96 US gpm)
Input torque change amount +71.9 N·m (53.03 lb ft)
+1/4
(rotation)
Flow control start current value change
Flow control feature adjustment
amount (mA) (proportional valve 20 MPa (2901.00 psi)
secondary pressure)
Flow change amount +17.4 L/min (4.60 US gpm)
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SMIL14CEX2005HB 6
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SMIL14CEX2006HB 7
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Pump control valve - Tool description

Tools
Tool name Tool type

Hexagon wrench 4 mm, 5 mm, 6 mm [dimension B]
Monkey wrench Medium type (quantity 1)
Screwdriver Medium-sized flathead screwdriver (quantity 1)
Stop ring TSR-150
Snap ring pliers
Locking ring TRR-150
Torque wrench Ones tightening to the specific torques are possible.
Steel rod φ4 or less in diameter, L = 100 mm (3.937 in)
Hexagon socket head bolt For removal of the adjusting ring M4, L = 50 mm (1.969 in) or equivalent
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Pump control valve - Prepare

1. The regulator is configured by precision components;
therefore, disassembly and assembly require some-
what complicated procedures.
2. Read the disassembly procedure thoroughly and take
the following procedures when disassembling the reg-
ulator.
Numbers in parentheses following the component
names indicate codes in the Pump control valve -
Sectional view (35.102).
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Pump control valve - Disassemble

NOTICE: Components are small. Pay close attention not to lose them.
1. Choose a disassembly site.
• Choose a clean site.
• Place a rubber plate or cloth on the work platform
in order to prevent making hit marks on the compo-
nents.
2. Remove dirt, rust, and other materials on the regulator
surface by using cleaning oil or other means.
3. Remove the hexagon socket head bolt (438) to remove
the cover (C) (629).
• The cover (C) has the adjusting screw (C) (628),
the adjusting ring (C) (627), the lock nut (630), the
hexagon nuts (801) and (802), and the hexagon
socket head retaining screw (924). Do not loosen
these screws and nuts. The pressure - flow set that
is already adjusted changes if the screws and the
nuts are loosened.
SMIL14CEX2199AA 1
4. After removing the cover (C) (629) subassembly, re-

move the outer spring (625), the inner spring (626), and
the spring seat (C) (624) from the compensation sec-
tion. Then, remove the adjusting ring (Q) (645), the pi-
lot spring (646)), and the spring seat Q (644) from the
pilot section.
• Removing the adjusting ring (Q) (645) becomes easy
when a M4 bolt is used for drawing out.
SMIL14CEX2200AA 2
SMIL14CEX2201AA 3
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5. Remove the hexagon socket head bolt (439) to remove

the pilot cover (641).
After removing the pilot cover (641), remove the pin
(898) from the compensation section, and the set
spring (655) from the pressure control section.
SMIL14CEX2202AA 4
6. Remove the stop ring (814) to remove the spring seat

(653), the return spring (654), and the sleeve (651).
• The sleeve (651) has the retaining ring (836).
• When removing the stop ring (814), be careful not to
lose the return spring (654) because it jumps out.
SMIL14CEX2203AA 5
7. Remove the locking ring (858) to remove the fulcrum

plug (614) and the adjusting plug (615).becomes easy
when a M6 bolt is used for drawing out.
SMIL14CEX2204AA 6
SMIL14CEX2205AA 7
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8. Remove the lever (2) (613). Do not remove the pin

(875).
• To facilitate work, you are recommended to use
tweezers.
SMIL14CEX2206AA 8
9. Remove the pin (874) to remove the feedback lever

(611).
• The pin (874) (pin diameter: φ4) should be pushed
out from above with a thin steel rod so as not to
interfere with the lever (1) (612).
SMIL14CEX2207AA 9
SMIL14CEX2208AA 10
10. Remove the lever (1) (612). Do not remove the pin
(875).
11. Remove the pilot piston (643) and the spool (652).
12. Remove the piston case (622), the compensation pis-
ton (621), and the compensation rod (623).
• The piston case (622) can be removed by pushing
out the compensation rod (623) from the opposite
side of the piston case (622).
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13. Remove the VP plug (466) from the pilot cover (641).
SMIL14CEX2209AA 11
14. Remove the spool (642) and the spring (662) from the
pilot cover (641).
SMIL14CEX2210AA 12
15. Remove the hexagon socket head bolt (418) to re-

move the electromagnetic proportional pressure re-
ducing valve (079) from the pilot cover (641). Now
the disassembly of the regulator main unit completes.
• Pay attention to the damage at the connector sec-
tion of the electromagnetic proportional pressure
reducing valve (079).
SMIL14CEX2211AA 13
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Pump control valve - Assemble

Assembly requires reversed procedure of disassembly.
Pay close attention to the following points.
1. Surely repair all components, which are damaged
during disassembly, and prepare the replacement
components in advance.
2. Mixing of a foreign object leads malfunctions.
Clean the components thoroughly with the clean-
ing oil and air blow. Operate in a clean place.
3. Surely apply clean hydraulic fluid to the sliding sec-
tions before assembling.
4. Basically, replace seals such as Orings to new
ones.
5. Use a torque wrench for mounting bolts and plugs
at each section and tighten with a specific torque
in Torque – Bolt and nut ().
1. Choose an assembly site.
• Choose a clean site.
• Place a rubber plate or cloth on the work platform
in order to prevent making hit marks on the compo-
nents.
2. Assemble the compensation rod (623) to the compen-
sation hole in the casing (601).
3. Insert the pin (875) pressed in the lever (1) (612) into
the groove in the compensation rod (623), and assem-
ble the lever (1) (612) to the pin (875) pressed in the
casing (601).
4. Assemble the spool (652) and the sleeve (651) to the
spool (652) hole in the casing (601).
• Check that the spool (652) and the sleeve (651)
smoothly slide in the casing (601) without a catch.
• Pay attention to the spool (652) orientation.
5. Assemble the feedback lever (611), and insert the pin
(874) into the pin hole in the feedback lever (611).
• To facilitate work, you are recommended to insert the
pin (874) into the feedback lever (611) beforehand.
• Observe the correct orientation of the feedback lever
(611).
6. Assemble the pilot piston (643) to the pilot (643) hole
in the casing (601).
1. Check that the pilot piston (643) smoothly slides
without a catch.
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7. Insert the pin (875) pressed in the lever (2) (613) into
the groove in the pilot piston (643), and assemble the
lever (2) (613).
SMIL14CEX2208AA 1
8. Assemble the fulcrum plug (614) in a way that inserts

the pin (875) pressed in the fulcrum plug (614) into the
pin hole in the lever (2) (613), and attach the locking
ring Insert the adjusting plug (615), and attach the lock-
ing ring (858).
SMIL14CEX2212AA 2
9. Insert the adjusting plug (615), and attach the locking

ring (858).
• Be careful not to confuse insertion holes between the
fulcrum plug (614) and the adjusting plug (615).
• At this time, move the feedback lever (611) to check
to see if it is free of backlash and catch.
SMIL14CEX2204AA 3
10. Assemble the return spring (654) and the spring seat
(653) to the spool (652) hole, and attach the stop ring
(814).
SMIL14CEX2203AA 4
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11. Assemble the set spring (655) to the spool (652) hole,
and assemble the compensation piston (621), the pis-
ton case (622), and the pin (898) to the compensation
hole.
• Check whether the pin (898) moves smoothly.
SMIL14CEX2213AA 5
12. Attach the electromagnetic proportional pressure re-

ducing valve (079) to the pilot cover (641), and tighten
the hexagon socket head bolt (481).
• Pay attention to the damage at the connector sec-
tion of the electromagnetic proportional pressure
reducing valve (079).
SMIL14CEX2211AA 6
13. Assemble the spool (642)and the spring (662) to the

pilot cover (641).
SMIL14CEX2210AA 7
14. Attach the VP plug (466) to the pilot cover (641).
SMIL14CEX2209AA 8
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15. Attach the pilot cover (641), and tighten the hexagon
socket head bolt (439).
SMIL14CEX2214AA 9
16. Assemble the spring seat (Q) (644), the pilot spring
(646), and the adjusting ring (Q) (645) to the pilot hole,
and assemble the spring seat (Q) (644), the inner
spring (626), and the outer spring (625) to the com-
pensation hole.
• Observe the correct orientation of the spring seat
(Q) (644).
SMIL14CEX2215AA 10
17. Attach the cover (C) (629) where the adjusting screw
(C) (628), the adjusting ring (C) (627), the lock nut
(630), the hexagon nuts (801) and (802), and the
hexagon socket head retaining screw (924) are set,
and tighten the hexagon socket head bolt (438). Now,
the regulator main unit assembly completes.
SMIL14CEX2216AA 11
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Index

Pump control valve - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pump control valve - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Pump control valve - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Pump control valve - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pump control valve - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pump control valve - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Pump control valve - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pump control valve - Tool description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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Combination pump units - 304

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Contents
FUNCTIONAL DATA
Pump
Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Hydraulic systems - Combination pump units
Pump - Dynamic description

Gear pump internal structure diagram
SMIL14CEX3930GB 1
(a) Front case side
(b) Gear case side
(c) To main pump
(*1) 2 locations
Component number (quantity)

Code Part name Quantity
or type
300 Poppet subassembly 1 set 307 (1PC),308 (1PC)
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Hydraulic systems - Combination pump units
Code Part name Code Part name

307 Poppet (Quantity 1) 433 Flange socket (Quantity 2)
308 Seat (Quantity 1) 434 Flange socket (Quantity 2)
309 Ring (Quantity 1) 435 Flange socket (Quantity 4)
310 Spring (Quantity 1) 466 VP plug (Quantity 1)
311 Adjusting screw (Quantity 1) 700 Square ring (Quantity 1)
312 Lock nut (Quantity 1) 710 O-ring (Quantity 1)
351 Gear case (Quantity 1) 725 O-ring (Quantity 1)
353 Driving gear (Quantity 1) 732 O-ring (Quantity 1)
354 Driven gear (Quantity 1) 850 Locking ring (Quantity 1)
355 Filter (Quantity 1) 887 Pin (Quantity 2)
361 Front case (Quantity 1)
Structure
The casing comprises the front case (361) and gear case (351). Inside the casing the drive gear (353), driven gear
(354) pair and the relief valve for setting the discharge pressure are installed.
The relief valve comprises the filter (355), poppet (307), seat (308), spring (310), ring (309), adjusting screw (311),
and lock nut (312).
In order to prevent oil leaking to the outside, an angle ring (700) and O-ring (710)) are mounted on the front case
(361).
Operation
Oil suctioned in from suction port B3 is discharged from discharge port A3 by the drive and driven gears.
The discharge oil is held at the set pressure of 4 MPa (566 psi) by the relief valve. Unnecessary discharge oil is
drained from the drain port via the relief valve.
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Index

Pump - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Main control valve - 359

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Contents
FUNCTIONAL DATA
Main control valve

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Stacked control valves
Component diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
SERVICE
Main control valve

Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Relief valve
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
DIAGNOSTIC

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Relief valve
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Hydraulic systems - Main control valve
Main control valve - Overview

Relief valve
SMIL14CEX3565GB 1
1. Arm out 7. Main a (normal use)

2. Boom down 8. Main b (pressure boost)
3. Bucket Close 9. Standard lock nut
4. Arm in 10. Pressure boost lock nut
5. Boom up 11. Pressure boost adjusting screw
6. Bucket open 12. Standard pressure adjusting screw
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SMIL14CEX3566GA 2
Port Port size Port name Port Port size Port name
P1 – Pressure line T1 Return line
A1 – Left travel (forward) line pb1 G3/8 Left travel backward pilot line
B1 – Left travel (forward) line pb6 G3/8 Right travel backward pilot line
A2 – Option line pb3 G3/8 Left swing pilot line
B2 – Option line pb5, pb9 G3/8 Arm-in pilot line
A3 – Swing right line pb7 G3/8 Bucket-close pilot line
B3 – Swing left line pb8, pb4 G3/8 Boom-down pilot line
A5 – Arm-out line PH G1/4 Pressure boost signal port
B5 – Arm-in line Pb2 G3/8 Option line
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SMIL14CEX3567GA 3
Port Port size Port name Port Port size Port name
P2 – Pressure line pa6 G3/8 Right travel forward pilot line
A6 – Right travel (forward) line DR3p G3/8 Straight travel drain line
B6 – Right travel (backward) line pa7 G3/8 Bucket-open pilot line
A7 – Bucket-open line pa3 G3/8 Right swing pilot line
pa8,
B7 – Bucket-close line G3/8 Boom-up pilot line
pa4
pa5,
A8 – Boom-up line G3/8 Arm-out pilot line
pa9
B8 – Boom-down line Pa2 G3/8 Option line
T2 – Return line P3 G3/4 Backup confluence line
pa1 G3/8 Left travel forward pilot line
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Main control valve - Dynamic description

Basic configuration
The control valve is configured to enable installation of the inlet, the add-on section and the outlet on top of the P2
side housing, using the main unit housing which is a back-to-back coalescence of the P1 side housing and the P2
side housing as a base.
Operation of main unit
1. With every spool in neutral
Neutral path [Fig. 1, Fig. 2]

Oil fed from the P1 port enters the tank path (Ta) from the neutral path (L1) via the orifice (Lc1) of the low pressure
relief to return to the T1-T4 port.
Oil fed from the P2 port flows through the tank path (Ta) from the neutral path (R1) via the orifice (Rc1) of the low
pressure relief to return to the T1-T4 port.
Pressure in the pressure chamber (L2), (R2) at upper stream of the low pressure relief is led to the pump from the
ps1, ps2 port to control discharge volume of the P1, P2 pump.
When excessive oil flows to the neutral path (L1), opening the poppet activates the low pressure relief. This prevents
abnormally high pressure at the ps1, ps2 port.
Refer to the paragraph for activation of the relief valve for the structure of the low pressure relief.
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SMIL14CEX3805FB 1
1. Low-pressure relief valve (L) 9. Inlet

2. Arm 1 (section 5) 10. Low-pressure relief valve (R)
3. Boom 2 (section 4) 11. Arm 2 (section 9)
4. Swing (section 3) 12. Boom 1 (section 8)
5. Option (section 2) 13. Bucket (section 7)
6. Travel (section 1) 14. Travel (section 6)
7. Outlet 15. Travel straight (section ST)
8. Attachment 1 (section R1)
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SMIL14CEX3806GB 2
1. Arm regeneration release 9. Neutral cut

2. Arm 1 (section 5) out/in 10. Arm 2 semi-parallel
3. Boom 2 (section 4) up/down 11. Arm 2 (section 9) in/out
4. Swing (section 3) 12. Boom 1 (section 8) down/up
5. Option (section 2) 13. Bucket (section 7) close/open
6. Travel (section 1) 14. Travel (section 6)
7. Arm 1 semi-parallel 15. Travel straight (section ST)
8. Attachment 1 (section R1)
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2. Independent operation
Travel spool switchover [Fig. 3, Fig. 4]

Oil fed from the P1 port flows to the B2 A1 port via neck of the spool from the neutral path (L1) when the travel spool
is switched by pressurizing it from the pilot port Pb1 (Pa1) of the travel (section 1). Returning oil returns to the tank
path (Ta) via neck of the spool from the A1 B1 port.
Oil fed from the P2 port flows to the B6 A6 port via neck of the spool or the path (S6-1) from the neutral path (R1)
when the travel spool is switched by pressurizing it from the pilot port Pb6 of the travel (section 6).
The poppet S6–2 does not open because the parallel path (R3) and the path S6–1 are under the same pressure
during independent operation of travel only.
Returning oil returns to the tank path (Ta) via neck of the spool from the A6 B6 port.
SMIL14CEX3807FB 3
1. Switching state 3. Neutral state

2. Option (section 2) 4. Travel (section 6)
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SMIL14CEX3808FB 4

2. Travel (section 1) 4. Travel straight (section ST)
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Option spool switchover [Fig. 5, Fig. 6]

The neutral path (L1) closes when the option spool is switched by pressurizing it from the pilot port Pb2 (Pa2) of the
option (section 2). Oil fed from the P1 port flows to the B2 A2 port via the load check valve (S2-2), the path (S2-1)
and neck of the spool from the parallel path (L3). Returning oil returns to the tank path (Ta) via neck of the spool from
the (A2), (B2) port. Oil flows through inside of the load check valve (S2-2) and merges in the path (S2-1) when it is
fed from the P4 port.
The option (section2) should be used with the cap of (A2), (B2) and the plug of (pa2), (pb2) removed.
Refer to Stacked control valves - Disassemble (35.359) and Relief valve - Disassemble (35.359) to disassemble
the cap.
SMIL14CEX3807FB 5

2. Option (section 2) 4. Travel (section 6)
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SMIL14CEX3808FB 6
1, Switching state 3. Neutral state

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Swing spool switchover [Fig. 7]

The neutral path (L1) closes when the swing spool is switched by pressurizing it from the pilot Pb3port (Pa3) of the
swing (section 3). Oil fed from the P1 port flows to the B3 A3 port via the load check valve (S3-2), the path (S3-1) and
neck of the spool from the parallel path (L3). Returning oil returns to the tank path (Ta) via neck of the spool from the
A3 B3 port.
SMIL14CEX3809FB 7

2. Swing (section 3) 4. Bucket (section 7)
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Bucket spool switchover [Fig. 8, Fig. 9]
a. Close (regeneration) [Fig. 8]

The neutral path (R1) closes when the bucket spool is switched by pressurizing it from the pilot port Pb7 of the bucket
(section 7). Oil fed from the P2 port flows to the B7 port via the parallel path (R3), the load check valve S7–2, the
path S7–1 and neck of the spool. At the same time, returning oil from the A7 port returns to the tank path (Ta). A part
of the returning oil pushes and opens the poppet (S7-3) inside the bucket spool, followed by merges to the B7 port to
prevent cavitation in the cylinder head side. It is also accompanied with the effect of cylinder speed up and P2 port
pressure reduction depending on pressure condition in each port.
b. Open [Fig. 9]
The neutral path (R1) closes when the bucket spool is switched by pressurizing it from the pilot port Pa7 of the bucket
(section 7). Oil fed from the P2 port flows to the A7 port via the parallel path (R3), the load check valve (S7-2), the
path (S7-1) and neck of the spool. Returning oil returns to the tank path (Ta) via neck of the spool from the B7 port.
SMIL14CEX3810FB 8
1, Swing (section 3) 3. Bucket (section 7)

2. Neutral state 4. Switching state
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SMIL14CEX3811FB 9
1. Swing (section 3) 3. Bucket (section 7)

2. Neutral state 4. Switching state
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Boom spool switchover [Fig. 10 - 13]
a. Neutral [Fig. 10]

This valve is equipped with the antidrift valve on the cylinder head (A8) side of the boom 1. The poppet (AD1) cuts-off
returning oil from the A8 port by securely seating itself by own pressure of the A8 port that is led to the spring chamber
(AD4) via the path (AD2) and the spool (AD3) during neutral state.
b. Boom-up (2 pumps flow) [Fig. 11]

The neutral path (R1) closes when the boom 1 spool is switched by pressurizing it from the pilot port Pa8 of the boom
1 (section 8). Oil fed from the P2 port flows to the A8 port via the parallel path (R3), the load check valve (S8-2), the
path (S8-1) and neck of the spool. The neutral path (L1) closes when the boom 2 spool is switched by pressurizing
the pilot port Pa4 of the boom 2 (section 4) as well. Oil fed from the P1 port merges in the A8 port via the parallel
path (L3), the load check valve (S4-2), the path (S4-1) and neck of the spool. Returning oil returns to the tank path
(Ta) via neck of the spool from the B8 port.
c. Boom down (regeneration) [Fig. 12]

The neutral path (R1) closes when the boom 1 spool is switched by pressurizing it from the pilot port pb8 of the boom
1 (section 8). Oil fed from the P2 port flows to the B8 port via the parallel path (R3), the load check valve (S8-2), the
path (S8-1) and neck of the spool.
The poppet (AD1) opens by reducing pressure of the spring chamber (AD4) when the pilot pressure applied to the
pb8 switches the spool at the same time it moves the spool (AD3) of the antidrift valve via a path built in the housing.
This movement releases cut-off of the A8 port prior to switching the spool.
Then, returning oil from the A8 port returns to the tank path (Ta).
A part of the returning oil pushes and opens the poppet (S8-3) inside the boom 1 spool, followed by merges to the B8
port to prevent cavitation in the cylinder rod side.
It is also accompanied with the effect of cylinder speed up and P2 port pressure reduction depending on pressure
condition in each port.
d. Regeneration [Fig. 13]

While switching the boom 2 spool by pressurizing it from the pilot port pb4 during the aforementioned boom down
(regeneration) closes the neutral path (L1), a part of returning oil from the A8 port pushes and opens the poppet (S4-3)
inside the boom 2 spool and merges in the path (L1).
Therefore, it enables the cylinder to speed up in the lower stream section.
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SMIL14CEX3812FB 10
1. Boom 2 (section 4) 3. Boom 1 (section 8)

2. Neutral state
SMIL14CEX3813FB 11
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2. Switchover state
SMIL14CEX3814FB 12
1. Neutral state 3. Switchover state

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SMIL14CEX3815FB 13

2. Switchover state
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Arm spool switchover [Fig . 14 - 17]
a. Neutral [Fig. 14]

This valve is equipped with the antidrift valve on the cylinder rod side of the arm 1. The poppet (AD1) cuts-off returning
oil from the A5 port by securely seating itself by own pressure of the A5 port that is led to the spring chamber (AD4)
via the path (AD2) and the spool (AD3) during neutral state.
SMIL14CEX3816FB 14
1. Arm 1 (section 5) 3. Arm 2 (section 9)

2. Neutral state
b. Arm in (2 pumps flow) [Fig. 15]

Oil fed from the P1 port flows to the B5 port via the load check valve (S5-2), the path (S5-1) and neck of the spool from
the neutral path (L1) when the arm 1 spool is switched by pressurizing it from the pilot port Pb5 of the arm 1 (section
5). Oil fed from the P2 port merges in the B5 port via the load check valve (S9-2) and the path (S9-1) from the neutral
path (R1) when the arm 2 spool is switched by pressurizing it from the pilot port Pb9 of the arm 2 (section 9) as well.
The poppet (AD1) opens by reducing pressure of the spring chamber (AD4) when pilot pressure applied to the pb5
switches the spool at the same time it moves the spool (AD3) of the antidrift valve via a path built in the housing. This
movement releases cut-off of the A5 port prior to switching the spool.
Then, returning oil from the A5 port is divided into a flow regenerating to the B5 port via the regeneration check inside
the spool and a flow returning to the tank path (Ta) via the regeneration control valve.(Refer to the arm in (regeneration
release) in the next paragraph "c." for the detail of the regeneration function.)
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SMIL14CEX3817FB 15
1. To regeneration control valve 3. Switchover state

c. Arm in (regeneration release) [Fig. 16]

During operation of arm in, after returning oil from the A5 port passes through a notch of (a), it is divided into
the following two types of flows:
1. Returning to the tank path (Ta) passing through a notch of (d) of the regeneration control valve.
2. Merging in the bridge path (S5-1) after passing through (b) fixed orifice, (c) regeneration check and (i) fixed orifice
in the arm 1 spool.
Pressurizing the par port at this moment activates the arm regeneration release valve (e), and then increases the
notch opening area of (d) to increase the amount of oil returning to the tank path (Ta).
On the other hand, the amount of oil regenerating to the B5 port decreases.
This mechanism enables both of ensuring the regeneration ratio at low load and reducing the returning back pressure
at high load at the same time.
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SMIL14CEX3818FB 16
1. Arm 1 (section 5) 3. Arm regeneration release

2. Switchover state
d. Arm out (2 pumps flow) [Fig. 17]

Oil fed from the P1 port flows to the A5 port via the load check valve (S5-2), the path (S5-1) and neck of the spool
from the neutral path (L1) when the arm 1 spool is switched by pressurizing it from the pilot port Pa5 of the arm 1
(section 5).
Oil fed from the P2 port merges in the arm 1 section to flow to the A5 port via the load check valve (S9-2) and the
path (S9-1) from the neutral path (R1) when the arm 2 spool is switched by pressurizing it from the pilot port pa9 of
the arm 2 (section 9) as well. Returning oil from the B5 port returns to the tank path (Ta) via neck of the spool.
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SMIL14CEX3819FB 17

2. Switchover state
Parallel orifice for arm [Fig. 18]

Orifices utilizing the spool are installed at the parallel path for arm 1 and arm 2 of this valve to control the amount of
feeding oil to the arm section for combined operation.
Oil fed from the parallel path (L3) of the arm 1 (section 5) pushes and opens the poppet (S5-3), and then it passes
through the orifice (Lc8) of the adjustable orifice spool and is connected to the path (L5).
In the same manner, oil fed from the parallel path (R3) of the arm 2 (section 9) pushes and opens the poppet (S9-3),
and then it passes through the adjustable orifice spool (Rc8) and is connected to the path (R5).
The amount of reduction at orifice (Lc8), (RC8) is adjusted by pressurizing the pilot port (pc3), (pap).
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SMIL14CEX3820FB 18
1. Low-pressure relief valve (L) 4. Neutral state

2. At boom up (at pressurizing pc3) 5. At boom up (at pressurizing pap)
3. Neutral state
Relief valve
a. Main relief valve [Fig. 19]

Oil fed from the P1 port flows through the poppet (LP), and oil fed from the P2 port flows through the poppet (RP) and
the path (2) to be led to the main relief valve. Activation of the main relief valve controls the maximum pressure of the
pump at P1 and P2 side.
b. Overload relief valve [Fig. 20]

The overload relief valve is installed on each cylinder port of the boom 1, the arm 1, the bucket and the add-on to
prevent abnormal raise of actuator pressure due to external force and the like.
This relief valve has a function to prevent cavitation by sucking oil from the tank (suction function) when the cylinder
port pressure becomes negative pressure.
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SMIL14CEX3821FB 19
SMIL14CEX3822EA 20
a. Suction function; during activation
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3. Combination operation
Travel combination operation [Fig. 21]

In the event of simultaneous operation of the travel left/right and the front system, the pst port is pressurized by
external signal to maintain travel straightness by switching the travel straight spool.
1. In the event of front operation during the travel left/right simultaneous operation (forward, backward or pivot turn).
2. In the event of simultaneous operation of travel left/right during the front system operation.
a. Main unit circuit [Fig. 21]

Switching the travel straight spool allows oil to flow from the neutral path (L1) to the travel (section1) as well as to the
travel (section6) via the path (3), neck of the travel straight spool and the neutral path (R1) to enable feeding to the
travel left/right.
On the other hand, oil fed from the P2 flows to the parallel path (R3) as well as to the parallel path (L3) via neck of
the travel straight spool and the path (1) to enable feeding to all of the front system.
Also, in the event of switching the front system during traveling and the negative pressure is higher than that of the
travel (section 6), a part of oil fed from the P2 port pushes up the poppet (S6-2) from the parallel path (R3) to merge
in the path (S6-1) via the orifice at the end of the poppet.
This mitigates a shock to the machine body due to abrupt speed reduction that occurs at switchover to 1 pump travel.
As mentioned above, operation that activates the travel (section 1 and 6) by oil fed from the P1 port and activates
working system other than travel by oil fed from the P2 port prevents curving travel during combination operation to
maintain travel straightness.
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SMIL14CEX3823GB 21

2. Switchover state 5. Path 1
3. Travel (section 1) 6. Path 3
4. Antidrift valve [Fig. 22 - 24]

The antidrift valve is installed at the cylinder port of the arm rod (boom head) side in order to prevent self-dropping of
the arm (boom) cylinder.
It is also activated by leading relief signal from the pilot signal via the internal path. (Arm side (A5) is shown as
representative example)
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Neutral ( A5 port hold) [Fig. 22]
SMIL14CEX3824EB 22
1. Main spool
• Holding pressure of the A5 port is led to the spring chamber d of the poppet 1 from the path a via the path b and
the path c.
• Therefore, pressure oil at the A5 port is cut-off by the seat section S1 and the seat section S2.
Pressurizing release signal [Fig. 23]
SMIL14CEX3825EB 23
1. Main spool
• Pressuring the pi port moves the piston 2 to activate the spool 3.

• The spool 3 also activates the poppet 4.
• Activation of the poppet 4 then cuts-off continuity between the A5 port and the spring chamber d.
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Releasing holding state [Fig. 24]
SMIL14CEX3826EB 24
1. Main spool
• Activation of the piston 2 continues the spring chamber d to the drain chamber (DR) at T2 section via the path c
and the path e.
• Pressure in the spring chamber d becomes drain pressure to activate the main poppet 1.
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5. Neutral cut spool

This valve is equipped with the neutral cut spool at the lowest down stream of the neutral path (R1) of the P2 side
housing as a standard equipment.
Switching the neutral cut spool by pressurizing the pcc port cuts-off a path connected to the low pressure relief via
the orifice (Lc7) to enable external output from the P3 port. [Fig. 25] Switching the neutral cut spool by pressurizing
the pdp port enables dividing flow to direction of the low pressure relief by the orifice (Lc8). [Fig. 26]
SMIL14CEX3827EA 25
SMIL14CEX3828EA 26
6. Add-on [Fig. 27, 28]
Main relief valve for add-on [Fig. 27]

Oil fed from the Pr port is led to the main relief valve for add-on. Activation of the relief valve regulates the maximum
pressure of the Pr pump.
Spool section [Fig. 28]

he neutral path (Pg) closes when the spool is switched by pressurizing it from the pilot port par1 (pbr1) of the add-on
(section 10). Oil fed from the Pg port flows to the (AR1), (BR1) port via the load check valve (S10-1), path (S10-2)
and neck of the spool from the parallel path (Rg).
Returning oil returns to the tank path (Ta) via neck of the spool from the BR1, AR1 port.
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SMIL14CEX3829EB 27
1. Main relief valve for add-on
SMIL14CEX3830EB 28
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Activation of relief valve
Main relief valve

Main unit main relief valve activation
A. The relief valve is incorporated between the neutral path "HP" and the low-pressure path "LP" to allow oil to flow
via the orifice hole of the main poppet (C) to fill the internal space (D). And, the sleeve (E) and the main poppet
(C) are securely seated due to difference of areas between "A" and "B."
SMIL14CEX3831EB 29
B. The pilot poppet (F) opens when pressure of the neutral path "HP" reaches set force of the pilot spring. Oil flows
around the pilot poppet (C) to be led to the tank path "LP" via the drill hole (G).
SMIL14CEX3832EB 30
C. Opening the pilot poppet reduces pressure in the internal space (D), and opening the main poppet (C) allows oil
in "HP" to directly flow to the path "LP."
SMIL14CEX3833EB 31
D. Boost pressure activation

Pressurizing the pilot port "HP" moves the piston (H) to a position set by the plug (I). This raises the force of the
pilot spring to raise pressure at "HP."
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SMIL14CEX3834EB 32
Overload relief valve

Overload relief valve activation
A. This relief valve is incorporated between the cylinder port "HP" and the low-pressure path "LP" to allow oil to flow
via a hole of the piston (C) to fill the internal space (G). The sleeve (K) and the main poppet (D) are securely
seated acting to difference of areas between "A" and "B."
SMIL14CEX3835EB 33
B. The pilot poppet (E) opens when pressure of the cylinder port "HP" reaches the set force of the spring of the pilot
poppet. Oil flows around the poppet to be led to the low-pressure side "LP" via the drill hole (H).
SMIL14CEX3836EB 34
C. Opening the poppet (E) causes oil flow through the orifice (I) of the piston (C) to generate a pressure difference
between the path "HP" and the back side of the piston (C), which allows the piston (C) to move to be seated on
the poppet (E).
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SMIL14CEX3837EB 35
D. Oil flow from the path "HP" to the back side of the poppet (D) is limited to those through ring shape gap between
the poppet (D) and the piston (C), and through the orifice (F), which causes a higher pressure difference. This
causes the poppet (D) to open to allow oil to flow directly to the path "LP."
SMIL14CEX3838EB 36
Suction action
The anti-void unit that feeds oil in case of occurrence of cavitation at the cylinder port "HP" is incorporated in this
relief valve. The sleeve (K) opens due to a difference of areas between "A" and "B" when pressure at the cylinder
port "HP" is lower than that at the low-pressure side "LP."
Oil enters the cylinder port "HP" from the low-pressure side "LP" to prevent cavitation.
SMIL14CEX3839EA 37
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Low-pressure relief valve

Generating signal pressure (when pressurizing Pn1, Pn2 port)
Oil fed from the (P1 (P2)) pump port flows to the tank path (Ta) via the neutral path (L1 (R1)), the low pressure relief
path (L2 (R2)) and the orifice (Lc1 (Rc1)).
At this moment, a pressure generated at the path (L2 (R2)) due to the orifice (Lc1 (Rc1)) is led to the low-pressure
relief signal port (ps1 (ps2)).
Activating the main spool at the upper stream of the path (L2), (R2) reduces the volume of oil flowing the path (L2),
(R2) to lower the signal pressure at ps1, ps2.
SMIL14CEX3840EB 38
1. Low-pressure relief valve (L)
Activation of low-pressure relief valve

The poppet is activated by a pressure generated in the path (L2 (R2)) due to the orifice (Lc1 (Rc1)) when excessive
volume of oil flows in the path (L2 (R2)).
Oil flows to the tank path (Ta) via a drill hole of the plug from the path due to the activation of this poppet.
SMIL14CEX3841EB 39
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Main relief valve for add-on

Main relief valve for add-on activation
A. This relief valve is incorporated between the neutral path "HP" and the tank path "LP" to allow oil to flow via the
orifice hole of the main poppet (1) to fill the internal space (C). And, the sleeve (2) and the main poppet (1) are
securely seated due to difference of areas between "A" and "B."
SMIL14CEX3842EB 40
B. The pilot poppet (3) opens when pressure of the neutral path "HP" reaches set force of the pilot spring.
Oil flows around the pilot poppet (3) to be led to the tank path "LP" from the drill hole (E) via the ring shape gap (D).
SMIL14CEX3843EB 41
C. Opening the pilot poppet (3) reduces pressure in the internal space (C), and opening the main poppet (1) allows
oil in "HP" to directly flow to the path "LP."
SMIL14CEX3844EB 42
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Stacked control valves - Component diagram
SMIL14CEX3643HB 1
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[For lifting eye bolt] 2- M10 X 1.5 effective thread

a. *1. Arm 1
depth 17
b. 5- M10 X 1.5 effective thread depth 17 *2. Boom 2
c. 2- M12 X 1.75 effective thread depth 19 *3. Swing
d. 3- M10 X 1.5 effective thread depth 17 *4. Option
e. 4- M16 X 2 effective thread depth 27 *5. Travel
f. 2- M10 X 1.5 effective thread depth 17
SMIL14CEX3644FB 2
a. 2- M10 X 1.5 effective thread depth 17 *3. Bucket

b. 1- M10 X 1.5 effective thread depth 17 *4. Travel
*1. Arm 2 *5. Straight travel
*2. Boom 1
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SMIL14CEX3645HB 3
*1. Parallel *7. Arm 2 semi-parallel

*2. Reservoir *8. Arm 2 in/out
*3. Drain *9. Boom 1 down/up
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*4. C port *10. Bucket close/open

*5. Pilot *11. Travel
*6. Neutral cut *12. Straight travel
SMIL14CEX3646HB 4
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*1. Arm regeneration release *9. Drain

*2. Arm 1 semi-parallel *10. Cylinder
*3. Arm 1 out/in *11. Straight travel
*4. Boom 2 up/down *12. Parallel
*5. Swing *13. Common
*6. Option *14. Pilot
*7. Travel *15. C port
*8. reservoir
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SMIL14CEX3647HB 5
*1. Neutral cut *6. Out/in

*2. Arm regeneration release *7. Arm 2
*3. Arm 2 semi-parallel *8. Boom 2
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*4. Arm 1 semi-parallel *9. Up/down

*5. Arm 1 *10. Boom 1
SMIL14CEX3648HB 6
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*1. Swing *5. Travel

*2. Open/close *6. Travel
*3. Bucket *7. Straight travel
*4. Option
Part list
Code Part Name Code Part Name
1 Valve housing (Quantity 1) 40 Spacer (Quantity 2)
2 Spool assembly (Quantity 1) 41 O-ring (Quantity 2)
3 Spool assembly (Quantity 1) 42 Backup ring (Quantity 2)
5 Spool assembly (Quantity 2) 44 Spool assembly (Quantity 1)
6 Spool assembly (Quantity 1) 45 Spool assembly (Quantity 1)
7 O-ring (Quantity 20) 46 Spacer (Quantity 1)
8 Cap (Quantity 6) 47 Sleeve (Quantity 1)
9 Cap (Quantity 4) 48 Poppet (Quantity 1)
10 Cap (Quantity 10) 49 Spring (Quantity 1)
11 Valve housing (Quantity 1) 50 Flange (Quantity 1)
14 Spool assembly (Quantity 1) 53 Antidrift valve assembly (Quantity 2)
15 Spool assembly (Quantity 1) 54 Relief valve kit (Quantity 1)
16 Cap (Quantity 1) 55-1 Relief valve kit (Quantity 5)
17 Spool assembly (Quantity 1) 55-2 Relief valve kit (Quantity 1)
18 O-ring (Quantity 4) 56 Relief valve assembly (Quantity 2)
19 Cap (Quantity 3) 57 Plug assembly (Quantity 4)
20 Spool assembly (Quantity 1) 58 Plug assembly (Quantity 4)
21 Poppet (Quantity 2) 60 Socket head bolt (Quantity 12)
22 Spring (Quantity 2) 61 Socket head bolt (Quantity 40)
23 Poppet (Quantity 7) 62 Socket head bolt (Quantity 40)
24 Spring (Quantity 8) 63 Socket head bolt (Quantity 10)
25 O-ring (Quantity 8) 64 Socket head bolt (Quantity 8)
26 Flange (Quantity 6) 65 Name plate (Quantity 1)
27 Poppet (Quantity 2) 66 Drive screw (Quantity 2)
28 Spring (Quantity 2) 67 O-ring (Quantity 3)
29 O-ring (Quantity 2) 68 Cap (Quantity 2)
30 O-ring (Quantity 6) 69 O-ring (Quantity 2)
31 Flange (Quantity 1) 70 Plug (Quantity 1)
32 Poppet (Quantity 1) 71 O-ring (Quantity 1)
33 Spring (Quantity 1) 72 Plug assembly (Quantity 2)
34 Plug (Quantity 1) 73 Plug assembly (Quantity 2)
35 O-ring (Quantity 1) 75 Outlet housing (Quantity 1)
36 Spring (Quantity 1) 76 Tie rod (Quantity 4)
37 Poppet (Quantity 1) 77 Nut (Quantity 4)
38 Poppet (Quantity 1) 81 Plug assembly (Quantity 1)
39 Flange (Quantity 2)
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Main control valve - Prepare

WARNING
Chemical hazard!
cals.
W0371A
WARNING
Escaping fluid!
doctor immediately.
W0178A
WARNING
Avoid injury!
W1128A
WARNING
Crushing hazard!
latches.
W0256A
WARNING
Heavy objects!
W0398A
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Items to prepare:
• Wrenches [ 7 mm, 17 mm, 19 mm, 22 mm, 24 mm]
• Hexagon wrenches [ 8 mm, 10 mm]
• Wire cutters
• Wire rope (with the required lifting capacity)
• Marking pen
• Cap
• Plug
• Rag
• Cleaning fluid
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Main control valve - Remove

Pay attention to the followings when removing the hy-
draulic hose.
• Apply marking at each location of the lines and hoses
so as to match connections at assembling.
• Attach caps and plugs at the lines and hoses so as
to prevent invasion of water, dust and dirt.
• Spray parts cleaner to wash each section of piping in
order to prevent adhering dirt to and damaging joints.
1. Extend the attachment to contact ground.
SMIL14CEX1502AA 1
2. Drain oil from the hydraulic reservoir.

3. Remove the 10 bolts (2) with a wrench [ 19 mm] after
opening the engine hood (1) to remove the top cover
(3) and (4).
SMIL14CEX1503BB 2
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54.21 lb ft)
SMIL14CEX1501AB 3

SMIL14CEX1504BB 4
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6. Remove the 5 bolts (1) with a wrench [ 17 mm] to dis-

connect the 9 connectors (2).
SMIL14CEX1505BB 5

19 mm].
22 mm].
SMIL14CEX1506BB 6
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wrench [ 8 mm] to remove the 7 hydraulic hoses (2).
[ 10 mm] to remove the hydraulic hose (4).
SMIL14CEX1507BB 7
9. Remove the hydraulic hose (1) with a wrench [ 41 mm].

22 mm].
19 mm].
SMIL14CEX1508BB 8
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19 mm].
Remove the bolts (2) with a wrench [ 17 mm].
Remove the 4 hexagon bolts (3) with a hexagon
wrench [ 8 mm] to remove the 6 stack solenoid valve
(4).
SMIL14CEX1509BB 9

wrench [ 8 mm] to remove the 7 hydraulic hoses (2).
Remove the 4 hexagon bolts (3) with a hexagon
wrench [ 10 mm] to remove the hydraulic hose (4).
SMIL14CEX1510BA 10
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12. Remove the 4 bolts (1) of the control valve with a

wrench [ 24 mm].
230.12 lb ft)
SMIL14CEX1511AB 11
13. Attach the 2 eyebolts (1) ( M10) to the control valve.
SMIL14CEX1512AB 12
14. Attach the shackle (1) to the eyebolt and then lift the
control valve (3) with a lifting equipment and wire rope
(2).
SMIL14CEX1513BB 13
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15. Settle the control valve (1) on a wood plank (2) or other
block.
SMIL14CEX1514AB 14
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Main control valve - Install

dure.
Tighten bolts to the specified torque.
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Stacked control valves - Disassemble

Caution for disassembly
1. The main unit shall be kept in level on level site and all
of the working system shall be grounded.
Travel and swing shall be thoroughly confirmed to be in
condition that they will not activated by themselves.
Then, stop the engine and release pressure from each
actuator.
CAUTION:
○ Replacing the valve assembly or disassembling

the valve with pressurized condition is danger-
ous due to possible bursting out of a high pres-
sure oil or abrupt drop off of components.
○ The bucket shall be grounded before disassem-
bling and pressure in the circuit shall be re-
leased.
2. Air pressure inside the tank shall be released.
3. Surrounding area of the portion to be disassembled
shall be thoroughly cleaned to prevent invasion of for-
eign substances into the valve during disassembling.
4. Disassembled component shall be identified by tags to
identify position to be re-assembled to.
5. All of the disassembled seals (O-rings and backup
rings) shall be replaced with new ones.
6. The spool shall not be replaced since it is selected and
fitted to the valve housing and the sleeve.
Removal of long cap and pulling out of main spool

1. Loosen and remove the cap (8) and the socket head
bolt (62) (hexagon socket diameter 8 mm) of the cap
(9).
2. Remove the O-ring (7) from the valve housing.
3. Pull out each spool from the valve housing in state of
sub-assembly.
CAUTION:
○ Pay attention not to create hit mark or scratch

during pulling out the spool.
○ Disassembled spool shall be identified by tags
so as to be re-assembled to the right position.
4. Disassembling spool assembly.
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CAUTION:
○ The spool shall be sandwiched by wooden

blocks and clamped by a vice so as not to
damage outer circumference of the spool.
○ Heat up thread section of circumference of the
spool with an industrial purpose dryer to melt
adhesive agent since adhesive agent is applied
at the thread section at the end of the spool.
○ Heating temperature of the spool shall be 200
- 250 °C (392.0 - 482.0 °F), which allows the
spool end to be loosened easily.
SMIL14CEX3642AA 1
○ The spring shall be replaced with a new one in
the event of over heating.
1. Loosen the spool ends and the hexagon socket

diameter 8 mm (0.315 in) of the spool assembly
(2) - (6), (12) - (15) to disassemble the spring and
the spring sheet.
2. While the spool of the spool assembly (3), (4), (12)
and (13) incorporates the poppet, the spring, the
plug and the spacer, they shall not be disassemble
unless it is necessary to do so.
In the event that disassembly is inevitable, heat up
outer circumference of the spool to melt adhesive
agent on the thread section, and then remove the
plug.
During assembling, the O-ring and the backup ring
must be replaced with new ones.
Wooden blocks for spool assembly/disassem-
bly
L1 30 - 40 mm (1.181 - 1.575 in)
L2 3 - 6 mm (0.118 - 0.236 in)
L3 70 - 100 mm (2.756 - 3.937 in)
Disassembly of arm 1, 2 parallel-tandem spool, neutral cut spool, arm regeneration release
spool section
1. Loosen and remove the socket head bolt (64) (hexagon
socket diameter 5 mm (0.197 in)) of the cap (16) and
(19).
3. Pull out the spool (17), (20), (44) and (45) from the
valve housing in state of subassembly.
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4. Disassembling spool assembly
CAUTION:
○ The spool shall be sandwiched by wooden

blocks (refer to diagram in the previous page)
and clamped by a vice so as not to damage
outer circumference of the spool.
○ Heat up the thread section of circumference of
the spool with an industrial purpose dryer to
melt adhesive agent since adhesive agent is
applied at the thread section at the end of the
spool.
○ Heating temperature of the spool shall be 200
- 250 °C (392.0 - 482.0 °F), which allows the
spool end to be loosened easily.
○ The spring shall be replaced with a new one in
the event of over heating.
1. Loosen the spool end (hexagon socket diameter

5 mm (0.197 in)) of each spool to disassemble the
spring and the spring sheet.
Disassembly of load check valve section

CAUTION:
○ Removing the plug is subject to danger that

components may pop out due to the internal
pressure trapped inside.
○ The plug shall be loosen slowly and be disas-
sembled checking that there is no resistance
due to the trapped pressure.
1. Loosen and remove the socket head bolt (61) (4 in each
section, hexagon socket diameter 8 mm (0.315 in)) of
the flange (26) (5 locations), (50) (1 location). (50)shall
be separated from (26) since it is the only one that has
different shape.
2. Remove the spring (24) and (49), the poppet (23) and
(48) and the O-ring (25) from the valve housing.
Remove the sleeve (47) of the arm 2 (cross-section E
- E).
3. Loosen and remove the socket head bolt (61) (hexagon
socket diameter 8 mm (0.315 in)) of the flange (39) (2
locations).
4. Remove the spacer (40) from the valve housing, and
then remove the O-ring (41) and the backup ring (42)
from the spacer (40).
5. Remove the spring (24) and the poppet (23) from the
valve housing.
6. Loosen and remove the plug (57) (hexagon socket di-
ameter 10 mm (0.394 in)). (Cross-section D - D)
valve housing.
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ameter 10 mm (0.394 in)). (Cross-section D - D)
9. Remove the spacer (46), the spring (22) and the poppet
(21) from the valve housing.
ameter 35 mm (1.378 in)). ( P4 section, cross-section
H - H)
11. Loosen and remove the socket head bolt (60) (4 loca-
tions) (hexagon socket diameter 8 mm (0.315 in)) of
the flange (31).
12. Remove the spring (33), the poppet (32) and the
O-ring (25) from the valve housing.
13. Loosen and remove the plug (34) (hexagon socket
diameter 27 mm (1.063 in)) to remove the O-ring (35).
(Crosssection H - H)
valve housing.
the flange (26). (Cross-section I - I)
16. Remove the spring (24), the poppet (38) and the
O-ring (25) from the valve housing.
Disassembly of antidrift valve section (sub component in assembly is expressed by (min

number - sub number).)
CAUTION:
○ Removing the antidrift valve assembly is sub-

ject to danger that components such as seal
may pop out due to the internal pressure
trapped inside.
○ The socket head bolt shall be loosen slowly and
be disassembled checking that there is no re-
sistance due to the trapped pressure.
the antidrift valve assembly (53) (2 locations).
valve housing.
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4. Disassembling antidrift valve assembly
CAUTION:
○ Removing the antidrift valve internal component

in a state assembled to the valve housing is
subject to danger that components may pop out
due to the internal pressure trapped inside.
○ The plug assembly (53-12) shall be loosen
slowly and be disassembled checking that there
is no resistance due to the trapped pressure.
1. Loosen and remove the plug assembly (53-12)

(hexagon socket diameter 38 mm (1.496 in)) to
remove the O-ring.
2. Remove the piston (53-3), the spool (53-4) and the
spring (53-6).
3. Loosen and remove the sleeve (53-5) (hexagon
socket diameter 14 mm (0.551 in)) to remove the
O-ring (53-8, 9, 14) and the backup ring (53-10, 11)
at outer circumference of the sleeve.
4. Remove the poppet (53-2), the spring seat (53-13)
and the spring (53-7) from the back of the hole.
5. Loosen and remove the plug (53-15) : hexagon
socket diameter 5) to remove the O-ring.
Disassembly of relief valve

CAUTION:
○ The relief valve should be removed by loosen-

ing the plug at the main unit installation section.
○ Do not loosen the set pressure adjustment plug
and the lock nut.
○ Turning the set pressure adjustment plug
changes the set pressure, which is dangerous.
1. Loosen and remove the overload relief valve (55)
(hexagon socket diameter 32 mm (1.260 in)).
2. Loosen and remove the main relief valve (54) (hexagon
socket diameter 32 mm (1.260 in)).
3. Loosen and remove the low-pressure relief valve as-
sembly (56) (2 locations) (hexagon socket diameter
32 mm (1.260 in)) to remove the O-ring (56-5, 6) .
4. Loosen and remove the main relief valve assembly
(80) for add-on (hexagon socket diameter 24 mm
(0.945 in)).
Disassembly of option section

ameter 22 mm (0.866 in)) and the plug assembly (81)
(hexagon socket diameter 22 mm (0.866 in)) from the
cap (8) to remove the Oring.
2. Loosen and remove the socket head bolt (61: 4 in
each section) of the cap (68: 2 locations) to remove
the O-ring (69).
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Disassembly of add-on section

1. Loosen and remove the hexagon nut (77) (4 locations)
(hexagon socket diameter 22 mm (0.866 in)).
2. Pull out the outlet housing (75).
The following procedure 3 - 4 are to be done as neces-
sary.
3. Pull out the spool section assembly (78) and then re-
move the O-ring (78-10, 11) at the mating surface.
4. Pull out the inlet section assembly (79) and then re-
move the O-ring (79-3, 4) at the mating surface.
5. Remove the O-ring (43) (67) at the main unit mating
surface.
6. Loosen the tie rod (76) to remove from the main unit
valve housing (1). (use a wrench and the like.)
CAUTION:
○ Pay attention not to create hit mark or scratch

on the mating surface during pulling out the
add-on section. Hit mark or scratch may cause
operation problem due to oil leak from the mat-
ing surface.
○ Pay attention not to allow foreign substance to
invade the oil paths. It may cause sticking spool
due to invasion to the spool sliding section, or
abnormal movement of the actuator or disabling
controlled stop due to the defective seating of
the load check.
Disassembly of valve housing coalescence bolt

CAUTION:
○ Do not disassemble the coalescence bolt (63)

unless necessary.
○ It should be disassembled with the main unit
placed on level work table if it is necessary to
disassemble.
○ Prepare O-ring (30), (51) and (52) for replace-
ment.
tions) (hexagon socket diameter 14 mm (0.551 in)).
Re-tightening torque: 166 - 177 N·m (122.44 -
130.55 lb ft).
2. Remove the O-ring (30), (51) and (52) at the valve
housing mating surface.
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Stacked control valves - Cleaning

Clean all of the disassembled components thoroughly
with clean mineral oil.
Dry them out with compressed air, and then place each
component on clean paper or plastic sheets for inspec-
tion.
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Stacked control valves - Inspect

Inspect for any burr, scratch, scar or other defect on the
entire surface of each component.
1. Inspect for any scratch or scar on the load check
sheet surface of the valve housing, or any dirt,
dent or rust. Minor damage can be removed by
oil stone.
2. Check for any scratch or hit mark on outer circum-
ference of the spool.
Minor damage can be removed by oil stone.
3. All slide ways need to be move lightly.
Every groove and path need to be free of any for-
eign substance.
4. Replace any spring with breakage or excessive de-
formation or wear.
5. Inspect in accordance with “ Relief valve - In-
spect (35.359)” if the relief valve does not operate
smoothly.
6. All of the O-rings and backup rings of disassem-
bled component shall be replaced with new ones.
7. Check for any residual paint debris around the
body holes or the plug seats after removing the
caps or the plugs. (Invasion of paint debris inside
the valves may cause operation failure or oil leak-
age due to sticking or clogging.)
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Stacked control valves - Assemble

Caution for handling O-ring
1. Do not use any O-ring with defect in formation or with
damage during handling.
2. Thoroughly lubricate the O-ring and the O-ring mount-
ing section with grease or hydraulic fluid to allow
smooth installation.
3. Do not expand the O-ring to cause permanent defor-
mation.
4. Pay attention not to roll in the O-ring when assembling
it.
(Twisted O-ring may not easily return its twist after in-
stallation and may cause oil leak.)
Caution for handling spool

1. Make sure to obey the specified torque since excessive
torque applied to the thread section may cause opera-
tion failure of the spool.
2. Pay attention to keep the same combination of each
spool, the spring and the spool end before and after
disassembly.
Method to apply adhesive agent (male and female thread section of components requiring
bonding)
1. Cleaning (de-greasing)
Clean using steam de-greasing with acetate or ether, or
using alkaline cleaning agent.
2. Drying
Dry out bonded surface by blowing clean air or leave it
to dry out by itself.
Insufficient drying out may cause deteriorated bonding
effect.
3. Applying adhesive agent
Apply a little amount of adhesive agent ( LOCTITE®
638™ or equivalent) on a couple of pitches of female
thread on entry end of the spool.
During this work, pay attention not to touch the applied
portion to the spring seat.
CAUTION: Do not use the “Loctite primer T”

hardening promoter agent in order to avoid deteri-
orating bonding strength.
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4. Hardening period of adhesive agent Opening to atmos-

phere for the following time period after tightening the
spool end in order to ensure hardening of adhesive
agent.
Atmosphere temperature around 22 °C (71.6 °F):
For 8 h or longer
For 3 h or longer
For 24 h or longer
CAUTION: Exposure time not reaching the

aforementioned time period may cause insufficient
bonding strength.
Assembly procedure of sub-assembly

CAUTION: Make sure to check the quantity
of each component, location to be installed and
required tools before commencing assembling.
Assembly of spool assembly (main spool)

1. Apply adhesive agent on the thread section of the spool
(2) - (6), (12) - (15) and then assemble the spring seat,
the spring and the spring end.
2. Sandwich the spool with wooden blocks (the ones used
for disassembly), and then clamp them with a vice to
tighten the spool end with specified torque.
Torque: 19.6 - 21.6 N·m (14.46 - 15.93 lb ft)
3. The spool (3), (4), (12) and (13) is to be tightened after
inserting the poppet and the spring from the side oppo-
site to the spool end, and applying adhesive agent on
the thread section of the plug with the O-ring and the
backup ring attached.
Torque: 9.8 - 11.8 N·m (7.23 - 8.70 lb ft)
CAUTION:
○ Pay attention not to allow adhesive agent to

seep into inside the spool by applying too much.
○ Pay attention that excessive torque at tighten-
ing the spool end may cause preventing smooth
movement of the spool.
○ Pay attention to assemble correct spring since
there are 2 types of them. (only the boom 2 has
different one.)
Assembly of arm 1, 2 parallel-tandem spool, neutral cut spool, arm regeneration release
spool assembly
1. Apply adhesive agent on the thread section of the spool
(17), (20), (44) and (45) and then assemble the spring
seat, the spring and the spring end.
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2. Sandwich the spool with wooden blocks (the ones used

for disassembly), and then clamp them with a vice to
tighten the spool end with specified torque.
Torque 19.6 - 21.6 N·m (14.46 - 15.93 lb ft)
CAUTION:
○ Pay attention not to allow adhesive agent to

seep into inside the spool by applying too much.
○ Pay attention that excessive torque at tighten-
ing the spool end may cause preventing smooth
movement of the spool.
○ Pay attention to assemble correct spring since
there are 2 types of them. (2 types of the spring
for the spool (17) and (45) and the spring for the
spool (20) and (44)).
Assembly of antidrift valve assembly

1. Assemble the O-ring (53-8), (9) and (14)), the backup
ring (53-10), (11)) to outer circumference groove of the
sleeve (53-5).
CAUTION:
○ Pay attention to assemble the O-ring and the

backup ring to the correct assembling position.
○ Assembling in reverse manner may cause dam-
age of the O-ring to increase self-dropping of
the actuator.
2. Insert the poppet (53-2), the spool (53-4) to the sleeve
hole. Pay attention for the orientation of the spool.
3. Assemble the spring seat (53-13) to small diameter
section at the end of the poppet, place the spring (53-7)
and then screw the sleeve (53-5) into the body (53-1)
to tighten-up.
Torque: 73 - 79 N·m (53.84 - 58.27 lb ft)
CAUTION: It is recommended to apply grease

to a seat before assembling so as to ensure that
the spring and the spring seat are secured on the
seat of the poppet.
4. Assemble the spring (53-6), the piston (53-3) on the
sleeve (53-5).
5. Tighten the plug assembly (53-12) with the O-ring in-
stalled to the body (53-1).
Torque: 93 - 108 N·m (68.59 - 79.66 lb ft)
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Assembly procedure of control valve main unit
Assembly of relief valve

CAUTION:
○ Make sure to tighten the plug at the main unit

installation section when assembling the relief
valve.
○ Do not tighten with the set pressure adjustment
plug and the lock nut.
○ Turning the set pressure adjustment plug
changes the set pressure, which is dangerous.
1. Screw in and tighten the main relief valve (54).
Torque: 78 - 88 N·m (57.53 - 64.91 lb ft)
2. Screw in and tighten the overload relief valve (55) (8
locations).
Torque: 78 - 88 N·m (57.53 - 64.91 lb ft)
3. Install the O-ring to the plug (56-1), the sleeve (56-4) of
the low-pressure relief valve and then tighten them.
Torque: 103 - 113 N·m (75.97 - 83.34 lb ft)
4. Screw in and tighten the main relief valve (80) for add-
on.
Torque: 49 - 59 N·m (36.14 - 43.52 lb ft)
Assembly of load check valve

1. Attach the O-ring (25) to the arm 1 (cross-section E-E),
the boom 1, 2 (cross-section F-F), the swing and the
bucket (cross-section G-G) sections, and then assem-
ble the poppet (23) and the spring (24).
Cap the flange (26) to tighten with the socket head bolt
(61).
Torque 58 - 64 N·m (42.78 - 47.20 lb ft)
2. Attach the O-ring (25) to the arm 2 (cross-section E-E)
section and assemble the sleeve (47), the poppet (48)
and the spring (49), and then cap the flange (50) to
tighten with the socket head bolt (61).
Torque 58 - 64 N·m (42.78 - 47.20 lb ft)
3. Assemble the poppet (37) and the spring (36) to the
travel (cross-section H-H) section, and tighten with the
plug (34) to which the O-ring (35) is attached.
Torque: 103 - 113 N·m (75.97 - 83.34 lb ft)
4. Attach the O-ring (25) to the travel (cross-section I-I)
section, and then assemble the poppet (38) and the
spring (24).
(61).
Torque: 103 - 113 N·m (75.97 - 83.34 lb ft)
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5. Attach the O-ring (25) to the option section (cross-sec-

tion H-H), and then assemble the poppet (32) and the
spring (33).
(60).
Torque: 58 - 64 N·m (42.78 - 47.20 lb ft)
common check section (cross-section J-J), and then
insert the spacer (40) to which the O-ring (41) and the
backup ring (42) are attached.
Tighten the flange (39) with the socket head bolt (61).
Torque: 39 - 44 N·m (28.76 - 32.45 lb ft)
CAUTION:
○ Pay attention to assemble the O-ring and the

backup ring to the correct assembling position.
○ Reversing the position may cause damage to
the O-ring, which may cause external leakage.
arm 1 parallel-tandem section (cross-section D-D).
Screw in and tighten the plug assembly (57) to which
the O-ring is attached.
Torque 116 - 128 N·m (85.56 - 94.41 lb ft)
8. Assemble the poppet (21), the spring (22) and the
spacer (46) to the arm 2 parallel-tandem section
(cross-section D-D).
Screw in and tighten the plug assembly (57) to which
Torque 116 - 128 N·m (85.56 - 94.41 lb ft)
Assembly of antidrift valve

1. Attach the O-ring (29) to the mounting surface of the
antidrift valve of the arm 1 section (cross-section E-E),
the boom 1 section (cross-section F-F).
2. Assemble the poppet (27) and the spring (28).
3. Assemble the antidrift valve assembly (53) (2 locations)
and then tighten with the socket head bolt (60).
Torque 58 - 64 N·m (42.78 - 47.20 lb ft)
Assembly of option section

1. Assemble the cap (68) (2 locations) to which the O-ring
(69) is attached, and then tighten with the socket head
bolt (61).
Torque: 58 - 64 N·m (42.78 - 47.20 lb ft)
2. Screw in and tighten the plug assembly (72) to which
the O-ring and the backup ring are attached.
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Assembly of arm 1 parallel-tandem spool

1. Assemble the spool (17) in subassembly state to the
valve housing.
CAUTION: Slide it after inserting the spool to

check for any jerking or knocking.
2. Assemble the O-ring (18) to the housing, and then
tighten the cap (16) with the socket head bolt (64).
Torque: 8.8 - 10.8 N·m (6.49 - 7.97 lb ft)
Assembly of arm 2 parallel-tandem spool, neutral cut spool, arm regeneration release spool
1. Assemble the spool (20), (44) and (45) in sub-assembly
state to the valve housing.
CAUTION: Slide it after inserting the spool to

check for any jerking or knocking.
2. Assemble the O-ring (18) to the housing, and then
tighten the cap (19) with the socket head bolt (64).
Torque: 8.8 - 10.8 N·m (6.49 - 7.97 lb ft)
Assembly of main spool

1. Attach the O-ring (7) to cap the mating surface of the
valve housing.
2. Assemble the spool assembly (2) - (6), (12) - (15) in
sub-assembly state to the same location as it was as-
sembled before disassembly.
CAUTION:
○ Keep the spool up right to a hole and insert

gently.
○ Slide it after inserting the spool to check for any
jerking or knocking.
○ Inserting the spool with jerking or knocking may
cause operation failure of the spool.
3. Attach the long cap (8) and (9) , and then tighten with
the socket head bolt (62).
Torque 39 - 44 N·m (28.76 - 32.45 lb ft)
4. Attach the short cap (10), and then tighten with the
socket head bolt (62).
Torque 39 - 44 N·m (28.76 - 32.45 lb ft)
the O-ring is attached to the short cap of the option sec-
tion (cross-section H-H). Torque: 39 - 44 N·m (28.76 -
32.45 lb ft)
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6. Screw in and tighten the plug (70) to which the O-ring

(71) is attached to the long cap of the option section
(crosssection H-H). Torque: 39 - 44 N·m (28.76 -
32.45 lb ft)
CAUTION:
○ Pay attention not to apply excessive torque dur-

ing tightening the plug to the cap.
○ Applying excessive torque may cause breaking
thread of the cap.
Assembly of add-on section

1. Screw in the tie rod (76) to the main unit valve housing
(1).
2. Attach the O-ring (43) and (67) to the main unit mating
surface.
The following procedure 3 - 4 are to be done as neces-
sary.
3. Attach the O-ring (79-3) and (4) of the mating surface,
and then place the inlet section assembly (79).
4. Attach the O-ring ( 78-10) and (11) of the mating sur-
face, and then place the spool section assembly (78).
5. Attach the outlet housing (75).
6. Tighten the hexagon nut (77) (4 locations) (hexagon
socket diameter 22 mm (0.866 in)
Torque 116 - 128 N·m (85.56 - 94.41 lb ft)
Assembly of other plugs

Torque: 73 - 79 N·m (53.84 - 58.27 lb ft)
the O-ring and the backup ring are attached.
Torque: 78 - 88 N·m (57.53 - 64.91 lb ft)
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Relief valve - Disassemble

Disassemble procedure of main relief valve
SMIL14CEX3649EB 1
1. Plug [hexagon diameter 32 mm (1.260 in)] 7. Hexagon nut [hexagon diameter 30 mm (1.181 in)]
2. O-ring 8. Plug [hexagon diameter 27 mm (1.063 in)]
3. O-ring 9. 1-1/16-12UN-2A
4. Hexagon nut [hexagon diameter 36 mm (1.417 in)] 10. Piston
5. O-ring 11. PF1/4 JIS O-ring type
6. Plug [hexagon diameter 27 mm (1.063 in)]
This unit needs to be replaced as an assembly.

For replacement, loosen the plug (1) (hexagon diameter
32 mm (1.260 in)) with a wrench to remove the O-ring
(2).
In the event of oil leak from the nut (4) (hexagon diam-
eter 36 mm (1.417 in)), loosen the nut (4) (hexagon di-
ameter 36 mm (1.417 in)) and the plug (1) (hexagon di-
ameter 32 mm (1.260 in)), and then replace the O-ring
(3).
Also, in the event of oil leak from the nut (7) (hexagon di-
ameter 30 mm (1.181 in)), loosen the nut (7) (hexagon
diameter 30 mm (1.181 in)) and the plug (8) (hexagon
diameter 27 mm (1.063 in), and then replace the O-ring
(5).
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Disassemble procedures of overload relief
SMIL14CEX3650EB 2
1. Cap 6. Spring
2. O-ring 7. 1-1/16-12UN-2A
3. Adjuster kit section 8. Cap (hexagon diameter 31.75 mm (1.250 in))
4. O-ring 9. Lock nut (hexagon diameter 17 mm (0.669 in))
5. Poppet 10. Adjuster (hexagon diameter 6 mm (0.236 in))

For replacement, loosen the cap (1) (hexagon diame-
ter 31.75 mm (1.250 in)) with a wrench to remove the
O-ring (2).
Also, in the event of oil leak from the adjuster kit section,
loosen the adjuster kit, and then replace the lock nut (3)
(hexagon diameter ( 17 mm (0.669 in)) and O-ring (4) .
CAUTION: Pay attention to popping-out of

components due to the spring, and loosing the
poppet during disassembling the adjuster kit.
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Disassemble procedure of low-pressure relief valve
SMIL14CEX3651EB 3
1. PF1/4-A 4. O-ring
2. Plug 5. 1 3/16-12UN-2A
3. O-ring
This unit needs to be replaced as an assembly without

disassemble since it is pressed-fit at “D” section.
Disassemble procedure of main relief valve for Add-On
SMIL14CEX3652EB 4
1. Plug (hexagon diameter 32 mm (1.26 in)) 6. Spring

2. O-ring 7. 1-5/16-12UN-2A
3. Adjuster kit section 8. Plug (hexagon diameter 24 mm (0.94 in))

For replacement, loosen the plug (1) (hexagon diameter
32 mm (1.260 in) with a wrench to remove the O-ring
(2) .
Also, in the event of oil leak from the adjuster kit section
(3), loosen the adjuster kit, and then replace the O-ring
(4).
CAUTION: Pay attention to popping-out of

components due to the spring, and loosing the
poppet during disassembling the adjuster kit.
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Relief valve - Assemble

Assembly procedure of main relief valve
SMIL14CEX3649EB 1
1. Plug [hexagon diameter 32 mm (1.260 in)] 7. Hexagon nut [hexagon diameter 30 mm (1.181 in)]
2. O-ring 8. Plug [hexagon diameter 27 mm (1.063 in)]
3. O-ring 9. 1-1/16-12UN-2A
4. Hexagon nut [hexagon diameter 36 mm (1.417 in)] 10. Piston
5. O-ring 11. PF1/4 JIS O-ring type
6. Plug [hexagon diameter 27 mm (1.063 in)]
Check thoroughly for any dirt or paint debris around

thread section of the plug (1) (hexagon diameter 32 mm
(1.260 in), (6) (hexagon diameter 27 mm (1.063 in)),
(8) (hexagon diameter 27 mm (1.063 in)) and the nut
(4) (hexagon diameter 36 mm (1.417 in)), (7) (hexagon
diameter 30 mm (1.181 in)), and then assemble the
new O-ring.
Thoroughly clean the relief installation section of the
valve housing, install the relief valve, and then tighten
the plug (1) (hexagon diameter 32 mm (1.260 in)).
• Tightening torque: 78 - 88 N·m (57.53 - 64.91 lb ft)
Adjust pressure referring to the paragraph for adjust-
ment of the relief valve when the plug is disassembled.
CAUTION: Specified values of the tightening

torque are all in a wet condition (hydraulic fluid
applied state).
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Assembly procedures of overload relief
SMIL14CEX3650EB 2
1. Cap 6. Spring
2. O-ring 7. 1-1/16-12UN-2A
3. Adjuster kit section 8. Cap (hexagon diameter 31.75 mm (1.250 in))
Check thoroughly for any dirt or paint debris around

the thread section of the cap (1) (hexagon diameter
31.75 mm (1.250 in)), lock nut (3) (hexagon diameter
17 mm (0.669 in)), and then assemble the new O-ring.
the cap (1) (hexagon diameter 31.75 mm (1.250 in)).
ment of the relief valve when the adjuster kit is disas-
sembled.

applied state).
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Assembly procedure of low-pressure relief valve
SMIL14CEX3651EB 3
1. PF1/4-A 4. O-ring
2. Plug 5. 1 3/16-12UN-2A
3. O-ring
Check thoroughly for any dirt or paint debris around the

thread section of the plug (1) (hexagon diameter 32 mm
(1.260 in), and then assemble the new O-ring (5).
Assemble the new O-ring (6) to the sleeve.
valve housing, and then tighten the plug (hexagon di-
ameter 32 mm (1.260 in)) of the relief assembly.
• Tightening torque: 103 - 113 N·m (75.97 - 83.34 lb
ft)

applied state).
Assembly procedure of main relief valve for Add-On
SMIL14CEX3652EB 4
1. Plug (hexagon diameter 32 mm (1.26 in)) 6. Spring

2. O-ring 7. 1-5/16-12UN-2A
3. Adjuster kit section 8. Plug (hexagon diameter 24 mm (0.945 in))
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Check thoroughly for any dirt or paint debris around the

thread section of the plug, and then assemble the new
O-ring (2).
the plug (1).
ment of the relief valve when the adjuster kit is disas-
sembled.
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Relief valve - Adjust

CAUTION: Please be aware that any pres-
sure adjustment may violate guarantee for oper-
ation since this item is non-disassembly compo-
nent which is not supposed to be adjusted (to be
replaced as assembly).
Main relief valve (common for both main unit and add-on)
1. Attach an accurate pressure gauge at the entrance cir-
cuit.
2. Run the pump at rated speed.
3. Switch the spool of the control valve to read value of
the pressure gauge at stroke end of the cylinder.
CAUTION: The spool to be switched is that of

the actuator whose setting pressure of the over-
load relief valve is higher than that of the main re-
lief valve.
4. High pressure set (single step) (refer to Relief valve -
Disassemble (35.359))
A. Tighten the plug (8) until the piston touch end of
the plug (6) (* mark section). Tightening torque of
the plug (8) shall be 19.6 N·m (14.46 lb ft) or less.
Pay attention not to turn the plug (6) together with
the plug (8) when tightening it (A dimension: 4 mm
(0.157 in) or more).
B. Tighten the plug (6) in state of a. to adjust pres-
sure (tighten the plug (11) as monitoring a pres-
sure gauge: pressure increase per plug 1 turn is
28 MPa (4119 psi)).
Lock with the hexagon nut (4) after the pressure is
set.
5. Low pressure set (2 step)
Loose the plug (8) to adjust pressure at the high
pressure set state.
(loosening the plug (8) moves the piston to right
side of the diagram to reduce spring load: pressure
reduction per plug 1 turn is 21 MPa (3090 psi).)
Lock with the hexagon nut (7) after the pressure is
set.
6. Check that it is in the specified pressure by increasing
pressure again.
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Overload relief valve

CAUTION: The overload relief valve shall
be replaced with the relief valve that has already
been set as an assembly without adjusting it, if its
set pressure is higher than that of the main relief
valve.
1. Switch the spool of the control valve to read value of
the pressure gauge at stroke end of the cylinder.
2. Turn the adjuster clockwise direction until required
pressure is reached. Single turn of the adjuster in-
creases pressure for 21 MPa (3075 psi).
3. Upon reaching the specified pressure, hold the adjuster
so as to prevent turning, and then tighten the lock nut.
Torque: 27 - 31 N·m (19.91 - 22.86 lb ft)
4. Check that it is in the specified pressure by increasing
pressure again.
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Relief valve - Install

1. Pay attention not to apply unnecessary force to the
valves by the pipings.
2. Every mounting bolt shall be tightened evenly.
3. Pay attention that welding work adjacent to the valves
may cause damage to the seals due to excessive heat
or spatter.
4. Do not remove curing of each port until piping work in
order to prevent invasion of dusts.
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Relief valve - Inspect

1. Operation shall be started after confirming that the hy-
draulic circuits and hydraulic fluid are clean.
2. Hydraulic oil with aniline point at 82 - 113 °C (179.6 -
235.4 °F) shall be used.
3. Relief valve setting shall not exceeds the specified set-
ting pressure.
4. Setting pressure of the main relief valve and that of
the overload relief valve shall apart 2 MPa (290 psi) or
more.
5. Actual work shall be started after completing air bleed-
ing and warming up.
The following precautions shall be observed when
starting under low hydraulic fluid temperature or valve
temperature in order to prevent sticking of the spool
due to heat shock.
• Continuous operation of the main relief valve or the
overload relief valve from the beginning shall be
avoided. Each section shall be warmed up evenly
by operating so as to circulate hydraulic fluid in each
actuator.
• Inching operation and combination operation shall
not be abruptly started under low temperature due
to heating at each orifice.
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Stacked control valves - Troubleshooting

No stroke of spool Abnormally high oil temperature Remove resistance to flow of oil in piping
Dirty hydraulic fluid Replace hydraulic oil and wash circuit at the
same time
Excessively tight joint of piping port Check torque
Deformation of valve housing Loosen mounting bolt and check
Excessively high pressure Attach pressure gauge to pump port and
cylinder port to check pressure
Spool bent Replace as a valve assembly
Return spring damaged Replace damaged component
Spring or cap is not aligned Loosen cap to re-align and then tighten
Uneven temperature distribution in valve Warming up entire circuit
Clogged valve with dust Remove (flash) dust
Insufficient pilot pressure Inspect pilot valve and pilot relief pressure
Failure to hold load Oil leak from cylinder Check sealing of cylinder
Bypass of oil from spool Check damage on spool
Oil leak from overload relief valve Clean valve housing seat section and relief
valve seat section
Drop load when switching Dirt in load check valve Disassemble and clean check valve
spool from neutral to up
position
Damage on poppet or seat section of check Replace poppet or lap poppet and seat sec-
valve tion
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Relief valve - Troubleshooting

No pressure increase at Sticking and no closure of main poppet, Replace relief valve
all sleeve or pilot poppet, or dust at seat sec-
tion of valve
Unstable relief pressure Damaged seat of pilot poppet Replace relief valve
Sticking of piston or main poppet Replace relief valve
Wrong relief pressure Wear of seat section due to dust Replace relief valve
Loose in lock nut and adjuster Reset pressure and tighten lock nut at
specified torque
Oil leak Damage on relief valve seat section Replace relief valve
Sticking of each component due to dust Replace relief valve
Wear on O-ring Replace O-ring of adjuster or mounting
section
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Index

Main control valve - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Main control valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Main control valve - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Main control valve - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Main control valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Relief valve - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Relief valve - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Relief valve - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Relief valve - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Relief valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Relief valve - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Stacked control valves - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Stacked control valves - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Stacked control valves - Component diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Stacked control valves - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Stacked control valves - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Stacked control valves - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
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Pilot system - 357

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Contents
Pilot system - 357
FUNCTIONAL DATA
System solenoid block

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pilot solenoid valve block
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pilot accumulator
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SERVICE

Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Pilot solenoid valve block
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
DIAGNOSTIC

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Hydraulic systems - Pilot system
System solenoid block - Overview

6 Stack proportional valve
SMIL14CEX3577FA 1
Port Port size

A G1/4
B G1/4
C G1/4
D G1/4
E G1/4
F G1/4
A1 G3/8
P1 G3/8
T1 G3/8
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SMIL14CEX3578FA 2
1. Bucket (close) solenoid valve

2. Straight travel solenoid valve
3. Arm 2 parallel solenoid valve
4. Arm 1 recycle solenoid valve
5. Boom (down) solenoid valve
6. Arm 1 parallel solenoid valve
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System solenoid block - Exploded view

The 6 stack solenoid valve consists of a body, sleeves, spools, a poppet, and proportional solenoids.
SMIL14CEX3712GB 1
Normally open Normally closed

Solenoid: S1 Solenoid: S2 to S6
1 Body (Quantity 1) 1 -
2 Spool (O) (Quantity 1) 3 Spool (C) (Quantity 5)
4 Spring (O) (Quantity 1) 5 Spring (C) (Quantity 5)
6 Adjusting screw (Quantity 1) 6 Adjusting screw (Quantity 5)
7 Poppet (Quantity 1) 12 Sleeve (C) (Quantity 5)
9 Plug (Quantity 1) 14 Proportional solenoid (Quantity 5)
10 Spring (Quantity 1) 15 Hexagon socket head bolt (Quantity 10)
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Normally open Normally closed

Solenoid: S1 Solenoid: S2 to S6
11 Sleeve (O) (Quantity 1) 16 Wave washer (Quantity 5)
14 Proportional solenoid (Quantity 1) 25 Hexagon nut (Quantity 5)
15 Hexagon socket head bolt (Quantity 2) 26 Fastening seal (Quantity 5)
16 Wave washer (Quantity 1) 29 O-ring
17 O-ring (Quantity 1) 30 O-ring
25 Hexagon nut (Quantity 1)
26 Fastening seal (Quantity 1)
29 O-ring
30 O-ring
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System solenoid block - Sectional view

SMIL14CEX1368GB 1
1. Body 11. Sleeve (O) 21. Cable tie (white)

2. Spool (O) 12. Sleeve (C) 22. Cable tie (pink)
3. Spool (C) 13. Name plate 23. Cable tie (blue)
4. Spring (O) 14. Proportional solenoid 24. Hexagon socket head plug
5. Spring (C) 15. Hexagon socket head bolt 25. Hexagon nut
6. Adjusting screw 16. Corrugated washer 26. Fastening seal
7. Poppet 17. O-ring 27. Spring pin
8. Seat 18. Cable tie (red) 28. Rivet
9. Plug 19. Cable tie (yellow) 29. O-ring
10. Spring (C) 20. Cable tie (green) 30. O-ring
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System solenoid block - Dynamic description

6 Stack solenoid valve
SMIL14CEX2022EA 1
For the pressure oil supplied from the pressure port ( A1 or P1), the spool works according to the size of the current
applied to the proportional solenoids ( S1 to S6) to decrease the pressure of the secondary pressure ports ( A to F).
At this time, drain oil is drained from the tank port ( T1).
Solenoid number Designation Flow with current OFF

S1 Normally open A1 → A flow
S2 to S6 Normally closed Block function
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Pilot solenoid valve block - Overview

SMIL14CEX3568FA 1
Port Port size

C1 G1/4
C2 G3/8
C3 G1/4
C12 G1/4
D1 G3/8
P0 G3/8
P1 G3/8
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SMIL14CEX3569FB 2
1. Center cut solenoid valve

2. Pilot pressure solenoid valve
3. 2-stage travel solenoid valve
4. High-output solenoid valve
5. Swing brake solenoid valve
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Pilot solenoid valve block - Sectional view

This valve consists of a body and an electromagnetic switchover valve.
SMIL14CEX3845FB 1
Normal-closed-type solenoid: SP, S1, S3, S4

Normal-open-type solenoid: S2
1. Electromagnetic switchover valve

2. Body
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Pilot solenoid valve block - Dynamic description

SMIL14CEX3846EA 1
The pressure oil supplied from the P0 port is supplied, by energizing the electromagnetic switchover valve SP, to the
ports C3 to C1, on the basis of whether the electromagnetic switchover valves S1 to S3 are energized. The port C12
is supplied, by energizing the electromagnetic switchover valve SA, with the pressure oil, regardless of whether the
electromagnetic switchover valve SP is energized.
Electromagnetic switchover valves S1, S3, S4 → Oil passes under energization.

Electromagnetic switchover valve S2 → Oil passes under non-energization.
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Pilot accumulator - Overview

Manifold (accumulator section)
SMIL14CEX3581FA 1

P G1/2 P3 G1/2
P1 G1/4 P0 G3/8
P2 G1/4
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System solenoid block - Service instruction

Maintenance standards
Replace the component if there is any harmful wear,
flaw, chip, etc. in the inner diameter surface of the
sleeve, the outer diameter surface of the spool, or the
control edge section.
SMIL14CEX3730EB 1
a. Control edge section

b. Normally open (S1)
c. Normally closed (S2 to S6)
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System solenoid block - Disassemble

Precautions
1. When disassembling the valve, check the surrounding
conditions, and bear safety in mind enough.
2. When disassembling the valve, remove it from the ma-
chine beforehand. In that case, be careful of an outflow
of oil, and prepare an oil pan etc. as necessary.
3. Be very careful not to damage the O-ring and compo-
nents during work. Moreover, be careful to avoid the
adhesion and intrusion of foreign substances such as
dirt during work.
Proportional solenoid
1. Remove the 2 hexagon socket head bolts (15).
Tool: Hexagon wrench 4 mm
SMIL14CEX2008AB 1
2. Remove the proportional solenoid (14) from the body

(1).
Be aware that the proportional solenoid cannot be dis-
assembled because it has a one-piece structure.
During removal of the proportional solenoid, be careful
not to force it out or damage the body with a flat head
screwdriver etc.
SMIL14CEX2009AB 2
Sleeve and spool

1. Loosen the hexagon nut (25) to remove the adjusting
screw (6) and the fastening seal (26).
SMIL14CEX2012AB 3
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Remove the spring.

S1: Spring (O) (4)
S2 to S6: Spring (C) (5)
SMIL14CEX2013AB 4
2. Remove the spool.

• For normally open (S1)
Pull out the spool (O) (2) from a hole for the adjust-
ing screw of the body (1).
• For normally closed (S2 to S6)
Pull out the spool (C) (3) from the sleeve (C) (12).
c. Normally open (S1)
d. Normally closed (S2 to S6)
SMIL14CEX3720AA 5
3. Remove the sleeve.

Pull out the sleeve from the body (1) using a jig for
removing sleeve.
• Remove the sleeve (O), (C) in the same manner.
• Pay attention not to damage the body during remov-
ing the sleeve.
• Remove the sleeve paying attention not to damage
the inner surface of the sleeve by the jig.
• Check for any harmful damage or crack inside and
control edge when reusing the sleeve.
e. Jig SMIL14CEX3721AB 6
f. Pull out the sleeve by hooking on its port
hole.
Poppet (Check valve for normally open)

1. Loosen the plug (9) to remove the poppet (7) and the
spring (10).
SMIL14CEX3727AB 7
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System solenoid block - Assemble

Precautions
1. Be very careful not to damage the O-ring and compo-
nents during work. Moreover, be careful to avoid the
adhesion and intrusion of foreign substances such as
dirt during work.
2. Do not reuse any seal components. There is a risk of
oil leakage.
Proportional solenoid
1. Assemble the wave washer (16) to the inside of the
groove in the sleeve.
The wave washer shell be doubled for assembly.
SMIL14CEX3715AB 1
2. Assemble the O-ring (30) to the groove of the body (1).

Do not reuse the O-ring (30).
SMIL14CEX3716AA 2
3. Assemble the proportional solenoid (14) to the body (1)

Tighten the hexagon socket head bolts (15).
Tightening torque: 5.0 - 6.2 N·m (3.7 - 4.6 lb ft)
SMIL14CEX2011AA 3
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Sleeve and spool

1. Assemble the sleeve.
Assemble the O-ring (29) to the O-ring groove of the
sleeve.
Quantity: 3 (per single sleeve)
• Do not reuse the O-ring (29).
g. Tank port
h. Identification mark
i. Secondary side pressure port
j. Pressure port
SMIL14CEX3722AB 4
2. Apply hydraulic fluid to the outer surface of the O-ring

assembled to the sleeve. Temporarily insert the sleeve
to the body (1) with its groove outside.
At this moment, accurately align it so as to have the
secondary side pressure port of the sleeve comes to
upper side of the valve.
• While the secondary side pressure port is installed
at 2 locations (penetrate from top to bottom), either
one of the port holes can be aligned to the upper side
of the valve.
k. Valve upper side
l. Valve mounting side SMIL14CEX3723AA 5
m. Align the secondary side pressure port to the
valve upper side.
h. Groove to outside
3. Secure the body with a jig so as to keep the body hole
upright.
Insert the sleeve to the body (1) using a hand press.
• Pay attention not to damage the O-ring during inser-
tion.
o. Insert to the body using a hand press
p. Secondary side pressure port
q. Jig
r. Keep the body upright
s. Press straight upright
SMIL14CEX3724AA 6
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4. Assemble the spool.

• For normally open (S1)
Insert the spool (O) (2) to a hole for the adjusting
screw of the body (1). At this moment, pay attention
not to have the spool collide against the body.
• For normally closed (S2 to S6)
Insert the spool (C) (3) to the sleeve (C) (12).
• Be careful of the direction in which the spool is in-
serted.
• Make sure it is inserted carefully.
e. Normally open (S1)
7
f. Normally closed (S2 to S6) SMIL14CEX3725AA
t. Insert upright
5. Assemble the 2-wave washers (16), the O-ring (30) and
the proportional solenoid (14) to the body (1).
• For the assembly procedure of the proportional so-
lenoid, refer to the paragraph "Replacement of Pro-
portional Solenoid."
• Insert the spring (O) or the spring (C), and assemble
the adjusting screw (6), the hexagon nut (25), and
the fastening seal (26).
• The hexagon nut should be given final tightening af-
ter the secondary pressure adjustment.
• Do not reuse the fastening seal (26).
SMIL14CEX3726AB 8
Poppet (Check valve for normally open)

1. Insert the poppet (7) into the body (1).
• Be aware that the seat cannot be disassembled be-
cause it is pressed in the body (1).
SMIL14CEX3728AA 9
2. Insert the spring (10), and tighten the plug (9).

• Do not reuse the O-ring. Tightening torque: 35 -
45 N·m (25.81 - 33.19 lb ft)
SMIL14CEX3729AA 10
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Pilot solenoid valve block - Prepare

WARNING
Escaping fluid!
doctor immediately.
W0178A
WARNING
Avoid injury!
W1128A

Items to prepare:
• Wrench [ 19 mm, 22 mm]
• Marking pen
• Cap
• Plug
• Rag
• Cleaning fluid
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Pilot solenoid valve block - Remove

1. Mount the dedicated adapter (1) at the location from
which the air breather has been removed and then set
the vacuum pump (2).
Keep inside of the hydraulic reservoir in negative pres-
sure with a vacuum pump.
SMIL14CEX1433AB 1
2. Remove the 5 connectors (2) from the cover (1).

• Apply marking at each location of the connectors so
as to match connections at assembling.
Disconnect the 5 connectors (2).
Remove the 2 bolts (3) with a wrench [ 13 mm] remove
the cover (1).
SMIL14CEX1434BB 2
3. Remove the hose (1) with a wrench [ 19 mm].

Remove the 3 hoses (2) with a wrench [ 22 mm].
• Apply marking to the solenoid valve and the hoses
• Attach caps and plugs at the solenoid valve and the
hoses so as to prevent invasion of water, dust and
dirt
• Wash each location of the solenoid valve and the
SMIL14CEX1435AB 3
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4. Remove the 2 hoses (1) with a wrench [ 19 mm].

Remove the 2 hoses (2) with a wrench [ 22 mm].
• Apply marking to the solenoid valve and the hoses
• Attach caps and plugs at the solenoid valve and the
hoses so as to prevent invasion of water, dust and
dirt.
• Wash each location of the solenoid valve and the
hering dirt at connections and not to damage them
SMIL14CEX1436AB 4

move the solenoid valve (2).
SMIL14CEX1544AB 5
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Pilot solenoid valve block - Install

Mount the valve in the reversed order of the procedure
for removal.
Refer to the Torque – Bolt and nut () for those without
specified torque.
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System solenoid block - Troubleshooting

The secondary pressure Malfunction due to foreign substances Removal of foreign substances, disassem-
cannot be adjusted bly and washing, replacement of hydraulic
fluid
Wear on sleeve and spool Replacement of sleeve and spool
Failure in proportional solenoid Replacement of proportional solenoid
The hysteresis of the Wear on sleeve and spool Replacement of sleeve and spool
secondary pressure is Wear on control edge section
large
Malfunction of proportional solenoid Replacement of proportional solenoid
The secondary pressure Malfunction due to foreign substances Removal of foreign substances, disassem-
does not become 0 MPa bly and washing, replacement of hydraulic
(0 psi) fluid
Malfunction of spool Replacement of sleeve and spool
Malfunction of proportional solenoid Replacement of proportional solenoid
The secondary pressure Large exciting force acted on the valve Reduce the exciting force (oscillation)
oscillates
Clogging in orifice or drain hole in spool or Disassembly and washing, replacement of
sleeve hydraulic fluid
Failure in proportional solenoid Replacement of proportional solenoid
The proportional solenoid Loose connector Inspection of connector
does not work
Damaged coil Replacement of proportional solenoid “Coil
resistance” 10.3 Ω ± 5 % (at 20 °C (68 °F))
Malfunction of iron core (plunger or push Replacement of proportional solenoid
rod)
External leak of hydraulic Loose screw section Additional tightening with specified torque
fluid Loose hexagon socket head plug
Damaged O-ring or fastening seal Component replacement
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Index
Pilot system - 357

Pilot accumulator - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pilot solenoid valve block - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pilot solenoid valve block - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Pilot solenoid valve block - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pilot solenoid valve block - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Pilot solenoid valve block - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Pilot solenoid valve block - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
System solenoid block - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
System solenoid block - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
System solenoid block - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
System solenoid block - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
System solenoid block - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
System solenoid block - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
System solenoid block - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
System solenoid block - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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Hydraulic hand control - 355

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Contents
TECHNICAL DATA
Hand control
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUNCTIONAL DATA
Hand control
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hand control hoses
Overview - 2-way selector valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Cushion valve
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Detailed view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Drainage block
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
SERVICE
Hydraulic hand control

Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Remove – Left side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Install – Left side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Remove – Right side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Install – Right side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Hand control
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Cushion valve
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
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Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
DIAGNOSTIC
Hand control
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Hydraulic systems - Hydraulic hand control
Hand control - Special tools

Detailed diagram of main unit jig
SMIL14CEX1447GA 1
NOTE: All the dimensions in figure are in mm (in).
*1 (1) Material: SCM415 (N) carburized *3 Bolt width

Hole H6 + 0.13
*2 (2) Material: S45C *4
Shaft n6 + 0.028
NOTE: (1) and (2) are inserted by tightening.
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Detailed diagram of joint disassembly jig
SMIL14CEX1448FA 2
(c) bushing
NOTE: All the dimension in figure are in mm (in).
With joint installed Material: SCM415 (N) carburized (Quantity 2)
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Hand control - Overview

Port diagram
SMIL14CEX3571EB 1
Right Left
Port name Port name Port size
side side
1 Bucket close 1 Swing right G3/8
2 Boom down 2 Arm in G3/8
3 Bucket open 3 Swing left G3/8
4 Boom up 4 Arm out G3/8
P Pressure P Pressure G1/4
T Return T Return G3/8
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Hand control - Sectional view

Assembly cross-section diagram
SMIL14CEX1446GB 1
a. Grease application to top c. Grease application to rotating sliding sections. Be

careful with the installation direction.
b. Secondary pressure adjustment shim. Design d. Hydraulic symbols
central value t = 0.4 mm (0.0157 in), 1 shim
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101 Casing (Quantity 1) 217 Washer (Quantity 4)
151 Plate (Quantity 1) 221-1 Return spring (port 1) (Quantity 1)
201 Spool (Quantity 4) 221-2 Return spring (port 3) (Quantity 1)
211 Plug (Quantity 4) 221-3 Return spring (ports 2, 4) (Quantity 2)
Secondary pressure spring (ports 1, 3) (Quantity
212-1 Push rod (ports 1, 3) (Quantity 2) 241-1
2)
Secondary pressure spring (ports 2, 4) (Quantity
212-2 Push rod (ports 2, 4) (Quantity 2) 241-2
2)
213 Seal (Quantity 4) 301 Joint (Quantity 1)
214 O-ring (Quantity 4) 302 Disk (Quantity 1)
216-1 Spring seating (ports 1, 3) (Quantity 2) 312 Adjusting nut (Quantity 1)
216-2 Spring seating (ports 2, 4) (Quantity 2) 501 Bellows (Quantity 1)
Code Screw size Tightening torque

301 M14 44.2 - 50.0 N·m (32.600 - 36.878 lb ft)
302
M14 63.7 - 73.5 N·m (46.983 - 54.211 lb ft)
312
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Hand control - Dynamic description

Structure
The structure of the remote control valve is as shown in the sectional view. There is a longitudinal axial hole in the
casing and the pressure reduction valve is installed in it.
The pressure reduction valve comprises the spool (201), secondary pressure setting spring (241), return spring (221),
spring seating (216), and washer 2 (217).
The secondary pressure setting spring (241) is set so that the secondary pressure calculation is 0.5 - 1 MPa (72 -
145 psi) (depending on the model).
The spool (201) is pressed against the push rod (212) by the return spring (221).
When the push rod (212) is pushed down by tilting the handle or another operation, the spring seating goes down at
the same time and the secondary pressure setting spring (241) setting is changed.
The casing (101) has the oil inlet (primary pressure) port P and the outlet (tank) port T and, furthermore, the secondary
pressure is taken out from the ports 1, 2, 3, 4.
Basic functions
The remote control valve is for controlling the control valve spool stroke quantity, direction, etc. This is done by
operating the pilot valve output pressure on the control valve spool end section.
In order to satisfy this function, the remote control valve is made up of the following elements:
1. Inlet port ( P) to which the oil is fed from the hydraulic pump.
2. Multiple output ports ( 1, 2, 3, 4) for operating the feed pressure from the inlet port on the control valve spool end.
3. Tank port ( T) required for controlling the above output pressure.
4. Spool connecting the output port to the inlet port or tank port.
5. Mechanical means including a spring operating on the above spool in order to control the output pressure.
Main part functions

The function of the spool (201) is to switch the oil path either to have the hydraulic pressure fed from the hydraulic
pump received by the P port and lead the P port pressure oil to the output ports ( 1, 2, 3 and 4) or to lead the output
port pressure oil to the T port. The output pressure operating on this spool (201) is determined by the secondary
pressure setting spring (241).
In order to change the deflection quantity of the secondary pressure setting spring (241), the push rod (212) is inserted
into the plug (211) in such a way that it can slide.
The return spring (221) operates on the casing (101) and spring seating (216) and operates to return the push rod
(212) in the displacement zero direction regardless of the output pressure and makes the spool (201) neutral return
reliable. It also has the effect of a counter-force spring for giving an operator an appropriate operation feel.
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Operation
Operation of the remote control valve is explained based on the hydraulic circuit diagram (Fig. 1) and operation
explanation diagrams (Fig. 2 - Fig. 4).
Fig. 1 is a typical usage example for the remote control valve.
LPIL12CX01993FB 1
1. Pilot valve 4. Control valve

2. Pilot pump 5. Hydraulic motor
3. Main pump 6. Hydraulic cylinder
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When the handle is in neutral (See Fig. 2)

The force of the secondary pressure setting spring (241) that determines the remote control valve output pressure
does not operate on the spool (201). Therefore, the spool (201) is pushed up by the return spring (221) (spring seating
(216)) and the output ports ( 2 and 4) are connected with the T port. Therefore, the output pressure is the same as
the tank pressure.
SMIL13CEX6010FB 2
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When the handle is tilted (See Fig. 3)

When the handle is tiled and the push rod (212) is moved through a stroke, the (spring seating (216)) spool (201)
moves down and the oil fed from the pilot pump flows out to the ports ( 2, 4) through the P port and the ports ( 2, 4)
and pressure is generated.
LPIL12CX01995FB 3
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When the handle is held (See Fig. 4)

When the handle is tilted and the pressure of the ports ( 2, 4) rises to a pressure equivalent to the set spring force
(241), the hydraulic pressure and the spring force are in balance. When the ports ( 2, 4) pressure becomes higher
than the set pressure, the ports ( 2, 4) and the P port (2) close and the ports ( 2, 4) and the T port (1) open. When the
ports ( 2, 4) pressure becomes lower than the set pressure, the ports ( 2, 4) and the P port (2) open and the ports ( 2,
4) and the T port (1) close, so the secondary pressure is held constant.
LPIL12CX01996FB 4
1. T port 2. P port
Operation in area in which the handle tilt is large (depends on the model)
For certain models, when the handle is flipped down beyond a certain angle, the spool top end section touches the
push rod bore bottom section and the output pressure goes into the state of still being connected with the P port
pressure.
Furthermore, with the structure in which the spring seating and spring are installed inside the push rod, when the
handle is flipped down beyond a certain angle, the push rod bore bottom section and the spring touch. That spring
force changes the 2nd pressure gradient and after that the push rod bore bottom section and the spring seating top
end section touch, and the output pressure remains connected to the P port.
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Hand control hoses - Overview - 2-way selector valve

Port diagram
Remote control valve side
SMIL14CEX3574AA 1
Cushion valve side
SMIL14CEX3575AA 2
Port Port name *ISO type Port size Port Port name *ISO type Port size
Remote control valve
A G3/8 1 Cushion valve side port G3/8
side/swing-left port
B G3/8 2 Cushion valve side port G3/8
side/arm-in port
C G3/8 3 Cushion valve side port G3/8
side/arm-in port
D G3/8 4 Cushion valve side port G3/8
side/arm-out port
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Structure
SMIL14CEX5025EA 3
Circuit diagram
Operation/Work
A Left valve / Left side 1 Arm / Dirt removal
B Left valve / Draw-in 2 Swing / Left
C Left valve / Right side 3 Arm / Excavation
D Left valve / Push-out 4 Swing / Right
Circuit combination table

Type D: ISO Type C: JD
A-2 A-1
B-1 B-2
C-4 C-3
D-3 D-4
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SMIL14CEX3863FB 4
Valve structure
1. Decal 11. plate

2. plate 12. lever
3. plate 13. Hexagon socket head bolt
4. Collar 14. Washer
5. knob 15. Rivet screw
6. Bracket 16. Parallel pin
7. Pin 17. O-ring
8. Sleeve 18. O-ring
9. spring 19. Stopper assembly
10. Pin
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Exploded view
SMIL14CEX3865HB 5
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Operation explanation
This valve is a rotary switchover valve.
It is placed between the remote control valve and the main control valve for hydraulic excavator work.
By operating the lever (12) toward the position of each type (rotating the plate (2)), the circuit of the valve is changed,
and the operation type is changed as shown in Fig. 1
Refer to Fig.3 for valve structure (circuit diagram)
Operation method by type I (ISO)

Arm Boom
Dirt removal Down
Bucket Bucket
Left swing Right swing
Excavation Dirt removal
Arm Boom
Excavation Up
Operation method by type S (JD)

Boom Arm
Down Dirt removal
Bucket Bucket
Left swing Right swing
Excavation Dirt removal
Boom Arm
Up Excavation
L. Left
R. Right
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Cushion valve - Overview

Port diagram
SMIL14CEX3573FA 1
Port Port name Port size Port Port name Port size
E, F Boom up G3/8 V – G1/4
G, H Boom down G3/8 T Return (drain line) G1/4
O, P Bucket open G3/8 R Heat Circuit G1/4
Arm (out) pressure
M, N Bucket Close G3/8 P, D G1/4
sensor signal
Arm (in) pressure
C, D Arm out G3/8 P, B G1/4
sensor signal
Boom (up) pressure
A, B Arm in G3/8 P, F G1/4
sensor signal
Bucket (close) pressure
K, L Swing left G3/8 P, N G1/4
sensor signal
Bucket (down) pressure
I, J Swing right G3/8 P, H G1/4
sensor signal
Swing pressure sensor Bucket (open) pressure
Q G1/4 P, P G1/4
signal sensor signal
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Cushion valve - Detailed view

Check plunger table
Part No. Name Metering orifice diameter (D)
65301-11705 Check plunger 0.5 mm (0.02 in)
65301-11710 Check plunger 1 mm (0.04 in)
Cushion valve assembly diagram
SMIL14CEX1334FB 1
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Cross section X
SMIL14CEX1335AB 2
Cross section Y
SMIL14CEX1336AB 3
Cross-section V
SMIL14CEX1337EB 4
1. Body 13. Spring

2. Spool 14. Plug
3. Spring 15. O-ring
4. Plug 16. Steel ball
5. O-ring 17. Seat
6. Cap screw 18. O-ring
7. O-ring 19. Plug
8. Plug 20. O-ring
9. Check plunger 21. Name plate
10. Check plunger 22. Drive screw
11. Check plunger 23. Plug
12. Check plunger 24. Plug
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Cushion valve - Dynamic description

This valve consists of the cushion valve with heat circuit section and the shuttle valve section.
The cushion valve with heat circuit, which connects between the control valve and the pilot operation valve of the
hydraulic excavator, reduces the shaking of the vehicle due to operator's sudden stop operation (cushion function).
This valve also has a circuit that disables the cushion function during reverse operation by the operator's intention.
The shuttle valve chooses a higher signal pressure from two lines of signal pressures.
This valve has one circuit.
SMIL14CEX3856FB 1
*1. Arm *2. Boom
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During normal operation

The pressure oil supplied from the pilot operation valve to the port A (or the port C, E, G) pushes up the check plunger,
and is sent to the port B (or the port D, F, H).
The pressure oil that has passed through the port B acts on the spool of the control valve to operate the actuator.
The oil pushed out of the spool of the control valve passes through the port D (or the port B, F, H), and flows into the
port T.
SMIL14CEX3857FA 2
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During cushion operation

When the pressure oil being supplied from the pilot operation valve to the port A (or the port C, E, G) is interrupted by
the pilot operation valve, the pressure oil acting on the spool of the control valve will be pushed back to the port B (or
the port D, F, H) by the return spring of the spool.
The returned oil is sent to the port A (or the port C, E, G) through the orifice in the check plunger, and drained from
the pilot operation valve.
At this time, since it passes through the orifice, the spool speed of the control valve is controlled to prevent the actuator
from stopping suddenly, thereby reducing the shaking of the vehicle. (Cushion function)
SMIL14CEX3858FA 3
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Reverse operation
When the pressure oil being supplied from the pilot operation valve to the port A (or the port C, E, G) is switched to the
port C (or the port A, E, G), the pressure oil acting on the spool of the control valve will be pushed back to the port B.
Since the oil pushed back flows into the port T without passing through the orifice in the check plunger, the spool
speed of the control valve is not controlled, and the cushion function is not activated.
SMIL14CEX3859FA 4
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Heat circuit
When the pilot operation valve is in the neutral position, the oil supplied to the port R flows through the reverse oper-
ation spool into the port T to heat up the inside of the valve.
When the pressure oil is being supplied from the pilot operation valve to the port A (or the port C, E, G), the oil supplied
to the port R flows into the port C (or the port A, E, G) to heat up the inside of the valve and the circuit to the pilot
operation valve.
SMIL14CEX3860FA 5
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Shuttle valve
Since the steel ball is pressed in the direction from the higher pressure toward the lower pressure (of the two pres-
sures: that between the ports I - J and that between the ports K - L), the higher pressure oil is supplied to the port Q.
SMIL14CEX3861EA 6
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Drainage block - Overview

Manifold under cab
SMIL14CEX3580EA 1

P1 G3/8 T1 G3/8
P2 G3/8 T2 G3/8
P3 G3/8 T3 G3/8
P4 G1/4 T4 G1/4
P5 G1/4 T5 G1/4
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Hydraulic hand control - Prepare

WARNING
Escaping fluid!
doctor immediately.
W0178A
WARNING
Avoid injury!
W1128A
Items to prepare:
• Phillips screwdriver
• Marking pen
• Cap
• Plug
• Rag
• Cleaning fluid
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Hydraulic hand control - Remove – Left side

1. Roll up the boot (1) of the control lever and use a
Phillips screwdriver or box wrench [ 10 mm] to remove
the 2 bolts (2) from the console top cover.
SMIL14CEX1296AB 1
2. Use a Phillips screwdriver to remove the 2 screws (2),

and then remove the handle of the tilt lever (1).
SMIL14CEX1297AB 2
3. Use a hexagon wrench [ 5 mm] to remove the 2 bolts

(2), and remove the grip (1) of the gate lock lever.
SMIL14CEX1298AB 3
4. Use a Phillips screwdriver to remove the 2 screws (1)

of the console top cover.
SMIL14CEX1299AB 4
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5. Remove the 3 connectors (2) and remove the console

top cover (1).
SMIL14CEX1300AB 5
6. Use a Phillips screwdriver or box wrench [ 10 mm] to

remove the 5 bolts (2) and remove the cover (1).
SMIL14CEX1401AB 6
7. Roll up the boot (1) of the control lever, remove the

connector (2) of the horn switch, and cut the wire band
(3).
SMIL14CEX1402AB 7
8. While fastening the nut (2) with a wrench [ 22 mm],

use a wrench [ 19 mm] to remove the lock nut (3) and
remove the control lever (1).
SMIL14CEX1403AB 8
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9. Roll back the hose cover (1).
SMIL14CEX1404AB 9
10. Use a wrench [ 22 mm] to remove the 6 hoses (1).

• Mark the joystick remote control valve and hoses so
that the connectors match at the time of installation.
• Use caps and plugs to cover the joystick remote
control valve and hoses to prevent any entry of wa-
ter, dust or dirt.
• Clean the joystick remote control valve and hoses
by spraying them with a parts cleaner to prevent
scratches and prevent dirt from accumulating on
the connectors.
SMIL14CEX1405AB 10

(1) and 3 washers (2).
SMIL14CEX1406AB 11
12. Remove the joystick remote control valve (1).
SMIL14CEX1407AB 12
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Hydraulic hand control - Install – Left side

1. Clean all the parts with a rag.
SMIL14CEX1408AA 1
2. Install the joystick remote control valve (1).
SMIL14CEX1409AB 2
3. Use a hexagon wrench [ 5 mm] to install the 3 bolts (1)

and 3 washers (2).
SMIL14CEX1406AB 3
4. Use a wrench [ 22 mm] to install the 6 hoses (1).

• P port
Hose adapter tightening torque: 25.4 - 31.4 N·m
(18.734 - 23.159 lb ft)
Hydraulic hose tightening torque: 44 - 54 N·m (32.45
- 39.83 lb ft)
• T port, 1 - 4 ports
Hose adapter, hydraulic hose tightening torque: 44 -
54 N·m (32.45 - 39.83 lb ft)
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5. Put the hose cover (1) in place.
SMIL14CEX1404AB 5
6. While fastening the nut (2) with a wrench [ 22 mm], use

a wrench [ 19 mm] to install the lock nut (3) and install
the control lever (1).
SMIL14CEX1403AB 6
7. Install the horn switch connector (2), bundle with the

wire band (3), and then cover the control lever boot (1).
SMIL14CEX1402AB 7

install the 5 bolts (2), and then install the cover (1).
SMIL14CEX1401AB 8
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9. Install the 3 connectors (2) and install the console top

cover (1).
SMIL14CEX1410AB 9
10. Use a Phillips screwdriver to install the 2 screws (1)

on the console top cover.
SMIL14CEX1411AB 10
11. Use a hexagon wrench [ 5 mm] to install the 2 bolts

(2), and install the grip (1) of the gate lock lever.
SMIL14CEX1412AB 11
12. Use a Phillips screwdriver to install the 2 screws (2),

and then install the handle of the tilt lever (1).
SMIL14CEX1413AB 12
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install the 2 bolts (2) on the console top cover and
cover the control lever boot (1).
SMIL14CEX1414AB 13
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Hydraulic hand control - Remove – Right side

1. Roll up the boot (1) of the control lever and use a
Phillips screwdriver or box wrench [ 10 mm] to remove
the 2 bolts (2) from the console top cover.
SMIL14CEX1415AB 1
2. Use a Phillips screwdriver to remove the 2 screws (2),

and then remove the handle of the tilt lever (1).
SMIL14CEX1416AB 2
3. Use a Phillips screwdriver to remove the 2 screws (1)

of the console top cover.
SMIL14CEX1417AB 3
4. Remove the 3 connectors (2) and remove the console

top cover (1).
SMIL14CEX1418AB 4
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remove the 5 bolts (2) and remove the cover (1).
SMIL14CEX1419AB 5
6. Roll up the boot (1) of the control lever, remove the

connector (2) of the horn switch, and cut the wire band
(3).
SMIL14CEX1420AB 6

a wrench 19 mm to remove the lock nut (3) and remove
SMIL14CEX1421AB 7
8. Roll back the hose cover (1).
SMIL14CEX1422AB 8
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9. Use a wrench [ 22 mm] to remove the 6 hoses (1).

• Mark the joystick remote control valve and hoses so
that the connectors match at the time of installation.
• Use caps and plugs to cover the joystick remote con-
trol valve and hoses to prevent any entry of water,
dust or dirt.
• Clean the joystick remote control valve and hoses
by spraying them with a parts cleaner to prevent
scratches and prevent dirt from accumulating on the
connectors.
SMIL14CEX1423AB 9

(1) and 3 washers (2).
SMIL14CEX1424AB 10
11. Remove the joystick remote control valve (1).
SMIL14CEX1425AB 11
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Hydraulic hand control - Install – Right side

1. Clean all the parts with a rag.
SMIL14CEX1408AA 1
2. Install the joystick remote control valve (1).
SMIL14CEX1425AB 2
3. Use a hexagon wrench [ 5 mm] install the 3 bolts (1)

and 3 washers (2).
SMIL14CEX1424AB 3
4. Use a wrench [ 22 mm] to install the 6 hoses (1).

• P port
Hose adapter tightening torque: 25.4 - 31.4 N·m
(18.734 - 23.159 lb ft)
Hydraulic hose tightening torque: 44 - 54 N·m (32.45
- 39.83 lb ft)
• T port, 1 - 4 ports
Hose adapter, hydraulic hose tightening torque: 41 -
54 N·m (30.24 - 39.83 lb ft)
SMIL14CEX1423AB 4
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5. Put the hose cover (1) in place.
SMIL14CEX1422AB 5

a wrench [ 19 mm] to install the lock nut (3) and install
SMIL14CEX1427AB 6
7. Install the horn switch connector (2), bundle with the

wire band (3),and then cover the control lever boot (1).
SMIL14CEX1428AB 7

install the 5 bolts (2), and then install the cover (1).
SMIL14CEX1419AB 8
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9. Install the 3 connectors (2) and install the console top

cover (1).
SMIL14CEX1429AB 9
10. Use a Phillips screwdriver to install the 2 screws (1)

on the console top cover.
SMIL14CEX1430AB 10
11. Use a Phillips screwdriver to install the 2 screws (2),

and then install the handle of the tilt lever (1).
SMIL14CEX1431AB 11

install the 2 bolts (2) on the console top cover and
cover the control lever boot (1).
SMIL14CEX1432AB 12
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Hand control - Service instruction

Maintenance inspection
Standard Remarks
item
When handle is in neutral: 1 L/min (0.264 US
gpm) or more Conditions
During operation: 2 L/min (0.528 US gpm) or Primary pressure 2.94 MPa
Leak amount
more (426.4470 psi)
If either condition occurs, replace the remote Oil viscosity 23 mm²/s
control valve as one unit
When wear on the sliding sections exceeds The same approximate conditions as
wear on the non-sliding sections by 10 μm or those listed above for leak amount are
Spool
more, replace the remote control valve as one expected when the condition on the
unit left occurs
If the end section is worn by 1 mm (0.039 in) or more, replace.
Push rod
Replace the operation section disk (302) and Make adjustments if the backlash is
Operation section
joint section (301) if there is backlash of 2 mm due to looseness in the tightening
backlash
(0.079 in) or more due to wear sections
If abnormal noise, hunting, or a drop in primary
pressure occurs and the problem cannot
Operation stability be resolved with “Causes of Trouble and
Countermeasures”, replace the remote control
valve as a unit
NOTE: It is desirable for seal materials such as O-rings to be replaced with each disassembly, but it is acceptable
to reuse these after it is confirmed that they are not damaged.
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Hand control - Prepare

CAUTION:
• To ensure safe operations, wear protective devices before beginning work and follow all precautions.
• Be sure to repair any parts damaged during disassembly, and prepare replacement parts in advance.
• If any parts are significantly rusted or dirty, clean them before disassembling.
• Any foreign matter entering the equipment during assembly can create a malfunction. Therefore, after thoroughly
cleaning the equipment with cleaning oil, air blow the equipment, and assemble in a clean location.
• When assembling sliding parts, be sure to coat them with new hydraulic oil.
• As a rule, replace all O-rings and other seal parts with new parts.
General cautions
• Be careful not to drop precision parts or let bump them with other parts during work.
• Do not forcefully open or hit parts in an effort to speed up operations.
Pay careful attention and proceed slowly so as not to damage any parts, create any oil leaks, or compromise the
efficiency of the equipment, etc.
• Disassembled parts can easily rust or collect dust. Therefore, immediately after disassembling parts, take
precautions to prevent the parts from rusting or collecting dust.
Required tools and tightening torque

Tools Dimensions Part No. Part name Screw size Tightening torque
63.7 - 73.5 N·m
22 mm 312 Adjusting nut M14
Wrench (46.983 - 54.211 lb ft)
32 mm 302 Disk M14
44.2 - 50.0 N·m
Special jig 24 mm 301 Joint M14
(32.600 - 36.878 lb ft)
Other
• Vapor corrosion inhibitor
• White kerosene
• Heat-resistant grease
• Sandpaper (#1000, #2000)
• Whetstone
• Vise
• Screwdriver
• Torque wrench
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Hand control - Disassemble

1. Use copper plate (or lead plate) to fasten the remote
control valve in a vise, and then remove the bellows
(1).
• Be careful not to tear the bellows.
SMIL14CEX1572AB 1
2. Use a wrench on the bolt width of the adjusting nut

(1) and disk (2) to loosen them, and then remove the
adjusting nut and disk.
SMIL14CEX1573AB 2
3. Use a jig (1) to remove the joint.
SMIL14CEX1574AB 3
4. If the return springs are strong, the plate (2), plugs,

and push rods (3) will rise at the same time the joint
(1) is loosened, so be careful of parts flying off when
removing the joint.
SMIL14CEX1575AB 4
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5. Remove the plate (1).
SMIL14CEX1576AB 5
6. If the return springs are weak, the plugs (1) will re-
main in the casing due to the sliding resistance of the
O-rings, so use a flathead screwdriver to remove it.
• Use the groove in the outer circumference of the
plugs and remove them while making sure they are
not damaged by an unbalanced load.
• Use caution as plugs may fly off when they are being
removed due to the return springs.
SMIL14CEX1577AB 6
7. Remove the push rods (1), plugs (2), pressure reduc-

ing valve assembly, and the return springs (3) from the
casing.
• Record the relation of parts to the casing hole posi-
tions through marking, etc.
SMIL14CEX1578AB 7
8. For disassembly of pressure reducing valve, press in

the spring seating (1), move the spring seating to the
side while bending the secondary pressure spring (2),
and remove the spring from the spools (3) by passing
through the larger hole.
• Do not press in the spring seating by 6 mm
(0.236 in) or more.
SMIL14CEX1579AB 8
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9. Separate the spool (1), spring seating (2), secondary

pressure spring (3), and washer (4).
• Be careful not to scratch the surface of the spools.
• Handle as an assembly until assembly is performed.
SMIL14CEX1580AB 9
10. Remove push rod (2) from the plug (1).
SMIL14CEX1581AB 10
11. Remove the O-ring (2) from the plug (1).

• The O-rings cannot be reused.
Replace it with new part.
SMIL14CEX1582AB 11
12. Remove the seal (1).

Use a small screwdriver to remove the seal.
• The seal cannot be reused.
Replace it with new part.
SMIL14CEX1583AB 12
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Cleaning
Clean all parts by placing them in a rough cleaning
container filled with white kerosene. (rough cleaning)
Clean each part by placing it in a finish cleaning con-
tainer filled with white kerosene, and thoroughly clean
each part, including the interior, while slowly rotating
the part. (finish cleaning)
Use a clean rag to thoroughly remove any white
kerosene stuck to parts.
• Scratching can easily occur if cleaning of a part is be-
gun just after parts are immersed in white kerosene,
so let each part sit in white kerosene until debris and
grease sufficiently loosen from the surface of the part
and float to the surface.
• If the white kerosene is dirty, this will encourage
damage to parts and result in reduced performance
after reassembly. Thoroughly manage the level of
cleanliness of the white kerosene.
• Do not dry parts with compressed air, as this will
damage parts and cause rust to form due to debris
and moisture being dispersed into the atmosphere.
Preventing rust on parts

Apply an anti-rust agent to each part.
• Rust will form on parts if they are left as is after clean-
ing, and this will cause reduced performance of func-
tions after reassembly.
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Hand control - Assemble

1. Insert the washer (4), the secondary pressure spring
(3), and the spring seating (2) onto each of the spools
(1) in that order.
SMIL14CEX1584AB 1
2. Press in the spring seating (1) and move it to the side

while bending the secondary pressure spring (2) to
pass the seating over the larger hole and install it on
each of the spools.
• Do not press in the spring seating by 6 mm (0.24 in)
or more.
SMIL14CEX1585AB 2
3. Install the return springs (1) in the casing (2).

Install the pressure reducing valve assemblies (3) in the
casing (2).
• Install them in the positions they were in before dis-
assembly.
SMIL14CEX1586AB 3
4. Install the O-ring (2) on the plug (1).
SMIL14CEX1587AB 4
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5. Install the seal (1) on the plug (2).

• Install so that the seal lips are as shown in the dia-
gram below.
a. Hydraulic oil application
3. Push rod
SMIL14CEX1588AB 5
SMIL14CEX1589AB 6
6. Install the push rod (1) in the plug (2).

• Apply hydraulic oil to surface of the push rod.
SMIL14CEX1437AB 7
7. Install the plug assemblies (1) in the casing (2).

If the return spring is weak, it will be stopped by the
sliding resistance of the O-ring.
• Be careful not to scratch the casing hole by forcing
in the spool.
SMIL14CEX1438AB 8
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8. If the return spring is strong, use the plate (1) to install

all 4 plug assemblies at the same time and temporarily
tighten them with the joint (2).
• Be careful of the plug assemblies and plate flying off.
SMIL14CEX1439AB 9
9. Install the plate (1).
SMIL14CEX1440AB 10
10. Use a jig, and tighten the joint (1) to the casing (2) to
the specified torque.
Tightening torque: 44.2 - 50.0 N·m (32.600 - 36.878 lb
ft)
SMIL14CEX1441AB 11
11. Install the disk (1) onto the joint (2).

• Screw the disk in until it is equally touching each
of the 4 push rods (3). Secondary pressure will
cause faulty operation of the machine if the disk
is screwed in too much, so pay attention to adjust-
ment of the tightening position.
SMIL14CEX1442AB 12
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12. Install the adjusting nut, use a wrench on the bolt width
of the disk (1) to secure it, and tighten the adjusting nut
to the specified torque.
• Tightening torque: 63.7 - 73.5 N·m (46.983 -
54.211 lb ft)
• During tightening, do not move the disk position.
SMIL14CEX1443AB 13
13. Apply grease to the rotating section of the joint and to

the top of the push rods (1).
SMIL14CEX1444AB 14
14. Install the bellows (1).

• Inject vapor corrosion inhibitor into each port, and
then place plugs in the ports.
SMIL14CEX1445AB 15
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Cushion valve - Prepare

WARNING
Escaping fluid!
doctor immediately.
W0178A
WARNING
Avoid injury!
W1128A
Items to prepare:
• Marking pen
• Cap
• Plug
• Waste oil can
• Rag
• Cleaning fluid
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Cushion valve - Remove

the vacuum pump (2).
sure with a vacuum pump.

SMIL14CEX1546AB 2
3. Prepare a waste oil can (1).
SMIL14CEX1547AB 3
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4. Remove the 7 sensors.

Remove the hoses connected to each port with a
wrench [ 19 mm, 22 mm].
• Mark the cushion valve, hoses and lines so that the
connectors match at the time of assembly.
• Attach caps and plugs at the cushion valve, hoses
and lines so as to prevent invasion of water, dust
and dirt.
• Wash each location of the cushion valve, hoses and
lines by blowing parts cleaner so as to prevent ad-
*1. Use a wrench [ 19 mm].
SMIL14CEX1548BB 4
5. Remove the 4 bolts (1) at bottom of the cushion valve

with a wrench [ 17 mm] to remove the cushion valve.
SMIL14CEX1549AB 5
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Cushion valve - Disassemble

This valve has a structure that forms small gaps. It is
precision processed and the parts are carefully selected
and fit together, so do not disassemble it as much as
possible.
If disassembly is unavoidable, pay attention to the fol-
lowing. (The product warranty may be invalidated.)
• Only disassemble in a clean location with minimal
dirt.
• Use only clean tools and cleaning oil and handle
them with care.
• Use plugs, caps to cover ports to prevent any entry
of dirt and clean the outside of the assembly.
• Check the internal structure before starting work,
and carefully study the disassembly objective and
scope.
Reverse operation spool section

1. Remove the plugs (1) and O-rings (2).
• Remove the springs (3).
• Remove the spools (4) with the cap screws and
O-rings assembled in them.
SMIL14CEX1326AB 1
2. Fasten the spool (3) assemblies taken out in 1. in a

vise.
• Remove the cap screws (1) and O-rings (2).
CAUTION: Use a piece of wood (jig) (4) to

prevent scratches.
SMIL14CEX1327AB 2
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Check plunger section with throttle

1. Remove the plugs (1) and O-rings (2).
Remove the springs (3) and remove the check
plungers (4).
CAUTION: The check plungers have similar

shapes, so identify them in such a way that no one
will mix them up with each other.
SMIL14CEX1328AB 3
Shuttle valve section

1. Remove the plugs (1) and O-ring (2), and then remove
the seat (4) and O-ring (3).
1. Remove the steel balls (5).
SMIL14CEX1329AB 4
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Cushion valve - Assemble

This valve has a structure that forms small gaps. It is
precision processed and the parts are carefully selected
and fit together, so do not disassemble it as much as
possible.
If assembly and disassembly is unavoidable, pay atten-
tion to the following. (The product warranty may be in-
validated.)
• Only assemble in a clean location with minimal dirt.
• Use only clean tools and cleaning oil and handle
them with care.
• Clean the disassembled parts and prepared parts.
• Study the internal structure before starting the work
and prepare the parts required by the disassembly
objective and scope.
Reverse operation spool section

1. Install the cap screw (1) with the O-ring (2) attached on
the spool (3).
Tightening torque: 9.80 - 14.70 N·m (7.23 -
10.84 lb ft)
CAUTION: Use a piece of wood (jig) (4) to

prevent scratches.
SMIL14CEX1330AB 1
2. Insert the spool assemblies (1) assembled in 1. into the

body.
CAUTION: The spool assemblies are sym-

metrical, so the insertion direction does not mat-
ter.
• Insert the springs (2) and install the plugs (3) with the
O-rings (4) attached.
• Tightening torque: 39.2 - 49 N·m (28.91 - 36.14 lb
ft)
SMIL14CEX1331AB 2
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Check plunger section with throttle

1. Insert the check plungers (1).
CAUTION: The check plungers have similar

shapes, so be careful to insert each one in its cor-
rect position.
• Insert the springs (2) and install the plugs (4) with the
O-rings (3) attached.
• Tightening torque: 29.4 - 31.4 N·m (21.68 - 23.16 lb
ft)
SMIL14CEX1332AB 3
Shuttle valve section

1. Insert the steel ball (1).
• Install the seat (2) with O-ring (3) and the plug (4)
with O-ring (5).
• Tightening torque: 39.20 - 49.00 N·m (28.91 -
36.14 lb ft).
SMIL14CEX1333AB 4
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Cushion valve - Install

1. Tighten the 4 bolts (1) at bottom of the cushion valve
with a wrench [ 17 mm] to mount the cushion valve.
SMIL14CEX1550AB 1
2. Connect the hoses to each port with a wrench [ 19 mm,

22 mm].
Mount 7 sensors.
SMIL14CEX1548BB 2
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• Connection destination of hoses are as followings.

1. Arm in, pressure sensor
2. Boom up, pressure sensor
3. Swing right
4. Bucket close, pressure sensor
5. Heat circuit line
6. Arm out, pressure sensor
7. Boom down, pressure sensor
8. Swing left
9. Bucket open
10. Pressure sensor (swing)
12. Drain line
SMIL14CEX1552CB 3
3. Tighten the 5 bolts (2) with a wrench [ 19 mm] to mount

the under cover (1).
SMIL14CEX1546AB 4
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4. Tighten the 4 bolts (1) with a hexagon wrench [ 5 mm]

to mount the air breather (2) of the hydraulic reservoir.
• Bolt (1) tightening torque: 2.94 - 4.90 N·m (2.1684 -
3.6141 lb ft)
SMIL14CEX1554AB 5
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Hand control - Troubleshooting

Secondary pressure is Primary pressure is insufficient Maintain primary pressure
not rising
Secondary pressure spring (241) is broken Replace with new part
or worn
The gap between spool (201) and the cas- Replace with the remote control valve unit
ing (101) is abnormally large
There is backlash in the handle section Assemble/disassemble and replace the
handle section
Secondary pressure is Sliding parts are sticking Repair the sticking sections
unstable
Tank line pressure is variable Return directly to the oil tank
Air is getting into lines Perform operation several times and bleed
out air
Secondary pressure is Tank line pressure is high Return directly to the oil tank
high
Sliding parts are sticking Repair the sticking sections
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Index

Cushion valve - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Cushion valve - Detailed view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Cushion valve - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Cushion valve - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Cushion valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Cushion valve - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Cushion valve - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Cushion valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Drainage block - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Hand control - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Hand control - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Hand control - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hand control - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hand control - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Hand control - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hand control - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Hand control - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hand control - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Hand control hoses - Overview - 2-way selector valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Hydraulic hand control - Install – Left side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Hydraulic hand control - Install – Right side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Hydraulic hand control - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Hydraulic hand control - Remove – Left side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Hydraulic hand control - Remove – Right side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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Hydraulic foot control - 356

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Contents
TECHNICAL DATA
Pedal control
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Pedal control
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE
Hydraulic foot control

Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Pedal control
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
DIAGNOSTIC
Pedal control
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Hydraulic systems - Hydraulic foot control
Pedal control - Special tools

Jig dimension
SMIL14CEX1500EB 1
NOTE: All the dimensions in figure are in mm (in)

c. Center hole possible ([D 2 mm (0.079 in)] or less)
1. Bushing removal jig
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Pedal control - Overview

Remote control valve (Travel)
SMIL14CEX3572FB 1

1 Backward left G1/4
2 Forward left G1/4
3 Backward right G1/4
4 Forward right G1/4
P Pressure G1/4
T Return G1/4
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Pedal control - Sectional view

Structural diagram
SMIL14CEX3855GB 1
101. Casing (Quantity 1) 225. Steel ball (Quantity 12)

102. Casing (damper) (Quantity 1) 271. Hexagon socket head bolt (Quantity 2)
105. Plug (Quantity 1) 301. Spool (Quantity 4)
171. Hexagon socket head bolt (Quantity 2) 311. Spring seat (Quantity 4)
201. Cover (Quantity 2) 313. Washer 3 (Quantity 4)
202. Plug (Quantity 4) 324. Spring (Quantity 4)
203. Grease cup (Quantity 4) 335. Spring (Quantity 4)
204. Cover 2 (Quantity 1) 336. Spring (Quantity 4)
210. NHU packing (Quantity 4) 337. Spring (Quantity 4)
211. O-ring (Quantity 2) 412. Bushing (Quantity 4)
212. O-ring (Quantity 4) 413. Camshaft (Quantity 2)
213. O-ring (Quantity 4) 420. Cam (Quantity 2)
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214. Push rod (Quantity 4) 423. Hexagon socket head retaining screw (Quantity 2)
217. Washer 2 (Quantity 4) 471. Retaining screw (Quantity 4)
218. Spring seat (Quantity 4) 472. Lock nut (Quantity 4)
220. Hexagon socket head bolt (Quantity 2) 501. Bellows (Quantity 2)
224. Piston 2D085 (Quantity 4)
A. Apply grease to the top

B. Fill grease cup with grease
NOTE: Since hydraulic equipment is crucial to safety, we cannot guarantee performance and functions if disassembly
and reassembly are performed.
Tightening torque list

Code Screw size Tightening torque
220 M6 7.8 - 9.8 N·m (5.753 - 7.228 lb ft)
271 M12 45.2 - 64.8 N·m (33.338 - 47.794 lb ft)
423 M6 5.9 - 7.9 N·m (4.352 - 5.827 lb ft) ( LOCTITE® coating)
472 M10 29.9 - 36.7 N·m (22.053 - 27.069 lb ft)
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Pedal control - Dynamic description

Operation
The remote control valve with built-in damper (hereinafter, remote control valve with damper) is a remote control valve
that incorporates into the remote control valve main unit a damping function for preventing the man-machine system
hunting (lever hunting) phenomenon.
Operation of the remote control valve with damper is divided into the pressure reduction valve section and the oper-
ation section damping mechanism section. The explanations in these 2 sections are based on the hydraulic circuit
diagram, assembly cross-section diagram, and damping operation explanation diagram below. The diagram below is
a typical usage example for the remote control valve.
LPIL12CX01998FB 1
1. Remote control valve 4. Control valve

2. Pilot pump 5. Hydraulic motor
3. Main pump 6. Hydraulic cylinder
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Pressure reduction valve section

For the neutral state
• The spool (301) is pushed up by the return spring (335) via the spring seating (311) and washer 1 (215) and is in
the neutral position shown in the assembly Pedal control - Sectional view (35.356).
• Therefore, since the output port is connected only to port T by the spool switching function, the pressure at output
ports 1 and 2 is the same as the pressure at port T.
When the remote control valve operation section is tilted from a neutral state
• When, in the assembly cross-section diagram, the cam (420) is turned clockwise, the push rod on the port 1 side
(214) will be pushed down, that spool will move downward through the spring seat, the spring for secondary pres-
sure setting (324), the washer 2 (217), and the washer 3 (313), the port P and the port 1 will conduct to each other,
and the oil supplied from the pilot pump will flow into the port 1 to generate pressure.
• When the operation section is tilted to increase the pressure of the port 1 up to that equivalent to the set spring
force for secondary pressure setting, the hydraulic pressure on the spool and that spring force will be balanced with
each other to keep the output pressure of the port 1 constant. The spool on the port 2 side remains in a neutral
state, and the oil from the control valve is drained through the port T.
• When the operation section is tilted at almost the maximum angle, the push rod will come in contact with the spool
top directly to push the spool in forcibly, and the port P and the output port will conduct to each other to achieve the
same pressure.
Damping mechanism in operation section

1. In a neutral state
• The push rod is pushed up by the damping spring ( (336), (337)) through the piston (224), and located in the position
shown in the assembly cross-section diagram.
2. When the operation section is tilted from a neutral state (refer to damping operation explanation diagram 1.)
• When, in the assembly cross-section diagram, the cam is turned clockwise, the push rod on the port 1 side will be
pushed down, and the piston will move downward (3).
At this time, the oil in the damping piston chamber is drained from the orifice in the piston, and the resulting pressure
produces damping force (2).
On the other hand, the push rod on the port 2 side is moved up by the damping spring through the piston.
At this time, the oil in the tank chamber is sucked into the damping piston chamber through the ball check section
(3 locations) that consists of steel ball (225).
The oil outside the piston chamber drains out of the passage leading from the casing top end to the port T.
3. When the operation section is tilted in the opposite direction from a fully tilted state (refer to damping operation
explanation diagram 2)
• When, in the assembly cross-section diagram, the cam is fully tilted clockwise and then turned counter-clockwise,
the push rod on the port (2) side will be pushed down, and the piston will move downward.
At this time, as above, the oil in the damping piston chamber is drained from the orifice in the piston, and the
resulting pressure produces damping force (3-1).
On the other hand, the push rod on the port 1 side is moved up by the return spring (335) and the damping spring
(3-2).
At the same time, the oil in the tank chamber is sucked into the damping piston chamber through the ball check
section (3 locations) that consists of steel ball (3-3).
The oil outside the piston chamber drains out of the passage leading from the casing top end to the tank port (3-4).
In other words, damping force will act for either operation: tilting from the neutral position to the fully tilted position
or tilting from the fully tilted position to the neutral position.
Damping operation explanation diagram

1. When the lever is given a stroke from a neutral state
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SMIL14CEX3853HB 2
1. Push rod 3. Piston

2. Orifice 4. Piston chamber
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2. In a lever stroke state and during reverse operation
LPIL12CX02000HB 3
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*1. Neutral *3. (Þ during operation)

*2. Full stroke 12.5 ° *4. Oil drains to T.
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Hydraulic foot control - Prepare

WARNING
Escaping fluid!
doctor immediately.
W0178A
WARNING
Avoid injury!
W1128A
Items to prepare:
• Wrench [ 19 mm]
• Marking pen
• Cap
• Plug
• Rag
• Cleaning fluid
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Hydraulic foot control - Remove

1. Remove the floor mat (1).
SMIL14CEX1543AB 1
2. Remove the respective 2 bolts (2) in left and right with

a hexagon wrench [ 8 mm] to remove the travel pedals
(1) in left and right.
SMIL14CEX1528AB 2
3. Remove the respective 2 bolts (2) of levers in left and

right with a hexagon wrench [ 8 mm] to remove the
levers (1).
SMIL14CEX1530AB 3

SMIL14CEX1539AB 4
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5. Remove the 6 hoses (1) with a wrench [ 19 mm].

• Apply marking to the valve and the hoses so as to
• Attach caps and plugs at each location of the valve
and hoses so as to prevent invasion of water, dust
and dirt.
• Wash each location of the valve and the hoses by
SMIL14CEX1529AB 5
6. Remove the 2 hose adapters (1) with a wrench [

19 mm].
SMIL14CEX1531AB 6
7. Remove the 2 connectors (2) from the pressure switch

(1).
Remove the 2 pressure switches (1) with a wrench [
19 mm].
SMIL14CEX1532AB 7
8. Remove the respective 2 bolts (1) of travel levers in left

and right with a hexagon wrench [ 8 mm].
SMIL14CEX1533AB 8
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9. Pull up the travel remote control valve (1) into the cab
to remove the travel remote control valve.
SMIL14CEX1534AB 9
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Hydraulic foot control - Install

Ensure the correct connection of the hydraulic hoses.
Check that the hose adapters are not loosen prior to
connecting the hoses, and then retighten them with
specified torque.
specified torque.
1. Pull down the travel remote control valve (1) into the
cab to mount the travel remote control valve.
SMIL14CEX1536AB 1
2. Attach the respective 2 bolts (1) of travel levers in left

and right with a hexagon wrench [ 8 mm].
SMIL14CEX1538AB 2
3. Attach the 2 pressure switches (1) with a wrench [

19 mm].
Connect the 2 connectors (2) to the pressure switch (1).
• Secure the harnesses with wire bands.
SMIL14CEX1532AB 3
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4. Attach the 2 hose adapters (1) with a wrench [ 19 mm].
SMIL14CEX1535AB 4
5. Attach the 6 hoses (1) with a wrench [ 19 mm].

ft) / 44 - 54 N·m (32.453 - 39.828 lb ft)
SMIL14CEX1537AB 5
6. Attach the 6 bolts (2) with a wrench [ 19 mm] to mount

the under cover (1).
SMIL14CEX1539AB 6
7. Attach the respective 2 bolts (2) of levers in left and right

with a hexagon wrench [ 8 mm] to mount the levers (1).
SMIL14CEX1541AB 7
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8. Attach the respective 2 bolts (2) in left and right with a

hexagon wrench [ 8 mm] to mount the travel pedals (1)
in left and right.
SMIL14CEX1542AB 8
9. Mount the floor mat (1).
SMIL14CEX1543AB 9
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Pedal control - Service instruction

Causes of trouble and countermeasures
It is not easy to discover trouble locations.
A few problems that may occur are listed in the table
Pedal control - Troubleshooting (35.356).
Repairs are difficult, so refer to the suggested causes
and solutions in the table Pedal control - Trou-
bleshooting (35.356).
The table Pedal control - Troubleshooting (35.356)
shows general symptoms, suggested causes, and also
actions.
However, the cause of machine problems are often not
rooted in just a single part. Problems are often due to
the relationship of one part with another.
Also keep in mind that actions other than those listed
in the table Pedal control - Troubleshooting (35.356)
may sometimes be necessary.
The numbers in parentheses after the part names are
the codes indicated in Pedal control - Sectional view
(35.356).
Also, the table below does not include all possible
causes and countermeasures.
Further investigation of problems and causes should be
done by an experienced and qualified repair person, as
necessary.
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Pedal control - Prepare

CAUTION:
• To ensure safe operations, wear protective devices before beginning work and follow all precautions.
• When removing devices or positioning devices at the time of installation, use a removal jig and a hammer
or steel rod.
• Follow the precautions below when suspending the load.
• The lifting equipment must be operated by a qualified operator.
• Do not stand or pass under the suspended load.
• Check the weight of the load to determine whether it can be carried by hand or whether a lifting equipment
must be used.
• Any foreign matter entering the equipment during assembly can create a malfunction.
Therefore, after thoroughly cleaning the equipment with cleaning oil, air blow the equipment, and assemble in
a clean location.
General cautions
Pay careful attention and proceed slowly so as not to damage any parts, create any oil leaks, or compromise the
• Disassembled parts can easily rust or collect dust.
Therefore, immediately after disassembling parts, take precautions to prevent the parts from rusting or collecting
dust.
Items to prepare:
• Wrench
• Screwdriver
• Specialty jigs
• Vise
• LOCTITE® 262™
• Special fiber cloth (Kimwipe)
• White kerosene
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Pedal control - Disassemble

1. Use a shock plate to secure the remote control valve in
a vise, and then remove the bellows (1) from the cover
(2).
SMIL14CEX1449AB 1
2. Use a hexagon wrench (1) on the hexagon socket head

locking screws to loosen them.
Be careful, as application of LOCTITE® 241 makes the
loosening torque high.
SMIL14CEX1450AB 2
3. Place a round rod [D 8 mm (0.315 in) or less] against

one end of the cam shaft (1) and lightly strike it with a
hammer to remove the shaft.
SMIL14CEX1451AB 3
4. Remove the cams (1) as an assembly with the locking

screws and lock nuts attached.
Record the positions of the cams in relation to the cov-
ers (2).
• Be careful when removing, as the push rods (3) may
fly off.
SMIL14CEX1452AB 4
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5. Use a hexagon wrench (1) on the hexagon socket head

bolts to loosen and remove them.
SMIL14CEX1453AB 5
6. Remove the covers (1).

• Record the positions of the covers in relation to the
casing (4).
Be careful when removing, as the push rods (2) or
plugs (3) may fly off due to the damping springs.
(The plugs are only kept in the casing by the sliding
resistance of the O-rings.)
SMIL14CEX1454AB 6
7. Remove push rod (2) from the plug (1).

Record the positions of the plugs in relation to the push
rods.
Be careful not to scratch the surface of the push rods.
Be careful when removing, as the plugs may fly off.
SMIL14CEX1455AB 7
8. Remove the plugs (1) with the grease cups and NHU
packings attached.
Record the positions of the plugs in relation to the cas-
ing holes.
Be careful when removing parts, as the pistons (3) may
fly off due to the damping springs (2).
SMIL14CEX1456AB 8
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9. Remove the pistons (1).

Record the positions of the pistons in relation to the
casing holes.
SMIL14CEX1457AB 9
10. Remove the damping springs (2) and (3) from the cas-
ing (1).
Record the positions of the damping springs in relation
to the casing holes.
SMIL14CEX1458AB 10
11. Remove the spring seatings (2) from the casing (1).
• Record the positions of the spring seatings in rela-
tion to the casing holes.
SMIL14CEX1459AB 11
12. Use a magnet, etc. to remove steel balls (1).

Be careful not to lose the steel balls.
SMIL14CEX1460AB 12
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13. Use the hexagon wrench to remove the hexagon

socket head bolts (1).
SMIL14CEX1461AB 13
14. Remove the damper casing (1) and remove the

O-rings (4) and (3) from the casing.
• Record the positions of the damper casing in rela-
tion to the casing (2).
• Be careful when removing parts, as the pressure
reducing valve assembly may fly off due to the re-
turn springs.
SMIL14CEX1462AB 14
15. Remove the pressure reducing valve assemblies (1)

from the casing (2).
• Record the positions of these parts in relation to the
casing holes.
SMIL14CEX1463AB 15
16. Remove the return springs (1) from the casing (2).
SMIL14CEX1464AB 16
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17. Lay the covers (1) on their sides on a level surface,

place the special tool 1 against the bushings, and re-
move the bushings by lightly striking them with a ham-
mer.
SMIL14CEX1465AB 17
18. Secure each cam assembly (1) in a vise, use a wrench

to loosen the lock nuts (2), and remove the lock nuts
and locking screws (3).
• As neutral adjustment of locking screws is neces-
sary during assembly, handle them as part of the
cam assembly as long as replacement of locking
screws is not necessary.
SMIL14CEX1466AB 18
19. For disassembly of the pressure reducing valve as-

semblies, place the bottom end of the spools (1) per-
pendicular on a level work platform, lower the spring
seating (2), and use the end of a small flathead screw-
driver to remove the 2 half-circle washers 1 (3).
Be careful not to scratch the surface of the spool.
Do not press in the spring seating by 4 mm (0.157 in)
or more.
SMIL14CEX1467AB 19
20. Separate the spools (1), spring seating (2), secondary

pressure springs (3), washers 2 (4), and washers 3
(5).
Handle as an assembly until assembly is performed.
Washers 2 are used for pre-set adjustment of the sec-
ondary pressure springs, so thickness is different for
each spool assembly. Additionally, these are some-
times not used, so record the status for each assembly.
SMIL14CEX1468AB 20
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21. Remove the grease cups (2) from the plugs (1).
SMIL14CEX1469AB 21
22. Remove the NHU packings (2) from the plugs (1).
Use a small flathead screwdriver, etc. to remove.
• Be careful not to scratch the inner surface of the
plugs.
SMIL14CEX1470AB 22
23. Remove the O-ring (2) from the plug (1).
SMIL14CEX1471AB 23
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24. Cleaning parts

• Clean all parts by placing them in a rough cleaning
container filled with white kerosene. (rough clean-
ing).
• Scratching can easily occur if cleaning of parts
is begun just after parts are immersed in white
kerosene, so let each part sit in white kerosene
until debris and grease sufficiently loosen off from
the surface of parts and float to the surface.
• If the white kerosene is dirty, this will encourage
damage to parts and result in reduced performance
after reassembly.
Thoroughly manage the level of cleanliness of the
white kerosene.
• Clean each part by placing it in a finish cleaning
container filled with white kerosene, and thoroughly
clean each part, including the interior, while slowly
rotating it. (finish cleaning)
Use a clean rag to thoroughly remove any white
kerosene stuck to parts.
• Do not dry parts with compressed air, as this will
damage parts and cause rust to form due to debris
and moisture being dispersed into the atmosphere.
• Preventing rust on parts
Apply an anti-rust agent to each part.
Rust will form on parts if they are left as is after
cleaning, and this will cause reduced performance
of functions after reassembly.
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Pedal control - Assemble

1. Install the washer 3 (5), washer 2 (4), secondary pres-
sure spring (3), and the spring seating (2) onto each of
the spools (1) in that order.
Washers 2 are used for pre-set adjustment of the sec-
ondary pressure springs, so thickness is different for
each spool assembly.
Additionally, these are sometimes not used.
Check the status recorded during disassembly and in-
stall parts accordingly.
SMIL14CEX1468AB 1
2. Place the bottom end of the spool (1) perpendicular on

a level work platform, push the spring seating (2) down,
and install the 2 half-circle washers 1 (3) onto the spring
seating in such a way that they are not on top of each
other.
SMIL14CEX1472AB 2
• Install the washer 1 so that the sharp edge side (a)

faces up and the washer catches the head of the
spool.
Do not press in the spring seating by 4 mm
(0.157 in) or more.
SMIL14CEX1473AA 3
3. Install the return springs (1) in the casing (2).

assembly.
SMIL14CEX1474AB 4
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4. Install the pressure reducing valve subassemblies (1)

assembled in Steps 1 and 2 above into the casing (2).
assembly.
SMIL14CEX1475AB 5
• When installing the pressure reducing valve sub-

assemblies, be careful not to strongly strike the cas-
ing corners (b) with the bottom ends of the spools.
SMIL14CEX1476AA 6
5. Install O-rings (1) and (2) on the casing (3).
SMIL14CEX1477AB 7
6. Tighten the damper casing (1) and casing (2) with the
hexagon socket head bolts (3) to the specified torque.
assembly.
• Tighten the 2 hexagon socket head bolts (3) evenly,
and tighten the damper casing (1) in a parallel orien-
tation.
• Hexagon socket head bolt (3) tightening torque: 7.8
- 9.8 N·m (5.753 - 7.228 lb ft)
SMIL14CEX1478AB 8
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7. Install the steel balls (1) into the bushing.
SMIL14CEX1479AB 9
8. Install the spring seatings (1) on the bushing.

assembly.
SMIL14CEX1480AB 10
9. Install the damping springs (2) and (3) in the casing (1).
assembly.
SMIL14CEX1458AB 11
10. Install the pistons (1).

assembly.
SMIL14CEX1457AB 12
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11. Install the O-ring (2) on the plug (1).
SMIL14CEX1481AB 13
12. Install NHU packing into the plug (1).
SMIL14CEX1482AB 14
• When installing the NHU packing (1), be careful of

the installation direction. (See the diagram.)
Before installing NHU packings, apply a thin layer of
grease.
SMIL14CEX1483AB 15
13. Install the grease cup (2) on the plug (1).
SMIL14CEX1484AB 16
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14. Install the push rod (2) on the plug (1).

• Before installing the push rod, apply hydraulic oil to
the rod surface.
Do not press the rod in strongly, as this may dam-
age the NHU packing lip section.
SMIL14CEX1485AB 17
15. Install the push rod subassemblies assembled in

Steps 11, 12, 13and 14 above into the casing (1).
SMIL14CEX1486AB 18
16. Use special tool 1 on the covers (1) to press down

the bushings, and lightly strike the bushings with a
hammer to press fit them.
• Be careful that the ends of the bushings do not stick
out from within the cover.
SMIL14CEX1487AB 19
17. Install the cover (1) on the casing (2).

assembly.
• Be careful of the cover rising up due to the damping
springs.
SMIL14CEX1488AB 20
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18. Tighten the hexagon socket head bolt to the specified

torque.
• Be careful that the cover is horizontal.
• Hexagon socket head bolt tightening torque: 45.2 -
64.8 N·m (33.338 - 47.794 lb ft)
SMIL14CEX1489AA 21
19. Temporarily install the locking screws (3) and lock nuts
(2) on the cams (1).
SMIL14CEX1466AB 22
20. Install the cams (1) on the covers (2).

assembly.
SMIL14CEX1490AB 23
21. While holding the cams (1), insert the cam shafts (2)
from the outside.
SMIL14CEX1491AB 24
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22. Apply LOCTITE® 241 or the equivalent to the surfaces

of the hexagon socket head locking screws (1).
SMIL14CEX1492AB 25
23. Tighten the hexagon socket head locking screw to the

specified torque.
• Hexagon socket head locking screw tightening
torque: 5.9 - 7.9 N·m (4.352 - 5.827 lb ft)
SMIL14CEX1493AA 26
24. Adjust the height of the locking screws so that the top
surfaces of the cams (1) and the bottom surfaces of
the covers (2) are parallel, and tighten the lock nuts
to the specified torque after rotating the cams left and
right to check if there is any neutral backlash.
Even if the push rods are pressed in too much by
the locking screws, backlash during neutral will oc-
cur. Use caution as this may cause sudden movement
when starting the engine.
• Locking screw tightening torque: 29.9 - 36.7 N·m
(22.053 - 27.069 lb ft)
SMIL14CEX1494AB 27
25. Tilt the cams (1) and fill the grease cups of the plugs
with grease while coating the top of the push rods with
grease.
• For grease application and filling, use a flat object
made of soft material so as to not scratch the push
rod or plug surfaces.
SMIL14CEX1495AB 28
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26. After mounting the top end of the bellows (1) on the
cams, mount the bottom end into the grooves on the
covers (2).
• Before mounting the bottom end of the bellows into
the grooves of the covers, spray anti-rust oil on the
parts within the bellows.
• Be careful that the bellows are properly mounted
in the grooves and not twisted, as this may reduce
anti-rust and anti-moisture protection.
SMIL14CEX1496AB 29
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Pedal control - Troubleshooting

Secondary pressure is Primary pressure is insufficient Maintain primary pressure
not rising
Secondary pressure spring (324) is worn Replace with new part
The gap between spool and the casing is Replace spool and casing assembly
abnormally large
There is backlash in the operation section Disassemble and assemble, and replace
operation section parts
Secondary pressure is Sliding parts are sticking Repair the sticking sections
unstable
Tank line pressure is variable. Return directly to the oil tank
Air is getting into lines Perform operation several times and let out
air
Secondary pressure is Tank line pressure is high Return directly to the oil tank
high
Damping is not working Air is gathering in the piston chamber Perform operation several times and let out
air
Damping springs (336) (337) are worn Replace with new part
The gap between piston (224) and the cas- Replace piston and casing assembly
ing is abnormally large
There are check valve operation problems Disassemble and investigate the check
valve section
The piston metering hole is abnormally Replace piston
large
Damping torque is high Sliding parts are sticking Repair the sticking sections
Piston metering hole is clogged Repair or replace piston
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Index

Hydraulic foot control - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Hydraulic foot control - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Hydraulic foot control - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pedal control - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Pedal control - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Pedal control - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pedal control - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Pedal control - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Pedal control - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pedal control - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Pedal control - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pedal control - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
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Hydraulic swing system - 352

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Contents
TECHNICAL DATA
Swing reduction motor

Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FUNCTIONAL DATA
Hydraulic swing system

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SERVICE

Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Swing reduction motor
Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Prepare – For disassemble and assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
DIAGNOSTIC

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Hydraulic systems - Hydraulic swing system
Swing reduction motor - Service limits

1. Replacement standards for worn parts
If wear on any part exceeds the standard values below, replace or readjust.
However, parts should be replaced regardless of these standards if they appear to be extremely damaged based on
appearance.
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Part replacement standards

Recommended
Item Standard dimensions Solution
replacement value
Clearances between piston Replace the piston or
0.028 mm (0.001102 in) 0.058 mm (0.002283 in)
and cylinder bore (D-d) cylinder.
Piston and shoe caulking Replace the piston and
0 0.3 mm (0.0118 in)
section backlash (δ) shoe assembly.
Replace the piston and
Shoe thickness (t) 5.5 mm (0.2165 in) 5.3 mm (0.2087 in)
shoe assembly.
Friction plate thickness 2.0 mm (0.0787 in) 1.6 mm (0.0630 in) Replace
SMIL14CEX731ICO 1
SMIL14CEX732ICO 2
Clearance (D-d) Piston and shoe backlash (δ)
SMIL14CEX733ICO 3
Shoe thickness (t)
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2. Sliding surface repair standards

If the roughness of the sliding surface in any section exceeds the standard values below, repair or replace.
Sliding surface repair standards

Part name Standard surface roughness Surface roughness requiring repair
Shoe 0.8 - Z (Ra = 0.2) (lapping) 3 - Z (Ra = 0.8)
Shoe plate 0.4 - Z (Ra = 0.1) (lapping) 3 - Z (Ra = 0.8)
Cylinder 1.6 - Z (Ra = 0.4) (lapping) 12.5 - Z (Ra = 3.2)
Valve plate 0.8 - Z (Ra = 0.2) (lapping) 6.3 - Z (Ra = 1.6)
NOTE:
A. Using lapping, make the degree of surface roughness of each sliding surface equal to or lower than the standard
value.
B. If the plate spring and cylinder spherical surface sliding section are rough, these should be replaced as a set.
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Swing reduction motor - Special tools
SMIL14CEX2948GB 1
NOTE: All the dimensions in figure are in mm.
Code Order No. Jig name Remarks

1 Oil seal assembly jig 　
2 Pinion shaft assembly jig 　
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SMIL14CEX2949GB 2

3 Brake piston removal jig 　
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Hydraulic swing system - Overview
SMIL14CEX3583GB 1
*1. Air bleed port (when applying grease)

M Make up G1
DB Drain G1/2
PG Brake release G1/4
A Right swing -
B Left swing -
PA, PB Pressure measurement G1/4
Dr Gear oil drain port PT3/8
SGr Grease-up port PT1/8, PT1/4 (*1)
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Hydraulic swing system - Sectional view
SMIL14CEX3918HB 1
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SMIL14CEX3919GB 2
SMIL14CEX3920EB 3
Brake spring layout diagram
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Reverse prevention valve subassembly (Quantity

52. 303. Valve casing H2 (Quantity 1)
1 set)
100. Casing (Quantity 1) 351. Plunger H2 (Quantity 2)
151. ROH plug (Quantity 2) 355. Spring H2 (Quantity 2)
161. O-ring (Quantity 2) 390. Plate (Quantity 1)
162. O-ring (Quantity 2) 391. Driving tack (Quantity 2)
163. O-ring (Quantity 2) 401. Hexagon socket head bolt (Quantity 4)
171. Hexagon socket head bolt (Quantity 4) 443. Cylinder roller bearing (Quantity 1)
400. Reverse prevention valve (Quantity 2 sets) 444. Cylinder roller bearing (Quantity 1)
400-1. O-ring (Quantity 2) 451. Pin (Quantity 2)
400-2. Backup ring (Quantity 2) 469. ROMH plug (Quantity 2)
51. Relief valve (Quantity 2 sets) 472. O-ring (Quantity 1)
051-1. O-ring (Quantity 2) 488. O-ring (Quantity 2)
10. Piston; Subassembly (Quantity 1 set) 491. Oil seal (Quantity 1)
101. Drive shaft (Quantity 1) 702. Brake piston (Quantity 1)
111. Cylinder (Quantity 1) 706. O-ring (Quantity 1)
114. Plate spring (Quantity 1) 707. O-ring (Quantity 1)
121. Piston (Quantity 9) 712. Brake spring (Quantity 18)
122. Shoe (Quantity 9) 742. Friction plate (Quantity 2)
123. Holder plate (Quantity 1) 743. Separator plate (Quantity 4)
124. Shoe plate (Quantity 1) 984. Masking plug (Quantity 1 set)
131. Valve plate B (Quantity 1) 985. Masking plug (Quantity 1 set)
20. Valve casing H2 subassembly (Quantity 1 set) 986. Masking plug (Quantity 1 set)
301. Casing JA1 (Quantity 1) 994. Insert plug (Quantity 1)
A. Identification mark
Bolt and plug tightening torque

Part No. Screw size Tightening torque Hexagon bolt width
51 M33 X 1.5 177 N·m (130.55 lb ft) 41 mm (1.614 in)
151 G1/4 36 N·m (26.55 lb ft) 6 mm (0.236 in)
171 M8 29 N·m (21.39 lb ft) 6 mm (0.236 in)
400 M22 X 1.5 69 N·m (50.89 lb ft) 24 mm (0.945 in)
401 M20 430 N·m (317.15 lb ft) 17 mm (0.669 in)
469 M36 X 1.5 539 N·m (397.55 lb ft) 17 mm (0.669 in)
984 G1/2 2.7 N·m (1.991 lb ft) 8 mm (0.315 in)
985 G1 5.6 N·m (4.130 lb ft) 14 mm (0.551 in)
986 G1/4 0.9 N·m (0.664 lb ft) 6 mm (0.236 in)
994 Rc3/4 98 N·m (72.28 lb ft) 14 mm (0.551 in)
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Hydraulic swing system - Dynamic description

Hydraulic motor section
As the diagram below shows, when the high-pressure oil passes through the valve plate (1) inlet-side port (a) and flows
into the cylinder, the hydraulic pressure operates on the piston (5) and a force F is generated in the axial direction.
This force F is divided into 2 vectors, a force F1 perpendicular to the swash plate (3) via the shoe (2) and a force F2
perpendicular to the shaft.
This force F2 is transmitted to the cylinder block (4) via the piston (5), generating a rotational couple around the output
shaft.
9 pistons (5) are arrayed in the cylinder block. Rotation torque is transmitted sequentially to the output shaft (6) by
multiple pistons (5) linked with the high-pressure oil inlet-side port.
When the oil in and out directions are reversed, the rotation of the output shaft (6) also reverses. The theoretical
output torque T [N・m (lbf・ft)] is given by the following equation.
SMIL14CEX3955FB 1
Motor section operation explanation diagram
q. Compartments per rotation [cm3]

p. Effective pressure difference [MPa (lbf・ft)]
*1. Low-pressure oil
*2. High-pressure oil
*3. Outlet
*4. Inlet
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Valve casing section
Anti-cavitation check section

Because the system using this type of motor does not have a valve with a counter-balance function, the motor some-
times rotates more than the quantity of oil fed.
In order to prevent cavitation due to insufficient oil, there is a check valve to take in the oil shortfall.
SMIL14CEX3956EB 2
1. M port
2. Control valve
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Brake section
The cylinder (111) is coupled with the drive shaft (101) by the gear. Also, the separator plate (743) is constrained for
circumferential rotation by the arc groove cut into the casing (301).
When the friction plate (742) that is gear coupled to the cylinder outer circumference section is pressed to the casing
(301) by the brake spring (712) via the separator plate (743) and the brake piston (702), friction force is generated
between the friction plate and casing and between the separator plate and the brake piston. The drive shaft is con-
strained and braked by this friction force.
On the other hand, when brake release pressure is applied to the oil chamber (1) formed between the brake piston
and the casing and the hydraulic pressure (3) wins out over the spring force (2), the brake piston moves, the force
pressing the friction plate against the casing disappears, and the brake is released.
SMIL14CEX3957FB 3
Brake operation diagram
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Relief valve operation explanation (relief valve model: KRD22EK10)
Operation explanation for when the relief valve is pressurized

In the case where the P port is pressurized with the tank pressure,the P and R ports are initially at the tank pressure
and the valve status is as shown in Diagram 4 (1).
At the pressure where there is balance between the hydraulic pressure determined by the product of the pressure
P and the pressurized area A1 of the plunger (301) on the one hand and the hydraulic pressure determined by the
product of the spring (321) load FSP and plunger (301) pressurized area A2 and the g chamber pressure Pg on the
other, the relief valve starts to operate.
After that, the g chamber pressure rises and the piston (302) starts its stroke.
Accompanying this movement, the load on the spring (321) increases.
Through the operation above, the relief pressure P is increased from P1 to Ps in the pressure boost time t1.
This process is explained below in terms of the relationship between the movement state of the parts in diagrams 4-
(2) - (4) and the relief pressure.
1. State shown in Diagram 4- (2)
When the relief valve P port is pressurized, pressure is generated in the g chamber via the orifice m in the plunger
(301).
When the hydraulic pressure operating on the plunger (301) increases and reaches the pressure at which it bal-
ances the spring (321) load FSP, the relief valve carries out the relief operation at pressure P1.
The relationship at this time is expressed by the following equation.
P1 x A1 = FSP1 + Pg1 x A2 FSP1: Initial set load for the spring (321)
The g chamber pressure operates on pressurized areas A3 and A4 of the piston (302). When this hydraulic pres-
sure becomes larger than the load on the spring (321), the piston starts to move to the left.
At this time, the oil in the h chamber formed between the piston and the adjusting plug (401) is discharged into the
g chamber via the orifice n set up on the piston (302) while the piston moves to the left, so the h chamber functions
as a damping chamber.
Through this, the spring load gradually increases until the piston reaches the adjusting plug end section and the
relief pressure P rises smoothly.
When the piston (302) reaches the adjusting plug (401) end section, it does not move farther to the left, so the
constant relief state is reached and the relief pressure is held at P2.
Through the processes (1) - (4) above, the relief pressure varies as in Diagram 5.
2. Operation explanation for when the relief valve is depressurized

In the case where the P port pressure falls, the P port pressure and the g chamber pressure fall together to the tank
pressure when the pressurization of the P port ends.
Through this process, the plunger (301) which was open moves to the left and is placed in the seat (401).
At the same time, the piston (302) also is moved to the right by the spring (321) and returns to the state in Diagram
4- (1).
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SMIL14CEX3958GB 4
Relief valve operation explanation diagram
a. Orifice m d. Orifice n
b. h chamber e. g chamber
c. A1 pressurized area
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SMIL14CEX3959EA 5
Pressure boost characteristics
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Hydraulic swing system - Service instruction

Causes of trouble and solutions
This list consists of actions to be taken when an abnor-
mality is sensed or there are problems with functions
during use of the hydraulic motor.
Additionally, details concerning disassembly, inspection
and reassembly are listed after this, but sufficient cau-
tion should be exercised in handling during these ac-
tions so as to prevent scratching of sliding parts of the
motor.
General cautions
This list consists of actions to be taken when an abnor-
mality is sensed during use of the hydraulic motor.
General cautions are listed below.
1. Think before attempting to fix a problem.
Determine the nature of the abnormality before begin-
ning work and think whether this same kind of problem
has occurred before.
Also, reconfirm whether the motor is the source of the
problem.
2. Be careful about dust and dirt.
The cause of wear is very often dust and dirt. So be
careful that dust and dirt do not get into parts during
disassembly.
3. Parts handling
Parts are manufactured with a high degree of precision,
so be careful not to scratch them during handling.
4. Do not damage O-rings or gasket surfaces while per-
forming work.
Also, it is recommended that O-rings are replaced for
new ones during disassembly.
Investigating abnormalities in the motor main unit

It is very difficult to search for the source of troubles in
the hydraulic circuits.
Inspect the following items and thoroughly investigate
whether the motor is the source of troubles.
1. Inspecting oil within the casing
Remove the drain plug and inspect the hydraulic oil
within the casing.
If a large amount of metal particles come out at the
same time as oil, it is very likely that there is damage
with parts within the motor.
2. Existence of abnormal noise
Check whether abnormal noise is coming from the mo-
tor main unit.
3. Measure pressure for each part.
Do not perform disassembly and inspection carelessly.
Measure pressure for each part and look for abnormal-
ities in each area.
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4. Measure the amount of oil drained from the motor.

A. Operation is normal if about 6 L/min (1.585 US
gpm) or less of oil drains from the motor when
pressure oil is applied after the swing is locked.
B. Operation is normal if 2 L/min (0.528 US gpm) or
less of oil drains at constant swing.
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Hydraulic swing system - Prepare

WARNING
Escaping fluid!
doctor immediately.
W0178A
WARNING
Avoid injury!
W1128A
WARNING
Burn hazard!
Before performing any service on the hydraulic system, you must allow it to cool. Hydraulic fluid
temperature should not exceed 40 °C (104 °F).
W0241A
WARNING
Crushing hazard!
latches.
W0256A
WARNING
Heavy objects!
W0398A
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Items to prepare:
• Pliers
• Hammer
• Grease
• Specialty adapter for vacuum pump connection
• Vacuum pump (vacuum pump power supply)
• Extension cable
• Marking pen
• Cap
• Plug
• Rag
• Cleaning fluid
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Hydraulic swing system - Remove

1. Remove the 4 bolts (1) with a hexagon wrench [ 5 mm]
to remove the air breather (2) of the hydraulic reservoir.
3.6141 lb ft)
SMIL14CEX3545AB 1

the vacuum pump.
sure with a vacuum pump (2).
SMIL14CEX1517AB 2

move the center cover (2).
SMIL14CEX3546AB 3
4. Remove the 8 hexagon bolts with a hexagon wrench [

8 mm] to remove the hose (1) and (2).
Also, remove the hose (3) with a wrench [ 41 mm], and
the hose (4) and (5) with a wrench [ 36 mm].
• Apply marking to the swing motor and the hose so
• Attach caps and plugs at each location of the swing
motor and hose so as to prevent invasion of water,
dust and dirt.
• Wash each location of the swing motor and the hose
by blowing parts cleaner so as to prevent adhering
dirt at connections and not to damage them. SMIL14CEX3547AB 4
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SMIL14CEX1501AB 5
6. Remove the bolt (3) of the clamp (2) of the drain hose
(1) with a wrench [ 13 mm].
SMIL14CEX3548AB 6
7. Remove the 12 bolts (1) of the swing unit with a box

wrench [ 36 mm].
774.44 lb ft)
SMIL14CEX3549AB 7
8. Lift the swing motor by a crane by winding a wire rope

(1) around it.
• Installation section of the swing unit has the knock
pin (2) knocked in. Apply lubricating oil and pull out
it together with main unit of the swing motor while
taping with a hammer or other tool.
SMIL14CEX3550AB 8
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9. Make sure that you have a safe site, and then settle the
swing unit on a wood plank (1).
• Make sure to secure the swing unit so as to prevent
it from falling.
SMIL14CEX3551AB 9
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Hydraulic swing system - Install

1. To install, perform the reverse of the removal proce-
dure.
When installing the swing unit, be careful with the po-
sition of the knock pin.
torque.
If the torque is not specified, see Torque – Bolt and
nut ().
2. Before driving, be sure to fill the inside of the motor
casing with hydraulic oil from the drain port (1).
Use the level gauge (2) to check that gear oil for the
reduction gear is filled to the stipulated volume.
SMPH14CEX6553BB 1
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Swing reduction gear - Prepare

CAUTION:
1. Read and understand the contents of this maintenance manual before performing disassembly, reassembly,
inspection, repair, or other such work of this product.
2. Handle this product according to the separate “Usage Precautions”.
3. When removing this product from the equipment it is mounted on, stop that equipment system and wait for the
surface temperature of this product to fall to about 40 °C (104.0 °F) or below before removing it. Working on this
product while it is still hot can cause burns. Additionally, always bleed out the pressure before removing any line
from this product. Removing a pressurized line can result in oil spraying out and causing injury or oil leak.
4. Use the specialty tools and measurement instruments for disassembly, reassembly, inspection, and repair, etc.
of this product. Using an inappropriate tool may result in injury or product damage.
5. Be careful of parts falling when performing disassembly, reassembly, inspection or repair, etc. of this product.
This may result in injury or parts damage.
6. Do not directly touch with bare hands the machined edges or threaded sections of parts during disassembly,
reassembly, inspection, or repair etc. of this product. Doing so may result in injury.
7. Check performance after reassembly. Do not resume use unless performance is fully recovered. Using this
product at a sub-par performance level may result in product damage.
8. The cautions (mark !) listed in this maintenance manual do not cover all possible dangers. Always think of
safety first during disassembly, inspection, reassembly, repair, or other such work.
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Swing reduction gear - Disassemble

1. Making a reference mark on the unit matching surface
It is useful for reassembly to place a reference mark
(*1) on the matching surface of the housing (1) and ring
gear (2) with paint, etc.
SMIL14CEX3553AB 1
2. Removal of level gauge assembly

Remove the level gauge assembly (3) and cap (4) [
27 mm (1.063 in) hexagon diameter)].
SMIL14CEX3554AB 2
3. Gear oil draining from reduction gear (5).

Loosen the drain hose (*2) end plug, and then drain the
gear oil.
• Gear oil cannot be reused.
SMIL14CEX3555BB 3
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4. Removal of hose from reduction gear (5).

Remove the drain hose (*2).
SMIL14CEX3556AB 4
5. Removal of motor
Use the hexagon wrench [ 17 mm] to loosen and re-
move the 12 hexagon socket head bolts (6).
Use the make-up port (G1) to raise the motor and re-
move it.
• Liquid packing has been applied to the matching sur-
faces of the housing (7) and ring gear (8), so use the
notch sections (*3) to remove the motor.
SMIL14CEX3557BB 5
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Swing reduction gear - Assemble

1. Applying liquid packing
After cleaning and degreasing the reduction gear ring
gear (1) and the motor housing matching surfaces, ap-
ply liquid packing (ThreeBond Co., Ltd. “1215” gray or
the equivalent) as shown in the diagram on the right
(*1).
SMIL14CEX3558AB 1
2. Installing the motor

Lift the motor and gently install it in the reduction gear,
and then use a hexagon wrench [ 17 mm] to tighten the
hexagon socket head bolts (2) to the tightening torque
of 568 - 649 N·m (418.94 - 478.68 lb ft).
• Align the housing (3) and ring gear (4) according to
the reference mark (*2) made before disassembly.
SMIL14CEX3559BB 2
3. Filling with gear oil
SMIL14CEX3560AB 3
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Install a plug in the female side of the hose, and install

a hose (*3) in the drain port on the gear case (5).
Fill with gear oil [ 6 L (1.59 US gal)] from the housing
(3) gear oil fill port.
SMIL14CEX3561AB 4
4. Installing level gauge assembly

Install the cap (6) [ 27 mm (1.063 in) hexagon diame-
ter] on the pipe by tightening it to the tightening torque
of 98 N·m (72.28 lb ft), and insert the level gauge as-
sembly (7).
SMIL14CEX3562AB 5
5. Grease-up
Remove the plug (8) [ 5 mm (0.197 in) hexagon socket
diameter] from the gear case (5) and inject grease [
1.00 L (0.26 US gal)] from the grease fill port (9).
• When injecting grease, the reduction gear oil seal
may be damaged by internal pressure, so release
the air bleed port plug before injecting grease.
Tighten the plug to the gear case to the tightening
torque of 20 N·m (14.75 lb ft).
After injection, tighten the plug into the gear case.
SMIL14CEX3563AB 6
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Swing reduction motor - Drain fluid

Preparations
Measuring condition

Mode SP mode
Oil temperature About 50 °C
NOTE: be aware that the drain volume varies greatly depending on the oil temperature.
Swing motor drain volume measurement

CAUTION: During measurement, since the
travel drain plug becomes disconnected from the
tank, be careful to avoid traveling.
1. Remove 2 drain hoses (1), and attach plugs to both
hose sides. (Wrench size: 36 mm (1.42 in), holding
36 mm (1.42 in) (hose side)).
SMIL14CEX2218AB 1
2. Attach the extension hose for drain volume measure-

ment (1) to one side on the T-shaped nipple.
Make sure that the hose is attached to the side conve-
nient for measurement, and attach the plug (2) to the
other side.
SMIL14CEX2219AB 2
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3. Prepare a waste oil receiver and the measuring con-

tainer (1), and set them as in the diagram on the right.
For the swing motor locking procedure, refer to Hy-
draulic systems - Pressure setting (35.000).
4. In SP mode, relieve the swing operation, and move the
extension hose to the measuring container (1) at the
same time the motor starts (At starting, start measure-
ment with a stop watch (2)).
5. After 60 s, move the extension hose (3) to the waste oil
can (4).
6. Measure the volume of oil in the measuring container
(1) as the drain volume for 60 s.
(a). 60 s
Measure at least 3 times each for left and right.
Right Left
SMIL14CEX2220BB 3
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Swing reduction motor - Prepare – For disassemble and assemble

CAUTION:
1. Read and understand the contents of this maintenance manual before performing disassembly, reassembly,
inspection, repair, or other such work of this product.
2. Handle this product according to the separate “Usage Precautions”.
3. When removing this product from the equipment it is mounted on, stop that equipment system and wait for the
surface temperature of this product to fall to about 40 °C (104 °F) or below before removing it. Working on this
product while it is still hot can cause burns.Additionally, always bleed out the pressure before removing any line
from this product.Removing a pressurized line can result in oil spraying out and causing injury or oil leak.
4. Use the specialty tools and measurement instruments for disassembly, reassembly, inspection, and repair, etc.
of this product. Using an inappropriate tool may result in injury or product damage.
5. Be careful of parts falling when performing disassembly, reassembly, inspection or repair, etc. of this
product.This may result in injury or parts damage.
6. Do not directly touch with bare hands the machined edges or threaded sections of parts during disassembly,
reassembly, inspection, or repair etc. of this product.This may result in injury.
7. Check performance after reassembly. Do not resume use unless performance is fully recovered.Using this
product at a sub-par performance level may result in product damage.
8. The cautions (mark !) listed in this maintenance manual do not cover all possible dangers. Always think of
safety first during disassembly, inspection, reassembly, repair, or other such work.
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Swing reduction motor - Disassemble

1. Wrap the wire rope around the outer circumference of
the motor, lift the motor with a lifting equipment, and
then clean with white kerosene.
After cleaning, dry the motor using compressed air.
• To prevent foreign matter from entering the motor,
mask each port with tape, etc. Also clean off adhered
dirt and dust.
2. From the drain plug, drain the oil inside the housing.
3. Point the shaft end of the drive shaft downwards and
place a reference mark (*1) on the matching surface of
valve casing H0 (303) and casing JA1 (301) with paint,
etc.
Place a rubber plate or cloth on the work platform so
SMIL14CEX3735AB 1
4. Loosen the relief valves (051) and remove them from

valve casing H0 (303).
• Be sure to replace the O-ring (051-1).
The O-ring (051-1) is damaged when the relief valve
is loosened.
SMIL14CEX3736AB 2
5. Remove the ROH plug (469) from valve casing H0

(303) and take out the springs and plungers.
Be careful not to scratch the plunger seating sections.
SMIL14CEX3737AB 3
6. Loosen the hexagon socket head bolt (401) and re-

move valve casing H0 (303) from casing JA1 (301).
• The valve casing H0 (303) will rise up from the casing
JA1 (301) when the bolts are removed due to the
force of the brake springs (712).
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7. Remove valve plate B (131) from valve casing H0

(303).
• Do this carefully so as not to let valve plate B (131)
fall from valve casing H0 (303). (Valve plate B (131)
may be attached to the cylinder side.)
• When prying open the matching surface with a
screwdriver, be careful not to scratch the surface.
SMIL14CEX3738AB 4
8. Take out the brake springs (712) from the brake piston
(702).
SMIL14CEX3739AB 5
9. Use a jig and remove the brake piston (702) from cas-
ing JA1 (301).
• Apply the tips of the jig to the grooves of the brake
piston, and pull straight up.
SMIL14CEX3740AB 6
10. Reposition the motor on its side, and remove the cylin-
der (111) from the drive shaft.
Next, remove the pistons (121), holder plate (123),
plate spring (114), and shoe plate (124).
• Be careful not to scratch the sliding surfaces of the
cylinder (111), shoe (122), etc.
SMIL14CEX3741AB 7
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11. Take out the friction plate (742) and separator plate
(743) from casing JA1 (301).
SMIL14CEX3742AB 8
12. Take out the drive shaft (101) and shoe plate (124).
• The spline will damage the oil seal (491) when the
drive shaft is removed, so wrap the spline section of
the drive shaft with vinyl tape, etc. (*2).
SMIL14CEX3743AB 9
SMIL14CEX3744AB 10
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13. Perform the following as necessary. Do not reuse a

removed bearing.
• Use a press to remove the inner race of the roller
bearing (443) from the drive shaft (101).
When using a steel rod to hit the inner race of the
roller bearing, hit the inner race evenly while being
careful not to damage the bearing.
• Using a steel rod, tap from the housing section side
of the oil seal, and pull out the outer race of the roller
bearing from the housing.
• Use a slide hammer bearing puller (*3) to remove the
roller bearing (404) from valve casing H0 (303).
SMIL14CEX3745AB 11
SMIL14CEX3746AB 12
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Swing reduction motor - Assemble

1. Check each part for scratches from use or from dis-
assembly. If there are any scratches, remove them
with a whetstone or sandpaper of the necessary
grain, clean with pure cleaning oil, and then dry off
with an air blower.
2. Replace seal parts with new ones.
3. Thoroughly clean all parts with cleaning fluid and
dry with compressed air.
4. When assembling sliding sections, apply clean hy-
draulic oil before assembling.
1. Place the housing on an appropriate platform with the
cover on top.
2. If the roller bearing (443) was removed, shrink fit the
inner race of the roller bearing to the drive shaft (101).
• Be careful with the direction of the flange of the roller
bearing.
SMIL14CEX3747AB 1
3. Use a jig to insert the oil seal (491) into casing JA1
(301).
• Be careful with the direction of the oil seal.
• Apply a thin layer of grease to the oil seal lip section.
• Be careful to evenly hit it without scratching the outer
circumference.
SMIL14CEX3748AB 2
4. Use a steel rod to install the outer race of the roller

bearing (443) into casing JA1 (301).
SMIL14CEX3749AB 3
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5. Mount the drive shaft (101) in casing JA1 (301).

• Carefully insert it so as not to scratch the lip section
of the oil seal (491).
• Wrap vinyl tape, etc. around the shaft spline section
to protect it.
SMIL14CEX3750AB 4
6. Lay casing JA1 (301) horizontal and insert the shoe

plate (124).
• Install with the larger chamfered side of the shoe
plate (124) on the casing JA1 side.
• Apply a thin layer of grease to the matching surface
to prevent it from falling out.
SMIL14CEX3901AB 5
7. Set the plate spring (114) on the holder plate (123), and
then set the pistons (121).
SMIL14CEX3902AB 6
8. Install the piston subassembly (10) on the cylinder

(111).
SMIL14CEX3903AB 7
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9. Align the piston subassembly (10) and cylinder (111)

with the drive shaft spline and insert into the housing.
SMIL14CEX3904AB 8
10. Set the housing down with the oil seal side facing
downwards, and alternately install separator plates
(743) and friction plates (744) in that order to the hous-
ing. Install the 4 separate plates and 3 friction plates.
SMIL14CEX3905AB 9
SMIL14CEX3906AB 10
11. Mount the O-rings (706) (707) on casing JA1 (301).

• If grease is applied to the O-rings, it will not break
easily when inserting the brake piston.
SMIL14CEX3907AB 11
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12. Install the brake piston (702) into the housing.
SMIL14CEX3908AB 12
13. Install the brake springs (712) into the brake piston
(702).
SMIL14CEX3909AB 13
14. If the roller bearing (444) was removed, use a hammer

and steel rod to insert it into valve casing H0 (303).
SMIL14CEX3910AB 14
15. Install valve plate B (131) in valve casing H0 (303).

• Apply a thin layer of grease to the matching surface
(*1) of the valve plate.
SMIL14CEX3911AB 15
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16. Mount the O-ring (472) to the cover.

• Apply grease to the O-ring.
SMIL14CEX3912AB 16
17. Install valve casing H0 (303) on casing JA1 (301) and

tighten with the bolt (401).
• Be careful with the installation direction of the valve.
• Make sure that valve plate B (131) does not fall over.
• Make sure that the brake springs (712) do not fall
over.
SMIL14CEX3913AB 17
18. Insert plungers H2 (351) and springs (355) into valve

casing H0 (303) and tighten the ROMH plugs (469)
with the O-rings (488) mounted on them.
• Check that plunger H2 (351) moves smoothly.
SMIL14CEX3914AB 18
19. Mount the relief valve (051) in valve casing H0 (303).

SMIL14CEX3915AB 19
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20. Assembly confirmation

Open the input/output ports, apply 3 - 5 MPa (464 -
711 psi) of pilot pressure to the brake release port
to check if the output shaft rotates smoothly for at
least 1 rotation with about 30 - 40 N·m (22.13 -
29.50 lb ft) of torque.
There is an assembly problem if it does not rotate,
so disassemble again and adjust it.
• At this time, have the drain port open.
SMIL14CEX3916AA 20
This completes the assembly.

• Check that the set pressure of the relief assembly is
at the correct pressure after the hydraulic motor is
installed in the actual machine.
Relief internal structural diagram
1. Seat
2. Poppet
3. Spring
4. Spring seat
5. Shim
SMIL14CEX3917AA 21
6. Liner
7. Piston
8. Cap
9. Backup ring
10. O-ring
11. Holder
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Hydraulic swing system - Troubleshooting

The pressure does not Incorrect setting of the circuit safety valve Reset safety valve correctly
rise
Operation problems with relief valve Disassemble and inspect
1. Plunger sticking 1. Repair or replace sticking section
2. Clogged plunger orifice
2. Disassemble and clean
Plunger seating problem Check seating section and replace
scratched part
The pressure rises Overload Eliminate load
Seizing of driving part Inspect and repair piston/shoe, cylin-
der/valve plate, etc.
No release pressure acting on the brake Inspect and repair circuit
Piston sticking to the brake Disassemble and inspect
Spool for brake release sticking Disassemble and inspect
Friction plate seizing Disassemble and inspect. Replace seizing
part
Direction of rotation is Direction of rotation of the motor reversed Check the direction of rotation and assem-
reversed ble correctly
Input and output for line reversed Correct line configurations
Rotation speed does not Insufficient oil flow amount Check the pump discharge volume and the
reach the setting value circuit up to the motor
High temperature and severe leak of oil Lower the temperature of the oil
Wear or damage on each sliding section Replace
Brake torque is Wear on the friction plate Disassemble and inspect
insufficient Replace part worn beyond the limit
Brake piston sticking Disassemble and inspect
Releasing brake off pressure impossible Inspect and repair circuit
Spool for brake release sticking Disassemble and inspect
Damaged friction plate spline Disassemble and inspect
Replace damaged part
Slipping is severe when Operation problems with relief valve Disassemble and inspect
an external driving torque 1.Plunger sticking 1. Repair or replace sticking section
acts on the hydraulic 2.Clogged plunger orifice
motor 2. Disassemble and clean
Plunger seating problem Check seating section and replace
scratched part
Oil leak from oil seal Debris lodged in lip causing scratching Replace oil seal
Shaft scratched or worn Stagger the position of the lip and shaft or
replace
Pressure within the casing becoming ab- Repair any clogged drain line
normally high caused oil seal lip to turn up
Shaft rusted Disassemble and repair
Oil leak from matching O-ring not inserted Insert O-ring and assemble correctly
surface
Scratched O-ring Replace
Scratched seal surface Disassemble and repair
Loosened or damaged bolt Tighten to the specified torque or replace
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Index

Hydraulic swing system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Hydraulic swing system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Hydraulic swing system - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hydraulic swing system - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Hydraulic swing system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Hydraulic swing system - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hydraulic swing system - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Hydraulic swing system - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Swing reduction gear - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Swing reduction gear - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Swing reduction gear - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Swing reduction motor - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Swing reduction motor - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Swing reduction motor - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Swing reduction motor - Prepare – For disassemble and assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Swing reduction motor - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Swing reduction motor - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Hydraulic travel system - 353

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Contents
TECHNICAL DATA
Hydraulic travel system

Travel motor
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
FUNCTIONAL DATA

Travel motor
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Component localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
SERVICE

Travel motor
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
DIAGNOSTIC

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Hydraulic systems - Hydraulic travel system
Hydraulic travel system - General specification

Introduction
Before using the travel motor, be sure to read this chapter to fully understand the contents. Failure to observe the
contents in this chapter may lead to an accident.
Contents
The description includes the use, structure, usage precautions, maintenance, and inspection of the travel motor.
Disassembly and assembly of this product

For consumable and replacement parts, be sure to use genuine parts.
Warning terms
General guidelines and precautions for using the travel motor safely are written in this chapter. For better understand-
ing of the contents, warning terms for safety are used as follows. According to the degree of risk (or accident), they
are classified into four levels in the following table. Understand the meanings of these warning terms, and follow their
instructions.
• Categories and meanings of warning terms

Warning term Meaning
This is used for such an imminent hazardous condition as failure to avoid it results in death or
DANGER serious injury.
This is used for such a potential hazardous condition as failure to avoid it results in death or
WARNING serious injury.
This is used for such a potential hazardous condition as failure to avoid it may result in
CAUTION moderate or minor injury.
This is used for such information as requires particular attention or emphasis, or such a
NOTE condition as failure to observe procedures or instructions may damage equipment and
devices.
NOTE: Note that there are no danger and warning items in this chapter.
Use of product
This equipment is a hydraulically-operated rotary actuator. The hydraulic motor, the reduction gear, the brake, and
the brake valve are integrated into the compact equipment.
It is used as a travel actuator for the construction machinery that needs low-speed rotation and high torque.
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Specifications
These specifications describe general specifications for each item.
The combination of specifications in the below table is different from that of the installed travel motor.
Item
Type GM60VB
Rated output torque 59400 N·m (43811.19 lb ft)
Maximum operating speed 45 RPM
Reduction ratio 1 / 41.824
Maximum stroke volume 290.7 cm³/rev
Maximum speed 1610 RPM
Hydraulic motor
Maximum pressure 35 MPa (5077 psi)
2-speed switchover pressure 1.96 - 6.86 MPa (284 - 995 psi)
Braking torque 1170 N·m (862.95 lb ft)
Parking brake
Brake off pressure 1.60 MPa (232.08 psi)
Type indication
The type is indicated on a product decal.
SMIL14CEX3933EB 1
1. Model code 4. Reduction ratio identification code (A →1/ 41.824)

Hydraulic motor volume identification number
2. Size number 5.
(cm3/rev.)
3. Model identification code 6. Design number (product identification number)
Weight table
Applicable component (Structural
Name Weight
diagram)
Travel motor assembly About 405 kg (892.872 lb)
1 Ring gear About 54 kg (119.050 lb)
15 Housing About 47 kg (103.617 lb)
101 Spindle About 91 kg (200.6207 lb)
301 or others Rear flange assembly About 30 kg (66.139 lb)
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Travel motor - Special tools
SMIL14CEX2935GB 1

1 Holder fitting 　
2 Rear cover guide pin 　
3 Brake piston removal jig 　
4 Shim thickness adjustment jig No diagram
5 Oil seal insertion jig
6 Rear bearing insertion jig
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SMIL14CEX2936GB 2

7 Brake piston insertion jig
When the rear cover bolts are used as is:
8 Piston and shoe measurement jig D1: 2-20 drill, D2: 10 - Plain flat washer
with rounded finish 18 mm
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SMIL14CEX2937GB 3

9 Motor assembly pedestal *1: Welding (8 locations)
Snap ring removal and installation
10
(removal) jig
11 Ball bearing removal and installation jig
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SMIL14CEX2938FB 4

12 Holder A subassembly lifting jig
13 Holder B subassembly lifting jig
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SMIL14CEX2939GB 5

*1: Socket head bolt (1)
14 Holder C subassembly lifting jig *2: M10 nut (1)
*3: JIS B1354 Type A equivalent (2)
Motor-assembly disassembly and assembly
15
rod
16 Angular bearing press-fit jig
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SMIL14CEX2940HB 6
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*1: 4 - M6 X 1.0 equipartition
17 Floating seal press-fit jig 1 *2: 4 - 7 mm equipartition
*3: 4 - 11 mm equipartition
*1: 4 - M6 X 1.0 equipartition
18 Floating seal press-fit jig 2 *2: 4 - 7 mm equipartition
*3: 4 - 11 mm equipartition
SMIL14CEX2941GB 7

19 Floating seal press-fit jig 3
20 Oil seal press-fit jig
21 Bearing press-fit jig
22 M12 X 1.75 x L45 socket head bolt
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Standard tools
No. Name Type and dimension Quantity
Hexagon wrench and 4 (for PT 1/16, for M6), 5 (for PF 1/8), 6 (for PF 1/4), 10 (for PF 1/2),
1 1 each
hexagon socket 12 (for PF 3/4), 14 (for M18), 17 (for PF 1)
2 Socket for torque wrench 19 (for M12), 35 (for ORV), 46 (for M38) 1
Socket wrench (ratchet
3 Oval 1
handle) (JIS B 4641)
Dial: 50 N (11.24 lb)
Dial: 200 N (44.96 lb)
4 Torque wrench (JIS B 4650) 1 each
Dial: 300 N (67.44 lb)
Dial: 400 N (89.92 lb)
5 Adapter for torque wrench 　 1 each
6 Extension bar (JIS B 4637) 150 mm (5.906 in) 1
7 Hammer Various 1 each
8 Plastic hammer 400 mm (15.7480 in) 1
Flathead screwdriver (JIS B
9 About 150 mm (5.906 in) 1 each
4609)
10 Pliers for retaining ring For holes 1 each
11 Magnet 　 1 each
Lifting load 9800 N (2203.13 lb) or more 1 set
Eyebolt (for M10) (3)
12 Lifting equipment Eyebolt (for M20) (2)
Eyebolt (for PF 3/4) (2)
Wire with hook (2-wire sling, 3-wire sling) (1 each)
General-purpose vat W 450 mm (17.717 in) x D 300 mm
13 Container 2
(11.811 in)x H 120 mm (4.724 in)
14 Leather glove 1 pair
Bolts
1 Long hexagon socket head bolt M24 (P3.0) x 50 mm (1.969 in) 2
Equipment
Applicable component
(usage or component Name Type and standards Quantity
number)
Disassembly and assembly of
General work platform 1 set
product
Washing of product and each
Washing tank Rough washing / Final washing 1 set
component
22, 24: Press capacity 9800 N
22, 24, 149 Press work platform (2203.13 lb) or more 149: Press 1 set
capacity 1960 N (440.63 lb) or more
Heating capacity 100 °C (212.0 °F) or
149 Heating tank 1 set
more Volume 500 x 500 x 500 or above
Drying after disassembly and
Compressed air Pressure 0.29 - 0.49 MPa (42 - 71 psi)
washing of each component
Sealing compounds
1 LOCTITE® 515™ 1
2 LOCTITE® 242® 1
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Manufacture tools
Name: Work platform for travel motor
• This is a work platform for easy and safe disassembly
and reassembly of travel motor.
SMIL14CEX3285AA 8
Name: Oil seal press-fit jig

• This is for pressing the oil seal (132) into the oil seal
fitting hole in the spindle (101)
SMIL14CEX3286AA 9
Name: Lock washer insertion jig .

• This is a jig for inserting the lock washer (22) into the
groove in the spindle (101)
SMIL14CEX3287AA 10
Name: Main bearing press-fit jig

• This is for pressing the angular ball bearing (24) into the
housing (15)
SMIL14CEX3288AA 11
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Name: Steel rod (I)

• This is for removing the cover (14) from the ring gear
(1).
SMIL14CEX3289AA 12
Name: Long eyebolt

• This is for lifting the travel motor, the carriers (2) and
(7), the spindle (101), the housing (15), and the ring
gear (1).
Application “A”
Housing M20
Spindle M24
Carrier (2) M10
SMIL14CEX3290AA 13
Name: Brake piston removal jig

• This is for removing the brake piston (112) from the ring
gear (1).
SMIL14CEX3291AA 14
Name: Guide pin (M18)

• This is used for easy positioning of the bolt holes in rear
flange (301) during disassembly and assembly of rear
flange (301).
SMIL14CEX3292AA 15
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Name: Spatula
• This is used for removing the valve plate (109) from the
rear flange (301).
SMIL14CEX3293AA 16
Name: Floating seal fitting jig (I)

• This is for fitting the floating seal (31) into the housing
(15).
SMIL14CEX3294AA 17
Name: Floating seal fitting jig (II)

• This is for fitting the floating seal (31) into the housing
(15) and the spindle (101) .
SMIL14CEX3295AA 18
Name: Floating seal fitting jig (III)

• This is for fitting the floating seal (31) into the spindle
(101).
SMIL14CEX3296AA 19
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Name: Holder fitting (II)

• This is for pulling out the conical roller bearing (149)
from the shaft (102).
SMIL14CEX3297AA 20
Name: Holder fitting (III)

• This is for pressing the conical roller bearing (149) into
the shaft (102).
SMIL14CEX3298AA 21
Name: Conical roller bearing outer ring fitting jig

• This is for fitting the outer ring of conical roller bearing
(149) into the spindle (101).
SMIL14CEX3299AA 22
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Travel motor - Torque

Applicable Bolt/Nut
component
Hexagon bolt width Quantity Tightening torque
(Structural Name Nominal
diagram)
9.85 - 14.75 N·m
30 Hexagon socket head plug PF 1/8 5 mm (0.197 in) 4
(7.26 - 10.88 lb ft)
132.3 - 161.7 N·m
33 Hexagon socket head plug PF 3/4 12 mm (0.472 in) 2 (97.58 - 119.26 lb
ft)
19 mm (0.748 in) 86.3 - 117.7 N·m
34 Hexagon bolt M12 (P1.75) 18
(Socket) (63.65 - 86.81 lb ft)
416.2 - 339.8 N·m
14 mm (0.551 in)
35 Hexagon socket head bolt M18 (P2.5) 25 (306.97 - 250.62 lb
(Socket)
ft)
304 - 324 N·m
46 mm (1.811 in)
324 Plug M38 (P1.5) 2 (224.22 - 238.97 lb
(Socket)
ft)
294 - 196 N·m
326 Plug PF 1 17 mm (0.669 in) 2 (216.84 - 144.56 lb
ft)
401.9 - 294.1 N·m
343 Hexagon socket head bolt M18 (P2.5) 14 mm (0.551 in) 10 (296.43 - 216.92 lb
ft)
9.85 - 14.75 N·m
352 Plug PF 1/8 5 mm (0.197 in) 1
(7.26 - 10.88 lb ft)
131 11.77 - 7.85 N·m
Hexagon socket head plug NPTF1/16 4 mm (0.157 in) 11
354 (8.68 - 5.79 lb ft)
11.77 - 7.85 N·m
379 Flanged plug M6 (P1.0) 4 mm (0.157 in) 1
(8.68 - 5.79 lb ft)
117.7 - 78.5 N·m
382 Plug PF 1/2 10 mm (0.394 in) 2
(86.81 - 57.90 lb ft)
34.3 - 24.5 N·m
391 Plug PF 1/4 6 mm (0.236 in) 2
(25.30 - 18.07 lb ft)
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Hydraulic travel system - Dynamic description

Travel reduction gear
1. Function
This reduction gear consists of the 2-stage planetary gear mechanism, which slows down the high-speed rotational
motion from hydraulic motor and converts it into low-speed high torque to obtain ring gear (1) rotation.
2. Operation explanation
Rotational motion of the hydraulic motor shaft is transmitted to the 1st-stage sun gears (1) and (4) that are splined to
the shaft (102).
At this time, since the 1st-stage planetary gears (1) and (5) have engaged with the sun gears (1) and (4), the planetary
gears (1) and (5) engage with the ring gear (1) while they are rotating to make orbital motion. This orbital motion
rotates the carriers (1) and (3) fixing the planetary gears (1) and (5), and the 2nd-stage sun gears (2) and (8) coupled
with the carriers (1) and (3). This rotation is transmitted to the ring gear (1) via the 2nd-stage planetary gears (2) and
(9) included in the carriers (2) and (7) splined to the spindle (101), thereby making output rotation of the reduction
gear. Rotation is transmitted also from the 1st-stage planetary gears (1) and (5).
SMIL14CEX3939FB 1
1. Ring gear 9. Planetary gear (2)

3. Carrier (1) 101. Spindle
4. Sun gear (1) 102. Shaft
5. Planetary gear (1) a. Input
7. Carrier (2) b. Output
8. Sun gear (2)
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Travel motor
1. Function
Function of hydraulic motor
This hydraulic motor is called the swash plate-type axial piston motor, which converts force of the pressure oil from
pump into rotational motion.
Function of brake valve
A. It controls the inertial force that makes the travel motor rotate by the inertia of the main unit when the travel motor
stops, and applies the brake smoothly to make a stop.
B. It has a check valve function for preventing cavitation when the hydraulic motor stops.
C. It opens the port that releases parking brake force when the travel motor is working, and closes the port when the
motor stops.
Function of parking brake
The parking brake prevents a runaway or a slip when the power shovel is parked or stopped on a slope by using the
friction plate-type brake mechanism, and is integral with the hydraulic motor section.
Function of 2-speed switchover mechanism
Function of the switchover valve and the control piston changes the tilting angle of swash plate (103) to change the
piston stroke volume of hydraulic motor, thereby allowing 2-step switchover between high-speed low torque rotation
and low-speed high torque rotation.
2. Operation principle and operation explanation

Hydraulic motor
The pressure oil from hydraulic motor enters the rear flange (301) of travel motor, passes through the brake valve
mechanism, and is led from the valve plate (109) into the cylinder block (104). This pressure oil will be led only to
one side of (Y1) - (Y2) connecting the top and the bottom dead center of piston (105) stroke. The pressure oil that
has entered one side in the cylinder block (104) pushes each piston (105) (4 or 5 pieces) to generate force (F (N) =
P (MPa) x A (mm2)). This force acts on the swash plate (103); however, since the swash plate (103) is fixed at an
angle (α°) with the axis of motor shaft (102), it is divided into components ( (F2) and (F3)).
Among these components, the radial component (F3) generates each torque (T = F3 x ri) for (Y1)- (Y2). This torque
resultant {T = Σ (F3 x ri)} works as turning force to rotate the cylinder block (104) via the piston (105). Since this
cylinder block (104) is splined to the motor shaft (102), the motor shaft (102) rotates to transmit torque.
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SMIL14CEX3940HB 2
102. Motor shaft 105. Piston

103. Swash plate 109. Valve plate
104. Cylinder block
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Brake valve
a. During steady operation

When pressure oil is supplied from the port (A) , the pressure oil will open the valve (327a) and enter the suction-side
port (C) of hydraulic motor to attempt to rotate the hydraulic motor. At the same time, the pressure oil enters the (a)
chamber from the orifice of spool (323) and acts on the end face of spool (323) to generate force, and the spool (323)
in a neutral state is slid to the right side by force of the spring 328a. At this time, the oil pushed out of the (b) chamber
is discharged through the orifices of spring retainer (325b) and spool (323) to the B port. Passing through the orifice
triggers a damper effect to slow down the spool (323) motion and absorb a shock at startup.
When the spool (323) slides, the spool groove will form a clearance (path) between that and the rear flange (301).
Since this path makes the D port of return-side path of hydraulic motor and another port (B) lead to each other, and
makes return oil return to the tank side, the hydraulic motor can rotate. Furthermore, the spool (323) slides to make
the pressure oil enter the E port. The pressure oil that has entered the E port operates the brake piston (112) of
parking brake to release parking brake force. (For details, refer to the explanation of "Parking brake" operation.) If
pressure oil is supplied from the B port, the spool (323), the valve (327a), the spring (328a), and the spring retainer
(325b) rotate backward because their motion is reversed.
SMIL14CEX3941GB 3
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112. Brake piston 325b. Spring retainer

323. Spool 328a. Spring
327a. Valve
b. Stop operation (Brake operation)

When the pressure oil supplied from the A port is stopped during traveling, the hydraulic pressure pushing the spool
(323) will be lost, and the spool (323) slid to the right side will attempt to return to a neutral state via the spring retainer
(325b) by force of the spring (328b). At this time, the oil in (a) chamber attempts to go through the spool (323) out to
the A port side; however, back pressure occurs by the orifice effect of spool (323) and spring retainer (325b) to control
the return speed of spool (323) . Since, at the same time, the hydraulic motor attempts to rotate by inertial force even
if the pressure oil is stopped, the return oil of hydraulic motor attempts to return from the D port through the clearance
(path) between spool groove and rear flange to the B port side.
When the spool (323) has returned to a neutral state completely, the hydraulic motor return-side path will be com-
pletely interrupted by the spool (323), and the hydraulic motor will stop. During work, this brake valve throttles the
hydraulic motor return-side path by the sliding speed control of spool (323) and the groove shape of spool (323) to
generate back pressure, thereby smoothly stopping the hydraulic motor that attempts to rotate by inertial force. On
the other hand, when the brake is applied to attempt to stop the hydraulic motor, inertial force will work and it will
keep rotating to attempt to pump oil in even if supply of the pressure oil is stopped. However, the inlet-side path is
interrupted by the spool (323); therefore, no more oil can be supplied and cavitation attempts to occur. At this time,
the valve (327a) operates by very slight negative pressure, and opens the oil path between A port-side circuit and
motor inlet section C port to prevent cavitation of the hydraulic motor. Note that, if pressure oil is supplied from the
port B, each motion of the above parts is reversed to stop the hydraulic motor.
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SMIL14CEX3942GB 4
112. Brake piston 328a. Spring

323. Spool 325b. Spring retainer
327a. Valve 328b. Spring
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c. Self-traveling prevention function

When the hydraulic motor enters the state where it is rotated by external force during steady operation, a self-traveling
(runaway) phenomenon will occur. For example, when it is used as the travel motor of power shovel, going down
a steep slope produces the phenomenon. We explain the mechanism that prevents this phenomenon. When the
hydraulic motor enters the state where it is rotated by external force during steady operation, the pressure of supplied
hydraulic fluid ( A port or B port) will decrease. When pressure approaches the one that starts self-traveling, the spool
(323) will start moving to a neutral position in the center. As the spool (323) moves, the path area of hydraulic fluid
from D port on hydraulic motor exit side to B port becomes small, and the flow of hydraulic fluid discharged from the
D port to the B port is also restricted. At the same time, the pressure (back pressure) of D port also increases. In this
way, the self traveling phenomenon is prevented by controlling the flow and pressure of hydraulic motor exit port.
SMIL14CEX3943GB 5
323. Spool
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Parking brake
a. During traveling.
When pressure oil is supplied from the brake valve, the spool (323) of brake valve in hydraulic motor section will
operate, the path to parking brake will open, and it will be led to the cylinder chamber (a) that consists of the spindle
(101) and the brake piston (112). When the pressure oil reaches 2 MPa (232 psi) or more, it will overcome force of
the brake spring (113) to move the brake piston (112) toward the rear flange (301). By movement of this brake piston
(112), the pushing force from brake piston (112) to partner plate (116) and friction plate (115) is lost, motion of the
friction plate (115) inserted in the cylinder block (104) in hydraulic motor section becomes free, and the brake force
to cylinder block (104) is released.
b. At stop.
When the pressure oil is interrupted from the brake valve, and the pressure in cylinder chamber (a) reaches 2 MPa
(232 psi) or less, the brake piston (112) will attempt to return by force of the brake spring (113).
By force of this brake spring (113), the brake piston (112) is pushed, and the partner plate (116) and friction plate
(115) that are in a free state are pushed against the spindle (101). The frictional force generated by this pushing stops
turning force of the cylinder block (104), and gives braking torque 1170 N·m (862.95 lb ft) to the hydraulic motor shaft.
Note that it operates smoothly because oil is controlled by the appropriate hydraulic path.
SMIL14CEX3944FB 6
101. Spindle 115. Friction plate

104. Cylinder block 116. Partner plate
112. Brake piston 301. Rear flange
113. Brake spring 323. Spool
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Explanation of relief mechanism operation
a. At startup
The pressure oil supplied from the pump is led from the A port to the C port. Since the C port is connected with the
hydraulic motor, and that pressure oil gives turning force to the hydraulic motor.
At this time, in the relief valve "A", the pressure oil passed through the orifice of socket (201a) and the path of pilot
body (206a) acts on the piston (207a) to slide the piston (207a). In the relief valve "B", when the C port pressure
increases, this pressure will be applied to the effective diameter section seated on the valve seat (203b) of valve
(202b), also to the link piston (204b) inside valve through a small pore in the valve (202b), and increase up to the C
port pressure. The valve (202b) will oppose the adjusting spring (209b) by the area difference between valve seat
effective diameter section and link piston (204b) pore diameter section to attain the specified set pressure.
SMIL14CEX3945GB 7
1. Relief valve A 207b. Piston

2. Relief valve B 202b. Valve
201a. Socket 203b. Valve seat
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206a. Pilot body 204b. Link piston

207a. Piston 209b. Adjusting spring
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Pressure state of C port for the case of the above operation
SMIL14CEX3946EB 8
1. Pressure 3. Time
2. R/V "B" release
However, if the piston 207b has reached the stroke end according to the last stop condition, the valve 202b of relief
valve "B" does not open.
Therefore, the pressure that acts on the C port is as follows.
SMIL14CEX3947EB 9
1. Pressure 2. Time
As explained above, the pressure when the C port starts up varies with the position of piston (207b).
• If the pressure oil supplied from the pump is led from the B port to the D port, the relief valve "A" and the relief valve"
B" are interchanged with each other in the above operation principle and explanation.
b. At stop
For the hydraulic motor rotating by the pressure oil supplied from the A port to the C port, when no more pressure
oil is supplied to the A port, the counter balance valve will return to a neutral state. When the counter balance valve
returns to a neutral state, the D port on exit side will be interrupted and the hydraulic motor will rotate only by inertia,
thereby applying pressure to the inside of D port.
When, in the relief valve "A", the D port pressure increases, it will be applied to the piston (207a) through a small
pore in the valve and a small pore in the link piston (204a), and the piston (207a) will slide all the way to the lid
(205a). During this time, the valve (202a) is forced open by the pressure oil of D port, and it is discharged to the
low-pressure-side C port.
When the piston (207a) reaches the stroke end, the pressure of (f) chamber of relief valve "A" will increase, and the
valve (202a) will close. In this case, when the system pressure of excavator is exceeded, the relief valve "A" will be
relieved to stop the hydraulic motor. Motion of the relief valve "B" is the same as that of the relief valve "A" at startup.
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SMIL14CEX3948GB 10
1. Relief valve A 204a. Link piston

2. Relief valve B 205a. Lid
201a. Socket 207a. Piston
202a. Valve
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Pressure state diagram of hydraulic motor ( D port) with the above pressure oil supply stopped
SMIL14CEX3949EB 11
1. Pressure 3. Relief valve A released

2. Piston 207a moving 4. Time
The pressure during movement of the piston (207a) is commonly called the "relief primary pressure (low pressure)."
The pressure after movement of the piston (207a) is commonly called the "relief secondary pressure (high pressure)."
c. Explanation of automatic 2-speed switchover mechanism
a) At low speed
If the pilot pressure is not supplied from the P port, the spool (363) is pushed to the left end by force of the spring
(366) and by the pressure oil from A port or B port.
The pressure oil of C is interrupted, and the oil of W chamber is released to the drain (motor case) via the spool (363).
Therefore, since the swash plate (103) reaches the maximum tilting angle θ1, the stroke volume of hydraulic motor is
maximized to attain low-speed rotation.
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SMIL14CEX3950FB 12
1. Pilot pressure 170. Piston

2. Drain 363. Spool
103. Swash plate 366. Spring
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b) At high speed
If the pilot pressure is supplied from the P port, it overcomes force of the spring (366) and that of the pressure oil from
A port or B port. Consequently, the spool (363) is pushed to the right end, and the pressure oil of C port is led to the
W chamber via the spool (363).The piston (170) pushes up the swash plate (103) all the way to the (X) surface and
holds it.
At this time, since the swash plate (103) reaches the minimum tilting angle θ2, the stroke volume of hydraulic motor
is minimized to attain high-speed rotation.
SMIL14CEX3951FB 13

2. X surface 363. Spool
c) Operation explanation of automatic switchover to low speed during high-speed operation If load increases during
high-speed operation, the pressure oil of A port or B port also increases. When reaching the specified pressure, it will
overcome the pilot pressure of P port, and the spool (363) will be pushed back to the left end.
The oil of W chamber is released to the drain (motor case) via the spool (363). At this time, the swash plate (103)
moves all the way to the spindle (Y) surface to reach the maximum tilting angle θ1, and is held to attain low-speed
rotation.
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SMIL14CEX3952FB 14

3. Y surface 363. Spool
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Travel motor - Overview
SMIL14CEX3584FA 1

D1, D2 Drain port G1/2
P Pilot port G1/4
P1, P2, P3, P4 Pressure detection port G1/4
A, B Main port G1
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Travel motor - Component localization
SMIL14CEX3934GB 1
NOTE: All the dimensions in figure are in mm
D1. Drain port (PF 1/2)

D2. Drain port (PF 1/2)
A. Main port (PF 1)
B. Main port (PF 1)
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SMIL14CEX3935GB 2
P. Pilot port (PF 1/4)

P2. Pressure detection port (2-PF 1/4)
P3. Pressure detection port (2-PF 1/4)
1. C/V spool removal allowance
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SMIL14CEX3936FA 3
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Travel motor - Sectional view
SMIL14CEX3937HB 1
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SMIL14CEX3938HB 2
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Carrier (2) assembly 135 D-ring (Quantity 1)
7 Carrier (2) (Quantity 1) 139 D-ring (Quantity 1)
9 Planetary gear (2) (Quantity 4) 143 O-ring (Quantity 2)
10 Carrier pin (Quantity 4) 149 Conical roller bearing (Quantity 1)
12 Thrust washer (2) (Quantity 8) 150 Conical roller bearing (Quantity 1)
17 Parallel pin (Quantity 4) 170 Piston (Quantity 1)
28 Needle pin roller bearing with retainer (Quantity 4) 176 Pivot (Quantity 2)
30 Hexagon socket head plug (Quantity 4) 190 Spring (Quantity 1)
Floating seal kit (Quantity 1) ORV-240L6S1 assembly (Quantity 2)

31 Floating seal (Quantity 2) 201 Socket (Quantity 1)
202 Valve (Quantity 1)
1 Ring gear (Quantity 1) 203 Valve seat 1 (Quantity 1)
3 Carrier (1) (Quantity 1) 204 Link piston (Quantity 1)
4 Sun gear (1) (Quantity 1) 205 Lid (Quantity 1)
5 Planetary gear (1) (Quantity 3) 206 Pilot body (Quantity 1)
8 Sun gear (2) (Quantity 1) 207 Piston (Quantity 1)
11 Thrust washer (1) (Quantity 3) 208 Shim (Quantity 1)
13 Thrust plate (Quantity 1) 209 Adjusting spring (Quantity 1)
14 Cover (Quantity 1) 210 O-ring (Quantity 1)
15 Housing (Quantity 1) 211 Backup ring (Quantity 2)
22 Lock washer (Quantity 2) 212 O-ring (Quantity 2)
23 Shim (rank) (Quantity 1) 213 Backup ring (Quantity 1)
24 Angular ball bearing (Quantity 2)
27 Needle pin roller bearing with retainer (Quantity 3) Rear flange assembly
29 Inner ring (Quantity 3) 301 Rear flange (Quantity 1)
33 Hexagon socket head plug_ PF 3/4 (Quantity 2) 323 Spool (Quantity 1)
34 Hexagon bolt (Quantity 18) 324 Plug (Quantity 2)
35 Hexagon socket head bolt (Quantity 25) 325 Spring retainer (Quantity 2)
36 Steel ball (Quantity 1) 326 Plug (Quantity 2)
37 O-ring (Quantity 2) 327 Valve (Quantity 2)
38 Washer (Quantity 1) 328 Spring (Quantity 2)
330 Spring (Quantity 2)
Piston kit (Quantity 1) 336 O-ring (Quantity 2)
Piston assembly (Quantity 9) 338 O-ring (Quantity 2)
105 Piston (Quantity 1) 339 O-ring (Quantity 2)
106 Shoe (Quantity 1) 340 O-ring (Quantity 1)
101 Spindle (Quantity 1) 342 O-ring
102 Shaft (Quantity 1) 352 Plug (Quantity 1)
103 Swash plate (Quantity 1) 354 Hexagon socket head plug (Quantity 10)
104 Cylinder block (Quantity 1) 363 Spool (Quantity 1)
107 Retainer plate (Quantity 1) 366 Spring (Quantity 1)
108 Thrust ball (Quantity 1) 376 M6 orifice (Quantity 1)
109 Valve plate (Quantity 1) 377 M6 orifice (Quantity 1)
112 Brake piston (Quantity 1) 378 Steel ball (Quantity 1)
113 Brake spring (Quantity 14) 379 Flanged plug (Quantity 1)
114 Cylinder spring (Quantity 9) 382 Plug (Quantity 2)
115 Friction plate (Quantity 6) 391 Plug (Quantity 2)
116 Partner plate (Quantity 7) 392 O-ring (Quantity 2)
119 Shim (Quantity 1-2) 341 Parallel pin (Quantity 1)
131 Hexagon socket head plug (Quantity 1) 343 Hexagon socket head bolt (Quantity 10)
132 Oil seal (Quantity 1) 398 Rivet (Quantity 3)
133 Round R-shaped retaining ring (Quantity 1) 399 Name plate (Quantity 1)
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Hydraulic travel system - Service instruction

Installation instructions
Before installation, unplug the oil check port, and check
that lubricant for reduction gear (gear oil) is filled up to
the oil check port.
CAUTION:
○ During use, observe the use conditions de-

scribed in the specifications and operational
agreement of the construction machinery that
uses the travel motor. Failure to observe the
use conditions may cause severe personal
injury and critical property damage.
○ The travel motor weighs about 410 kg
(903.895 lb). When transporting it, be sure to
use a transporter, such as a forklift and a lifting
equipment.
○ Make sure that only the qualified operator oper-
ates a forklift, a lifting equipment, etc.
○ During transport, be sure to wear a helmet and
safety shoes.
○ Use such lifting equipment as can bear the
weight of travel motor enough. Moreover, do
not lift the travel motor with the lifting eye bolt
loosened. Otherwise, the travel motor may
drop to cause injury.
○ When lifting the travel motor, it should be raised
perpendicularly in a balanced manner. If being
out of balance, it may drop to cause injury.
○ When lifting the travel motor for transport or in-
stallation, never go under the travel motor. Do-
ing so may cause injury.
SMIL14CEX3953EB 1
1. Main unit mount

2. Sprocket mount
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• During installation, use bolt holes without hammer-

ing the travel motor.
NOTE: You are recommended to use such mounting
bolts as are equivalent to JIS strength category 10.9
or more.
• Mounting bolt tightening torque
Thread size Recommended tightening torque

Main unit mounting bolt (Quantity 18) M24 (P3.0) 601 - 817 N·m (443.27 - 602.59 lb ft)
414.60 - 571.40 N·m (305.79 -
Sprocket mounting bolt (Quantity. 26) M20 (P2.5)
421.44 lb ft)
NOTE: Failure to observe the recommended tightening torque may cause the travel motor to drop.
Line
• When it is delivered, line ports (main port and motor
drain port) are plugged.
This is for preventing the entry of dust, weld scale,
etc.
Do not remove the plugs until finally installing lines.
CAUTION: Before installing lines, check the

direction of rotation of travel motor and the posi-
tions of line ports. (Refer to the outside dimension
diagram.) Otherwise, the direction of rotation may
become opposite to the desired one to cause in-
jury.
NOTE: Before operating the motor, be sure to fill up the

motor casing with hydraulic fluid. Required oil amount in
casing: About 1.5 L (0.40 US gal) Otherwise, the hydraulic
motor may suffer early damage.
If the drain port and the 2-speed switchover port are con-
nected erroneously, the inside of hydraulic motor becomes
damaged.
• When selecting the line size, make sure that the back
pressure of motor drain port is 0.20 MPa (29.01 psi)
or less {at peak, 0.69 MPa (100.08 psi) or less}.
Hydraulic fluid
Hydraulic fluid in the hydraulic motor casing is removed
prior to shipment. Before operation, be sure to fill up
the casing with hydraulic fluid.
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Daily inspection
Every day, before operating the travel motor, check the
following maintenance and inspection items.
CAUTION:
○ Make sure that, except checking for abnormal

noise among the following five items, mainte-
nance and inspection are performed with the
travel motor stopped. Performing them during
operation may cause injury and burns.
○ Moreover, checking for abnormal noise should
be performed in the safety area. Touching or
approaching parts during operation may cause
injury and burns.
1. Check that no oil is leaking. (Hydraulic fluid and gear
oil)
2. Check that no bolts are loosened.
3. Check that there is no abnormal noise.
4. Check that the temperature of case body has not in-
creased abnormally.
5. Check that gear oil is replaced properly. (Refer to the
following description about lubricant.)
CAUTION:
○ Just after operation, the case is hot.

○ In order to prevent burns, measure the temper-
ature with a thermometer without touching it im-
mediately.
Replacement of hydraulic fluid

• If the hydraulic fluid is deteriorated significantly, re-
place it on the basis of the following standards even
if its standard replacement time has not elapsed.
Test item Replacement standard

Viscosity change ( 40 °C) [%] ±10[%]
Total acid value [mgKOH/g] *
Moisture [%] 0.1[%]
Impurity [mg/100mL] 10 [mg/100 mL]
Insoluble content [%] 0.05[%]
Color - Changed significantly
Lubricant
Although the lubricant for reduction gear (gear oil) is
supplied prior to shipment, be sure to check that it is
supplied before operation.
Replacement of gear oil

1. Replacement standard based on property analysis (ref-
erence)
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Replacement limit Application

Progress of
Within 10 % against oxidization
Viscosity change (at 40 °C) [mm2/s]
new oil degradation Entry
of dissimilar oil
Oxides, carbon,
Moisture [%] 0.2 or less additives, abrasion
powder, dust, etc.
Pentane insoluble [%] 1.0 or less
Increased by 0.5
Total acid value [mgKOH/g]
against new oil
Al [ppm] 150 or less
Cr [ppm] 20 or less
Metal analysis Cu [ppm] 20 or less
Fe [ppm] 600 or less
Si [ppm] 350 or less
Avoid the entry of dissimilar lubricant. When chang-

ing the oil type of lubricant, perform flushing inside
the reduction gear.
Gear oil replacement amount

• 9.5 L (2.51 US gal)
Precautions for handling gear oil

• Before handling gear oil, be sure to read the precau-
tions indicated on the container of gear oil for correct
use. Misuse of it may lead to a severe accident.
• Wear protective eyewear to keep gear oil out of eyes.
Contact with eyes can cause inflammation.
• Wear rubber gloves to keep gear oil out of skin. Con-
tact with skin can cause inflammation.
• Do not eat or put it into mouth. Intake of it will cause
diarrhea and vomiting.
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Gear oil replacement procedure

CAUTION:
○ Just after operation, the case may be hot.

○ Touching it may result in burns.
○ Furthermore, if you remove the plug while it is
hot, hot gear oil may spurt out when the pres-
sure inside the reduction gear escapes, result-
ing in burns.
○ Wait until the case temperature has fully fallen
before replacement.
NOTE: If, for any reason, the gear oil has decreased, check
the cause of this. Before supplying gear oil, take the mea-
sures against that.
When removing the gear oil, be sure to drain it into the
container without draining it onto the ground. Furthermore,
follow the applicable laws and regulations for the disposal
of drain oil.
When you remove the plug, the oil may spurt out. Turn
the plug slowly to release the internal pressure, and then
remove it carefully.
SMIL14CEX3954EB 2
1. Oil check port ( PF 3/4)

2. Oil drain port ( PF 3/4)
3. Figure A
4. Figure B
Use gear oil for replacement and supply of the same
brand, and do not mix that of the different brand.
1. Stop the travel motor rotation with the oil drain port
located at the bottom. (Refer to the above figure A.)
2. Place a waste oil receiver under the travel motor.
3. In the case of replacement, remove the two port plugs
to drain the gear oil.
After draining the oil, tighten the plug in the oil drain
port.
119.26 lb ft)
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4. Supply the gear oil via the oil check port.

Stop replenishing just before the gear oil overflows from
the oil check port.
NOTE: If the gear oil is supplied as shown in Figure B, the
overflow from oil check port is different in amount. There-
fore, make sure that the oil check port is positioned as
shown in Figure A to check the oil level.
5. Tighten the plug in the oil check port.
119.26 lb ft)
6. In the case of refilling, remove the plug from the oil
check port.
After that, supply the gear oil following the above 4 to 5
steps.
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Travel motor - Prepare

WARNING
Escaping fluid!
doctor immediately.
W0178A
WARNING
Pressurized fluid can penetrate the skin and cause severe injuries.
The grease in the cylinder is under high pressure. Never loosen the grease fitting adaptor completely
in order to speed up the flow of grease.
W0261A
WARNING
Crushing hazard!
latches.
W0256A
WARNING
Heavy objects!
W0398A
Items to prepare:
• Box wrenches [ 19 mm, 36 mm]
• Hammer (to remove the master pin)
• Striking jig (to remove the master pin)
• Rag
• Cleaning fluid
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Travel motor - Remove

1. Raise the shoes (2) to apart from ground by supporting
the system with the bucket (1) as shown in the right
figure.
SMIL14CEX3265AB 1
2. Rotate the shoes slowly to bring the joint section (3) of

the shoes to the position shown in the right figure.
3. Place a wood plank (4) or other block underneath the
shoes and then return the bucket.
4. Bleed air from the hydraulic line. Refer to the “ Hy-
draulic systems - Bleed (35.000)” for detail.
SMIL14CEX3266BB 2
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5. Loosen tension of the shoes by turning the check valve

(5) of the grease cylinder by a box wrench [ 19 mm].
• Prepare a rag to catch grease running out.
Do not position yourself right in front of the check
valve at this time since the valve may pop out if you
loosen it too much.
SMIL14CEX3267BB 3
6. Pull out the S-pin (6) at the back of the joint section.
SMIL14CEX3268AB 4
7. Place a fixture (9) to the master pin (7) and then knock it
with a hammer (8) to remove the master pin to outside.
SMIL14CEX3269AB 5
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8. Open the shoes (2) to rearward.
SMIL14CEX3270AB 6

remove the cover (11).
SMIL14CEX3271AB 7
10. Remove the drain hose (13) and the two high pressure
hoses (12) with a wrench [ 27 mm for the drain hose,
41 mm (1.6142 in) for the high pressure hose].
• Make sure to plug the removed drain hose and high
pressure hoses.
SMIL14CEX3272AB 8
11. Remove the pilot hose (14) and the elbow (15) shown
in the figure with a wrench [ 19 mm].
SMIL14CEX3273AB 9
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12. Attach a wire rope (17) to the travel motor (16) as

shown in the figure.
Adjust the wire rope so as to place it in the center of
gravity and then lift it up to give it some tension by a
lifting equipment.
SMIL14CEX3274AB 10
13. Remove all 18 bolts (18) with a box wrench [ 36 mm].
SMIL14CEX3275AB 11
14. Remove the travel motor (16).
SMIL14CEX3276AB 12
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Travel motor - Disassemble

Safety precautions
1. Follow this chapter when disassembling or inspecting
the travel motor.
2. When disassembling or assembling the travel motor,
use the special tools shown in Travel motor - Special
tools (35.353).
3. For consumable and replacement parts, be sure to use
genuine parts.
4. Categories and meanings of warning terms.
According to the degree of risk (or accident), this chap-
ter classifies warning terms into four levels in the fol-
lowing table.
Understand the meanings of these warning terms, and
follow their instructions.
Warning term Meaning

This is used for such an imminent hazardous condition as failure to avoid it results in
DANGER death or serious injury.
This is used for such a potential hazardous condition as failure to avoid it results in
WARNING death or serious injury.
This is used for such a potential hazardous condition as failure to avoid it may result in
CAUTION moderate or minor injury.
This is used for such information as requires particular attention or emphasis, or such
NOTE a condition as failure to observe procedures or instructions may damage equipment
and devices.
Prepare
1. Preparation of work platform
• Prepare the work platform for travel motor.
• Make sure that the work platform to be prepared is
such robust as you can disassemble and assemble
the internal components of travel motor, it is wide
enough to accommodate components, and it keeps
components from dropping or moving during work.
• Place a rubber mat or a vinyl mat on the work plat-
form.
2. Preparation of tools and materials
• Prepare the tools and materials shown in the Travel
motor - Special tools (35.353).
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General work precautions

CAUTION: In order not to get burned, wait un-
til the temperature of motor falls to normal before
disassembly.
CAUTION:
○ During disassembly, gear oil and hydraulic oil

adhere to the internal components and they be-
come slippery.
○ Be careful enough in handling the components
because you may get injured or they may get
damaged if they are slipped down.
CAUTION: Such a flammable as refined

kerosene is used for washing components. Be
careful enough in handling the flammable be-
cause its high flash point may cause fire or burns.
1. Before disassembly, correctly understand the inspec-
tion items and the current abnormalities, and then fol-
low the disassembly procedure.
2. Since each component is made very precisely, be care-
ful enough not to bump or drop the components while
handling them.
3. Even if components are stuck, do not hit or pry them
by force. Otherwise, burrs will come out or they will
get damaged, causing assembly failure or poor perfor-
mance. Therefore, take care enough and persevere
with work.
4. If disassembled or half-disassembled components are
left unattended, they may be rusted by humidity or dirt.
Therefore, if work is interrupted unavoidably, protect
them against rust and dust.
5. Before disassembly, place alignment marks on the mat-
ing surfaces of each part.
6. Always sort out each of the removed components so
that they may not get damaged or lost during disas-
sembly.
7. In principle, seals should be replaced after disassem-
bly, even if no damage is found. Prepare the replace-
ments before disassembly.
8. The figures use a representative model for description.
Even if it is partially different from the product in use,
the disassembly procedure remains the same.
Disassembly procedure
1. Washing of travel motor

1. Tighten eyebolts to the M24 screw holes for mounting
the spindle (101), lift the travel motor with a lifting equip-
ment, and carry it to the washing tank.
NOTE: Make sure that the 2 eyebolts are symmetrically
tightened to the spindle mounting M24 screw holes.
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2. Wash each part of the travel motor with a carwash

brush.
NOTE: Wash the clearance (where the floating seal is fit)
between housing (15) and spindle (101) with extra care
because earth and sand have entered there.
2. Installation of travel motor to the work platform

1. Remove the 3 hexagon bolts (34) almost evenly that
are screwed in the cover (14), and attach the eyebolts
(M12) to lift it.
CAUTION: The travel motor should be lifted

horizontally.
2. Attach the travel motor to the work platform by tighten-
ing the 2 hexagon socket head bolts symmetrically.
NOTE: While aligning the screw holes in spindle (101) with
the screw holes in work platform, put the travel motor into
the mounting holes in work platform gently.
WARNING:
○ Prevent hands from getting caught between

work platform and travel motor, or do not drop
any lifted components onto feet.
○ The hexagon socket head bolts should be tight-
ened up.
○ If they are not tightened up, it may drop to cause
injury when the travel motor is turned.
3. Removal of lubricant
1. Put the travel motor into a sideways position (the oil
drain port shall be located in the lower part).
2. Loosen the plug (33) of oil supply port (oil check port) to
bleed the reduction gear of pressure, and lightly close
the plug (33) again.
NOTE: If the inside of reduction gear is pressurized, loos-
ening the plug of oil drain port may cause lubricant to spurt
out.
3. Place an oil pan under the oil drain port, and slowly
loosen and remove the plug (33) of oil drain port to drain
lubricant.
NOTE: Select such a container as sufficiently holds the
amount of lubricant in reduction gear, 9.5 L (2.51 US gal)
4. If lubricant does not drain well, slowly loosen and re-
move the plug of another port.
5. Remove the O-rings (37) from the removed plugs (33)
(both the plugs of oil supply port [oil check port] and oil
drain port).
NOTE: Do not reuse the removed O-rings (37). Failure to
observe this may cause oil leakage.
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4. Removal of cover
1. Turn the travel motor (to locate the reduction gear side
in the upper part).
2. Loosen and remove the remaining hexagon bolts (34)
(15 pieces).
3. Since a sealing compound is applied on the mating sur-
face between cover (14) and ring gear (1), put a dolly
block on the projection of cover (14), and hit it obliquely
upward to remove the cover (14).
CAUTION: When it is hit obliquely upward, the

cover (14) may leap up and drop. Be careful not
to drop the cover (14) onto feet etc.
SMIL14CEX3300AA 1
4. Attach eyebolts to the PF3/4 ports, and lift and move

the cover (14) from the ring gear (1).
SMIL14CEX3301AA 2
5. Removal of thrust plate

1. Hold the thrust plate (13), and remove it.
SMIL14CEX3302AA 3
6. Removal of sun gear (1)

1. Hold the sun gears (1) and (4), and remove it.
NOTE: Be careful not to drop the sun gears (1) and (4)
because they are slippery with lubricant.
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2. Remove the steel ball (36) from the sun gears (1) and
(4).
Use a magnet if it is hard to remove the steel ball (36).
SMIL14CEX3303AA 4
7. Removal of 1st-stage gears

1. Remove the planetary gears (1) and (5) (3 pieces).
2. Remove the needle pin roller bearings with retainer (27)
(3 pieces).
3. Remove the inner rings (29) (3 pieces).
4. Remove the thrust washers (1) and (11) (3 pieces).
SMIL14CEX3304AA 5
8. Removal of carrier (1)

1. Attach 3 eyebolts (M10) to the carriers (1) and (3), and
lift them with a lifting equipment.
CAUTION: If you attempt to remove it holding

the pillars of carriers (1) and (3), the component
may slip with oil and drop. Be careful.
SMIL14CEX3305AA 6
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9. Removal of carrier (2)

1. Attach 2 eyebolts (M10) to the carriers (2) and (7), and
lift them with a lifting equipment.
NOTE: Make sure that the carriers (2) and (7) are lifted
slowly with the center axes of ring gear (1) and carriers (2)
and (7) aligned so that the internal teeth of ring gear (1)
may not get damaged.
2. Remove the sun gears (2) and (8).
SMIL14CEX3306AA 7
10. Disassembly of carrier (2) assembly

NOTE: If you store the carrier pin (10) for reuse, put a code so that the pre-disassembly combination of the holes in
carriers (2) and (7) and the carrier pin (10) may be recovered.
1. Remove the hexagon socket head plugs (30).
NOTE: Do not reuse the removed hexagon socket head
plugs (30). It cannot be reused because a sealing com-
pound has peeled off.
SMIL14CEX3307AA 8
2. By using a flathead screwdriver or the like, push the

parallel pin (17) out of the center hole in the carrier pin
(10).
SMIL14CEX3308AA 9
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3. Remove the carrier pin (10).
CAUTION: If the carriers (2) and (7) are in-

clined, the planetary gears (2) and (9) may slip
down with oil when you remove the carrier pin (10).
Make sure that work is performed on the horizon-
tal work platform.
SMIL14CEX3309AA 10
4. Remove the planetary gears (2) and (9), the needle pin
roller bearing with retainer (28), and the thrust washers
(2) and (12) (2 pieces each) from the carriers (2) and
(7).
CAUTION: Be careful enough to prevent

hands from getting caught between the planetary
gears (2) and (9) and the carriers (2) and (7).
SMIL14CEX3310AA 11
11. Removal of lock washer

1. Put a flathead screwdriver or the like on the clearance
between 2 lock washers (22), and lightly hit the lock
washers (22) with a plastic hammer obliquely down-
ward to remove them.
WARNING: If the inversion platform is inclined

after the lock washers (22) are removed, the ring
gear assembly (about 110 kg (242.508 lb) may
drop from the motor. Never incline the inversion
platform until the ring gear assembly is removed.
SMIL14CEX3311AA 12
12. Removal of ring gear assembly

1. Attach 3 eyebolts (M12) to the ring gear (1) evenly,
and lift the ring gear assembly (about 110 kg
(242.508 lb)with a lifting equipment.
WARNING: Make sure that the ring gear as-

sembly is lifted little by little slowly in parallel with
the axis of spindle (101). If it is lifted obliquely,
great power is applied. Therefore, lifting equip-
ment, eyebolts, etc. may cut off to hit and injure
you. If it is not removed easily, use a pressing ma-
chine to remove it safely without lifting it by force.
SMIL14CEX3312AA 13
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13. Removal of floating seal

1. Remove the floating seal (31) from the ring gear (1) and
the spindle (101). Hold the bore side of floating seal
(31) with hands, and apply force upward to remove it.
NOTE: Hands may be cut with the edge of floating seal
(31). You are recommended to wear gloves during re-
moval. Furthermore, if mud has entered and adhered, use
leverage to remove it with a flathead screwdriver or the like.
SMIL14CEX3313AA 14
14. Disassembly of ring gear assembly

1. Attach 3 eyebolts (M20) to the housing (15) at regular
intervals, and place it on a pedestal with the ring gear
(1) located in the lower part.
2. Remove the hexagon socket head bolts (35) other than
the 2 diagonal bolts.
3. A sealing compound is applied on the mating surface
between housing (15) and ring gear (1); therefore, by
loosening the remaining 2 hexagon socket head bolts
(35) and then hitting their heads, remove the ring gear
(1) from the housing (15).
SMIL14CEX3314AB 15
15. Removal of rear flange

1. Turn the travel motor (to locate the motor side in the
upper part).
2. Loosen the socket (201) to remove the overload relief
valve.
NOTE: Since the valve seat (203) comes off free when the
overload relief valve is removed, be careful to prevent it
from dropping into the rear flange (301).
SMIL14CEX3315AA 16
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3. Loosen the plugs (324) (2 pieces), the plugs (326) (2

pieces), and the plug (382) (1 piece).
NOTE: The purpose of this work is to remove the plugs
easily when the inside of rear flange (301) is disassembled.
At this time, make sure that the plugs are loosened so that
they may be removed by hand. If not disassembling the
inside of rear flange (301), do not loosen the plugs.
SMIL14CEX3316AA 17
4. Tilt the travel motor about 80 °

NOTE: When putting the travel motor into a sideways po-
sition, place an oil pan because oil spills.
5. Loosen the 2 hexagon socket head bolts (343) diago-
nally, and attach guide pins.
6. Loosen the remaining 8 hexagon socket head bolts
(343) to remove them from the rear flange (301).
NOTE: Make sure the hexagon socket head bolts (343) (8
pieces) are loosened evenly so that the rear flange (301)
may not be inclined, because the internal brake springs
(113) will make it float gradually from the mating surface.
SMIL14CEX3317AA 18
7. Remove the rear flange (301) from the spindle (101).
CAUTION: When the rear flange (301) is re-

moved, the cylinder block (104) may drop along
with that. Before removing the rear flange, check
that the cylinder block is separated. Since the rear
flange (301) weighs 30 kg (66.139 lb), heavy load
will be applied to hands when it is separated from
the guide pins. Hold it firmly with both hands, and
be careful enough not to drop it onto feet.
SMIL14CEX3318AA 19
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8. Remove the O-rings (143) (2 pieces) from the spindle

(101).
NOTE: Do not reuse the removed O-rings (143).
SMIL14CEX3319AA 20
16. Disassembly of rear flange accouterments

1. Place the rear flange (301) on the work platform with
the mating surface against spindle (101) facing upward.
2. Remove the brake springs (113) (14 pieces).
SMIL14CEX3320AA 21
3. Remove the valve plate (109) from the rear flange

(301).
CAUTION: When you remove the valve plate

(109), hands may be cut with the edge. Be careful
enough.
SMIL14CEX3321AA 22
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4. Remove the outer ring of conical roller bearing (150)

from the rear flange (301).
NOTE: There is a shim (119) under the outer ring of conical
roller bearing (150). Be careful not to lose it during disas-
sembly.
SMIL14CEX3322AA 23
17. Disassembly of brake valve components in rear flange

1. Remove the plugs (342) (2 pieces) from the rear flange
(301).
2. Remove the O-rings (336) from the plugs (324).
3. Remove each of the 2 springs (328) and spring retain-
ers (325) from the rear flange (301).
SMIL14CEX3323AA 24
4. Remove the spool (323) from the rear flange (301).

NOTE: Since the spool (323) will slip down when it is in-
clined with one plug port of rear flange (301) located in the
lower part, hold its tip during removal.
SMIL14CEX3324AA 25
5. Remove the plugs (326) (2 pieces) from the rear flange

(301).
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SMIL14CEX3325AA 26
7. Remove each of the 2 springs (330) and valves (327)

SMIL14CEX3326AA 27
18. Disassembly of 2-speed switchover spool

1. Remove the plugs (382) from the rear flange (301).
SMIL14CEX3327AA 28
3. By using a magnet, remove the spool (363) and the

spring (366) from the rear flange (301).
SMIL14CEX3328AA 29
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19. Removal of conical roller bearing

1. Turn it to locate the rear flange side in the upper part.
2. Remove the conical roller bearing (150) from the shaft
(102) (clearance fit).
NOTE: If it is not removed easily, use leverage to remove
it with a flathead screwdriver or the like. In that case, put a
rag etc. not to damage each component.
SMIL14CEX3329AA 30
20. Disassembly of parking brake section

1. Insert a bolt into the M6 M6 screw hole in brake piston
(112) via the removal jig, and draw out the brake piston
(112).
CAUTION: The force of removal may result in

falling. Be careful enough while doing so.
2. Remove the D-rings (135) and (139)1 from the brake
piston (112).
NOTE: Do not reuse the removed D-rings (135) and (139).
SMIL14CEX3330AA 31
21. Disassembly of hydraulic motor components

1. By using a magnet etc., remove the partner plates (116)
(7 pieces) and the friction plates (115) (6 pieces).
NOTE: Check both the end faces of friction plate (115) for
partial wear. Replace it if any partial wear is found.
CAUTION: Be aware that partial wear on fric-

tion plate (115) may hinder successful generation
of braking force.
SMIL14CEX3331AA 32
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2. Tilt the travel motor about 80 °

NOTE: When putting the travel motor into a sideways po-
sition, place an oil pan because oil spills.
CAUTION: Since the shaft (102) is not fixed,

the motor components may drop along with the
shaft (102) when it is inclined. Be sure to keep
the position higher than the level, or fix the shaft
(102).
SMIL14CEX3332AA 33
3. Hold the cylinder block (104) by hand, and turn it 2 to

3 times alternately to separate the shoe (106) from the
swash plate (103).
NOTE: Be aware that, if the cylinder block (104) is removed
without doing this step, the shoe (106) adheres and re-
mains in the swash plate (103), and then the piston (105),
the shoe (106), etc. separate from the cylinder block (104)
to drop into the spindle (101).
4. Remove the cylinder block (104) from the shaft (102).
SMIL14CEX3333AA 34
5. Remove the piston assembly (piston (105)) and shoe

(106)) and the retainer plate (107) from the cylinder
block (104).
NOTE: During removal, hold the retainer plate (107) with
both hands. The piston (105) and the shoe (106) are gath-
ered up into one piece at the spherical section of piston
(105). It is not possible to separate the piston (105) and the
shoe (106) without damaging the shoe (106). If required,
they should be replaced in pairs.
SMIL14CEX3334AA 35
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6. Draw out the piston assemblies ( (105)and (106)) (9

pairs) from the retainer plate (107).
NOTE: If you store the piston assembly for reuse, put a
code so that the pre-disassembly combination of the hole
in retainer plate (107) and the piston assembly may be re-
covered.
SMIL14CEX3335AA 36
7. Remove the thrust ball (108) from the cylinder block

(104).
8. Remove the cylinder springs (114) (9 pieces) from the
cylinder block (104).
SMIL14CEX3336AA 37
9. Remove the swash plate (103) from the shaft (102).

NOTE: Be aware that the pivot (176) may have adhered
to the swash plate (103) when the swash plate (103) is
removed.
10. Remove the pivot (176) from the spindle (101).
SMIL14CEX3337AA 38
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11. Remove the shaft (102) from the spindle (101).

NOTE: Check the spline of shaft (102) for wear. Replace
it if any wear is found.
CAUTION: Be careful not to cut hands with

the spline section.
SMIL14CEX3338AA 39
12. Remove the piston (170) and the spring (190) from the
spindle (101). If the piston (170) is not removed easily,
lightly press a rag etc. against the piston (170), and
inject air from the drill hole in spindle (101) to remove
it.
CAUTION: During removal with air, the piston

may burst out, resulting in injury. Be careful.
SMIL14CEX3339AA 40
22. Rough washing of each component

1. Sort components into 5 ones (ring gear (1), housing
(15), cover (14), spindle (101), rear flange (301)) and
others (hereafter called the internal components).
2. Put the ring gear (1), the housing (15), the cover (14),
the spindle (101), and the rear flange (301) into the
washing tank to wash them.
NOTE: Since earth and sand may have adhered to the
outer surface of each part, wash them away carefully
CAUTION: Refined kerosene is a flammable.

Be careful enough in handling it because it may
cause fire or burns.
NOTE: If dirty components are washed in oil from the be-

ginning, they tend to get flawed; therefore, soak them until
dirt and grease sufficiently separate and float.
3. Put the internal components into the rough washing
tank with refined kerosene to wash them.
23. Final washing

1. Put the components into the final washing tank with re-
fined kerosene, and wash up to the inside while rotating
each of them slowly.
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2. Wipe refined kerosene off each component with a clean

rag.
NOTE: The inside of ring gear (1) and spindle (101) should
be dried by blowing compressed air at a place without dust
or humidity. After drying the components, apply hydraulic
fluid to them. The inside of rear flange (301), the hydraulic
motor components, and the gears should be air-dried at
a place without dust or humidity. After drying the compo-
nents, apply hydraulic fluid.
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Travel motor - Assemble

In principle, assembly is the reverse of disassembly.
Preparations
As with the section on disassembly, prepare a work plat-
form, tools, and materials.

1. Observe the same general work precautions as those
in the section on disassembly.
2. Before assembly, remove metal fragments and foreign
substances from all components, and check that there
is no burr, dent, etc. in the components. If any burr or
dent is found, remove it with an oilstone.
3. Replace each O-ring, oil seal (132) , and floating seal
(31) with new ones.
4. Remove the adhesives remaining in the M12 screw
holes (18 points) and M18 screw holes (25 points) in
the ring gear (1) via the M12 P1.75 and M18 P2.5 taps.
Remove the adhesives remaining in the PT 1/8 holes (4
points) in the carriers (2) and (7)via the PT 1/8 taps. Af-
ter that, wash and degrease the screw holes, and blow
air on them to remove the cleaning fluid.
Replace hexagon bolts (34), hexagon socket head
bolts (35), and hexagon socket head plugs (30)
with new ones.
5. By using a spatula etc., remove the sealing compounds
from the ring gear (1) -cover (14) and the ring gear (1)
-housing (15). At this time, be careful not to damage
the components.
6. When attaching each O-ring, oil seal (132), and floating
seal (31), be careful not to damage them (in order to
smooth them, apply a small amount of grease).
7. Be sure to apply clean hydraulic fluid (grade 9 or more
of NAS standards) to the moving and sliding compo-
nents in hydraulic motor section and valve section be-
fore assembly.
8. Do not use cloth gloves during assembly (in order to
prevent a piece of fiber from causing a malfunction).
9. Tighten bolts and plugs following the torque values
shown in the tightening torque table.
10. When assembly is completed, plug all the ports to pre-
vent the entry of dirt.
11. The figures use a representative model for descrip-
tion. Even if it is partially different from the product in
use, the assembly procedure remains the same.
Assembly procedure
NOTE: When replacing and reassembling components,
check whether the following components are replaced be-
fore assembly, because the angular ball bearing (24) and
the conical roller bearings (149) and (150) need pre-load
adjustment. 　
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Replacements that need pre-load adjustment of angu-

lar ball bearing (24) 　
Housing (15), spindle (101) Angular ball bearing (24),
lock washer (22)
Replacements that need pre-load adjustment of conical
roller bearings (149) and (150) 　
Spindle (101), shaft (102)
Conical roller bearings (149) and (150), rear flange
(301)
NOTE: When replacing and reassembling the above com-
ponents, be sure to use the individually adjusted compo-
nents for reassembly. Be sufficiently aware that, if unad-
justed components are used for reassembly, the travel mo-
tor malfunctions to cause early damage.
1. Assembly of spindle section

1. Attach the spindle (101) to the work platform by tight-
ening the hexagon socket head bolts symmetrically.
WARNING: The hexagon socket head bolts

should be tightened up. If they are not tightened
up, the spindle (101) (about 91 kg (200.621 lb)
may drop to cause injury when the travel motor is
turned.
SMIL14CEX3340AA 1
2. Assembly of motor components inside spindle

1. By using the oil seal press-fit jig and a plastic hammer,
press the oil seal (132) into the spindle (101).
NOTE: When fitting the oil seal (132), apply lithium grease
to the lip section in the oil seal (132). Be careful of the
direction in which the oil seal (132) is fit.
2. Fix the oil seal (132) with the round Rshaped retaining
ring (133).
3. Insert the outer ring of conical roller bearing (149) from
the spindle (101) motor side (clearance fit).
a. Oil seal insertion jig
SMIL14CEX3341AB 2
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4. After apply grease to the spring (190) and attaching it

to the piston (170), attach it to the spindle (101).
SMIL14CEX3342AA 3
3. Fitting of shaft
CAUTION: Since you may get burned, use
leather gloves during insertion. Be careful not to
get burned.
1. Put the conical roller bearing (149) (3) into the heating
tank, heat it for 10 min at 90 - 110 °C (194 - 230 °F),
and press it into the shaft (102) (2).
a. Pressing machine
b. Shaft (102)
c. Conical roller bearing (149)
d. Holder fitting (III)
SMIL14CEX3343AB 4
2. Insert the shaft (102) into the spindle (101).

3. After applying a light coating of grease to the pivot (176)
fitting section, attach it to the spindle (101).
CAUTION: Be careful not to cut hands with

the spline section.
SMIL14CEX3344AA 5
4. Fit the swash plate (103) into the spindle (101).

NOTE: Apply grease to the mating surface of swash plate
(103) against the spindle (101). When inserting the swash
plate (103) into the spindle (101), align the pivot mounting
holes in swash plate (103) with the pivots (176) (2 pieces)
inserted in the spindle (101).
SMIL14CEX3345AA 6
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4. Assembly of inside of cylinder block

1. Put the cylinder springs (114) (9 pieces) into the cylin-
der block (104).
SMIL14CEX3346AA 7
2. Attach the thrust ball (108) to the cylinder block (104).

NOTE: Be careful not to incline the thrust ball (108) dur-
ing insertion. If it is left inclined during assembly, this may
cause damage to the motor components.
SMIL14CEX3347AA 8
3. Insert 9 pieces of piston assemblies into the retainer

plate (107).
NOTE: After assembly, soak the whole in hydraulic fluid.
Make sure that the pre-disassembly combination of the
hole in retainer plate (107) and the piston assembly can
be recovered.
4. Assemble the retainer plate (107) and 9 pieces of piston
assemblies to the cylinder block (104).
NOTE: Neatly align the retainer plate (107) and the spher-
ical section of thrust ball (108) with each other, and check
that they slide.
SMIL14CEX3348AA 9
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5. Insert the cylinder block (104) into the shaft (102).

NOTE: When inserting the cylinder block (104), align the
spline hole with the spline axis of shaft (102).
CAUTION: If the shaft (102) is not fixed, the

shaft (102) topples over during insertion and the
swash plate (103) separates from the spindle
(101) end face, causing assembly failure. Be
careful.
SMIL14CEX3349AA 10
5. Assembly of parking brake section

NOTE: The friction plate (115) should be soaked in hy-
draulic fluid before fitting.
2. Fit the partner plates (116) (7 pieces) and the friction
plates (115) (6 pieces) into the cylinder block (104) al-
ternately.
3. Fit the D-rings (135) and (139) into the D-ring grooves
in brake piston (112). At this time, apply a light coating
of grease to the D-rings (135) and (139).
SMIL14CEX3350AA 11
4. Fit the brake piston (112) into the spindle (101).

NOTE: If the brake piston (112) is not fit easily into the
spindle (101) because of resistance of the Drings (135) and
(139), lightly hit the end face of brake piston (112) with a
plastic hammer to fit it in. When fitting the brake piston
(112), be careful not to damage the D-rings (135) and (139).
SMIL14CEX3501AA 12
5. Insert the conical roller bearing (150) into the shaft

(102).
SMIL14CEX3502AA 13
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6. Assembly of 2-speed switchover spool in rear flange

1. Insert the spring (366) and the spool (363) into the rear
flange (301).
2. Attach the O-rings (338) to the plugs (382).
NOTE: Apply grease to the O-rings (338).
SMIL14CEX3503AA 14
3. Temporarily tighten the plugs (382) to the rear flange

(301) with a hexagon wrench.
SMIL14CEX3504AA 15
7. Reassembly of brake valve section

1. Insert each of the 2 valves (327) and springs (330) into
the rear flange (301).
SMIL14CEX3505AA 16

3. Screw the plugs (326) into the rear flange (301).
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4. Temporarily tighten the plugs (326) to the rear flange

(301) with a hexagon wrench.
SMIL14CEX3506AA 17
5. Insert the spool (323) into the rear flange (301).

NOTE: Apply hydraulic fluid to the spool (323), and insert
the spool (323) into the rear flange (301). When attaching
the spool (323), align the axial core of spool (323) with
the hole center in rear flange (301), to prevent damage
to the inside of rear flange (301) and damage to the outer
periphery of spool (323) due to interference. Be aware that,
if damage due to interference occurs in the hole section of
rear flange (301) and the outer surface of spool (323), this
causes internal leakage after reassembly, thereby resulting
in poor performance of the travel motor.
SMIL14CEX3507AA 18

7. Fit the spring retainers (325) and the springs (328) into
the plugs (324).
8. Screw the plugs (324) (2 pieces) into the rear flange
(301).
NOTE: When screwing the plugs (324) into the rear flange
(301), be careful not to deform the spring (328).
9. Temporarily tighten the plugs (324) (2 pieces) to the
rear flange (301).
SMIL14CEX3508AA 19
8. Pre-load adjustment of conical roller bearing

NOTE: After the rear flange (301), the spindle (101), the
shaft (102), or the conical roller bearings (149) and (150)
are replaced, perform pre-load adjustment. If pre-load is
not proper, the conical roller bearings (149) and (150) may
get damaged in a short time.
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1. Measure the dimension X of the conical roller bearing

(150) mount of rear flange (301).
2. Attach the conical roller bearing (150) to the shaft (102),
and measure the dimension Y.
SMIL14CEX3509AA 20
3. Subtract the dimension Y from X, and select a shim

(119) from the following ranks to create clearance of 0
- 0.1 mm (0 - 0.004 in)
Code mm (in)
06 0.9 mm (0.035 in)
05 0.8 mm (0.031 in)
04 0.7 mm (0.028 in)
03 0.6 mm (0.024 in)
02 0.5 mm (0.020 in)
01 0.4 mm (0.016 in)
SMIL14CEX3510AA 21
9. Assembly of rear flange accouterments

1. Insert the shim (119) and the outer ring of conical roller
bearing (150) into the rear flange (301).
2. Insert the parallel pin (341) into the pin hole in rear
flange (301).
3. Apply grease to the mating surface of valve plate (109)
against the rear flange (301).
SMIL14CEX3511AA 22
4. Apply grease to the contact surface of valve plate (109)

against the rear flange (301) to keep it from separating
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5. Using the parallel pin (341) as a guide, attach the valve

plate (109)to the rear flange (301).
NOTE: When attaching the valve plate (109), closely fit the
valve plate (109) to the rear flange (301). Closely fitting the
valve plate (109) will prevent it from dropping from the rear
flange (301) when you attach the rear flange (301) to the
spindle (101).
SMIL14CEX3512AA 23
6. Sufficiently apply grease to the brake springs (113) (14

pieces), and be careful during attachment that they do
not drop from the rear flange (301).
NOTE: Make sure that grease is sufficiently applied to the
brake springs (113) to fix them so that they may not drop
from the rear flange (301)
SMIL14CEX3513AA 24
10. Link between rear flange and spindle

1. Fit the O-rings (143) (2 pieces) into the O-ring grooves
in spindle (101).
NOTE: When fitting the O-rings (143), do not apply grease
to them. If they are reassembled with grease applied, the
grease oozes from the mating surface between rear flange
(301) and spindle (101) while the travel motor is operating,
which may be mistaken for oil leakage; therefore, do not
apply any grease.
SMIL14CEX3514AA 25
2. Tilt the travel motor about 80 °.

NOTE: The force of inclining it may cause the cylinder block
(104) to jump out. Be careful.
3. Attach guide pins to the spindle (101) diagonally, align
the guide pins with the pin holes in rear flange (301),
and fit it into the spindle (101).
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4. Temporarily tighten the hexagon socket head bolts

(343) (10 pieces) to the spindle (101) with a hexagon
wrench.
NOTE: Make sure the hexagon socket head bolts (343) (10
pieces) are tightened evenly so that the rear flange (301)
may not be inclined, because the internal brake springs
(113) will make it float gradually from the mating surface.
SMIL14CEX3515AA 26
11. Tighten with the specified torque.

3. Tighten the hexagon socket head bolts (343) (10
pieces) to the spindle (101) with the specified torque.
296.43 lb ft)
4. Tighten the plugs (324) (2 pieces) with the specified
torque.
Tightening torque: 304 - 324 N·m (224.22 -
238.97 lb ft)
4. Tighten the plugs (326) (2 pieces) with the specified
torque. SMIL14CEX3516AA 27
216.84 lb ft)
5. Tighten the plug (382) (1 piece) with the specified
torque.
ft)
SMIL14CEX3517AA 28
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12. Attachment of overload relief valve

1. Apply a little grease to the socket (201) and the valve
seat (203), and attach it taking care not to drop the
valve seat (203).
NOTE: Attaching it to the rear flange (301) with the valve
seat (203) inclined can cause poor performance or damage
to the motor. Be careful.
2. Attach the overload relief valve to the rear flange (301).
87.03 lb ft)
SMIL14CEX3518AA 29
13. Supply of hydraulic fluid

1. Put 1.50 L (0.40 US gal) of hydraulic fluid in the spindle
(101) via the drain port.
2. Attach the plugs (382) (2 pieces) to the drain port.
86.81 lb ft)
SMIL14CEX3519AA 30
14. Assembly of ring gear section

1. Put the housing (15) on the press work platform.
2. Insert the angular ball bearing (24) into the housing
(15), put the main bearing press-fit jig on the outer ring
of angular ball bearing (24), and press it into the hous-
ing (15).
3. Turn the housing (15) upside down.
4. As with the above [2], press the angular ball bearing
(24) into the housing (15).
NOTE: Be careful of the direction in which the angular ball
bearing (24) is fit.
A. Ball bearing
B. Pressing machine
C. Ball bearing press-fit jig
D. Housing
E. Pedestal
F. Press work platform
SMIL14CEX3520AB 31
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5. Seamlessly apply LOCTITE® 515™ (1) to the mating

surface of housing (15) against the ring gear (1).
NOTE: It should be applied seamlessly, because failure to
do so leads to lubricant leakage.
6. Attach 3 eyebolts M20 to the housing (15) to lift it with
wires, and attach it to the ring gear (1) while aligning
the M18 bolt holes.
SMIL14CEX3521AB 32
7. Apply LOCTITE® 242® to the hexagon socket head bolts

(35) (25 pieces), and tighten them with the specified
torque.
306.97 lb ft)
SMIL14CEX3314AB 33
8. Apply hydraulic fluid to the O-ring of floating seal (31),

and fit the floating seal (31) into the floating seal groove
in housing (15).
NOTE: When applying hydraulic fluid to the O-ring of float-
ing seal (31) (c), remove the O-ring from the floating seal
(31), and apply a light coating of it to the entire perimeter
of O-ring.
NOTE: To fit the floating seal (31), put the F/S fitting jig (I),
the floating seal (31), and the F/S fitting jig (II) (a) in this
order, and then push the F/S fitting jig (II) all the way to the
F/S fitting jig (I) (b). Remove the F/S fitting jigs, and check
that the housing (15) end face and the floating seal surface
are parallel within 1 mm (0.039 in) SMIL14CEX3522AB 34
15. Assembly of spindle section

1. Apply hydraulic fluid to the O-ring of floating seal (31)
(c), and fit the floating seal (31) into the floating seal
groove in spindle (101), (d).
NOTE: To fit the floating seal (31), put the F/S fitting jig (III)
(b), the floating seal (31), and the F/S fitting jig (II) (a) in this
order, and then push the F/S fitting jig (II) all the way to the
F/S fitting jig (III). Remove the fitting jigs, and check that
the spindle groove end face and the floating seal surface
are parallel within 1 mm (0.039 in).
SMIL14CEX3523AB 35
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16. Pre-load adjustment of angular ball bearing

NOTE: After the housing (15), the angular ball bearing (24), or the spindle (101) is replaced, perform pre-load adjust-
ment. If pre-load is not proper, the angular ball bearing (24) may get damaged in a short time.
1. Temporarily assemble the lock washer (22) to the spin-
dle (101), and measure the dimension (A).
2. Measure the assembly width (B) of angular ball bearing
(24).
NOTE: Before measuring the dimension, turn the housing
(15) and the angular ball bearing (24)several times to elim-
inate floating.
SMIL14CEX3524AB 36
3. Subtract the dimension (B) from (A), and select 2 shims

(23) from the following ranks to create clearance of
-0.080 - 0.020 mm (-0.003 - 0.001 in)
Code mm (in) Code mm (in)
2.0 mm 1.40 mm
A N
(0.079 in) (0.055 in)
1.95 mm 1.35 mm
B P
(0.077 in) (0.053 in)
1.900 mm 1.300 mm
C Q
(0.075 in) (0.051 in)
1.850 mm 1.25 mm
D R
(0.073 in) (0.049 in)
1.80 mm 1.20 mm SMIL14CEX3525AB 37
E S
(0.071 in) (0.047 in)
1.75 mm 1.15 mm
F T
(0.069 in) (0.045 in)
1.70 mm 1.100 mm
G U
(0.067 in) (0.043 in)
1.65 mm 1.05 mm
H V
(0.065 in) (0.041 in)
1.60 mm 1.00 mm
J W
(0.063 in) (0.039 in)
1.55 mm 0.95 mm
K X
(0.061 in) (0.037 in)
1.50 mm 0.90 mm
L Y
(0.059 in) (0.035 in)
1.450 mm
M
(0.057 in)
17. Fitting of ring gear assembly

1. Attach the shim (23) (1 piece) selected in (16) to the
spindle (101).
2. While aligning the center axes of lifted ring gear assem-
bly and spindle (101), slowly lower the ring gear as-
sembly to insert the angular ball bearing (24) included
in housing (15)into the spindle (101).
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3. Press the inner lace section of angular ball bearing (24)

with a pressing machine (a) to insert it as far as it will
go.

hands from getting caught between components,
or not to drop any lifted components onto feet.
SMIL14CEX3526BB 38
4. Align the lock washer (22) with the groove in the spindle
(101).
SMIL14CEX3527AA 39
5. By using the jig, push the lock washer (22) into the
groove in the spindle (101).
NOTE: In order to prevent interference with the lock washer
(22) when the carriers (2) and (7) are fit, push the lock
washer (22) fully into the groove.
6. Check whether the lock washer (22) is fully pushed into
the groove in the spindle (101).
SMIL14CEX3528AA 40
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7. Turn the ring gear assembly 2 to 3 times.

NOTE: By turning the ring gear assembly, the sliding sur-
face of floating seal (31) is fit well to prevent false leakage.
SMIL14CEX3529AA 41
18. Assembly of carrier (2) assembly

1. Insert the planetary gears (2) and (9), the needle pin
roller bearing with retainer (28), and the thrust washers
(2) and (12) (2 pieces each) into the carriers (2) and
(7). Attach the thrust washers (2) and (12) to sandwich
the planetary gears (2) and (9).

hands from getting caught between the planetary
gears (2) and (9) and the carriers (2) and (7).
SMIL14CEX3530AA 42
2. Align the carrier pin (10) with the parallel pin hole, and
insert it into the carriers (2) and (7).
3. Insert the parallel pin (17) into the carriers (2) and (7)
and the carrier pin (2) and (10).
NOTE: It will be easy to insert the parallel pin (17) when
you push up the carrier pin (10).
SMIL14CEX3531AA 43
4. Tighten the hexagon socket head plugs (30) with the

specified torque.
NOTE: The new hexagon socket head plugs (30) should
be used.
ft)
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5. Fit the sun gears (2) and (8) into the carriers (2) and
(7).
SMIL14CEX3532AA 44
19. Fitting of carrier (2) assembly

1. Attach 2 eyebolts M10 to the carriers (2) and (7), and
fit the carrier (2) assembly with a lifting equipment.
NOTE: Make sure that the carrier (2) assembly is fit slowly
with the center axes of ring gear (1) and carriers (2) and (7)
aligned so that the internal teeth of ring gear (1) may not
get damaged at the end face.
SMIL14CEX3533AA 45
2. Make sure that the carrier (2) assembly is splined to

the spindle (101) with the hydraulic line port surface (a)
and the carrier (2) assembly located as shown in the
below figure.
b. 2-speed piston hole
SMIL14CEX3534AB 46
20. Assembly of 1st-stage gear

1. Attach 3 eyebolts M10 to the carriers (1) and (3), and
fit the carriers (1) and (3) with a lifting equipment while
aligning the splines of sun gears (2) and (8).
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2. Attach the thrust washers (1) and (11) to each pillar of

carriers (1) and (3).
SMIL14CEX3535AA 47
3. Attach the inner rings (29) (3 pieces) to each pillar of

carriers (1) and (3).
4. Attach the needle pin roller bearings with retainer (27)
(3 pieces) to each pillar of carriers (1) and (3).
SMIL14CEX3536AA 48
5. Attach the planetary gears (1) and (5) (3 pieces) to each

pillar of carriers (1) and (3).
NOTE: After fitting the planetary gears (1) and (5), check
that the thrust plate mounting surfaces of carriers (1) and
(3) are located above the planetary gears (1) and (5).
6. Fit the sun gears (1) and (4) while aligning the spline of
shaft (102).
SMIL14CEX3537AA 49
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7. Insert the steel ball (36) into the steel ball fitting holes
in sun gears (1) and (4).
NOTE: Grease should be applied to the steel ball (36) to
prevent it from dropping when the cover (14) is fit.
SMIL14CEX3538AA 50
8. Fit the thrust plate (13) into the carriers (1) and (3).
SMIL14CEX3539AA 51
21. Assembly of cover

1. As with assembly of the ring gear (1), seamlessly apply
the sealing compound LOCTITE® 515™ to the mating
surface of ring gear (1) against the cover (14).
NOTE: It should be applied seamlessly, because failure to
do so leads to lubricant leakage.
SMIL14CEX3540AA 52
2. Attach eyebolts to the PF 3/4 ports of cover (14), and

put it on the ring gear (1) while aligning the bolt holes.
SMIL14CEX3541AA 53
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3. Tighten the hexagon bolts (34) with the specified

torque.
NOTE: The new hexagon bolts (34) should be used.
Tightening torque: 86.30 - 117.70 N·m (63.65 - 86.81 lb ft)
SMIL14CEX3542AA 54
22. Supply of lubricant

1. Supply lubricant via the oil supply port.
NOTE: The amount of lubricant to supply should be 9.5 L
(2.51 US gal)
2. Attach the O-rings (37) (2 pieces) to the hexagon
socket head plugs_ PF 3/4 (33).
3. Attach the hexagon socket head plugs_ PF 3/4 (33) to
each port, and tighten them with the specified torque.
87.98 lb ft)
SMIL14CEX3543AA 55
23. Removal of travel motor from the work platform

1. Turn the travel motor 90 °
2. Wind a belt around the position of the center of gravity
of travel motor.
3. Hook the belt on a lifting equipment.
4. While checking the position of the center of gravity, re-
move the travel motor mounting bolts from the work
platform, and remove the travel motor from the work
platform.
SMIL14CEX3544AA 56
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Travel motor - Install

1. Install the travel motor (1) to the lower frame as shown
in the figure.
• Pay attention to installation angle.
SMIL14CEX3277AB 1
2. Apply LOCTITE® 262™ to the thread area of mounting

bolts (2).
Tighten them top to bottom alternately so as to ap-
ply even diagonal tightening force with specified
torque as shown in the figure below.
Mounting bolt tightening torque: 900 - 1051 N·m
(663.81 - 775.18 lb ft)
SMIL14CEX3278AB 2
SMIL14CEX3279AB 3
3. Mount the elbow (15) and the pilot hose (14) with a
wrench [ 19 mm].
SMIL14CEX3273AB 4
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4. Mount the drain hose (13) and the 2 high pressure

hoses (12) with a wrench [ 27 mm for the drain hose,
41 mm for the high pressure hose].
SMIL14CEX3272AB 5
5. Mount the 4 bolts (7) with a wrench [ 19 mm] to mount

the cover (8).
Mounting bolt tightening torque: 63.7 - 73.5 N·m
(46.983 - 54.211 lb ft)
SMIL14CEX3280AB 6
6. Wind in the shoes (9).
SMIL14CEX3281AB 7
7. Insert the master pin (11).

Insert the S-pin (10) and bend it so as to prevent falling
out.
SMIL14CEX3282AB 8
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8. Tighten the check valve (12).

Fill grease to the grease cylinder while checking ten-
sion of the track shoe.
SMIL14CEX3283AB 9
9. Raise the lower side frame while adjusting tension of

the track shoe as shown in the figure.
Place a wood plank (13) or other block to the lower
frame to prevent falling.
SMIL14CEX3284AB 10
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Travel motor - Service instruction

Follow these maintenance standards when disassem-
bling or inspecting the travel motor. Make sure that es-
pecially the moving and the sliding section are free from
any flaw.
Seals
All seals (each O-ring, oil seal (132), floating seal (31))
should be replaced with new ones after disassembly,
even if no damage is found.
Maintenance standards for worn components

1. Replace any component with significant damage on its
exterior.
2. Replace any component with one of the following ab-
normalities (phenomena).
Standard value Tolerance

Part number Part name Phenomenon
(gauge) (criterion)
• Serious damage on the exterior
• Pitching has occurred in the ring gear
1 Ring gear (1) tooth flank - -
• Abnormal wear such as seizing is
found
• Serious damage on the exterior
101 Spindle • Abnormal wear such as seizing is - -
found
3, 7 Carrier • Abnormal wear such as seizing is - -
found
4 Sun gear 1 • Pitching has occurred in the tooth
8 Sun gear 2 flank
- -
5 Planetary gear 1 • Flaking has occurred on the bearing
9 Planetary gear 2 rolling contact surface
• An impression is found
24 Angular ball bearing • Flaking has occurred - -
• Partial wear is found
301 Rear flange • The sliding section between spools - -
(323) and (363) is flawed
• The working face against oil seal
102 Shaft (132) is worn out - -
• The spline is worn out
• The shoe (106) sliding surface has
seized up
103 Swash plate - -
• The piston (170) working face is
abnormally worn out
• The spline section is worn out
• The bore inner surface is significantly
worn out.
104 Cylinder block - -
• The sliding surface against the valve
plate (109) is flawed or partially worn
out
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Standard value Tolerance

Part number Part name Phenomenon
(gauge) (criterion)
• There is a clearance between piston
Piston assembly (105) and shoe (106) in the axial Clearance
105 direction
Piston - 0.30 mm
106
Shoe • The shoe (106) is abnormally or (0.012 in)
partially worn out
• The sliding section against shoe
(106) is partially worn out
107 Retainer plate • The sliding surface against the thrust - -
ball (108) is flawed or partially worn
out
• The spherical sliding section against
108 Thrust ball retainer plate (107) is partially worn - -
out
109 Valve plate • The sliding surface has seized up or - -
is partially worn out
• Both the end faces are worn out Braking torque
115 Friction plate 1050 N·m
• The specified torque is not produced -
116 Partner plate (774.44 lb ft) or
• It has seized up more
112 Brake piston • The outer circumference is flawed - -
• An impression is found.
149 Conical roller
• Flaking has occurred - -
150 bearing
• Wear is found
• The outer circumference is
abnormally worn out
170 Piston - -
• The spherical section is abnormally
or partially worn out
• The outer circumference is flawed
Diametral
207 Piston • The clearance against pilot body -
clearance 25 μ
(206) is large
• The seat surface is flawed.
• The clearance against valve (202) is
201 large. Diametral
Socket valve -
202 • The outer circumference is flawed clearance 25 μ
• The outer circumference is partially

worn out
• The outer circumference is partially
323 worn out
Spool - -
363
• The outer circumference is flawed
327 Valve • The seat surface is flawed - -
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Travel motor - Check

Performance check test
After servicing the travel motor, conduct a performance
check test following the below procedure.
1. Required measuring instruments
1 Pressure gauge for 3 MPa (498 psi) 2 pieces

2 Graduated cylinder for 5 L (1.32 US gal) 1 piece
3 Stop watch 1 piece
Test procedure
1. Installation and piping of travel motor
Install the travel motor to the body (frame section) and
install piping.
However, do not install the track shoe. [Because of
the subsequent performance test (no-load operation)
of travel motor]
• While installing piping, make sure that attachment of
pressure gauges (main circuit) and measurement of
the drain volume of hydraulic motor are available.
• Make sure that the travel motor is installed gently by
using bolt holes without hammering it.
2. Running-in of travel motor
Switchover Travel motor speed Pressure Direction of rotation Operating time

Low-speed rotation 10 RPM
No load Left/Right 1 min or more each
High-speed rotation 20 RPM
3. Travel motor performance check test

A. Pre-test preparatory operation
Perform preparatory operation until the following
temperatures are attained.
Hydraulic fluid temperature 45 - 55 °C (113.0 - 131.0 °F)

External temperature of reduction gear ring gear 40 - 80 °C (104.0 - 176.0 °F)
B. Check test
Measure the following items at low speed, and
make a pass/fail decision.
Acceptance criteria
Travel motor drive pressure difference 1 MPa (184 psi) or less at 10 RPM
Hydraulic motor drain volume 1.0 L/min (0.264 US gpm) at 10 RPM
Pass: Install the track shoe.

Fail: Perform disassembly and adjustment again.
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Travel motor - Replace

• The below table shows the seals that are mounted
in the travel motor and replaceable on the spot or at
the service factory because of oil leakage.
• Since rough handling during assembly or disassem-
bly causes oil leakage, be extra careful in handling,
and make sure that the disassembled seals are re-
placed with new ones.
No. Part name Part number Remarks

ES100-336X360X40.8A (Quantity
1 Floating seal kit 31
1)
2 O-ring JIS B 2401-P24-90 (Quantity 2) 37
3 Oil seal TCZ-65X90X9-F743 (Quantity 1) 132
4 O-ring 2274-3-175617-01 (Quantity 1) 135
5 O-ring 2274-3-175621-01 (Quantity 1) 139
11 O-ring 6254-3-078495-66 (Quantity 1) 342
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Travel motor - Storing

Before storing the travel motor, close the cap of each
port. Furthermore, in order to avoid rust, corrosion, and
deterioration of seals, do not store it in the following
places.
• Hot, humid, or freezing place
• Place that may be directly exposed to the weather
• Vicinity of such chemicals as organic solvent, acid,
and alkali, or place that may be affected by vapor
• Place exposed to corrosive gas or dust
• Place where condensation may occur because of
wide temperature variations
• Place where the floor is unstable
• Place where the floor strength is insufficient
• Place exposed to much vibration
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Travel motor - Drain fluid

Preparations
Measuring condition

Mode SP mode
Oil temperature About 50 °C
NOTE: Be aware that the drain volume varies greatly depending on the oil temperature.
Travel motor drain volume measurement

1. Allow the bucket (2) to touch the ground so as to elevate
one shoe crawler (1) as in the diagram on the right.
SMIL14CEX2122AB 1
2. Remove the bolts (2), then remove the cover (1).
SMIL14CEX2123AB 2
3. Always lay a rag (2) underneath before removing the

drain hose (1).
4. Use a wrench to remove the drain hose (1). (Always
install a cap on the removed drain hose (1)).
SMIL14CEX2124AB 3
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5. Install the extension hose for measurement (1) on the

side of the motor from which the drain hose was re-
moved.
SMIL14CEX2125AB 4
6. Prepare a waste oil can (1) and measuring container

(2) and set them as in the diagram on the right.
SMIL14CEX2126AB 5
7. Catch the stopper (1) between the sprocket section and

the frame to lock the travel motor.
SMIL14CEX2185BB 6
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8. In SP mode at medium speed, relieve the travel oper-

ation, and move the extension hose to the measuring
container (2) at the same time the motor starts. (At
starting, start measurement with a stop watch (3)).
9. After 30 s., move the extension hose to the waste oil
can (1).
10. Measure the volume of oil in the measuring container
(2) as the drain volume for 30 s.
NOTE: Measure at least 3 times each for left, right, forward
and backward.
(a). 30 s
SMIL14CEX2186BB 7
Forward Backward
1st speed 2nd speed 1st speed 2nd speed
Right
Left
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Hydraulic travel system - Troubleshooting

Not start up Pressure does not increase: The relief set Set it correctly
pressure is low
Pressure does not increase: Failure in Check whether there is any other motion
pump than traveling. Repair it if any failure is
found
Pressure does not increase: Failure in di- Check whether the spool is under normal
rection switchover valve conditions. Repair it if necessary
Pressure increases: Failure in brake valve Replace the spool, the valve, etc. if they
are seized up. For other reasons, repair
them
Pressure increases: Failure in hydraulic Replace it and check the hydraulic fluid.
motor Replace the hydraulic fluid if it is bad
Pressure increases: Damaged gear (re- Replace the motor with reduction gear
duction gear)
Pressure increases: Overload is applied Remove the load
Pressure increases: Clogging in parking Remove foreign substances from the ori-
brake path orifice fice
Oil leakage From mating surface: Flaw in mating sur- Correct the surface with a whetstone, pa-
face per, etc.
From mating surface: Loose bolts Check after additionally tightening them
From case: Loose plugs Retighten them
From case: Broken by stone etc. Replace the motor with reduction gear
From floating seal: Wear in sliding surface Replace the motor with reduction gear
From floating seal: Creeping O-ring Replace the motor with reduction gear
From hydraulic motor: Loose bolts Retighten them
From hydraulic motor: Damaged O-ring Replace the O-ring
From hydraulic motor: Flaw in seal surface Correct the surface with a whetstone, pa-
per, etc.
Slipping down on slop The volumetric efficiency of motor is bad: Replace the timing plate and the rotary sec-
Internal leakage tion
The volumetric efficiency of motor is bad: Replace the relief valve
Relief valve set pressure drop
Increase in leakage from brake valve Replace the brake valve and the spool as-
sembly
The parking brake is not functioning: Dam- Replace the spring
aged spring
The parking brake is not functioning: Wear Replace the friction plate and the partner
in friction plate plate
The parking brake is not functioning: Ori- Wash the path and the orifice
fice in path clogged with dirt
The surface temperature Deficiency of gear oil Supply it appropriately
of reduction gear case is
high
Pitching bearings and gears Replace the reduction gear component and
gear oil
Entry of hydraulic fluid into gear case Replace the oil seal and gear oil
Snaking At low pressure: Right and left discharge Repair the pump
volumes are different
At low pressure: Right and left motor drain Replace the timing plate and the rotary sec-
volumes are different tion
At high pressure: Right and left discharge Repair the pump and the regulator
volumes are different
At high pressure: Right and left motor drain Replace the timing plate and the rotary sec-
volumes are different tion
At high pressure: Right and left brake valve Replace the brake valve component (re-
motions are different place the rear flange)
At high pressure: Relief pressure drop of Achieve the correct set pressure
right or left control valve Replace the relief valve
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Loss of speed The discharge volume of pump is small: Correct the pump regulator surroundings
The pump regulator surroundings do not
operate correctly
The discharge volume of pump is small: Repair or replace the pump
The external leaks in pump are large
The volumetric efficiency of motor is bad: Replace the timing plate and the rotary sec-
Internal leakage tion
The volumetric efficiency of motor is bad: Replace the relief valve
Relief valve set pressure drop
Abnormal noise Damaged motor or reduction gear Replace the motor with reduction gear
Vibrating lines Clamp them
Switchover from low Malfunction of high-pressure selection Inspect it
speed to high speed is check valve Repair or replace it if necessary
disabled
Malfunction of switchover valve Check whether the spool is under normal
conditions
Replace it if necessary
The pilot pressure is low Set it to the specified pressure
Malfunction of 2-speed switchover piston Inspect it
Repair or replace it if necessary
Clogging in 2-speed path orifice Remove foreign substances from the ori-
fice
Malfunction of switchover valve Check whether the spool is under normal
conditions
Replace it if necessary
Malfunction of 2-speed switchover piston Inspect it
Repair or replace it if necessary
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Index

Hydraulic travel system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Hydraulic travel system - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic travel system - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Hydraulic travel system - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Travel motor - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Travel motor - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Travel motor - Component localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Travel motor - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Travel motor - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Travel motor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Travel motor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Travel motor - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Travel motor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Travel motor - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Travel motor - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Travel motor - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Travel motor - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Travel motor - Storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Travel motor - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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Hydraulic central joint - 354

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Contents
TECHNICAL DATA
Hydraulic swivel
Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FUNCTIONAL DATA
Hydraulic swivel
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SERVICE
Hydraulic swivel
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Prepare - For disassemble and assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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Hydraulic systems - Hydraulic central joint
Hydraulic swivel - Dimension
SMIL14CEX1349HB 1
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*1. Maximum gap 10 mm (0.39 in) *3. 4 x 4 - M10 , screw depth 16, bottom hole depth 18
Minimum gap 8.5 mm (0.33 in)
*2. Maximum gap 0.7 mm (0.03 in) *4. 3 - M16, screw depth 22, bottom hole depth 27
Minimum gap 0.3 mm (0.01 in)
1. Axle 8. O-ring
2. V-ring 9. Cover
3. Rotor 10. Hexagon socket head bolt
4. O-ring 11. LOCTITE® 262™
5. Packing ring 12. Plate
6. Thrust plate 13. Driving tack
7. Hexagon socket head bolt 　　
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Hydraulic swivel - Special tools

a. Axle removal jig
*1. M16 - M20 full threaded bolt
L = 370 - 420 mm (14.57 - 16.54 in)
*2. M16 - M20 female thread
*3. Cover (9) installation dimensions
*4. Hexagon socket head bolt (7) M10 X 25
*5. Backing plate
Axle (1) outer diameter - about 5 mm (0.20 in)
t = about 5 mm (0.20 in)
SMIL14CEX1350BB 1
b. Removal jig (for O-ring and V-ring)
SMIL14CEX1351AB 2
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Hydraulic swivel - Overview
SMIL14CEX3585FA 1

A’ Forward right (connected to travel motor) G1
B' Forward left (connected to travel motor) G1
C’ Backward right (connected to travel motor) G1
D' Backward left (connected to travel motor) G1
P’ Pilot port (connected to travel motor) G1/4
T Drain port G1/2
A Forward right (connected to control valve) 34.47 MPa (5000 psi) x 1
B Forward left (connected to control valve) 34.47 MPa (5000 psi) x 1
C Backward right (connected to control valve) 34.47 MPa (5000 psi) x 1
D Backward left (connected to control valve) 34.47 MPa (5000 psi) x 1
P Pilot port (connected to control valve) G1/4
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Hydraulic swivel - Exploded view
SMIL14CEX1348FB 1
1. Axle (Quantity 1) 7. Hexagon socket head bolt (Quantity 4)

2. V-ring (Quantity 1) 8. O-ring (Quantity 1)
3. Rotor (Quantity 1) 9. Cover (Quantity 1)
4. O-ring (Quantity 1) 10. Hexagon socket head bolt (Quantity 4)
5. Packing ring (Quantity 7) 11. LOCTITE® 262™ (Quantity 8)
6. Thrust plate (Quantity 1)
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Hydraulic swivel - Prepare

WARNING
Avoid injury!
W1128A
WARNING
Crushing hazard!
latches.
W0256A
WARNING
Heavy objects!
W0398A
Items to prepare:
• Specialty adapter for vacuum pump connection
• Vacuum pump (vacuum pump power supply)
• Extension cable
• Marking pen
• Cap
• Plug
• Rag
• Cleaning fluid
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Hydraulic swivel - Remove

(1), and then remove the air breather (2) on the hy-
draulic tank.
Tightening torque for bolt installation: 2.94 - 4.90 N·m
(2.17 - 3.61 lb ft)
SMIL14CEX1516AB 1
2. Install the specialty adapter (1) to the area where the

air breather is removed, and set the vacuum pump (2).
Create negative pressure in the hydraulic tank using
the vacuum pump.
SMIL14CEX1517AB 2
3. Use a box wrench [ 19 mm] to remove the 8 bolts (1),

and then remove the lower under cover (2).
SMIL14CEX1519AB 3
4. Prepare a waste oil can (1) to receive the oil that spills
out under the center joint.
SMIL14CEX1515AB 4
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5. Use a wrench [ 41 mm] to remove the 4 travel hoses

(1) and a wrench [ 27 mm] to remove the 2 drain hoses
(2), and a wrench [ 22 mm] to remove the 2 pilot hoses
(3).
• Mark the center joint and hoses so that the connec-
tors match at the time of installation.
• Install caps or plugs to the center joint and hoses to
prevent any entry of water, dust or dirt.
• Clean the center joint and hoses by spraying them
with a parts cleaner to prevent scratches and prevent
dirt from accumulating on the connectors.
SMPH15CEX0454AB 5
6. Use a wrench [ 27 mm] to remove the drain hose (1)

and a wrench [ 22 mm] to remove the pilot hose (2).
• Install caps or plugs to the center joint and hoses to
• Clean the center joint and hoses by spraying them
with a parts cleaner to prevent scratches and prevent
dirt from accumulating on the connectors.
SMPH15CEX0455AB 6
7. Use a wrench [ 24 mm] to remove the 3 bolts (1), and

then remove the center joint lock bar (2).
Tightening torque for installation: 267 - 312 N·m
(196.93 - 230.12 lb ft)
SMIL14CEX1522AB 7
8. Use a hexagon wrench [ 8 mm] to remove each group

of 4 hexagon bolts (1), and then remove the 4 travel
hoses (2).
• Mark the hoses so that the connectors match at the
time of installation.
• Install caps or plugs to the hoses to prevent any entry
of water, dust or dirt.
• Clean the hoses by spraying them with a parts
cleaner to prevent scratches and prevent dirt from
accumulating on the connectors.
Tightening torque for bolt installation: 37.2 - 47.2 N·m
(27.44 - 34.81 lb ft) SMIL14CEX1525AB 8
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9. Wrap wire ropes (1) around the center joint and sus-
pend it with a lifting equipment so that the center joint
does not fall during removal and installation operations.
SMIL14CEX1521AB 9
10. Use a wrench [ 19 mm] to remove the 3 bolts (1) from

the center joint.
Tightening torque for installation: 109 - 127 N·m
(80.39 - 93.67 lb ft)
SMIL14CEX1523AB 10
11. Use the wire ropes (2) and lifting equipment to lift the
center joint (1).
SMIL14CEX1524AB 11
12. Thoroughly check that the location is safe before low-

ering the center joint on wood planks.
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Hydraulic swivel - Prepare - For disassemble and assemble

CAUTION:
• The following cautions for hydraulic equipment should be observed with these parts.
• To ensure safe operations, wear protective gears for the work and follow all precautions.
or steel rod.
○ Make sure that the jig is used for disassembly of the axle and rotor.
○ Follow the precautions below when suspending the load.
○ The lifting equipment must be operated by a qualified operator.
• Check the weight of the load to determine whether it can be carried by hand or whether a lifting equipment
must be used.
• When assembling V-rings, O-rings, and other sliding parts, be sure to coat them with new grease.
General cautions:
• Do not forcefully open or hit parts in an effort to speed up operations. Pay careful attention and proceed slowly
so as not to deform any parts, create any oil leaks, or compromise the efficiency of the equipment, etc.
• Make sure that foreign matter such as debris and moisture does not enter.
• The work platform used should be solid, stable, and sufficiently spacious. Also, items should be clean and free of
debris and moisture. Remove debris and moisture before performing work.
• Inspect, remove debris and moisture, and clean tools and jigs before work.
• Jigs and tools that are appropriate to the contents of work should be used.
Items to prepare:
• Hexagon wrenches [ 6 mm, 8 mm, 14 mm, 17 mm]
• Torque wrench
• Socket wrenches [ 6 mm, 8 mm, 14 mm, 17 mm]
• Lights
• Mirror
• Brush (plastic)
• Specialty jigs
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Hydraulic swivel - Disassemble

1. Use a hexagon wrench [ 8 mm] to remove the 4
hexagon socket head bolts (10), and then remove the
cover (9).
SMIL14CEX1352BB 1
2. Remove the O-ring (8).
SMIL14CEX1353AB 2
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thrust plate (6).
SMIL14CEX1354BB 3
4. Use the axle removal jig “a” to push out the axle (1)
from the rotor (3).
• Do not strike it with a hammer at this time.
SMIL14CEX1355AB 4
5. Use the removal jig “b” or the like to remove the V-ring
(2) from the axle (1).
SMIL14CEX1356AB 5
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6. Use the removal jig “b” or the like to remove the O-ring
(4) and packing rings (5) from the rotor (3).
SMIL14CEX1357AB 6
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Hydraulic swivel - Assemble

1. Place parts in a rough cleaning container filled with
kerosene to clean off any adhered matter that can form
sharp points and cause scratches.
• Immerse in kerosene until dust, grease, and other
adhered matter comes off and floats to the surface.
SMIL14CEX1358AA 1
2. Place parts in a finish cleaning container filled with

kerosene and clean while gently moving the parts.
After cleaning, wipe away the kerosene with a clean
rag.
• Place the parts in a location free of dust and moisture
and use compressed air to dry the parts.
After drying, coat parts with engine oil.
• Polish away burrs, barbs, and scratches with a whet-
stone.
SMIL14CEX1359AA 2
3. Use cleaning fluid or compressed air to clean the rotor

(3).
After cleaning, check inside the rotor and in the
groove sections for burrs, barbs and scratches and for
scratches caused by striking.
SMIL14CEX1360AB 3
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4. Check the quantity of packing rings (5) and O-ring (4).

Coat with grease and install in the sequence below.
• Set 1 packing ring (5) in each of the 7 grooves from
the 2nd groove on the axle insertion side to the thrust
plate side.
• Set the O-ring (4) in the front-most groove on the axle
insertion side.
• Use new packing rings (5) and a new O-ring (4).
SMIL14CEX1361BB 4
5. After installing the O-ring and packing rings, use the

mirror to check for any parts that are sticking out or are
twisted.
Also, check for installation mistakes.
After checking, coat with grease.
After coating with grease, check again for any parts
sticking out, etc.
SMIL14CEX1362AB 5
6. Install the V-ring (2) on the axle (1) and coat sufficiently
with grease.
Be careful that no water or dirt gets into the grease.
• Use a new V-ring (2).
SMIL14CEX1363AB 6
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7. Install the axle (1) on the rotor (3).

• Set in a way that the V-ring (2) will not be cut or
damaged.
SMIL14CEX1364AB 7
8. Using a hexagon wrench [ 6 mm], coat the hexagon

socket head bolts (7) with LOCTITE®, install the thrust
plate (6) on the axle (1), and tighten to the specified
tightening torque.
Installation bolt tightening torque: 31.4 - 37.3 N·m
(23.16 - 27.51 lb ft)
SMIL14CEX1365BB 8
9. Install the O-ring (8) on the rotor (3).

• Use a new O-ring (8).
SMIL14CEX1366AB 9
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10. Using a hexagon wrench [ 8 mm], coat the hexagon

socket head bolts (10) with LOCTITE® 262™, install the
cover (9) on the rotor (3), and tighten to the specified
tightening torque.
Installation bolt tightening torque: 62.7 - 72.5 N·m
(46.25 - 53.47 lb ft)
SMIL14CEX1367BB 10
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Hydraulic swivel - Install

dure.
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Index

Hydraulic swivel - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Hydraulic swivel - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic swivel - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Hydraulic swivel - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hydraulic swivel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Hydraulic swivel - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic swivel - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hydraulic swivel - Prepare - For disassemble and assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Hydraulic swivel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hydraulic swivel - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Boom hydraulic system - 736

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Contents
TECHNICAL DATA
Boom hydraulic system

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Boom cylinder
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FUNCTIONAL DATA
Boom cylinder
Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Boom lifting cylinder holding valve
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SERVICE
Boom cylinder
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Prepare – For disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Boom lifting cylinder holding valve
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
DIAGNOSTIC
Boom cylinder
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Hydraulic systems - Boom hydraulic system
Boom hydraulic system - Special tools

Special jigs part number list
• Select jigs for the cylinder head according to the rod diameter.
• Select jigs for the piston according to the cylinder bore.
Order No. Jig name (applicable rod diameter) Remarks
KHV0511 Cylinder head assembly and disassembly jig (65)
Order No Jig name (applicable rod diameter) Remarks

KHV0526 Seal ring insertion and calibration jig (100)
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Attachment special tool
SMIL14CEX4201FB 1

*1: Arm, *2: Arm, *3: Center pin,
1 380200121 ( KRV10620) Wrench assembly (U1)
*4: Pin, *5: Set screw
2 KRV10570 Expander
3 KRV10600 Clamp 120 - 135
4 KRV10610 Clamp 100 - 115
5 KRV10580 Ring (rubber band) 120 - 135
6 KRV10590 Ring (rubber band) 100 - 115
7 KRV10630 Bushing tool kit No diagram
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Boom cylinder - Special tools

General tool
No. Tool name Quantity
Screwdriver (flathead
1 1
screwdriver)
2 Hexagon wrench 1 set
3 Vise 1
Wrench (for piston

4 1 set
nuts)
5 Punch 1
6 Torque wrench 1 set
Hammer (plastic
7 1
hammer)
8 Monkey wrench 1
9 Scoop 1 pair
Special jig (for TOYO)

1.Hexagon wrench (JIS B 4648)
Table 1
Unit: mm (in.)
For line pipe flange For piston nut locking
Cylinder For rod cover bolts For check valve plug
bolts screws
Arm 17 mm (0.669 in) 10 mm (0.394 in) 8 mm (0.315 in) 8 mm (0.315 in)
Boom 17 mm (0.669 in) 10 mm (0.394 in) 8 mm (0.315 in) —
Bucket 14 mm (0.551 in) 10 mm (0.394 in) 8 mm (0.315 in) —
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2.Closed wrench (JIS B 4632) or wrench (JIS B 4630)
Table 2
Unit: mm (in.)
For 1/4 grease
Cylinder For line band bolts For line clamp bolts For 1/8 grease nipples
nipples
Arm 18 mm (0.709 in) 24 mm (0.945 in) 10 mm (0.394 in) 14 mm (0.551 in)
Boom 18 mm (0.709 in) 17 mm (0.669 in) 10 mm (0.394 in) 14 mm (0.551 in)
Bucket 18 mm (0.709 in) 24 mm (0.945 in) 10 mm (0.394 in) —
3.Dedicated special wrench
• For piston nuts : See diagram 1 + table 3

• For piston : See diagram 2 + table 3
Table 3
Unit: mm
(in.)
Cylin- Multipur-
A B C D E F G T
der pose bolt
12 -
175 mm 132 mm 400 mm 90 mm 40 mm
15 mm
Arm (6.890 - (1.197 - (15.748 (3.543 (1.575 -
(0.473 -
in) in) in) in) in)
For piston 0.590 in)
nuts Boom 12 - -
150 mm 112 mm 400 mm 90 mm 40 mm
15 mm
(5.906 - (4.409 - (15.748 (3.543 (1.575
Bucket (0.473 - -
in) in) in) in) in)
0.590 in)
12 -
105 mm 160 135 mm 14 mm 300 mm 70 mm 40 mm
15 mm
Arm (4.134 mm (6. (5.315 (0.551 (11.811 (2.756 (1.575 M12 X 25 (2)
(0.473 -
in) 299 in) in) in) in) in) in)
0.590 in)
12 -
83 mm 145 110 mm 14 mm 300 mm 70 mm 40 mm
15 mm
For piston Boom (3.268 mm (5. (4.331 (0.551 (11.811 (2.756 (1.575 M12 X 25 (2)
(0.473 -
0.590 in)
12 -
86 mm 150 115 mm 14 mm 300 mm 70 mm 40 mm
15 mm
Bucket (3.386 mm (5. (4.428 (0.551 (11.811 (2.756 (1.575 M12 X 25 (2)
(0.473 -
0.590 in)
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Diagram 1: For piston nuts (A commercially available hook wrench can also be used.)
a. Plate thickness: T
SMIL14CEX3663BA 1
Diagram 2: For pistons

a. Hole DD
b. Plate thickness: T
SMIL14CEX3664BA 2
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4.Pin bushing press-fit jig: See diagram 3 + table 4
Table 4
Unit: mm
(in.)
Cylinder DA DB DC DD E F G H I
99.4 - 9 114.4 - 1 7.4 -
9.5 mm 14.6 mm 145 mm 120 mm 7.6 mm 70 mm
20 mm ( 10 mm 100 mm
Arm (3.913 (4.504 - (5.709 (4.724 (0.2914 (2.756
0.787 in) (0.394 in) (3.937 in)
- 3.917 4.5118 in) in) - 0.2992 in)
in) in) in)
109.4
124.4 - 1 8.9 -
- 109.
24.6 mm 150 mm 130 mm 9.1 mm 70 mm
5 mm 20 mm ( 10 mm 100 mm
Rod side (4.8977 (5.907 (5.118 (0.3504 (2.756
(4.3071 0.787 in) (0.394 in) (3.937 in)
- 4.9055 in) in) - 0.3582 in)
- 4.311
in) in)
Boom 0 in)
89.4 - 8 104.4 - 1 6.4 -
9.5 mm 04.6 mm 115 mm 95 mm 6.6 mm 70 mm
Head 20 mm ( 10 mm 100 mm
(3.5197 (4.1103 (4.528 (3.740 (0.2520 (2.756
side 0.787 in) (0.394 in) (3.937 in)
- 3.523 - 4.1181 in) in) - 0.2598 in)
6 in) in) in)
104.4
119.4 - 1
- 104.
19.6 mm 135 mm 105 mm 70 mm
5 mm 20 mm ( 10 mm 100 mm
Rod side (4.7008 (5.315 (4.134 (2.756
(4.1103 0.787 in) (0.394 in) (3.937 in)
- 4.7086 in) in) in)
- 4.114
in)
Bucket 1 in)
94.4 - 9 109.4 - 1 6.4 -
4.5 mm 09.6 mm 120 mm 100 mm 6.6 mm 70 mm
Head 20 mm ( 10 mm 100 mm
(3.7166 (4.3071 (4.724 (3.937 (0.2520 (2.756
side 0.787 in) (0.394 in) (3.937 in)
- 37204 - 4.3149 in) in) - 0.2598 in)
in) in) in)
Bore DA1=DA-20 (ok without DA1 hole)
SMIL14CEX3665EA 3
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5. Rod bushing press-fit jig: See diagram 4 + table 5
Table 5
Cylinder A B C D E
Unit: mm (in.)
119.9 - 120 mm 126.7 - 126.9 mm
115 mm 150 mm
ARM (4.7205 - (4.9882 - 45 mm (1.772 in)
(4.528 in) (5.906 in)
4.7244 in) 4.9960 in)
99.9 - 100 mm 96.7 - 96.9 mm
100 mm 130 mm
BOOM (3.9331 - (3.8071 - 30 mm (1.181 in)
(3.937 in) (5.118 in)
3.9370 in) 3.8149 in)
104.9 - 105 mm 99.7 - 99.9 mm
140 mm
BUCKET (4.1300 - (3.9252 - 40 mm (1.575 in) 90 mm (3.543 in)
(5.512 in)
4.1338 in) 3.9330 in)
Bore DA1=DA-20 (ok without DA1 hole)
SMIL14CEX3666EA 4
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6.Dust seal press-fit jig: See diagram 5 + table 6
Table 6
Cylinder A B C D E F G H I J
Unit:
mm (in.)
125 mm 25 mm
130 mm ( 135 mm ( 150 mm ( 80 mm ( 5 mm (0. 5 mm (0. 15 mm 5 mm (0
ARM (4.921 (0.984
5.118 in) 5.315 in) 5.906 in) 3.150 in) 197 in) 1969 in) (0.591 in) .197 in)
in) in)
105 mm
108 mm ( 113 mm ( 128 mm (
BOOM (4.134
4.252 in) 4.449 in) 5.039 in)
in)
110 mm
115 mm ( 120 mm ( 140 mm (
BUCKET (4.331
4.528 in) 4.724 in) 5.512 in)
in)
SMIL14CEX3667EA 5
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7.Rod cover insertion jig: See diagram 6 + table 7
Table 7
Unit: mm
(in.)
Cylinder A B C D E F G
115.2 - 119.9 -
101 mm 110 mm 115.4 mm 120 mm 33 mm 28.5 mm 210 mm
ARM
(3.976 in) (4.331 in) (4.5354 - (4.7205 - (1.299 in) (1.1220 in) (8.268 in)
4.5433 in) 4.7244 in)
95.2 - 99.9 -
78.5 mm 90 mm 95.4 mm 100 mm 33 mm 28.5 mm 170 mm
BOOM
(3.0906 in) (3.543 in) (3.7481 - (3.9331 - (1.299 in) (1.1220 in) (6.693 in)
3.7559 in) 3.9370 in)
100.2 - 104.9 -
82.5 mm 95 mm 100.4 mm 105 mm 33 mm 28.5 mm 170 mm
BUCKET
(3.2480 in) (3.740 in) (3.9449 - (4.1300 - (1.299 in) (1.1220 in) (6.693 in)
3.9527 in) 4.1338 in)
SMIL14CEX3668EA 6
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Boom cylinder - Static description

Troubling diagnostics
Hydraulic cylinder trouble, countermeasure and solution
It is not easy to discover trouble locations.
The table below shows general symptoms, suggested causes and also solutions.
For repairs, see the suggested causes and solutions in Boom cylinder - Troubleshooting (35.736).
The cause of machine problems are often not rooted in just a single part. Problems are often due to the relationship
of one part with another.
In some cases, solutions are required other than those given in Boom cylinder - Troubleshooting (35.736).
In such a case, contact with our company to investigate the problem and its cause further and take appropriate mea-
sures.
Item Symptom
1. Piston rod sliding section oil leak (For the judgment values, see Boom cylinder - Inspect (35.736) .)
2. Cylinder head matching section oil leak
3. Pipe and cylinder tube welding section oil leak
4. Operation defect
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Boom cylinder - Sectional view
SMIL14CEX3709HB 1
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*2. Outer periphery knurling processing *9. For right: Serial No. stamping position
*3. Cushion stroke *10. For left: Serial No. stamping position
Pay attention for orientation of semicircle during
*4. *11. With poly-cap
assembly.
Female screw effective depth 21 mm
*5. Slit direction is as indicated in the diagram. *12.
(0.827 in)
Female screw effective depth 18 mm
*6. To the bottom pin center *13.
(0.709 in)
After tightening, crimp two locations around the
*7. *14. Hexagon bolt width 115 mm (4.528 in)
perimeter by punching.
*8. Through (4-M10 x 1.5) *15. 106 mm (4.173 in) or more (for both sides)
L1 Maximum shrinkage length: 2090 mm (82.283 in)

L2 Stroke: 1495 mm (58.858 in)
1. Tube subassembly (Quantity 1) 21. Nut (M80 x 3) (Quantity 1)

2. Rod subassembly (Quantity 1) 22. Retaining screw ( M14 x 2) (Quantity 1)
3. Cylinder head (Quantity 1) 23. Steel ball (Quantity 1)
4. Bushing (Quantity 1) 24. Pin bushing (Quantity 1)
5. Retaining ring (Quantity 1) 25. Wiper ring (Quantity 2)
6. Buffer ring (Quantity 1) 26. Pin bushing (Quantity 1)
7. U-ring (Quantity 1) 27. Wiper ring (Quantity 2)
8. Backup ring (Quantity 1) 28. Pipe subassembly (Quantity 1)
9. Wiper ring (Quantity 1) 29. Pipe subassembly (Quantity 1)
10. O-ring (Quantity 1) 30. O-ring (Quantity 2)
Hexagon socket head bolt ( 4-M12 x 1.75) (Quantity
11. Backup ring (Quantity 1) 31.
8)
Hexagon socket head bolt ( 10-M20 x 2.5)
12. 32. Band subassembly (Quantity 1)
(Quantity 10)
13. Cushion ring (Quantity 1) 33. Band (Quantity 1)
14. Cushion seal (Quantity 1) 34. Bolt ( 2-M10 x 1.5) (Quantity 2)
15. Piston (Quantity 1) 35. Washer (Quantity 2)
16. Seal ring assembly (Quantity 1) 36. Pipe holder (Quantity 2)
17. Backup ring (Quantity 2) 37. Bolt (M14 x 2) (Quantity 1)
18. Slide ring (Quantity 2) 38. Spring washer (Quantity 1)
19. Slide ring (Quantity 2) 39. Grease nipple(Quantity 1)
20. Shim (Quantity 1)
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Boom lifting cylinder holding valve - Overview
SMIL14CEX3579FA 1
Port Port size

A SAE 6000psi 1
B SAE 6000psi 1
C G1/4
DR G3/8
PL G1/4
G1 G3/8
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Boom cylinder - Service instruction

Precautions for removal and installation of the cylinder
When installing the cylinder on the machine body or re-
moving it from the machine body, secure the piston rod
at the fully retracted position, check safety, and sus-
pend.
CAUTION:
• Never suspend the cylinder from the line section. This would not only pose the danger of falling but could
also damage the cylinder.
• Use a band to secure the piston rod in the fully retracted state. If the piston rod is not in the fully retracted state,
it could be easily damaged. This could create the need for repair or make the piston rod unusable. Also, not
securing the piston rod is dangerous because the piston rod might fly out unexpectedly.
Do not weld after the cylinder has been mounted on the

machine body.
CAUTION: Electric welding on the cylinder or even at a position separated from the cylinder can generate a
spark within the cylinder and damage parts. This could cause extensive damage, making it necessary to replace
parts or replace the cylinder.
When painting the machine body, mask the piston rod

and wiper ring.
CAUTION: If the cylinder is operated with paint sticking to the piston rod surface and the wiper ring, the wiper
ring does not function adequately, greatly interfering with cylinder functions. For example, dirt and paint from the
outside may get into the cylinder easily and damage seal parts and cause an oil leak.
Clean the cylinder before installing it.
Usage Cautions
Use under the determined conditions.
CAUTION:
• Use of hydraulic oil other than specified can cause rapid deterioration of and damage to seal parts. If the
relief valve is set to a value higher than that on the assembly diagram, there is a danger of this leading to
cylinder damage.
• General sealing materials cannot handle high ambient temperature [about 100.0 °C (212.0 °F) or higher]
or low ambient temperature [ -20.0 °C (-4.0 °F) or lower], so the cylinder would be damaged if used at such
temperatures. Such temperatures require special seal materials, so check if the cylinder being used complies
with this requirement.
• The number one cause of cylinder trouble is oil leaks due to piston rod scratches. Operate very carefully to
avoid scratching.
• If the piston rod is scratched, handle this according to Boom cylinder - Inspect (35.736).
Warm up the equipment adequately before beginning

work.
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CAUTION:
• After the cylinder has been stopped for a long time, the seal parts inside the cylinder are stuck to the metal of
sliding surfaces, so do not suddenly pressurize or operate such a cylinder.
• A new cylinder or one that has been left unused for a long time has much air built up inside, so it does not
operate smoothly. Also, if the cylinder is suddenly operated or pressurized without bleeding out the air, the
adiabatic compression of the air generates high temperatures, which may burn and carbonize seal parts,
leading to a drastically reduced functionality.
• Before starting work, always warm up the cylinder by moving slowly through a few full strokes under no load to
bleed off any air in the cylinder.
For stopping the machine temporarily or storing it, al-

ways have the machine in a safely secure posture.
CAUTION:
• When extended, the cylinder cannot hold a load for a long time in a fixed position. This is because the cylinder is
extended and retracted by very minor oil leaks from hydraulic circuits and from inside the cylinder and changes in
the volume of the hydraulic oil due to oil temperature variation. This results in the danger of machine moving
unexpectedly, which can lead to serious accidents.
• For stopping the machine temporarily or storing it, always have the machine in a safely secure position.
Maintenance and Inspection Cautions

Always carry out daily maintenance inspections.
CAUTION:
• The most important point for realizing the cylinder functions for a longer time is "daily maintenance inspections".
• In order to ensure adequate functioning, execute Boom cylinder - Inspect (35.736).
• Constantly clean off any mud, water, dust, oil or grease stuck to the piston rod and keep the piston rod in a
clean state.
• However, do not use water or the like to clean the wiper ring section and seal section. Wipe with a rag.
• When leaving the machine unused for a week or longer, apply anti-rust oil to the surface of the piston rod in
order to prevent rusting.
Use genuine TOYO parts for replacement parts.
CAUTION:
• If replacement parts are used that are not genuine TOYO parts, adequate functioning cannot be attained.
• Always use genuine TOYO parts.
• Specialty jigs have been produced so that assembly work and disassembly work can be done safely and
quickly, so order them.
Be careful about assembly and disassembly too.
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CAUTION:
• Disassembling a cylinder still installed on the machine body is extremely dangerous because it can cause
unexpected movement of the machine body.
• Always remove the cylinder from the machine body before disassembling it.
• Assembling with dirty hands can get dirt inside the cylinder and not only reduce the cylinder service life but
also damage other hydraulic equipment.
• Assemble under clean conditions.
• Use the thread part tightening torque indicated in the diagram.
• If the torque is either too low or too high, this can cause thread damage.
Strictly observe the cylinder storage standards.
CAUTION: Execute according to "disassemble and assemble procedures".
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Boom cylinder - Prepare

WARNING
Improper operation or service of this machine can result in an accident.
Raised equipment or machine movement without an operator can cause serious injury. Always do the
following before performing any maintenance:
Park the machine on flat, level ground.
Lower the attachment to the ground.
Shut down the engine and remove the ignition key.
Lock the tracks.
W0944D
WARNING
Assign a supervisor to direct worksite operations. Agree on all safety measures, procedures, and
suitable hand signals.
W0287A
WARNING
Avoid injury!
Use Personal Protective Equipment (PPE), including protective goggles, gloves, and safety footwear.
W1036A
WARNING
Crushing hazard!
latches.
W0256A
WARNING
Heavy objects!
W0398A
NOTICE: When working together with others, always be sure to exchange signals and pay adequate attention to
safety.
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Items to prepare:
• Wrench [ 19 mm, 30 mm, 36 mm]
• Crowbar
• Wire rope (with the required lifting capacity)
• Nylon sling
• Marking pen
• Cap
• Plug
• Hammer
• Striking rod
• Grease
• Rag
• Cleaning fluid
• Crosstie
• Wires
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Boom cylinder - Remove

• When removing only the boom cylinder, put the at-
tachments in the temporary decommissioning pos-
ture.
• To remove the boom, first remove the bucket, bucket
link, bucket cylinder, arm, arm cylinder according to
their respective removal and installation procedures.
Bring the boom top in contact with the ground.
1. Use a lifting equipment and nylon sling (1) to secure
the boom cylinders (right) (left) (2), (3).
SMIL14CEX2172AB 1
2. Use a wrench [ 19 mm] to remove the grease hoses (1)

on the left and right sides.
• Use caps or plugs to prevent any entry of water, dust
or dirt.
SMIL14CEX1855AB 2
3. Use 2 wrenches [ 36 mm] to remove the 2 double nuts

(1) and pull the bolt (2) out, and then remove the fas-
tening ring (3).
Also, remove the cab side in the same way.
SMIL14CEX1853AB 3
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4. Use a hammer (2) and striking rod (3) to push the pin
(1) out.
Start the engine, move the boom down at idle, and
retract the boom cylinder (right) (left) rods.
SMIL14CEX2175AB 4
5. Tie the cylinder rods on the left and right sides with wire
(1) so that they cannot come out.
SMIL14CEX2176AB 5
6. Turn the key switch (1) OFF to stop the engine.
SMIL14CEX2141AB 6
7. Turn the key switch ON again, and then turn the control
levers (1) about 10 times to bleed out any pressure.
SMIL14CEX2142AB 7
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8. Move the travel lever (1) back and forth about 5 times
to bleed off the pressure.
• Turn the key switch OFF.
SMIL14CEX2143AB 8
9. Press the air breather button (1) on top of the hydraulic

tank to release the pressure inside the tank.
SMIL14CEX2177AB 9
10. Remove the hoses that are connected to the HBCV.

See Boom lifting cylinder holding valve - Remove
(35.736).
• Mark the lines and hoses so that the connectors
match at the time of installation.
• Use caps or plugs to cover the hoses and lines to
• Clean the hoses and lines by spraying them with a
parts cleaner to prevent scratches and prevent dirt
from accumulating on the connectors.
11. Use a wrench [ 30 mm] to remove the bolt (1) and
spacer (2).
Also, remove the cab side in the same way.
SMIL14CEX2178AB 10
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12. Use a crowbar to remove the pin (1). Also, remove

the cab side in the same way.
SMIL14CEX2179AB 11
13. Use a lifting equipment and a nylon sling (1) to lift the
boom cylinders (right) (left) (2), (3) and remove.
• Place the boom cylinders (right) (left) (2), (3) on
crossties.
SMIL14CEX2180AB 12
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Boom cylinder - Install

• When installing the bolts, tighten them to the speci-
fied torque.
• When the torque is not specified, check the “ Torque
– Bolt and nut ()”.
1. Clean each pin and pin hole.
SMIL14CEX2181AA 1
2. Tie the cylinder rods on the left and right sides with wire
(1) so that they cannot come out.
SMIL14CEX2176AB 2
3. Use a lifting equipment and a nylon sling (1) to lift the

boom cylinders (right) (left) (2), (3).
SMIL14CEX2180AB 3
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4. Align the boom cylinders (right) (left) with the swing

frame pin holes and use a hammer (2) to push in the
pin (1).
• When inserting the pin, be careful not to damage the
installed dust seals.
SMIL14CEX2182AB 4
5. Use a wrench [ 30 mm] to tighten the bolt (1) and

spacer (2).
Install the cab side in the same way.
SMIL14CEX2183AB 5
6. Install the hoses that are connected to the HBCV.

See “ Boom lifting cylinder holding valve - Install
(35.736)”.
• The O-rings cannot be reused. Use new parts.
7. Start the engine, raise the boom at idle, and extend the
boom cylinder (right) (left) (1), (2) rods.
Align the boom cylinders (right) (left) (1), (2) with the
boom pin holes and use a hammer (4) to push in the
pin (3).
• If the insertion of a shim is possible according to the
tolerance, adjust the shim.
SMIL14CEX2184AB 6
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8. Use 2 wrenches [ 36 mm] to install the 2 double nuts

(1) and bolt (2), and install the fastening ring (3).
Also, install the cab side in the same way.
SMIL14CEX1854AB 7
9. Use a wrench [ 19 mm] to install the grease hoses (1)

on the left and right sides.
• Grease up.
• When installing as far as the boom, first install the
bucket, bucket link, bucket cylinder, arm, arm cylin-
der according to their respective removal and instal-
lation procedures.
SMIL14CEX1855AB 8
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Boom cylinder - Prepare – For disassemble

Preparations prepare the following before starting disassembly.
1. Work platform preparation
Prepare a sufficiently spacious, solid and stable work
surface so that parts will not fall or move during work.
2. Tool and materials preparation
Prepare the tools and materials shown on the following
pages.

1. Thoroughly clean any dirt or mud from the outside walls
of the cylinder before starting disassembly.
2. Each part has been manufactured with a high degree
of precision, so be careful to not let parts bump each
other or fall when handling them.
3. If parts are struck or pried off with excessive force dur-
ing work because they are tight, this may cause burrs
or damage which causing reduction in performance or
oil leaking. Perform work carefully and thoroughly.
4. If a cylinder is left disassembled, humidity and dirt can
cause rust on parts. If a pause in the work is unavoid-
able, be careful to prevent rust and keep off dust.
Replace sliding parts and seal parts as follows.
1. Bushing
When 1/4 of the circumference is worn brown over the
entire length.
2. Seals and slide rings
Replace with new parts when the cylinder is disassem-
bled.
3. Pin bushing
When there is severe seizing.
4. Piston rod
When the piston rod is bent 0.5 mm (0.0197 in) / 1 m
(3.281 ft) or more.
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Boom cylinder - Disassemble

Operating environment
It is necessary to emphasize that foreign matter (sand, metal filings, welding slug, and other hard material) and
scratches to sliding surfaces are bad for hydraulic cylinders. (Depending on the level of the scratches on a sliding
surface, it may be impossible to repair and use the hydraulic cylinder.) For this reason and because hydraulic
cylinders are heavy, the location and environment of the facility used for disassembly and assembly must be clean.
The “Facility” above is the place that has a hoist or lifting equipment and adequate cleaning oil, compressed air,
rag, etc. for maintaining cleanliness, and the full complement of general tools. (It is desirable that it has a source of
hydraulic pressure so that simple tests can be performed.)
Work platform preparation

There must be a sturdy, unmoving work platform with enough space for all of the parts and such that parts do not
fall off or move around during the work.

A. Before disassembly, clean off all dirt, dust, and grease from the outer circumference of the cylinder.
B. Each part has been manufactured with a high degree of precision. Pay adequate attention when handling them
and be careful not to let parts bump each other or fall.
C. Striking parts or pulling them with excessive force during work because they are tight or stuck may cause burrs
or damage, making it impossible to use them again, and may also lead to oil leaks and reduced performance.
Perform work carefully.
D. Rust may form on parts due to moisture or debris if the valve is left disassembled or if work is abandoned in
the middle of disassembly. If work must be halted, take measures to prevent rust from forming and dust
from settling on parts.
Tools required for disassembly and assembly and where they are used prepare the tools
as shown in the below table.
No Tools Remarks
1 Hammer • Steel hammer, Plastic hammer
2 Screwdriver 2 - 3 types of flathead screwdrivers (small and large)
3 Vise Can grip the rod cover
4 Wrench • Hexagon wrench, standard wrench, closed wrench, torque wrench
5 Pipe For extending wrench handle
6 Scoop Made of metal and has smooth corner
7 Wood auger One with sharp end
8 Specialty jig/tool • For piston nut, for piston, jig for seal assembly, for rod cover insertion, for
bushing press fit
For details on the sizes and other information of tools and jigs used for each hydraulic cylinder, see the separate
table.
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Example of structure of hydraulic cylinder made by DongYang Mechatronics
SMIL14CEX3669EA 1
1. Knukle 6. Piston
2. Rod cover 7. Piston nut
3. Rod 8. Pipe plunge
4. Tube 9. Head cover
5. Cushion ring 10. Check valve
A standard cylinder is used as an example in the

photographs of disassembly and assembly processes.
In actual work, proceed referencing the drawings
and structural diagrams for each individual cylinder.
Also, for the sizes of tools and jigs used in each work
process, see the separate tool and jig table.
Disassembly procedures
1. Installation (cylinder fastening) and oil removal
Place the crossties on the work platform and place
the cylinder horizontal on them. Using the flat sur-
face of the head cover side, clamp the cylinder in
place so that it does not move.
Never fasten the cylinder using the cylinder tube or
line pipe section.
After removing the plugs from the ports, supply air to
the head side port to move the rod and remove any oil
remaining in the cylinder.
SMIL14CEX3670AA 2
The remaining oil will spray out of the rod side port
forcefully, so use a vinyl hose as a temporary line to
lead the discharged oil into an oil drain can.
SMIL14CEX3671AA 3
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2. Disassembly of line pipe and line flange

Loosen and remove the line flange bolts and clamp
bolts.
[Tools]
Cylinder For flange bolts
ARM 12 mm hexagon wrench
BOOM
10 mm hexagon wrench
BUCKET
Use a pipe to extend the handle as necessary.
SMIL14CEX3672AA 4
[Tools]
Cylinder For clamp bolt
ARM M16 wrench
BOOM M12 wrench
BUCKET M16 wrench
SMIL14CEX3673AA 5
3. Loosening and removal of rod cover bolt.

Loosen and remove the tightening bolt on the rod cover.
[Tools]
Cylinder For rod cover bolts
ARM
17 mm hexagon wrench
BOOM
BUCKET 14 mm hexagon wrench
SMIL14CEX3674AA 6
Be particularly careful not to damage the rod surface

when loosening or removing bolts. (Wrapping a cloth
(even a rag is fine) around the rod surface to prevent
damage to the surface makes the work easier.)
SMIL14CEX3675AA 7
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4. Disassembly of rod cover

Before starting rod cover disassembly, lift up the rod
with the lifting equipment so that the rod and the cylin-
der tube form a straight line and support the weight of
the extended rod.
Place a plastic hammer against the rod cover line port
flange section corner, and then strike the plastic ham-
mer with a steel hammer to open up a gap between the
mating surfaces.
Then, insert a screwdriver into the gap and pry to grad-
ually widen the gap and take out the rod cover fitting
section.
SMIL14CEX3676AA 8
5. Removal of rod assembly

Hoist up the rod aiming for the center of gravity of the
rod assembly, and then gradually remove the rod as-
sembly while swinging the rod up and down, left and
right.
The moment the rod comes out, the center of gravity of
the hoisted load shifts and the rod may tilt and the hoist
belt slip. Therefore, support the rod securely so that it
does not tilt. (In order to make it harder for the rod to
slip, we recommend wrapping the belt around the rod
and hoisting it tightly.)
SMIL14CEX3677AA 9
6. Installation and fastening of rod assembly

Temporarily place the removed rod assembly level and
stable on crossties.
In order to prevent scratches on the rod surface, cover
the crossties with a rag, and then place the rod assem-
bly on the rag.
Using the flat surface of the rod head, clamp the rod in
place so that the rod assembly does not move to install
it in preparation for disassembly.
SMIL14CEX3678AA 10
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7. Disassembly of piston nut

First, loosen and remove the locking screw of the pis-
ton nut section. There is caulking around the outer cir-
cumference of the piston nuts so that the locking screw
does not come out. Therefore, repeatedly apply oil to
the screw section, loosen slightly, and then return to the
original position to gradually remove the locking screw.
(If you forcibly loosen the screw with high torque, the
threads will seize up and removal will become impos-
sible. Work carefully and patiently.)
1. Set screw caulking (2 places)
[Tools]
Cylinder For locking screw
ARM
BOOM 8 mm hexagon wrench
BUCKET

After loosening and removing the locking screw, use a
special tool to loosen the piston nut and disassemble.
SMIL14CEX3679BA 11
[Tools]
Cylinder For piston nuts
ARM Dedicated special
BOOM wrench (See the sepa-
BUCKET rate tool table.)
SMIL14CEX3680AA 12
8. Disassembly of piston
The piston also has threads on its inner diameter and
is screwed onto the rod. Using the bolt holes in the end
surface of the piston, put the specialty tool in place,
loosen, and remove.
[Tools]
Cylinder For piston
ARM Dedicated special
BOOM wrench (See the sepa-
BUCKET rate tool table.)

SMIL14CEX3681AA 13
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9. Removal of rod cover

Remove the rod cover from the rod, and then take it
out. For a cylinder with cushion, remove together with
the cushion ring, which is on the inner diameter section
of the rod cover.
When the rod cover is pulled off, there is resistance.
This is because there is tension on the rod seal. If re-
moval is hard, gently strike the rod cover flange sec-
tion diagonally with a plastic hammer while rotating and
pulling out. This makes it comparatively easy to re-
move the rod cover.
SMIL14CEX3682AA 14
10. Removal of seal parts from disassembled piston

A. If you spread open the abutment section by hand,
the wear ring and dust ring can be taken out eas-
ily from the groove.
B. Spread the abutment section by hand and take
out the backup rings from both sides of the pis-
ton seal. The center seal ring and back ring are
removed by cutting through them. Use a screw-
driver and hammer to cut the rings.
To cut the rings, place the piston on a V block
shaped platform or fasten with a vise in order to
make the piston stable.
Also, be careful not to strike too hard with the
hammer and damage the seal groove.
C. Use a scoop to take out the O-ring and backup
ring from the piston inner diameter section.
SMIL14CEX3683EA 15
1. Wear ring 3. Piston

2. Dust ring 4. Piston seal
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SMIL14CEX3684EA 16
1. Minus driver 6. Back up ring

2. O-ring 7. Hammer
3. Detail 8. Buckling
4. Seal ring 9. Scraper
5. Piston
11. Removal of seal parts from disassembled rod cover
SMIL14CEX3685EA 17
1. Scrape 6. U packing
2. Back up ring 7. Back up seal
3. O-ring 8. Rod bush
4. Rod 9. Snap ring
5. Dust seal 10. Gimlet
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Stand the rod cover on a flat, stable work platform.

Spread a rag to place the rod cover on, both to prevent
slipping and scratches.
A. First, use a scoop to remove the O-ring and backup
ring from the outer circumference section.
B. Then, turn the rod cover upside down, stick a sharp
tipped tool (such as a wood auger) to pry the buffer
seal, U packing, and backup ring on the inner di-
ameter section, pull them to the inner diameter
side, and remove them.
When sandwiching with a vise, place a plastic plate
or a copper plate at the mouthpiece section so that
the rod cover does not get scratched by the vise.
C. In order to remove the dust seal, sandwich the rod
cover with a vise to fasten, place a screwdriver with
a long handle on the U shaped groove on the dust
seal, then tap with a hammer to remove the dust
seal.
D. There is no need to remove a rod bushing unless
severe scratches or wear makes replacement nec-
essary.
When replacement is necessary, because the rod
bushing is press fit strongly into the rod cover, re-
moval intact is too difficult. Chip it out with a lathe.
(Remove the retaining ring from the rod bushing,
center correctly, chip away at the bushing until its
wall is thin, then insert a thin-tipped screwdriver
into the mouth chamfer gap and fold over to re-
move the bushing.)
SMIL14CEX3686EA 18
1. Hammer 3. Dust seal

2. Minus driver 4. Vise
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12. Disassembly of pin bushing

The pin bushing is press fit strongly. To remove it,
use a screwdriver to remove the pin seal at each
end, and then use a press with a metal block to push
out the pin bushing.
SMIL14CEX3687EA 19
1. Support ring 3. Pin bush

2. Rod 4. Gantry
13. Removal of check valve (arm, swing cylinder only)

Use a hexagon wrench to loosen and remove the
check valve plug, and then remove all the parts.
SMIL14CEX3688EA 20
The cushion plunger in the arm cylinder rod end section

cannot be disassembled.
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SMIL14CEX3689EA 21
1. Cylinder rod
2. Cushion plunge
The rod end section cushion plunger cannot be disas-
sembled.
14. Check, cleaning, and storing of the disassembled
parts
Check for any handling scratches and strike marks
from the disassembly. If there are any scratches,
use a file or sandpaper to repair them.
Removed seals cannot be reused.
Clean disassembled parts, coat them with anti-rust
oil, and store them until they are reused.
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Boom cylinder - Assemble

Assembly preparations and cleaning
Before assembling, check the appearance and dimen-
sions of all the components, including the new replace-
ment components, check that there is nothing abnor-
mal, and then prepare the components so that there
are the correct number of each component.
Removed seals cannot be reused. It is recommended
to replace all seals used in re-assembly with new ones,
even O-rings and backup rings that look totally normal.
For assembly, work on the subassemblies first. Imme-
diately before the assembly, clean the components to
be used for the subassemblies again, and check that
they are free of dust, foreign matter, or other abnormal-
ity.
Installation of pin bushing

Use a specialty press-fit jig to install each pin bushing.
For the pin bushing position, aim for the center of the in-
stallation hole, place vertically without any tilt, and press
fit. Applying a small amount of hydraulic oil to the walls
inside the hole makes insertion easier.
1. Press
2. Pin bush
3. Gantry
4. Rod
[Tools]
For pin bushing press
Cylinder SMIL14CEX3690AA 1
fitting
ARM Specialty press-fit jig
BOOM (See the separate jig ta-
BUCKET ble.)
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Assembly of rod cover

A. Use a specialty press-fit jig to install the rod bush-
ing. (Only when removed)
Press fit the bushing straight in without any tilt. Ap-
plying a small amount of hydraulic oil to the walls
inside the hole makes insertion easier.
B. Press fitting the rod bushing creates press fitting
shavings. Clean again to remove foreign matter.
C. After cleaning, mount the retaining ring in the
groove in the rod cover inner diameter section
on the rod bushing end surface. (Mount the re-
taining ring by hand and check that it is securely
mounted.)
SMIL14CEX3691AA 2
1. Press tool
2. Rod bush
3. Rod cover
[Tools]
For rod bushing press
Cylinder
fitting
BUCKET ble.)
D. For the dust seal installation, using the specialty

press-fit jig, tap with a hammer to press fit it.
For the dust seal position, aim for the center of the
installation hole, place horizontally without any tilt,
and press fit. Also, carefully center the dust seal by
bringing the press-fit jig into balanced contact with
the metal ring circumference of the dust seal.
Applying a small amount of hydraulic oil to the walls
inside the hole makes insertion easier. Carefully re-
move any dust (shavings from press fitting) gener-
ated during press fitting.
1. Press tool
2. Dust seal SMIL14CEX3692AA 3
3. Rod cover
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E. Mount the retaining ring in the groove in the rod

cover inner diameter section on the dust seal end
surface. (Mount the retaining ring by hand and
check that it is securely mounted.)
1. Press tool
2. Dust seal
3. Metal ring
[Tools]
For dust seal press
Cylinder
fitting
BOOM (See the separate jig ta- SMIL14CEX3693AA 4
BUCKET ble.)
F. Next, install the U packing backup ring, U packing,

buffer seal, and buffer seal backup ring, in that or-
der.
For installation, hand mounting is possible.
The U packing backup ring has a bias cut in 1 place.
Mount it in such a way that it slides in at a slant
from one side of the opening created by the cut. (It
does not matter which way it faces.) The U-pack-
ing, buffer seal, and buffer seal backup ring are un-
cut. Mount them deformed into a heart shape. Be
sure to mount them facing the correct direction. The
positions and directions of the components installed
in the rod cover are as in the figure.
SMIL14CEX3694EA 5
1. Insert from this direction
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SMIL14CEX3695EA 6
1. Dust seal 6. O-ring

2. Back up ring 7. Snap ring
3. U-packing 8. Buffer seal back up ring
Detail of the mounting orientation
4. Buffer seal 9. R part
5. Rod bush
G. Mount the rod cover outer circumference side

O-rings (2 locations) and backup ring. For installa-
tion, hand mounting is possible. (It does not matter
which way they face.)
Assembly of piston
The positions of the components installed on the piston
are as in the figure.
SMIL14CEX3696EA 7
1. Dust ring 4. Back up ring

2. Piston 5. Wear ring
3. O-ring 6. Piston seal
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A. First start by installing the piston seal backup ring.

Using a screwdriver with rounded corners, slide it
in.
B. Next, use the mounting jig to install the seal ring.
It is too difficult to deform the seal ring at normal
temperature. Immerse it in hydraulic oil heated up
to about 150 - 180 °C for about 5 min. to soften
it. Use the mounting jig to slide it in the piston seal
groove before it can cool off.
Use gloves to handle the heated seal ring, but
mount it quickly and with extreme care to avoid
burns. Also, heat the hydraulic oil with an electric
heater. (Using a flame would be dangerous. Ab-
solutely do not use a flame.)
C. Use the calibration jig to return the mounted seal
ring from its stretched state to its normal state.
D. Mount the backup rings on both sides of the seal
ring.
Be sure to mount the backup rings facing the cor-
rect direction.
E. Install the O-ring and backup rings (2 locations) on
the inner diameter side.
The wear rings and the dust rings are not installed
at this time because they are installed after rod
assembly, right before the rod assembly is inserted
into the cylinder tube.
SMIL14CEX3697EA 8
1. Tool to mounting 5. Seal ring corection

2. Heating seal ring 6. Back up ring
3. Buckling 7. Seal ring
4. Piston 8. O-ring
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SMIL14CEX3698EA 9
1. Rod 4. Piston Assy

2. Rod cover Assy’ 5. Set screw
3. Cushion ring 6. Piston nut
Rod assembly preparation (rod installation)

Place the rod horizontally using crossties on the work
platform and fasten strongly using the flat section of the
rod head so that the rod does not move.
SMIL14CEX3699AA 10
Installation of rod cover assembly

Install the rod cover assembly using the rod cover as-
sembly insertion jig. If you apply an appropriate amount
of hydraulic oil on the surfaces of the rod and the inser-
tion jig, the insertion resistance is less and the work is
easier. Use clean hydraulic oil with no dirt. (New oil is
recommended.)
1. Inserting
[Tools]
Cylinder For rod cover insertion
BUCKET ble.)
SMIL14CEX3700AA 11
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Cushion ring installation

Install the cushion ring.
This step is not necessary for a bucket cylinder or blade
cylinder because they have no cushion.
SMIL14CEX4103AA 12
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Installation and tightening of piston assembly

Before installation, apply a small amount of hydraulic oil
to the O-ring and threads of the inner diameter surface
section. Also, when screwing in, be careful with biting
in on the first thread. Forcing it in can cause seizing
and make assembly impossible.
SMIL14CEX3701EA 13
[Tightening torque] [Jig used]

Cylinder For piston For piston
ARM
883 - 1079 N·m (651.27 - 795.83 lb Dedicated special wrench (See the
BOOM
ft) separate tool table.)
BUCKET
Installation and tightening of piston nut

Screw in and tighten the piston nut.
Before installation, apply a small amount of hydraulic
oil to the threads. Also, when screwing in, be careful
with biting in on the first thread. Forcing it in can cause
seizing and make assembly impossible.
SMIL14CEX3702EA 14
[Tightening torque] [Jig used]

Cylinder For piston nuts For piston nuts
ARM
1674 - 2046 N·m (1234.68 - Dedicated special wrench (See the
BOOM
1509.05 lb ft) separate tool table.)
BUCKET
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For cylinder with cushion: After tightening the piston nut

to the specified torque, check that the cushion ring is not
stuck but has a gap of about 0.5 mm (0.0197 in) in the
shaft direction and can move freely.
If it is stuck, disassemble again and check its dimen-
sions.
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Installation of locking screw and handling looseness after tightening

Apply an appropriate amount of Loctite (#242) to 2 or 3
threads, then tighten by screwing the locking screw into
the screw hole in the outer circumference of the piston
nut. After tightening, wipe away any extruded Loctite.
SMIL14CEX3703EA 15
1. Torque wrench
2. Center punch
3. As shown caulkings
After tightening, use a center punch to perform lock
caulking at 2 locations (target positions) near the screw
hole.
[Tightening torque] [Tool used]: Torque wrench

Cylinder For locking screw For locking screw
ARM
BOOM 64 N·m (47.20 lb ft) Wrench dimension: 8 mm
BUCKET
Cylinder assembly preparation

Place the cylinder tube horizontally using crossties on
the work platform and fasten strongly using the flat sec-
tion of the head cover so that the rod cannot move.
Install the wear ring and dust ring in the piston external
circumference section of the rod assembly and apply
a small amount of hydraulic oil to the piston assembly
external circumference section.
Insertion of rod assembly into cylinder tube

Hoist the center of gravity of the rod assembly, and then
gradually insert it into the cylinder tube while swinging
the rod up and down, left and right.
During the insertion work, the wear ring or dust ring may
come out of its groove and bite in. Work carefully so that
this does not happen.
If insertion is difficult, place a plastic hammer against
the rod cover bolt installation surface and strike the
plastic hammer with a steel hammer.
SMIL14CEX3704AA 16
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Installation and tightening of rod cover bolt

While paying attention to the rod cover line flange di-
rection, line up the rod cover bolt hole position and the
cylinder tube side screw hole position, and then screw
in the bolt to tighten. Tighten bolts in order at the target
positions ensuring that they are evenly tightened.
During the insertion work, the wear ring or dust ring may
come out of its groove and bite in. Work carefully so that
this does not happen.
Be particularly careful not to damage the rod surface
when installing and tightening bolts. (Wrapping a cloth
(even a rag is fine) around the rod surface to prevent
damage to the surface makes the work easier.)
SMIL14CEX3705EA 17

Cylinder For rod cover bolts For bolts
ARM
628 - 677 N·m (463.19 - 499.33 lb ft) Wrench dimension: 17 mm
BOOM
BUCKET 471 - 490 N·m (347.39 - 361.41 lb ft) Wrench dimension: 14 mm
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Installation of line pipe

Mount the O-ring on the line flange mating surface sec-
tion, and then while lining up the cylinder side flange
surface position and line clamp position, temporarily
fasten with a bolt. After the positioning is complete, fully
tighten the line flange section bolt and line clamp sec-
tion bolt.
SMIL14CEX3706EA 18

Cylinder For rod cover bolts For bolts
ARM 137 - 147 N·m (101.05 - 108.42 lb ft) Wrench dimension: 12 mm
BOOM
108 - 116.00 N·m (79.66 - 85.56 lb ft) Wrench dimension: 10 mm
BUCKET
Head cover section cushion check valve installation (for arm and swing cylinder only)
Assemble the check valve, spring, spring bearing, plug
(with O-ring) in that order.
1. Check valve
2. Check valve spring
3. Spring bearing
4. O-ring
5. Check valve plug
Tightening torque
Cylinder For check valve plug
ARM 44.1 - 53.9 N·m (32.526 - 39.755 lb ft)
SMIL14CEX3707AA 19
[Tool used]: Torque wrench
Cylinder For check valve plug
ARM Hexagon head dimension: 8 mm
SMIL14CEX3708AA 20
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Boom cylinder - Inspect

Maintenance inspection and service
In order to ensure a hydraulic cylinder functions prop-
erly for a long time, periodically carry out maintenance
inspection and service based on the "Autonomous in-
spection table". Repair any trouble locations quickly
based on the Trouble Diagnostics.
CAUTION: For periodic inspection and service, first work to prevent any hazard to operators. Strive to prevent
hazards by working with an attitude based on good sense.
Inspection and
maintenance Inspection and service detail Daily Monthly Yearly Remarks
locations
Is the cylinder clean (especially
rod sliding sections)?
Is any oil leaking from line
Appearance installation sections or other fixed
sections?
Is there missing or peeling paint
or rust?
Is operation smooth and free of
abnormal noise and any other
abnormality?
Is the responsiveness good?
Is any oil leaking from sliding
Operation
sections?
Are there internal leaks? O
Is the operating pressure normal?
Is the overload relief valve set
pressure normal?
Is hydraulic oil dirty or
deteriorated?
Hydraulic oil Is hydraulic oil replaced
periodically?
Are filters inspected periodically?
Is the supply of grease to pins
adequate?
Do pin sections have any
abnormal noises or seizing?
Section for Do pin sections have any
installation with backlash or wear?
main unit
Are pin seals normal? O
Are any installation screws loose
or fallen out?
Retighten installation screws O
Are sliding sections worn? O When leaving
Are sliding sections scratched or piston rod
dented? sliding
Is sliding section plating peeling sections
Piston rod section off? exposed for
Are sliding sections bent? O long periods,
apply anti-rust
Are there any welding section oil to the
cracks or damage? piston rod.
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Inspection and
maintenance Inspection and service detail Daily Monthly Yearly Remarks
locations
Are there any loose bolts or nuts
(screws)?
Cylinder tube Retighten installation screws
section (including (bolts and nuts (screws))
line sections) Are there any welding section
cracks or damage?
Are there large dents on the tube?
Inspection after assembly

Dimension
Check the maximum retracted length and stroke as instructed on the diagram.
inspection
Pressure
Check for looseness, permanent deformation, and external leaks when the test pressure instructed
withstand
on the diagram is applied to each stroke end for at least 3 min.
inspection
Check the amount of oil leak at the rod section.
• Judgment value for rod section oil leak amount Move the piston rod back and forth 20 times with
the oil at a temperature from 20 - 104 °C (68 - 104 °F) then judge by the state of the oil ring formed
on the rod surface. If the oil ring is in a broken down A state, this is judged to be trouble. See
Boom cylinder - Troubleshooting (35.736) for information on how to solve this.
External leak
inspection
SMIL14CEX3653AB 1
Internal leak Oil leak amount unit: 10 min.
inspection Inner diameter Oil leak amount Inner diameter Oil leak amount
32 mm 100 mm 1 160 mm
0.4 4.0 10.0
(1.26 in) (3.94 in) (6.30 in)
40 mm 125 mm 180 mm
0.6 5.6 12.6
(1.57 in) (4.92 in) (7.09 in)
Internal leak 50 mm 140 mm 200 mm
1.0 6.0 15.6
inspection (1.97 in) (5.51 in) (7.87 in)
63 mm 220 mm
1.6 20.0
(2.48 in) (8.66 in)
80 mm 250 mm
2.3 22.0
(3.15 in) (9.84 in)
1. Oil ring
A. Acceptable
B. Not acceptable
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Boom cylinder - Storing

When a hydraulic cylinder is shipped from the plant, every measure is taken, but in order to prevent trouble during
storage and to extend the product service life, pay attention to the following items.
Storing parts individually (In principle, store indoors)

• Storing Parts Individually (In principle, store indoors)
• Before shipment, we operate the cylinder with hydraulic oil to which a fixed quantity of vaporizing anti-rust agent
has been added (in order to prevent rust within the cylinder), carry out the pre-shipping inspection, retract the
piston rod with ultra-dry air (condensation point -35 °C (-31 °F) or lower) (in order to prevent condensation due to
temperature difference), and then put caps on the ports and line joints before shipping the cylinder.
• Any product that has been in storage in our product warehouse longer than the standard storage period is
disassembled and inspected before being shipped. Therefore, do not store or leave a cylinder unused with a cap
removed or with the remaining oil in the cylinder drained.
Storage for 6 month or longer (3

Storage for 1 month or longer Storage for 1 year or longer
months for cylinder alone)
Operate the cylinder back and forth
Clean any dust from the cylinder, Since there is a danger
with clear hydraulic oil, and then
and then apply antirust oil to the pin of packings deterioration,
pour anti-rust oil into the cylinder
1 bushings, flange sections, piston disassemble, inspect, and
and store in compliance with the
rod, and other sections that rust replace packings.Also, check for
items on the left for storage of 1
easily. rust inside the cylinder.
month.
If a cylinder that has been stored
If the cylinder cannot be operated, for a long time is used as is, oil may
2 –
seal in anti-rust oil. leak due to temporary running-in
defects of seals.
When storing, be extremely careful not to let parts drop, let them collide with anything, or let anything strike
3
them.
When mounted on vehicle body

1. Operate the cylinder at least once per month.
2. Retract the cylinder so that as much as possible outside air does not touch the piston rod and apply antirust oil
at least once per month to the exposed part of the piston rod.
3. Handle carefully to absolutely avoid scratching the piston rod.
4. When putting the cylinder into an environment where rust occurs particularly easily, for example due to
exposure to sea breezes during export, always apply anti-rust oil to the piston rod and as much as possible
protect with polyethylene sheets or VCI paper (vaporizing anti-rust paper).
5. Anti-rust oil and other solvents can have negative impacts on seals, so select anti-rust oil carefully and as
much as possible keep it off dust seals etc.
Recommended anti-rust oil

Vaporizing anti-rust oil
a. Ferro Gard #1009 (from USC Limited)
a. Knuckle Oil #105S (from Parker Industries, Inc.)
For inside cylinder For both a. and b., add 3 - 5 % of the
hydraulic oil.
By volume,
Ferro Gard: 5/100
Knuckle Oil: 3/100
For piston rod Anti-rust P-1300 (from the Nippon Oil Corporation)
For machine worked surfaces
other than parts with oil Select from JIS K 2246 (anti-rust oil) NP-1 through NP-6.
sealed in
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Boom lifting cylinder holding valve - Prepare

WARNING
Lock the tracks.
W0944D
WARNING
W0287A
WARNING
Escaping fluid!
doctor immediately.
W0178A
safety.
Items to prepare:
• Wrench [ 19 mm, 22 mm, 27 mm]
• Marking pen
• Cap
• Plug
• Rag
• Cleaning fluid
• Crosstie
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Boom lifting cylinder holding valve - Remove

1. Use wrenches [ 19 mm, 22 mm] to remove the hoses
(1), (2), (3) and (4) from the tool box side boom HBCV.
• Mark the HBCV and hoses so that the connectors
• Use caps or plugs to cover the HBCV and line to
• Clean the HBCV and line by spraying them with a
1. Pilot hose [use 22 mm wrench)]
2. Drain hose [use 22 mm wrench]
SMIL14CEX1341AB 1
line (2).
SMIL14CEX1342AB 2

boom HBCV (2).
SMIL14CEX1343AB 3
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4. Use wrenches [ 19 mm, 22 mm] to remove the hoses

(1), (3), (4) and (5) from the cab side boom HBCV as
in 1, and use a wrench [ 27 mm] to remove the boom
bottom pressure sensor (6).
• Mark the HBCV and hoses so that the connectors
1. Pilot hose [use 22 mm wrench)] SMIL14CEX1344AB 4

line (2) and O-ring (1).
SMIL14CEX1345AB 5

boom HBCV (2) and O-ring (1).
SMIL14CEX1346AB 6
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Boom lifting cylinder holding valve - Install

1. Set the O-ring (1) on the boom HBCV (2), and then
install with 4 hexagon socket head bolts (3).
• The O-ring cannot be reused.
Replace with a new part.
81.058 lb ft).
SMIL14CEX1346AB 1
2. Set the O-ring (1) on the line (2), and then install with 4
hexagon socket head bolts (3).
81.058 lb ft).
SMIL14CEX1345AB 2
3. Use wrenches [ 19 mm, 22 mm] to install the boom

HBCV hoses (1), (3), (4) and (5), and then use a wrench
[ 27 mm] to install the boom bottom pressure sensor
(6).
• Install at the position where the HBCV and hoses are
marked so that the connectors match at the time of
installation.
SMIL14CEX1344AB 3
4. Set the O-ring (1) on the boom HBCV (2), and then
install with 4 hexagon socket head bolts (3).
81.058 lb ft)
SMIL14CEX1346AB 4
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81.058 lb ft)
SMIL14CEX1345AB 5
6. Use wrenches [ 19 mm, 22 mm] to install the boom

HBCV hoses (1), (2), (3) and (4) on the tool box side.
installation.
SMIL14CEX1347AB 6
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Boom cylinder - Troubleshooting

NOTICE: The hydraulic oil expands and contracts with changes in temperature and pressure.
This causes the cylinder to extend and retract too, so it can be mistaken for an internal oil leak.
For internal oil leaks, always check the temperature and pressure under the same conditions.
Piston rod sliding section Piston rod: A sliding surface has rust and 1. Remove the scratches with a whetstone
oil leak scratches that catch on a fingernail to make the sliding surface smooth (1.5
s or lower). If the oil leak continues,
the rod scratches may have damaged
the U-ring or other seal, so disassemble
and inspect
2. If the scratches or rust cover too large
an area to be repaired with a whetstone,
replace the piston rod and the U-ring,
wiper ring, or other seal and the piston
rod bearing part
Piston rod: Plating is peeling off 1. Replate or replace the piston rod
2. At this time, inspect the seals and piston
rod bearing part as well and replace any
that are damaged
Rod packing (buffer ring and Uring): There 1. Remove the foreign matter
is foreign matter caught in the inner or outer 2. If the packing is damaged, replace it
diameter section
Rod packing (buffer ring and Uring): There Replace the part
are scratches on the inner or outer diame-
ter section
Rod packing (buffer ring and Uring): The 1. This may be scorching due to adiabatic
lips and groove section are locally car- compression of air remaining in the
bonized (scorched) cylinder
2. When operating the cylinder for the first
time after replacing a packing, run at
low pressure and low speed to ade-
quately bleed off the air
Rod packing (buffer ring and Uring): The 1. Replace the part
packing has lost its rubber elasticity and is 2. This may be the end of the packing
in tatters service life, deterioration of the hydraulic
oil, or high temperature of the hydraulic
oil
A. Replace with new hydraulic oil
B. Check the temperature of the hy-
draulic oil. (The oil temperature should
be no higher than 80 °C.)
C. Check for local high temperature
Rod packing (buffer ring and Uring): The lip 1. Replace the part
section is defective all the way around 2. This may be the end of the packing
service life, deterioration of the hydraulic
oil, or high temperature of the hydraulic
oil
A. Replace with new hydraulic oil
B. Check the temperature of the hy-
draulic oil. (The oil temperature should
be no higher than 80 °C.)
C. Check for local high temperature
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Rod packing (buffer ring and Uring): There 1. Replace the part
is major extrusion of the packing heel sec- 2. Abnormally high pressure may be op-
tion erating on the packing
A. Check the pressure during operation
B. There may be trouble with the buffer
ring section
Inspect the buffer ring section
Piston rod sliding section Backup ring: The part is greatly deformed 1. As a rule, replace the rod packing too at
oil leak the same time
2. Abnormally high pressure is often the
cause. The check items for this are the
same as those given above for packing
heel section extrusion
Wiper ring: There is foreign matter caught Remove the foreign matter
in the lip
Wiper ring: The lip is damaged. There is Replace the part
other abnormal damage
Bearing part (bushing): There is major Replace the part
wear of the bushing and the gap with the
piston rod exceeds the limit on inner diam-
eter wear in “ Boom cylinder - Inspect
(35.736)”
Bearing part (bushing): There are large 1. Replace the part
scratches on a sliding surface 2. Inspect the piston rod sliding surfaces
for scratches and rust
Cylinder head: A seal mounting section 1. Remove the scratches or rust with a
has scratches and rust whetstone
2. If the repair does not solve the problem,
replace the cylinder head
Cylinder head matching O-ring: There is foreign matter caught in 1. Remove the foreign matter
section oil leak the inner or outer diameter. There is dam-
2. If the O-ring is damaged, replace it
age to the O-ring
3. Tube interior surface inspection: If there
are any scratches or rust, use a whet-
stone to make the surface smooth
4. Cylinder head O-ring groove inspection:
Same as above
5. Backup ring inspection: If the backup
ring is deformed or extruded, replace it
Check the above and replace the Oring
Backup ring: The part is deformed or ex- Replace together with the O-ring
truded
Cylinder head: A part is loose 1. Disassemble the cylinder head and in-
spect the O-ring and backup ring. If
there is damage, replace
2. Check the tube and cylinder head
threads for damage and if there is any
damage, replace
3. When the inspection is complete,
tighten to the specified torque. See “
Boom cylinder - Assemble (35.736)”
4. Stop rotation
Bolt: There is looseness, stretching, or Replace all the bolts and tighten to the
breakage specified torque
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Cylinder tube: There is an abnormal 1. Replace with a new one
swelling 2. Oil leaks at matching sections may be
caused by abnormally high pressure
(including cushion pressure), so if the
tube is swollen or deformed, replace it
with a new one. Also inspect the circuit
pressure
Pipe and cylinder tube Pipe and cylinder tube: There are cracks Replace with a new one
welding section oil leak on the welding section
Pipe and cylinder tube: There are cracks The crack progresses and ultimately the
on the welding section part fractures
A fracture is extremely dangerous, so if
a crack is seen, quickly stop work and
replace that part
Welding over a crack is ineffective
Oil leak from cylinder line Pipe assembly: Line fastening bolt is loose Tighten to the specified torque according to
connection section the work procedure
Pipe assembly: The line is bent Replace with a new one
Pipe assembly: There are scratches on a 1. Use a whetstone to make the surface
contact surface smooth
2. If the oil leak does not stop, replace
Operation defect Piston rod Cylinder tube: The bending 1. Replace with a new one
Movement is not smooth is large and exceeds the stipulated bend 2. There may also be damage to seals and
warp. (Bend warp: See “ Boom cylinder sliding parts, so inspect them. If there is
- Inspect (35.736)”.) any abnormality, replace
Cylinder tube: There are dents Replace with a new one. Inspect the seal
and sliding parts the same as above
Piston rod Cylinder tube Sliding part: Ab- 1. Replace with a new one. Inspect the
normal wear of sliding parts and damage, seal and sliding parts the same as
foreign matter caught at the piston section above
or the cylinder head sliding section 2. Remove the foreign matter. Inspect
the seal and sliding parts the same as
above
Internal oil leak The Piston seal: There are scratches, wear, or Replace with a new one. Also inspect the
piston rod extends and other damage cylinder tube interior surfaces
retracts on its own and
drops abnormally during
operation. Also, the
stipulated speed is not
output
Cylinder tube: There are scratches and 1. Use honing or a whetstone to eliminate
rust on interior surface the scratches and rust and make the
surface smooth. If the scratches cover
too large an area to be repaired, replace
the cylinder tube with a new one
2. Replace with a new piston seal
Piston nut: Tightening is insufficient 1. Tighten to the specified torque. See “
Boom cylinder - Assemble (35.736)”
2. The piston rod thread section could be
stretched. Measure the diameter where
the rod and piston fit together and if this
area is tapered, replace the piston rod
assembly
Valves: Leak from valve Inspect the amount of valve leakage and
perform maintenance
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Operation is unsteady Air: There is air remaining in the cylinder Perform air bleeding operation
A. Cylinder with no air bleeding Bleed out
the air by moving the cylinder back and
forth a few times at low pressure and low
speed
B. Cylinder with air bleeding (air
breather)
After securing the machine so that the
cylinder does not move, bleed the air
from the air breather
Reference
The cylinder may extend or retract some-
what when the cylinder stops suddenly.
This phenomenon occurs due to the
compressibility of the hydraulic oil. This
occurs particularly easily for cylinders
with long strokes
The impact is high when Pin bushing Pin: The gap between the in- Measure the pin and pin bushing dimen-
switching over between stallation section and the pin bushing is en- sions and replace any part that exceeds its
extension and retraction larged specified dimension
Cylinder sliding Pin bushing Pin: The oil or grease feed is Apply oil or grease
operations make sounds inadequate
Pin bushing Pin: There is seizing at match- Replace with a new part and apply oil or
ing section grease
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Index

Boom cylinder - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Boom cylinder - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Boom cylinder - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Boom cylinder - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Boom cylinder - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Boom cylinder - Prepare – For disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Boom cylinder - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Boom cylinder - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Boom cylinder - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Boom cylinder - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Boom cylinder - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Boom cylinder - Storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Boom cylinder - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Boom hydraulic system - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Boom lifting cylinder holding valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Boom lifting cylinder holding valve - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Boom lifting cylinder holding valve - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Boom lifting cylinder holding valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
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Dipper hydraulic system - 737

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Contents
FUNCTIONAL DATA
Dipper cylinder
Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Arm cylinder holding valve
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE
Dipper cylinder
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Arm cylinder holding valve
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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Hydraulic systems - Dipper hydraulic system
Dipper cylinder - Sectional view
SMIL14CEX3710HB 1
NOTE: All the dimensions in figure are in mm(in)
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*2. Outer periphery knurling processing *10. Non-directional

*3. Hexagon bolt width 135 mm (5.315 in) *11. Serial No. stamping position
After tightening, crimp two locations around the perimeter Female screw effective depth 23 mm
*4. *12.
by punching. (0.906 in)at two locations
*5. *13. 152 mm (5.984 in)or more for both sides
assembly.
*6. Cushion stroke *14. Depth: 25 mm (0.984 in)(4-M14 x 2)
*7. To the bottom center *15. With poly-cap
*8. Slit direction is as indicated in the diagram. *16. With a hole, one location
*9. 2 locations
L1. Maximum shrinkage length: 2445 mm (96.260 in)

L2. Stroke: 1748 mm (68.819 in)
1. Tube subassembly (Quantity 1) 22. Retaining screw (M16 x 2) (Quantity 1)

2. Rod subassembly (Quantity 1) 23. Steel ball (Quantity 1)
3. Cylinder head (Quantity 1) 24. Cushion ring (Quantity 1)
4. Bushing (Quantity 1) 25. Cushion seal (Quantity 1)
5. Retaining ring (Quantity 1) 26. Stopper (Quantity 2)
6. Buffer ring (Quantity 1) 27. Snap ring (Quantity 1)
7. U-ring (Quantity 1) 28. Pin bushing (Quantity 2)
8. Backup ring (Quantity 1) 29. Wiper ring (Quantity 4)
9. Wiper ring (Quantity 1) 30. Pipe subassembly (Quantity 1)
10. O-ring (Quantity 1) 31. Pipe subassembly (Quantity 1)
11. Backup ring (Quantity 1) 32. O-ring (Quantity 2)
Hexagon socket head bolt ( 12 - M22 x 2.5) (Quantity Hexagon socket head bolt ( 4 - M14 x2)
12. 33.
12) (Quantity 8)
13. Cushion ring (Quantity 1) 34. Band subassembly (Quantity 1)
14. Cushion seal (Quantity 1) 35. Band (Quantity 1)
15. Piston (Quantity 1) 36. Bolt ( 2-M10 x 1.5) (Quantity 2)
16. Seal ring assembly (Quantity 1) 37. Washer (Quantity 2)
17. Backup ring (Quantity 2) 38. Pipe holder (Quantity 2)
18. Snap ring (Quantity 2) 39. Bolt ( M14 x 2) (Quantity 2)
19. Snap ring (Quantity 2) 40. Spring washer (Quantity 2)
20. Shim (Quantity 1) 41. Grease nipple (Quantity 1)
21. Nut ( M95 x 4) (Quantity 1) 　
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Arm cylinder holding valve - Overview
SMIL14CEX3579FA 1
Port Port size

A SAE 6000psi 1
B SAE 6000psi 1
C G1/4
DR G3/8
PL G1/4
G1 G3/8
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Dipper cylinder - Prepare

WARNING
Lock the tracks.
W0944D
WARNING
W0287A
WARNING
Avoid injury!
W1036A
WARNING
Crushing hazard!
latches.
W0256A
WARNING
Heavy objects!
W0398A
safety.
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Items to prepare:
• Wrench [ 19 mm, 30 mm ]
• Hexagon wrench [ 12 mm ]
• Nylon sling (with the required lifting capacity)
• Cap
• Plug
• Hammer
• Striking rod
• Grease
• Rag
• Cleaning fluid
• Crosstie
• Wires
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Dipper cylinder - Remove

1. Use a lifting equipment and nylon sling (1) to fasten the
arm cylinder (2).
SMIL14CEX2156AB 1

spacer (2).
SMIL14CEX2157AB 2
3. Use a hammer (2) and striking rod (3) to remove the

pin (1).
Be careful. The arm and arm cylinder rod may come
out of place at this time.
SMIL14CEX2158AB 3
4. Start the engine, move the arm out at idle, and retract
the arm cylinder (1) rod.
SMIL14CEX2159AB 4
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5. Tie the cylinder rod with wire (1) so that it cannot come
out.
SMIL14CEX2160AB 5
6. Turn the key switch (1) OFF to stop the engine. Turn
the key switch ON again, and then turn the control lever
(2) about 10 times to bleed off any pressure.
Do not operate the arm at this time.
SMIL14CEX2141AB 6
SMIL14CEX2142AB 7
to bleed off the pressure.
SMIL14CEX2143AB 8
8. Turn the key switch OFF.
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SMIL14CEX2161AB 9

hexagon socket head bolts (1) from the hose (2), and
then remove the 2 split flanges (5) and O-ring (4).
• Remove the hose (3) with the same procedure.
SMIL14CEX2162AB 10
11. Use a wrench [ 19 mm] to remove the grease hose

(1).
• Use caps or plugs to prevent any entry of water,
dust or dirt.
SMIL14CEX2163AB 11

spacer (2).
SMIL14CEX2164AB 12
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(3) out.
• If the pin is hard to remove, there is a load on the
pin.
• When removing the pin, be careful not to damage
the installed O-rings or dust seals.
SMIL14CEX2165AB 13
14. Lift the arm cylinder (1), and then place it on the
crosstie.
SMIL14CEX2166AB 14
NOTE: To disassemble the cylinder, see “ Boom cylinder - Disassemble (35.736)”.

To assemble the cylinder, see “ Boom cylinder - Assemble (35.736)”.
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Dipper cylinder - Install

• Tighten lines and bolts being installed to the speci-
fied torque.
• When the torque is not specified, refer to “ Torque –
Bolt and nut ()”.
SMIL14CEX2167AA 1
out.
SMIL14CEX2160AB 2
3. Use a lifting equipment and nylon sling (2) to lift the arm
cylinder (1).
• Wrap the nylon sling to the inside of the line so that
it is not crushed.
SMIL14CEX2168AB 3
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4. Align the arm cylinder with the boom and use a hammer
(2) to push in the pin (1).
• If the pin is hard to insert, there is a load on the pin.
SMIL14CEX2169AB 4
5. Use a wrench [ 30 mm (1.181 in) ] to tighten the bolt

(1) and spacer (2).
SMIL14CEX2164AB 5
6. Use a wrench [ 19 mm (0.748 in) ] to install the grease

hose (1).
SMIL14CEX2163AB 6
7. Set the O-ring (4) on the line side, and then install the
hose (2) with 2 split flanges (5) and 4 hexagon socket
head bolts (1).
• Install the hose (3) with the same procedure.
• The O-rings cannot be reused. Use a new part.
Tightening torque for installation: 85.2 - 101.2 N·m
(62.840 - 74.641 lb ft)
SMIL14CEX2162AB 7
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8. Start the engine, move the arm in at idle, and extend

the arm cylinder (1) rod.
SMIL14CEX2170AB 8
9. Align the arm cylinder (1) with the arm pin hole and use
a hammer (3) to insert the pin (2).
Be careful. The arm and arm cylinder rod may come
out of place at this time.
SMIL14CEX2171AB 9

spacer (2).
• Grease up.
SMIL14CEX2157AB 10
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Arm cylinder holding valve - Prepare

WARNING
Lock the tracks.
W0944D
WARNING
W0287A
WARNING
Escaping fluid!
doctor immediately.
W0178A
safety.
Items to prepare:
• Wrench [ 22 mm]
• Marking pen
• Cap
• Plug
• Rag
• Cleaning fluid
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Arm cylinder holding valve - Remove

1. Use a wrench [ 22 mm] to remove the lines (1) (2).
• Mark the HBCV and line locations so that the con-
nectors match at the time of installation.
• Use caps or plugs to cover the lines and HBCV to
• Clean the lines and HBCV by spraying them with a
SMIL14CEX1338AB 1

line (2) and O-ring (3).
SMIL14CEX1339AB 2

arm HBCV (2) and O-ring (3).
SMIL14CEX1340AB 3
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Arm cylinder holding valve - Install

1. Set the O-ring (3) on the arm HBCV (2), and then install
with 4 hexagon socket head bolts (1).
• The O-ring cannot be reused. Replace it with a new
part.
Tightening torque: 74.9 - 109.9 N·m (55.2 - 81.1 lb ft).
SMIL14CEX1340AB 1
• The O-ring cannot be reused. Replace it with a new
part.
Tightening torque: 74.9 - 109.9 N·m (55.2 - 81.1 lb ft).
SMIL14CEX1339AB 2
3. Install the line assemblies (1) and (2).

installation.
SMIL14CEX1338AB 3
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Index

Arm cylinder holding valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Arm cylinder holding valve - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Arm cylinder holding valve - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Arm cylinder holding valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Dipper cylinder - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Dipper cylinder - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Dipper cylinder - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Dipper cylinder - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Excavator and backhoe bucket hydraulic system - 738

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Contents
FUNCTIONAL DATA
Bucket cylinder
Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Bucket cylinder
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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Hydraulic systems - Excavator and backhoe bucket hydraulic system
Bucket cylinder - Sectional view
SMIL14CEX3711HB 1
NOTE: All the dimensions in figure are in mm(in)
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Female screw effective depth 21.000 mm

*2. Outer periphery knurling processing *8.
(0.827 in) at two locations
After tightening, crimp two locations around the
*3. *9. Serial No. stamping position
perimeter by punching.
*4. Hexagon bolt width 115 mm (4.528 in) *10. 105 mm (4.134 in) or more
*5. Cushion stroke L1. Maximum shrinkage length: 1870 mm (73.622 in)
*6. L2. Stroke: 1210 mm (47.638 in)
assembly.
*7. To the bottom pin center

1 Tube subassembly (Quantity 1) 20 Nut ( M80 x 3 ) (Quantity 1)
2 Rod subassembly (Quantity 1) 21 Retaining screw ( M14 X 2) (Quantity 1)
3 Cylinder head (Quantity 1) 22 Steel ball (Quantity 1)
4 Bushing (Quantity 1) 23 Pin bushing (Quantity 1)
5 Retaining ring (Quantity 1) 24 Wiper ring (Quantity 2)
6 Buffer ring (Quantity 1) 25 Pin bushing (Quantity 1)
7 U-ring (Quantity 1) 26 Wiper ring (Quantity 2)
8 Backup ring (Quantity 1) 27 Joint subassembly (Quantity 1)
9 Wiper ring (Quantity 1) 28 Pipe subassembly (Quantity 1)
10 O-ring (Quantity 1) 29 O-ring (Quantity 1)
11 Backup ring (Quantity 1) 30 Hexagon socket head bolt (Quantity 8)
Hexagon socket head bolt (12 - M20 X 2.5)
12 31 Band subassembly (Quantity 1)
(Quantity 12)
13 Cushion ring (Quantity 1) 32 Band subassembly (Quantity 1)
14 Piston (Quantity 1) 33 Bolt (2- M10 X 1.5) (Quantity 2)
15 Seal ring assembly (Quantity 1) 34 Washer (Quantity 2)
16 Backup ring (Quantity 2) 35 Pipe holder (Quantity 1)
17 Slide ring (Quantity 2) 36 Bolt ( M12 X 1.75) (Quantity 1)
18 Slide ring (Quantity 2) 38 Spring washer (Quantity 1)
19 Shim (Quantity 1) 39 Grease nipple (Quantity 2)
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Bucket cylinder - Prepare

WARNING
Lock the tracks.
W0944D
WARNING
W0287A
WARNING
Avoid injury!
W1036A
WARNING
Crushing hazard!
latches.
W0256A
WARNING
Heavy objects!
W0398A
safety.
Items to prepare:
• Wrench [ 30 mm]
• Hammer
• Striking rod
• Grease
• Rag
• Cleaning fluid
• Crosstie
• Wires
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Bucket cylinder - Remove

• Remove the bucket. (For details, see “ Bucket -
Remove (84.100)”.)
• Remove the bucket link. (For details, see “ Link and
rod - Remove (84.100)”.)
1. Bring the arm (1) top in contact with the ground.
Retract the bucket cylinder rod.
SMIL14CEX2139AB 1
out.
SMIL14CEX2140AB 2
3. Turn the key switch (1) OFF and stop the engine.
SMIL14CEX2141AB 3
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4. Turn the key switch ON again, and then turn the control
levers (1) about 10 times to bleed out any pressure.
CAUTION: Do not operate the bucket at this

time.
SMIL14CEX2142AB 4
to bleed off the pressure. Return the key switch to OFF.
SMIL14CEX2143AB 5

SMIL14CEX2144AB 6
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hexagon socket head bolts (3) from the hose (2), and
then remove the 2 split flanges (4) and O-ring (5).
Remove the hose (1) in the same way.
SMIL14CEX2145BB 7
8. Use a lifting equipment and nylon sling (2) to fasten the

bucket cylinder (1).
it is not crushed.
SMIL14CEX2146AB 8

spacer (2).
SMIL14CEX2147AB 9
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(1) out.
SMIL14CEX2148AB 10
11. Lift the bucket cylinder (1) and then place it on the
crosstie.
SMIL14CEX2149AB 11
NOTE: To disassemble the cylinder, see “ Boom cylinder - Disassemble (35.736)”.

To assemble the cylinder, see “ Boom cylinder - Assemble (35.736)”
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Bucket cylinder - Install

• Tighten lines and bolts being installed to the speci-
fied torque.
• When the torque is not specified, refer to “ Torque –
Bolt and nut ()”.
SMIL14CEX2150AA 1
out.
SMIL14CEX2151AB 2
3. Use a lifting equipment and nylon sling (2) to lift the

bucket cylinder (1).
it is not crushed.
SMIL14CEX2152AB 3
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4. Align the bucket cylinder (1) with the arm and use a
hammer (3) to push in the pin (2).
• If the pin is hard to insert, the cylinder is tilted.
installed O-rings or dust seals.
SMIL14CEX2153AB 4
5. Use a wrench [ 30 mm] to install the bolt (1) and spacer

(2).
SMIL14CEX2154AB 5
6. Set the O-ring (5) on the line side, and then install the
hose (2) with 2 split flanges (4) and 4 hexagon socket
head bolts (3).
• Install the hose (1) with the same procedure.
• The O-rings cannot be reused. Use a new part.
• Install the bucket link. (For details, see Bucket
cylinder - Install (35.738))
• Install the bucket. (For details, see Bucket cylinder
- Install (35.738))
SMIL14CEX2155BB 6
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Index

Bucket cylinder - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Bucket cylinder - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Bucket cylinder - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Bucket cylinder - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Hammer and rotating bucket hydraulic system - 360

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Contents
FUNCTIONAL DATA
Rotating bucket valve

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hammer shears selection valve
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overview - Relief valve (electromagnetic proportional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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Hydraulic systems - Hammer and rotating bucket hydraulic system
Rotating bucket valve - Overview

SMIL14CEX3570FA 1
Port Port size

A1 G1/4
A2 G1/4
G G1/4
P G1/4
T G1/4
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Hammer shears selection valve - Overview

Direction valve
SMIL14CEX3576EA 1
Port Port size Port Port size Port Port size

A G1 T1 G1 PP G1/4
B G1 T2 G3/4 DR G1/4
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Hammer shears selection valve - Sectional view

Direction valve (3 directions)
SMIL14CEX3866GB 1
Diagram 1
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SMIL14CEX3867EA 2
Circuit diagram
1. Cover 7. Spring
2. Name plate 8. Hexagon socket head bolt
3. Spool 9. Hexagon socket head bolt
4. Spring 10. Hexagon socket head bolt
5. Body 11. Rivet screw
6. Cover 12. O-ring
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Hammer shears selection valve - Dynamic description

Direction valve (3 direction)
This valve switches the direction with the pilot pressure.
1. When the spool is in neutral ( PP port no load) Double-acting circuit, 2 pumps flow circuit selected
When the pilot pressure is not fed to the PP port, the spool (3) is held in the neutral position by the springs (4) (7).Con-
tinuity is established with the A port and B port and the T1 and T2 port pressure oil are cut off by the spool (3). (See
Diagram 1)
SMIL14CEX3868FB 1
(a) To control valve
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2. When the spool operates ( PP port pressurized) Breaker circuit selected
When pressure is fed to the PP port, force [F] ( PP port pressure x spool cross-sectional area) works on the spool (3)
in the left direction. When F becomes larger than the set load of springs (4) (7), the spool (3) moves to the left and
continuity with the A port and the T1 and T2 ports is established.
Also, at this time, the pressure oil at the B port is cut off by the spool (3). (See Diagram 2)
SMIL14CEX3869FB 2
(a) To hydraulic tank
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Hammer shears selection valve - Overview - Relief valve

(electromagnetic proportional)
SMIL14CEX0576EB 1
Port Port size

A G1
B G1
C G3/4
T G3/4
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Index

Hammer shears selection valve - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hammer shears selection valve - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hammer shears selection valve - Overview - Relief valve (electromagnetic proportional) . . . . . . . . . . . . . . . . . . . . . 9
Hammer shears selection valve - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rotating bucket valve - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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EN
SERVICE MANUAL
Frames and ballasting

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39
Contents
Frames and ballasting - 39
[39.140] Ballasts and supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1
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39
Ballasts and supports - 140

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Contents
SERVICE
Counterweight
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Frames and ballasting - Ballasts and supports
Counterweight - Prepare
WARNING
Avoid injury!
W1128A
WARNING
Crushing hazard!
latches.
W0256A
WARNING
Heavy objects!
W0398A
NOTICE: Thoroughly secure the removed counterweight with the wire ropes and lifting equipment so that it does not
fall over.
Items to prepare:
• Balance lifting device
• Wire rope (with the required breaking load) x 4
• Rag
• Cleaning fluid
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Counterweight - Remove
1. Remove the following before beginning work.
• Engine hood, gas damper and lock stay
• Rear view camera and electrical components
bracket
2. Install the shackles (1), and then use the wire ropes
(2) and lifting equipment to secure the counterweight
so that it does not fall during removal and installation
operations.
SMIL14CEX3870AB 1
3. Use a box wrench [ 50 mm] to remove the 4 bolts (1)

at the bottom section of the counterweight.
SMIL14CEX3871AB 2
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4. Use the wire ropes and lifting equipment to lift and re-
move the counterweight.
• Move the counterweight about 50 cm (19.685 in) to
the rear while lifting it so that it does not interfere with
the housing, engine parts and pipes.
SMIL14CEX3872BA 3
SMIL14CEX3873AA 4
5. Thoroughly check that the location is safe before low-

ering the counterweight on wood planks (1).
• Thoroughly secure the counterweight with the wire
ropes and lifting equipment so that it does not fall
over.
SMIL14CEX3874AB 5
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Counterweight - Install
1. Install the shackles (1), and then use the wire ropes
(2) and lifting equipment to secure the counterweight
so that it does not fall during removal and installation
operations.
SMIL14CEX3875AB 1
2. Use the wire ropes and lifting equipment to lift and in-
stall the counterweight.
• Suspend the counterweight so that it does not inter-
fere with the housing, engine parts and pipes.
SMIL14CEX3876AA 2
3. Coat the threaded section of the bolt (1) with LOCTITE®,

and use a box wrench [ 50 mm] to fasten the counter-
weight using the 4 bolts (1) and 4 high-strength wash-
ers (2) at the bottom section of the counterweight.
1517.90 lb ft)
4. Install the following after finishing work.
• Engine hood, gas damper and lock stay.
• Rear view camera and electrical components
bracket.
SMIL14CEX3871AB 3
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Index

Counterweight - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Counterweight - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Counterweight - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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EN
SERVICE MANUAL
Tracks and track suspension

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48
Contents
Tracks and track suspension - 48
[48.130] Track frame and driving wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.1
[48.100] Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.2
[48.134] Track tension units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.3
[48.138] Track rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.4
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Track frame and driving wheels - 130

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Contents
TECHNICAL DATA
Driving wheel
Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Driving wheel
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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Tracks and track suspension - Track frame and driving wheels
Driving wheel - Service limits
SMIL14CEX2908FA 1
NOTE: See the gauge list for measurement gauges (see Driving wheel - Dimension (48.130)).
Part name Code Standard value Usage limit Judgment Solution

Acceptable/
a 83 mm (3.27 in) 73 mm (2.87 in)
Unacceptable
Ø 660.7 mm Ø 650.7 mm Acceptable/
b
(26.01 in) (25.62 in) Unacceptable
Ø 748 mm Ø 738 mm Acceptable/
c
(29.45 in) (29.06 in) Unacceptable Clad by welding
Drive sprocket
Ø 732.5 mm Acceptable/ or replace
d –
(28.84 in) Unacceptable
Acceptable/
e 40 mm (1.57 in) 45 mm (1.77 in)
Unacceptable
215.9 mm Acceptable/
p –
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Driving wheel - Dimension

Inspection gauge for drive sprocket
SMIL14CEX2925FA 1
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Driving wheel - Prepare

WARNING
The grease in the track tensioning mechanism is under high pressure. Keep face and body away from
grease nipple. Never loosen the grease nipple more than one complete turn.
W0959A
WARNING
Crushing hazard!
latches.
W0256A
WARNING
Heavy objects!
W0398A
NOTICE: Before removing the shoes, be sure to bleed off any air in the hydraulic circuits.
Items to prepare:
• Box wrenches [ 19 mm]
• Hammer (to remove the master pin)
• Striking jig (to remove the master pin)
• Rag
• Cleaning fluid
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Driving wheel - Remove

1. Allow the bucket (1) to touch the ground so as to elevate
the shoe (2) of the side to be removed as in the diagram
on the right.
SMIL14CEX1303AB 1
2. Slowly rotate the shoe so that the shoe joint section (1)
is aligned as in the diagram on the right.
Place wood planks (2) under the shoe and return the
bucket to its original position.
Perform air bleeding for the hydraulic line. For details,
see Hydraulic systems - Bleed (35.000).
SMIL14CEX1304BB 2
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3. Use a box wrench [ 19 mm] to rotate the grease cylin-

der check valve (1) and loosen the shoe tension.
• Grease will flow out, so have rag ready. At this time,
if the check valve is too loose, it may fly off.
Do not place your body in front of the check valve.
SMIL14CEX1305BB 3
4. Pull out the S-pin (1) from the rear of the joint section.
SMIL14CEX1306AB 4
5. Place a striking jig (2) against the master pin (1) and hit
it with a hammer (3) to push the master pin out.
SMIL14CEX1307AB 5
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6. Open the shoe (1) to the rear.
SMIL14CEX1308AB 6
7. Use a wrench [ 30 mm] to remove the 26 bolts (18).
SMIL14CEX1309AB 7
8. Remove the drive sprocket (1) from the travel motor (2)
using a wire rope.
SMIL14CEX1310AB 8
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Driving wheel - Install

dure.
• Tightening torque M20: 521 - 608 N·m (384.27 -
448.44 lb ft)
• Apply LOCTITE® 262™ to the bolts.
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Index

Driving wheel - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Driving wheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Driving wheel - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Driving wheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Driving wheel - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Tracks - 100

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Contents
Tracks - 100
TECHNICAL DATA
Track chain
Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Track chain
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Prepare – Shoe plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Remove – Shoe plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Install – Shoe plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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Tracks and track suspension - Tracks
Track chain - Service limits
SMIL14CEX2912FA 1

Acceptable/
Shoe plate a 49 mm (2 in) 34 mm (1 in) Replace
Unacceptable
Acceptable/ Clad by welding or
Link b 129 mm (5 in) 123 mm (5 in)
Unacceptable replace
Ø 47.9 mm Acceptable/
c –
Master bushing Replace
d
Master pin e – Replace
220.4 mm Acceptable/
f 215.9 mm (8.5 in)
Link pitch 4 linked (8.7 in) Unacceptable
Replace
sections 864.6 mm 882.6 mm Acceptable/
f'
Track bushing c' – Replace
Track bushing d' Replace
Track pin e' – Replace
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Track chain - Prepare

WARNING
W0959A
WARNING
Avoid injury!
W1128A
NOTICE: The check valve adjustment procedure should not be done in front of the check valve.
NOTICE: Do not get under the main unit when it is jacked up. Make sure to place the main unit on crossties to prevent
falling.
Items to prepare:
• Wrench [ 19 mm]
• Hammer
• Striking jig
• Crowbar
• Rag
• Lifting equipment (with the required breaking load)
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Track chain - Remove

1. Rotate the shoe and align it so that the master pin (1)
is next to the take-up roller.
SMIL14CEX2051AA 1
2. Use a box wrench [ 19 mm] to loosen the check valve

(1) to release grease, and then loosen the track shoe
tension.
Do not loosen the check valve all at once. Loosen
it slowly while monitoring the grease output and shoe
loosening.
Use a rag to catch grease that trickles out of the check
valve.
If the check valve is loosened too much at this time, it
may fly off. Be careful not to work in front of the check
valve.
WARNING:
• If the check valve (1) is too loose, it may fly off.
• Do not place your body in front.
SMIL14CEX2052BB 2
3. Use a wrench [ 19 mm] to remove the bolt (1), and then

remove the check valve (2) and stopper (3).
• If the check valve (2) is removed, it is easier to loosen
the track shoe tension.
SMIL14CEX2053AB 3
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4. Strike one side of the S-pin (2) that is attached to the

master pin (1) with a hammer to straighten it, and then
use a crowbar or other tool to remove it.
SMIL14CEX2054AB 4
5. Use a hammer (2) and striking rod (3) to push the mas-
ter pin (1) out.
SMIL14CEX2055AB 5
6. Remove the track shoe (1).

At this time, place a wood plank (2) under the bottom
track shoe (1) so that it does not fall.
SMIL14CEX2056AB 6
7. Start the engine, raise the lower side frame of the track
shoe to be removed about 20 cm (7.874 in), slowly set
the travel lever to backwards, and move the track shoe
(1) to remove it from the lower frame.
SMIL14CEX2057AA 7
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Track chain - Install

1. Raise the lower side frame by about 20 cm (7.9 in).
Lift the track shoe (1), and align it with the sprocket (2).
Be careful not to confuse front and rear of the track
shoe.
SMIL14CEX2128BB 1
2. Operate the travel lever slowly toward the forward po-

sition to send the track shoe toward the take-up roller
as shown in the figure.
While passing the upper roller on the way, use a crow-
bar etc. to raise the track shoe. After sending the
shoes to the position A in the figure, lower the lower
side frame.
SMIL14CEX2129AA 2
3. Wrap the end of the track shoe (1) on the take-up roller
(2).
Place wood planks (3) to raise the lower link, and align
the positions for the master pin.
SMIL14CEX2130AB 3
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4. Insert the master pin (1).

Insert the S-pin (2) and bend it so as to prevent falling
out.
SMIL14CEX2131AB 4

SMIL14CEX2062AB 5
6. Raise the lower side frame with wood planks (1) while
checking tension of the track shoe as shown in the fig-
ure.
SMIL14CEX2065AB 6
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Track chain - Prepare – Shoe plate

WARNING
Avoid injury!
W1128A
Items to prepare:
• Grease
• Rag
• Cleaning fluid
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Track chain - Remove – Shoe plate

1. Use a box wrench [ 32 mm] to remove the 4 shoe bolts
(1).
SMIL14CEX1254AB 1
2. Remove the shoe plate (1).
SMIL14CEX1255AB 2
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Track chain - Install – Shoe plate

1. Install the shoe plate (1).
SMIL14CEX1255AB 1
2. Use a box wrench [ 32 mm] to install the 4 shoe bolts

(1).
Bolt (1) tightening torque: 1236 - 1510 N·m (911.63
- 1113.72 lb ft).
SMIL14CEX1254AB 2
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Index
Tracks - 100
Track chain - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Track chain - Install – Shoe plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Track chain - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Track chain - Prepare – Shoe plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Track chain - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Track chain - Remove – Shoe plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Track chain - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Track tension units - 134

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Contents
TECHNICAL DATA
Track tensioner
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Idler wheel
Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FUNCTIONAL DATA
Track tensioner
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Idler wheel
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SERVICE
Track tension units

Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Track tensioner
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Idler wheel
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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Tracks and track suspension - Track tension units
Track tensioner - Special tools

Jig dimension diagram
A. Dust seal press-fit jig
B. Removal jig
SMIL14CEX1160BA 1
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Idler wheel - Service limits
SMIL14CEX2909FA 1
NOTE: See the gauge list for measurement gauges (see Idler wheel - Dimension (48.134)).

Ø 560 mm Acceptable/
a –
Acceptable/ Clad by welding or
Take-up roller b 22.5 mm (0.89 in) 25.5 mm (1.00 in)
Unacceptable replace
Acceptable/
c 102 mm (4.02 in) 100 mm (3.94 in)
Unacceptable
Shaft d Ø 85 mm (3.35 in) Replace
d Ø 85 mm (3.35 in)
Bushing Replace
Acceptable/
e 82 mm (3.23 in) 81 mm (3.19 in)
Unacceptable
Acceptable/
Hub f 24 mm (0.94 in) 23.6 mm (0.93 in) Replace
Unacceptable
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Idler wheel - Dimension

Inspection gauge for take up roller
SMIL14CEX2926FA 1
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Idler wheel - Special tools

Jig dimension diagram
A. Bushing removal jig
B. Bushing press-fit jig
C. Floating seal installation jig
SMIL14CEX1128CA 1
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Track tensioner - Exploded view

1. Dust seal (Quantity 1)
2. Piston rod (Quantity 1)
3. U-packing (Quantity 1)
4. Stop ring (Quantity 1)
5. Grease cylinder (Quantity 1)
6. High-strength bolt (Quantity 1)
7. Spring washer (Quantity 1)
8. Bracket (Quantity 1)
9. Check valve assembly (Quantity 1)
SMIL14CEX1158AB 1
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Track tensioner - Component identification

1. Dust seal
2. Piston rod
3. U-packing
4. Retaining ring
5. Grease cylinder
6. High-strength bolt
7. Spring washer
8. Bracket
9. Check valve assembly
SMIL14CEX1159BB 1
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Idler wheel - Exploded view

1. Take-up roller (Quantity 1)
2. Wrapping bearing (Quantity 2)
3. Floating seal (Quantity 2)
4. O-ring (Quantity 2)
5. Roller shaft (Quantity 1)
6. Pin hub (Quantity 2)
7. Hub (with plug) (Quantity 1)
8. Plug (Quantity 1)
9. Hub (without plug) (Quantity 1)
SMIL14CEX1126BB 1
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Idler wheel - Component identification

1. Take-up roller
2. Wrapping bearing
3. Floating seal
4. O-ring
5. Roller shaft
6. Pin hub
7. Hub (with plug)
8. Plug
9. Hub (without plug)
SMIL14CEX1127BB 1
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Track tension units - Prepare

WARNING
W0959A
WARNING
Avoid injury!
W1128A
NOTICE: Do not get under the machine when the main unit is jacked up.
NOTICE: Make sure to place the main unit on wood planks or the like to prevent falling.
NOTICE: Align the shoe assembly feed location and stop the engine except when working.
Items to prepare:
• Wrench [ 24 mm]
• Hammer
• Lifting equipment
• Striking jig
• Crowbar
• Rag
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Track tension units - Remove

1. Remove the shoe assembly. See Track chain - Re-
move (48.100).
2. Use a crowbar (3) to pull off the take-up roller (1) and
recoil spring assembly from the side frame (2).
SMIL14CEX1311AB 1
3. Install the lifting equipment (4) on the take-up roller (1)

and recoil spring assembly (3) and hang them from the
side frame (2) with the lifting equipment.
SMIL14CEX1312AB 2
4. Place the take-up roller (1) and recoil spring assembly

(2) onto wood planks (4) as in the diagram.
Use a wrench [ 24 mm] to remove the take-up roller
bolt (3) and separate the roller and the recoil spring
assembly.
SMIL14CEX1313AB 3
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Track tension units - Install

1. Place the take-up roller (1) and recoil spring assembly
(2) onto wood planks (4) as in the diagram.
Use a wrench [ 24 mm] to fasten the take-up roller (1)
and recoil spring assembly (2) with the bolt (3).
At this time, be sure to coat the bolt with LOCTITE®
262™.
Installation bolt tightening torque: 267 - 312 N·m
(196.93 - 230.12 lb ft)
SMIL14CEX1313AB 1
2. Install the lifting equipment (4) on the take-up roller (1)

and recoil spring assembly (3) as in the diagram, lift
them up with the lifting equipment, and insert them into
the side frame (2).
Push in with the crowbar until the recoil spring assem-
bly contacts the grease cylinder.
3. Install the shoe assembly. For details on installation,
see Track chain - Install (48.100).
SMIL14CEX1312AB 2
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Track tensioner - Prepare

WARNING
W0959A
WARNING
Avoid injury!
W1128A
NOTICE: Do not get under the machine when the main unit is jacked up.
NOTICE: Make sure to place the main unit on wood planks or the like to prevent falling.
NOTICE: Align the shoe assembly feed location and stop the engine except when working.
Items to prepare:
• Hammer
• Lifting equipment
• Striking jig
• Crowbar
• Wood plank
• Rag
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Track tensioner - Remove

1. Remove the shoe assembly. See Track chain - Re-
move (48.100).
2. Use a crowbar (3) to pull off the take-up roller (1) and
recoil spring assembly about 100 mm (3.94 in) from
the side frame (2).
When removing the grease cylinder, use a wood plank
(4) or the like to prevent the take-up roller (1) and recoil
spring assembly from coming out.
SMIL14CEX1153AB 1
3. Jack up the side frame on the side where the grease

cylinder is being removed as shown in the diagram.
Jack up so that the shoe is floating about 30 cm
(11.81 in), and insert wood planks (1) under the lower
SMIL14CEX1154AB 2
4. Use a wrench [ 36 mm] to remove the bolts (1) and

washers (2), and then remove the track guard (3).
Tightening torque for bolt installation: 650 - 750 N·m
(479.42 - 553.17 lb ft)
SMIL14CEX1155AB 3
5. Install the wire (2) on the grease cylinder assembly (1),

and then lift it with the lifting equipment so that it is
slightly tensed.
SMIL14CEX1156AB 4
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6. Use a wrench or box wrench [ 24 mm] to remove the

bolt (1), then remove the grease cylinder (2).
Lower the lifting equipment as is to lower to under
the frame, and then take out from between the lower
rollers.
SMPH15CEX0445BB 5
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Track tensioner - Prepare - For disassemble and assemble

CAUTION:
• To ensure safe operations, wear protective gear before beginning work and follow all precautions.
or steel rod.
○ Do not stand or pass under the suspended load.
○ Check the weight of the grease cylinder to determine whether it can be carried by hand or whether a lifting
equipment must be used.
General cautions:
Items to prepare:
• Hammer
• Wrench [ 19 mm]
• Screwdriver
• Specialty jigs
• Marking pen
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Track tensioner - Disassemble

1. Clean the grease cylinder with kerosene, remove the
bolt (1) and washer (2), and remove the bracket (3).
Remove the check valve (5) from the grease cylinder
(4).
SMIL14CEX1161AB 1
2. Pull out the piston rod (2) from the grease cylinder (1).
SMIL14CEX1162AB 2
3. Use the removal jig (B) to remove the dust seal (2) from
the grease cylinder (1).
SMIL14CEX1163AB 3
4. Remove the snap ring (2) from the piston rod (1), and
then use the removal jig (B) to remove the U-packing
(3).
SMIL14CEX1164AB 4
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Track tensioner - Assemble

1. Place parts in a rough cleaning container filled with
kerosene to clean off any adhered matter that can form
sharp points and cause scratches.
• Immerse in kerosene until dust, grease, and other
adhered matter comes off and floats to the surface.
2. Place parts in a finish cleaning container filled with
kerosene and clean while gently moving the parts. Af-
ter cleaning, wipe away the kerosene with a clean rag.
• Place the parts in a location free of dust and mois-
ture and use compressed air to dry the parts. After
drying, coat parts with engine oil.
3. Install the U-packing (1) coated with grease onto the
piston rod (2), and then install the snap ring (3).
• Use a new U-packing (1).
• Make sure that the U-packing (1) faces correctly.
SMIL14CEX1165AB 1
4. Use the jig (A) and hammer (C) to install the dust seal
(2) on the grease cylinder (1). Apply grease to the lip
section of the dust seal (2).
Use a new dust seal (2).
SMIL14CEX1166BB 2
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5. Coat the surface of the piston rod (1) with grease and
insert into the grease cylinder (2).
SMIL14CEX1167AB 3
6. Tighten the check valve (1) to the grease cylinder (2) to

the specified tightening torque.
Install the bracket (3) and secure it with the spring
washer (4) and the bolt (5).
Check valve tightening torque: 48.99 - 68.61 N·m
(36.1332 - 50.6041 lb ft).
Bracket installation bolt tightening torque: 58.8 N·m
(43.369 lb ft).
SMIL14CEX1168AB 4
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Track tensioner - Install

dure.
Grease cylinder installation bolt tightening torque: 267
- 312 N·m (196.93 - 230.12 lb ft)
When installing bolts, coat the threaded sections with
LOCTITE® 262™.
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Idler wheel - Prepare - For disassemble and assemble

CAUTION:
or steel rod.
○ Do not stand or pass under the suspended load.
○ Check the weight of the roller to determine whether it can be carried by hand or whether a lifting equipment
must be used.
• Fasten the roller to a level surface so it does not roll.
• When assembling sliding (5) parts, be sure to coat them with new hydraulic oil.
• The take-up roller is a heavy object and requires at least 2 workers to handle.
General cautions
Pay careful attention and proceed slowly so as not to deform any parts, create any oil leaks, or compromise the
Items to prepare:
• Hammer
• Pliers
• Gear puller
• Screwdriver
• Engine oil
• Specialty jigs
• Pressing machine
• LOCTITE®
• Micrometer caliper
• Caliper
• Cylinder gauge
• Seal tape
• Oil pan (drain pan)
• Water container for inspection
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Idler wheel - Disassemble

1. After cleaning the roller with kerosene, use the hexagon
wrench (1) to remove the plug (2) from the hub (3).
• The plug is coated with seal nylon, which comes off
when the plug is removed. Seal tape is necessary
for reusing.
SMIL14CEX1129AB 1
2. Face down the part of the roller from which the plug
was removed and empty the oil from within the roller.
• It may take a few hours to completely empty the oil.
• Place an oil pan (1) underneath to catch the oil.
SMIL14CEX1130AB 2
3. Remove the pin hub (2) from the hub (1), and remove
the hub (1) from the shaft (3).
• Only remove on one side.
SMIL14CEX1131AB 3
4. After removing the O-ring (2) on the shaft (1), pull the
shaft (1) out from the roller (3).
• The O-ring cannot be reused. Replace it with new
part.
SMIL14CEX1132AB 4
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5. Remove the pin hub (2) from the hub (1).

Next, after removing the hub (1) from the shaft (3), re-
move the O-ring (4) from the shaft (3).
SMIL14CEX1133AB 5
6. Remove the floating seals (2) from the hub (1).
SMIL14CEX1134AB 6
7. Remove the floating seals (2) from the roller (1).
SMIL14CEX1135AB 7
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8. Use a micrometer caliper (4), cylinder gauge (5), and

caliper (6) to measure the roller (with bushing) (1), hub
(2), and shaft (3) for wear and deformation. Replace
with new parts as necessary.
SMIL14CEX1136BB 8
9. When replacing the bushing (1), remove it by placing

a striking rod (2) against the end surface and striking
that with a hammer (3) uniformly left and right as in the
diagram.
• Do not disassemble the bushing (1) unless it has
become unusable due to wear, etc.
• Be careful not to scratch the inside of the roller when
striking the end of the bushing.
SMIL14CEX1137AB 9
10. Invert the roller (1), use jig A (2) to push up against
the bushing (3), and press with a rod-shaped object
(4) (such as a shaft).
The bushing comes off.
SMIL14CEX1138AB 10
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Idler wheel - Assemble

1. Clean all parts.
• In order to clean off adhered matter that forms sharp
points and causes scratches, immerse parts in
cleaning fluid (1) until dirt and grease float to the top.
SMIL14CEX1139AB 1
2. After cleaning the parts, air blow them to remove any

remaining cleaning fluid or debris.
• If the parts are to be left as is for a long time after
drying them, apply engine oil.
SMIL14CEX1140AA 2
3. If the bushing (1) was removed during disassembly, put

it into the roller (2).
Use a pressing machine (3) to press in both the left and
right sides.
SMIL14CEX1141AB 3
4. Use the jigs (1) and (2) attached to the pressing ma-
chine to install the bushing (3).
Use the pressing machine to press from the opposite
side.
Next, use a special fiber cloth to remove all dust and
debris.
SMIL14CEX1142AB 4
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5. Install the floating seal (2) to the hub (1). Use jig C (3)
to push it into position.
SMIL14CEX1143AB 5
6. Use jig C (3) to install the floating seal (2) to the roller
(1) side.
SMIL14CEX1144AB 6
7. Use a special fiber cloth to thoroughly wipe the slid-

ing surface of the floating seal to prevent any dust or
scratches.
SMIL14CEX1145AB 7
8. Apply engine oil to the floating seals (1) on the hubs (2)
and (3).
SMIL14CEX1146AB 8
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9. Install the O-ring (2) on the shaft (1), and then install
the shaft to the hub (3) and fasten it with the pin hub
(4).
SMIL14CEX1147AB 9
10. Install the shaft (2) and O-ring (3) on the roller (1).
SMIL14CEX1148AB 10
11. Install the O-ring (4) on the shaft (1), and then install
the hub (2) and fasten it with the pin hub (3).
SMIL14CEX1149AB 11
12. Inject compressed air [ 0.2 MPa (29.010 psi) ] from

the oil fill port and immerse in water to check that there
are no leaks.
SMIL14CEX1150AA 12
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13. Fill the roller main unit with engine oil ( 270 cm³
(16.48 in³)).
• The roller main unit can be very unstable, so be
careful in securing it.
SMIL14CEX1151AA 13
14. After filling the oil, use a hexagon wrench [ 6 mm] (2)
to tighten the plug (1) with the nylon seal applied.
• To reuse a plug, wrap it with seal tape.
SMIL14CEX1152AB 14
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Index

Idler wheel - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Idler wheel - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Idler wheel - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Idler wheel - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Idler wheel - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Idler wheel - Prepare - For disassemble and assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Idler wheel - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Idler wheel - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Track tension units - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Track tension units - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Track tension units - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Track tensioner - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Track tensioner - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Track tensioner - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Track tensioner - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Track tensioner - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Track tensioner - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Track tensioner - Prepare - For disassemble and assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Track tensioner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Track tensioner - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Track rollers - 138

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Contents
Track rollers - 138
TECHNICAL DATA
Track frame roller

Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Track support roller
Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FUNCTIONAL DATA
Track frame roller

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SERVICE
Track frame roller

Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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Tracks and track suspension - Track rollers
Track frame roller - Service limits
SMIL14CEX2911FA 1
NOTE: See the gauge list for measurement gauges (see Track frame roller - Dimension (48.138)).

a Ø 180 mm Ø 168 mm Acceptable/
Acceptable/ Clad by welding
Track roller b 25 mm (0.98 in) 20 mm (0.79 in) Unacceptable or replace
c 216 mm (8.50 in) 222 mm (8.74 in) Acceptable/
Unacceptable
Shaft e Ø 75 mm Ø 74 mm Acceptable/ Replace
e
Bushing Replace
f
Acceptable/
Collar g 17.0 mm (0.67 in) 16.5 mm (0.65 in) Replace
Unacceptable
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Track frame roller - Dimension

Inspection gauge for lower roller
SMIL14CEX2928FA 1
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Track frame roller - Special tools

B. Bushing press-fit jig
SMIL14CEX1285CA 1
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Track support roller - Service limits
SMIL14CEX2910FA 1
NOTE: See the gauge list for measurement gauges (see Track support roller - Dimension (48.138)).

Acceptable/
a Ø 150 mm (5.91 in) 138 mm (5.43 in)
Unacceptable
Acceptable/ Clad by welding
Carrier roller b 15 mm (0.59 in) –
Unacceptable or replace
Acceptable/
c 104 mm (4.09 in) –
Unacceptable
Acceptable/
Shaft d Ø 65 mm (2.56 in) Ø 64 mm (2.52 in) Replace
Unacceptable
Acceptable/
Bushing d Ø 65 mm (2.56 in) Ø 66 mm (2.60 in) Replace
Unacceptable
Acceptable/
Bushing e 69 mm (2.72 in) 68 mm (2.68 in) Replace
Unacceptable
Acceptable/
Thrust plate f 9 mm (0.35 in) 8.5 mm (0.33 in) Replace
Unacceptable
Acceptable/
Cover g 15 mm (0.59 in) – Replace
Unacceptable
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Track support roller - Dimension

Inspection gauge for upper roller
SMIL14CEX2927FA 1
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Track support roller - Special tools

B1. For bushing (9) press-fit jig
B2. For bushing (7) press-fit jig
SMIL14CEX1258CA 1
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Track frame roller - Exploded view

1. Roller (Quantity 1)
2. Shaft (Quantity 1)
3. Bushing (Quantity 2)
6. Collar (with plug) (Quantity 1)
7. Wire clip (Quantity 2)
9. Collar (without plug) (Quantity 1)
SMIL14CEX1283BB 1
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Track frame roller - Component identification

1. Roller
2. Shaft
3. Bushing
4. Floating seal
5. O-ring
6. Collar (with plug)
7. Wire clip
8. Plug
9. Collar (without plug)
SMIL14CEX1284BB 1
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Track support roller - Exploded view

1. Cover (Quantity 1)
4. Hexagon bolt (Quantity 6)
5. LOCTITE® (Quantity 6)
6. Thrust plate (Quantity 1)
8. Shaft (Quantity 1)
10. Roller (Quantity 1)
12. Bracket (Quantity 1)
SMIL14CEX1256BB 1
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Track support roller - Component identification

*1. Press-in length
1. Cover
2. O-ring
3. Plug
4. Hexagon bolt
5. LOCTITE®
6. Thrust plate
7. Bushing
8. Shaft
9. Bushing
10. Roller
11. Floating seal
12. Bracket
SMIL14CEX1257BB 1
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Track frame roller - Prepare

WARNING
W0959A
WARNING
Avoid injury!
W1128A
NOTICE: Do not get under the main unit when it is jacked up. Make sure to place the main unit on wood planks to
prevent falling.
Items to prepare:
• Rag
• Cleaning fluid
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Track frame roller - Remove

1. Use a box wrench [ 19 mm] to loosen the check valve
(1), and then loosen the shoe tension.
Do not loosen the check valve all at once. Loosen
it slowly while monitoring the grease output and shoe
loosening.
• Grease drains out, so provide rag (2) close to the
drain port.
SMIL14CEX2064AB 1
2. Jack up the side frame on the side where the roller is

being replaced as shown in the diagram.
Jack up so that the shoe is floating about 30 cm
(11.8 in), and insert wood planks (1) under the lower
SMIL14CEX2065AB 2
3. If it is impossible to insert wood planks (3) under the

lower frame, insert wood planks (3) between the side
frame and the link shoe (2) to separate the link shoe
and lower roller (1) by about 15 mm (0.6 in).
SMIL14CEX2066AB 3

and then remove the lower roller (1).
SMIL14CEX2067AB 4
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Track frame roller - Install

1. Insert wood planks (4) between the side frame and the
link shoe (3), and tighten the 4 bolts (2) with a box
wrench [ 36 mm] to install the lower roller (1).
• Bolt (2) tightening torque: 902 - 1049 N·m (665.3 -
773.7 lb ft).
SMIL14CEX2127AB 1

SMIL14CEX2062AB 2
3. Raise the lower side frame while adjusting tension of

Put wood planks (1) under the lower frame to prevent
falling.
SMIL14CEX2065AB 3
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Track frame roller - Prepare - For disassemble and assemble

CAUTION:
or steel rod.
• Check the weight of the roller to determine whether it can be carried by hand or whether a lifting equipment
must be used.
General cautions
Items to prepare:
• Hammer
• Wire clip
• Pliers
• Gear puller
• Screwdriver
• Gear oil
• Specialty jigs
• LOCTITE®
• Caliper
• Cylinder gauge
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Track frame roller - Disassemble

1. Stand the roller vertically and use a hexagon wrench [
6 mm] (1) to remove the plug (2).
• The plug is coated with seal nylon, which comes off
when the plug is removed. To reuse the plug, using
seal tape is necessary.
SMIL14CEX1286AB 1
2. Face down the part of the roller from which the plug
was removed and empty the oil from within the roller.
• It may take a few hours to completely empty the oil.
• Place an oil pan (1) underneath to catch the oil.
• Securely fasten so that the roller does not fall over.
SMIL14CEX1287AB 2
3. Remove the wire clip (1). Tap another wire (2) with the
hammer (3) from the outside to push out the wire clip
that is already in the roller.
• Place the roller horizontally and secure it so it does
not roll before doing this work.
• The wire in the roller is very securely fixed, so pre-
pare several wire clips. Also be sure to coat with
lubricant.
SMIL14CEX1288AB 3
4. Use pliers (2) to remove the pushed out wire clip (1).
SMIL14CEX1289AB 4
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5. Use a gear puller (2) to remove the collar (1). If the

collar is difficult to remove, hook the collar on the bolt
and catch the puller on that part.
• If the collar has rusted or is difficult to remove due
to an accumulation of debris, subject it to a shock,
for example by hitting it with a hammer, to make it
easier to move.
• When hitting it with a hammer, be careful not to dent
it.
SMIL14CEX1290AB 5
6. Check whether the sliding surface of the floating seal

(2) against the removed collar (1) has rusted or is dam-
aged.
Also make sure the O-ring (3) on the seal ring (4) is not
twisted.
part.
SMIL14CEX1291AB 6
7. Remove the floating seal (1) on the roller.

As described in Step 6, check whether the sliding sur-
face has rusted or is damaged.
Also make sure the O-ring is not twisted.
SMIL14CEX1292AB 7
8. Remove the O-ring (2) on the shaft (1).

part.
SMIL14CEX1293AB 8
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9. Remove the shaft (1).
SMIL14CEX1294AB 9
10. Check whether the sliding surface of the floating seal

(2) against the removed collar (1) on the opposite side
has rusted or is damaged.
Also make sure the O-ring (3) on the seal ring (4) is not
twisted.
part.
SMIL14CEX1291AB 10
11. As described in Steps 6 and 7, remove the floating

seal (1) on the opposite side.
SMIL14CEX1295AB 11
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12. Use a caliper (6), micrometer caliper (5), and cylinder

gauge (7) to measure the roller (with bushing) (1), col-
lars (2), (3), and shaft (4) for wear and deformation.
Replace with new parts as necessary.
SMIL14CEX1189BB 12
13. When replacing a bushing, insert jig A (3) into the

bushing (1), and use a cylindrical object (such as a
shaft) (2) to push from the top.
The bushing comes off.
SMIL14CEX1190AB 13
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Track frame roller - Assemble

1. Clean all parts by immersing them in cleaning fluid (1).
SMIL14CEX1191AB 1
2. After cleaning the parts, air blow them to remove any

remaining cleaning fluid or debris.
SMIL14CEX1192AA 2
3. If the bushing (2) was removed during disassembly, put

it into the roller (1). Restraining from above using jig B
(3), push in with the pressing machine (4). Invert the
roller and insert the bushing on the opposite side in the
same manner.
SMIL14CEX1193AB 3
4. Use jig C (5) to push the floating seal (4) into the collars
(2), (3) and roller (1) by hand.
SMIL14CEX1194AB 4
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5. Use a special fiber rag to wipe the surfaces of the float-

ing seals so as to increase adhesion and prevent dust
from entering.
SMIL14CEX1195AA 5
6. Apply gear oil to the floating seals (3) on the collars (1),
(2).
SMIL14CEX1196AB 6
7. Attach O-rings (3) to the shaft (2) and mount into the
roller (1).
SMIL14CEX1197AB 7
8. Install the collars (1), (2) on both sides.
SMIL14CEX1198AB 8
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9. Attach the wire clip (1).

• When attaching the wire clip, secure the roller main
unit so that it does not roll.
SMIL14CEX1199AB 9
10. Turn the main unit and check that the roller rotates
properly.
SMIL14CEX1200AA 10
11. Inject compressed air 0.2 MPa (29.01 psi) from the oil
fill port and immerse in water to check that there are
no leaks.
SMIL14CEX1301AA 11
12. Fill gear oil [about 400 cm³ (24.4 in³)] into the roller.
Use a hexagon wrench ( 6 mm ) (2) to tighten the plug
(1) with the nylon seal applied.
• CASE AKCELA GEAR 135 H EP 80W-90 is recom-
mended for use.
• To reuse a plug, wrap it with seal tape.
• Plug (1) tightening torque: 24.5 N·m (18.07 lb ft).
SMIL14CEX1302AB 12
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Track support roller - Prepare

WARNING
W0959A
WARNING
Avoid injury!
W1128A
NOTICE: The check valve adjustment procedure should not be done in front of the check valve.
Items to prepare:
• Jack (with the required lifting weight)
• Rag
• Cleaning fluid
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Track support roller - Remove

1. Use a box wrench [ 19 mm] to loosen the grease cylin-
der check valve (1), and then loosen the shoe tension.
• Grease drains out, so provide rag (2) close to the
drain port.
Do not loosen the check valve all at once.
Loosen it slowly while monitoring the grease output
and shoe loosening.
SMIL14CEX2058AB 1
2. Use a jack (3) to lift the top of the shoe, and then insert
wood planks (4) to separate the shoe (2) and upper
roller (1) by about 10.0 mm (0.4 in).
SMIL14CEX2059AB 2

and then remove the upper roller (1).
SMIL14CEX2060AB 3
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Track support roller - Install

1. Use a jack (2) to raise the upper part of the shoes (1),
and insert wood planks (3).
SMIL14CEX2061AB 1
2. Tighten the 4 bolts (2) with a box wrench [ 30 mm] to

install the upper roller (1).
• LOCTITE® shall be applied.
• Bolt (2) tightening torque: 521 - 608 N·m (384.3 -
448.4 lb ft).
SMIL14CEX2060AB 2

SMIL14CEX2062AB 3
4. Raise the lower side frame while checking tension of

Put wood planks (1) under the lower frame to prevent
falling.
SMIL14CEX2063AB 4
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Track support roller - Prepare - For disassemble and assemble

CAUTION:
or steel rod.
• Check the weight of the roller to determine whether it can be carried by hand or whether a lifting equipment
must be used.
General cautions:
Pay careful attention and proceed slowly so as not to deform any parts, create any oil leaks, or compromise the
Items to prepare:
• Hammer
• Wrench [ 17 mm]
• Screwdriver
• Gear oil
• Specialty jigs
• Marking pen
• Caliper
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Track support roller - Disassemble

1. Place the roller vertically on its bottom and pull out the
plug (2) with a hexagon wrench [ 6 mm] (1).
• You will need a seal tape to re-use the plug since the
seal nylon applied to the plug will be removed.
SMIL14CEX1259AB 1
2. Drain oil inside the roller by standing it on its side of

removing the plug.
• Draining oil completely will take a couple of hours.
• Place the oil pan (1) or other container to catch oil
running out.
SMIL14CEX1260AB 2
3. Use a wrench [ 17 mm] to remove 3 bolts (1) attached

to the cover (2) and then remove the cover.
SMIL14CEX1261AB 3
4. Remove 3 bolts (1) in the roller with a box wrench [

17 mm] and then remove the thrust plate (2).
SMIL14CEX1262AB 4
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5. Lift the roller (1) to remove the shaft (2).
SMIL14CEX1263AB 5
6. Remove the floating seal (2) on the side of the roller (1).
Check for any rust or any damage on the slide way.
SMIL14CEX1264AB 6
7. Remove the floating seal (2) attached on the shaft (1).
SMIL14CEX1265AB 7
8. Remove the O-ring (2) on the side of the cover (1).

• Check that the O-ring is not twisted.
Replace it with a new one if twisted.
SMIL14CEX1266AB 8
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9. Check condition of wear or deformation of the roller

(with bushing) (1), the bracket (2) and the shaft (3) with
a caliper (4), micrometer caliper (5) or cylinder gauge
(6), and replace with new one as necessary.
SMIL14CEX1267BB 9
10. When replacing the bushings (1) and (2), hold them
with a fixture A (4) from the side of pulling out the shaft
(3) and then push them out with a pressing machine
(5).
SMIL14CEX1268AB 10
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Track support roller - Assemble

1. Clean all the parts by immersing them in cleaning fluid
(1).
• Chose a clean site.
• Place a rubber sheet or cloth on work platform to
prevent damaging the component.
SMIL14CEX1269AB 1
2. Blow out remaining cleaning fluid and dirt after wash-

ing.
SMIL14CEX1270AA 2
3. Insert the bushing (1) into the roller (2) if the bushing
has been removed at assembly.
Place the side of attaching the thrust plate upward and
then hold it with a fixture B2 (3) on the top to press it in
with a pressing machine (4).
SMIL14CEX1271AB 3
4. Reverse the roller (1) to insert the bushing (2).

Hold it with a fixture B1 (3) on the top to press it in with a
pressing machine (4). In this step, make sure to press
it in until the fixture B1 stops.
SMIL14CEX1272AB 4
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5. Insert the floating seal (3) into the roller (1) and the
bracket (2).
Press it in using a fixture C (4).
SMIL15CEX4931AB 5
6. Wipe the surface with special fiber cloth so as to in-

crease intensity of adherence of floating seal surface
and to prevent invasion of dirt or other foreign sub-
stances.
SMIL14CEX1274AA 6
7. Apply hydraulic fluid to the roller (1).
SMIL14CEX1275AB 7
8. Install the shaft (1) to the roller (2).
SMIL15CEX4933AB 8
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9. Wipe the surface thoroughly with special fiber cloth so

as to prevent adhering dirt to or damaging the thrust
plate (1).
SMIL14CEX1277AB 9
10. Install the thrust plate (1) with 3 bolts (2). Thoroughly
remove oil from the bolts and apply LOCTITE® (3) to
the bolt holes to tighten them. Draw markings (4) after
tightening them.
Bolt (2) tightening torque: 62.8 - 72.6 N·m (46.319

- 53.547 lb ft)
SMIL15CEX4934AB 10
11. Install the cover (1) with 3 bolts (2).

Remove oil from the bolts and apply LOCTITE® (3) to
the bolt holes to tighten them.
Draw markings (4) after tightening them.
Bolt (2) tightening torque: 62.8 - 72.6 N·m (46.319

- 53.547 lb ft)
SMIL15CEX4935AB 11
12. Rotate the roller in direction of arrow to check that it

rotates smoothly.
SMIL14CEX1280AA 12
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13. Check that there is no leakage by applying com-

pressed air [ 0.2 MPa (29.010 psi)] from the oil fill
port and then soak it in water.
SMIL14CEX1281AA 13
14. Fill engine oil (about 160.00 cm³ (9.76 in³)) in the
roller.
Tighten the plug (2) (with seal nylon applied) with a
hexagon wrench (1) after filling oil.
Draw markings (3) after tightening them.
• Wind seal tape around the plug if you reuse it.
Plug (2) tightening torque: 24.5 N·m (18.070 lb ft)
SMIL14CEX1282AB 14
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Index
Track rollers - 138

Track frame roller - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Track frame roller - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Track frame roller - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Track frame roller - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Track frame roller - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Track frame roller - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Track frame roller - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Track frame roller - Prepare - For disassemble and assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Track frame roller - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Track frame roller - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Track frame roller - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Track support roller - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Track support roller - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Track support roller - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Track support roller - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Track support roller - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Track support roller - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Track support roller - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Track support roller - Prepare - For disassemble and assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Track support roller - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Track support roller - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Track support roller - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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EN
SERVICE MANUAL
Cab climate control

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Contents
Cab climate control - 50
[50.100] Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1
[50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.2
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Heating - 100

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Contents
Heating - 100
SERVICE
Heater core
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Heating, Ventilation, and Air-Conditioning (HVAC) unit
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Cab climate control - Heating
Heater core - Replace

NOTICE: Remove while being careful not to apply excessive force to the pipe.
1. Drain the coolant.
• Remove the 4 Phillips screws (1) and remove the link
cover (2).
Phillips screws (1): M5 x 16
• Remove the mode actuator connector (3), and re-
move the heater core (4).
• The installation procedure is the reverse of the re-
moval procedure.
SMIL14CEX1812AB 1
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Cab climate control - Heating
Heating, Ventilation, and Air-Conditioning (HVAC) unit - Remove

NOTICE: At this time, perform work with the heater core removed from the heater case.
NOTICE: The evaporator sensor cord is sandwiched in the groove of the HVAC unit, so carefully check it and remove
it while making sure not to damage it.
Removal of right heater case and left heater case

1. Remove the 10 Phillips screws (1) and remove the right
heater case (2) and left heater case (3).
• Phillips screws (1): M4 x 16
SMIL14CEX1813AB 1
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Index
Heating - 100
Heater core - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Heating, Ventilation, and Air-Conditioning (HVAC) unit - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Air conditioning - 200

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Contents
TECHNICAL DATA
Air conditioning
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Air conditioning
Overview - Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overview - Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Overview - Air conditioner unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
A/C schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SERVICE
Air conditioning
Service instruction - Work precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Service instruction - Work procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Air-conditioning compressor
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Air-conditioning condenser
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Receiver/Dryer
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Air-conditioning evaporator
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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Cab climate control - Air conditioning
Air conditioning - Special tools

Gas filling special tool
SMIL14CEX4136FB 1
Code Description
1 Gauge manifold
2 Charging hose
3 Quick joint 27.5 mm (1.1 in)
4 Quick joint 23.5 mm (0.9 in)
5 T joint
6 Service can valve
7 Vacuum pump adapter
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Air conditioning - Overview - Frame
SMIL14CEX1949HB 1
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SMIL14CEX1889HB 2
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a. Air-conditioner unit f. Heater (unit outlet)

b. Engine g. Heater (unit inlet)
c. Heater (engine return) h. Connect to air-conditioner unit
d. White making i. White making Connect to air-conditioner unit
e. Heater (engine output)
1. Cooler hose (liquid 2) (Quantity 1) 7. Tension pulley (with cover) (Quantity 1)

2. Cooler hose (suction) (Quantity 1) 8. Air-condenser (Quantity 1)
3. Rubber hose 16 x 4600 (Quantity 2) 9. Receiver dryer (D60.5) (Quantity 1)
4. Cooler hose (discharge) (Quantity 1) 10. Cooler hose (liquid 1) (Quantity 1)
5. Air-conditioner compressor (Quantity 1) 11. Receiver bracket (D60.5) (Quantity 1)
6. Slide shaft (Quantity 1) 12. V belt B-45.5 (Quantity 1)
* in the hose connection table indicates clamping location and the numerical value indicates hose length.
NOTE: All the torques in figures are in Nm.
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Air conditioning - Overview - Cab
SMIL14CEX1890HB 1
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SMIL14CEX1891HB 2
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1. Solar radiation sensor (Quantity 1) 12. Duct; Vent (Right) (Quantity 1)

2. Duct; Face-A (Quantity 1) 13 Air filter (Fresh) (Quantity 1)
3. Duct; Def-A (Quantity 1) 14. Duct; Intake-A (Fresh) (Quantity 1)
4. Grille; Air vent (Quantity 7) 15. Duct; Intake-B (Fresh) (Quantity 1)
5. Duct; Face-B (Quantity 1) 16. Unit; Air-conditioner (Quantity 1)
6. Duct; Def-C (Quantity 1) 17. Duct; Foot (Quantity 1)
7. Duct; Face-C (Quantity 1) 18. Duct; Def-B
8. Duct; H and C box (Quantity 1) 19. Control panel (AC) (Quantity 1)
9. Bracket; Box (Quantity 1) 20. Drain hose (Quantity 2)
10. Box; Hot and cool (Quantity 1) 21. Flange plate (Quantity 1)
11. Duct; Vent (Left) (Quantity 1)
a. Monitor display g. Cooler hose (Liquid)

b. Trim side; Front (Right) h. Cover; Top (Console left)
c. Trim side; Front (left) i. Should be connected with the console harness.
d. Heater hose (Eng.Return) j. Wire harness (Console)
e. Heater hose (Eng.Out) k. Floor
f. Cooler hose (Suction)
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Air conditioning - Overview - Air conditioner unit
SMIL14CEX1892HB 1
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1. Motor actuator (mode) 6. Blower motor

2. Compressor relay 7. Blower amp
3. Blower “OFF” relay 8. Motor actuator (air mix)
4. Motor actuator (refresh/recirculate switch) 9. Evaporator sensor
5. Interior temperature sensor
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Air conditioning - A/C schema

Air-conditioner circuit diagram
SMIL14CEX1893HB 1
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SMIL14CEX1894HB 2
5 V series
Applying 5 V continuously
Analog signal: 0 - 5 V is applied
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GND
P W B R Y G L Br Lg O Sb V
Lettuce
Pink White Black Red Yellow Green Blue Brown Orange Sky blue Purple
green
1. Main key switch 10. Blower motor

2. CAN signal 11. Blower amp
3. A/C main power supply 12. Compressor relay
4. Compressor clutch power supply 13. Control panel (TKS-CP208C0)
5. Controller power supply 14. Evaporator sensor
6. Solar radiation sensor 15. Inside air sensor
7. Pressure switch (receiver dryer) 16. Motor actuator (air mix)
8. Compressor 17. Motor actuator (mode)
9. Blower “OFF” relay 18. Motor actuator (refresh/recirculate switch)
• Unspecified wire diameter is to be 0.5.

• Dashed lines indicate wiring in vehicle side.
• Cord color observed from connection port of connector is shown for connector display.
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Air conditioning - Service instruction - Work precautions

WARNING
Pressurized system!
Refrigerant under pressure. Service, repair, or recharging must be performed only by trained service
technician.
W1180A
WARNING
Escaping refrigerant may cause frostbite!
Always wear protective goggles when handling refrigerant. If you get refrigerant in your eye, immedi-
ately flush your eyes with water for 15 minutes. Seek medical assistance immediately.
W0339A
WARNING
Explosion hazard!
Air-conditioning refrigerant boils at -12 °C (10 °F)!
-NEVER expose any part of the air-conditioning system to a direct flame or excessive heat.
-NEVER disconnect or disassemble any part of the air-conditioning system.
Discharging refrigerant gas into the atmosphere is illegal in many countries.
W0340A
WARNING
Escaping refrigerant may cause frostbite!
If you get refrigerant on your skin:
-Warm the area with your hand or lukewarm water, 32 - 38 °C (90 - 100 °F).
-Cover the area loosely with a bandage to protect the area and the prevent infection.
-Seek medical assistance immediately.
W0341A
NOTICE: Refrigerant in the liquid state is very cold [about -26 °C (-14.8 °F) ], so be very careful during handling.
Always use R134A refrigerant.
• Storage
Keep service cans (hereinafter, cans) with refriger-
ant in them at 40 °C (104.0 °F) or below.
The insides of the cans are highly pressurized and
filled with refrigerant, so if the temperature rises
there is the danger of internal pressure rising sharply
and an explosion occurring.
Never store in direct sunlight, in a closed vehicle, or
near open flames.
Be careful not to drop cans or have them collide with
other objects.
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• Filling operation
When cans are heated in order to fill them with re-
frigerant, make sure that the service can valve and
gauge manifold low-pressure valve are open and
heat with water at 40 °C (104.0 °F) or below.
Direct heating or heating to 40 °C (104.0 °F) or
higher may cause explosions, so use caution.
If refrigerant filling is done after the engine is started,
never open the gauge manifold high-pressure valve.
This is very dangerous, as the high-pressure gas will
flow in the opposite direction and may cause a can
or charging hose explosion.
Be careful not to allow the entry of dust or dirt into
the air conditioner circuit.
Air, moisture and dirt are very bad for the cooling
cycle.
Perform work quickly and accurately, and be espe-
cially careful to prevent the entry of foreign matter.
Be careful not to overfill with gas.
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Air conditioning - Service instruction - Work procedures

Air conditioner refrigerant filling
The air conditioner refrigerant filling is divided into the
“vacuum operation" and the "gas filling operation".
1. The "vacuum operation" consists of eliminating mois-
ture in the air conditioner circuit.
If there is any moisture left inside the air conditioner
circuit, various problems may occur during operation
such as freezing in the small hole of the expansion
valve causing the circuit to clog and rust developing in
the circuit.
For this reason, perform vacuuming before filling the
circuit with refrigerant. This operation consists of elim-
inating moisture inside the circuit through boiling and
evaporation.
2. The "gas filling operation" consists of filling the circuit
with refrigerant after the vacuum operation.
Gas filling does not only affect the cooling capabilities
of the air conditioner, it also affects the life of the parts
which make up the circuit.
Severely overfilling the circuit will cause pressure in-
side the circuit to be abnormally high, and this will
cause reductions in the cooling ability of the air con-
ditioner.
Additionally, if pressure is extremely low, the circulation
of lubricating oil within the compressor will be poor and
this will cause seizing with sliding parts of the compres-
sor.
Because the gas filling operation itself involves han-
dling high-pressure gas, performing the operation us-
ing an incorrect procedure is very dangerous.
Follow the operation and observe all precautions indi-
cated in this text to correctly perform refrigerant filling.
Operation chart
30 min or longer ( 750 mm Hg
Vacuuming start
(29.5 in Hg) or less)
↓
Vacuuming stop Let sit for 5 min
Vacuuming operation
↓
Gauge display abnormality
Airtightness check
(connectors check and repair)
↓
Fill with refrigerant gas up to a gauge
Refrigerant filling
pressure of 0.098 MPa (14.215 psi).
↓
Refrigerant filling operation
Gas leak check
↓
Refrigerant filling
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Tools
Part name: Gauge manifold (Quantity 1)
Application: –
SMIL14CEX1827AA 1
Part name: Charging hose (Quantity 3)

Application: Red: high-pressure side
Blue: low-pressure side
Yellow: vacuum pump side
SMIL14CEX1828AA 2
Part name: Quick joint (Quantity 1)

Application: –
SMIL14CEX1829AA 3
Part name: Quick joint (Quantity 1)

Application: Low-pressure side
SMIL14CEX1830AA 4
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Part name: T joint (Quantity 1)

Application: For service can valve
SMIL14CEX1831AA 5
Part name: Service can valve (Quantity 2)

Application: For service can
SMIL14CEX1832AA 6
Part name: Vacuum pump adapter (Quantity 1)

Application: For vacuum pump
SMIL14CEX1833AA 7
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Air conditioning - Filling

NOTICE: Because gauge manifold specifications such as hose color are different depending on the manufacturer,
read the operator's manual for the gauge manifold to be used for details.
Charging hose connection position
SMIL14CEX1834FB 1
1. High pressure side (DIS) service valve 4. Condenser

2. Low pressure side (SUC) service valve 5. Receiver dryer
3. Air-conditioner compressor 6. Air-conditioner unit
Connecting gauge manifold

1. Close the high pressure valve (HI) (12) and low pres-
sure valve (LO) (11) of the gauge manifold (13).
2. Connect the charging hoses (red, blue) to the service
valve.
Red hose (14): gauge manifold high pressure side (HI)
→ compressor high pressure side (DIS) service valve
(1):
Blue hose (15): gauge manifold low pressure side (LO)
→ compressor low pressure side (SUC) service valve
(2):
Make absolutely sure to connect the correct hoses to
the high pressure side and low pressure side and insert
them all the way until they make clicking sound.
3. Connect the charging hose (yellow) (7) to the vacuum
pump (8).
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SMIL14CEX1835GB 2
9. Low pressure gauge

10. High pressure gauge
Vacuuming
1. Open the high-pressure valve (HI) (12) and low-pres-
sure valve (LO) (11) of the gauge manifold (13).
2. Turn the vacuum pump (8) switch on and vacuum for
at least 30 min.
3. After the prescribed vacuuming time has elapsed (de-
gree of vacuuming achieved: -750.0 mm Hg (-29.5 in
Hg) or less), close the gauge manifold (13) high-pres-
sure valve (12) and low-pressure valve (11).
4. Next, turn the vacuum pump (8) switch off.
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5. Perform a check of air-tightness.

Let the gauge manifold (13) sit for at least 5 min. with
the high-pressure valve (12) and low-pressure valve
(11) closed, and check that the gauge indicator does
not go back to 0.
If the gauge indicator starts to swing back to 0, this
indicates there is a leak. Tighten the line connections,
perform vacuuming again, and check to see if there is
still a leak.
SMIL14CEX1836EB 3
Gas filling operation, high-pressure side

First, prepare the regulation amount of refrigerant, and
then start the filling operation from the high-pressure
side.
1. After repeating vacuuming, switch the charging
hose (yellow) (7) of the gauge manifold (13) from
the vacuum pump to the service can (16).
2. Air purging
Open the valve for the service can (17). (However,
keep the gauge manifold high-pressure and low-
pressure valves closed.)
Next, press the air purge valve (18) of the side
service port on the gauge manifold low-pressure
side with a screwdriver to discharge the air inside
the charging hose using the refrigerant pressure.
(Complete after the swooshing sound stops.)
3. Open the high-pressure valve (12) of the gauge
manifold (13), and fill with coolant. (Fill with re-
frigerant gas up to a gauge pressure of 0.098 MPa
(14.215 psi) ).
After filling, close the gauge manifold high-pres-
sure valve and valve for the service can (17).
Never operate the compressor. (This is very dan-
gerous, as the refrigerant will flow in the opposite
direction and may cause a service can or hose ex-
plosion.)
4. Gas leak check
Check for gas leaks in the cycle using the gas leak
tester.
If there are leaks, eliminate them through tighten-
ing.
Always use the tester for R134A.
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SMIL14CEX1837EB 4
Gas filling work, low pressure side

CAUTION:
○ Never open the high pressure valve of the

gauge manifold.
○ Never let the service can fall. It may cause
damaging the compressor.
Complete working on the high pressure side filling then
fill the low pressure side.
1. Make sure that the high pressure valve (12) and
the low pressure valve (11) of the gauge manifold
(13), and the service can valve (17) are closed.
2. Start up the engine to set RPM to 1400 -
1600 RPM, and then fully open the cap door and
window.
3. Turn on the air conditioner switch to set the fan
switch to the maximum volume and the tempera-
ture adjustment switch to the coolest.
4. Discharging volume of the compressor during fill-
ing is set to 1.37 - 1.57 MPa (198.72 - 227.73 psi).
5. Open the low pressure valve (11) of the gauge
manifold (13) and the service can valve (17) to fill
specified volume of refrigerant, and then confirm
that bubbles in the sight glass (19) of the receiver
are cleared.
SMIL14CEX1838EB 5
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SMIL14CEX1839EB 6
Judgment of refrigerant volume seen from the sight glass of the receiver dryer
You can see a few bubbles after A/C-ON

Adequate and then it turns to clear and show thin
milky color
SMIL14CEX1840AA 7
Excessive
No bubble is seen after A/C-ON
filling
SMIL14CEX1841AA 8
Insufficient
Continuous bubbles are seen after
filling
A/C-ON
volume
SMIL14CEX1842AA 9
Total gas filling volume: 950 - 1050 g (33.5 - 37.0 oz)
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6. Upon completion of filling refrigerant, close the low

pressure valve (11) of the gauge manifold (13) and the
service can valve (17), and then stop the engine.
• Operating the air conditioner with very low volume
of refrigerant ( R134A ) causes bad effect on the
compressor.
• Filling excessive volume of refrigerant (over charge)
may cause insufficient cooling on the contrary, and it
is also dangerous to cause abnormally high pressure
in the circuit.
Keep adequate volume.
• Never open the high pressure valve (12) of the
gauge manifold.
• Never let the service can fall upside down. (It causes
suction in liquid state which may damage the com-
pressor valve).
7. Remove the gauge manifold and hose after filling re-
frigerant and inspection.
Remove the low pressure side charge hose (blue) (15)
quicker than the low pressure side (SUC) service valve.
Leave the high pressure side until indication of the high
pressure gauge drops to 0.098 MPa (14.215 psi) or
less.
Confirm that it has dropped, and then remove the high
pressure side charge hose (red) (14) quicker than the
high pressure side (DIS) service valve.
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Air-conditioning compressor - Prepare

WARNING:
• Be careful when loosening the lines. The air conditioner circuit is filled with high-pressure gas, so there is
the danger of gas splaying out.
CAUTION:
• Be sure to stop the engine before beginning work.
• When removing and installing the compressor, check the compressor oil quantity.
Items to prepare:
• Wrench [ 13 mm]
• Rag
• Cleaning fluid
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Air-conditioning compressor - Remove

SMIL14CEX1820AB 1
2. Use a box wrench ( 13 mm) to loosen the bolts (1) on

the lines in the 2 locations, and then remove the 2 lines
(2) and (3).
• Always remove the low-pressure side line (2) first.
• Install caps or plugs to the compressor and lines to
Tightening torque for bolt installation: 19.6 -
24.5 N·m (14.5 - 18.1 lb ft)
SMIL14CEX1821AB 2
3. Use a wrench ( 13 mm) to remove the 4 bolts (1), and

then remove the compressor (2).
Tightening torque for bolt installation: 19.6 -
24.5 N·m (14.5 - 18.1 lb ft)
SMIL14CEX1822AB 3
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Air-conditioning compressor - Install

dure.
torque.
2. Check the compressor oil quantity.
The compressor contains 135 cm³ (8.2 in³) of oil.
The oil quantity being low will cause compressor seiz-
ing and a reduction in durability. The oil quantity being
high will cause a reduction in cooling capabilities.
Make sure to check the oil quantity and adjust if
needed.
Measure the oil quantity of the removed compres-
sor. Only this oil quantity is necessary, so subtract
this quantity from 135 cm³ (8.2 in³) to determine the
amount by which the oil quantity of the new compres-
sor should be reduced.
Example
If the remaining oil quantity of the removed compressor
is 30 cm³ (1.8 in³):
Remove 135 cm³ (8.2 in³) - 30 cm³ (1.8 in³) = 105 cm³
(6.4 in³) from the new compressor to be installed.
Resupply oil: SP-10 or SP-20 ( CNH PAG OIL )
3. Perform air conditioner gas charging.
For details, refer to Air conditioning - Filling (50.200).
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Air-conditioning condenser - Prepare

WARNING:
• Use extra care for loosening piping joints. The circuit of the air conditioner is filled with high pressure gas so
that it is dangerous with bursting injection of gas.
CAUTION:
• Make sure to stop the engine before starting work.
• Check and fill compressor oil if the condenser has been removed or installed.
Items to prepare:
• Cap
• Plug
• Rag
• Cleaning fluid
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Air-conditioning condenser - Remove

1. Open the backward left door.
Remove the low pressure hose (1) with a wrench [
32 mm].
Remove the high pressure hose (2) with a wrench [
24 mm].
• Attach caps and plugs to the condenser and piping
in order to prevent invasion of water, dust and dirt.
Low pressure hose tightening torque: 20 - 25 N·m
(14.8 - 18.4 lb ft)
High pressure hose tightening torque: 12 - 15 N·m SMIL14CEX1823AB 1
(8.9 - 11.1 lb ft)
move the condenser (2).
SMIL14CEX1824AB 2
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Air-conditioning condenser - Install

1. To install, follow the removal procedure in reverse.
Tighten the lines and bolts to the specified torque.
If the torque is not specified for a bolt, see the Torque
– Bolt and nut ().
2. Make sure to resupply and check the compressor oil
quantity.
ing and a reduction in durability.
The oil quantity being high will cause a reduction in
cooling capabilities.
Make sure to check the oil quantity and adjust if
needed.
Resupply quantity: 40 cm³ (2.4 in³)
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Receiver/Dryer - Prepare
WARNING:
• Use extra care for loosening piping joints. The circuit of the air conditioner is filled with high pressure gas so
that it is dangerous with bursting injection of gas.
CAUTION:
• Make sure to stop the engine before starting work.
• Check and fill compressor oil if the receiver dryer has been replaced.
Items to prepare:
• Wrench [ 10 mm]
• Cap
• Plug
• Rag
• Cleaning fluid
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Receiver/Dryer - Remove
1. Open the backward left door to remove the connector
(1) .
Remove the bolt (2) with a wrench [ 10 mm] to remove
the high pressure hose (3) and (4).
• Attach caps and plugs to the receiver and piping in
order to prevent invasion of water, dust and dirt.
High pressure hose (3) tightening torque: 7.8 -
11.8 N·m (5.75 - 8.70 lb ft)
High pressure hose (4) tightening torque: 7.8 -
11.8 N·m (5.75 - 8.70 lb ft) SMIL14CEX1825AB 1

move the receiver (2).
SMIL14CEX1826AB 2
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Receiver/Dryer - Install
1. To install, follow the removal procedure in reverse.
When installing the lines and bolts, tighten them to the
specified torque.
When the torque is not specified, check the Torque –
Bolt and nut ().
2. Check the compressor oil quantity.
ing and a reduction in durability. The oil quantity being
high will cause a reduction in cooling capabilities. Make
sure to check the oil quantity and adjust if needed.
Resupply quantity: 20 cm³ (1.2 in³)
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Air-conditioning evaporator - Replace

NOTICE: Be careful of the O-rings getting caught, etc., when installing the expansion valve.
NOTICE: The evaporator sensor cord is sandwiched in the groove of the HVAC unit, so carefully check it and remove
it while making sure not to damage it.
1. Turn the HVAC unit upside down and place it on a
stand.
• Remove the 4 Phillips screws (1) and remove the
drain case (2).
• Remove the 1 Phillips screw (1) and remove the
evaporator pipe stay (3).
• Remove the evaporator sensor connector (4) and
remove the evaporator (5).
SMIL14CEX1814AB 1

expansion valve (2).
• Install O-rings (3) on the new evaporator (4) (1 NF
O-ring 5/8 and 1 NF O-ring 1/2).
Bolt (1) tightening torque: 6.90 N·m (5.09 lb ft).
SMIL14CEX1815AB 2
Installation of evaporator sensor

NOTICE: Be careful that the sensor cord does not get squeezed in the case when the case is assembled.
1. Make sure to install the harness holder (1) and thermis-
tor holder (2) in the original position of the evaporator
(4) as shown in the diagram.
• Install the evaporator sensor (3) end and thermistor
holder (2) as shown in the diagram.
a. Thermistor holder position
b. 20 mm (0.79 in)
c. 73 mm (2.87 in)
d. 9th row
e. 27th row
SMIL14CEX1816AB 3
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Index

Air conditioning - A/C schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Air conditioning - Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Air conditioning - Overview - Air conditioner unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Air conditioning - Overview - Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Air conditioning - Overview - Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Air conditioning - Service instruction - Work precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Air conditioning - Service instruction - Work procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Air conditioning - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Air-conditioning compressor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Air-conditioning compressor - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Air-conditioning compressor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Air-conditioning condenser - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Air-conditioning condenser - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Air-conditioning condenser - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Air-conditioning evaporator - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Receiver/Dryer - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Receiver/Dryer - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Receiver/Dryer - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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47843027 21/05/2015
EN
SERVICE MANUAL
Electrical systems

47843027 21/05/2015
55
Contents
Electrical systems - 55
[55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1
[55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2
[55.525] Cab engine controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3
[55.015] Engine control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4
[55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5
[55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6
[55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7
[55.202] Cold start aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8
[55.011] Fuel tank system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9
[55.010] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.10
[55.014] Engine intake and exhaust system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.11
[55.988] Selective Catalytic Reduction (SCR) electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.12
[55.989] Exhaust Gas Recirculation (EGR) electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.13
[55.012] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.14
[55.013] Engine oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.15
[55.640] Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.16
[55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.17
[55.036] Hydraulic system control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.18
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[55.051] Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls. . . . . . . . . . . . . . . . . . . 55.19
[55.050] Heating, Ventilation, and Air-Conditioning (HVAC) control system. . . . . . . . . . . . . . . . . 55.20
[55.524] Cab controls (Lift arm, Boom, Dipper, Bucket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.21
[55.416] Swing control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.22
[55.417] Travel control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.23
[55.530] Camera. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.24
[55.518] Wiper and washer system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.25
[55.404] External lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.26
[55.514] Cab lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.27
[55.408] Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.28
[55.992] Anti-theft system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.29
[55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.30
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Electrical system - 000

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Contents
TECHNICAL DATA
Electrical system
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Electrical system
Overview - Electrical symbol list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Electrical schema index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Electrical schema - Overall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Electrical schema - Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Electrical schema - Connector wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Wiring schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
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Electrical systems - Electrical system
Electrical system - Special tools

Common probes
number
Description Connector test adapter
kit
SMIL14CEX2953AA 1
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Electrical system - General specification

Starter relay
Part No.: KHH13250
SMIL14CEX4080BA 1
Battery relay
Model: For 24 V DC+
Part No.: KHR1241E-A
SMIL14CEX4081BA 2
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Starter motor
Model: 5 kW - 24 V
Isuzu Part No.: 898060-8540
SMIL14CEX4082BA 3
Alternator
Model: 50 kW - 24 V
SMIL14CEX4083BA 4
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Battery
Model: 180G51
Part No.: KHR4197X-A
SMIL14CEX4084BA 5
Washer motor
(tank + motor)
SMIL14CEX4085BA 6
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Fusible link
(safety relay 1)
(safety relay 2)
Rated current: 60 A
Part No.: KHR12950
SMIL14CEX4086BA 7
Fusible link
(back-up)
Rated current: 50 A
Part No.: KHR3850
SMIL14CEX4087BA 8
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Fuse ( SCR )
Rated current: 20 A
SMIL14CEX4088BA 9
Relay condenser
Part No.: KHR3802X-B
SMIL14CEX4089BA 10
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Throttle volume
Model: RA30Y2 30SKB1KΩK
SMIL14CEX4090BA 11
Starter switch
Rated voltage: 24 V DC
Part No.: KHR15660-B
SMIL14CEX4091BA 12
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Fuel level sensor

Part No.: KWH0025X-B
SMIL14CEX4092BA 13
Fuel feed pump

Rated voltage: 24 V DC
Part No.: KHH11880-B
SMIL14CEX4093BA 14
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Reserve tank limit switch

Part No.: KHH10850-A
SMIL14CEX4094BA 15
Vacuum sensor
Part No.: KHH17440
SMIL14CEX4095BA 16
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Glow plug
SMIL14CEX4096BA 17
EGR motor
EGR position sensor
EGR valve accessory
EGR valve; Isuzu Part No.: 898170-5921
SMIL14CEX4097BA 18
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Common rail pressure sensor

Common rail accessory
Common rail; Isuzu Part No.: 898027-4560
SMIL14CEX4098BA 19
Cam position sensor

SMIL14CEX4099BA 20
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Crank position sensor

SMIL14CEX4100BA 21
Engine oil pressure sensor

SMIL14CEX4101BA 22
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Manifold air pressure sensor

SMIL14CEX4102BA 23
Manifold air temperature sensor

SMIL14CEX4104BA 24
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Fuel temperature sensor

Supply pump accessory
SMIL14CEX4105BA 25
Suction control valve

Supply pump accessory
Supply pump; Isuzu Part No.: 898091-5651
SMIL14CEX4106BA 26
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Injector
SMIL14CEX4107BA 27
Mass air flow sensor

Part No.: KHH13270
SMIL14CEX4108BA 28
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Engine coolant temperature sensor

SMIL14CEX4109BA 29
Main controller
SMIL14CEX4110BA 30
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Sub-controller
Part No.: -
SMIL14CEX4111BA 31
Glow relay
Part No.: KHH13260
SMIL14CEX4112BA 32
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DC-DC converter
SMIL14CEX4113BA 33
Alarm (feed pump)

SMIL14CEX4114BA 34
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Feed pump
Part No.: KHR12840
SMIL14CEX4115BA 35
Feed pump switch

Part No.: KHR12900
SMIL14CEX4116BA 36
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Lamp (front right, housing)

Specification: 24 V 70 W
SMIL14CEX4117BA 37
Lamp (boom)
Part No.: KHR0957E-A
SMIL14CEX4118BA 38
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Lamp (cab, top)

SMIL14CEX4119BA 39
Speaker (right, left)

SMIL14CEX4120BA 40
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Monitor display
Part No.: KHR43200
SMIL14CEX4121CA 41
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Pressure sensor
(P1) (P2)
(boom bottom)
(arm bottom)
Specification: 50 MPa (7252.5 psi)
SMIL14CEX4122BA 42
Pressure sensor
(N1) (N2)
(swing)
(upper)
(travel)
(option)
Specification: 5.0 MPa (725.2 psi)
SMIL14CEX4123BA 43
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Pressure switch
(2nd option)
Specification: 0.49 MPa (71.07 psi)
SMIL14CEX4124BA 44
5 stack solenoid valve

Part No.: KHJ28510-B
SMIL14CEX4137BA 45
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Flow control proportional valve

(P1) (P2)
Part No.: KSJ18291-B
SMIL14CEX4138BA 46
Standard seat
Part No.: KHN38810-C
SMIL14CEX4139BA 47
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Hydraulic oil temperature sensor

SMIL14CEX4140BA 48
Right knob (with one-touch switch)

Model: With 4 switches
SMIL14CEX4141BA 49
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Left knob (with horn switch and radio mute)

Model: With 4 switches
SMIL14CEX4142BA 50
Travel alarm
Basic frequency: 2560 Hz
SMIL14CEX4143BA 51
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Horn (LOW)
Part No.: KHR11440
SMIL14CEX4144BA 52
Horn (HIGH)
Part No.: KHR11450
SMIL14CEX4145BA 53
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Gate lock limit switch

Part No.: KHR14930-A
SMIL14CEX4146BA 54
Radio
Model: AM/FM ST ( 12 V/ 24 V)
Part No.: KHR32800
SMIL14CEX4147BA 55
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Lamp (room lamp)

Part No.: KHN2714
SMIL14CEX4148BA 56
Accessory socket
Model: 12 V DC
SMIL14CEX4149BA 57
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Cigar lighter
Model: 24 V DC
SMIL14CEX4150BA 58
Air conditioner unit

Part No.: KHR27160
SMIL14CEX4151BA 59
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Limit switch (front window, door)

Part No.: KHN26000
SMIL14CEX4152BA 60
Wiper motor
Part No.: KHN25780-A
SMIL14CEX4153BA 61
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Wiper controller
Part No.: KHN3392
SMIL14CEX4154BA 62
Solar radiation sensor

Part No.: KHR10540
SMIL14CEX4155BA 63
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Receiver dryer (switch)

Part No.: KHR13590
SMIL14CEX4156BA 64
Air conditioner compressor

(magnetic clutch)
Part No.: KHR3197
SMIL14CEX4157BA 65
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Motor actuator
(air mix mode)
(inside/outside air)
Part No.: KHR27530
SMIL14CEX4158BA 66
Evaporator sensor
Part No.: KHR27650
SMIL14CEX4159BA 67
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Refresh/recirculate temperature sensor

Part No.: KHR27490
SMIL14CEX4160BA 68
Relay (compressor)
(blower OFF)
Part No.: KHR2836
SMIL14CEX4161BA 69
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Blower motor
Part No.: KHR27850
SMIL14CEX4162BA 70
Blower amp
Part No.: KHR27840
SMIL14CEX4163BA 71
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Air conditioner switch panel

SMIL14CEX4164BA 72
Horn select switch

Part No.: KHR28540
SMIL14CEX4165BA 73
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Emergency stop switch

SMIL14CEX4166BA 74
6 stack proportional valve

(arm 1 sub-controller, arm 2 sub-controller, boom regen-
eration, arm regeneration, travel, bucket-close)
SMIL14CEX4167BA 75
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Fuel filter sensor

Part No.: KHH14450
SMIL14CEX4168BA 76
DOC temperature sensor (center)

Part No.: KHH15090
SMIL14CEX4169BA 77
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DOC temperature sensor (Isuzu) (front)

Part No.: KHH15080
SMIL14CEX4170BA 78
EGR cooler temperature sensor

(in, out)
Part No.: -
Isuzu Part No.: -
SMIL14CEX0668BA 79
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VGS TURBO
Part No.: -
SMIL14CEX4171BA 80
Dosing module
Part No.: KHH15351
SMIL14CEX4172BA 81
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NOx sensor
(in, out)
Part No.: KHH15310
SMIL14CEX4173BA 82
SCR temperature sensor

Part No.: KHH15320
SMIL14CEX4174BA 83
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Urea sensor
Part No.: KSH14010-B
SMIL14CEX4175BA 84
Intercooler temperature sensor

Part No.: KHH15300
SMIL14CEX4176BA 85
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Part No.: KHH15330
SMIL14CEX4177BA 86
Supply module
Part No.: KHH15341
SMIL14CEX4178BA 87
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Intake throttle DC motor

Throttle body accessory
Part No.: -
SMIL14CEX4179BA 88
Solenoid valve
(free swing)
Part No.: KHJ0659U-A
SMIL14CEX4180BA 89
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Electromagnetic proportional valve

SMIL14CEX4181BA 90
Beacon switch
Part No.: KHR15480-C
SMIL14CEX4187BA 91
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Warning select switch

Part No.: KHR15850
SMIL14CEX4188BA 92
Free swing switch / Overload switch

NOTE: Free swing (North America only).
SMIL14CEX4189BA 93
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2 stack solenoid valve

SMIL14CEX4190BA 94
Reducing valve
Part No.: MFJ71500-A
SMIL14CEX4191BA 95
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CCD camera
SMIL14CEX4192BA 96
Engine control module

Part No.: KSH12520
SMIL14CEX4193BA 97
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Dosing control unit

Part No.: KSH12990
SMIL14CEX4194BA 98
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Electrical system - Component localization

Electrical equipment layout diagram
SMIL14CEX1207HB 1
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1. Main unit left side (radiator chamber) 4. Main unit center section
2. Engine 5. In cab
3. Main unit right side (pump chamber)
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Main unit left-side layout diagram
SMIL14CEX1208HB 2
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1. Reserve tank limit switch 11. Battery relay

2. Washer motor 12. Receiver dryer (switch)
3. Fuse 10 A: UREA pump 13. Battery
Fuse 20 A: Spare
4. Fusible link 1 60 A: Safety relay 14. Bucket (open) pressure sensor
5. Fusible link 2 60 A: Safety relay 15. Arm (in) pressure sensor
6. Fusible link 50 A: Backup 16. Boom (up) pressure sensor
7. Fuse 10 A: Fuel pump 17. Bucket (close) pressure sensor
Fuse 15 A: Fuel pump
8. Fuse 60 A: Time delay 18. Arm (out) pressure sensor
Fuse 100 A: Time delay
9. Fuse - A: Not used 19. Boom (down) pressure sensor
Fuse 20 A: SCR
10. Starter relay 20. Swing pressure sensor
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Engine section layout diagram
SMIL14CEX1209HB 3
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1. Engine coolant temperature sensor 9. Crank position sensor

2. MAT sensor 10. Suction control valve
3. Intake throttle DC motor 11. Fuel temperature sensor
4. MAP sensor 12. Cam position sensor
5. EGR Valve 13. Starter motor
6. Air-conditioner compressor 14. VGS motor
7. Common rail pressure sensor 15. Alternator
8. Engine oil pressure sensor
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SMIL14CEX1210HB 4
1. Dosing module 11. Urea sensor

2. Nox sensor (in) 12. Fuel level sensor
3. DOC temperature sensor (center) 13. Coolant control valve
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4. DOC temperature sensor (front) 14. Fuel feed pump

5. Urea hose 15. Supply module
6. Nox sensor (out) 16. Feed pump
7. SCR temperature sensor 17. Feed pump switch
8. Inter-cooler temperature sensor 18. Feed pump alarm
9. MAF sensor 19. Travel alarm
10. Vacuum sensor 　
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Main unit right side layout diagram (pump chamber)
SMIL14CEX1211GB 5
1. P1 flow control proportional valve 7. Swing lock

2. P2 flow control proportional valve 8. Pressure boost
3. Hydraulic oil temperature sensor 9. Travel 2nd speed
4. P1 pressure sensor 10. Lever lock
5. P2 pressure sensor 11. Hydraulic pressure load
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Main unit center section layout diagram
SMIL14CEX1212GB 6
1. Arm cylinder (bottom) pressure sensor 7. Arm 2 variable parameter control

2. N2 pressure sensor 8. Arm regeneration release control
3. N1 pressure sensor 9. Boom down regeneration
4. 6 stack proportional valve 10. Arm variable parameter control
5. Bucket stroke restriction 11. Arm cylinder (rod) pressure sensor
6. Straight travel control
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Cab layout diagram 1
SMIL14CEX1213HB 7
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1. Sunlight sensor 8. Radio

2. Monitor display 9. Accessory socket
3. Knob right (with one-touch switch) 10. Wiper motor
4. Throttle volume 11. Emergency stop switch
5. Cigar lighter 12. Air-conditioner switch panel
6. Starter switch 13. Gate lock limit switch
7. Horn volume switch 14. Knob left (with horn switch and radio mute)
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Cab layout diagram 2
SMIL14CEX1214HB 8
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1. Speaker 6. ECM (Engine Control Module)

2. Fuse box 7. Main controller
3. Relay 8. Fuse box 1
4. DC-DC converter 9. Fuse box 2
5. DCU (Dosing Control Unit)
No. Name No. Name

CN.A6 ECM relay CN.A13 Cab light relay
CN.A7 Starter cut relay CN.A14 Beacon relay
CN.A8 Neutral start relay CN.A15 Boom, house light relay
CN.A9 Accessory 1 relay CN.A16 Left speaker relay
CN.A10 Accessory 2 relay CN.A17 Right speaker relay
CN.A11 Key ON relay CN.A18 Horn relay
CN.A12 Room lamp relay 　
SMIL14CEX1215GB 9
1. Fuse box 1 2. Fuse box 2
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Fuse box 1
No. Name No. Name
Air-conditioner
F1 Key switch 10 A F9 5A
compressor
F2 Accessories 10 A F10 Engine controller 20 A
F3 GPS controller 10 A F11 Monitor (back-up) 10 A
F4 Monitor 10 A F12 Back-up 10 A
F5 Controller 10 A F13 Solenoid 15 A
Proportional
F6 Gate lock 10 A F14 15 A
solenoid
Air-conditioner
F7 5A F15 Horn 15 A
unit
Air-conditioner
F8 15 A
blower motor
Fuse box 2
No. Name No. Name
Seat suspension,
F1 10 A F7 Beacon 10 A
heater
F2 Wiper, washer 15 A F8 Lamp (cab) 15 A
Lamp (boom,
F3 Cigar lighter 10 A F9 15 A
housing)
F4 DC/DC converter 10 A F10 Options 10 A
F5 FVM 10 A F11 Spare 2 10 A
F6 Spare 1 10 A F12 Spare 3 15 A
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Layout around operator seat
SMIL14CEX1216HB 10
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1. Cup holder 7. Tilt lever left

2. Starter switch 8. Glove box
3. Rocker switch space 9. Air-conditioner control panel
4. Radio 10. Emergency stop switch
5. Throttle volume 11. Gate lock lever
6. Tilt lever right
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Electrical system - Overview - Electrical symbol list

Symbol Name Symbol Name
Fuse Variable solenoid valve
Diode Resistor
LED Variable resistor
Toggle switch "a" contact Variable resistor
Push switch "a" contact Alarm
Limit switch "a" contact Buzzer
Limit switch "b" contact Horn
Relay coil Motor
Relay contact "a" contact Solar radiation sensor
Relay contact "b" contact Speaker
Solenoid valve Lamp
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Electrical system - Electrical schema index

A1 Controller X4 M23 VGS turbo
A2 Engine controller M24 Intake throttle DC motor
A4 Wiper controller M25 Exhaust gas recirculation valve (A)
A6 Blower controller P1 Instrument panel
A9 Air-conditioner controller P4 Monitor Display
A17 DOSING control unit P5 Hour meter
B1 Coolant temperature sensor P6 Air conditioner switch panel
B2 Hydraulic oil temperature sensor P10 Switch panel
B3 Fuel temperature sensor P15 Radio set
B5 Evaporator Sensor P21 Knob, right, 4 switches
B21 Engine oil pressure sensor P22 Knob, left, 4 switches
B22 Swing pilot pressure sensor P23 Knob, right, 2 switches
B28 2nd option pilot circuit 1 pressure switch P24 Knob, left, 2 switches
B40 Pump pressure sensor (negative control P2 ) P24 Knob, right, proportional lever
B42 Pump pressure sensor ( P1) P26 Knob, left, proportional lever
B43 Pump pressure sensor (negative control P1) R1 Glow plug
B44 Pump pressure sensor ( P2) R3 Throttle volume
B49 Crankshaft position sensor R4 Thermistor internal temperature
B52 Common rail pressure sensor R5 Fuel sensor
B61 Sunload sensor S1 Key switch
B82 Feed pump stop alarm S2 Travel mode switch
B83 Pressure sensor (pilot arm-in) S4 Auto idle switch
B84 Pressure sensor (pilot bucket-in) S9 Engine emergency stop switch
B85 Pressure sensor (pilot boom up) S10 Working light switch
B87 Cam angle (MRE) sensor S11 Wiper switch
B88 Fuel filter sensor S12 Washer switch
B90 Exhaust temperature sensor (CNT) S15 Horn switch
B91 Exhaust temperature sensor (FNT) S16 Idle switch
B92 Horn low (left) S22 Free swing/overload
B93 Horn high (right) S28 Travel alarm switch
B95 Air intake sensor flow & temperature S51 Hydraulic function release lever switch
B97 Pressure sensor (hydraulic oil filter) S52 Air-conditioner compressor clutch switch
B101 Pressure sensor (travel pilot, right) S53 Door limit switch
B102 Pressure sensor (travel pilot, left) S54 Front window limit switch
B103 Pressure sensor (pilot 1 pedal) S55 Reserve tank low switch
B104 Pressure sensor (pilot boom down) S61 Feed pump switch
B105 Pressure sensor (pilot arm-out) S62 Air cleaner sensor
B106 Pressure sensor (pilot bucket-out) S69 Radio mute switch
B108 Pressure sensor (boom cylinder bottom) S85 Beacon
B109 Pressure sensor (arm cylinder bottom) S87 ATT selector
B110 Pressure sensor (option pilot) S88 Menu
B114 Inter-cooler temperature sensor S89 SEL display
B116 NOx sensor (SCR OUT) S90 Trip/camera
B117 SCR temperature sensor S94 Battery switch
B118 Manifold air pressure & boost temperature sensor S100 Pressure switch option (lever up)
B119 EGR cooler OUT temperature sensor S101 Pressure switch option (lever down)
B120 EGR cooler IN temperature sensor S104 Proportional lever switch
B133 Pressure sensor (arm rod) S105 Switch (P-SOL2: 100%)
B138 Pressure sensor (1st option pilot up) S127 Horn switchover
B139 Pressure sensor (1st option pilot down) S128 Crane switch
B140 UREA sensor S129 Quick coupler
E1 Working light (upper structure) S130 Fan rotation
E2 Working light (attachment) U1 DC-DC ( 24 V - 12 V) converter
E3 Working light (cab) X4 Engine test point connector
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E4 Cab light X5 Controller test point connector

E51 Cigar lighter X7 Lubricator
E52 Air-conditioner X9 Anti-theft system connector
F34 Fuse box X15 Accessory socket
F41 Fusible 50 A; link backup X23 Memory clear 1
F47 Fuse 10 A; SCR control unit X24 Memory clear 2
F55 Fuse 20 A; spare/ 10 A; AdBL pump X25 To controller C
F56 Fuse 15 A; fuel pump/ 10 A; fuel pump X27 To GPS unit
F57 Fusible 60 A; link 1 safety relay X36 12 V output table (for radio)
F58 Fusible 60 A; link 2 safety relay X44 FVM optional power supply
G1 Battery X45 Air suspension & seat heater
G2 Alternator X47 Supply module
H1 Voice warning device X49 UREA pump
H2 Travel alarm X50 Spare
H4 Speaker (right) Y2 Pilot pressure solenoid valve (blue band)
H5 Speaker (left) Y3 Swing brake solenoid valve (white band)
H10 Camera 1 (rear) Y4 2-stage travel solenoid valve (red band)
H11 Camera 2 (right side) Y5 High output solenoid valve (yellow band)
H12 Buzzer 24 V Y8 Air-conditioner magnetic clutch
H13 Camera 3 (left side) Y11 Main pump P1 flow proportional solenoid
K2 Glow plug relay Y18 Free swing solenoid valve
K3 Horn relay Y24 1st option solenoid valve (red tape)
K6 Air-conditioner condenser fan relay Y25 2nd option solenoid valve (red band)
K7 Battery relay Y26 2nd option solenoid valve (blue band)
K10 Working light relay (upper structure/attachment) Y27 Option selector solenoid valve
K11 Working light relay (cab) Y35 Suction control valve
K17 Blower OFF relay Y62 Option pressure proportional solenoid valve
K30 Feed pump relay Y63 INJ1 (#1)
K31 Feed pump stop relay Y64 INJ2 (#5)
K34 Starter cut relay Y65 INJ3 (#3)
K35 Room lamp relay Y66 INJ4 (#6)
K36 Speaker (left) relay Y69 INJ5 (#2)
K37 Speaker (right) relay Y70 INJ6 (#4)
K63 ECM relay Y99 Center cut solenoid valve (green tape)
K64 Key ON relay Y102 Main pump P2 flow proportional solenoid
Arm 1 SUB-CONT proportional solenoid valve
K68 Neutral start relay Y103
(blue tape)
Boom REGENE proportional solenoid valve (pink
K69 Starter relay Y104
tape)
Arm REGENE proportional solenoid valve (white
K77 Beacon relay Y105
tape)
Arm 2 SUB-CONT proportional solenoid valve
K95 Accessory relay 1 Y106
(green tape)
Travel STRATE proportional solenoid valve (yellow
K96 Accessory relay 2 Y107
tape)
Bucket C-CONT proportional solenoid valve (red
M1 Starter motor Y108
tape)
M3 Wiper motor Y109 Quick coupler
M4 Washer motor Y110 1st option proportional solenoid valve (lever up)
M5 Motor (ventilation) Y111 1st option proportional solenoid valve (lever down)
M6 Motor actuator (mode) Y112 2nd option proportional solenoid valve (lever up)
2nd option proportional solenoid valve (lever
M7 Motor actuator (air mix) Y113
down)
M8 Blower motor Y116 Coolant control valve
M14 Fuel feed pump motor Y117 DOSING valve
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Electrical system - Electrical schema - Overall
SMIL14CEX1219HA 1
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SMIL14CEX1220HA 2
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SMIL14CEX1221HA 3
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Electrical system - Electrical schema - Block diagram

Main controller
SMIL14CEX1222HA 1
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DCU
SMIL14CEX1223GA 2
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ECM
SMIL14CEX1224HA 3
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Monitor
SMIL14CEX1225GA 4
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Air conditioner
SMIL14CEX1226HA 5
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Gate lock
SMIL14CEX1227FA 6
Horn
SMIL14CEX1228EA 7
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Working light
SMIL14CEX1229EA 8
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Option
SMIL14CEX1230HA 9
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Other
SMIL14CEX1231GA 10
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Electrical system - Electrical schema - Connector wiring diagram

Main frame
1. Install the fuse box and blade fuse on CN.D68F, CN.D69F, and CN.D70F.
Install the fuse holder, 60 A fuse ( KHR39840) and 100 A fuse ( KHR39850) on CN.D79 - CN.D82, 50 A fuse
2.
( KHR3850) on CN.D67F, 60 A fuse (KHR12950) on CN.D71M and CN.D72M.
For connectors marked with * ( CN.D32F, CN.D33F, CN.D34F, CN.D43F, CN.D46F, CN.D51M, CN.D52F,
3. CN.D60F, CN.D61F, CN.D62F, CN.D89F), install the suitable housing, waterproof plug, and rear holder
assembly.
4. For connectors marked with # ( CN.D12, CN.D73, CN.D74), install the suitable rubber cap.
5. Install the joint connector (7322-7489-40) on CN.D90F (CN JOINT GND).
The connector ( CN.D51M, CN.D60F, CN.D61F) The connector ( CN.D38F) must be fastened with
a. f.
must be fastened with red tape. red tape.
The connector ( CN.D32F, CN.D33F, CN.D34F) The connector ( CN.D85F) must be fastened with
b. g.
must be fastened with red tape. red tape.
The connector ( CN.D52F) must be fastened with The connector ( CN.D90F) must be fastened with
c. h.
red tape. red tape.
The connector ( CN.D62F) must be fastened with The connector ( CN.D46F) must be fastened with
d. i.
red tape. red tape.
The connector ( CN.D89F) must be fastened with
e.
red tape.
*1. Plate *6. Yellow adhesive tape

*2. Black adhesive tape *7. Green adhesive tape
*3. White adhesive tape *8. Computer unit (ECM) details
*4. Blue adhesive tape *9. Computer unit (DCU) details
*5. Red adhesive tape
CN.A50F Cab main harness: A CN.D45F Air-conditioner compressor

CN.A51F Cab main harness: B CN.D46F Travel alarm
CN.A52F Cab main harness: C CN.D47F Coolant tank switch
CN.A53F Cab main harness: D CN.D48M Air cleaner switch
CN.A54F Cab main harness: E CN.D49F P1 pressure sensor
CN.A55F Cab main harness: F CN.D50F P2 pressure sensor
CN.A56F Cab main harness: G CN.D51M Return room sensor
CN.C18F Cab harness: Rear camera CN.D52F Boom cylinder (bottom)
CN.D1F DCU: 1 CN.D53F Fuel level sensor
CN.D2F DCU: 2 CN.D54F Oil temperature sensor
CN.D3F ECM: 1 CN.D55F Lever lock solenoid valve
CN.D4F ECM: 2 CN.D56F Swing brake solenoid valve
CN.D7F Engine harness: A CN.D57F Travel high-speed solenoid valve
CN.D8M Engine harness: B CN.D58F Pressure boost relief solenoid valve
CN.D9M Engine harness: C CN.D59F Hydraulic load solenoid valve
CN.D10M Engine harness: D CN.D60F Free swing solenoid valve
CN.D11M Engine harness: H CN.D61F Quick coupler solenoid valve
CN.D12 Starter motor: S CN.D62F Option harness proportional solenoid valve
CN.D13 Alternator: B CN.D63F P1 flow proportional solenoid valve
CN.D14F Alternator: L/R CN.D64F P2 flow proportional solenoid valve
CN.D15 Alternator: E CN.D65M Control valve sensor
CN.D16 Alternator: GND CN.D66M Control valve PWM
CN.D17M SCR harness CN.D67F Fuse 50 A: +B
CN.D18F Supply module CN.D68F Fuse: 1
CN.D19F Coolant control valve CN.D69F Fuse: 3
CN.D20F Urea sensor CN.D70F Fuse: 2
CN.D21F MAF sensor CN.D71M Fuse 60 A: ST 1
CN.D22F Suction air temperature CN.D72M Fuse 60 A: ST 2
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CN.D23F Floor harness: 1 CN.D73 Battery relay: Coil 1

CN.D24F Floor harness: 2 CN.D74 Battery relay: Coil 2
CN.D25F Swing pressure sensor CN.D75M Battery relay: GND
CN.D26F Boom-up pressure sensor CN.D76 Battery relay: B1
CN.D27F Boom-down pressure sensor CN.D77 Battery relay: B2
CN.D28F Arm-out pressure sensor CN.D78 Battery relay: IGN
CN.D29F Arm-in pressure sensor CN.D79 Fuse 60 A: 1
CN.D30F Bucket-open pressure sensor CN.D80 Fuse 100 A: 2
CN.D31F Bucket-close pressure sensor CN.D81 Fuse 60 A: 2
CN.D32F Urea pump CN.D82 Fuse 100 A: 1
CN.D33F Lubricator CN.D83F Starter relay: B/C
CN.D34F Refueling pump harness CN.D84F Starter relay: S/E
CN.D35F Boom lamp harness CN.D85F Starter: Diode
CN.D36F Housing lamp CN.D86F Glow relay: 2
CN.D37F Washer motor CN.D87F Glow relay: 1
CN.D38F Washer motor: Diode CN.D88F Glow relay coil
CN.D39F Horn: L+ CN.D89F Option power supply
CN.D40F Horn: L- CN.D90F Ground joint connector
CN.D41F Horn: H+ CN.D91 G2 GND
CN.D42F Horn: H- CN.D92 G1 GND
CN.D43F Beacon harness CN.E18M CCD harness
CN.D44F Receiver dryer
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SMIL14CEX5001JB 1
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Control valve harness

*1. Plate *5. Blue adhesive tape
*2. Red adhesive tape *6. Pink adhesive tape
*3. Yellow adhesive tape *7. White adhesive tape
*4. Green adhesive tape
CN.D65F Frame main harness: 1 CN.D66-1 F Bucket-close: Solenoid valve

CN.D65-1 F N1 pressure sensor CN.D66-2 F Straight travel: Solenoid valve
CN.D65-2 F N2 pressure sensor CN.D66-3 F Arm 2 parallel: Solenoid valve
Arm cylinder (rod) pressure
CN.D65-3 F CN.D66-4 F Arm 1 regeneration: Solenoid valve
sensor
Arm cylinder (bottom) pressure
CN.D65-4 F CN.D66-5 F Boom 2 down: Solenoid valve
sensor
CN.D66F Frame main harness: 2 CN.D66-6 F Arm 1 parallel: Solenoid valve
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SMIL14CEX5002JB 2
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SCR harness
NOTE: Install the rear covers on connectors CN.D17-8M and CN.D17-9M.
a. CN.D17-2F must be fastened with red tape.

b. CN.D17-4M must be fastened with red tape.
*1. Plate
*2 White adhesive tape
CN.D17F Frame main harness CN.D17-5 F SCR inlet NOx sensor

CN.D17-1 F Fuel pump CN.D17-6 F Fuel pump sensor
CN.D17-2 F Fuel pump: Diode CN.D17-7 F SCR upstream temperature sensor
CN.D17-3 F DOSING valve CN.D17-8 M Exhaust temperature sensor (FNT)
CN.D17-4 M CN J1939 CN.D17-9 M Exhaust temperature sensor (CNT)
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SMIL15CEX0579JB 3
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Cab main harness

NOTE: 1. Install the joint connector (7257-9322-40) on connectors CN.A33F, CN.A34F, CN.A37F and CN.A38F.
2. Install the joint connector (6440-0128) on connectors CN.A35F and CN.A36F .
3. For connectors marked with *, install the suitable housing.
CN.A47M and CN.A47F must be fastened with CN.A33 and CN.A34 must be fastened with red
a. g.
red tape. tape.
CN.A30 and CN.A31 must be fastened with red
b. h. CN.A26 must be fastened with red tape.
tape.
CN.A28M and CN.A28F must be fastened with
c. i. CN.A25F must be fastened with red tape.
red tape.
CN.A35 and CN.A36 must be fastened with red
d. j. CN.A21F must be fastened with red tape.
tape.
CN.A24M and CN.A24F must be fastened with
e. CN.A46 must be fastened with red tape. k.
red tape.
f. CN.A27 must be fastened with red tape.
*1. White adhesive tape *3. Fuse box: 1

*2. Plate position *4. Fuse box: 2
CN.A1F Computer: CN1 CN.A28M Hour meter: -

CN.A2F Computer: CN2 CN.A29F DC converter
CN.A3F Computer: CN3 CN.A30F Diode 1
CN.A4F Computer: CN4 CN.A31F Diode 2
CN.A5F Computer: CN5 CN.A33F Joint connector: CONT1
CN.A6F ECM relay CN.A34F Joint connector: CONT2
CN.A7F Starter cut relay CN.A35F Joint connector: A
CN.A8F Neutral start relay CN.A36F Joint connector: B
CN.A9F ACC1 relay CN.A37F Joint connector: Ground 1
CN.A10F ACC2 relay CN.A38F Joint connector: Ground 2
CN.A11F Key ON relay CN.A39 Cab ground
CN.A12F Room lamp relay CN.A40F Cab harness: A
CN.A13F Cab lamp relay CN.A41F Cab harness: B
CN.A14F Beacon relay CN.A42M Console harness: A
CN.A15F Upper lamp relay CN.A43M Console harness: B
CN.A16F Speaker (L) relay CN.A44M Console harness: C
CN.A17F Speaker (R) relay CN.A45M Console harness: D
CN.A18F Horn (R) relay CN.A46F Horn jumper
CN.A19F EST-B (F) connector CN.A47F Immobilizer
CN.A20F Diagnostic connector CN.A47M Immobilizer ground
CN.A21F EST-A harness CN.A50M Frame harness: A
CN.A24F Buzzer: - CN.A51M Frame harness: B
CN.A24M Buzzer: + CN.A52M Frame harness: C
CN.A25F Option harness CN.A53M Frame harness: D
CN.A26F Computer T harness CN.A54M Frame harness: E
CN.A27F Computer C harness CN.A55M Frame harness: F
CN.A28F Hour meter: + CN.A56M Frame harness: G
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SMIL14CEX5004JB 4
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EST-A harness
SMIL14CEX5006EB 5
CN.52F Cab main harness

CN.228M EST connector: A
Console harness
NOTE: For connectors marked with *, install the suitable housing.
The terminals ( CN.B24F, CN.25F, CN.26F) must

a. d. CN.B4F must be fastened with red tape.
be fastened with red tape.
b. CN.B6F must be fastened with red tape. e. CN.B8F must be fastened with red tape.
c. CN.B21F must be fastened with red tape.
*1. White adhesive tape *3. Blue adhesive tape

*2. Red adhesive tape *4. Plate position
CN.A42F Cab main harness: A CN.B13F Travel alarm switch

CN.A43F Cab main harness: B CN.B14F Air-conditioner panel: A
CN.A44F Cab main harness: C CN.B15F Air-conditioner panel: B
CN.A45F Cab main harness: D CN.B16F Air-conditioner unit: A
CN.B1F Starter switch CN.B17F Air-conditioner unit: B
CN.B2M Engine throttle switch CN.B18F Radio
CN.B3F Gate limit switch CN.B19M Option harness
CN.B4F Gate: Diode CN.B20F Suspension seat
CN.B5F Knob right 1: Switch CN.B21F Seat: Diode
CN.B6F Knob right 2: Switch CN.B22F Air-conditioner GND
CN.B7F Knob left 1: Switch CN.B23F Computer GND
CN.B8F Knob left 2: Switch CN.B24F +B 12 V
CN.B9F Engine stop switch CN.B25F Ignition 12 V
CN.B10F Fan reverse switch CN.B26M GND 12 V
CN.B11F Overload CN.B27F Free swing switch
CN.B12F Beacon switch
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SMIL14CEX5005JB 6
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Electrical system - Wiring schema

Frame
CN.A50F Cab main harness: A (2-pin) CN.D37F Washer motor: 2-pin
CN.A51F Cab main harness: B (8-pin) CN.D39F Horn (low) +
CN.A52F Cab main harness: C (8-pin) CN.D40F Horn (low) -
CN.A53F Cab main harness: D (14-pin) CN.D41F Horn (high) +
CN.A54F Cab main harness: E (22-pin) CN.D42F Horn (high) -
CN.A55F Cab main harness: F (20-pin) CN.D43 Beacon harness: 2-pin
CN.A56F Cab main harness: G (18-pin) CN.D44F Receiver dryer: 2-pin
CN.C18F CCD harness (rear): 4-pin CN.D45F Air-conditioner compressor
CN.D1F DCU: 1 (53-pin) CN.D46F Travel alarm: 2-pin
CN.D2F DCU: 2 (86-pin) CN.D47F LLC tank switch: 2-pin
CN.D3F ECM: 1 (91-pin) CN.D48M Air cleaner switch: 2-pin
CN.D4F ECM: 2 (105-pin) CN.D51 Return room sensor: 3-pin
CN.D17M SCR harness: 16-pin CN.D53F Fuel level sensor: 2-pin
CN.D18F Supply module: 12-pin CN.D60 Free swing solenoid valve: 2-pin
CN.D19F Coolant control valve: 2-pin CN.D61 Quick coupler solenoid valve: 2-pin
Option proportional solenoid valve
CN.D20F UREA sensor: 4-pin CN.D62
harness: 2-pin
CN.D21F MAF sensor: 5-pin CN.D65F Frame main harness: 1 (8-pin)
CN.D22F Suction air temperature: 2-pin CN.D65M Control valve sensor: 8-pin
CN.D23F Floor harness: 1 (6-pin) CN.D65-1F N1 pressure sensor: 3-pin
CN.D24F Floor harness: 2 (8-pin) CN.D65-2F N2 pressure sensor: 3-pin
CN.D25F Swing pressure sensor: 3-pin (ID: Black tape) CN.D65-3F Arm cylinder (rod) pressure sensor: 3-pin
Boom (up) pressure sensor: 3-pin (ID: Yellow Arm cylinder (bottom) pressure sensor:
CN.D26F CN.D65-41
tape) 3-pin
Boom (down) pressure sensor: 3-pin (ID: Blue
CN.D27F CN.D66F Frame main harness: 2 (12-pin)
tape)
Arm (open) pressure sensor: 3-pin (ID: Red
CN.D28F CN.D66M Control valve PWM: 12-pin
tape)
Arm (close) pressure sensor: 3-pin (ID: White Bucket (close) solenoid valve: 2-pin (ID:
CN.D29F CN.D66-1F
tape) Red tape)
Straight travel solenoid valve: 2-pin (ID:
CN.D30F Bucket (open) pressure sensor: 3-pin CN.D66-2F
Yellow tape)
Bucket (close) pressure sensor: 3-pin (ID: Arm 2 parallel solenoid valve: 2-pin (ID:
CN.D31F CN.D66-3F
Green tape) Green tape)
Arm 1 recycle solenoid valve: 2-pin (ID:
CN.D33F Lubricator: 2-pin CN.D66-4F
White tape)
Boom (down) solenoid valve: 2-pin (ID:
CN.D34F Refueling pump harness: 3-pin CN.D66-5F
Pink tape)
Arm 1 parallel solenoid valve: 2-pin (ID:
CN.D35F Boom light harness: 2-pin CN.D66-6F
Blue tape)
CN.D36F House light: 2-pin CN.D89 Option power supply: 2-pin
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SMIL14CEX5007JB 1
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NOTE: 1. When installing the ground terminals marked with *, it should be confirmed that the frame seating surface
is not coated. If the surface is coated, installation should be performed after removing the coating.
2. The clamp positions of the electrical wiring that comes out from connectors should be adjusted so that the wiring
does not form sharp rounded shapes. [R = 10 mm (0.394 in) or more]
a. Fasten together with the LLC line c. Fasten together with the starter cable
b. Marking position: Align white tape on harness d. Fasten together with the air conditioner hose
*1. KHR14280 Boom light harness *4. ECM computer (engine accessory)
*2. Supply module (engine accessory) 5. DCU computer (engine accessory)
*3. Coolant control valve (engine accessory)

Pressure sensor [ 5 MPa (725 psi)] G1/4
1 Frame main harness (Quantity 1) 6
(Quantity 11)
2 Horn (high) (Quantity 1) 7 Ground wire: Floor (Quantity 1)
3 Horn (low) (Quantity 1) 8 Travel alarm (Quantity 1)
4 Working light: 24 V x 70 W (Quantity 1) 9 Control valve wire harness (Quantity 1)
Pressure sensor [ 50 MPa (7253 psi)] M18
5 1 pedal wire harness (travel) (Quantity 1) 10
(Quantity 2)
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SMIL14CEX5008JB 2
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Engine and pump

NOTE: 1. Before fitting, clean the terminal of the connectors marked with * using a cleaning agent and coat it with an
anti-rust agent.
2. When installing the ground terminals marked with #, check that the frame seating surface is not coated.
If the surface is coated, installation should be performed after removing the coating.
a. Marking position: Align white tape on harness

b. Fasten together with the LLC line
*1. NOx sensor (engine accessory) *5. SCR temperature sensor (engine accessory)
*2. Dosing module (engine accessory) *6. Engine harness (engine accessory)
*3. Temperature sensor CT (engine accessory) *7. Engine ground (engine accessory)
*4. Temperature sensor FT (engine accessory) *8. KSR15250 Frame main wire harness

1 Oil temperature sensor (Quantity 1) 3 SCR wire harness (Quantity 1)
Pressure sensor [ 50 MPa (7253 psi)] M18
2 4 Battery cable (starter) (Quantity 1)
(Quantity 2)
Exhaust gas temperature sensor

*CN.D7F Engine harness: A (32-pin) CN.D17-8M
(center): 2-pin
Exhaust gas temperature sensor (front):
*CN.D8M Engine harness: B (16-pin) CN.D17-9M
2-pin
P1 pressure sensor: 3-pin (ID: Red
*CN.D9M Engine harness: C (14-pin) CN.D49F
tape)
P2 pressure sensor: 3-pin (ID tape:
*CN.D10M Engine harness: D (20-pin) CN.D50F
Blue)
*CN.D11M Engine harness: H CN.D54F Oil temperature sensor: 2-pin
Lever lock solenoid valve: 2-pin (ID:
CN.D12 Starter motor: S CN.D55F
Blue tape)
Swing brake solenoid valve: 2-pin (ID:
CN.D13 Alternator: B CN.D56F
White tape)
Travel high-speed solenoid valve: 2-pin
CN.D14F Alternator: L/R (2-pin) CN.D57F
(ID: Red tape)
Boost relief solenoid valve: 2-pin (ID:
CN.D15 Alternator: E CN.D58F
Yellow tape)
Hydraulic load solenoid valve: 2-pin (ID:
CN.D16 Alternator GND CN.D59F
Green tape)
P1 flow proportional solenoid valve:
CN.D17F Frame main harness: 16-pin CN.D63F
2-pin (ID: Red tape)
P2 flow proportional solenoid valve:
CN.D17-2F Fuel pump diode: 2-pin CN.D64F
2-pin (ID: Blue tape)
CN.D17-3F Dosing valve: 2-pin CN.D90 Joint connector GND
CN.D17-6F Fuel filter sensor: 3-pin CN.D91 D2 GND
CN.D17-7F SCR upstream temperature sensor: 2-pin CN.E18M CCD harness
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SMIL14CEX5009JB 3
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Attachments
NOTE: The clamp positions of the electrical wiring that comes out from connectors should be adjusted so that the
wiring does not form sharp rounded shapes. [R = 10 mm (0.394 in) or more]
a. Fasten harness to the boom seating with a wire band

b. Fasten together with the arm line
Code Part name

1. Boom light wire harness (Quantity 1)
2. Working light (Quantity 1)
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SMIL14CEX5010JB 4
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Battery
NOTE: 1. When installing the ground terminals marked with *, it should be confirmed that the frame seating surface
is not coated.
a. Install the battery in such a way that the indicator is completely visible
b. Marking position: Align white tape on harness
*1. Battery details *4. Starter relay (engine accessory)

*2. Battery relay box details *5. KHR35390 Battery cable (starter relay)
*3. Glow relay (engine accessory) *6. KSR15250 Frame main wire harness

1 Battery cable B+ relay (Quantity 1) 7 Fuse (fusible link) 50 A (Quantity 1)
2 Battery cable bridge (Quantity 1) 8 PEC fuse holder (Quantity 3)
3 Battery cable switch (Quantity 1) 9 PEC fuse 100 A (Quantity 1)
4 Battery cable GND (Quantity 1) 10 PEC fuse 60 A (Quantity 1)
5 Battery 180G51 (Quantity 2) 11 Battery relay (Quantity 1)
6 Fuse (fusible link) 60 A (Quantity 2) 12 Battery switch (Quantity 1)
CN.D67M Fuse 50 A: +B (2-pin) (ID: Red tape) CN.D78 Battery relay: IGN
CN.D68F Fuse 1: 4-pin (ID: Red tape) CN.D79 Fuse 60 A: 1
CN.D69F Fuse 3 CN.D80 Fuse 100 A: 2
CN.D70F Fuse 2: 4-pin (ID: Blue tape) CN.D81 Fuse 60 A: 2
CN.D71M Fuse 60 A: ST1 (2-pin) (ID: Blue tape) CN.D82 Fuse 100 A: 1
CN.D72M Fuse 60 A: ST2 (2-pin) (ID: Blue tape) CN.D83F Starter relay: B/C (2-pin)
CN.D73 Battery relay coil 1 CN.D84F Starter relay: S/E (2-pin)
CN.D74 Battery relay coil 2 CN.D86F Glow relay 2
CN.D76 Battery relay: B1 CN.D87F Glow relay 1
CN.D77 Battery relay: B2 CN.D88 Glow relay coil
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SMIL14CEX5011JB 5
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Cab
NOTE: When installing the ground terminals marked with *, it should be confirmed that the frame seating surface is
not coated.
Fasten the harness and corrugated hydraulic hose

a. Connect with the supplied cab harness d.
together
b. Marking position (Align white tape on harness.) e. Fasten the harness and the antenna together
Fasten the harness with the clip Fasten the harness, antenna, and frame main
c. f.
The clip is a console accessory harness together
*1. Monitor *4. Side trim (upper)

*2. Computer *5. Fuse box 1 (cab main harness accessory)
*3. ECM *6. Fuse box 2 (cab main harness accessory)

1 Wire harness: Cab main 7 Switch rocker (emergency stop)
2 Wire harness: Console 8 Ground wire: Cab
3 Changeover relay: 24 V 10 Code: Antenna
4 Wire harness: Indicator jumper 11 Rocker switch (ambient light)
5 Switch: Starter assembly 12 Rocker switch (horn switchover)
6 Switch rocker (travel alarm) 13 Rocker switch (beacon)
CN.A1F Computer: CN1 (34-pin) CN.A44F Cab main harness: C (14-pin)

CN.A2F Computer: CN2 (35-pin) CN.A44M Console harness: C (14-pin)
CN.A3F Computer: CN3 (35-pin) CN.A45F Cab main harness: D (18-pin)
CN.A4F Computer: CN4 (31-pin) CN.A45M Console harness: D (18-pin)
CN.A5F Computer: CN5 (21-pin) CN.A46F Horn jumper: 2-pin
CN.A6F ECM relay: 5-pin CN.A47F Immobilizer: 1-pin
CN.A7F Starter cut relay: 5-pin CN.A47M Immobilizer ground: 1-pin
CN.A8F Neutral start relay: 5-pin CN.A50M Frame harness: A (2-pin)
CN.A9F ACC1 relay: 5-pin CN.A51M Frame harness: B (8-pin)
CN.A10F ACC2 relay: 5-pin CN.A52M Frame harness: C (8-pin)
CN.A11F Key ON relay: 5-pin CN.A53M Frame harness: D (14-pin)
CN.A12F Room lamp relay: 5-pin CN.A54M Frame harness: E (22-pin)
CN.A13F CAB lamp relay: 5-pin CN.A55M Frame harness: F (20-pin)
CN.A14F Beacon relay: 5-pin CN.A56M Frame harness: G (18-pin)
CN.A15F Upper lamp relay: 5-pin CN.B1F Starter switch: 6-pin
CN.A16F Speaker (L) relay: 5-pin CN.B2M Engine throttle switch: 3-pin
CN.A17F Speaker (R) relay: 5-pin CN.B3F Gate limit switch: 2-pin
CN.A18F Horn (R) relay: 5-pin CN.B5F Knob (R) 1 switch: 8-pin
CN.A19F EST-B (F) connector: 12-pin CN.B6F Knob (R) 2 switch: 6-pin
CN.A20F Diagnostic connector: 16-pin CN.B7F Knob (L) 1 switch: 8-pin
CN.A21F EST-A harness: 6-pin CN.B8F Knob (L) 2 switch: 6-pin
CN.A25F Option harness: 4-pin CN.B9F Emergency stop switch: 10-pin
Fan reverse switch: 10-pin (ID: Red
CN.A26F Computer T harness: 10-pin CN.B10F
tape)
CN.A27F Computer C harness: 10-pin CN.B11F Overload warning switch: 10-pin
CN.A28F Hour meter: + (1-pin) CN.B12F Beacon switch: 10-pin (ID: Red tape)
Travel alarm switch: 10-pin (ID: Blue
CN.A28M Hour meter: - (7-pin) CN.B13F
tape)
CN.A29F DC converter: 7-pin CN.B14F Air-conditioner panel: A (20-pin)
CN.A33F Joint connector: Computer 1 (6-pin) CN.B15F Air-conditioner panel: B (16-pin)
CN.A34F Joint connector: Computer 2 (6-pin) CN.B16F Air-conditioner unit: A (6-pin)
CN.A35 Joint connector A: 20-pin CN.B17F Air-conditioner unit: B (22-pin)
CN.A36 Joint connector B: 20-pin CN.B18F Radio: 9-pin
CN.A37 Joint connector: GND1 (6-pin) CN.B19 Option harness: 16-pin
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CN.A38 Joint connector: GND2 (6-pin) CN.B20 Seat suspension: 2-pin

CN.A39 Cab GND CN.B22F Air-conditioner GND: 1-pin
CN.A40F Cab harness A: 14-pin CN.B23F Computer GND: 1-pin
CN.A41F Cab harness B: 18-pin CN.B24F 12 V:+B (1-pin)
CN.A42F Cab main harness: A (10-pin) CN.B25F 12 V:IGN (1-pin)
CN.A42M Console harness: A (10-pin) CN.B26M 12 V:GND (1-pin)
Free swing switch: 10-pin (ID: Red
CN.A43F Cab main harness: B (8-pin) CN.B27F
tape)
CN.A43M Console harness: B (8-pin)
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SMIL15CEX0578JB 6
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Index

Electrical system - Component localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Electrical system - Electrical schema - Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Electrical system - Electrical schema - Connector wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Electrical system - Electrical schema - Overall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Electrical system - Electrical schema index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Electrical system - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electrical system - Overview - Electrical symbol list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Electrical system - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Electrical system - Wiring schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
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Harnesses and connectors - 100

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Contents
FUNCTIONAL DATA
Wiring harnesses
Electrical schematic sheet 01 - STARTING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Electrical schematic sheet 02 - POWER DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Electrical schematic sheet 03 - POWER DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Electrical schematic sheet 04 - POWER DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Electrical schematic sheet 05 - MAIN CONTROLLER A1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Electrical schematic sheet 12 - ENGINE CONTROLLER A2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Electrical schematic sheet 15 - DOSING CONTROL UNIT-A17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Electrical schematic sheet 16 - SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Electrical schematic sheet 19 - SENSORS AND SUCTION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Electrical schematic sheet 20 - ENGINE, VGS TURBO, EGR VALVE, THROTTLE MOTOR . . . . . . . . . 50
Electrical schematic sheet 21 - INJECTORS AND AIR INTAKE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . 52
Electrical schematic sheet 22 - OPTION PEDAL, SOLENOID, PROPORTIONAL CIRCUIT . . . . . . . . . 54
Electrical schematic sheet 23 - OPTION PROPORTIONAL SOLENOID CIRCUIT . . . . . . . . . . . . . . . . . . 56
Electrical schematic sheet 24 - KNOB-RIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Electrical schematic sheet 25 - KNOB LEFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Electrical schematic sheet 26 - AIR CONDITIONER SWITCH PANEL & UNIT . . . . . . . . . . . . . . . . . . . . . 62
Electrical schematic sheet 27 - AIR CONDITIONER UNIT & REFUEL PUMP . . . . . . . . . . . . . . . . . . . . . 64
Electrical schematic sheet 28 - CCD CAMERA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Electrical schematic sheet 29 - MAIN CAB-ECM INTER CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Electrical schematic sheet 30 - MAIN CAB-INTER CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Electrical schematic sheet 31 - MAIN CAB-RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
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Electrical schematic sheet 32 - MAIN CAB-RELAYS, RADIO AND CONVERTER . . . . . . . . . . . . . . . . . . 74
Electrical schematic sheet 33 - PROPORTIONAL S/V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Electrical schematic sheet 34 - MAIN CAB-MONITOR DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Electrical schematic sheet 35 - WIPER CONTROLLER, WIPER MOTOR AND SENSOR . . . . . . . . . . . 80
Electrical schematic sheet 36 - ACC SOCKET, CIGAR LIGHTER, IMMOBILIZER . . . . . . . . . . . . . . . . . . 82
Electrical schematic sheet 37 - OPTION POWER / FVM, KEY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Electrical schematic sheet 38 - OVER LOAD, BEACON, TRAVEL ALARM, REVERSE FAN, FREE SWING
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Electrical schematic sheet 39 - LAMP, PUMP, WASHER, HORN, UREA PUMP . . . . . . . . . . . . . . . . . . . . 88
Electrical schematic sheet 40 - SOLENOID VALVE, MAGNET CLUTCH, RECEIVER DRYER . . . . . . . 90
Wire connectors
Component diagram 00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Component diagram 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 01 - STARTING

CIRCUIT
Type Component Connector Description
Voltage source G1 Battery
Voltage source G1 Battery
Voltage source G2 Alternator
Relay K2 Glow plug relay
Relay K7 Battery relay
Relay K69 Starter relay
Motor M1 Starter motor
Solenoid R1 Glow plug
Switch S94 Battery switch
Connector CN.D11 CN.D11 Glow plug
Connector CN.D12 CN.D12 Starter motor - S
Connector CN.D13 CN.D13 Alternator - B
Connector CN.D14 Alternator - L/R
Connector CN.D15 CN.D15 Alternator - E
Connector CN.D16 CN.D16 Alternator - GND
Connector CN.D206 Battery switch
Connector CN.D207 Battery switch
Connector CN.D208 Battery
Connector CN.D73 CN.D73 Battery relay - Coil 1
Connector CN.D74 CN.D74 Battery relay - Coil 2
Connector CN.D75 CN.D75 Battery relay
Connector CN.D76 CN.D76 Battery relay - B1
Connector CN.D77 CN.D77 Battery relay - B2
Connector CN.D78 CN.D78 Battery relay - IGN
Connector CN.D83 CN.D83 Starter relay B/C
Connector CN.D84 CN.D84 Starter relay S/E
Diode CN.D85 CN.D85 Starter Diode
Connector CN.D86 CN.D86 Glow relay 2
Connector CN.D87 CN.D87 Glow relay 1
Connector CN.D88 CN.D88 Glow relay coil
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Wire Break
Component Connector / Link Description
WB-029 Wiring harnesses - Electrical schematic sheet 12 - ENGINE CONTROLLER A2 (55.100)
WB-1031 Wiring harnesses - Electrical schematic sheet 02 - POWER DISTRIBUTION (55.100)
WB-1401 Wiring harnesses - Electrical schematic sheet 09 - MAIN CONTROLLER A1 (55.100)
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SMIL14CEX6531JA 1
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Wiring harnesses - Electrical schematic sheet 02 - POWER Wire Break

DISTRIBUTION Component Connector / Link Description
WB-032 Wiring harnesses - Electrical schematic sheet 15 - DOSING CONTROL UNIT-A17 (55.100)
Type Component Connector Description WB-056 Wiring harnesses - Electrical schematic sheet 39 - LAMP, PUMP, WASHER, HORN, UREA
PUMP (55.100)
Fuse F58 Fusible link 2 safety RL
WB-1031 Wiring harnesses - Electrical schematic sheet 01 - STARTING CIRCUIT (55.100)
Fuse F57 Fusible link 1 safety RL WB-1087 Wiring harnesses - Electrical schematic sheet 01 - STARTING CIRCUIT (55.100)
Fuse F56 Refuel pump - fuel pump WB-1390 Wiring harnesses - Electrical schematic sheet 21 - INJECTORS AND AIR INTAKE SENSOR
Fuse F59 Spare - urea pump (55.100)
Fuse F47 SCR control unit
Fuse F41 Fusible - link back up WB-366 Wiring harnesses - Electrical schematic sheet 01 - STARTING CIRCUIT (55.100)
Connector X50 Option power supply WB-462 Wiring harnesses - Electrical schematic sheet 01 - STARTING CIRCUIT (55.100)
Connector CN.D67 CN.D67 Fusible link back up WB-915 Wiring harnesses - Electrical schematic sheet 01 - STARTING CIRCUIT (55.100)
Connector CN.D68 CN.D68 SCR control unit WB-927 Wiring harnesses - Electrical schematic sheet 04 - POWER DISTRIBUTION (55.100)
WB-953 Wiring harnesses - Electrical schematic sheet 27 - AIR CONDITIONER UNIT & REFUEL
Connector CN.D69 CN.D69 Spare - urea pump PUMP (55.100)
Connector CN.D70 CN.D70 Refuel pump - fuel pump WB-962 Wiring harnesses - Electrical schematic sheet 04 - POWER DISTRIBUTION (55.100)
Connector CN.D71 CN.D71 Fusible link 1 safety RL
Connector CN.D72 CN.D72 Fusible link 2 safety RL
Connector CN.D79 CN.D79
Connector CN.D89 CN.D89 Option power supply
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SHT_3 1
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WB-1081 Wiring harnesses - Electrical schematic sheet 37 - OPTION POWER / FVM, KEY SWITCH
Type Component Connector Description (55.100)
Fuse F09 Lamp (boom, house) (55.100)
Fuse F14 Wiper washer WB-119 Wiring harnesses - Electrical schematic sheet 31 - MAIN CAB-RELAYS (55.100)
Fuse F18 Cigar lighter WB-1218 Wiring harnesses - Electrical schematic sheet 37 - OPTION POWER / FVM, KEY SWITCH
Fuse F21 Beacon (55.100)
WB-1269 Wiring harnesses - Electrical schematic sheet 22 - OPTION PEDAL, SOLENOID,
Fuse F26 Lamp cab PROPORTIONAL CIRCUIT (55.100)
Fuse F68 Seat SUS and heater (Relay_SPK) WB-1311 Wiring harnesses - Electrical schematic sheet 31 - MAIN CAB-RELAYS (55.100)
Fuse F69 DC/DC convertor WB-1341 Wiring harnesses - Electrical schematic sheet 35 - WIPER CONTROLLER, WIPER MOTOR
Fuse F70 Field view monitor AND SENSOR (55.100)
Fuse F71 Spare1 WB-574 Wiring harnesses - Electrical schematic sheet 31 - MAIN CAB-RELAYS (55.100)
Fuse F72 Option (prop-lever) WB-613 Wiring harnesses - Electrical schematic sheet 31 - MAIN CAB-RELAYS (55.100)
Fuse F73 Spare2 (Quick and CTWT) WB-774 Wiring harnesses - Electrical schematic sheet 37 - OPTION POWER / FVM, KEY SWITCH
Spare3 (CONT_C) (55.100)
Fuse F74
Connector CN.A41 CN.A41
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SHT_4 1
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Type Component Connector Description WB-086 Wiring harnesses - Electrical schematic sheet 31 - MAIN CAB-RELAYS (55.100)
Fuse F01 CN.F1 Key switch WB-089 Wiring harnesses - Electrical schematic sheet 27 - AIR CONDITIONER UNIT & REFUEL
PUMP (55.100)
Fuse F02 CN.F2 Accessory WB-1066 Wiring harnesses - Electrical schematic sheet 05 - MAIN CONTROLLER A1 (55.100)
Fuse F03 CN.F3 GPS controller WB-1078 Wiring harnesses - Electrical schematic sheet 26 - AIR CONDITIONER SWITCH PANEL &
Fuse F04 CN.F4 Back up UNIT (55.100)
Fuse F05 CN.F5 Lever lock (gate)
(55.100)
Fuse F06 CN.F6 Horn WB-1482 Wiring harnesses - Electrical schematic sheet 05 - MAIN CONTROLLER A1 (55.100)
Fuse F07 CN.F7 Monitor WB-1551 Wiring harnesses - Electrical schematic sheet 26 - AIR CONDITIONER SWITCH PANEL &
Fuse F17 Air conditioner compressor UNIT (55.100)
Fuse F61 Engine controller
Fuse F62 Monitor (back up) (55.100)
Fuse F63 Controller (IMMOBI) WB-450 Wiring harnesses - Electrical schematic sheet 05 - MAIN CONTROLLER A1 (55.100)
Fuse F64 Solenoid (controller) WB-551 Wiring harnesses - Electrical schematic sheet 06 - MAIN CONTROLLER A1 (55.100)
Fuse F65 Prop. Solenoid (controller)
WB-709 Wiring harnesses - Electrical schematic sheet 31 - MAIN CAB-RELAYS (55.100)
Fuse F66 Air conditioner unit WB-873 Wiring harnesses - Electrical schematic sheet 30 - MAIN CAB-INTER CONNECTOR (55.100)
Fuse F67 Air conditioner blower motor WB-876 Wiring harnesses - Electrical schematic sheet 32 - MAIN CAB-RELAYS, RADIO AND
Connector CN.A42 CN.A42 Console harness - A CONVERTER (55.100)
Connector CN.A44 CN.A44 Console harness - C WB-921 Wiring harnesses - Electrical schematic sheet 26 - AIR CONDITIONER SWITCH PANEL &
UNIT (55.100)
Connector CN.A50 CN.A50 Frame harness - A WB-927 Wiring harnesses - Electrical schematic sheet 02 - POWER DISTRIBUTION (55.100)
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SHT_5 1
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Wiring harnesses - Electrical schematic sheet 05 - MAIN

CONTROLLER A1
Controller A1 CN.A1 Controller X4
Diode CN.A31 CN.A31 Diode 2
Connector CN.A42 CN.A42 Console harness - A
Connector CN.A43 CN.A43 Console harness - B
Connector CN.A5 CN.A5 Computer CN5
Connector CN.A56 CN.A56 Frame harness - G
Connector CN.D59 CN.D59 Hydraulic load solenoid valve
Connector CN.D61 CN.D61 Quick coupler solenoid valve
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Wire Break
WB-065 Wiring harnesses - Electrical schematic sheet 32 - MAIN CAB-RELAYS, RADIO AND
CONVERTER (55.100)
PROPORTIONAL CIRCUIT (55.100)
WB-095 Wiring harnesses - Electrical schematic sheet 29 - MAIN CAB-ECM INTER CONNECTOR
(55.100)
WB-1004 Wiring harnesses - Electrical schematic sheet 33 - PROPORTIONAL S/V (55.100)
CONVERTER (55.100)
(55.100)
WB-1105 Wiring harnesses - Electrical schematic sheet 40 - SOLENOID VALVE, MAGNET CLUTCH,
RECEIVER DRYER (55.100)
(55.100)
WB-1299 Wiring harnesses - Electrical schematic sheet 38 - OVER LOAD, BEACON, TRAVEL ALARM,
REVERSE FAN, FREE SWING (55.100)
(55.100)
(55.100)
(55.100)
(55.100)
WB-159 Wiring harnesses - Electrical schematic sheet 30 - MAIN CAB-INTER CONNECTOR (55.100)
WB-222 Wiring harnesses - Electrical schematic sheet 24 - KNOB-RIGHT (55.100)
(55.100)
(55.100)
(55.100)
PUMP (55.100)
(55.100)
(55.100)
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(55.100)
WB-924 Wiring harnesses - Electrical schematic sheet 25 - KNOB LEFT (55.100)
(55.100)
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Wiring harnesses - Electrical schematic sheet 06 - MAIN CONTROLLER Wire Break

A1 Component Connector / Link Description
Type Component Connector Description RECEIVER DRYER (55.100)
Controller A1 CN.A1 CONTROLLER X4 RECEIVER DRYER (55.100)
Connector CN.A4 CN.A4 Computer CN4 WB-1022 Wiring harnesses - Electrical schematic sheet 29 - MAIN CAB-ECM INTER CONNECTOR
Connector CN.A45 CN.A45 Computer CN5 (55.100)
Connector CN.A45 CN.A45 Console harness - D WB-1042 Wiring harnesses - Electrical schematic sheet 40 - SOLENOID VALVE, MAGNET CLUTCH,
Connector CN.A56 CN.A56 Frame harness - G WB-1045 Wiring harnesses - Electrical schematic sheet 29 - MAIN CAB-ECM INTER CONNECTOR
Connector CN.D56 CN.D56 Swing brake solenoid valve (55.100)
Connector CN.D57 CN.D57 Travel high-speed solenoid valve WB-107 Wiring harnesses - Electrical schematic sheet 12 - ENGINE CONTROLLER A2 (55.100)
Connector CN.D58 CN.D58 Pressure boost relief solenoid valve WB-1120 Wiring harnesses - Electrical schematic sheet 12 - ENGINE CONTROLLER A2 (55.100)
Connector CN.D60 CN.D60 Free swing solenoid valve WB-1215 Wiring harnesses - Electrical schematic sheet 21 - INJECTORS AND AIR INTAKE SENSOR
Connector CN.D90 CN.D90 Ground joint connector (55.100)
(55.100)
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Controller A1 CN.A1 Controller X4 (55.100)
Connector CN.A19 CN.A19 EST-B (F) connector WB-186 Wiring harnesses - Electrical schematic sheet 09 - MAIN CONTROLLER A1 (55.100)
Connector CN.A19_M CN.A19 EST-B (F) connector WB-297 Wiring harnesses - Electrical schematic sheet 01 - STARTING CIRCUIT (55.100)
Diode CN.A30-A CN.A30-A WB-327 Wiring harnesses - Electrical schematic sheet 01 - STARTING CIRCUIT (55.100)
Computer CN5 WB-345 Wiring harnesses - Electrical schematic sheet 32 - MAIN CAB-RELAYS, RADIO AND
Connector CN.A4 CN.A4 CONVERTER (55.100)
Connector CN.A52 CN.A52 Frame harness C WB-501 Wiring harnesses - Electrical schematic sheet 08 - MAIN CONTROLLER A1 (55.100)
Connector CN.A56 CN.A56 Frame harness G WB-816 Wiring harnesses - Electrical schematic sheet 29 - MAIN CAB-ECM INTER CONNECTOR
(55.100)
(55.100)
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Switch S55 Level switch (reserve tank) WB-1185 Wiring harnesses - Electrical schematic sheet 33 - PROPORTIONAL S/V (55.100)
Connector CN.A19 CN.A19 EST-B (F) connector WB-1224 Wiring harnesses - Electrical schematic sheet 06 - MAIN CONTROLLER A1 (55.100)
Connector CN.A3 CN.A3 Computer CN3 WB-1239 Wiring harnesses - Electrical schematic sheet 29 - MAIN CAB-ECM INTER CONNECTOR
(55.100)
Connector CN.A43 CN.A43 Console harness - B
Connector CN.A55 CN.A55 Frame harness - F WB-1263 Wiring harnesses - Electrical schematic sheet 33 - PROPORTIONAL S/V (55.100)
Connector CN.D47 CN.A47 Coolant tank switch WB-1375 Wiring harnesses - Electrical schematic sheet 12 - ENGINE CONTROLLER A2 (55.100)
(55.100)
(55.100)
(55.100)
WB-673 Wiring harnesses - Electrical schematic sheet 36 - ACC SOCKET, CIGAR LIGHTER,
IMMOBILIZER (55.100)
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Type Component Connector Description WB-1051 Wiring harnesses - Electrical schematic sheet 32 - MAIN CAB-RELAYS, RADIO AND
CONVERTER (55.100)
Switch S62 Air cleaner switch (55.100)
Connector CN.A3 CN.A3 Computer - CN3 WB-1117 Wiring harnesses - Electrical schematic sheet 32 - MAIN CAB-RELAYS, RADIO AND
Connector CN.A44 CN.A44 Console harness - C CONVERTER (55.100)
Connector CN.A45 CN.A45 Console harness - D
Connector CN.A52 CN.A52 Frame harness - C CONVERTER (55.100)
Connector CN.A54 CN.A54 Frame harness - E WB-1364 Wiring harnesses - Electrical schematic sheet 15 - DOSING CONTROL UNIT-A17 (55.100)
Connector CN.A56 CN.A56 Frame harness -G WB-1401 Wiring harnesses - Electrical schematic sheet 01 - STARTING CIRCUIT (55.100)
Connector CN.D48 CN.D48 Air cleaner switch WB-1407 Wiring harnesses - Electrical schematic sheet 38 - OVER LOAD, BEACON, TRAVEL ALARM,
CONVERTER (55.100)
(55.100)
(55.100)
(55.100)
CONVERTER (55.100)
CONVERTER (55.100)
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WB-041 Wiring harnesses - Electrical schematic sheet 34 - MAIN CAB-MONITOR DISPLAY (55.100)
Type Component Connector Description WB-071 Wiring harnesses - Electrical schematic sheet 33 - PROPORTIONAL S/V (55.100)
Controller A1 CN.A1 CONTROLLER X4 WB-1016 Wiring harnesses - Electrical schematic sheet 29 - MAIN CAB-ECM INTER CONNECTOR
(55.100)
X25 To controller C WB-1194 Wiring harnesses - Electrical schematic sheet 30 - MAIN CAB-INTER CONNECTOR (55.100)
J207 WB-1398 Wiring harnesses - Electrical schematic sheet 30 - MAIN CAB-INTER CONNECTOR (55.100)
P526 WB-150 Wiring harnesses - Electrical schematic sheet 33 - PROPORTIONAL S/V (55.100)
J541 WB-1515 Wiring harnesses - Electrical schematic sheet 33 - PROPORTIONAL S/V (55.100)
P541 WB-174 Wiring harnesses - Electrical schematic sheet 37 - OPTION POWER / FVM, KEY SWITCH
(55.100)
Connector CN.A2 CN.A2 Computer - CN2 WB-246 Wiring harnesses - Electrical schematic sheet 40 - SOLENOID VALVE, MAGNET CLUTCH,
Connector CN.A27 CN.A27 Computer C harness RECEIVER DRYER (55.100)
Connector CN.A40 CN.A40 Cab harness - A WB-249 Wiring harnesses - Electrical schematic sheet 09 - MAIN CONTROLLER A1 (55.100)
Connector CN.A40_M WB-306 Wiring harnesses - Electrical schematic sheet 35 - WIPER CONTROLLER, WIPER MOTOR
CN.A40
AND SENSOR (55.100)
Connector CN.A42 CN.A42 Console harness - A WB-309 Wiring harnesses - Electrical schematic sheet 30 - MAIN CAB-INTER CONNECTOR (55.100)
Connector CN.A52 CN.A52 Frame harness - C WB-369 Wiring harnesses - Electrical schematic sheet 33 - PROPORTIONAL S/V (55.100)
Connector CN.A54 CN.A54 Frame harness - E WB-423 Wiring harnesses - Electrical schematic sheet 16 - SENSORS (55.100)
Connector CN.A55 CN.A55 Frame harness - F WB-438 Wiring harnesses - Electrical schematic sheet 35 - WIPER CONTROLLER, WIPER MOTOR
AND SENSOR (55.100)
Connector CN.A56 CN.A56 Frame harness - G
WB-507 Wiring harnesses - Electrical schematic sheet 17 - SENSORS (55.100)
WB-700 Wiring harnesses - Electrical schematic sheet 35 - WIPER CONTROLLER, WIPER MOTOR
AND SENSOR (55.100)
(55.100)
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Type Component Connector Description WB-035 Wiring harnesses - Electrical schematic sheet 18 - SENSORS (55.100)
Controller A1 CN.A1 Controller X4 WB-047 Wiring harnesses - Electrical schematic sheet 16 - SENSORS (55.100)
Connector CN.A1 CN.A1 Computer CN1
Connector CN.A54 CN.A54 Frame harness - E PROPORTIONAL CIRCUIT (55.100)
Connector CN.A55 CN.A55 Frame harness - F WB-1007 Wiring harnesses - Electrical schematic sheet 33 - PROPORTIONAL S/V (55.100)
Connector CN.A56 CN.A56 Frame harness - G WB-110 Wiring harnesses - Electrical schematic sheet 17 - SENSORS (55.100)
Connector CN.D65 CN.D65 Control valve sensor WB-1144 Wiring harnesses - Electrical schematic sheet 17 - SENSORS (55.100)
WB-1147 Wiring harnesses - Electrical schematic sheet 26 - AIR CONDITIONER SWITCH PANEL &
UNIT (55.100)
UNIT (55.100)
UNIT (55.100)
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Wiring harnesses - Electrical schematic sheet 12 - ENGINE Wire Break

CONTROLLER A2 Component Connector / Link Description
Type Component Connector Description WB-074 Wiring harnesses - Electrical schematic sheet 20 - ENGINE, VGS TURBO, EGR VALVE,
THROTTLE MOTOR (55.100)
ECU A2 CN.A2 Engine controller
Connector CN.D3 CN.D3 ECM 1 WB-1072 Wiring harnesses - Electrical schematic sheet 01 - STARTING CIRCUIT (55.100)
Connector CN.A53 CN.A53 Frame harness D WB-1093 Wiring harnesses - Electrical schematic sheet 15 - DOSING CONTROL UNIT-A17 (55.100)
Connector CN.D9 Engine harness C WB-1120 Wiring harnesses - Electrical schematic sheet 06 - MAIN CONTROLLER A1 (55.100)
WB-1227 Wiring harnesses - Electrical schematic sheet 21 - INJECTORS AND AIR INTAKE SENSOR
(55.100)
(55.100)
WB-276 Wiring harnesses - Electrical schematic sheet 20 - ENGINE, VGS TURBO, EGR VALVE,
(55.100)
(55.100)
(55.100)
UNIT (55.100)
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Wiring harnesses - Electrical schematic sheet 13 - ENGINE Wire Break

CONTROLLER A2 Component Connector / Link Description
Type Component Connector Description REVERSE FAN, FREE SWING (55.100)
ECU A2 CN.A2 Engine controller THROTTLE MOTOR (55.100)
Connector CN.A53 CN.A53 Cab main harness D WB-1114 Wiring harnesses - Electrical schematic sheet 18 - SENSORS (55.100)
Connector CN.D17 CN.D17 SCR harness WB-1129 Wiring harnesses - Electrical schematic sheet 21 - INJECTORS AND AIR INTAKE SENSOR
Connector CN.D3 CN.D3 ECM 1 (55.100)
Connector CN.D4 CN.D4 ECM 2
Connector CN.D7 CN.D07 Engine harness A THROTTLE MOTOR (55.100)
Connector CN.D9 Engine harness WB-1266 Wiring harnesses - Electrical schematic sheet 05 - MAIN CONTROLLER A1 (55.100)
WB-1287 Wiring harnesses - Electrical schematic sheet 19 - SENSORS AND SUCTION VALVE (55.100)
(55.100)
(55.100)
(55.100)
(55.100)
(55.100)
(55.100)
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Wiring harnesses - Electrical schematic sheet 14 - ENGINE

CONTROLLER A2
ECU A2 CN.A2 Engine controller
Switch CN.A24 CN.A24 Over heat SW.
Connector CN.D4 CN.D4 ECM 2
Connector CN.D10 CN.D10 Engine harness D
Connector CN.D7 CN.D07 Engine harness A
Connector CN.D8 CN.D8 Engine harness B
Connector CN.D9 Engine harness C
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Wire Break
(55.100)
(55.100)
(55.100)
(55.100)
(55.100)
(55.100)
(55.100)
(55.100)
(55.100)
(55.100)
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Wiring harnesses - Electrical schematic sheet 15 - DOSING CONTROL Wire Break

UNIT-A17 Component Connector / Link Description
Type Component Connector Description IMMOBILIZER (55.100)
Module X47 Supply module
ECU A17 CN.A17 Dosing control unit IMMOBILIZER (55.100)
Connector CN.A41 CN.A41 Cab harness B WB-1057 Wiring harnesses - Electrical schematic sheet 36 - ACC SOCKET, CIGAR LIGHTER,
Connector CN.A53 CN.A53 Frame harness D IMMOBILIZER (55.100)
Connector CN.D1-2 CN.D1-2
Connector CN.D17 CN.D17 SCR harness (55.100)
Connector CN.D18 CN.D18 Supply module WB-1153 Wiring harnesses - Electrical schematic sheet 36 - ACC SOCKET, CIGAR LIGHTER,
(55.100)
AND SENSOR (55.100)
CONVERTER (55.100)
(55.100)
CONVERTER (55.100)
CONVERTER (55.100)
CONVERTER (55.100)
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Wiring harnesses - Electrical schematic sheet 16 - SENSORS Wire Break

Type Component Connector Description Component Connector / Link Description
Sensor B22 CN.B22 Swing pilot pressure sensor WB-047 Wiring harnesses - Electrical schematic sheet 11 - MAIN CONTROLLER A1 (55.100)
Sensor B85 Press. Sensor (pilot boom up) WB-1281
Sensor B104 Press. Sensor (pilot boom ) WB-136 Wiring harnesses - Electrical schematic sheet 11 - MAIN CONTROLLER A1 (55.100)
Sensor B105 Press. Sensor (pilot arm open) WB-1367 Wiring harnesses - Electrical schematic sheet 11 - MAIN CONTROLLER A1 (55.100)
Sensor B83 Press. Sensor (pilot arm close) WB-1404 Wiring harnesses - Electrical schematic sheet 22 - OPTION PEDAL, SOLENOID,
Sensor B106 Press. Sensor (pilot arm bucket open) PROPORTIONAL CIRCUIT (55.100)
Sensor B84 Press. Sensor (pilot arm bucket close) WB-1428 Wiring harnesses - Electrical schematic sheet 11 - MAIN CONTROLLER A1 (55.100)
Sensor R5 Fuel sensor WB-381 Wiring harnesses - Electrical schematic sheet 11 - MAIN CONTROLLER A1 (55.100)
Connector CN.D25 CN.D25 Swing pressure sensor WB-423 Wiring harnesses - Electrical schematic sheet 10 - MAIN CONTROLLER A1 (55.100)
Connector CN.D26 CN.D26 Boom (up) pressure sensor WB-545 Wiring harnesses - Electrical schematic sheet 22 - OPTION PEDAL, SOLENOID,
Connector CN.D27 CN.D27 Boom (down) pressure sensor PROPORTIONAL CIRCUIT (55.100)
Connector CN.D28 CN.D28 Arm (open) pressure sensor
Connector CN.D29 CN.D29 Arm (close) pressure sensor
Connector CN.D30 CN.D30 Bucket (open) pressure sensor
Connector CN.D31 CN.D31 Bucket (close) pressure sensor
Connector CN.D53 CN.D53 Fuel level sensor
Connector CN.A54 CN.D54 Frame harness E
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Sensor B2 CN.B2 Hydraulic oil temperature sensor WB-1144 Wiring harnesses - Electrical schematic sheet 11 - MAIN CONTROLLER A1 (55.100)
Sensor B101 Press. Sensor (travel pilot right) WB-1150 Wiring harnesses - Electrical schematic sheet 22 - OPTION PEDAL, SOLENOID,
Sensor B102 Press. Sensor (travel pilot left) PROPORTIONAL CIRCUIT (55.100)
Press. Sensor (pilot 1pedal) WB-285 Wiring harnesses - Electrical schematic sheet 11 - MAIN CONTROLLER A1 (55.100)
Sensor B103
Sensor B97 Press. Sensor (hydraulic Filter) WB-360
Sensor B108 Press. Sensor (boom cylinder bottom) WB-390 Wiring harnesses - Electrical schematic sheet 11 - MAIN CONTROLLER A1 (55.100)
Connector CN.D23 CN.D23 Floor harness 1 WB-402
Connector CN.D51 CN.D51 Return room sensor WB-495 Wiring harnesses - Electrical schematic sheet 11 - MAIN CONTROLLER A1 (55.100)
Connector CN.D52A CN.D52A WB-810 Wiring harnesses - Electrical schematic sheet 11 - MAIN CONTROLLER A1 (55.100)
Connector CN.D54 CN.D54 Oil temperature sensor WB-828 Wiring harnesses - Electrical schematic sheet 22 - OPTION PEDAL, SOLENOID,
Connector CN.D23-1 CN.D23-1 Press. Sensor (travel pilot right) PROPORTIONAL CIRCUIT (55.100)
Connector CN.D23-2 CN.D23-2 Press. Sensor (travel pilot left)
Connector CN.D23-3 CN.D23-3 Press. Sensor (pilot 1pedal)
Connector CN.D51-A CN.D51-A Press. Sensor (hydraulic Filter)
Connector CN.D52-B CN.D52-B Press. Sensor (boom cylinder bottom)
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Sensor B42 Pump pressure sensor (P1) WB-1025 Wiring harnesses - Electrical schematic sheet 14 - ENGINE CONTROLLER A2 (55.100)
Sensor B44 Pump pressure sensor (P2) WB-1102 Wiring harnesses - Electrical schematic sheet 14 - ENGINE CONTROLLER A2 (55.100)
Sensor B43 Pump pressure sensor (NEGA-CONT.1) WB-1114 Wiring harnesses - Electrical schematic sheet 13 - ENGINE CONTROLLER A2 (55.100)
Sensor B40 Pump pressure sensor (NEGA-CONT.2) WB-1156 Wiring harnesses - Electrical schematic sheet 14 - ENGINE CONTROLLER A2 (55.100)
Sensor B133 Press. Sensor (arm cylinder rod)
Sensor B109 Press. Sensor (arm cylinder bottom) WB-1272 Wiring harnesses - Electrical schematic sheet 14 - ENGINE CONTROLLER A2 (55.100)
Sensor B49 Crankshaft position sensor WB-1293 Wiring harnesses - Electrical schematic sheet 11 - MAIN CONTROLLER A1 (55.100)
Sensor B52 Common rail pressure sensor WB-1431 Wiring harnesses - Electrical schematic sheet 11 - MAIN CONTROLLER A1 (55.100)
Sensor B21 CN.B21 Engine oil pressure sensor
Connector CN.D49 CN.D49 P1 pressure sensor WB-162 Wiring harnesses - Electrical schematic sheet 11 - MAIN CONTROLLER A1 (55.100)
Connector CN.D50 CN.D50 P2 pressure sensor WB-261 Wiring harnesses - Electrical schematic sheet 11 - MAIN CONTROLLER A1 (55.100)
Connector CN.D65-1 CN.D65-1 N1 pressure sensor WB-354 Wiring harnesses - Electrical schematic sheet 14 - ENGINE CONTROLLER A2 (55.100)
Connector CN.D65-2 CN.D65-2 N2 pressure sensor WB-510 Wiring harnesses - Electrical schematic sheet 11 - MAIN CONTROLLER A1 (55.100)
Connector CN.D65-3 CN.D65-3 Arm cylinder (rod) pressure sensor WB-625 Wiring harnesses - Electrical schematic sheet 11 - MAIN CONTROLLER A1 (55.100)
Connector CN.D65-4 CN.D65-4 Arm cylinder (bottom) pressure sensor WB-640 Wiring harnesses - Electrical schematic sheet 13 - ENGINE CONTROLLER A2 (55.100)
Connector CN.E4 CN.E04 Crank ANG(MRE) sensor WB-724 Wiring harnesses - Electrical schematic sheet 14 - ENGINE CONTROLLER A2 (55.100)
Connector CN.E5 CN.E5 Common rail press sensor WB-727 Wiring harnesses - Electrical schematic sheet 11 - MAIN CONTROLLER A1 (55.100)
Connector CN.E7 CN.E7 Oil press sensor
Connector CN.D7 CN.D07 Engine harness
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Wiring harnesses - Electrical schematic sheet 19 - SENSORS AND Wire Break

SUCTION VALVE Component Connector / Link Description
Type Component Connector Description WB-026 Wiring harnesses - Electrical schematic sheet 14 - ENGINE CONTROLLER A2 (55.100)
Sensor B87 CAM ANG (MRE) SENSOR WB-1126 Wiring harnesses - Electrical schematic sheet 14 - ENGINE CONTROLLER A2 (55.100)
Sensor B88 FUEL FILTER SENSOR WB-1168 Wiring harnesses - Electrical schematic sheet 14 - ENGINE CONTROLLER A2 (55.100)
Sensor B1 CN.B1 WATER TEMP.SENSOR WB-1206 Wiring harnesses - Electrical schematic sheet 14 - ENGINE CONTROLLER A2 (55.100)
Sensor Y35 SUCTION CONT.VALVE WB-1287 Wiring harnesses - Electrical schematic sheet 13 - ENGINE CONTROLLER A2 (55.100)
Sensor Y117 DOSING VALVE WB-1290 Wiring harnesses - Electrical schematic sheet 13 - ENGINE CONTROLLER A2 (55.100)
Sensor Y116 COOLANT CONT VALVE WB-1296 Wiring harnesses - Electrical schematic sheet 14 - ENGINE CONTROLLER A2 (55.100)
Sensor B144 SCR UPSTREAM TEMP SENSOR
Sensor B91 EXHAUST TEMP SENSOR(FNT)(DCU-IN) WB-1422 Wiring harnesses - Electrical schematic sheet 14 - ENGINE CONTROLLER A2 (55.100)
Sensor B90 EXHAUST TEMP SENSOR(CNT)(CSF-IN) WB-1467 Wiring harnesses - Electrical schematic sheet 13 - ENGINE CONTROLLER A2 (55.100)
Sensor B119 EGR COOLER-OUT TEMP WB-1476 Wiring harnesses - Electrical schematic sheet 15 - DOSING CONTROL UNIT-A17 (55.100)
Sensor B120 19 WB-1518 Wiring harnesses - Electrical schematic sheet 14 - ENGINE CONTROLLER A2 (55.100)
Sensor B3 CN.B3 FUEL TEMP. SENSOR
Sensor B114 INTERCOOLER-IN TEMP.SENSOR WB-243 Wiring harnesses - Electrical schematic sheet 15 - DOSING CONTROL UNIT-A17 (55.100)
Connector CN.E12 CN.E12 CAM ANG (MRE) SENSOR WB-288 Wiring harnesses - Electrical schematic sheet 14 - ENGINE CONTROLLER A2 (55.100)
Connector CN.D17-6 CN.D17-6 FUEL FILTER SENSOR WB-339 Wiring harnesses - Electrical schematic sheet 15 - DOSING CONTROL UNIT-A17 (55.100)
Connector CN.E11 CN.E11 WATER TEMP.SENSOR WB-384 Wiring harnesses - Electrical schematic sheet 14 - ENGINE CONTROLLER A2 (55.100)
Connector CN.D17-3 CN.D17-3 SUCTION CONT.VALVE
Connector CN.D19 CN.D19 DOSING VALVE WB-468 Wiring harnesses - Electrical schematic sheet 14 - ENGINE CONTROLLER A2 (55.100)
Connector CN.D17-7 CN.D17-7 COOLANT CONT VALVE WB-589 Wiring harnesses - Electrical schematic sheet 15 - DOSING CONTROL UNIT-A17 (55.100)
Connector CN.D17-8 CN.D17-8 SCR UPSTREAM TEMP SENSOR WB-619 Wiring harnesses - Electrical schematic sheet 14 - ENGINE CONTROLLER A2 (55.100)
Connector CN.D17-9 CN.D17-9 EXHAUST TEMP SENSOR(FNT)(DCU-IN) WB-730 Wiring harnesses - Electrical schematic sheet 15 - DOSING CONTROL UNIT-A17 (55.100)
EXHAUST TEMP SENSOR(CNT)(CSF-IN) WB-804 Wiring harnesses - Electrical schematic sheet 13 - ENGINE CONTROLLER A2 (55.100)
Connector CN.E10-A CN.E10-A
Connector CN.E10-B CN.E10-B EGR COOLER-OUT TEMP
Connector CN.E8 CN.E8 EGR COOLER-IN TEMP
Connector CN.E10 CN.E10 FUEL TEMP. SENSOR
Connector CN.D17 CN.D17 INTERCOOLER-IN TEMP.SENSOR
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Wiring harnesses - Electrical schematic sheet 20 - ENGINE, VGS TURBO, Wire Break
EGR VALVE, THROTTLE MOTOR Component Connector / Link Description
Sensor B118 Manifold air press and boost temp. Sensor WB-1191 Wiring harnesses - Electrical schematic sheet 14 - ENGINE CONTROLLER A2 (55.100)
Control unit M23 VGS Turbo WB-1275 Wiring harnesses - Electrical schematic sheet 14 - ENGINE CONTROLLER A2 (55.100)
Motor M24 Intake throttle DC-motor WB-1278 Wiring harnesses - Electrical schematic sheet 15 - DOSING CONTROL UNIT-A17 (55.100)
Sensor B140 Urea sensor WB-1323 Wiring harnesses - Electrical schematic sheet 15 - DOSING CONTROL UNIT-A17 (55.100)
Valve M25 Exhaust gas recirculation valve WB-1393 Wiring harnesses - Electrical schematic sheet 14 - ENGINE CONTROLLER A2 (55.100)
Connector CN.D20 CN.D20 Urea sensor WB-1458 Wiring harnesses - Electrical schematic sheet 14 - ENGINE CONTROLLER A2 (55.100)
Connector CN.E3 CN.E03
Connector CN.D9 Engine harness C WB-252 Wiring harnesses - Electrical schematic sheet 14 - ENGINE CONTROLLER A2 (55.100)
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Wiring harnesses - Electrical schematic sheet 21 - INJECTORS AND Wire Break

AIR INTAKE SENSOR Component Connector / Link Description
Actuator Y63 Injector 1 WB-1215 Wiring harnesses - Electrical schematic sheet 06 - MAIN CONTROLLER A1 (55.100)
Actuator Y65 Injector 3 WB-1378 Wiring harnesses - Electrical schematic sheet 14 - ENGINE CONTROLLER A2 (55.100)
Actuator Y66 Injector 4 WB-1390 Wiring harnesses - Electrical schematic sheet 02 - POWER DISTRIBUTION (55.100)
Actuator Y70 Injector 6
Resistor DEV249 WB-270 Wiring harnesses - Electrical schematic sheet 15 - DOSING CONTROL UNIT-A17 (55.100)
Sensor B95 Air intake sensor mass and temp (MAF) WB-336 Wiring harnesses - Electrical schematic sheet 14 - ENGINE CONTROLLER A2 (55.100)
Sensor B114 Intercooler -IN temp. WB-465 Wiring harnesses - Electrical schematic sheet 14 - ENGINE CONTROLLER A2 (55.100)
Sensor B115 Nox sensor (SCR IN) WB-483 Wiring harnesses - Electrical schematic sheet 14 - ENGINE CONTROLLER A2 (55.100)
Pump M14 Fuel feed pump motor WB-598 Wiring harnesses - Electrical schematic sheet 13 - ENGINE CONTROLLER A2 (55.100)
Connector CN.E14 CN.E14 WB-604 Wiring harnesses - Electrical schematic sheet 13 - ENGINE CONTROLLER A2 (55.100)
Connector CN.E18-A CN.E18-A
Connector CN.E19-A CN.E19-A WB-936 Wiring harnesses - Electrical schematic sheet 13 - ENGINE CONTROLLER A2 (55.100)
Connector CN.D17 CN.D17 Frame main harness
Connector CN.D17-1 CN.D17-1 Fuel pump
Connector CN.D17-2 CN.D17-2 Fuel pump - Diode
Connector CN.D17-4 CN.D17-4 CN J1939
Connector CN.D17-5 CN.D17-5 SCR inlet NOx sensor
Connector CN.D21 CN.D21 MAF sensor
Connector CN.D22 CN.D22 Suction air temperature
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Wiring harnesses - Electrical schematic sheet 22 - OPTION PEDAL, Wire Break

SOLENOID, PROPORTIONAL CIRCUIT Component Connector / Link Description
Type Component Connector Description WB-077 Wiring harnesses - Electrical schematic sheet 11 - MAIN CONTROLLER A1 (55.100)
Sensor B110 Press. Sensor (pilot option) WB-080 Wiring harnesses - Electrical schematic sheet 05 - MAIN CONTROLLER A1 (55.100)
Solenoid Y24 (S2) Option 1 solenoid valve (red tape) WB-1150 Wiring harnesses - Electrical schematic sheet 17 - SENSORS (55.100)
Solenoid Y25 (S2) Option 2 solenoid valve (red band) WB-1212 Wiring harnesses - Electrical schematic sheet 23 - OPTION PROPORTIONAL SOLENOID
Solenoid Y26 (S1) Option 2 solenoid valve (blue band) CIRCUIT (55.100)
Y26-A (S1) Option 2 solenoid valve (blue band) WB-1233 Wiring harnesses - Electrical schematic sheet 25 - KNOB LEFT (55.100)
Solenoid
Solenoid Y27 Option select solenoid valve WB-1269 Wiring harnesses - Electrical schematic sheet 03 - POWER DISTRIBUTION (55.100)
Connector CN.B19 CN.B19 Option harness WB-1317 Wiring harnesses - Electrical schematic sheet 23 - OPTION PROPORTIONAL SOLENOID
Connector CN.D24 CN.D24 Floor harness CIRCUIT (55.100)
Option 1 solenoid valve (red tape) connector WB-1404 Wiring harnesses - Electrical schematic sheet 16 - SENSORS (55.100)
Connector CN.G1 CN.G01
Connector CN.G2 CN.G02 Option 1 solenoid valve (red tape) connector WB-1437 Wiring harnesses - Electrical schematic sheet 40 - SOLENOID VALVE, MAGNET CLUTCH,
Connector CN.G4 CN.G4 Option 2 solenoid valve (red tape) connector RECEIVER DRYER (55.100)
Connector CN.G7 CN.G7 Option 1 solenoid valve (red tape) connector WB-144 Wiring harnesses - Electrical schematic sheet 23 - OPTION PROPORTIONAL SOLENOID
CIRCUIT (55.100)
Connector CN.G8 CN.G8 Option 1 solenoid valve (red tape) connector WB-1488 Wiring harnesses - Electrical schematic sheet 23 - OPTION PROPORTIONAL SOLENOID
Connector CN.G11 CN.G11 Press. Sensor (pilot option) connector CIRCUIT (55.100)
Connector CN.G16 Option 2 solenoid valve (blue band) connector WB-1554 Wiring harnesses - Electrical schematic sheet 24 - KNOB-RIGHT (55.100)
Option 2 solenoid valve (blue band) connector WB-180 Wiring harnesses - Electrical schematic sheet 24 - KNOB-RIGHT (55.100)
Connector CN.G17
WB-294 Wiring harnesses - Electrical schematic sheet 23 - OPTION PROPORTIONAL SOLENOID
CIRCUIT (55.100)
(55.100)
CIRCUIT (55.100)
CIRCUIT (55.100)
CIRCUIT (55.100)
CIRCUIT (55.100)
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Wiring harnesses - Electrical schematic sheet 23 - OPTION Wire Break

PROPORTIONAL SOLENOID CIRCUIT Component Connector / Link Description
Type Component Connector Description PROPORTIONAL CIRCUIT (55.100)
Solenoid B138 Press. Sensor (pilot option 1 up) PROPORTIONAL CIRCUIT (55.100)
Solenoid B139 Press. Sensor (pilot option 1 down) WB-144 Wiring harnesses - Electrical schematic sheet 22 - OPTION PEDAL, SOLENOID,
Solenoid S102 Pressure switch option 2 (lever up) PROPORTIONAL CIRCUIT (55.100)
Pressure switch option 2 (lever down) WB-1488 Wiring harnesses - Electrical schematic sheet 22 - OPTION PEDAL, SOLENOID,
Solenoid S103
Solenoid Y110 Option 1 proportional solenoid valve (lever up) WB-294 Wiring harnesses - Electrical schematic sheet 22 - OPTION PEDAL, SOLENOID,
Solenoid Y111 Option 1 proportional solenoid valve (lever down) PROPORTIONAL CIRCUIT (55.100)
Solenoid Y112 Option 2 proportional solenoid valve (lever up) WB-513 Wiring harnesses - Electrical schematic sheet 22 - OPTION PEDAL, SOLENOID,
Solenoid Y113 Option 2 proportional solenoid valve (lever down) WB-563 Wiring harnesses - Electrical schematic sheet 22 - OPTION PEDAL, SOLENOID,
Connector CN.G9 CN.G9 Option 1 proportional solenoid valve (lever up) connector PROPORTIONAL CIRCUIT (55.100)
Connector CN.G10 CN.G10 Option 1 proportional solenoid valve (lever up) connector WB-807 Wiring harnesses - Electrical schematic sheet 22 - OPTION PEDAL, SOLENOID,
Connector CN.G11-A CN.G11-A Press. Sensor (pilot option 1 up) connector WB-930 Wiring harnesses - Electrical schematic sheet 22 - OPTION PEDAL, SOLENOID,
Connector CN.G12 CN.G12 Press. Sensor (pilot option 1 down) connector PROPORTIONAL CIRCUIT (55.100)
Connector CN.G18 CN.G18 Option 2 proportional solenoid valve (lever up) connector
Connector CN.G19 CN.G19 Option 2 proportional solenoid valve (lever down) connector
Connector CN.G20 CN.G20 Pressure switch option 2 (lever up) connector
Connector CN.G21 CN.G21 Pressure switch option 2 (lever down) connector
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Wiring harnesses - Electrical schematic sheet 24 - KNOB-RIGHT Wire Break

Switch S11 Wiper switch WB-038 Wiring harnesses - Electrical schematic sheet 22 - OPTION PEDAL, SOLENOID,
Switch S16 Idle switch PROPORTIONAL CIRCUIT (55.100)
Connector CN.B5 CN.B5 Knob-right idle connector WB-1308 Wiring harnesses - Electrical schematic sheet 25 - KNOB LEFT (55.100)
Connector CN.B6 CN.B6 Knob-right wiper connector WB-1452 Wiring harnesses - Electrical schematic sheet 25 - KNOB LEFT (55.100)
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Wiring harnesses - Electrical schematic sheet 25 - KNOB LEFT Wire Break

Switch S15 Horn switch WB-1039
Switch S69 Radio mute switch WB-1233 Wiring harnesses - Electrical schematic sheet 22 - OPTION PEDAL, SOLENOID,
Switch S104 Proportional lever switch PROPORTIONAL CIRCUIT (55.100)
Switch S105 Switch (p-SOL.2 : 100 %) WB-1248 Wiring harnesses - Electrical schematic sheet 22 - OPTION PEDAL, SOLENOID,
Connector CN.B7 CN.B7 knob left 4 switch horn connector WB-1251 Wiring harnesses - Electrical schematic sheet 08 - MAIN CONTROLLER A1 (55.100)
Connector CN.B8 CN.B8 knob left 4 switch mute connector WB-1308 Wiring harnesses - Electrical schematic sheet 24 - KNOB-RIGHT (55.100)
WB-1545
WB-189
WB-492
WB-950
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Wiring harnesses - Electrical schematic sheet 26 - AIR CONDITIONER Wire Break

SWITCH PANEL & UNIT Component Connector / Link Description
Type Component Connector Description WB-1063 Wiring harnesses - Electrical schematic sheet 27 - AIR CONDITIONER UNIT & REFUEL
PUMP (55.100)
Controller A6 CN.A6 Blower controller
Sensor B5 CN.B5 Evaporator sensor WB-1078 Wiring harnesses - Electrical schematic sheet 04 - POWER DISTRIBUTION (55.100)
Relay K17 Blower off relay WB-1108 Wiring harnesses - Electrical schematic sheet 30 - MAIN CAB-INTER CONNECTOR (55.100)
Relay K103 Air conditioner compressor relay WB-1147 Wiring harnesses - Electrical schematic sheet 11 - MAIN CONTROLLER A1 (55.100)
Motor M8 Blower motor WB-1197
WB-1245
Relay R4 Thermistor inner temperature WB-1320 Wiring harnesses - Electrical schematic sheet 37 - OPTION POWER / FVM, KEY SWITCH
Connector CN.A44 CN.A41 Console harness C (55.100)
Connector CN.B15 CN.B15 Air conditioner panel B WB-1344 Wiring harnesses - Electrical schematic sheet 37 - OPTION POWER / FVM, KEY SWITCH
(55.100)
Connector CN.B16 CN.B16 Air conditioner unit A
WB-1350
Connector CN.B17 CN.B17 Air conditioner unit B WB-1359
Connector CN.F1 CN.F1 Relay compressor WB-1416 Wiring harnesses - Electrical schematic sheet 27 - AIR CONDITIONER UNIT & REFUEL
Connector CN.F2 CN.F2 Relay blower OFF PUMP (55.100)
WB-1503
Connector CN.F3 CN.F3 Blower motor WB-1548 Wiring harnesses - Electrical schematic sheet 34 - MAIN CAB-MONITOR DISPLAY (55.100)
Connector CN.F4 CN.F4 Blower AMP WB-1551 Wiring harnesses - Electrical schematic sheet 04 - POWER DISTRIBUTION (55.100)
Connector CN.F5 CN.F5 Temp. sensor (recirculate) WB-1566
Connector CN.F6 CN.F6 Temp.sensor (evaporator) WB-192
PUMP (55.100)
(55.100)
WB-258
PUMP (55.100)
PUMP (55.100)
WB-429
PUMP (55.100)
WB-592
PUMP (55.100)
PUMP (55.100)
WB-780
WB-801
PUMP (55.100)
PUMP (55.100)
PUMP (55.100)
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Wiring harnesses - Electrical schematic sheet 27 - AIR CONDITIONER Wire Break

UNIT & REFUEL PUMP Component Connector / Link Description
Alarm B82 Refuel pump stop alarm UNIT (55.100)
Relay K30 Refuel pump relay WB-1203 Wiring harnesses - Electrical schematic sheet 39 - LAMP, PUMP, WASHER, HORN, UREA
Relay K31 Refuel pump stop relay PUMP (55.100)
Motor (air changing) WB-1257 Wiring harnesses - Electrical schematic sheet 39 - LAMP, PUMP, WASHER, HORN, UREA
Motor M5 PUMP (55.100)
Motor M6 Air vent direction control motor WB-1416 Wiring harnesses - Electrical schematic sheet 26 - AIR CONDITIONER SWITCH PANEL &
Motor M7 Motor actuator (air-mix) UNIT (55.100)
Motor M14 Fuel feed pump motor WB-201 Wiring harnesses - Electrical schematic sheet 26 - AIR CONDITIONER SWITCH PANEL &
UNIT (55.100)
Switch S61 Refuel pump switch WB-234 Wiring harnesses - Electrical schematic sheet 39 - LAMP, PUMP, WASHER, HORN, UREA
Connector CN.F7 Motor actuator (air-mix) connector PUMP (55.100)
Connector CN.F8 CN.F7 Motor actuator (mode) connector WB-330 Wiring harnesses - Electrical schematic sheet 39 - LAMP, PUMP, WASHER, HORN, UREA
PUMP (55.100)
Connector CN.F9 CN.F9 Motor actuator (fresh/reculate) connector WB-348 Wiring harnesses - Electrical schematic sheet 26 - AIR CONDITIONER SWITCH PANEL &
Connector CN.D34 CN.D34 Fuel feed pump UNIT (55.100)
Connector CN.D34-1 Fuel feed pump (refuel pump) WB-357 Wiring harnesses - Electrical schematic sheet 26 - AIR CONDITIONER SWITCH PANEL &
UNIT (55.100)
Connector CN.D34-2 Fuel feed pump (switch rocker manual/auto)
Connector CN.D34-3 Fuel feed pump (relay pump) UNIT (55.100)
Connector CN.D34-4 Fuel feed pump (relay stop) WB-751 Wiring harnesses - Electrical schematic sheet 05 - MAIN CONTROLLER A1 (55.100)
Connector CN.D34-5 Fuel feed pump (alarm) WB-763 Wiring harnesses - Electrical schematic sheet 26 - AIR CONDITIONER SWITCH PANEL &
UNIT (55.100)
Connector CN.D34-6 Fuel feed pump (alarm) WB-771 Wiring harnesses - Electrical schematic sheet 26 - AIR CONDITIONER SWITCH PANEL &
Connector CN.D34-7 UNIT (55.100)
UNIT (55.100)
UNIT (55.100)
UNIT (55.100)
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Wiring harnesses - Electrical schematic sheet 28 - CCD CAMERA Wire Break

Camera H10 Camera 1 (Rear) WB-1173 Wiring harnesses - Electrical schematic sheet 34 - MAIN CAB-MONITOR DISPLAY (55.100)
Camera H11 Camera 2 (Right side) WB-1176 Wiring harnesses - Electrical schematic sheet 34 - MAIN CAB-MONITOR DISPLAY (55.100)
Camera H13 Camera 3 (Left side) WB-1254 Wiring harnesses - Electrical schematic sheet 34 - MAIN CAB-MONITOR DISPLAY (55.100)
Connector CN.E18 CN.E18 CCD harness (Camera 1 (Rear)) WB-1284 Wiring harnesses - Electrical schematic sheet 34 - MAIN CAB-MONITOR DISPLAY (55.100)
Connector CN.E19 CN.E19 CCD harness (Camera 2 (Right side))
Connector CN.E20A CN.E20A CCD harness (Camera 3 (Left side)) WB-1563 Wiring harnesses - Electrical schematic sheet 34 - MAIN CAB-MONITOR DISPLAY (55.100)
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Wiring harnesses - Electrical schematic sheet 29 - MAIN CAB-ECM Wire Break

INTER CONNECTOR Component Connector / Link Description
Connector X4 CN.A20_M Diagnostic connector CONVERTER (55.100)
Connector X5 CN.52CN.A52 EST connector WB-083 Wiring harnesses - Electrical schematic sheet 30 - MAIN CAB-INTER CONNECTOR (55.100)
Connector X27 CN.A26CN.A26 TO GPS unit WB-095 Wiring harnesses - Electrical schematic sheet 05 - MAIN CONTROLLER A1 (55.100)
CONVERTER (55.100)
CONVERTER (55.100)
CONVERTER (55.100)
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Wiring harnesses - Electrical schematic sheet 30 - MAIN CAB-INTER Wire Break

CONNECTOR Component Connector / Link Description
Connector CN.A19 CN.A19 EST-B (F) connector
Connector CN.A35 CN.A35 Joint connector A WB-1108 Wiring harnesses - Electrical schematic sheet 26 - AIR CONDITIONER SWITCH PANEL &
Connector CN.A36 CN.A36 Joint connector B UNIT (55.100)
Connector CN.A51 CN.A51 Frame harness B WB-113 Wiring harnesses - Electrical schematic sheet 06 - MAIN CONTROLLER A1 (55.100)
CONVERTER (55.100)
(55.100)
WB-324 Wiring harnesses - Electrical schematic sheet 39 - LAMP, PUMP, WASHER, HORN, UREA
PUMP (55.100)
(55.100)
PUMP (55.100)
(55.100)
PUMP (55.100)
UNIT (55.100)
PUMP (55.100)
CONVERTER (55.100)
(55.100)
PUMP (55.100)
UNIT (55.100)
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Wiring harnesses - Electrical schematic sheet 31 - MAIN CAB-RELAYS Wire Break

Relay K3 Horn relay WB-1028 Wiring harnesses - Electrical schematic sheet 29 - MAIN CAB-ECM INTER CONNECTOR
Relay K11 Working light (cab) relay (55.100)
Relay K10 Working light (upper structure / attachment) relay WB-119 Wiring harnesses - Electrical schematic sheet 03 - POWER DISTRIBUTION (55.100)
Relay Starter cut relay WB-1311 Wiring harnesses - Electrical schematic sheet 03 - POWER DISTRIBUTION (55.100)
K34
Relay K36 Speaker left relay WB-1425 Wiring harnesses - Electrical schematic sheet 05 - MAIN CONTROLLER A1 (55.100)
Relay K37 Speaker right relay WB-1434 Wiring harnesses - Electrical schematic sheet 15 - DOSING CONTROL UNIT-A17 (55.100)
Relay K63 ECM relay WB-1440 Wiring harnesses - Electrical schematic sheet 12 - ENGINE CONTROLLER A2 (55.100)
Relay K68 Neutral start relay WB-1536 Wiring harnesses - Electrical schematic sheet 15 - DOSING CONTROL UNIT-A17 (55.100)
Relay K77 Beacon relay WB-441 Wiring harnesses - Electrical schematic sheet 12 - ENGINE CONTROLLER A2 (55.100)
Connector CN.A6 CN.A6 ECM relay connector WB-504 Wiring harnesses - Electrical schematic sheet 29 - MAIN CAB-ECM INTER CONNECTOR
Connector CN.A7 CN.A7 Starter cut relay connector (55.100)
Neutral start relay connector WB-574 Wiring harnesses - Electrical schematic sheet 03 - POWER DISTRIBUTION (55.100)
Connector CN.A13 CN.A13 Cab lamp relay connector WB-682 Wiring harnesses - Electrical schematic sheet 05 - MAIN CONTROLLER A1 (55.100)
Connector CN.A14 CN.A14 Beacon relay connector WB-709 Wiring harnesses - Electrical schematic sheet 04 - POWER DISTRIBUTION (55.100)
Connector CN.A15 CN.A15 Upper lamp relay connector WB-748 Wiring harnesses - Electrical schematic sheet 29 - MAIN CAB-ECM INTER CONNECTOR
(55.100)
Connector CN.A16 CN.A16 Speaker (L) relay connector
Connector CN.A17 CN.A17 Speaker (R) relay connector WB-831 Wiring harnesses - Electrical schematic sheet 12 - ENGINE CONTROLLER A2 (55.100)
Connector CN.A18 CN.A18 Horn (R) relay connector WB-840 Wiring harnesses - Electrical schematic sheet 09 - MAIN CONTROLLER A1 (55.100)
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Wiring harnesses - Electrical schematic sheet 32 - MAIN CAB-RELAYS, Wire Break

RADIO AND CONVERTER Component Connector / Link Description
Relay K35 Room lamp relay
Relay K85 Relay ACC:1 WB-1051 Wiring harnesses - Electrical schematic sheet 09 - MAIN CONTROLLER A1 (55.100)
Relay K96 Relay ACC:2 WB-1096 Wiring harnesses - Electrical schematic sheet 29 - MAIN CAB-ECM INTER CONNECTOR
Relay K64 Relay key ON (55.100)
Relay P15 Radio set WB-1338 Wiring harnesses - Electrical schematic sheet 09 - MAIN CONTROLLER A1 (55.100)
Relay U1 DC/DC(24V/12V) WB-1413 Wiring harnesses - Electrical schematic sheet 09 - MAIN CONTROLLER A1 (55.100)
Connector CN.A9 CN.A9 Relay ACC:1 WB-171 Wiring harnesses - Electrical schematic sheet 29 - MAIN CAB-ECM INTER CONNECTOR
Connector CN.A10 CN.A10 Relay ACC:2 (55.100)
Connector CN.A11 CN.A11 Relay key ON WB-228 Wiring harnesses - Electrical schematic sheet 15 - DOSING CONTROL UNIT-A17 (55.100)
Connector CN.A12 CN.A12 Room lamp WB-345 Wiring harnesses - Electrical schematic sheet 07 - MAIN CONTROLLER A1 (55.100)
Connector CN.A29 CN.A29 DC/DC(24V/12V) Connector WB-420 Wiring harnesses - Electrical schematic sheet 29 - MAIN CAB-ECM INTER CONNECTOR
Connector CN.B18 CN.B18 Radio set connector (55.100)
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Wiring harnesses - Electrical schematic sheet 33 - PROPORTIONAL S/V Wire Break

Solenoid Y11 Main pump P1 flow proportional solenoid WB-071 Wiring harnesses - Electrical schematic sheet 10 - MAIN CONTROLLER A1 (55.100)
Valve Y18 Free swing solenoid valve WB-1004 Wiring harnesses - Electrical schematic sheet 05 - MAIN CONTROLLER A1 (55.100)
Valve Y61 (S1) Bucket close proportional solenoid valve (red tape) WB-1007 Wiring harnesses - Electrical schematic sheet 11 - MAIN CONTROLLER A1 (55.100)
Valve Y62 Option press. Proportional solenoid valve WB-1054 Wiring harnesses - Electrical schematic sheet 08 - MAIN CONTROLLER A1 (55.100)
Valve Y102 Main pump P2 flow proportional solenoid
Coupler Y109 Quick coupler WB-1497 Wiring harnesses - Electrical schematic sheet 10 - MAIN CONTROLLER A1 (55.100)
Valve Y107 (S2) Travel strate proportional solenoid valve (yellow tape) WB-150 Wiring harnesses - Electrical schematic sheet 10 - MAIN CONTROLLER A1 (55.100)
Valve Y125 (S3) Arm2 parallel proportional solenoid valve (green tape) WB-1515 Wiring harnesses - Electrical schematic sheet 10 - MAIN CONTROLLER A1 (55.100)
Valve Y126 (S4) Arm1 recycle proportional solenoid valve (white tape)
Valve Y127 (S5) Boom2 down proportional solenoid valve (pink tape) WB-486 Wiring harnesses - Electrical schematic sheet 10 - MAIN CONTROLLER A1 (55.100)
Valve Y128 (S6) Arm1 parallel proportional solenoid valve (blue tape) WB-528 Wiring harnesses - Electrical schematic sheet 08 - MAIN CONTROLLER A1 (55.100)
Connector CN.D60 CN.D60 Free swing solenoid valve WB-560 Wiring harnesses - Electrical schematic sheet 05 - MAIN CONTROLLER A1 (55.100)
Connector CN.D61-A CN.D61-A Quick coupler solenoid valve WB-646 Wiring harnesses - Electrical schematic sheet 11 - MAIN CONTROLLER A1 (55.100)
Connector CN.D62 CN.D62 Option harness proportional solenoid valve WB-733 Wiring harnesses - Electrical schematic sheet 08 - MAIN CONTROLLER A1 (55.100)
Connector CN.D63 CN.D63 P1 flow proportional solenoid valve WB-736 Wiring harnesses - Electrical schematic sheet 10 - MAIN CONTROLLER A1 (55.100)
Connector CN.D64 CN.D64 P2 flow proportional solenoid valve WB-837 Wiring harnesses - Electrical schematic sheet 08 - MAIN CONTROLLER A1 (55.100)
Connector CN.D66-1 CN.D66-1 Control valve PWM proportional S/V WB-974 Wiring harnesses - Electrical schematic sheet 10 - MAIN CONTROLLER A1 (55.100)
Connector CN.D66-2 CN.D66-2 Control valve PWM proportional S/V
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Wiring harnesses - Electrical schematic sheet 34 - MAIN CAB-MONITOR Wire Break

DISPLAY Component Connector / Link Description
Type Component Connector Description AND SENSOR (55.100)
Monitor P1 Monitor display
Connector CN.A40 CN.A40 Cab harness A AND SENSOR (55.100)
Connector CN.C1 CN.C1 WB-053 Wiring harnesses - Electrical schematic sheet 28 - CCD CAMERA (55.100)
Connector CN.C21 CN.C21 WB-068
Connector CN.C3 CN.C3 WB-1036 Wiring harnesses - Electrical schematic sheet 30 - MAIN CAB-INTER CONNECTOR (55.100)
Connector CN.C3_M PUMP (55.100)
Connector CN.C4 CN.C04 WB-1090 Wiring harnesses - Electrical schematic sheet 35 - WIPER CONTROLLER, WIPER MOTOR
Connector CN.C4_M AND SENSOR (55.100)
Connector CN.C21 CN.C21
WB-1173 Wiring harnesses - Electrical schematic sheet 28 - CCD CAMERA (55.100)
AND SENSOR (55.100)
(55.100)
UNIT (55.100)
AND SENSOR (55.100)
AND SENSOR (55.100)
WB-757
AND SENSOR (55.100)
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Wiring harnesses - Electrical schematic sheet 35 - WIPER CONTROLLER, Wire Break

WIPER MOTOR AND SENSOR Component Connector / Link Description
Type Component Connector Description WB-050 Wiring harnesses - Electrical schematic sheet 34 - MAIN CAB-MONITOR DISPLAY (55.100)
Wiper A4 CN.A4 Wiper controller WB-1090 Wiring harnesses - Electrical schematic sheet 34 - MAIN CAB-MONITOR DISPLAY (55.100)
Sensor B61 Sun load sensor WB-1341 Wiring harnesses - Electrical schematic sheet 03 - POWER DISTRIBUTION (55.100)
Motor M3 Wiper motor WB-1473 Wiring harnesses - Electrical schematic sheet 15 - DOSING CONTROL UNIT-A17 (55.100)
Horn S127 Horn select WB-291 Wiring harnesses - Electrical schematic sheet 34 - MAIN CAB-MONITOR DISPLAY (55.100)
Switch S128 Crane switch WB-306 Wiring harnesses - Electrical schematic sheet 10 - MAIN CONTROLLER A1 (55.100)
Coupler S129 Quick coupler WB-438 Wiring harnesses - Electrical schematic sheet 10 - MAIN CONTROLLER A1 (55.100)
Connector CN.C5 CN.C5 Sun load sensor connector
Connector CN.C6 CN.C6 Wiper controller connector IMMOBILIZER (55.100)
Connector CN.C7 CN.C7 Wiper motor connector WB-700 Wiring harnesses - Electrical schematic sheet 10 - MAIN CONTROLLER A1 (55.100)
Connector CN.C12 CN.C12 Crane switch connector WB-789 Wiring harnesses - Electrical schematic sheet 36 - ACC SOCKET, CIGAR LIGHTER,
Connector CN.C12-B CN.C12-B Quick coupler connector WB-834 Wiring harnesses - Electrical schematic sheet 36 - ACC SOCKET, CIGAR LIGHTER,
Connector CN.C12-A CN.C12-A Horn select connector IMMOBILIZER (55.100)
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Wiring harnesses - Electrical schematic sheet 36 - ACC SOCKET, CIGAR Wire Break
LIGHTER, IMMOBILIZER Component Connector / Link Description
Type Component Connector Description WB-092 Wiring harnesses - Electrical schematic sheet 15 - DOSING CONTROL UNIT-A17 (55.100)
Light E3 CN.E03 Working light (cab) WB-1057 Wiring harnesses - Electrical schematic sheet 15 - DOSING CONTROL UNIT-A17 (55.100)
Light E4 CN.E04 Cab light WB-1236 Wiring harnesses - Electrical schematic sheet 34 - MAIN CAB-MONITOR DISPLAY (55.100)
Accessory E51 Cigarette lighter WB-1410 Wiring harnesses - Electrical schematic sheet 34 - MAIN CAB-MONITOR DISPLAY (55.100)
Speaker H4 Speaker right WB-1512 Wiring harnesses - Electrical schematic sheet 34 - MAIN CAB-MONITOR DISPLAY (55.100)
Speaker H5 Speaker left WB-165 Wiring harnesses - Electrical schematic sheet 34 - MAIN CAB-MONITOR DISPLAY (55.100)
Switch S53 Door limit switch
Switch S54 Front window limit switch AND SENSOR (55.100)
Accessory X15 Accessory socket WB-673 Wiring harnesses - Electrical schematic sheet 08 - MAIN CONTROLLER A1 (55.100)
Connector CN.A26 CN.A26 Lamp cab WB-789 Wiring harnesses - Electrical schematic sheet 35 - WIPER CONTROLLER, WIPER MOTOR
AND SENSOR (55.100)
Connector CN.A27 CN.A27 Lamp cab
Connector CN.A28 CN.A28 Lamp cab AND SENSOR (55.100)
Connector CN.A29 CN.A29 Lamp cab WB-870 Wiring harnesses - Electrical schematic sheet 15 - DOSING CONTROL UNIT-A17 (55.100)
Connector CN.A30 CN.A30 Front window limit switch WB-971 Wiring harnesses - Electrical schematic sheet 30 - MAIN CAB-INTER CONNECTOR (55.100)
Connector CN.A31 CN.A31 Front window limit switch
Connector CN.A47 CN.A47 Immobilizer
Connector CN.C8 CN.C8 Cab lamp
Connector CN.C9 CN.C9 Door limit switch
Connector CN.C10 CN.C10 Speaker
Connector CN.C11 CN.C11 Front window limit switch
Connector CN.C13 CN.C13 Cigarette lighter
Connector CN.C14 CN.C14 Cigarette lighter
Connector CN.C15 CN.C15 Accessory socket
Connector CN.C16 CN.C16 Accessory socket
Connector CN.C24 CN.C24 Speaker right
Connector CN.C25 CN.C25 Speaker left
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Wiring harnesses - Electrical schematic sheet 37 - OPTION POWER / Wire Break

FVM, KEY SWITCH Component Connector / Link Description
module X44 Option power/FVM
Relay R3 Throttle vol. WB-1099 Wiring harnesses - Electrical schematic sheet 09 - MAIN CONTROLLER A1 (55.100)
Switch S51 Limit switch (GATE) WB-116 Wiring harnesses - Electrical schematic sheet 03 - POWER DISTRIBUTION (55.100)
Switch S1 Key switch WB-1218 Wiring harnesses - Electrical schematic sheet 03 - POWER DISTRIBUTION (55.100)
Load carrier X45 Air suspension WB-1242 Wiring harnesses - Electrical schematic sheet 05 - MAIN CONTROLLER A1 (55.100)
Connector CN.A25 CN.A25 Option power/FVM UNIT (55.100)
Connector CN.B2 CN.B2 Throttle vol. WB-1344 Wiring harnesses - Electrical schematic sheet 26 - AIR CONDITIONER SWITCH PANEL &
Connector CN.B1 CN.B1 Key switch UNIT (55.100)
Connector CN.B3 CN.B3 Limit switch (GATE)
Connector CN.B3_M Limit switch (GATE) WB-1500 Wiring harnesses - Electrical schematic sheet 05 - MAIN CONTROLLER A1 (55.100)
Connector CN.B20 CN.B20 Air suspension WB-174 Wiring harnesses - Electrical schematic sheet 10 - MAIN CONTROLLER A1 (55.100)
Connector CN.B20_M Air suspension WB-204 Wiring harnesses - Electrical schematic sheet 26 - AIR CONDITIONER SWITCH PANEL &
UNIT (55.100)
Connector CN.B21 CN.B21
Diode CN.B4 CN.B24 WB-312 Wiring harnesses - Electrical schematic sheet 05 - MAIN CONTROLLER A1 (55.100)
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Wiring harnesses - Electrical schematic sheet 38 - OVER LOAD, Wire Break

BEACON, TRAVEL ALARM, REVERSE FAN, FREE SWING Component Connector / Link Description
Type Component Connector Description WB-1299 Wiring harnesses - Electrical schematic sheet 05 - MAIN CONTROLLER A1 (55.100)
Switch S13 Over load (No tape) WB-1326 Wiring harnesses - Electrical schematic sheet 05 - MAIN CONTROLLER A1 (55.100)
Switch S85 Beacon (Red tape) WB-1446 Wiring harnesses - Electrical schematic sheet 09 - MAIN CONTROLLER A1 (55.100)
Switch S28 Travel alarm (Blue tape) WB-1446 Wiring harnesses - Electrical schematic sheet 09 - MAIN CONTROLLER A1 (55.100)
Switch S9 Engine stop(No tape) WB-153 Wiring harnesses - Electrical schematic sheet 06 - MAIN CONTROLLER A1 (55.100)
Switch S130 Fan reverse (Red tape) WB-177 Wiring harnesses - Electrical schematic sheet 09 - MAIN CONTROLLER A1 (55.100)
Switch S22 Free swing (Blue tape)
Connector CN.B11 CN.B11 Over load (No tape) UNIT (55.100)
Connector CN.B12 CN.B12 Beacon (Red tape) WB-237 Wiring harnesses - Electrical schematic sheet 05 - MAIN CONTROLLER A1 (55.100)
Connector CN.B13 CN.B13 Travel alarm (Blue tape) WB-303 Wiring harnesses - Electrical schematic sheet 05 - MAIN CONTROLLER A1 (55.100)
Connector CN.B9 CN.B9 Engine stop(No tape) WB-631 Wiring harnesses - Electrical schematic sheet 09 - MAIN CONTROLLER A1 (55.100)
Connector CN.B10 CN.B10 Fan reverse (Red tape) WB-864 Wiring harnesses - Electrical schematic sheet 05 - MAIN CONTROLLER A1 (55.100)
Connector CN.B27 CN.B27 Free swing (Blue tape) WB-965 Wiring harnesses - Electrical schematic sheet 09 - MAIN CONTROLLER A1 (55.100)
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SHT_39 1
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Wiring harnesses - Electrical schematic sheet 39 - LAMP, PUMP, Wire Break

WASHER, HORN, UREA PUMP Component Connector / Link Description
Type Component Connector Description WB-101 Wiring harnesses - Electrical schematic sheet 40 - SOLENOID VALVE, MAGNET CLUTCH,
Module X49 Urea pump
Module X7 Lubricator RECEIVER DRYER (55.100)
Diode E2 CN.E02 Lamp(boom) WB-1203 Wiring harnesses - Electrical schematic sheet 27 - AIR CONDITIONER UNIT & REFUEL
Diode E1 CN.E1 Lamp(house) PUMP (55.100)
Motor M4 Washer RECEIVER DRYER (55.100)
Actuator B92 Horn low(left) WB-1257 Wiring harnesses - Electrical schematic sheet 27 - AIR CONDITIONER UNIT & REFUEL
Actuator B93 Horn high(right) PUMP (55.100)
Diode X56 Beacon
Connector CN.D32 CN.D32 Urea pump WB-234 Wiring harnesses - Electrical schematic sheet 27 - AIR CONDITIONER UNIT & REFUEL
Connector CN.D33 CN.D33 Lubricator PUMP (55.100)
Connector CN.G2-A Lamp(boom) WB-324 Wiring harnesses - Electrical schematic sheet 30 - MAIN CAB-INTER CONNECTOR (55.100)
Connector CN.D36 CN.D36 Lamp(house) PUMP (55.100)
Diode CN.D38 CN.D38 Dev449 WB-477 Wiring harnesses - Electrical schematic sheet 30 - MAIN CAB-INTER CONNECTOR (55.100)
Connector CN.D37 CN.D37 Washer WB-652 Wiring harnesses - Electrical schematic sheet 30 - MAIN CAB-INTER CONNECTOR (55.100)
Connector CN.D39 CN.D39 Horn low(left) WB-712 Wiring harnesses - Electrical schematic sheet 30 - MAIN CAB-INTER CONNECTOR (55.100)
Connector CN.D40 CN.D40 Horn low(left)
Connector CN.D41 CN.D41 Horn high(right) RECEIVER DRYER (55.100)
Connector CN.D42 CN.D42 Horn high(right)
Connector CN.D43 CN.D43 Beacon
Connector CN.D35_M
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SHT_40 1
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Wiring harnesses - Electrical schematic sheet 40 - SOLENOID VALVE, Wire Break

MAGNET CLUTCH, RECEIVER DRYER Component Connector / Link Description
Type Component Connector Description PUMP (55.100)
Solenoid Y2 (SP) Solenoid valve (Blue tape)
Solenoid Y3 (S2) Solenoid valve (White tape PUMP (55.100)
Solenoid Y4 (S1) Solenoid valve (Red tape) WB-1010 Wiring harnesses - Electrical schematic sheet 06 - MAIN CONTROLLER A1 (55.100)
Solenoid Y5 (S3) Solenoid valve (Yellow tape) WB-104 Wiring harnesses - Electrical schematic sheet 39 - LAMP, PUMP, WASHER, HORN, UREA
PUMP (55.100)
Solenoid Y99 (S*) Solenoid valve (Green tape) WB-1042 Wiring harnesses - Electrical schematic sheet 06 - MAIN CONTROLLER A1 (55.100)
switch S52 Dual switch (Receiver dryer) WB-1105 Wiring harnesses - Electrical schematic sheet 05 - MAIN CONTROLLER A1 (55.100)
switch Y8 Magnet clutch (Compressor) WB-1221 Wiring harnesses - Electrical schematic sheet 39 - LAMP, PUMP, WASHER, HORN, UREA
PUMP (55.100)
Actuator H2 Travel alarm 24V,107dB
Connector CN.D44 CN.D44 Dual switch (Receiver dryer) PUMP (55.100)
Connector CN.D45 CN.D45 Magnet clutch (Compressor) WB-1335 Wiring harnesses - Electrical schematic sheet 07 - MAIN CONTROLLER A1 (55.100)
Connector CN.D46 CN.D46 Travel alarm 24V,107dB WB-1384 Wiring harnesses - Electrical schematic sheet 06 - MAIN CONTROLLER A1 (55.100)
PUMP (55.100)
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SHT_41 1
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Wire connectors - Component diagram 00

CONNECTOR CN.A1 – CONTROLLER 1 (34-PIN) (Male)
SMIL14CEX5190AA 1
SMIL14CEX6467AA 2
Pin From Wire Description Color-Size Frame

1 CN.A55 pin-20 912D LY SHEET 11
2 CN.A55 pin-8 911C Y
3 CN.A55 pin-9 912A L
4 SP-440A pin-X 440I BL - 0.85
5 SP-430 pin-X 430 W - 0.85
6 SP-445A pin-X 445 BW - 0.85
7 SP-435A pin-X 435 WB - 0.85
8 SP-440A-pin-X 440A BL - 0.85
9 CN.A55 pin-19 911B BY
10 SP-445A pin-X 445A BW - 0.85
11 CN.A54 pin-8 406 LW
13 CN.A54 pin-13 411 OR
14 SP-430 pin-X 430A-1 W - 0.85
15 CN.A44 pin-8 416 RW - 0.85 SHEET 26
16 CN.A56 pin-16 418 L SHEET 11
17 SP-435A pin-X 435A WB - 0.85
18 CN.A54 pin-4 402 Br
19 CN.A54 pin-7 405 LR
20 CN.A54 pin-11 409 GR
21 CN.A54 pin-10 408 YG
22 CN.A54 pin-15 413 O
23 CN.A54 pin-16 414 LgR
24 CN.A54 pin-17 415 WL
25 CN.A56 pin-17 419 R
26 CN.A56 pin-15 417 Y
27 CN.A54 pin-18 421 Gr
28 CN.A54 pin-5 403 BrR
29 CN.A54 pin-6 404 Lg
30 CN.A54 pin-9 407 YR
31 CN.A54 pin-12 410 GW
32 CN.A54 pin-14 412 OL
33 CN.A56 pin-18 420 G
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SMIL14CEX5194AA 3
SMIL14CEX6468AA 4

1 SP-601F pin-X 601H BG - 1.25 SHEET 10
2 CN.A55 pin 1 901A RW
3 CN.A55 pin 2 902A O
4 CN.A55 pin 5 906A LR
5 CN.A55 pin 7 908A R
6 CN.A55 pin 14 905A GR
7 CN.A55 pin 16 906B LB
9 CN.A55 pin 10 901B RB
11 CN.A55 pin 11 902B BO
15 SP-601F pin-X 601F BG
19 CN.A55 pin 18 908B BR
20 CN.A27 pin-6 542 OR
24 CN.A35_M pin-17 501O G SHEET 30
25 SP-515A pin-X 515A Br - 0.85 SHEET 09
26 CN.A54 pin-20 426 GL - 0.85
27 CN.A55 pin 15 905B GW
28 CN.A40_M pin-6 547 WR
29 CN.A56 pin-12 539 GY - 0.85
31 CN.A27 pin-5 541 YR
32 CN.A35_M pin-18 501C G SHEET 30
33 SP-840C pin-X 840A RY
34 CN.A54 pin-19 425 Y - 0.75
35 CN.A54 pin-3 401 YG - 0.85
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SMIL14CEX5192AA 5
SMIL14CEX6469AA 6

1 CN.A55 pin 4 904A YR - 0.85 SHEET 08
2 CN.A55 pin 6 907A G - 0.85
3 CN.A55 pin 3 903A Lg - 0.85
4 CN.A55 pin 17 907B GY - 0.85
7 CN.A36_M pin-1 CL0 PG SHEET 30
8 CN.A35_M pin-1 CH0 P
9 CN.A55 pin 13 904B YB - 0.85 SHEET 08
10 CN.A47F pin 1 532 VG SHEET 36
11 CN.A34_M pin-3 601C BG SHEET 29
12 CN.A56 pin 10 533 GrR - 0.85
13 CN.A55 pin 12 903B LgR - 0.85
14 CN.A45 pin 5 544 LY SHEET 09
18 CN.A52 pin 8 AL0 YG
19 CN.A52 pin 7 AH0 Y
21 CN.A45 pin 4 538 WG
22 CN.A43 pin 1 531 LR SHEET 08
23 CN.A45 pin 6 540 YL SHEET 09
24 CN.A45 pin 18 543 GW - 0.85
26 CN.A45 pin 3 536 GR
28 CN.A34_M pin-4 601D BG SHEET 29
29 SP-BL0 pin-X BL0-B LG SHEET 08
30 SP-BH0 pin-X BH0 L
31 CN.A44 pin 6 535 LB SHEET 09
32 CN.A56 pin 11 534 LW
33 CN.A54 pin 22 546 LgW
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SMIL14CEX5288AA 7
SMIL14CEX6470AA 8

1 CN.A56 pin 5 806 Lg SHEET 06
2 SP-812 pin-X 812 WR SHEET 07
3 CN.A56 pin 3 803 YR - 0.75 SHEET 06
4 CN.A56 pin 1 801 WG - 0.75
5 CN.A56 pin 6 807 RY - 0.75 SHEET 07
6 CN.A56 pin 2 802 LR - 0.75 SHEET 06
7 SP-804 pin-X 804D Br - 0.85
8 CN.A33_M pin-5 701E B SHEET 29
10 CN.A19_M pin-9 064 YL SHEET 07
11 CN.A19_M pin-7 060 R
12 CN.A19_M pin-12 061 RL
14 SP-BH1 pin-X BH1 L SHEET 08
15 SP-BL1 pin-X BL1 LG
16 SP-AH1 pin-X AH1 Y SHEET 06
17 SP-AL2 pin-X AL1 YG SHEET 12
18 SP-145A pin-X 145C W SHEET 06
19 SP-145A pin-X 145A W
20 CN.A19_M pin-8 066 LW SHEET 07
21 CN.A19_M pin-10 065 GW
22 CN.A19_M pin-11 062 BR
23 CN.A26 pin 7 069 BY SHEET 29
26 SP-811B pin-X 811 LY SHEET 32
27 CN.A19_M pin-4 063 GR SHEET 08
28 CN.A26 pin 6 068 LB SHEET 29
29 CN.A26 pin 5 067 WB SHEET 29
30 CN.A35_M pin-2 CH1 P SHEET 30
31 CN.A36_M pin-2 CL1 PG SHEET 30
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SMIL14CEX6487AA 9
SMIL14CEX6471AA 10

1 CN.A43 pin 6 809 V SHEET 05
2 SP-808 pin-X 808 GW - 0.75
3 CN.A53 pin 14 805A BrY SHEET 13
4 CN.A24M pin-1 816A LG SHEET 37
5 CN.A56 pin 9 817 YG - 0.85 SHEET 05
6 CN.A33_M pin-3 701C B - 1.25 SHEET 29
7 SP-160A pin-X 160B LR - 1.25 SHEET 04
8 SP-160A pin-X 160A LR - 1.25
9 SP-155A pin-X 155 GR - 1.25
10 CN.A35_M pin-12 135A RL SHEET 30
11 CN.A33_M pin-1 701A B - 1.25 SHEET 29
12 CN.A33_M pin-2 701B B - 1.25
14 SP-813 pin-X 813 OG SHEET 05
15 CN.A56 pin 8 815 VG - 0.85
17 CN.A33_M pin-4 701D B - 1.25 SHEET 29
18 CN.A34_M pin-1 601A BG - 1.25
19 CN.A34_M pin-2 601B BG - 1.25
20 SP-155A pin-X 155A GR - 1.25 SHEET 04
21 CN.A35_M pin-13 135B RL SHEET 30
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CONNECTOR CN.A6 – ECM RELAY 1 (5-PIN) (Male)
SMIL14CEX5242AA 11
SMIL14CEX5243AA 12

1 CN.A53 pin 3 370C YR - 0.85 SHEET 12
2 CN.A37_M pin-1 703 B - 0.85 SHEET 29
3 F61 pin-2 125 RW - 1.25 SHEET 04
5 SP-126D pin-X 126J W - 1.25 SHEET 31
CONNECTOR CN.A7 – STARTER CUT RELAY 2 (5-PIN) (Male)
SMIL14CEX5244AA 13
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SMIL14CEX5245AA 14

1 SP-126D pin-X 126D W - 1.25 SHEET 31
2 CN.A53 pin 4 373-A LR - 0.85 SHEET 12
3 SP-011A pin-X 011A Y - 0.85 SHEET 31
4 CN.A52pin 5 012B GrR - 0.85 SHEET 07
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CONNECTOR CN.A8 – NEUTRAL START RELAY 3 (5-PIN) (Male)
SMIL14CEX5246AA 15
SMIL14CEX5247AA 16

1 SP-845A pin-X 845E GR - 0.85 SHEET 31
2 CN.A37_M pin-2 704 B - 0.85 SHEET 29
3 CN.A42 pin5 010 BrR - 0.85 SHEET 05
4 SP-011A pin-X 011C Y SHEET 31
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CONNECTOR CN.A9 – ACC1 RELAY 4 (5-PIN) (Male)
SMIL14CEX5248AA 17
SMIL14CEX5249AA 18

1 CN.A42 pin 2 290 RB - 0.85 SHEET 05
2 CN.A37_M pin-4 706 B SHEET 29
3 SP-115B pin-X 115 RW SHEET 32
5 CN.A10 pin 3 116 RY
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CONNECTOR CN.B1 – STARTER SWITCH (6-PIN) (Male)
SMIL14CEX5274AA 19
SMIL14CEX5275AA 20

1 CN.A42_M pin-5 010A BrR - 0.85 SHEET 05
3 CN.A42_M pin-2 290A RB - 0.85
4 CN.A42_M pin-1 110A R - 0.85 SHEET 37
6 CN.A42_M pin-4 500A LgR - 0.85 SHEET 05
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CONNECTOR CN.B2 – ENGINE THROTTLE SWITCH (3-PIN) (Male)
SMIL14CEX5272AA 21
SMIL14CEX5273AA 22

1 CN.A44_M pin-7 430B-5 W - 0.85 SHEET 28
2 CN.A44_M pin-8 416A RW - 0.85
3 CN.A44_M pin-9 440K BL - 0.85
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CONNECTOR CN.B3 – GATE LIMIT SWITCH (2-PIN) (Female)
SMIL14CEX5279AA 23
SMIL14CEX5280AA 24

1 CN.A42_M pin-3 150 VW - 0.85 SHEET 04
2 SP-840A pin-X 840I RY - 0.85 SHEET 37
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CONNECTOR CN.B4 – DIODE SWITCH (2-PIN) (Male)
SMIL14CEX6482AA 25

1 CN.A42_M pin-7 845D GR - 0.85 SHEET 05
2 SP-840A pin-X 840A-1 RY - 0.85 SHEET 37
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CONNECTOR CN.B05 – KNOB SWITCH 1 (8-PIN) (Female)
SMIL14CEX5926AA 26
SMIL14CEX5925AA 27

1 CN.B19 pin 6 852D OR - 0.85 SHEET 22
2 SP-726 pin-X 724 O - 0.85 SHEET 24
3 CN.B19 pin 5 850C GR - 0.85 SHEET 22
4 CN.A43 pin 2 594 YG - 0.85 SHEET 08
5 SP-622 pin-X 621A BG - 0.85 SHEET 24
6 CN.A43 pin 1 531A LR - 0.85 SHEET 08
7 SP-622 pin-X 622A BG - 0.85 SHEET 24
8 SP-725 pin-X 725A B - 0.85
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CONNECTOR CN.B06 – KNOB -RIGHT PROPORTIONAL LEVER (Female)
SMIL14CEX5930AA 28
SMIL14CEX5929AA 29

1 DEV301 pin-PIN11 230E R - 0.85 SHEET 24
2 DEV301 pin-PIN12 953B Br - 0.85
3 DEV301 pin-PIN13 954B W - 0.85
4 DEV301 pin-PIN14 955C G - 0.85
6 DEV301 pin-PIN15 726A B - 0.85
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CONNECTOR CN.B07 – KNOB 1 (8-PIN) (Female)
SMIL14CEX5928AA 30
SMIL14CEX5927AA 31

1 DEV293 pin-IN 856 O - 0.85 SHEET 25
2 DEV293 pin-OUT 720 O - 0.85
3 DEV294 pin-IN 854F G - 0.85
4 S69 pin-IN 591B O - 0.85
5 S69 pin-OUT 620-1 B - 0.85
6 S15 pin-IN 841B Gr - 0.85
7 S15 pin-OUT 721A L - 0.85
8 DEV294 pin-OUT 722B G - 0.85
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CONNECTOR CN.B8 – FOR PROPORTIONAL LEVER (16–PIN (Female)
SMIL14CEX5932AA 32
SMIL14CEX5931AA 33

1 DEV301 pin-PIN11 230D R - 0.85 SHEET 05
2 DEV301 pin-PIN12 956C Br - 0.85
3 DEV301 pin-PIN13 957C W - 0.85
4 DEV301 pin-PIN14 958D G - 0.85
6 DEV301 pin-PIN15 723A B - 0.85
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CONNECTOR CN.B09 – EMERGENCY STOP SWITCH (NO TAPE) (10-PIN) (Male)
SMIL14CEX5308AA 34
SMIL14CEX5307AA 35

2 CN.A44_M pin-5 302B LG - 0.85 SHEET 38
3 CN.A44_M pin-4 126C W - 1.25 SHEET 26
5 SP-623A pin-X 623A BG - 0.85 SHEET 05
6 CN.A44_M pin-6 535A LB - 0.85 SHEET 09
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CONNECTOR MONITOR DISPLAY – (20-PIN) (Male)
SMIL14CEX6484AA 36

1 CN.C3_M pin-1 130B RL - 0.85 SHEET 34
2 CN.C3_M pin-2 140B W - 1.25
3 CN.C3_M pin-3 097A V
4 CN.C3_M pin-4 516 BrW - 0.85
5 CN.C3_M pin-5 C01H P
6 CN.C3_M pin-6 C01L PG
7 CN.C3_M pin-7 099A G
8 CN.C3_M pin-8 070A WL
9 CN.C3_M pin-9 071A W
10 CN.C3_M pin-10 960A R
11 CN.C3_M pin-11 961A B
12 CN.C3_M pin-12 098A VG
15 CN.C3_M pin-15 611 BG - 1.25
19 CN.C3_M pin-19 072A BL
20 CN.C3_M pin-20 610D BG - 1.25
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CONNECTOR CN.C2 – MONITOR DISPLAY (20-PIN) (Female) (Male)
SMIL14CEX6483AA 37
82003121 38
82003121
1 CN.C4_M pin-1 962A Y SHEET 34
2 CN.C4_M pin-2 967 YB
3 CN.C4_M pin-3 972 YR
4 CN.C4_M pin-4 590 O
5 CN.C4_M pin-5 591C YL
6 CN.C4_M pin-6 592 V
7 CN.C4_M pin-7 593 OL
8 CN.C4_M pin-8 594C YG
9 CN.C4_M pin-9 595 VR
10 CN.C4_M pin-10 596 Br
11 CN.C4_M pin-12 963A W
12 CN.C4_M pin-13 968 WB
13 CN.C4_M pin-14 973 WR
14 CN.C4_M pin-15 820 GR
15 CN.C4_M pin-16 821 Lg
16 CN.C4_M pin-17 822A VG
17 CN.C4_M pin-18 823 WG
18 CN.C4_M pin-19 824 LY
19 CN.C4_M pin-20 825 LG
20 CN.C4_M pin-21 826 OR
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CONNECTOR CN.C3 – MONITOR DISPLAY (20-PIN) (Female) (Female)
SMIL14CEX5196AA 39

1 CN.A40 pin 1 130A RL - 0.85 SHEET 34
2 CN.A40 pin 2 140A W - 1.25
3 CN.C21_M pin-1 097 V
4 CN.A40 pin 3 516A BrW - 0.85
5 CN.A40 pin 4 CH2 P
6 CN.A40 pin 5 CL2 PG
7 CN.C21_M pin-3 099 G
8 CN.A40 pin 9 070 WL
9 CN.A40 pin 10 071 W
10 CN.C20 pin 1 970 R - 0.75 SHEET 28
10 CN.C18 pin 1 960 R - 0.75
10 CN.C19 pin 1 965 R - 0.75
11 CN.C18 pin 2 961 B - 0.75
11 CN.C20 pin 2 971 B - 0.75
11 CN.C19 pin 2 966 B - 0.75
12 CN.C21_M pin-2 098 VG SHEET 34
15 SP-610 pin-X 611A BG - 1.25
19 CN.C40 pin 11 072 BL
20 SP-610 pin-X 610C BG - 1.25
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CONNECTOR CN.C4 – CN.C04 (22-PIN)
SMIL14CEX5197AA 40

1 CN.C18 pin 3 962B Y- 0.00 SHEET 28
2 CN.C19 pin 3 967A YB- 0.00
3 CN.C20 pin 3 972A YR- 0.00
4 CN.C11 pin 6 590A A- 0.00
5 CN.A43 pin 4 591A YL- 0.00
6 CN.A41 pin 13 592A YR- 0.00
7 CN.C9 pin 2 593A OL- 0.00 SHEET 36
8 CN.A43 pin 2 594A YG- 0.00
9 CN.C12 pin 1 596A Br- 0.85 SHEET 35
10 CN.C12 pin 3 595A VR - 0.85
11 CN.A40 pin 12 949B WB- 0.00 SHEET 34
12 CN.C18 pin 4 963B W- 0.00 SHEET 28
13 CN.C19 pin 4 968A WB- 0.00
14 CN.C20 pin 4 973A WR- 0.00
15 CN.C6 pin 11 820A GR- 0.00 SHEET 35
16 CN.C6 pin 12 821A Lg- 0.00 SHEET 34
17 CN.C6 pin 13 822B VG- 0.00 SHEET 35
18 CN.A41 pin 7 823A WG- 0.00 SHEET 15
19 CN.A41 pin 8 824A LY- 0.00
20 CN.A41 pin 9 825A LG- 0.00
21 CN.A41 pin 10 826A OR- 0.00
22 CN.A40 pin 13 950B BW- 0.00 SHEET 34
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CONNECTOR CN.C5 – SUNLOAD SENSOR (2-PIN) (Male)
SMIL14CEX6485AA 41

1 CN.C4_M pin-11 949C WB SHEET 34
2 CN.C4_M pin-22 950A BW
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CONNECTOR CN.C6 – WIPER CONTROLLER (13-PIN) (Male)
SMIL14CEX5198AA 42

1 CN.A41 pin 1 190A BrR - 0.85 SHEET 03
2 CN.A41 pin 4 829 WY - 0.85 SHEET 15
5 CN.C7 pin 1 827 LR - 0.85 SHEET 35
6 CN.C7 pin 3 828 LB - 0.85
7 CN.C7 pin 4 485 G - 0.85
8 CN.C7 pin 6 486 L - 0.85
10 SP-710A pin-X 710 B - 1.25
11 CN.C4 pin 15 820A GR SHEET 34
12 CN.C4 pin 16 821A Lg
13 CN.C4 pin 17 822B VG
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CONNECTOR CN.C7 – WIPER MOTOR (6-PIN) (Male)
SMIL14CEX5199AA 43

1 CN.C6 pin 5 827 LR - 0.85 SHEET 35
3 CN.C6 pin 6 828 LB - 0.85
4 CN.C6 pin 7 485 G - 0.85
5 SP-711 pin-X 711 B - 1.25
6 CN.C6 pin 8 486 L - 0.85
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CONNECTOR CN.C8 – CAB LAMP (2-PIN) (Female)
SMIL14CEX5200AA 44

1 CN.C22 pin 2 888B G SHEET 36
2 CN.C22 pin 1 843 Y
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CONNECTOR CN.C9 – DOOR LIMIT SWITCH (4-PIN) (Female)
SMIL14CEX5201AA 45

1 CN.C23 pin 3 613 BG SHEET 36
2 CN.C23 pin 1 593-B OL
4 CN.C23 pin 2 843B Y
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CONNECTOR CN.D1-2 – DCU 1 (23-PIN) (Male)
SMIL14CEX5881AA 46

108 CN.D19 pin 1 578 W - 1.25 SHEET 19
112 CN.D17 pin 6 581A BY - 0.75 SHEET 15
117 CN.D18 pin 3 577 Gr - 0.85
118 CN.D18 pin 4 575 BW - 0.85
119 CN.D18 pin 2 576 WG - 0.85
124 CN.D18 pin 10 572 LR - 0.85
126 CN.D18 pin 8 571 B - 1.25
132 CN.D17 pin 5 580A Y - 0.75
133 CN.D17 pin 7 582 L - 0.75
134 CN.D17 pin 8 583 GB - 0.75
146 CN.D18 pin 9 570 R - 1.25
165 CN.D18 pin 12 574 LB - 1.25
185 CN.D19 pin 2 579 RB - 1.25 SHEET 19
186 CN.D18 pin 11 573 YR - 1.25 SHEET 15
201 SP-785A pin-X 785 B - 2.0
203 SP-785A pin-X 785A B - 2.0
204 SP-785B pin-X 785B B - 2.0
207 SP-105A pin-X 105 R - 2.0
209 SP-105A pin-X 105A R - 2.0
211 SP-AH3 pin-X AH3 Y SHEET 12
212 SP-AL3 pin-X AL3 YG
214 SP-DH1 pin-X DH1 W - 0.75 SHEET 15
215 SP-DL1 pin-X DL1 WG - 0.75
246 CN.D1-2 pin 247 DH0 W - 0.75
247 CN.D1-2 pin 246 DH0 W - 0.75
248 CN.D1-2 pin 249 DL0 WG - 0.75
249 CN.D1-2 pin 248 DL0 WG - 0.75
252 SP-501 pin-X 501Q G - 0.85
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CONNECTOR CN.D3 – ECM 1 (91-PIN) (Male)
SMIL14CEX5385AA 47
SMIL14CEX5384AA 48

V1 SP-126A pin-X 126I W - 1.25 SHEET 12
V2 SP-780A pin-X 780C B - 1.25
V3 SP-126A pin-X 126A W - 1.25
V4 SP-780A pin-X 780A B - 1.25
V5 SP-126 pin-X 126B W - 1.25
V6 SP-780B pin-X 780B B - 1.25
V7 CN.A53_M pin-12 080 PL
V11 SP-347B pin-X 347 G - 0.75 SHEET 13
V16 CN.D17 pin 13 334 WB - 0.75
V17 CN.D17 pin 14 335 GW - 0.75
V18 CN.D17 pin 15 346 RW - 0.75
V19 CN.D17 pin 11 348 R - 0.75
V21 CN.D22 pin 1 308 Y - 0.75
V29 CN.D21 pin 2 350 BrR
V35 CN.D17 pin 12 349 BW - 0.75
V36 CN.D21 pin 4 339 GY
V37 CN.D21 pin 5 337 WG
V40 SP-370A pin-X 370 YR - 0.85 SHEET 12
V41 SP-680A pin-X 680C BG - 0.85
V42 SP-680A pin-X 680A BG - 0.85
V44 CN.A53_M pin-11 082 PB SHEET 13
V49 CN.A53_M pin-14 805 BrY
V50 CN.A53_M pin-6 302 LG - 0.85
V57 SP-370A pin-X 370A YR - 0.85 SHEET 12
V60 CN.A53_M pin-9 BH0-A L
V64 SP-AH2 pin-X AH2-C Y - 0.75
V74 CN.A53_M pin-4 373 LR - 0.85
V75 SP-680B pin-X 680B BG - 0.85
V76 SP-501M pin-X 501M G - 0.85 SHEET 09
V77 CN.A53_M pin-10 BL0-D BY SHEET 12
V81 SP-AL1 pin-X AL2-B YG - 0.75
V82 CN.A53_M pin-5 011 Y - 0.85
V88 CN.D21 pin 3 338 LW SHEET 13
V91 CN.D88 pin 2 372 L - 0.85 SHEET 12
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CONNECTOR CN.D4 – ECM 2 (105-PIN) (Male)
SMIL14CEX5913AA 49
SMIL14CEX5964AA 50

E1 CN.D10 pin 3 383A RL - 1.25 SHEET 14
E2 CN.D10 pin 2 379-A RL - 1.25
E3 CN.D10 pin 9 381-A BW - 1.25
E4 CN.D10 pin 4 377-A L - 1.25
E11 CN.D7_M pin-24 320 GW - 0.75 SHEET 13
E11 CN.D9 pin 13 393 GR - 0.75
E12 CN.D7_M pin-10 314 L - 0.75
E12 CN.D7_M pin-9 344 BR - 0.75
E14 CN.D8 pin 12 304 L - 0.75
E15 CN.D8 pin 9 306 P - 0.75
E17 CN.D7_M pin-25 323 YB - 0.75
E18 CN.D7_M pin-7 300 Y - 0.75 SHEET 14
E20 CN.D7_M pin-31 342 YG - 0.75
E23 CN.D10 pin 5 374-A B - 1.25
E24 CN.D10 pin 6 378-B RB - 1.25
E25 CN.D10 pin 7 382-A L - 1.25
E26 SP-352A pin-X 352C Y - 0.75 SHEET 13
E39 CN.D7_M pin-3 340 RW - 0.75 SHEET 14
E42 SP-396A pin-X 396A RW - 0.75
E43 CN.D10 pin 1 375-A W - 1.25
E44 CN.D10 pin 8 376-A Y - 1.25
E45 CN.D10 pin 13 380-B B - 1.25
E46 CN.D10 pin14 384-A W - 1.25
E49 SP-318A pin-X 318 G - 0.75
E50 SP-327O pin-X 327 G - 0.75 SHEET 13
E50 SP-325A pin-X 325 RW - 0.75
E53 CN.D7_M pin-15 312 G - 0.75
E53 CN.D8 pin 1 353 GB - 0.75
E54 CN.D8 pin 2 354 W - 0.75
E55 CN.D8 pin 3 355 GR - 0.75
E59 CN.D7_M pin-1 310 W - 0.75
E59 SP-356 pin-X 356 RG - 0.75
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E63 SP-396A pin-X 396 RW - 0.75 SHEET 14
E69 SP-316A pin-X 316 R - 0.75
E71 SP-692A pin-X 692A BL - 0.85
E74 SP-690A pin-X 690A B - 0.85 SHEET 13
E78 CN.D7_M pin-6 311 R - 0.75
E84 SP-394A pin-X 394A RG - 0.75 SHEET 13
E85 CN.D10 pin 10 385-A RB - 1.25
E91 CN.D8 pin 7 388 WL - 0.75 SHEET 13
E91 SP-691A pin-X 691A BW - 0.85
E92 CN.D9 pin 11 326 P - 0.75
E92 CN.D8 pin 6 387 WB - 0.75
E93 CN.D8 pin 5 386 WR - 0.75
E93 CN.D9 pin 12 392 B - 0.75
E99 CN.D10 pin 18 317A L - 0.75 SHEET 14
E105 SP-394A pin-X 394 RG - 0.75
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CONNECTOR CN.D8 – ENGINE HARNESS B (16-PIN) (Female)
SMIL14CEX6486AA 51
SMIL14CEX5967AA 52

1 CN.D4 pin E53 353 GB - 0.75 SHEET 14
2 CN.D4 pin E54 354 W - 0.75
3 CN.D4 pin E55 355 GR - 0.75
4 SP-352A pin-X 352 Y - 0.75
5 CN.D4 pin E93 386 WR - 0.75
6 CN.D4 pin E92 387 WB - 0.75
7 CN.D4 pin E91 388 WL - 0.75
8 SP-356B pin-X 356-B RG - 0.75
9 CN.D4 pin E15 306 P - 0.75
10 SP-327D pin-X 327D G - 0.75
11 SP-327D pin-X 327E G - 0.75
12 CN.D4 pin E14 304 L - 0.75
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CONNECTOR CN.E1 – NVGS TURBO & C/UNIT (7-PIN) (Male)
SMIL14CEX5900AA 53

2 CN.D9_M pin-2 789A YR - 0.75 SHEET 20
3 CN.D9_M pin-3 126C-1 LR - 0.75
6 CN.D9_M pin-6 BrL
7 CN.D9_M pin-7 L
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CONNECTOR CN.E2 – INTAKE THROTTLE DC-MOTOR (5-PIN)
SMIL14CEX5901AA 54

2 CN.D9_M pin-2 392 BL 0.75 BL SHEET 20
1 CN.D9_M pin-1 393 G 0.75 G
5 CN.D9_M pin-5 325 L 0.75 L
3 CN.D9_M pin-3 326 VW 0.75 VW
4 CN.D9_M pin-34 327 LW 0.75 LW
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CONNECTOR CN.E3 – EGR VALVE (8-PIN)
SMIL14CEX5914AA 55

1 CN.D8_M pin-1 353A 0.75 GB SHEET 14
2 CN.D8_M pin-2 354A 0.75 GW
3 CN.D8_M pin-3 355A 0.75 GY
4 CN.D8_M pin-4 352B 0.75 L
5 CN.D8_M pin-5 386 O.75WR
6 CN.D8_M pin-6 387A 0.75WB
7 CN.D7_M pin-7 388A 0.75WL
8 CN.D9_M pin-8 356C 0.75RG
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CONNECTOR CN.E4 – CRANK ANG(MRE) SENSOR (3-PIN)
SMIL14CEX5902AA 56

1 CN.D7_M pin-5 310A O.75VW SHEET 13
2 CN.D7_M pin-6 311A 0.75GrB
3 CN.D7_M pin-7 312A 0.75WB
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CONNECTOR CN.E5 – COMMON RAIL PRESS SENSOR (3-PIN) (Male)
SMIL14CEX5903AA 57

1 CN.D7_M pin-5 316D L - 0.75 SHEET 14
2 CN.D7_M pin-10 LW
3 CN.D7_M pin-7 318D Br - 0.75
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CONNECTOR CN.E7 – OIL PRESS SENSOR (3-PIN) (Male)
SMIL14CEX5904AA 58

1 CN.D7_M pin-30 352D WB - 0.75 SHEET 14
2 CN.D7_M pin-25 323A LY - 0.75
3 CN.D7_M pin-6 356B BY - 0.75 SHEET 18
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CONNECTOR CN.E8 – FUEL TEMP. SENSOR (2-PIN) (Male)
SMIL14CEX5907AA 59

1 CN.D7_M pin-31 342A YG - 0.75 SHEET 14
2 CN.D7_M pin-13 356A LW - 0.75
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CONNECTOR CN.F1 – RELAY COMPRESSOR (4-PIN) (Male)
SMIL14CEX6488AA 60

1 SP-180A pin-X 180D LR - 0.85 SHEET 26
2 SP-180A pin-X 180A LR - 0.85
3 CN.B16 pin-4 943B GW - 0.85
4 CN.B17 pin-1 942A BrW
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CONNECTOR CN.F2 – RELAY BLOWER OFF (4-PIN) (Male)
SMIL14CEX6489AA 61

1 CN.B16 pin-1 175B WR - 2.0 SHEET 26
2 CN.B16 pin-3 170D VR
3 CN.F3 pin-1 937 LR - 2.0
4 CN.B17 pin-2 936A VW
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CONNECTOR CN.F3 – BLOWER MOTOR (2-PIN) (Male)
SMIL14CEX6490AA 62

1 CN.F2 pin-3 937 LR - 2.0 SHEET 26
2 SP-938 pin-X 939B RL - 2.0
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CONNECTOR CN.F4 – BLOWER AMP (3-PIN) (Male)
SMIL14CEX5935AA 63

1 CN.B16 pin-6 732 B SHEET 26
2 CN.B17 pin-3 940A BrY
3 SP-938 pin-X 938 RL - 2.0
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CONNECTOR CN.F5 – TEMP. SENSOR (RECIRCULATE) (2-PIN) (Male)
SMIL14CEX6492AA 64

1 CN.B17 pin-8 945A Sb SHEET 26
2 SP-948 pin-X 946C BW
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CONNECTOR CN.F6 – TEMP. SENSOR (EVAPORATOR) (2-PIN) (Male)
SMIL14CEX6493AA 65

1 CN.B17 pin-9 947A L SHEET 26
2 SP-948 pin-X 948 BW
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CONNECTOR CN.F7 – MOTOR ACTUATOR (AIR MIX) (7-PIN) (Male)
SMIL14CEX5937AA 66

2 SP-926 pin-X 926B LY SHEET 27
3 CN.B17 pin-19 929A GL SHEET 26
4 SP-932 pin-X 932B BL SHEET 27
6 CN.B17 pin-12 921A GW SHEET 26
7 CN.B17 pin-11 920A GR
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CONNECTOR CN.F8 – MOTOR ACTUATOR (MODE) (7-PIN) (Male)
SMIL14CEX5938AA 67

2 SP-927 pin-X 927 LY SHEET 27
3 CN.B17 pin-20 930A YL SHEET 27
4 SP-933 pin-X 933 BL SHEET 27
6 CN.B17 pin-14 923A YW SHEET 26
7 CN.B17 pin-13 922A YR
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CONNECTOR CN.F9 – MOTOR ACTUATOR (FRESH/RECIRCULATE) (7-PIN) (Male)
SMIL14CEX5939AA 68

2 SP-927 pin-X 928 LY SHEET 26
3 CN.B17 pin-21 931A LG
4 SP-933 pin-X 934 BL
6 CN.B17 pin-16 925A LW
7 CN.B17 pin-15 924A LR
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CONNECTOR CN.G1 – 1ST OPTION ( PEDAL + SOLENOID + PROPORTIONAL SOLENOID ) (2-PIN) (Male)
SMIL14CEX5959AA 69

1 CN.D24 pin-1 435-F WB - 0.85 SHEET 22
2 CN.D24 pin-3 415B WL - 0.85
3 CN.D24 pin-4 445-F BW - 0.85
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CONNECTOR CN.G2 – 1ST OPTION ( PEDAL + SOLENOID + PROPORTIONAL SOLENOID ) (2-PIN)
SMIL14CEX5381AA 70

1 CN.B19 pin-3 808A GW - 0.00 SHEET 22
2 SP 730A pin-X 730B B - 0.00
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CONNECTOR CN.G4 – 2ND OPT ( PEDAL+ SOL. + PROPORTIONAL SOL. ) (8-PIN) (Female)
SMIL14CEX5944AA 71

1 CN.B19_M pin-1 230A-4 W - 0.85 SHEET 22
2 CN.B19_M pin-13 956 RG - 0.85
3 CN.B19_M pin-14 957 RW - 0.85
4 CN.B19_M pin-15 958 BY - 0.85
5 CN.B19_M pin-7 854 G - 0.85
6 CN.B19_M pin-8 856B O - 0.85
7 CN.D24 pin-5 539D GY - 0.85
8 CN.D24 pin-8 653 BG - 0.85
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CONNECTOR CN.G7 – SOLENOID VALVE (2-PIN) (Female)
SMIL14CEX5365AA 72

1 CN.B19_M pin-1 230 W 0.85 SHEET 22
2 CN.B19_M pin-5 850 G0.85
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CONNECTOR CN.G8 – SOLENOID VALVE (2-PIN) (Female)
SMIL14CEX5366AA 73

1 CN.B19_M pin-1 230 W 0.85 SHEET 22
2 CN.B19_M pin-6 852 0 0.85
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CONNECTOR CN.G9 – PROPORTIONAL SOLENOID (2-PIN) (Female)
SMIL14CEX5945AA 74

1 CN.B19_M pin-9 953 RL 0.85 SHEET 22
2 CN.B19_M pin-11 954 BW 0.85
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CONNECTOR CN.A10 – ACC2 RELAY (5-PIN) (Female)
SMIL14CEX5250AA 1
SMIL14CEX5251AA 2

1 SP-811B pin X 811B LY SHEET 32
2 CN.A37_M pin 5 707 B SHEET 29
3 CN.A9 pin 5 116 RY SHEET 32
4 SP-117A pin X 117D R
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CONNECTOR CN.A11 – KEY ON RELAY (5-PIN) (Female)
SMIL14CEX5252AA 3
SMIL14CEX5253AA 4

1 SP-811B pin X 811-1 LY SHEET 32
2 CN.A37_M pin 3 705 B SHEET 29
3 CN.A42 pin 4 500 LgR - 0.85 SHEET 05
4 SP-501F pin X 501I G - 0.85 SHEET 32
5 SP-811B pin X 811A LY
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CONNECTOR CN.A12 – ROOM LAMP RELAY (5-PIN) (Female)
SMIL14CEX5254AA 5
SMIL14CEX5255AA 6

1 SP-115B pin X 115B RW SHEET 32
2 CN.A41_M pin 10 826B OR SHEET 15
3 CN.A41_M pin 11 888 G
4 SP-117A pin X 117A R SHEET 32
5 SP-115A pin X 115A RW
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CONNECTOR CN.A13 – CAB LAMP RELAY (5-PIN) (Female)
SMIL14CEX5256AA 7
SMIL14CEX5257AA 8

1 SP-205A pin X 205A GrR - 1.25 SHEET 31
2 SP-823A pin X 823D WG
3 SP-205A pin X 205 GrR - 1.25
5 CN.A41_M pin 5 875 GR - 1.25 SHEET 15
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CONNECTOR CN.A14 – BEACON RELAY (5-PIN) (Female)
SMIL14CEX5258AA 9
SMIL14CEX5259AA 10

1 SP-200A pin X 200A GW SHEET 31
2 SP-842A pin X 842C LG SHEET 09
3 SP-200A pin X 200 GW SHEET 31
5 CN.A51_M pin 5 885 R SHEET 30
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CONNECTOR CN.A15 – UPPER LAMP RELAY (5-PIN) (Female)
SMIL14CEX5260AA 11
SMIL14CEX5261AA 12

1 SP-210A pin X 210A LW - 1.25 SHEET 30
2 SP-823A pin X 823C WG
3 SP-210A pin X 210B LW - 1.25
5 CN.A51_M pin 4 870 Y - 1.25
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CONNECTOR CN.A16 – SPEAKER (LEFT) (5-PIN) (Female)
SMIL14CEX5262AA 13
SMIL14CEX5263AA 14

1 SP-185C pin X 185D LW SHEET 31
2 SP-825A pin X 825C LG
3 CN.A45_M pin 11 981B L - 0.85 SHEET 09
4 CN.A41_M pin 16 985 LB - 0.85 SHEET 15
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CONNECTOR CN.A17 – SPEAKER (RIGHT) RELAY (5-PIN) (Female)
SMIL14CEX5264AA 15
SMIL14CEX5265AA 16

1 SP-185C pin X 185C LW SHEET 31
2 SP-825A pin X 825D LG
3 CN.A45_M pin 10 980B Y - 0.85 SHEET 08
4 CN.A41_M pin 15 984 YB - 0.85 SHEET 31
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CONNECTOR CN.A18 – HORN RELAY (5-PIN) (Female)
SMIL14CEX5266AA 17
SMIL14CEX5267AA 18

1 SP-165A pin X 165A LgW SHEET 31
2 CN.A43_M pin 3 841 LW SHEET 09
3 SP-165A pin X 165B LgW SHEET 31
5 SP-880A pin X 880 LR
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CONNECTOR CN.A19 – EST CONNECTOR B (12-PIN) (Male)
SMIL14CEX6494AA 19
SMIL14CEX6505AA 20

1 SP-BH0 pin X BH5 L SHEET 08
2 CN.A36_M pin 16 631 BG SHEET 30
3 SP-BL0 pin X BL5 LG SHEET 08
4 CN.A4_M pin 27 063 GR
7 CN.A4_M pin 11 060 R SHEET 07
8 CN.A4_M pin 20 066 LW
9 CN.A4_M pin 10 064 YL
10 CN.A4_M pin 21 065 GW
11 CN.A4_M pin 22 062 BR
12 CN.A4_M pin 12 061 RL
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CONNECTOR CN.B10– FAN REVERSE SWITCH (10-PIN) (Female)
SMIL14CEX5310AA 21
SMIL14CEX5309AA 22

2 SP-624 pin X 624 BG - 0.85 SHEET 05
3 CN.A45_M pin 6 540A YL - 0.85 SHEET 09
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CONNECTOR CN.B11 – OVERLOAD SWITCH (10-PIN) (Female)
SMIL14CEX5302AA 23
SMIL14CEX5301AA 24

2 SP-625A pin X 625A BG - 0.85 SHEET 05
3 CN.A45_M pin 3 536A GR - 0.85 SHEET 09
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CONNECTOR CN.B12 – BEACON SWITCH (10-PIN) (Female)
SMIL14CEX5304AA 25
SMIL14CEX5303AA 26

2 SP-727 pin X 727 B - 0.85 SHEET 05
3 CN.A45_M pin 9 842 LG - 0.85 SHEET 09
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CONNECTOR CN.B13 – TRAVEL ALARM SWITCH (10-PIN) (Female)
SMIL14CEX5306AA 27
SMIL14CEX5305AA 28

2 SP-625A pin X 628 BG - 0.85 SHEET 05
3 CN.A45_M pin 4 538A WG - 0.85 SHEET 09
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CONNECTOR CN.B14 – AIR CONDITIONER PANEL A (20-PIN) (Female)
SMIL14CEX6495AA 29
SMIL14CEX5973AA 30

1 SP-170 pin X 170A VR SHEET 04
2 CN.B17_M pin 16 925 LW
3 CN.B17_M pin 15 924 LR
4 CN.B17_M pin 14 923 YW
5 CN.B17_M pin 13 922 YR
6 CN.B17_M pin 12 921 GW
7 CN.B17_M pin 11 920 GR
11 SP-732 pin X 733 B
12 SP-950 pin X 946 BW
13 CN.B17_M pin 22 932 BL
15 CN.B17_M pin 18 926 LY
16 CN.A44_M pin 12 949 WB
18 CN.B17_M pin 9 947 L
19 CN.B17_M pin 8 945 Sb
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CONNECTOR CN.B15 – AIR CONDITIONER PANEL B (16-PIN) (Female)
SMIL14CEX6496AA 31
SMIL14CEX5974AA 32

1 CN.B17_M pin 4 939 RL SHEET 26
2 CN.B17_M pin 21 931 LG
3 CN.B17_M pin 20 930 YL
4 CN.B17_M pin 19 929 GL
6 CN.A44_M pin 11 CL3A PG
7 CN.A44_M pin 10 CH3 P
14 CN.B17_M pin 3 940 BrY
15 CN.B17_M pin 1 942 BrW
16 CN.B17_M pin 2 936 VW
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CONNECTOR CN.B16 – AIR CONDITIONER UNIT A (6-PIN) (Female)
SMIL14CEX5934AA 33
SMIL14CEX5933AA 34

1 CN.F2 pin 1 175B WR - 2.0 SHEET 26
2 SP-180A pin X 180C LR - 0.85
3 CN.F2 pin 2 170D VR
4 CN.F1 pin 3 943B GW - 0.85
6 CN.F4 pin 1 732 B
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CONNECTOR CN.B17 – AIR CONDITIONER UNIT B (22-PIN) (Female)
SMIL14CEX5326AA 35
SMIL14CEX5325AA 36

1 CN.F1 pin 4 942A BrW SHEET 26
2 CN.F2 pin 4 936A VW
3 CN.F4 pin 2 940A BrY
4 SP-938 pin X 939A RL
8 CN.F5 pin 1 945A Sb
9 CN.F6 pin 1 947A L
10 SP-948 pin X 946B BW
11 CN.F7 pin 7 920A GR
12 CN.F7 pin 6 921A GW
13 CN.F8 pin 7 922A YR
14 CN.F8 pin 6 923A YW
15 CN.F9 pin 7 924A LR
16 CN.F9 pin 6 925A LW
18 SP-926 pin X 926A LY
19 CN.F7 pin 3 929A GL
20 CN.F8 pin 3 930A YL
21 CN.F9 pin 3 931A LG
22 SP-932 pin X 932A BL
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CONNECTOR CN.B18 – RADIO (9-PIN) (Female)
SMIL14CEX6131AA 37
SMIL14CEX5300AA 38

2 P15 pin PIN10 117 ACC R SHEET 32
3 P15 pin PIN11 980 R(+) GrR - 0.85
4 P15 pin PIN12 981 L(+) GR - 0.85
6 P15 pin PIN13 135H BACK UP OW
7 P15 pin PIN14 731 GND B - 1.25
8 P15 pin PIN15 982 R(-) Gr
9 P15 pin PIN16 983 L(-) G - 0.85
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CONNECTOR CN.B19 – OPTION HARNESS (16-PIN) (Male)
SMIL14CEX6497AA 39
SMIL14CEX6132AA 40

2 CN.A43_M pin 6 809A V SHEET 05
3 CN.A43_M pin 5 808A-1 GW
4 CN.A45_M pin 5 544A LY - 0.85 SHEET 09
5 CN.B5_M pin 3 850C GR - 0.85 SHEET 22
6 CN.B5_M pin 1 852D OR - 0.85
7 CN.B7_M pin 3 854E G - 0.85
8 CN.B7_M pin 1 856F O - 0.85
9 CN.B6_M pin 2 953A RL - 0.85
10 CN.B6_M pin 3 954A RY - 0.85
11 CN.B6_M pin 4 955B BW - 0.85
13 CN.B8_M pin 2 956B RG - 0.85
14 CN.B8_M pin 3 957B RW - 0.85
15 CN.B8_M pin 4 958C BY - 0.85
16 SP-730 pin X 730 B - 0.85 SHEET 05
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CONNECTOR CN.C10 – SPEAKER (4-PIN) (Female)
SMIL14CEX5202AA 41

1 CN.C24 pin 2 984B YR SHEET 36
2 CN.C25 pin 2 985B LR
3 CN.C24 pin 1 982B BL - 0.85
4 CN.C25 pin 1 983C BL - 0.85
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CONNECTOR CN.C11 – LIMIT SWITCH WINDOW (6-PIN) (Female)
SMIL14CEX5203AA 42

1 SP-876 pin X 875C GR - 1.25 SHEET 36
3 CN.C31F pin 1 614D BG
4 SP-714 pin X 714C B - 1.25
6 CN.A30M pin 1 590-B O
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CONNECTOR CN.C12 – CRANE SWITCH (10-PIN) (Male)
SMIL14CEX6432AA 43

1 CN.C4 pin 9 596-A Br - 0.85 SHEET 34
2 SP-616 pin X 615 BG - 0.85 SHEET 35
3 CN.C4 pin 10 595-A VR - 0.85 SHEET 34
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CONNECTOR CN.C12-A – HORN SELECT (10-PIN) (Male)

1 CN.A40 pin 8 881 YR - 0.85 SHEET 10
2 CN.A40 pin 7 880E LR - 0.85
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CONNECTOR CN.C12-B – QUICK COUPLER (10-PIN) (Male)

2 SP-616 pin X 616 BG - 0.85 SHEET 10
3 CN.A40 pin 6 547A WR - 0.85
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CONNECTOR CN.C13 – CIGAR LIGHTER (1-PIN) (Male)

1 CN.A41 pin 2 195A YR - 0.85 SHEET 03
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CONNECTOR CN.C14 – CIGAR LIGHTER (1-PIN) (Male)

1 SP-712 pin X 713 B - 0.85 SHEET 36
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CONNECTOR CN.C15 – ACC SOCKET (1-PIN) (Male)

1 CN.A41 pin 3 281D WR - 0.85 SHEET 15
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CONNECTOR CN.C16 – ACC SOCKET (1-PIN) (Male)

1 SP-712 pin X 712 B - 0.85 SHEET 36
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CONNECTOR CN.C17 – GROUND (1-PIN)

M8 SP-711A pin X 711A B - 1.25 SHEET 35
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CONNECTOR CN.C18 – CCD CAMERA 1 REAR (4-PIN) (Female)
SMIL14CEX5922AA 44
SMIL14CEX5921AA 45

1 CN.C3 pin 10 960 R - 0.75 SHEET 28
2 CN.C3 pin 11 961 B - 0.75
3 CN.C4 pin 1 962B Y
4 CN.C4 pin 12 963B W
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CONNECTOR CN.C19 – CCD CAMERA 2 RIGHT (4-PIN) (Female)
SMIL14CEX5923AA 46

1 CN.C3 pin 10 965 R - 0.75 SHEET 28
2 CN.C3 pin 11 966 B - 0.75
3 CN.C4 pin 2 967A YB
4 CN.C4 pin 13 968A WB
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CONNECTOR CN.D10 – ENGINE HARNESS D (20-PIN) (Male)
SMIL14CEX5324AA 47
SMIL14CEX5323AA 48

1 CN.D4 pin E43 375-A W - 1.25 SHEET 14
2 CN.D4 pin E2 379-A RL - 1.25
3 CN.D4 pin E1 383A RL - 1.25
4 CN.D4 pin E4 377-A L - 1.25
5 CN.D4 pin E23 374-A B - 1.25
6 CN.D4 pin E24 378-B RB - 1.25
7 CN.D4 pin E25 382-A L - 1.25
8 CN.D4 pin E44 376-A Y - 1.25
9 CN.D4 pin E3 381-A BW - 1.25
10 CN.D4 pin E85 385-A RB - 1.25
13 CN.D4 pin E45 380-B B - 1.25
14 CN.D4 pin E46 384-A W - 1.25
15 SP-629 pin X 692C BL - 0.75
16 SP-396A pin X 396B RW - 0.75
17 SP-316A pin X 316B R - 0.75
18 CN.D4 pin E99 317A L - 0.75
19 SP-318A pin X 318B G - 0.75
20 SP-394A pin X 394B RG - 0.75
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CONNECTOR CN.D11 – GLOW PLUG (1-PIN) (Male)
SMIL14CEX5347AA 49
SMIL14CEX5346AA 50

1 CN.D86 pin 1 021 L - 5.0 SHEET 01
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CONNECTOR CN.D12 – STARTER MOTOR S (1-PIN)
SMIL14CEX6168AA 51

M4 CN.D83 pin 2 004 Y - 5.0 SHEET 01
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CONNECTOR CN.D13 – ALTERNATOR B (1-PIN)
SMIL14CEX6133AA 52

M6 CN.D82 pin 1 030 R - 20.0 SHEET 01
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CONNECTOR CN.D15 – ALTERNATOR E (1-PIN)
SMIL14CEX6134AA 53

M5 CN.D16 pin JST 797 B - 20.0 SHEET 01
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CONNECTOR CN.D16 – ALTERNATOR GND (1-PIN)
SMIL14CEX6135AA 54

JST CN.D15 pin M5 797 B - 20.0 SHEET 01
JST SP-770 pin X 770A B - 1.25
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CONNECTOR CN.D17 – SCR HARNESS (16-PIN) (Male)
SMIL14CEX6155AA 55

1 CN.D70 pin 1 250C YG - 0.75 SHEET 21
2 SP-501 pin X 501G G - 0.75 SHEET 15
3 SP-DH1 pin X DH1-A W - 0.75
4 SP-DL1 pin X DL1-A WG - 0.75
5 CN.D1-2 pin 132 580A Y - 0.75
6 CN.D1-2 pin 112 581A BY - 0.75
7 CN.D1-2 pin 133 582 L - 0.75
8 CN.D1-2 pin 134 583 GB - 0.75
9 CN.D3 pin V18 346 RW - 0.75 SHEET 13
10 SP-347A pin X 347C G - 0.75 SHEET 19
11 CN.D3 pin V19 348 R - 0.75 SHEET 13
12 CN.D3 pin V35 349 BW - 0.75
13 CN.D3 pin V16 334 WB - 0.75
14 CN.D3 pin V17 335 GW - 0.75
16 SP-752 pin X 752G Br - 1.25 SHEET 12
16 CN.D90_M pin 1 752E Br - 1.25
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CONNECTOR CN.D17-1 – FUEL PUMP (2-PIN) (Female)
SMIL14CEX6498AA 56

1 SP-250A pin X 250E BY - 2.0 SHEET 21
2 SP-752A pin X 752F Br - 1.25
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CONNECTOR CN.D17-2 – FUEL PUMP DIODE (2-PIN) (Female)
SMIL14CEX6499AA 57
SMIL14CEX6156AA 58

1 SP-250A pin X 250A YG - 0.75 SHEET 21
2 SP-752A pin X 752A Br - 0.75
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CONNECTOR CN.D17-3 – DOSING VALVE (2-PIN) (Female)
SMIL14CEX5894AA 59
SMIL14CEX5893AA 60

1 CN.D17_M pin 5 580 Y - 0.75 SHEET 15
2 CN.D17_M pin 6 581 BY SHEET 19
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CONNECTOR CN.D17-4 – DEV 249 (2-PIN) (Male)

A SP-DH2 pin X DH1-B W - 0.75 SHEET 21
B SP-DL2 pin X DL1-B WG - 0.75
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CONNECTOR CN.D17-5 – SCR INLET NOx SENSOR (5-PIN) (Female)
SMIL14CEX5895AA 61

1 CN.D17_M pin 2 501R G - 0.75 SHEET 15
2 SP-752C pin X 752D B - 0.75 SHEET 21
3 SP-DL2 pin X DL2 WG - 0.75
4 SP-DH2 pin X DH2 W - 0.75
5 SP-752C pin X 752C B - 0.75
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CONNECTOR CN.D17-6 – FUEL FILTER SENSOR (3-PIN) (Female)
SMIL14CEX6157AA 62

1 SP-349A pin X 349C BW - 0.75 SHEET 13
2 CN.D17_M pin 13 334A WB - 0.75
3 CN.D17_M pin 14 335A GW - 0.75
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CONNECTOR CN.D17-7 – SCR UPSTREAM TEMPERATURE SENSOR (2-PIN) (Female)
SMIL14CEX5897AA 63
SMIL14CEX5896AA 64

1 CN.D17_M pin 7 582A L - 0.75 SHEET 15
2 CN.D17_M pin 8 583A GB - 0.75
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CONNECTOR CN.D17-8 – EXHAUST TEMPERATURE SENSOR (FNT) (2-PIN) (Male)
SMIL14CEX5890AA 65
SMIL14CEX5889AA 66

1 CN.D17_M pin 11 348A R - 0.75 SHEET 13
2 SP-349A pin X 349B BW - 0.75
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CONNECTOR CN.D17-9 – EXHAUST TEMPERATURE SENSOR (CNT) (2-PIN) (Male)
SMIL14CEX5888AA 67
SMIL14CEX5887AA 68

1 CN.D17_M pin 9 346A RW - 0.75 SHEET 13
2 CN.D17_M pin 10 347D G - 0.75 SHEET 19
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CONNECTOR CN.D18 – SUPPLY MODULE (12-PIN) (Female)
SMIL14CEX5882AA 69

2 CN.D1-2 pin 119 576 WG - 0.85 SHEET 15
3 CN.D1-2 pin 117 577 Gr - 0.85
4 CN.D1-2 pin 118 575 BW - 0.85
8 CN.D1-2 pin 126 571 B - 1.25
9 CN.D1-2 pin 146 570 R - 1.25
10 CN.D1-2 pin 124 572 LR - 0.85
11 CN.D1-2 pin 186 573 YR - 1.25
12 CN.D1-2 pin 165 574 LB - 1.25
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CONNECTOR CN.D19 – COOLANT CONTROL VALVE (2-PIN) (Female)
SMIL14CEX6500AA 70
SMIL14CEX6158AA 71

1 CN.D1-2 pin 108 578 W - 1.25 SHEET 15
2 CN.D1-2 pin 185 579 RB - 1.25
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CONNECTOR CN.D20 – UREA SENSOR (2-PIN) (Female)
SMIL14CEX5883AA 72
SMIL14CEX5884AA 73

1 SP-501H pin X 501H G SHEET 15
2 SP-600B pin X 665 BG SHEET 12
3 SP-DH1 pin X DH3 W - 0.75 SHEET 15
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CONNECTOR CN.E10 – INTERCOOLER-IN TEMPERATURE SENSOR (2-PIN) (Male)
SMIL14CEX5908AA 74

1 CN.D7 pin 1 300A WR - 0.75 SHEET 14
2 CN.D7 pin 2 327K GY - 0.75
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CN.E10-A – EGR COOLER-OUT TEMPERATURE SENSOR (2-PIN) (Male)
SMIL14CEX6159AA 75

1 CN.D8_M pin 9 306A WR - 0.75 SHEET 14
2 CN.D8_M pin 10 327J GY - 0.75
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CN.E10-B - EGR COOLER-IN TEMPERATURE SENSOR (2-PIN) (Male)
SMIL14CEX6160AA 76

1 CN.D8_M pin 12 304A WR - 0.75 SHEET 14
2 CN.D8_M pin 11 327I GY - 0.75
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CONNECTOR CN.E11 – WATER TEMPERATURE SENSOR (3-PIN) (Male)
SMIL14CEX5906AA 77

1 CN.D7 pin 3 340A RB - 0.75 SHEET 14
2 CN.D7 pin 16 327L BY - 0.75
3 CN.D7 pin 8 R - 0.75
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CONNECTOR CN.E12 – CAM ANG (MRE) SENSOR (3-PIN) (Male)
SMIL14CEX5905AA 78

1 CN.D10_M pin 17 316C Y - 0.75 SHEET 19
2 CN.D10_M pin 19 318C OB
3 CN.D10_M pin 18 317 T - 0.75
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CONNECTOR CN.E13 – SUCTION CONTROL VALVE (2-PIN) (Male)
SMIL14CEX6501AA 79

1 CN.D10_M pin 16 396C RW - 0.75 SHEET 14
2 CN.D10_M pin 20 394C RB - 0.75
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CONNECTOR CN.E14 – INJ1 (#1) (2-PIN) (Male)
SMIL14CEX6507AA 80
84182901 81

1 SP-316 pin X 374 BW 1.25 SHEET 14
2 CN.E20_M pin 1 375 L 1.25
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SMIL14CEX6502AA 82
84182901 83

1 SP-317 pin X 374 BW 1.25 SHEET 14
2 CN.E20_M pin 3 383 G 1.25
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SMIL14CEX6503AA 84
84182901 85

1 SP-318 pin X 378A R 1.25 SHEET 14
2 CN.E20_M pin 2 379 WB 1.25
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SMIL14CEX5917AA 86

1 SP-319 pin X 376 B 1.25 SHEET 14
2 CN.E20_M pin 2 377 WL 1.25
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CONNECTOR CN.E18 - CCD HARNESS (4-PIN) (Male)
SMIL14CEX5955AA 87
SMIL14CEX5918AA 88

1 CN.C18_M pin 1 960C R - 0.75 SHEET 28
2 CN.C18_M pin 2 961C G - 0.75
3 CN.C18_M pin 3 962C L - 0.75
4 CN.C18_M pin 4 963C W - 0.75
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CONNECTOR CN.E18-A – INJ6 (#4) (2-PIN) (Male)
84182901 89

1 SP-320 pin X 376 B 1.25 SHEET 14
2 CN.E21_M pin 10 385 P 1.25
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CONNECTOR CN.E19 - CCD HARNESS (4-PIN) (Male)
SMIL14CEX5920AA 90

1 CN.C19_M pin 1 965B R - 0.75 SHEET 28
2 CN.C19_M pin 2 966B B - 0.75
3 CN.C19_M pin 3 967C Y - 0.75
4 CN.C19_M pin 4 968B W - 0.75
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CONNECTOR CN.E19-A – INJ4 (#6) (2-PIN) (Male)
84182901 91

1 SP-321 pin X 380 LR 1.25 SHEET 14
2 CN.E21_M pin 9 381 BR 1.25
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CONNECTOR CN.G10 – OPTION 1 (LEVER DOWN) (2-PIN)
SMIL14CEX5946AA 92

1 CN.B19 pin 10 954 RY 0.85 SHEET 23
2 SP-955A pin X 955A BW 0.85
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CONNECTOR CN.G11 – PRESSURE SENSOR (PILOT OPTION 1) (3-PIN)
SMIL14CEX5949AA 93

1 CN.D24.pin 1 435-F WB - 0.85 SHEET 23
2 CN.D24.pin 3 415B WL - 0.85
3 CN.D24.pin 4 445-F BW - 0.85
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CONNECTOR CN.G11-A - PRESSURE SENSOR (PILOT OPTION 1 UP) (3-PIN) (Male)
SMIL14CEX5949AA 94

1 SP-435-D pin X 435-C WB - 0.85 SHEET 23
2 CN.D24.pin 3 415C WL - 0.85
3 SP-445Z pin X 445-A BW - 0.85
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CONNECTOR CN.G12 – PRESSURE SENSOR (PILOT OPTION 1 DOWN) (3-PIN) (Male)
SMIL14CEX5949AA 95

1 SP-435-D pin X 435-D WB - 0.85 SHEET 22
2 CN.D24.pin 2 401B YG - 0.85
3 SP-445Z pin X 445Y BW - 0.85
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CONNECTOR CN.G16 – SOLENOID VALVE (S2) (2-PIN) (Male)
SMIL14CEX5960AA 96

JST CN.D15.pin M5 797 B - 20.0 SHEET 22
JST SP-770 pin X 770A B - 1.25
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CONNECTOR CN.G17 – SOLENOID VALVE (S1) (2-PIN) (Male)
SMIL14CEX6504AA 97

1 SP-230A pin X 230A-1 R SHEET 22
1 SP-856A pin X 856E B
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CONNECTOR CN.G18 – PROPORTIONAL SOLENOID OPTION 2 (LEVER UP) (2-PIN) (Male)
SMIL14CEX5947AA 98

1 CN.G4.pin 2 956A RG 0.85 SHEET 23
1 SP-958A pin X 958E BY 0.85
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CONNECTOR CN.G19 - OPTION 2 PROPORTIONAL SOLENOID (LEVER DOWN) (2-PIN) (Male)
SMIL14CEX5948AA 99

1 CN.G4.pin 3 957A RW 0.85 SHEET 23
1 SP-958A pin X 958A BY 0.85
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CONNECTOR CN.A20 – DIAGNOSTIC CONNECTOR (16-PIN) (Male)
SMIL14CEX5212AA 1
SMIL14CEX5189AA 2

1 CN.A35_M pin 7 CH6 P SHEET 30
4 SP-635 pin X 635 BG SHEET 29
5 SP-635 pin X 634A BG
6 SP-AH1 pin X AH2 Y SHEET 06
7 SP-080A pin X 080C PL SHEET 29
9 CN.A36_M pin 7 CL6 PG SHEET 30
11 SP-BL2 pin X BL2 LG SHEET 12
12 CN.A53 P-11 082A PB SHEET 13
14 SP-AL2 pin X AL2 YG SHEET 12
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CONNECTOR CN.A21 – EST-A HARNESS (6-PIN) (Female)
SMIL14CEX5210AA 3
SMIL14CEX5211AA 4

1 CN.52 pin 1 631A BG SHEET 29
2 CN.52 pin 2 166 RL
3 CN.52 pin 3 040H P
4 CN.52 pin 4 041H PG
5 CN.52 pin 5 081 PL
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CONNECTOR CN.A24 - OVER HEAT SWITCH (1-PIN) (Male)
SMIL14CEX6509AA 5

M4 CN.D7 pin 4 G G 0.75 SHEET 14
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CONNECTOR CN.A24M - Buzzer: + (1-PIN) (Male)
SMIL14CEX5909AA 6

1 CN.A5 pin 4 816A LG SHEET 05
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CONNECTOR CN.A24F - Buzzer: -(1-PIN) (Female)
SMIL14CEX5299AA 7

1 SP-235A pin X 235A LgR SHEET 03
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CONNECTOR CN.A25 – OPTION POWER/FVM (4-PIN) (Female)
SMIL14CEX5217AA 8
SMIL14CEX5218AA 9

1 F70 pin 1 220 GR SHEET 03
2 F71 pin 1 225 LR
4 CN.A38_M pin 5 741 B - 1.25 SHEET 29
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CONNECTOR CN.A26 – TO GPS UNIT HARNESS (10-PIN) (Male)
SMIL14CEX5206AA 10

1 F03 pin 2 120 RB - 0.85 SHEET 04
2 CN.A35_M pin 20 501E G - 0.85 SHEET 30
3 SP-515B pin X 515B Br - 0.85 SHEET 09
4 SP-845A pin X 845A GR - 0.85 SHEET 31
5 CN.A4 pin 29 067 WB SHEET 07
6 CN.A4 pin 28 068 LB
7 CN.A4 pin 23 069 BY
9 SP-BL3 pin X BL3 LG
10 CN.A39 pin M8 745 B - 1.25 SHEET 29
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CONNECTOR CN.A26F - LAMP (CAB) (1-PIN) (Female)
SMIL14CEX5293AA 11

2 SP-876 pin X 875D GR - 1.25 SHEET 36
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CONNECTOR CN.A27 – TO CONTROLLER C HARNESS (10-PIN) (Male)
SMIL14CEX5387AA 12

1 F74 pin 1 240 WR - 0.85 SHEET 03
2 CN.A35_M pin 19 501D G - 0.85 SHEET 30
3 SP-840B pin X 840B RY - 0.85 SHEET 10
4 SP-842A pin X 842A LG SHEET 09
5 CN.A2 pin 31 541 YR SHEET 10
6 CN.A2 pin 20 542 OR
7 CN.A35_M pin 5 CH4 P SHEET 30
8 CN.A36_M pin 5 CL4 PG
9 CN.A38_M pin 4 740 B - 1.25 SHEET 29
10 CN.A36_M pin 18 636 BG - 1.25 SHEET 30
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SMIL14CEX5291AA 13
SMIL14CEX5290AA 14

1 E3 pin N 714 W - 1.25 SHEET 36
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CONNECTOR CN.A28 – LAMP (CAB) (1-PIN) (Female)
SMIL14CEX5297AA 15
SMIL14CEX5189AA 16

2 SP-876 pin X 876A GR - 1.25 SHEET 36
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CONNECTOR CN.A29 – DC/DC(24V/12V) CONVERTER (7-PIN) (Male)
SMIL14CEX5214AA 17

1 SP-281A pin X 281 WR - 0.85 SHEET 32
2 CN.A35_M pin 15 135D RL SHEET 30
3 CN.A45 pin 14 280 RY - 0.85 SHEET 09
4 CN.A45 pin 16 735 BW - 0.85
5 CN.A38_M pin 2 709 B - 0.85 SHEET 29
6 F69 pin 1 215 OR - 0.85 SHEET 03
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SMIL14CEX5295AA 18
SMIL14CEX5189AA 19

1 E3 pin N 715A W - 1.25 SHEET 36
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CONNECTOR CN.B20 – AIR SUSPENSION SEAT (2-PIN) ( (Female)
SMIL14CEX5958AA 20
SMIL14CEX5957AA 21

1 X45 pin IN 185 R - 1.25 SHEET 37
2 X45 pin OUT 728 B - 1.25
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CONNECTOR CN.B21 – DIODE (2-PIN) (Male)

1 SP-185G pin X 185H LW SHEET 37
2 SP-728 pin X 729 B SHEET 05
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CONNECTOR CN.B22 – AIR CONDITIONED GND (1-PIN)
SMIL14CEX6161AA 22

M8 CN.B18_M pin 7 731A B - 1.25 SHEET 32
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CONNECTOR CN.B24 – 12V OUTPUT (FOR RADIO) (1-PIN) (Female)
SMIL14CEX5282AA 23
SMIL14CEX5281AA 24

1 CN.A45_M pin 14 280A RY - 0.85 SHEET 09
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CONNECTOR CN.B25 – 12V OUTPUT (FOR RADIO) (1-PIN) (Female)
SMIL14CEX5284AA 25
SMIL14CEX6162AA 26

1 CN.A45_M pin 15 281C WR - 0.85 SHEET 09
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CONNECTOR CN.B26 – 12V OUTPUT (FOR RADIO) (1-PIN) (Male)
SMIL14CEX5286AA 27
SMIL14CEX5285AA 28

1 CN.A45_M pin 16 735A BW - 0.85 SHEET 09
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CONNECTOR CN.B27 – FREE SWING SWITCH (10-PIN) (Male)
SMIL14CEX5312AA 29
SMIL14CEX5311AA 30

2 SP-627 pin X 627 BG - 0.85 SHEET 05
3 CN.A45_M pin 18 543A GW - 0.85 SHEET 09
7 SP-627 pin X 626 BG - 0.85 SHEET 05
8 CN.A45_M pin 8 804B Br - 0.85 SHEET 06
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CONNECTOR CN.C20 – CAB HARNESS (BLUE TAPE) (4-PIN) (Female)
SMIL14CEX5924AA 31

1 CN.C3 pin 10 970 R - 0.75 SHEET 28
2 CN.C3 pin 11 971 B - 0.75
3 CN.C4 pin 3 972A YR
4 CN.C4 pin 14 973A WR
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CONNECTOR CN.C21 – MONITOR DISPLAY CONNECTOR (6-PIN) (Female)
SMIL14CEX5219AA 32

1 CN.C3 pin 3 97 V SHEET 34
2 CN.C3 pin 12 98 VG
3 CN.C4 pin 7 99 G
6 SP-612 pin X 612 BG SHEET 36
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CONNECTOR CN.C22 - ROOM LAMP (2-PIN) (Male)
SMIL14CEX6463AA 33

1 CN.C8 pin 2 843 Y SHEET 36
2 CN.C8 pin 1 888B G
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CONNECTOR CN.C23 – LIMIT SWITCH (DOOR) (3-PIN) (Male)
SMIL14CEX5216AA 34

1 CN.C9 pin 2 593-B OL SHEET 36
2 CN.C9 pin 4 843B Y
3 CN.C9 pin 1 613 BG
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CONNECTOR CN.C24 – SPEAKER RIGHT (2-PIN) (Male)
SMIL14CEX6464AA 35

1 CN.C10 pin 3 982B BL - 0.85 SHEET 36
2 CN.C10 pin 1 984B YR
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CONNECTOR CN.C25 – SPEAKER LEFT (2-PIN) (Male)
SMIL14CEX6465AA 36
Pin From Wire Description Color-SizeT Frame

1 CN.C10 pin 4 983C BL - 0.85 SHEET 36
2 CN.C10 pin 2 985B LR
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CONNECTOR CN.D20 – UREA SENSOR (4-PIN) (Female)
SMIL14CEX5884AA 37
SMIL14CEX5883AA 38

1 SP-501H pin X 501H G SHEET 15
2 SP-600B pin X 665 BG SHEET 12
3 SP-DH1 pin X DH3 W - 0.75 SHEET 15
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CONNECTOR CN.D21 – AIR INTAKE SENSOR MASS & TEMPERATURE (MAF) (5-PIN) (Female)
SMIL14CEX5886AA 39
SMIL14CEX5885AA 40

1 SP-347A pin X 347A G SHEET 13
2 CN.D3 pin V29 350 BrR
3 CN.D3 pin V88 338 LW
4 CN.D3 pin V36 339 GY
5 CN.D3 pin V37 337 WG
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CONNECTOR CN.D22 – INTERCOOLER-IN TEMPERATURE (2-PIN) (Female)
SMIL14CEX5892AA 41
SMIL14CEX5891AA 42

1 CN.D3 pin V21 308 Y - 0.75 SHEET 13
2 SP-347B pin X 347B G - 0.75
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CONNECTOR CN.D23 – FLOOR HARNESS 1 (6-PIN) (Female)
SMIL14CEX5372AA 43
SMIL14CEX5371AA 44

1 SP-435U pin X 435M WL - 0.85 SHEET 17
2 CN.D23-1 pin 2 411B OR - 0.85
3 CN.D23-2 pin 2 412B OL - 0.85
4 CN.D23-3 pin 2 413B OW - 0.85
6 SP-445U pin X 445M BW - 0.85
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CONNECTOR CN.D23-1 – PRESSURE SENSOR (PILOT TRAVEL LEFT) (3-PIN) (Male)
SMIL14CEX6511AA 45

2 CN.D23 pin 2 411B OR - 0.85 SHEET 17
3 SP-445T pin X 445S BW - 0.85
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CONNECTOR CN.D23-2 – PRESSURE SENSOR (PILOT TRAVEL RIGHT) (3-PIN) (Male)
SMIL14CEX6522AA 46

1 SP-435T pin X 435T WL - 0.85 SHEET 17
2 CN.D23 pin 3 412B OL - 0.85
3 SP-445T pin X 445T BW - 0.85
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CONNECTOR CN.D23-3 – PRESSURE SENSOR (PILOT TRAVEL ONE PEDAL) (3-PIN) (Male)
SMIL14CEX6523AA 47

1 SP-435U pin X 435U WL - 0.85 SHEET 17
2 CN.D23 pin 4 413B OW - 0.85
3 SP-445U pin X 445U BW - 0.85
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CONNECTOR CN.D23-A - GROUND
SMIL14CEX6524AA 48

M8 CN.A43_M pin 8 601G BG - 1.25 SHEET 29
M8 CN.A43_M pin 7 701 B - 1.25
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CONNECTOR CN.D24 – FLOOR HARNESS 2 (8-PIN) (Female)
SMIL14CEX5374AA 49
SMIL14CEX5373AA 50

1 SP-435-D pin X 435-E WB - 0.85 SHEET 22
1 CN.G11 pin 1 435-F WB - 0.85
2 CN.G12 pin 2 401B YG - 0.85
3 CN.G11-A pin 2 415C WL - 0.85
3 CN.G11 pin 2 415B WL - 0.85
4 CN.G11 pin 3 445-F BW - 0.85
4 SP-445Z pin X 445Z BW - 0.85
5 CN.G4 pin 7 539D GY - 0.85
8 CN.G4 pin 8 653 BG - 0.85
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CONNECTOR CN.D25 – PRESSURE SENSOR (PILOT SWING) (3-PIN) (Female)
SMIL14CEX6525AA 51
SMIL14CEX6163AA 52

1 SP-435C pin X 435L WL - 0.85 SHEET 16
2 CN.A54_M pin 6 404A LgR - 0.85
3 SP-435B pin X 445X BW - 0.85
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CONNECTOR CN.D26 – PRESSURE SENSOR (PILOT BOOM UP) (3-PIN) (Female)
SMIL14CEX6526AA 53
SMIL14CEX6164AA 54

1 SP-435C pin X 435W WL - 0.85 SHEET 16
2 CN.A54_M pin 7 405A LR - 0.85 SHEET 11
3 SP-435B pin X 445-B BW - 0.85 SHEET 16
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CONNECTOR CN.D27 – PRESSURE SENSOR (PILOT BOOM DOWN) (3-PIN) (Female)
SMIL14CEX6527AA 55
SMIL14CEX6165AA 56

1 SP-435Q pin X 435S WL - 0.85 SHEET 16
2 CN.A54_M pin 8 406A LW - 0.85 SHEET 11
3 SP-435D pin X 445-C BW - 0.85 SHEET 16
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CONNECTOR CN.D28 – PRESSURE SENSOR (PILOT ARM OUT) (3-PIN) (Female)
SMIL14CEX6528AA 57
SMIL14CEX6166AA 58

1 SP-435E pin X 435X WL - 0.85 SHEET 16
2 CN.A54_M pin 9 407A YR - 0.85 SHEET 11
3 SP-435F pin X 445-D BW - 0.85 SHEET 16
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CONNECTOR CN.D29 – PRESSURE SENSOR (PILOT ARM IN) (3-PIN) (Female)
SMIL14CEX6529AA 59
SMIL14CEX6167AA 60

1 SP-435R pin X 435Y WL - 0.85 SHEET 16
2 CN.A54_M pin 10 408A YG - 0.85 SHEET 11
3 SP-445F pin X 445A-1 BW - 0.85 SHEET 16
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CONNECTOR CN.E20 – INJECTOR INTERMEDIATE HARNESS (6-PIN) (Male)
SMIL14CEX5915AA 61

1 CN.D10_M pin 1 375 L 1.25 SHEET 14
2 CN.D10_M pin 2 379 WB 1.25
3 CN.D10_M pin 3 383 G 1.25
5 CN.D10_M pin 5 374 BW 1.25
6 SP-382 pin X 378-A R 1.25
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CONNECTOR CN.E20A - CAMERA 3 (LEFT) (4 PIN) (Female)
SMIL14CEX6530AA 62

1 CN.C20_M pin 1 970B R - 0.75 SHEET 28
2 CN.C20_M pin 2 971B B - 0.75
3 CN.C20_M pin 3 972C Y - 0.75
4 CN.C20_M pin 4 973C W - 0.75
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CONNECTOR CN.E21 – INJECTOR INTERMEDIATE HARNESS (6-PIN) (Female)
SMIL14CEX5916AA 63

4 CN.D10_M pin 4 377 WL 1.25 SHEET 14
8 CN.D10_M pin 8 376 B 1.25
9 CN.D10_M pin 9 381 BR 1.25
10 CN.D10_M pin 10 385 P 1.25
13 SP-382 pin X 380 LR 1.25
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CONNECTOR CN.G20 – (2ND OPTION) PRESSURE SWITCH 1.96MPa (LEVER UP) (2-PIN) (Female)
SMIL14CEX5950AA 64

1 S102 pin IN 653D B - 0.85 SHEET 23
2 S102 pin OUT 539K B - 0.85
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CONNECTOR CN.G21 – (2ND OPTION) PRESSURE SWITCH 1.96MPa (LEVER DOWN) (2-PIN) (Female)
SMIL14CEX5950AA 65

1 S103 pin IN 653C B - 0.85 SHEET 23
2 S103 pin OUT 539B B - 0.85
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CONNECTOR CN.A30M - LIMIT SWITCH (WINDOW) (1 PIN) (Male)
SMIL14CEX6480AA 1

1 CN.C11-P-4 590-B O SHEET 36
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CN.A30-A - DIODE 1 (2-PIN) (Male)
SMIL14CEX5268AA 2

1 SP-812-P-X 812A WR SHEET 07
2 SP-515C-P-X 515C Br - 0.85 SHEET 09
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CONNECTOR CN.A31 - DIODE 2 (2-PIN) (Male)
SMIL14CEX5269AA 3

1 SP-813-P-X 813A OG SHEET 05
2 SP-145-P-X 145B W SHEET 04
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CONNECTOR CN.A31F - LIMIT SWITCH (WINDOW) (1 PIN) (Male)
SMIL14CEX6481AA 4

1 CN.C11-P-3 614D BG SHEET 36
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CONNECTOR CN.A33_M - JOINT CONNECTOR 1 (6-PIN) (Male)
SMIL14CEX5234AA 5
SMIL14CEX5235AA 6

1 CN.A5-P-11 701A B 1.25 SHEET 05
2 CN.A5-P-12 701B B 1.25
3 CN.A5-P-6 701C B 1.25
4 CN.A5-P-17 701D B 1.25
5 CN.A4-P-8 701E B SHEET 06
6 CN.A43-P-7 701F B 1.25 SHEET 29
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CONNECTOR CN.A34_M - JOINT CONNECTOR 2 (6-PIN) (Male)
SMIL14CEX5236AA 7
SMIL14CEX5235AA 8

1 CN.A5-P-18 601A BG 1.25 SHEET 05
2 CN.A5-P-19 601B BG 1.25
3 CN.A3-P-11 601C BG SHEET 08
4 CN.A3-P-17 601D BG SHEET 09
5 SP-601F-P-X 601E BG 1.25 SHEET 10
6 CN.A43-P-8 601 BG 1.25 SHEET 29
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CONNECTOR CN.A35_M - JOINT CONNECTOR A (20-PIN) (Male)
SMIL14CEX6457AA 9
SMIL14CEX5191AA 10

1 CN.A3-P-8 CH0 P SHEET 09
3 CN.A40_M-P-4 CH2-A P SHEET 34
4 CN.A44-P-10 CH3-A P SHEET 26
7 CN.A20_M-P-1 CH6 P SHEET 29
11 SP-135-P-X 135 RL SHEET 04
12 CN.A5-P-10 135A RL SHEET 05
13 CN.A5-P-21 135B RL
14 CN.A45-P-1 135C RL SHEET 09
15 CN.A29-P-2 135D RL SHEET 32
16 SP-501A-P-X 501L G 0.85 SHEET 32
17 CN.A2-P-24 501O G SHEET 10
18 CN.A2-P-32 501C G
19 CN.A27-P-2 501D G 0.85
20 CN.A26-P-2 501E G 0.85 SHEET 29
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CONNECTOR CN.A36_M - JOINT CONNECTOR B (20-PIN) (Male)
SMIL14CEX6457AA 11
SMIL14CEX5191AA 12

1 CN.A3-P-7 CL0 PG SHEET 09
3 CN.A40_M-P-5 CL2-A PG SHEET 34
7 CN.A20_M-P-9 CL6 PG SHEET 29
11 SP-600A-P-X 600F BG SHEET 30
12 CN.A47_M-P-1 605 BG SHEET 36
13 CN.A40_M-P-14 610 BG 1.25 SHEET 34
14 CN.A42-P-10 620 BG 0.85 SHEET 05
15 CN.A21_M-P-1 630 BG SHEET 29
16 CN.A19_M-P-2 631 BG SHEET 30
17 CN.A20_M-P-5 634 BG SHEET 29
18 CN.A27-P-10 636 BG 1.25 SHEET 10
19 CN.A54-P-21 660A BG 0.85 SHEET 16
20 SP-600A-P-X 600A BG 1.25 SHEET 30
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CONNECTOR CN.A37_M - JOINT CONNECTOR GROUND 1 (6-PIN) (Male)
SMIL14CEX5238AA 13

1 CN.A6-P-2 703 B 0.85 SHEET 31
2 CN.A8-P-2 704 B 0.85
3 CN.A11-P-2 705 B SHEET 32
4 CN.A9-P-2 706 B
5 CN.A10-P-2 707 B
6 CN.A38_M-P-1 708 B SHEET 29
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CONNECTOR CN.A38 - JOINT CONNECTOR GROUND 2 (6-PIN) (Male)
SMIL14CEX5240AA 14

1 CN.A37_M-P-6 708 B 1.25 SHEET 29
2 CN.A29-P-5 709 B 0.85 SHEET 32
3 CN.A42-P-9 720D B 0.85 SHEET 05
4 CN.A27-P-9 740 B 1.25 SHEET 10
5 CN.A25-P-4 741 B 1.25 SHEET 37
6 CN.A51-P-7 700 B 1.25 SHEET 29
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CONNECTOR CN.A39 - CAB GROUND (1-PIN)
SMIL14CEX6478AA 15
SMIL14CEX5191AA 16

M8 CN.C11-P-4 745 B 1.25 SHEET 29
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CONNECTOR CN.D30 - PRESSURE SENSOR (PILOT BUCKET OPEN) (3-PIN) (Male)
87691311 17
SMIL14CEX6169AA 18

1 SP-435G-P-X 435G WL - 0.85 SHEET 16
2 CN.A54_M-P-11 409A GR - 0.85 SHEET 12
3 SP-445G-P-X 445G BW - 0.85 SHEET 16
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CONNECTOR CN.D31 - PRESS. SENSOR (PILOT BUCKET CLOSE) (3-PIN) (Male)
87691311 19
SMIL14CEX6180AA 20

1 SP-435H-P-X 435H WL - 0.85 SHEET 16
2 CN.A54_M-P-12 410A GW - 0.85 SHEET 11
3 SP-445H-P-X 445H BW - 0.85 SHEET 16
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CONNECTOR CN.D32 - UREA PUMP (2-PIN) (Male)
SMIL14CEX6453AA 21

1 CN.D69-P-1 260 YR - 0.85 SHEET 02
2 SP-768B-P-X 768B B - 0.85 SHEET 27
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CONNECTOR CN.D33 - LUBRICATOR (2-PIN) (Male)
47565672 22
SMIL14CEX6179AA 23

1 SP-564-P-X 255A W - 1.25 SHEET 27
2 SP-768A-P-X 768A B - 1.25
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CONNECTOR CN.D34 - REFUELING PUMP HARNESS (3-PIN) (Male)
SMIL14CEX5376AA 24
SMIL14CEX5375AA 25

1 CN.D34-3-P-3 250 W - 1.25 SHEET 27
2 SP-764-P-X 822 YL - 0.85
3 765 B 0.85 765 B 0.85
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CONNECTOR CN.D34_M - REFUELING PUMP HARNESS (3-PIN) (Male)
SMIL14CEX6472AA 26
SMIL14CEX5375AA 27

1 SP-564-P-X 255B W 2.0 SHEET 27
2 CN.A56_M-P-8 815A VG 0.85 SHEET 05
3 SP-768A-P-X 768C YL - 0.85 SHEET 27
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CONNECTOR CN.D34-1 - REFUEL PUMP (2-PIN) (Male)
87714689 28

1 SP-765-P-X 764 B - 1.25 SHEET 27
2 CN.D34-3-P-5 892 LR - 1.25
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CONNECTOR CN.D34-2 - SWITCH ROCKER MANUAL/AUTO (3-PIN) (Male)
SMIL14CEX6473AA 29

1 SP-895-P-X 845 VR - 0.85 SHEET 27
2 SP-251-P-X 251 W - 0.85
3 SP-847-P-X 846 L - 0.85
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CONNECTOR CN.D34-3 - RELAY PUMP (5-PIN) (Male)
SMIL14CEX6474AA 30

1 SP-895-P-X 845B VR - 0.85 SHEET 27
2 SP-764-P-X 766 B - 0.85
3 SP-251-P-X 250B W - 1.25
5 CN.D34-1-P-2 892 LR - 1.25
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CONNECTOR CN.D34-4 - RELAY STOP (5-PIN) (Male)
SMIL14CEX6475AA 31

1 SP-847-P-X 847 L - 0.85 SHEET 27
2 SP-765-P-X 822 YL - 0.85
3 SP-847-P-X 846A L - 0.85
4 CN.D34-7-P-2 894 WR - 0.85
5 CN.D34-5-P-1 893 BrR - 0.85
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CONNECTOR CN.D34-5 - ALARM (1-PIN)
SMIL14CEX6476AA 32

1 CN.D34-4-P-5 893 BrR - 0.85 SHEET 27
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CONNECTOR CN.D34-6 - ALARM (1-PIN)
SMIL14CEX6477AA 33

2 CN.D34-P-3 765 B - 0.85 SHEET 27
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CONNECTOR CN.D34-7 - DIODE (2-PIN) (Male)
84182901 34

1 SP-895-P-X 895 VR - 0.85 SHEET 27
2 CN.D34-4-P-4 894 WR - 0.85
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CONNECTOR CN.D35 - BOOM LIGHT HARNESS (2-PIN) (Male)
SMIL14CEX5348AA 35

1 CN.G2-A-P-1 871 Y - 1.25 SHEET 39
2 CN.G2-A-P-2 758B B - 1.25
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CONNECTOR CN.D36 - HOUSE LIGHT (2-PIN) (Male)
SMIL14CEX5378AA 36
SMIL14CEX5377AA 37

1 SP-870A-P-X 870C Y - 1.25 SHEET 39
2 SP-761-P-X 761 B - 1.25 SHEET 40
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CONNECTOR CN.D37 - WASHER MOTOR (2-PIN) (Male)
SMIL14CEX5380AA 38
SMIL14CEX5379AA 39

1 SP-829A-P-X 829D WG - 0.85 SHEET 39
2 SP-771A-P-X 771B B - 0.85 SHEET 40
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CONNECTOR CN.D38 - DEV449 DIODE (2-PIN) (Male)
SMIL14CEX6451AA 40
84182901 41

1 SP-829A-P-X 829A WG - 0.85 SHEET 39
2 SP-771A-P-X 771A B - 0.85
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CONNECTOR CN.D39 - HORN LOW (LEFT) (1-PIN) (Male)
SMIL14CEX6479AA 42
SMIL14CEX6178AA 43

1 CN.A51_M-P-2 880F LR - 0.85 SHEET 30
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CONNECTOR CN.A40 – CAB HARNESS A (14-PIN) (Female)
SMIL14CEX5227AA 1
SMIL14CEX5228AA 2

1 CN.C3 pin 1 130A RL - 0.85 SHEET 34
2 CN.C3 pin 2 140A W - 1.25
3 CN.C3 pin 4 516A BrW - 0.85
4 CN.C3 pin 5 CH2 P
5 CN.C3 pin 6 CL2 PG
6 CN.C12-B pin 3 547A WR - 0.85 SHEET 35
7 CN.C12-A pin 2 880E LR - 0.85
8 CN.C12-A pin 1 881 YR - 0.85
9 CN.C3 pin 8 070 WL SHEET 34
10 CN.C3 pin 9 071 W
11 CN.C3 pin 19 072 BL
12 CN.C4 pin 11 949B WB
13 CN.C4 pin 12 950B BW
14 SP-614 pin X 610A BG - 1.25
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CONNECTOR CN.A41 – CAB HARNESS B (18-PIN) (Female)
SMIL14CEX5220AA 3
SMIL14CEX5221AA 4

1 CN.C6 pin 1 190A BrR - 0.85 SHEET 35
2 CN.C13 pin 1 195A YR - 0.85 SHEET 36
3 CN.C15 pin 1 281D WR - 0.85 SHEET 36
4 CN.C6 pin 1 829 WY - 0.85 SHEET 35
5 CN.C11_M pin 1 875A GR - 1.25 SHEET 36
7 CN.C4 pin 8 823A WG SHEET 34
8 CN.C4 pin 19 824A LY
9 CN.C4 pin 20 825A LG
10 CN.C4 pin 21 826A OR
11 CN.C8_M pin 1 888A G SHEET 36
13 CN.C4 pin 6 592-A V SHEET 34
15 CN.C10_M pin 1 984A YR SHEET 36
16 CN.C10_M pin 2 985A LR
17 CN.C10_M pin 3 982D BY - 0.85
18 CN.C10_M pin 4 983D BL - 0.85
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CONNECTOR CN.A42 – CAB MAIN HARNESS A (10-PIN) (Female)
SMIL14CEX5270AA 5
SMIL14CEX5271AA 6

1 F01 pin 2 110 R - 0.85 SHEET 04
2 CN.A9 pin 1 290 RB - 0.85 SHEET 32
3 F05 pin 2 150A VW - 0.85 SHEET 04
4 CN.A11 pin 3 500 LgR - 0.85 SHEET 32
5 CN.A8 pin 3 010 BrR - 0.85 SHEET 31
6 SP-840C pin X 840D RY - 0.85 SHEET 10
7 SP-845A pin X 845C GR - 0.85 SHEET 31
8 SP-813 pin X 813B OG SHEET 10
9 CN.A38_M pin 3 720D B - 0.85 SHEET 29
10 CN.A36_M pin 14 620 BG - 0.85 SHEET 30
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CONNECTOR CN.A43 – CAB MAIN HARNESS B(10-PIN) (Female)
SMIL14CEX5316AA 7
SMIL14CEX5315AA 8

1 CN.A3 pin 22 531 LR SHEET 08
2 CN.C4 pin 8 594A YG SHEET 34
3 CN.A18 pin 2 841 LW SHEET 31
4 CN.C4 pin 5 591A YL SHEET 34
5 SP-808 pin X 808A GW SHEET 05
6 CN.A5 pin 1 809 V
7 CN.A33_M pin 6 701F B - 1.25 SHEET 29
8 CN.A34_M pin 6 601 BG - 1.25
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CONNECTOR CN.A44 – CAB MAIN HARNESS C (14-PIN) (Female)
SMIL14CEX5314AA 9
SMIL14CEX5313AA 10

1 F66 pin 2 170 VR SHEET 04
2 F67 pin 2 175C WR - 0.85
3 F17 pin 2 180 LR
4 SP-126B pin X 126F W - 1.25 SHEET 12
5 CN.A53 pin-6 302A LG - 0.85 SHEET 13
6 CN.A3 pin-31 535 LB SHEET 09
7 SP-430B pin X 430B-4 W SHEET 11
8 CN.A1 pin-15 416 RW - 0.85 SHEET 26
9 SP-440 pin X 440L BL SHEET 11
10 CN.A35_M pin 4 CH3-A P SHEET 26
11 CN.A36_M pin 4 CL3 PG
12 CN.A40_M pin 12 949A WB
13 CN.A40_M pin 13 950C BW
14 CN.51 pin-1 943C GW - 0.85
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CONNECTOR CN.A45 – CAB MAIN HARNESS D (18-PIN) (Female)
SMIL14CEX5222AA 11
SMIL14CEX5223AA 12

1 CN.A35_M pin 14 135C RL SHEET 11
2 SP-185 pin X 185B LW SHEET 03
3 CN.A3 pin-26 536 GR SHEET 10
4 CN.A3 pin-21 538 WG
5 CN.A3 pin-14 544 LY
6 CN.A3 pin-23 540 YL
7 F72 pin 1 230 W SHEET 04
8 SP-804 pin X 804A Br SHEET 07
9 SP-842A pin X 842B LG SHEET 09
10 CN.A17 pin-3 980B Y - 0.85
11 CN.A16 pin-3 981B L - 0.85
12 CN.A41_M pin 17 982C BY - 0.85
13 CN.A41_M pin 18 983B BL - 0.85
14 CN.A29 pin-3 280 RY - 0.85
15 SP-281A pin X 281B WR - 0.85
16 CN.A29 pin-4 735 BW - 0.85
17 SP-117A pin X 117C R
18 CN.A3 pin-24 543 GW - 0.85
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CN.A47F - X9- IMMOBILIZER (Female)
SMIL14CEX5980AA 13
SMIL14CEX5245AA 14

1 CN.A3 pin-10 532 VG SHEET 08
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CN.A47M - X9- IMMOBILIZER (Male)
SMIL14CEX6136AA 15
SMIL14CEX5979AA 16

1 CN.A36_M pin 12 605 BG SHEET 30
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CONNECTOR CN.D40 – HORN (LOW) (1-PIN) (Male)
SMIL14CEX6438AA 17

1 SP-763 pin X 763 B - 0.85 SHEET 39
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CONNECTOR CN.D41 – HORN (HIGH) (1-PIN) (Male)
SMIL14CEX6439AA 18

1 CN.A51_M pin 3 881C YR - 0.85 SHEET 30
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CONNECTOR CN.D42 – HORN (HIGH) (1-PIN) (Male)
SMIL14CEX6171AA 19

1 SP-764B pin X 764B B - 0.85 SHEET 39
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CONNECTOR CN.D43 – BEACON HARNESS (2-PIN) (Male)
SMIL14CEX6446AA 20
SMIL14CEX6172AA 21

1 CN.A51_M pin 5 885A R - 0.85 SHEET 30
2 SP-765A pin X 765A B - 0.85 SHEET 39
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CONNECTOR CN.D44 – RECEIVER DRYER (2-PIN) (Male)
SMIL14CEX6442AA 22
SMIL14CEX6173AA 23

1 CN.D45 pin-1 944 W - 1.25 SHEET 40
2 CN.A51_M pin 1 943D GW - 0.85 SHEET 30
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CONNECTOR CN.D45 – AIR CONDITIONER COMPRESSOR (1-PIN) (Male)

1 CN.D44 pin-1 944 W - 1.25 SHEET 40
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CONNECTOR CN.D46 – TRAVEL ALARM (2-PIN) (Male)
SMIL14CEX6444AA 24
SMIL14CEX6174AA 25

1 SP-765A pin X 767 B - 0.75 SHEET 40
2 CN.A56_M pin 6 807A RY - 0.75 SHEET 07
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CONNECTOR CN.D47 – LLC TANK SWITCH (2-PIN) (Male)
SMIL14CEX6446AA 26
SMIL14CEX6175AA 27

1 SP-651 pin X 651 BG - 0.85 SHEET 08
2 CN.A56_M pin 10 533A GrR - 0.85
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CONNECTOR CN.D48 – AIR CLEANER SWITCH (2-PIN) (Male)
SMIL14CEX6448AA 28
SMIL14CEX6176AA 29

1 SP-651 pin X 650 BG - 0.85 SHEET 09
2 CN.A56_M pin 11 534A LW - 0.85
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CONNECTOR CN.D49 – CN.A49 (3-PIN) (Male)
SMIL14CEX6450AA 30
SMIL14CEX6177AA 31

1 SP-430A pin X 430B W - 0.75 SHEET 18
2 CN.A56_M pin 15 417A Y - 0.75 SHEET 11
3 SP-440H pin X 440H BL - 0.75 SHEET 18
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CONNECTOR CN.A50 – CAB MAIN HARNESS A (2-PIN) (Male)
SMIL14CEX5319AA 1
SMIL14CEX5317AA 2

1 SP-103B pin X 103 RW - 5.0 SHEET 04
2 SP-109B pin X 109A R - 8.0
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CONNECTOR CN.A51 – CAB MAIN HARNESS B (8-PIN) (Female)
SMIL14CEX6181AA 3
SMIL14CEX6170AA 4

1 CN.A44 pin 14 943C GW - 0.85 SHEET 26
2 SP-880A pin X 880D LR SHEET 30
3 SP-881A pin X 881B YR SHEET 10
4 CN.A15 pin 5 870 Y - 1.25 SHEET 31
5 CN.A14 pin 5 885 R
6 CN.A41_M pin 4 829B WV - 0.85 SHEET 15
7 CN.A38_M pin 6 700 B - 1.25 SHEET 29
8 SP-600A pin X 600B BG - 1.25 SHEET 30
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CONNECTOR CN.A52 – CAB MAIN HARNESS C (8-PIN) (Male)
SMIL14CEX5208AA 5
SMIL14CEX5209AA 6

1 SP-235A pin X 235B LgR SHEET 03
2 SP-501A pin X 501 G - 0.85 SHEET 09
3 SP-812 pin X 812B WR - 1.25 SHEET 07
4 SP-515B pin X 515E Br - 0.85 SHEET 09
5 CN.A7 pin 4 012B GrR - 0.85 SHEET 31
6 SP-840B pin X 840H RY - 0.85 SHEET 10
7 CN.A3 pin 19 AH0 Y SHEET 09
8 CN.A3 pin 18 AL0 YG
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CONNECTOR CN.A53 – CAB MAIN HARNESS D (14-PIN) (Male)
SMIL14CEX5229AA 7
SMIL14CEX5231AA 8

1 SP-126B pin X 126H W - 1.25 SHEET 12
2 SP-501F pin X 501T G - 0.85 SHEET 15
3 CN.A6 pin 1 370C YR - 0.85 SHEET 12
4 CN.A7 pin 2 373-A LR - 0.85
5 SP-011A pin X 011B Y - 0.85
6 CN.A44 pin 5 302A LG - 0.85 SHEET 13
7 SP-AH1 pin X AH1-B Y SHEET 12
8 SP-AL2 pin X AL1-B YG
9 SP-BH2 pin X BH0-B L
10 SP-BL2 pin X BL0-C LG
11 CN.A20 pin 12 082A PB SHEET 13
12 SP-080A pin X 080B PL SHEET 12
14 CN.A5 pin 3 805A BrY SHEET 13
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CONNECTOR CN.A54 – CAB MAIN HARNESS E (22-PIN) (Male)
SMIL14CEX5329AA 9
SMIL14CEX5328AA 10

1 SP-435A pin X 435B WB - 0.85 SHEET 11
2 SP-445A pin X 445B BW - 0.85
3 CN.A2 pin 35 401 YG - 0.85 SHEET 10
4 CN.A1 pin 18 402 Br SHEET 11
5 CN.A1 pin 28 403 BrR
6 CN.A1 pin 29 404 Lg
7 CN.A1 pin 19 405 LR
8 CN.A1 pin 11 406 LW
9 CN.A1 pin 30 407 YR
10 CN.A1 pin 21 408 YG
11 CN.A1 pin 20 409 GR
12 CN.A1 pin 31 410 GW
13 CN.A1 pin 13 411 OR
14 CN.A1 pin 32 412 OL
15 CN.A1 pin 22 413 O
16 CN.A1 pin 23 414 LgR
17 CN.A1 pin 24 415 WL
18 CN.A1 pin 27 421 Gr
19 CN.A2 pin 34 425 Y - 0.75 SHEET 10
20 CN.A2 pin 26 426 GL - 0.85
21 CN.A36_M pin 19 660A BG - 0.85 SHEET 30
22 CN.A3 pin 33 546 LgW SHEET 09
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CONNECTOR CN.A55 – CAB MAIN HARNESS F(20-PIN) (Male)
SMIL14CEX5276AA 11
SMIL14CEX5278AA 12

1 CN.A2 pin 2 901A RW SHEET 10
2 CN.A2 pin 3 902A O
3 CN.A3 pin 3 903A Lg - 0.85 SHEET 08
4 CN.A3 pin 1 904A YR - 0.85
5 CN.A2 pin 4 906A LR SHEET 10
6 CN.A3 pin 2 907A G - 0.85 SHEET 08
7 CN.A2 pin 5 908A R SHEET 10
8 CN.A1 pin 2 911C Y SHEET 11
9 CN.A1 pin 3 912A L
10 CN.A2 pin 9 901B RB SHEET 10
11 CN.A2 pin 11 902B BO
12 CN.A3 pin 13 903B LgR - 0.85 SHEET 08
13 CN.A3 pin 9 904B YB - 0.85
14 CN.A2 pin 6 905A GR SHEET 10
15 CN.A2 pin 27 905B GW
16 CN.A2 pin 7 906B LB
17 CN.A3 pin 4 907B GY - 0.85 SHEET 08
18 CN.A2 pin 19 908B BR SHEET 10
19 CN.A1 pin 9 911B BY SHEET 11
20 CN.A1 pin 1 912D LY
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CONNECTOR CN.A56 – CAB MAIN HARNESS G (18-PIN) (Male)
SMIL14CEX5224AA 13
SMIL14CEX5226AA 14

1 CN.A4 pin 4 801 WG - 0.75 SHEET 06
2 CN.A4 pin 6 802 LR - 0.75
3 CN.A4 pin 3 803 YR - 0.75
4 SP-804 pin X 804E Br - 0.85
5 CN.A4 pin 1 806 Lg
6 CN.A4 pin 5 807 RY - 0.75 SHEET 07
7 SP-808 pin X 808B GW - 0.75 SHEET 05
8 CN.A5 pin 15 815 VG - 0.85
9 CN.A5 pin 5 817 YG - 0.85
10 CN.A3 pin 12 533 GrR - 0.85 SHEET 08
11 CN.A3 pin 32 534 LW SHEET 09
12 CN.A2 pin 29 539 GY - 0.85 SHEET 10
13 SP-430B pin X 430A W - 0.85 SHEET 11
14 SP-440 pin X 440 BL - 0.85
15 CN.A1 pin 26 417 Y
16 CN.A1 pin 16 418 L
17 CN.A1 pin 25 419 R
18 CN.A1 pin 33 420 G
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CONNECTOR CN.D50 – PRESSURE SENSOR (BLUE TAPE) (3-PIN) (Male)
SMIL14CEX6183AA 15
SMIL14CEX6508AA 16

1 SP-430A pin X 430A-3 W - 0.75 SHEET 18
2 CN.A56_M pin 16 418A L - 0.75 SHEET 11
3 SP-440H pin X 440D BL - 0.75 SHEET 18
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CONNECTOR CN.D51 – RETURN ROOM SENSOR (3-PIN) (Female)
SMIL14CEX6185AA 17
SMIL14CEX6184AA 18

1 CN.D51-A pin 1 435K WL - 0.85 SHEET 17
2 CN.D51-A pin 2 414B LgR - 0.85
3 CN.D51-A pin 3 445P BW - 0.85
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CN.D52A PRESSURE SENSOR BOOM CYLINDER (BOTTOM) (3-PIN) (Female)
SMIL14CEX6437AA 19

1 CN.D52-B pin 1 435J WL - 0.85 SHEET 17
2 CN.D52-B pin 2 421B Gr - 0.85
3 CN.D52-B pin 3 445I BW - 0.85
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CONNECTOR CN.D52-B - CN.D52B (Male)

1 CN.D52A pin 1 435J WL - 0.85 SHEET 17
2 CN.D52A pin 2 421B Gr - 0.85
3 CN.D52A pin 3 445I BW - 0.85
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CONNECTOR CN.D53 – FUEL LEVEL SENSOR (2-PIN) (Male)
SMIL14CEX6187AA 20
SMIL14CEX6186AA 21

1 CN.A54_M pin 21 660 BG - 0.85 SHEET 16
2 CN.A54_M pin 20 426A GL - 0.85 SHEET 10
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CONNECTOR CN.D54 – OIL TEMPERATURE SENSOR (2-PIN) (Male)
SMIL14CEX6189AA 22
SMIL14CEX6188AA 23

1 SP-445P pin X 445W BW - 0.75 SHEET 17
2 CN.A54_M pin 19 425A Y - 0.75 SHEET 10
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CONNECTOR CN.D55 – LEVEL LOCK SOLENOID VALVE (2-PIN) (Male)
SMIL14CEX5350AA 24
SMIL14CEX5349AA 25

1 SP-519 pin X 840G R - 0.75 SHEET 40
2 SP-520 pin X 754B B - 0.75
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CONNECTOR CN.D56 – SWING BRAKE SOLENOID VALVE (2-PIN) (Male)
SMIL14CEX6191AA 26
SMIL14CEX5351AA 27

1 SP-521 pin X 801B R - 0.75 SHEET 40
2 SP-522 pin X 755A B - 0.75
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CONNECTOR CN.D57 – TRAVEL HIGH SPEED SOLENOID VALVE (2-PIN) (Male)
SMIL14CEX5354AA 28
SMIL14CEX5353AA 29

1 SP-523 pin X 802B R - 0.75 SHEET 40
2 SP-524 pin X 756A B - 0.75
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CONNECTOR CN.D58 – PRESSURE BOOST RELIEF SOLENOID VALVE (2-PIN) (Male)
SMIL14CEX5356AA 30
SMIL14CEX5355AA 31

1 SP-525 pin X 803B R - 0.75 SHEET 40
2 SP-526 pin X 757A B - 0.75
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CONNECTOR CN.D59 – HYDRAULIC LOAD SOLENOID VALVE (2-PIN) (Male)
SMIL14CEX5358AA 32
SMIL14CEX5357AA 33

1 SP-527 pin X 808D R - 0.75 SHEET 40
2 SP-528 pin X 758A B - 0.75
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CONNECTOR CN.D60 – FREE SWING SOLENOID VALVE (2-PIN) (Female)
SMIL14CEX5360AA 1
SMIL14CEX5359AA 2

1 SP509 pin X 804 BrW - 0.85 SHEET 33
2 SP510 pin X 759A B - 0.75
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CONNECTOR CN.D60–A – FREE SWING SOLENOID VALVE (2-PIN) (Male)

M8 SP-752 pin X 700D B - 2.0 SHEET 33
M8 SP-600B pin X 600 BG - 2.0
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CN.D60–B – GROUND (2-PIN) (Male)

M8 SP-752 pin X 700D B - 2.0 SHEET 12
M8 SP-600B pin X 600 BG - 2.0
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CONNECTOR CN.D61 – QUICK COUPLER SOLENOID VALVE (2-PIN) (Male)
SMIL14CEX5362AA 3
SMIL14CEX5361AA 4

M8 SP-752 pin X 235C B - 2.0 SHEET 33
M8 SP-600B pin X 817A BG - 2.0
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CONNECTOR CN.D62–A – PROPORTIONAL SOLENOID VALVE (2-PIN) (Female)
SMIL14CEX5364AA 5
SMIL14CEX5363AA 6

1 CN.D62 pin-1 902A-2 902A-2 VR - 0.85 SHEET 33
2 CN.D62 pin-1 902B-2 902B-2 VG - 0.85
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CONNECTOR CN.D63 – P1 FLOW PROPORTIONAL SOLENOID VALVE (2-PIN) (Male)
SMIL14CEX5962AA 7
SMIL14CEX5961AA 8

1 CN.A55_M pin 8 911A Y - 0.75 SHEET 11
2 CN.A55_M pin 19 911D BY - 0.75
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CONNECTOR CN.D64 – P2 FLOW PROPORTIONAL SOLENOID VALVE (2-PIN) (Male)
SMIL14CEX5966AA 9
SMIL14CEX5965AA 10

1 CN.A55_M pin 9 912C L - 0.75 SHEET 11
2 CN.A55_M pin 20 912B BL - 0.75
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CONNECTOR CN.D65 – FRAME MAIN HARNESS (8-PIN) (Female)
SMIL14CEX5368AA 11
SMIL14CEX5367AA 12

1 SP-430D pin X 430B-1 W - 0.85 SHEET 11
2 SP-440B pin X 440E BL - 0.85
3 CN.A56_M pin 17 419A R - 0.85
4 CN.A56_M pin 18 420A G - 0.85
5 SP-435 pin X 435D WL - 0.85
6 SP-445E pin X 445E BW - 0.85
7 CN.A54_M pin 4 402A BrW - 0.85
8 CN.A54_M pin 5 403A BrR - 0.85
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CONNECTOR CN.D65–1 – N1 PRESSURE SENSOR (3-PIN) (Male)
SMIL14CEX5972AA 13
SMIL14CEX5969AA 14

1 SP-430C pin X 430B-3 W - 0.85 SHEET 18
2 CN.D65_M pin 3 419B R - 0.85 SHEET 11
3 SP-440C pin X 440G BL - 0.85 SHEET 18
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CONNECTOR CN.D65–2 – N2 PRESSURE SENSOR (3-PIN) (Male)
SMIL14CEX5972AA 15
SMIL14CEX5971AA 16

1 SP-430C pin X 430C W - 0.85 SHEET 18
2 CN.D65_M pin 4 420B G - 0.85 SHEET 11
3 SP-440C pin X 440C BL - 0.85 SHEET 18
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CONNECTOR CN.D65–3 – ARM CYLINDER (ROD) PRESSURE SENSOR (3-PIN) (Male)
SMIL14CEX5975AA 17
SMIL14CEX5976AA 18

1 SP-435I pin X 435Z WL - 0.85 SHEET 18
2 CN.D65_M pin 7 402B BrW - 0.85 SHEET 11
3 SP-445O pin X 445-E BW - 0.85 SHEET 18
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CONNECTOR CN.D65–4 – ARM CYLINDER (BOTTOM) PRESSURE SENSOR (3-PIN) (Male)
SMIL14CEX5977AA 19
SMIL14CEX6510AA 20

1 SP-435I pin X 435I WL - 0.85 SHEET 18
2 CN.D65_M pin 8 403B BrR - 0.85 SHEET 11
3 SP-445O pin X 445O BW - 0.85 SHEET 18
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CONNECTOR CN.D66 – FRAME MAIN HARNESS (12-PIN) (Male)
SMIL14CEX5370AA 21
SMIL14CEX5369AA 22

1 CN.A55_M pin 14 905A-1 GR - 0.85 SHEET 10
2 CN.A55_M pin 15 905B-1 GW - 0.85
3 CN.A55_M pin 7 908A-1 R - 0.85
4 CN.A55_M pin 18 908B-1 BO - 0.85
5 CN.A55_M pin 6 907A-1 G - 0.85 SHEET 08
6 CN.A55_M pin 17 907B-1 GY - 0.85
7 CN.A55_M pin 5 906A-1 LR - 0.85 SHEET 10
8 CN.A55_M pin 16 906B-1 LY - 0.85
9 CN.A55_M pin 4 904A-1 YR - 0.85 SHEET 08
10 CN.A55_M pin 13 904B-1 YB - 0.85
11 CN.A55_M pin 3 903A-1 WG - 0.85
12 CN.A55_M pin 12 903B-1 LgR - 0.85
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CONNECTOR CN.D66–1 – BUCKET CLOSE PROPORTIONAL SOLENOID VALVE (2-PIN) (Male)
SMIL14CEX6142AA 23
SMIL14CEX6141AA 24

1 CN.D66_M pin 1 905A-2 GR - 0.85 SHEET 33
2 CN.D66_M pin 2 905B-2 GW - 0.85
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CONNECTOR CN.D66–2 – TRAVEL STRAIGHT PROPORTIONAL SOLENOID VALVE (2-PIN) (Male)
SMIL14CEX6143AA 25
SMIL14CEX6144AA 26

1 CN.D66_M pin 4 908A-2 BO - 0.85 SHEET 33
2 CN.D66_M pin 3 908B-2 R - 0.85
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CONNECTOR CN.D66–3 – ARM2 PARALLEL PROPORTIONAL SOLENOID VALVE (2-PIN) (Male)
SMIL14CEX6146AA 27
SMIL14CEX6145AA 28

1 CN.D66_M pin 5 907A-2 G - 0.85 SHEET 33
2 CN.D66_M pin 6 907B-2 GY - 0.85
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CONNECTOR CN.D66–4 – ARM1 RECYCLE PROPORTIONAL SOLENOID VALVE (2-PIN) (Male)
SMIL14CEX6148AA 29
SMIL14CEX6147AA 30

1 CN.D66_M pin 8 906A-2 LY - 0.85 SHEET 33
2 CN.D66_M pin 7 906B-2 LR - 0.85
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CONNECTOR CN.D66–5 – BOOM2 DOWN PROPORTIONAL SOLENOID VALVE (2-PIN) (Male)
SMIL14CEX6150AA 31
SMIL14CEX6149AA 32

1 CN.D66_M pin 9 904A-2 YR - 0.85 SHEET 33
2 CN.D66_M pin 10 904B-2 YB - 0.85
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CONNECTOR CN.D66–6 – ARM1 PARALLEL PROPORTIONAL SOLENOID VALVE (2-PIN) (Male)
SMIL14CEX6154AA 33
SMIL14CEX6153AA 34

1 CN.D66_M pin 11 903A-2 WG - 0.85 SHEET 33
2 CN.D66_M pin 12 903B-2 LgR - 0.85
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CONNECTOR CN.D67 – FUSIBLE 50 A: LINK BACK UP (2-PIN) (Male)
SMIL14CEX6220AA 35
SMIL14CEX6219AA 36

1 K7 pin 30 102 102 RW - 5.0 SHEET 01
2 SP-103A pin X 103E 103E RW - 5.0 SHEET 02
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CONNECTOR CN.D68 – FUSE 10 A: SCR CONTROL UNIT (4-PIN) (Male)
SMIL14CEX5333AA 37
SMIL14CEX5332AA 38

3 SP-105A pin X 105B 105B R - 2.0 SHEET 15
4 K7 pin 30 104 104 R - 2.0 SHEET 01
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CONNECTOR CN.D69 – FUSIBLE 20 A: UREA PUMP (4-PIN) (Male)
SMIL14CEX5335AA 39
SMIL14CEX5334AA 40

1 CN.D32 P1 260 YR - 0.85 SHEET 39
2 SP-106C pin X 106C R - 3.0 SHEET 02
3 CN.D89 P1 265 R - 1.25
4 SP-106C pin X 106 R - 3.0
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CONNECTOR CN.D70 – FUEL PUMP (4-PIN) (Male)
SMIL14CEX5337AA 1
SMIL14CEX5336AA 2

1 CN.D17 P1 250C YG - 0.75 SHEET 21
2 SP-106A pin X 106A R - 0.85 SHEET 02
3 SP-564 pin X 255 W - 2.0 SHEET 27
4 SP-106B pin X 106B R - 1.25 SHEET 02
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CONNECTOR CN.D71 – FUSIBLE LINK 1 SAFTY RL (2-PIN) (Male)
SMIL14CEX5339AA 3
SMIL14CEX5338AA 4

1 SP-002 pin X 002 R - 5.0 SHEET 02
2 SP-003 pin X 003 R - 5.0
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CONNECTOR CN.D72 – FUSIBLE LINK 2 SAFETY RL (2-PIN) (Male)
SMIL14CEX5341AA 5
SMIL14CEX5340AA 6

1 SP-002 pin X 002A R - 5.0 SHEET 02
2 SP-003 pin X 003A R - 5.0
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CONNECTOR CN.D73 – BATTERY RELAY COIL 1 (Male)
SMIL14CEX6212AA 7

M4 SP-501B pin X 501K G - 1.25 SHEET 01
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CONNECTOR CN.D74 – BATTERY RELAY COIL 2 (Male)
SMIL14CEX6213AA 8

M4 CN.A52_M pin 3 812C WR - 1.25 SHEET 07
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CONNECTOR CN.D75 – BATTERY RELAY GROUND (1-PIN) (Male)
SMIL14CEX5343AA 9
SMIL14CEX5342AA 10

1 SP-751 pin X 751 B - 0.85 SHEET 01
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CONNECTOR CN.D76 – BATTERY RELAY B1 (Male)
SMIL14CEX6215AA 11

M8 CN.D211 P M10 101 R - 60.0 SHEET 01
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CONNECTOR CN.D77 – BATTERY RELAY B2 (Male)
SMIL14CEX6216AA 12

M8 CN.D68 P M10 101 R - 104 SHEET 02
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CN.D78 - BATTERY RELAY IGN (Male)
SMIL14CEX6217AA 13

M8 P89 P M10 001 R - 60.0 SHEET 01
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CONNECTOR CN.D79 – FUSE 60 A: 1 (Male)
SMIL14CEX6218AA 14

1 SP-002 pin X 106D 106D R - 3.0 SHEET 02
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SMIL14CEX6195AA 1

1 K7 pin 87A 031 R - 20.0 SHEET 01
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SMIL14CEX6196AA 2

1 CN.A50_M pin 2 109 R - 8.0 SHEET 04
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SMIL14CEX6197AA 3

1 CN.D13 pin M6 030 R - 20.0 SHEET 01
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CONNECTOR CN.D83 – STARTER RELAY: B / C (2-PIN) (Male)
SMIL14CEX6201AA 4
SMIL14CEX6200AA 5

1 SP-003 pin X 003B R - 5.0 SHEET 02
2 CN.D12 pin M4 004 Y - 5.0 SHEET 01
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CONNECTOR CN.D84 – STARTER RELAY: S/E (2-PIN) (Male)
SMIL14CEX6199AA 6
SMIL14CEX6198AA 7

1 SP-012 pin X 012 GrR - 0.85 SHEET 01
2 SP-750 pin X 750 B - 0.85
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CONNECTOR CN.D85 – STARTER: DIODE (2-PIN) (Male)
SMIL14CEX6203AA 8
SMIL14CEX6202AA 9

1 SP-012 pin X 012A GrR - 0.85 SHEET 01
2 SP-750 pin X 750A B - 0.85
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CONNECTOR CN.D86 – GLOW RELAY: 2 (1-PIN) (Male)
SMIL14CEX6205AA 10
SMIL14CEX6204AA 11

1 CN.D11 pin 1 021 L - 5.0 SHEET 01
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CONNECTOR CN.D87 – GLOW RELAY: 1 (1-PIN) (Male)
SMIL14CEX6207AA 12
SMIL14CEX6206AA 13

1 SP-103A pin X 103C RW - 5.0 SHEET 01
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CONNECTOR CN.D88 – GLOW RELAY COIL (2-PIN) (Male)
SMIL14CEX6209AA 14
SMIL14CEX6208AA 15

1 SP-501C pin X 501P G - 0.85 SHEET 09
2 CN.D3 pin V91 372 L - 0.85 SHEET 12
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CONNECTOR CN.D89 – OPTION POWER SUPPLY (2-PIN) (Male)
SMIL14CEX6211AA 16
SMIL14CEX6211AA 17

1 CN.D69 pin 3 265 R - 1.25 SHEET 02
2 SP-770 pin X 770 B - 1.25 SHEET 01
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CONNECTOR CN.D90 – GROUND JOINT CONNECTOR (8 PIN) (Female)
SMIL14CEX6193AA 1
SMIL14CEX6192AA 2

1 CN.D90_M pin 8 760 Br - 1.25 SHEET 06
3 CN.D66_M pin2 754 B 0.75 SHEET 40
4 CN.D56_M pin2 755 B 0.75 SHEET 06
5 CN.D57_M pin2 756 B 0.75
6 CN.D58_M pin2 757 B 0.75
8 CN.D91_M pin8 760 Br 1.25
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CONNECTOR CN.D91 – G2 GROUND
SMIL14CEX6194AA 3

M8 CN.D90_M pin 8 760 Br - 1.25 SHEET 06
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CONNECTOR CN.D92 – G1 GROUND (Male)

M8 SP674 pin X 700F B - 2.0 SHEET 40
M8 SP-759 pin X 700A B - 2.0 SHEET 29
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Index

Wiring harnesses - Electrical schematic sheet 02 - POWER DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Wiring harnesses - Electrical schematic sheet 03 - POWER DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Wiring harnesses - Electrical schematic sheet 04 - POWER DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Wiring harnesses - Electrical schematic sheet 06 - MAIN CONTROLLER A1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Wiring harnesses - Electrical schematic sheet 12 - ENGINE CONTROLLER A2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Wiring harnesses - Electrical schematic sheet 15 - DOSING CONTROL UNIT-A17 . . . . . . . . . . . . . . . . . . . . . . . . 40
Wiring harnesses - Electrical schematic sheet 16 - SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Wiring harnesses - Electrical schematic sheet 19 - SENSORS AND SUCTION VALVE . . . . . . . . . . . . . . . . . . . . . 48
Wiring harnesses - Electrical schematic sheet 20 - ENGINE, VGS TURBO, EGR VALVE, THROTTLE MOTOR 50
Wiring harnesses - Electrical schematic sheet 21 - INJECTORS AND AIR INTAKE SENSOR . . . . . . . . . . . . . . . 52
Wiring harnesses - Electrical schematic sheet 22 - OPTION PEDAL, SOLENOID, PROPORTIONAL CIRCUIT 54
Wiring harnesses - Electrical schematic sheet 23 - OPTION PROPORTIONAL SOLENOID CIRCUIT . . . . . . . . 56
Wiring harnesses - Electrical schematic sheet 24 - KNOB-RIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Wiring harnesses - Electrical schematic sheet 25 - KNOB LEFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Wiring harnesses - Electrical schematic sheet 26 - AIR CONDITIONER SWITCH PANEL & UNIT . . . . . . . . . . . . 62
Wiring harnesses - Electrical schematic sheet 27 - AIR CONDITIONER UNIT & REFUEL PUMP . . . . . . . . . . . . 64
Wiring harnesses - Electrical schematic sheet 28 - CCD CAMERA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Wiring harnesses - Electrical schematic sheet 29 - MAIN CAB-ECM INTER CONNECTOR . . . . . . . . . . . . . . . . . 68
Wiring harnesses - Electrical schematic sheet 30 - MAIN CAB-INTER CONNECTOR . . . . . . . . . . . . . . . . . . . . . . 70
Wiring harnesses - Electrical schematic sheet 31 - MAIN CAB-RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Wiring harnesses - Electrical schematic sheet 32 - MAIN CAB-RELAYS, RADIO AND CONVERTER . . . . . . . . . 74
Wiring harnesses - Electrical schematic sheet 33 - PROPORTIONAL S/V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Wiring harnesses - Electrical schematic sheet 34 - MAIN CAB-MONITOR DISPLAY . . . . . . . . . . . . . . . . . . . . . . . 78
Wiring harnesses - Electrical schematic sheet 35 - WIPER CONTROLLER, WIPER MOTOR AND SENSOR . . 80
Wiring harnesses - Electrical schematic sheet 36 - ACC SOCKET, CIGAR LIGHTER, IMMOBILIZER . . . . . . . . 82
Wiring harnesses - Electrical schematic sheet 37 - OPTION POWER / FVM, KEY SWITCH . . . . . . . . . . . . . . . . . 84
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Wiring harnesses - Electrical schematic sheet 38 - OVER LOAD, BEACON, TRAVEL ALARM, REVERSE FAN,
FREE SWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Wiring harnesses - Electrical schematic sheet 39 - LAMP, PUMP, WASHER, HORN, UREA PUMP . . . . . . . . . . 88
Wiring harnesses - Electrical schematic sheet 40 - SOLENOID VALVE, MAGNET CLUTCH, RECEIVER DRYER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Wire connectors - Component diagram 00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Wire connectors - Component diagram 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Wiring harnesses - Electrical schematic sheet 01 - STARTING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Cab engine controls - 525

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Contents
FUNCTIONAL DATA
Cab engine controls

Dynamic description - Auto idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Dynamic description - One-touch idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Dynamic description - Auto warm up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Dynamic description - Idle shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Accelerator potentiometer
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Dynamic description - Throttle volume position detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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Electrical systems - Cab engine controls
Cab engine controls - Dynamic description - Auto idle

Purpose/overview
The system lower the engine speed when the system is not operated for a certain time continuously.
SMIL14CEX3432FB 1
1. Monitor 7. Pressure sensor (option 1)

2. Main controller 8. Pressure sensor (option 2)
3. Engine 9. Pressure sensor (upper)
4. ECM 10. Pressure sensor (swing)
5. One-touch idle switch 11. Pressure sensor (travel)
6. Throttle volume
Operation condition
The auto idle is activated with the following conditions.
• The auto idle switch is pressed and the auto idle mode is ON.
• The operation lever is not operated for a certain time continuously. (Either one of the following pressure sensors is
OFF for a certain time continuously; upper, swing, travel, option 1, option 2)
Stop condition
The system releases auto idle with the following conditions.
• When the operation lever is operated. (Either one of the following pressure sensors is ON; upper, swing, travel,
option 1, option 2)
• When the throttle volume is operated.
• When the one-touch idle switch is pressed.
• The auto idle is not activated if the engine speed is lower than auto idle RPM (during low idle) or if the fan is reversed.
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Cab engine controls - Dynamic description - One-touch idle

Purpose/overview
The system lowers speed to low idle speed when the one-touch idle switch is pressed, and resumes to original speed
if it is pressed again.
SMIL14CEX3433FB 1

5. One-touch idle switch 11. Pressure sensor (travel)
6. Throttle volume
Operation condition
The one-touch idle is activated with the following conditions.
• The operation lever is not operated. (Either one of the following pressure sensors is OFF; upper, swing, travel,
option 1, option 2)
Stop condition
The one-touch idle is released with the following conditions.
• When the one-touch idle switch is pressed during one-touch idle.
• When the operation lever is operated. (Either one of the following pressure sensors is ON; upper, swing, travel,
option 1, option 2)
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Cab engine controls - Dynamic description - Auto warm up

Purpose/overview
In case of low coolant temperature when the engine is started, the engine is warmed up automatically. (Auto warm-up)
When the outside air temperature is -10 °C (14 °F) or less, a warm-up will be carried out so that urea may not freeze.
(Urea thawing, heat insulating and warm-up)
The urea thawing, heat insulating and warm-up operation always performs a warm-up according to how you operate
the machine.
When, during the auto warm-up, the outside air temperature is -10 °C (14 °F) or less, a warm-up will be carried out to
ensure the heating performance. (Quick warm-up)
Since the urea thawing, heat insulating and warm-up operation overrides the quick warm-up, the quick warm-up is
carried out as only a part of the auto warm-up.
SMIL14CEX6811EB 1
a Normal e The engine is started.

b Auto warm-up f The coolant temperature increases.
c Quick warm-up g The machine is operated.
d Urea thawing, heat insulating and warm-up h The machine is not operated.
There are three warm-up controls:

• Auto warm-up
• Quick warm-up
• Urea thawing, heat insulating and warm-up
During the warm-up, the monitor displays the following.

• During the auto or the quick warm-up, the auto warm-up message appears on the monitor.
• During the urea thawing, heat insulating and warm-up, only the icon appears on the monitor.
SMIL14CEX6812EB 2
1 Message display
2 Icon display
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Configuration
SMIL14CEX3434GB 3
1. Monitor 9. One-touch idle switch

2. Main controller 10. Throttle volume
3. ECM 11. Oil temperature sensor
4. Pressure sensor (upper) 12. Coolant temperature sensor
5. Pressure sensor (swing) 13. Suction air temperature sensor
6. Pressure sensor (travel) 14. Hydraulic pressure load solenoid
7. Pressure sensor (option 1) 15. Neutral half cut
8. Pressure sensor (option 2) 16. Engine
Operation (auto warm-up)

The engine speed during auto warm-up operation changes in stages as follows.
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SMIL14CEX6813EA 4
a. 5 min e. Warm-up level 4/SP mode rotation

b. 3 min f. Warm-up level 3/A mode rotation
c. 3 min g. Warm-up level 2/Auto idle rotation
d. 3 min h. Warm-up level 1/Low idle rotation
Controls (auto/quick warm-up)

When all the following conditions are fulfilled, the machine starts auto warm-up operation and displays "Auto
Warm Up" on the monitor.
• Engine OFF → ON.
• Coolant temperature ＜ 50 °C (122 °F).
• The fan is not reversing.
• The counterweight removal/installation mode is not established.
• The lifting magnet is attracting nothing.
• Not during inducement (Final).
• The ECM has not generated a diagnostic trouble code. (Except some SCR-related DTCs)
• Oil temperature sensor trouble (DTC: 7041) has not occurred.
• Oil temperature 70 °C (158 °F).
• Not during SCR CLEANING.
• Not during auto calibration.
When the following conditions are fulfilled during auto warm-up operation (warm-up level 2 to 4), the quick warm-up
control will start to apply the hydraulic pressure load.
• Outside air temperature -10 °C (14 °F)
NOTE: Outside air temperature = Intake air temperature -10 °C (14 °F)
NOTE: By changing the neutral cut spool, the hydraulic pressure load uses a center bypass cut to control the pump
flow.
When the following conditions are fulfilled during auto warm-up operation (warm-up level 2 to 4), the quick warm-up
control will end to release the hydraulic pressure load.
• Outside air temperature ＞ -10 °C (14 °F)
When one of the following conditions is fulfilled, the machine ends auto warm-up operation and hides "Auto Warm
Up" on the monitor.
• Auto warm-up ends. (Fourteen minutes have passed.)
• Engine OFF.
• Coolant temperature 50 °C (122 °F).
• The fan is reversing.
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• The counterweight removal/installation mode is established.

• The lifting magnet is attracting something.
• Inducement (Final) has occurred.
• The ECM has generated a diagnostic trouble code. (Except some SCR-related DTCs)
• Lever operation. (Either one of the following pressure sensors is ON; upper, swing, travel, option 1, option 2)
• Throttle volume operation.
• The one-touch idle switch is pressed.
• Oil temperature sensor trouble (DTC: 7041) has occurred.
• SCR CLEANING is started.
• Auto calibration is started.
Operation (urea thawing, heat insulating and warm-up)

In order to maintain the target coolant temperature, thawing, heat insulating and warm-up operation is carried out.
The target coolant temperature is maintained by applying the hydraulic pressure load with the engine speed main-
tained.
In case of low coolant temperature, it will take a long time for the coolant temperature to become stable after the load
is applied.
Controls (urea thawing, heat insulating and warm-up)

When all the following conditions are fulfilled, the machine starts urea thawing, heat insulating and warm-up
operation and displays the icon on the monitor.
While the engine is running
• Lever operation is not performed. (All the following pressure sensors are OFF; upper, swing, travel, option 1, option
2)
• The throttle volume is not operated.
• The one-touch idle switch is not pressed.
In these situations, 2 min or more have passed. (If the auto warm-up has been carried out for 2 min or more, the
urea thawing, heat insulating and warm-up starts immediately.)
• Outside air temperature -10 °C (14 °F).
• The actual coolant temperature is less than or equal to the target coolant temperature for urea thawing, heat insu-
lating and warm-up.
• The fan is not reversing.
• The counterweight removal/installation mode is not established.
• The lifting magnet is attracting nothing.
• Not during inducement (Final).
• The ECM has not generated a diagnostic trouble code. (Except some SCR-related DTCs)
• Oil temperature sensor trouble (DTC: 7041) has not occurred.
• Not during SCR CLEANING.
• Not during auto calibration.
When one of the following conditions is fulfilled, the machine ends urea thawing, heat insulating and warm-up
operation and hides the icon on the monitor.
• Outside air temperature -8 °C (18 °F). (For initial judgment, outside temperature ＞ -10 °C (14 °F))
• Engine OFF.
• The fan is reversing.
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• The counterweight removal/installation mode is established.

• The lifting magnet is attracting something.
• Inducement (Final) has occurred.
• The ECM has generated a diagnostic trouble code. (Except some SCR-related DTCs)
• Lever operation. (Either one of the following pressure sensors is ON; upper, swing, travel, option 1, option 2)
• Throttle volume operation.
• The one-touch idle switch is pressed.
• Oil temperature sensor trouble (DTC: 7041) has occurred.
• SCR CLEANING is started.
• Auto calibration is started.
Even if the coolant temperature is beyond the target one, the urea thawing, heat insulating and warm-up continues.
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Cab engine controls - Dynamic description - Idle shutdown

Purpose/overview
The machine stops the engine automatically when idling condition continues for a certain time period.
SMIL14CEX3436FB 1

3. ECM 9. Gate lever limit switch
4. Pressure sensor (upper) 10. Battery relay
5. Pressure sensor (swing) 11. Engine
6. Pressure sensor (travel) 12. M line
Operation
1. The machine starts time count when the idle mode switch is pressed and idle shutdown mode is selected.
2. It displays "Stopping Engine" on the monitor and sounds alarm intermittently when the time count reaches idle
shutdown time.
3. In further 10 s, it activates idle shutdown control and sounds the alarm continuously at the same time.
4. If the idle shutdown control is activated, the controller turns ON (energizes) the key ON relay to cut the M line of
the key switch.
5. The ECM judges as the Key OFF to stop the engine when the M line is cut.
6. It turns OFF the key ON relay to release the cut of the M line if the key is set to OFF.
Stop condition
The idling stop function is not activated with the following conditions.
• The operation lever is operated. (Either one of the following pressure sensors is ON; upper, swing, travel, option
1, option 2)
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• The gate lever is closed (gate lever switch is ON).

• The engine RPM is 1200 RPM or more.
• During auto warm up operation
• During fan reverse mode
• Not during auto calibration
• Not during purge control
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Accelerator potentiometer - Overview

Purpose/overview
The system commands target RPM of the engine based on degree of opening of the throttle volume (work mode
selection).
SMIL14CEX3431FB 1
1. Work mode icon 4. ECM

2. Monitor 5. Engine
3. Main controller 6. Throttle volume
Operation
1. Turn ON the key.
2. The system calculates target RPM to the engine based on voltage signal of the throttle VOL.
3. It displays icon to indicate the work mode on the monitor.
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Accelerator potentiometer - Dynamic description - Throttle volume

position detection
Purpose/overview
The system allows work mode to be selected by operating the throttle volume. It computes the target engine speed
from the degree of opening of the throttle volume, and controls the engine speed so that it may achieve the target
speed.
SMIL14CEX1027FB 1
1 Throttle volume 3 Potentiometer

2 Main controller
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Throttle volume position

A click feel is produced by a detent and notches. (No. of notches: 15, Notch 1: “SP mode” position)
SMIL14CEX1028FB 2
1 Detent d Large notch: 1 - 3

a Clockwise e Hysteresis (about 2.5°)
b Counterclockwise f Notch N
c Small notch: 4 - 15
Control
Operation condition:
1. Detent number judgment:
A hysteresis (about 2.5°) is used to absorb an error, and the notch position (throttle volume position) is detected.
○ Clockwise: When the detent reaches the position N-, it will be judged to be in the notch N.
○ Counterclockwise: When the detent reaches the position N+, it will be judged to be in the notch N.
Detent number 4 3 2 1
Theoretical degree of opening of
64.0 76.0 88.0 100.0
throttle volume [%]
2. Operation judgment: When the threshold value is exceeded by ±3% from the current value, it will be judged to be
moved.
3. Position correction:
When the throttle volume is placed in H mode (detent number 2), the system will set the difference between the
theoretical position and the actual position of the H mode as a correction amount, and the position after correction
will be calculated as “actual throttle volume position + correction amount.”
*The maximum correction amount is 10%.
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Target engine speed

The target engine speed is calculated from the degree of opening (position) of the throttle volume.
SMIL14CEX1029FB 3
1. Engine speed [min-1]Detent number c. rpm-A

2. Detent number d. rpm-Lo
3. Hysteresis e. Position Lo (fixed at 10%)
4. Throttle volume position [%] (position) f. Position A
5. h play g. Position H
a. rpm-SP h. Position SP
b. rpm-H
Control
Calculation of target speed:
1. Required throttle speed
Required throttle speed (engine Variable name in

Detent number Degree of opening of volume
speed) Fig.
1 SP mode speed rpm-SP
2 H mode speed rpm-H
3 A mode speed rpm-A
Calculated from degree of opening
4 or above 10% or more of volume (e-f in Fig.) and linear
expression in Fig.
4 or above Less than 10% Low idle speed rpm-Lo
2. Target engine speed

○ Offset of speed:
Although the offset speed is usually zero, it dynamically varies with AES, BES, etc. Therefore, the output speed
(target engine speed) should be obtained by subtracting the offset speed from the throttle speed.
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○ Lower limit of speed:

If the speed after offset is lower than the lower-limit speed, the output speed should be obtained by increasing
it up to the lower-limit speed so that it may not fall below the lower limit speed.
○ Upper limit of speed:
If the speed after offset is higher than the upper-limit speed, the output speed should be obtained by discarding
that higher than the upper-limit speed so that it may not exceed the upper-limit speed.
3. Change of lower/upper limit of speed
○ When lifting magnet mode is ON:
If the target speed is lower than the lifting magnet mode speed, it is increased up to the lifting magnet mode
speed (the lifting magnet mode speed acts as the lower-limit speed).
○ When idle up is ON:
If the target speed is lower than the idle up speed, it is increased up to the idle up speed (the idle up speed acts
as the lower-limit speed).
○ When crane mode is ON:
If the target speed is higher than the crane mode speed, it is decreased down to the crane mode speed (the
crane mode speed acts as the upper-limit speed).
a. Characteristics of potentiometer
SMIL14CEX1030FB 4
*1 Voltage [V] *4 Abnormality

*2 Angle [deg] *5 normal
*3 Throttle operation range *6 Potentiometer operation range
b. Calculation of degree of opening of throttle volume
The degree of opening (%) of the throttle volume, which can be checked on the CHK screen, is calculated on the
following criteria.
100%: When the detent is in the position 1+
0%: When the detent is in the position 15-
Therefore, even if the detent is in the position 1 (SP), the degree of opening is not always 100%.
Likewise, even if the detent is in the position 15, it is not always 0%.
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c. Table
Refer to the following table for the angle, voltage, and degree of opening of each detent position.
detent Angle [deg] Voltage [V] Degree of opening [%]

1+ 131.2 ° 4.86 V 100.0 %
1 128.7 ° 4.77 V 98.0 %
1- 126.2 ° 4.67 V 96.1 %
2+ 109.6 ° 4.06 V 83.0 %
2 107.1 ° 3.97 V 81.1 %
2- 104.6 ° 3.87 V 79.1 %
3+ 95.2 ° 3.53 V 71.7 %
3 92.7 ° 3.43 V 69.8 %
3- 90.2 ° 3.34 V 67.8 %
4+ 88.0 ° 3.26 V 66.1 %
4 85.5 ° 3.17 V 64.1 %
4- 83.0 ° 3.07 V 62.2 %
5+ 80.8 ° 2.99 V 60.4 %
5 78.3 ° 2.90 V 58.5 %
5- 75.8 ° 2.81 V 56.5 %
6+ 73.6 ° 2.73 V 54.8 %
6 71.1 ° 2.63 V 52.8 %
6- 68.6 ° 2.54 V 50.9 %
7+ 66.4 ° 2.46 V 49.1 %
7 63.9 ° 2.37 V 47.2 %
7- 61.4 ° 2.27 V 45.2 %
8+ 59.2 ° 2.19 V 43.5 %
8 56.7 ° 2.10 V 41.5 %
8- 54.2 ° 2.01 V 39.6 %
9+ 52.0 ° 1.93 V 37.8 %
9 49.5 ° 1.83 V 35.9 %
9- 47.0 ° 1.74 V 33.9 %
10+ 44.8 ° 1.66 V 32.2 %
10 42.3 ° 1.57 V 30.2 %
10- 39.8 ° 1.47 V 28.3 %
11+ 37.6 ° 1.39 V 26.5 %
11 35.1 ° 1.30 V 24.6 %
11- 32.6 ° 1.21 V 22.6 %
12+ 30.4 ° 1.13 V 20.9 %
12 27.9 ° 1.03 V 18.9 %
12- 25.4 ° 0.94 V 17.0 %
13+ 23.2 ° 0.86 V 15.2 %
13 20.7 ° 0.77 V 13.3 %
13- 18.2 ° 0.67 V 11.3 %
14+ 16.0 ° 0.59 V 9.6 %
14 13.5 ° 0.50 V 7.6 %
14- 11.0 ° 0.41 V 5.7 %
15+ 8.8 ° 0.33 V 3.9 %
15 6.3 ° 0.23 V 2.0 %
15- 3.8 ° 0.14 V 0.0 %
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Index

Accelerator potentiometer - Dynamic description - Throttle volume position detection . . . . . . . . . . . . . . . . . . . . . . . 13
Accelerator potentiometer - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cab engine controls - Dynamic description - Auto idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cab engine controls - Dynamic description - Auto warm up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cab engine controls - Dynamic description - Idle shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cab engine controls - Dynamic description - One-touch idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Engine control system - 015

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Contents
TECHNICAL DATA
Engine Control Unit (ECU)

Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Engine control system

Wiring schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Fault code index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
SERVICE
Engine control system

Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Engine speed/RPM sensor
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Engine timing sensors
Camshaft sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Camshaft sensor - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Camshaft sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
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Electrical systems - Engine control system
Engine Control Unit (ECU) - Service limits

The purpose of data list is for checking the status of the machine and each equipment.
This data is used in trouble diagnosis by comparing the each machine data with standard values, and checking
whether the vehicle data is temporarily or always different from the reference values.
This display menu is subject to change without notice.
Idle speed
Data display items Unit Reference value
Battery voltage V
Desired engine speed RPM
Engine speed RPM
Accelerator pedal position sensor 1 （APP1） V
Accelerator pedal position sensor 2 APP2） V
Accelerator pedal position （APP）％
Fuel rail pressure sensor V
Fuel rail pressure feedback 　
Engine coolant temperature sensor V
Coolant temperature °C
Intake air temperature sensor V
Intake air temperature °C
Fuel temperature sensor V
Fuel temperature °C
Barometric pressure sensor V
Barometric pressure kPa
Boost temperature sensor voltage V
Boost pressure sensor kPa
No. 1 cylinder fuel correction amount mm3/st
Engine mode 　
EGR valve 1 drive duty ％
EGR position 1 ON/OFF
Ignition switch ON/OFF
Glow relay ON/OFF
Fuel delivery rate data 1 　
Two pump relief

Data Display Items Unit Reference value
Battery voltage V
Desired engine speed RPM
Engine speed RPM
Accelerator pedal position sensor 1
V
（APP1）
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Data Display Items Unit Reference value

Accelerator pedal position sensor 2
V
（APP2）
Accelerator pedal position （APP） %
Fuel rail pressure sensor V
Fuel rail pressure feedback
Engine coolant temperature sensor V
Coolant temperature °C
Intake air temperature sensor V
Intake air temperature °C
Fuel temperature sensor V
Fuel temperature °C
Barometric pressure sensor V
Barometric pressure kPa
Boost temperature sensor voltage V
Boost pressure sensor kPa
Engine mode
EGR valve 1 drive duty %
Glow relay ON/OFF
Fuel delivery rate data 1
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Engine control system - Static description

Engine control system overview and implementation.
The engine control system is an electronic control system that controls the engine so as to always be in the optimal
combustion state according to the driving condition, and consists of the electronic control fuel injection system, the
EGR, and the idling control.
Also, besides controlling the engine, the engine control system has a QOS system, engine speed signal output, self
diagnosing functionality, and CAN communication SAE J1939/21 and SAE J1939/11 system control functions.
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Engine control system - Component identification

System control schematic
The specifications vary depending on the machine, so refer to the manual for the machine.
SMIL14CEX3891GB 1
Correction
Engine coolant temperature correction
Barometric pressure correction
a. Fuel temperature boost pressure correction
Interval correction of cylinders
Q resistance correction
QR correction
*1. Required engine speed *11. Machine control unit

*2. Boost sensor input *12. Coolant temperature sensor input
*3. CKP sensor input *13. Common rail pressure sensor
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*4. CMP sensor input *14. Common rail

*5. Engine Control Module (ECM) *15. SCV
*6. Basic fuel injection quantity *16. Supply pump
*7. Correction *17. Fuel tank
*8. SCV open/close timing is decided *18. Injector coil
*9. Injector coil electrified time and timing decision *19. Injector
*10. CAN communication
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Engine control system - Dynamic description

Fuel injection correction
The ECM calculates the basic injection quantity based on
the signals from the accelerator position sensor, boost
sensor, CKP sensor, CMP sensor, etc. Then, the open/
close timing of the SCV and the energizing time of the
injector are controlled based on conditions such as the
common rail (fuel rail) pressure and engine coolant tem-
perature, which allows for optimal corrections to the injec-
tion timing and the injection quantity.
About the initial fuel delivery rate The ECM implements

the initial fuel delivery rate when the initial fuel delivery
rate is less than the specified engine speed when the en-
gine is started. Also, when the engine speed is lower than
the system can recognize, the ECM cannot implement the
initial fuel delivery rate and cannot start the engine be-
cause it does not recognize the engine speed.
*1. Idle speed

*2. Specified engine speed for starting Q correction
*3. Minimum starting engine speed
*4. System recognized engine speed
A. Engine speed (r/min)
SMIL14CEX3892EB 1
About high altitude correction

The ECM calculates the current altitude using signals from
the barometric pressure sensor.
According to conditions such as the current altitude, the

fuel flow rate is optimally calibrated.
*1. Altitude
A. Barometric pressure kPa
B. Fuel flow limit（mm3/st）
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SMIL14CEX3893EB 2
Control during overheat

To protect the engine, restriction on fuel flow is started
when the engine coolant temperature exceeds 100 °C
(212 °F). When the engine coolant temperature increases
further, the fuel flow is also restricted further. When the
temperature reaches 110 °C (230 °F), the DTC is set and
a failure is recorded in the ECM. The fuel flow is restricted
to a predetermined level around 120 °C (248 °F). The
setting varies depending on the machine manufacturer.
The machine is designed to issue an alarm starting at

105 °C (221 °F). By reducing the load applied to the ma-
chine upon alarm issuance, it is possible to avoid an op-
eration condition where fuel flow is restricted.
*1. Warning display

*2. DTC set
A. Fuel flow
B. Engine coolant temperature
SMIL14CEX3894EB 3
If the ECM is equipped with an emergency stop function

by a high engine coolant temperature, it stops the engine
when the temperature has reached 105 °C (221 °F).
*1. Engine emergency stop

A. Fuel flow
B. Engine coolant temperature
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SMIL14CEX3895EB 4
Engine emergency stop function

The ECM is designed to make an emergency engine stop
when there is input from the engine stop switch, when
there is a decrease in the engine oil pressure, when there
is an increase in the engine coolant temperature, or when
an overrun occurs.
For an emergency stop made due to a decrease in the en-

gine oil pressure, an increase in the engine coolant tem-
perature, or an overrun, the control is performed when the
corresponding function is added to the calibration of the
ECM.
Input from the engine stop switch The engine stops when
battery voltage is applied to ECM terminal No. B50.
*1. Engine emergency stop switch

*2. Starter switch (ON)
SMIL14CEX3896EB 5
Decrease in engine oil pressure

When the engine oil pressure drops to 100 kPa (15 psi) or less, an alarm for the engine oil pressure decrease is
issued and the engine is stopped.
Increase in engine coolant temperature When the engine coolant temperature increases to 105 °C (221 °F) or more,
the engine coolant temperature increase alarm is issued and the engine is stopped.
Overrun
When the engine speed reaches a specified value or more, an overrun alarm is issued and the engine is stopped.
The specified value varies depending on the machine manufacturer.
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I/O Table
SMIL14CEX3897GA 6
*1. Sensor input *31. Air cleaner switch

*2. CKP sensor *32. Memory clear switch
*3. CMP sensor *33. Engine emergency stop switch
*4. Coolant temperature sensor *34. ECM
*5. Fuel temperature sensor *35. Barometric pressure sensor (Built-in ECM)
*6. IAT sensor *36. Injection control output
*7. IMT sensor *37. Suction control valve
*8. Fuel pressure sensor *38. TWV (injector)
*9. Boost temperature sensor *39. Actuator control output
*10. Barometric pressure sensor *40. EGR DC motor
*11. Accelerator position sensor *41. Intake throttle motor
*12. EGR position sensor *42. Relay, lamp control output
*13. Intake throttle position sensor *43. Glow relay
*14. Charge air cooler temperature sensor *44. Starter cut relay
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*15. Exhaust gas temperature sensor (1: Filter inlet, 2: *45. ECM main relay
Catalyst inlet)
*16. Boost sensor *46. Hour meter relay
*17. Oil pressure sensor *47. Diagnostic lamp
*18. Fuel filter pressure sensor *48. Glow lamp
*19. MAF sensor *49. Engine hydraulic pressure lamp
*20. EGR gas temperature sensor 1 (1: EGR cooler *50. Overheat lamp
inlet, 2: EGR cooler outlet)
*21. Switch input *51. Engine overrun lamp
*22. Key switch (ON/start) *52. Restart prohibited warning light
*23. Diagnostic switch *53. Output restricted warning light
*24. Idling control select switch *54. Abnormal urea fluid injection warning light
*25. Idling control switch (Up/Down) *55. Refill urea fluid warning light
*26. Mode map switch 0 *56. Abnormal urea fluid quality warning light
*27. Mode map switch 1 *57. Communication
*28. Mode map switch 2 *58. Speed signal
*29. Regulation mode switch *59. Diagnostic scan tool
*30. Load advance switch *60. CAN (ECU on the machine)
Electronic control fuel injection system

This is the system in which the ECM obtains information such as engine speed and engine load, and sends electrical
signals based on this information to the supply pump, injectors, etc., to properly control the fuel injection quantity and
the injection timing for each cylinder.
Injection quantity control

To optimize the injection quantity, the fuel injection quantity is controlled by regulating the injector based mainly on
the signals from the engine speed and the accelerator opening position or the instructed rotation from the control unit
in the machine.
SMIL14CEX3898FB 7
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• Boost pressure
a. • Engine coolant temperature
• Barometric pressure
*1. Accelerator pedal position *6. Final fuel injection quantity

*2. Engine speed *7. Fuel injection quantity correction
*3. Basic fuel injection quantity *8. Injector on time determination
*4. Maximum fuel injection quantity *9. Cylinder by cylinder correction
*5. Fuel reduction ratio
Injection pressure control

The injection pressure is controlled by regulating the fuel pressure inside the common rail (fuel rail). The proper
pressure inside the common rail (fuel rail) is controlled based on calculations of the engine speed, the fuel injection
quantity, etc., and the appropriate amount of fuel is discharged and force fed to the common rail (fuel rail) via regulation
of the supply pump.
Injection timing control

This control is performed by calculating the proper fuelinjection timing mainly from the engine speed or the injection
quantity in substitution of the timer function to regulate the injector.
Injection rate control

To improve combustion inside the cylinder, only a small amount of fuel is injected first to be ignited, and then the
second injection is performed when ignition is made.
To improve combustion inside the cylinder, only a small amount of fuel is injected first to be ignited, and then the
second injection is performed when ignition is made.
This control of the injection timing and injection quantity is performed by regulating the injector.
Maximum fuel injection quantity

The maximum fuel injection quantity is the quantity of fuel injection calculated by adjustment of the initial injection
quantity according to the water temperature, the limitation of the maximum injection quantity according to the boost
pressure, and the control of the injection quantity for high altitudes according to the barometric pressure.
Inter-cylinder correction
It is not used for this engine.
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System schematic
SMIL14CEX3899FB 8
a. Sensors (Throttle, boost, coolant temperature etc.)
*1. Electromagnetic pump *7. Pressure limiter

*2. Fuel filter *8. Flow damper
*3. Pre-fuel filter *9. Injector
*4. Supply pump *10. CMP sensor
*5. Fuel pressure sensor *11. CKP sensor
*6. Common rail *12. ECM
Fuel system
The fuel is supplied to the supply pump from the fuel tank, and then it is boosted by the pump before being supplied
to the common rail (fuel rail). At this time, the fuel amount to be supplied to the common rail (fuel rail) is controlled by
regulating the FRP regulator based on the signal from the ECM.
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SMIL14CEX3900FA 9
1. Electromagnetic pump 5. Fuel return pipe

2. Fuel filter 6. Fuel tank
3. Common rail 7. Supply pump
4. Fuel injector 8. Pre-fuel filter
Removing air from the fuel system

Place an appropriate pan under the air removal plug.
Turn the ignition switch ON, and activate the electromagnetic pump.
Loosen the air removal plug of the fuel filter sufficiently, and operate the priming pump 20 times or more until the fuel
comes out from near the plug.
Tighten the plug, and operate the priming pump 10 times or more until the fuel permeates.
Wait for approx. 1 min, and then loosen the plug to remove the air in the fuel filter. This should be repeated at least
3 times until no air comes out from the plug.
Securely tighten each plug, and wipe up any fuel spilled in the vicinity. Operate the priming pump 10 - 15 timesuntil
the fuel permeates and then is fed to the engine.
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SMIL14CEX3971FB 10
a. On the machine with electromagnetic pump
*1. Pre-fuel filter *4. Supply pump

*2. Electromagnetic pump *5. Fuel tank
*3. Fuel filter
EGR
The EGR system recirculates part of the exhaust gas to the intake manifold, and by mixing in inert gas with the intake
air, combustion temperature is lowered and the generation of nitrogen oxide is suppressed.
The EGR amount is controlled by opening and closing the EGR valve installed between the exhaust manifold and
intake manifold. The EGR amount is determined from the engine speed and engine load ratio, and the EGR valve
is operated to control the EGR amount. By providing the EGR cooler on the path of the EGR gas, high-temperature
EGR gas is cooled by the EGR cooler and then mixed with air to further lower the combustion temperature in order
to reduce the NOx amount.
Further, the EGR system is also equipped with a check valve to prevent the EGR from flowing in the opposite direction
to increase the EGR amount.
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EGR control
The ECM controls the EGR valve lift amount by operat-
ing the motor according to the engine status, determined
by the engine speed and engine load, etc. The valve
lift amount is detected by the EGR position sensor. The
darker portions of the diagram represent large valve lift
amounts, and the darkest portion represents a lift amount
of nearly 100 %.
*1. No EGR control during idling

A. Engine speed
B. Accelerator position
SMIL14CEX3972AB 11
EGR system schematic diagram
SMIL14CEX3888GA 12
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1. EGR position sensor 8. EGR gas temperature sensor 1

2. EGR valve 9. IMT sensor
3. Intake throttle position sensor 10. Intake throttle valve
4. EGR gas temperature sensor 2 11. Boost pressure sensor/boost temperature sensor
5. Coolant outlet 12. MAF/IAT sensor
6. Coolant inlet 13. Engine speed
7. EGR cooler 14. Engine load
EGR and turbine noise

Depending on the engine, high frequency sounds may
be generated based on the turbine speed. The high fre-
quency sounds can be muted by installing an appropriate
silencer. Depending on the OEM, if use in residential ar-
eas is not expected, the silencer high-frequency sound
countermeasure specification may not be included and
some high-frequency sounds may remain audible. The
high frequency sounds tend to lessen in intensity during
EGR control and return to their original sound levels when
control stops.
*1. Without EGR

*2. With EGR
SMIL14CEX3973AB 13
Turbocharger control
The turbocharger is a system which efficiently uses boostpressure to enable a turbocharger effect even when turbo
is weakest (when engine speed and exhaust energy are low). The turbocharger optimizes turbine speed by varying
the opening position of the nozzle inside the turbine housing and adjusting the inlet area of the turbo based on engine
speed and load to control boost pressure.
The ECM sends the desired nozzle opening position based on information from each sensor to the turbo control unit
via CAN communication in order to properly control the boost pressure in accordance with the engine load require-
ments. The turbo control unit drives the turbo actuator based on the information received from the ECM and controls
the nozzle vane via the control rod.
SMIL14CEX3974EB 14
*1. ECM *6. Exhaust gas inlet

*2. CAN communication *7. Exhaust gas outlet
*3. Control rod *8. Turbine wheel
*4. ECU built-in actuator *9. Nozzle
*5. Nozzle close direction
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Engine operation control

There are the following 4 types of operation control instructions, and the selection varies depending on each speci-
fication. Voltage input by APS, 1 - 4 V Accelerator opening position instructions given through CAN communication
control, 0 - 100 %, speed instruction Speed instructions given through mode map switch control, speed instruction and
change instructions given by the APS. Increase and decrease instructions for each rotation given by the idle switch.
Mode map switch

The mode map switch has 6 rotation control mode types: H, S, L, B, I, and LM.
The rotational setting is H > S > L > B and I > LM.
The H, S, L, and B speeds can be lowered with the APS,

but I and LM cannot be changed from the APS.
SMIL14CEX3975AA 15
When the regulation mode switch input is present in ad-

dition to the mode map switch, the following 2 types of
control methods are available.
*1. Regulation setting start speed
SMIL14CEX3976AB 16
*1. Regulation setting start speed
SMIL14CEX3977AB 17
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H, S, L and B of the mode map switch change as follows

depending on the APS input.
SMIL14CEX3978AA 18
Mode map switch and meaning of each mode

Engine speed can be lowered from each mode position in
models with APS.
The set engine speeds for H, S, L, and B are determined

by calibration of the ECM.
SMIL14CEX3979AA 19
CAN communication
When CAN controller does not exist on the machine side
*1. Diagnostic scan tool

*2. MCX
*3. ECM
*4. LCD
*5. TCM
*6. Shift Control
SMIL14CEX3980AB 20
When CAN controller exists on the machine side
*1. Diagnostic scan tool

*2. MCX
*3. ECM
*4. TCM
*5. Shift Control
SMIL14CEX0567AB 21
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Mode map switch control

*1. Throttle position sensor
*2. Engine stop switch
*3. Idling select switch
*4. Idle up switch
*5. Idle down switch
*6. Mode map switch 0
*9. Regulation mode switch
*10. Load advance switch
SMIL14CEX3981BB 22
Outer switch
Operation mode Control
MAP0 MAP1 MAP2
OFF OFF OFF
H OFF ON ON Basic operations
ON ON ON
S ON OFF OFF Maximum rotation count control #1
L OFF ON OFF Maximum rotation count control #2
I OFF OFF ON Constant rotation operation #1
B ON ON OFF Maximum rotation count control #3
LM ON OFF ON Constant rotation operation #2
I, LM and H modes

*2. Idle speed
*3. Maximum speed
SMIL14CEX3982AB 23
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H, S, L, and B modes
*1. Idle speed

*2. Maximum speed
SMIL14CEX3983AB 24
H, S, L, and B modes (irrigation pump)
*1. Idle speed

*2. Maximum speed
SMIL14CEX3984AB 25
Accelerator position switch

By operating the accelerator position switch, the output
voltage changes between 1 - 4 V Voltages between 0.2
- 1.05 V are recognized as 1 V. If below 0.2 V or above
1.05 V, an error is detected.
If ECM terminal numbers B30 and B27 do not have the

same potential, DTC P2138 is set.
*1. Throttle position sensor
SMIL14CEX3985BB 26
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Accelerator position switch, with APS learning control

If APS learning control is available, when the ignition cy-
cle ends with the accelerator position at 2 V, for example
(1), the accelerator position learning causes the 2 V sta-
tus to be recognized as the opening position 0 %, and the
control range changes from 2 - 4 V (2).
SMIL14CEX3986AA 27
Regulation mode switch

When there is input from the regulation mode switch, the
engine speed will change to the following.
SMIL14CEX3987BB 28
Idling control
By operating the idling control change switch during the warm-up operation, the minimum idling speed can be ad-
justed. In addition, by operating the idling control change switch, the minimum idling speed can be automatically set
to the optimum value in accordance with the engine coolant temperature.
NOTE: The specifications vary depending on the machine, so availability of functions also differ.
Idling control change switch

By operating the idling control change switch, the idling control functions can be switched.
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Idling control switch

By operating the idling control switch, the idling speed can be adjusted.
NOTE: For the installation positions of the idling control change switch and the idling control switch, refer to the manual
for the machine. The engine speed upper limit varies depending on the engine type, the machine specifications, and
the engine warm-up condition.
Up
While the Up side of the switch is pressed, the engine speed is increased and the idling speed can be raised.
Down
While the Down side of the switch is pressed, the engine speed is decreased and the idling speed can be lowered.
However, the engine speed cannot be lowered to below the minimum idling speed.
Control during ignition switch OFF state

There are 2 types of controls provided when the ignition switch is turned OFF after the idling control switch is operated,
and either one of them is performed depending on the specification. The engine speed adjusted by the idling control
switch is recorded in the ECM, and the next time the vehicle is operated, the engine speed is set to the speed it was
at when the ignition switch was turned OFF.
The engine speed adjusted by the idling control switch is not recorded in the ECM, and the next time the vehicle is
operated, the engine speed is set to the default speed.
For verification and questions regarding the specifications, contact an Isuzu service representative.
Idle manual control
SMIL14CEX3988FB 29
*1. Starter switch *5. Idle speed

*2. Idle up switch *6. Idle up switch
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*3. Idle down switch *7. Idle down switch

*4. Engine speed
Preheat control QOS system

The ECM determines the glow time according to the engine coolant temperature, and activates the glow relay and
the QOC indicator light. The QOS system is a system for facilitating engine starting in low temperatures as well as
reducing the amount of white smoke and noise generated immediately after the engine is started. When the ignition
switch is turned ON, the ECM detects the temperature of the engine coolant based on the signal sent from the engine
coolant temperature sensor to change the glow time, so the engine can always be started under optimum conditions.
Also, the after-glow function can stabilize the idling immediately after the engine is started.
SMIL14CEX3989EB 30
a. LCD or lamp *4. QOS indicator lamp

*1. Starter switch (ON) *5. （ECM）
*2. Battery *6. Coolant temperature sensor
*3. Glow relay *7. Glow plug
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SMIL14CEX3990GA 31
1. Engine 6. Silencer
2. MAF/IAT sensor 7. SCR catalyst
3. Air cleaner 8. Oxidation catalyst 2
4. Various sensors 9. Oxidation catalyst 1
5. ECM 10. EGT sensor
ECM
The ECM constantly monitors the information sent from various sensors, and controls the various systems of the
powertrain. The ECM performs the diagnostic functions of the system, detects operational problems with the system,
warns the operator via the diagnostic light, and records the DTC.
The DTC identifies the areas where problems have occurred to assist the repair operation performed by the technician.
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The ECM outputs voltages (e.g. 5 V) to supply power to

various sensors or switches. The ECM controls the output
circuit by controlling the ground or power supply circuit via
one of the devices.
NOTE: As for the ECM installation position, refer to the
manual of the machine.
SMIL14CEX3991BA 32
ECM and components

The ECM is designed to maintain regulation levels of exhaust gases while obtaining excellent performance and fuel
efficiency. The ECM monitors various engine functions via sensors such as the CKP sensor.
ECM voltage
The ECM applies the specified voltage to various switches and sensors. The ECM is able to apply voltage in such a
way because the ECM resistance is very high, and the voltage that is actually applied to the circuit is low. Therefore,
the test lamp may not illuminate even if it is connected to the circuit. The voltmeter that is normally used at mainte-
nance factories may not display a correct reading because its input impedance is too low. An accurate voltage reading
can be obtained by using a digital multimeter (for example, 5-8840-2691-0) with an input impedance of 10 MΩ.
Electrically Erasable Programmable Read Only Memory, EEPROM

EEPROM contains various programs and calibration information necessary for the ECM to control the powertrain
operations. If a malfunction is found with the EEPROM, replace the ECM. The program and calibration information for
the ECM powertrain control includes the engine type, engine number, ECM part number, DTC, inter-cylinder correction
learning value, QR, Q adjustment, and EGR correction learning value.
Notes on ECM maintenance

The ECM has been designed to withstand the regular current consumption associated with the machine operation.
Make sure that the circuit does not overload.
When testing for an open circuit or short circuit, do not ground or apply voltage to any of the ECM circuits unless
instructed to do so. When performing these circuit tests, make sure to use digital multimeter 5-8840-2691-0.
NOTE: Use the ECM with the part No. corresponding to the machine.
When performing welding work on the machine, start the work after disconnecting the negative terminal of the battery.
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Turning OFF the ECM power supply

In approximately 10 s after turning the ignition switch OFF,
the internal power supply of the ECM is not turned OFF.
When it is necessary to turn OFF the ECM power supply,
e.g., when clearing the memory, it is necessary to wait
10 s or more after turning the ignition switch OFF.
*1. Starter switch ON

*2. Starter switch OFF
SMIL14CEX3992AB 33
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Engine control system - Component localization

The locations, shapes, and existence or nonexistence of components vary depending on the specifications of the
machine.
SMIL14CEX3993FA 1
1. Overheat switch 8. Fuel temperature sensor

2. Engine coolant temperature sensor 9. FRP regulator
3. Injector 10. Oil pressure sensor
4. Glow plug 11. Oil level switch
5. Boost pressure sensor/boost temperature sensor 12. EGR valve
6. IMT sensor 13. CMP sensor
7. FRP sensor 14. CKP sensor
Supply pump
The supply pump highly pressurizes the fuel using the
engine torque, and force feeds the fuel to the common rail
(fuel rail). The FRP regulator and fuel temperature sensor
are also installed to the supply pump.

SMIL14CEX3994AA 2
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FRP regulator
The FRP regulator is installed on the supply pump and
controls the fuel force fed to the common rail (fuel rail).
The ECM controls the fuel discharge amount by regulating
the energizing time for the FRP regulator.
1. FRP regulator
SMIL14CEX3994AA 3
Fuel temperature sensor

The fuel temperature sensor is installed on the supply
pump, and the thermistor changes the resistance accord-
ing to the temperature change. The resistance becomes
lower when the fuel temperature is high, and higher when
the fuel temperature is low. The ECM applies 5 V to the
fuel temperature sensor through the pull-up resistor, and
calculates the fuel temperature from changes in the volt-
age, which is used to control the supply pump, etc. The
voltage becomes lower when the resistance is lower, and
it becomes higher when the resistance is higher.
NOTE: Do not replace the fuel temperature sensor. When
a malfunction is found, replace the supply pump assem-
bly.
SMIL14CEX3995AA 4
Common rail (fuel rail)

The common rail (fuel rail) receives the fuel from the sup-
ply pump, retains the fuel pressure, and distributes the
fuel to each cylinder. The FRP sensor and the pressure
limiter are installed on the common rail (fuel rail).
1. Pressure limiter
2. Fuel pressure sensor
3. Common rail
SMIL14CEX3996AA 5
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Pressure limiter
The pressure limiter is activated when the pressure in the
common rail (fuel rail) becomes unusually high so as to
release the pressure inside the common rail (fuel rail).
1. Pressure limiter
SMIL14CEX3997AA 6
FRP sensor
The FRP sensor, installed on the common rail (fuel rail),
detects the fuel pressure inside the common rail (fuel rail),
converts pressure into a voltage signal, and sends it to the
ECM. The voltage becomes higher when the pressure is
higher, and it becomes lower when the pressure is lower.
The ECM calculates the actual fuel pressure from the volt-
age signal sent from the sensor, and uses it to control fuel
injection, etc.
1. Fuel pressure sensor
SMIL14CEX3998AA 7
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Injector
The injector is installed on the cylinder head portion, and
is controlled by the ECM to perform fuel injection. The
ECM internally increases the voltage for driving the injec-
tors and applies this voltage to the injectors. Then, by
controlling the period of time in which the injectors are en-
ergized, the ECM performs fuel injection quantity control,
as well as control of the fuel injection period.
SMIL14CEX3999BA 8

The engine coolant temperature sensor is installed on the
cylinder head, and the thermistor resistance changes ac-
cording to the temperature change. The resistance be-
comes lower when the engine coolant temperature is high,
and higher when the engine coolant temperature is low.
The ECM applies 5 V to the engine coolant temperature
sensor through the pull-up resistor, and calculates the en-
gine coolant temperature from changes in the voltage.
This value is used in various control mechanisms, such
as fuel injection control. The voltage becomes lower when
the resistance is lower, and it becomes higher when the
resistance is higher.
SMIL14CEX4000AA 9
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Overheat switch
The overheat switch is installed to the water outlet pipe
and turns ON if the engine coolant temperature exceeds
105 °C (221 °F).
SMIL14CEX4001AA 10
CKP sensor
The CKP sensor is installed on the flywheel housing and
generates a CKP signal when the protruding section on
the flywheel passes by the sensor. The ECM determines
the cylinder and specifies the crank angle using the CMP
signal input from the CMP sensor, and uses the informa-
tion for the fuel injection control and the calculation of the
engine speed. While these controls are usually performed
using the CKP signal, the CMP signal is used instead
when the CKP sensor is faulty.
SMIL14CEX4002AA 11
CMP sensor
The CMP sensor is installed on the rear part of the cylin-
der head and generates a CMP signal when the cam sec-
tion of the camshaft passes by the sensor. The ECM de-
termines the cylinder and specifies the crank angle using
the CMP signal input from the CMP sensor, and uses the
information for the fuel injection control and the calcula-
tion of the engine speed. While these controls are usually
performed using the CKP signal, the CMP signal is used
instead when the CKP sensor is faulty.
1. Camshaft gear
2. Rotational direction
3. CMP sensor
SMIL14CEX4003AA 12
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Oil pressure sensor

The oil pressure sensor is installed near the starter motor
on the cylinder block, and it detects the pressure of the
engine oil, converts it into a voltage signal, and sends it
to the ECM.
The voltage becomes higher when the pressure is higher,

and it becomes lower when the pressure is lower.
SMIL14CEX4004AA 13
Accelerator position sensor

The accelerator position sensor is installed on the console
panel of the machine and supplies to the ECM a voltage
signal that varies in accordance with the accelerator vol-
ume angle. The ECM calculates the accelerator position
from the voltage signal, and uses it for fuel injection con-
trol and many other controls.
NOTE: As for the installation position of the accelerator
position sensor, refer to the manual of the machine.
Barometric pressure sensor

The barometric pressure sensor is installed in the ECM,
and it converts the barometric pressure to a voltage sig-
nal. The ECM uses this voltage signal to calibrate the
injection quantity and injection timing for altitude compen-
sation.
SMIL14CEX3991BA 14
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EGR position sensor

This sensor is installed inside the EGR valve to detect the
EGR valve lift amount.
NOTE: Do not disassemble the EGR position sensor.
When an abnormality is found, replace the EGR valve
assembly.
SMIL14CEX4005AA 15
Boost pressure sensor

The boost pressure sensor detects the boost pressure of
the inlet pipe and converts the pressure into a voltage sig-
nal to send to the ECM. The voltage becomes higher when
the pressure is higher, and it becomes lower when the
pressure is lower. The ECM calculates the boost pressure
from the voltage signal sent from the sensor and uses it
to control the fuel injection, etc.
Boost temperature sensor

The boost temperature sensor measures the temperature
of air entering the inlet pipe. When the sensor is cold, the SMIL14CEX4006AA 16
sensor resistance is high. As the air temperature rises,
the sensor resistance decreases. The ECM detects a high
voltage in the signal circuit when the sensor resistance is
high. The ECM detects a low voltage in the signal circuit
when the sensor resistance is low.
Fuel filter pressure sensor

The fuel filter pressure sensor is installed on the fuel filter
and converts the vacuum in the fuel filter into a voltage
signal. The ECM calculates the vacuum in the fuel filter
based on the voltage signal to determine clogging in the
fuel filter.
SMIL14CEX4007AA 17
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MAF sensor
The MAF sensor measures the amount of air entering the
engine, and is installed to the duct between the air cleaner
and turbocharger. The MAF sensor consists of an MAF
sensor and IAT sensor, and measures a portion of the air
that passes through the measurement duct. When the
amount of air entering the engine is small, it indicates de-
celeration or idling speed. When the amount of air is large,
it indicates acceleration or a high load state.
IAT sensor
The IAT sensor is installed to the duct between the air SMIL14CEX4008AA 18
cleaner and the turbocharger. The IAT sensor is a variable
resistor located inside the MAF sensor and measures the
temperature of the air flowing into the engine. When the
IAT sensor is cold, the sensor resistance is high. As the air
temperature rises, the sensor resistance decreases. The
ECM detects a high voltage in the signal circuit when the
sensor resistance is high. The ECM detects a low voltage
in the signal circuit when the sensor resistance is low.
Intake throttle valve

The intake throttle valve is installed on the inlet of the inlet
manifold. The ECM controls the opening position of the
intake throttle valve based on the operating conditions of
the engine. The motor inside the intake throttle valve is
controlled according to duty ratio signals sent from the
ECM. The opening position of the intake throttle valve is
changed in the appropriate increments from a duty ratio of
0 %. The valve closes with increases in duty signals and
opens as duty signals decrease. The opening position of
the intake throttle valve is detected by the position sensor.
The position sensor outputs signals related to the opening
position of the intake throttle valve.
The ECM detects a low signal voltage when the valve SMIL14CEX4009AA 19
opening is small or closed. Also, the ECM detects a high
signal voltage when the valve opening is large.
EGT sensor
The EGT sensors are variable resistors installed in front of
oxidation catalyst 1 and oxidation catalyst 2. EGT sensor
1 measures the temperature of the exhaust gas in front
of oxidation catalyst 2, while EGT sensor 2 measures the
temperature of the exhaust gas in front of oxidation cat-
alyst 1. When the EGT sensor is cold, the sensor re-
sistance is high. As the exhaust temperature rises, the
sensor resistance decreases. The ECM detects a high
high. Also, the ECM detects a low voltage in the signal
circuit when the sensor resistance is low.
SMIL14CEX4010AA 20
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IMT sensor
The IMT sensor is a variable resistor that is installed to the
intake manifold and measures the intake air temperature
of the intake manifold. Sensor resistance is high when the
sensor is cool and lowers as the intake air temperature
increases. The ECM detects a low voltage in the signal
circuit when the sensor resistance is low.
SMIL14CEX4011AA 21
Charge air cooler temperature sensor 1

Charge air cooler temperature sensor 1 is installed to the
upstream side of the intercooler. Charge air cooler tem-
perature sensor 1 is a variable resistor. Charge air cooler
temperature sensor 1 measures the temperature of the
air flowing into the intercooler. When the intercooler tem-
perature sensor is cold, the sensor resistance is high. As
the air temperature increases, the sensor resistance de-
creases. The ECM detects a high voltage in the signal
circuit when the sensor resistance is high. The ECM de-
tects a low voltage in the signal circuit when the sensor
resistance is low.
SMIL14CEX4011AA 22
EGR gas temperature sensor 1

EGR gas temperature sensor 1 is installed to the EGR
cooler duct. EGR gas temperature sensor 1 is a variable
resistor and measures the temperature of the exhaust gas
at the EGR cooler inlet. The EGR gas temperature sen-
sor1 resistance is high at low temperatures. As the ex-
haust gas temperature rises, the sensor resistance de-
creases.
The ECM detects a high voltage in the signal circuit when

the sensor resistance is high. The ECM detects a low
low.
SMIL14CEX4012AA 23
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EGR gas temperature sensor 2

EGR gas temperature sensor 2 is installed to the EGR
cooler duct. EGR gas temperature sensor 2 is a variable
resistor and measures the exhaust gas temperature of the
EGR cooler outlet. The EGR gas temperature sensor 2
resistance is high at low temperatures. As the exhaust
gas temperature rises, the sensor resistance decreases.
The ECM detects a high voltage in the signal circuit when
the sensor resistance is high. The ECM detects a low
low.
SMIL14CEX4011AA 24
Turbocharger
The actuator built into the control unit is installed to the tur-
bocharger. The opening degree of the turbocharger vari-
able nozzle is driven by the actuator. The built-in control
unit performs CAN communication, and the ECM adjusts
the opening position of the nozzle to control changes in
boost pressure according to the load requirements of the
engine.
1. Turbo actuator
SMIL14CEX4013AA 25
Diagnostic light
By turning ON the diagnostic switch, the DTC is indicated by flashing.
NOTE: As for the installation position of the diagnostic light, refer to the manual of the machine.
DLC
The DLC is the connector for communication and connec-
tion between the trouble diagnosis scanning tool and var-
ious controllers.
NOTE: As for the DLC installation position, refer to the
manual of the machine.
SMIL14CEX4014AA 26
Diagnostic switch
The diagnostic switch shorts DLC terminal No. 12 and No. 4 or No. 5 and flashes the diagnostic light to indicate the
DTC.
NOTE: As for the installation position and shape of the diagnostic switch, refer to the manual of the machine.
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Memory clear switch

This is used when clearing the recorded DTCs in the ECM by operating the diagnostic switch and memory clear
switch.
NOTE: As for the installation position of the memory clear switch, refer to the manual of the machine.
Mode change switch (0, 1, 2)

The operation can be performed at the engine speed specified for each mode by switching the mode change switch.
NOTE: As for the installation position of the mode change switch, refer to the manual of the machine.
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Engine Control Unit (ECU) - Wiring schema

Some sensors may not be connected to the ECM depending on the specifications of the machine.
Since some sensors may perform input/ output with the ECM using CAN communication, check the specifications of
the machine.
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SMIL14CEX4015HB 1
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SMIL14CEX4016HB 2
*1. Accelerator position sensor *39. Refill urea fluid warning light
*2. MAF sensor *40. Restart prohibited warning light
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*3. IAT sensor *41. Abnormal urea fluid quality warning light
*4. Charge air cooler temperature sensor *42. Glow relay
*5. EGT sensor 1 *43. Glow plug
*6. EGT sensor 2 *44. CKP sensor
*7. Fuel filter pressure sensor *45. CMP sensor
*8. Engine stop switch *46. FRP sensor
*9. Idling control change switch *47. Boost pressure sensor
*10. Idling control switch Up *48. Intake throttle position sensor
*11. Idling control switch Down *49. Engine coolant temperature sensor
*12. Mode map switch 0 *50. IMT sensor
*13. Mode map switch 1 *51. EGR gas temperature sensor 2
*14. Mode map switch 2 *52. EGR gas temperature sensor 1
*15. Regulation mode switch *53. Boost temperature sensor
*16. Load advance switch *54. EGR position sensor
*17. Air cleaner switch *55. Oil pressure sensor
*18. Memory clear switch *56. Fuel temperature sensor
*19. Diagnostic switch *57. Starter cut rela
*20. ECM *58. Hour meter relay
*21. Ignition switch ON *59. Starter
*22. Ignition switch start *60. Tachometer
*23. ECM main relay *61. TOOL
*24. Key switch *62. OEM unit
*25. Battery *63. Termination resistance
*26. ECM case GND *64. DCU
*27. Signal GND *65. Turbo unit
*28. Signal GND *66. Termination resistance
*29. ECM power supply GND *67. EGR DC motor
*30. ECM power supply GND *68. Intake throttle motor
*31. ECM power supply GND *69. Injector drive signal 1 (No. 1 cylinder)
*32. Diagnosis light *70. Injector drive signal 3 (No. 3 cylinder)
*33. Engine hydraulic light *71. Injector drive signal 5 (No. 2 cylinder)
*34. Glow light *72. Injector drive signal 2 (No. 5 cylinder)
*35. Overheat light *73. Injector drive signal 4 (No. 6 cylinder)
*36. Engine overrun light *74. Injector drive signal 6 (No. 4 cylinder)
*37. Output restricted warning light *75. Suction control valve
*38. Abnormal urea fluid injection warning light
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ECM pin assignment
SMIL14CEX4017GA 3
105 pin (A connector)

Pin No. Terminal name Connection
1 OS-INJ5 No. 2 cylinder injector control
5 SP-5V6 CKP sensor power supply
6 - -
7 - -
8 - -
9 - -
10 IA-IDMPOS Intake throttle position sensor signal
11 IA-MAP Boost pressure sensor signal
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12 IA-THTCO Boost temperature sensor signal
13 - -
14 IA-EGRTI1 EGR gas temperature sensor 1 signal
15 IA-EGRTO1 EGR gas temperature sensor 2 signal
16 IA-PFUEL1 FRP sensor signal
17 IA-OILPRESS Oil pressure sensor signal
18 IA-IMT IMT sensor signal
19 - -
20 IA-THL Fuel temperature sensor signal
21 - -
22 - -
23 OP-COM1A Injector power supply 1 (Cylinder No. 1)
24 OP-COM1B Injector power supply 1 (No. 3 cylinder )
25 OP-COM1C Injector power supply 1 (No. 2 cylinder )
26 SP-5V9 EGR position sensor, oil pressure sensor power supply
27 - -
28 - -
29 - -
30 - -
31 - -
32 - -
33 - -
34 - -
35 - -
36 - -
37 - -
38 - -
39 IA-THW Engine coolant temperature sensor signal
40 - -
41 - -
42 IA-SCVLO SCV-LO drive
43 OS-INJ1 Cylinder No. 1 injector control
44 OP-COM2A Injector power supply 2 (No. 5 cylinder )
45 OP-COM2B Injector power supply 2 (No. 6 cylinder )
46 OP-COM2C Injector power supply 2 (No. 4 cylinder )
47 - -
48 SG-5VRT6 CKP sensor GND
49 SG-5VRT7 CMP sensor, FRP sensor GND
Boost pressure sensor, intake throttle position sensor, engine coolant
50 SG-5VRT8 temperature sensor, IMT sensor, EGR gas temperature sensor 1, EGR gas
temperature sensor 2, boost temperature sensor GND
51 - -
52 - -
53 IS-EBMPOS1 EGR position sensor signal U
54 IS-EBMPOS2 EGR position sensor signal V
55 IS-EBMPOS3 EGR position sensor signal W
56 - -
57 - -
58 - -
59 SG-5VRT EGR position sensor, oil pressure sensor, fuel temperature sensor GND
60 - -
61 - -
62 - -
63 IA-SCVLO SCV-LO drive
64 - -
65 - -
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66 - -
67 - -
68 SP-5V8 Boost pressure sensor, intake throttle position sensor power supply
69 SP-5V7 CMP sensor, FRP sensor power supply
70 - -
71 SG-SLD6 CMP sensor shield
72 - -
73 SG-SLD7 FRP sensor shield
74 SG-SLD4 CKP sensor shield
75 OS-ADBIL Abnormal urea fluid injection warning light
76 OS-ADBFUL Refill urea fluid warning light
77 - -
78 IF-CRANK CKP sensor signal
79 - -
80 OS-CEMMIL Restart prohibited warning light
81 - -
82 - -
83 - -
84 OP-SCVHI SCV-HI drive
86 - -
87 - -
88 - -
89 OM-IDM2 Intake throttle motor drive Low
90 OM-IDM1 Intake throttle motor drive High
91 OM-EBM3 EGR valve DC servo motor drive W
92 OM-EBM2 EGR valve DC servo motor drive V
93 OM-EBM1 EGR valve DC servo motor drive U
94 OS-IADBL Abnormal urea fluid quality warning light
95 - -
96 - -
97 - -
98 - -
99 IF-CAM CMP sensor signal
100 - -
101 - -
102 - -
103 - -
104 - -
105 OP-SCVHI SCV-HI drive
91 pin (B connector)
1 PS-+B Battery power supply
2 PG-POWER ECM power supply GND
7 CC-KW2000 Data link connector
8 - -
9 SG-5VRT1 Accelerator position sensor GND
10 - -
11 SG-5VRT3 IAT sensor, charge air cooler temperature sensor 1, EGT sensor 1 GND
12 - -
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13 - -
14 - -
15 SP-5V1 Accelerator position sensor power supply
16 SP-5V5 Fuel filter pressure sensor power supply
17 IA-FIPRESS Fuel filter pressure sensor signal
18 IA-THCSFI EGT sensor 1 signal
19 IA-THDOCI EGT sensor 2 signal
20 - -
21 IA-THCAI Charge air cooler temperature sensor 1 signal
22 - -
23 OF-TACHO Tachometer
24 - -
25 - -
26 - -
27 IA-ACCEL2 Accelerator position sensor 2 signal
28 - -
29 IA-IAT IAT sensor signal
30 IA-ACCEL1 Accelerator position sensor 1 signal
31 - -
32 - -
33 - -
34 - -
35 SG-5VRT5 Fuel filter pressure sensor, EGT sensor 2 GND
36 SG-12VRT MAF sensor GND
37 SP-12V MAF sensor power supply
38 OS-OVRL Engine overrun light
39 OS-DIAGL Diagnosis light
40 OS-MAINR ECM main relay control
41 PG-SIGN Signal GND
42 PG-SIGN Signal GND
43 - -
44 IS-DIAG Diagnostic switch signal
45 IS-MEMCL Memory clear switch signal
46 IS-AC Air cleaner switch signal
47 IS-IDLDWN Idling control switch Down signal
48 - -
49 - -
50 IS-ENGSTP Engine stop switch signal
51 - -
52 - -
53 - -
54 OS-TRQRL Output restricted warning light
55 OS-OILPL Engine hydraulic light
56 - -
57 OS-MAINR ECM main relay control
58 SG-SLD1 Accelerator position sensor shield
59 - -
60 CC-CAN-H CAN-High
61 IA-MDMAP2 Mode map switch 2 signal
62 - -
63 - -
64 CC-ISO CANH1 ISO CAN-High
65 IS-MDMAP0 Mode map switch 0 signal
66 - -
67 - -
68 IS-REG Regulation mode switch signal
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69 - -
70 IS-MDMAP1 Mode map switch 1 signal
71 IS-IDLUP Idling control switch Up signal
72 OS-HOUR Hour meter relay
73 - -
74 OS-STARTR Starter cut relay
75 PG-CASE ECM case GND
76 IS-IGKEY Ignition switch ON signal
77 CC-CAN-L CAN-Low
78 - -
79 - -
80 - -
81 CC-ISO CANL1 ISO CAN-Low
82 IS-START Ignition switch start signal
83 - -
84 - -
85 - -
86 IS-LOAD Load advance switch signal
87 IS-IDLMNL Idling control change switch signal
88 IA-MAF MAF sensor signal
89 OS-GLOWL Glow light
90 OS-OVHL Overheat light
91 OS-GLOWR Glow relay
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Engine Control Unit (ECU) - Fault code index

ECM diagnostic trouble code
Diagnostic trouble code Diagnostic trouble mode
U0001 ISO-CAN bus abnormality
P0016 Cam sensor phase shift
P0045 VNT turbo abnormality
P0047 EVRV drive system GND short
U0073 CAN bus abnormality
P0087 Pressure limiter open
P0089 Common rail abnormal pressure (excessive pumping)
P0091 SCV drive system disconnection, GND short-circuit
P0092 SCV drive system +B short-circuit
P0097 Manifold temperature sensor abnormality (low voltage abnormality)
P0098 Manifold temperature sensor abnormality (high voltage abnormality)
U0101 CAN time-out abnormality
P0102 Airflow sensor abnormality (low voltage abnormality)
P0103 Airflow sensor abnormality (high voltage abnormality)
U010E ISO-CAN DCU communication abnormality
U0110 CAN VNT time-out abnormality
P0112 Intake air temperature sensor abnormality (low voltage abnormality)
P0113 Intake air temperature sensor abnormality (high voltage abnormality)
P0117 Water temperature sensor abnormality (low voltage abnormality)
P0118 Water temperature sensor abnormality (high voltage abnormality)
P0122 Intake throttle position sensor abnormality (low voltage abnormality)
P0123 Intake throttle position sensor abnormality (high voltage abnormality)
P0182 Fuel temperature sensor abnormality (low voltage abnormality)
P0183 Fuel temperature sensor abnormality (high voltage abnormality)
P0192 Common rail pressure sensor abnormality (low voltage abnormality)
P0193 Common rail pressure sensor abnormality (high voltage abnormality)
P0201 Injection nozzle #1 drive system disconnection
P0217 Overheating
P0219 Overrun
P0234 Boost pressure exceeded
P0237 Boost pressure sensor abnormality (low voltage abnormality)
P0238 Boost pressure sensor abnormality (high voltage abnormality)
P0299 Boost pressure decrease
P0335 Crank sensor abnormality (no signal)
P0336 Crank sensor abnormality (signal abnormality)
P0340 Cam sensor abnormality (no signal)
P0380 Glow relay abnormality
P0401 EGR flow abnormality
P0404 EGR valve control abnormality
P0409 EGR position sensor abnormality (brushless type)
P040C EGR cooler outlet 2 gas temperature sensor abnormality (low voltage abnormality)
P040D EGR cooler outlet 2 gas temperature sensor abnormality (high voltage abnormality)
U0411 VNT communication abnormality
P041C EGR cooler outlet 1 gas temperature sensor abnormality (low voltage abnormality)
P041D EGR cooler outlet 1 gas temperature sensor abnormality (high voltage abnormality)
P0427 Exhaust temperature sensor 1 abnormality (DOC outlet) (low voltage abnormality)
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P0428 Exhaust temperature sensor 1 abnormality (DOC outlet) (high voltage abnormality)
P042C Exhaust temperature sensor 2 abnormality (DOC inlet) (low voltage abnormality)
P042D Exhaust temperature sensor 2 abnormality (DOC inlet) (high voltage abnormality)
P045B EGR2 valve control abnormality
P0522 Engine oil pressure sensor abnormality (low voltage abnormality)
P0523 Engine oil pressure sensor abnormality (high voltage abnormality)
P0545 EGR cooler inlet 1 gas temperature sensor abnormality (low voltage abnormality)
P0546 EGR cooler inlet 1 gas temperature sensor abnormality (high voltage abnormality)
P0548 EGR cooler inlet 2 gas temperature sensor abnormality (low voltage abnormality)
P0549 EGR cooler inlet 2 gas temperature sensor abnormality (high voltage abnormality)
P0560 12 V circuit abnormality
P0563 Battery-system high voltage abnormality
P0601 ROM abnormality
P0602 QR code abnormality
P0604 RAM abnormality
P0606 CPU abnormality
P060C A/D conversion abnormality
P0638 Intake throttle control abnormality
P0641 SMP 5 V power supply abnormality
P0685 Main relay system abnormality (not enabled)
P0687 Main relay system abnormality (not disabled)
P06A6 5 V power supply 1 voltage abnormality
P06AF INJ-IC abnormality
P06AF INJ-IC communication abnormality
P06AF INJ-IC checksum abnormality
P06D5 5 V power supply 5 voltage abnormality
P1062 PCV1 flyback abnormality
P1076 Inter-cooler inlet temperature sensor abnormality (low voltage)
P1077 Inter-cooler inlet temperature sensor abnormality (high voltage)
P1093 Common rail pressure decrease (insufficient pumping)
P1097 Boost temperature sensor abnormality (low voltage abnormality) (intercooler outlet)
P1098 Boost temperature sensor abnormality (high voltage abnormality) (intercooler outlet)
P1236 Inter-cooler performance deterioration
P1261 Charge circuit abnormality (bank 1)
P1404 EGR 0-point learning abnormality
P140B EGR 2 position sensor abnormality
P140C EGR 2 Zero-point learning abnormality
P1606 SWIC-1 abnormality
P1606 SWIC-1 communication abnormality
P1606 SWIC-2 abnormality
P1606 SWIC-2 communication abnormality
P160B ADIC abnormality
P160C ADIC2 abnormality
P1621 EEPROM abnormality
P1669 DPD lamp abnormality
P204F SCR system abnormality (without IND)
P207F Urea quality abnormality
P20C9 SCR system abnormality (with IND)
P20DF Fuel filter clogging sensor abnormality (low voltage abnormality)
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P20E0 Fuel filter clogging sensor abnormality (high voltage abnormality)
P2122 Accelerator sensor 1 abnormality (low voltage abnormality)
P2123 Accelerator sensor 1 abnormality (high voltage abnormality)
P2127 Accelerator sensor 2 abnormality (low voltage abnormality)
P2128 Accelerator sensor 2 abnormality (high voltage abnormality)
P2138 Accelerator sensor 1 and 2 comparison abnormality
P2146 Injection nozzle common 1 drive system abnormality
P2228 Atmospheric sensor abnormality (low voltage abnormality)
P2229 Atmospheric sensor abnormality (high voltage abnormality)
P2295 PCV2 drive system disconnection or GND short-circuit
P2296 SCV2 drive system +B short-circuit
P2457 EGR cooler performance deterioration
P2458 Excessive PURGE time-outs
P2BA7 Insufficient urea solution
P2BAA SCR system abnormality (with IND and no purging)
P3093 Common rail pressure drop (insufficient pump pressure @ low fuel temperature)
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Engine control system - Inspect

OBD system check description of function
The OBD system check is a systematic method for
checking problems caused by functional failures in the
engine control system, and is also the starting point for
all diagnoses for driveability complaints. By correctly
using this diagnostic step, it is possible to reduce the
time for diagnosis and prevent the replacement of parts
that are not defective.
NOTE: Points to remember regarding the OBD system
check.
• If there are no complaints on driveability, do not
perform these diagnostic steps unless otherwise
instructed in other sections.
• Check the service technical report before starting the
diagnosis.
• Do not delete the DTCs unless it is instructed in a
diagnostic step.
• If a malfunction is found in the engine starting sys-
tem, inspect the starting system.
• The battery should be fully charged.
• The battery cable should be normal and securely
connected.
• The GND of the ECM should be securely connected
in the correct position.
• The harness connector of the ECM should be clean
and correctly connected.
OBD system check inspection

Inspection for determining the failure location in the
OBD system
2. Check if the diagnostic light is illuminated.
• If the machine does not have a diagnostic light set-
ting, do not perform this operation.
• If the diagnostic light is not illuminated, inspect the
diagnostic light illumination circuit system.
3. Short the DTC.
• Short the No.4 terminal and No.12 terminal.
4. Check if the diagnostic light is blinking.
• If the diagnostic light is not blinking, inspect the di-
agnostic light blinking circuit system.
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5. Use the trouble diagnosis scan tool and confirm the

DTCs of the ECU that has communication established.
Loss of communication with the trouble diagnosis scan
tool occurs due to the abnormalities in the communica-
tion circuit of each ECU and the trouble diagnosis scan
tool.
• If the starter does not operate, inspect the starter
circuit system.
• If the engine does not start, check the DTC.
• If the DTC is detected, inspect the corresponding
DTC.
• If no DTC has been detected, inspect the starting
system.
7. Check the engine stalling for problems.
8. Check the engine hunching and rough idling for prob-
lems.
9. Check if there are problems with insufficient engine out-
put, blowup failure, or engine hesitation.
10. Check for problems with sudden stopping.
11. Check for problems with sudden change.
12. Check for problems with insufficient output or blowup
failure.
13. Check for problems with engine hesitation or acceler-
ation failure.
14. Check for problems with dark smoke.
15. Check for problems with white smoke.
16. Check for problems with the idling revolution speed
maladjustment.
17. Check for problems with the idling revolution speed
not decreasing.
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Engine Control Unit (ECU) - Prepare

NOTICE: Transfer engine information and injector information from the old ECM to the new ECM when the ECM is
replaced. Refer to Instrument cluster - Dynamic description - Engine information (55.512).
Items to prepare:
• Wrench [ 13 mm]
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Engine Control Unit (ECU) - Remove

2. Remove the rear trim.
Refer to Cab and platform - Remove (90.150)
3. Remove the connectors (1) and (2).
move the ECM (4).
SMIL14CEX3877AB 1
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Engine Control Unit (ECU) - Install

1. Mount the ECM in the reversed order of the procedure
for removal.
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Engine speed/RPM sensor - Remove

2. Disconnect the harness connector from the crankshaft
position sensor (1).
3. Remove the crankshaft position sensor (1) from the fly-
wheel housing (2).
NOTICE: Be careful not to subject the sensor to shock.
SMIL14CEX3131AB 1
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Engine speed/RPM sensor - Inspect

1. Inspect the crankshaft position sensor.
NOTE: Condition of the sensor installation.
Grime on the sensor and connector.
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Engine speed/RPM sensor - Install

1. Install the crankshaft position sensor (1) to the flywheel
housing (2).
NOTICE: Be careful not to subject the sensor to shock.
2. Connect the harness connector to the crankshaft posi-
tion sensor (1).
SMIL14CEX3131AB 1
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Engine timing sensors Camshaft sensor - Remove

CMP sensor removal

1. Disengage the harness connector from the CMP sen-
sor.
2. Remove the CMP sensor from the cylinder head as-
sembly.

sor to shock.
SMIL14CEX3024AA 1
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Engine timing sensors Camshaft sensor - Inspect

1. Inspect the CMP sensor.
NOTE: Condition of the sensor installation.
Grime on the sensor and connector.
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Engine timing sensors Camshaft sensor - Install

2. Install the CMP sensor to the cylinder head assembly.

sor to shock.
3. Connect the harness connector to the CMP sensor.
SMIL14CEX3024AA 1

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Index

Engine Control Unit (ECU) - Fault code index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Engine Control Unit (ECU) - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Engine Control Unit (ECU) - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Engine Control Unit (ECU) - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Engine Control Unit (ECU) - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine Control Unit (ECU) - Wiring schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Engine control system - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine control system - Component localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Engine control system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine control system - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Engine control system - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine speed/RPM sensor - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Engine speed/RPM sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Engine speed/RPM sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Engine timing sensors Camshaft sensor - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Engine timing sensors Camshaft sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Engine timing sensors Camshaft sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
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Engine starting system - 201

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Contents
FUNCTIONAL DATA
Engine starting system

Dynamic description - Neutral start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Dynamic description - Power-cut delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Dynamic description - Idling start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Dynamic description - Idle up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Dynamic description - Swing brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Dynamic description - Static horsepower control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Dynamic description - Battery save . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Dynamic description - Engine emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Dynamic description - Gate lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Dynamic description - Horsepower reduction control (in uplands) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Dynamic description - Horsepower reduction control (at engine failure) . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Engine starter
SERVICE
Engine starting system

Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Engine starter
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
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Electrical systems - Engine starting system
Engine starting system - Dynamic description - Neutral start

Purpose
When the gate lock lever is in the unlocked (operation) state, the engine does not start. (No cranking)
It prevents incorrect operation even if you touch the operation lever when starting the engine.
Configuration
LPIL12CX00388FB 1
1. Key switch 6. Battery relay

2. Gate lock limit switch 7. Starter relay
3. Starter motor 8. Safety relay
4. Starter cut relay 9. ECM
5. Gate lock solenoid
1. Put the gate lock lever into the unlocked (operation) state.
2. The starter cut relay will be energized and the energization of the safety relay will be interrupted.
3. Engine cranking will be prohibited.
4. When the gate lock lever is put into the locked (non-operation) state, cranking will be permitted.
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Engine starting system - Dynamic description - Power-cut delay

Purpose/overview
The system delays power shut-off in order to allow history writing into the memory after stopping the engine.
SMIL14CEX1026EB 1
1. Battery 3. Battery relay

2. Key switch 4. Main controller
Operation
1. The battery relay is turned ON to enter “normal” state when operator turns ON the key.
2. The engine stops to terminate output to the alternator when the key is turned OFF after starting the engine. The
system detects this to enter “delaying” state (battery relay ON) and then turns ON the immobilizer power.
3. After elapsing 5 s, the system turns OFF the battery relay and the system starts writing history into the memory to
enter “end ready” state.
4. The system turns OFF the immobilizer power and enters “internal power OFF” state when writing to the memory
completes and immobilizer power ON time is finished.
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Engine starting system - Dynamic description - Idling start

Purpose/overview
The system starts the engine with low idling speed at its starting up regardless of the position of the throttle volume.
SMIL14CEX1031EB 1
1. Throttle volume 5. Pressure sensor (swing)

2. Main controller 6. Pressure sensor (travel)
3. One-touch idle switch 7. Pressure sensor (option 1)
4. Pressure sensor (upper) 8. Pressure sensor (option 2)
Operation condition
• The system sets the engine speed to low idle RPM if the engine coolant temperature is not in low coolant temper-
ature status (coolant temperature less than 50 °C (122.0 °F)).
Stop condition
The system releases low idle speed with the following conditions.
• When the operation lever is operated. (Either one of the following pressure sensors is ON, upper, swing, travel,
option 1, option 2)
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Engine starting system - Dynamic description - Idle up

Purpose
The machine increases the engine speed to maintain the system speed.
SMIL14CEX1032EB 1
1. Throttle volume 4. ECM

2. Main controller 5. Engine
3. Pressure sensor (travel)
During SP mode traveling

1. Idle up operation conditions
It will operate when all the following conditions are fulfilled.
A. When travel operation is performed. (Travel pressure sensor ON)
B. When work mode is SP mode.
2. Idle up clear conditions
It is cleared under the following conditions.
A. When work mode is not SP mode.
B. When travel operation is not performed.
At low speed
1. Idle up operation conditions
It will operate when all the following conditions are fulfilled.
A. When the target speed is below the idle up speed.
B. When attachment operation is performed.
C. When swing, travel, or option (1 or 2) operation is not being performed.
2. Idle up clear conditions
It is cleared under the following conditions.
A. When attachment operation is not being performed.
B. When swing, travel, or option (1 or 2) operation is performed.
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Engine starting system - Dynamic description - Swing brake

Purpose/overview
The system turns ON the swing brake when the key is set to ON.
It turns OFF the swing brake automatically when swing starts, and then turns ON the swing brake after the swing
stops completely. This improves operability and safety.
SMIL14CEX1033EB 1
1. Main controller 4. Swing brake solenoid

2. Pressure sensor (upper) 5. Swing brake
3. Pressure sensor (swing)
Operation condition
The swing brake is activated under the following conditions.
• During no upper operation. (The upper pressure sensor is OFF)
* The swing brake is engaged at 1 s after the upper pressure sensor is OFF. (The swing brake solenoid is ON)
• During no swing operation. (The swing pressure sensor is OFF)
* The swing brake is engaged at 5 s after the swing pressure sensor is OFF. (The swing brake solenoid is ON)
• The swing brake continues to be engaged until the power is OFF during the key is OFF.
Stop condition
The swing brake is released under the following conditions.
• During upper operation. (The upper pressure sensor is ON)
• During swing operation. (The swing pressure sensor is ON)
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Engine starting system - Dynamic description - Static horsepower

control
Purpose/overview
The system allows the pump to absorb the maximum engine horsepower by the pump (as much as not to cause stall)
by controlling horsepower absorbed by the hydraulic pump in accordance with amount of engine down (Engine stop
prevention and energy-saving).
SMIL14CEX1034FB 1
1. Main controller 8. Hydraulic pressure sensor (swing)

2. ECM 9. Pressure sensor (travel)
3. Electromagnetic load proportional valve 10. Pressure sensor (option 1)
4. Hydraulic pump 11. Pressure sensor (option 2)
5. Engine 12. Throttle volume
6. Crank position sensor a. Target RPM to the engine
7. Hydraulic pressure sensor (upper) b. Discharge volume increase/decrease
Operation
1. The system gradually decreases pump horsepower to the lower limit based on judgment that absorbing horse-
power of the hydraulic pump exceeds output horsepower of the engine when an amount of engine down becomes
30 RPM or more due to a load on the engine by the manipulation of the lever.
2. It gradually increases the pump horsepower when amount of down becomes less than 30 RPM due to recovery
of the engine.
Calculation for amount of engine down: Engine down amount = Target engine RPM - Actual engine RPM
* Amount of down is 0 when the actual RPM exceeds the target RPM.
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Operation condition
• Pump horsepower is controlled to be contained within range of preset upper limit horsepower and lower limit horse-
power.
• The upper limit and lower limit of horsepower is determined by work mode, and horsepower adjustment based on
each output value of failure horsepower decrease control /low speed range horsepower decrease control/travel
horsepower boost control/sharp operation horsepower boost control/high load horsepower boost control/ boom up
horsepower boost control.
Stop condition
• Pump horsepower is controlled by upper limit horsepower during non-operation (with lever in neutral).
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Engine starting system - Dynamic description - Battery save

Purpose/Overview
The system reduces battery consumption by eliminating unnecessary output to the devices before starting and after
stopping the engine.
Operation condition
The system turns OFF outputs to the following devices regardless of control result at stopping the engine.
Relay
• Heat tube
Solenoid
• Travel 2nd speed switchover
• Pressure boost
• Free swing
• 2 pumps flow
• Hydraulic pressure load
• Option return
• Center bypass cut
Electromagnetic proportional valve

• Hydraulically-operated fan
• Option relief pressure
• Arm 1 semi-parallel
• Boom 2 down Pi
• Bucket close Pi
• Arm 1 regeneration release
• Arm 2 semi-parallel
• Straight travel
• Option 1
• Option 2
• Tilting 1
• Tilting 2
*Override (forced drive) that commands the devices directly from the monitor by taking control authority from the
controller is not activated during battery save.
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Engine starting system - Dynamic description - Engine emergency

stop
Purpose/overview
The system stops the engine when the emergency stop switch is pressed. The engine emergency stop control is
designed in redundant concept in accordance with EU Standards.
SMIL14CEX1042EB 1
1. Main controller 3. Engine emergency stop switch

2. Engine 4. ECM
Operation
1. Turning ON the emergency stop switch applies 24 V to the comparator input port of ECM. ECM, in response, stops
the engine.
2. The switch input port of the controller is connected to GND at the same time turning ON the switch due to 2-contact
linked type design of the emergency stop switch. The controller, in response, sends requests for stopping the
engine to ECM via CAN communication.
* The requests for stopping the engine are sent to ECM via 2 routes as (1) and (2).
The system activates the following operations when the emergency stop switch is pressed.
• The engine is stopped.
• Message of "Engine Emergency Stop" is displayed on the monitor.
• The alarm sounds intermittently ( 1 s ON, 1 s OFF).
The system enables re-starting up the engine after the engine stop by turning OFF the key once, turning OFF the
emergency stop switch and then turning ON the key.
The system sounds alarm and displays message on the monitor if the key is turned ON with the emergency stop
switch left ON. The engine tries cranking but will not start up if the engine is started up in this condition.
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Engine starting system - Dynamic description - Gate lock

While the gate lock lever is in the locked (non-operation) state (the gate lever is open), the lever operation is disabled
to prevent incorrect operation.
SMIL14CEX6810FB 1
a. Gate lock lever in unlocked (operation) state 3. Gate lock solenoid

b. Gate lock lever in locked (non-operation) state 4. Battery relay
1. Gate lock limit switch 5. Gate lever
2. Neutral start relay
The engine is started by turning ON the key switch. (For details on the control of neutral start, refer to the operation
explanation of neutral start.)
Since the gate lock lever is in the locked (non-operation) state, the gate lock limit switch is OFF, and power to the gate
lock solenoid is interrupted.
When the gate lock solenoid is OFF, hydraulic pressure to the remote control valve is interrupted, and the lever op-
eration is disabled.
When the gate lock lever is put into the unlocked (operation) state (the gate lever is closed), the gate lock limit switch
will turn ON to operate the lever lock solenoid.
When the gate lock solenoid is ON, hydraulic pressure is applied to the remote control valve, and the lever operation
is enabled.
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Engine starting system - Dynamic description - Horsepower

reduction control (in uplands)
Purpose/overview
In order to secure performance in uplands, the whole pump horsepower is reduced by a certain amount accordingly.
The adjustment amount is entered by the service engineer on the monitor (not automatically).
SMPH15CEX0441EA 1
a. Discharge volume increase/decrease

1. Monitor 3. Electromagnetic load proportional valve
2. Main controller 4. Hydraulic pump
Control
The factory-default adjustment amount is 0.
When necessary, enter the adjustment amount on the service support screen, SET UP - PARAMETERS - PUMP
POWER REDUCTION.
This control is carried out actually at the end of horsepower input to the pump. Simply, the adjustment amount is
subtracted from the current horsepower.
The output pump horsepower ratio becomes zero if it is a minus value as a result of subtraction.
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Engine starting system - Dynamic description - Horsepower

reduction control (at engine failure)
Purpose/overview
In case of the control (EPF) that controls the engine speed or stops it when engine failure occurs, the pump horse-
power is reduced accordingly.
SMPH15CEX0442EA 1
a. Discharge volume increase/decrease

1. ECM 4. Electromagnetic load proportional valve
2. Engine 5. Hydraulic pump
3. Main controller
Control
Horsepower is reduced only when necessary, not against all the failure.
The diagnostic trouble codes triggering the control are as follows.

P0016 Cam sensor phase shift
P0045 VNT turbo abnormality
P0047 EVRV drive system GND short circuit
P0087 Pressure limiter open
P0089 Common rail abnormal pressure (excessive pumping)
P0091 SCV drive system disconnection, GND short-circuit
P0092 SCV drive system +B short-circuit
P0112 Intake air temperature sensor abnormality (low voltage abnormality)
P0113 Intake air temperature sensor abnormality (high voltage abnormality)
P0117 Water temperature sensor abnormality (low voltage abnormality)
P0118 Water temperature sensor abnormality (high voltage abnormality)
P0122 Intake throttle position sensor abnormality (low voltage abnormality)
P0123 Intake throttle position sensor abnormality (high voltage abnormality)
P0192 Common rail pressure sensor abnormality (low voltage abnormality)
P0193 Common rail pressure sensor abnormality (high voltage abnormality)
P0219 Overrun
P0234 Boost pressure exceeded
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P0335 Crank sensor abnormality (no signal)
P0336 Crank sensor abnormality (signal abnormality)
P0340 Cam sensor abnormality (no signal)
P0404 EGR valve control abnormality
P0409 EGR position sensor abnormality
P045B EGR2 valve control abnormality
P0560 12 V circuit abnormality
P0601 ROM abnormality
P0604 RAM abnormality
P0606 CPU abnormality
P060A CPU monitoring IC abnormality
P060C A/D conversion abnormality
P0638 Intake throttle control abnormality
P06AF INJ-IC abnormality
P06D5 5 V power supply 5 voltage abnormality
P1093 Common rail pressure decrease (insufficient pumping)
P1404 EGR 0-point learning abnormality
P140B EGR 2 position sensor abnormality
P140C EGR 2 Zero-point learning abnormality
P160B ADIC abnormality
P2228 Atmospheric sensor abnormality (low voltage abnormality)
P2229 Atmospheric sensor abnormality (high voltage abnormality)
P2295 PCV2 drive system disconnection or GND short-circuit
P2296 SCV2 drive system +B short-circuit
P3093 Common rail pressure drop (insufficient pump pressure @ low fuel temperature)
U0001 ISO-CAN bus abnormality
U0073 CAN bus abnormality
U0101 CAN time-out abnormality
U0110 CAN VNT time-out abnormality
U0411 VNT communication abnormality
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Engine starter - Static description

The starter is 5 kW and is the reduction type.
The gear housing and the armature end bearing housing are made of aluminum. Brush assembly is the replaceable
type. The commutator bar is insulated with mica and is not undercut.
The starter circuit is started using the battery.
The battery cable is connected to a large terminal on the starter.
The wiring is connected from the terminal to the engine control switch and the starter relay.
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Engine starter - Dynamic description

The starter is a magnetic-shift-type, inner gearing mesh method reduction starter.
When the ignition switch is turned ON, the plunger is drawn in, the contact point of the magnetic switch closes and
the armature rotates. At the same time, the pinion is pushed to the front via the shift lever to mesh with the ring gear.
When the ring gear rotates, the crankshaft is turned to start the engine. After the engine starts and the ignition switch
is turned OFF, the plunger returns, the pinion separates from the ring gear, and the armature stops rotating. When
the engine speed becomes faster than the pinion, the pinion attempts to turn in reverse, but it just idles due to the one
way clutch function, so the armature is not driven.
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Engine starter - Component identification
SMIL14CEX3890FA 1
1. Brush holder 5. Clutch

2. Magnetic switch assembly 6. Internal gear
3. Lever assembly 7. Armature
4. Pinion 8. Yoke
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Engine starting system - Service instruction

Engine start problem - Symptoms
Cranking rotation is low.
The cranking rotation is normal, but the engine does not
start.
The engine starts, but the engine speed cannot be sta-
bilized and maintained or the engine cannot be revved.
Engine start problem - Diagnosis
Preliminary inspection
Before using this section, perform a functional inspec-
tion and OBD system check to check all of the following
items.
Check whether there is an excessive load on the actual
machine.
The ECM and monitor are operating correctly.
Check DTCs.
The scan tool data is within the normal operation range.
Check the condition of the actual machine and find ap-
plicable symptoms.
Confirm with the customer that the stipulated engine oil
and fuel are being used.
Visual inspection
Some symptoms detection procedures require careful
visual inspection.
This allows for problems to be repaired without perform-
ing further inspection, which saves valuable time.
The following items are included in this inspection.
Check whether the fuel filter is dirty or clogged.
Check for connector connection problems.
Especially important for CKP and CMP sensors.
Check whether the battery terminal voltage is low.
Check for correct wiring connections, tightness, and
disconnections, and then check whether the power sup-
ply for commercially-available accessories is being di-
verged from the ECM power supply.
Check whether the ECM ground is dirty and check that
it is securely installed in the correct location.
Check that pipes and hoses for fuel, air, and oil are not
broken or twisted and that they are correctly connected.
Thoroughly check for any leaking or clogging.
Check whether the layout of the fuel filter, pre-filter and
charge fuel pump makes it easy for air pockets to form.
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Isuzu genuine pre-filter does not have an air-bleed plug.

Check that parts are arranged so as to prevent the for-
mation of air pockets.
Also, check that the layout of the charge fuel pump suc-
tion and discharge ports is appropriate.
Correct layouts where the suction port of the charge fuel
pump is on the upper side or the discharge port faces
in the moving direction of the machine.
Check for fuel leaks and damage and denting on pipes
in the fuel system.
Suction air system parts abnormality and exhaust sys-
tem parts abnormality
A. Pre-filter
B. Charge fuel pump
C. Fuel filter
SMIL14CEX3438AA 1
Diagnostic aid
Fuel cut-off, fuel freezing, air entering fuel line, filter ab-
normality, line abnormality, fuel quality, fuel tank and
other fuel system abnormalities, filter clogging, suction
air line and other suction air system abnormalities. If
a low viscosity fuel such as kerosene is used, this will
accelerate wear in the supply pump and plunger areas
that will cause discharge problems and starting prob-
lems.
In these cases, replacement of the supply pump is nec-
essary.
If a starting problem occurs, check with the customer
what fuel is being used. If a low viscosity fuel such as
kerosene is being used, instruct the customer not to use
low viscosity fuels because the same problem will occur
even if the supply pump is replaced.
Long-term storage fuels and mixed fuels such as be-
fouls that contain organic materials oxidize easily.
Fuel that has oxidized will contribute to wear in cam
shaft-related parts inside the supply pump, and this will
cause starting problems due to discharge problems.
In these cases, replacement of the supply pump is nec-
essary.
Supply pump replacement due to longterm storage fu-
els and mixed fuels such as befouls that contain organic
materials is not covered under warranty, so instruct the
customer not to use these fuels.
If fuel with a high water content is used, add a large-
scale sedimenter to the prefuel filter so that water will
not enter the fuel system.
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Supply pump abnormality, non-pressure fuel feeding

ECM does not set the trouble codes for non-pressure
fuel feeding of supply pump unless an engine rota-
tion of 900 RPM and an absolute pressure of 15 MPa
(2176 psi) or less are maintained for at least 3 s.
Accordingly, if the engine does not start due to non-
pressure fuel feeding caused by a supply pump abnor-
mality, no diagnostic trouble code is be detected.
NOTE: CKP sensor abnormalities are not diagnosed un-
less the crank rotates at least 14 times. Crank the engine
for 14 s. or more at 60 RPM.
CKP sensor diagnostic trouble codes may not be detected
for CKP sensor problems during low rotation of the engine.
For intermittent trouble, increase the engine speed to the
maximum with no load and check whether a CKP sensor
related diagnostic trouble code is detected.
*1. Required engine speed for P0093 judgment
*4. Engine speed (r/min)
SMIL14CEX3439AB 2
*1. Non-judgment area

*2. P0093 judgment area
*3. P0093 established area
A. Absolute pressure
B. Engine speed (r/min)
SMIL14CEX3440AB 3
Check for flow damper and pressure limiter opera-

tions/internal sealant deterioration and other common
rail abnormalities, injector abnormalities, fuel not
injected, system down due to trouble, engine abnormal-
ities such as seizing, compression pressure deficiency,
and other mechanical troubles, ACG trouble, troubles
related to the hydraulic pump and other device on
the actual machine, effect of electrical components
installed after purchasing such as wireless devices
and lights, ECM trouble, connector connection prob-
lems, abnormalities involving friction or breaking in
harnesses, any wires inside harnesses separated and
touching another circuit and causing a short.
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Also, perform functional diagnosis inspection, check

operations and control in each area, and repair any
abnormalities.
Engine stalling - Symptoms

The engine cranks but does not start for a long time.
The engine starts after a while or it starts but stops im-
mediately.
Engine stalling - Diagnosis
items.
Check whether there is an excessive load on the actual
machine.
CKP sensor abnormalities are not diagnosed unless the
crank rotates at least 14 times. Crank the engine for
14 s. or more at 60 RPM.
Check DTCs.
CKP sensor diagnostic trouble codes may not be de-
tected for CKP sensor problems during low rotation of
the engine.
For intermittent trouble, increase the engine speed to
the maximum with no load and check whether a CKP
sensor related diagnostic trouble code is detected.
plicable symptoms.
Check whether there is any fuel.
Visual inspection
visual inspection.
Especially important for CKP and CMP sensors.
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in the fuel system.
in the moving direction of the actual machine.
A. Pre-filter
B. Charge fuel pump
C. Fuel filter
SMIL14CEX3438AA 4
Diagnostic aid
ECM does not set the trouble codes for fuel cut-off, fuel
freezing, air entering fuel line, filter abnormality, line ab-
normality, fuel quality, fuel tank and other fuel system
abnormalities, filter clogging, suction air line and other
suction air system abnormalities, supply pump abnor-
mality, and no fuel pressure feed of supply pump unless
an engine rotation of 900 RPM or less and an absolute
pressure of 15 MPa (2176 psi) or less are maintained
for at least 3 s.
Accordingly, if the engine does not start due to non-
pressure fuel feeding caused by a supply pump abnor-
mality, no diagnostic trouble code is be detected.
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*1. Required engine speed for P0093 judgment

*4. Absolute pressure
SMIL14CEX3439AB 5
*1. Non-judgment area

*2. P0093 judgment area
*3. P0093 established area
A. Absolute pressure
B. Engine speed (r/min)
SMIL14CEX3440AB 6
Check for flow damper and pressure limiter operations/

internal sealant deterioration and other common rail ab-
normalities, injector abnormalities, system down due to
fuel not being injected or seizing, compression pressure
deficiency, engine abnormalities caused by other me-
chanical troubles, ACG trouble, troubles related to the
hydraulic pump and other device on the actual machine,
effect of electrical components installed after purchas-
ing such as wireless devices and lights, ECM trouble,
connector connection problems, abnormalities involv-
ing friction or breaking in harnesses, any wires inside
harnesses separated and touching another circuit and
causing a short.
abnormalities.
Engine hunting, rough idling - Symptoms

The engine idling speed varies or the engine idling
speed changes.
When the problem is severe, the engine or the machine
vibrates.
If any of these states becomes severe, it may cause the
engine to stall.
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Engine hunting, rough idling - Diagnosis
items. The ECM and monitor are operating correctly.
Check DTCs. The scan tool data is within the normal
operation range.
plicable symptoms.
Visual inspection
visual inspection.
Check whether the battery terminal voltage is low.
in the fuel system.
in the moving direction of the actual machine.
in the fuel system.
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A. Pre-filte
B. Charge fuel pump
C. Fuel filter
SMIL14CEX3438AA 7
Diagnostic aid
Check for fuel cut-off, fuel freezing, air entering fuel
line, filter abnormality, line abnormality, fuel quality,
fuel tank and other fuel system abnormalities, filter
clogging, air intake pipe and other air intake system
abnormalities, supply pump abnormality, non-pressure
fuel feeding switch input, throttle position sensorcircuit
system abnormality, harness/coolant temperature sen-
sor and other sensor input circuit system abnormalities,
compression pressure deficiency, abnormal seizing on
throttle position sensor system, engine abnormalities
caused by as other mechanical troubles, troubles
related to the hydraulic pump and other device on
the actual machine, effect of electrical components
installed after purchasing such as wireless devices and
lights, connector connection problems, abnormalities
involving friction or breaking in harnesses, any wires
inside harnesses separated and touching another
circuit and causing a short.
abnormalities.
Excessive white smoke in exhaust gas - symptoms

There is a great deal of white smoke during operation.
Excessive white smoke in exhaust gas - diagnosis
items.
Check DTCs.
plicable symptoms.
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Visual inspection
visual inspection.
Check for injector connector connection problems.
disconnections.
Check whether the power supply for commer-
cially-available accessories is being diverged from the
ECM power supply.
in the fuel system.
Suction air system parts abnormality Exhaust system
parts abnormality.
Diagnostic aid
Fuel quality, for example non-regulation product with
low cetane number being used.
If low viscosity fuel such as kerosene is used, spray ab-
normalities will occur due to abnormal wear on the in-
jector seat section and white smoke may be produced.
In these cases, replacement of the injector is necessary.
Injector replacement due to use of low viscosity fuel
such as kerosene is not covered under warranty. In-
struct the customer not to use these fuels.
Long-term idling.
Coolant temperature sensor, fuel temperature sensor,
IAT sensor, boost sensor, barometric pressure sensor
troubles.
Engine main unit abnormalities caused by compres-
sion pressure deficiency, piston-related problems, tur-
bocharger problems, and rise/decline of oil ECM trou-
ble.
Excessive black smoke in exhaust gas - symptoms

There is a great deal of black smoke during operation.
Excessive black smoke in exhaust gas - diagnosis
items.
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Check DTCs.
plicable symptoms.
Visual inspection
visual inspection.
Check whether the air filter element is dirty or clogged.
disconnections.
Check whether the power supply for commer-
cially-available accessories is being diverged from the
ECM power supply.
in the fuel system.
Suction air system parts abnormality.
Exhaust system parts abnormality.
Diagnostic aid
Fuel quality, for example non-regulation product being
used.
Filter clogging, suction air line abnormality and other
suction air system abnormalities.
EGR control system abnormality.
Exhaust pipe abnormality and other exhaust system ab-
normalities.
Coolant temperature sensor abnormality.
Boost sensor trouble.
Engine main unit abnormalities caused by compres-
sion pressure deficiency, piston-related problems, tur-
bocharger problems, and rise of oil.
Abnormal noise - symptoms

The engine combustion noise is abnormal.
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Abnormal noise - diagnosis
items.
See the manual for the machine to inspect for abnormal
noise.
Check DTCs.
plicable symptoms.
Visual inspection
visual inspection.
disconnections.
in the fuel system.
Diagnostic aid
other fuel system abnormalities.
EGR valve abnormality and other suction air system
abnormalities.
Injector abnormality, fuel not injected Engine abnormal-
ity caused by seizing, compression pressure deficiency
and other mechanical troubles.
Troubles related to the hydraulic pump and other device
on the machine and ECM trouble.
Inspect for connector connection problems, abnor-
malities involving friction or breaking in harnesses,
any wires inside harnesses separated and touching
another circuit and causing a short.
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abnormalities.
High fuel consumption - symptoms

Fuel consumption is markedly more than what is listed
in the manual for the machine.
High fuel consumption - diagnosis
items.
Check the estimated fuel consumption of the machine
manufacturer (A) as fuel consumption will vary widely
depending on the handling of the machine.
Estimated fuel consumption (L (qt)/hr.).
Check the actual fuel consumption (B).
Actual fuel consumption (L (qt)/hr.).
If B is larger than A, see the manual for the machine
and check the settings on the machine.
Check whether there is an excessive load on the ma-
chine.
See the service list table in the Operator's Manual and
perform inspection according to the machine usage
time.
For a machine in which the usage time is over 3000 h,
see the manual for the machine and perform the inspec-
tions.
Check DTCs.
plicable symptoms.
Check whether engine oil replacement and periodic
maintenance for the air cleaner filter and fuel filter have
been implemented.
Visual inspection
visual inspection.
disconnections.
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in the fuel system.
Diagnostic aid
other fuel system abnormalities.
EGR valve abnormality and other suction air system
abnormalities.
Excessive fuel injection and other injector abnormali-
ties.
Engine abnormality caused by seizing, compression
pressure deficiency and other mechanical troubles.
Troubles related to the hydraulic pump and other device
on the machine ECM trouble.
Inspect for connector connection problems, abnor-
malities involving friction or breaking in harnesses,
any wires inside harnesses separated and touching
another circuit and causing a short.
abnormalities.
Engine intake/exhaust system inspection locations In-
spect for clogging, crushing, breakage, and other ab-
normalities.
In addition to the engine main unit inspection locations,
perform inspection of the air cleaner, intercooler, and
muffler.
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SMIL14CEX3441FB 8
1. Primary EGR cooler 5. From air cleaner

2. EGR duct 6. To intercooler
3. EGR valve 7. Exhaust pipe
4. From intercooler 8. Secondary EGR cooler
High oil consumption - symptoms

Oil consumption is markedly more than what is listed in
the manual for the machine.
High oil consumption - diagnosis
items.
Check the rough oil consumption of the machine manu-
facturer (A) as oil consumption will vary widely depend-
ing on handling of the machine.
Rough oil consumption for engine by itself (rough oil
consumption/time): 4 L/ 100 h.
Check the actual oil consumption (B).
Actual oil consumption /hr.
See the service list table in the Operator's Manual and
perform inspection according to the machine usage
time.
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For a machine in which the usage time is over 3000 h,

see the manual for the machine and perform the inspec-
tions.
Check DTCs.
plicable symptoms. Confirm with the customer that the
stipulated engine oil and fuel are being used.
Visual inspection
visual inspection.
Is bluish smoke continuously produced during engine
running?
Is excessive blow-by gas being produced? Check for
any oil mixed in with the coolant.
Check that pipes and hoses for oil are not broken or
twisted and that they are correctly connected.
Check for oil leaks and damage and denting on pipes
in the lubrication system.
Check the turbocharger and other suction air system
parts abnormalities.
Diagnostic aid
Decline of oil, rise of oil, excessive blow by gas and
other suction air system abnormalities.
Engine abnormality caused by oil combustion and ex-
cessive blow-by gas.
abnormalities.
Engine output deficiency - symptoms

The engine output is lower than expected, output does
not change even if the engine throttle switch (throttle
lever) is raised, and responsiveness is poor.
Engine output deficiency - diagnosis
items.
Check DTCs. The scan tool data is within the normal
operation range.
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plicable symptoms.
There are various possible causes for output deficien-
cies. Thoroughly investigate the relationship between
the engine and the actual machine.
Check under what kind of operation conditions the out-
put deficiency occurs.
If the output deficiency symptoms include hesitation
and lag down, it is related to the controls on the ac-
tual machine. Contact the manufacturer of the actual
machine.
With the trouble diagnostic scan tool, the engine output
at the rated point can be checked easily by checking
the boost at the rated point.
Visual inspection
Some symptoms detection procedures require care-
ful visual inspection. This allows for problems to be
repaired without performing further inspection, which
saves valuable time.
Check whether the air filter element is dirty or clogged.
disconnections Check whether the power supply for
commercially-available accessories is being diverged
from the ECM power supply.
in the fuel system.
Check for increased resistance among suction air sys-
tem parts, especially resulting from a dirty air cleaner
element, clogging, and crushing in the suction air line.
Check for exhaust system parts abnormality.
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Diagnostic aid
Check for fuel cut-off, fuel freezing, air entering fuel
line, filter abnormality, line abnormality, fuel quality, fuel
tank and other fuel system abnormalities, filter clogging,
air intake pipe and other air intake system abnormali-
ties, exhaust pipe and other exhaust system abnormal-
ities, sensor input circuit system abnormalities such as
throttle position sensor and harness, switch input cir-
cuit system abnormality, engine abnormalities such as
compression pressure deficiency and other mechanical
troubles which includes valve clearance/turbocharger/
supply pump/ injector/common rail, troubles related to
the hydraulic pump and other device on the actual ma-
chine, effect of electrical components installed after pur-
chasing such as wireless devices and lights, connector
connection problems, abnormalities involving friction or
breaking in harnesses, any wires inside harnesses sep-
arated and touching another circuit and causing a short.
abnormalities.
Output reduction due to fuel flow restriction resulting
from overheating, insufficient output due to fuel flow re-
striction resulting from high altitude operation.
Control for overheating

In order to protect the engine, the ECM starts controlling
the fuel flow if the engine coolant temperature exceeds
100 °C (212 °F).
If the engine coolant temperature rises further, the fuel
flow is further restricted.
Near 120 °C (248 °F), the fuel flow is restricted to a con-
stant level.
Varies depending on the manufacturer of the actual ma-
chine.
The system emits a warning through the actual machine
from 105 °C (221 °F).
By lowering the load applied to the actual machine in
addition to the warning, it is possible to avoid an oper-
ation condition in which the fuel flow is restricted. SMIL14CEX3442AB 9
a. Fuel flow
b. Engine coolant correction
*1. Warning display
*2. DTC set
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High altitude correction

The ECM calculates the current altitude from the baro-
metric pressure sensor signals.
The SCV opening and closing interval and the injector
electrified time are controlled according to the high al-
titude conditions at this time, and correction is made to
achieve the optimum fuel flow.
a. Flue flow limit (mm3/st)
b. Barometric pressure kPa
*1. High altitude
SMIL14CEX3443AB 10
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Engine starting system - Inspect

Start system inspection - Functions
This diagnosis chart is a systematized approach to
grasping the condition causing a state in which the
engine does not start.
You can use this diagnosis chart for appropriate system
diagnosis.
• The battery must be fully charged to perform this
diagnosis.
• The battery cables must be securely connected to
perform this diagnosis.
• The engine speed during cranking must be normal
to perform this diagnosis.
• Appropriate fuel must be supplied adequately to per-
form this diagnosis.
• There must be no fuel leaks to perform this diagno-
sis.
• Air must not be mixed in with the fuel to perform this
diagnosis.
• The air filter element must be clean to perform this
diagnosis.
• The fuel filter must be clean to perform this diagno-
sis.
Start system inspection - Inspection

Inspection performed when the starter operates and
cranks the engine, but the engine does not start.
1. Turn the emergency stop switch OFF.
2. Inspect the overheat switch circuit.
3. If a problem is found, repair the circuit.
4. Check for a DTC.
NOTE: If a DTC is detected, inspect for the relevant DTC.
5. Use the trouble diagnosis scan tool to check the display
of the SCV F/B while cranking the engine.
Standard value: 900 mA
6. If it is below the standard value, repair the SCV-LO
drive circuit.
7. Disconnect the harness connector from the SCV.
8. Crank the engine.
9. If the engine does not start, inspect the fuel system.
10. Inspect the coolant temperature sensor.
11. Inspect the fuel pressure sensor.
12. Inspect the EGR position sensor.
13. Inspect the injector.
14. Inspect the engine mechanical timing.
15. Inspect the installation status of the flywheel.
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16. Inspect the suction air system.

17. Inspect the exhaust pipes for crushing, breakage, and
exhaust leaks.
18. Repair or replace any parts in which problems are
found.
Start circuit system inspection
Start circuit system inspection - Functions

ECM turns ON the starter relay when the starter switch
is put in the START position.
When the starter relay turns ON, the starter operates
and the engine starts.
Start circuit system inspection - Inspection

Inspection performed when the starter does not oper-
ate.
1. Turn the emergency stop switch OFF.
2. Check for a DTC.
NOTE: If DTC P0117, P0118, or P0380 is detected, inspect
for the relevant DTC.
3. Turn the starter switch OFF.
4. Remove the starter cut relay.
5. Inspect the starter cut relay.
• Check the continuity between the switch side termi-
nals.
Standard value: 100 Ω or lower
6. If a problem is found, replace the relay.
7. Remove the starter relay.
8. Inspect the starter relay.
• Connect the battery between the coil side terminals
and check the continuity between the switch side
terminals.
10. Inspect the starter switch start signal circuit.
• There must be no disconnection or high resistance
between the starter switch and ECM.
• There must be no short circuit to ground between the
starter switch and the ECM.
Standard value: 10 Ω or higher
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12. Inspect the start circuit.

• There must be no disconnection between the
starter switch and the starter cut relay.
starter cut relay and the starter relay.
starter relay and ground.
starter relay and the starter.
14. Inspect the starter.
Starter inspection.
15. If a problem is found, replace the starter.
16. Replace the ECM.
17. Replace the ECM, and then perform EGR learning.
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Engine starter - Prepare

WARNING
Battery gas can explode!
To prevent an explosion: 1. Always disconnect the negative (-) battery cable first. 2. Always connect
the negative (-) battery cable last. 3. Do not short circuit the battery posts with metal objects. 4. Do
not weld, grind, or smoke near a battery.
W0011A
WARNING
Avoid injury!
W1128A
Items to prepare:
• Rag
• Cleaning fluid
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Engine starter - Remove

1. Turn OFF the battery disconnect switch. or remove the
cable connected to minus side of the battery.
Or protect them with a rubber cap or other cap to
prevent sparks.
remove the under cover (4).
54.211 lb ft)
SMIL14CEX3449AB 1
3. Remove the 2 bolts (1) and the nut (2) to remove the 2
harnesses (3).
SMIL14CEX3450AB 2
4. Remove the bolt (10) with a wrench [ 14 mm] to remove

the wiring (9) connected to ground side.
SMIL14CEX3451AB 3
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5. Remove the 2 nuts (11) with a wrench [ 17 mm] to re-

move the starter motor (12).
Nut tightening torque: 82.4 N·m (60.775 lb ft)
SMIL14CEX3452AB 4
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Engine starter - Disassemble

CAUTION:
○ Make the alignment marks in relation to the

magnetic switch, yoke, front bracket, and rear
bracket before disassembling the starter as-
sembly.
○ Remove the pinion first.
1. Disconnect the lead wire with terminals (3) from the
magnetic clutch.
NOTE: Remove the M terminal nut of the magnetic switch.
2. Connect the starter assembly to the battery 24 V (4).
3. Close the switch.
NOTE: When the switches SW1 (1) and SW2 (2) are
closed, the pinion advances to the cranking position and
the armature rotates.
CAUTION: Remove the pinion within 10 s af-

ter supplying electricity.
SMIL14CEX3453AB 1
4. Open the switch.

NOTE: Open the switch SW2 (2) to stop the rotation of the
armature.
5. Prepare the pipe (1).
NOTE: Prepare a pipe (1) which fits the outer diameter of
the stop ring (2).
6. Press the stop ring (2) using the pipe (1).
NOTE: Push the stop ring (2) into the pinion side by tapping
the pipe (1) using a hammer.
7. Remove the snap ring (3) from the overrunning clutch
(4).
CAUTION: Do not reuse the snap ring (3).

SMIL14CEX3454AB 2
8. Remove the stop ring (2) from the overrunning clutch
(4).
9. Remove the pinion (5) from the overrunning clutch (4).
10. Remove the pinion spring (6) from the overrunning
clutch (4).
11. Remove the magnetic switch from the front bracket.
NOTE: Loosen the magnetic switch tightening screw using
a impact driver.
12. Remove the rear bracket from the yoke.
NOTE: Remove the brush holder tightening screw and pen-
etration bolt.
CAUTION: Do not reuse the removed O-ring.
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13. Prepare the socket.

NOTE: Socket size: 32 mm Outer diameter
14. Align the socket to the armature.
NOTE: Attach the socket to the commutator of the arma-
ture.
15. Remove the yoke from the front bracket.
NOTE: Slide the brush on the socket, and while the brush
is on top of the socket, remove the yoke.
CAUTION: Do not reuse the removed O-ring.

16. Remove the brush holder from the yoke.
NOTE: Pull up the brush spring, remove the brush from the
brush holder, and remove the brush holder.
17. Remove the armature from the gear shaft.
CAUTION: Be careful not to lose the ball.

18. Remove the bearing from the armature.
19. Remove the plate from the front bracket.
20. Remove the gasket from the gear shaft.
21. Remove the planetary gear from the gear shaft.
22. Disengage the overrunning clutch (4) from the front
bracket.
NOTE: Pull out the internal gear, gear shaft, overrunning
clutch (4) and lever together from the front bracket.
23. Remove the lever from the overrunning clutch (4).
NOTE: Make sure to remember the direction of the lever.
24. Remove the E-ring from the gear shaft.
CAUTION: Do not reuse the E-rings.

25. Remove the overrunning clutch (4) from the gear
shaft.
NOTE: Remove the overrunning clutch (4) from the gear
shaft by rotating it by 1 spline tooth.
26. Remove the internal gear from the gear shaft.
27. Remove the washer from the gear shaft.
28. Remove the bearing from the front bracket.
29. Remove the brush from the yoke.
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Engine starter - Inspect

Armature inspection
1. Inspect the armature using the growler tester.
NOTE: Inspect the armature for an internal short circuit.
CAUTION: Replace the armature if an internal

short circuit has been found.
SMIL14CEX3459AA 1
2. Inspect the armature using the circuit tester.

NOTE: Inspect the armature for an insulation.
CAUTION: Replace the armature if an internal

short circuit has been found.
SMIL14CEX3460AA 2
3. Measure the commutator using the vernier caliper.

NOTE: Inspect the outer diameter of the commutator for
worn.
Specified value: 32 mm (1.260 in)
Limit: 31.4 mm (1.236 in)
SMIL14CEX3461AA 3
4. Measure the commutator (1) using the gauge.

NOTE: Inspect the depth of the insulated mold (2).
CAUTION: Before starting inspection, remove

the powder generated by wear of the brush.

Limit: 0.2 mm (0.0079 in)
5. Inspect the gear.
NOTE: Inspect the gear for worn and damage.
SMIL14CEX3462AB 4
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Yoke inspection
1. Inspect the feed coil using the circuit tester.
NOTE: Inspect the coil for continuity.
CAUTION: Replace the yoke if there is an

open circuit.
SMIL14CEX3463AA 5
2. Inspect the feed coil using the circuit tester.

NOTE: Inspect the coil for insulation.
CAUTION: Replace the yoke if an insulation

problem has been found.
SMIL14CEX3464AA 6
Brush holder inspection

1. Measure the brush using the vernier caliper.
Limit: 11.0 mm (0.4331 in)
CAUTION: Replace the brush holder if the

NOTE: Replace only the brush if the brush on the yoke side
is worn.
2. Inspect the brush holder.
NOTE: Confirm that the brush moves smoothly.
3. Inspect the brush holder using the circuit tester.
NOTE: Confirm that there is no continuity by attaching the
probe of the tester between the bush holder plate and in-
sulated holder (2).
1. Brush length
CAUTION: Replace the brush holder if there

is continuity.
SMIL14CEX3465AB 7
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Overrunning clutch inspection

1. Inspect the overrunning clutch.
NOTE: Hold the housing section of the overrunning clutch
and turn the pinion over using your hands to confirm that
the pinion moves smoothly in one direction with a certain
degree of resistance while not moving to the other direc-
tion.
CAUTION:
○ Do not use a cleaning agent when cleaning the

overrunning clutch.
○ Use a cloth to clean the overrunning clutch.
SMIL14CEX3466AA 8
2. Inspect the pinion.

NOTE: Replace the pinion if abnormal worn or damage has
been found.
Front bracket inspection

1. Inspect the oil seal.
2. Inspect the bearing.
CAUTION: Replace the front bracket if worn

or damage has been found.
Internal gear inspection

1. Inspect the internal gear.
CAUTION: Replace the internal gear if abnor-

mal worn or damage has been found.
Planetary gear inspection

1. Inspect the planetary gear.
CAUTION: Replace the planetary gear if ab-

normal worn or damage has been found.
Lever inspection
1. Inspect the lever.
NOTE: Inspect the lever and overrunning clutch sliding
sections (1) for worn.
1. Inspection locations
SMIL14CEX3467AB 9
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Magnetic switch inspection

1. Inspect the magnetic switch using the circuit tester.
CAUTION:
○ Replace the magnetic switch if there is no con-

tinuity between the M terminal (1) and body.
○ Replace the magnetic switch if there is continu-
ity on the B terminal (3) or M terminal (1).
1. M terminal
2. S terminal
3. B terminal
SMIL14CEX3468AB 10
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Engine starter - Assemble

NOTE: Grease application area when assembling the starter assembly.
SMIL14CEX3455FB 1
1. Plunger surface - small amount applied

2. Gear shaft spline section
3. Clutch shaft sliding section
4. Oil seal
5. Gear shaft sliding section
6. Lever and overrunning clutch sliding sections
7. Sleeve bearing and ball
8. Armature shaft gear, planetary gear, internal gear
9. Surface of the armature bearing outer circumfer-
ence - small amount applied
Application area List of recommended grease brands

1.
3.
4.
Kyodo Yushi MULTEMP 6129
5.
6.
9.
2. Kyodo Yushi MULTEMP OA-171
7.
Dow Corning MOLYKOTE AG650
8.
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1. Install the washer (1) to the gear shaft (2).

2. Install the internal gear (4) to the gear shaft (2).
3. Install the overrunning clutch (5) to the gear shaft (2)
as follows:
• Install the overrunning clutch (5) on the gear shaft by
rotating it by 1 spline tooth.
• Confirm that it does not come off the gear shaft (2)
when pulling the overrunning clutch (5).
4. Install the E-ring (3) to the gear shaft.
CAUTION: Use new E-rings (3). SMIL14CEX3456AB 2
5. Install the lever to the overrunning clutch (5).
CAUTION: Pay attention to the direction of the

lever when installing.
6. Install the overrunning clutch to the front bracket as
follows:
• Combine and then insert the internal gear, gear
shaft, overrunning clutch, and lever.
7. Install the planetary gear to the gear shaft.
8. Install the plate to the front bracket.
9. Install the gasket to the front bracket.
10. Install the gasket to the planetary gear.
11. Install the plate to the planetary gear.
12. Install the bearing to the armature.
13. Install the armature to the gear shaft as follows:
• Put the ball into the gear shaft and insert the arma-
ture.
14. Install the brush to the brush holder.
15. Install the O-ring to the yoke.

16. Install the yoke to the armature.
17. Install the O-ring to the yoke.

18. Install the rear bracket to the yoke.
Tightening torque: 8 - 13 N·m (70.8 - 115.1 lb in)
Penetration bolt
Brush holder tightening bolt
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19. Install the pinion (1) spring to the overrunning clutch

(2).
20. Install the pinion (1) to the overrunning clutch (2).
21. Install the stop ring (3) to the overrunning clutch (2).
22. Install the snap ring (4) to the overrunning clutch (2).
CAUTION: Use new snap rings.
NOTE: After installing, tightly pull the snap ring to the stop
ring side using a puller.
5. Groove SMIL14CEX3457AB 3
6. Pinion spring
23. Install the magnetic switch to the front bracket.
24. Connect the starter assembly to the battery 24 V (4).
NOTE: When the switches SW1 (1) and SW2 (2) are
closed, the pinion advances to the cranking position and
the armature rotates.
26. Open the switch.
NOTE: Open the switch SW2 (2) to stop the rotation of the
armature.
27. Measure the starter assembly using the dial gauge.
NOTE: Lightly push back the leading end of the shaft of SMIL14CEX3453AB 4
the overrunning clutch using your hands and measure the
travel distance.
Specified value: 0.5 - 2 mm (0.0197 - 0.0787 in)
NOTE: If the value is not within the specified value, adjust
by increasing or decreasing the number of gaskets located
between the magnetic switch and front bracket or replace
the lever.
Thickness of the gasket: 0.5 mm (0.02 in)
NOTE: Number of gaskets used: 2 or less
28. Connect the lead wire with terminal (3) to the magnetic
switch.
Tightening torque: 20 - 26 N·m (14.8 - 19.2 lb ft) M
terminal nut
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29. Connect the starter assembly to the battery.

NOTE: Connect the starter assembly as indicated in the
diagram after adjusting the pinion protrusion position.
1. Current meter
2. Voltage meter
3. SW
4. Battery 24 V
CAUTION:
○ Use a very thick electric wire. SMIL14CEX3458AB 5

○ Fully tighten the joint section.
NOTE: Read the current and voltage.
Voltage: 23 V
Current: Less than 85 A
Revolution speed: More than 3300 RPM
NOTE: If the value is not within the specified value, disas-
semble the part and inspect it again.
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Engine starter - Install

Tighten bolts and nuts to the specified torque.
For bolts for which the torque is not specified, see the
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Index

Engine starter - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Engine starter - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Engine starter - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Engine starter - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Engine starter - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Engine starter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Engine starter - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Engine starter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Engine starter - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Engine starting system - Dynamic description - Battery save . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engine starting system - Dynamic description - Engine emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine starting system - Dynamic description - Gate lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Engine starting system - Dynamic description - Horsepower reduction control (at engine failure) . . . . . . . . . . . . . 14
Engine starting system - Dynamic description - Horsepower reduction control (in uplands) . . . . . . . . . . . . . . . . . . 13
Engine starting system - Dynamic description - Idle up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine starting system - Dynamic description - Idling start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine starting system - Dynamic description - Neutral start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine starting system - Dynamic description - Power-cut delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine starting system - Dynamic description - Static horsepower control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine starting system - Dynamic description - Swing brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine starting system - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Engine starting system - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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Alternator - 301

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Contents
Alternator - 301
FUNCTIONAL DATA
Alternator
Dynamic description - Solenoid sticking prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE
Alternator
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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Electrical systems - Alternator
Alternator - Static description

The main components of the charging system are the battery, the generator, and the battery discharge indicator light
circuit. The generator is the self-rectifier type with a regulator built in.
Generator
The generator is the brushless type.
The main components include the rotor, stator, rectifier assembly, front bracket, rear bracket, IC regulator, bearing,
and pulley.
The moving parts are the rotor and the pulley. The field coil is fixed to the rear bracket.
6 main diodes and 2 additional diodes are used to change the three-phase alternating current generated in the stator
coil to a direct current.3 out of the 6 main diodes are referred to as positive diodes, and the rest are referred to as
negative diodes. In addition, 3 small diodes that are referred to as the triodiode are used to supply the field current.
This generator has 3 terminals: the B terminal (direct current output terminal), the L terminal, and the R terminal.
Since the L terminal is connected to the field coil, it works as an input terminal for the initial excitation current together
with the R terminal until the generator starts generating power.
Also, it functions as an output terminal. (Current capacity is 1 A.) When the L terminal voltage reaches the battery
voltage, the charge light turns OFF. Since both bearings are sealed, periodic lubrication is not required. The IC regu-
lator cannot be disassembled, so it should be handled as an assembly.
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Alternator - Component identification
SMIL14CEX3889FA 1
1. Rear bracket 6. Rotor

2. Regulator 7. Bearing
3. Bearing 8. Pulley
4. Rectifier 9. Front bracket
5. Stator 10. Field coil
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Alternator - Dynamic description - Solenoid sticking prevention
SMIL14CEX0908EB 1
a. Key switch
b. Solenoid
c. Normal control
Purpose/Overview
It is turned ON/OFF when the key is turned ON in order to prevent solenoid sticking.
Operation
1. An operator turns ON the key.
2. The machine turns ON the target solenoid, and the turns it OFF in 0.25 s.
Stop operation
• The machine releases the sticking prevention control to resume normal control if the engine is started up during the
sticking prevention control.
• The sticking prevention control is not activated if the key is turned ON again during power-cut delay.
Solenoids to be object of control:

• Travel 2nd speed switchover solenoid
• Pressure boost solenoid
• Free swing solenoid
• 2 pumps flow solenoid
• Hydraulic pressure load solenoid
• Option return line switchover solenoid
• Quick coupler solenoid
• Fan reverse solenoid
• Gate lock solenoid
• Bucket lock and patrol light solenoid
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Alternator - Prepare
WARNING
Battery gas can explode!
To prevent an explosion: 1. Always disconnect the negative (-) battery cable first. 2. Always connect
the negative (-) battery cable last. 3. Do not short circuit the battery posts with metal objects. 4. Do
not weld, grind, or smoke near a battery.
W0011A
WARNING
Avoid injury!
W1128A
Items to prepare:
• Wrenches [ 10 mm, 17 mm, 20 mm ]
• Rag
• Cleaning fluid
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Alternator - Remove
1. Remove the fan belt.
2. Remove the cooling fan.
3. Turn OFF the battery disconnect switch. Or remove the
cable connected to minus side of the battery.
Or protect them with a rubber cap or other cap to
prevent sparks.
Remove the 2 bolts (2) and the nut (3) to remove the SMIL14CEX3469AB 1
harness (4).
5. Remove the bolt (2) and the nut (3) to remove the al-
ternator (1).
Bolt tightening torque: 126 N·m (92.93 lb ft)
SMIL14CEX3470AB 2
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Alternator - Disassemble
CAUTION: Before disassembling, make align-
ment marks on the front and rear bracket.
1. Remove the penetration bolt from the generator.
2. Disconnect the front bracket from the rear bracket.
NOTE: Pry up the position between the stator and front
bracket using the tip of a flat-blade screwdriver, and care-
fully separate the pulley, rotor, and front bracket together
from the rear bracket.
CAUTION: Be careful not to damage the stator

coil.
3. Fasten the rotor to the vise.
CAUTION:
○ Be careful not to distort the rotor pole.

○ Be sure to clamp the section indicated by the
arrow in the diagram when tightening the rotor
with a vise.
○ Do not clamp section (1) in the diagram be-
cause the rigidity is weak.
SMIL14CEX3471AB 1
4. Remove the generator pulley from the rotor.

NOTE: Remove the pulley tightening nut, and then remove
the washer, pulley, fan, spacer, and front bracket.
5. Remove the bearing from the front bracket.
CAUTION:
○ Do not remove the bearing except when replac-

ing.
○ Do not reuse the removed bearing.
6. Remove the bearing from the rotor using the puller.
CAUTION:
○ Do not remove the bearing except when replac-

ing.
○ Do not reuse the removed bearing.
7. Remove the screw from the generator.
NOTE: Remove the regulator assembly installation screw.
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8. Remove the screw from the generator.

NOTE: Remove the field coil installation screw. (2)
CAUTION: Do not remove the field coil instal-

lation screw (2) when the regulator assembly in-
stallation screw (1) is attached.
SMIL14CEX3472AB 2
9. Remove the field coil from the rear bracket.

10. Remove the screw (2) from the rectifier (7).
11. Remove the nut (4) from B -terminal (5).
12. Remove the screw (2) from the regulator assembly
(1).
13. Remove the rectifier (7) from the rear bracket.
NOTE: Remove the stator together with the rectifier (7)
from the rear bracket.
The tube (6) remains at the rear bracket.
CAUTION: Be careful not to lose the tube of

the terminal bolt (3).
14. Remove the regulator (1) assembly from the rear
bracket.
15. Remove the stator from the rectifier (7).
NOTE: Remove the 4 stator coil lead wires and then re-
move the stator from the rectifier.
CAUTION: Remove within 5 s using a 180 -

270 W soldering iron.
1. Regulator assembly
2. Screw
3. Terminal bolt
4. Nut
SMIL14CEX3473AB 3
5. B terminal
6. Tube
7. Rectifier
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Alternator - Inspect
CAUTION:
○ Use a current meter (1) with a rated current of

100 A.
○ Use a voltage meter (7) with a rated current of
30 V.
○ Use a variable type load resistance (4) with a
rated current of 70 A or higher.
1. Inspect the generator using the tester.

NOTE: Check the L terminal of the generator (6) using a
test light ( 24 V - 3 W or less) (5). SMIL14CEX3474AB 1
Confirm that the test light (5) is illuminated when switch 2
(2) is closed.
CAUTION: Open switch 3 (3).
5. Light ( 24 V - 3 W or less)
2. Measure the voltage using the tester.
NOTE: Measure the voltage on the L terminal if the test
light is not illuminated up when switch 2 (2) is closed.
If the voltage is close to the battery voltage, inspect the
generator (6).
If the voltage is low, check if there is an open circuit in the
light or the light circuit.
3. Inspect the generator using the tester.
NOTE: Gradually accelerate the generator revolution
speed to confirm that the test light turns off before the
revolution speed reaches approximately 1300 RPM .
If the test light does not turn off, inspect the generator.
NOTE: Measure the voltage when the generator revolution
speed is approximately 1300 RPM.
If the voltage exceeds 30 V, inspect the regulator assem-
bly.
If the voltage does not exceed the battery voltage, inspect
the generator.
5. Inspect the regulator assembly using the tester.
NOTE: Accelerate the generator revolution to check
the current when the revolution speed is approximately
5000 RPM.
If the current meter reading is 5 A or higher, continue charg-
ing until it becomes 5 A or lower, or replace the battery with
a fully charged one.
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Regulator threshold voltage adjustment： 28.00 -
29.00 V
NOTE: If the current is 5 A or less when the generator revo-
lution speed is approximately 5000 RPM, measure the reg-
ulator adjustment voltage.
CAUTION: If the regulator adjustment voltage

is not within the specified value, replace the regu-
lator assembly.
7. Stop the generator.
NOTE: Close switch 2.
CAUTION: Confirm that the test light is illumi-

nated.
NOTE: Maximize the no-load resistance value, and close
switch 3.
10. Adjust the current to maximum value using the resis-
tance.
NOTE: Adjust the load resistance so that the output current
is maximized while keeping the generator revolution speed
at approximately 5000 RPM.
Keep the condition above for 15 min and increase the gen-
erator temperature.
11. Adjust the current to maximum value using the resis-
tance.
NOTE: Adjust the no-load resistance so that the output cur-
rent is maximized when the generator revolution speed is
2500 RPM and 5000 RPM.
12. Measure the current using the tester.
NOTE: Inspect the generator if the measured value is un-
der the specified value.
5000 RPM 50 A or higher
Stator inspection
1. Inspect the stator.
NOTE: Inspect for damage, loose connections, and discol-
oration on wires.
1. Terminal 1
2. Terminal 2
3. Terminal 3
4. Terminal 4
SMIL14CEX3475AA 2
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2. Inspect the stator using the circuit tester.

NOTE: Check the stator coil lead wire for continuity using
a circuit tester.
CAUTION: If the status of continuity differs

from the table inside the diagram, replace the sta-
tor.
3. Inspect the stator using the circuit tester.
NOTE: Check the continuity between the stator coil termi-
nal 2 and core using a circuit tester.
1. Terminal 1
2. Terminal 2
3. Terminal 3
4. Terminal 4
CAUTION: Replace the stator if there is con-

tinuity.
SMIL14CEX3476AA 3
Rotor inspection
1. Inspect the rotor.
NOTE: Inspect the rotor for damage.
Field coil inspection

1. Inspect the field coil (2) using the circuit tester.
Field coil resistance: 4.40 - 5.10 Ω 20 °C
NOTE: Measure the resistance between both ends of the
terminal (1) section of the field coil (2) using a circuit tester.
CAUTION: Replace the field coil if the mea-

sured value is not within the range of the specified
value.
SMIL14CEX3477AB 4
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Rectifier inspection
1. Inspect the rectifier using the circuit tester.
1. Heat sink section
2. Regulator connection
3. Terminal
4. Terminal
5. Terminal
6. Terminal
7. Heat sink section
NOTE: Check the continuity condition of each diode using
an analog tester.
Tester polarity display
Continuity
Minus Plus
7 Exist
3,4,5,6
1 Not exist
7 Not exist
3,4,5,6
1 Exist
2 3,5,6 Not exist
3,5,6 2 Exist
NOTE: The table shows that the diode is normal if there is

continuity when applying the positive terminal of the tester
to 3, and the negative terminal to 7.
SMIL14CEX3478BB 5
CAUTION: Replace the rectifier if the continu-

ity condition is not shown on the table.
SMIL14CEX3479AA 6
Bearing inspection
1. Inspect the bearing.
NOTE: Inspect the grease leakage.
Rotate the bearings with your hands, and inspect for ab-
normalities such as noise or looseness.
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Regulator assembly inspection

Regulator threshold voltage adjustment: 28.00 -
29.00 V
NOTE: If the current is 5 A or less when the generator revo-
lution speed is approximately 5000 RPM, measure the reg-
ulator adjustment voltage.
CAUTION: Replace the regulator assembly if

the measured value is not within the range of the
specified value.
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Alternator - Assemble
1. Install the regulator assembly (1) to the rear bracket.
1. Regulator assembly
2. Screw
3. Terminal bolt
4. Nut
5. B terminal
6. Tube
7. Rectifier
2. Install the rectifier (7) to the rear bracket.
3. Install the nut (4) to the rectifier (7). SMIL14CEX3473AB 1

4. Install the stator to the rear bracket.
NOTE: Crimp the 4 stator coil lead wires on the terminal
section of the rectifier.
CAUTION: Install within 5 s using a 180 -

270 W soldering iron.
5. Install the field coil to the rear bracket.
6. Install the screw to the regulator assembly.
7. Install the bearing to the rotor.
NOTE: Bearing is filled with grease and sealed, so there is
no need to apply grease.
CAUTION:
○ Do not reuse the bearing once it is removed.

○ Thoroughly wipe off the oil on the bearing box
section of the rear bracket.
○ Never apply oil to the bearing of the rotor shaft
with a resin band.
8. Install the regulator assembly (1) to the rear bracket.
CAUTION: Do not reuse the bearing once it is

removed.
9. Install the retainer to the front bracket.
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10. Fasten the rotor to the vise.
CAUTION:
○ Be careful not to distort the rotor pole.

○ Be sure to clamp the section indicated by the
arrow in the diagram when tightening the rotor
with a vise.
○ Do not clamp section (1) in the diagram be-
cause the rigidity is weak.
SMIL14CEX3471AB 2
11. Install the rotor to the front bracket.

12. Install the generator pulley to the rotor.
Tightening torque: 132 - 162 N·m (97.4 - 119.5 lb
ft)
NOTE: Install the fan, pulley, and washer in order to the
shaft of the rotor, then tighten the pulley tightening nut.
13. Connect the front bracket to the rear bracket.
Penetration bolt
NOTE: Heat the bearing box section of the rear bracket to
50 - 60 °C before assembling.
CAUTION: After assembling the generator, ro-

tate the pulley using your hands and confirm that
the rotor turns smoothly.
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Alternator - Install
dure.
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Index
Alternator - 301
Alternator - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Alternator - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Alternator - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Alternator - Dynamic description - Solenoid sticking prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Alternator - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Alternator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Alternator - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Alternator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Alternator - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Battery - 302

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Contents
Battery - 302
FUNCTIONAL DATA
Battery connect and disconnect system

SERVICE
Battery
Service instruction - Battery charge abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Electrical systems - Battery
Battery connect and disconnect system - Static description

Purpose
A switch to enable safe and easy cut off of the electrical circuit for maintenance involving electrical system repair or
welding repair of the main unit.
Location of mounting: Vicinity of battery
SMIL14CEX0912FB 1
1. Cover 4. Label battery cut-off switch

2. Bracket 5. Battery switch cable
3. Battery switch
By-effect of turning OFF the battery cut-off switch

Setting of clock/radio Reset
Model setting of controller Log is maintained
Monitor information Log is maintained
(Battery OFF within 30 s after key OFF)
Error code
Not recorded
(Battery ON within 60 s after key ON)
G navigation position information
No acquisition
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Battery - Service instruction - Battery charge abnormality

Configuration (with fuses omitted)
SMIL14CEX0907GB 1
*1 To load
1. Main controller 5. 10 V comparator

2. Key switch 6. Monitor
3. Battery relay B: Charge
L: Running signal
7.
4. Alternator R: Initial energization
E: GND
Operation
In 10 s after the engine starts, detection of a battery
charge warning starts.
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The L -terminal output voltage of the alternator is

checked by the 10 V comparator.
ON when L -terminal voltage 10 V
OFF when L -terminal voltage < 10 V
* The threshold 10 V has a tolerance of ± 1 V.
Detection of power generation failure

If, although the engine is running, the 10 V comparator
input turns OFF, it is judged as a power generation fail-
ure.
Refer to \ Engine Control Unit (ECU) - Fault code
index (55.015) for the details on judgment criteria.
Warning
When the monitor receives the command for a battery
charge failure, the following operation will be triggered.
1. Message: "ALTERNATOR" appears.
2. Buzzer: It starts to sound simultaneously with the mes-
sage display, and stops in 5 s.
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Index
Battery - 302
Battery - Service instruction - Battery charge abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Battery connect and disconnect system - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Cold start aid - 202

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Contents
FUNCTIONAL DATA
Cold start aid

SERVICE
Cold start aid

Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Glow plug system
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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Electrical systems - Cold start aid
Cold start aid - Static description

Preheat system
The preheat system adopts the glow plug type QOS system. Also, energization is controlled by the ECM.
Preheat
Purpose/overview
The system warms up inside of the engine cylinder at key ON (at starting up) to improve starting up characteristics.
SMIL14CEX3430FB 1
1. Glow lamp icon 5. Glow relay

3. Main controller 7. Glow plug
4. ECM 8. Coolant temperature sensor
Control
Operation:
1. Turn ON the key.
2. The system calculates a time for pre-glow based on the current coolant temperature when the key is turned ON
and then energizes the glow relay during that period to illuminate the glow lamp simultaneously.
3. It turns OFF the glow lap when the pre-glow is completed to prompt cranking.
4. It cranks to start the engine.
5. The system calculates after glow time based on the current coolant temperature when the engine starts up to
continue pre-heating during that period.
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Cold start aid - Inspect

Glow control system - Functions
CAUTION: The QOSII circuit is the same for
both starter ECM control models and safety relay
models.
The QOSII system consists of the ECM, glow relay,
glow plug, and QOSII indicator lamp.
If the starter switch is turned ON with the engine coolant
temperature low, the ECM determines the glow time ac-
cording to the engine coolant temperature and operates
the glow relay and the QOSII indicator lamp.
When a certain time has passed, the ECM turns OFF
the glow relay and the QOSII indicator lamp.
Glow control system - Inspection

there is an abnormality in locations related to QOSII
system control.
1. Check the OBD system.
2. Check for a DTC.
NOTE: If DTC P0117, P0118, or P0380 is detected, inspect
for the relevant DTC.
3. Switch the starter switch ON.
4. Check the operation of the QOSII indicator lamp.
• Even when the QOS is not operating, the QOSII indi-
cator lamp is lit up by the lamp check function when
the starter switch is turned ON.
• The QOSII indicator lamp stops flashing within 10 s
5. If the QOSII indicator lamp does not light up or go off,
inspect the circuit.
• The fuse must not be blown.
• There must be no disconnection between the fuse
and the QOSII indicator lamp.
• There must be no disconnection or short between
the QOSII indicator lamp and the ECM.
• The valve for the QOSII indicator lamp must not be
blown.
6. If a problem is found, repair or replace the circuit.
7. Inspect the glow relay.
9. Remove all the glow plugs.
10. Measure the resistance between the glow plug termi-
nals and ground using a digital multi-meter.
Standard value: 6 Ω for normal temperature
NOTE: If a resistance is outside the standard value range,
replace the relevant glow plug.
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11. If a resistance is outside the standard value range,

replace the relevant glow plug.
12. Connect the digital multi-meter with the glow plug con-
nector and ground.
13. Switch the starter switch ON.
14. Use the trouble diagnosis scan tool to perform an ac-
tuator test for the glow plug relay.
Standard value: 0 V
NOTE: Turn the command OFF and check the voltage
value on the digital multi-meter.
15. If the voltage is outside the standard value range, in-
spect the circuit.
NOTE: There must be no short circuit to the battery or igni-
tion power supply circuit between the glow relay and glow
plug.
17. Use the trouble diagnosis scan tool to perform an ac-
tuator test for the glow plug relay.
Standard value: 18 V
NOTE: Turn the command ON and check the voltage value
on the digital multi-meter.
18. If the voltage is below the standard value, inspect the
circuit.
• The fuse must not be blown.
• There must be no disconnection between the fuse
and the glow relay.
• There must be no disconnection between the glow
relay and glow plug.
• There must be no disconnection between the glow
relay and ECM.
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Glow plug system - Remove

Removing the intake throttle valve

throttle valve.
NOTE: Pull the lock operation section (1) to release the
lock.
2. Lock release
3. Lock
SMIL14CEX2993AB 1
SMIL14CEX2994AB 2
Removing the glow plug

SMIL14CEX2997AA 3
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bly.
SMIL14CEX2998AA 4
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Glow plug system - Test

1. Use a circuit tester to measure the resistance.
Standard resistance: 5.00 Ω
CAUTION:
○ If the measurement value is outside the stan-

dard value, replace the glow plugs.
○ Use a set of 6 glow plugs from the same man-
ufacturer.
SMIL14CEX3480AA 1
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Glow plug system - Install

1. Install the glow plug on the cylinder head assembly.
CAUTION: Be careful not to tighten beyond

the specified torque.
SMIL14CEX2998AA 1
2. Install the glow plug connector on the glow plug.

CAUTION: Check that the glow plug connec-

tor is not interfering with peripheral parts.
SMIL14CEX2997AA 2
Installing the intake throttle valve

1. Install the gasket (2) and the intake throttle valve (1) on
the inlet pipe (3).
2. Install the air duct on the intake throttle valve (1).
SMIL14CEX2994AB 3

valve.
NOTE: Connect the harness connector, and then push in
the lock operation section (1) to lock.
2. Lock release
3. Lock
SMIL14CEX2993AB 4
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Index

Cold start aid - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cold start aid - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Glow plug system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Glow plug system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Glow plug system - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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Fuel tank system - 011

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Contents
FUNCTIONAL DATA
Fuel transfer pump

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Electrical systems - Fuel tank system
Fuel transfer pump - Dynamic description

Feed pump automatic stop
The machine stops the feed pump automatically and sounds alarm when the tank is full with fuel.
Fuel can be added if more fuel is required.
Purpose/overview
SMIL14CEX0904FB 1
a. Manual (momentary type) c. Over head

b. Auto (alternate type) d. Reserve
1. Main controller 4. Feed pump relay

2. Fuel level sensor 5. Alarm
3. Feed pump stop relay 6. Feed pump
The feed pump switch consists of 3 positions of (MANUAL) - (OFF) - (AUTO). The pump is driven only during the
switch is pressed in momentary type for "MANUAL," and it is driven when the switch is ON in alternate type for
"AUTO."
Operation condition
Auto mode
1. The feed pump is driven when the key is turned ON, the feed switch is pressed for "AUTO" without starting up
the engine, and all of the following conditions are established.
○ The engine stops (engine speed is 200 RPM or less).
○ The tank is not full (fuel level at 95 % or less continues for 3 s ).
○ The fuel level sensor does not malfunction.
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Electrical systems - Fuel tank system
2. The machine stops the feed pump and sounds alarm when the tank is full with fuel.
○ Condition for full tank (fuel level at 95 % or more continues for 3 s)
3. The alarm stops when the feed switch is turned OFF.
Manual mode
1. Press [MANUAL] of the feed switch for adding fuel. The pump is driven only during the switch is pressed and held.
○ The feed pump does not automatically stop even when the tank reaches full if the switch is kept pressed and
held in the manual mode.
Conditions to stop: The feed pump is not activated or stops and sounds alarm under the following conditions.
• [AUTO] of the feed switch is pressed during the engine is running.

• [AUTO] of the feed switch is pressed when the tank is full.
• [AUTO] of the feed switch is pressed when the feed level sensor malfunctions.
• The feed level sensor malfunctions during feeding fuel in the auto mode.
• The engine is started up during feeding fuel in the auto mode.
* The alarm stops when the feed switch is turned OFF when the alarm is sounded under the conditions listed above.
Time chart
SMIL14CEX0905FB 2
1. Fuel level
2. Feed pump stop relay
a. 98 % d. OFF
b. 95 % e. 3s
c. ON
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Index

Fuel transfer pump - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Contents
SERVICE
Fuel filter restriction sensor

Service instruction - Fuel filter clogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel shutoff solenoid
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Electrical systems - Fuel injection system
Fuel filter restriction sensor - Service instruction - Fuel filter

clogging
Purpose/overview
Excessive clogging of the fuel filter may cause cavita-
tion in fuel to damage the engine.
Therefore, the system generates a message to prompt
replacement of the fuel filter as necessary as well as it
lowers engine speed automatically to protect the engine
if it is kept used without filter replacement.
SMIL14CEX4197FB 1
1. Fuel filter negative pressure sensor

2. ECM
3. Engine
4. Main controller
5. Monitor
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Operation
1. ECM judges clogging state of the fuel filter based on
signal of the negative pressure sensor installed on out-
let side of the fuel main filter to control the system
in 3 phases of "No clogging," "Phase 1 clogging" and
"Phase 2 clogging."
2. The controller sends signal to the monitor upon receiv-
ing judgment signal of clogging of the fuel filter from
ECM.
3. The monitor receives the signal from the controller to
display a message and sounds alarm.
Operation condition
1. Clogging judgment of the fuel filter starts when the fol-
lowing conditions are established.
• Fuel temperature is 0 °C or more.
• 3 s elapsed after starting up the engine.
2. Clogging of the fuel filter is judged under the following
conditions.
• Phase 1 clogging: State that negative pressure at
the filter outlet is -30 kPa or less continues for 5 s or
more.
• Phase 2 clogging: State that negative pressure at
the filter outlet drops to -38 kPa.
3. State of fuel filter clogging initiates the following ac-
tions.
• Phase 1 clogging: The monitor displays message
"FUEL FILTER" and sounds alarm for 5 s.
• Phase 2 clogging: Engine speed is kept reduced
until negative pressure at the filter outlet increases
to -30 kPa.
• Engine speed lower limit value: Rated speed
-300 RPM
The monitor continues to display message "FUEL
FILTER" and sounds alarm for 5 s.
Stop condition
1. If the state that negative pressure at the filter outlet is
-5 kPa or more continues for 5 s or more, the system
judges as "No clogging" to stop control of the warning.
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Fuel shutoff solenoid - Remove

Battery ground cable Disconnect
Suction control valve Removal

CAUTION: Before removing the suction con-
trol valve, clean the surrounding area.
SMIL14CEX3481AA 1
1. Disengage the harness connector from the suction con-

trol valve.
2. Remove the suction control valve (4) from the fuel sup-
ply pump.
1. Relief valve
2. Union
SMIL14CEX3482AA 2
3. Remove the O-ring (1) from the fuel supply pump.
SMIL14CEX3483AB 3
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Fuel shutoff solenoid - Install

Suction control valve installation
1. Install the O-ring (1) to the fuel supply pump.
SMIL14CEX3483AB 1
3. Temporarily tighten the suction control valve to the fuel

supply pump.
NOTE: Temporarily tighten by hand until it adheres the sup-
ply pump.
CAUTION: Be careful not to allow the O-ring

to caught in.
4. Securely tighten the suction control valve (4) to the fuel

supply pump.
5. Connect the harness connector to the suction control SMIL14CEX3482AA 2
valve (4).
1. Relief valve
2. Union
Battery ground cable Connect

Fuel air bleed

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Index

Fuel filter restriction sensor - Service instruction - Fuel filter clogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel shutoff solenoid - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fuel shutoff solenoid - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Engine intake and exhaust system - 014

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Contents
SERVICE
Air cleaner restriction sensor

Service instruction – Air filter clogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Intake air pressure and temperature sensor
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Boost temperature sensor
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Inlet air temperature sensor
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Throttle Valve Actuator (TVA)
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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Electrical systems - Engine intake and exhaust system
Air cleaner restriction sensor - Service instruction – Air filter

clogging
Purpose/Overview
The system generates warning when it detects clogging
of the air filter to restrain fuel injection quantity of the
engine in order to protect the turbo and the DPF against
increased black smoke.
SMIL14CEX4196FB 1
1. Air filter clogging switch 4. ECM

3. Monitor
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Operation
1. The controller makes clogging judgment of the air fil-
ter based on signal (ON/OFF) of the air filter clogging
switch and then sends the result to ECM and the mon-
itor via CAN communication.
2. ECM restrains fuel injection quantity upon receiving the
signal from the controller.
3. The monitor receives the signal from the controller to
display a message and sounds alarm.
Operation condition
1. Start control at 10 s after starting up the engine (wait
for stabilized suction air).
2. It judges as a clogging of the air filter when the air filter
clogging switch is ON to execute the following actions.
• Message "AIR FILTER" is displayed on the monitor.
• Alarm sounds for 5 s.
• Fuel injection quantity is restrained.
• The diagnostic trouble code is recorded in the trouble
log.
• Continuing work by operator ignoring the warning
may result in exemption from system warranty. The
engine will not be forced to stop.
Stop condition
1. When the air filter clogging switch continues to be OFF
for 3 s or more, the system executes the following ac-
tions.
• Message of the monitor is hidden.
• Normal operation resumes from restraint of fuel in-
jection quantity.
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Intake air pressure and temperature sensor - Remove

2. Remove the harness connector from the boost pres-
3. Remove the boost pressure sensor/ boost temperature
sensor (1) from the inlet pipe.
2. Harness clip
3. Intake manifold temperature sensor
SMIL14CEX2995AB 1
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Intake air pressure and temperature sensor - Inspect

1. Inspect the boost pressure sensor/ boost temperature
sensor.
• Body fouling
• Body damage
• Terminal malfunction
NOTICE: The sensor body must not be cleaned because
doing so may damage the sensor internally.
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Intake air pressure and temperature sensor - Install

1. Install the boost pressure sensor/ boost temperature
sensor (1) to the inlet pipe.
2. Harness clip
SMIL14CEX2995AB 1
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Boost temperature sensor - Remove

2. Disconnect the connector from charge air cooler tem-
perature sensor 1.
3. Remove charge air cooler temperature sensor 1 from
the intercooler.
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Boost temperature sensor - Inspect

NOTE: Charge air cooler temperature sensor 1 is a thermistor-type sensor in which electric resistance decreases as
temperature increases.
1. Inspect the charge air cooler temperature sensor 1.
NOTE: Inspect the sensor and connector sections for dam-
age or fouling.
2. Measure the resistance using a DMM.
Temperature Resistance
200 °C (392 °F) 0.064 kΩ
140 °C (284 °F) 0.186 kΩ
100 °C (212 °F) 0.508 kΩ
80 °C (176 °F) 0.875 kΩ
0 °C (32 °F) 15.0 kΩ
–40 °C (–40 °F) 112.5 kΩ
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Boost temperature sensor - Install

1. Install charge air cooler temperature sensor 1 to the
intercooler.
2. Connect the connector to charge air cooler temperature
sensor 1.
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Inlet air temperature sensor - Remove

1. Disconnect the harness connector from the intake man-
ifold temperature sensor (3).
2. Remove the intake manifold temperature sensor (3)
from the inlet pipe.
1. Boost pressure sensor/boost temperature sensor
2. Harness clip
SMIL14CEX2995AB 1
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Inlet air temperature sensor - Install

CAUTION:
• Because the sensor characteristics are different, trouble diagnosis will be activated if it is assembled incorrectly.

Intake manifold temperature sensor Gray
1. Install the intake manifold temperature sensor (3) to the

inlet pipe.
2. Connect the harness connector to the intake manifold
temperature sensor (3).
1. Boost pressure sensor/boost temperature sensor
2. Harness clip
SMIL14CEX2995AB 1
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Throttle Valve Actuator (TVA) - Remove

throttle valve.
2. Lock release
3. Lock
SMIL14CEX2993AB 1
SMIL14CEX2994AB 2
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Throttle Valve Actuator (TVA) - Install

the inlet pipe (3).
SMIL14CEX2994AB 1

valve.
the lock.
2. Lock release
3. Lock
SMIL14CEX2993AB 2
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Index

Air cleaner restriction sensor - Service instruction – Air filter clogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Boost temperature sensor - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Boost temperature sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Boost temperature sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inlet air temperature sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Inlet air temperature sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Intake air pressure and temperature sensor - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Intake air pressure and temperature sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Intake air pressure and temperature sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Throttle Valve Actuator (TVA) - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Throttle Valve Actuator (TVA) - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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Selective Catalytic Reduction (SCR) electrical system - 988

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Contents
FUNCTIONAL DATA
Selective Catalytic Reduction (SCR) electrical system

Dynamic description - SCR cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Dynamic description - Inducement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Dosing control unit
Fault code index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
SERVICE
Selective Catalytic Reduction (SCR) electrical system

Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Dosing control unit
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Diesel Exhaust Fluid (DEF)/AdBlue® supply module
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Filter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Filter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Prepare - Urea pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Remove - Urea pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Install - Urea pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Diesel Exhaust Fluid (DEF)/AdBlue® dosing module
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Nitrogen Oxides (NOx) sensor
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Diesel Exhaust Fluid (DEF)/AdBlue® tank level and temperature sensor
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Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
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Electrical systems - Selective Catalytic Reduction (SCR) electrical system
Selective Catalytic Reduction (SCR) electrical system - Static

description
Urea SCR system
The urea SCR system converts NOx contained in the exhaust gas emitted from diesel engines into harmless nitrogen
through a reduction reaction.
This system facilitates the reaction in the SCR catalyst, using the urea fluid that causes the reduction reaction.
Using the information sent by the engine control module (ECM), NOx sensors, etc., the dosing control unit (DCU)
calculates the desired urea fluid injection quantity, and then injects urea fluid pressurized by the urea fluid supply
module, from the dosing module installed in the exhaust pipe. Urea fluid injected into the muffler is hydrolyzed to
ammonia with heat of the exhaust gas, and the generated ammonia causes the reduction reaction with emitted NOx.
Through this reaction, the ammonia decomposes the NOx into water and nitrogen, and reduces the amount of NOx.
SMIL14CEX4018FB 1
• Warming lights
a. • Warning buzzer
• DEF (Urea fluid) tank gauge
*1. DEF (Urea fluid) *8. DEF (Urea fluid) tank heater coolant control valve
*2. Engine coolant *9. Ammonia slip catalyst
*3. DEF (Urea fluid) supply module *10. SCR catalyst
*4. DEF (Urea fluid) tank level sensor *11. DEF (Urea fluid) injector
*5. DEF (Urea fluid) quality sensor *12. Exhaust gas temperature (EGT) sensor 3
*6. DEF (Urea fluid) tank temperature sensor *13. NOx sensor
*7. DEF (Urea fluid) tank
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I/O table
DEF (Urea fluid) injection control
→ output
Sensor inputs
• Dosing module
• DEF (Urea fluid) tank temperature
Actuator control outputs
sensor (CAN)
• DEF (Urea fluid) supply module
• DEF (Urea fluid) level sensor →
(CAN) • DEF (Urea fluid) reverting valve
• DEF (Urea fluid) quality sensor • NOx sensor heater
(CAN) Relay control outputs
→ DCU
• DEF (Urea fluid) pump temperature → • DEF (Urea fluid) tank heater
sensor coolant control valve relay
• DEF (Urea fluid) pump pressure Communication (CAN)
sensor
• ECM
• Exhaust gas temperature (EGT)
sensor 3 → • DEF (Urea fluid) sensor
• NOx sensor (CAN) • NOx sensor

• Scan tool
SMIL14CEX4019FB 2
a. SCR = NOx reduction
*1. Hydrocarbon *8. NOx reduction

*2. Carbon monoxide *9. Ammonia reduction
*3. Oxidation catalyst 1 *10. SCR catalyst
*4. Oxidation catalyst 2 *11. Oxidation catalyst (for ammonia slip)
*5. Dosing module (DEF (Urea fluid) injector) *12. Water
*6. Ammonia *13. Nitrogen
*7. Carbon dioxide
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Urea fluid ((NH2)2CO+H2O) is hydrolyzed by heat of the exhaust gas, and ammonia (NH3) is generated. The gen-
erated ammonia (NH3) reduces the nitrogen oxide (NOx) through the SCR catalyst, and decomposes the NOx into
nitrogen (N2) and water (H2O).
Excessive ammonia (4NH3) is oxidized and is decomposed into nitrogen (2N2) and water (6H2O) in the oxidation
catalyst (for ammonia slip).
NOTE: Ammonia slip is a phenomenon which induces ammonia odor in the surrounding area due to ammonia that
is emitted from the exhaust pipe without being purified through the reaction in the ammonia slip catalyst while the
temperature is high.
NOx reduction mechanism

Urea fluid ((NH2)2CO+H2O) injected by the dosing module is hydrolyzed by the heat of the exhaust gas, and ammonia
(NH3) is generated. The generated ammonia (NH3) reduces the nitrogen oxide (NOx), and decomposes the NOx
into nitrogen (N2) and water (H2O).
DCU
The DCU monitors the information sent from each sensor
and ECM, and controls the urea SCR system.
The DCU also has a system diagnostic function. If this

function detects any problem in the system, it warns the
operator by way of an abnormal urea fluid injection warn-
ing light, and sets a DTC (Diagnostic Trouble Code).
SMIL14CEX4020AA 3
When the engine starts and the operating conditions for the urea fluid pump are met, the urea fluid supply module
operates the diaphragm pump and pressurizes the urea fluid up to 900 kPa (131 psi). Then, the DCU calculates the
pressure based on the value of the urea fluid pressure sensor in the urea fluid supply module, and maintains the urea
fluid pressure at approx. 900 kPa (131 psi). When the engine stops, to prevent the dosing module, etc., from being
broken due to freezing, the module returns any urea fluid remaining in the dosing module, urea fluid piping, and urea
fluid supply module to the urea fluid tank by operating the urea fluid pump after switching ON the reverting valve.
Also, a supply module temperature sensor is embedded in the urea fluid supply module, and when the engine is cold,
engine coolant is circulated inside the urea fluid supply module to defrost the urea fluid and keep it warm, and heater
control is performed to prevent the urea fluid from freezing.
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Urea fluid supply module
SMIL14CEX4021FA 4
1. Supply module bracket 9. Urea fluid pressure sensor power supply

2. Coolant inlet connector 10. Urea fluid pressure sensor signal
3. Coolant outlet connector 11. Urea fluid pressure sensor signal
4. Urea fluid backflow connector 12. Urea fluid pump motor GND
5. Urea fluid outlet connector 13. Urea fluid pump motor power supply
6. Urea fluid inlet connector 14. Urea fluid pump motor PWM
7. Supply module filter (Internal) 15. Reverting valve power supply
8. Air hole 16. Reverting valve signal
Dosing module
The dosing module is installed at the inlet of the SCR catalyst. It injects urea fluid pressurized by the supply module
from the injector into the exhaust pipe according to signals from the DCU. To cool the injector, the engine coolant is
circulated in the dosing module.
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SMIL14CEX4022FA 5
1. Urea fluid connector 4. Coolant connector

2. Injector 5. Injector High
3. Housing 6. Injector Low
Urea fluid sensor

The urea fluid sensors are installed in the urea fluid tank,
and consist of the urea fluid temperature sensor, urea fluid
level sensor, and urea fluid quality sensor.
Information for the urea fluid in the urea fluid tank obtained
from each sensor is sent to the DCU via the CAN circuit.
NOTE: The specifications vary depending on the machine
manufacturer.
1. Urea fluid level sensor

2. Urea fluid quality sensor
3. Urea fluid temperature sensor
SMIL14CEX4023BA 6
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The urea fluid temperature sensor measures the urea fluid

temperature using a thermistor that changes resistance
according to changes in temperature. The resistance be-
comes lower when the urea fluid temperature is high, and
higher when the urea fluid temperature is low. The DCU
performs the urea fluid defrosting control and thermal con-
trol based on the signal from the urea fluid temperature
sensor.
The urea fluid level sensor consists of a float and pipe.
The float contains a magnet, and a board mounted with

reed switches with different resistances is built in the pipe.
The fluid level is detected by reading the resistance when

the reed switches mounted on the board are turned ON
according to the magnetic force of the float that fluctuates
synchronously with the surface level of urea fluid. Based
on signals from the urea fluid level sensor, the DCU deter-
mines whether the urea fluid level warning or the engine
restart inhibition warning should be issued.
manufacturer.
1. Pipe
2. Float
SMIL14CEX4024BA 7
The urea fluid quality sensor measures the concentration of urea fluid by applying ultrasonic waves to the urea fluid
and measuring the time between the transmission and reception of the waves. The DCU determines whether the
urea fluid quality is abnormal, based on the signal from the urea fluid quality sensor.
NOTE: The specifications vary depending on the machine manufacturer.
SMIL14CEX4025EA 8
1. Urea fluid quality sensor
NOx sensor
NOx sensor is installed onto the SCR mixer chamber, and measures the NOx concentration in the exhaust gases
upstream of the SCR catalyst. NOx sensor signals are sent to the DCU via the CAN circuit. The DCU calculates the
required urea fluid injection quantity based on the signals from the NOx sensors.
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SMIL14CEX4026FA 9
1. NOx sensor power supply 4. CAN High

2. NOx sensor GND 5. –
3. CAN Low
EGT sensor 3
EGT sensor 3 is a resistance temperature detector, and is installed at the inlet of the SCR catalyst. It measures the
temperature of exhaust gas in front of the SCR catalyst, and sends the temperature signal to the DCU. Based on the
signal from the exhaust temperature sensor, the DCU controls the urea SCR.
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SMIL14CEX4027FA 10
1. EGT sensor 3 GND

2. EGT sensor 3 signal

The opening and closing of the coolant control valve is controlled by signals from the DCU. The valve circulates engine
coolant in the urea fluid tank and the supply module to defrost the urea fluid and keep it warm.
However, the engine coolant that cools the injector in the dosing module branches off just in front of the coolant control
valve, and does not pass through the valve itself.
SMIL14CEX4028EA 11
1. Coolant control valve power supply

2. Coolant control valve control
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Urea fluid tank

The urea fluid tank is a lightweight and robust tank made
of a special resin. The urea fluid sensor is installed in the
tank. A clear level gauge for checking the full fluid level is
installed outside of the urea fluid tank.
manufacturer.
1. Tank body
2. Breather hose
3. Urea fluid sensor
4. Filler cap
5. Urea fluid tank level gauge
6. Drain plug
SMIL14CEX4029BA 12
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Urea SCR piping
SMIL14CEX4030GA 13
1. Urea fluid 7. Supply module filter

2. Engine coolant - for cooling the dosing module 8. Urea fluid sensor
3. Engine coolant - for defrosting the urea fluid 9. Urea fluid tank
4. Coolant control valve 10. Dosing module
5. Urea fluid supply module 11. SCR assembly
6. Supply module pump motor
Urea SCR control overview

About the heater control When the ignition switch is turned ON, the DCU determines whether the heater control is
needed. Heater control is the defrosting control or thermal control which is performed by the DCU if the signals
from the urea fluid temperature sensor, supply module temperature sensor, and outside air temperature sensor (MAF
sensor) are less than or equal to the specified values when the ignition switch is turned ON.
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SMIL14CEX4031FB 14
a. When the DEF (urea fluid) is frozen

b. When the outside air temperature is low
*1. Ignition switch is ON *9. NOx sensor operation

*2. Heater control *10. Dosing control based on NOx sensor information
*3. Defrosting control *11. Control completion
*4. Thermal control *12. Urea SCR System Shut-Off
*5. At room temperature *13. NOx sensor control
*6. Startup control *14. After-run control
*7. Dosing control through calculation *15. Ignition switch is OFF
*8. NH3 storage control
About defrosting control

If any one of the signals from the urea fluid temperature sensor, supply module temperature sensor, or outside air
temperature sensor (MAF sensor) is less than or equal to the specified value, the DCU judges that it needs to defrost
the urea fluid, opens the coolant control valve, and starts engine coolant circulation into the urea fluid tank and the urea
fluid supply module. When all signals from the urea fluid temperature sensor, supply module temperature sensor, and
outside air temperature sensor (MAF sensor) exceed the specified values, the defrosting control finishes by closing
the coolant control valve.
About thermal control

After a predetermined period of time has elapsed since the defrosting control was started, if the urea fluid temperature
sensor or outside air temperature (MAF sensor) is less than or equal to the specified value, the defrosting control
transitions to the thermal control with the coolant control valve opened.
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SMIL14CEX4032FA 15
• DEF (Urea fluid) tank temperature sensor

The temperatures other than the outside air
a. • DEF (Urea fluid) pump temperature sensor f.
temperature are at or below the specified values
• Outside air temperature sensor
All temperatures are at or above the specified g.
b. Defrosting control is started again
values
The outside air temperature is at or below the
c. Defrosting control termination h.
specified value
d. Any of them is under the specified temperature i. Thermal control
DEF (Urea fluid) tank heater coolant control valve
e.
opened
About startup control

After the ignition switch is turned ON, if the heater control defrosting control is completed (including if the DCU judges
that the defrosting control is not required), the SCR catalyst temperature is the specified value or more, and the
engine is running, then the DCU operates the urea fluid supply module and dosing module in order to fill the urea fluid
piping between the urea fluid supply module and the dosing module with urea fluid and pressurize the urea fluid up to
900 kPa (131 psi). After the pressure is increased, it is maintained at 900 kPa (131 psi) using the urea fluid pressure
sensor built into the urea fluid supply module.
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SMIL14CEX4031FB 16


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Refilling the urea fluid
SMIL14CEX4033FB 17
*1. Pump motor *7. Ammonia slip catalyst

*2. DEF (Urea fluid) reverling valve *8. SCR catalyst
*3. Supply module *9. DEF (Urea fluid) injector
*4. Supply module filter *10. DEF (Urea fluid)
*5. DEF (Urea fluid) pump pressure sensor *11. Air
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Urea fluid pressurization
SMIL14CEX4034FB 18

About NOx sensor control

To protect the NOx sensors, moisture in the exhaust pipe must be removed immediately after the engine is started.
In order to do that, the DCU calculates the amount of heat required to evaporate the moisture. After that, the DCU
calculates the amount of heat actually generated using the exhaust gas temperature and the exhaust gas flow. If the
amount of heat exceeds the required amount of heat for moisture evaporation, dosing control by the NOx sensors is
started.
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SMIL14CEX4035FB 19


About dosing control

The DCU calculates the optimal urea fluid injection quantity, and instructs the dosing module. Depending on the
condition of the machine, either of two methods for calculating the urea fluid injection quantity can be used: one is
based on calculation of the ECM information, and the other is based on values measured by NOx sensors.
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SMIL14CEX4036FB 20


Dosing control by means of calculation

No feedback from the NOx sensors is available until NOx sensor control is completed; therefore, the DCU calculates
and determines the urea fluid injection quantity based on information sent from the ECM (engine speed, fuel injection
quantity, engine coolant temperature, and exhaust flow rate).
Dosing control based on NOx sensor information

After calculating the urea fluid injection quantity based on the value measured by the NOx sensors, the DCU com-
pensates and determines the urea fluid injection quantity based on information such as the temperature before the
SCR catalyst and ECM information.
About the NH3 storage control

The DCU determines the urea fluid injection quantity by considering the amount of NH3 that can be absorbed in the
SCR catalyst in relation to the urea fluid injection quantity calculated by the DCU itself (the dosing control by means
of the calculation and dosing control by the NOx sensors).
Therefore, the urea fluid injection quantity may not change in proportion to NOx concentration.
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SMIL14CEX4037FB 21


About after-run control

When the engine stops, the DCM stops directing the urea fluid supply module to pressurize the dosing module.
Then, to prevent the urea fluid from freezing while the engine is stopped, the urea dosing control unit (DCU) turns
ON the reverting valve in the supply pump, and returns the urea fluid filled in the dosing module, the urea fluid supply
module, and the piping between both of these modules to the urea fluid tank.
Although operation noise can be heard from the urea fluid tank or the supply module after the engine stops, the noise
stops after all urea fluid is returned to the tank (approx. 2 min).
Finally, the DCU shuts down by switching OFF the reverting valve.
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SMIL14CEX4038FB 22


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SMIL14CEX4039FB 23

About SCR purging function

In order to keep the SCR functioning, automatic SCR purging (cleaning of the SCR interior) is performed after a
predetermined period of time passes. If automatic purging is not completed within a predetermined period of time,
the indicator or light, etc., illuminates to request that the operator manually performs the purging.
If manual purging has not been performed within the predetermined period of time since the manual purging request,
either the trouble display of the machine or the diagnostic light will be illuminated, and manual purging will not be
possible by operating the machine. If manual purging is not possible, perform SCR purging using the actuator test
function of a trouble diagnosis scan tool.
Urea fluid level display

The remaining urea fluid level in the urea fluid tank is displayed in levels by way of signals sent from the urea fluid
level sensor installed in the urea fluid tank.
The level numbers displayed vary depending on the machine.
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SMIL14CEX4040GB 24
*1. NOx sensor *15. Valve High

*2. CAN-Low *16. Valve Low
*3. CAN-High *17. Valve supply
*4. DEF (Urea fluid) sensor *18. DEF (Urea fluid) injector
*5. Resistor *19. DEF (Urea fluid) tank heater contorol valve
*6. Signal *20. Motor supply
*7. GND *21. Motor control
*8. Exhaust gas temperature (EGT) sensor 3 *22. Valve control
*9. DEF (Urea fluid) tank level sensor *23. Sensor supply
*10. DEF (Urea fluid) tank temperature sensor *24. DEF (Urea fluid) pump
*11. A: 86 pin, B: 53 pin *25. DEF (Urea fluid) reverting valve
*12. IG-SW *26. DEF (Urea fluid) pump pressure sensor
*13. Ignition switch *27. DEF (Urea fluid) supply module
*14. Battery
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SMIL14CEX4041GA 25
A connector (86 pin)

Pin
Connection
no
1 –
2 –
3 –
4 –
5 –
6 –
7 –
8 Coolant control valve power supply
9 –
10 –
11 –
12 Dosing module (Low)
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13 –
14 –
15 –
16 –
17 Urea fluid pressure sensor signal
18 Urea fluid pressure sensor GND
19 Urea fluid pressure sensor power supply
20 –
21 –
22 –
23 –
24 Urea fluid pump motor PWM
25 –
26 Urea fluid pump motor GND
27 –
28 –
29 –
30 –
31 –
32 Dosing module (High)
33 EGT sensor signal
34 EGT sensor GND
35 –
36 –
37 –
38 –
39 –
40 –
41 –
42 –
43 –
44 –
45 –
46 Urea fluid pump motor power supply
47 –
48 –
49 –
50 –
51 –
52 –
53 –
54 –
55 –
56 –
57 –
58 Urea fluid tank level sensor, urea fluid tank temperature sensor GND
59 Urea fluid tank level sensor signal
60 –
61 –
62 –
63 –
64 –
65 Reverting valve control
66 –
67 –
68 –
69 –
70 –
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71 –
72 –
73 –
74 –
75 –
76 –
77 –
78 –
79 Urea fluid tank temperature sensor signal
80 –
81 –
82 –
83 –
84 –
85 Coolant control valve GND
86 Reverting valve power supply
B connector (53 pin)

Pin
Connector
no
1 DCU GND
2 DCU GND
3 DCU GND
4 DCU GND
5 DCU GND
6 DCU power supply
7 DCU power supply
8 DCU power supply
9 DCU power supply
10 –
11 CAN1 High
12 CAN1 Low
13 –
14 CAN0 High
15 CAN0 Low
16 –
17 –
18 –
19 –
20 –
21 –
22 –
23 –
24 –
25 –
26 –
27 –
28 –
29 –
30 –
31 –
32 –
33 –
34 –
35 –
36 –
37 –
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38 –
39 –
40 –
41 –
42 –
43 –
44 –
45 –
46 CAN0 termination switch 1B
47 CAN0 termination switch 1A
48 CAN0 termination switch 2B
49 CAN0 termination switch 2A
50 –
51 –
52 Ignition switch
53 –
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Selective Catalytic Reduction (SCR) electrical system - Dynamic

description - SCR cleaning
Purpose
SCR (Selective Catalytic Reduction) CLEANING has the following purposes, and increases the exhaust temperature
temporarily at regular intervals of operation ( 30 h ) to maintain the function of SCR.
• NH3 (ammonia) CLEANING
In order to purge NOx, a fixed amount of NH3 (ammonia) calculated by the DCU is absorbed into the SCR catalyst.
However, an error arises between the calculated value and the actual amount of adsorption. The calculated value
and the actual value are reset periodically by forcedly zeroing the actual amount of adsorption by SCR CLEANING.
• HC (hydrocarbon) CLEANING
Almost all HC (hydrocarbons) are oxidized by the oxidation catalyst 1. However, if the activity of the catalyst has
decreased because of low temperature etc., HC slips to the oxidation catalyst 2. If HC is absorbed into the SCR
catalyst, adsorption of NH3 that is a NOx reducing agent is inhibited. That is removed by SCR CLEANING.
• Removal of white products
Some injected urea turns into white products. If these products have accumulated excessively, they block the gas
passage, thereby building up exhaust gas pressure. Such products are removed periodically by SCR CLEANING.
• S (sulfur) CLEANING
The sulfur content absorbed into the oxidation catalyst and the SCR catalyst is removed by SCR CLEANING.
Configuration
SMIL14CEX1035FB 1
*1. ECM *7. Exhaust temperature sensor (FNT)

*2. Main controller *8. Dosing control unit
*3. Monitor *9. Pump flow P- solenoid valve
*4. SCR switch *10. Boom 2 P- solenoid valve
*5. Coolant temperature sensor *11. Lever lock solenoid valve
*6. Exhaust temperature sensor (CNT)
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There are three SCR CLEANING methods as follows.
• AUTO SCR CLEANING: It is carried out automatically while the machine is running. (Approx. 10 min )
The machine can work as usual.
• MANUAL SCR CLEANING: It is activated with the SCR switch, if AUTO SCR CLEANING is incomplete (a failure
in AUTO SCR CLEANING occurs twice continuously). (Approx. 18 min )
Moreover, if SCR CONFIGURATION-SCR MANUAL MODE is turned ON in the user information mode on the mon-
itor, AUTO SCR CLEANING is not carried out but only MANUAL SCR CLEANING is carried out.
The machine cannot operate.
• SCR CLEANING by device test (forced SCR CLEANING): It is carried out forcedly, regardless of the SCR CLEAN-
ING conditions. (AUTO SCR CLEANING: Approx. 10 min, MANUAL SCR CLEANING: Approx. 18 min ) Operation
by the service engineer is required.
The machine cannot operate.
SMIL14CEX6814FA 2
The message ＜ PUSH SCR SWITCH TO

a. AUTO SCR CLEANING starts (every 30 h). h. CLEANING ＞ appears, prompting for MANUAL
SCR CLEANING.
AUTO SCR CLEANING completes (approx. MANUAL SCR CLEANING starts. ＜ Push SCR
b. i.
10 min). switch ＞
AUTO SCR CLEANING is paused. ＜ Push SCR MANUAL SCR CLEANING completes (approx.
c. j.
switch ＞ 18 min).
MANUAL SCR CLEANING failed Failure
condition 1: MANUAL SCR CLEANING has been
interrupted for 10 h. Failure condition 2: MANUAL
AUTO SCR CLEANING is paused. ＜ Push SCR
d. k. SCR CLEANING has been carried out for 39 min.
switch ＞
Failure condition 3: The fuel injection quantity
for MANUAL SCR CLEANING has reached the
specified value.
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AUTO SCR CLEANING failed (1st time) Failure

condition 1: The entire AUTO SCR CLEANING
SCR CLEANING by device test (forced
(AUTO SCR CLEANING + AUTO SCR CLEANING
SCR CLEANING) ＜ SERVICE SUPPORT
e. on standby + AUTO SCR CLEANING interrupted) l.
SCREEN-DEVICE TEST SCR CLEANING START
has been carried out for 4 h. Failure condition
＞
2: The fuel injection quantity for AUTO SCR
CLEANING has reached the specified value.
SCR CLEANING by device test completes (AUTO
After the SCR CLEANING failed, the ECM retries
f. m. SCR CLEANING: approx. 10 min, MANUAL SCR
starting AUTO SCR CLEANING.
CLEANING: approx. 18 min).
AUTO SCR CLEANING failed (2nd time) Failure
condition 1: After the 1st failure in AUTO SCR
CLEANING, the entire AUTO SCR CLEANING
(AUTO SCR CLEANING + AUTO SCR CLEANING
g. on standby + AUTO SCR CLEANING interrupted)
has been carried out for 4 h. Failure condition 2:
After the 1st failure in AUTO SCR CLEANING, the
fuel injection quantity for AUTO SCR CLEANING
has reached the specified value.
1. Turn ON the key for work.

NH3, HC, and S absorbed into catalysts, and accumulated products burn themselves continuously by the hot
exhaust gas from the running engine..
2. In case of low-load work, the exhaust temperature is low, so NH3, HC, and S will be kept absorbed in catalysts,
and products will accumulate without burning themselves.
The ECM increases the exhaust temperature forcedly every 30 h to burn the NH3, HC, and S absorbed in catalysts,
and the accumulated products. (Refer to AUTO SCR CLEANING.)
3. Normally, continuous SCR CLEANING and AUTO SCR CLEANING in [2] prevent the amount of NH3, HC, and S
absorbed in catalysts and that of accumulated products from exceeding a certain amount. However, if a failure
in AUTO SCR CLEANING occurs twice continuously under certain operating conditions, the ECM forbids AUTO
SCR CLEANING in order to avoid the risk of damaging the SCR assembly due to excessive temperature rise
during SCR CLEANING, and requests the operator to conduct MANUAL SCR CLEANING.
The operator starts the SCR CLEANING by request. (Refer to MANUAL SCR CLEANING.)
4. If you ignore the request for MANUAL SCR CLEANING and continue work, 〈EXCESS ADSORPTION IN CATA-
LYSTS / EXCESSIVELY ACCUMULATED PRODUCTS (FAILURE IN MANUAL SCR CLEANING)〉 occurs and
the ECM generates the diagnostic trouble code. In this situation, usual SCR CLEANING by the operator is dis-
abled and special SCR CLEANING with the service tool is required. (Refer to SCR CLEANING by device test.)
5. If the following failure occurs during SCR CLEANING, hydraulic pressure load stops.
〈EXCESS ADSORPTION IN CATALYSTS / EXCESSIVELY ACCUMULATED PRODUCTS (FAILURE IN MAN-
UAL SCR CLEANING)〉
If the amount of NH3, HC, and S absorbed in catalysts or that of accumulated products exceeds the limit, the
system behaves as follows.
• The hydraulic assist load ends.
• Low engine output icon turns on.
• Engine check lamp turns on.
• The message “CHECK ENGINE” is displayed.
AUTO SCR CLEANING

SCR CLEANING is carried out automatically while the machine is running. The machine can work as usual.
The ECM will perform AUTO SCR CLEANING when operation has been carried out for 30 h since the last SCR
CLEANING.
1. Conditions for starting AUTO SCR CLEANING: AUTO SCR CLEANING will start when the following conditions
are fulfilled.
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○ The engine is running.

○ The engine coolant temperature is 70 °C (158 °F) or more and less than 90 °C (194 °F).
○ Urea solution is contained.
○ The exhaust temperature (DOC outlet) is 680 °C (1256 °F) or less.
○ There is no sensor-related failure.
○ The battery voltage is 21 V or more.
○ The device test is not in process.
2. AUTO SCR CLEANING standby conditions: If one of the following conditions is fulfilled, AUTO SCR CLEANING
goes on standby without starting.
○ The engine coolant temperature is 65 °C (149 °F) or more and less than 100 °C (212 °F).
○ Urea solution has become low.
○ The exhaust temperature (DOC outlet) is 700 °C (1292 °F) or more.
○ There is a sensor-related failure.
○ The battery voltage is 20 V or less.
○ The device test is in process.
When, in the AUTO SCR CLEANING standby state, the conditions for starting AUTO SCR CLEANING in [1] are
fulfilled, AUTO SCR CLEANING will be started.
Moreover, when these conditions are fulfilled during AUTO SCR CLEANING, it will be interrupted and go on standby.
3. Start of AUTO SCR CLEANING: The following controls will start when the conditions in [1] are fulfilled.
○ SCR CLEANING icon (green) turns on.
○ A warning buzzer sounds for 2 seconds.
○ The message "AUTO SCR CLEANING" appears.
4. Manual interruption of AUTO SCR CLEANING: The SCR CLEANING will be interrupted when the following
operation is performed.
During interruption, SCR CLEANING icon turns off.
To resume the SCR CLEANING, eliminate the cause of interruption.
○ By pressing the SCR switch on the monitor during AUTO SCR CLEANING, the SCR CLEANING is interrupted.
(The message "PUSH SCR CLEANING SWITCH" appears on the monitor. Pressing it again resumes AUTO
SCR CLEANING.)
○ The SCR CLEANING is interrupted while the engine is stopped.
5. Manual resumption of AUTO SCR CLEANING: AUTO SCR CLEANING will resume when the following
conditions are fulfilled.
○ The engine is started.
6. End of AUTO SCR CLEANING: The controls will be finished at the end of AUTO SCR CLEANING.
○ SCR CLEANING icon (green) turns off.
○ The message "AUTO SCR CLEANING" turns off.
MANUAL SCR CLEANING

MANUAL SCR CLEANING is requested if AUTO SCR CLEANING is incomplete (a failure in AUTO SCR CLEANING
occurs twice continuously).
The machine cannot operate during MANUAL SCR CLEANING.
Assist load is controlled for the SCR CLEANING.
1. Request for MANUAL SCR CLEANING: It will be displayed on the monitor when you are requested to perform
MANUAL SCR CLEANING.
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○ SCR CLEANING icon (orange) blinks.

○ The message "PUSH SCR CLEANING SWITCH" appears.
2. Conditions for starting MANUAL SCR CLEANING: The engine speed will reach the specified one and then
MANUAL SCR CLEANING will start when the following conditions are fulfilled and the SCR switch is pressed.
○ The gate lever limit switch is OFF (hydraulic operation is disabled).
○ The conditions for starting AUTO SCR CLEANING are fulfilled.
3. Start of MANUAL SCR CLEANING: The main controller will start the following controls when the above
conditions are fulfilled.
○ SCR CLEANING icon (orange) turns on.
○ A warning buzzer sounds for 2 s.
○ The messages "MANUAL SCR CLEANING" and "DO NOT OPERATE" are displayed alternately.
○ The hydraulic assist load control is started (to increase the exhaust temperature).
4. Interruption of MANUAL SCR CLEANING: The SCR CLEANING will be interrupted when the following operation
is performed.
During interruption, SCR CLEANING icon (orange) blinks.
The message "PUSH SCR CLEANING SWITCH" appears.
To resume the SCR CLEANING, eliminate the cause of interruption, and then press the SCR switch.
○ The SCR CLEANING will be interrupted when the gate lock limit switch of the gate lever is ON (hydraulic oper-
ation is enabled).
○ By pressing the SCR switch on the monitor during MANUAL SCR CLEANING, the SCR CLEANING is inter-
rupted.
○ If the hydraulic assist proportional valve is broken during SCR CLEANING
○ When the throttle is operated
○ When the engine is stopped
5. Resumption of MANUAL SCR CLEANING
○ The engine is started.
○ The gate lock limit switch of the gate lever turns OFF.
○ The SCR switch is pressed.
6. End of MANUAL SCR CLEANING: The controls will be finished at the end of MANUAL SCR CLEANING, when
the engine is stopped.
○ SCR CLEANING icon (orange) turns off.
○ The messages "MANUAL SCR CLEANING" and "DO NOT OPERATE" turn off.
7. Hydraulic load assist for SCR CLEANING: During MANUAL SCR CLEANING, load is applied to the pump to
make the exhaust temperature hot.
○ The flow of the pump flow proportional valve is increased gradually to increase load on the boom 2 proportional
valve.
○ In 30 s, the pump flow proportional valve is controlled so that the exhaust temperature (DOC inlet) may be fixed
at 270 °C (518 °F).
If the (DOC inlet) temperature exceeds 400 °C (752 °F), the hydraulic load is interrupted.
It will resume when the temperature reaches less than 250 °C (482 °F).
SCR CLEANING by device test (forced SCR CLEANING)

If MANUAL SCR CLEANING fails and the diagnostic trouble code appears, SCR CLEANING by device test is re-
quired.
The SCR CLEANING requires operation by the service engineer.
The machine cannot operate during SCR CLEANING.
Operating method
Refer to SERVICE SUPPORT SCREEN-DEVICE TEST-SCR CLEANING START.
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Selective Catalytic Reduction (SCR) electrical system - Dynamic

description - Inducement
Purpose
In order to prevent deterioration in exhaust gas or a failure in the engine, the engine output is limited (inducement) in
the following cases.
• If DEF/AdBlue® (urea solution) is not added in spite of warning display on the monitor.
• If any abnormalities, such as degradation in DEF/AdBlue® (urea solution), addition of the discrepant one, and
dilution, have occurred.
• If harness disconnection in the SCR-related electrical parts or clogging in the urea solution line has occurred.
Types of inducement
There are two types of inducement: Early inducement and Final inducement. Warning occurs in the preceding stage.
The machine operates according to the state as shown in the table.
Status Normal Warning Early inducement Final inducement

Engine output limited (Fuel injection Drop by 40 %
None None Drop by 30 %
quantity limited) (idling only)
Low output icon None None Displayed Displayed
Message icon None None None Displayed

Continuous beeps
One long beep ( Three short beeps (continues at
Warning buzzer None
5s) ( 1 s x 3 times) intervals of 1 s
)
DEF/AdBlue®
10 % or more Less than 10 % Less than 5 % 0
tank level
(Indicator bar and
2 or more 1 1 (blinking) 0
icon)
Inducement due (Indicator color) White Orange Orange (blinking) Red
to remaining urea
REFILL AdBlue
level
icon
None Lit Blinking Blinking quickly
Text message None

DEF/AdBlue®
icon
None Lit Blinking Blinking quickly
Inducement due
to urea solution
quality/urea Low output icon
injection stop/
SCR system None None Displayed Displayed
failure/ NCD
target component EXH.SYSTEM
failure/EGR icon
system failure None Displayed Displayed Displayed
Text message None

Allowed more
Output reduction cancel - - Allowed once
than once
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Control
Overview of control
1. Inducement control logic consists of the three blocks:
1. Inducement operation start condition
2. Inducement judgment
3. Communication with excavator/engine output limit
2. Control details
a. Inducement operation start condition
Inducement start time

First time Repeated
Operation condition Trouble diagnosis name DTC Early Final Early Final
7428
Remaining urea In-
Inducement (urea level low) 7429 Instantly Instantly Instantly
level stantly
7430
Urea solution
Urea quality abnormality P207F
quality
SCR system abnormality (with
P20C9
Urea injection stop / inducement)
3h 3.5 h Instantly 30 min
SCR system failure P2048
(Dosing valve disconnected or shorted)
P2049
Suction air temperature sensor
P0113
abnormally high voltage
Suction air temperature sensor
P0112
abnormally low voltage
Coolant temperature sensor
P0118
Coolant temperature sensor
P0117
Boost pressure sensor abnormally
P0238
NCD-target high voltage
component failure Boost pressure sensor abnormally low
P0237 3h 3.5 h Instantly 30 min
voltage
P0193
P0192
Airflow sensor abnormally high voltage P0103
Airflow sensor abnormally low voltage P0102
Airflow sensor flow abnormality P0101
DCU communication abnormality U010E
EGR position sensor abnormality P0409
EGR2 position sensor abnormality P140B
EGR valve control abnormality P0404
EGR system failure EGR2 valve control abnormality P045B 36 h 100 h Instantly 5h
EGR 0-point learning abnormality P1404
EGR2 0-point learning abnormality P140C
EGR flow abnormality P0401
b. Inducement judgment
Inducement judgment differs between the “remaining urea level” and the “trouble diagnosis (including others)”.
Remaining urea level: Inducement level is determined by the remaining level.
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Trouble diagnosis: Inducement is determined by the operating hours that have passed since a trouble diagnosis was
established.
There are also two types of stages in the judgment based on a trouble diagnosis.
1. If an operation condition occurs in normal mode.
2. If an operation condition recurs within the predetermined time after it occurs. (Repeat offense (Repetition))
Processing and judgment time differ between (1) and (2).
Judgment in normal mode
The concept of judgment flow is as follows. Since this is just a concept, the actual control logic differs a little. It also
differs according to the operation condition.
Remaining urea level

Step Judgment condition in normal mode Yes No
Since the key was ON, 4 s has passed, and
1. To step 2 Status quo maintained
also DCU-ECM communication is normal
2. The remaining urea level remains 0 % for 10 s Final inducement triggered To step 3
The remaining urea level remains 5 % or less
3. Early inducement triggered To step 4
for 10 s
The remaining urea level remains 10 % or less
4. Put into the warning state Put into the normal state
for 10 s
Urea solution quality / Urea injection stop / SCR system failure / NCD-target component failure

also DCU-ECM communication is normal
The abnormality detection state remains for
2. Final inducement triggered To step 3
3.5 h
3. The abnormality detection state remains for 3 h Early inducement triggered To step 4
4. Put into the warning state Put into the normal state
10 s.
EGR system failure

1. An EGR system-related error code occurred To step 2 Status quo maintained
2. An EGR system failure remains for 100 h Final inducement triggered To step 3
Put into the warning state
3. An EGR system failure remains for 36 h Early inducement triggered simultaneously with the
EGR system failure
Judgment in repeat offense (repetition) mode
Repeat offense is only triggered when the same failure is repeated.
Transitions between normal and repeat offense states (modes) are shown below.

1. (1) In normal mode To step 2 -
2. Inducement is triggered To step 3 Status quo maintained
3. The inducement condition is cleared To step 4 Status quo maintained
4. (2) Repeat offense mode is established To step 5 -
(2) 40 h or more have passed since repeat
5. To step 1 To step 4
offense mode.
In step 3 (the inducement condition is cleared), when the DTC is cleared during inducement due to trouble diagnosis,
this condition will be passed and repeat offense mode will be established.
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The brief concept of judgment flow is as follows. Since this is just a concept, the actual control logic differs a little.
Conditions also differ according to the operation requirement.
Urea solution quality / Urea injection stop / SCR system failure / NCD-target component failure.

also DCU-ECM communication is normal.
2. Final inducement triggered To step 3
30 min.
3. The abnormality detection state remains for 10 s Early inducement triggered Put into the normal state
EGR system failure

1. An EGR system-related error code occurred. To step 2 Put into the normal state.
Put into the early
inducement state
2. An EGR system failure remains for 5 h. Final inducement triggered
simultaneously with
the EGR system failure.
Output reduction cancel function
• This is a function to cancel the fuel injection quantity and speed limits due to inducement within only the predeter-
mined time.
• A request for output reduction cancel is only accepted in the early or the final inducement state. It is not accepted in
the normal or the warning state. The output reduction cancel starts simultaneously with acceptance of the request.
• The output reduction cancel function lasts for 30 min per request. Once the emergency override is triggered, it will
last for 30 min and cannot be interrupted.
• If the key is turned OFF during output reduction cancel, it will resume for the remaining time when the key is turned
ON next time.
• The inducement level at the end of output reduction cancel is determined according to [1] Judgment in normal mode.
• The output reduction cancel method differs according to the inducement level. (Refer to the table below.)
Inducement
Target Method
level
Early USER INFORMATION MODE SCREEN-SCR CONFIGURATION-
Customer
inducement OUTPUT REDUCTION CANCEL ON (Press the → button.)
With the above output reduction cancel display grayed out, holding
Final
Service engineer down the → button for 10 s will establish normal mode and start output
inducement
reduction cancel. (The cancel is allowed only once.)
c. Communication with excavator body / engine output limit
Communication with the excavator body is carried out via CAN communication between DCU and ECM. An icon turns
on or blinks and a message appears according to the situation. (Refer to Types of inducement)
The following limit is triggered according to the inducement level.
Inducement level Fuel injection quantity limit Speed limit

Early inducement Drop by 30 % None
Final inducement Drop by 40 % Idle speed
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Dosing control unit - Fault code index

DCU diagnostic trouble code
0002 DCU-ECM communication error
0100 ISO-CAN bus OFF
029D Communication error between DCU and NOx sensor
029D J1939CAN bus OFF
0607 DCU functional error not involving movement
060B Read predefined test voltage value / Read converted A/D value
062F DCU EEPROM abnormality
0641 5 V power supply or something else is out of range
6580 SM or CCV power supply GND short
0659 SM or CCV power supply +B short
1462 Communication error between DCU and urea quality sensor
1464 Main relay early open or seized error
1465 Switch reset-1 or switch reset-2
1468 DCU internal temperature is high.
1491 Urea injection high pressure abnormality ( 1050 kPa or higher)
1493 Driver chip temperature error
149C DCU was not powered off properly
149C Pressure drop error when key was turned OFF
149D Urea solution overheating in tank
203B Urea solution level sensor seized
203C Level sensor error (short circuit)
203D Level sensor error (disconnection)
2048 Dosing module GND short
2049 Dosing module +B short
204B Urea pressure abnormality
204C Urea pressure sensor low voltage abnormality
204D Urea pressure sensor high voltage abnormality
205B Diagnostic check of urea solution and intake air temperature appropriateness
205C Urea solution temperature (tank) sensor error (short circuit)
205D Urea solution temperature (tank) sensor error (disconnection)
206A Urea quality sensor reset error
206B Urea sensor unit high temperature abnormality
206C Urea quality or temperature sensor short circuit
206D Urea quality or temperature sensor disconnection
207F Urea solution quality too low
208A Supply module disconnection
208B Supply module pump motor target vs. actual RPM comparison
208C Supply module GND short
208D Supply module +B short
208E Seized dosing valve
20A0 Reverting valve circuit disconnection
20A2 Reverting valve GND short
20A3 Reverting valve +B short
20AC Urea solution temperature (S/M) sensor abnormality
20AD Diagnostic check of urea solution temperature (S/M) appropriateness
20B1 Coolant control valve disconnection
20B3 Coolant control valve GND short
20B4 Coolant control valve +B short
20E8 Urea injection low pressure abnormality (during constant conditions)
20E9 Urea injection high pressure abnormality ( 1250 kPa or higher)
20EA DCU power shut OFF before emptying finished
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20FE Urea injection low pressure abnormality (during startup)
2201 Diagnostic check of NOx sensor concentration value appropriateness
2206 NOx sensor (disconnection)
2207 NOx sensor (short circuit)
242B Diagnostic check of SCR temperature sensor appropriateness after DOC
242C SCR inlet temperature sensor low voltage abnormality
242D SCR inlet temperature sensor high voltage abnormality
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Selective Catalytic Reduction (SCR) electrical system - Inspect

Diagnostic system check-urea selective catalytic reduction system
The urea SCR control system inspection is a systematic
method for checking problems caused by malfunctions
in the urea SCR control system. It is the starting point
for diagnosis related to drivability complaints. Move
from the system inspection to the next logical step to
diagnose problems. Understanding and correctly using
the diagnostic chart reduces diagnostic time and pre-
vents the replacement of good parts.
NOTE: If there are no complaints on drivability, do not per-
form these diagnostic steps unless otherwise instructed in
other sections.
If there are no complaints on drivability, do not perform
these diagnostic steps unless otherwise instructed in
other sections. Do not clear the DTC unless instructed
to do so in a diagnostic step.
The battery should be fully charged.
The battery cable should be normal and securely con-
nected.
The GND of the DCU should be securely connected to
the correct position.
Verify that the DCU harness connector has no exces-
sive fouling and is correctly connected.
Verify that the DCU terminals have no excessive fouling
and are correctly connected.
The machine must be completely maintained.
Programming of the DCU must be performed correctly.
If a urea SCR system DTC is set, first diagnose the
sensor DTCs, solenoid DTCs, and actuator DTCs.
Diagnostic system check-urea selective catalytic reduction system

1. Turn ON the ignition switch without starting the engine.
2. Observe the DCU and ECM DTC information with a
scan tool.
3. Check if a DTC beginning with U or a DTC related to
another ECU is set.
NOTE: If a DTC beginning with U or a DTC related to an-
other ECU is set, inspect the applicable DTC.
When a DTC beginning with U is set, it indicates that there
is no communication with other ECUs.
4. Observe whether DCU DTC 0607, 060B, 062F, or 1464
is set.
NOTE: Inspect the applicable DTC if a DTC is set.
5. Observe whether DCU DTC 0641, 0658, or 0659 is set.
6. Check all of the ECUs for DTC codes that have not yet
been diagnosed.
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7. Check whether the customer's concern is related to the

engine.
NOTE: If there is a concern relating to the engine, inspect
the engine control system.
8. Check for excessive urea fluid consumption.
9. Check for a significant ammonia odor.
10. Check for the adherence of white crystal powder.
Intermittent conditions of urea selective catalytic reduction system description of symptom

NOTE: Important preliminary inspections before starting.
Before using the symptom list, inspect the urea SCR
control system and verify all of the following items.
The warning light and indicator light operate normally.
The trouble diagnosis scan tool data is within the normal
range of operation values.
Verify the customer's complaint, and locate the appro-
priate symptom in the table of contents. Inspect the
items presented for the symptom.
NOTE: Visual inspection and actual inspection.
Careful visual inspection and actual inspection are re-
quired for some symptom procedures. This procedure
is extremely important. By conducting visual and ac-
tual inspections, it is possible to save valuable time by
fixing problems without performing further inspections.
Check for the following items.
The GND of the DCU should be clean and firmly se-
cured in the correct position.
The exhaust pipe should not be crushed or damaged.
The wiring and terminals of the urea SCR system
harness should be appropriately connected, and they
should not be pinched or disconnected.
NOTE: Intermittent conditions.
If an intermittent condition exists, inspect for improper
installation of electronic equipment. Inspect for any ad-
ditionally installed electronic equipment, lights, mobile
phones, wireless devices, etc.
Verify that any device that was additionally installed is
not connected to a serial data circuits such as CAN.
Depending on the problem, the warning light may illu-
minate or DTCs may be recorded. An intermittent con-
dition is often caused by an improper electrical connec-
tion or wiring. Conduct a careful visual inspection, or
conduct an actual inspection to see whether the follow-
ing conditions exist in the suspected connector.
Incomplete connection between connectors Seating
failure of terminal Damage or deformation of terminal
Repair or replace the connector terminal of the circuit
with the problem, and appropriately connect. Remove
the terminals from the connector body and inspect the
wires of the terminals for poor connections.
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Connect the DMM to the suspected circuit and perform

a test-run of the machine. If an abnormal value is dis-
played when the malfunction occurs, it can be deter-
mined that there is a problem in the monitored circuit.
The trouble diagnosis scan tool is useful in detecting
intermittent conditions. The trouble diagnosis scan tool
has the following convenient functions.
The snapshot function records the engine parameters
at the time when a malfunction occurs. It is possible to
review the recorded information and know the particular
operation condition that resulted in the malfunction.
By using the plot function on the trouble diagnosis scan
tool, it is possible to graph the selected data parame-
ters.
This recorded information can be reviewed, and the lo-
cation of the intermittent condition can be checked.
Check for improper installation of optional electronic ac-
cessories such as lights or mobile phones.
Under the following conditions, DTCs are not recorded,
and the warning light may illuminate intermittently.
The GND of the DCU is loose or dirty.
Intermittent short circuit to the GND circuit in the warn-
ing light.
Interference exists in the electric system due to a failure
in a relay, in a solenoid driven by the DCU, or in a switch.
Electronic components may cause sharp increases in
voltage. Normally, a problem occurs when a compo-
nent that is malfunctioning is in operation.
The diode has an open circuit.
In the following list of symptoms, causes for each symp-
tom are organized. There is no significance to the order
of this procedure. If the value on the trouble diagnosis
scan tool does not indicate a malfunction, the next pro-
cedure to perform should be the one that can be most
easily inspected or is most likely to be the cause.
Use the following list when diagnosing symptoms of
complaints.
Excessive urea fluid consumption Significant ammonia
odor Adherence of white crystal powder There is no
current problem, but a past DTC exists. Or, there is a
complaint from the customer not related to a DTC, and
that symptom cannot be reproduced.
Intermittent conditions of urea selective catalytic reduction system diagnostics

NOTE: Preliminary inspection.
Inspect the urea SCR control system.
NOTE: Harness and connector.
Intermittent open circuits or short circuits are often
caused by the harness or connector moving due to
vibrations, engine torque, or bumps in the road.
Move the related connectors and wiring while observing
the applicable scan tool data.
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Command the components ON or OFF using the scan

tool, and move the related connectors and wiring.
Check the operation of the components.
With the engine operating, move the related connectors
and wiring while checking the operating status of the
urea SCR.
If the harness or connector movement affects the dis-
played data, component, system operation, or opera-
tion of the engine, inspect the harness or connection,
and repair as necessary.
NOTE: Electrical connection of wiring.
An intermittent condition is often caused by an improper
electrical connection, terminal installation, or wiring.
Defective connections between connectors or improper
terminal seating to the connector body Terminal defor-
mation or damage Test the terminals for improper in-
stallation.
Defective connections between the terminals and
wires, including pressure bonding terminals with insu-
lation.
This requires the terminal to be removed from the con-
nector body.
Corrosion or water intrusion Moisture can enter the
wiring when the insulation area has holes or is dam-
aged.
The conductor inside the insulation area corrodes, but
this usually cannot be checked visually. Look for any
swollen or stiff sections in the wires of the suspected
circuit.
Wiring damaged inside the insulation area Wiring that
is pinched, cut, or rubbed through.
Verify that the wiring does not come in contact with a
hot exhaust system component.
NOTE: Power supply and GND of the control module, and
power supply and GND of the components.
Various symptoms can occur due to poor connections
at the power supply or GND.
Test all control module power supply circuits. In many
machines, there are multiple circuits that supply power
to the control module. Other components in the system
have separate power supply circuits that also need to
be tested.
Inspect the connections and fuses of the module and
the component connectors, as well as intermediate
connections between the power supply, the module,
and the components. A test lamp or a DMM may
indicate that voltage is present, but neither of them
tests the ability of the circuit to carry sufficient current.
Check whether sufficient current necessary to operate
the components is flowing in the circuit.
Test all control module GND circuits and system GND
circuits. Some control modules have multiple GND cir-
cuits.
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Other components in the system have a separate GND

that also needs to be tested. Inspect whether the GND
is clean and is securely connected to the ground point.
Inspect the connections of the components and the
splice pack. Check whether sufficient current neces-
sary to operate the components is flowing in the circuit.
NOTE: Effects caused by temperature.
An intermittent condition may occur when a component
or connection reaches its operating temperature. For
intermittent conditions that may occur only when the
components or connections are cold or only when they
are hot, failure records or snapshot data can be helpful,
where possible.
If an intermittent condition is related to heat, review the
data relating to the following items.
High outside air temperature.
Heat given off by the engine.
Heat emitted from the circuits due to defective connec-
tions or high loads Load conditions higher than normal If
an intermittent condition is related to low temperatures,
review the data relating to the following items.
Low outside air temperature In extremely low tempera-
tures, ice may form in a connection or component. Test
for water intrusion.
This condition only occurs in a cold start.
This condition does not occur after the vehicle has been
warmed up.
Based on the information from the customer, determine
if the failure is caused by temperature.
NOTE: EMI and electrical noise.
Certain electronic components and circuits may re-
spond sensitively to electrical noise from the EMI, etc.
A harness is too close to high voltage or high current
devices such as the injection part, motor, or generator,
due to incorrect wiring. These components may induce
electrical noise on a circuit that could interfere with nor-
mal circuit operation.
Interference exists in the electric system due to a fail-
ure in a relay, in a solenoid driven by the DCU, or in
a switch. There may be cases where the voltage in-
creases sharply due to this condition.
Normally, a problem occurs when a component that is
malfunctioning is in operation.
Improper installation of non-genuine or aftermarket
add-on accessories such as lights, 2-way radios, ampli-
fiers, electric motors, remote starters, alarm systems,
mobile phones, etc. These accessories may lead to an
emission related failure when they are in use, but do
not cause interference when not in use.
Test the diode for an open circuit. Certain relays include
clamping diodes.
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Inspect the rectifier bridge of the generator for problems

that may cause AC noise in the electrical system.
NOTE: Reproduction of failure conditions.
If none of the previous tests are successful, attempt to
duplicate or record the failure conditions.
An alternative method is to perform a test run of the
machine with the DMM connected to the suspect circuit.
If an abnormal value is displayed on the DMM when
the problem occurs, this can be helpful in identifying the
defective area.
NOTE: Scan tool snapshot.
By connecting a scan tool, it is possible to take param-
eter snapshots available via serial data. The snapshot
function records actual data for a predetermined period
of time.
The recorded data can be replayed and analyzed. Also,
the scan tool can display a single parameter or multiple
parameters as a graph for comparison. The snapshot
function can be set to start recording manually when the
symptom occurs, or to start recording when the DTC is
set.
Abnormal values in the recorded data may indicate sys-
tems or components that require further inspection.
Urea fluid consumption too high description of symptom

Although the usage condition is conventionally the
same, the number of refills is increasing.
Urea fluid consumption too high diagnostics

Check for the possibility of variations in the urea fluid
injection quantity due to the operating method of the
operator or the machine status.
Check the operating habits of the operator.
Inspect the urea fluid quality.
Check with the owner whether an ammonia odor has
been smelled from the exhaust pipe or around the tank
recently.
Check with the owner whether white crystals have been
found under the machine, in the urea fluid piping, or in
the muffler recently.
Instruct the owner to recheck the consumption after re-
filling the urea fluid. Inspect whether the hour meter is
operating properly in order to calculate the exact time
unit of consumption.
Check whether the status of each sensor is correct.
Check for related Service Bulletins.
NOTE: Urea fluid piping system inspection.
Is the urea fluid tank drain off or loose?
Do white crystals remain around the urea fluid tank?
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Is the urea fluid tank broken?

Is the urea fluid piping or the joint broken?
Is the urea fluid supply pump broken?
NOTE: Sensor inspection.
Is the NOx sensor value appropriate?
Is the EGT sensor 3 value appropriate?
Is the urea fluid level sensor value appropriate?
Is the MAF sensor value correct?
NOTE: Dosing module inspection.
Is the dosing module broken, damaged by heat, or cor-
roded?
Is the dosing module installed correctly?
Is it time for regular replacement of the dosing module?
NOTE: Other inspections.
This symptom may be an effect of excessive fuel con-
sumption. Refer to "Poor fuel economy" under Diagno-
sis by symptom in the Engine workshop manual.
Ammonia smell noticeable description of symptom

An abnormal odor is smelled from the exhaust gas tem-
porarily or continuously.
Ammonia smell noticeable diagnostics

Identify whether the abnormal odor originates from
around the tank or the exhaust gas.
Check whether the status of each sensor is correct.
Are the urea fluid piping and the coolant piping for the
urea fluid supply pump assembled incorrectly?
Is the coolant control valve stuck open?
roded?
If the urea SCR-related parts have been replaced, was
the urea SCR system data reset as necessary?
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Does SCR catalyst degradation or ammonia slip due to

ammonia storage amount saturation occur?
White crystalline powder visible description of symptom

White crystal powder adheres to the exhaust pipe or the
urea SCR system related parts.
White crystalline powder visible diagnostics

When refilling the urea fluid, verify it is not refilled above
the F line of the level gauge.
Is the urea fluid tank drain off or loose?
Is the urea fluid tank broken?
Is there urea fluid leaking from the urea fluid tank?
Is there urea fluid leaking from the urea fluid supply
pump?
Is the filter cover of the urea fluid supply pump loose?
Is the urea fluid piping or the joint broken?
Is there urea fluid leaking from the urea fluid piping or
the joint?
Are the urea fluid piping and the coolant piping for the
urea fluid supply pump assembled incorrectly?
If there are crystals adhering inside the urea fluid tank,
is the coolant control valve stuck open?
roded?
If the urea SCR-related parts have been replaced, was
the urea SCR system data reset as necessary?
Has an SCR catalyst that was installed to another ma-
chine been installed recently?
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Dosing control unit - Prepare

Items to prepare:
• Wrench [ 13 mm]
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Dosing control unit - Remove

2. Remove the rear trim. Refer to the Cab and platform
- Remove (90.150).
3. Remove the connectors (1) and (2).
SMIL14CEX3879AB 1

move the DCU (2).
SMIL14CEX3880AB 2
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Dosing control unit - Install

1. Mount the DCU in the reversed order of the procedure
for removal.
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Diesel Exhaust Fluid (DEF)/AdBlue® supply module - Remove

DEF coolant piping safety information
CAUTION:
○ Use a clean cloth soaked in water when remov-

ing any foreign materials adhering to the urea
fluid piping.
○ Do not use compressed air as foreign matter in
the urea fluid passage may cause failure.
○ Cover the disconnected connector and the pip-
ing with a plastic bag, etc., to prevent dirt or for-
eign material from becoming attached.

Coolant drain
CAUTION:

SMIL14CEX2956AB 1

6. Install the drain plug to (1) the cylinder block.
SMIL14CEX2973AB 2
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DEF supply module removal

1. Disconnect the coolant piping from the urea fluid supply
module.
2. Disconnect the urea fluid piping from the urea fluid sup-
ply module.
3. Disconnect the connector from the urea fluid supply
module.
4. Remove the urea fluid supply module from the ma-
chine.
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Diesel Exhaust Fluid (DEF)/AdBlue® supply module - Disassemble

DEF supply module disassembly
CAUTION:
○ Use a clean cloth when removing any foreign

materials adhering to the urea fluid supply mod-
ule.
1. Remove the connector from the urea fluid supply mod-
ule.
NOTE: Remove the coolant piping connector (1) and urea
fluid piping connector (2) from the urea fluid supply module.
SMIL14CEX3235AB 1
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Diesel Exhaust Fluid (DEF)/AdBlue® supply module - Assemble

DEF supply module reassembly
1. Install the connector to the urea fluid supply module.
NOTE: Install the urea fluid piping connector (1) to the urea
fluid supply module.
Install the coolant piping connector to the urea fluid supply
module.
2. Coolant inlet connector
3. Urea fluid backflow connector
4. Coolant outlet connector
SMIL14CEX3236AB 1
5. Urea fluid outlet connector
Urea fluid supply module connector

Parts Name Material, color Size Wrench size
Urea fluid inlet
1 Plastic, black 3/8 in 17 mm
connector
Coolant inlet
2 Metal 3/8 in 15 mm
connector
Urea fluid backflow
3 Plastic, light yellow 3/8 in 17 mm
connector
Coolant outlet
4 Metal 3/8 in 15 mm
connector
Urea fluid outlet
5 Plastic, black 5/16 in 17 mm
connector
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Diesel Exhaust Fluid (DEF)/AdBlue® supply module - Install

DEF coolant piping safety information
CAUTION:
○ Use a clean cloth soaked in water when remov-

ing any foreign materials adhering to the urea
fluid piping.
DEF supply module installation

1. Install the urea fluid supply module to the machine.
2. Connect the connector to the urea fluid supply module.
3. Connect the urea fluid piping to the urea fluid supply
module.
CAUTION:
○ Insert until a clicking sound can be heard.

○ After pushing in, gently pull to confirm it does
not come out and that the lock is secure.
4. Connect the coolant piping to the urea fluid supply mod-
ule.
CAUTION:


Coolant filling
CAUTION:

tem parts.
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SMIL14CEX2956AB 1

tering the system.
With the pressurized reserve tankspecification, it is not



8. Stop the engine.
CAUTION:

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NOTE: Add an amount of coolant equal to thedifference
mouth.


come warm.

form step 12 again.

cooled.
NOTE: Add an amount of coolant equal to thedifference
mouth.



to the MAX line.
DEF supply module setting

CAUTION: If the urea fluid supply module is
replaced, reset the data with the trouble diagnosis
scan tool.
1. Connect the trouble diagnosis scan tool to the DLC.
3. Select search.
NOTE: Input the engine No. and select search.
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4. Select diagnosis.
5. Select the engine.
6. Select urea SCR.
7. Select data reset.
8. Select urea fluid injection control module data reset.
NOTE: Reset the data by following the on-screen instruc-
tions.
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Diesel Exhaust Fluid (DEF)/AdBlue® supply module Filter - Remove

1. Remove the cover from the urea fluid supply module.
NOTE: Remove the supply module filter cover (2).
CAUTION:
○ Note that the urea fluid may leak during re-

moval.
materials adhering to the urea fluid supply mod-
ule.
SMIL14CEX5016AB 1
2. Remove the urea fluid supply module filter from the

urea fluid supply module.
CAUTION:
When replacing the supply module filter, al-

ways use a filter kit (1) and replace the two
parts together
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Diesel Exhaust Fluid (DEF)/AdBlue® supply module Filter - Install

1. Install the urea fluid supply module filter (1) to the urea
fluid supply module.
CAUTION:
When replacing the supply module filter, al-

ways use a filter kit and replace the two parts
together.
2. Install the cover (2) to the urea fluid supply module.

NOTE: Install the supply module filter cover.
SMIL14CEX5016AB 1
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Diesel Exhaust Fluid (DEF)/AdBlue® supply module - Prepare -

Urea pump
WARNING
Escaping fluid!
doctor immediately.
W0178A
WARNING
Avoid injury!
W1128A
Items to prepare:
• Marking pen
• Cap
• Plug
• Waste oil can
• Rag
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Diesel Exhaust Fluid (DEF)/AdBlue® supply module - Remove -

Urea pump
move the cover (2).
SMIL14CEX1910AB 1

move the step (2).
SMIL14CEX1911AB 2

Remove the 2 coolant hoses (2).
Remove the 3 urea hoses (3).
move the urea pump (5).
• Attach caps and plugs at the hoses so as to prevent
invasion of water, dust and dirt.
• Apply marking at each location of the hoses so as to
SMIL14CEX1912BB 3
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Diesel Exhaust Fluid (DEF)/AdBlue® supply module - Install - Urea

pump
1. Install the urea pump in the reversed order of the pro-
cedure for removal.
After installation, add coolant and refill urea solution.
For details, follow their respective procedures and de-
scriptions.
NOTICE: After installation of the urea pump, the coolant piping of coolant control valve piping needs to be bled of air.
For air bleeding for the coolant piping of coolant control valve piping, refer to Coolant control valve - Install (10.500).
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Diesel Exhaust Fluid (DEF)/AdBlue® dosing module - Remove

Coolant drain
CAUTION:

With the pressurized reserve tankspecification, it is not
2. Gasket
SMIL14CEX2956AB 1

SMIL14CEX2973AB 2
Dosing module removal

1. Disconnect the coolant piping from the dosing module.
2. Disconnect the urea fluid piping from the dosing mod-
ule.
3. Disconnect the connector from the dosing module.
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4. Remove the dosing module from the mixer chamber.
CAUTION:

materials adhering to the dosing module.
5. Remove the gasket from the dosing module.
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Diesel Exhaust Fluid (DEF)/AdBlue® dosing module - Disassemble

1. Remove the gasket (2) from the dosing module.
2. Remove the connector from the dosing module.
NOTE: Remove the coolant piping connector (1) from the
dosing module.
SMIL14CEX3234AB 1
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Diesel Exhaust Fluid (DEF)/AdBlue® dosing module - Assemble

1. Install the connector to the dosing module.
NOTE: Install the coolant piping connector (1) to the dosing
module.
CAUTION: Do not pinch the O-ring.
2. Install the gasket (2) to the dosing module.
CAUTION: Do not reuse the removed gasket

(2).
SMIL14CEX3234AB 1
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Diesel Exhaust Fluid (DEF)/AdBlue® dosing module - Install

1. Install the gasket to the dosing module.
2. Install the dosing module to the mixer chamber.
3. Connect the connector to the dosing module.
4. Connect the coolant piping to the dosing module.
CAUTION:
○ Insert firmly until a clicking sound can be heard.

5. Connect the urea fluid piping to the dosing module.
CAUTION:

Coolant filling
CAUTION:

tem parts.
SMIL14CEX2956AB 1

tering the system.
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8. Stop the engine.
CAUTION:

mouth.


come warm.

form step 12 again.
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cooled.
mouth.



to the MAX line.
Dosing module setting

CAUTION: If the dosing module is replaced,
reset the data with the trouble diagnosis scan tool.
3. Select Search.
4. Select Diagnosis.
5. Select the Engine.
6. Select Urea SCR.
7. Select Data Reset.
8. Select urea fluid injector data reset.
tions.
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Nitrogen Oxides (NOx) sensor - Remove

CAUTION: Do not disconnect the battery ca-

ble for 3 minutes after turning OFF the ignition
switch.
NOx sensor removal

1. Disconnect the connector from the NOx sensor con-
troller.
CAUTION: Do not disconnect the NOx sensor

or NOx sensor controller.
2. Remove the NOx sensor from the mixer chamber.
CAUTION: Immediately after turning OFF the

ignition switch, be careful of burns as the temper-
ature of the sensor measurement section is high
due to the heater.
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Nitrogen Oxides (NOx) sensor - Install

NOx sensor installation
CAUTION: Clean the old anti-seize lubricant
on the sleeve nut, and apply new anti-seize lubri-
cant to the threaded portion of the sleeve nut.
NOTE: If the NOx sensor is replaced with a new one, it is
not necessary to apply new anti-seize lubricant.
CAUTION:
○ When assembling the tip of the sensor, do not

hit the mating boss.
○ Do not use a sensor that has scratches or dents
from drops or impacts, etc.
○ Do not hit the protruding section after assem-
bling the sensor.
○ After starting the engine, check for gas leaks,
and verify that it is securely sealed.
1. Apply anti-seize lubricant to the NOx sensor.
the threaded portion of the NOx sensor.
2. Install the NOx sensor to the mixer chamber.
Tightening torque: 50 N·m (37 lb ft) Sleeve nut
Tightening torque: 8.5 N·m (6.3 lb ft) Sensor con-
troller
3. Connect the connector to the NOx sensor controller.

NOx sensor setting

CAUTION: If the NOx sensor is replaced, re-
set the data with the trouble diagnosis scan tool.
3. Select Search.
6. Select urea SCR.
8. Select NOx sensor data 1 reset.
tions.
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Diesel Exhaust Fluid (DEF)/AdBlue® tank level and temperature

sensor - Remove
DEF sensor removal

1. Disconnect the urea fluid piping from the urea fluid sen-
sor.
CAUTION:
○ If the connector is dirty, clean off the dirt with

compressed air, etc., before removing the parts.
○ After removing, cover the connector and mating
pipe with a plastic bag, etc., to prevent dirt, etc.,
from becoming attached.
2. Disconnect the breather hose from the urea fluid sen-
sor.
3. Disconnect the connector from the urea fluid sensor.
4. Remove the urea fluid sensor from the urea fluid tank.
5. Remove the O-ring from the urea fluid sensor.
CAUTION:
○ Do not reuse the O-ring.

○ If the sensor is dropped, do not reuse it.
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Diesel Exhaust Fluid (DEF)/AdBlue® tank level and temperature

sensor - Install
DEF sensor installation
1. Apply grease to the O-ring.
2. Install the O-ring to the urea fluid sensor.

3. Install the urea fluid sensor to the urea fluid tank.
CAUTION:
○ If the sensor is dropped, do not reuse it.

○ When removing foreign material, wipe off with a
clean cloth.
4. Connect the connector to the urea fluid sensor.
5. Connect the breather hose to the urea fluid sensor.
6. Connect the urea fluid piping to the urea fluid sensor.

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Index

Diesel Exhaust Fluid (DEF)/AdBlue® dosing module - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Diesel Exhaust Fluid (DEF)/AdBlue® dosing module - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Diesel Exhaust Fluid (DEF)/AdBlue® dosing module - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Diesel Exhaust Fluid (DEF)/AdBlue® dosing module - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Diesel Exhaust Fluid (DEF)/AdBlue® supply module - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Diesel Exhaust Fluid (DEF)/AdBlue® supply module - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Diesel Exhaust Fluid (DEF)/AdBlue® supply module - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Diesel Exhaust Fluid (DEF)/AdBlue® supply module - Install - Urea pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Diesel Exhaust Fluid (DEF)/AdBlue® supply module - Prepare - Urea pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Diesel Exhaust Fluid (DEF)/AdBlue® supply module - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Diesel Exhaust Fluid (DEF)/AdBlue® supply module - Remove - Urea pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Diesel Exhaust Fluid (DEF)/AdBlue® supply module Filter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Diesel Exhaust Fluid (DEF)/AdBlue® supply module Filter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Diesel Exhaust Fluid (DEF)/AdBlue® tank level and temperature sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Diesel Exhaust Fluid (DEF)/AdBlue® tank level and temperature sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . 73
Dosing control unit - Fault code index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Dosing control unit - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Dosing control unit - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Dosing control unit - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Nitrogen Oxides (NOx) sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Nitrogen Oxides (NOx) sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Selective Catalytic Reduction (SCR) electrical system - Dynamic description - Inducement . . . . . . . . . . . . . . . . . . 34
Selective Catalytic Reduction (SCR) electrical system - Dynamic description - SCR cleaning . . . . . . . . . . . . . . . . 29
Selective Catalytic Reduction (SCR) electrical system - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Selective Catalytic Reduction (SCR) electrical system - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Exhaust Gas Recirculation (EGR) electrical system - 989

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Contents
SERVICE
Exhaust Gas Recirculation (EGR) electrical system

Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Exhaust Gas Recirculation (EGR) temperature sensors
Remove - Temperature sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install - Temperature sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Inspect - Temperature sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Remove - Temperature sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspect - Temperature sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install - Temperature sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Remove - Temperature sensor 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Install - Temperature sensor 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Diesel Oxidation Catalyst (DOC) inlet temperature sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Diesel Oxidation Catalyst (DOC) inlet temperature sensor - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Diesel Oxidation Catalyst (DOC) inlet temperature sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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Electrical systems - Exhaust Gas Recirculation (EGR) electrical system
Exhaust Gas Recirculation (EGR) electrical system - Inspect

EGR control system inspection - Functions
The ECM controls the EGR valve based on the engine
speed, engine coolant temperature, suction air temper-
ature, fuel injection quantity, and barometric pressure.
The EGR valve is driven by the EGR motor. The open-
ing of the EGR valve is detected by the EGR position
sensor.
EGR control system inspection - Inspection

there is an abnormality in locations related to the EGR.
1. Check for a DTC.
NOTE: If a DTC is detected, inspect for the relevant DTC.
2. Start the engine and warm it up until the coolant tem-
perature is at or above the standard value.
Standard value: 70 °C (158 °F)
3. Check the indicated EGR position with the trouble di-
agnosis scan tool.
Standard value: (-3) -3%
4. If the indicated EGR position is outside the standard
value, use the trouble diagnosis scan tool to perform
actuator test EGR control.
5. Execute Up and Down commands for the EGR valve
and check the indicated EGR position.
value range, inspect the EGR pipes.
There must be no damage or gas leaks.
8. Start the engine and warm it up until the coolant tem-
perature is at or above the standard value.
Standard value: 70 °C (158 °F)
9. Check the indicated EGR position with the trouble di-
agnosis scan tool.
value range, replace the EGR valves.
See Exhaust Gas Recirculation (EGR) valve - Re-
move (10.501).
See Exhaust Gas Recirculation (EGR) valve - Install
(10.501).
11. If the EGR valve has been replaced, execute EGR
learning on the ECM.
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Exhaust Gas Recirculation (EGR) temperature sensors - Remove

- Temperature sensor 1
pipe A.
SMIL14CEX2980AB 1
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Exhaust Gas Recirculation (EGR) temperature sensors - Install

CAUTION:

sor.
dropped, etc.
sor 1.
ture sensor 1.
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Exhaust Gas Recirculation (EGR) temperature sensors - Inspect

NOTE: The EGR gas temperature sensor is a thermis-
tor-type sensor in which electric resistance decreases with
rises in temperature.
1. Inspect the EGR gas temperature sensor 1.
age or fouling.
900 °C (1652 °F) 0.083 - 0.096 kΩ
850 °C (1562 °F) 0.100 - 0.115 kΩ
800 °C (1472 °F) 0.123 - 0.141 kΩ
750 °C (1382 °F) 0.153 - 0.175 kΩ
700 °C (1292 °F) 0.194 - 0.222 kΩ
650 °C (1202 °F) 0.253 - 0.289 kΩ
600 °C (1112 °F) 0.341 - 0.386 kΩ
550 °C (1022 °F) 0.469 - 0.538 kΩ
500 °C (932 °F) 0.671 - 0.784 kΩ
450 °C (842 °F) 1.01 - 1.20 kΩ
400 °C (752 °F) 1.50 - 1.97 kΩ
350 °C (662 °F) 2.74 - 3.49 kΩ
300 °C (572 °F) 5.15 - 6.79 kΩ
250 °C (482 °F) 10.6 - 14.6 kΩ
200 °C (392 °F) 25.0 - 37.1 kΩ
150 °C (302 °F) 71.8 - 118 kΩ
100 °C (212 °F) 272 - 515 kΩ
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pipe B.
SMIL14CEX2981AB 1
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Exhaust Gas Recirculation (EGR) temperature sensors - Inspect

NOTE: The EGR gas temperature sensor is a thermistor-type sensor in which electric resistance decreases with rises
in temperature.
1. Inspect the EGR gas temperature sensor 2.
age or fouling.
400 °C (752 °F) 0.038 - 0.066 kΩ
300 °C (572 °F) 0.137 - 0.224 kΩ
200 °C (392 °F) 0.840 - 1.197 kΩ
100 °C (212 °F) 11.17 - 15.33 kΩ
0 °C (32 °F) 602.9 - 1089 kΩ
-40 °C (-40 °F) 5994 - 14872 kΩ
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CAUTION:
• Because the sensor characteristics are different, trouble diagnosis will be activated if it is assembled incorrectly.

IMT sensor Gray
CAUTION:

sor 2.
ture sensor 2.
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Exhaust gas temperature sensor 3 removal

1. Remove the harness connector from EGT sensor 3.
2. Remove EGT sensor 3 from the front chamber.
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CAUTION:
• Clean the old anti-seize lubricant on the sleeve nut, and apply new anti-seize lubricant to the threaded portion
of the sleeve nut.
• When assembling the tip of the sensor, do not hit the mating boss.
• Do not use a sensor that has scratches or dents caused by being dropped or hit.
• Do not hit the protruding section after assembling the sensor.
• After starting the engine, check for gas leaks, and verify that it is securely sealed.
• If the temperature sensor connector is removed from the bracket, replace the connector fixing clip with a new one.
1. Apply anti-seize lubricant to EGT sensor 3.

NOTE: Apply high temperature stainless Never- Seez:
5-87411-039-0, manufactured by Bostik in the U.S., etc.
to the threaded portion of EGT sensor 3.
2. Install EGT sensor 3 to the front chamber.
3. Connect the harness connector to EGT sensor 3.

Exhaust gas temperature sensor 3 setting

CAUTION: If EGT sensor 3 is replaced, reset
the data with the trouble diagnosis scan tool.

3. Select Search.
NOTE: Input the engine No. and select Search.
6. Select urea SCR.
8. Select EGT Sensor 3 data reset.
tions. Select Next.
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Exhaust Gas Recirculation (EGR) temperature sensors Diesel

Oxidation Catalyst (DOC) inlet temperature sensor - Remove
Exhaust gas temperature sensor removal

1. Disconnect the harness connector from the exhaust
gas temperature sensor.
NOTE: To prevent incorrect assembling, make an align-
ment mark on the connector before disconnecting.
Remove EGT sensor 1 and 2 together.
2. Remove the EGT sensor from the oxidation catalyst
assembly.
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Oxidation Catalyst (DOC) inlet temperature sensor - Inspect
1. Measure the resistance using the circuit tester.
NOTE: The reference values for the sensor characteristics
are indicated in the diagram.
Temperature Resistance value

1000 °C 115 - 127 Ω
950 °C 130 - 143 Ω
900 °C 147 - 163 Ω
850 °C 167 - 187 Ω
800 °C 192 - 219 Ω
750 °C 226 - 258 Ω
700 °C 267 - 309 Ω
650 °C 333 - 360 Ω
600 °C 406 - 442 Ω
550 °C 504 - 552 Ω
500 °C 640 - 709 Ω
450 °C 835 - 937 Ω
400 °C 1130 - 1280 Ω
350 °C 1590 - 1850 Ω
300 °C 2360 - 2830 Ω
200 °C 6230 - 7830 Ω
150 °C 11900 - 16300 Ω
100 °C 27600 - 41200 Ω
50 °C 82000 - 137000 Ω
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Oxidation Catalyst (DOC) inlet temperature sensor - Install
CAUTION:
• Clean the old anti-seize lubricant on the sleeve nut, and apply new anti-seize lubricant to the threaded portion
of the sleeve nut.
• Do not subject the tip of the exhaust gas temperature sensor to shock when installing.
• Replace the oxidation catalyst assembly if damage has been found in the sensor installation section of the
oxidation catalyst assembly.
1. Apply anti-seize lubricant to the EGT sensor.

NOTE: Apply high temperature stainless Never- Seez:
5-87411-039-0, manufactured by Bostik in the U.S., etc.
to the threaded portion of the EGT sensor.
2. Temporarily tighten the EGT sensor to the oxidation
catalyst assembly.
NOTICE: To prevent damage to the sensor installation area
caused by incorrect sensor assembly, temporarily tighten
manually.
NOTE: Exhaust gas temperature sensor identification
Sensor type Screw size Connector color

Exhaust gas temperature sensor 2 M12X1.75 Dark gray
Exhaust gas temperature sensor 1 M12X1.25 Light gray
3. Final tighten the EGT sensor to the oxidation catalyst

assembly.
4. Connect the harness connector to the exhaust gas tem-
perature sensor.
NOTICE: Be careful not to twist the harness.
NOTE: Start the engine after assembling each part, and
check for gas leaks from each joint and for vibration.

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Index

Exhaust Gas Recirculation (EGR) electrical system - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Exhaust Gas Recirculation (EGR) temperature sensors - Inspect - Temperature sensor 1 . . . . . . . . . . . . . . . . . . . . 6
Exhaust Gas Recirculation (EGR) temperature sensors - Inspect - Temperature sensor 2 . . . . . . . . . . . . . . . . . . . . 8
Exhaust Gas Recirculation (EGR) temperature sensors - Install - Temperature sensor 1 . . . . . . . . . . . . . . . . . . . . . 5
Exhaust Gas Recirculation (EGR) temperature sensors - Install - Temperature sensor 2 . . . . . . . . . . . . . . . . . . . . . 9
Exhaust Gas Recirculation (EGR) temperature sensors - Install - Temperature sensor 3 . . . . . . . . . . . . . . . . . . . . 11
Exhaust Gas Recirculation (EGR) temperature sensors - Remove - Temperature sensor 1 . . . . . . . . . . . . . . . . . . . 4
Exhaust Gas Recirculation (EGR) temperature sensors - Remove - Temperature sensor 2 . . . . . . . . . . . . . . . . . . . 7
Exhaust Gas Recirculation (EGR) temperature sensors - Remove - Temperature sensor 3 . . . . . . . . . . . . . . . . . . 10
Exhaust Gas Recirculation (EGR) temperature sensors Diesel Oxidation Catalyst (DOC) inlet temperature sensor
- Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
- Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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Contents
FUNCTIONAL DATA

Dynamic description - Coolant level decrease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Dynamic description - Hot shutdown warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Electrical systems - Engine cooling system
Engine cooling system - Dynamic description - Coolant level

decrease
Purpose/overview
The system generates the coolant level decrease warning if level of engine coolant decreases.
SMIL14CEX4077EB 1
1. Coolant level switch

2. Main controller
3. Monitor
Operation
1. The controller detects signal of the coolant level switch (ON at low level) to send warning signal to the monitor.
2. The monitor receives the signal to display message "LOW COOLANT" and sounds alarm for 5 s.
• It records a diagnostic trouble code in the trouble log simultaneously with the warning.
Operation condition
• When state of the coolant level switch ON (low level) continues for 3 s or more.
Stop condition
• When state of the coolant level switch OFF continues for 3 s or more.
• It starts from state of warning OFF when the key is turned ON.
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Engine cooling system - Dynamic description - Hot shutdown

warning
The machine warns an operator to perform cooling operation before stopping the engine in order to protect the tur-
bocharger.
SMIL14CEX4071FB 1

3. ECM 9. Engine
4. Pressure sensor (upper) 10. Coolant temperature sensor
5. Pressure sensor (swing) 11. Crank position sensor
6. Pressure sensor (travel)
Operation
1. The engine is started by turning ON the key.
2. The engine is stopped after completing a work.
3. The system displays "Cooling Down Required" on the monitor and then sounds alarm for 5 s if it judges that cooling
down operation has not been performed in hot status of the engine. At the same time, cooling time distribution is
recorded in the engine log.
Operation condition
If all the following conditions are fulfilled, the engine is judged hot.
• Engine coolant temperature is 80 °C (176 °F) or more.
• 3 min or more elapsed after starting up the engine.
• One or more operation(s) of upper, travel, swing, option 1 or option 2 during starting up the engine.
Judgment of cooling operation completion
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• When 3 min or more elapses without operation of upper, travel, swing, option 1, or option 2 in the state that engine
speed is 1250 RPM or less.
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Engine coolant temperature sensor - Remove

Overheat switch removal
1. Disconnect the harness connector from the overheat
switch (1).
2. Remove the overheat switch (1) from the cylinder head
assembly.
SMIL14CEX3022AB 1
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Engine coolant temperature sensor - Install

Overheat switch installation
1. Install the overheat switch (1) to the cylinder head as-
sembly.
Connect the harness connector to the overheat switch.
SMIL14CEX3022AB 1
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Index

Engine coolant temperature sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine coolant temperature sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine cooling system - Dynamic description - Coolant level decrease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine cooling system - Dynamic description - Hot shutdown warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Engine oil system - 013

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Contents
SERVICE
Engine oil level sensor

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine oil pressure sensor and switch
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Electrical systems - Engine oil system
Engine oil level sensor - Remove

Engine oil drain
2. Drain the engine oil from the oil pan
Oil level sensor removal

1. Disengage the harness connector from the oil level
sensor (2).
2. Remove the spacer (3), the oil level sensor (2) and the
O-ring (1) from the oil pan.
SMIL14CEX3215AB 1
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Engine oil level sensor - Install

Oil level sensor installation
1. Install the O-ring (1) to the oil pan.
2. Install the oil level sensor (2) and the spacer (3) to the
oil pan.
CAUTION: Confirm that the O-ring is not mis-

aligned or bent.

3. Connect the harness connector to the oil level sensor
(2). SMIL14CEX3215AB 1
Engine oil filling

1. Replenish the engine oil.

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Engine oil pressure sensor and switch - Remove

sensor (2).
2. Remove the oil pressure sensor (2) from the oil port
cover (1).
SMIL14CEX3222AB 1
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Engine oil pressure sensor and switch - Inspect

sensor.
3. Inspect the continuity using the circuit tester.
CAUTION: Replace the oil pressure sensor if

there is no continuity.
SMIL14CEX3489AA 1

5. Inspect the circuit using the jumper wire.
6. Check lighting of the warning light.
NOTE: If the warning light does not illuminate, inspect the
circuit between the meter and the oil pressure.
SMIL14CEX3490AA 2
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Engine oil pressure sensor and switch - Install

1. Install the oil pressure sensor (2) to the oil port cover
(1).
2. Connect the harness connector to the oil pressure sen-

sor (2).
SMIL14CEX3222AB 1
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Index

Engine oil level sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine oil level sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine oil pressure sensor and switch - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine oil pressure sensor and switch - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine oil pressure sensor and switch - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Electronic modules - 640

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Contents
FUNCTIONAL DATA
Electronic modules
Fault code index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Electronic module
Electrical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Controller Area Network (CAN) data bus
SERVICE
Electronic module
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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Electrical systems - Electronic modules
Electronic modules - Fault code index

7000 Pressure sensor P1 abnormality
7001 Pressure sensor P2 abnormality
7002 Pressure sensor N1 abnormality
7003 Pressure sensor N2 abnormality
7004 Pressure sensor boom cylinder bottom abnormality
7006 Pressure sensor boom cylinder rod abnormality
7007 Pressure sensor arm cylinder rod abnormality
7021 Pressure sensor swing pilot abnormality
7023 Pressure sensor arm-in pilot abnormality
7040 Level sensor fuel abnormality
7041 Temperature sensor hydraulic oil abnormality
7060 Boom angle sensor signal abnormality
7061 Arm angle sensor signal abnormality
7062 Offset angle sensor signal abnormality
7065 Pressure sensor boom-up pilot abnormality
7067 Pressure sensor bucket-in pilot abnormality
7068 Pressure sensor boom-down pilot abnormality
7069 Pressure sensor arm-out pilot abnormality
7070 Pressure sensor bucket-out pilot abnormality
7071 Pressure sensor travel right pilot abnormality
7072 Pressure sensor travel left pilot abnormality
7073 Pressure sensor travel 1 pedal abnormality
7074 Pressure sensor 1st option pilot (common/front pedal) abnormality
7075 Pressure sensor arm cylinder bottom abnormality
7078 Pressure sensor 1st option pilot (rear pedal) abnormality
7200 Swing brake solenoid abnormality
7201 Travel 2nd-speed switchover solenoid abnormality
7202 Pressure boost solenoid abnormality
7203 Travel alarm buzzer abnormality
7206 Option return line switchover solenoid abnormality
7207 Free swing solenoid abnormality
7208 Fan reverse solenoid abnormality
7210 Crane buzzer abnormality
7211 Revolving light, bucket lock relay abnormality
7212 Gate lock solenoid abnormality
7213 Quick coupler buzzer abnormality
7214 Quick coupler solenoid abnormality
7242 Hydraulically-operated fan proportional valve abnormality
7243 Boom-up pilot proportional valve abnormality
7244 Arm-in pilot proportional valve abnormality
7245 Offset left pilot proportional valve abnormality
7246 2nd-speed merge solenoid abnormality
7247 Boom 2-down pilot proportional valve abnormality
7249 Bucket-in pilot proportional valve abnormality
7250 Option relief pressure proportional valve abnormality
7251 Battery relay abnormality
7252 Idle stop relay abnormality
7263 Immobilizer power supply output abnormality
7265 Arm 1 semi-parallel proportional valve abnormality
7266 Arm 2 semi-parallel proportional valve abnormality
7267 Arm 1 regeneration release proportional valve abnormality
7270 Tilting 1 proportional valve abnormality
7271 Tilting 2 proportional valve abnormality
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7273 Straight travel proportional valve abnormality
7400 Water temperature overheating 1
7401 Water temperature overheating 2
7404 Oil temperature overheating
7405 Boost temperature overheating 1
7406 Boost temperature overheating 2
7420 Alternator power generation failure
7421 Coolant level decrease
7422 Engine oil pressure decrease
7423 Air cleaner clogging
7424 Return filter clogging
7426 Fuel filter clogging 1
7427 Fuel filter clogging 2
7428 Inducement remaining urea level low) - Warning
7429 Inducement (remaining urea level low) - Early
7430 Inducement (remaining urea level low) - Final
7602 ECM communication abnormality
7603 Controller S communication abnormality
7605 ECM not-matched
7606 EEPROM abnormality
7608 Camera abnormality
7612 Air conditioner communication abnormality
7613 Monitor communication (CAN) abnormality
7615 Sub-controller communication abnormality
7617 RTC failure
7618 DCU communication abnormality
7619 A5V-A power supply abnormality
7620 A5V-B power supply abnormality
7621 12 V power supply abnormality
7800 Signal line disconnection (lifting magnet currently not supported)
7801 Output voltage decrease (lifting magnet currently not supported)
7802 Excessive magnet heating (lifting magnet currently not supported)
7803 Power generator voltage abnormality (lifting magnet currently not supported)
7804 Excessive magnet current (lifting magnet currently not supported)
7805 Excessive control board heating (lifting magnet currently not supported)
7806 Battery voltage decrease (lifting magnet currently not supported)
7807 Excessive battery voltage (lifting magnet currently not supported)
7810 Short-circuit (lifting magnet currently not supported)
7811 Control board overheating (lifting magnet currently not supported)
7812 Disconnection (lifting magnet currently not supported)
7813 CPU abnormality (lifting magnet currently not supported)
7814 Excessive condenser voltage (lifting magnet currently not supported)
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Electronic module - Electrical schema

Connector pin layout of the main controller
SMIL14CEX1217HB 1
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Controller Area Network (CAN) data bus - Dynamic description
SMIL14CEX4198FB 1
Main controller
Power supply voltage

• 24 V, 108 W
• Controller fuse 10 A
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Controller ground
• BG 601
• B 701
SMIL14CEX4199EA 2
• 24 V circuit
After the key switch is turned ON and the engine starts, 24 V is applied to the circuit. The controller establishes
a grounded circuit with a PNP transistor.
• Swing brake SOL
• 2-stage travel SOL
• 2-stage relief SOL
• Pressure boost SOL
• Free swing SOL
• Battery relay
• Idle stop relay
• Immobilizer power supply
• Travel alarm
5 V circuit items
• Hydraulic fluid temperature sensor
• Fuel level sensor
• P1 pressure sensor
• P2 pressure sensor
• N1 pressure sensor
• N2 pressure sensor
• Swing pressure sensor
• Upper pressure sensor
• Travel pressure sensor
• Throttle angle sensor
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Connection of electrical parts via CAN
SMIL14CEX4200FB 3
1. Main controller 5. AC controller

2. Engine controller 6. VGT controller
3. Dosing control unit 7. GPS unit
4. Monitor
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Electronic module - Prepare

Items to prepare:
• Wrench [ 13 mm]
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Electronic module - Remove

2. Remove the rear trim. (Refer to Cab and platform -
Remove (90.150) for details.)
3. Remove the ECM. (Refer to Engine Control Unit
(ECU) - Remove (55.015) for details.)
4. Remove the connectors (1), (2), (3), (4) and (5).
move the main controller (7).
SMIL14CEX3878AB 1
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Electronic module - Install

1. Mount the main controller in the reversed order of the
procedure for removal.
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Index

Controller Area Network (CAN) data bus - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Electronic module - Electrical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Electronic module - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Electronic module - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electronic module - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Electronic modules - Fault code index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Cab controls - 512

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Contents
Cab controls - 512
FUNCTIONAL DATA
Cab controls
Dynamic description - Work mode control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Dynamic description - Travel speed selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cab radio set
Dynamic description - Radio mute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Horn control switch
Clock
Instrument cluster
Electrical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Overview - Screen display list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Overview - Service Monitor Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Overview - CHECK screen list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Overview - SETUP screen list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Overview - CALIBRATE screen list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Dynamic description - Fuel gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Dynamic description - Coolant temperature gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Dynamic description - Oil temperature gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Dynamic description - Monitor display dimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Dynamic description - Selective catalytic reduction (SCR) gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Dynamic description - Diagnostic trouble code indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Dynamic description - Fuel economy gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Dynamic description - Engine information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
SERVICE
Clock
Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Instrument cluster
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Adjust - Screen brightness setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
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Electrical systems - Cab controls
Cab controls - Dynamic description - Work mode control

Purpose
The system allows the operator to select work mode according to what is regarded as important, such as speed and
fuel economy.
At the same time, it adjusts the engine speed. (Throttle adjustment)
SMIL14CEX3437GB 1
1. MONITOR DISPLAY 5. target engine speed

2. Work mode display 6. ECM
4. Throttle volume
Operation
1. Manual switchover (main mode)
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The operator can select one of the following work modes by turning the throttle volume.
Refer to the attached table for correspondence between the throttle volume and the work mode.
Mode Aim Display Monitor buzzer

Two short beeps when
(1) SP mode Speed as important
selected
Both speed and fuel
(2) H mode A short beep when selected
economy as important
(3) A mode Fuel economy as important A short beep when selected
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Cab controls - Dynamic description - Travel speed selection

Purpose/overview
The system changes swash plate angle of the travel motor to switch travel speed in two steps by operation of the
travel mode select switch.
It is fixed to low-speed mode when crane mode is ON.
SMIL14CEX4070HB 1
1. Main Controller 4. Monitor

2. Travel mode select switch 5. Travel 2nd speed switchover solenoid
3. Travel Motor
Operation
1. The system recognizes that an operator has pressed the travel mode select switch by the monitor to transmit to
the controller via CAN communication.
2. Upon receiving the signal, the controller drives the travel 2nd speed switchover solenoid to change angle of the
swash plate of the travel motor, and simultaneously command to display travel mode icon is transmitted to the
controller via CAN communication.
3. The system displays low speed or high speed travel mode icon on the monitor upon receiving the command to
display icon.
Operation condition
• The system switches between low speed travel mode and high speed travel mode alternatively each time an oper-
ator presses the travel mode select switch.
• It turns OFF the travel 2nd speed switchover solenoid and displays the low speed travel mode icon on the monitor
when low speed travel mode is selected.
• It turns ON the travel 2nd speed switchover solenoid and displays the high speed travel mode icon on the monitor
when high speed travel mode is selected.
• Turning OFF the key once and turning the system ON again starts it in low speed travel mode regardless of the
condition when it was turned OFF.
Stop condition
• It is not switched from low speed travel mode to high speed travel mode when crane mode is ON.
• Turning ON crane mode during selecting high speed travel mode automatically switches the system to low speed
mode.
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Cab radio set - Dynamic description - Radio mute

Purpose/overview
The system sets radio volume to zero with one-touch. The system cuts off output to the speakers so as to enable
mute regardless of an installed radio. (Support a radio without mute function)
SMIL14CEX1039FB 1
1. Main controller 5. Speaker (L) relay

2. Radio mute switch 6. Speaker (R) relay
3. ECM 7. Speaker (L)
4. Radio 8. Speaker (R)
Operation
1. The monitor detects state of the radio mute switch to send it to the controller via CAN communication.
2. The controller controls the radio mute and then transmits the result of it to the monitor via CAN communication.
3. The monitor activates the speaker relay based on received control information.
4. The signal line of the speaker is cut off to set volume to zero when the radio mute relay is turned ON.
Operation condition
1. The system detects that the radio mute switch is pressed to turn ON the mute relay and then displays mute icon
on the monitor.
2. The system detects that the radio mute switch is pressed from the state that the mute relay is ON, to turn OFF the
mute relay and then set mute icon on the monitor to hide.
3. The system resets the previous mode to start with the radio mute OFF when the key switch is turned On from OFF.
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Horn control switch - Dynamic description

Purpose/overview
The machine sounds horn when the horn switch is pressed to warn operators around. Horn volume can be selected
from 2 steps by the horn volume switch.
SMIL14CEX6809FB 1
1. Main controller 5. Horn (LO)

2. Horn switch 6. Horn (HI)
3. Horn volume switch a. The main controller does nothing.
4. Horn relay
Operation
1. Pressing the horn switch energizes the horn relay to apply 24 V to 2 horns (LO/HI) to sound the horn (direct acti-
vation).
2. The monitor detects state of the horn volume switch to send it to the controller via CAN communication.
3. The controller controls the horn volume relay and then transmits the result of it to the monitor via CAN communi-
cation.
4. The monitor activates the horn volume relay based on the received control information (activation command) to
turn icon of the monitor light on.
5. Pressing the horn switch with the horn volume relay ON sounds the horn LO only.
Operation condition
• Pressing the horn switch sounds the horns LO and HI simultaneously and releasing it stops them. (When horn
volume relay OFF)
• The system switches ON/OFF of the horn volume relay each time the horn volume switch is pressed.
• The system turns icon of the monitor light on when volume is low (horn volume relay ON).
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• Turning the key OFF and then turning the key ON again activates the horn volume relay in accordance with the
previous horn volume that has been saved in the system. (Initial value starts the horn volume from HI)
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Clock - Dynamic description

Purpose/overview
The system displays the time on the monitor based on information of the GPS.
SMIL14CEX1024EB 1
1. Monitor 4. G@NAV terminal

2. Main controller 5. Communication antenna
3. GPS antenna a. Software processing
Control
1. The controller obtains year/month/day/hour/minute from the RTC or the GPS, and obtains setting format saved in
the memory.
2. The controller sends obtained display format and date/time information to the monitor via CAN communication.
3. The monitor displays year/month/day/hour/minute in specified format based on received information.
Control condition
• The monitor enters clock mode that displays hour/minute only and does not display year/month/day if the CAN is
disconnected.
• The monitor displays a time that is backed up in the monitor based on the time received from the controller at the
latest in the clock mode.
• The colon does not blink in 24 h display during backing up.
• Display of the clock becomes “0:00” if the back up power source of the monitor is terminated.
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Instrument cluster - Electrical schema

Monitor
SMIL14CEX1218GA 1
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Instrument cluster - Overview - Screen display list
SMIL14CEX4126HB 1
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a. Hold down for 3 s. 4. Light switch

1. Travel speed select switch 5. Wiper switch
2. Attachment selection switch 6. Auto idle switch
3. Menu switch
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Instrument cluster - Overview - Service Monitor Structure
SMIL14CEX0913HB 1
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1. Service support 18. Communication terminal

2. Check 19. Monitor
3. Machine status 20. Air-conditioner
4. Hydraulic status 21. Setting
5. Engine status 22. Model selection
6. Trouble log 23. Dimension
7. Work log 24. Parameter setting
8. Hydraulic log 25. Engine information
9. Engine log 26. Camera setting
10. Device test 27. Password setting
11. Control unit 28. Adjustment
12. Main controller 29. Throttle volume adjustment
13. Sub-controller 1 30. Angle sensor adjustment
14. Sub-controller 2 31. Relief pressure adjustment
15. Sub-controller 3 32. Proportional valve adjustment
16. ECM 33. Reset
17. DCU
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Instrument cluster - Overview - CHECK screen list

In CHECK mode, not only the system status (each cur-
rent value, hydraulic pressure, temperature, etc.) but also
the input/output state of sensors and switches can be
checked.
1. Section
Refer to the attached sheet for the types of sections in the

CHECK mode and their descriptions.
By pressing and on the monitor, MACHINE STA-
TUS, HYDRAULIC HISTORY, etc. can be selected.
Detailed data for the selected item can be seen by press-
ing . SMIL14CEX0914AB 1
MACHINE STATUS
1/9
SMIL14CEX0915EB 2
Display Explanation Range

ENGINE SPEED Actual engine speed 0 - 2500 RPM
ENGINE SPEED TARGET target engine speed 500 - 2500 RPM
ENGINE LOAD RATIO Engine torque (load ratio) 0 - 100 %
P1 PRESS P1 pressure 0 - 50 MPa (0 - 7253 psi)
N1 PRESS N1 pressure 0 - 5 MPa (0 - 725 psi)
PUMP1 FLOW RATE Pump 1 target flow rate 0 - 100 %
PUMP2FLOW RATE Pump 2 target flow rate 0 - 100 %
HYD.OIL TEMP Temperature sensor; hydraulic oil -40 - 210 °C (-40 - 410 °F)
COOLANT TEMP Coolant temperature -40 - 210 °C (-40 - 410 °F)
POWER BOOST SOL Pressure boost solenoid ON/OFF
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2/9
SMIL14CEX0916EB 3

FUEL INJECTION LIMIT Fuel injection quantity restriction level 0 - 100 %
Inducement level
0: Normal
1: Warning
INDUCEMENT LEVEL 0-4
2: Early Inducement
3: Severe Inducement
4: Final Inducement
INDUCEMENT TIMER Inducement timer 0 -250.59 hr.min
Escape mode
ESCAPE MODE "++++": ON ON/OFF
"----": OFF
Repeat offense
REPEAT OFFENCE "++++": ON ON/OFF
"----": OFF
PUMP POWER LIMIT Pump output limit 0 - 100 %
LOCKED BY - -
EMERGENCY ENGINE STOP SWITCH Engine emergency stop SW ON/OFF

IDLE STOP RELAY Idling stop REL ON/OFF
GATE CLOSED Gate open/close SW ON/OFF
GATE LOCK SOL Gate Lock SOL ON/OFF
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3/9
SMIL14CEX0917EA 4

AIR INLET TEMP Intake air temperature -40 - 210 °C (-40 - 410 °F)
Hydraulically-operated fan proportional
HYD.OIL FAN P.SOL valve 0 - 1000 mA
･ 450 or later models only
FAN REVERSE SOL Fan reverse solenoid ON/OFF
DEF/AdBlue TEMP (TANK) Urea temperature (inside tank) -40 - 210 °C (-40 - 410 °F)
DEF/AdBlue TEMP (S/M) Urea temperature (inside supply module) -40 - 210 °C (-40 - 410 °F)
COOLANT CONTROL VALVE Temperature sensor; hydraulic oil ON/OFF
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4/9
SMIL14CEX0918EA 5

ENGINE OIL PRESS Engine oil pressure 0 - 1000 kPa (0 - 145 psi)
FUEL LEVEL Level sensor; fuel 0 - 100 %
AUTO REFUEL STOP RELAY Refueling stop REL ON/OFF
DEF/AdBlue LEVEL Remaining urea level 0 - 100 %
DEF/AdBlue CONCENTRATION Urea concentration 0 - 100 %
COOLANT LEVEL LOW Coolant level SW ON/OFF
AIR FILTER CLOGGED Air cleaner clogging signal ON/OFF
Fuel filter clogging status
0: OFF
FUEL FILTER CLOG LEVEL 0-2
1: Step1
2: Step2
HYD.OIL FILTER CLOG PRESS Pressure sensor; hydraulic oil F clogging 0 - 1 MPa (0 - 145 psi)
BATTERY CHARGING Alternator voltage ON/OFF
BATTERY VOLT Battery voltage 0 - 100 V
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5/9
SMIL14CEX0919EA 6

THROTTLE VOL OPENING Degree of opening of throttle volume 0 - 100 %
KEY ON Key ON ON/OFF
BATTERY RELAY Battery REL ON/OFF
IMMOBI-KEY POWER OUT Immobilizer power supply ON/OFF
FRONT WINDOW CLOSED Front window SW ON/OFF

DOOR CLOSED Door close SW ON/OFF
GATE CLOSED Gate open/close SW ON/OFF
QUICK COUPLER SW Quick coupler SW ON/OFF
QUICK COUPLER SOL Quick coupler SOL ON/OFF
QUICK COUPLER BUZZER Quick coupler buzzer ON/OFF
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6/9
SMIL14CEX0920EA 7

ONE-TIME WIPER SW One-time wiper SW ON/OFF
WIPER-INT OUT Wiper INT output ON/OFF
WIPER-CNT OUT Wiper CNT output ON/OFF
WASHER OUT Washer output ON/OFF
WORKING SIGNAL OUT - -

RADIO MUTE RELAY Radio mute REL ON/OFF
ROOM LAMP RELAY Room lamp REL ON/OFF
WORKING LIGHT RELAY Working light REL ON/OFF
AUTO REFUEL STOP RELAY Refueling stop REL ON/OFF
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7/9
SMIL14CEX0921EA 8

LATITUDE1 GPS latitude 1 (deg.) 0 - 9999 °
LATITUDE2 GPS latitude 2 (min.) 0 - 99.99 ‘
LONGITUDE1 GPS longitude 1 (deg.) 0 - 9999 °
LONGITUDE2 GPS longitude 2 (min.) 0 - 99.99 ‘
ALTITUDE Altitude 0 - 9999 m
UTC(YEAR) Universal Time (year) 0 - 9999
UTC(MONTH.DAY) Universal Time (month, day) 0 - 12.31
UTC(HOUR) Universal Time (hour) 0 - 23
UTC(MIN.SEC) Universal Time (min., sec.) 0 - 59.59
GPS positioning status
0: GPS non-operating
GPS STATUS 1: GPS positioning 0-3
2: 2D positioning status
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8/9
SMIL14CEX0922EA 9

Geofence
0: Not set
AREA LOCK 0-2
1: Set but not locked
2: Set and locked
Curfew
0: Not set
TIME LOCK 0-2
2: Set and locked
Antenna lock
0: Not set
ANTENNA REMOVE LOCK 0-2
2: Set and locked
Remote lock
REMOTE LOCK 1: Not locked 1-2
2: Locked
Handshake lock
･ It is triggered by removing a
communication terminal.
TERMINAL REMOVE LOCK 0-2
0: Not set
2: Set and locked
Serial number lock
･ It is triggered by replacing a
communication terminal.
TERMINAL REPLACE LOCK 0-2
0: Not set
2: Set and locked
GPS reception failure lock
0: Not set
GPS BAD RECEPTION LOCK 0-2
2: Set and locked
Trace mode
TRACE MODE 0: OFF 0-1
1: ON
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9/9
SMIL14CEX0923EA 10

PRESET TEMP. Current set temperature 18 - 32 °C (64.4 - 89.6 °F)
AUTO BLOWER CONTROL Automatic air flow control mode ON/OFF
AUTO MODE CONTOL Automatic blow mode control ON/OFF
A/C BLOWER DUTY Air conditioner blower duty 0 - 100%
MODE M/A POS. Blow mode motor actuator position 0 - 90 °
AIRMIX M/A POS Air mix motor actuator position 0 - 90 °
REC/FRE M/A POS Recirculate/Refresh M/A position 0 - 90 °
A/C RECIRC AIR TEMP Air conditioner inside air temperature -40 - 80 °C (-40 - 176 °F)
A/C EVA TEMP Air conditioner EVA temperature -20 - 40 °C (-4 - 104 °F)
SUNLOAD Amount of solar radiation 0 - 1000 W/m2
COMP. CLUTCH RELAY Compressor clutch ON/OFF
A/C LIMIT CONTROL Air conditioner air flow restriction 0-3
To switch to a page from 1 to 9, press the light switch while the MACHINE STATUS screen is displayed, and
select the desired page.
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HYDRAULIC STATUS
1/11
SMIL14CEX0924EA 11

PUMP1 TILT P.SOL Pump 1 tilting proportional valve 0 - 1000 mA
Boom 2-down pilot pressure proportional
BOOM2 DOWN REGEN. P.SOL 0 - 1000 mA
valve
Arm 1 regeneration release proportional
ARM1 CLOSE REGEN. P.SOL 0 - 1000 mA
valve
ARM1 SEMI-PARA P.SOL Arm 1 semi-parallel proportional valve 0 - 1000 mA
Bucket-close pilot pressure proportional
BUCKET CLOSE P.SOL 0 - 1000 mA
valve
TRAVEL STRAIGHT P.SOL Straight travel proportional valve 0 - 1000 mA
Option line relief pressure proportional
OPT.LINE RELIEF P.SOL 0 - 1000 mA
valve
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2/11
SMIL14CEX0925EA 12

SWING BRAKE SOL Swing brake solenoid ON/OFF
FREE SWING SOL Free swing solenoid ON/OFF
TRAVEL 2 SPEED SOL Travel 2nd speed switchover solenoid ON/OFF
BREAKER CIRC. SOL Breaker circuit solenoid ON/OFF
2-PUMP SPEED SOL 2 pumps flow solenoid ON/OFF
QUICK COUPLER SOL Quick coupler SOL ON/OFF
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3/11
SMIL14CEX0926EA 13

BOOM UP PC.PRESS Boom-up pilot pressure 0 - 5 MPa (0 - 725 psi)
BOOM DOWN PC.PRESS Boom-down pilot pressure 0 - 5 MPa (0 - 725 psi)
ARM OPEN PC.PRESS Arm-out pilot pressure 0 - 5 MPa (0 - 725 psi)
ARM CLOSE PC.PRESS Arm-in pilot pressure 0 - 5 MPa (0 - 725 psi)
BUCKET OPEN PC.PRESS Bucket-open pilot pressure 0 - 5 MPa (0 - 725 psi)
BUCKET CLOSE PC.PRESS Bucket-close pilot pressure 0 - 5 MPa (0 - 725 psi)
SWING PC.PRESS Swing pilot pressure 0 - 5 MPa (0 - 725 psi)
TRAVEL LEFT PC.PRESS Travel left pilot pressure 0 - 5 MPa (0 - 725 psi)
TRAVEL RIGHT PC.PRESS Travel right pilot pressure 0 - 5 MPa (0 - 725 psi)
TRAVEL ONE-PEDAL PC.PRESS Travel 1 pedal pilot pressure 0 - 5 MPa (0 - 725 psi)
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4/11
SMIL14CEX0927EA 14

OPT.LINE1 PC.PRESS (COM/F) 1st option pilot pressure (common/front) 0 - 5 MPa (0 - 725 psi)
OPT.LINE1 PC.PRESS (R) 1st option pilot pressure (rear) 0 - 5 MPa (0 - 725 psi)
OPT.LINE2 PC.PRESS 2nd option / blade pilot pressure ON/OFF
BOOM SWING PC.PRESS Boom swing pilot pressure
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5/11
SMIL14CEX0928EA 15

P1+P2 PRESS P1+P2 pressure 0 - 100 MPa (0 - 14505 psi)
PUMP POWER LIMIT Pump output limit 0 - 100 %
BOOST PRESS Boost pressure 0 - 500 kPa (0 - 73 psi)
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6/11
SMIL14CEX0929EA 16

BOOM UP PC.PRESS Boom-up pilot pressure 0 - 5 MPa (0 - 725 psi)
BOOM DOWN PC.PRESS Boom-down pilot pressure 0 - 5 MPa (0 - 725 psi)
BOOM CYL. BOTTOM PRESS Boom cylinder bottom pressure 0 - 50 MPa (0 - 7253 psi)
BOOM CYL.ROD PRESS Boom cylinder rod pressure 0 - 50 MPa (0 - 7253 psi)
BOOM SWING PC.PRESS Boom swing pilot pressure
Boom 2-down pilot pressure proportional

BOOM2 DOWN REGEN. P.SOL 0 - 1000 mA
valve
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7/11
SMIL14CEX0930EA 17

ARM OPEN PC.PRESS Arm-out pilot pressure 0 - 5 MPa (0 - 725 psi)
ARM CLOSE PC.PRESS Arm-in pilot pressure 0 - 5 MPa (0 - 725 psi)
ARM CYL.BOTTOM PRESS Arm cylinder bottom pressure 0 - 50 MPa (0 - 7253 psi)
ARM CYL.ROD PRESS Arm cylinder rod pressure 0 - 50 MPa (0 - 7253 psi)
Arm 1 regeneration release proportional
ARM1 CLOSE REGEN. P.SOL 0 - 1000 mA
valve
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8/11
SMIL14CEX0931EA 18

BUCKET OPEN PC.PRESS Bucket-open pilot pressure 0 - 5 MPa (0 - 725 psi)
BUCKET CLOSE PC.PRESS Bucket-close pilot pressure 0 - 5 MPa (0 - 725 psi)
SWING PC.PRESS Swing pilot pressure 0 - 5 MPa (0 - 725 psi)
SWING BRAKE SOL Swing brake solenoid ON/OFF

FREE SWING SOL Free swing solenoid ON/OFF
Bucket-close pilot pressure proportional
BUCKET CLOSE P.SOL 0 - 100 mA
valve
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9/11
SMIL14CEX0932EA 19

TRAVEL LEFT PC.PRESS Travel left pilot pressure 0 - 5 MPa (0 - 725 psi)
TRAVEL RIGHT PC.PRESS Travel right pilot pressure 0 - 5 MPa (0 - 725 psi)
TRAVEL ONE-PEDAL PC.PRESS Travel 1 pedal pilot pressure 0 - 5 MPa (0 - 725 psi)
TRAVEL 2 SPEED SOL Travel 2nd speed switchover solenoid ON/OFF
TRAVEL ALARM BUZZER Travel alarm BUZ ON/OFF
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10/11
SMIL14CEX0933EA 20

OPT.LINE1 PC.PRESS (COM/F) 1st option pilot pressure (common/front) 0 - 5 MPa (0 - 725 psi)
OPT.LINE1 PC.PRESS (R) 1st option pilot pressure (rear) 0 - 5 MPa (0 - 725 psi)
OPT.LINE2 PC.PRESS 2nd option / blade pilot pressure ON/OFF
2-PUMP SPEED SOL 2 pumps flow solenoid ON/OFF
BREAKER CIRC. SOL Breaker circuit solenoid ON/OFF
Option line relief pressure proportional
OPT.LINE RELIEF P.SOL 0 - 1000 mA
valve
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11/11
SMIL14CEX0934EA 21

DEF/AdBlue TEMP (TANK) Urea temperature (inside tank) -40 - 210 °C (-40 - 410 °F)
DEF/AdBlue TEMP (S/M) Urea temperature (inside supply module) -40 - 210 °C (-40 - 410 °F)
COOLANT CONTROL VALVE Temperature sensor; hydraulic oil ON/OFF
To switch to a page from 1 to 11, press the light switch while the HYDRAULIC STATUS screen is displayed, and
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ENGINE STATUS
1/7
SMIL14CEX0935EA 22
Display Explanation Value

AIR INLET TEMP Intake air temperature -40 - 210 °C (-40.00 - 410 °F)
AIR INLET FLOW Suction air volume per cylinder 3 - 12 g
BAROMETRIC PRESS Barometric pressure 0 - 125 kPa (0 - 18 psi)
VG TURBO OPENING VG turbo opening (degree) 0 - 100 %
INTERCOOLER INLET TEMP Inter-cooler inlet temperature -40 - 210 kPa (-6 - 30 psi)
INTAKE TH. OPENING Intake throttle opening (degree) 0 - 100 %
BOOST TEMP Boost temperature -40 - 210 °C (-40.00 - 410 °F)
BOOST PRESS Boost pressure 0 - 500 kPa (0 - 73 psi)
Manifold internal intake-air
MANIFOLD INNER TEMP -40 - 210 °C (-40.00 - 410 °F)
temperature
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2/7
SMIL14CEX0936EA 23

EGR #1 INLET TEMP EGR #1 inlet gas temperature 0 - 1000 °C (32 - 1832 °F)
EGR #1 OUTLET TEMP EGR #1 outlet gas temperature 0 - 1000 °C (32 - 1832 °F)
EGR #1 VALVE OPENING EGR#1 degree of opening 0 - 100 %
EGR #2 INLET TEMP EGR #2 inlet gas temperature 0 - 1000 °C (32 - 1832 °F)
EGR #2 OUTLET TEMP EGR #2 outlet gas temperature 0 - 1000 °C (32 - 1832 °F)
EGR #2 VALVE OPENING EGR#2 degree of opening 0 - 100 %
Manifold internal intake-air
MANIFOLD INNER TEMP -40 - 210 °C (-40.00 - 410.00 °F)
temperature
DOC INLET TEMP DOC inlet temperature 0 - 1000 °C (32 - 1832 °F)
DOC OUTLET TEMP DOC outlet temperature 0 - 1000 °C (32 - 1832 °F)
SCR INLET TEMP SCR inlet temperature -273 - 1735 °C (-459 - 3155 °F)
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3/7
SMIL14CEX6786EA 24

DOC INLET TEMP DOC inlet temperature 0 - 1000 °C (32 - 1832 °F)
DOC OUTLET TEMP DOC outlet temperature 0 - 1000 °C (32 - 1832 °F)
SCR INLET TEMP SCR inlet temperature -273 - 1735 °C (-459 - 3155 °F)
HYD. LOAD SOL Hydraulic pressure load solenoid on/off

PUMP FLOW RATE Target flow rate of pump 1 or 2 0 - 100 %
MANUAL CLEANING SIGNAL OUT Manual SCR cleaning start signal on/off
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4/7
SMIL14CEX0938EA 25

DEF/AdBlue® LEVEL Remaining urea level 0 - 100 %
DEF/AdBlue® CONCENTRATION Urea concentration 0 - 100 %
DEF/AdBlue® TEMP (TANK) Urea temperature (inside tank) -40 - 210 °C (-40 - 410 °F)
Urea temperature (inside supply
DEF/AdBlue® TEMP (S/M) -40 - 210 °C (-40 - 410 °F)
module)
DEF/AdBlue® S/M DUTY Supply module DUTY 0 - 100 %
DEF/AdBlue® PRESS Urea pressure 0 - 300 kPa (0 - 44 psi)
DEF/AdBlue® D/V OPENING Degree of opening of dosing valve 0 - 100 %
DEF/AdBlue® TOTAL
CONSUMPTION
COOLANT CONTROL VALVE Temperature sensor; hydraulic oil on/off
Reverting valve status"++++":
REVERTING VALVE on/off
Reverse"----": Normal
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5/7
SMIL14CEX0939EA 26

HYD.OIL FAN P.SOL Hydraulically-operated fan
proportional valve* 450 or later 0 - 1000 mA
models only
FAN REVERSE SOL Fan reverse solenoid on/off
DEF/AdBlue® TEMP (TANK) Urea temperature (inside tank) -40 - 210 °C (-40 - 410 °F)
DEF/AdBlue® TEMP (S/M) Urea temperature (inside supply
-40 - 210 °C (-40 - 410 °F)
module)
COOLANT CONTROL VALVE Temperature sensor; hydraulic oil on/off
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6/7
SMIL14CEX0940EA 27
Display Explanation Unit

FUEL SUPPLY PUMP PRESS Fuel supply pump inlet pressure -100 - 300 kPa (-15 - 44 psi)
COMMON RAIL PRESS common rail pressure 0 - 250 MPa (0 - 36262 psi)
COMMON RAIL DIFF. PRESS Common rail differential pressure -125 - 250 MPa (-18131 - 36262 psi)
FUEL INJECTION Target fuel injection quantity 0 500 mm3/st
FUEL FLOW Fuel flow rate 0 - 3212 L/hour
FUEL TEMP Fuel temperature -40 - 210 °C (-40 - 410 °F)
FUEL INJECTION LIMIT Fuel injection quantity restriction level 0 - 100 %
FUEL FILTER CLOG LEVEL Fuel filter clogging status
0: OFF
0–2
1: STEP 1
3: STEP 2
FUEL TOTAL CONSUMPTION Lifelong accumulated fuel 0 - 2105540607.50 L (0 -
consumptions 556224983.69 US gal)
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7/7
SMIL14CEX0941EA 28

ENGINE SPEED TARGET Target engine speed 500 - 2500 RPM
DPF MODE DPF mode 0-255
NOx SENSOR STATUS NOx sensor status 0-255
DCU STATUS DCU status 0-255
DOSING MODULE STATUS Dosing module status 0-255
To switch to a page from 1 to 7, press the light switch while the ENGINE STATUS screen is displayed, and select
the desired page.
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FAULT HISTORY
In FAULT HISTORY, you can confirm the troubles oc-
curred in the past based on the content of the occurring
trouble.
SMIL14CEX0942AA 29
Display Explanation Unit No. of digits

DTC Diagnostic trouble code None 5
Occurrence count (up to
COUNT Times 3
250)
Trouble status (0: Normal,
STATUS None 1
1: Recovering, 2: Occurred)
First occurrence time (hour
FIRST-HR Hour 5
meter time)
Last occurrence time (hour
LAST-HR Hour 5
meter time)
• Diagnostic trouble codes that has generated will be displayed in "DTC-1" through "DTC-10."
• Move the cursor with switches on the monitor. (The cursor moves between "DTC-1" and "DTC-10.")
• Diagnostic trouble codes up to 60 items can be displayed.To switch to a page from 1 to 6 press the light switch
while the FAULT HISTORY screen is displayed and select the desired page.
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WORK HISTORY
Operation times for mechanical parts, electrical parts, etc., and operation counts for switches can be displayed.
1/11
SMIL14CEX0943EA 30
Judgment start
Display Explanation Unit Judgment condition
condition
KEY-ON TIME Key ON time hour IGN-ON None
KEY-ON COUNT Key ON count times IGN-OFF→ON None
Engine in-operation
ENGINE-ON TIME Engine ON time hour None
judgment = ON
Engine in-operation
ENGINE-ON COUNT Engine ON count times None
judgment OFF → ON
(Total operation
OPERATION TIME Total operation time hour Engine in operation
judgment = ON)
(Total operation
SP-MODE SP mode time hour judgment = ON) + Engine in operation
(Work mode = SP)
(Total operation
H-MODE H mode time hour judgment = ON) + Engine in operation
(Work mode = H)
(Total operation
A-MODE A mode time hour judgment = ON) + Engine in operation
(Work mode = A)
(Total operation
AL-MODE AL mode time hour judgment = ON) + Engine in operation
(Work mode = AL)
(Total operation
Pressure boosting
POWER BOOST hour judgment = ON) + Engine in operation
time
(Boost SOL = ON)
POWER SAVING (Power save control =
Power saving time hour Engine in operation
TIME ON)
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2/11
SMIL14CEX0944EA 31
Judgment start
condition
Boom operation time Boom operation
BOOM OPR. TIME hour Engine in operation
(both up and down) judgment = ON
Boom-up operation Boom-up operation
UP hour Engine in operation
time judgment = ON
Boom-down operation Boom-down operation
DOWN hour Engine in operation
time judgment = ON
Bucket operation time Arm operation
ARM OPR. TIME hour Engine in operation
(both open and close) judgment = ON
Bucket-open
Bucket-open
OPEN hour operation judgment = Engine in operation
operation time
ON
Bucket-close
Bucket-close
CLOSE hour operation judgment = Engine in operation
operation time
ON
Bucket operation time Bucket operation
BUCKET OPR. TIME hour Engine in operation
(both open and close) judgment = ON
Bucket-open
Bucket-open
OPEN hour operation judgment = Engine in operation
operation time
ON
Bucket-close
Bucket-close
CLOSE hour operation judgment = Engine in operation
operation time
ON
Upper operation
UPPER OPR. TIME Upper operation time hour Engine in operation
judgment = ON
Swing operation
SWING OPR. TIME Swing operation time hour Engine in operation
judgment = ON
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3/11
SMIL14CEX0945EA 32
Judgment start
condition
Travel operation time Travel operation
TRAVEL OPR. TIME hour Engine in operation
(both right and left) judgment = ON
Left travel operation Left travel operation
LEFT hour Engine in operation
time judgment = ON
Right travel operation Right travel operation
RIGHT hour Engine in operation
time judgment = ON
(Travel operation
judgment = ON) +
LO-SPEED 1st speed travel time hour Engine in operation
(2nd speed travel
SOL = OFF)
(Travel operation
judgment = ON) +
HI-SPEED 2nd speed travel time hour Engine in operation
(2nd speed travel
SOL = ON)
(Travel judgment
Independent travel
SOLO hour = ON) + (Upper Engine in operation
time
judgment = OFF)
1st (both with and
1st option operation
OPT.LINE OPR. TIME without 2 pumps flow) hour Engine in operation
judgment = ON
option operation time
(1st option operation
judgment = ON) + (2
ONE-PUMP FLOW (without 2 pumps hour Engine in operation
pumps flow SOL =
flow) time
OFF)
(1st option operation
judgment = ON) + (2
TWO-PUMP FLOW (with 2 pumps flow) hour Engine in operation
pumps flow SOL =
time
ON)
2nd OPT.LINE OPR. 2nd option operation 2nd option operation
hour Engine in operation
TIME time judgment = ON
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4/11
SMIL14CEX0946EA 33
Judgment start
condition
Frequency
TRAVEL OPR. TIME distribution of Continuous travel
times Engine in operation
RANGE 1 continuous travel time < 10 s.
time
Frequency
RANGE 2 continuous travel time < 30 s.
time
Frequency
RANGE 3 continuous travel time < 1 min.
time
Frequency
time
Frequency
time
Frequency
time
Frequency
RANGE 7 continuous travel time 30 min.
time
TRAVEL OPR. TIME Continuous travel Continuous travel
sec Engine in operation
MAX 1st time ranking time: 1st rank
MAX 2nd time ranking time: 2nd rank
MAX 3rd time ranking time: 3rd rank
MAX 4th time ranking time: 4th rank
MAX 5th time ranking time: 5th rank
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5/11
SMIL14CEX0947EA 34
Judgment start
condition
(Idle mode = Auto
AUTO IDLE MODE Auto idle mode ON
hour idle) or (Idle mode = Engine in operation
TIME time
Auto idle + Idle stop)
When the engine
Auto idle actuation
AUTO IDLE COUNT times speed is decreased Engine in operation
count
by auto idle control
(Idle mode = Idle stop)
IDLE-STOP MODE Idle stop mode ON
hour or (Idle mode = Auto Engine in operation
TIME time
idle + Idle stop)
When the engine is
Idle stop actuation
IDLE-STOP COUNT times stopped by idle stop Engine in operation
count
control
ONE-TOUCH IDLE One-touch Idle One-touch idle SW
COUNT actuation count OFF → ON
BREAKER MODE Breaker mode ON Option line mode =
TIME time Breaker 1 to 5
(Option line mode
BREAKER OPR. Time during which a = Breaker 1 to 5) +
TIME breaker is operated (1st option operation
judgment = ON)
CRUSHER MODE Crusher mode ON Option line mode =
TIME time Crusher 1 to 5
(Option line mode
CRUSHER OPR. Time during which a = Crusher 1 to 5) +
TIME crusher is operated (1st option operation
judgment = ON)
QUICK COUPLER Quick coupler Quick coupler SW =
OPR.TIME operation time ON
QUICK COUPLER Quick coupler Quick coupler SW
OPR.COUNT operation count OFF → ON
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6/11
SMIL14CEX0948EA 35
Judgment start
condition
Radio mute SW OFF
RADIO MUTE Radio mute ON count times Key ON
→ ON
OVERLOAD Overload warning
hour Overload SW = ON Engine in operation
WARNING MODE mode ON time
Time during which
TRAVEL ALARM Travel alarm mode
the travel alarm is in hour Engine in operation
CONT. MODE SW = ON
continuous mode
Free swing mode ON Free swing mode =
FREE-SWING MODE hour Engine in operation
time ON
Working light REL =
WORKING LIGHT Working light ON time hour Key ON
ON
When the camera
Time during which the
METER POSITION. layout on the meter
gauge was set on the hour Key ON
LEFT TIME screen is A, B, C, D,
left
and E
When the camera
METER POSITION layout on the meter
gauge was set at the hour Key ON
TOP TIME screen is F, G, H, I,
top
and J
When the camera
1 SCREEN CAMERA Camera displaying layout on the meter
hour Key ON
TIME time with 1 screens screen is A, B, C, H,
I, and J
When the camera
2 SCREEN CAMERA Camera displaying layout on the meter
hour Key ON
TIME time with 2 screens screen is D, E, F, and
G
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7/11
SMIL14CEX0949EA 36
Judgment start
condition
CRANE MODE TIME Crane mode ON time hour Crane mode = ON Engine in operation
Anti-interference
Anti-interference
ANTI-INTF. CANCEL temporary
temporary sec Engine in operation
TIME cancellation SW =
cancellation time
ON
Anti-interference
Anti-interference
ANTI-INTF. CANCEL temporary
temporary times Engine in operation
COUNT cancellation SW OFF
cancellation count
→ ON
MAGNET MODE Lifting magnet mode Lifting magnet SW =
TIME ON time ON
Lifting magnet Lifting magnet suction
MAGNET ON TIME hour Engine in operation
suctioning time SW = ON
Lifting magnet suction Lifting magnet suction
MAGNET ON COUNT times Engine in operation
operation count SW OFF → ON
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8/11
SMIL14CEX0950EA 37
Judgment start
condition
Wiper (INT) operation Wiper control mode =
WIPER-INT. MODE hour Key ON
time INT
Wiper (CNT) Wiper control mode =
WIPER-CNT. MODE hour Key ON
operation time CNT
WASHER OPR. Washer operation Washer SW OFF →
times Key ON
COUNT count ON
ONE-TIME WIPER One-time wiper One-time wiper SW
times Key ON
COUNT operation count OFF → ON
Front window open Front window status =
WINDOW-OPEN hour Key ON
time Open
WINDOW-OPEN Front window open Front window status:
times Key ON
COUNT count Open → Closed
DOOR-OPEN Door open time hour Door status = Open Key ON
DOOR-OPEN Door status: Open →
Door open count times Key ON
COUNT Closed
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9/11
SMIL14CEX0951EA 38
Judgment start
condition
A/C POWER ON A/C power ON time hour AC air flow duty = 0 Key ON
AC air flow level; time
A/C BLOWER-Lo hour AC air flow = Lo Key ON
distribution
A/C BLOWER-M1 hour AC air flow = M1 Key ON
distribution
distribution
distribution
distribution
A/C BLOWER-Hi hour AC air flow = Hi Key ON
distribution
Time during which
LIMIT CON- the AC air flow level AC air flow level
TROL(BLOWER is OFF by cold blast hour limited = Cold blast Key ON
OFF) prevention control prevention (OFF)
function
Time during which
the AC air flow level AC air flow level
LIMIT CON-
is Lo by cold blast hour limited = Blast Key ON
TROL(BLOWER LO)
prevention control prevention (Lo)
function
AC air flow level
LIMIT CON- AC air flow level is
hour limited = Door open Key ON
TROL(DOOR OPEN) limited by door open
control
control
COMPRESSOR ON AC compressor ON AC compressor relay
hour Key ON
TIME time = ON
COMPRESSOR ON AC compressor ON AC compressor relay
x 100 times Key ON
COUNT count OFF → ON
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10/11
SMIL14CEX0952EA 39
Judgment start
condition
TARGET TEMP. AC set temperature; Set temperature <
hour Key ON
COOL- MAX time distribution 18.5 °C (65.3 °F)
hour Key ON
RANGE 1 time distribution 22 °C (71.6 °F)
hour Key ON
hour Key ON
RANGE 3 time distribution 26.5 °C (79.7 °F)
hour Key ON
RANGE 4 time distribution 28.5 °C (83.3 °F)
hour Key ON
TARGET TEMP. AC set temperature; Set temperature
hour Key ON
HOT-MAX time distribution 32 °C (89.6 °F)
RECIRC.AIR TEMP Highest inside air
C (°F) Key ON
MAX temperature
RECIRC.AIR TEMP Lowest inside air
C (°F) Key ON
MIN temperature
INTAKE AIR TEMP Highest outside air
C (°F) Key ON
MAX temperature
INTAKE AIR TEMP Lowest outside air
C (°F) Key ON
MIN temperature
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11/11
SMIL14CEX0953EA 40
Judgment start
condition
Time during which
the AC air flow level
AUTO BLOW (Air flow = AUTO) +
auto control and the hour Key ON
VOLUME (Blow ≠ AUTO)
AC blow mode auto
control are used
Time during which
(Air flow ≠ AUTO) +
AUTO BLOW MODE auto control and the hour Key ON
(Blow = AUTO)
AC blow mode auto
control are used
Time during which
AUTO BLOW (Air flow = AUTO) +
auto control and the hour Key ON
VOLUME & MODE (Blow = AUTO)
AC blow mode auto
control are used
FACE MODE hour Blow mode = Face Key ON
blow mode is used
VENT MODE hour Blow mode = Vent Key ON
blow mode is used
FOOT MODE TIME hour Blow mode = Foot Key ON
blow mode is used
BI-LEVEL MODE hour Blow mode = Bi-level Key ON
blow mode is used
DEFROST MODE Time during which the
hour Blow mode = Defrost Key ON
TIME blow mode is used
A/C RECIRC.AIR Inside/Outside air
recirculate mode is hour Key ON
TIME setting = Inside air
selected
Time during which
Inside/Outside air
A/C FRESH AIR TIME the refresh mode is hour Key ON
setting = Outside air
selected
To switch to a page from 1 to 11, press the light switch while the WORK HISTORY screen is displayed, and select
the desired page.
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HYDRAULIC HISTORY
P1, P2, pilot pressure distribution, etc. can be displayed.
1/19
SMIL14CEX0954EA 41
Judgment start
condition
P1 pressure; time Less than 10 MPa
P1 PRESS RANGE 1 hour Engine in operation
distribution 1 (1450 psi)
P1 pressure; time 35 MPa (5077 psi) or
distribution 7 more
MPa
P1 PRESS MAX Maximum P1 pressure – Engine in operation
(psi)
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2/19
SMIL14CEX0955EA 42
Judgment start
condition
P2 pressure; time 35 MPa (5077 psi) or
distribution 7 more
MPa
P2 PRESS MAX Maximum P2 pressure – Engine in operation
(psi)
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3/19
SMIL14CEX0956EA 43
Judgment start
condition
N1 pressure; time
N1 PRESS RANGE 1 hour 1 MPa (145 psi) Engine in operation
distribution 1
N1 pressure; time Less than 1.5 MPa
N1 PRESS RANGE 2 hour Engine in operation
distribution 2 (217.6 psi)
N1 pressure; time Less than 2 MPa
N1 pressure; time 3.5 MPa (507.7 psi) or
distribution 7 more
MPa
N1 PRESS MAX Maximum N1 pressure – Engine in operation
(psi)
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4/19
SMIL14CEX0957EA 44
Judgment start
condition
N2 pressure; time
N2 PRESS RANGE 1 hour 1 MPa (145 psi) Engine in operation
distribution 1
N2 pressure; time 3.5 MPa (507.7 psi) or
distribution 7 more
MPa
N2 PRESS MAX Maximum N2 pressure – Engine in operation
(psi)
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5/19
SMIL14CEX0958EA 45
Judgment start
condition
P1 pressure during
TRAVEL P1 PRESS independent travel Less than 10 MPa
RANGE 1 operation; time (1450 psi)
distribution 1
P1 pressure during
distribution 2
P1 pressure during
distribution 3
P1 pressure during
distribution 4
P1 pressure during
distribution 5
P1 pressure during
distribution 6
P1 pressure during
TRAVEL P1 PRESS independent travel 35 MPa (5077 psi) or
RANGE 7 operation; time more
distribution 7
Maximum P1 pressure
MPa
TRAVEL P1 PRESS MAX during independent travel – Engine in operation
(psi)
operation
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6/19
SMIL14CEX0959EA 46
Judgment start
condition
P2 pressure during
distribution 1
P2 pressure during
distribution 2
P2 pressure during
distribution 3
P2 pressure during
distribution 4
P2 pressure during
distribution 5
P2 pressure during
distribution 6
P2 pressure during
TRAVEL P2 PRESS independent travel 35 MPa (5077 psi) or
RANGE 7 operation; time more
distribution 7
Maximum P2 pressure
MPa
TRAVEL P2 PRESS MAX during independent travel – Engine in operation
(psi)
operation
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7/19
SMIL14CEX0960EA 47
Judgment start
condition
P1+ P2 PRESS RANGE P1+ P2 pressure; time Less than 20 MPa
1 distribution 1 (2901 psi)
P1+ P2 PRESS RANGE P1+ P2 pressure; time 70 MPa (10154 psi) or
7 distribution 7 more
Maximum P1+ P2 MPa

P1+ P2 PRESS MAX – Engine in operation
pressure (psi)
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8/19
SMIL14CEX0961EA 48
Judgment start
condition
Hydraulic oil F
HYD.OIL FILTER PRESS Less than 0.1 MPa
clogging pressure; time hour Engine in operation
RANGE 1 (14.5 psi)
distribution 1
Hydraulic oil F
RANGE 2 (29.0 psi)
distribution 2
Hydraulic oil F
RANGE 3 (43.5 psi)
distribution 3
Hydraulic oil F
RANGE 4 (58.0 psi)
distribution 4
Hydraulic oil F
RANGE 5 (87.0 psi)
distribution 5
Hydraulic oil F
RANGE 6 (116.0 psi)
distribution 6
Hydraulic oil F
HYD.OIL FILTER PRESS 0.8 MPa (116.0 psi) or
RANGE 7 more
distribution 7
HYD.OIL FILTER PRESS Maximum hydraulic oil F MPa

– Engine in operation
MAX clogging pressure (psi)
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9/19
SMIL14CEX0962EA 49
Judgment start
condition
HYD.OIL TEMP RANGE Oil temperature; time In 10 s after the engine
hour Less than 45 °C (113 °F)
1 distribution 1 starts
hour 98 °C (208 °F) or more
Highest oil temperature In 10 s after the engine

HYD.OIL TEMP MAX °C (°F) –
in the past starts
Lowest oil temperature in In 10 s after the engine
HYD.OIL TEMP MIN °C (°F) –
the past starts
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10/19
SMIL14CEX0963EA 50
Judgment start
condition
Swing brake SOL ON
SWING BRAKE SOL hour The ON time is counted. Engine in operation
time
FREE SWING SOL Free swing SOL ON time hour The ON time is counted. Engine in operation
Travel 2-speed
TRAVEL 2 SPEED SOL switchover SOL ON hour The ON time is counted. Engine in operation
time
POWER BOOST SOL Boost SOL ON time hour The ON time is counted. Engine in operation
Breaker circuit switchover
BREAKER CIRC. SOL hour The ON time is counted. Engine in operation
SOL ON time
2 pumps flow SOL ON
2-PUMP SPEED SOL hour The ON time is counted. Engine in operation
time
Quick coupler SOL ON
QUICK COUPLER SOL hour The ON time is counted. Engine in operation
time
Fan reverse SOL ON
FAN REVERSE SOL hour The ON time is counted. Engine in operation
time
GATE LOCK SOL Gate lock SOL ON time hour The ON time is counted. Engine in operation
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11/19
SMIL14CEX0964EA 51
Judgment start
condition
Swing brake SOL ON The number of times of
SWING BRAKE SOL x 1000 times Engine in operation
count OFF → ON is counted.
Free swing SOL ON The number of times of
FREE SWING SOL times Engine in operation
Travel 2-speed
TRAVEL 2 SPEED The number of times of
switchover SOL ON x 1000 times Engine in operation
SOL OFF → ON is counted.
count
The number of times of
POWER BOOST SOL Boost SOL ON count times Engine in operation
OFF → ON is counted.
Breaker circuit
The number of times of
BREAKER CIRC. SOL switchover SOL ON times Engine in operation
OFF → ON is counted.
count
2 pumps flow SOL ON The number of times of
2-PUMP SPEED SOL times Engine in operation
QUICK COUPLER Quick coupler SOL ON The number of times of
SOL count OFF → ON is counted.
Fan reverse SOL ON The number of times of
FAN REVERSE SOL times Engine in operation
Gate lock SOL ON The number of times of
GATE LOCK SOL times Engine in operation
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12/19
SMIL14CEX0965EA 52
Judgment start
condition
PUMP 1 FLOW RATE P1 flow rate; time
hour Less than 40 % Engine in operation
RANGE 1 distribution 1
hour 90 % or more Engine in operation
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13/19
SMIL14CEX0966EA 53
Judgment start
condition
RANGE1 distribution 1
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14/19
SMIL14CEX0967EA 54
Judgment start
condition
PUMP 1+2 FLOW RATE P1+P2 flow rate;
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15/19
SMIL14CEX0968EA 55
Judgment start
condition
BOOM CYL.BTM PRESS Boom CYL bottom Less than 10 MPa
RANGE 1 pressure; distribution 1 (1450 psi)
BOOM CYL.BTM PRESS Boom CYL bottom 35 MPa (5077 psi) or
RANGE 7 pressure; distribution 7 more
BOOM CYL.BTM PRESS Maximum boom CYL MPa

MAX bottom pressure (psi)
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16/19
SMIL14CEX0969EA 56
Judgment start
condition
BOOM CYL.ROD Boom CYL rod pressure; Less than 10 MPa
PRESS RANGE 1 distribution 1 (1450 psi)
BOOM CYL.ROD Boom CYL rod pressure; 35 MPa (5077 psi) or
PRESS RANGE 7 distribution 7 more
BOOM CYL.ROD Maximum boom CYL rod MPa

PRESS MAX pressure (psi)
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17/19
SMIL14CEX0970EA 57
Judgment start
condition
Arm CYL bottom
ARM CYL.BTM PRESS Less than 10 MPa
pressure; distribution hour Engine in operation
RANGE 1 (1450 psi)
1
Arm CYL bottom
RANGE 2 (2176 psi)
2
Arm CYL bottom
RANGE 3 (2901 psi)
3
Arm CYL bottom
RANGE 4 (3626 psi)
4
Arm CYL bottom
RANGE 5 (4352 psi)
5
Arm CYL bottom
RANGE 6 (5077 psi)
6
Arm CYL bottom
ARM CYL.BTM PRESS 35 MPa (5077 psi) or
RANGE 7 more
7
ARM CYL.BTM PRESS Maximum arm CYL MPa

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18/19
SMIL14CEX0971EA 58
Judgment start
condition
Arm CYL bottom
ARM CYL.ROD PRESS Less than 10 MPa
RANGE 1 (1450 psi)
1
Arm CYL bottom
RANGE 2 (2176 psi)
2
Arm CYL bottom
RANGE 3 (2901 psi)
3
Arm CYL bottom
RANGE 4 (3626 psi)
4
Arm CYL bottom
RANGE 5 (4352 psi)
5
Arm CYL bottom
RANGE 6 (5077 psi)
6
Arm CYL bottom
ARM CYL.ROD PRESS 35 MPa (5077 psi) or
RANGE 7 more
7
ARM CYL.ROD PRESS Maximum arm CYL MPa

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19/19
SMIL14CEX0972EA 59
Judgment start
condition
PUMP BACKUP1 Pump backup 1; Pump backup 1 OFF →
COUNT occurrence count ON
Pump backup 1;
PUMP BACKUP1 TIME hour Pump backup 1 = ON Engine in operation
occurrence time
PUMP BACKUP2 Pump backup 2; Pump backup 2 OFF →
Pump backup 2;
PUMP BACKUP2 TIME hour Pump backup 2 = ON Engine in operation
occurrence time
VALVE BACKUP1 Valve backup 1; Valve backup 1 OFF →

Valve backup 1;
VALVE BACKUP1 TIME hour Valve backup 1 = ON Engine in operation
occurrence time
VALVE BACKUP2 Valve backup 2; Valve backup 2 OFF →
Valve backup 2;
VALVE BACKUP2 TIME hour Valve backup 2 = ON Engine in operation
occurrence time
To switch to a page from 1 to 19, press the light switch while the HYDRAULIC HISTORY screen is displayed, and
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ENGINE HISTORY
The engine speed, coolant temperature, fuel temperature, intake air temperature distribution, etc. can be displayed.
1/31
SMIL14CEX0973EA 60
Judgment start
condition
Actual speed; time
ACTUAL SPEED RANGE 1 hour Less than 1025 RPM Engine in operation
distribution
Actual speed; time
distribution
Actual speed; time
distribution
Actual speed; time
distribution
Actual speed; time
distribution
Actual speed; time
distribution
Actual speed; time
ACTUAL SPEED RANGE 7 hour 2025 RPM or more Engine in operation
distribution
Maximum value of actual

ACTUAL SPEED MAX min-1 – Engine in operation
speed
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2/31
SMIL14CEX0974EA 61
Judgment start
condition
Coolant temperature; In 10 s after the engine
COOLANT TEMP RANGE 1 hour Less than 77 °C
time distribution starts
Coolant temperature; In 10 s after the engine
Actual speed; time In 10 s after the engine
distribution starts
distribution starts
distribution starts
distribution starts
COOLANT TEMP RANGE 7 hour 105 °C or more
distribution starts
Maximum value of In 10 s after the engine

COOLANT TEMP MAX °C (°F) –
coolant temperature starts
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3/31
SMIL14CEX0975EA 62
Judgment start
condition
HOT SHUTDOWN Hot shutdown count times No cooling time Engine in operation
COOL SHUTDOWN Cooling operation count times Total of the following: Engine in operation
COOLDOWN TIME RANGE Cooling time; count
times Less than 10 s Engine in operation
1 distribution
2 distribution
3 distribution
4 distribution
5 distribution
times 180 s or more Engine in operation
6 distribution
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Judgment start
condition
Fuel temperature; time In 10 s after the engine
FUEL TEMP RANGE 1 hour Less than 40 °C
distribution starts
distribution starts
distribution starts
distribution starts
distribution starts
distribution starts
FUEL TEMP RANGE 7 hour 90 °C or more
distribution starts
Maximum value of fuel In 10 s after the engine
FUEL TEMP MAX °C (°F) –
temperature starts
Minimum value of fuel In 10 s after the engine
FUEL TEMP MIN °C (°F) –
temperature starts
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Judgment start
condition
Suction air temperature; In 10 s after the engine
INLET AIR TEMP RANGE 1 hour Less than –20 °C
INLET AIR TEMP RANGE 2 hour Less than 0 °C
INLET AIR TEMP RANGE 7 hour 60 °C or more
Maximum value of inlet In 10 s after the engine

INLET AIR TEMP MAX °C (°F) –
air temperature starts
Minimum value of inlet In 10 s after the engine
INLET AIR TEMP MIN °C (°F) –
air temperature starts
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Judgment start
condition
Boost temperature; time In 10 s after the engine
BOOST TEMP RANGE 1 hour Less than 0 °C
distribution starts
distribution starts
distribution starts
distribution starts
distribution starts
distribution starts
BOOST TEMP RANGE 7 hour 80 °C or more
distribution starts
Maximum value of boost In 10 s after the engine

BOOST TEMP MAX °C (°F) –
temperature starts
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Judgment start
condition
Barometric pressure; In 10 s after the engine
BARO PRESS RANGE 1 hour Less than 60 kPa
BARO PRESS RANGE 7 hour 105 kPa or more
Maximum value of boost kPa In 10 s after the engine

BARO PRESS MIN –
temperature (psi) starts
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Judgment start
condition
Oil pressure; time In 10 s after the engine
OIL PRESS RANGE 1 hour Less than 0 kPa
distribution starts
distribution starts
distribution starts
distribution starts
distribution starts
distribution starts
OIL PRESS RANGE 7 hour 750 kPa or more
distribution starts
Maximum value of oil kPa In 10 s after the engine

OIL PRESS MAX –
pressure (psi) starts
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Judgment start
condition
OIL PRESS RISE TIME Oil pressure rise time;
times Less than 2 s –
RANGE 1 count distribution
times 30 s or more –
OIL PRESS RISE TIME Maximum value of oil

sec – –
MAX pressure rise time
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Judgment start
condition
Boost pressure; time In 10 s after the engine
BOOST PRESS RANGE 1 hour Less than 100 kPa
distribution starts
distribution starts
distribution starts
distribution starts
distribution starts
distribution starts
BOOST PRESS RANGE 7 hour 300 kPa or more
distribution starts
Maximum value of boost kPa In 10 s after the engine

BOOST PRESS MAX –
pressure (psi) starts
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Judgment start
condition
Load ratio; time In 10 s after the engine
LOAD RATIO RANGE 1 hour Less than 30%
distribution starts
distribution starts
distribution starts
distribution starts
distribution starts
distribution starts
LOAD RATIO RANGE 7 hour 80% or more
distribution starts
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SMIL14CEX0983EA 71
Judgment start
condition
distribution starts
distribution starts
distribution starts
distribution starts
distribution starts
distribution starts
LOAD RATIO RANGE 7 hour 80% or more
distribution starts
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SMIL14CEX0985EA 72
Judgment start
condition
Load ratio (H); time In 10 s after the engine
LOAD RATIO H RANGE 1 hour Less than 30%
distribution starts
distribution starts
distribution starts
distribution starts
distribution starts
distribution starts
LOAD RATIO H RANGE 7 hour 80% or more
distribution starts
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SMIL14CEX0986EA 73
Judgment start
condition
Load ratio (A); time In 10 s after the engine
LOAD RATIO A RANGE 1 hour Less than 30%
distribution starts
distribution starts
distribution starts
distribution starts
distribution starts
distribution starts
LOAD RATIO A RANGE 7 hour 80% or more
distribution starts
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Judgment start
condition
Supply pump inlet
SUPPLY PUMP PRESS In 10 s after the engine
pressure; time hour Less than -40 kPa
RANGE 1 starts
distribution
Supply pump inlet
RANGE 2 starts
distribution
Supply pump inlet
RANGE 3 starts
distribution
Supply pump inlet
RANGE 4 starts
distribution
Supply pump inlet
pressure; time hour Less than 0 kPa
RANGE 5 starts
distribution
Supply pump inlet
pressure; time hour Less than 10 kPa
RANGE 6 starts
distribution
Supply pump inlet
pressure; time hour 10 kPa or more
RANGE 7 starts
distribution
SUPPLY PUMP PRESS Load ratio (A); time kPa In 10 s after the engine
–
MIN distribution (psi) starts
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Judgment start
condition
DOC inlet temperature; In 10 s after the engine
DOC IN TEMP RANGE 1 hour Less than 200 °C
DOC IN TEMP RANGE 7 hour 700 °C or more

DOC IN TEMP MAX °C (°F) –
distribution starts
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Judgment start
condition
DOC outlet temperature; In 10 s after the engine
DOC OUT TEMP RANGE 1 hour Less than 200 °C
DOC OUT TEMP RANGE 7 hour 700 °C or more
Maximum value of DOC In 10 s after the engine

DOC OUT TEMP MAX °C (°F) –
outlet temperature starts
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Judgment start
condition
SCR inlet temperature; In 10 s after the engine
SCR IN TEMP RANGE 1 hour Less than 200 °C
SCR IN TEMP RANGE 7 hour 700 °C or more
Maximum value of SCR In 10 s after the engine

SCR IN TEMP MAX °C (°F) –
inlet temperature starts
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Judgment start
condition
EGR#1 inlet
In 10 s after the engine
EGR#1 IN TEMP RANGE 1 temperature; time hour Less than 200 °C
starts
distribution
EGR#1 inlet
starts
distribution
EGR#1 inlet
starts
distribution
EGR#1 inlet
starts
distribution
EGR#1 inlet
starts
distribution
EGR#1 inlet
starts
distribution
EGR#1 inlet
EGR#1 IN TEMP RANGE 7 temperature; time hour 700 °C or more
starts
distribution

EGR#1 IN TEMP MAX °C (°F) –
EGR#1 inlet temperature starts
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Judgment start
condition
EGR#1 outlet
EGR#1 OUT TEMP RANGE In 10 s after the engine
temperature; time hour Less than 50 °C
1 starts
distribution
EGR#1 outlet
2 starts
distribution
EGR#1 outlet
3 starts
distribution
EGR#1 outlet
4 starts
distribution
EGR#1 outlet
5 starts
distribution
EGR#1 outlet
6 starts
distribution
EGR#1 outlet
temperature; time hour 150 °C or more
7 starts
distribution
Maximum value
EGR#1 OUT TEMP MAX of EGR#1 outlet °C (°F) –
starts
temperature
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Judgment start
condition
EGR#2 inlet
starts
distribution
EGR#2 inlet
starts
distribution
EGR#2 inlet
starts
distribution
EGR#2 inlet
starts
distribution
EGR#2 inlet
starts
distribution
EGR#2 inlet
starts
distribution
EGR#2 inlet
EGR#2 IN TEMP RANGE 7 temperature; time hour 700 °C or more
starts
distribution

EGR#2 IN TEMP MAX °C (°F) –
EGR#2 inlet temperature starts
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Judgment start
condition
EGR#2 outlet
1 starts
distribution
EGR#2 outlet
2 starts
distribution
EGR#2 outlet
3 starts
distribution
EGR#2 outlet
4 starts
distribution
EGR#2 outlet
5 starts
distribution
EGR#2 outlet
6 starts
distribution
EGR#2 outlet
7 starts
distribution
Maximum value
EGR#2 OUT TEMP MAX of EGR#2 outlet °C (°F) –
starts
temperature
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Judgment start
condition
Intercooler inlet
INTER COOLER TEMP In 10 s after the engine
RANGE 1 starts
distribution
Intercooler inlet
RANGE 2 starts
distribution
Intercooler inlet
RANGE 3 starts
distribution
Intercooler inlet
RANGE 4 starts
distribution
Intercooler inlet
RANGE 5 starts
distribution
Intercooler inlet
RANGE 6 starts
distribution
Intercooler inlet
RANGE 7 starts
distribution
Maximum value
of intercooler inlet °C (°F) –
MAX starts
temperature
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Judgment start
condition
Intake manifold
MANIFOLD TEMP RANGE In 10 s after the engine
1 starts
distribution
Intake manifold
2 starts
distribution
Intake manifold
3 starts
distribution
Intake manifold
4 starts
distribution
Intake manifold
5 starts
distribution
Intake manifold
6 starts
distribution
Intake manifold
7 starts
distribution
Maximum value of intake In 10 s after the engine

MANIFOLD TEMP MAX °C (°F) –
manifold temperature starts
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Judgment start
condition
Urea solution
DEF/AdBLUE TEMP In 10 s after the engine
temperature (tank); hour Less than -12 °C
(TANK)RANGE 1 starts
time distribution
Urea solution
temperature (tank); hour Less than 0 °C
time distribution
Urea solution
time distribution
Urea solution
time distribution
Urea solution
time distribution
Urea solution
time distribution
Urea solution
temperature (tank); hour 80 °C or more
time distribution
Maximum value of urea

DEF/AdBLUE TEMP (TANK) In 10 s after the engine
solution temperature °C (°F) –
MAX starts
(tank)
Minimum value of urea
DEF/AdBLUE TEMP (TANK) In 10 s after the engine
MIN starts
(tank)
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Judgment start
condition
Urea solution
DEF/AdBLUE TEMP (S/ In 10 s after the engine
temperature (S/M); hour Less than -12 °C
M)RANGE 1 starts
time distribution
Urea solution
temperature (S/M); hour Less than 0 °C
M)RANGE 2 starts
time distribution
Urea solution
M)RANGE 3 starts
time distribution
Urea solution
M)RANGE 4 starts
time distribution
Urea solution
M)RANGE 5 starts
time distribution
Urea solution
M)RANGE 6 starts
time distribution
Urea solution
temperature (S/M); hour 80 °C or more
M)RANGE 7 starts
time distribution
Maximum value of urea

DEF/AdBLUE TEMP (S/M) In 10 s after the engine
MAX starts
(S/M)
Minimum value of urea
DEF/AdBLUE TEMP (S/M) In 10 s after the engine
MIN starts
(S/M)
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Judgment start
condition
Urea solution
DEF/AdBLUE CONCE. In 10 s after the engine
concentration; time hour Less than 15%
RANGE 1 starts
distribution
Urea solution
RANGE 2 starts
distribution
Urea solution
RANGE 3 starts
distribution
Urea solution
RANGE 4 starts
distribution
Urea solution
RANGE 5 starts
distribution
Urea solution
RANGE 6 starts
distribution
Urea solution
concentration; time hour 40% or more
RANGE 7 starts
distribution
DEF/AdBLUE CONCE. Maximum value of urea In 10 s after the engine

°C (°F) –
MAX solution concentration starts
Minimum value of urea In 10 s after the engine
DEF/AdBLUE CONCE. MIN °C (°F) –
solution concentration starts
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Judgment start
condition
Urea solution
DEF/AdBLUE PRESS In 10 s after the engine
concentration; time hour Less than 200 kPa
RANGE 1 starts
distribution
Urea solution
RANGE 2 starts
distribution
Urea solution
RANGE 3 starts
distribution
Urea solution
RANGE 4 starts
distribution
Urea solution
RANGE 5 starts
distribution
Urea solution
RANGE 6 starts
distribution
Urea solution
concentration; time hour 1200 kPa or more
RANGE 7 starts
distribution
Maximum value of urea kPa In 10 s after the engine

DEF/AdBLUE PRESS MAX –
solution pressure (psi) starts
Minimum value of urea kPa In 10 s after the engine
DEF/AdBLUE PRESS MIN –
solution pressure (psi) starts
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Judgment start
condition
COMMON RAIL PRESS Common rail pressure; In 10 s after the engine
hour Less than 40 MPa
RANGE 1 time distribution starts
hour 240 MPa or more
COMMON RAIL PRESS Maximum value of MPa In 10 s after the engine

–
MAX common rail pressure (psi) starts
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Judgment start
condition
Common rail differential
COMMON RAIL DIFF In 10 s after the engine
pressure; time hour Less than 5 MPa
PRESS RANGE 1 starts
distribution
distribution
distribution
distribution
distribution
distribution
pressure; time hour 30 MPa or more
distribution
Maximum value of
COMMON RAIL DIFF MPa In 10 s after the engine
common rail differential –
PRESS MAX (psi) starts
pressure
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Judgment start
condition
Auto SCR cleaning start When auto SCR
AUTO CLEANING START times Engine in operation
count cleaning is started
Auto SCR cleaning When auto SCR
AUTO CLEANING FINISH times Engine in operation
completion count cleaning is completed
MANUAL CLEANING Manual SCR cleaning When manual SCR
START start count cleaning is started
MANUAL CLEANING Manual SCR cleaning When manual SCR
FINISH completion count cleaning is completed
x1 When escape mode is
ESCAPE MODE START Escape mode start count Engine ON
times started
To switch to a page from 1 to 31, press the light switch while the ENGINE HISTORY screen is displayed, and
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DEVICE TEST
ECM/DCU memory clear

Purpose
• To reset the DIAG mode, and delete the engine diagnostic trouble codes in ECM.
SMIL14CEX1104EB 91
Display Explanation Unit Remarks

ECM MEMORY CLEAR ECM memory clear – The ECM memory is cleared
DCU MEMORY CLEAR DCU memory clear – The DCU memory is cleared
COMPONENT REPLACEMENT – –
Items selectable. Initialization can
DCU DCU replacement notice – be performed after the component
is replaced.
Oxidation catalyst replacement
OXI. CATALYST – be performed after the component
notice
is replaced.
SCR CATALYST SCR filter replacement notice – be performed after the component
is replaced.
Dosing module replacement
DOSING MODULE – be performed after the component
notice
is replaced.
NOx SENSOR NOx sensor replacement notice – be performed after the component
is replaced.
SCR temperature sensor
SCR TEMP SENSOR – be performed after the component
replacement notice
is replaced.
Condition for the test

• The key is ON.
Execution
• Select “ECM MEMORY CLEAR” (ECM memory clear) or “DCU MEMORY CLEAR” (DCU memory clear) using SW
(3) and (4).
• Hold down SW (2) for 3 s, and “ ” changes to “ ”.
• The engine diagnostic trouble codes in ECM will be deleted right away.
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SCR cleaning
Purpose
• If MANUAL SCR CLEANING fails and the diagnostic trouble code appears, SCR CLEANING is carried out forcedly.
SMIL14CEX6788EB 92

SCR CLEANING START(AUTO) AUTO SCR CLEANING starts
SCR CLEANING START(MAN-
MANUAL SCR CLEANING starts
UAL)
SCR CLEANING STOP SCR CLEANING stops
min-1
ENGINE SPEED Actual engine speed
(rpm)
ENGINE LOAD RATIO Engine torque (load ratio) %
COOLANT TEMP Coolant temperature degC
DOC INLET TEMP DOC inlet temperature degC
DOC OUTLET TEMP DOC outlet temperature degC
SCR INLET TEMP SCR inlet temperature degC
HYD.LOAD SOL Hydraulic pressure load solenoid on/off
PUMP TILT P.SOL Pump tilting proportional valve mA

• None.
Execution
• Select "SCR CLEANING START(AUTO)" (AUTO SCR CLEANING start) or "SCR CLEANING START(MANUAL)"
(MANUAL SCR CLEANING start) using SW (3) and (4).
• Hold down SW (2) for 3 s, then " " changes to " " and the test starts.
• The test for AUTO SCR CLEANING and that for MANUAL SCR CLEANING will continue for approx. 10 min and
approx. 18 min respectively.
Test finish
• In approx. 10 min for AUTO SCR CLEANING or approx. 18 min for MANUAL SCR CLEANING, the engine will
automatically return to the normal state.
Urea line leak test

Purpose
• To check the urea line for leaks.
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SMIL14CEX4182EB 93

DEF/AdBlue LEAK TEST Urea line leak test –
min-1
(rpm)
SCR INLET TEMP SCR inlet temperature degC
KPa
DEF/AdBlue PRESS Urea pressure
(psi)
SUPPLY MODULE DUTY Supply module DUTY %
DOSING VALVE DUTY Dosing DUTY %
Test execution
• Select "DEF/AdBlue LEAK TEST" (urea line leak test) using SW (3) and (4). Hold down SW (2) for 3 s, then " "
changes to " " and the test starts. The test will be continued for 10 s.
Test finish
• After 10 s, the engine automatically returns to the normal state.
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CCV operation test

Purpose
• To check the coolant control valve operation.
SMIL14CEX4183EB 94

Items selectable. Select ++++ and
TARGET STATUS Coolant control valve status on/off ---- when it is open and closed
respectively. (Initial value: ----)
Coolant control valve operation The coolant control valve is driven
COOLANT C/V TEST –
test (for 10 s).
min-1
COOLANT C/V Coolant control valve operation on++++, off----
(rpm)
ENGINE SPEED Actual engine speed %
ENGINE LOAD RATIO Engine torque (load ratio) degC
COOLANT TEMP Coolant temperature degC
DEF/AdBlue TEMP(TANK) Urea temperature (inside tank) degC
DEF/AdBlue TEMP(S/M) degC
module)
KPa
(psi)
SUPPLY MODULE DUTY Supply module DUTY %

• None
Set the CCV status

• Select "TARGET STATUS" (coolant control valve status) using SW (3) and (4).
• Use SW (1) and SW (2) to turn it OFF and ON respectively.
• After the setting is completed, press SW (5).
Test execution
• Select "COOLANT C/V TEST" (coolant control valve operation test) using SW (3) and (4).
• The test will be continued for 10 s.
Test finish
• After 10 s the engine automatically returns to normal state.
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Dosing test
Purpose
• To check the dosing valve operation.
SMIL14CEX4184EB 95

Items selectable. The degree of
TARGET DUTY Degree of opening of dosing valve % opening of the dosing valve can
be specified. Initial value: 50.0
The dosing valve is driven (for
DOSING VALVE TEST Dosing valve test –
10 s).

kPa
(psi)
module)
Condition for test

• The engine is stopped.
Set the target dosing valve position.

• Select "TARGET DUTY" (degree of opening target dosing valve) using SW (3) and (4).
• Press SW (1) and (2) to set the target test position.
• Available set range: 0 - 100 %
Test execution
• Select "DOSING VALVE TEST" (dosing valve test) using SW (3) and (4).
• Hold down SW (2) for 3 s, then “ ” changes to “ ” and the test starts.
Test finish
Reverting valve operation test

Purpose
• To check the reverting valve operation.
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SMIL14CEX4195EB 96

Items selectable. Select ++++ and
TARGET STATUS Reverting valve status on/off ---- when it is open and closed
respectively. (Initial value: ----)
The reverting valve is driven (for
REVERTING VALVE TEST Reverting valve test –
10 s).
REVERTING VALVE Actual reverting valve status on/off on++++, off----

kPa
(psi)
module)

• The engine is not stopped or frozen.
Set the reverting valve status

• Select "TARGET STATUS" (reverting valve status) using SW (3) and (4).
• Use SW (1) and SW (2) to turn it OFF and ON respectively.
Test execution
• Select "REVERTING VALVE TEST" (reverting valve test) using SW (3) and (4).
Test finish
• After 10 s, the engine automatically returns to normal state.
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Common rail pressure test

Purpose
• To check that the common rail pressure has increased as the ECM commands.
SMIL14CEX1105EB 97

Items selectable. The common
MPa
TARGET PRESS Target common rail pressure rail pressure can be set. Initial
(psi)
value: 50
The common rail pressure test is
C.RAIL PRESS TEST Common rail pressure test –
conducted (for 10 s).
MPa
C. RAIL PRESS Common rail pressure
(psi)
MPa
C. RAIL DIFF. PRESS Common rail differential pressure
(psi)
min-1
(rpm)

• The engine is running [ 550 - 3000 RPM 550 min-1 (550 rpm) to 3000 min-1 (3000 rpm)].
Set the target common rail pressure.

• Select "TARGET PRESS" (target common rail pressure) using SW (3) and (4).
• Available set range: 30 - 80 MPa (4352 - 11604 psi)
Test execution
• Select "C.RAIL PRESS TEST" (common rail pressure test) using SW (3) and (4).
Test finish
• After 10 s., the engine automatically returns to normal state.
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Idle Speed Test / Injector Test
SMIL14CEX1107EB 98

Items selectable. The engine
min-1
TARGET SPEED target engine speed speed can be increased or
(rpm)
decreased from the current one.*
The engine is driven at the
IDLE SPEED TEST Idle speed test –
specified idle speed (for 100 s).
Items selectable. The injector to

test can be selected. (Selectable
TARGET CYLINDER# Injector selection – up to 4 and 6 for the 4-cylindered
and the 6-cylindered one
respectively.)
The selected injector is stopped
INJ. BALANCE TEST Injector balance test –
(for 10 s).
The selected injector is driven (for
INJ. FORCED DRIVE TEST Injector forced drive –
10 s).
min-1
(rpm)
1. Idle speed test
Purpose
• The desired engine speed can be attained.
NOTE: For example, when the current engine speed is 1000 RPM , selecting -200 can attain 800 RPM.

• The engine is running [ 300 - 1500 RPM].
Setting of target engine speed (RPM)

• Select "TARGET SPEED" (idle speed) using SW (3) and (4).
• Press SW (1) and (2) to specify the target idle speed.
• Available set range: -500 RPM (low idle speed) to +500 RPM
Test execution
• Select "IDLE SPEED TEST" (idle speed test) using SW (3) and (4).
• Hold down SW (2) for 3 s, then “ ” changes to “ ”. Then, the set engine speed is attained and maintained for
100 s.
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Test finish
• In 100 s, the engine will automatically return to the normal state.
2. Injector balance test
Purpose
• If the engine speed is low, one of the injectors can be stopped to check the condition of the injector.

• The engine is running [ 300 - 1500 RPM].
Set the engine speed to a low idle, and select an injector.

• Select "TARGET SPEED" (idle speed) using SW (3) and (4).
• Press SW (1) and (2) to specify the target idle speed.
• Available set range: -500 RPM (low idle speed) to +500 RPM
• Select "TARGET CYLINDER#" (injector selection) using SW (3) and (4).
• Press SW (1) and (2) to set the injector number to stop.
Test execution
• Select "IDLE SPEED TEST" (idle speed test) using SW (3) and (4).
• Hold down SW (2) for 3 s, then “ ” changes to “ ”. Then, the set engine speed is attained and maintained for
100 s.
• While the set engine speed is attained, select "INJ. BLANCE TEST" (injector balance test) using SW (3) and (4).
• Hold down SW (2) for 3 s, then "- - - -" changes to "+ + + +" and the test starts.
• The test will continue for 10 s.
Test finish
3. Injector forced drive test
Purpose
• The injector operation can be checked.

• The engine is stopped with the key ON.
• The common rail pressure shall be 5 MPa (725 psi) or less.
Select the injector applicable for a forced drive.

• Select "TARGET CYLINDER#" (injector selection) using SW (3) and (4).
• Press SW (1) and (2) to set the cylinder number.
Test execution
• Select "INJ.FORCED DRIVE TEST" (injector forced drive test) using SW (3) and (4).
• The test will continue for 10 s.
Test finish
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EGR valve control test

Purpose
• To check the EGR valve operation.
SMIL14CEX4185EB 99

Degree of opening of target EGR
TARGET OPENING % opening of the EGR valve can be
valve
specified. Initial value: 50.0
EGR VALVE TEST EGR valve test – The EGR valve is driven (for 10 s).
EGR #1 VALVE OPENING Degree of opening of EGR #1 %

min-1
(rpm)
kPa
BOOST PRESS Boost pressure
(psi)
VG TURBO OPENING VG turbo opening (degree) %
INTAKE TH. OPENING Intake throttle opening (degree) %

• The key is ON, or the engine is running [ 1500 RPM or less].
Set the target EGR valve position (%).

• Select "TARGET OPENING" (target EGR valve) using SW (3) and (4).
Test execution
• Select "EGR VALVE TEST" (EGR valve test) using SW (3) and (4).
Test finish
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VG turbo control test

Purpose
• To check the VG turbo operation.
SMIL14CEX4186EB 100

Degree of opening of target VG
TARGET OPENING % opening of the VG turbo can be
turbo
VG TURBO TEST G turbo test – The VG turbo is driven (for 10 s).
VG TURBO OPENING Degree of opening of EGR #1 %
min-1
(rpm)
kPa
BOOST PRESS Boost pressure
(psi)
INTAKE TH. OPENING Intake throttle opening (degree %

Set the target VG turbo (%).

• Select "TARGET OPENING" (degree of opening of target VG turbo) using SW (3) and (4).
Test execution
• Select "VGT TURBO TEST" (VG turbo test) using SW (3) and (4).
Test finish
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Intake throttle control test

Purpose
• To check the intake throttle operation.
SMIL14CEX1108EB 101

Degree of opening of target intake
TARGET OPENING % opening of the VG turbo can be
throttle
The intake throttle is driven (for
INTAKE TH. TEST Intake throttle test –
10 s).
INTAKE TH. OPENING Intake throttle opening (degree) %

Setting the target intake throttle valve (%)

• Select "TARGET OPENING" (target intake throttle) using SW (3) and (4).
Test execution
• Select "INTAKE TH. TEST" (intake throttle test) using SW (3) and (4).
Test finish
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CONTROL UNIT
SMIL14CEX1109EA 102
Refer to the attached sheet for the types of sections in the “CONTROL UNIT” mode and their descriptions.
By pressing and on the monitor, MCM-MAIN, MCM-SUB1, etc. can be selected. Detailed data for the selected
item can be seen by pressing .
MCM-MAIN
1/7
SMIL14CEX1110EA 103

SWITCH IN 1-6 Switch input (0: OFF, 1: ON) –
COMPARATOR IN 1-4 Comparator input (0: OFF, 1: ON)
FREQUENCY IN Frequency input Hz
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2/7
SMIL14CEX1111EA 104

NPN OUT TARGET 1-4 Command value of NPN output (0: OFF, 1: ON) –
NPN OUT ACTUAL 1-4 Actual value of NPN output (0: OFF, 1: ON) –
PNP OUT TARGET 1-6 Command value of PNP output (0: OFF, 1: ON) –
PNP OUT TARGET 7-12 Command value of PNP output (0: OFF, 1: ON) –
PNP OUT TARGET 13 Command value of PNP output (0: OFF, 1: ON) –
PNP OUT ACTUAL 1-6 Actual value of PNP output (0: OFF, 1: ON) –
PNP OUT ACTUAL 7-12 Actual value of PNP output (0: OFF, 1: ON) –
PNP OUT ACTUAL 13 Actual value of PNP output (0: OFF, 1: ON) –
12 Voutput (0: OFF, 1: ON, 2: Disconnection,

EXT.POWER OUTPUT 12 V –
3: Overcurrent)
5 V output (0: OFF, 1: ON, 2: Disconnection, 3:
EXT.POWER OUTPUT 5 V –
Overcurrent)
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3/7
SMIL14CEX1112EA 105

POTENTIO IN 1 Potentio-meter input voltage v
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4/7
SMIL14CEX1113EA 106

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5/7
SMIL14CEX1114EA 107

SENSOR IN 1 Resistance of sensor input 1 Ω
SENSOR IN 2 Resistance of sensor input 2 Ω
SENSOR IN 1 Voltage of sensor 1 v
SENSOR IN 2 Voltage of sensor 2 v
6/7
SMIL14CEX1115EA 108

PWM OUT 1 TARGET PWM target current mA
ACTUAL Actual current mA
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7/7
SMIL14CEX1116EA 109

To switch to a page from 1 to 7, press the light switch while the CONTROLLER MAIN screen is displayed, and
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MCM-SUB
1/3
SMIL14CEX1117EA 110

SWITCH IN 1-6 Switch input (0: OFF, 1: ON)
SWITCH IN 7-8 Switch input (0: OFF, 1: ON)
PNP OUT TARGET 1-4 PNP output command (0: OFF, 1: ON)
PNP output status (0: OFF, 1: ON, 2:
PNP OUT ACTUAL 1-4
Disconnection, 3: Overcurrent)
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2/3
SMIL14CEX1118EA 111

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3/3
SMIL14CEX1119EA 112

X-ACCELERRATION Acceleration
Y-ACCELERRATION Acceleration
Z-ACCELERRATION Acceleration
X-ANGULAR VELOCITY Angular acceleration

Y-ANGULAR VELOCITY Angular acceleration
Z-ANGULAR VELOCITY Angular acceleration
To switch to a page from 1 to 3, press the light switch while the MCM-SUB screen is displayed, and select the
desired page.
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COMMU. TERMINAL
1/3
SMIL14CEX1120EA 113

Satellite communication capture status
SATELLITE CAPTURED 1: GPS positioning 0-3
TRANSMIT GCC NUMBER Transmitting GCC number 0 - 130
CAPTURED GCC1 NUMBER Captured GCC1 number 0 - 130
CAPTURED GCC2 NUMBER Captured GCC2 number 0 - 130
Registration (initial setting communication)
RESISTRATION STATUS –
status
Transmitting/receiving status (Transmitting/
Tx/Rx STATUS –
receiving/idling)
Tx WAITING MESSAGE Number of messages waiting to be transmitted –
DISABLE TRANSMISSION Setting to disable transmission –
TIME TO NEXT Tx Time to next transmission hr.min
SERIAL NO. Serial number of terminal
ACTIVATE
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2/3
SMIL14CEX1121EA 114

ELEC.WAVE STRENGTH Strength of electric wave db
OTA OTA status –
OTASP OTASP status –
OTAPA OTAPA status –
Registration (initial setting communication)
RESISTRATION STATUS –
status
Transmitting/receiving status (Transmitting/
Tx/Rx STATUS –
receiving/idling)
Tx WAITING MESSAGE Number of messages waiting to be transmitted –
DISABLE TRANSMISSION Setting to disable transmission –
TIME TO NEXT Tx Time to next transmission hr.min
SERIAL NO. Serial number of terminal
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3/3
SMIL14CEX1122EA 115

LATITUDE1 GPS latitude 1 (deg.) 0 - 9999 °
LATITUDE2 GPS latitude 2 (min.) 0 - 99.99 ‘
LONGITUDE1 GPS longitude 1 (deg.) 0 - 9999 °
LONGITUDE2 GPS longitude 2 (min.) 0 - 99.99 ‘
ALTITUDE Altitude 0 - 9999 m
UTC(YEAR) Universal Time (year) 0 - 9999
UTC(MONTH.DAY) Universal Time (month, day) 0 - 12.31
UTC(HOUR) Universal Time (hour) 0 - 23
UTC(MIN.SEC) Universal Time (min., sec.) 0 - 59.59
GPS positioning status
GPS STATUS 1: GPS positioning 0-3
To switch to a page from 1 to 3, press the light switch while the “COMMU.TERMINAL” screen is displayed, and
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Instrument cluster - Overview - SETUP screen list

The model selection, work mode speed, etc. can be
changed.
SMIL14CEX1123AA 1
By pressing and on the monitor, MACHINE SELECT, DIMENSION, etc. can be selected.
Detailed data for the selected item can be seen by pressing .
MACHINE SELECT
Machine's destination information, etc. are registered.
Model selection
SMIL14CEX1124EA 2
MODEL Model
TERRITORY Destination
BRAND Brand
ATT. TYPE Attachment type
1st. OPTION LINE 1st option line circuit
RELIEF PRESS. Electrical option pressure adjustment
OPERATION TYPE Operating method
2nd. OPTION LINE 2nd option line circuit
QUICK COUPLER Quick coupler
OVERLOAD WARNING Overload warning
ANTI-INTERFERENCE Interference prevention
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Model
Model Remarks
120–7
160–7
180–7
200–7
240–7
300–7
350–7 "?" appears in white when the screen is changed.
450–7
700–7
800–7
75–7
125–7
225–7
Territory
Value Contents Remarks
0 JAPAN
1 EX
2 NA
3 EU
“?” appears in white when the screen is changed.
4 -
5 TURK
6 CHINA
7 AUSTRALIA
Brand
0 SUMITOMO
1 LBX
2 CASE
3 IHI
ATT. type
0 Standard
1 Offset
2 Ultra-long
3 Swing boom
4 2–piece
5 3–piece
1st. Option line

0 None
1 Independent
2 Double-acting
3 Double-acting 2 pumps flow
4 Multi-purpose 1 pump flow
5 Multi-purpose 2 pumps flow
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Relief press
0 None "-" appears in gray when the screen is changed.
"?" appears in white when "1st. OPTION LINE" is
1 Independent
1 or more.
Operation type
0 Foot pedal type "-" appears in gray when the screen is changed.
1 S/V type "?" appears in white when "1st. OPTION LINE" is
2 Proportional type 1 or more.
2nd. Option line

0 None
1 Available
Quick coupler
0 None
1 Available
Overload warning
0 None
1 Available (EU Type) “?” appears in white when the screen is changed.
2 Available (Japan Type)
Anti-interference
0 None
1 Available
Model selection
SMIL14CEX6784EA 3
FREE SWING Free swing

ONE-PEDAL TRAVEL One-pedal travel
TRAVEL ALARM Travel alarm
FUEL PUMP AUTO STOP Feed pump with automatic stop function
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ELEVATOR CAB Elevator cab

LIFTING MAGNET Lifting magnet
HARVESTER Harvester
FAN Fan
ICT Informational construction
BUCKET POSITION SENSOR Bucket position detection sensor
GCHC Grapple close holding circuit
Free swing
0 None
1 Available
One-pedal travel
0 None
1 Available
Travel alarm
0 None Only 1 can be selected when the destination
is North America. The setting will be forcibly
1 Available changed to 1 if the destination is changed to North
America later.
Fuel pump auto stop

0 None
1 Available
Elevator cab
0 None
1 Available
Lifting magnet
0 None
1 Available (SPS) “?” appears in white when the screen is changed.
2 Available (XXX)
Harvester
0 None
1 LM / MF
2 MH
3 TL
4 PN “?” appears in white when the screen is changed.
5 RB
6 RT
7 BP (Stroke)
8 BP (Roller)
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Fan
0 Standard fan Only 1 can be selected when the model selection
1 Hydraulically-operated fan is 46t or more. When the model selection is less
than 46t, 1 cannot be selected. If, with 1 selected,
2 Reversible fan the model less than 46t is selected, 0 is selected
forcibly.
ICT
0 None
1 Available
Bucket position sensor

0 None
1 Stroke sensor Fixed at 1 when ICT is available
2 Angle sensor
GCHC
0 None
Fixed at 0 when the 1st option line circuit is 0.
1 Available
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DIMENSIONS
• You can move to this screen only when the following settings are specified on the model selection screen.
OVERLOAD-WARNING 2: Available (Japan Type)
ANTI-INTERFERENCE 1: Available
• The items that can be input vary depending on the combination of the two items above.
SMIL14CEX1053EA 4
Item Available option Display

• 0: STD
ARM LENGTH TYPE • 1: LONG Initially "?" appears in white.
• 2: SHORT
• 0: STD
BOOM/ARM WEIGHT TYPE Initially "?" appears in white.
• 1: HEAVY
• 0: STD
END-ATT.1 WEIGHT TYPE Initially "?" appears in white.
• 1: HEAVY
Initially the model-specific default
END-ATT.1 LENGTH 0000 - 9999
value is set.
END-ATT.1 WIDTH 0000 - 9999
value is set.

END-ATT.2 LENGTH 0000 - 9999
value is set.
END-ATT.2 WIDTH 0000 - 9999
value is set.
• 0: STD
ELEVATOR CAB TYPE Initially "?" appears in white.
• 1: HEAVY
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PARAMETERS
You can lock the screens or make the automatic dimming settings.
1/3
SMIL14CEX1054EA 5

AUTO IDLE TIME Auto idle time 1 - 30 s
Low idle speed – A mode
AUTO IDLE SPEED Auto idle speed
speed (min-1 (rpm))
IDLE STOP TIME Idle stop time 3 - 10 min
TRAVEL ALARM TIME Travel alarm time 1 - 30 s
Last travel speed maintained
TRAVEL SPEED MEMORY on/off
• Maintained when ++++ is set
Service due warning
MAINTENANCE MESSAGE on/off
• Displayed when ++++ is set
On/Off of EPF function
EPF(ENGINE PROTECTION) on/off
• On when ++++ is set
10 - 35 MPa (1450.5 -
OVERLOAD PRESS Overload set pressure
5076.8 psi)
ITEM-1
ITEM-2
ITEM-3
ITEM-4
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2/3
SMIL14CEX1055EA 6

Fuel economy gauge; average fuel
AVERAGE FUEL CONS DISPLAY on/off
economy display
Fuel economy gauge; instant fuel economy
INSTANT. FUEL CONS DISPLAY on/off
display
MAINTENANCE SCREEN LOCK Maintenance information screen lock on/off
OPT. LINE SETUP SCREEN LOCK Option line setting screen lock on/off
MACHINE INFO SCREEN LOCK System information screen lock on/off
DISPLAY CFG. SCREEN LOCK Display configuration screen lock on/off
5 alternatives below
• 0 w/m2
Semiautomatic dimming; amount of solar • 20 w/m2
AUTO DIMMER SUNLOAD
radiation as start criterion • 40 w/m2
• 60 w/m2
• 80 w/m2
AUTO DIMMER TIME Semiautomatic dimming; time 10 - 300 s
ITEM-1
ITEM-2
ITEM-3
ITEM-4
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3/3
SMIL14CEX6785EA 7

PUMP POWER REDUCTION Pump horsepower reduction -40 - 0 %
IDLE UP Idle up on/off
50 - 100 °C (122 -
WARMUP TARGET TEMP Target coolant temperature for warm-up
212 °F)
SRC (SWING RELIEF CUT) Option line setting screen lock on/off
BES (BOOM-DN ENERGY SAVE) ON/OFF of BES control on/off
Horsepower reduction function at engine
ENGINE TROUBLE BACKUP on/off
failure
PRESS BOOST Pressure boost function on/off
ITEM-1
ITEM-2
ITEM-3
ITEM-4
ITEM-5
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CAMERA
The combination of cameras that are shown when the camera switch is pressed can be selected.
The rear camera is installed in this machine, and acts as the rear mirror (the rear mirror is not installed).
Note the following points during a setup so that the customer can always check the rear camera image.
• Whichever camera setting number (#1 to #5) the customer selects, the rear camera or the FVM image shall always
be displayed.
• The right camera or the left camera image shall not be displayed exclusively.
When the right camera or the left camera image is allocated to one of the two screens, the rear camera or the FVM
image shall always be allocated to the other screen.
SMIL14CEX1065EA 8
Connection
Select a type of the connected camera for "INPUT 1," "INPUT 2," and "INPUT 3."
NOTICE: The type NO-CAMERA cannot be selected for "INPUT1."
Camera direction
Type Normal/Mirror image Brightness
indicator
NO-CAMERA Normal image NORMAL
REAR Normal image NORMAL
REAR (MIRROR) Mirror image NORMAL
LEFT Normal image NORMAL
RIGHT Normal image NORMAL
UNDER Normal image NORMAL
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Display configuration
Type Meter position Camera input Display
A SIDE INPUT 1
SMIL14CEX1066AA 9
B SIDE INPUT 2
SMIL14CEX1067AA 10
C SIDE INPUT 3
SMIL14CEX1068AA 11
F TOP INPUT 1+2
SMIL14CEX1071AA 12
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G TOP INPUT 1+3
SMIL14CEX1072AA 13
H TOP INPUT 1
SMIL14CEX1073AA 14
I TOP INPUT 2
SMIL14CEX1074AA 15
J TOP INPUT 3
SMIL14CEX1075AA 16
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Z – –
SMIL14CEX1076AA 17
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PASSWORD
Summary
Set an anti-theft password.
SMIL14CEX1077EB 18
1. Password management screen 2. Setting screen
Meanings of the numbers on the password management screen
Item Contents
Password#1 Manual lock
Password#2 Geofence / Curfew / Remote lock
Password#3 Service support screen lock
Register a new password
SMIL14CEX1078EB 19
3. New registration screen
A. Enter the password management screen (1).

B. Choose the desired item for password setup.
C. Choose "TURN PASSWORD ON."
D. Enter the password to register. (Enter it on the new registration screen (3).)
E. On completion of the process, the password management screen (1) will be redisplayed.
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Delete the password
SMIL14CEX1079EB 20
4. Deletion screen

C. Choose "TURN PASSWORD OFF."
D. Enter the registered password. (Enter it on the deletion screen (4).)
E. On completion of the process, the password management screen (1) will be redisplayed.
• When a wrong password is entered, the previous screen will be redisplayed without deleting the password.
Change password
SMIL14CEX1080EB 21
5. Change screen (from old to new) 6. Change screen (new)

C. Choose "CHANGE PASSWORD."
D. Enter the registered password. (Enter it on the change screen (5).)
E. Enter the new password to register. (Enter it on the change screen (6).)
F. On completion of the process, the password management screen (1) will be redisplayed.
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Change the number of digits
SMIL14CEX1081EB 22
5. Change screen (from 4 digits to 6 digits) 7. Change screen (6 digits)

C. Change "PASSWORD DIGIT" from 4 to 6 (from 6 to 4). (The following description for the 4-6 case is also applicable
to the 6-4 case.)
D. Enter the registered password. (Enter it on the change screen (5).)
E. Enter the new password to register. (Enter it on the change screen (6).)
F. On completion of the process, the password management screen will be redisplayed.
Reset password
SMIL14CEX1082EB 23
A. Display the setting screen for the password to reset.

B. Remove the rear cover, and connect the 1 -pin connector (1).
C. Then wait for 10 min (no need to start the engine).
D. The password will be deleted.
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Instrument cluster - Overview - CALIBRATE screen list

In the CALIBRATE mode, you can adjust the throttle vol-
ume, the angle sensor, the option line relief pressure and
the electronically-controlled pump.
It is necessary to perform a calibration setup in order to
adjust the individual difference (tolerance) of the machine
(component) after replacement of the applicable compo-
nent.
The calibration setup is performed for the following com-

ponents.
1. Throttle volume
The calibration setup is required when the throttle vol-

SMIL14CEX1083AA 1
ume is replaced.
2. Electronically-controlled pump
The calibration setup is required when the electroni-

cally-controlled pump is replaced.
3. Option relief pressure control
If the option electromagnetic relief proportional valve is

installed, the calibration setup is required when the re-
lief valve is replaced or added, or when the hydraulic
pump is replaced. The calibration setup is not required
if it is not installed or "NO ELECTROMAGNETIC RE-
LIEF" is set in Model Setting.
4. Attachment angle sensor
Vehicles equipped with the angle sensor (when the fol-

lowing are set on the model selection screen)
• OVER LOAD WARNINNG: 1 (Liftcrane)

• ANTI-INTFERENCE: 1 (Anti-interference is enabled)
The calibration setup is required when the angle sensor

is replaced.
By pressing and on the monitor, THROTTLE

VOLUME, ANGLE SENSOR, etc. can be selected.
Detailed data for the selected item can be seen by
pressing .
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Throttle volume
Correct the throttle volume installation error.
The calibration setup is required when the throttle volume
is replaced.
1. If the throttle volume adjustment is not finished, the

(red) initial screen is displayed.
SMIL14CEX1084AA 2
2. Press , and the system displays the H mode

screen.
SMIL14CEX1085AA 3
3. When the throttle volume is turned to the H mode and
is pressed, the system displays the SP screen.
SMIL14CEX6789AA 4
4. When the throttle volume is turned to the SP mode and
is pressed, the system displays a screen indicat-

ing an adjustment in progress and the calculation of
throttle volume correction starts.
SMIL14CEX6790AA 5
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5. When the correction calculation is finished, the system

displays the (green) result screen.
SMIL14CEX1087AA 6
6. Press , and the system displays the (green) initial

screen.
SMIL14CEX1088AA 7
If the calibration fails or you press the menu SW in the

middle of the process, the system will be interrupted and
display the (red) result screen "FAILURE" with an error
code.
• 001 = engine stopped, throttle operated
• 002 = timeout (not complete in 90 s or more)
• 003 = throttle abnormal
• 004 = machine abnormal (in case of an error)
• 005 = setting value abnormal
• 006 = interrupted
SMIL14CEX1089AA 8
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OPT.line relief
Adjust the option line relief pressure (only applicable for
the models with electromagnetic relief valve).
The calibration setup is required when the option relief
proportional valve is replaced or the pump is replaced.
This is disabled unless the calibration setup and adjust-
ment for the hydraulic pump are completed in advance.
(You cannot enter the screen.)
1. If the relief pressure adjustment is not finished, the

(red) initial screen is displayed.
SMIL14CEX6791AA 9
2. When is pressed, the system displays the engine

start screen.
SMIL14CEX6792AA 10
3. When the engine is started and is pressed, the

system displays the SP mode screen.
SMIL14CEX6793AA 11
4. When the work mode is turned to the SP mode
and is pressed, the system displays the oil tem-

perature raise screen.
SMIL14CEX6794AA 12
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5. When the oil temperature has reached the target value
and is pressed, the system displays the option line

operation request screen. (The screen switches to a
screen indicating an adjustment in progress if you step
on the pedal, while the screen switches back to the
option line operation request screen if you release the
pedal.)
SMIL14CEX6807BA 13
6. When the relief pressure adjustment is finished, the

system displays the (green) result screen.
SMIL14CEX6795AA 14

screen.
SMIL14CEX6796AA 15
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code.
• 001 = engine stopped, throttle operated, oil temperature
dropped
• 003 = P1/P2, N1/N2, pump proportional valve abnormal
• 006 = interrupted SMIL14CEX6797AA 16
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Pump flow
Adjust proportional valves of the electronically-controlled
pump.
The calibration setup is required when the electronically-
controlled pump is replaced.
In this case, the message "INITIAL SETTING INCOM-
PLETE" does not appear.
1. If an adjustment of the electronically controlled pump

is not finished, the (red) initial screen is displayed.
SMIL14CEX6798AA 17
2. When is pressed, the system displays the engine

start screen.
SMIL14CEX6799AA 18
3. When the engine is started and is pressed, the

system displays the SP mode screen.
SMIL14CEX6800AA 19
4. When the work mode is turned to the SP mode
and is pressed, the system displays the oil tem-

perature raise screen.
SMIL14CEX6801AA 20
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5. When the oil temperature reaches the target value
and is pressed, the system displays the gate open

screen.
SMIL14CEX6802AA 21
6. When the gate is opened and is pressed, the

system displays a screen indicating an adjustment in
progress and the pump adjustment starts.
SMIL14CEX6803AA 22
7. When the pump adjustment is finished, the system

displays the (green) result screen.
SMIL14CEX6804AA 23

screen.
SMIL14CEX6805AA 24
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code.
• 001 = engine stopped, throttle operated, oil temperature
dropped
• 003 = P1/P2, N1/N2, pump proportional valve abnormal
• 006 = interrupted SMIL14CEX6806AA 25
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Instrument cluster - Dynamic description - Fuel gauge

Purpose/overview
Indicating fuel level by 9 levels between 0 and 8.
Reaching level 1 causes warning alarm. Level 0 indicates sensor malfunction (normal sensor is indicated by level 1
to 8).
Configuration
*1. Monitor
*2. Main controller
*3. Over head
*4. Fuel sensor
*5. Reserve ( 1 h work)
*6. Fuel tank
SMIL14CEX0506BB 1
Operation
1. The controller obtains a lever angle ratio from the fuel sensor.
2. The controller transmits the obtained lever angle ratio to the monitor via CAN communication by converting it to a
gauge level.
3. The monitor displays the segment level on screen once it receives the level.
Lever position Resistance [ohm] Fuel sensor [%]

MAX 10 Ω 100 %
MID 38 Ω 50 %
MIN 80 Ω 0%
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1. Fuel gauge
2. Monitor
a. Vehicle information; left side display
b. Vehicle information; upper side display
SMIL14CEX3415BB 2
• The table below shows threshold value for conversion from a lever angle ratio to a segment level.
Lever angle ratio Gauge level
100 % or more 8
83 % or more 7
67 % or more 6
50 % or more 5
33 % or more 4
17 % or more 3
1 % or more 2
Less than 1 % 1
Functions
• Refueling warning: Message of "LOW FUEL" is displayed on the monitor and alarm is sounded for 5 sif the gauge
level becomes 1.
• Preventing flickering: The lever angle ratio is treated by filter (rolling average) and its result is used for judgment of
displaying level in order to prevent flickering of monitor display due to fuel level change.
Filtering time = 32 s
Lever angle ratio measurement cycle = 1 s
• Pointer needle type: The system reads the lever angle ratio immediately after the key is turned ON, and then
instantly judges display level to display it on the monitor. Therefore, this enables confirming remaining fuel level
without waiting for filtering time due to preventing flickering.
• Operation at failure: The gauge level indicates zero at failure. It displays original monitor after resuming from failure
status.
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Instrument cluster - Dynamic description - Coolant temperature

gauge
Purpose/overview
Coolant temperature is displayed as the number of illuminated segments (level).
SMIL14CEX3416FB 1
1. Coolant temperature gauge 5. Coolant temperature sensor

3. Main controller a. Vehicle information; left side display
4. ECM b. Vehicle information; upper side display
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Operation
1. The ECM reads coolant temperature from the coolant temperature sensor and transmits it to the controller via
CAN communication.
2. The controller transmits the obtained coolant temperature to the monitor via CAN communication by converting it
to a gauge level.
3. The monitor displays the gauge level on screen once it receives the level.
Remarks
The table below shows threshold value of coolant temperature and gauge level.
It never reaches zero except for failure.
Coolant temperature Gauge level

105 °C or more 8
102 °C or more 7
100 °C or more 6
97 °C or more 5
92 °C or more 4
77 °C or more 3
50 °C or more 2
Less than 50 °C 1
Functions
• Coolant temperature warning: Message of "OVER HEAT" is displayed on the monitor and alarm is sounded for 5 s
if the gauge level becomes 8.
• Preventing flickering: Coolant temperature is treated by filter (rolling average) and its result is used for judgment of
displaying level.
Coolant temperature measurement cycle = 1 s
• Pointer needle type: The system reads coolant temperature immediately after the key is turned ON, and then in-
stantly judges display level to display it on the monitor.
Therefore, this enables confirming remaining coolant temperature without waiting for filtering time due to preventing
flickering.
status.
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Instrument cluster - Dynamic description - Oil temperature gauge

Purpose/overview
Oil temperature is displayed as the number of illuminated segments (level).
SMIL14CEX3417FB 1
1. Oil temperature gauge 5. Hydraulic tank

2. Monitor 6. Oil temperature sensor
3. Main controller a. Hydraulic pump
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Operation
1. The controller reads oil temperature from the oil temperature sensor.
2. The controller transmits the oil temperature to the monitor via CAN communication by converting it to a gauge
level.
3. The monitor displays the gauge level on screen once it receives the level.
Remarks
The table below shows threshold value of oil temperature and gauge level.
It never reaches zero except for failure.
Oil temperature Gauge level

98 °C or more 8
95 °C or more 7
88 °C or more 6
80 °C or more 5
60 °C or more 4
45 °C or more 3
25 °C or more 2
Less than 25 °C 1
Functions
• Oil temperature warning: Message of "OVER HEAT" is displayed on the monitor and alarm is sounded for 5 s if the
gauge level becomes 8.
• Preventing flickering: Oil temperature is treated by filter (rolling average) and its result is used for judgment of
displaying level.
Oil temperature measurement cycle = 1 s
• Pointer needle type: The system reads oil temperature immediately after the key is turned ON, and then instantly
judges display level to display it on the monitor.
Therefore, this enables confirming remaining oil temperature without waiting for filtering time due to preventing
flickering.
status.
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Instrument cluster - Dynamic description - Monitor display dimming

Purpose/overview
Brightness of backlight is adjusted in accordance with the working light and solar radiation sensor.
SMIL14CEX3418FB 1
1. Monitor 5. Working light relay

2. Main controller a. Dimming level automatic adjustment by solar radiation sensor
3. Solar radiation sensor b. Working light linked dimming by working light relay
4. Working light switch
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Operation
1. The monitor will set brightness of the screen to "brightness (day)" when operator turns ON the key.
2. The monitor will set brightness of the screen to "brightness (night)" when operator turns ON the working light. (=
Working light linked dimming)
• If working light linked dimming is turned OFF on the service support screen, the monitor sets brightness of the
screen with working light ON to that judged by the solar radiation sensor, instead of "brightness (night)." (= Dimming
level automatic adjustment)
• Brightness when the working light is OFF becomes "brightness (day)," regardless of ON or OFF of the working light
linked dimming.
3. Operator can set "brightness (day)" or "brightness (night)" in the menu screen.
• Brightness of the screen is kept retained even after replacing the controller since it is memorized in the monitor.
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Instrument cluster - Dynamic description - Selective catalytic

reduction (SCR) gauge
Purpose
Icons and a bar graph are displayed to indicate the remaining urea level.
SMIL14CEX3419FB 1
1. SCR Gauge
2. Monitor
3. Main controller
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When the remaining urea level is low
SMIL15CEX3318EA 2
(A) (B) (C) (D)

DEF/AdBlue® tank level 10 % or more Less than 10 % Less than 5 % 0%
Engine output Normal Normal 70 % 60 %
Engine speed Unaffected ” ” Idling only
(Indicator bar and
2 or more 1 1 (flashing) 0
Level gauge icon)
(Indicator color) White Orange Orange (flashing) Red
REFILL AdBlue None Steady light Flashing Fast flashing
Low output icon None None Displayed Displayed
Message icon None None None Displayed

Warning buzzer None One long beep Three short beeps Continuous beep
Text message None
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If anything other than urea solution has been added or the SCR system becomes abnormal
SMIL14CEX2527EA 3
(A) (B) (C) (D)

DEF/AdBlue® deterioration, urea
Occurred 3 h since (B) 30 min since (C)
SCR failure, SCR system abnormality
Engine output Normal Normal 70 % 60 %
Engine speed Unaffected ” ” Idling only
Level gauge (Indicator color) White White White White
DEF/AdBlue®
None Displayed Flashing Fast flashing
icon
Output reduction
None None Displayed Displayed
icon
Messages icon None None None Displayed

Messages icon None Displayed Displayed Displayed
Warning buzzer None One long beep Three short beeps Continuous beep
Text message None
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If an SCR system abnormality is detected within 40 h after the completion of repair or the replacement of DEF/Ad-
Blue® (urea solution) and then that abnormality persists for 10 s, or if a DEF/AdBlue® (urea solution) deterioration
is detected and then that abnormality persists for 10 s
SMIL14CEX2530EA 4
(C) (D)
Solution other than
DEF/AdBlue® is repeatedly
Repeat 30 min since (C)
refilled to SCR system
within 40 h
Engine output 70 % 60 %
Engine speed Unaffected Idling only
DEF/AdBlue® icon Flashing Fast flashing
Output reduction icon Displayed Displayed
Messages icon None Displayed

Messages icon Displayed Displayed
Warning buzzer Three short beeps Continuous beep
Text message
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When the output reduction cancel is actuated
SMIL14CEX4937EA 5
The message icon (ESCAPE MODE) and the text message (OUTPUT REDUCTION CANCELED) appear. With such
displays, restriction of the engine output will be canceled for 30 min only.
This function is not available in the state D (the engine output is reduced to 60 %, and idling is only allowed).
When SCR auto CLEANING or manual regeneration is performed
Manual SCR CLEANING

Auto SCR CLEANING
requested
Indicator color Green Orange
Warning buzzer 2s 2s
Purge icon Displayed Blinking
Text message
Manual SCR Manual SCR Manual SCR

CLEANING started CLEANING stopped CLEANING disabled
Indicator color Orange Orange Red
Warning buzzer 2s None 2s
Purge icon Displayed Blinking Displayed
Text message
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Instrument cluster - Dynamic description - Diagnostic trouble code

indicator
Purpose/overview
The diagnostic trouble code is displayed on the monitor when any trouble occurs. (Simplifying troubleshooting)
SMIL14CEX3428FB 1
1. Trouble code
2. Monitor
3. Main controller
Control
The monitor displays "!" mark and the diagnostic trouble code when any trouble occurs.
• The diagnostic trouble code is displayed in 5 digits including alphabet in the event of engine side trouble, and in 4
digits in the event of trouble in main unit side.
• It is displayed in cyclic manner in 5 s interval in the event of multiple troubles.
The diagnostic trouble code is cleared at completion of trouble repair.
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Instrument cluster - Dynamic description - Fuel economy gauge

Purpose/overview
The machine displays average fuel economy (upper row) and instant fuel economy (lower row) on the monitor.
SMIL14CEX3429FB 1
1. Fuel economy gauge

2. Monitor
3. Main controller
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Operation condition
Value on the upper row
• Fuel economy display (average or instant).
Average fuel economy linked to the trip meter.
• Setting in display/hide is available depending on destination.
• Switching instant/accumulate in the service support screen is available.
No need for switching in the menu screen.
Lower row gauge

• Instant fuel economy display.
• The gauge displays numerical value line without correction.
• Display update cycle of the gauge is updated in high speed within readable range.
• Setting in display/hide is available depending on destination.
• Switching instant/accumulate in the back screen is available.
No need for switching in the menu screen.
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Instrument cluster - Dynamic description - Engine information

Engine information
• When ECM is replaced, the data on the old ECM can be transferred to the new ECM.
• When the controller is replaced, the engine information can be obtained again.
• When the injector is replaced, the injector code can be updated.
SMIL14CEX1057EA 1
Display Detail
FROM • Source of the information displayed (Two types including “BACK UP” and “ECM”)
• 6-digit engine serial number
• When the FROM tab is set to "BACK UP" and the backup has not been obtained,
ENGINE SERIAL NO entire digits are displayed as zero.
• When the FROM tab is set to “ECM” and communication is established with
ECM, entire digits are displayed as zero.
• 10-digit ECM part number
• When the FROM tab is set to “BACK UP” and the backup has not been obtained,
ECM PART NO. entire digits are displayed as zero.
• 6-digit Q resistance code
• When the FROM tab is set to “BACK UP” and the backup has not been obtained,
Q-TRIM NO. entire digits are displayed as zero.
INJECTOR NO. • Injector number
• 24-digit injector code
• The cursor moves to this line only during the injector code edit mode. (FROM
tab set to “BACK UP”)
INJECTOR CODE (Not
displayed on screen) • When the FROM tab is set to “BACK UP” and the backup has not been obtained,
entire digits are displayed as zero.
• Edit the injector code (Backup value).
INPUT INJECTOR CODE • This line is displayed when the FROM tab is set to “BACK UP”.
• This line is not displayed when the FROM tab is set to “ECM”.
• Obtain the engine information from ECM again.
BACK UP FROM ECM • This line is displayed when the FROM tab is set to “BACK UP”.
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Display Detail
• Write the backup values of the engine information, including the injector code,
to ECM.
RESTORE TO ECM
• This line is displayed when the FROM tab is set to “BACK UP”.
Data confirmation procedure
SMIL14CEX1058EB 2
1. Select “FROM” (data source) using switch (3) and (4) .

”BACK UP” or “ECM” can be selectable using switch (1) and (2).
Data transfer (copy) procedure
SMIL14CEX1058EB 3
1. Transfer from ECM to MCM

Select “FROM” (data source) using switch (3) and (4).
Select “BACK UP” using switch (1) and (2).
Select “BACK UP FROM ECM” using switch (3) and (4).
Hold down SW (2) for 3 s.
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SMIL14CEX1059EA 4
2. Transfer from MCM to ECM

Select “FROM” (data source) using switch (3) and (4).
Select “BACK UP” using switch (1) and (2).
Select “RESTORE TO ECM” using switch (3) and (4) .
Hold down switch (2) for 3 s.
SMIL14CEX1060EA 5
QR (Injector) code
Injector number
SMIL14CEX1061EB 6
*1. Front of engine 1, 2. Numerical change, movement of the page

*2. Rear of engine 3, 4. Movement of the cursor
*3. Injector number 5. Back to the previous screen
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Screen Layout
SMIL14CEX1062EB 7
*1. Injector QR code
Data source selection procedure
SMIL14CEX1063EB 8
1. Select "FROM" (data source) using SW (3) and (4).

"BACK UP" or "ECM" can be selectable using SW (2).
2. After the selection, press SW (5).
Manual Input procedure
SMIL14CEX1064EB 9
1. Select "BACK UP" at "FROM" (data source).

2. Move the cursor to "INJECTOR No." using SW (3) and (4) and then select the target injector number using SW
(1) and (2).
Move the cursor to "INPUT INJECTOR CODE" using SW (3) and (4).
Press SW (2) for 3 s. The cursor will be placed on the first digit of "INJECTOR CODE" and the code can be edited.
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Press SW (3) or (4) to select the value.

Press SW (1) or (2) to move the cursor to the right or left.
3. After the QR code is entered, press SW (5).
The setting result will be displayed in the message area.
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Clock - Adjust
Summary
Adjust the clock that is displayed on the monitor.
• Refer to the page for information on the clock.
Configuration
(*1) Color monitor
SMIL14CEX0908AB 1
1. The system will display "--:--" on the monitor when the
key is turned to the ON position.
2. The operator sets the time using the "Time Adjustment"
function on the menu screen.
Move the cursor left to right, and change the time by
moving up and down, and press the menu switch to
confirm the values.
3. • The clock data is stored in the monitor, so the time
data remains stored even if the sub-controller is re-
placed.
If the monitor is replaced, the time must be set again.
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How to adjust the clock

1. Press button (1) to display the menu screen.
2. Press button (2) or (3) and select "Clock Adjustment"
on the menu screen.
3. Press button (5).
4. • Press either button (2) or (3) to switch between hour
and minute.
• Press either button (4) or (5) to increase or decrease
the number.
5. Press button (1) to return to the menu screen.
SMIL14CEX0909AB 2
SMIL14CEX0910AB 3
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Instrument cluster - Prepare

Items to prepare:
• Wrench [ 10 mm]
• Hexagon wrench
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Instrument cluster - Remove

remove the 2 bolts (1), and then remove the side front
lower trim (2).
5.753 lb ft)
SMIL14CEX1927AB 1
2. Use a flathead screwdriver or longnose pliers to re-

move the clip pins (1), and then remove the air-con-
ditioner ducts (2) by pulling them forward.
SMIL14CEX1928AB 2

remove the 2 bolts (1), use a hexagon wrench [ 5 mm]
to remove the 3 bolts (2) and 3 washers (3), and then
remove the front upper trim assembly (4).
5.753 lb ft)
SMIL14CEX1929AB 3

move the truss head tapping screws (1), and then re-
move ducts (2) and (3).
SMIL14CEX1930AB 4
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move the truss head tapping screw (1), use a wrench
[ 10 mm] remove the 1 bolt (2), and then remove the
side front right trim (3).
SMIL14CEX1931AB 5
6. Remove the connectors (1).
SMIL14CEX1932AB 6

then remove the monitor (1).
3.688 lb ft)
SMIL14CEX1933AB 7
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Instrument cluster - Install

dure.
For bolts for which the torque is not specified, refer to
Cab glazing - Torque (90.156).
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Instrument cluster - Adjust - Screen brightness setting

Summary
Brightness of the screen backlight is determined in ac-
cordance with the working light and solar radiation sen-
sor.
The screen brightness when the working light is ON
or OFF can be selected on the Display Configuration
screen.
1. Working Light OFF: Normal (with key ON), "Brightness
(day)" setting
2. Working Light ON: The monitor brightness is reduced
and the display automatically changes to the "Bright-
ness (night)" setting.
3. Brightness settings: "Brightness (day)" and "Bright-
ness (night)" can be set on the Display Configuration
screen.
SMIL14CEX0911AB 1
4. Dimming by solar radiation sensor: When the working
light-linked dimming is set to OFF on the Display Con-
figuration screen, the dimming level is automatically ad-
justed to the ambient brightness by the solar radiation
sensor.
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Index
Cab controls - 512

Cab controls - Dynamic description - Travel speed selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cab controls - Dynamic description - Work mode control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cab radio set - Dynamic description - Radio mute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Clock - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Clock - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Horn control switch - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Instrument cluster - Adjust - Screen brightness setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Instrument cluster - Dynamic description - Coolant temperature gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Instrument cluster - Dynamic description - Diagnostic trouble code indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Instrument cluster - Dynamic description - Engine information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Instrument cluster - Dynamic description - Fuel economy gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Instrument cluster - Dynamic description - Fuel gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Instrument cluster - Dynamic description - Monitor display dimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Instrument cluster - Dynamic description - Oil temperature gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Instrument cluster - Dynamic description - Selective catalytic reduction (SCR) gauge . . . . . . . . . . . . . . . . . . . . . . 161
Instrument cluster - Electrical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Instrument cluster - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Instrument cluster - Overview - CALIBRATE screen list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Instrument cluster - Overview - CHECK screen list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Instrument cluster - Overview - SETUP screen list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Instrument cluster - Overview - Screen display list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Instrument cluster - Overview - Service Monitor Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Instrument cluster - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Instrument cluster - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
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Hydraulic system control - 036

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Contents
FUNCTIONAL DATA
Hydraulic system control

Power boost pressure solenoid
SERVICE
Hydraulic fluid filter restriction sensor

Service instruction - Hydraulic filter clogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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Electrical systems - Hydraulic system control
Hydraulic system control - Dynamic description

Overview
The main controller detects negative control pressure, pump pressure, pilot pressure, and cylinder pressure by the
sensor, computes the optimum pump flow, and then controls the flow by the pump proportional valve.
For the electronically-controlled pump, the flow is controlled by the electromagnetic proportional valve for both the
front and rear sides.
SMIL14CEX3931FB 1
1. Operation remote control valve 6. Bucket cylinder

2 Travel remote control valve 7. Main controller
3. Arm cylinder 8. Electromagnetic proportional valve (front)
4. Control valve 9. Electromagnetic proportional valve (rear)
5. Boom cylinder 10. Electronically-controlled hydraulic pump
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Specifications
SMIL14CEX3932FB 2
1. Electromagnetic proportional valve secondary pressure (normal control)

2. Main pressure (control at failure)
Control
Horsepower flow control (pump torque control)

The control is based on the electromagnetic proportional valve secondary pressure (normal control).
P1and P2 pressure sensor values are input to the main controller, flow is computed so that the design pump torque
may be achieved at the pump proportional valve secondary pressure, and the flow is controlled.
The pump torque flow is changed by changing the torque computed by the main controller (pump torque change).
Negative control flow control

The control is based on the electromagnetic proportional valve secondary pressure (normal control).
N1 and N2 pressure sensor values are input to the main controller, flow is controlled so that the design flow may be
achieved at the proportional valve secondary pressure.
Flow control at failure

The control is based on the main pressure (control at failure).
By reducing the proportional valve secondary pressure, the pump torque flow control based on the current P1 and P2
pressures is carried out (however, there is no torque change function). When the electromagnetic proportional valve
has broken, the regulator is operated at the main pressure of the pump to fix the torque.
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The regulator is usually operated at pilot pressure to achieve the correct flow; however, since the pilot pressure will
be interrupted when the control proportional valve is stuck, the regulator is operated at the main pressure to adjust
the flow.
Regulator flow selection

The control is based on the electromagnetic proportional valve secondary pressure (normal control)
The lower flow, among the main-controller-computed horsepower flow and negative control flow, is selected as control
flow, and the proportional valve secondary pressure is controlled by the selected flow.
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SWING RELIEF CUT
Purpose/overview
The system increases/decreases volume of pump flow in order to adjust P1 pump pressure (swing side pressure)
to match target pressure during independent swing operation or at the starting point of boom down swing to control
(reduce) excessive oil discharged from the swing motor relief valve.
SMIL14CEX1049FB 3
1. Main controller 7. N1 pressure sensor

2. Pressure sensor (swing) 8. P1 pressure sensor
3. Pressure sensor (boom) 9. P1 pump
4. Pressure sensor (arm) 10. Pressure regulator
5. Pressure sensor (travel) 11. P1 electromagnetic proportional valve
6. Pressure sensor (option 1)
a. Arm (1) d. Option 1

b. Boom (2) e. Travel (left)
c. Swing
Operation
1. The controller makes judgment based on signal of the pressure sensors (swing, boom, arm, travel or option 1)
and signal of P1 pump pressure to control the electromagnetic proportional valve.
2. The control is made so as to maintain P1 pressure at target value between lower limit flow volume % and upper
limit flow volume % after starting it.
The system starts control under the following conditions.
• Swing starts (swing pressure sensor ON)
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• P1 pressure reaches at or above P1 pressure of starting swing (control starts).
Stop condition:
The system stops control under the following conditions.
• Swing stops (swing pressure sensor OFF).

• P1 pressure drops.
• Function relating to P1 other than swing (travel, arm, boom UP or option 1) is operated.
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STROKE CONTROL
Purpose/overview
Strokes of the boom regeneration spool and the bucket spool are controlled in order to reduce pressure loss during
digging and to improve operability.
SMIL14CEX1050FB 4
a. Boom 2 down c. Bucket close

b. Boom 2 up d. Bucket open
Boom regeneration electromagnetic proportional

1. Main controller 6.
value
2. Pressure sensor (boom up) 7. Boom 2 spool
3. Pressure sensor (arm in) 8. Bucket electromagnetic proportional valve
4. Pressure sensor (bucket close) 9. Bucket spool
5. Pressure sensor (travel) 10. Remote control valve
Operation:
The controller judges condition of digging work based on signal of the pressure sensors (boom, arm, bucket or
travel) and controls the electromagnetic proportional valve to control stroke of the spool.
Boom up spool stroke control operation outline:

The boom 2 spool is pushed back at digging work (boom up).
Control starts when the following conditions are established.
• Digging judgment is ON.
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However, control will not start when one of the following is established.
• During travel operation
• Crane mode is ON.
Stop condition:
Control stops when the following conditions are established.
• Digging judgment is OFF.
Bucket spool (close) stroke control operation outline

The system controls the bucket spool (close) so as to narrow opening of the bucket by restricting spool stroke
normally in consideration of combination operation with the boom and the arm. The stroke restriction is released to
open the opening for digging work.
• Release stroke restriction when digging judgment is ON.
• The stroke restriction will be released when the bucket is closed and opened continuously.
However, control will not start when one of the following is established. Even if the following conditions, preventing
the control from starting, are no longer established, the stroke restriction is not released.
• Lifting magnet mode is ON.
• Ultra long reach specification is selected in model selection.
• Crusher mode is established.
• Breaker mode is established.
Stop condition:
The stroke is restricted (opening is narrowed) under the following condition.
• Digging judgment is OFF.
• When boom up is full.
• Lifting magnet mode is ON.
• Ultra long reach specification is selected in model selection.
• When it is in the crusher mode.
• When it is in the breaker mode.
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BOOM DOWN ENERGY SAVE
Purpose/overview
The system reduces engine speed and pump flow to expect improvement of energy-saving effect during the
following operations.
• During operation cycle of the hydraulic excavator (digging → boom up swing → bucket open → boom down swing
→ digging).
• During independent swig, boom down swing.
• In the case of excavating work such as boom down/up swing when boom down energy save control is in effect.
SMIL14CEX1051EB 5
a. Engine speed control 5. P2 pressure sensor

4. P1 pressure sensor 9. Throttle volume
* Control refrains from starting when the work mode is SP and the crane mode is ON.
• During boom down swing (boom down Pi pressure/swing Pi pressure 0.5 MPa).
• During boom down swing and any other pilot is OFF (arm out/in Pi pressure/travel left/right Pi pressure/option 1 Pi
pressure 0.3 MPa).
Stop condition:
• Combination operation is started (arm out/in Pi pressure/boom up Pi pressure/option 1 Pi pressure/option 2 Pi
pressure 0.5 MPa).
• Travel starts (travel Pi pressure 0.5 MPa).
• Boom down swing stops (boom Pi pressure/swing Pi pressure 0.3 MPa).
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PUMP HORSEPOWER BOOST CONTROL
Purpose
The system prevents a decrease in the speed during high-load conditions, excavation, traveling, etc.
Operation
When detecting the following conditions, the system will raise the current of the pump horsepower control proportional
valve.
High load
• When the pressure of P1 + P2 is high
Travel operation
• When the travel pilot pressure sensor detects travel operation
Boom-up operation
• When the boom-up pilot pressure sensor detects boom-up full operation
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ARM 1 SEMI-PARALLEL CONTROL
Purpose/overview
The system improves workability by reducing pressure loss of operation of the arm (digging and dirt removal), pri-
oritizing boom up (preventing trapping tab tip at initial leveling), prioritizing swing operation, and prioritizing option
operation through controlling opening of the arm 1 semiparallel spool by the electromagnetic proportional valve.
SMIL14CEX0901EB 6

2. Pressure sensor (boom) 6. Pressure sensor (option)
Arm 1 semi-parallel electromagnetic proportional
3. Pressure sensor (arm) 7.
valve
4. Pressure sensor (swing) 7 8. Arm 1 semi-parallel spool
Operation
The controller judges work state based on signal of the pressure sensors (boom, arm, bucket or travel) to control the
electromagnetic proportional valve.
Operation condition
1. No lever operation
The arm 1 semi-parallel spool opening is narrowed.
2. Operation 1 (boom, arm, bucket)
The system divides the combination of boom up/down and arm out/in into the following seven types (including
independent operation), and controls the state of the arm 1 semi-parallel spool opening through the supplemental
use of bucket pilot pressure, boom cylinder pressure, and arm cylinder bottom pressure.
○ Boom up + Arm in: The arm 1 semi-parallel spool opening is changed according to the digging state.
○ Boom up + Arm out: The arm 1 semi-parallel spool opening is opened.
○ Boom down + Arm out: The arm 1 semi-parallel spool opening is opened.
○ Boom down + Arm in: The arm 1 semi-parallel spool opening is narrowed.
○ Independent boom operation (both up and down): The arm 1 semi-parallel spool opening is narrowed.
○ Independent arm-in operation: The arm 1 semi-parallel spool opening is narrowed.
○ Independent arm-out operation: The arm 1 semi-parallel spool opening is opened.
3. Operation 2 (travel, swing, option)
During travel operation, swing operation, or option (crusher mode) full operation, the arm 1 semi-parallel spool
opening is narrowed unconditionally.
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ARM 2 SEMI-PARALLEL CONTROL
Purpose/overview
The system reduces pressure loss of the arm during digging work and late half of leveling work.
SMIL14CEX0902EB 7

2. Pressure sensor (boom) 6. Arm 2 semi-parallel electromagnetic proportional valve
3. Pressure sensor (arm) 7. Arm 2 semi-parallel spool
4. Pressure sensor (bucket)
Operation
The controller judges work state based on signal of the pressure sensors (boom, arm, bucket or travel) to control the
electromagnetic proportional valve.
Operation condition
1. No lever operation
The arm 1 semi-parallel spool opening is narrowed.
2. Operation 1 (boom, arm, bucket)
The system divides the combination of boom up/down and arm out/in into the following seven types (including
independent operation), and controls the state of the arm 2 semi-parallel spool opening through the supplemental
use of bucket pilot pressure, boom cylinder pressure, and arm cylinder bottom pressure.
○ Boom up + Arm in: The arm 2 semi-parallel spool opening is changed according to the digging state.
○ Boom up + Arm out: The arm 2 semi-parallel spool opening is opened.
○ Boom down + Arm out: The arm 2 semi-parallel spool opening is opened.
○ Boom down + Arm in: The arm 2 semi-parallel spool opening is narrowed.
○ Independent boom operation (both up and down): The arm 2 semi-parallel spool opening is narrowed.
○ Independent arm-in operation: The arm 2 semi-parallel spool opening is narrowed.
○ Independent arm-out operation: The arm 2 semi-parallel spool opening is opened.
3. Operation 2 (travel, swing, option)
During traveling or crane mode ON, the arm 2 semi-parallel spool opening is narrowed unconditionally.
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BREAKER MODE
Purpose/overview
The system is capable for setting maximum 5 units of maximum flow and maximum pressure per each breaker in use.
Operation
1. Pressing the attachment select switch switches normal mode → breaker mode → crusher mode → normal
mode each time.
Maximum flow of each switched mode is displayed on the monitor for 3 s.
○ While the breaker mode has just the breaker mode 1 only in initial state, it can be added in the flow setting
screen.
2. Selecting the breaker mode enables using the breaker.
○ The maximum flow and the maximum pressure are set in the flow setting screen at first.
○ 2 pumps flow is set if a flow set in setting requires it.
3. It judges if a flow is correct for the breaker.
The system displays the message "CHECK FLOW RATE" and sounds alarm for 3 s if it exceeds correct flow rate.
○ The message is displayed only during the breaker is operated. Ending the operation hides the display and stops
the alarm as well.
4. Turning OFF the key once and then turning ON the key next time holds the attachment mode previously selected.
Operation condition
1. Flow restriction
○ The pump is controlled in accordance with set flow rate when the breaker is operated in non travel state.
○ The pump is controlled in the maximum flow rate (100%) when the breaker and travel are operated simultane-
ously. (Travel priority)
2. Pressure restriction
○ The pump is controlled in accordance with pressure setting when selecting option mode.
3. Condition of 2 pumps flow
○ 2nd speed flow rate setting + option 1 pressure 2 MPa or more
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CRUSHER MODE
Purpose/overview
The system is capable for setting maximum 5 units of maximum flow and maximum pressure per each crasher in use.
Operation
1. Pressing the attachment select switch switches normal mode → breaker mode→ crusher mode → normal
mode each time.
Maximum flow of each switched mode is displayed on the monitor for 3 s.
○ While the crasher mode has just the crasher mode 1 only in initial state, it can be added in the flow setting
screen.
2. Selecting the crasher mode enables using the crasher.
○ The maximum flow and the maximum pressure are set in the flow setting screen at first.
○ 2 pumps flow is set if a flow set in setting requires it.
3. Turning OFF the key once and then turning ON the key next time holds the attachment mode previously selected.
Operation condition
1. Flow restriction
○ The pump is controlled in accordance with set flow rate when the crasher is operated in independent operation.
○ The pump is controlled in the maximum flow rate (100%) when the crasher and other operation are operated
simultaneously. (Travel/crasher priority)
2. Pressure restriction
○ The pump is controlled in accordance with pressure setting when selecting option mode.
3. Condition of 2 pumps flow
○ 2nd speed flow rate setting + option 1 pressure 2 MPa or more
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QUICK COUPLER
Purpose/overview
This is a device for one-touch replacement of the end attachment.
While the switch is pressed, a buzzer sounds and the coupler is unlocked. When the coupler switch is released, the
coupler will be locked automatically.
Configuration
SMIL14CEX0903FB 8
1. Quick coupler buzzer 4. Coupler cylinder

2. Quick coupler switch 5. Coupler solenoid valve
3. Main controller
Control
• When the solenoid valve is OFF, pilot pressure is supplied to the bottom side of the coupler cylinder to force the
coupler into a locked state.
• When the solenoid valve is ON, pilot pressure is supplied to the rod side of the coupler cylinder to unlock the coupler.
Operation condition
• While the coupler switch is pressed, a buzzer sounds and the solenoid valve turns ON. Then, pilot pressure is
supplied to unlock the coupler.
• Only when the coupler switch is set from OFF to ON, the solenoid valve and a buzzer will be activated. They will
not be activated if the coupler switch has been ON since the key was turned ON.
• If a buzzer disconnection is detected, the coupler solenoid valve will not be activated (fixed at OFF) even when the
coupler switch is pressed.
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Power boost pressure solenoid - Dynamic description

Purpose/overview
Power of digging is increased by boosting relief pressure of the main relief valve.
SMIL14CEX4076GB 1
a. Auto pressure boost icon 8. Control valve

1. Main controller 9. Main relief valve
2. Monitor 10. Pressure boost solenoid
3. Pressure sensor (upper) 11. P1 pressure sensor
4. Pressure sensor (travel) 12. P2 pressure sensor
5. Pressure sensor (swing) 13. P2 pump
6. Pressure sensor (option 1) 14. P1 pump
7. Pressure sensor (option 2)
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Operation
1. The controller judges condition of high load work based on signal of the pressure sensors (upper, travel, swing,
option 1 or option 2) and signal of pump pressure to control the pressure boost solenoid.
2. Controlling the pressure boost solenoid changes pressure for open/close of main relief valve to boost relief pres-
sure.
3. The controller sends signal to the monitor when pressure boost control starts, and then turns auto pressure boost
icon light on.
Auto pressure boost

Operation condition
The system judges as a high load work under the following conditions to start auto pressure boost control.
• During upper (boom up/down ON or arm out/in ON or bucket open/close ON) operation.
• P1 or P2 pressure is 32.8 MPa or more.
• Both 2 conditions above continue for 0.3 s.
Stop condition
The system does not start auto pressure boost control under the following conditions.
• Traveling (travel ON).
• Option operating (option 1 or option 2 ON).
• The lever is left on after pressure boost has stopped (upper ON).
The system stops auto pressure boost control under the following conditions.
• It has elapsed for 8 s after starting auto pressure boost control.
• Upper operation is stopped.
• Travel or option operation is started.
Travel pressure boost

Operation condition
• Travel operation starts (travel ON).
Stop condition
• Travel operation stops (travel OFF).

• Travel pressure boost is prohibited.
Option pressure boost

Operation condition
• Option 1 or option 2 operation starts (option 1 or option 2 ON).
Stop condition
• Option 1 or option 2 operation stops (option 1 or option 2 OFF)

• Option pressure boost is prohibited.
Always pressure boost

Operation condition
• Pressure is boosted when work mode is A or crane mode is ON.
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Hydraulic fluid filter restriction sensor - Service instruction -

Hydraulic filter clogging
Summary
In case of hydraulic filter clogging, the system gener-
ates warning.
Configuration
SMIL14CEX0906FB 1
*1. Monitor *4. Hydraulic filter clogging sensor

*2. Main controller *5. Hydraulic tank
*3. Breaker/Crusher (1st option) pedal *6. 1st option pressure sensor
If clogging occurs in the return filter in the hydraulic tank,
the message and diagnostic trouble code appear on the
monitor, and a warning buzzer sounds. (For breaker
and multi-purpose system only)
1. Detection of clogging is started in 10 s after the engine
starts. It is detected under the following conditions.
• When oil temperature is 35 °C (95 °F) or more
• During independent breaker operation
• During independent travel operation
2. When the monitor receives the command for filter clog-
ging, the following operation will be triggered.
• Message: "FLUID FILTER" appears, and a buzzer
sounds for 5 s.
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Index

Hydraulic fluid filter restriction sensor - Service instruction - Hydraulic filter clogging . . . . . . . . . . . . . . . . . . . . . . . . 19
Hydraulic system control - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Power boost pressure solenoid - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls -

051

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Contents
Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls - 051
FUNCTIONAL DATA
Air-conditioning switch panel

SERVICE
Air-conditioning switch panel

Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Electrical systems - Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls
Air-conditioning switch panel - Static description

Function of each switch
SMIL14CEX1966FB 1
1 Main power switch 5 Air-conditioner ON/OFF switch

2 Auto control switch 6 Defrost switch
3 Temperature control switch 7 Diffuser select switch
4 Air flow select switch 8 Refresh/recirculate select switch
Through the operation of its internal microcomputer, the control panel compares, operates on, and processes the
sensor input signals and control panel switch input signals, switches the output side actuators (refresh/recirculate
switching, mode switching, air mix) and comprehensively controls the fan motor and compressor.
Also, it is equipped with self-diagnosis functions to make trouble diagnosis easier. (For details see the air conditioner
troubleshooting Air-conditioning switch panel - Service instruction (55.051) )
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Air-conditioning switch panel - Service instruction

Self-diagnosis function with panel display
Motor actuator and sensor abnormalities can be
checked on the panel display.
Abnormality display position
SMIL14CEX1953EA 1
a. This segment is displayed only in the monitor mode below.

b. Error is displayed on the 3-digit 7- segment display.
Motor actuator abnormality

1. HL. E displayed on 3-digit 7-segment display.
Check the air mix damper motor actuator for a harness
disconnection or disconnected connector.
This is also displayed when locked due to air mix motor
actuator abnormality and link abnormality.
SMIL14CEX1954AA 2
2. flashes.
Check the blow mode damper motor actuator for a har-
ness disconnection or disconnected connector.
SMIL14CEX1955AA 3
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3. flashes.
Check the refresh/recirculate damper motor actuator
for a harness disconnection or disconnected connector.
SMIL14CEX1956AA 4
CAUTION:
• The above display and flashing is displayed on the 3-digit 7-segment display when trouble occurs with the
panel ON/OFF switch ON status.
• After trouble occurs, when the panel ON/OFF switch is switched ON, the function is displayed.
• After trouble is resolved, the abnormality display and flashing are not ended until the main switch is switched
OFF → ON.
Sensor abnormality
1. HL. * displayed on 3-digit 7-segment display
Check the inside air sensor and check its harness for
disconnection, short, or connector connection defect.
a. (* is any number 0 - 9.)
SMIL14CEX1957AA 5
2. **.E and the mark flashing are flashing on the

3-digit 7-segment display. (** displays the set temper-
ature value at that time still remaining.)
Check the evaporator sensor and check its harness
for disconnections, shorts, or connector connection de-
fects.
SMIL14CEX1958AA 6
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CAUTION:
• The display in 1 and 2 above is displayed on the 3-digit 7-segment display when trouble occurs with the panel
ON/OFF switch ON status.
• After the trouble section is repaired, end the abnormality display by switching the panel ON/OFF switch OFF
→ ON.
Explanation of monitor mode

When sensor abnormality is displayed, the sensor sta-
tus (disconnection, short) can be checked in monitor
mode.
Monitor mode display position
SMIL14CEX1959FA 7
a. 3-digit 7-segment
b. 7-segment dedicated to monitor display
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Monitor mode display operating method
SMIL14CEX1960EB 8
1. Refresh/recirculate select switch

2. Blower switch UP/DOWN switch
3. ON/OFF switch
1. Hold down the refresh/recirculate select switch and the

ON/OFF switch at the same time for 1 s or longer.
2. Press the AUTO switch.
(All the 7 segments light up for 1 s, then the system
enters monitor mode.)
3. Numbers 0 - 9 or letters A - F are displayed in the 2nd
and 3rd digit of the 3-digit 7-segment display.
"H" is displayed in the 1st-digit.
4. The display of 0 - 2 on the dedicated 7-segment display
is carried out with the blower UP/ DOWN switches. The
necessary sensor is selected from the table below.
7-segment display table dedicated to monitor

0 Inside air sensor
1 Evaporator sensor
2 Solar radiation sensor
(Display other than the above (3 - 9, B - F) is not used

during service.)
SMIL14CEX1961AA 9
5. To end the monitor display, either hold down the re-

fresh/recirculate select switch and the ON/OFF switch
at the same time for 1 s again or longer or switch the
vehicle main switch OFF.
CAUTION:
• During monitor mode, operations and settings of basic control through all the switches are not possible until the
air conditioner control operation is stopped and monitor mode ended.
• During monitor mode, even if a sensor is repaired, the abnormality display is recorded in memory, and until the
ON/OFF switch is switched OFF, then ON again, the abnormality display is not ended.
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Display contents in monitor mode

See the dedicated monitor 7-segment display table and
3-digit 7-segment table.
1. Display example 1
The dedicated monitor 7-segment display is 0 (in-
dicates the inside air sensor state).
From the 3-digit 7-segment table 3F → The sensor
is normal. → The inside air sensor is normal.
SMIL14CEX1962AA 10
dicates the evaporator sensor state).
From the 3-digit 7-segment table 0C → The sen-
sor is disconnected. → The evaporator sensor is
disconnected.
SMIL14CEX1963AA 11
dicates the solar radiation sensor state).
From the 3-digit 7-segment table D5 → The sensor
is shorted on the 5 V side. → The solar radiation
sensor is shorted.
SMIL14CEX1964AA 12
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3-digit 7-segment table
SMIL14CEX1965FA 13
a. 2nd digit of 7-segment display f. Sensors normal

b. Inside air sensor disconnection OCH0 display g. Solar radiation sensor 5 V side short D5H2 display
c. Evaporator sensor disconnection OCH1 display h. Inside air sensor short F6H0 display
d. Solar radiation sensor short OCH2 display i. Evaporator sensor short F6H1 display
e. 3rd digit of 7-segment display
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Air conditioner troubleshooting

The blow temperature does not go down.
* M/A means motor actuator.
Standard
Step Action Yes No
value
• The air mix motor actuator
connector is disconnected or has
When the AUTO switch or
a contact defect.
AC switch is pressed, HL. E
1 Go to Step 2
is displayed in the panel set • Air mix motor actuator defect
temperature display section
• Main harness continuity defect
Inspect and repair or replace part
HL. * is displayed on the panel
2 set temperature display section. Go to Step 3 Go to Step 4
* is No. 0 to 9
• Inside air sensor
or harness
disconnection
or short
• Inside air sensor and • The inside air
evaporator sensor simultaneous sensor connector
3 The panel snow mark flashes disconnection or short is disconnected
• Computer breakdown or has a contact
See the Monitor Mode section too defect
See the Monitor
Mode section too.
Inspect and repair
or replace part
• The evaporator sensor connector
is disconnected or there is a
contact defect
4 The panel snow mark flashes • Evaporator sensor simultaneous Go to Step 5
disconnection or short
See the Monitor Mode section too.
When the set temperature is
18.0 and the blow mode is set to 18.0 °C
5 Go to Step 6 Go to Step 7
vent mode, the blow temperature (64.4 °F)
drops
Computer
breakdown or
Cool air is flowing into the inside Inspect the duct or eliminate the
6 inside air sensor
air sensor section cause of the cool air infiltration
defect
Inspect and replace
Switch compressor clutch ON/OFF
The air mix damper is at the and inspect and repair the power
7 Go to Step 8
COOLMAX position supply circuit.
See the cooling cycle troubleshooting
• Inspect, repair,
or replace the
If motor actuator operation stops motor actuator
midway, remove the cause or lever link section.
1.5 kgf or Motor actuator breakdown or
8 correct the problem, and then
less controller breakdown Replace • Clean the lever
measure the operating force. Is it
1.5 kgf or less? link section,
and then apply
grease
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The blow temperature does not go up

Standard
Step Action Yes No
value
• The air mix motor actuator
connector is disconnected or has
HL. E is displayed on the panel a contact defect
1 Go to Step 2
set temperature display section • Air mix motor actuator defect
• Main harness continuity defect
• Inside air sensor or harness
HL. * is displayed on the panel • The inside air sensor connector
2 set temperature display section is disconnected or has a contact Go to Step 3
* is No. 0 to 9 defect
When the set temperature is 32.0
32.0 °C
3 and the blow mode is set to foot Go to Step 4 Go to Step 5
(89.6 °F)
mode, the blow temperature rises
Computer
breakdown or
Warm air is flowing into the inside Inspect the duct or eliminate the
4 inside air sensor
air sensor section cause of the warm air infiltration
defect Inspect and
replace
The air mix damper is at the
5 Inspect the warm coolant lines Go to Step 6
HOTMAX position
• Inspect, repair,
or replace the
If motor actuator operation stops motor actuator
midway, remove the cause or lever link section
1.5 kgf or Motor actuator breakdown or
6 correct the problem, and then
less controller breakdown Replace • Clean the lever
measure the operating force.
Is it 1.5 kgf or less? link section,
and then apply
grease
The blower motor does not rotate

Standard
Step Action Yes No
value
With the flow set to HI, battery
voltage is applied to the terminals
1 Replace the blower motor Go to Step 2
(+ and -) of the blower motor.
(Note: 1)
The battery voltage is applied
between the blower motor (+)
power supply red/blue and the
body
Voltage of about 10 V is applied
3 between the blower amp About 10 V Go to Step 4 Replace computer
brown/yellow line and ground
Remove the blower amp and
refer to the section on Blower Eliminate the cause
Amp Inspection. Is there any of the trouble, and
4 Inspect and repair the wire harness
abnormality? then replace the
No abnormality → Yes blower amp
Abnormality → No
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Standard
Step Action Yes No
value
Inspect the blower motor relay.
When the blower motor relay Inspect, repair, or
5 white/red and blue/red are Go to Step 6 replace the wire
directly connected, the blower harness
motor rotates. (Note: 2)
The battery voltage is applied Inspect, repair, or
6 between the blower motor relay Go to Step 7 replace the wire
white/red and the body harness
When the blower motor relay
Inspect or repair the wire harness or
7 purple/white is dropped to ground, Replace the relay
replace the computer
the blower motor rotates
CAUTION:
• Measure with the connector connected.

• For the sake of safety, have the air conditioner, vehicle key switch and light switch all OFF when working
with direct connections in place.
The blower motor speed does not change

Part 1
Step Action Yes No
• Inside air sensor or harness
HL. * is displayed on the panel set
• The inside air sensor connector is Replace the blower
1 temperature display section.
disconnected or has a contact defect amp or computer
* is No. 0 to 9.
Part 2
Step Action Yes No
Does the blower motor fail to change
1 speed when the mode is other than Go to Step 2 See Part 1
FACE?
While operating under restrictive control
2 Is the door or front window open? See Part 1
by door switch or front window switch
The magnetic clutch does not engage

Step Action Yes No
The snow mark
When the AUTO switch or AC switch flashes and E is
1 Go to Step 2
is pressed, the snow mark lights up displayed on the
panel display section
2 Voltage is applied to the clutch Clutch defect. Replace the compressor Go to Step 3
Pressure switch defect or coolant pressure
Voltage is applied between the
3 abnormally high or low Go to Step 4
harness and pressure switch
See the cooling cycle troubleshooting
Voltage is applied between the vehicle
4 side harness connector blue/red and Go to Step 5 Inspect the clutch fuse
ground (black)
Is there trouble in the air conditioner
5 Replace computer Replace the harness
harness?
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Refresh/recirculate mode does not switch

Step Action Yes No
The refresh/recirculate motor actuator
The refresh/recirculate mode display
connector is disconnected, there is a
1 on the operation panel LCD display Go to Step 2
contact defect, or there is trouble with the
section is flashing
motor actuator or the main harness
There is foreign matter on the
refresh/recirculate motor actuator Remove the foreign matter or replace the Replace the motor
2
lever section or the motor actuator part actuator
lever section is broken
The mode is not switched

Standard
Step Action Yes No
value
The refresh/recirculate motor
actuator connector is disconnected,
The passenger icon display on
there is a contact defect, or there is
1 the operation panel LCD display Go to Step 2
trouble with the motor actuator or the
section is flashing
main harness.
Inspect or replace
The motor actuator rod is
2 Go to Step 3 Correction
correctly in place
A damper lever is correctly in
3 Go to Step 4 Correction
place
• Foreign matter or breakage at cam
section or damper shaft section
• Operation defect due to soiling
When the cam with the rod with grease or the like Replace the
2 kgf or
4 removed is moved by hand, it is motor actuator
more • Remove the foreign matter or
sluggish ( 2 kgf or more) or computer
replace the part
• Clean the cam section, and then
apply grease
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Index
Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls - 051

Air-conditioning switch panel - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Air-conditioning switch panel - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Heating, Ventilation, and Air-Conditioning (HVAC) control system -

050

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Contents
Heating, Ventilation, and Air-Conditioning (HVAC) control system - 050
FUNCTIONAL DATA
Heating, Ventilation, and Air-Conditioning (HVAC) control system

Air-conditioning system pressure switch
Temperature sensor
Evaporator temperature sensor - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Sun load sensor
SERVICE
Heating, Ventilation, and Air-Conditioning (HVAC) control system

Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Cab heater blower unit
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Blower
Replace - Blower amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Replace - Motor actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Blower motor
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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Electrical systems - Heating, Ventilation, and Air-Conditioning (HVAC) control system

Static description
Blower
The power transistor receives the base current from the control unit and changes the speed of the fan motor.
Blower amp inspection
The blower amp can be easily judged by removing the blower amp connector and checking for continuity across the
blower amp terminals.
SMIL14CEX1967EB 1
Terminal No.
Continuity
1 2 3
+ --- - Yes ( 4.7 kΩ)
Tester - + --- No
+ - --- Yes (diode parallel forward direction)
SMIL14CEX1968EA 2
a. Temperature fuse: 132 - 138 °C (269.6 - 280.4 °F)
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Relay
4-pole relays are used for the blower OFF relay and compressor relay.
SMIL14CEX1969EA 3
Blower OFF relay
This relay receives the signal from the control amp and switches the blower OFF relay ON. When the blower OFF
relay is switched ON, the power supply voltage is fed to the blower motor via the blower amp and the blower motor
is started.
Compressor relay
The compressor relay is switched ON/OFF by the control amp compressor control.
Relay inspection contents
1. Relay
2. Coil resistor: 0.32 kΩ
3. Specification voltage: DC 20 - 30 V
4. Be careful. The coil side of this relay must be installed with the poles facing correctly.
5. Inspection: Inspect for continuity between 3 and 4 under the conditions below.
20 - 30 V applied between terminals 1 and 2 : Continuity

No voltage applied between terminals 1 and 2 : No continuity
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Air mix actuator

NOTICE: The air conditioning system voltage specifications are 24 V, but the motor actuator has 12 V specifications.
The air mix actuator is installed at the center of the air conditioner unit contained behind the link cover. It opens and
closes the air mix damper via the link.
Built into the air mix actuator is the potentiometer which switches linked with the actuator shaft. When the target air
mix door position is determined by the temperature control switch, the control unit reads in the potentiometer position
in the actuator and determines whether the motor turns forward or reverse.
The contacts move linked with the motor. When the contacts move open or the control unit output signal goes OFF,
the motor stops.
SMIL14CEX1970EA 4
SMIL14CEX1971EB 5
1. M/A 1 4. Potentiometer
2. M/A 2 5. 5 V DC
3. GND
Terminal
Direction of rotation 1 2
Clockwise (forward) + -
Counter-clockwise (reverse) - +
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Refresh/recirculate actuator
SMIL14CEX1972EA 6
The refresh/recirculate switch actuator is installed on the blower intake unit. It opens and closes the refresh/recirculate
door via the link.
Built into the refresh/recirculate switch actuator is the potentiometer that switches linked with the actuator shaft.
When the refresh/recirculate door position is determined by the refresh/recirculate switch on the control panel, the
control unit reads in the signal of the potentiometer in the actuator and determines whether the motor turns forward
or reverse.
The position detection switch also rotates linked with the motor and stops the refresh/recirculate door at the set po-
sition.
Blow mode actuator
SMIL14CEX1973EA 7
The blow mode actuator is installed at the center of the air conditioner unit contained behind the link cover. It opens
and closes the mode door via the link.
Built into the blow mode actuator is the potentiometer which switches linked with the actuator shaft.
When blow mode is determined by the temperature control switch, the control unit reads in the potentiometer position
in the actuator and determines whether the motor turns forward or in reverse.
The contacts move linked with the motor. When the contacts move open or the control unit output signal goes OFF,
the motor stops.
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Dynamic description
Back-up function
Even when air-conditioner operation is stopped (switched OFF) with the vehicle main key power supply or operation
panel ON/OFF switch, the set temperature and all the other setting states are stored in memory, so the next time air
conditioner operation starts, it goes into the same state as before it was stopped.
When the vehicle main key power supply is cut off, the data is backed up by storing it in the internal EEPROM.
However, if the main key power supply is cut off within 0.5 s of switch input, that switch input is not stored into memory.
Also, the data read out from EEPROM when the power is switched ON is judged to see if it is within the valid range. If
data outside the valid range was written into memory, for example due to noise, then operation starts from the default
setting values to avoid abnormal operation.
Fahrenheit temperature display

To switch, hold down both the temperature setting UP and DOWN switches for 5 s.
The display toggles between Celsius and Fahrenheit display each time the switches are both held down for 5 s.
The Fahrenheit display is a 2-digit integer and below the decimal point is not used, so "F" is displayed.
However, in case of trouble, this display takes priority.
When this display is switched, the new status is backed up in memory, so even if the main key power supply is
switched OFF, the display status is retained.
Internal calculations are all done in Celsius. Only the operation panel display is in Fahrenheit.
Therefore, the display may differ slightly from the exact Fahrenheit temperature.
Air mix motor actuator control

1. Summary explanation.
The provisional target degree of opening is determined from the target blow temperature and the current blow
mode, various restrictions are applied, and the target degree of opening is calculated.
Then drive is output to move the motor actuator position to the target degree of opening. Below are the details.
2. Heater unit hysteresis correction operation (motor actuator one-direction stop).
After the actuator moves to the target degree of opening, it returns to the specified position. However, if the target
degree of opening is less than 0°, the actuator is treated as having reached the target degree of opening when it
reaches 0°, then it moves to the specified position. (A stop in the fully-open direction is used as the reference.)
3. Motor actuator operation priority order.
The operation priority for this motor actuator is No. 1.
This means that if the target degree of opening for this motor actuator changes and operation becomes necessary,
even if some other motor actuator is operating, that other motor operation is paused, and this motor actuator
operates.
4. Motor actuator retry control.
Even when there are no changes to the target values after the target is attained, if the difference between the
current value and the target value once every 5 min is equal to or greater than the operation start angle, the motor
actuator is operated.
Blow mode motor actuator control

1. Summary explanation.
The blow mode is switched by rotating the diffuser switching damper with the motor actuator. There are 2 types
of control: auto and manual.
2. Auto control.
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When AUTO blow mode is set, the blow mode changes to auto control.
During auto control, the diffuser is switched according to the target blow temperature.
Auto control continues until operation of the blow mode select switch is recognized.
SMIL14CEX1895EB 1
*1. Target blow temperature *4. Mode 3 B/L

*2. Blow mode *5. Mode 4 foot
*3. Mode 2 vent
3. Manual control
A. When operation of the blow mode select switch is recognized, the blow mode motor actuator is driven to attain
the output shaft angle below and the display is switched too. Each time operation of the switch is recognized,
the display switches MODE 1 → MODE 2 → MODE 3 → MODE 4 → MODE 1 →.
However, if this switch is pressed during auto control, auto control is ended and the diffuser is fixed at its current
position.
B. MODE 5 in the table below only occurs when operation of the DEF select switch is recognized.
After that, when operation of the blow mode select switch is recognized, the blow mode becomes the one that
was in effect just before operation of the DEF select switch was recognized.
Also, even if the DEF switch is pressed again during this mode, the mode is not canceled.
Blow mode MODE 1 MODE 2 MODE 3 MODE 4 MODE 5

Blow mode
motor
actuator 90 ° 67 ° 48 ° 26 ° 0°
degree of
opening
FACE VENT B/L FOOT DEF
Panel display
4. Blow mode control priority order

The priority order for auto control and manual control is as follows.
1. Manual control
2. Auto control
Refresh/Recirculate switch motor actuator control

1. Recirculate mode
In refresh mode, when it is recognized that the refresh/recirculate select switch on the operation panel has been
closed, the system goes into recirculate mode. At this time, the display switches to recirculate and the motor actuator
operates to the refresh angle (damper angle) of 0 ° (motor actuator angle 90 °).
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2. Refresh mode
In recirculate mode, when it is recognized that the refresh/recirculate select switch on the operation panel has been
closed, the system goes into refresh mode. At this time, the display switches to refresh and the refresh/recirculate
switch motor actuator operates to the refresh angle.
A. Refresh mode I.
When blow mode control is manual and is set to B/L or FOOT, the set temperature is set to 32 °C (89.6 °F)
(HOTMAX), and air flow control is manual and is set to Hi, the refresh angle (damper angle) operates to 67 °
(motor actuator angle 48 °).
B. Refresh mode II.
When in a mode other than refresh mode I, the refresh angle (damper angle) operates to 30 ° (motor actuator
angle 0 °).
3. Operation stop judgment

A. The operation motor actuator stops when the current position comes within the target position range.
B. The stopped motor actuator operates when the current position goes beyond the target position range.
Refresh/recirculate mode and refresh/ recirculate display

Refresh/ recirculate mode Recirculate Outside air
Panel display
Blower amp control

1. Summary explanation
The air flow is controlled by outputting to the blower amp connected in series with the blower motor.
The air flow is switched by varying the analog voltage output by changing the PWM output duty ratio and increasing
or decreasing the blower motor speed.
There are 2 types of air flow control: auto air flow control and manual air flow control.
Also, in auto air flow control, the air flow is restricted by the cold blast prevention control etc.
2. Manual air flow control
Each time it is recognized that the air flow UP switch has been closed, the air flow is fixed to the next higher level of
air flow from Lo → M1 → M2 → M3 → M4 → Hi.
When Hi is already displayed, the air flow is not changed.
In the same way, each time it is recognized that the air flow DOWN switch has been closed, the air flow is fixed to the
next lower level of air flow from Hi → M4 → M3 → M2 → M1 → Lo. When Lo is already displayed, the air flow is not
changed.
The same is true when air flow control is switched from auto to manual. For example, when AUTO M1 is displayed,
if it is recognized that the air flow DOWN switch has been closed, the display becomes Lo and AUTO is no longer
displayed.
Also, the change speed for air flow output switchover is the same as discussed for auto below.
Relationship between air flow and display during manual operation

Lo (minimum Hi (maximum
Air flow M1 M2 M3 M4
air flow) air flow)
Blower air flow
40 % 46 % 54 % 64 % 80 % 100 %
%
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Relationship between air flow and display during manual operation
Display
3. Auto air flow control
When it is recognized that the AUTO switch has been closed, the air flow is controlled automatically and AUTO is
displayed.
1. During auto air flow control, the air flow is set according to the target blowing temperature as shown in the
diagram below.
2. Auto air flow control continues until closing of either the air flow UP or air flow DOWN switch is recognized.
3. The auto air flow amount calculation results are continuous, not divided into levels.
4. When it is recognized that the AUTO switch has been closed, the display becomes as in the table below ac-
cording to the results of the auto air flow amount calculation.
5. The normal auto air flow output change is roughly 5 V.
6. Auto air flow control is restricted by the cold blast prevention control described in (4), which is the next item.
SMIL14CEX1903EB 2
Relationship between air flow and target blow temperature
*1. Target blow temperature *5. M3

*2. Auto air flow *6. M2
*3. Hi *7. M1
*4. M4 *8. Lo
Display refreshing and air flow output correspondence table

Current display Item Target % (about)
Lo display Output range changed to M1 When 44 % or higher
M1 display Output range changed to Lo When 40 % or lower
M1 display Output range changed to M2 When 52 % or higher
Output range changed to M1 When 48 % or lower
M2 display
Output range changed to M3 When 61 % or higher
M3 display
Output range changed to M4 When 74 % or higher
M4 display
Output range changed to Hi When 88 % or higher
Hi display Output range changed to M4 When 84 % or lower
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4. Cold blast prevention control
The air flow is restricted according to the value of the coolant temperature data and other parameters sent from the
vehicle side via CAN communication.
The air flow restriction has 2 levels - air flow 0 and air flow Lo. Whether or not to use the restriction is determined
from the judgment results.
1. Conditions under which cold blast prevention control is used.

A. When air flow is set to AUTO.
B. When set temperature - inside air sensor temperature 11.
C. When the coolant temperature signal from vehicle is the lower than 30 °C (86 °F) signal or the 30 °C (86 °F)
or higher but lower than 45 °C (113 °F) signal.
Under the condition above, the inside air sensor temperature is the value immediately after the vehicle main
key power supply is switched ON and AUTO and Tset are according to the current switch states.
Therefore, when the AUTO switch is pressed after the air flow has been set manually, if the coolant temper-
ature is within the cold blast prevention range, the air flow is restricted.
In the same way, even if the set temperature is changed, if the conditions are met, the air flow is restricted.
While cold blast prevention control is being executed, the display corresponds to the restricted air flow.
2. Air flow 0 control

When the coolant temperature signal from vehicle is the lower than 30 °C (86 °F), the air flow is set to 0.
This continues until a coolant temperature signal of 30 °C (86 °F) or higher is received.
Once a coolant temperature signal of 30 °C (86 °F) or higher is received and these conditions are no longer met,
air flow 0 is ended.
3. Air flow Lo control
When the coolant temperature signal from vehicle is the 30 °C (86 °F) or higher but lower than 45 °C (113 °F)
signal, the air flow is set to Lo.
This continues until a coolant temperature signal of 45 °C (113 °F) or higher is received.
Also, the same as for air flow 0 control, this shift is irreversible. Once a coolant temperature signal of 45 °C
(113 °F) or higher is received, control is normal.
5. Blower air flow control when mode motor actuator angle switched
When the mode motor actuator is operated with the blower air flow at M1 or higher, the mode motor actuator is oper-
ated with the blower air flow first set to Lo. After the end of operation, the original blower air flow returns. Changes
to the blower output at this time are the same as normal auto air flow control. However, the blower display is not
changed during control.
6. Air flow control priority order
The priority order for auto air flow control, manual air flow control, and cold blast prevention control is as follows.
Priority order Control

1 Blower air flow control when mode motor actuator angle switched
2 Manual air flow control
3 COOLMAX control
4 Cold blast prevention control
5 HOTMAX control
6 Auto air flow control
Compressor clutch control

The compressor clutch is controlled by the power to the clutch coil being switched ON/OFF by an external relay.
This control is executed by thermo operation and the fletching prevention function.
Thermo operation has control mode 1 and control mode 2. These modes are applied according to the blow mode and
other conditions.
However, for blower air flow 0, the compressor clutch is switched OFF.
The operation temperature does not include the thermistor variation.
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2. Thermo operation (AC switch ON)
Control mode switchover
• When the blow mode is B/L and the target blow temperature is as in the diagram below, control mode 2 is used.
As the diagram shows, there is hysteresis between control modes 1 and 2.
• Other than the above is all control mode 1.
SMIL14CEX1904EB 3
*1 Target blow temperature

*2 Control mode 1
*3 Control mode 2
3. Fletching prevention function
Operation conditions
1. After the end of initial operation, if 4 - 5 min continue with the air flow M3 or higher and the compressor clutch
not coming ON even once, the compressor clutch is switched ON one time.
This control is cleared by the vehicle main key power supply being switched OFF and this control starts again
when this power supply is switched ON again.
2. This control takes priority over all other control.
4. AUTO switch link function
When operation of the AUTO switch is recognized, compressor clutch control comes ON and AUTO is displayed.
1. Compressor clutch control is the same control as for the AC switch being switched ON.
2. When it is recognized that the AC switch has been switched OFF, the AUTO display goes out.
Even when it is recognized that the AC switch has been switched ON again, AUTO is not displayed.
However, at this time, if the main key power supply is switched OFF, then ON again, since the AC ON, air flow
AUTO, and blow mode AUTO conditions are all met, AUTO is displayed.
COOLMAX control and HOTMAX control

When the set temperature is 18 °C (64.4 °F) [COOLMAX]
1. The air mix motor actuator is set to the 0 ° limiter position (fully closed).
2. For auto air flow control, the air flow is set to Hi.
3. For AUTO blow mode control, the blow mode is set to VENT.
When the set temperature is 32 °C (89.6 °F) [HOTMAX]

1. The air mix motor actuator is set to the 90 ° limiter position (fully open).
2. For auto air flow control, the air flow is set to M4.
3. For AUTO blow mode control, the blow mode is set to FOOT.
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Abnormality detection and control after abnormality detected

If there is an abnormality in a motor actuator drive line or sensor computer input circuit, the abnormality is detected
and control after detection is performed as described below. In all cases, abnormality control does not end once
abnormality has been detected and the location is returned to normal.
Trouble control is only ended when the vehicle main key power supply is switched OFF or when air conditioner
operation is stopped with the ON/OFF switch on the operation panel. However, motor actuator restriction is only
ended by switching OFF the main key power supply.
2. Trouble in a motor actuator and its input/output circuits

A. Disconnection detection
After the main key power supply is switched ON, if a motor actuator potentio-meter line is disconnected or
shorted, the display in the table below for that motor actuator is carried out and that motor actuator is not
driven until the main key power supply is switched OFF, then ON again.
Abnormality location Abnormality display

HL. E is displayed on the set temperature display LCD.
Air mix motor actuator
See the diagram below.
Blow mode motor actuator The passenger icon display flashes.
Refresh/recirculate switch motor actuator The refresh/recirculate mark flashes.
SMIL14CEX1905EB 4
B. Motor lock detection

If the output shaft rotation angle of a motor actuator does not reach the target value within 15 s, locking is detected,
output to that motor is stopped, and the abnormality is displayed on the computer according to the abnormality
location.
Abnormality location Abnormality display

HL. E is displayed on the set temperature display LCD.
Air mix motor actuator
See the diagram below.
Blow mode motor actuator The passenger icon display flashes.
Refresh/recirculate switch motor actuator The refresh/recirculate mark flashes.
SMIL14CEX1905EB 5
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3. Trouble in a sensor or its input circuit (disconnection or short)
Disconnection or short in the inside air sensor or its input circuit

A. Operator compartment temperature control end
○ The operator compartment temperature control (all control related to target blow temperature) is stopped and
the air mix degree of opening is directly adjusted according to the temperature adjustment switch input.
○ Accompanying this, the operation panel set temperature display changes as in the diagram below.
○ HL.*
* is a value between 0 - 9, and each time the DOWN switch is closed, this value decreases by 1; each time the
UP switch is closed, this value increases by 1.
*value Motor actuator degree of opening (°)

0 0°
1–8 * value x 10°
9 90°
B. Auto air flow control end

■ The air flow is temporarily fixed at the setting that was in effect when the inside air sensor abnormality was
detected.
■ The AUTO display is set flashing.
■ After this, the air flow can be switched by the manual air flow switch.
C. AUTO blow mode control end

■ The air flow is temporarily fixed at the setting that was in effect when the inside air sensor abnormality was
detected.
■ The AUTO display is set flashing.
■ After this, the air flow can be switched by the manual air flow switch.
D. Air mix damper degree of opening display priority

■ Even if the trouble shown by one of the items below occurs during inside air sensor trouble, E is not displayed
in the * section below the decimal point and the air mix damper degree of opening display is given priority.
■ HL.E is only displayed for air mix motor actuator trouble.
E. Thermo operation control mode fixed

■ Switching of the control mode according to the blow mode and target blow temperature is stopped and the
control mode is fixed at control mode 1.
Disconnection or short in the inside evaporator sensor or its input circuit
A. Compressor control is not executed and the compressor clutch is always OFF.
B. E is displayed in the first fraction position of the set temperature display LCD. See the diagram below. (The tem-
perature setting is in 33.8 °F steps.) However, E is not displayed for inside air sensor trouble.
C. The AC mark flashes.
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SMIL14CEX1906EB 6
Disconnection or short in the inside evaporator sensor or its input circuit
*1. The AC mark flashes

*2. E is not displayed
Disconnection or short in the solar radiation sensor or its input circuit
A. The solar radiation compensation data is set to 0.

B. E is not displayed in the first fraction position of the set temperature display LCD as it is for other sensors.
Coolant temperature signal trouble.

Cold blast prevention control does not work and normal control is used.
4. CAN communication abnormality processing
Recovery from bus off

A. Initial retry processing: 5 ms.
B. Re-retry processing: every 1 s.
C. Bus off retry processing is performed at the above rate.
Receiving data abnormality

A. Definition: The data field is outside the prescribed range regardless of whether the receiving data is operating
normally or abnormally.
B. Processing: In the case of the former, all data that time are discarded and the previous data are retained.
C. In the case of the latter, data is discarded only for those items determined to be abnormal.
Communication interruption abnormality

A. Interruption judgment
Monitor Display: When normal reception is not possible 1 s or more since the previous normal reception.
Engine: When normal reception is not possible 10 s or more since the previous normal reception.
B. Internal use data: Shift to alternate data (processing).
C. Sending process: Continue.
D. Recover: As soon as valid data is received.
Alternate data (processing)
Send node: ENGINE ECU

A. Outside air data abnormality
Perform estimated outside air control.
*However, once there is a shift to estimated outside air, estimated outside air control continues until the ignition is
switched OFF.
B. Coolant temperature data abnormality
Control the internal coolant temperature data to 45 °C (113 °F) (the temperature at which to avoid cold air preven-
tion control).
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Send node: MONITOR DISPLAY ECU

A. Open window signal data abnormality.
Perform control with the internal open window data closed.
B. Open door signal data abnormality.
Perform control with the internal open door data closed.
Alternate data (processing) up to initial normal reception
Send node: ENGINE ECU

A. Outside air data abnormality.
Within 5 s after ignition is turned on: No data.
After 5 s after ignition is turned on: Perform estimated outside air control.
B. Coolant temperature data abnormality
Within 5 s after ignition is turned on: Perform control at 30 °C (86 °F) (the temperature at which to control cold air
prevention).
After 5 s after ignition is turned on: Perform control at 45 °C (113 °F) (the temperature at which to avoid cold air
prevention control).
Send node: MONITOR DISPLAY ECU

A. Open window signal data abnormality.
Perform control with the internal open window data closed.
B. Open door signal data abnormality.
Perform control with the internal open door data closed.
Monitor mode
Monitor mode is a mode for understanding abnormalities in the operation panel itself or in other control.
The system goes into monitor mode when there is the special switch input below on the operation panel.
2. Starting monitor mode

When the air conditioner is operating with basic control, if the operation panel ON/OFF switch closed path contin-
ues for 1 s while the refresh/recirculate select switch closed path is ongoing, monitor mode is started.
3. Monitor contents
A. LCD segment diagnosis
When monitor mode is entered, the target LCD lights up for 1 s
An LCD with trouble does not light up.
B. Sensor diagnosis
The detection value [AD value or °C (°F)] for each sensor is displayed.
C. Coolant temperature signal recognition value
This displays the reception status for the coolant temperature signal sent from the vehicle.
4. Display contents in monitor mode

In monitor mode, the data (detection value for each sensor, coolant temperature signal recognition, etc.) is dis-
played in the 3-digit of the 7-segment display for the temperature setting.
The data displayed is selected with the blower UP/DOWN switches and AUTO switch.
The blower UP/DOWN switches move the display on the dedicated monitor mode 7-segment display through 16
displays, 0 - F, and the corresponding data is displayed. (Table A)
Hexadecimal data display and decimal data display can be selected with the AUTO switch.
Only for the coolant temperature signal recognition value, the value detected immediately before entry into monitor
mode is displayed.
The difference between hexadecimal data and decimal data is indicated by the 3rd digit of the 7-segment display.
For hexadecimal data, "H" is displayed there and for decimal data, numbers (0 - 9) are displayed there.
A. Hexadecimal display
AD values 00H - FFH are displayed.
When the AD value corresponds to that in Table B (or Table C for the solar radiation sensor), this indicates a
disconnection or short.
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In the hexadecimal display, when the value of a sensor changes in monitor mode, the hexadecimal display
changes with it.
If the display before entering monitor mode was , the error judgment value is displayed. (In other words,
the detected value before the abnormality was detected) In the same way, if the display before entering monitor
mode was , the display becomes **.E and the error judgment value is displayed.
B. Decimal display
From -99.9 - 99.9 °C (-147.8 - 211.8 °F) is displayed with decimals.
Also, the "-" minus display is displayed on the left side of the 3 digit segment.
5. Air-conditioner operation in monitor mode

When the system enters monitor mode, all output (operation) through control is stopped and until monitor mode is
ended, operations and settings of basic control through all the switches are not possible.
6. Ending monitor mode

In monitor mode, if the operation panel ON/OFF switch closed path continues for 1 s while the refresh/recirculate
select switch closed path is ongoing, monitor mode is ended and the system returns to the basic control state.
The same also occurs if the vehicle main key power supply is switched OFF.
Table A
Exclusively for
monitor mode Display contents
7-segment
0 Inside air sensor temperature data
1 Evaporator sensor temperature data
2 Solar radiation compensation data
3 Outside air data
4 –
Coolant temperature signal status data
30 °C (86 °F) or
Lower than 30 °C 45 °C (113 °F) or
C Abnormal higher Lower than
(86 °F) higher
45 °C (113 °F)
4 1 2 3
5–F Data (sensor diagnosis etc.)
Table B
Sensor name Short Disconnection
Inside air sensor F6H 0CH
Evaporator sensor F6H 0CH
Table C
Sensor name 5 V short Ground short
Solar radiation sensor D5H 0CH
Door switch control

This control adds a restriction to air-conditioner operation with the door switch or front window switch. Its purpose
is to prevent overheating of the vehicle main unit.
Concretely, it suppresses condenser heating and controls in a way restricted in order to obtain a feeling of comfort.
2. Door switch/front window switch signal

Due to data sent from CAN communication.
Message ID: 0x18FF1028

Send node: Monitor Display
Send cycle: 10 ms
Data: Open door signal and open window signal data
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Data judgment: Set with continuous 5 times of the same data for 20 ms cycle sampling
3. Control restricted by door switch/front window switch
A. Starting restricted control

When either the door or front window is open continuously for 1 s or longer, it is recognized that the switch is
open.
At the count of 60 s, the buzzer buzzes the same way as for switch input to tell the operator that restricted
control is starting and that control starts.
B. Restricted control
■ For both auto and manual blow mode control

Regardless of being selected in either auto or manual blow mode, unless the blow mode is FACE, the following
air flow restriction is executed. (If the blow mode is FACE, the air flow is not restricted.)
I. If the target blow temperature < 68.0 °F, the air flow upper limit is set to M1.
II. If the target blow temperature 77.0 °F, the air flow restriction in I is ended.
■ When the current blow mode control is AUTO
Auto control with the AUTO blow mode VENT changed to FACE is used.
■ When the current blow mode control is manual selection
Only if the blow mode is VENT immediately after the open switch is recognized, that mode is changed to FACE.
After this, all the blow modes can be selected with manual operation.
C. Ending the restriction

When both the door and front window are closed continuously for 1 s or longer, it is recognized that the switches
are closed.
After a count of 1 s, the buzzer buzzes the same way as for switch input to tell the operator that restricted control
has been ended.
When the restricted control is ended, the restriction on the air flow discussed in 1. above and the change from
VENT to FACE in 3. are ended and control returns to normal.
However, if the blow mode has been manually selected, even if the mode was changed from VENT to FACE by
the above restriction, it does not return to VENT when the restricted control is ended.
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Air-conditioning system pressure switch - Static description

Dual pressure switch
LPIL12CX02362EA 1
The dual pressure switch is installed on the receiver dryer. When there is pressure trouble in the coolant high-pressure
side line (abnormally high pressure or abnormally low pressure), the dual pressure switch contacts open up to cut off
the compressor power and protect the cooling cycle.
SMPH14CEX6783EB 2
Dual pressure switch specifications
1 Lower-pressure side
2 High-pressure side
Simple inspection method for dual pressure switch.

1. With the cooling cycle stopped, remove the connector from the switch and check for continuity between the switch
side connector terminals using the tester. If there is continuity, the switch is normal. (When the outside air tem-
perature is 0 °C (32 °F) or higher)
2. Connect the gauge manifold high-pressure side hose to the high-pressure side charge port. With the cooling cycle
operating, the condenser front surface is covered with a plate shaped object and the high pressure rises. If the
compressor stops around 3.14 MPa (455.457 psi) , the switch is normal.
3. With the refrigerant removed, check for continuity between the switch side connector terminals using the tester. If
there is no continuity, the switch is normal.
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Temperature sensor - Static description

Inside air sensor
SMIL14CEX1978EA 1
The inside air sensor is installed in the inside air side intake port of the air conditioner unit and switches the tempera-
ture inside the cab to the resistance.
This resistance value is converted into a voltage value in the control panel and processed.
Inside air sensor inspection method

• Remove the inside air sensor connector from the main harness and measure the resistance between the sensor
side connector terminals using the tester.
Inside air sensor inspection details (specifications)

For 0 °C (32 °F) 7.2 kΩ ± 3 %
Resistance between terminals
For 25 °C (77 °F) 2.2 kΩ ± 3 %
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Temperature sensor Evaporator temperature sensor - Static

description
Evaporator sensor
In order to prevent the evaporator from freezing, the evaporator blow temperature is detected and the compressor
ON/OFF is controlled.
SMIL14CEX1974EA 1
Evaporator sensor inspection method

• Remove the evaporator sensor connector from the main harness and measure the resistance between the sensor
side connector terminals using the tester.
Specifications value
Detected temperature at sensor
7.2 kΩ
section: 0 °C (32 °F)
Resistance between terminals
Detected temperature at sensor
2.2 kΩ
section: 25 °C (77 °F)
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Sun load sensor - Static description

Solar radiation sensor
This is the air conditioner solar radiation correct sensor. It detects the strength of sunlight with a photodiode, converts
it into milli-amp and sends that to the controller.
SMIL14CEX1977EA 1
Solar radiation sensor inspection method

• Disconnect the solar radiation sensor connector from the harness and measure the voltage between the sensor
side connector terminals using the tester's voltage measurement mode. The voltage must be different when light is
striking the photoreceiver section and when it is not. (The voltage is about 0 V when absolutely no light is striking
the photoreceiver.)
NOTICE: Always measure with the tester in voltage measurement mode (V mode). Measuring in resistance mode (Ω
mode) would destroy the sensor
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Inspect
Air mix motor actuator inspection
SMIL14CEX1950EB 1
1. Control panel 3. Connector 1

2. Air mix motor actuator 4. Connector 9
Step Action Standard value Yes No

Press the temperature setting
switches and set to COOLMAX 18 °C
(64.4 °F) Does the actuator operate
at all?
Damper lock or link
2 Is an error displayed? Go to Step 6
defect
Press the temperature setting
switches and set to HOTMAX 32 °C
(89.6 °F)Does the actuator operate at
all?
4 Is an error displayed? Go to Step 5 Control panel defect
Actuator defect or
Is there continuity in harness between
5 damper lock or link Harness defect
the actuator and control panel?
defect
Remove the actuator connector (9).Is
6 the resistance between L/Y and B/L of About 4.7 kΩ Go to Step 7 Actuator defect
the actuator about 4.7 kΩ?
Is there continuity between the G/L
7 and L/Y and between G/L and B/L of Control panel defect Actuator defect
the actuator?
Set temperature Air mix motor actuator position

COOLMAX 18 °C (64.4 °F) 0°
HOTMAX 32 °C (89.6 °F) 90 °
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Refresh/recirculate switch motor actuator inspection
SMIL14CEX1951EB 2

2. Refresh/recirculate motor actuator 4. Connector 11

Press the refresh/recirculate switch.
Does the actuator operate at all?
Damper lock or link
defect
Actuator defect or
defect
Remove the actuator connector (11).Is
5 the resistance between L/Y and B/L of About 4.7 kΩ Go to Step 6 Actuator defect
the actuator about 4.7 kΩ?
Is there continuity between the L/G
6 and L/Y and between L/G and B/L of Control panel defect Actuator defect
the actuator?
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Mode motor actuator inspection
SMIL14CEX1952EB 3

2. Mode motor actuator 4. Connector 10

Press the refresh/recirculate switch.
Does the actuator operate at all?
Actuator defect or
defect
Damper lock or link
defect
Remove the actuator connector
5 (10).Is the resistance between L/Y About 4.7 kΩ Go to Step 6 Actuator defect
and B/L of the actuator about 4.7 kΩ?
Is there continuity between the Y/L
6 and L/Y and between Y/L and B/L of Control panel defect Actuator defect
the actuator?
Blow mode MODE 1 MODE 2 MODE 3 MODE 4 MODE 5

Blow mode motor
actuator degree of 90 ° 67 ° 48 ° 26 ° 0°
opening
FACE VENT B/L FOOT DEF
Panel display
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Cab heater blower unit - Replace

WARNING
Avoid injury!
W1128A
1. Remove the connectors connected to the refresh/recir-

culate motor actuator connector (1), blower motor con-
nector (2), inside air sensor connector (3), evaporator
sensor connector (4) and relay connector (5).
SMIL14CEX1809AB 1
2. Remove the filter cover (1) and inside air filter (2).
• Remove the 4 Phillips screws (3) M5x16 and remove
the intake case (4).
SMIL14CEX1809AB 2

dure.
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Blower - Replace - Blower amplifier

CAUTION:
• Never disassemble the blower amp.

• Removing with the power on can suddenly increase the blower amp temperature, damaging the part.
• Also, touching the surface could cause burns.
1. Remove the connector (1) from the blower amp (2).

the blower amp (2).
• To install, perform the reverse of the removal proce-
dure.
SMIL14CEX1811AB 1
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Blower - Replace - Motor actuator

1. Replacement of mode motor actuator
• Remove the link cover.
• Remove the connector (2) from the motor actuator
(1).
• Remove the 3 Phillips screws (3) M4x16 securing
the motor actuator (1), remove the rod (4) attached
to the motor actuator (1) from the rod hole on the
mode cam, and then install the new motor actuator
(1). The installation procedure is the reverse of the
removal procedure.
SMIL14CEX1817AB 1
2. Replacement of air mix motor actuator

(1)
• Remove the 3 Phillips screws (3) M4x16 securing
the motor actuator (1), remove the rod (4) attached
to the motor actuator (1) from the rod hole on the
damper lever, and then install the new motor actua-
tor (1). The installation procedure is the reverse of
the removal procedure.
SMIL14CEX1818AB 2
3. Replacement of refresh/recirculate motor actuator

(1)
• Remove the 3 Phillips screws (3) M4x16 securing the
motor actuator (1), remove the lever pin (4) attached
to the motor actuator (1) from the slot hole, and then
install the new motor actuator (1). The installation
procedure is the reverse of the removal procedure.
SMIL14CEX1819AB 3
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Blower motor - Replace

CAUTION: Do not remove the fan from the blower motor.
1. Remove the cooling hose (2) from the air conditioner

unit (1).
the blower motor (4).
• To install, perform the reverse of the removal proce-
dure.
SMIL14CEX1810AB 1
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Index
Heating, Ventilation, and Air-Conditioning (HVAC) control system - 050

Air-conditioning system pressure switch - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Blower - Replace - Blower amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Blower - Replace - Motor actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Blower motor - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Cab heater blower unit - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Heating, Ventilation, and Air-Conditioning (HVAC) control system - Dynamic description . . . . . . . . . . . . . . . . . . . . . 7
Heating, Ventilation, and Air-Conditioning (HVAC) control system - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Heating, Ventilation, and Air-Conditioning (HVAC) control system - Static description . . . . . . . . . . . . . . . . . . . . . . . . 3
Sun load sensor - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Temperature sensor - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Temperature sensor Evaporator temperature sensor - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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Cab controls (Lift arm, Boom, Dipper, Bucket) - 524

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Contents
FUNCTIONAL DATA
Overload switch
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Electrical systems - Cab controls (Lift arm, Boom, Dipper, Bucket)
Overload switch - Dynamic description

Purpose/overview
Overload warning device for lifting work of the excavator.
The machine sounds alarm with a judgment of possible falling when bottom pressure of the boom cylinder exceeds
specified pressure (overload warning).
SMIL14CEX4202EB 1
(*1) Overload switch

(*2) Color monitor
(*3) Main controller
(*4) Overload pressure sensor
Operation condition
The machine sounds alarm under the following conditions when the overload switch is ON. No alarm is sounded
when the overload switch is OFF.
• Starting overload alarm - Established by continuing (boom bottom pressure setting pressure) for 1 s.
• Stopping overload alarm - (boom bottom pressure setting pressure - 1 MPa (145.05 psi)) for 1 s.
The monitor displays "OVER LOAD" during the overload warning.
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Index

Overload switch - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Swing control system - 416

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Contents
FUNCTIONAL DATA
Swing control system

Dynamic description - Swing speed limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Dynamic description - Swing lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Electrical systems - Swing control system
Swing control system - Dynamic description - Swing speed limit

Purpose/overview
The machine applies limitation to prevent excessively high swing speed (during independent swinging only).
SMIL14CEX1048FB 1

2. Throttle volume 9. N2 pressure sensor
3. Pressure sensor (boom up) 10. P1 pressure sensor
4. Pressure sensor (arm out/in) 11. P2 pressure sensor
5. Pressure sensor (travel left/right) 12 Pressure regulator
6. Pressure sensor (swing) 13. P1 electromagnetic proportional valve
7. Pressure sensor (option 1) 14. P2 electromagnetic proportional valve
a. Arm (1) f. Arm (2)

b. Boom (2) g. Boom (1)
c. Swing h. Bucket
d. Option 1 i. Travel (right)
e. Travel (left)
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Operation
The controller controls the electromagnetic proportional valve based on signal of the pressure sensors ( N1, N2, P1,
P2) during swing independent operation to decrease flow volume of the P1 pump to the limit lowest value.
1. This initial value of output flow is 100 %, and it is gradually decreased to the limit lowest value ( 98.3 %) after the
control starts.
2. The output flow is gradually increased to 100 % after completion of the control.
• Pump flow is at no limit maximum flow volume when it is in 100 %, and is at lowest flow volume when in 0 %.
Work condition: Control starts by detecting the following conditions.

• Work mode is SP mode.
• Independent swing operation: (Swing pressure 0.5 MPa) + (travel left/right pressure 0.3 MPa) + (boom up
pressure 0.3 MPa) + arm out/in pressure 0.3 MPa + (option 1 pressure 0.3 MPa)
• The work mode is no longer SP or H .
Stop condition: Control stops by detecting the following conditions.

• Swing operation stop: (Swing pressure 0.3 MPa)
• No longer in independent swing operation: (Boom up pressure 1.0 MPa) or (arm out/in pressure 1.0 MPa)
Interruption condition: Control is interrupted by detecting the following conditions.

• Travel operation start: (Travel left/right pressure 0.5 MPa)
• Option operation start: (Option 1 pressure 0.5 MPa)
• Output flow volume is to be set to 100 % immediately in order to prevent zigzag travel or hesitating travel if control
is interrupted.
When, after the control stop or interruption conditions are eliminated, the control is started again, flow is changed
gradually in order to prevent shock due to sudden change in flow.
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Swing control system - Dynamic description - Swing lock

Purpose/overview
The swing lock function prevents any swing by turning ON the swing brake continuously for maintenance purpose
such as pressure resistance inspection in plant or swing relief pressure measurement.
SMIL14CEX4075EB 1
1. Monitor 5. Main controller

2. Working light switch 6. Swing brake solenoid
3. Auto idle switch 7. Swing brake
4. Travel mode select switch
Operation
1. The monitor monitors statuses of the travel mode select switch, the working light switch, and the auto idle switch
to transmit them to the main controller via CAN communication.
2. The main controller makes judgment/control of statuses of the respective switches based on received signal to
activate the swing brake solenoid (and the free swing solenoid as well depending on the status).
Operation condition
• Pressing and holding down the travel mode select switch + the working light switch + the auto idle switch for 3 s
turns ON the swing brake to display the swing lock icon on the monitor.
• When turning ON the key, the system starts with the swing lock ON if the swing lock was ON at the previous key
OFF. (Sustaining the previous mode)
• The system holds the swing brake ON even with operation of the upper or the swing during swing lock.
NOTE: Driving force of the swing motor exceeding brake force may cause swinging even during swing lock.
• Swing lock has a priority in the following cases.

When the swing lock is operated during free swing.
When the free swing switch is pressed during swing lock.
Stop condition
• Pressing and holding down the travel mode select switch + the working light switch + the auto idle switch for 3 s
during swing lock turns OFF the swing brake to hide the swing lock icon on the monitor.
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Index

Swing control system - Dynamic description - Swing lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Swing control system - Dynamic description - Swing speed limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Travel control system - 417

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Contents
FUNCTIONAL DATA
Travel alarm
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Electrical systems - Travel control system
Travel alarm - Dynamic description

Purpose/overview
The machine sounds alarm while traveling in order to enhance safety by cautioning operators around.
SMIL14CEX4074FB 1
1. Main controller
2. Travel pressure sensor
3. Travel alarm
Operation
• The controller applies 24 V to the travel alarm to sound the travel alarm when it detects traveling operation by the
travel pressure sensor.
Operation condition
• It sounds the travel alarm for 0.4 s to warn operators when the key is turned ON. (Key ON alarm)
• The machine checks on/off setting of the travel alarm when it detects traveling operation and sounds the travel
alarm accordingly.
Stop condition
• It stops the travel alarm when traveling operation is stopped.
• It stops the travel alarm 10 s after starting traveling operation.
• It stops the travel alarm but sounds the key ON alarm when on/off setting of the travel alarm is turned OFF.
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Index

Travel alarm - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Camera - 530

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Contents
Camera - 530
FUNCTIONAL DATA
Camera
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Electrical systems - Camera
Camera - Dynamic description

Back/side view monitor
Purpose
The system displays the image of the camera on the excavator on the monitor. (To ensure rearward visibility. To
ensure safety)
SMIL14CEX1044EB 1
1. Monitor 4. Rear camera

2. Camera screen switch 5. Side camera
3. Camera select switch
1. When the key is set in the ON position, you can view the camera screen by pressing the camera screen switch.
• Pressing the camera screen switch will toggle between the work screen and the camera screen.
• The camera screen is selectable between that with gauge and that without gauge.
2. When the camera screen is displayed, you can select a target camera by pressing the camera select switch.
• To select a camera, you need to turn ON the camera on the camera setting screen.
• The camera select switch is enabled when two or more cameras are set.
3. When a lost image is detected due to a failure (disconnection etc.) in the camera, the monitor will display the
message "CHECK CAMERA CONNECTION."
* When the work screen is displayed, pressing the camera select switch will serve as the trip meter select switch.
* If the camera is not installed, the camera screen switch is disabled.

Precautions for camera installation
1. The installation angle (1) is 40 ° and 35 ° for the rear

view camera and the side camera respectively.
2. Wipe the lens clean if it is dirty.
SMIL14CEX1045AB 2
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Index
Camera - 530
Camera - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Wiper and washer system - 518

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Contents
FUNCTIONAL DATA
Wiper and washer system

SERVICE
Windshield wiper arm

Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Windshield wiper motor
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Wiper relays
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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Electrical systems - Wiper and washer system
Wiper and washer system - Dynamic description

Purpose/overview
Control mode of the wiper consists of three types of intermittent, continuous and one-time, and the washer operates
linked to the wiper.
SMIL14CEX6742FB 1
a OPEN (ON) d CNT

b CLOSE (OFF) e WASHER
c INT
1 Monitor 6 One-time wiper switch

2 Main controller 7 Front window limit switch
3 CAN bus 8 Wiper controller
4 Washer switch 9 Wiper motor
5 Wiper switch 10 Washer motor
Operation
1. The monitor detects state of ON/OFF for each of the wiper switch, the one-time wiper switch, the front window
limit switch and the washer switch to send it to the controller via CAN communication.
2. The controller controls/processes based on the received signal to activate the wiper motor relay 1/2/3 and the
washer relay.
If CAN communication is abnormal:

• If given no instructions from MCM for 1 second or more, the monitor judges that an abnormality has occurred in
CAN and enters backup mode.
• In the backup mode, the wiper and the washer are controlled by only the monitor.
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Blade position
SMIL14CEX1041EB 2
1. Retract position 3. Lower reverse position

2. Upper reverse position
Wiper mode
Operation
Mode Blade operation
OFF Blade is returned to retract position to stop
The blade makes a single reciprocal operation and then pauses at upper reverse
Intermittent
position to start the next reciprocal operation after 3 s
The blade instantly starts next reciprocal operation after completing its single
Continuous
reciprocal operation
1. The system confirms that the blade is in retract position after the key is turned ON to start in the wiper mode OFF.
2. The wiper is switched to the wiper mode "Intermittent" when the wiper switch is pressed, and then the successive
wiper mode switches in sequence of OFF, "Intermittent," "Continuous" then OFF each time the wiper switch is
pressed. It links to icon on the monitor to switch it simultaneously.
3. Wiper mode "Intermittent" (icon on monitor light on)
A. The system confirms that the front window is closed and then moves the blade from retracted position to upper
reverse position.
B. The system continues to transit to wiping operation to move the blade to lower reverse position (forward), then
return it to upper reverse position (backward).
C. The system puts the blade in pause when it reaches the upper reverse position. After elapsing for 3 s, move
the blade reciprocally again. The system continues this action during the intermittent mode.
4. Wiper mode "Continuous" (icon on monitor light on)
A. The system does not put the blade in pause even it reaches the upper reverse position to restart reciprocal
operation. The system continues this action during the continuous mode.
5. Wiper mode OFF (icon on monitor light off)
A. The system keeps the blade moving to the retract position when it reaches the upper reverse position.
Operation condition
• The system does nothing when the blade is not in retract position when the key is turned ON. (The blade will not
be returned to retract position automatically.)
• The blade operation enters emergency stop under the following cases. (icon on monitor light off)
○ The front window is open (no starting blade operation).
○ The front window is open during blade operation (stop blade operation).
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* Blade operation is not resumed even when the front window is closed after the emergency stop. The system
confirms that the front window is closed when the wiper mode is switched to intermittent/continuous in the next
time, and then starts blade operation.
• The machine stops blade as abnormal operation with judgment as a blade lock under the following cases. (icon
on monitor continues to light on)
○ The blade is still in retract position when elapsing for 4 s after the wiper mode has been switched to intermittent/
continuous.
○ The blade is not returned to upper reverse position when elapsing for 4 s after the blade has started reciprocal
operation.
○ The blade is not retracted when elapsing for 4 s after the wiper mode was switched to OFF and the blade has
been commanded to be retracted.
* It resumes to be retracted by turning OFF the key once in the case of abnormal stop.
• It immediately starts reciprocal operation when the mode is switched to continuous during pausing at upper reverse
position in the intermittent mode.
• The blade is lowered to the lower reverse position and then pass upper reverse position to be returned to retract
position without being reversed instantly when the mode is switched to stop during the blade is moving downwards
(forward).
• The machine forces the wiper mode to OFF to retract the blade if the key is turned to OFF without returning the
wiper mode to OFF. (Auto rise up function)
One-time wiper
Operation
The blade is reciprocally operated by pressing and holding down the one-time wiper switch. The icon on the monitor
is turned off at this moment.
Operation condition
• Pressing the one-time wiper switch sets the wiper mode to "Continuous."
• Releasing the one-time wiper switch sets the wiper mode to OFF.
• Pressing the wiper mode switch while pressing and holding down the one-time wiper switch does not change the
wiper mode.
Washer
Operation
1. Washer fluid is sprayed while pressing the washer switch.
2. Pressing and holding down the washer switch for 0.5 s or more switches the wiper mode to "Continuous" (washer
link wiper). The icon on the monitor is turned off at this moment.
3. Releasing the washer switch stops spraying washer fluid, and then the wiper mode is switched to OFF after elaps-
ing 4 s.
Operation condition
• The machine stops washer fluid spraying when the front window is opened while pressing and holding down the
washer switch. Closing the front window while pressing the switch does not restart spraying.
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Windshield wiper arm - Prepare

Items to prepare:
• Wrench [ 17 mm]
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Windshield wiper arm - Remove

1. Use a wrench [ 17 mm] to remove the 1 nut (1), and
then remove the wiper arm (2).
Nut (1) tightening torque: 12 - 16 N·m (8.85 - 11.80 lb
ft)
SMIL14CEX1887AB 1
2. Use the Phillips screwdriver to remove the 2 screws (1),

and then remove the wiper (2).
SMIL14CEX1888AB 2
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Windshield wiper arm - Install

dure.
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Windshield wiper motor - Prepare

Items to prepare:
• Flathead screwdriver (longnose pliers)
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Windshield wiper motor - Remove

remove the 2 bolts (1), and then remove the side front
lower trim (2).
Bolt (1) tightening torque: 5.9 - 7.8 N·m (4.4 - 5.8 lb
ft)
SMIL14CEX1921AB 1

move the clip pins (1), and then remove ducts B (2).
SMIL14CEX1922AB 2

remove the 2 bolts (1), use a hexagon wrench [ 5 mm]
to remove the 3 bolts (2) and 3 washers (3), and then
remove the front upper trim assembly (4).
Bolt (1) tightening torque: 5.9 - 7.8 N·m (4.4 - 5.8 lb
ft)
SMIL14CEX1923AB 3
4. Use a wrench [ 17 mm] to remove the 1 nut (1), and

then remove the wiper arm (2).
Tightening torque for installation: 12 - 16 N·m (8.85
- 11.80 lb ft)
SMIL14CEX1924AB 4
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5. Remove the cover (1), and then use a wrench [ 27 mm]

to remove the 1 nut (2).
Remove the 1 washer (4) and 1 packing (3).
Tightening torque for installation: 11 - 13 N·m (8.11
- 9.59 lb ft)
SMIL14CEX1925AB 5

and then remove the wiper motor assembly (2).
SMIL14CEX1926AB 6
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Windshield wiper motor - Install

dure.
• Be careful about the wiper link and wiper arm instal-
lation location.
• Check the wiper arm wipe location and stop location.
• Tighten bolts being installed to the specified torque.
For bolts for which the torque is not specified, refer
to Cab glazing - Torque (90.156).
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Wiper relays - Prepare

Items to prepare:
• Wrench [ 10 mm]
• Flathead screwdriver
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Wiper relays - Remove

remove the 4 bolts (1), and then remove the side rear
B trim (2).
SMIL14CEX1918AB 1
2. Remove the connector (2) from the wiper controller (1).
SMIL14CEX1919AB 2
3. Use a flathead screwdriver to slightly bend the 4 instal-

lation clips (1), and then remove the wiper controller
(2).
SMIL14CEX1920AB 3
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Wiper relays - Install

dure.
For bolts for which the torque is not specified, refer to
Cab glazing - Torque (90.156).
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Index

Windshield wiper arm - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Windshield wiper arm - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Windshield wiper arm - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Windshield wiper motor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Windshield wiper motor - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Windshield wiper motor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Wiper and washer system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Wiper relays - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Wiper relays - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Wiper relays - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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External lighting - 404

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Contents
FUNCTIONAL DATA
Work light
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Electrical systems - External lighting
Work light - Dynamic description

Purpose/Overview
The working light turns ON/OFF each time the working light switch is pressed. (Improving visibility in night operation)
SMIL14CEX4072FB 1
a. Dimming level automatic adjustment by solar 3. Working light relay

radiation sensor
b. Working light linked dimming by working light relay 4. Working light switch
1. Monitor 5. Solar radiation sensor
2. Main controller
Operation
1. The monitor recognizes that an operator presses the working light switch.
2. The monitor sends state of pressing the switch to the controller via CAN communication.
3. The controller controls the working light and then transmits the result of it to the monitor via CAN communication.
4. The monitor activates the working light relay based on received control information to turn on the working light.
Operation condition
When an operator presses the working light switch to turn on the working light:
• The working light icon on the monitor is turned ON.
• Intensity of the back light of the monitor is set to day time brightness.
• Illumination of the switch panel is turned ON.
When an operator presses the working light switch to turn off the working light:
• The working light icon on the monitor is turned OFF.
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Electrical systems - External lighting
• Intensity of the back light of the monitor is set to night time brightness.
• Illumination of the switch panel is turned OFF.
• The system starts the working light from OFF state when an operator has turned the key switch from OFF to ON.
(Previous data is reset)
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Index

Work light - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Cab lighting - 514

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Contents
Cab lighting - 514
FUNCTIONAL DATA
Cab lighting
Dynamic description - LED Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cab interior light
Dynamic description - Room lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Electrical systems - Cab lighting
Cab lighting - Dynamic description - LED Light

Purpose/overview
The working light and the camera light turn ON/OFF each time the working light switch is pressed. (Improving visibility
in night operation)
SMIL14CEX1037FB 1
1. Monitor
2. Working light relay
Control
The camera light (5) can only be turned ON/OFF when the working light (3) is lit.
Operation condition
The camera light (5) will light up when all the following conditions are fulfilled.
• When the working light (3) is ON
• When the camera light switch (4) is ON
Clear condition
It will be cleared when one of the working light (3) and the camera light switch (4) is turned OFF.
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Cab interior light - Dynamic description - Room lamp

Purpose/overview
The room lamp is turned ON/OFF linked to open/close of the door. The room lamp is turned OFF automatically after
elapsing 30 s with the door left open. (Battery drain prevention function)
SMIL14CEX1038FB 1
1. Main controller 5. Room lamp

2. ECM a. Open (ON)
3. Door limit switch b. Close (OFF)
4. Room lamp relay
Position and function of the room lamp select switch
Position Function
OFF Always lamp OFF
DOOR Lamp ON with door opened, OFF with closed
ON Always lamp ON
Operation
1. The monitor detects state of the door limit switch to send it to the controller via CAN communication.
2. The controller controls the room lamp and then transmits the result of it to the monitor via CAN communication.
3. The monitor activates the room lamp relay based on received control information.
4. While the system applies voltage to the room lamp once the room lamp relay is turned ON, whether turning ON or
OFF the room lamp depends on position of the select switch and state of the door switch.
Operation condition
The room lamp is turned ON under the following conditions.
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• When the door is opened with position of the room lamp select switch in DOOR, and the door limit switch is turned
ON.
• Position of the room lamp select switch is in ON.
The room lamps is turned OFF under the following conditions.

• When the door is closed with position of the room lamp select switch in DOOR, and the door limit switch is turned
OFF.
• When the door is opened with position of the room lamp select switch in DOOR (the door limit switch is ON), and
then it has elapsed for 30 s.
• When the key switch is turned OFF with position of the room lamp select switch in ON, and then it has elapsed for
30 s.
• Position of the room lamp select switch is in OFF.
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Index
Cab lighting - 514

Cab interior light - Dynamic description - Room lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cab lighting - Dynamic description - LED Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Warning indicators, alarms, and instruments - 408

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Contents
SERVICE
Warning indicators, alarms, and instruments

Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Electrical systems - Warning indicators, alarms, and instruments
Warning indicators, alarms, and instruments - Inspect

Monitor warning light lighting circuit system
Functions
The monitor is supplied with power supply voltage via
the starter switch and is lit by a signal from the ECM.
The ECM lights up the monitor during a lamp check
when the starter switch is ON and when a DTC is set.
Also, if the DLC body ground and diagnostic switch ter-
minal are shorted, the monitor is flashed according to
the detected DTC.
The ECM has a monitor circuit and monitors lamp op-
erations.
Inspection
Inspection performed when the monitor does not light
up when the starter switch is turned ON.
1. Check the OBD system.
2. Inspect the monitor valve.
3. If a problem is found, replace the valve.
4. Inspect the monitor circuit.
between the fuse and the monitor.
between the monitor and ECM.
6. Replace the ECM.
Monitor warning light blinking circuit system
Functions
The monitor is supplied with power supply voltage via
the starter switch and shows an abnormality display due
to a signal from the ECM.
The ECM makes the monitor show an abnormality dis-
play during a lamp check when the starter switch is ON
and when the DTC is set.
It also blinks the monitor depending on the detected
DTC when the body ground terminal and diagnostic
switch terminal of the DLC are shorted.
A monitor circuit is incorporated inside the ECM and
monitors operation of the warning light.
Inspection
Inspection if the monitor continues showing an abnor-
mality display and does not flash when the diagnostic
switch is switched ON
8. Perform the OBD system check.
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Electrical systems - Warning indicators, alarms, and instruments
9. Turn OFF the starter switch.

10. Connect the DMM between the DLC diagnostic switch
terminal and GND.
12. Confirm that the voltage displayed on the DMM ex-
ceeds the standard value.
Standard: 18 V
13. Inspect the diagnostic switch circuit between the ECM
and DLC using the DMM if it is under the standard
value.
• No open circuit or high resistance should be found.
Standard value: 100 Ω or less
• No short circuit with GND should be found.
Standard value: 100 Ω or more
14. Repair if a problem is discovered.
15. Turn OFF the starter switch.
16. Confirm that there is continuity between the DLC body
ground and GND.
18. Short the DTC.
NOTE: Short the No.4 terminal and No.12 terminal.
19. Check if the monitor is blinking.
NOTE: If it does not blink, inspect the monitor blinking cir-
cuit system.
21. After replacing the ECM, perform EGR learning.
23. Short the body ground terminal and diagnostic switch
terminal of the DLC.
24. Check if the monitor is blinking.
25. Perform the OBD system check.
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Index

Warning indicators, alarms, and instruments - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Anti-theft system - 992

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Contents
FUNCTIONAL DATA
Anti-theft system
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Electrical systems - Anti-theft system
Anti-theft system - Dynamic description

Purpose/overview
In order to prevent theft and tampering,
• Manual lock
• Geofence / curfew / remote lock
• Service support screen lock are available with a password on the monitor. For each of them, you can turn ON/OFF
the password function and change the number of digits of or the number settings of a password at the service
support screen.
As the other anti-theft measure, an immobilizer key is provided.
The following screens also have a function that allows the car-rental agency to lock these screens when renting the
system to the customers so that they may view but not change the settings.
• Customer-specific system information screen
• Maintenance information screen
• Option line setting screen
For each of them, you can turn ON/OFF the lock function at the service support screen.
Manual lock
The manual lock is a function that puts the system into an immobilized state if a wrong password is entered on the
monitor after the key is turned ON to start operation.
In the immobilized state:

• A travel alarm sounds.
• Swing is locked.
• A monitor buzzer sounds continuously.
• The started engine is fixed at a low idle.
• Operating the lever stops the engine running at a low idle.
• You will be alerted via the GPS simultaneously with the engine stop (for the system with GPS device only).
Includes the actions above.
When you start the engine before entering the password, these limits will also be imposed. If authentication fails a
total of three times including the first entry, the controller will no longer accept any input. In this case, turn OFF the
key and start all over again.
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Electrical systems - Anti-theft system
Service support screen lock

The service support screen lock is a function that prevents the service support screen display unless the correct
password is entered.
If a wrong password is entered, a buzzer sounds for 1 s and the previous (meter) screen is redisplayed.
Customer-specific system information screen lock

The customer-specific system information screen has a function that allows the car-rental agency to lock this screen
when renting the system to the customers so that they may view but not change the settings on the screen (2nd and
3rd pages).
For the setting procedure, refer to SERVICE SUPPORT SCREEN-SET UP-PERAMETERS.
• When it is locked, “LONG PUSH TO RESET ON THIS PAGE” will no longer appear on the message area. Cursor
movement is not limited. (Choosing the customer-specific system information screen tab is allowed.)
• The customers are allowed to turn the pages to view information. However, they are no longer allowed to reset the
total time or the total consumption.
Maintenance information screen lock

The maintenance information screen has a function that allows the car-rental agency to lock this screen when renting
the system to the customers so that they may view but not change the settings on the screen (remaining time and
replacement interval).
• When it is locked, a cursor movement is limited to the title line. (Choosing the maintenance information screen tab
is allowed.)
• The customers are allowed to turn the pages to view the remaining time. However, they are no longer allowed to
reset the remaining time or change the replacement interval.
Option line setting screen lock

The option line setting screen has a function that allows the car-rental agency to lock this screen when renting the
system to the customers so that they may view but not change the settings on the screen (flow setting and pressure
setting).
• When it is locked, a cursor movement is limited to the ATT number selection line. (Choosing the option line setting
screen tab is allowed. Selecting an ATT type or selecting an ATT number is also allowed.)
• The customers are allowed to change the ATT type selection or the ATT number selection and view the current
settings. However, they are not allowed to change them.
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Index

Anti-theft system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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FAULT CODES - DTC

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Contents
FAULT CODES - DTC
DIAGNOSTIC
029D-Lost communication with NOx sensor 1 [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

0002-CAN Bus off [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
0100-Lost communication with ECM [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
0607-Control module performance [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
060B-Internal control module A/D processing performance [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
062F-Control module EEPROM error [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
0641-Sensor reference voltage 1 circuit [DCU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
0658-Actuator supply voltage circuit [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
0659-Actuator supply voltage circuit [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1462-Urea fluid quality sensor timeout error [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1464-Main relay performance [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1468-DCU overtemperature [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1491-Urea fluid overpressure [DCU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1493-DCU driver overtemperature [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
149C-Urea fluid pressure reduction malfunction [DCU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
149D-Urea fluid tank overtemperature [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
203B-Urea Fluid Tank Level Sensor Stuck [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
203C-Urea fluid tank level sensor low voltage [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
203D-Urea fluid tank level sensor high voltage [DCU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2048-Urea fluid injector circuit low voltage [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2049-Urea fluid injector circuit high voltage [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
204B-Urea fluid pressure sensor performance [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
204C-Urea fluid pressure sensor circuit low voltage [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
204D-Urea fluid pressure sensor circuit high voltage [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
205B-Urea fluid tank temperature sensor performance [DCU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
205C-Urea fluid tank temperature sensor low voltage [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
205D-Urea fluid tank temperature sensor high voltage [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
206A-Urea fluid quality sensor circuit [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
206B-Urea sensor over temperature condition [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
206C-Urea fluid quality sensor circuit low voltage [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
206D-Urea fluid quality sensor circuit high voltage [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
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207F-Urea fluid concentration too low [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
208A-Urea fluid pump control circuit [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
208B-Urea fluid pump performance [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
208C-Urea fluid pump control circuit low voltage [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
208D-Urea fluid pump control circuit high voltage [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
208E-Urea fluid injector stuck [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
20A0-Urea fluid reverting valve circuit open [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
20A2-Urea fluid reverting valve circuit low voltage [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
20A3-Urea fluid reverting valve circuit high voltage [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
20AC-Urea fluid pump temperature sensor performance [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
20AD-Urea fluid pump module temperature sensor performance [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
20B1-Urea fluid tank heater coolant control valve circuit open [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
20B3-Urea fluid tank heater coolant control valve circuit low voltage [DCU] . . . . . . . . . . . . . . . . . . . . . . . . 87
20B4-Urea fluid tank heater coolant control valve circuit high voltage [DCU] . . . . . . . . . . . . . . . . . . . . . . . 89
20E8-Urea fluid pressure underpressure [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
20E9-Urea fluid overpressure [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
20EA-Urea fluid pressure reduction malfunction [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
20FE-Urea fluid pressure build-up error [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
242B-Exhaust gas temperature (EGT) sensor 3 performance [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
242C-Exhaust gas temperature (EGT) sensor 3 circuit low voltage [DCU] . . . . . . . . . . . . . . . . . . . . . . . . 102
242D-Exhaust gas temperature (EGT) sensor 3 circuit high voltage [DCU] . . . . . . . . . . . . . . . . . . . . . . . 104
2201-Upstream NOx sensor performance [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
2206-NOx sensor heater control circuit low voltage sensor 1 [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
2207-NOx sensor heater control circuit high voltage sensor 1 [DCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
7000-P1 Pressure sensor signal abnormality [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
7001-P2 Pressure sensor signal abnormality [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
7002-N1 Pressure sensor signal abnormality [MCM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
7003-N2 Pressure sensor signal abnormality [MCM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
7004-Bottom pressure sensor signal abnormality [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
7007-Pressure sensor arm cylinder rod abnormality [MCM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
7021-Swing pressure sensor signal abnormality [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
7023-Arm-in pressure sensor signal abnormality [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
7040-Fuel level sensor signal abnormality [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
7041-Oil temperature sensor signal abnormality [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
7065-Boom-up pilot pressure sensor signal abnormality [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
7067-Bucket-close pilot pressure sensor signal abnormality [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
7068-Pressure sensor boom-down pilot abnormality [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
7069-Pressure sensor arm-out pilot abnormality [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
7070-Pressure sensor bucket-open pilot abnormality [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
7071-Pressure sensor travel right pilot abnormality [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
7072-Pressure sensor travel left pilot abnormality [MCM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
7073-Pressure sensor travel 1 pedal abnormality [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
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7074-Pressure sensor 1st option pilot (common/front pedal) abnormality [MCM] . . . . . . . . . . . . . . . . . . 145
7075-Pressure sensor arm cylinder bottom abnormality [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
7078-Pressure sensor 1st option pilot (rear pedal) abnormality [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
7200-Swing brake solenoid signal abnormality [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
7201-Travel high-speed solenoid signal abnormality [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
7202-Pressure boost solenoid signal abnormality [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
7203-Travel alarm buzzer signal abnormality [MCM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
7206-Option line switchover solenoid signal abnormality [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
7207-Free swing solenoid signal abnormality [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
7213-Quick coupler buzzer abnormality [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
7214-Quick coupler solenoid abnormality [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
7247-Boom-down proportional valve signal abnormality [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
7249-Bucket-Close Pilot Proportional Valve Abnormality [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
7250-Option relief pressure proportional valve signal abnormality [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . 166
7265-Arm 1 Semi-Parallel Proportional Valve Abnormality [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
7266-Arm 2 Semi-Parallel Proportional Valve Abnormality [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
7267-Arm 1 Regeneration Release Proportional Valve Abnormality [MCM] . . . . . . . . . . . . . . . . . . . . . . . 172
7270-Tilting 1 Proportional Valve Abnormality [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
7271-Tilting 2 Proportional Valve Abnormality [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
7273-Straight Travel Proportional Valve Abnormality [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
7400-Abnormally high coolant temperature [105◦ C (221.0◦F) or higher] 105◦ C (221.0◦F) or higher]
(55.640-G.30.C.10) [[MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
7401-Abnormally high coolant temperature [110◦ C (230.0◦F) or higher] 110◦ C (230.0◦F) or higher] (55.640-
G.30.C.10) [[MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
7404-Abnormally high oil temperature [95 °C ( 203.0 °F ) or higher] 95 °C ( 203.0 °F ) or higher] (55.640-
G.30.C.10) [[MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
7405-Abnormally high boost temperature [80◦ C (176.0◦F) or higher] 80◦ C (176.0◦F) or higher] (55.640-
G.30.C.10) [[MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
7406-Abnormally high boost temperature [90◦ C (194.0◦F) or higher] 90◦ C (194.0◦F) or higher] (55.640-
G.30.C.10) [[MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
7420-Abnormally low alternator voltage [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
7421-Coolant level reduction [MCM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
7422-Abnormally low engine oil pressure [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
7423-Air cleaner clogged [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
7424-Return filter clogging (breaker specifications) [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
7426-Fuel filter clogging 1 [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
7427-Fuel filter clogging 2 [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
7428-Inducement (Remaining Urea Level Low) - Warning [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
7429-Inducement (Remaining Urea Level Low) - Early [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
7430-Inducement (Remaining Urea Level Low) - Final [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
7602-ECM communication abnormality [MCM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
7605-ECM mismatch [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
7606-EEPROM data abnormality [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
7608-Camera abnormality [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
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7612-Air-conditioner communication abnormality [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
7613-Monitor communication CAN abnormality [MCM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
7615-Sub-Controller Communication Abnormality [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
7618-DCU Communication Abnormality [MCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
P041C-EGR cooler outlet 1 temperature sensor circuit low [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
P041D-EGR cooler outlet 1 temperature sensor circuit high [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
P0016-Crankshaft position - Camshaft position correlation [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
P0045-Turbocharger Boost Control Solenoid Circuit [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
P0087-Fuel rail system pressure low pressure error [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
P0089-Fuel pressure regulator performance [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
P0091-Fuel rail regulator control system low input [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
P0092-Fuel rail regulator control system high input [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
P0097-Intake air temperature (IAT) sensor 2 circuit low voltage [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
P0098-Intake air temperature (IAT) sensor 2 circuit high voltage [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . 230
P0102-Mass air flow circuit low input [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
P0103-Mass air flow circuit high input [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
P0112-Intake temperature sensor signal - Shorted to low source [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . 234
P0113-Intake temperature sensor signal - Shorted to high source [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . 235
P0117-Coolant temperature sensor signal - Shorted to low source [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . 237
P0118-Coolant temperature sensor signal - Shorted to high source [ECU] . . . . . . . . . . . . . . . . . . . . . . . . 238
P0122-Throttle position sensor, low input [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
P0123-Throttle position sensor, high input [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
P0182-Fuel temperature sensor - Shorted to low source [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
P0183-Fuel temperature sensor - Shorted to high source [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
P0192-Fuel rail pressure sensor, low input [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
P0193-Fuel rail pressure sensor, high input [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
P0201-Injector circuit - Cylinder 1 [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
P0217-Engine coolant over temperature condition [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
P0219-Engine overspeed condition [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
P0234-Turbocharger overboost condition [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
P0237-Turbocharger boost sensor circuit low [ECM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
P0238-Turbocharger boost sensor circuit high [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
P0335-Crankshaft position sensor circuit [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
P0336-Crankshaft position sensor circuit range/performance [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
P0340-Camshaft position sensor circuit [ECM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
P0380-Glow plug circuit [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
P0401-EGR flow insufficient detected [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
P0404-EGR control circuit range/performance [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
P0409-Exhaust gas recirculation 1 sensor circuit [ECM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
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P0427-Catalyst temperature sensor circuit low sensor 1 [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
P0428-Catalyst temperature sensor circuit high sensor 1 [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
P042C-Catalyst temperature sensor circuit low sensor 2 [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
P042D-Catalyst temperature sensor circuit high sensor 2 [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
P0522-Oil pressure sensor circuit low [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
P0523-Oil pressure sensor circuit high [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
P0545-EGR cooler inlet 1 temperature sensor circuit low [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
P0546-EGR cooler inlet 1 temperature sensor circuit high [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
P0560-System voltage [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
P0563-System voltage high [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
P0601-ECU memory fault - Bad Intelligent device [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
P0602-Control module programming error [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
P0604-Internal control module random access memory (RAM) error [ECM]. . . . . . . . . . . . . . . . . . . . . . . 297
P0606-Internal control module CPU error [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
P060A-Internal control module CPU IC error [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
P060C-Internal control module A/D processing performance [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
P0615-Starter relay circuit [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
P0638-Throttle actuator control range/performance [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
P0685-ECM power relay control circuit open [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
P06A6-Sensor reference voltage 1 circuit [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
P0687-ECM power relay control circuit high [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
P06AF-Torque management system - Forced engine shutdown [ECM]. . . . . . . . . . . . . . . . . . . . . . . . . . . 313
P06D5-Sensor reference voltage 5 circuit [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
P1076-Charge air cooler (CAC) temperature sensor 1 circuit low voltage [ECM]. . . . . . . . . . . . . . . . . . . 315
P1077-Charge air cooler (CAC) temperature sensor 1 circuit high voltage [ECM] . . . . . . . . . . . . . . . . . . 316
P1093-Fuel rail pressure (FRP) too low [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
P1097-Compressor outlet temperature sensor circuit high [ECM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
P1098-Compressor outlet temperature sensor circuit high [ECM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
P1236-Charge air cooler performance failure [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
P1261-Injector positive voltage control circuit group 1 [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
P1262-Injector positive voltage control circuit group 2 [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
P1404-Exhaust gas recirculation 1 closed position performance [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . 329
P1606-SW-IC 1 internal failure [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
P160B-AD-IC failure error [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
P160C-AD-IC2 failure error [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
P204F-SCR system error (No inducement) [ECM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
P207F-Urea fluid concentration too low [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
P20C9-SCR system error [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
P1621-Control Module Long Term Memory Performance [ECM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
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P1669-DPD Lamp control circuit [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
P2122-Pedal position sensor 1 circuit low input [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
P2123-Pedal position sensor 1 circuit high input [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
P2127-Pedal position sensor 2 circuit low input [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
P2128-Pedal position sensor 2 circuit high input [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
P2138-Pedal position sensor 1 – 2 voltage correlation [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
P2146-Fuel injector group 1 supply voltage circuit [ECM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
P2149-Fuel injector group 2 supply voltage circuit [ECM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
P2228-Barometric pressure circuit low [ECM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
P2229-Barometric pressure circuit high [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
P2457-Exhaust gas recirculation (EGR) cooling system performance [ECM] . . . . . . . . . . . . . . . . . . . . . . 356
P2BA7-Urea fluid quantity too low [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
P2458-Purge time out error [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
P2BAA-SCR system error (Inducement, no purge) [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
P3093-Fuel rail pressure too low [ECM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
U0001-CAN-Bus Malfunction [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
U0073-CAN-Bus Malfunction [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
U0101-Lost communication with TCM [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
U010E-Lost communications with dosing control module [ECM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
U0110-Lost communication with VNT system [ECM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
U0411-Lost CAN communications with VNT control module [ECM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
U2106-Lost CAN communications with wheel loader transmission control system [ECM] . . . . . . . . . . . 375
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Electrical systems - FAULT CODES
029D-Lost communication with NOx sensor 1

Control Module : DCU
Solution:
1. Check if diagnostic trouble code 1462 is set at the same time, and go to each diagnosis. Diagnosis when diag-
nostic trouble code 029D is set independently.
Turn OFF the ignition switch.
Disconnect the NOx sensor harness connector CN.D17-5.
Inspect the NOx sensor harness connector CN.D17-5.
NOTE:
• Make sure that there should be no intermittent conditions, poor connections, or corrosion.
• Make sure that there should be no water intrusion or adhering foreign material.
A. If a problem is found, repair the connector CN.D17-5.
B. If there are no problems, proceed to Step 2

2. Inspect the NOx sensor power supply circuit for an open circuit or breakage.
A. If a problem is found, repair the NOx sensor power supply circuit.

3. Connect a test lamp between the power supply circuit and the GND circuit.
A. If the test lamp does not illuminate, repair the open circuit or high resistance in the NOx sensor GND circuit.
B. If the test lamp illuminate, proceed to Step 4

Measure the voltage between the CAN Low circuit and the DCU harness GND connection, and between the CAN
High circuit and the DCU harness GND connection.
A. If the voltage is outside the range 1.5 - 3.5 V, repair the open circuit or high resistance in the NOx sensor GND
circuit.

5. Replace the NOx sensor. (Refer to “ Nitrogen Oxides (NOx) sensor - Remove (55.988) and Nitrogen Oxides
(NOx) sensor - Install (55.988)”)
NOTE: If the NOx sensor is replaced, perform NOx sensor data reset with the trouble diagnosis scan tool.
Diagnosis when diagnostic trouble code 1462 and 029D are set at the same time.
Inspect the NOx sensor power supply circuit.
NOTE:
• Make sure that there should be no open circuit, breakage, or high resistance.
• Make sure that there should be no short to the GND circuit.
• Make sure that there should be no short to a metal component, such as the frame.

6. Inspect the NOx sensor GND circuit between the NOx sensor and the DCU harness GND connection.
NOTE: Make sure that there should be no open circuit, breakage, or high resistance.
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7. Inspect the urea fluid sensor power supply circuit.
NOTE:
A. If a problem is found, repair the urea fluid sensor power supply circuit.

8. Inspect the urea fluid sensor GND circuit between the urea fluid sensor and the DCU harness GND connection.
NOTE:
Make sure that there should be no open circuit, breakage, or high resistance.

Disconnect the urea fluid sensor harness connector CN.D20.
Observe the diagnostic trouble code information with a trouble diagnosis scan tool.
If diagnostic trouble code 1462 is set but 029D is not set,
NOTE:
A. If a problem is found, repair the connector CN.D20.

10. Replace the urea fluid sensor. (Refer to “ Diesel Exhaust Fluid (DEF)/AdBlue® tank level and temperature
sensor - Remove (55.988) and Diesel Exhaust Fluid (DEF)/AdBlue® tank level and temperature sensor -
Install (55.988)”)
If diagnostic trouble code 1462 and 029D are both set, turn the ignition switch OFF until communication with the
trouble diagnostic scan tool is discontinued.
Measure the resistance between the CAN Low and CAN High circuits.
A. If the resistance between the CAN Low and High circuits is more than or equal to 115 - 125 Ω , measure the
resistance of the termination resistor.
B. If the resistance of the termination resistor is outside the 115 - 125 Ω, replace the termination resistor.
C. If the resistance of the termination resistor is within the 115 - 125 Ω, inspect the DCU, joint connector, CAN
circuit between the termination resistors, and CAN jumper wire for an open circuit or high resistance.
D. If a problem is found, repair the CAN circuit.
E. If the resistance between the CAN Low and High circuits is less than or equal to 55 - 65 Ω, disconnect the
NOx sensor harness connector CN.D17-5 and check the resistance.
F. If the resistance is within the 55 - 65 Ω, inspect the NOx sensor harness connector CN.D17-5.
G. If a problem is found, repair the connector CN.D17-5.
H. If there are no problems, proceed to Step 11
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NOTE:
A. If the resistance is outside the 55 - 65 Ω, disconnect the DCU harness connector CN.D1-2 and check the
resistance of the DMM.
B. If the resistance is outside the 115 - 125 Ω, repair the short together in the CAN circuits between the DCU,
NOx sensor, urea fluid sensor, and termination resistors.
C. If the resistance is within the 115 - 125 Ω, inspect the DCU harness connector CN.D1-2.
D. If a problem is found, repair the connector CN.D1-2.
E. If there are no problems, proceed to Step 12

NOTE:
12. Replace the DCU. (Refer to “ Dosing control unit - Remove (55.988) and Dosing control unit - Install
(55.988)”)
13. Confirm resolution:
1. Clear the diagnostic trouble code using the trouble diagnosis scan tool.
NOTE:
• After clearing the DCU diagnostic trouble code, observe whether ECM diagnostic trouble code P20C9 is set.
• If diagnostic trouble code P20C9 is set, clear it.
2. Turn OFF the ignition switch until communication with the trouble diagnosis scan tool is discontinued.
4. Observe the diagnostic trouble code information with the trouble diagnosis scan tool. A diagnostic trouble
code should not be set.
Wiring harnesses - Electrical schematic sheet 21 (55.100) Wiring harnesses - Electrical schematic sheet
20 (55.100) Wiring harnesses - Electrical schematic sheet 15 (55.100)
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0002-CAN Bus off

Solution:
1.
NOTE: The applicable diagnostic trouble code may be set after CSP work. If the applicable diagnostic trouble
code is set after CSP work, simply clear the diagnostic trouble code because it is not a malfunction of the machine.
Disconnect the harness connector CN.D3 from the ECM.
Inspect the ECM harness connector CN.D3.
Turn ON the ignition switch.
Observe the diagnostic trouble code information with the trouble diagnosis scan tool.
A. If a diagnostic trouble code is not set, replace the ECM. (Refer to Engine Control Unit (ECU) - Remove
(55.015) and Engine Control Unit (ECU) - Install (55.015))
Set the Injector ID Code, fuel delivery rate and engine No. for the ECM.

Connect the harness connector CN.D3 to the ECM.
Disconnect the harness connector CN.A4 from the control unit of the machine.
Inspect the machine control unit harness connector CN.A4.
Observe the diagnostic trouble code information with the trouble diagnosis scan tool.
A. If a diagnostic trouble code is not set, replace the control unit of the machine.

3. Connect the harness connector CN.A4 to the control unit of the machine.
Disconnect the harness connector from the termination resistor if a diagnostic trouble code is set.
Inspect the terminal resistor harness connector.
Measure the resistance of the termination resistor.
A. If the resistance of the termination resistor exceeds the 115 - 125 Ω, replace the termination resistor.
B. If a diagnostic trouble code is set, inspect the CAN Low and CAN High circuits.
C. If a problem is found, repair the CAN circuit.
D. If there are no problems, proceed to Step 4

NOTE:
• Make sure that there should be no short to the battery power supply or ignition power supply circuit.
• Make sure that there should be no high resistance.
• Make sure that there should be no short together between CAN circuits.
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4. If the CAN circuit is normal, inspect the DCU harness connector CN.D1-2.
NOTE:
Replace the DCU. (Refer to Dosing control unit - Remove (55.988) and Dosing control unit - Install (55.988))
NOTE:
4. Observe the diagnostic trouble code information with the trouble diagnosis scan tool. A diagnostic trouble code
should not be set.
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0100-Lost communication with ECM

Solution:
1.
NOTE: The applicable diagnostic trouble code may be set after CSP work. If the applicable diagnostic trouble
code is set after CSP work, simply clear the diagnostic trouble code because it is not a malfunction of the machine.
Disconnect the ECM harness connector CN.D3.
Disconnect the DCU harness connector CN.D1-2.
Inspect the CAN High circuit between the DCU and the ECM for an open circuit, short circuit, or breakage.
A. If a problem is found, repair the CAN High circuit.

2. Inspect the CAN Low circuit between the DCU and the ECM for an open circuit, short circuit, or breakage
A. If a problem is found, repair the CAN Low circuit.

3. Inspect the ECM harness connector CN.D3.
NOTE:

4. Inspect the DCU harness connector CN.D1-2.
NOTE:

5. Observe the diagnostic trouble code information with the trouble diagnosis scan tool. If a diagnostic trouble code
is set, disconnect the harness connector from the termination resistor.
A. If the resistance of the termination resistor exceeds the 115 - 125 Ω, replace the termination resistor.

6. Observe the diagnostic trouble code information with the trouble diagnosis scan tool. If a diagnostic trouble code
is set, inspect the CAN High and CAN Low circuits.
NOTE:
• Make sure that there should be no short to the battery power supply or ignition power supply circuit.
• Make sure that there should be no high resistance.
• Make sure that there should be no short together between CAN circuits.
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A. If a problem is found, repair the CAN circuit.

7. Replace the ECM. (Refer to Engine Control Unit (ECU) - Remove (55.015) and Engine Control Unit (ECU) -
Install (55.015))
Perform the unit difference learning of fuel supply pumps on the ECM.
Replace the DCU. (Refer to Dosing control unit - Remove (55.988) and Dosing control unit - Install (55.988))
NOTE:
should not be set.
15 (55.100)
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0607-Control module performance

Solution:
1. Inspect the DCU harness GND connection terminal for intermittent conditions, improper tightening, or corrosion.
A. If a problem is found, repair the mounting of the DCU harness GND connection terminal.

Inspect the DCU harness connector CN.D1-2.
NOTE:

3. Inspect the battery power supply circuit between the urea SCR fuse and the DCU for an open circuit or high
resistance
A. If a problem is found, repair the battery power supply circuit or connector CN.D68.

4. Inspect the DCU GND circuit for an open circuit or high resistance
A. If a problem is found, repair the GND circuit or connector.

5. Replace the DCU. (Refer to “ Dosing control unit - Remove (55.988) and Dosing control unit - Install (55.988)”)
NOTE:
should not be set.
Wiring harnesses - Electrical schematic sheet 15 (55.100)
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060B-Internal control module A/D processing performance

Solution:
Turn ON the ignition switch without starting the engine.
Check whether the diagnostic trouble code is a current failure with the trouble diagnosis scan tool.
A. If the diagnostic trouble code is a past failure, perform the urea SCR system intermittent diagnosis.
B. If the diagnostic trouble code is a current failure, replace the DCU. (Refer to “ Dosing control unit - Remove
(55.988) and Dosing control unit - Install (55.988)”)
NOTE:
should not be set.
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062F-Control module EEPROM error

Solution:
1.
NOTE: If a relevant diagnostic trouble code is set after the following conditions occur, the DCU is normal, and the
diagnostic trouble code should simply be cleared.
The battery enters a low voltage condition. If the battery enters a low voltage condition due to cranking or operation
of the machine's electronic components, the DCU will temporarily turn OFF.
The battery or urea SCR fuse is removed before turning the DCU power supply OFF after turning OFF the ignition
switch (during after-run control or within 3 minutes of turning OFF the ignition switch).
Turn OFF the ignition switch until communication with the trouble diagnosis scan tool is discontinued.
Inspect the DCU harness GND connection terminal for intermittent conditions, improper tightening, or corrosion.

NOTE:

resistance.

4. Inspect the DCU GND circuit for an open circuit or high resistance.

Check whether the diagnostic trouble code is a current failure with the trouble diagnosis scan tool.
If diagnostic trouble code 1464 is set as a current failure or past failure at the same time, treat that first.
A. If the diagnostic trouble code is a past failure, perform the urea SCR system intermittent diagnosis.
B. If the diagnostic trouble code is a current failure, replace the DCU. (Refer to “ Dosing control unit - Remove
(55.988) and Dosing control unit - Install (55.988)”)
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NOTE:
should not be set.
02 (55.100)
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0641-Sensor reference voltage 1 circuit

Solution:
Disconnect the urea fluid supply module harness connector CN.D18.
NOTE: The urea fluid pump, reverting valve, and urea fluid pressure sensor are built in.
Inspect the urea fluid supply module harness connector CN.D18.
NOTE:

Measure the voltage between the 5 V power supply circuit and the DCU harness GND connection.
A. If the reading is within the 4.8 - 5.2 V, replace the urea fluid supply module. (Refer to “ Diesel Exhaust Fluid
(DEF)/AdBlue® supply module - Remove (55.988) and Diesel Exhaust Fluid (DEF)/AdBlue® supply mod-
ule - Install (55.988)”)
B. If the reading is more than or equal to 4.8 - 5.2 V, inspect the 5 V power supply circuit between the DCU and
the urea fluid pressure sensor.
C. If a problem is found, repair the 5 V power supply circuit.
NOTE:
• Make sure that there should be no short to the battery or short to the ignition power supply.
• Make sure that there should be no short to other power supply circuits.
3. If the reading is less than or equal to the 4.8 - 5.2 V, inspect the 5 V power supply circuit between the DCU and
the urea fluid pressure sensor.
NOTE:
• Make sure that there should be no short to other GND circuits.
• Make sure that there should be no short to metallic parts such as the frame.
A. If a problem is found, repair the 5 V power supply circuit.

4. Disconnect the DCU harness connector CN.D1-2.
NOTE:

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NOTE:
should not be set.
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0658-Actuator supply voltage circuit

Solution:
Disconnect the coolant control valve harness connector CN.D19.
Inspect the coolant control valve harness connector CN.D19.
NOTE:

If diagnostic trouble code 20B1 is set but 0658 is not set, replace the coolant control valve. (Refer to “ Coolant
control valve - Remove (10.500) and Coolant control valve - Install (10.500)”)
NOTE:

If diagnostic trouble code 20A0 and 20B1 are set but 0658 is not set, replace the urea fluid supply module. (Refer
to “ Diesel Exhaust Fluid (DEF)/AdBlue® supply module - Remove (55.988) and Diesel Exhaust Fluid (DEF)/
AdBlue® supply module - Install (55.988)”)
Inspect the battery voltage supply circuit between the DCU and the coolant control valve for a short to any metallic
components, such as the frame.
A. If a problem is found, repair the battery voltage supply circuit.

4. Inspect the battery voltage supply circuit between the DCU and the urea fluid supply module.
NOTE:
• Make sure that there should be no short to other GND circuits.
• Make sure that there should be no short to other power supply circuits.
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NOTE:

NOTE:
should not be set.
15 (55.100)
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0659-Actuator supply voltage circuit

Solution:
1. Check and diagnose the below fault code before you proceed with the diagnostic code 0659.
Diagnostic trouble code 208D

Diagnostic trouble code 20A3
Diagnostic trouble code 20B4
NOTE:

If diagnostic trouble code 20B1 is set but 0659 is not set, replace the coolant control valve. (Refer to “ Coolant
NOTE:

If diagnostic trouble code 20A0 and 20B1 are set but 0659 is not set, replace the urea fluid supply module. (Refer
to “ Diesel Exhaust Fluid (DEF)/AdBlue® supply module - Remove (55.988) and Diesel Exhaust Fluid (DEF)/
If 0659 is detected, inspect the battery voltage supply circuit between the DCU and the coolant control valve for a
short to the battery or a short to the ignition power supply
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5. Inspect the battery voltage supply circuit between the DCU and the urea fluid supply module for a short to the
battery or a short to the ignition power supply.

NOTE:

NOTE:
should not be set.
15 (55.100)
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1462-Urea fluid quality sensor timeout error

Solution:
Inspect the urea fluid sensor harness connector CN.D20.
NOTE:

Connect a test lamp between the urea fluid sensor power supply circuit and the DCU harness GND connection.
A. If the test lamp does not illuminate, repair the open circuit or high resistance in the urea fluid sensor power
supply circuit.

A. If the test lamp does not illuminate, repair the open circuit or high resistance in the urea fluid sensor GND
circuit.

Measure the voltage between the CAN Low circuit and the DCU harness GND connection, and between the CAN
High circuit and the DCU harness GND connection.
If the voltage is outside the 1.5 - 3.5 V, inspect the CAN Low circuit and the CAN High circuit between the urea
fluid sensor and the DCU.
NOTE:
• Make sure that there should be no open circuit or high resistance in the CAN High circuit.
• Make sure that there should be no open circuit or high resistance in the CAN Low circuit.
• Make sure that there should be no open circuit or high resistance in the termination resistor.
A. If a problem is found, repair the CAN circuit or replace the termination resistor

6. Replace the urea fluid supply module. (Refer to “ Diesel Exhaust Fluid (DEF)/AdBlue® supply module - Re-
move (55.988) and Diesel Exhaust Fluid (DEF)/AdBlue® supply module - Install (55.988)”)
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NOTE:
should not be set.
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1464-Main relay performance

Solution:
1.
NOTE: If a relevant diagnostic trouble code is set after the following conditions occur, the DCU is normal, and the
diagnostic trouble code should simply be cleared.
The battery enters a low voltage condition. If the battery enters a low voltage condition due to cranking or operation
of the machine's electronic components, the DCU will temporarily turn OFF.
The battery or urea SCR fuse is removed before turning the DCU power supply OFF after turning OFF the ignition
switch (during after-run control or within 3 minutes of turning OFF the ignition switch).
Inspect the DCU harness GND connection terminal for intermittent conditions, improper tightening, or corrosion.

NOTE:

resistance.

4. Inspect the DCU GND circuit for an open circuit or high resistance.

NOTE:
should not be set.
NOTE: Repeat Step 2 and Step 3 several times, and check if a diagnostic trouble code is set.
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02 (55.100)
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1468-DCU overtemperature
Solution:
1. Check and diagnose all the diagnostic trouble codes that were set at the same time before you proceed with the
diagnostic code 1468.
If there are diagnostic trouble codes that were set at the same time, treat those first.
Check whether any equipment which could cause abnormally high temperature is installed in the area around the
DCU.
A. If a problem is found, take countermeasures to prevent abnormally high temperature.

2. Ask the operator whether or not there were any external factors in the past which could have caused abnormally
high temperature close to the DCU.
If there is the possibility that abnormally high temperature occurred in the past, inspect the corresponding location.
NOTE: This diagnostic trouble code is set for the purpose of recording information. It is not a malfunction of the
DCU. Replacement of the DCU is not necessary.
3. Without starting the engine, observe the diagnostic trouble code information with the trouble diagnosis scan
tool. A diagnostic trouble code should not be set. Turn ON the switch.
should not be set.
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1491-Urea fluid overpressure

Solution:
Diagnostic trouble code 204B

Diagnostic trouble code 204C
NOTE: If diagnostic trouble code 20E9 is set as a current failure or past failure at the same time, treat that first.
2. Inspect the backflow piping between the urea fluid supply module and the urea fluid tank.
NOTE:
• Make sure that there should be no clogging caused by twisting or bending.
• Make sure that there should be no clogging caused by foreign material.
• Make sure that there should be no clogging caused by urea fluid freezing.
• Make sure that there should be no layout changes in the urea fluid piping that differ from the specified layout.
CAUTION:
Do not blow air onto the urea fluid connector on the urea fluid supply module.
A. If a problem is found, repair or replace.

3. Inspect the urea fluid sensor backflow line.
NOTE:
A. If a problem is found, replace the urea fluid supply module. (Refer to “ Diesel Exhaust Fluid (DEF)/AdBlue®
supply module - Remove (55.988) and Diesel Exhaust Fluid (DEF)/AdBlue® supply module - Install
(55.988)”)

4. Inspect the backflow connector CN.D18 of the urea fluid supply module.
NOTE:
• Make sure that check valve should not be clogged or stuck closed.
• Make sure that there should be no clogging caused by deformation of the connector.
A. If a problem is found, repair the backflow connector CN.D18. (Refer to “ Diesel Exhaust Fluid (DEF)/AdBlue®
supply module - Disassemble (55.988) and Diesel Exhaust Fluid (DEF)/AdBlue® supply module - Install
(55.988)”)

NOTE:
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Inspect each circuit between the DCU and the urea fluid supply module.
NOTE:
• Make sure that there should be no short circuit or improper modification.
A. If a problem is found, repair the applicable circuit.

NOTE:

8. Replace the urea fluid supply module. (Refer to “ Diesel Exhaust Fluid (DEF)/AdBlue® supply module - Re-
4. Perform the leak test with the trouble diagnosis scan tool.
CAUTION:
Do not perform the leak test when the urea fluid is frozen.
NOTE: Verify that the urea fluid tank temperature and outside air temperature are 5 °C (41 °F) or more when the
leak test is performed.
Check whether the urea fluid pressure is less than or equal to 1250 kPa (181 psi) with the trouble diagnosis scan
tool.
Observe the diagnostic trouble code information with the trouble diagnosis scan tool. A diagnostic trouble code
should not be set.
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1493-DCU driver overtemperature

Solution:
1. Check and diagnose all the diagnostic trouble codes that were set at the same time before you proceed with the
diagnostic code 1493.
If there are diagnostic trouble codes that were set at the same time, treat those first.
DCU.

high temperature close to the DCU.
NOTE: This diagnostic trouble code is set for the purpose of recording information. It is not a malfunction of the
DCU. Replacement of the DCU is not necessary.
should not be set.
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149C-Urea fluid pressure reduction malfunction

Solution:
1. Check and diagnose the below fault code before you proceed with the diagnostic code 149C.

2. There should be no damage to or clogging of the supply module filter.
CAUTION:
A. If a problem is found, replace the supply module filter. (Refer to “ Diesel Exhaust Fluid (DEF)/AdBlue®
supply module Filter - Remove (55.988) and Diesel Exhaust Fluid (DEF)/AdBlue® supply module Filter
- Install (55.988)”)

3. Inspect the suction piping between the urea fluid supply module and the urea fluid tank
NOTE:
• Make sure that there should be no layout changes in the urea fluid piping that differ from the specified layout.
CAUTION:

4. Inspect the urea fluid sensor suction line.
NOTE:
(55.988)”)

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NOTE:

Inspect each circuit between the DCU and the urea fluid supply module
NOTE:
• Make sure that there should be no open circuit or high resistance

NOTE:

Perform Urea Fluid Reverting Valve on the trouble diagnosis scan tool and inspect for sticking of the reverting
valve.
(55.988)”)
CAUTION:
Do not perform the leak test when the urea fluid is frozen.
NOTE: Verify that the urea fluid tank temperature and outside air temperature are 5 °C (41 °F) or more when the
leak test is performed.
should not be set.
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149D-Urea fluid tank overtemperature

Solution:
1. Perform Urea fluid tank heater coolant control valve on the trouble diagnosis scan tool and inspect the operation
of the coolant control valve
NOTE:
• Make sure that there should be no sticking of the coolant control valve.
• Make sure that there should be no circuit malfunction in the coolant control valve.

NOTE:

3. Inspect the urea fluid sensor in the urea fluid tank for engine coolant leakage.
a. Drain the urea fluid from the drain plug of the urea fluid tank.
b. Check the color of the drained urea fluid, and inspect for an intrusion of engine coolant.
c. If an intrusion of engine coolant is found, remove the urea fluid sensor and visually inspect for engine coolant
leakage from the engine coolant pipe and pipe installation section.
A. If a problem is found, replace the urea fluid sensor.

4. Inspect the urea fluid temperature sensor for characteristic malfunctions.
a. Connect the urea fluid sensor harness connector CN.D20 to the removed urea fluid sensor.
b. Put the urea fluid sensor in a container with water or warm water at 60 °C (140 °F) or less.
NOTE:
• The temperature sensing element on the bottom end of the urea fluid sensor should be submerged in the water.
• Do not use warm water at 70 °C (158 °F) or more. This may cause the diagnostic trouble code to be set.
c. Measure the temperature of the water or warm water in the container using an engine coolant temperature
gauge.
d. Turn ON the ignition switch.
e. Compare the urea fluid tank temperature display on the trouble diagnosis scan tool with the value of the engine
coolant temperature gauge, and check whether the difference is less than or equal to the 5 °C (9 °F).
NOTE: It takes time for the temperature display on the trouble diagnosis scan tool to stabilize. Determine after
the temperature display is stable.
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f. Measure 2 - 3 times at different temperatures and check whether the temperature difference is less than or
equal to the 5 °C (9 °F).
A. If the temperature difference is more than or equal to 5 °C (41 °F), replace the urea fluid sensor.
NOTE:
should not be set.
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203B-Urea Fluid Tank Level Sensor Stuck

Solution:
1. Check and diagnose the below fault codes before you proceed with the diagnostics code 203B.

NOTE: Check the frequency with which urea fluid is added, because this diagnostic trouble code may be set if
urea fluid is repeatedly added with a high amount of urea fluid remaining in the urea fluid tank.
2. Remove the urea fluid tank level sensor.
Inspect the urea fluid tank level sensor.
A. If a problem is found, repair or replace the urea fluid tank level sensor.
NOTE:
• Make sure that there is no bending of the level sensor tube.
• The float should not be stuck and there should be no foreign material that restricts the movement of the float.
• Make sure that there is no leaning or delayed response of the level sensor.
• The urea fluid tank should not be deformed or broken.
Observe the urea fluid tank level display on the trouble diagnosis scan tool while slowly moving the float.
A. If a problem is found, turn OFF the ignition switch.
NOTE:
• The display changes gradually between 18 - 90 % in accordance with the float movement.
• It may take some time for the scan tool display to change in accordance with the float movement.
4. Disconnect the harness connector CN.D20 from the urea fluid sensor.
NOTE:
• Make sure that there is no intermittent conditions, poor connections, or corrosion.
• Make sure that there is no water intrusion or adhering foreign material.
supply circuit.
B. If the test lamp illuminates, proceed to Step 5

circuit.

6. Disconnect the harness connector CN.D1-2 from the DCU.
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NOTE:
Inspect each circuit for high resistance.
A. If a problem is found, repair the harness connector CN.D1-2 or circuit.

7. Replace the urea fluid tank level sensor.
NOTE:
4. Observe the urea fluid tank level display on the trouble diagnosis scan tool while slowly pouring urea fluid into
the urea fluid tank.
• The display should change depending on the urea fluid quantity.
NOTE: Wait for approximately. 30 s after adding the urea fluid, and then observe the remaining oil level.
should not be set.
15 (55.100)
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203C-Urea fluid tank level sensor low voltage

Solution:
Disconnect the harness connector CN.D20 from the urea fluid sensor.
NOTE:
supply circuit.

circuit.

3. Inspect the signal side circuit between the DCU and urea fluid tank level sensor.
NOTE:
• Make sure that there is no short to ground.
• Make sure that there is no short to the GND circuit.
A. If a problem is found, repair the signal circuit.
B. If there are no problems, Replace the urea fluid sensor. (Refer to “ Diesel Exhaust Fluid (DEF)/AdBlue® tank
level and temperature sensor - Remove (55.988) and Diesel Exhaust Fluid (DEF)/AdBlue® tank level and
temperature sensor - Install (55.988)”)
NOTE: There should be no intermittent conditions, poor connections, or corrosion.
A. If a problem is found, repair the harness connector CN.D1-2.
B. If there are no problems, Replace the DCU. (Refer to “ Dosing control unit - Remove (55.988) and Dosing
control unit - Install (55.988)”)
NOTE:
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should not be set.
15 (55.100)
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203D-Urea fluid tank level sensor high voltage

Solution:
Connect the DMM between the urea fluid tank level sensor signal circuit and a known good GND.
Observe the DMM voltage display.
A. If the reading is more than or equal to the specified value range of 4.6 - 5.2 V, inspect the signal circuit between
the DCU and the urea fluid tank level sensor for a short to the battery or a short to the ignition power supply.
B. If a problem is found, repair the signal circuit.
C. If the reading is less than or equal to the specified value range of 4.6 - 5.2 V , inspect the signal circuit between
the DCU and the urea fluid tank level sensor for an open circuit or high resistance.
D. If a problem is found, repair the signal circuit.
E. If the reading is within the specified value range of 4.6 - 5.2 V , connect the DMM between the urea fluid tank
level sensor signal circuit and the GND circuit.
2. Observe the DMM voltage display.
A. If the reading is less than or equal to the specified value range of 4.6 V , inspect the GND circuit between the
DCU and the urea fluid tank level sensor for an open circuit or high resistance.
C. If there are no problems, proceed to Step 3

NOTE:
• The urea fluid tank level sensor shares the GND circuit with other sensors.
• diagnostic trouble codes on sensors that share this circuit may be set.
3. Inspect for poor connections at the urea fluid sensor harness connector CN.D20.
A. If a problem is found, repair the harness connector CN.D20.
B. If there are no problems, replace the urea fluid sensor. (Refer to “ Diesel Exhaust Fluid (DEF)/AdBlue® tank
4. Inspect for poor connections at the DCU harness connector CN.D1-2.
NOTE:
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should not be set.
15 (55.100)
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2048-Urea fluid injector circuit low voltage

Solution:
Disconnect the dosing module harness connector CN.D17-3.
Measure the voltage between the injector drive circuit (High) and the DCU harness GND connection.
If the reading is less than or equal to the specified value range of 5.5 V, inspect the injector drive circuit (High)
between the DCU and dosing module.
NOTE:
• Make sure that there is no open circuits.
• Make sure that there is no short to metallic parts such as the frame.
• Make sure that there is no short to the injector drive circuit (Low).
• Make sure that there is no high resistance.
A. If a problem is found, repair the injector drive circuit (High).

2. Measure the voltage between the injector drive circuit (High) and the injector drive circuit (Low).
If the reading is less than or equal to the specified value range of 5.5 V, inspect the injector drive circuit (Low)
between the DCU and dosing module.
NOTE:
• Make sure that there is no open circuits.
• Make sure that there is no high resistance.
A. If a problem is found, repair the injector drive circuit (Low).

3. Inspect the dosing module harness connector CN.D17-3.
NOTE:

4. Measure the internal resistance between the dosing module connector CN.D17-3 terminals.
A. If the reading is outside the value range of 11 - 15 Ω , Replace the dosing module. (Refer to “ Diesel Exhaust
Fluid (DEF)/AdBlue® dosing module - Remove (55.988) and Diesel Exhaust Fluid (DEF)/AdBlue® dosing
module - Install (55.988)”)
NOTE: When the dosing module is replaced, perform Dosing module data reset with the trouble diagnosis scan
tool.
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NOTE:
NOTE:
should not be set.
15 (55.100)
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2049-Urea fluid injector circuit high voltage

Solution:
1. Inspect the injector drive circuit (High) and the injector drive circuit (Low) between the DCU and the dosing module
for a short to the battery or a short to the ignition power supply.
A. If a problem is found, repair the injector drive circuit (High) or (Low).

Inspect the dosing module harness connector CN.D17-3.
NOTE:

3. Measure the internal resistance between the dosing module connector terminals.
A. If the reading is outside the specified value range of 11 - 15 Ω , Replace the dosing module. (Refer to “ Diesel
Exhaust Fluid (DEF)/AdBlue® dosing module - Remove (55.988) and Diesel Exhaust Fluid (DEF)/Ad-
Blue® dosing module - Install (55.988)”)

tool.
NOTE:
B. If there are no problems, replace the DCU. (Refer to “ Dosing control unit - Remove (55.988) and Dosing
NOTE:
should not be set.
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15 (55.100)
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204B-Urea fluid pressure sensor performance

Solution:

Inspect each circuit of the urea fluid pressure sensor between the DCU and the urea fluid supply module.
NOTE:

3. Inspect the urea fluid supply module harness connector CN.D18.
NOTE:

NOTE:

NOTE: Perform the following inspection only when it is cold, such as in winter.
5. Turn ON the Urea Fluid Tank Heater Coolant Control Valve under Actuator Test on the trouble diagnosis scan tool.
NOTE: The engine coolant should flow into the supply module.
A. If a problem is found, repair or replace the urea fluid heater control system.
B. If there are no problems, replace the urea fluid supply module. (Refer to “ Diesel Exhaust Fluid (DEF)/Ad-
Blue® supply module - Remove (55.988) and Diesel Exhaust Fluid (DEF)/AdBlue® supply module -
Install (55.988)”)
NOTE:
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should not be set.
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204C-Urea fluid pressure sensor circuit low voltage

Solution:
NOTE:

A. If diagnostic trouble code 204D is set but diagnostic trouble code 204C is not set, replace the urea fluid supply
module. (Refer to “ Diesel Exhaust Fluid (DEF)/AdBlue® supply module - Remove (55.988) and Diesel
Exhaust Fluid (DEF)/AdBlue® supply module - Install (55.988)”)
3. Inspect the signal circuit between the DCU and the urea fluid pressure sensor.
NOTE:

NOTE:
NOTE:
should not be set.
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204D-Urea fluid pressure sensor circuit high voltage

Solution:
1. Check and diagnose the below fault codes before you proceed with the diagnostics code 204D.
Diagnostic trouble code 0641
Measure the voltage between the signal circuit and the DCU harness GND connection.
If the reading is more than or equal to 5.5 V, inspect the signal circuit between the DCU and the urea fluid pressure
sensor for a short to the battery power supply or a short to the ignition power supply circuit.
CAUTION:
The urea fluid pressure sensor may be damaged if the sensor signal circuit is shorted to the power supply.
B. If the reading is less than or equal to 5.5 V, inspect the signal circuit between the DCU and the urea fluid
pressure sensor for an open circuit or a short to the 5.5 V power supply circuit.
C. If a problem is found, repair the signal circuit.

3. Measure the voltage between the 5 V power supply circuit and the DCU harness GND connection.
A. If the reading is less than or equal to 4.8 V, inspect the 5.5 V power supply circuit between the DCU and the
urea fluid pressure sensor for an open circuit or high resistance.
B. If a problem is found, repair the 5.5 V power supply circuit.

4. Measure the voltage between the 5 V power supply circuit and the DCU harness GND connection.
A. If the reading is less than or equal to 4.8 V, inspect the GND circuit between the DCU and the urea fluid pressure
sensor for an open circuit or high resistance.
B. If a problem is found, repair the GND circuit.

5. Inspect the urea fluid supply module harness connector CN.D18.
NOTE:
Install (55.988)”)
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NOTE:
NOTE:
should not be set.
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205B-Urea fluid tank temperature sensor performance

Solution:
All the diagnostic trouble codes that were set at the same time
2. If there are diagnostic trouble codes that were set at the same time, treat those first.
urea fluid tank.

high temperature close to the urea fluid tank.
NOTE:
NOTE:
3. Confirm that the temperature differences of 5 °C (41 °F) between the engine coolant temperature, intake air
temperature, and fuel start the engine.
NOTE: If the reading is not within the specified requirements, soak until it is.
should not be set.
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205C-Urea fluid tank temperature sensor low voltage

Solution:
NOTE:

supply circuit.

circuit.

4. Inspect the signal side circuit between the DCU and urea fluid tank temperature sensor.
NOTE:
• Make sure that there is no short to ground.
• Make sure that there is no short to the ground circuit.

NOTE: Make sure that there is no intermittent conditions, poor connections, or corrosion.
NOTE:
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should not be set.
15 (55.100)
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205D-Urea fluid tank temperature sensor high voltage

Solution:
Disconnect the harness connector CN.D20 from the urea fluid tank temperature sensor.
Connect the DMM between the urea fluid tank temperature sensor signal circuit and a known good GND.
If the reading is more than or equal to the specified value range of 4.6 - 5.2 V, inspect the signal circuit between the
DCU and the urea fluid tank temperature sensor for a short to the battery or a short to the ignition power supply.

2. If the reading is less than or equal to the specified value range of 4.6 - 5.2 V, inspect the signal circuit between the
DCU and the urea fluid tank temperature sensor for an open circuit or high resistance.

3. If the reading is within the specified value range of 4.6 - 5.2 V, connect the DMM between the urea fluid tank
temperature sensor signal circuit and the GND circuit.
If the reading is less than or equal to 4.6 V, inspect the GND circuit between the DCU and the urea fluid tank
temperature sensor for an open circuit or high resistance.
NOTE:
• The urea fluid tank temperature sensor shares the GND circuit with other sensors.

4. Inspect for poor connections at the urea fluid tank temperature sensor harness connector CN.D20.

5. Replace the urea fluid tank temperature sensor.
Inspect for poor connections at the DCU harness connector CN.D1-2.
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NOTE:
should not be set.
15 (55.100)
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206A-Urea fluid quality sensor circuit

Solution:
Inspect the urea fluid sensor power supply circuit between the ignition switch and the urea fluid sensor for an open
circuit or high resistance.
A. If a problem is found, repair the urea fluid sensor power supply circuit.

2. Inspect the urea fluid sensor harness connector CN.D20.
NOTE:
NOTE:
4. Check whether each display is the specified value on the trouble diagnosis scan tool.
Urea fluid tank level sensor error: No
Urea fluid concentration error: No
Urea fluid tank temperature sensor error: No
should not be set.
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206B-Urea sensor over temperature condition

Solution:
2. If there are diagnostic trouble codes that were set at the same time, treat those first.
NOTE:
• Make sure that there is no open circuit, breakage, or high resistance.
• Make sure that there is no short circuit or improper modification.

supply circuit.

circuit.

5. Check whether any equipment which could cause abnormally high temperature is installed in the area around the
urea fluid tank.

A. If there is the possibility that abnormally high temperature occurred in the past, inspect the corresponding
location.
NOTE:
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3. Confirm that the temperature differences 5 °C (41 °F) between the engine coolant temperature, intake air tem-
perature, and fuel temperature are all the specified value or less, and start the engine.
should not be set.
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206C-Urea fluid quality sensor circuit low voltage

Solution:
NOTE:

supply circuit.

circuit.


5. Inspect each circuit between the DCU and the urea fluid quality sensor for a short circuit.

6. Replace the urea fluid quality sensor.
4. Observe the following parameters on the trouble diagnosis scan tool.
• Urea fluid concentration sensor error

• Urea fluid conductivity sensor error
• Urea fluid tank temperature sensor error
• Urea fluid sensor error
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should not be set.
15 (55.100)
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206D-Urea fluid quality sensor circuit high voltage

Solution:
Disconnect the harness connector CN.D20 from the urea fluid quality sensor.
Inspect the power supply circuit of the urea fluid quality sensor for an open circuit.
A. If a problem is found, repair the power supply circuit.

2. Inspect for poor connections at the urea fluid quality sensor harness connector CN.D20.

3. Replace the urea fluid quality sensor.
4. Check if the following parameters change to "No" on the trouble diagnosis scan tool.
• Urea fluid concentration sensor error

• Urea fluid conductivity sensor error
• Urea fluid tank temperature sensor error
• Urea fluid sensor error
should not be set.
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207F-Urea fluid concentration too low

Solution:
1. Inspect the concentration of the urea fluid.
A. If a problem is found, add the specified urea fluid after cleaning the inside of the urea fluid tank.

2. Inspect the urea fluid tank.
NOTE: Make sure that there is no water intrusion caused by cracking or damage.
A. If a problem is found, replace the urea fluid tank.

3. Inspect the urea fluid sensor.
NOTE:
• Make sure that there is no coolant intrusion caused by cracking or damage of the coolant passages.
• Make sure that there is no water intrusion from the urea fluid sensor installation area or seal area.
Clear the diagnostic trouble code with the trouble diagnosis scan tool.
Observe the diagnostic trouble code information with a trouble diagnosis scan tool. diagnostic trouble code 207F
should not be set.
A. If diagnostic trouble code 207F is set, replace the urea fluid sensor.
should not be set.
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208A-Urea fluid pump control circuit

Solution:
NOTE:
• Make sure that there is no intermittent conditions, poor connections, or corrosion for any of the terminals.
• Make sure that there is no open circuit, high resistance, or short to any of the circuits.

NOTE:

3. Inspect the urea fluid pump power supply circuit between the DCU and the urea fluid supply module harness
connector for an open circuit or high resistance.
A. If a problem is found, repair the pump power supply circuit.

4. Inspect the GND circuit between the DCU and the urea fluid supply module harness connector CN.D18 for an
open circuit or high resistance
A. If a problem is found, repair the GND circuit.

5. Inspect the pump control circuit between the DCU and the urea fluid supply module harness connector CN.D18
for an open circuit.
A. If a problem is found, repair the pump control circuit.
Install (55.988)”)
6. replace the DCU. (Refer to “ Dosing control unit - Remove (55.988) and Dosing control unit - Install (55.988)”)
NOTE:
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should not be set.
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208B-Urea fluid pump performance

Solution:
Diagnostic trouble code 208A

NOTE:

NOTE:

4. Inspect the urea fluid pump power supply circuit between the DCU and the urea fluid supply module for an open

open circuit or high resistance.
NOTE: Perform the following inspection only when it is cold, such as in winter.
6. Turn ON the Urea Fluid Tank Heater Coolant Control Valve under Actuator Test on the trouble diagnosis scan tool.
A. If a problem is found, repair or replace the urea fluid heater control system.
Install (55.988)”)
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NOTE:
4.Test run at the specified speed or higher while observing the exhaust gas temperature 3 value 190 °C (374 °F)
with the trouble diagnosis scan tool.
should not be set.
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208C-Urea fluid pump control circuit low voltage

Solution:
NOTE:

NOTE:



A. If diagnostic trouble code 208A is set but 208C is not set,replace the urea fluid supply module. (Refer to “
Diesel Exhaust Fluid (DEF)/AdBlue® supply module - Remove (55.988) and Diesel Exhaust Fluid (DEF)/

Inspect the urea fluid pump control circuit between the DCU and the urea fluid supply module.
NOTE:
A. If a problem is found, repair the urea fluid pump control circuit.
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NOTE:
should not be set.
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208D-Urea fluid pump control circuit high voltage

Solution:
NOTE:

NOTE:


4. Inspect the GND circuit between the DCU and the urea fluid supply module harness connector for an open circuit
or high resistance.

A. If diagnostic trouble code 208A is set but 208D is not set, replace the urea fluid supply module. (Refer to “

Inspect the urea fluid pump control circuit between the DCU and the urea fluid supply module.
NOTE:
• Make sure that there is no short to the battery or short to the ignition power supply circuit.
• Make sure that there is no short to the battery voltage supply circuit.
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NOTE:
should not be set.
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208E-Urea fluid injector stuck

Solution:
1. Check and diagnose the below fault codes before you proceed with the diagnostics code 208E.

Inspect the dosing module harness connector CN.D17-3.
NOTE:

NOTE:

4. Inspect the injector drive circuit (High) and injector drive circuit (Low) between the DCU and the dosing module
for high resistance.
A. If a problem is found, repair the injector drive circuit (High) or (Low).
B. If there are no problems, remove the dosing module. (Refer to “ Diesel Exhaust Fluid (DEF)/AdBlue® dosing
module - Remove (55.988)”)
5. Inspect the dosing module.
NOTE:
• The dosing module should not be clogged by crystals adhering to its end.
• Make sure that there is no damage to or deformation of the dosing module unit.
Measure the internal resistance 11 - 15 Ω between the dosing module connector CN.D17-3 terminals.
Clean or replace the dosing module. (Refer to “ Diesel Exhaust Fluid (DEF)/AdBlue® dosing module - Install
(55.988)”)
tool.
Start the engine.
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Drive at the specified speed or higher while observing the exhaust gas temperature 3 value 190 °C (374 °F) with
the trouble diagnosis scan tool.
A. If the applicable diagnostic trouble code is set as a current failure, replace the DCU. (Refer to “ Dosing control
unit - Remove (55.988) and Dosing control unit - Install (55.988)”)
NOTE:
4. Drive at the specified speed or higher while observing the exhaust gas temperature 3 value 190 °C with the
trouble diagnosis scan tool.
should not be set.
15 (55.100)
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20A0-Urea fluid reverting valve circuit open

Solution:
NOTE:

Inspect the DCU harness connector CN.D1-2 .
NOTE:

3. Inspect the urea fluid reverting valve power supply circuit between the DCU and the urea fluid supply module for
an open circuit or high resistance.
A. If a problem is found, repair the urea fluid reverting valve power supply circuit.

4. Inspect the GND circuit between the DCU and the urea fluid supply module for an open circuit or high resistance.

Inspect the urea fluid reverting valve control circuit between the DCU and the urea fluid supply module.
NOTE:
Install (55.988)”)
6. replace the DCU. (Refer to “ Dosing control unit - Remove (55.988) and Dosing control unit - Install (55.988)”)
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NOTE:
should not be set.
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20A2-Urea fluid reverting valve circuit low voltage

Solution:
NOTE:

NOTE:



A. If diagnostic trouble code 20A0 is set but 20A2 is not set,replace the urea fluid supply module. (Refer to “

Inspect the control circuit between the DCU and reverting valve.
NOTE:
• Make sure that there is no short to other GND circuits.
A. If a problem is found, repair the control circuit.
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NOTE:
should not be set.
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20A3-Urea fluid reverting valve circuit high voltage

Solution:
NOTE:

NOTE:



A. If diagnostic trouble code 20A0 is set but 20A3 is not set, replace the urea fluid supply module. (Refer to “

Inspect the control circuit between the DCU and reverting valve.
NOTE:
• Make sure that there should be no short to the battery or short to the ignition power supply.
• Make sure that there should be no short to the power supply circuit.
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NOTE:
should not be set.
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20AC-Urea fluid pump temperature sensor performance

Solution:
1. Check and diagnose the below fault codes before you proceed with the diagnostics code 20AC.
Diagnostic trouble code 208A

NOTE:

NOTE:



6. Inspect the urea fluid pump control circuit between the DCU and the urea fluid supply module for abnormal harness
appearances.
NOTE: Make sure that should be no damage, deformation, etc.
B. If the control circuit is normal, replace the urea fluid supply module. (Refer to “ Diesel Exhaust Fluid (DEF)/
AdBlue® supply module - Remove (55.988) and Diesel Exhaust Fluid (DEF)/AdBlue® supply module -
Install (55.988)”)
NOTE: Make sure that there is no damage, deformation, etc.
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7. Clear the diagnostic trouble code with the trouble diagnosis scan tool.
A. If the diagnostic trouble code is set, turn OFF the ignition switch
B. If the diagnostic trouble code is not set, replace the DCU. (Refer to “ Dosing control unit - Remove (55.988)
and Dosing control unit - Install (55.988)”)
NOTE:
should not be set.
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20AD-Urea fluid pump module temperature sensor performance

Solution:
1. Check and diagnose the below fault codes before you proceed with the diagnostics code 20AD.
A. If there are diagnostic trouble codes that were set at the same time, treat those first.
NOTE:

supply circuit.

circuit.

5. Check whether any equipment which could cause abnormally high temperature is installed in the area around the
urea fluid tank.

A. If there is the possibility that abnormally high temperature occurred in the past, inspect the corresponding
location.
B. If there are no problems, replace the urea fluid sensor. (Refer to “ Diesel Exhaust Fluid (DEF)/AdBlue® tank
NOTE:
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3. Confirm that the temperature differences 5 °C (41 °F) between the engine coolant temperature, intake air tem-
perature, and fuel temperature are all the specified value or less, and start the engine.
should not be set.
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20B1-Urea fluid tank heater coolant control valve circuit open

Solution:
NOTE:

NOTE:

3. Inspect the power supply circuit between the DCU and the coolant control valve for an open circuit or high resis-
tance.

4. Inspect the control circuit between the DCU and the coolant control valve.
NOTE:
• Make sure that there is no open circuit or high resistance.

5. Perform Urea Fluid Tank Heater Coolant Control Valve under Actuator Test.
A. If the test lamp illuminates/turns OFF in accordance with the ON/OFF commands, replace the coolant control
valve. (Refer to “ Coolant control valve - Remove (10.500) and Coolant control valve - Install (10.500)”)
B. If the test lamp does not illuminate or turn OFF in accordance with the urea fluid tank heater coolant control
valve being turned ON or OFF with the Actuator Test, replace the DCU. (Refer to “ Dosing control unit -
Remove (55.988) and Dosing control unit - Install (55.988)”)
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NOTE:
should not be set.
15 (55.100)
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20B3-Urea fluid tank heater coolant control valve circuit low voltage
Solution:
NOTE:

NOTE:

3. Inspect the power supply circuit between the DCU and the coolant control valve for an open circuit or high resis-
tance.

4. Inspect the control circuit between the DCU and the coolant control valve.
NOTE:

A. If diagnostic trouble code 20B1 is set but 20B3 is not set, replace the coolant control valve. (Refer to “ Coolant
replace the DCU. (Refer to “ Dosing control unit - Remove (55.988) and Dosing control unit - Install (55.988)”)
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NOTE:
should not be set.
15 (55.100)
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20B4-Urea fluid tank heater coolant control valve circuit high

voltage
Solution:
NOTE:

A. If diagnostic trouble code 20B1 is set but 20B4 is not set, replace the coolant control valve. (Refer to “ Coolant
3. Inspect the control circuit between the DCU and the coolant control valve for a short to the battery or a short to the
ignition power supply.

NOTE:
NOTE:
should not be set.
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15 (55.100)
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20E8-Urea fluid pressure underpressure

Solution:
1. Check and diagnose the below fault codes before you proceed with the diagnostics code 20E8.

Diagnostic trouble code 208E
2. Inspect for urea fluid leakage.
NOTE:
• Make sure that there is no leakage from the urea fluid piping between the urea fluid supply module and dosing
module.
• Make sure that there is no leakage from the urea fluid piping between the urea fluid tank and urea fluid supply
module.
• Make sure that there is no leakage from the urea fluid piping connection.
• Make sure that there is no leakage from the urea fluid supply module unit.
• Make sure that there is no leakage from the dosing module unit.
A. If a problem is found, repair or replace DEF supply module (Refer to “ Diesel Exhaust Fluid (DEF)/AdBlue®
(55.988)”) and Dosing module. (Refer to “ Diesel Exhaust Fluid (DEF)/AdBlue® dosing module - Remove
(55.988) and Diesel Exhaust Fluid (DEF)/AdBlue® dosing module - Install (55.988)”)

tool.
3. Make sure that there is no clogging of the supply module filter.
A. If a problem is found, replace the supply module filter.. (Refer to “ Diesel Exhaust Fluid (DEF)/AdBlue®
supply module Filter - Remove (55.988) and Diesel Exhaust Fluid (DEF)/AdBlue® supply module Filter
- Install (55.988)”)

4. Inspect the suction piping between the urea fluid supply module and the urea fluid tank.
NOTE:
• Make sure that there is no clogging caused by twisting or bending.
• Make sure that there is no clogging caused by foreign material.
• Make sure that there is no clogging caused by urea fluid freezing.
• Make sure that there is no layout changes in the urea fluid piping that differ from the specified layout.

5. Inspect the urea fluid sensor.
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NOTE:
• Make sure that there is no clogging caused by bending of the breather hose or foreign material.
• Make sure that there is no clogging caused by bending of the suction line or foreign material.
A. If a problem is found, clean or replace the urea fluid sensor. (Refer to “ Diesel Exhaust Fluid (DEF)/AdBlue®
tank level and temperature sensor - Remove (55.988) and Diesel Exhaust Fluid (DEF)/AdBlue® tank
level and temperature sensor - Install (55.988)”)

6. Inspect for floating substances such as foreign material in the urea fluid tank which may cause clogging of the
filter.
A. If a problem is found, clean the inside of the urea fluid tank and replace the urea fluid.

NOTE:

NOTE:

9. Inspect each circuit of the urea fluid pressure sensor between the DCU and the urea fluid supply module for high
resistance.
B. If there are no problems, replace the urea fluid supply module. (Refer to “ Diesel Exhaust Fluid (DEF)/
AdBlue® supply module - Remove (55.988) and Diesel Exhaust Fluid (DEF)/AdBlue® supply module -
Install (55.988)”)
NOTE:
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5. Check whether the urea fluid pressure is more than or equal to 750 kPa (109 psi) with the trouble diagnosis
scan tool.
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20E9-Urea fluid overpressure

Solution:
1. Check and diagnose the below fault codes before you proceed with the diagnostics code 20E9.

2. Inspect the backflow piping between the urea fluid supply module and the urea fluid tank.
NOTE:
• Make sure that there is no layout changes in the urea fluid piping that differ from the specified layout.
CAUTION:

3. Inspect the urea fluid sensor backflow line.
NOTE:
A. If a problem is found, replace the urea fluid sensor. (Refer to “ Diesel Exhaust Fluid (DEF)/AdBlue® tank

4. Inspect the backflow connector CN.D18 of the urea fluid supply module.
NOTE:
• The check valve should not be clogged or stuck closed.
• Make sure that there is no clogging caused by deformation of the connector.
A. If a problem is found, repair the backflow connector CN.D18. (Refer to “ Diesel Exhaust Fluid (DEF)/Ad-
Install (55.988)”)

NOTE:
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Inspect each circuit between the DCU and the urea fluid supply module.
NOTE:

NOTE:
Install (55.988)”)
NOTE:
5. Check whether the urea fluid pressure is less than or equal to 1050 kPa (152 psi) with the trouble diagnosis
scan tool.
should not be set.
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20EA-Urea fluid pressure reduction malfunction

Solution:
1. Check and diagnose the below fault codes before you proceed with the diagnostics code 20EA.

A. If there are diagnostic trouble codes that were set at the same time, treat those first.
NOTE: If a diagnostic trouble code other than 20EA is set, perform the diagnosis for diagnostic trouble code 1464
first.
2. Make sure that there is no damage to or clogging of the supply module filter.
A. If a problem is found, replace the supply module filter. (Refer to “ Diesel Exhaust Fluid (DEF)/AdBlue® supply
module - Remove (55.988) and Diesel Exhaust Fluid (DEF)/AdBlue® supply module - Install (55.988)”)

3.
CAUTION:
• Make sure that there is no layout in the urea fluid piping that differs from the specified layout.

5. Disconnect the harness connector CN.D18 from the urea fluid supply module.
Inspect for poor connections at the urea fluid supply module harness connector CN.D18.

6. Inspect each circuit between the DCU and the urea fluid supply module.
• Make sure that there is no short circuit.
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7. Perform Reverting Valve under Actuator Test with the trouble diagnosis scan tool to check if the reverting valve is
stuck.
Replace the urea fluid supply module. (Refer to “ Diesel Exhaust Fluid (DEF)/AdBlue® supply module - Re-
NOTE:
should not be set.
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20FE-Urea fluid pressure build-up error

Solution:
1. Check and diagnose the below fault code before you proceed with the diagnostic code 20FE.

Diagnostic trouble code 208E
2. Make sure that there should be no damage to or clogging of the supply module filter.
CAUTION:
A. If a problem is found, replace the supply module filter. (Refer to “ Diesel Exhaust Fluid (DEF)/AdBlue®
(55.988)”)

• Make sure that there should be no layout in the urea fluid piping that differs from the specified layout.
• Make sure that there should be no poor connections at the urea fluid supply module inlet connector CN.D18
section.

4. Check whether or not the urea fluid supply module inlet connector CN.D18 remains closed.
A. If a problem is found, replace the urea fluid supply module.

5. Replace the suction hose between the urea fluid supply module and the urea fluid tank with a clear hose.
CAUTION:
The clamp should be installed to the hose.
Start the engine.
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Check for the intrusion of air.
A. If air intrusion is found, replace the urea fluid sensor.

6. Inspect the DCU system.
• Make sure that there should be no clogging caused by bending of the sensor tube of the urea fluid tank level
sensor in the tank, and no malfunctions caused by the float being at an angle.
• Make sure that there should be no layout of the urea fluid tank and urea fluid supply module which differs from
the specified layout.
• Make sure that there should be no damage to or clogging of the supply module filter. There should be no
clogging of the urea fluid quality sensor strainer.
• Make sure that there should be no freezing of the urea fluid suction line, pressure line, inside the tank, or in the
coolant piping.
• Make sure that there should be no clogging of the urea fluid tank vent hose.
• Make sure that the reverting valve should not be stuck in the normal position.
• Make sure that the dosing module should not remain open.
• Make sure that there should be no leakage from the urea fluid piping, urea fluid supply module, or dosing
module.
• Make sure that there should be no damage to or clogging caused by twisting of the pressure line between the
urea fluid supply module and the dosing module, and no layout which differs from the specified layout.
• Make sure that there should be no damage to or clogging caused by twisting of the suction line between the
urea fluid supply module and the tank, and no layout which differs from the specified layout.
• Make sure that there should be no damage to or clogging caused by twisting of the urea fluid sensor suction
piping, and no layout that differs from the specified layout.
• Make sure that the one-way valve of the backflow connector should not remain open.
• Make sure that there should be no clogging of the urea fluid supply module suction connector.
CAUTION:
Do not blow air onto the urea fluid supply module.
A. If a problem is found, repair or replace the applicable area.

7. Inspect for poor connections at the urea fluid supply module harness connector CN.D18.


9. Inspect each circuit between the DCU and the urea fluid supply module for high resistance.
Replace the urea fluid supply module. (Refer to “ Diesel Exhaust Fluid (DEF)/AdBlue® supply module - Re-
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NOTE:
4. Observe the urea fluid pressure 860 - 940 kPa (125 - 136 psi) display on the trouble diagnosis scan tool.
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242B-Exhaust gas temperature (EGT) sensor 3 performance

Solution:
1. Check and diagnose the below fault code before you proceed with the diagnostic code 242B.

Inspect the installation status of EGT sensor 3.
A. If a problem is found, repair the installation status of EGT sensor 3.

3. Disconnect the harness connector CN.D17-7 from EGT sensor 3.
Inspect for poor connections at the EGT sensor 3 harness connector CN.D17-7.
Disconnect the harness connector CN.D1-2 from the DCU.
Inspect each circuit between the DCU and EGT sensor 3 for high resistance.
A. If a problem is found, repair the circuit or connections.

4. Replace EGT sensor 3. (Refer to “ Exhaust Gas Recirculation (EGR) temperature sensors - Remove - Temper-
ature sensor 3 (55.989) and Exhaust Gas Recirculation (EGR) temperature sensors - Install - Temperature
sensor 3 (55.989)”)
NOTE: If EGT sensor 3 is replaced, reset the EGT sensor 3 data with the trouble diagnosis scan tool.
NOTE:
should not be set.
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242C-Exhaust gas temperature (EGT) sensor 3 circuit low voltage

Solution:
Disconnect the EGT sensor 3 harness connector CN.D17-7.
Inspect the EGT sensor 3 harness connector CN.D17-7.
NOTE:

A. If diagnostic trouble code 242D is set but 242C is not set, replace EGT sensor 3. (Refer to “ Exhaust Gas
Recirculation (EGR) temperature sensors - Remove - Temperature sensor 3 (55.989) and Exhaust Gas
Recirculation (EGR) temperature sensors - Install - Temperature sensor 3 (55.989)”)
3. Inspect the signal circuit between the DCU and EGT sensor 3.
NOTE:
• Make sure that there should be no short to metallic parts such as the frame.

NOTE:

NOTE:
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should not be set.
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242D-Exhaust gas temperature (EGT) sensor 3 circuit high voltage

Solution:
Disconnect the EGT sensor 3 harness connector CN.D17-7.
Measure the voltage between the signal circuit and the DCU harness GND connection.
If the reading is more than or equal to 5.2 V, inspect the signal circuit between the DCU and EGT sensor 3 for a
short to the battery or a short to the ignition power supply.
NOTE: EGT sensor 3 may be damaged if the sensor signal circuit is shorted to the power supply.

2. If the reading is less than 5.2 V, inspect the signal circuit between the DCU and EGT sensor 3 for an open circuit
or high resistance.

3. Measure the voltage between the signal circuit and the GND circuit.
If the reading is less than or equal to 4.6 V, inspect the GND circuit between the DCU and EGT sensor 3 for an

4. Inspect the EGT sensor 3 harness connector CN.D17-7.
NOTE:

5. Replace EGT sensor 3. (Refer to “ Exhaust Gas Recirculation (EGR) temperature sensors - Remove - Temper-
ature sensor 3 (55.989) and Exhaust Gas Recirculation (EGR) temperature sensors - Install - Temperature
sensor 3 (55.989)”)
NOTE:
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NOTE:
should not be set.
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2201-Upstream NOx sensor performance

Solution:

2. Inspect the NOx sensor.
Make sure that there should be no improper installation of the NOx sensor.
Make sure that there should be no damage to or clogging of the NOx sensor.
Make sure that there should be no exhaust gas leakage from the exhaust pipe.
Make sure that there should be no damage caused by crushing of the exhaust system.
A. If a problem is found, replace the NOx sensor. (Refer to “ Nitrogen Oxides (NOx) sensor - Remove (55.988)
and Nitrogen Oxides (NOx) sensor - Install (55.988)”)
NOTE:
should not be set.
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2206-NOx sensor heater control circuit low voltage sensor 1

Solution:
NOTE: If the NOx sensor is replaced, perform NOx sensor data 1 reset with the trouble diagnosis scan tool.
NOTE:
3. Start the engine and warm up until the NOx Sensor 1 NOx Detection display changes to Enabled on the scan
tool.
NOx sensor 1 heater system malfunction: No

NOx sensor 1 NOx detection system malfunction: No
NOx sensor 1 O2 detection system malfunction: No
should not be set.
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2207-NOx sensor heater control circuit high voltage sensor 1

Solution:
NOTE: If the NOx sensor is replaced, perform NOx sensor data 1 reset with the trouble diagnosis scan tool.
NOTE:
3. Start the engine and warm up until the NOx Sensor 1 NOx Detection display changes to Enabled on the scan
tool.
NOx sensor 1 heater system malfunction: No

NOx sensor 1 NOx detection system malfunction: No
NOx sensor 1 O2 detection system malfunction: No
should not be set.
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7000-P1 Pressure sensor signal abnormality

Control Module : MCM
Solution:
1. Use the below image for the fault code resolution process:
SMIL14CEX3491EB 1
1. Main controller
2. P1 Pressure sensor
Turn the key switch ON.
Inspect the connection status of each connector. Make sure that all the connectors are secured.
A. If diagnostic trouble code 7000 is displayed, proceed to Step 2.

2. Check the P1 pressure sensor (2) voltage on the service support screen.
A. If the voltage is more than or equal to 4.75 V, proceed to Step 3.
B. If the voltage is less than or equal to 0.25 V, proceed to Step 6.

3. Turn the key switch OFF and disconnect the P1 pressure sensor (2) connector CN.D49.
Measure the voltage between the ground and terminal 1 of the P1 pressure sensor (2) connector CN.D49 (har-
ness side).
A. If the voltage is not about 5 V, find and replace the short circuit on the wire ID W430.
B. If the voltage is about 5 V, proceed to Step 4.

4. Measure the voltage between the ground and terminal 2 of the P1 pressure sensor (2) connector CN.D49 (har-
ness side).
A. If the voltage is more than 4.75 V, find and replace the short circuit on the wire ID Y417.

ness side).
A. If the voltage is more than 0.25 V, find and repair the short circuit on the wire ID BL440.
B. If the voltage is less than or equal to 0.25 V, replace the main controller (1).
6. Inspect the P1 pressure sensor (2).
Turn the key switch OFF.
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Disconnect connector CN.D49.
Measure the resistance between terminals 1 and 3 of the P1 pressure sensor (2) connector CN.D49 (sensor
side).
A. If the voltage is not about 10 kΩ, replace the P1 pressure sensor (2).
B. If the voltage is about 10 kΩ, proceed to Step 7.

7. Inspect for continuity between the ground and terminal 1 of the P1 pressure sensor (2) connector CN.D49 (har-
ness side).
Inspect for continuity between the ground and terminal 2 of the P1 pressure sensor (2) connector CN.D49 (har-
ness side).
A. If there is continuity, find and repair the short circuit on the wire ID W430 and Y417.
B. If there is no continuity, proceed to Step 8.

ness side).
A. If there is no continuity, find and repair/replace the open circuit on the wire ID BL440.
B. If there is continuity, proceed to Step 9.

9. Turn the key switch ON.
Measure the voltage between the ground and terminal 1 of the connector P1 pressure sensor (2) CN.D49 (har-
ness side).
A. If the voltage is not about 5 V, find and repair/replace the open circuit on the wire ID W430.

ness side).
A. If the voltage is less than or equal to 0.25 V, find and repair the open circuit on the wire ID Y417.
B. If the voltage is more than or equal to 0.25 V, replace the main controller (1).
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7001-P2 Pressure sensor signal abnormality

Solution:
SMIL14CEX5188EB 1
1. Main controller
2. (P2) Pressure sensor

2. Check the P2 pressure sensor (2) connector on the service support screen.
A. If the voltage is more than equal to 4.75 V, proceed to Step 3.

3. Turn the key switch OFF and disconnect the P2 pressure sensor (2) connector CN.D50.
ness side).
A. If the voltage is not about 5 V, find and repair the short circuit on the wire ID W430a and W430.

ness side).
A. If the voltage is more than 4.75 V, find and repair the short circuit on the wire ID L418.

ness side).
A. If the voltage is more than 0.25 V, find and repair the short circuit on the wire ID BL440a and BL440.
6. Inspect the P2 pressure sensor (2).
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Disconnect P2 pressure sensor (2) connector CN.D50.
Measure the resistance between terminals 1 and 3 of the P2 pressure sensor (2) connector CN.D50 (sensor
side).
A. If the resistance is not about 10K Ω, replace the P2 pressure sensor (2).
B. If the resistance is about 10K Ω, proceed to Step 7.

ness side).
Inspect for continuity between the ground and terminal 2 of the P2 pressure sensor (2) connector CN.D50 (har-
ness side).
A. If there is continuity, find and repair the short circuit on the wire ID W430a, W430 and L418.

ness side).
A. If there is no continuity, find and repair the open circuit on the wire ID BL440a and BL440.

ness side).
A. If the voltage is not about 5 V, find and repair the open circuit on the wire ID W430a and W430.

ness side).
A. If the voltage is less than or equal to 0.25 V, find and repair the open circuit on the wire ID L418.
B. If the voltage is more than or equal to 0.25 V, replace the main controller (1) .
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7002-N1 Pressure sensor signal abnormality

Solution:
1. Use below image for the fault code process:
SMIL14CEX3492EB 1
1. Main controller
2. N1 Pressure sensor

2. Check the N1 pressure sensor (2) voltage on the service support screen.

3. Turn the key switch OFF and disconnect the N1 pressure sensor (2) connector CN.D65-1.
Measure the voltage between the ground and terminal 1 of the N1 pressure sensor (2) connector CN.D65-1
(harness side).
A. If the voltage is not about 5 V, find and repair the short circuit on the wire ID W430b and W430.

4. Measure the voltage between the ground and terminal 2 of the N1 pressure sensor (2) connector CN.D65-1
(harness side).
A. If the voltage is above 4.75 V, find and repair the short circuit on the wire ID R419.
B. If the voltage is 4.75 V or lower, proceed to Step 5.

(harness side).
A. If the voltage is more than 0.25 V, find and repair the short circuit on the wire ID BL440b and BL440.
6. Inspect the N1 pressure sensor (2).
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Disconnect N1 pressure sensor (2) connector CN.D65-1.
Measure the resistance between terminals 1 and 3 of the N1 pressure sensor (2) connector CN.D65-1 (sensor
side).
A. If the resistance is not about 10 kΩ, replace the N1 pressure sensor (2).
B. If the resistance is about 10 kΩ, proceed to Step 7.

7. Inspect for continuity between the ground and terminal 1 of the N1 pressure sensor (2) connector CN.D65-1
(harness side).
Inspect for continuity between the ground and terminal 2 of the N1 pressure sensor (2) connector CN.D65-1
(harness side).
A. If there is continuity, find and repair the short circuit on the wire ID W430b, W430, and R419.

(harness side).
A. If there is no continuity, find and repair the open circuit on the wire ID BL440b and BL440.

(harness side).
A. If the voltage is not about 5 V, find and repair the open circuit on the wire ID W430b and W430.

(harness side).
A. If the voltage is not more than or equal to 0.25 V, find and repair the open circuit on the wire ID R419.
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7003-N2 Pressure sensor signal abnormality

Solution:
SMIL14CEX3493EB 1
1. Main controller
2. N2 Pressure sensor

2. Check the N2 pressure sensor (2) connector on the service support screen.

3. Turn the key switch OFF and disconnect the N2 pressure sensor (2) connector CN.D65-2.
(harness side).
A. If the voltage is not about 5 V, find and repair the short circuit on the wire ID W430c, W430b and W430.

(harness side).
A. If the voltage is more than 4.75 V, find and repair the short circuit on the wire ID G420.

(harness side).
A. If the voltage is more than 0.25 V, find and repair the short circuit on the wire ID BL440c and BL440.
6. Inspect the N2 pressure sensor (2).
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Disconnect N2 pressure sensor (2) connector CN.D65-2.
Measure the resistance between terminals 1 and 3 of the N2 pressure sensor (2) connector CN.D65-2 (sensor
side).
A. If the resistance is not about 10K Ω replace the N2 pressure sensor (2).
B. If the resistance is about 10K Ω, proceed to Step 7.

(harness side).
Inspect for continuity between the ground and terminal 2 of the N2 pressure sensor (2) connector CN.D65-2
(harness side).
A. If there is continuity, find and repair the short circuit on the wire ID W430c, W430b, W430 and G420.

(harness side).
A. If there is no continuity, find and repair the open circuit on the wire ID BL440c and BL440.

(harness side).
A. If the voltage is not about 5 V, find and repair the open circuit on the wire ID W430c, W430b, and W430.

(harness side).
A. If the voltage is not more than 0.25 V, find and repair the open circuit on the wire ID G420.
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7004-Bottom pressure sensor signal abnormality

Solution:
SMIL14CEX3494EB 1
1. Main controller
2. Pressure sensor (boom cylinder bottom)

2. Check the bottom pressure sensor (2) voltage on the service support screen.

3. Turn the key switch OFF and disconnect the connector CN.D52.
Measure the voltage between the ground and terminal 1 of the connector CN.D52 (harness side).
A. If the voltage is not about 5 V, find and repair the short circuit on the wire WL435j, WL435 and WB435.

4. Measure the voltage between the ground and terminal 2 of the connector CN.D52 (harness side).
A. If the voltage is more than 4.75 V, find and repair the short circuit on the wire Gr421.

A. If the voltage is more than 0.25 V, find and repair the short circuit on the wire BW445j and BW445.
Disconnect the connector CN.D52.
Measure the resistance between terminals 1 and 3 of the connector CN.D52 bottom pressure.
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A. If the resistance is not about 10 kΩ, replace the bottom pressure sensor (2).

7. Inspect for continuity between the ground and terminal 1 of the connector CN.D52 (harness side).
Inspect for continuity between the ground and terminal 2 of the connector CN.D52 (harness side).
A. If there is continuity, find and repair the short circuit on the wire WL435j, WL435, WB435 and Gr421.

8. Inspect for continuity between the ground and terminal 3 of the connector CN.D52 (harness side).
A. If there is no continuity, find and repair the open circuit on the wire BW445j and BW445.

Measure the voltage between the ground and terminal 1 of the connector CN.D52 (harness side).
A. If the voltage is not about 5 V, find and repair the open circuit on the wire WL435j, WL435 and WB435.

A. If the voltage is less than 0.25 V, find and repair the open circuit on the wire Gr421.
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7007-Pressure sensor arm cylinder rod abnormality

Solution:
SMIL14CEX3495EB 1
1. Main controller
2. Pressure sensor (arm rod)
Turn the key switch ON

2. Check the (N2) pressure sensor voltage on the service support screen

3. Turn the key switch OFF and disconnect the connector CN.D65-3.
Measure the voltage between the ground and terminal 1 of the connector CN.D65-3 (harness side).
A. If the voltage is not about 5 V, find and repair the short circuit on the wire WL435 and WB435.

4. Measure the voltage between the ground and terminal 2 of the connector CN.D65-3 (harness side).
A. If the voltage is more than 4.75 V, find and repair the short circuit on the wire BrW402 and Br402.

A. If the voltage is more than 0.25 V, find and repair the short circuit on the wire BW445.
6. Inspect the arm rod pressure sensor (2).
Disconnect the connector CN.D65-3.
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Measure the resistance between terminals 1 and 3 of the connector CN.D65-3 arm rod pressure sensor (2).
A. If the resistance is not about 10 kΩ, replace the arm rod pressure sensor (2).

7. Inspect for continuity between the ground and terminal 1 of the connector CN.D65-3 (harness side).
Inspect for continuity between the ground and terminal 2 of the connector CN.D65-3 (harness side).
A. If there is continuity, find and repair the short circuit on the wire WL435, WB435, BrW402 and Br402.

8. Inspect for continuity between the ground and terminal 3 of the connector CN.D65-3 (harness side).
A. If there is no continuity, find and repair the open circuit on the wire BW445.

Measure the voltage between the ground and terminal 1 of the connector CN.D65-3 (harness side).
A. If the voltage is not about 5 V, find and repair the open circuit on the wire WL435 and WB435.

A. If the voltage is less than 0.25 V, find and repair the open circuit on the wire BrW402 and Br402.
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7021-Swing pressure sensor signal abnormality

Solution:
SMIL14CEX3496EB 1
1. Main controller
2. Pressure sensor (pilot swing)

2. Check the swing pressure sensor (2) voltage on the service support screen.

3. Turn the key switch OFF and disconnect the swing pressure sensor (2) connector CN.D25.
Measure the voltage between the ground and terminal 1 of the swing pressure sensor (2) connector CN.D25
(harness side).
A. If the voltage is not about 5 V, find and repair the short circuit on the wire ID WL435b, WL435 and WB435.

4. Measure the voltage between the ground and terminal 2 of the swing pressure sensor (2) connector CN.D25
(harness side).
A. If the voltage is more than 4.75 V, find and repair the short circuit on the wire ID LgR404 and Lg404.

5. Measure the voltage between the ground and terminal 3 of the swing pressure sensor (2) connector CN.D25
(harness side).
A. If the voltage is more than 0.25 V, find and repair the short circuit on the wire ID BW445b and BW445.
6. Inspect the swing pressure sensor (2).
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Disconnect the swing pressure sensor (2) connector CN.D25.
Measure the resistance between terminals 1 and 3 of the swing pressure sensor (2) connector CN.D25 (swing
pressure sensor side).
A. If the resistance is not about 10k Ω, replace the swing pressure sensor (2).
B. If the resistance is about 10k Ω, proceed to Step 7.

7. Inspect for continuity between the ground and terminal 1 of the swing pressure sensor (2) connector CN.D25
(harness side).
Inspect for continuity between the ground and terminal 2 of the swing pressure sensor (2) connector CN.D25
(harness side).
A. If there is continuity, find and repair the short circuit on the wire ID WL435b, WL435, WB435, LgR404 and
Lg404.

8. Inspect for continuity between the ground and terminal 3 of the swing pressure sensor (2) connector CN.D25
(harness side).
A. If there is no continuity, find and repair the open circuit on the wire ID BW445b and BW445.

Measure the voltage between the ground and terminal 1 of the swing pressure sensor (2) connector CN.D25
(harness side).
A. If the voltage is not about 5 V, find and repair the open circuit on the wire ID WL435b, WL435 and WB435.

10. Measure the voltage between the ground and terminal 2 of the swing pressure sensor (2) connector D25 (harness
side).
A. If the voltage is less than 0.25 V, find and repair the open circuit on the wire ID LgR404 and Lg404.
B. If the voltage is more than or equal 0.25 V, replace the main controller (1).
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7023-Arm-in pressure sensor signal abnormality

Solution:
SMIL14CEX3497EB 1
1. Main controller
2. Pressure sensor (arm in)

2. Check the arm in pressure sensor (2) voltage on the service support screen.

3. Turn the key switch OFF and disconnect the arm in pressure sensor (2) connector CN.D29.
Measure the voltage between the ground and terminal 1 of the arm in pressure sensor (2) connector CN.D29
(harness side).
A. If the voltage is not about 5 V, find and repair the short circuit on the wire ID WL435f, WL435 and WB435.

4. Measure the voltage between the ground and terminal 2 of the arm in pressure sensor (2) connector CN.D29
(harness side).
A. If the voltage is more than 4.75 V, find and repair the short circuit on the wire ID YG408.

(harness side).
A. If the voltage is more than 0.25 V, find and repair the short circuit on the wire ID BW445f and BW445.
6. Inspect the arm in pressure sensor (2).
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Disconnect arm in pressure sensor (2) connector CN.D29.
Measure the resistance between terminals 1 and 3 of the arm in pressure sensor (2) connector CN.D29 (arm in
pressure sensor side).
A. If the resistance is not about 10 Ω, replace the arm in pressure sensor (2).
B. If the resistance is about 10 Ω, proceed to Step 7.

7. Inspect for continuity between the ground and terminal 1 of the arm in pressure sensor (2) connector CN.D29
(harness side).
Inspect for continuity between the ground and terminal 2 of the arm in pressure sensor (2) connector CN.D29
(harness side).
A. If there is continuity, find and repair the short circuit on the wire ID WL435f, WL435, WB435 and YG408.

8. Inspect for continuity between the ground and terminal 3 of the arm in pressure sensor (2) connector CN.D29
(harness side).
A. If there is no continuity, find and repair the open circuit on the wire ID BW445f and BW445.

Measure the voltage between the ground and terminal 1 of the arm in pressure sensor (2) connector CN.D29
(harness side).
A. If the voltage is not about 5 V, find and repair the open circuit on the wire ID WL435f, WL435 and WB435.

(harness side).
A. If the voltage is less than 0.25 V, find and repair the open circuit on the wire ID YG408.
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7040-Fuel level sensor signal abnormality

Solution:
SMIL14CEX3498EB 1
1. Main controller
2. Fuel level sensor
Float position and resistance
Float position Full Half Empty

10 80
Resistance (Ω) 38
(Tolerance 0 - 4) (Tolerance 0 - 10)
* Temperature conditions: 5 - 35 °C (41 - 95 °F)
Inspect the connection status of each connector and ground. Make sure that all the connectors are secured.

2. Check the fuel level sensor (2) resistance on the service support screen.
A. If the resistance is more than or equal to 100 Ω, proceed to Step 3.
B. If the resistance is less than or equal to 2 Ω, proceed to Step 6.

3. Turn the key switch OFF and disconnect the fuel level sensor (2) connector CN.D53.
Measure the resistance between the terminal 1 and terminal 2 of the fuel level sensor (2) connector (fuel level
sensor side) CN.D53 (see the float position and resistance table).
A. If the resistance is not a standard value, replace the fuel level sensor (2).
B. If the resistance is within standard value, proceed to Step 4.

4. Inspect for continuity between the ground and terminal 1 of the fuel level sensor (2) connector CN.D53 (harness
side).
A. If there is no continuity, find and repair the open circuit on the wire ID BG660, BG600, BG605 and BG601.

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Measure the voltage between the ground and terminal 2 of the fuel level sensor (2) connector CN.D53 (harness
side).
A. If the voltage is not about 5 V, find and repair the open circuit on the wire ID GL426.
B. If the voltage is about 5 V, replace the main controller (1).

Connect the fuel level sensor (2) connector CN.D53.
Inspect for continuity between the ground and terminal 2 of the fuel level sensor (2) connector CN.D53 (harness
side).
A. If there is continuity, find and repair the short circuit on the wire ID GL426.

Measure the voltage between the ground and terminal 1 of the fuel level sensor (2) connector CN.D53 (harness
side).
A. If the voltage is not 0 V, find and repair the short circuit on the wire ID BG660, BG600, BG605 and BG601.
B. If the voltage is 0 V, replace the main controller (1).
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7041-Oil temperature sensor signal abnormality

Solution:
SMIL14CEX6808EB 1
1. Main controller
2. Oil temperature sensor
Oil temperature Resistance

-30 °C (-22 °F) 25400 Ω
-20 °C (-4 °F) 15040 Ω
-10 °C (14 °F) 9160 Ω
0 °C (32 °F) 5740 Ω
10 °C (50 °F) 3700 Ω
20 °C (68 °F) 2450 Ω
30 °C (86 °F) 1660 Ω
40 °C (104 °F) 1150 Ω
50 °C (122 °F) 811 Ω
60 °C (140 °F) 584 Ω
70 °C (158 °F) 428 Ω
80 °C (176 °F) 318 Ω
90 °C (194 °F) 240 Ω
100 °C (212 °F) 184 Ω
110 °C (230 °F) 142 Ω
120 °C (248 °F) 111 Ω

2. Inspect the connection status of each connector. Make sure that all the connectors are secured.

3. Check the oil temperature sensor (2) resistance (or voltage) on the service support screen.
A. If the resistance is more than or equal to 67200 Ω (or 4.93 V), proceed to Step 4.
B. If the resistance is less than or equal to 111 Ω (or 0.5 V), proceed to Step 7.
4. Turn the key switch OFF and disconnect the oil temperature sensor connector CN.D54.
Measure the resistance between the terminal 1 and terminal 2 of the oil temperature sensor connector CN.D54
(oil temperature sensor side) (see the oil temperature and resistance table).
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A. If the resistance is not standard value, replace the oil temperature sensor.
B. If the voltage is within standard value, proceed to Step 5.

5. Inspect for continuity between the ground and terminal 1 of the oil temperature sensor connector CN.D54 (harness
side).
A. If there is no continuity, find and repair the open circuit on the wire ID BW445p or BW445.

Measure the voltage between the ground and terminal 2 of the oil temperature sensor connector CN.D54 (harness
side).
A. If the voltage is not about 5 V, find and repair the open circuit on the wire ID Y425.
B. If the voltage is about 5 V, replace the main controller (1).
C. If there are no problem, proceed to Step 7.

Connect CN.D54.
Inspect for continuity between the ground and terminal 2 of the oil temperature sensor connector CN.D54 (harness
side).
A. If there is continuity, find and repair the short circuit on the wire ID Y425.

Measure the voltage between the ground and terminal 1 of the oil temperature sensor connector CN.D54 (harness
side).
A. If the voltage is not 0 V, find and repair the short circuit on the wire ID BW445p or BW445.
B. If the voltage is 0 V, replace the main controller (1).
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7065-Boom-up pilot pressure sensor signal abnormality

Solution:
SMIL14CEX3499EB 1
1. Main controller
2. Pressure sensor (boom up pilot)

2. Check the boom up pilot pressure sensor (2) voltage on the service support screen.

3. Turn the key switch OFF and disconnect the boom up pilot pressure sensor (2) (3-pin) connector CN.D26.
Measure the voltage between the ground and terminal 1 of the boom up pilot pressure sensor (2) (3-pin) CN.D26
(harness side).
A. If the voltage is not about 5 V, find and replace the short circuit on the wire ID WL435c, WL435 and WB435.

4. Measure the voltage between the ground and terminal 2 of the boom up pilot pressure sensor (2) (3-pin) CN.D26
(harness side).
A. If the voltage is more than 4.75 V, find and replace the short circuit on the wire ID LR405.

5. Measure the voltage between the ground and terminal 3 of the boom up pilot pressure sensor (2) (3-pin) CN.D26
(harness side).
A. If the voltage is more than 0.25 V, find and replace the short circuit on the wire ID BW445c and BW445.
6. Inspect the boom up pilot pressure sensor (2).
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Disconnect boom up pilot pressure sensor (2) CN.D26.
Measure the resistance between the terminal 1 and terminal 3 of the boom up pilot pressure sensor (2) (3-pin)
CN.D26pilot pressure sensor side.
A. If the resistance is not about 10 K Ω, replace boom up pilot pressure sensor (2).
B. If the resistance is about 10 K Ω, proceed to Step 7.

7. Inspect for continuity between the ground and terminal 1 of the boom up pilot pressure sensor (2) (3-pin) CN.D26
(harness side).
Inspect for continuity between the ground and terminal 2 of the boom up pilot pressure sensor (2) (3-pin) CN.D26
(harness side).
A. If there is continuity, find and replace the short circuit on the wire ID WL435c, WL435, WB435 and LR405.

8. Inspect for continuity between the ground and terminal 3 of the boom up pilot pressure sensor (2) (3-pin) CN.D26
(harness side).
A. If there is no continuity, find and repair/replace the open circuit on the wire ID BW445c and BW445.

Measure the voltage between the ground and terminal 1 of the boom up pilot pressure sensor (2) (3-pin) CN.D26
(harness side).
A. If the voltage is not about 5 V, find and repair/replace the open circuit on the wire ID WL435c, WL435 and
WB435.

10. Measure the voltage between the ground and terminal 2 of the CN.D26 (harness side).
A. If the voltage is less than 0.25 V, find and repair/replace the open circuit on the wire ID LR405.
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7067-Bucket-close pilot pressure sensor signal abnormality

Solution:
SMIL14CEX3500EB 1
1. Main controller
2. Pressure sensor (bucket close pilot)

2. Check the bucket close pilot pressure sensor (2) voltage on the service support screen.

3. Turn the key switch OFF and disconnect the bucket close pilot pressure sensor (2) connector (3-pin) CN.D31.
Measure the voltage between the ground and terminal 1 of the bucket close pilot pressure sensor (2) connector
(3-pin) CN.D31 (harness side).
A. If the voltage is not about 5 V, find and replace the short circuit on the wire ID WL435h, WL435 and WB435.

4. Measure the voltage between the ground and terminal 2 of the bucket close pilot pressure sensor (2) connector
A. If the voltage is more than 4.75 V, find and replace the short circuit on the wire ID GW410.

A. If the voltage is more than 0.25 V, find and replace the short circuit on the wire ID BW445h and BW445.
6. Inspect the bucket-close pilot pressure sensor (2).
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Disconnect bucket close pilot pressure sensor (2) connector (3-pin) CN.D31.
Measure the resistance between the terminal 1 and terminal 3 of the bucket close pilot pressure sensor (2) con-
nector (3-pin) CN.D31 bucket-close pilot pressure sensor side.
A. If the resistance is not about 10 kΩ, replace bucket close pilot pressure sensor (2).

7. Inspect for continuity between the ground and terminal 1 of the bucket close pilot pressure sensor (2) connector
Inspect for continuity between the ground and terminal 2 of the bucket close pilot pressure sensor (2) connector
(3-pin) D31 (harness side).
A. If there is continuity, find and replace the short circuit on the wire ID WL435h, WL435, WB435 and GW410.

8. Inspect for continuity between the ground and terminal 3 of the bucket close pilot pressure sensor (2) connector
A. If there is no continuity, find and repair/replace the open circuit on the wire ID BW445h and BW445.

Measure the voltage between the ground and terminal 1 of the bucket close pilot pressure sensor (2) connector
A. If the voltage is not about 5 V, find and repair/replace the open circuit on the wire ID WL435h, WL435 and
WB435.

A. If the voltage is less than 0.25 V, find and repair/replace the open circuit on the wire ID GW410.
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7068-Pressure sensor boom-down pilot abnormality

Solution:
SMIL14CEX3601EB 1
1. Main controller
2. Pressure sensor (boom down pilot)

Inspect the connectivity of each connector for poor insertion and wiring terminal disconnection
Disconnect each connector, and check for any wiring terminal abnormality. If there is no abnormality, reconnect
the connectors.

3. Check the boom down pilot pressure (2) voltage on the service support screen.

4. Turn the key switch OFF and disconnect the pressure connector CN.D27.
Measure the voltage between the ground and terminal 1 of the boom down pilot pressure sensor (2) connector
CN.D27 (harness side).
A. If the voltage is not about 5 V, find and replace the short circuit on the wire ID WL435d, WL435 and WB435

5. Measure the voltage between the ground and terminal 2 of the boom down pilot pressure sensor (2) connector
A. If the voltage is more than 4.75 V, find and replace the short circuit on the wire ID LW406.
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6. Measure the voltage between the ground and terminal 3 of the pressure sensor (2) connector CN.D27 (harness
side).
A. If the voltage is more than 0.25 V, find and replace the short circuit on the wire ID BW445d and BW445.
B. If the voltage is less than or equal to 0.25 V, replace the main controller (1) .
7. Inspect the boom down pilot pressure sensor (2).
Disconnect boom down pilot pressure sensor (2) connector CN.D27.
Measure the resistance between the terminal 1 and terminal 3 of the boom down pilot pressure sensor side
connector CN.D27.
A. If the resistance is not about 10 kΩ, replace the boom down pilot pressure sensor (2).

8. Inspect for continuity between the ground and terminal 1 of the boom down pilot pressure sensor CN.D27 (har-
ness side).
Inspect for continuity between the ground and terminal 2 of the boom down pilot pressure sensor CN.D27 (har-
ness side).
A. If there is continuity, find and replace the short circuit on the wire ID WL435d, WL435, WB435 and LW406.

9. Inspect for continuity between the ground and terminal 3 of the boom down pilot pressure sensor CN.D27 (har-
ness side).
A. If there is no continuity, find and repair/replace the open circuit on the wire ID BW445d and BW445.

Measure the voltage between the ground and terminal 1 of the boom down pilot pressure sensor CN.D27 (har-
ness side).
A. If the voltage is not about 5 V, find and repair/replace the open circuit on the wire ID WL435d, WL435 and
WB435.

11. Measure the voltage between the ground and terminal 2 of the boom down pilot pressure sensor CN.D27 (har-
ness side).
A. If the voltage is less than 0.25 V, find and repair/replace the open circuit on the wire ID LW406.
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7069-Pressure sensor arm-out pilot abnormality

Solution:
SMIL14CEX3602EB 1
1. Main controller
2. Pressure sensor (arm out pilot)

the connectors.

3. Check the arm out pilot pressure sensor (2) voltage on the service support screen.

4. Turn the key switch OFF and disconnect the arm out pilot pressure sensor (2) connector CN.D28.
Measure the voltage between the ground and terminal 1 of the arm out pilot pressure sensor (2) CN.D28 (harness
side).
A. If the voltage is not about 5 V, find and replace the short circuit on the wire ID WL435e, WL435 and WB435

5. Measure the voltage between the ground and terminal 2 of the arm out pilot pressure sensor (2) CN.D28 (harness
side).
A. If the voltage is more than 4.75 V, find and replace the short circuit on the wire ID YR407.
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side).
A. If the voltage is more than 0.25 V, find and replace the short circuit on the wire ID BW445e and BW445.
7. Inspect the arm out pilot pressure sensor (2).
Disconnect arm out pilot pressure sensor (2) CN.D28.
Measure the resistance between the terminal 1 and terminal 3 of the arm out pilot pressure sensor side CN.D28.
A. If the resistance is not about 10 kΩ, replace the arm out pilot pressure sensor (2).

8. Inspect for continuity between the ground and terminal 1 of the arm out pilot pressure sensor (2) CN.D28 (harness
side).
Inspect for continuity between the ground and terminal 2 of the arm out pilot pressure sensor (2) CN.D28 (harness
side).
A. If there is continuity, find and replace the short circuit on the wire ID WL435e, WL435, WB435 and YR407

9. Inspect for continuity between the ground and terminal 3 of the arm out pilot pressure sensor (2) CN.D28 (harness
side).
A. If there is no continuity, find and repair/replace the open circuit on the wire ID BW445e and BW445

Measure the voltage between the ground and terminal 1 of the arm out pilot pressure sensor (2) CN.D28 (harness
side).
A. If the voltage is not about 5 V, find and repair/replace the open circuit on the wire ID Repair or replace the
WL435e, WL435 and WB435.

side).
A. If the voltage is lower than 0.25 V, find and repair/replace the open circuit on the wire ID YR407.
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7070-Pressure sensor bucket-open pilot abnormality

Solution:
SMIL14CEX3603EB 1
1. Main controller
2. Pressure sensor (bucket open pilot)

the connectors.

3. Check the bucket open pilot pressure sensor (2) voltage on the service support screen.

4. Turn the key switch OFF and disconnect the bucket open pilot pressure sensor (2) connector CN.D30.
Measure the voltage between the ground and terminal 1 of the bucket open pilot pressure sensor (2) CN.D30
(harness side).
A. If the voltage is not about 5 V, find and replace the short circuit on the wire ID WL435g, WL435 and WB435.

5. Measure the voltage between the ground and terminal 2 of the bucket open pilot pressure sensor (2) CN.D30
(harness side).
A. If the voltage is more than 4.75 V, find and replace the short circuit on the wire ID GR409.
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(harness side).
A. If the voltage is more than 0.25 V, find and replace the short circuit on the wire ID BW445g and BW445.
7. Inspect the bucket open pilot pressure sensor (2).
Disconnect bucket open pilot pressure sensor (2) CN.D30.
Measure the resistance between the terminal 1 and terminal 3 of the bucket open pilot pressure sensor side
connector CN.D30.
A. If the resistance is not about 10 kΩ, replace the bucket open pilot pressure sensor (2).

8. Inspect for continuity between the ground and terminal 1 of the bucket open pilot pressure sensor (2) CN.D30
(harness side).
Inspect for continuity between the ground and terminal 2 of the bucket open pilot pressure sensor (2) CN.D30
(harness side).
A. If there is continuity, find and replace the short circuit on the wire ID WL435g, WL435, WB435, and GR409.

9. Inspect for continuity between the ground and terminal 3 of the bucket open pilot pressure sensor (2) CN.D30
(harness side).
A. If there is no continuity, find and repair/replace the open circuit on the wire ID BW445g and BW445.

Measure the voltage between the ground and terminal 1 of the bucket open pilot pressure sensor (2) CN.D30
(harness side).
A. If the voltage is not about 5 V, find and repair/replace the open circuit on the wire ID WL435g, WL435 and
WB435.

(harness side).
A. If the voltage is less than 0.25 V, find and repair/replace the open circuit on the wire ID GR409.
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7071-Pressure sensor travel right pilot abnormality

Solution:
SMIL14CEX3604EB 1
1. Main controller
2. Pressure sensor (travel right pilot)

the connectors.

3. Check the travel right pilot pressure sensor voltage (2) on the service support screen.

4. Turn the key switch OFF and disconnect the travel right pilot pressure sensor (2) connector CN.D23-1.
Measure the voltage between the ground and terminal 1 of the travel right pilot pressure sensor (2) CN.D23-1
(harness side).
A. If the voltage is not about 5 V, find and replace the short circuit on the wire ID WL435m, WL435 and WB435.

5. Measure the voltage between the ground and terminal 2 of the travel right pilot pressure sensor (2) CN.D23-1
(harness side).
A. If the voltage is more than 4.75 V, find and replace the short circuit on the wire ID OR411.
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(harness side).
A. If the voltage is more than 0.25 V, find and replace the short circuit on the wire ID BW445m and BW445.
7. Inspect the travel right pilot pressure sensor (2).
Disconnect travel right pilot pressure sensor (2) CN.D23-1.
Measure the resistance between the terminal 1 and terminal 3 of the travel right pilot pressure sensor side con-
nector CN.D23-1.
A. If the resistance is not about 10 kΩ, replace the travel right pilot pressure sensor (2).

8. Inspect for continuity between the ground and terminal 1 of the travel right pilot pressure sensor (2) CN.D23-1
(harness side).
Inspect for continuity between the ground and terminal 2 of the travel right pilot pressure sensor (2) CN.D23-1
(harness side).
A. If there is continuity, find and replace the short circuit on the wire ID WL435m, WL435, WB435 and OR411.

9. Inspect for continuity between the ground and terminal 3 of the pressure CN.D23-1 (harness side).
A. If there is no continuity, find and repair/replace the open circuit on the wire ID BW445m and BW445.

Measure the voltage between the ground and terminal 1 of the travel right pilot pressure sensor (2) CN.D23-1
(harness side).
A. If the voltage is not about 5 V, find and repair/replace the open circuit on the wire ID WL435m, WL435 and
WB435.

(harness side).
A. If the voltage is lower than 0.25 V, find and repair/replace the open circuit on the wire ID OR411.
B. If the voltage is 0.25 V or higher, replace the main controller (1).
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7072-Pressure sensor travel left pilot abnormality

Solution:
SMIL14CEX3605EB 1
1. Main controller
2. Pressure (travel left pilot)

the connectors.

3. Check the travel left pilot pressure sensor (2) voltage on the service support screen.

4. Turn the key switch OFF and disconnect the travel left pilot pressure sensor (2) connector CN.D23-2.
Measure the voltage between the ground and terminal 1 of the travel left pilot pressure sensor (2) CN.D23-2
(harness side).
A. If the voltage is not about 5 V, find and replace the short circuit on the wire ID WL435t, WL435m, WL435 and
WB435.

5. Measure the voltage between the ground and terminal 2 of the travel left pilot pressure sensor (2) CN.D23-2
(harness side).
A. If the voltage is more than 4.75 V, find and replace the short circuit on the wire ID OL412.
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(harness side).
A. If the voltage is more than 0.25 V, find and replace the short circuit on the wire ID BW445t, BW445m and
BW445.
7. Inspect the travel left pilot pressure sensor (2).
Disconnect travel left pilot pressure sensor (2) CN.D23-2.
Measure the resistance between the terminal 1 and terminal 3 of the travel left pilot pressure sensor side con-
nector CN.D23-2.
A. If the resistance is not about 10 kΩ, replace the travel left pilot pressure sensor (2).

8. Inspect for continuity between the ground and terminal 1 of the travel left pilot pressure sensor (2) CN.D23-2
(harness side).
Inspect for continuity between the ground and terminal 2 of the travel left pilot pressure sensor (2) CN.D23-2
(harness side).
A. If there is continuity, find and replace the short circuit on the wire ID WL435t, WL435m, WL435, WB435 and
OL412.

9. Inspect for continuity between the ground and terminal 3 of the travel left pilot pressure sensor (2) CN.D23-2
(harness side).
A. If there is no continuity, find and repair/replace the open circuit on the wire ID BW445t, BW445m and BW445.

Measure the voltage between the ground and terminal 1 of the travel left pilot pressure sensor (2) CN.D23-2
(harness side).
A. If the voltage is not about 5 V, find and repair/replace the open circuit on the wire ID WL435t, WL435m, WL435
and WB435.

(harness side).
A. If the voltage is less than 0.25 V, find and repair/replace the open circuit on the wire ID OL412.
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7073-Pressure sensor travel 1 pedal abnormality

Solution:
SMIL14CEX3606EB 1
1. Main controller
2. Pressure sensor (travel 1 pedal)

the connectors.

3. Check the travel 1 pedal pressure sensor (2) voltage on the service support screen.

4. Turn the key switch OFF and disconnect the travel 1 pedal pressure sensor (2) connector CN.D23-3.
Measure the voltage between the ground and terminal 1 of the travel 1 pedal pressure sensor (2) CN.D23-3
(harness side).
A. If the voltage is not about 5 V, find and replace the short circuit on the wire ID WL435u, WL435m, WL435 and
WB435.

5. Measure the voltage between the ground and terminal 2 of the travel 1 pedal pressure sensor (2) CN.D23-3
(harness side).
A. If the voltage is more than 4.75 V, find and replace the short circuit on the wire ID OW413.
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(harness side).
A. If the voltage is more than 0.25 V, find and replace the short circuit on the wire ID BW445u, BW445m and
BW445.
7. Inspect the travel 1 pedal pressure sensor (2).
Disconnect travel 1 pedal pressure sensor (2) connector CN.D23-3.
Measure the resistance between the terminal 1 and terminal 3 of the travel 1 pedal pressure sensor side
CN.D23-3.
A. If the resistance is not about 10 kΩ, replace the travel 1 pedal pressure sensor (2).

8. Inspect for continuity between the ground and terminal 1 of the travel 1 pedal pressure sensor (2) CN.D23-3
(harness side).
Inspect for continuity between the ground and terminal 2 of the travel 1 pedal pressure sensor (2) CN.D23-3
(harness side).
A. If there is continuity, find and replace the short circuit on the wire ID WL435u, WL435m, WL435, WB435,
O413 and OW413.

9. Inspect for continuity between the ground and terminal 3 of the travel 1 pedal pressure sensor (2) CN.D23-3
(harness side).
A. If there is no continuity, find and repair/replace the open circuit on the wire ID BW445u, BW445m, and BW445.

Measure the voltage between the ground and terminal 1 of the travel 1 pedal pressure sensor (2) CN.D23-3
(harness side).
A. If the voltage is not about 5 V, find and repair/replace the open circuit on the wire ID WL435u, WL435m,
WL435 and WB435.

(harness side).
A. If the voltage is less than 0.25 V, find and repair/replace the open circuit on the wire ID O413 and OW413.
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7074-Pressure sensor 1st option pilot (common/front pedal)

abnormality
Solution:
SMIL14CEX3607EB 1
1. Main controller
2. Pressure sensor (1st option front pedal)

the connectors.

3. Check the pressure sensor (2) voltage on the service support screen.

4. Turn the key switch OFF and disconnect the pressure sensor (2) connector CN.G12.
Measure the voltage between the ground and terminal 1 of the pressure sensor (2) CN.G12 (harness side).
A. If the voltage is not about 5 V, find and replace the short circuit on the wire ID WL435n, WL435 and WB435.

5. Measure the voltage between the ground and terminal 2 of the pressure sensor (2) CN.G12 (harness side).
A. If the voltage is more than 4.75 V, find and replace the short circuit on the wire ID WL415.

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A. If the voltage is more than 0.25 V, find and replace the short circuit on the wire ID BW445n and BW445.
7. Inspect the 1st option front pedal pressure sensor (2).
Disconnect pressure sensor (2) CN.G12.
Measure the resistance between the terminal 1 and terminal 3 of the pressure sensor side CN.G12.
A. If the resistance is not about 10 kΩ, replace the 1st option front pedal pressure sensor (2).

8. Inspect for continuity between the ground and terminal 1 of the pressure sensor (2) CN.G12 (harness side).
Inspect for continuity between the ground and terminal 2 of the pressure sensor (2) CN.G12 (harness side).
A. If there is continuity, find and replace the short circuit on the wire ID WL435n, WL435, WB435 and WL415.

A. If there is no continuity, find and repair/replace the open circuit on the wire ID BW445n and BW445.

A. If the voltage is not about 5 V, find and repair/replace the open circuit on the wire ID WL435n, WL435 and
WB435.

A. If the voltage is less than 0.25 V, find and repair/replace the open circuit on the wire ID WL415.
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7075-Pressure sensor arm cylinder bottom abnormality

Solution:
SMIL14CEX3608EB 1
1. Main controller
2. Pressure sensor (arm cylinder bottom)

the connectors.


4. Turn the key switch OFF and disconnect the pressure sensor (2) connector CN.D65-4.
Measure the voltage between the ground and terminal 1 of the pressure sensor (2) CN.D65-4 (harness side).
A. If the voltage is not about 5 V, find and replace the short circuit on the wire ID WL435a, WL435 and WB435.

5. Measure the voltage between the ground and terminal 2 of the pressure sensor (2) CN.D65-4 (harness side).
A. If the voltage is more than 4.75 V, find and replace the short circuit on the wire ID BrR403.

A. If the voltage is more than 0.25 V, find and replace the short circuit on the wire ID BW445a and BW445.
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7. Inspect the arm cylinder bottom pressure sensor (2).
Disconnect pressure sensor (2) connector CN.D65-4.
Measure the resistance between the terminal 1 and terminal 3 of the pressure sensor side CN.D65-4.
A. If the resistance is not about 10 kΩ, replace the arm cylinder bottom pressure sensor (2).

8. Inspect for continuity between the ground and terminal 1 of the pressure sensor (2) CN.D65-4 (harness side).
Inspect for continuity between the ground and terminal 2 of the pressure sensor (2) CN.D65-4 (harness side).
A. If there is continuity, find and replace the short circuit on the wire ID WL435a, WL435, WB435 and BrR403.

9. Inspect for continuity between the ground and terminal 3 of the pressure sensor (2) CN.D65-4 (harness side).
A. If there is no continuity, find and repair/replace the open circuit on the wire ID BW445a and BW445.

Measure the voltage between the ground and terminal 1 of the pressure sensor (2) CN.D65-4 (harness side).
A. If the voltage is not about 5 V, find and repair/replace the open circuit on the wire ID WL435a, WL435 and
WB435.

A. If the voltage is less than 0.25 V, find and repair/replace the open circuit on the wire ID BrR403.
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7078-Pressure sensor 1st option pilot (rear pedal) abnormality

Solution:
SMIL14CEX3609EB 1
1. Main controller
2. Pressure sensor (1st option rear pedal)

the connectors.


4. Turn the key switch OFF and disconnect the pressure sensor (2) connector CN.G11.
A. If the voltage is not about 5 V, find and replace the short circuit on the wire ID WL435n, WL435 and WB435.

A. If the voltage is more than 4.75 V, find and replace the short circuit on the wire ID YG401.

A. If the voltage is more than 0.25 V, find and replace the short circuit on the wire ID BW445n and BW445.
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7. Inspect the 1st option rear pedal pressure sensor (2).
Disconnect pressure sensor (2) connector CN.G11.
Measure the resistance between the terminal 1 and terminal 3 of the pressure sensor side CN.G11.
A. If the resistance is not about 10 kΩ, replace the 1st option rear pedal pressure sensor (2).

Inspect for continuity between the ground and terminal 2 of the pressure sensor (2) CN.G11 (harness side).
A. If there is continuity, find and replace the short circuit on the wire ID WL435n, WL435, WB435 and YG401.

A. If there is no continuity, find and repair/replace the open circuit on the wire ID BW445n and BW445.

A. If the voltage is not about 5 V, find and repair/replace the open circuit on the wire ID WL435n, WL435, and
WB435.

A. If the voltage is less than 0.25 V, find and repair/replace the open circuit on the wire ID YG401.
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7200-Swing brake solenoid signal abnormality

Solution:
SMIL14CEX3610EB 1
1. Main controller
2. Solenoid (swing brake)

2. Turn the key switch OFF and disconnect the swing brake solenoid valve (2) connector CN.D56.
Measure the resistance between the terminals 1 and 2 of the swing brake solenoid valve (2) CN.D56 side.
A. If the resistance is not within 34 Ω - 47 Ω, replace swing brake solenoid (2).
B. If the resistance is within 34 Ω - 47 Ω, proceed to Step 3.

3. Inspect for continuity between the ground and terminal 1 of the swing brake solenoid valve (2) CN.D56 (harness
side).
A. If there is continuity, find and repair the short circuit on the wire ID WG801.

4. Remove the CN.A4.
Inspect for continuity between the CN.A4 harness side terminal 4 and terminal 1 of the swing brake solenoid valve
(2) CN.D56 (harness side).
A. If there is no continuity, find and repair the open circuit on the wire ID WG801.

5. Inspect for continuity between the ground and terminal 2 of the swing brake solenoid valve (2) CN.D56 (harness
side).
A. If there is continuity, find and repair the open circuit on the wire ID B755 and Br760.
B. If there is no continuity, replace the main controller (1).
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7201-Travel high-speed solenoid signal abnormality

Solution:
SMIL14CEX3611EB 1
1. Main controller
2. Solenoid (travel high-speed)

2. Turn the key switch OFF and disconnect the travel high-speed solenoid (2) connector CN.D57.
Measure the resistance between the terminals 1 and 2 of the travel high-speed solenoid (2) CN.D57.
A. If the resistance is not within 34 Ω - 47 Ω, replace travel high-speed solenoid (2).

3. Inspect for continuity between the ground and terminal 1 of the travel high-speed solenoid (2) CN.D57 (harness
side).
A. If there is continuity, find and repair the short circuit on the wire ID GR802 and LR802.

4. Inspect for disconnection.
Remove the CN.A4.
Inspect for continuity between the CN.A4 harness side terminal 6 and terminal 1 of the travel high-speed solenoid
A. If there is no continuity, find and repair the open circuit on the wire ID GR802 and LR802.

5. Inspect for continuity between the ground and terminal 2 of the travel high-speed solenoid (2) CN.D57 (harness
side).
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7202-Pressure boost solenoid signal abnormality

Solution:
SMIL14CEX3612EB 1
1. Main controller
2. Solenoid (pressure boost)

2. Turn the key switch OFF and disconnect the pressure boost solenoid (2) connector CN.D58.
Measure the resistance between the terminals 1 and 2 of the pressure boost solenoid CN.D58.
A. If the resistance is not within 34 Ω - 47 Ω, replace pressure boost solenoid (2).

3. Inspect for continuity between the ground and terminal 1 of the pressure boost solenoid (2) CN.D58 (harness side).
A. If there is continuity, find and repair the short circuit on the wire ID YB803 and YR803.

4. Inspect for disconnection.
Remove the CN.A4.
Inspect for continuity between the CN.A4 harness side terminal 3 and terminal 1 of the pressure boost solenoid
A. If there is no continuity, find and repair the open circuit on the wire ID YB803 and YR803.

5. Inspect for continuity between the ground and terminal 2 of the pressure boost solenoid (2) CN.D58 (harness side).
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7203-Travel alarm buzzer signal abnormality

Solution:
SMIL14CEX3613EB 1
1. Main controller
2. Travel alarm: 24 V, 107 dB

2. Turn the key switch OFF and disconnect the travel alarm (2) connector CN.D46.
Connect the CN.D46 travel alarm (2) side terminal 2 to the battery's positive, connect its terminal 1 to the negative,
and inspect whether the travel alarm sounds.
A. If the travel alarm does not sounds, replace travel alarm (2).
B. If the travel alarm sounds, proceed to Step 3.

3. Inspect for continuity between the ground and terminal 2 of the travel alarm (2) CN.D46 (harness side).
A. If there is continuity, find and repair the short circuit on the wire ID RY807.

Inspect for continuity between the CN.A4 harness side terminal 5 and terminal 1 of the travel alarm CN.D46 (har-
ness side).
A. If there is no continuity, find and repair the open circuit on the wire ID RY807.

5. Inspect for continuity between the ground and terminal 1 of the travel alarm CN.D46 (harness side).
A. If there is continuity, find and repair the open circuit on the wire ID B767 and B700.
B. If there is no continuity, replace the main controller (1)
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7206-Option line switchover solenoid signal abnormality

Solution:
SMIL14CEX3614FB 1
1. Main controller
2. Solenoid (option line switch-over)

2. Turn the key switch OFF and disconnect the option line switch-over solenoid (2) connector CN.G01.
Measure the resistance between the terminals 1 and 2 of the option line switch-over solenoid (2) CN.G01.
A. If the resistance is not within 34 Ω - 47 Ω, replace option line switch-over solenoid (2).

3. Inspect for continuity between the ground and terminal 1 of the option line switch-over solenoid (2) CN.G01 (har-
ness side).
A. If there is continuity, find and repair the short circuit on the wire ID V809.

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Inspect for continuity between the CN.A5 harness side terminal 1 and terminal 1 of the option line switch-over
solenoid (2) CN.G01 (harness side).
A. If there is no continuity, find and repair the open circuit on the wire ID V809.

5. Inspect for continuity between the ground and terminal 2 of the option line switch-over solenoid (2) CN.G01 (har-
ness side).
A. If there is continuity, find and repair the open circuit on the wire ID B730, B720 and B700.
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7207-Free swing solenoid signal abnormality

Solution:
SMIL14CEX3615EB 1
1. Main controller
2. Solenoid (free swing)

2. Turn the key switch OFF and disconnect the free swing solenoid (2) connector CN.D60.
Measure the resistance between the terminals 1 and 2 of the free swing solenoid (2) CN.D60.
A. If the resistance is not within 34 Ω - 47 Ω, replace free swing solenoid (2).

3. Inspect for continuity between the ground and terminal 1 of the free swing solenoid (2) CN.D60 (harness side).
A. If there is continuity, find and repair the short circuit on the wire ID Br804.

Inspect for continuity between the CN.A4 harness side terminal 7 and terminal 1 of the free swing solenoid (2)
A. If there is no continuity, find and repair the open circuit on the wire ID BrW804 and Br804.

5. Inspect for continuity between the ground and terminal 2 of the free swing solenoid (2) CN.D60 (harness side).
A. If there is continuity, find and repair the open circuit on the wire ID B759 and B700.
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7213-Quick coupler buzzer abnormality

Solution:
SMIL14CEX3616FB 1
1. Battery relay
2. Quick coupler buzzer
3. Main controller
Check whether the fuse ( 100 A, 60 A, or 10 A) is blown.

2. Turn the key switch OFF and disconnect the quick coupler buzzer (2) CN.A24.
Connect the CN.A24 buzzer side male terminal to the battery's negative, connect its female terminal to the positive,
and inspect whether the buzzer sounds.
A. If the buzzer does not sounds, replace quick coupler buzzer (2).
B. If the buzzer sounds, proceed to Step 3.

3. Inspect for continuity between the ground and male terminal of the quick coupler buzzer (2) CN.A24 (harness
side).
A. If there is continuity, find and repair the short circuit on the wire ID LG816.
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4. Inspect for continuity between the ground and female terminal of the quick coupler buzzer (2) CN.A24 (harness
side).
A. If there is continuity, find and repair the short circuit on the wire ID LgR235a, LgR235, R109g, R109 and R031.

Inspect for continuity between the CN.A24 harness side male terminal and terminal 4 CN.A5 (harness side).
A. If there is no continuity, find and repair the open circuit on the wire ID LG816.

6. Inspect for continuity between the CN.A24 harness side female terminal and terminal of the battery relay (1)
CN.A78 (harness side).
A. If there is continuity, find and repair the open circuit on the wire ID LgR235a, LgR235, R109g, R109 and R031.
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7214-Quick coupler solenoid abnormality

Solution:
SMIL14CEX3617FB 1
1. Battery relay
2. Solenoid (quick coupler)
3. Main controller
Check whether the fuse ( 100 A, 60 A, or 10 A) is blown.

2. Turn the key switch OFF and disconnect the quick coupler solenoid (2) CN.D61.
Measure the resistance between the terminals 1 and 2 of the quick coupler solenoid side CN.D61.
A. If the resistance is not within 34 Ω - 47 Ω, replace the quick coupler solenoid (2).

Measure the voltage between ground and terminal 2 of quick coupler solenoid (2) CN.D61 (harness side).
A. If the voltage is not within 0 V, find and repair the short circuit on the wire ID B817 and YG817.
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B. If the voltage is within 0 V, proceed to Step 4.

Inspect for continuity between the ground and terminal 1 of the quick coupler solenoid (2) CN.D61 (harness side).
A. If there is continuity, find and repair the short circuit on the wire ID R235, LgR235, R109g, R109 and R031.

5. Inspect for continuity between the ground and terminal 2 of the quick coupler solenoid (2) CN.D61 (harness side).
A. If there is no continuity, find and repair the open circuit on the wire ID B817 and YG817.

Measure the voltage between ground and terminal 1 of quick coupler solenoid (2) CN.D61 (harness side).
A. If the voltage is not within 24 V, find and repair the short circuit on the wire ID R235, LgR235, R109g, R109
and R031.
B. If the voltage is within 24 V, replace the main controller (3).
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7247-Boom-down proportional valve signal abnormality

Solution:
SMIL14CEX3618EB 1
1. Main controller
2. Proportional valve (boom down)

2. Reset the diagnostic trouble code on the service support screen.
B. If diagnostic trouble code 7247 is not displayed, proceed to Step 4.

3. Turn the key switch OFF and disconnect the joint connector CN.D66-5.
Inspect for continuity between the ground and terminal 1 of the joint connector CN.D66-5 (harness side).
A. If there is continuity, find and repair the short circuit on the wire YR904a.
B. If there is no continuity, replace main controller (1).

Remove the CN.D66-5.
Inspect the continuity between terminal 1 and 2 of the connector CN.D66-5 boom-down proportional valve side.
A. If there is no continuity, replace the boom down proportional valve (2).

Inspect the continuity between terminal 1 of the connector CN.D66-5 harness side and terminal 1 of the connector
CN.A3 harness side.
A. If there is no continuity, repair or replace the YR904a harness
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6. Inspect the continuity between terminal 2 of the connector CN.D66-5 harness side and terminal 9 of the connector
CN.A3 harness side.
A. If there is no continuity, repair or replace the YB904b harness
B. If there is continuity, replace the main controller (1).
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7249-Bucket-Close Pilot Proportional Valve Abnormality

Solution:
SMIL14CEX3619EB 1
1. Main controller
2. Proportional valve (bucket close)

the connectors.


4. Turn OFF the key switch and remove the CN.D66-1.
Inspect for continuity between the ground and terminal 1 of the connector CN.D66-1 harness side.
A. If there is no continuity, replace the main controller (1).
B. If there is continuity, replace or repair the GR905a harness.

5. Turn OFF the key switch.
Inspect for continuity between the terminal 1 and 2 of the connector CN.D66-1 proportional valve side.
A. If there is no continuity, replace the proportional valve (2).

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Inspect for continuity between the terminal 1 of the connector CN.D66-1 harness side and terminal 6 of the con-
nector CN.A2 harness side.
A. If there is no continuity, repair or replace the GR905a harness.

7. Inspect for continuity between the terminal 2 of the connector CN.D66-1 harness side and terminal 27 of the con-
A. If there is no continuity, repair or replace the GW905b harness.
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7250-Option relief pressure proportional valve signal abnormality

Solution:
SMIL14CEX3620EB 1
1. Main controller
2. Proportional valve (option relief pressure)



Inspect for continuity between the ground and terminal 1 of the connector CN.D62 harness side.
A. If there is continuity, replace the VR902a and O902a harnesses.

Inspect for continuity between the terminals 1 and 2 of the connector CN.D62 option relief proportional valve side.
A. If there is continuity, proceed to Step 6.
B. If there is no continuity, replace the option relief pressure proportional valve (2).
Inspect for continuity between the terminals 1 of the connector CN.D62 harness side and 3 of the connector CN.A2
harness side.
B. If there is no continuity, repair or replace the VR902a and O902a harnesses.
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7. Inspect for continuity between the terminals 2 of the connector CN.D62 harness side and 11 of the connector
CN.A2 harness side.
A. If there is continuity, replace the main controller (1).
B. If there is no continuity, repair or replace the VG902b and BO902b harnesses.
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7265-Arm 1 Semi-Parallel Proportional Valve Abnormality

Solution:
SMIL14CEX3621EB 1
1. Main controller
2. Proportional valve (arm 1 parallel)

Inspect the connectivity of each connector for poor insertion and wiring terminal disconnection.
the connectors.
A. If the diagnostic trouble code: 7265 is displayed, proceed to Step 3.

3. Reset the diagnostic trouble code at the service support screen.
A. If the diagnostic trouble code: 7265 is displayed, proceed to Step 4
B. If the diagnostic trouble code: 7265 is not displayed, proceed to Step 5

A. If there is continuity, Replace or repair the WG903a and Lg903a harnesses.
B. If there is no continuity, Replace the main controller (1).

Inspect for continuity between the terminals 1 and 2 of the connector CN.D66-6 proportional valve side.
B. If there is no continuity, replace the proportional valve (2).

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B. If there is no continuity, repair or replace the WG903a and Lg903a harnesses.

A. If there is no continuity, repair or replace the LgR903b harness.
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7266-Arm 2 Semi-Parallel Proportional Valve Abnormality

Solution:
SMIL14CEX3622EB 1
1. Main controller
2. Proportional valve (arm 2 parallel)

the connectors.


A. If there is continuity, replace or repair the G907a harness.

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B. If there is no continuity, repair or replace the G907a harness.

B. If there is no continuity, repair or replace the GY907b harness.
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7267-Arm 1 Regeneration Release Proportional Valve Abnormality

Solution:
SMIL14CEX3623EB 1
1. Main controller
2. Proportional valve (arm 1 regeneration release)

the connectors.
Turn ON the key switch, and check whether the diagnostic trouble code: 7267 is displayed.


A. If there is continuity, replace or repair the LR906a harness.

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Inspect for continuity between the terminal 1of the connector CN.D66-4 harness side and terminal 4 of the con-
B. If there is no continuity, repair or replace the LR906a harness.

B. If there is no continuity, repair or replace the LY906b and LB906b harnesses.
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7270-Tilting 1 Proportional Valve Abnormality

Solution:
SMIL14CEX3624EB 1
1. Main controller
2. Proportional valve (tilting 1)

the connectors.

B. If the diagnostic trouble code: 7270 is not displayed, proceed to Step 5.

Remove the CN.D63.
A. If there is continuity, replace or repair the Y911a harness.

Remove the CN.D63.
Inspect for continuity between the terminals 1 and 2 of the connector CN.D63 proportional valve side.
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Inspect for continuity between the terminal 1of the connector CN.D63 harness side and terminal 2 of the connector
CN.A1 harness side.
B. If there is no continuity, repair or replace the Y911a harness.

7. Inspect for continuity between the terminal 2 of the connector CN.D63 harness side and terminal 9 of the connector
CN.A1 harness side.
B. If there is no continuity, repair or replace the BY911b harness.
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7271-Tilting 2 Proportional Valve Abnormality

Solution:
SMIL14CEX3625EB 1
1. Main controller
2. Proportional valve (tilting 2)

the connectors.


Remove the CN.D64.
A. If there is continuity, replace or repair the L912a harness.

Remove the CN.D64.
Inspect for continuity between the terminals 1 and 2 of the connector CN.D64 proportional valve side.
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Inspect for continuity between the terminal 1of the connector CN.D64 harness side and terminal 3 of the connector
CN.A1 harness side.
B. If there is no continuity, repair or replace the L912a harness.

7. Inspect for continuity between the terminal 2 of the connector CN.D64 harness side and terminal 1of the connector
CN.A1 harness side.
B. If there is no continuity, repair or replace the BL912b and LY912b harnesses.
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7273-Straight Travel Proportional Valve Abnormality

Solution:
SMIL14CEX3626EB 1
1. Main controller
2. Proportional valve (straight travel)

the connectors.


A. If there is continuity, replace or repair the R908a harness.

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B. If there is no continuity, repair or replace the R908a harness

B. If there is no continuity, repair or replace the BO908b and BR908b harnesses.
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7400-Abnormally high coolant temperature [105◦ C (221.0◦F) or

higher]
Solution:
SMIL14CEX3627FB 1
1. Engine computer
2. Main controller
3. Coolant temperature sensor
a. CAN communication

Perform a warm-up operation until engine is fully warmed up.
Check the diagnostic trouble code on the service support screen.

3. Inspect the engine unit.
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7401-Abnormally high coolant temperature [110◦ C (230.0◦F) or

higher]
Solution:
SMIL14CEX3627FB 1
1. Engine computer
2. Main controller


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7404-Abnormally high oil temperature [95 °C ( 203.0 °F ) or higher]

Solution:
SMIL14CEX3628FB 1
1. Engine computer
2. Main controller
Start the engine.

2. Inspect the hydraulic oil temperature.
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7405-Abnormally high boost temperature [80◦ C (176.0◦F) or higher]

Solution:
SMIL14CEX3629FB 1
1. Engine computer
2. Main controller
3. Boost temperature sensor


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7406-Abnormally high boost temperature [90◦ C (194.0◦F) or higher]

Solution:
SMIL14CEX3629FB 1
1. Engine computer
2. Main controller
3. Boost temperature sensor


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7420-Abnormally low alternator voltage

Solution:
SMIL14CEX3630FB 1
1. Engine computer
2. Relay battery
3. Alternator

A. If there is no trouble, proceed to Step 3.

Inspect for continuity between the ground and terminal 2 of the CN.D14 harness side.
A. If there is continuity, replace the Br515a and Br515 harnesses.

Measure the voltage between the ground and terminal 2 of the CN.D14 alternator side.
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A. If the voltage is less than or equal to 10 V, replace alternator.
B. If the voltage is more than 10 V, proceed to Step 5.

Connect CN.D14.
Disconnect CN.A2.
Start the engine.
Measure the voltage between the ground and terminal 25 of the CN.A2 harness side.
A. If the voltage is less than or equal to 10 V, find and repair the open circuit on the Br515a and Br515 harnesses.
B. If the voltage is more than 10 V, replace main controller (1).
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7421-Coolant level reduction

Solution:
SMIL14CEX3631EB 1
1. Main controller
2. Level switch (reserve tank)
Check that the “LOW COOLANT” is displayed.
Fill the coolant.
Check for the diagnostic trouble code at the service support screen.


Inspect for continuity between the terminals 1 and 2 of the connector CN.D47 coolant level switch side.
A. If there is continuity, replace coolant level switch (2).
B. If there is no continuity, replace main controller (1).
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7422-Abnormally low engine oil pressure

Solution:
SMIL14CEX3632FB 1
1. Engine computer
2. Main controller
3. Oil pressure sensor
Start the engine and wait for 30 s.

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7423-Air cleaner clogged

Solution:
SMIL14CEX3633EB 1
1. Main controller
2. Pressure switch (air cleaner)
Check that "AIR FILTER" is displayed.
Clean or replace the air cleaner element.
Start the engine and wait for 10 s.
Check for the diagnostic trouble code on the service support screen.

A. If diagnostic trouble code 7423 is displayed, proceed to Step .3.

Inspect for continuity between the terminals 1 and 2 of the connector CN.D48 air cleaner clog pressure switch side.
A. If there is continuity, replace air cleaner clog pressure switch (2).

4. Inspect for continuity between the ground and terminal 2 of the CN.D48 harness side.
A. If there is continuity, find and repair the short circuit on the wire ID LW534
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7424-Return filter clogging (breaker specifications)

Solution:
SMIL14CEX3634EB 1
1. Main controller
2. Return filter clogging sensor
Check that the "HYD. OIL FILTER" display appears.
Replace the return filter.


Remove the CN.D51.
Inspect for continuity between the terminals 1 and 2 of the connector CN.D51 return filter clog switch side.
A. If there is no continuity, replace return filter clog pressure switch (2).
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7426-Fuel filter clogging 1

Solution:
SMIL14CEX3635FB 1
1. Engine computer
2. Main controller
3. Fuel filter clog sensor
2. Check that the "FUEL FILTER" is displayed.
Replace the fuel filter.

3. Inspect the connection status of each connector and ground.

Inspect the continuity between terminal 2 and 3 of the connector CN.D17-6 fuel filter clogging sensor side.
A. If there is no continuity, replace defective sensor (3).
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Inspect the continuity between terminal V16 of the connector CN.D3 harness side and terminal 2 of the connector
CN.D17-6 harness side.
A. If there is no continuity, replace the harness.

6. Inspect the continuity between terminal V17 of the connector CN.D3 harness side and terminal 3 of the connector

A. If there is no continuity, repair or replace the harness.
B. If there is continuity, replace the sensor (3).
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7427-Fuel filter clogging 2

Solution:
1.
SMIL14CEX3635FB 1
1. Engine computer
2. Main controller
3. Fuel filter clog sensor
2. Check that the "FUEL FILTER" is displayed.
Replace the fuel filter.

3. Inspect the connection status of each connector and ground.

Inspect for continuity between terminals 2 and 3 of the connector CN.D17-6 fuel filter clog sensor side.
A. If there is no continuity, replace defective sensor (3).
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Inspect the continuity between terminal V16 of the connector CN.D3 harness side and terminal 2 of the connector


B. If there is continuity, replace the defective sensor (3).
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7428-Inducement (Remaining Urea Level Low) - Warning

NOTE: This diagnostic trouble code is not displayed on the monitor when trouble occurs. (On the monitor, the REFILL
DEF icon and the REFILL DEF message appear.) The trouble history is recorded on the service support screen.
Solution:
1. Check that "REFILL DEF" is displayed.

2. Inspect the connection status of each connector.


4. Check the level of DEF/AdBlue® (urea solution).
A. If the level is up to mark, proceed to Step 4.
B. If the level is not up to mark, refill the urea solution.

5. Check whether the other diagnostic trouble code is also displayed.
A. If other diagnostic trouble code is displayed, perform troubleshooting for the other diagnostic trouble code.
B. If other diagnostic trouble code is not displayed, replace the main controller.
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7429-Inducement (Remaining Urea Level Low) - Early

Solution:




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7430-Inducement (Remaining Urea Level Low) - Final

Solution:




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7602-ECM communication abnormality

Solution:
SMIL14CEX3636FB 1
1. Engine computer
2. Main controller

3. Check the display of code 7603.
A. If diagnostic trouble code 7603 is displayed at the same time, inspect the connection status of the connector
CN.A3 and CN.A4 in monitor display .
B. If diagnostic trouble code 7603 is not displayed at the same time, proceed to Step 4.
CN.A3 harness side and terminal 14 of the connector CN.A4 harness side.
A. If there is no continuity, repair or replace the L BH0 or L BH1 harness.
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CN.A3 harness side and terminal 15 of the connector CN.A4 harness side.
A. If there is no continuity, repair or replace the BY BL0, LG BL0, or LG BL1 harness.
B. If there is continuity, replace the ECM.
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7605-ECM mismatch
Solution:
SMIL14CEX3636FB 1
1. Engine computer
2. Main controller
A. If diagnostic trouble code 7605 is displayed, proceed to Step.3.

3. Check for an error on the service support model screen.
A. If the model selection screen is not correct, correctly set the model selection.
B. If the model selection screen is correct, proceed to Step4.

4. Check that the ECM which matches the model is installed.
A. If the ECM does not match the model, replace it with the ECM that matches with the model.
B. If the ECM match the model, replace ECM.
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7606-EEPROM data abnormality

Solution:

2. Check whether rewriting was performed on main controller before the diagnostic trouble code was displayed.
A. If there was rewriting performed on main controller before the diagnostic trouble code was displayed, rewriting
of the computer changed the used space of the EEPROM. Turn the key switch OFF, and then turn the key
switch ON again.
B. If there was rewriting performed on main controller before the diagnostic trouble code was not displayed, re-
place main controller.
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7608-Camera abnormality
Solution:
SMIL14CEX3637FB 1
1. Main controller 4. Camera 2 (right)

2. Monitor a. CAN communication
3. Camera 1 (rear)

Disconnect the connectors CN.C1, CN.C2, CN.E18 and CN.E19.
Inspect the continuity between the terminal 10 of the connector CN.C1 harness side and terminal 1 of the connector
CN.E18 harness side and terminal 1 of the connector CN.E19 harness side.
A. If there is no continuity, repair or replace the R960 and R965 harnesses.

4. Inspect the continuity between the terminal 11 of the connector CN.C1 harness side and terminal 2 of the connector
CN.E18 harness side and terminal 2 of the connector CN.E19 harness side.
A. If there is no continuity, repair or replace the B961, B966 and G961 harnesses.
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CN.E18 harness side.
A. If there is no continuity, repair or replace the Y962 harness.

A. If there is no continuity, repair or replace the W963 harness.

A. If there is no continuity, repair or replace the YB967 and Y967 harnesses.

A. If there is no continuity, repair or replace the WB968 and W968 harnesses.

A. If diagnostic trouble code 7608 is displayed, repair the defective monitor (2).
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7612-Air-conditioner communication abnormality

Solution:
SMIL14CEX3638FB 1
1. Main controller
2. Air conditioner panel
Inspect the connection status of each connector.

Disconnect the connectors CN.A4 and CN.B15.
Inspect the continuity between terminal 30 of the connector CN.A4 harness side and terminal 7 of the connector
CN.B15 harness side.
A. If there is no continuity, repair or replace the P CH1 and P CH3 harnesses.

4. Inspect the continuity between terminal 31 of the connector CN.A4 harness side and terminal 6 of the connector
CN.B15 harness side.
A. If there is no continuity, repair or replace the PG CL1 and PG CL3 harnesses.
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B. If there is continuity, proceed to Step5.

A. If diagnostic trouble code 7621 is not displayed, replace the air conditioner panel (2).
B. If diagnostic trouble code 7621 is displayed, replace the main controller (1).
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7613-Monitor communication CAN abnormality

Solution:
SMIL14CEX3639FB 1
1. Main controller
2. Monitor display

Disconnect the connectors CN.A4 and CN.C1.
CN.C1 harness side.
A. If there is continuity, repair or replace the P C01H, P CH2 and P CH1 harnesses.

CN.C1 harness side.
A. If there is continuity, repair or replace the PG C01L, PG CL2 and PG CL1 harnesses.
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A. If diagnostic trouble code 7613 is not displayed, replace defect monitor (2).
B. If diagnostic trouble code 7613 is displayed, replace the main controller (1).
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7615-Sub-Controller Communication Abnormality

Solution:
SMIL14CEX3640FB 1
1. Main controller
2. Sub-controller

Disconnect the connectors CN.A4 and CN.A27.
CN.A27 harness side.
A. If there is continuity, repair or replace the P CH1 and P CH4 harnesses.

CN.A27 harness side.
A. If there is continuity, repair or replace the PG CL1 and PG CL4 harnesses.
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A. If diagnostic trouble code 7615 is not displayed, replace the sub-controller (2).
B. If diagnostic trouble code 7615 is displayed, replace main controller (1).
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7618-DCU Communication Abnormality

Solution:
SMIL14CEX3641FB 1
1. Main controller
2. Engine computer
3. Dosing controller

Disconnect the connectors CN.A4, CN.D3 and CN.D1-2.
Inspect the continuity between terminal 16 of the connector CN.A4 harness side and terminal V64 of the connector
CN.D3 harness side and terminal 211 of the connector CN.D1-2 harness side.
A. If there is continuity, repair or replace the Y AH1, Y AH2, and Y AH3 harnesses.

4. Inspect the continuity between terminal 17 of the connector CN.A4 harness side and terminal V81 of the connector
CN.D3 harness side and terminal 212 of the connector CN.D1-2 harness side.
A. If there is continuity, repair or replace the YG AL1, YG AL2, and YG AL3 harnesses.
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A. If diagnostic trouble code 7613 is displayed, replace the dosing controller (3).
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P041C-EGR cooler outlet 1 temperature sensor circuit low

Control Module : ECM
Solution:
1. Check and diagnose the below fault codes before you proceed with the diagnostics code P041C.
Diagnostic trouble code P06A8
Disconnect the harness connector CN.E10-A from EGR gas temperature sensor 2.
Observe the 5 V adjustment display of EGR gas temperature sensor 2 on the trouble diagnosis scan tool.
A. If the reading is more than or equal to 4.5 V, replace EGR gas temperature sensor 2. (Refer to “ Exhaust Gas
Recirculation (EGR) temperature sensors - Remove - Temperature sensor 2 (55.989) and Exhaust Gas
Recirculation (EGR) temperature sensors - Install - Temperature sensor 2 (55.989)")

3. Inspect the signal circuit between the ECM and EGR gas temperature sensor 2 for a short to GND.

4. Inspect for poor connections at the ECM harness connector CN.D4.
B. If the harness connector CN.D4 is normal, replace the ECM. (Refer to “ Engine Control Unit (ECU) - Remove
(55.015) and Engine Control Unit (ECU) - Install (55.015)”)
5. Set the Injector ID Code, fuel delivery rate and engine No. for the ECM.
2. Turn OFF the ignition switch for at least 30 s.
4. Perform a test-run under the conditions for running the diagnostic trouble code.
NOTE:
• Conditions for setting engine run time or coolant temperature vary depending on the diagnostic trouble codes.
• For the conditions for setting the diagnostic trouble code, refer to the applicable code listed in 15E diagnostic
trouble code information.
5. Use the trouble diagnosis scan tool to confirm that a diagnostic trouble code has not been detected.
14 (55.100)
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P041D-EGR cooler outlet 1 temperature sensor circuit high

Solution:
1. Check and diagnose the below fault codes before you proceed with the diagnostics code P041D.
Disconnect the harness connector CN.E10-A from EGR gas temperature sensor 2.
Measure the voltage between the EGR gas temperature sensor 2 signal circuit and a known good GND.
A. If the reading is more than or equal to 5.5 V, inspect the signal circuit between the ECM and EGR gas temper-
ature sensor 2 for a short to the battery or a short to the ignition power supply.

3. Connect a fused jumper wire between the EGR gas temperature sensor 2 signal circuit and the GND circuit.
A. If the reading is less than or equal to 0.1 V, inspect the signal circuit between the ECM and the EGR gas
temperature sensor for a short to the 5 V power supply circuit.

4. Inspect for poor connections at the EGR gas temperature sensor 2 harness connector CN.E10-A.
A. If a problem is found, repair the harness connector CN.E10-A.
B. If the harness connector CN.E10-A is normal, replace EGR gas temperature sensor 2. (Refer to “ Exhaust
Gas Recirculation (EGR) temperature sensors - Remove - Temperature sensor 2 (55.989) and Exhaust
Gas Recirculation (EGR) temperature sensors - Install - Temperature sensor 2 (55.989)”)

5. Connect a fused jumper wire between the EGR gas temperature sensor 2 signal circuit and a known good GND.
A. If the reading is less than or equal to 0.1 V, inspect the EGR gas temperature sensor 2 GND circuit for an open

NOTE:
• EGR gas temperature sensor 2 shares the GND circuit with other sensors.
• Diagnostic trouble codes on sensors that share this circuit may be set.
6. Inspect the EGR gas temperature sensor 2 signal circuit for an open circuit or high resistance.
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NOTE:
14 (55.100)
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P0016-Crankshaft position - Camshaft position correlation

Solution:
1. Check and diagnose the below fault codes before you proceed with the diagnostics code P0016.
Diagnostic trouble code P0335

2. Inspect the CKP sensor. (Refer to “ Engine speed/RPM sensor - Inspect (55.015)”)
A. If a problem is found, replace the crankshaft position sensor. (Refer to “ Engine speed/RPM sensor - Remove
(55.015)” and “ Engine speed/RPM sensor - Install (55.015)”)

3. Inspect the CMP sensor. (Refer to “ Engine timing sensors Camshaft sensor - Inspect (55.015)”)
A. If a problem is found, replace the CMP sensor. (Refer to “ Engine timing sensors Camshaft sensor - Re-
move (55.015)” and “ Engine timing sensors Camshaft sensor - Install (55.015)”)

4. Inspect the flywheel.
• Make sure that the sensor rotor should not be damaged.
• Make sure that the ring gear should be installed correctly.
A. If a problem is found, repair the flywheel.

• Make sure that the camshaft gear should not be damaged.
• Make sure that the camshaft gear should be installed correctly.
A. If a problem is found, repair the camshaft gear.

NOTE: When the engine does not start, crank the engine for 10 s.
NOTE:
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P0045-Turbocharger Boost Control Solenoid Circuit

Solution:
Inspect the turbocharger assembly. (Refer to “ Turbocharger - Inspect (10.250)”)
A. If a problem is found, replace the turbocharger assembly. (Refer to “ Turbocharger - Remove (10.250) and
Turbocharger - Install (10.250)”)

3. Disconnect the harness connector CN.E01 from the turbo actuator.
Connect the test light between the motor operation terminal and GND of the turbo actuator harness connector
CN.E01.
Check if the test light does not come on or remains on.
NOTE:
• The inspection with a test light should be performed on each terminal.
• When it is normal, the test light comes on after the key switch is turned ON, and then goes out after a few
seconds.
If the test light does not come on or remains on, inspect the motor operation circuit between the turbo actuator
and turbo control unit.
• Make sure that there is no short to the battery power supply or ignition power supply circuit.
• Make sure that there is no short to GND.
A. If a problem is found, repair the motor operation circuit.

4. If the test light operates properly, inspect to see if a short with other circuit exists in the motor operation circuit
between the turbo actuator and turbo control unit.
A. If a problem is found, repair the motor operation circuit.

Measure the voltage between the position sensor power supply terminal and GND of the turbo actuator harness
connector CN.E01.
If the voltage is outside the 8.0 - 11.0 V, inspect the position sensor power supply circuit between the turbo ac-
tuator and the turbo control unit.
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A. If a problem is found, repair the position sensor power supply circuit.

6. If the circuit is normal, inspect to the turbo control unit harness connector CN.E01 for poor connection.
A. If a problem is found, repair the harness connector CN.E01.
B. If the harness connector CN.E01 is normal, replace the turbo control unit.

7. If the voltage is within the 4 - 6 V, measure the voltage between the position sensor signal terminal of the turbo
actuator harness connector CN.E01 and GND.
NOTE: Measurement of voltage value should be taken on each terminal.
If the voltage is outside the 4 - 6 V, inspect the position sensor signal circuit between the turbo actuator and the
turbo control unit.
A. If a problem is found, repair the position sensor signal circuit.

8. If the circuit is normal, inspect to the turbo control unit harness connector CN.E01 for poor connection.

9. If the voltage is within the 4 - 6 V, inspect to see if there is a short circuit with the position sensor signal circuit
between the turbo actuator and turbo control unit.
A. If a problem is found, repair the position sensor signal circuit.

Measure the voltage between the position sensor power supply terminal and position sensor GND terminal of the
turbo actuator harness connector CN.E01.
If the voltage is outside the 8.0 - 11.0 V, inspect the position sensor GND circuit between the turbo actuator and
the turbo control unit.
A. If a problem is found, repair the position sensor GND circuit.

11. If the circuit is normal, inspect to the turbo control unit harness connector CN.E01 for a poor connection.
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12. If the voltage is within the 8.0 - 11.0 V, inspect to see if there is a poor connection with the turbo actuator harness
connector CN.E01.
B. If the harness connector CN.E01 is normal, replace the turbocharger. (“ Turbocharger - Remove (10.250)
and Turbocharger - Install (10.250)”)
NOTE:
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P0087-Fuel rail system pressure low pressure error

Solution:
1. Check and diagnose the below fault codes before you proceed with the diagnostics code 0087.

Increase the engine speed while observing the diagnostic trouble code information with a trouble diagnosis scan
tool.
Check to see if the diagnostic trouble code P0087 is detected.
A. If the diagnostic trouble code P0087 is not detected, replace the fuel filter element. (Refer to “ Fuel filters -
Remove (10.206) and Fuel filters - Install (10.206)”)
B. if the diagnostic trouble code P0087 is detected, proceed to Step 3
NOTE: An intermittent problem due to foreign matter in the fuel is suspected.

Wait for 2 min until the fuel pressure is released from the common rail.
Check the fuel rail pressure sensor display with the trouble diagnosis scan tool.
If the fuel rail pressure sensor display is outside the 0.9 - 1.0 V, inspect the fuel pressure sensor harness con-
nector CN.E5 for a poor connection.
B. If there are no problems, proceed to Step 4.

4. Inspect the ECM harness connector CN.D4 for poor connection.

5. Inspect each circuit for high resistance.
A. If a problem is found, repair the circuit.
B. If the harness connector CN.E5 and each circuit are normal, replace the fuel pressure sensor. (Refer to “
Common rail - Remove (10.218) and Common rail - Install (10.218)”)
C. If there are no problems, proceed to Step 6.

6. If the fuel rail pressure sensor display is within the 0.9 - 1.0 V, start the engine.
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Perform the injector stop test with the trouble diagnosis scan tool.
Command each injector OFF, and confirm that the engine RPM changes on each injector.
A. If any injector does not change the engine RPM when OFF is instructed, replace the relevant injector. (Refer
to “ Fuel injectors - Remove (10.218) and Fuel injectors - Install (10.218)”)
B. When the injector has been replaced, set the injector ID Code on the ECM.
C. If there are no problems, proceed to Step 7.

7. Inspect to see if there is clogging with the fuel system between the fuel tank and the fuel supply pump.
A. If a problem is found, repair the clogging of the fuel system.

8. Inspect the fuel hose between the fuel tank and the fuel supply pump for a cut and crack.
NOTE:
• The fuel hose between the fuel tank and the fuel supply pump becomes negative pressure state when the
engine is running.
• When the fuel hose is not connected securely, the air can enter.
• When the engine RPM or the engine load increases while the air has intruded in the fuel system, fluctuation in
the common rail pressure is caused, and diagnostic trouble code 0087 may be detected.
A. If a problem is found, replace the fuel hose.

9. Check that an appropriate clamp is used between the fuel tank and the fuel supply pump.
A. If a problem is found, replace the clamp.

10. Operate the priming pump until the handle becomes heavy.
NOTE: When a leak exists in the fuel system between the priming pump and the fuel supply pump, the pressing
weight of the priming pump does not become heavy.
Start the engine.
Inspect the high-pressure side of the fuel system and check for fuel leak between the fuel supply pump and
common rail.
NOTE:
• The fuel may leak to the bottom section of the cylinder head cover from the high pressure hose inlet.
• The engine oil level increases when the fuel leaks to the bottom portion of the cylinder head cover.
• Inspect for fuel leaks into the engine oil.
A. If fuel leak if found, fix the problem.

Remove the fuel hose on the fuel supply pump side from the fuel filter.
NOTE:
• Use a pan to catch the fuel from the removed fuel hose.
• Clean the pressure gauge and connection hose before connecting to the fuel pipe.
• The fuel supply pump may be damaged due to foreign matter that has entered in the connection hose.
Connect the pressure gauge between the fuel filter and the removed fuel hose.
NOTE: Confirm that the fuel system is connected securely.
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Remove the air using the priming pump, and crank the engine for 5 s or shorter.
NOTE: Repeat this until the engine starts.
Leave the engine idling for 1 min or longer.
While allowing the engine to keep 1 min and the maximum engine speed, observe the pressure gauge.
Check if the pressure gauge shows a negative pressure value is equal or greater than 17 kPa (2.5 psi) during
inspection.
NOTE: Fuel clogging is checked with the negative pressure amount in the fuel system.
If the negative pressure is equal or greater than 17 kPa (2.5 psi), inspect to see if there is damage or twisting
with the fuel system between the fuel supply pump and the fuel tank.
A. If a problem is found, repair the fuel system.

12. Inspect the fuel tank bent hose.
A. If a problem is found, repair the bent hose.

13. Check to see if there is any foreign matter in the fuel tank or any foreign matter which can cause fuel clogging.
A. If a problem is found, replace the fuel filter element. (Refer to “ Fuel filters - Remove (10.206) and Fuel
filters - Install (10.206)”)

14. If the negative pressure is equal or lesser than 17 kPa (2.5 psi), pinch the fuel hose at a position as close as
possible to the fuel tank, so that the fuel does not flow.
NOTE: The fuel pipe can be disconnected and clogged with a plug.
Start the engine and use the idling control switch to increase the RPM to the highest level.
Check the pressure gauge. for 27 kPa (3.9 psi)
NOTE:
• When the pressure gauge is likely to indicate a value exceeding the standard value during inspection, release
the fuel being blocked.
• Air mixture is checked with the negative pressure amount while the fuel flow is being blocked.
If the negative pressure 17 kPa (2.5 psi) cannot be generated, inspect to see if there is a cut or crack with the
fuel hose.

15. Inspect to see if appropriate clamp is used.
A. If a problem is found, replace the clamp with an appropriate one.

Inspect the suction control valve harness connector CN.E13 for poor connection.
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17. Inspect the ECM harness connector CN.D4 for a poor connection.


19. If the suction control valve harness connector CN.E13 and the ECM harness connector CN.D4 are normal and
there is no high resistance in each circuit, replace the fuel supply pump (Refer to High pressure pump - Remove
(10.218) and High pressure pump - Install (10.218) ) and the fuel filter element. (Refer to Fuel filters - Remove
(10.206) and Fuel filters - Install (10.206))
NOTE: When replacing the fuel supply pump, it is required to also replace the fuel filter element at the same
time.
NOTE:
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P0089-Fuel pressure regulator performance

Solution:

2. Wait for 2 min until the fuel pressure is released from the common rail.
A. If the fuel rail pressure sensor display is outside the 0.9 - 1.0 V, inspect the fuel pressure sensor harness
connector CN.E5 for a poor connection.
B. If a problem is found, repair the harness connector CN.E5.


B. If the harness connector CN.E5 and each circuit are normal, replace the fuel pressure sensor. (Refer to “
Common rail - Remove (10.218) and Common rail - Install (10.218)”)

NOTE: Do not replace the fuel pressure sensor separately. If a problem is found, replace the common rail assem-
bly.
5. Inspect the suction control valve harness connector CN.E13 for a poor connection.


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Start the engine.
Increase the engine speed while observing the fuel rail pressure display on a trouble diagnosis scan tool.
Compare the fuel rail pressure display with the desired fuel rail pressure display on the trouble diagnosis scan tool
and observe whether the difference is within the 5 MPa (725 psi).
NOTE: If possible, compare with other machine equipped with the same model engine.
A. If it is within the specified range, replace the fuel filter element. (Refer to “ Fuel filters - Remove (10.206) and
Fuel filters - Install (10.206)”)
B. If it is outside the specified range, replace the fuel supply pump and the fuel filter element. (Refer to “ High
pressure pump - Remove (10.218) and High pressure pump - Install (10.218)”), (Refer to Fuel filters -
Remove (10.206) and Fuel filters - Install (10.206)”)
NOTE: When replacing the fuel supply pump, it is required to also replace the fuel filter element at the same time.
NOTE:
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P0091-Fuel rail regulator control system low input

Solution:
2. Disconnect the harness connector CN.E13 from the suction control valve.
Connect the test light between the suction control valve High side circuit and a normal GND.
Check if the test light comes on and then goes off.
If it does not turn off, inspect the High side circuit between the ECM and the suction control valve.
A. If a problem is found, repair the High side circuit.

Connect the test light between the suction control valve Low side circuit and battery power supply.
If it does not turn off, inspect the Low side circuit between the ECM and suction control valve.
• Make sure that there is no short to the battery or ignition power supply.
A. If a problem is found, repair the Low side circuit.

B. If the harness connector CN.E13 is normal, replace the suction control valve. (Refer to “ Fuel shutoff solenoid
- Remove (55.010)”)

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NOTE:
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P0092-Fuel rail regulator control system high input

Solution:
2. Inspect the High side circuit between the ECM and the FRP regulator for a short to the battery or a short to the
ignition power supply.
NOTE: When the High side circuit is shorted to the voltage, the engine stalls and does not start.

3. If it is within the specified range, inspect to see if there is a short circuit to the GND with the Low side circuit
between the ECM and the suction control valve.
A. f a problem is found, repair the Low side circuit.

Disconnect the harness connector CN.E13 from the suction control valve.
Connect the test light between the suction control valve High side circuit and a normal GND.
If it does not turn off, inspect the High side circuit between the ECM and the suction control valve.
• Make sure that there is no short to the Low side circuit.

Connect the test light between the suction control valve Low side circuit and battery power supply.
If it does not turn off, inspect the Low side circuit between the ECM and suction control valve.

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B. If the harness connector CN.E13 is normal, replace the suction control valve. (Refer to “ Fuel shutoff solenoid
- Remove (55.010)”)

NOTE:
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P0097-Intake air temperature (IAT) sensor 2 circuit low voltage

Solution:
Disconnect the harness connector CN.D21 from the IMT sensor.
Observe the 5 V adjustment display of intake air temperature sensor 3 on the trouble diagnosis scan tool.
A. If the reading is more than or equal to the specified value, replace the IMT sensor. (Refer to “ Inlet air tem-
perature sensor - Remove (55.014) and Inlet air temperature sensor - Install (55.014)”)

3. Inspect the signal circuit between the ECM and IMT sensor for a short to GND.

NOTE:
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P0098-Intake air temperature (IAT) sensor 2 circuit high voltage

Solution:
Disconnect the harness connector CN.D21 from the IMT sensor.
Measure the voltage between the IMT sensor signal circuit and a known good GND.
A. If the reading is more than or equal to 5.5 V, inspect the signal circuit between the ECM and IMT sensor for a
short to the battery or a short to the ignition power supply.

3. Connect a fused jumper wire between the IMT sensor signal circuit and GND circuit.
A. If the reading is less than or equal to 0.1 V, inspect the signal circuit between the ECM and IMT sensor for a
short to the 5 V power supply circuit.

4. Inspect for poor connections at the IMT sensor harness connector CN.D21.
B. If the harness connector CN.D21 is normal, replace the IMT sensor. (Refer to “ Inlet air temperature sensor
- Remove (55.014) and Inlet air temperature sensor - Install (55.014)”)

5. Connect a fused jumper wire between the IMT sensor signal circuit and a known good GND.
A. If the reading is less than or equal to the 0.1 V, inspect the GND circuit between the ECM and IMT sensor for

NOTE:
• The IMT sensor shares the GND circuit with other sensors.
6. Inspect the signal circuit between the ECM and the IMT sensor for an open circuit or high resistance.

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NOTE:
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P0102-Mass air flow circuit low input

Solution:
Disconnect the harness connector CN.D21 from the MAF sensor.
Inspect to see if there is an open circuit or high resistance in the 12 V power supply circuit between the ECM and
the MAF sensor.

3. Connect the test cable with fuse between the 12 V power supply circuit and the signal circuit of the MAF sensor
harness connector CN.D21.
Check the MAF sensor display with the trouble diagnosis scan tool.
If the reading is more than or equal to 4.9 V, inspect to see if there is a poor connection with the MAF sensor
harness connector CN.D21.
B. If the harness connector CN.D21 is normal, replace the MAF sensor.

4. Inspect the signal circuit between the ECM and the MAF sensor.
5. Set the Injector ID Code, fuel delivery rate and engine number for the ECM.
NOTE:
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P0103-Mass air flow circuit high input

Solution:
Check the MAF sensor display with the trouble diagnosis scan tool.
If the reading is more than or equal to 0.1 V, inspect the signal circuit between the ECM and the MAF sensor.
• Make sure that there is no short to the 12 V or 5 V power supply.

3. Inspect to see if there is an open circuit or high resistance in the GND circuit between the ECM and the MAF
sensor.

4. Inspect the MAF sensor harness connector CN.D21 for a poor connection.
B. If the harness connector CN.D21 is normal, replace the MAF sensor.

NOTE:
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P0112-Intake temperature sensor signal - Shorted to low source

Solution:
Disconnect the harness connector CN.D21 from the IAT sensor.
Observe the intake air temperature sensor display on the trouble diagnosis scan tool.
A. If the reading is more than or equal to 4.5 V, replace the IAT sensor.

3. Inspect the signal circuit between the ECM and IAT sensor for a short to GND.

Inspect for poor connections at the ECM harness connector CN.D3.
NOTE:
5. Observe the diagnostic trouble code information with a trouble diagnosis scan tool.
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P0113-Intake temperature sensor signal - Shorted to high source

Solution:
Disconnect the harness connector CN.D21 from the IAT sensor.
Measure the voltage between the IAT sensor signal circuit and a known good GND.
If the reading is more than or equal to 5.5 V, inspect the signal circuit between the ECM and the IAT sensor.
• Make sure that there is no short to the battery or the ignition power supply.
• Make sure that there is no short to the 12 V power supply.

3. Connect a fused jumper wire between the IAT sensor signal circuit and GND circuit.
If the reading is less than or equal to 0.1 V, inspect the signal circuit between the ECM and IAT sensor for a short
to the 5 V power supply circuit.

4. Inspect for poor connections at the IAT sensor harness connector CN.D21.
B. If the harness connector CN.D21 is normal, replace the IAT sensor.

5. Connect a fused jumper wire between the IAT sensor signal circuit and a known good GND.
If the reading is less than or equal to 0.1 V, inspect the GND circuit between the ECM and the IAT sensor for an
NOTE:
• The IAT sensor shares the GND circuit with other sensors.

6. Inspect the signal circuit between the ECM and the IAT sensor for an open circuit or high resistance.
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B. If the harness connector CN.D3 is normal,replace the ECM. (Refer to “ Engine Control Unit (ECU) - Remove
NOTE:
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P0117-Coolant temperature sensor signal - Shorted to low source

Control Module : ECU
Solution:
Disconnect the harness connector CN.E11 from the engine coolant temperature sensor.
Observe the engine coolant temperature sensor display on a trouble diagnosis scan tool.
A. If the reading is more than or equal to 4.5 V, replace the engine coolant temperature sensor. (Refer to “Engine
coolant temperature sensor removal and Engine coolant temperature sensor installation”)
B. If the reading is less than 4.5 V, proceed to Step 3

3. Inspect to see if there is a short circuit to the GND with the signal circuit between the ECM and the engine coolant
temperature sensor.

NOTE:
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P0118-Coolant temperature sensor signal - Shorted to high source

Control Module : ECU
Solution:
Disconnect the harness connector CN.E11 from the engine coolant temperature sensor.
Measure the voltage between the engine coolant temperature sensor signal circuit and normal GND.
A. If the reading is more than or equal to 5.5 V, inspect to see if there is a short circuit to the battery or ignition
power supply with the signal circuit between the ECM and the engine coolant temperature sensor.

3. Connect the test cable with fuse between the engine coolant temperature sensor signal circuit and GND circuit.
A. If the reading is less than or equal to 0.1 V, inspect to see if there is a short circuit to the 5 V power supply
circuit with the signal circuit between the ECM and the engine coolant temperature sensor.

4. Inspect to see if there is a poor connection with the engine coolant temperature sensor harness connector CN.D4.
B. If the harness connector CN.D4 is normal, replace the engine coolant temperature sensor. (Refer to “Engine
coolant temperature sensor removal and Engine coolant temperature sensor installation”)

5. Connect the test cable with fuse between the engine coolant temperature sensor signal circuit and normal GND.
A. If the reading is less than or equal to 0.1 V, inspect to see if there is an open circuit or high resistance with the
engine coolant temperature sensor GND circuit.

NOTE:
• The engine coolant temperature sensor shares the GND circuit with other sensors.
• The diagnostic trouble code set on a sensor which shares this circuit may be detected.
6. Inspect to see if there is a breakage or high resistance in the signal circuit of the engine coolant temperature
sensor.
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NOTE:
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P0122-Throttle position sensor, low input

Solution:
Disconnect the harness connector CN.E2 from the intake throttle valve.
Measure the voltage between the intake throttle position sensor 5 V power supply circuit and a normal GND.
5 V power supply circuit between the ECM and the intake throttle position sensor.
B. If a problem is found, repair the 5 V power supply circuit.

NOTE:
• The intake throttle position sensor shares the 5 V power supply circuit with other sensors.
3. Connect the test cable with fuse between the intake throttle position sensor 5 V power supply circuit and the signal
circuit.
Observe the intake throttle sensor display on the trouble diagnosis scan tool.
A. If the reading is more than or equal to 4.9 V, inspect to see if there is a poor connection with the intake throttle
valve harness connector CN.E2.
C. If the harness connector CN.E2 is normal, replace the intake throttle valve. (Refer to “ Throttle Valve Actuator
(TVA) - Remove (55.014) and Throttle Valve Actuator (TVA) - Install (55.014)”)
4. Inspect the signal circuit between the ECM and intake throttle position sensor.

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NOTE:
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P0123-Throttle position sensor, high input

Solution:
Disconnect the harness connector CN.B2 from the intake throttle valve.
Observe the intake throttle sensor display on the trouble diagnosis scan tool.
If the reading is more than or equal to 0.1 V, inspect the signal circuit between the ECM and the intake throttle
position sensor.
• There should be no short to the battery or ignition power supply.
• There should be no short to the 5 V power supply.

3. Inspect the intake throttle valve harness connector CN.D4 for a poor connection.
B. If the harness connector CN.D4 is normal, replace the intake throttle valve. (Refer to “ Throttle Valve Actuator
(TVA) - Remove (55.014) and Throttle Valve Actuator (TVA) - Install (55.014)”)

4. Inspect to see if there is an open circuit or high resistance in the GND circuit between the ECM and the intake
throttle position sensor.

NOTE:
• The intake throttle position sensor shares the GND circuit with other sensors.
5. Check the ECM harness connector CN.D4 for a poor connection.
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NOTE:
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P0182-Fuel temperature sensor - Shorted to low source

Solution:
1. Check and diagnose the below fault code before you proceed with the diagnostic code P0182.
Disconnect the harness connector CN.E8 from the fuel temperature sensor.
Observe the fuel temperature sensor display on the trouble diagnosis scan tool.
A. If the reading is more than or equal to the 4.5 V, replace the fuel temperature sensor. (Refer to “ High pressure
pump - Remove (10.218) and High pressure pump - Install (10.218)”)
B. If the reading is less than 4.5 V, proceed to Step 3.

NOTE: Do not replace the fuel temperature sensor separately. If a problem is found, replace the fuel supply pump
3. Inspect to see if there is a short circuit to the GND with the signal circuit between the ECM and fuel temperature
sensor.

B. If the harness connector CN.D4 is normal,replace the ECM. (Refer to “ Engine Control Unit (ECU) - Remove
NOTE:
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P0183-Fuel temperature sensor - Shorted to high source

Solution:
2. Turn OFF the ignition switch
Disconnect the harness connector CN.E8 from the fuel temperature sensor.
Turn ON the ignition switch
Measure the voltage between the fuel temperature sensor signal circuit and normal GND.
A. If the reading is more than or equal to 5.5 V, inspect to see if there is a short circuit to the battery or ignition
power supply with the signal circuit between the ECM and the fuel temperature sensor.

3. Connect the test cable with fuse between the fuel temperature sensor signal circuit and GND circuit.
A. If the reading is less than or equal to the 0.1 V, inspect to see if there is a short circuit to the 5 V power supply
circuit with the signal circuit between the ECM and the fuel temperature sensor.
C. If there are no problems,proceed to Step 4

4. Inspect to see if there is a poor connection with the fuel temperature sensor harness connector CN.E8.
B. If the harness connector CN.E8 is normal, replace the fuel temperature sensor. (Refer to “ High pressure
pump - Remove (10.218) and High pressure pump - Install (10.218)”)

NOTE: Do not replace the fuel temperature sensor separately. If a problem is found, replace the fuel supply pump.
5. Connect the test cable with fuse between the fuel temperature sensor signal circuit and normal GND.
NOTE:
• The fuel temperature sensor shares the GND circuit with other sensors.
A. If the reading is less than or equal to the 0.1 V, inspect to see if there is an open circuit or high resistance with
the GND circuit between the ECM and fuel temperature sensor.

6. Inspect to see if there is an open circuit or high resistance in the signal circuit between the ECM and the fuel
temperature sensor.
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NOTE:
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P0192-Fuel rail pressure sensor, low input

Solution:
Disconnect the harness connector CN.E5 from the fuel pressure sensor.
A. If the reading is less than or equal to 4.5 V, inspect to see if there is a short circuit to the GND with the signal
circuit between the ECM and the fuel pressure sensor.

3. Measure the voltage between the fuel pressure sensor 5 V power supply circuit and normal GND.
A. If the reading is more than or equal to the 4.5 V, inspect to see if there is a poor connection with the fuel
pressure sensor harness connector CN.E5.
C. If the harness connector CN.E5 is normal, replace the fuel pressure sensor. (Refer to “ Common rail - Remove
(10.218) and Common rail - Install (10.218)”)
bly.
4. Inspect to see if there is an open circuit or high resistance with the 5 V power supply circuit between the ECM and
fuel pressure sensor.
NOTE:
• The fuel pressure sensor shares the 5 V power supply circuit with other sensors.

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NOTE:
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P0193-Fuel rail pressure sensor, high input

Solution:
Measure the voltage between the fuel pressure sensor signal circuit and normal GND.
A. If the reading is more than or equal to the 5.5 V, inspect to see if there is a short circuit to the battery or ignition
power supply with the signal circuit between the ECM and the fuel pressure sensor.

3. Measure the voltage between the fuel pressure sensor signal circuit and normal GND.
A. If the reading is more than or equal to the 4.5 V, inspect to see if there is a short circuit to the 5 V power supply
circuit with the signal circuit between the ECM and the fuel pressure sensor.

4. Connect the test cable with fuse between the fuel pressure sensor signal circuit and GND circuit.
A. If the reading is less than or equal to the 0.1 V, inspect to see if there is a poor connection with the fuel pressure
sensor harness connector CN.E5.
C. If the harness connector CN.E5 is normal, replace the fuel pressure sensor. (Refer to “ Common rail - Remove
(10.218) and Common rail - Install (10.218)”)

bly.
5. Inspect to see if there is an open circuit or high resistance in the GND circuit between the ECM and the fuel
pressure sensor.
NOTE:
• The fuel pressure sensor shares the GND circuit with other sensors.

6. Inspect to see if there is an open circuit or high resistance in the signal circuit between the ECM and the fuel
pressure sensor.
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NOTE:
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P0201-Injector circuit - Cylinder 1

Solution:
Disconnect the injector harness intermediate connector CN.E20 from the cylinder head cover case.
Measure the resistance between No.1 cylinder injector power supply terminal and No.1 cylinder injector drive
signal terminal of the injector harness intermediate connector CN.E20.
A. If the reading is less than or equal to the 2.0 Ω, inspect the circuit between the ECM and the injector harness
intermediate connector CN.E20 for an open circuit or high resistance.
B. If a problem is found, repair the circuit.

3. Remove the cylinder head cover. (Refer to “ Valve cover - Remove (10.101)”)
Inspect the tightening nut of No.1 cylinder injector harness for looseness.
A. If looseness is found in the tightening nut of No.1 cylinder injector harness, tighten the nut.

4. Inspect for foreign material coming in contact with No.1 cylinder injector terminal.
A. If foreign material comes in contact with No.1 cylinder injector terminal, remove the foreign material.

5. Inspect for poor connections at the injector harness intermediate connector CN.E20.
A. If a problem is found, repair the connector CN.E20.

6. Inspect the circuit between No.1 cylinder injector CN.E14 and the intermediate connector CN.E20.
• Make sure that there is no short together between the injector circuits.
B. If the circuit is normal, replace No.1 cylinder injector. (Refer to “ Fuel injectors - Remove (10.218) and Fuel
injectors - Install (10.218)”)
If an injector has been replaced, set the Injector ID Code on the ECM.
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Solution:




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Solution:




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Solution:




6. Inspect the circuit between No.4 cylinder injector CN.E18-A and the intermediate connector CN.E21.
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NOTE:
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P0217-Engine coolant over temperature condition

Solution:
2. Inspect the engine cooling system.

Refer to “ Engine cooling system - Inspect (10.400)”
Refer to “ Belt - Inspect (10.414)”
Refer to “ Coolant thermostat - Inspect (10.400)”
Refer to “ Water pump - Inspect (10.400)”
Refer to “ Radiator - Inspect (10.400)”
While observing the coolant temperature display with the trouble diagnosis scan tool, start the engine.
Wait until the engine has been completely warmed up.
Check whether the engine coolant temperature display is more than or equal to 101 °C (214 °F) with the trouble
diagnosis scan tool.
A. If the reading is less than 101 °C (214 °F), check the operator if the overheat has occurred due to low engine
coolant level, etc.
Make sure to inspect the engine if it has experienced engine overheat in the past.
B. If the reading is more than or equal to 101 °C (214 °F), proceed to Step 2
3. Inspect the engine coolant temperature sensor. (Refer to “Engine coolant temperature sensor inspection”)
A. If any abnormality is found in the inspection results, replace the engine coolant temperature sensor. (Refer to
“Engine coolant temperature sensor removal and Engine coolant temperature sensor installation”)
3. While observing the engine coolant temperature display with the trouble diagnosis scan tool, start the engine
and wait until it is completely warmed up.
4. Observe that the engine coolant temperature display is not more than or equal to 101 °C (214 °F).
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P0219-Engine overspeed condition

Solution:

2. Turn OFF the ignition switch for 30 s.
Start the engine.
Check the engine speed display with the trouble diagnosis scan tool.
Increase the engine speed, as needed.
Check the engine speed display with the trouble diagnosis scan tool.
A. If the engine speed 2500 RPM (Shovel car) / 2800 RPM (Wheel loader) has not been exceeded, check with
the operator if an operation failure has occurred due to the overrun.
Make sure to inspect the engine if it has experienced engine overrun in the past.

A. If any abnormality is found in the inspection results,replace the CKP sensor. (Refer to “ Engine speed/RPM
sensor - Remove (55.015) and Engine speed/RPM sensor - Install (55.015)”)
3. Start the engine and increase the engine speed between idling and no load maximum speed while observing
the engine speed display on the trouble diagnosis scan tool.
4. Confirm that the engine speed display does not exceed 2500 RPM (Shovel car) / 2800 RPM (Wheel loader).
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P0234-Turbocharger overboost condition

Solution:

Check the difference between the boost pressure display and the barometric pressure display with the trouble
diagnosis scan tool.
NOTE: The value is normal if the boost pressure indicated by the trouble diagnosis scan tool is close to the
barometric pressure when the ignition switch is ON and the engine is stopped.
A. If the reading is less than or equal to the 10 kPa (1.5 psi), inspect to see if there is a failure with the actuator
which controls the turbocharger nozzle.
B. If a problem is found, repair the actuator.

3. Perform the intake throttle test with the trouble diagnosis scan tool to check the intake throttle valve for fixing.
A. If a problem is found, repair the intake throttle valve.

4. Check to see if there is oil mixing in the air intake piping.
A. If oil is attached inside the pipe, the intercooler, or the turbocharger, wipe it off.

5. Use the trouble diagnosis scan tool to confirm that the boost sensor signal is normal
Compare the sensor values under various load conditions to check for an abnormally high value.
A. If the reading is more than or equal to the 10 kPa (1.5 psi), compare the value of the barometric pressure with
the surrounding barometric pressure.

6. Use the trouble diagnosis scan tool to check if the barometric pressure display is within 10 kPa (1.5 psi).
NOTE: The barometric pressure in the trouble diagnosis scan tool normally indicates a value close to the sur-
rounding barometric pressure.
A. If the barometric pressure display is within the 10 kPa (1.5 psi), inspect the boost sensor system. (Refer to “
Intake air pressure and temperature sensor - Inspect (55.014)”)
B. If the inspection result of the boost sensor has a problem, replace the boost sensor. (Refer to “ Intake air
pressure and temperature sensor - Remove (55.014) and Intake air pressure and temperature sensor -
Install (55.014)”)
C. If the Barometric Pressure data display is outside the 10 kPa (1.5 psi), replace the ECM. (Refer to “ Engine
Control Unit (ECU) - Remove (55.015) and Engine Control Unit (ECU) - Install (55.015)”)
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NOTE:
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P0237-Turbocharger boost sensor circuit low

Solution:
Disconnect the harness connector P275 from the boost sensor.
Measure the voltage between the 5 V power supply circuit of the boost sensor harness connector P275 and a
normal GND.
the 5 V power supply circuit between the ECM and the boost sensor.

NOTE:
• The boost sensor shares the 5 V power supply circuit with other sensors.
3. Connect the test cable with fuse between the 5 V power supply circuit and the signal circuit of the boost sensor
harness connector P275.
Check the boost pressure sensor display with the trouble diagnosis scan tool.
A. If the reading is more than or equal to the 4.5 V, inspect to see if there is a poor connection with the boost
sensor harness connector P275.
B. If a problem is found, repair the harness connector P275.
C. If the harness connector P275 is normal, replace the boost sensor. (Refer to “ Intake air pressure and tem-
perature sensor - Remove (55.014) and Intake air pressure and temperature sensor - Install (55.014)”)

4. Inspect the signal circuit between the ECM and the boost sensor.

5. Inspect the ECM harness connector CN.D4 for a poor connection
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NOTE:
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P0238-Turbocharger boost sensor circuit high

Solution:
Disconnect the harness connector P275 from the boost sensor.
Check the boost pressure sensor display with the trouble diagnosis scan tool.
If the reading is more than or equal to the 0.1 V, inspect the signal circuit between the ECM and the boost sensor.

3. Inspect to see if there is an open circuit or high resistance in the GND circuit between the ECM and the boost
sensor.
NOTE:
• The boost sensor shares the GND circuit with other sensors.

4. Inspect the boost sensor harness connector P275 for a poor connection.
A. If a problem is found, repair the harness connector P275.
B. If the harness connector P275 is normal, replace the boost sensor. (Refer to “ Intake air pressure and tem-
perature sensor - Remove (55.014) and Intake air pressure and temperature sensor - Install (55.014)”)
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NOTE:
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P0335-Crankshaft position sensor circuit

Solution:

Disconnect the harness connector CN.E04 from the CKP sensor.
Measure the voltage between the 5 V power supply circuit and normal GND of the CKP sensor harness connector
CN.E04.
the 5 V power supply circuit between the ECM and the CKP sensor.

NOTE:
• The CKP sensor shares the 5 V power supply circuit with other sensors.
3. Measure the voltage between the signal circuit and normal GND of the CKP sensor harness connector CN.E04.
power supply with the signal circuit between the ECM and the CKP sensor.

4. Measure the voltage between the signal circuit of the CKP sensor harness connector CN.E04 and a normal GND
again.
If the reading is less than or equal to the 4.5 V, inspect the signal circuit between the ECM and the CKP sensor.

5. Connect the test light between the signal circuit and normal GND of the CKP sensor harness connector CN.E04.
Measure the voltage between the probe of the test light and a normal GND.
circuit with the signal circuit between the ECM and the CKP sensor.

6. Measure the voltage between the 5 V power supply circuit and GND circuit of the CKP sensor harness connector
CN.E04.
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A. If the reading is more than or equal to the 4.5 V, inspect to see if there is a poor connection with the CKP
C. If the harness connector CN.E04 is normal, inspect the CKP sensor. (Refer to “ Engine speed/RPM sensor
- Inspect (55.015)”)
D. If a problem is found, replace the CKP sensor. (Refer to “ Engine speed/RPM sensor - Remove (55.015)
and Engine speed/RPM sensor - Install (55.015)”)

7. Inspect the GND circuit between the ECM and the CKP sensor for an open circuit and high resistance.
NOTE:
• The boost sensor shares the GND circuit with other sensors.

NOTE:
14 (55.100)
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P0336-Crankshaft position sensor circuit range/performance

Solution:

2. Inspect the CKP sensor circuit.
• Make sure that there is enough clearance from the wiring or component of the fuel injection unit.
• Make sure that there is enough clearance from additionally installed electronic components.
• Make sure that there is enough clearance from the solenoids and relays.
A. If a problem is found, repair the CKP sensor circuit.

Inspect the ECM harness connector CN.D4 for a poor connection.

4. Disconnect the harness connector CN.E04 from the CKP sensor.
Inspect the CKP sensor harness connector CN.E04 for a poor connection.

A. If a problem is found, replace the CKP sensor. (Refer to “ Engine speed/RPM sensor - Remove (55.015) and
Engine speed/RPM sensor - Install (55.015)”)
NOTE:
14 (55.100)
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P0340-Camshaft position sensor circuit

Solution:

Disconnect the harness connector CN.E12 from the CMP sensor.
Measure the voltage between the 5 V power supply circuit and normal GND of the CMP sensor harness connector
CN.E12.
the 5 V power supply circuit between the ECM and the CMP sensor.

3. Measure the voltage between the signal circuit and normal GND of the CMP sensor harness connector CN.E12.
power supply with the signal circuit between the ECM and the CMP sensor.

4. Measure the voltage between the signal circuit of the CMP sensor harness connector CN.E12 and a normal GND
again.
If the reading is less than or equal to the 4.5 V, inspect the signal circuit between the ECM and the CMP sensor.

5. Connect the test light between the signal circuit and normal GND of the CMP sensor harness connector CN.E12.
Measure the voltage between the probe of the test light and a normal GND.
circuit with the signal circuit between the ECM and the CMP sensor.

6. Measure the voltage between the 5 V power supply circuit and GND circuit of the CMP sensor harness connector
CN.E12.
A. If the reading is more than or equal to the 4.5 V, inspect to see if there is a poor connection with the CMP
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C. If the harness connector CN.E12 is normal, inspect the CMP sensor. (Refer to “ Engine timing sensors
Camshaft sensor - Inspect (55.015)”)
D. If a problem is found, replace the CMP sensor. (Refer to “ Engine timing sensors Camshaft sensor -
Remove (55.015) and Engine timing sensors Camshaft sensor - Install (55.015)”)

• Make sure that camshaft gear is not damaged.
• Make sure that camshaft gear is installed correctly.
A. If a problem is found, repair the camshaft gear.

8. Inspect the GND circuit between the ECM and the CMP sensor for an open circuit and high resistance.
NOTE:
• The CMP sensor shares the GND circuit with other sensors.

B. If the harness connector CN.D4 is normal, replace the ECM .(Refer to “ Engine Control Unit (ECU) - Remove
NOTE:
14 (55.100)
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P0380-Glow plug circuit

Solution:
Replace the glow relay with a starter relay or a known good relay.
Perform the glow relay test with the trouble diagnosis scan tool.
Command the glow relay ON and OFF.
Check whether an operation sound is heard from the glow relay upon execution of each command.
If the operating sound of the glow relay can be heard, remove the glow relay.
Inspect for poor connections at the glow relay terminal.
A. If a problem is found, repair the glow relay terminal.
B. If the glow relay terminal is normal, replace the glow relay.

Inspect between the ignition switch and the glow relay coil side for an open circuit or high resistance.
A. If a problem is found, repair the circuit between the ignition switch and glow relay coil side.

3. Inspect the control circuit between the ECM and glow relay.

NOTE:
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P0401-EGR flow insufficient detected

Solution:

2. Inspect the air cleaner element.
A. If a problem is found, replace the air cleaner element.

3. Inspect the EGR system.
NOTE:
• Do not lose or damage the EGR gasket.
• The EGR valve should not be stuck.
• Make sure that there is no EGR gas leakage from the EGR passage between the exhaust manifold and the
intake manifold.
• Make sure that there is no collapsed or restricted flow in the EGR passage between the exhaust manifold and
the intake manifold.
A. If a problem is found, repair or replace the EGR system.

4. Inspect the air intake system.
NOTE:
• Make sure that there is no collapsing of the duct between the air cleaner and intake manifold, or a state where
flow is restricted or breakage is present.
• Make sure that there is no leakage in the air intake system.
• Make sure that there is no water in the air intake system.
A. If a problem is found, repair the air intake system.

5. Inspect the MAF sensor.
NOTE:
• Make sure that there is no dirt or foreign material blocking the ports of the MAF sensor
• Make sure that there is no misdetection or delayed response of the MAF sensor.
A. If a problem is found, replace the MAF sensor.

6. Inspect the exhaust system.
NOTE: Flow should not be in a restricted state.
A. If a problem is found, repair or replace the exhaust system.

7. Perform the EGR with a scan tool.
While observing the EGR Position 1 value, command the desired EGR opening position to increase and decrease.
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Compare the EGR position 1 display with the desired EGR opening position display on the trouble diagnosis scan
tool and observe whether the difference is within the specified range.
A. If the reading is outside the specified range, replace the EGR valve. (Refer to “ Exhaust Gas Recirculation
(EGR) valve - Remove (10.501) and Exhaust Gas Recirculation (EGR) valve - Install (10.501)”)
NOTE:
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P0404-EGR control circuit range/performance

Solution:
2. Remove the EGR valve assembly from the engine. (Refer to “ Exhaust Gas Recirculation (EGR) valve - Remove
(10.501)”)
Inspect the EGR valve.
• Make sure that there is no limit flow inside the EGR valve.
• Make sure that there is no excessive accumulates inside the EGR valve.
• Make sure that there is no bending with the valve shaft or valve itself inside the EGR valve.
Disconnect the harness connector CN.E03 from the EGR valve.
Inspect the EGR valve harness connector CN.D3 for a poor connection.

3. Disconnect the harness connector CN.D4 from the ECM.

4. Inspect to see if there is an open circuit or high resistance in the EGR control circuit.
A. If a problem is found, repair the EGR control circuit.

5. Inspect the EGR motor circuit between the ECM and EGR valve.
• Make sure that there is no short to the battery or ignition power supply circuit.
• Make sure that there is no short between the circuits.
• Make sure that there is no short to EGR position sensor circuit.
A. If a problem is found, repair the EGR motor circuit.
B. If the EGR motor circuit is normal, replace the EGR valve. (Refer to “ Exhaust Gas Recirculation (EGR)
valve - Remove (10.501) and Exhaust Gas Recirculation (EGR) valve - Install (10.501)”)

6. Restore the machine.
Clear the diagnostic trouble code using the trouble diagnosis scan tool.
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Turn OFF the ignition switch for at least 30 s.
Start the engine.
Perform a test-run.
Check the diagnostic trouble code using the trouble diagnosis scan tool.
A. If the diagnostic trouble code P0404 has been detected, replace the ECM. (Refer to “ Engine Control Unit
(ECU) - Remove (55.015) and Engine Control Unit (ECU) - Install (55.015)”)
NOTE:
14 (55.100)
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P0409-Exhaust gas recirculation 1 sensor circuit

Solution:
Use the trouble diagnosis scan tool to check if any of the EGR position 1, EGR position 2, and EGR position 3
shows ON.
If there is a data display showing ON, inspect the signal circuit between the ECM and EGR valve of the EGR
showing ON.
• Make sure that there is no short to the 5 V power supply circuit.

3. Measure the voltage between the EGR position sensor 5 V power supply circuit and a normal GND.
Inspect the GND circuit between the ECM and the CMP sensor for an open circuit and high resistance.
the 5 V power supply circuit between the ECM and the EGR position sensor.
NOTE:
• The EGR position sensor shares the 5 V power supply circuit with other sensors.
4. Measure the voltage between the EGR position sensor 5 V power supply circuit and the GND circuit.
the GND circuit between the ECM and EGR position sensor.
NOTE:
• The EGR position sensor shares the GND circuit with other sensors.
5. While momentarily disconnecting the test cable with fuse from the EGR position sensor 1 signal circuit and 5 V
power supply circuit, check the EGR position 1 display with the trouble diagnosis scan tool.
While momentarily disconnecting the test cable with fuse from the EGR position sensor 2 signal circuit and 5 V
While momentarily disconnecting the test cable with fuse from the EGR position sensor 3 signal circuit and 5 V
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Check to see if there is a data display which does not display ON when the EGR position sensor signal circuit
and 5 V power supply circuit are shorted.
If there is a data display which does not display ON, inspect the EGR position sensor circuit which does not
display ON.
• Make sure that there is no open circuit or high resistance between ECM and EGR position sensor.
• Make sure that there is no short to GND between ECM and EGR position sensor.
A. If a problem is found, repair the EGR position sensor circuit.

6. Inspect the EGR valve harness connector CN.E03 for a poor connection.

7. In the EGR solenoid circuit between the ECM and EGR valve, inspect to see if there is a short circuit with the
EGR position sensor.
A. If a problem is found, repair the EGR solenoid circuit.
B. If the EGR solenoid circuit is normal, replace the EGR valve. (Refer to “ Exhaust Gas Recirculation (EGR)
valve - Remove (10.501) and Exhaust Gas Recirculation (EGR) valve - Install (10.501)”)
NOTE:
14 (55.100)
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P0427-Catalyst temperature sensor circuit low sensor 1

Solution:
Disconnect the harness connector CN.D17-8 from the exhaust gas temperature sensor 1.
Check the exhaust temperature sensor (before the filter) display with the trouble diagnosis scan tool.
A. If the reading is more than or equal to 4.5 V, replace the exhaust gas temperature sensor 1. (Refer to “ Exhaust

3. Inspect to see if there is a short circuit to the GND with the signal circuit between the ECM and the exhaust gas
temperature sensor 1.

NOTE:
13 (55.100)
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P0428-Catalyst temperature sensor circuit high sensor 1

Solution:
Measure the voltage between the exhaust gas temperature sensor 1 signal circuit and normal GND.
power supply with the signal circuit between the ECM and the exhaust gas temperature sensor 1.

3. Connect the test cable with fuse between the exhaust gas temperature sensor 1 signal circuit and GND circuit.
A. If the reading is less than or equal to the 0.1 V, inspect to see if there is a short circuit to the 5.0 V power supply
circuit with the signal circuit between the ECM and the exhaust gas temperature sensor 1.
C. If the harness connector CN.D17-8 is normal, replace the exhaust gas temperature sensor 1. (Refer to “ Ex-
haust Gas Recirculation (EGR) temperature sensors - Remove - Temperature sensor 1 (55.989) and
Exhaust Gas Recirculation (EGR) temperature sensors - Install - Temperature sensor 1 (55.989)”)

4. Connect the test cable with fuse between the exhaust gas temperature sensor 1 signal circuit and normal GND.
A. If the reading is more than or equal to the 0.1 V, inspect to see if there is an open circuit or high resistance with
the signal circuit between the ECM and the exhaust gas temperature sensor 1.

5. Inspect to see if there is an open circuit or high resistance in the GND circuit between the ECM and the exhaust
gas temperature sensor 1.
NOTE:
• The exhaust gas temperature sensor 1 shares the GND circuit with other sensors.
• The diagnostic trouble code may be detected on a sensor which shares this circuit.

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3. Start the engine and warm it up until the coolant temperature exceeds 70 °C (158 °F).
4. Increase the engine speed while observing the exhaust temperature sensor (in front of the filter) display with
5. Use the trouble diagnosis scan tool to confirm that the exhaust temperature sensor (before the filter) display
does not exceed 4.8 V.
13 (55.100)
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P042C-Catalyst temperature sensor circuit low sensor 2

Solution:
1. Check and diagnose the below fault codes before you proceed with the diagnostics code P042C.
Diagnostic trouble code P06D5
Check the exhaust temperature sensor (before the oxidation catalyst) display with the trouble diagnosis scan tool.
A. If the reading is more than or equal to 4.5 V, replace the exhaust gas temperature sensor 2. (Refer to “ Exhaust

3. Inspect to see if there is a short circuit to the GND with the signal circuit between the ECM and the exhaust gas
temperature sensor 2.

NOTE:
13 (55.100)
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P042D-Catalyst temperature sensor circuit high sensor 2

Solution:
1. Check and diagnose the below fault codes before you proceed with the diagnostics code P042D.
Diagnostic trouble code P06D5
Measure the voltage between the exhaust gas temperature sensor 2 signal circuit and normal GND.
power supply with the signal circuit between the ECM and the exhaust gas temperature sensor 2.

3. Connect the test cable with fuse between the exhaust gas temperature sensor 2 signal circuit and GND circuit.
A. If the reading is less than or equal to the 0.1 V, inspect to see if there is a short circuit to the 5 V power supply
circuit with the signal circuit between the ECM and the exhaust gas temperature sensor 2.

4. Inspect to see if there is a poor connection with the exhaust gas temperature sensor 2 harness connector
CN.D17-9.
B. If the harness connector CN.D17-9 is normal, replace the exhaust gas temperature sensor 2. (Refer to “ Ex-
haust Gas Recirculation (EGR) temperature sensors - Remove - Temperature sensor 2 (55.989) and
Exhaust Gas Recirculation (EGR) temperature sensors - Install - Temperature sensor 2 (55.989)”)

5. Connect the test cable with fuse between the exhaust gas temperature sensor 2 signal circuit and normal GND.
A. If the reading is more than or equal to the 0.1 V, inspect to see if there is an open circuit or high resistance with
the signal circuit between the ECM and the exhaust gas temperature sensor 2.

6. Inspect to see if there is an open circuit or high resistance in the GND circuit between the ECM and the exhaust
gas temperature sensor 2.
NOTE:
• The exhaust gas temperature sensor 2 shares the GND circuit with other sensors.
• The diagnostic trouble code may be detected on a sensor which shares this circuit.
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3. Start the engine and warm it up until the coolant temperature exceeds 70 °C (158 °F).
4. Increase the engine speed while observing the exhaust temperature sensor (in front of the filter) display with
5. Use the trouble diagnosis scan tool to confirm that the exhaust temperature sensor (before the filter) display
does not exceed 4.9 V.
13 (55.100)
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P0522-Oil pressure sensor circuit low

Solution:
Disconnect the harness connector CN.E7 from the oil pressure sensor.
Measure the voltage between the 5 V power supply circuit and normal GND of the oil pressure sensor harness
connector CN.E7.
5 V power supply circuit between the ECM and the oil pressure sensor.

3. Connect the test cable with fuse between the 5 V power supply circuit and signal circuit of the oil pressure sensor
harness connector CN.E7.
Observe the oil pressure sensor display on the trouble diagnosis scan tool.
A. If the reading is more than or equal to 4.5 V, inspect to see if there is a poor connection with the oil pressure
C. If the harness connector CN.E7 is normal, replace the oil pressure sensor. (Refer to “ Engine oil pressure
sensor and switch - Remove (55.013) and Engine oil pressure sensor and switch - Install (55.013)”)

4. Inspect the signal circuit between the ECM and the oil pressure sensor.

(55.015) and Engine Control Unit (ECU) - Install (55.015)")
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NOTE:
14 (55.100)
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P0523-Oil pressure sensor circuit high

Solution:
Disconnect the harness connector CN.E7 from the oil pressure sensor.
Observe the oil pressure sensor display on the trouble diagnosis scan tool.
If the reading is more than or equal to the 0.1 V, inspect the signal circuit between the ECM and the oil pressure
sensor.

3. Inspect to see if there is an open circuit or high resistance in the GND circuit between the ECM and the oil pressure
sensor.

NOTE:
• The oil pressure sensor shares the GND circuit with other sensors.
4. Inspect the oil pressure sensor harness connector CN.E7 for a poor connection.
B. If the harness connector CN.E7 is normal, replace the oil pressure sensor. (Refer to “ Engine oil pressure

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NOTE:
14 (55.100)
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P0545-EGR cooler inlet 1 temperature sensor circuit low

Solution:
Disconnect the harness connector CN.E10-B from EGR gas temperature sensor 1.
Observe the EGR gas temperature sensor 5 V adjustment display on the trouble diagnosis scan tool.
A. If the reading is more than or equal to 4.5 V, replace the EGR gas temperature sensor 1. (Refer to “ Exhaust

3. Inspect the signal circuit between the ECM and EGR gas temperature sensor 1 for a short to GND.

NOTE:
14 (55.100)
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P0546-EGR cooler inlet 1 temperature sensor circuit high

Solution:
Disconnect the harness connector CN.E10-B from EGR gas temperature sensor 1.
Measure the voltage between the EGR gas temperature sensor 1 signal circuit and a known good GND.
A. If the reading is more than or equal to the 5.5 V, inspect the signal circuit between the ECM and EGR gas
temperature sensor 1 for a short to the battery or a short to the ignition power supply.

3. Connect a fused jumper wire between the EGR gas temperature sensor 1 signal circuit and the GND circuit.
A. If the reading is less than or equal to the 0.1 V, inspect the signal circuit between the ECM and the EGR gas
temperature sensor for a short to the 5 V power supply circuit.

4. Inspect for poor connections at the EGR gas temperature sensor 1 harness connector CN.E10-B.
A. If a problem is found, repair the harness connector CN.E10-B.
B. If the harness connector CN.E10-B is normal, replace EGR gas temperature sensor 1. (Refer to “ Exhaust

5. Connect a fused jumper wire between the EGR gas temperature sensor 1 signal circuit and a known good GND.
A. If the reading is less than or equal to the 0.1 V, inspect the EGR gas temperature sensor 1 GND circuit for an

NOTE:
• EGR gas temperature sensor 1 shares the GND circuit with other sensors.
6. Inspect the EGR gas temperature sensor 1 signal circuit for an open circuit or high resistance.
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2. Turn OFF the ignition switch for 30 s or more.
NOTE:
14 (55.100)
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P0560-System voltage
Solution:
Observe the diagnostic trouble code information for diagnostic trouble code P0560 with a trouble diagnosis scan
tool.
A. If a diagnostic trouble code has not been detected, inspect the MAF sensor harness connector CN.D21 for a
poor connection.
B. If a problem is found, repair the harness connector CN.D21.
C. If the harness connector CN.D21 is normal, replace the MAF sensor.

2. Inspect the 12 V power supply circuit between the ECM and the MAF sensor.

NOTE:
13 (55.100)
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P0563-System voltage high

Solution:
1. Check if the battery charger has been recently connected to the battery.
Start the engine, and idle it.
Check the ignition voltage display with the trouble diagnosis scan tool.
A. If the reading is more than or equal to the 32 V, inspect the charging system. (Refer to “ Alternator - Assemble
(55.301)”)
B. If a problem is found, repair the charging system.
C. If the charging system is normal, replace the ECM. (Refer to “ Engine Control Unit (ECU) - Remove (55.015)
and Engine Control Unit (ECU) - Install (55.015)”)
3. Start the engine, and idle it.
4. Check the ignition voltage display with the trouble diagnosis scan tool, and confirm that the value does not
exceed 32 V.
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P0601-ECU memory fault - Bad Intelligent device

Solution:
1. Replace the ECM. (Refer to “ Engine Control Unit (ECU) - Remove (55.015) and Engine Control Unit (ECU) -
Install (55.015)”)
NOTE:
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P0602-Control module programming error

Solution:
1. Confirm that the connecting sections of all tools are securely connected.
Confirm that the programming device is operating normally.
Verify that the correct injector ID Code and fuel delivery rate are input into the ECM with a trouble diagnosis scan
tool.
NOTE: If the injector ID Code and the fuel delivery rate are correctly input, clear the diagnostic trouble code with
a trouble diagnosis scan tool.
Use the trouble diagnosis scan tool to check if a diagnostic trouble code has been detected.
A. If a diagnostic trouble code has been detected, replace the ECM. (Refer to “ Engine Control Unit (ECU) -
Remove (55.015) and Engine Control Unit (ECU) - Install (55.015)")
NOTE:
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P0604-Internal control module random access memory (RAM) error

Solution:
Install (55.015)”)
NOTE:
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P0606-Internal control module CPU error

Solution:
Install (55.015)”)
Set the Injector ID Code, fuel delivery rate and engine number for the ECM.
NOTE:
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P060A-Internal control module CPU IC error

Solution:
Install (55.015)”)
NOTE:
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P060C-Internal control module A/D processing performance

Solution:
Install (55.015)”)
NOTE:
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P0615-Starter relay circuit

Solution:
1. Connect a trouble diagnosis scan tool.
Turn OFF the ignition switch for 30 s or more.
Turn ON the ignition switch. The engine must not be started.
Observe the diagnostic trouble code information for P0615 with a trouble diagnosis scan tool.
A. If a diagnostic trouble code is not set, start the engine.

2. Observe the diagnostic trouble code information for P0615 with a trouble diagnosis scan tool.
A. If a diagnostic trouble code is not set, an intermittent condition is suspected.
B. If a diagnostic trouble code is set, inspect for a short to the battery power supply circuit or ignition power supply
circuit in the control circuit of the ECM and starter cut relay.
C. If a problem is found, repair the control circuit of the ECM and starter cut relay.
D. If a diagnostic trouble code is set in, replace with another known good starter cut relay.

3. Turn ON the ignition switch. The engine must not be started.
Observe the diagnostic trouble code information for P0615 with a trouble diagnosis scan tool.
A. If a diagnostic trouble code is not set, replace the starter cut relay.
B. If a diagnostic trouble code is set, inspect for a short to GND in the control circuit of the ECM and starter cut
relay.
C. If a problem is found, repair the control circuit of the ECM and starter cut relay.

Install (55.015)”)
NOTE:
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P0638-Throttle actuator control range/performance

Solution:

2. Remove the air intake hose from the intake throttle valve. (Refer to “ Throttle Valve Actuator (TVA) - Remove
(55.014)”)
Inspect the intake throttle valve.
• Make sure that the intake throttle valve flow is not be limited.
• Make sure that there is no excessive deposit inside the throttle bore of the intake throttle valve.
• Make sure that there is no bending with the butterfly valve of the intake throttle valve.
• Make sure that the intake throttle valve is not be locked.
A. If a problem is found, replace the intake throttle valve. (Refer to “ Throttle Valve Actuator (TVA) - Remove
(55.014) and Throttle Valve Actuator (TVA) - Install (55.014)”)

Disconnect the harness connector CN.E02 from the intake throttle valve.
Inspect the intake throttle valve harness connector CN.E02 for a poor connection.


5. Inspect the intake throttle valve circuit for high resistance.

6. Inspect the motor circuit between the ECM and the intake throttle valve.
• Make sure that there is no short together between motor circuits.
• Make sure that there is no short to the intake throttle position sensor circuit.
A. If a problem is found, repair the motor circuit.
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B. If the motor circuit is normal, replace the intake throttle valve. (Refer to “ Throttle Valve Actuator (TVA) -
Remove (55.014) and Throttle Valve Actuator (TVA) - Install (55.014)”)

NOTE: The ignition switch must be once turned ON and then turned OFF before clearing the diagnostic trouble
code.
Start the engine.
Remove (55.015) and Engine Control Unit (ECU) - Install (55.015)”)
NOTE: The ignition switch must be once turned ON and then turned OFF before clearing the diagnostic trouble
code.
6. Perform a test-run while the intake throttle motor drive duty is 20 ％ or more.
14 (55.100)
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P0685-ECM power relay control circuit open

Solution:
Replace the main relay with a glow relay or normal relay.
Use the trouble diagnosis scan tool to check if a diagnostic trouble code is detected.
A. If a diagnostic trouble code has not been detected, replace the main relay.
B. If a diagnostic trouble code has been detected, proceed to Step 2.

2. Inspect the body grounding terminal for a poor connection.
A. If a problem is found, repair the terminal.

3. Inspect the slow blow fuse.
A. If a problem is found, replace the slow blow fuse.

NOTE: When the fuse is blown again, repair the cause of slow-blow fuse blowout.
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P06A6-Sensor reference voltage 1 circuit

Solution:
Disconnect the harness connector CN.E04 from the CKP sensor.
Measure the voltage between the CKP sensor 5 V power supply circuit of the CKP sensor harness connector
CN.E04 and the GND.
If the reading is more than or equal to 5.5 V, inspect the CKP sensor 5 V power supply circuit between the ECM
and the CKP sensor for a short to the battery or a short to the ignition power supply.
A. If a problem is found, repair the CKP sensor 5 V power supply circuit between the ECM and the CKP sensor.

2. If the reading is less than or equal to 5.5 V, measure the voltage between the 5 V power supply circuit of the CKP
sensor harness connector CN.E04 and the GND.
If the reading is more than or equal to 4.5 V, replace the CKP sensor. (Refer to “ Engine speed/RPM sensor -
Remove (55.015) and Engine speed/RPM sensor - Install (55.015)”)
If the reading is less than or equal to 4.5 V, inspect the CKP sensor 5 V power supply circuit between the ECM
and the CKP sensor for a short to GND.
A. If a problem is found, repair the CKP sensor 5 V power supply circuit.
B. If there are no problems, Replace the ECM. (Refer to “ Engine Control Unit (ECU) - Remove (55.015) and
Engine Control Unit (ECU) - Install (55.015)”)
NOTE:
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P0687-ECM power relay control circuit high

Solution:
Remove the main relay.
Use the trouble diagnosis scan tool to see if diagnostic trouble code P0685 is detected.
A. If the diagnostic trouble code P0685 is not detected, repair the short circuit to the battery power supply of the
power supply circuit between the ECM and main relay.
B. If the diagnostic trouble code P0685 is detected, proceed to Step 2.

Replace the main relay with a glow relay or normal relay.
Use the trouble diagnosis scan tool to check if diagnostic trouble code P0687 has been detected.
A. If the diagnostic trouble code P0687 is not detected, replace the main relay.
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Solution:
Disconnect the harness connector CN.E12 from the CMP sensor.
Measure the voltage between the CMP sensor 5 V power supply circuit of the CMP sensor harness connector
CN.E12 and the GND.
If the reading is more than or equal to 5.5 V, inspect the CMP sensor 5 V power supply circuit between the ECM
and the CMP sensor for a short to the battery or a short to the ignition power supply.
A. If a problem is found, repair the CMP sensor 5 V power supply circuit.

2. Inspect the FRP sensor 5 V power supply circuit between the ECM and the FRP sensor for a short to the battery
or a short to the ignition power supply.
A. If a problem is found, repair the FRP sensor 5 V power supply circuit.

3. If the reading is less than or equal to 5.5 V, measure the voltage between the CMP sensor 5 V power supply circuit
of the CMP sensor harness connector CN.E12 and the GND.
If the reading is more than or equal to 4.5 V, replace the CMP sensor. (Refer to “ Engine timing sensors Camshaft
sensor - Remove (55.015) and Engine timing sensors Camshaft sensor - Install (55.015)”)
If the reading is less than or equal to 4.5 V, turn OFF the ignition switch.
Measure the voltage between the CMP sensor 5 V power supply circuit of the CMP sensor harness connector
CN.E12 and the GND.
If the reading is more than or equal to 4.5 V, replace the FRP sensor. (Refer to “ Common rail - Remove (10.218)
and Common rail - Install (10.218)”)
If the reading is less than or equal to 4.5 V, inspect the CMP sensor 5 V power supply circuit between the ECM
and the CMP sensor for a short to GND.
A. If a problem is found, repair the CMP sensor 5 V power supply circuit.

4. Inspect the FRP sensor 5 V power supply circuit between the ECM and the FRP sensor for a short to GND.
A. If a problem is found, repair the FRP sensor 5 V power supply circuit.

Install (55.015)”)
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NOTE:
should not be set.
18 (55.100)
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Solution:
Disconnect the harness connector P275 from the boost pressure sensor.
Measure the voltage between the boost pressure sensor 5 V power supply circuit of the boost pressure sensor
harness connector P275 and the GND.
If the reading is more than or equal to 5.5 V, inspect the boost pressure sensor 5 V power supply circuit between
the ECM and the boost pressure sensor for a short to the battery or a short to the ignition power supply.
A. If a problem is found, repair the boost pressure sensor 5 V power supply circuit.

2. Inspect the intake throttle position sensor 5 V power supply circuit between the ECM and intake throttle position
sensor for a short to the battery or a short to the ignition power supply.
A. If a problem is found, repair the intake throttle position sensor 5 V power supply circuit.

3. If the reading is less than or equal to 5.5 V, measure the voltage between the boost pressure sensor 5 V power
supply circuit of the boost pressure sensor harness connector P275 and the GND.
If the reading is more than or equal to 4.5 V, replace the boost pressure sensor. (Refer to “ Intake air pressure and
temperature sensor - Remove (55.014) and Intake air pressure and temperature sensor - Install (55.014)”)
Disconnect the harness connector CN.B2 from the intake throttle position sensor.
Measure the voltage between the boost pressure sensor 5 V power supply circuit of the boost pressure sensor
harness connector P275 and the GND.
If the reading is more than or equal to 4.5 V, replace the intake throttle valve. (Refer to " Throttle Valve Actuator
(TVA) - Remove (55.014) and Throttle Valve Actuator (TVA) - Install (55.014)“)
If the reading is less than or equal to 4.5 V, inspect the boost pressure sensor 5 V power supply circuit between
the ECM and the boost pressure sensor for a short to GND.
A. If a problem is found, repair the boost pressure sensor 5 V power supply circuit.

4. Inspect the intake throttle position sensor 5 V power supply circuit between the ECM and intake throttle position
sensor for a short to GND.
A. If a problem is found, repair the intake throttle position sensor 5 V power supply circuit.

Install (55.015)”)
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NOTE:
should not be set.
37 (55.100)
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Solution:
Remove the harness connector CN.E03 from the EGR valve position sensor.
Measure the voltage between the EGR valve position sensor 5 V power supply terminal of the EGR valve position
sensor harness connector CN.E03 and the GND.
If the reading is more than or equal to 5.5 V, inspect the EGR valve position sensor 5 V power supply circuit
between the ECM and the EGR valve position sensor for a short to the battery or a short to the ignition power
supply.
A. If a problem is found, repair the EGR valve position sensor 5 V power supply circuit.

2. Inspect the oil pressure sensor 5 V power supply circuit between the ECM and oil pressure sensor for a short to
the battery or a short to the ignition power supply.
A. If a problem is found, repair the oil pressure sensor 5 V power supply circuit.

3. If the reading is less than or equal to 5.5 V, measure the voltage between the EGR valve position sensor 5 V power
supply terminal of the EGR valve position sensor harness connector CN.E03 and the GND.
If the reading is more than or equal to 4.5 V, replace the EGR valve. (Refer to “ Exhaust Gas Recirculation
(EGR) valve - Remove (10.501) and Exhaust Gas Recirculation (EGR) valve - Install (10.501)”)
Remove the harness connector CN.E7 from the oil pressure sensor.
Measure the voltage between the oil pressure sensor 5 V power supply terminal of the oil pressure sensor harness
connector CN.E7 and the GND.
If the reading is more than or equal to 4.5 V, replace the oil pressure sensor. (Refer to “ Engine oil pressure
If the reading is less than or equal to 4.5 V, inspect the EGR valve position sensor 5 V power supply circuit between
the ECM and the EGR valve position sensor for a short to GND.
A. If a problem is found, repair the EGR valve position sensor 5 V power supply circuit.

4. Inspect the oil pressure sensor 5 V power supply circuit between the ECM and oil pressure sensor for a short to
GND.
A. If a problem is found, repair the oil pressure sensor 5 V power supply circuit.

5. Replace the ECM. (Refer to " Engine Control Unit (ECU) - Remove (55.015) and Engine Control Unit (ECU) -
Install (55.015)“)
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NOTE:
should not be set.
18 (55.100)
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P06AF-Torque management system - Forced engine shutdown

Solution:
Install (55.015)”)
NOTE:
5. Observe the diagnostic trouble code information with the trouble diagnosis scan tool.
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P06D5-Sensor reference voltage 5 circuit

Solution:
Measure the voltage of the ECM SP-5V5 terminal.
If the reading is outside the specified range, replace the ECM. (Refer to “ Engine Control Unit (ECU) - Remove
NOTE:
should not be set.
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P1076-Charge air cooler (CAC) temperature sensor 1 circuit low

voltage
Solution:
Disconnect the harness connector CN.E10 from charge air cooler temperature sensor 1.
Observe the charge air cooler intake air temperature sensor 5 V display on the trouble diagnosis scan tool.
If the reading is more than or equal to 4.5 V, replace charge air cooler temperature sensor 1. (Refer to “ Boost
temperature sensor - Remove (55.014) and Boost temperature sensor - Install (55.014)”)
Inspect the signal circuit between the ECM and charge air cooler temperature sensor 1 for a short to GND.


4. If the harness connector CN.D4 is normal, replace the ECM. (Refer to “ Engine Control Unit (ECU) - Remove
NOTE:
14 (55.100)
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P1077-Charge air cooler (CAC) temperature sensor 1 circuit high

voltage
Solution:
Disconnect the harness connector CN.E10 from charge air cooler temperature sensor 1.
Measure the voltage between the charge air cooler temperature sensor 1 signal circuit and a known good GND.
If the reading is more than or equal to 5.5 V, inspect the signal circuit between the ECM and charge air cooler
temperature sensor 1 for a short to the battery or a short to the ignition power supply.

3. Connect a fused jumper wire between the charge air cooler temperature sensor 1 signal circuit and the GND circuit.
If the reading is less than or equal to 0.1 V, inspect the signal circuit between the ECM and charge air cooler
temperature sensor 1 for a short to the 5 V power supply circuit.

4. Inspect for poor connections at the charge air cooler temperature sensor 1 harness connector CN.E10.

5. If the harness connector CN.E10 is normal, replace charge air cooler temperature sensor 1. (Refer to “ Boost
temperature sensor - Remove (55.014) and Boost temperature sensor - Install (55.014)”)
Connect a fused jumper wire between the charge air cooler temperature sensor 1 signal circuit and a known good
GND.
If the reading is less than or equal to 0.1 V, inspect the charge air cooler temperature sensor 1 GND circuit for an
NOTE:
• Charge air cooler temperature sensor 1 shares the GND circuit with other sensors.

6. Inspect the charge air cooler temperature sensor 1 signal circuit for an open circuit or high resistance.
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2. Turn OFF the ignition switch for 30 s or more.
NOTE:
14 (55.100)
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P1093-Fuel rail pressure (FRP) too low

Solution:

Wait for 2 min until the fuel pressure is released from the common rail.
Use the trouble diagnosis scan tool to check if the fuel rail pressure sensor display is within 0.9 - 1.0 V
If the fuel rail pressure sensor display is outside the specified range, inspect the fuel pressure sensor harness
connector CN.E5 for a poor connection.



5. If the harness connector CN.E5 and each circuit are normal, replace the fuel pressure sensor. (Refer to “ Com-
mon rail - Remove (10.218) and Common rail - Install (10.218)”)
NOTE: Do not replace the fuel pressure sensor separately. If a problem is found, replace the common rail as-
sembly.
Inspect to see if there is clogging with the fuel system between the fuel tank and the fuel supply pump.

6. Inspect the fuel hose between the fuel tank and the fuel supply pump for a cut and crack.
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NOTE:
• The fuel hose between the fuel tank and the fuel supply pump becomes negative pressure state when the engine
is running.
• When the fuel hose is not connected securely, the air can enter.
• When the engine speed or the engine load increases while the air has intruded in the fuel system, fluctuation in
the common rail pressure is caused, and diagnostic trouble code P1093 may be detected.

8. Operate the priming pump until the handle becomes heavy.
NOTE: When a leak exists in the fuel system between the priming pump and the fuel supply pump, the pressing
weight of the priming pump does not become heavy.
Start the engine.
Inspect the high-pressure side of the fuel system and check for fuel leak between the fuel supply pump and
common rail.
NOTE:
• The fuel may leak to the bottom section of the cylinder head cover from the high pressure hose inlet.
• The engine oil level increases when the fuel leaks to the bottom portion of the cylinder head cover.
• Inspect for fuel leaks into the engine oil.
A. If fuel leak if found, fix the problem.

NOTE:
• Clean the pressure gauge and connection hose before connecting to the fuel pipe.
• The fuel supply pump may be damaged due to foreign matter that has entered in the connection hose.
Connect the pressure gauge between the fuel filter and the removed fuel hose.
NOTE: Confirm that the fuel system is connected securely.
Remove the air using the priming pump, and crank the engine for 5 s or shorter.
NOTE: Repeat this until the engine starts.
Leave the engine idling for 1 min or longer.
Check if the pressure gauge shows a negative pressure value at or above -17.0 kPa (-2.5 psi) during inspection.
NOTE: Fuel clogging is checked with the negative pressure amount in the fuel system.
If the negative pressure is more than or equal to -17.0 kPa (-2.5 psi), inspect to see if there is damage or twisting
with the fuel system between the fuel supply pump and the fuel tank.

10. Inspect the fuel tank bent hose.
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A. If a problem is found, repair the bent hose.

11. Check to see if there is any foreign matter in the fuel tank or any foreign matter which can cause fuel clogging.
A. If a problem is found, repair it.

12. Replace the fuel filter element. (Refer to “ Fuel filters - Remove (10.206) and Fuel filters - Install (10.206)”)
If the negative pressure is less than or equal to -17.0 kPa (-2.5 psi), pinch the fuel hose at a position as close as
possible to the fuel tank, so that the fuel does not flow.
Start the engine and increase the engine speed up to the maximum engine speed.
Check the pressure gauge.
NOTE:
• If the pressure gauge is likely to indicate a value exceeding -27 kPa (-4 psi) value during inspection, release
• Air mixture is checked with the negative pressure amount while the fuel flow is being blocked.
If the negative pressure -27 kPa (-4 psi) cannot be generated, inspect to see if there is a cut or crack with the
fuel hose.

A. If a problem is found, replace the clamp with an appropriate one.

Inspect the suction control valve harness connector CN.E13 for a poor connection.



17. If the suction control valve harness connector CN.E13 and the ECM harness connector CN.D4 are normal and
there is no high resistance in each circuit, replace the fuel supply pump and the fuel filter element. (Refer to “
High pressure pump - Remove (10.218) and High pressure pump - Install (10.218)”) and (Refer to “ Fuel
filters - Remove (10.206) and Fuel filters - Install (10.206)”)
NOTE: When replacing the fuel supply pump, it is required to also replace the fuel filter element at the same
time.
If the negative pressure is normal, turn OFF the ignition switch.
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Restore the fuel system.
Start the engine.
Perform the injector stop test with the trouble diagnosis scan tool.
Check to see if any injector does not change the engine speed when OFF is instructed.
If any injector does not change the engine speed when OFF is instructed, replace the relevant injector. (Refer to
“ Fuel injectors - Remove (10.218) and Fuel injectors - Install (10.218)”)
When the injector has been replaced, set the injector ID Code on the ECM.
If the engine speed changes when OFF is instructed to all injectors, replace the pressure limiter valve. (Refer to
“ Common rail - Remove (10.218) and Common rail - Install (10.218)”)
NOTE:
• The pressure limiter valve may be fixed open, or the operation pressure may decrease.
• Do not replace the pressure limiter valve separately. If a problem is found, replace the common rail assembly.
NOTE:
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P1097-Compressor outlet temperature sensor circuit high

Solution:
Disconnect the harness connector P275 from the boost temperature sensor.
Observe the boost temperature sensor display on the trouble diagnosis scan tool.
A. If the reading is more than or equal to the 4.5 V, replace the boost temperature sensor. (Refer to “ Intake air
pressure and temperature sensor - Remove (55.014) and Intake air pressure and temperature sensor -
Install (55.014)”)

3. Inspect the signal circuit between the ECM and boost temperature sensor signal circuit for a short to GND.

A. If a problem is found, the harness connector CN.D4.
5. Set the Injector ID Code, fuel delivery rate, and engine No. for the ECM.
NOTE:
14 (55.100)
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P1098-Compressor outlet temperature sensor circuit high

Solution:
Disconnect the harness connector P275 from the boost temperature sensor.
Measure the voltage between the boost temperature sensor signal circuit and a known good GND.
If the reading is more than or equal to 5.5 V inspect the signal circuit between the ECM and the boost temperature
sensor for a short to the battery or a short to the ignition power supply.

3. Connect a fused jumper wire between the boost temperature sensor signal circuit and GND circuit.
If the reading is less than or equal to 0.1 V, inspect the signal circuit between the ECM and the boost temperature
sensor for a short to the 5 V power supply circuit.

4. Inspect for poor connections at the boost temperature sensor harness connector P275.
B. If the harness connector P275 is normal, replace the boost temperature sensor, (Refer to “ Intake air pressure
and temperature sensor - Remove (55.014) and Intake air pressure and temperature sensor - Install
(55.014)”)
5. Connect a fused jumper wire between the boost temperature sensor signal circuit and a known good GND.
If the reading is less than or equal to 0.1 V, inspect the GND circuit between the ECM and the boost temperature
sensor for an open circuit or high resistance.
NOTE:
• The boost temperature sensor shares the GND circuit with other sensors

6. Inspect the signal circuit between the ECM and the boost temperature sensor for an open circuit or high resistance.

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NOTE:
14 (55.100)
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P1236-Charge air cooler performance failure

Solution:

Inspect the intercooler. (Refer to “ Aftercooler - Inspect (10.310)”)
A. If a problem is found, repair or replace the intercooler.

3. Disconnect the harness connector CN.E10 from charge air cooler temperature sensor 1.
Inspect for poor connections at the charge air cooler temperature sensor 1 harness connector CN.E10.

4. Disconnect the harness connector P275 from the boost temperature sensor.
Inspect for poor connections at the boost temperature sensor harness connector P275.


6. Inspect the circuit between the ECM and the charge air cooler temperature sensor 1 for high resistance.

7. Inspect the circuit between the ECM and the boost temperature sensor for high resistance.

8. Inspect the charge air cooler temperature sensor 1. (Refer to “ Boost temperature sensor - Inspect (55.014)”)
A. If a problem is found, replace the charge air cooler temperature sensor 1. (Refer to “ Boost temperature
sensor - Remove (55.014) and Boost temperature sensor - Install (55.014)”)

9. Inspect the boost temperature sensor. (Refer to “ Intake air pressure and temperature sensor - Inspect
(55.014)”)
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A. If a problem is found, replace the boost pressure sensor. (Refer to “ Intake air pressure and temperature
sensor - Remove (55.014) and Intake air pressure and temperature sensor - Install (55.014)”)
NOTE:
14 (55.100)
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P1261-Injector positive voltage control circuit group 1

Solution:
Install (55.015)”)
Set the Injector ID Code, fuel delivery rate, and engine No. for the ECM.
NOTE:
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P1262-Injector positive voltage control circuit group 2

Solution:
Install (55.015)”)
NOTE:
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P1404-Exhaust gas recirculation 1 closed position performance

Solution:

2. Remove the EGR valve assembly from the engine. (Refer to “ Exhaust Gas Recirculation (EGR) valve - Remove
(10.501)”)
Inspect the EGR valve.
There should be nothing to limit flow inside the EGR valve.
• Make sure that there is no excessive accumulates inside the EGR valve.
• Make sure that there is no bending with the valve shaft or valve itself inside the EGR valve.
A. If a problem is found,repair or replace the EGR valve. (Refer to “ Exhaust Gas Recirculation (EGR) valve -
Remove (10.501) and Exhaust Gas Recirculation (EGR) valve - Install (10.501)”)

Inspect the EGR valve harness connector CN.E03 for a poor connection.

A. If a problem is found, the harness connector CN.D4.

5. Inspect the EGR valve circuit between the ECM and the EGR valve for an open circuit and high resistance.
A. If a problem is found, repair the EGR valve circuit.

6. Inspect the motor circuit between the ECM and EGR valve.
• Make sure that there is no short to other circuits.
• Make sure that there is no short to EGR position sensor circuit.
A. If a problem is found, repair the motor circuit.
B. If the circuit is normal, replace the EGR valve. (Refer to “ Exhaust Gas Recirculation (EGR) valve - Remove
(10.501) and Exhaust Gas Recirculation (EGR) valve - Install (10.501)”)
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NOTE:
14 (55.100)
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P1606-SW-IC 1 internal failure

Solution:
Install (55.015)”)
NOTE:
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P160B-AD-IC failure error

Solution:
Install (55.015)”)
NOTE:
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P160C-AD-IC2 failure error

Solution:
Install (55.015)”)
NOTE:
should not be set.
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P204F-SCR system error (No inducement)

Solution:
1. Observe the DCU diagnostic trouble code information with a trouble diagnosis scan tool.
Diagnose the applicable diagnostic trouble code if a diagnostic trouble code is set.
2. Turn OFF the ignition switch for at least 30 s or more.
NOTE:
should not be set.
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P207F-Urea fluid concentration too low

Solution:
NOTE:
should not be set.
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P20C9-SCR system error

Solution:
1. Observe the DTU diagnostic trouble code information with a trouble diagnosis scan tool.
NOTE:
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P1621-Control Module Long Term Memory Performance

Solution:
1. Confirm that the connecting sections of all tools are securely connected.
Confirm that the programming device is operating normally.
Turn OFF the ignition switch, and wait for 30 s.
NOTE:
should not be set.
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P1669-DPD Lamp control circuit

Solution:
1. Verify that the monitor panel operates properly.
Inspect the fuse.
A. If a problem is found, replace the fuse.

NOTE: If the fuse is blown again, repair the cause of fuse blowout.
Check that the DPD lamp is turned OFF.
A. If the DPD lamp is not turned OFF, repair the short to GND in the DPD lamp control circuit between the ECM
and the monitor panel.

Remove the fuse.
Measure the voltage between the ECM harness connector CN.D3 DPD lamp control circuit and the GND.
A. If the reading is more than or equal to the 1.0 V, repair the short to the battery or the short to the ignition power
supply circuit in the DPD lamp control circuit between the ECM and the monitor panel.

Install the fuse.
Connect a fused jumper wire between the DPD lamp control circuit of the ECM harness connector CN.D3 and
the GND.
A. If the DPD lamp illuminates, inspect for poor connections at the ECM harness connector CN.D3.
B. If a problem is found, repair the harness connector CN.D3.
C. If the harness connector CN.D3 is normal, replace the ECM. (Refer to “ Engine Control Unit (ECU) - Remove
A. If the DPD lamp is not illuminated, remove the DPD lamp valve from the monitor panel.

6. Inspect the DPD lamp bulb.
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A. If a problem is found, replace the bulb.

7. Inspect the ignition power supply circuit between the fuse and the monitor panel for an open circuit or high resis-
tance.
A. If a problem is found, repair the ignition power supply circuit.

8. Inspect the DPD lamp control circuit between the ECM and the monitor panel for an open circuit or high resis-
tance.

9. Inspect for poor connections at the monitor panel harness connector CN.A5.
A. If a problem is found, repair the harness connector CN.A5.
B. If the harness connector CN.A5 is normal, replace the monitor panel.

3. Turn ON the ignition switch and wait for 40 s.
05 (55.100)
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P2122-Pedal position sensor 1 circuit low input

Solution:
Disconnect the harness connector CN.B2 from the accelerator position sensor.
Measure the voltage between the 5 V power supply circuit and GND of the accelerator position sensor.
the 5 V power supply circuit between the ECM and the accelerator position sensor.

3. Connect the test cable with fuse between the 5 V power supply circuit and sensor 1 signal circuit of the accelerator
position sensor.
Observe the accelerator pedal sensor 1 display on the trouble diagnosis scan tool.
A. If the reading is more than or equal to the 4.5 V, inspect to see if there is a poor connection with the accelerator
position sensor harness connector CN.B2.
B. If a problem is found, repair the harness connector CN.B2.
C. If the harness connector CN.B2 is normal, replace the accelerator position sensor.

4. If the reading is less than or equal to the 4.5 V, inspect the sensor 1 signal circuit between the ECM and accelerator
position sensor.
Make sure that there should be no open circuit or high resistance.
Make sure that there should be no short to GND.
A. If a problem is found, repair the sensor 1 signal circuit.

5. Inspect the ECM harness connector CN.A1 for a poor connection.
B. If the harness connector CN.A1 is normal, replace the ECM. (Refer to “ Engine Control Unit (ECU) - Remove
3. Start the engine and fully depress and release the accelerator pedal while observing the accelerator pedal
sensor 1 display on the trouble diagnosis scan tool.
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4. Confirm that the trouble diagnosis scan tool does not show a value at or below 0.2 V while depressing and then
releasing the pedal.
11 (55.100)
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P2123-Pedal position sensor 1 circuit high input

Solution:
If the reading is more than or equal to the 0.1 V, inspect the sensor 1 signal circuit between the ECM and the
accelerator position sensor.

3. Connect the test light between the accelerator position sensor GND circuit and battery power supply.
A. If the test light comes on, inspect the accelerator position sensor harness connector CN.B2 for a poor connec-
tion.
D. If the test light does not come on, inspect to see if there is an open circuit or high resistance with the GND
circuit between the ECM and the accelerator position sensor.
E. If a problem is found, repair the GND circuit.
F. If there are no problems, proceed to Step 4

4. Confirm that the trouble diagnosis scan tool does not show a value at or above the specified value while de-
pressing and then releasing the pedal.
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11 (55.100)
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P2127-Pedal position sensor 2 circuit low input

Solution:
Measure the voltage between the 5 V power supply circuit and GND of the accelerator position sensor.
the 5 V power supply circuit between the ECM and the accelerator position sensor.

3. Connect the test cable with fuse between the 5 V power supply circuit and sensor 2 signal circuit of the accelerator
position sensor.
A. If the reading is more than or equal to the 4.5 V, inspect to see if there is a poor connection with the accelerator
position sensor harness connector CN.B2.

4. If the reading is less than or equal to the 4.5 V, inspect the sensor 2 signal circuit between the ECM and accelerator
position sensor.
Make sure that there is no open circuit or high resistance.
Make sure that there is no short to GND.

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11 (55.100)
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P2128-Pedal position sensor 2 circuit high input

Solution:
If the reading is more than or equal to 0.1 V, inspect the sensor 2 signal circuit between the ECM and the accel-
erator position sensor.

3. Connect the test light between the accelerator position sensor GND circuit and battery power supply.
A. If the test light comes on, inspect the accelerator position sensor harness connector CN.B2 for a poor connec-
tion.

4. If the test light does not come on, inspect to see if there is an open circuit or high resistance with the GND circuit
between the ECM and the accelerator position sensor.

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11 (55.100)
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P2138-Pedal position sensor 1 – 2 voltage correlation

Solution:

Inspect the accelerator position sensor harness connector CN.B2 for a poor connection.
A. If a problem is found, repair the harness connector CN.B2.

3. Disconnect the harness connector CN.A1 from the ECM.
Inspect the ECM harness connector CN.A1 for a poor connection.

4. Inspect to see if there is high resistance in the circuit between the ECM and accelerator position sensor.

5. Inspect to see if there is a short between circuits in the signal circuit between the ECM and the accelerator position
sensor.
B. If the circuit is normal, replace the accelerator position sensor.

Start the engine.
While checking for a diagnostic trouble code with the trouble diagnosis scan tool, fully depress and then release
the accelerator pedal.
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4. While checking the diagnostic trouble code information with the trouble diagnosis scan tool, fully depress and
then release the accelerator pedal.
11 (55.100)
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P2146-Fuel injector group 1 supply voltage circuit

Solution:
Disconnect the harness connector from the cylinder head injector harness intermediate connector CN.E20.
Measure the voltage between the solenoid control circuit and GND.
NOTE:
• Solenoid control circuit and GND of the No.1 cylinder injector.
A. If the reading is less than or equal to 12 V, inspect to see if there is a short circuit to the GND with the control
circuit between the ECM and injector harness intermediate connector CN.E20.
B. If a problem is found, repair the control circuit.

2. Inspect the charge voltage circuit between the ECM and the injector harness intermediate connector CN.E20.
NOTE:
• No short circuit to the battery or ignition power is present.
• No short circuit to GND is present.
A. If a problem is found, repair the charge voltage circuit.
B. If the charge voltage circuit between the ECM CN.D4 and the injector harness intermediate connector CN.E20
is normal, replace the ECM. (Refer to “ Engine Control Unit (ECU) - Remove (55.015) and Engine Control
Unit (ECU) - Install (55.015)”)
Inspect the injector harness intermediate connector CN.E20 for a poor connection.
A. If a problem is found, repair the injector harness intermediate connector CN.E20.


5. Inspect to see if there is an open circuit or high resistance with the charge voltage circuit between the ECM and
the injector harness intermediate connector CN.E20.

6. Remove the cylinder head cover.(Refer to “ Valve cover - Remove (10.101)”)
Inspect the injector harness tightening nut for looseness.
A. If the injector harness tightening nut is loose, tighten it.
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7. Inspect to see if any foreign matter is attached to the injector terminal.
A. If any foreign matter is attached to the injector terminal, remove it.

8. Inspect the injector harness intermediate harness connector CN.E20 for a poor connection.
A. If a problem is found, repair the intermediate harness connector CN.E20.

9. Check if insulation resistance of the No. 1 cylinder and No.4 cylinder injector is at or above the resistance 1.0 MΩ
A. If the reading is less than or equal to 1.0 MΩ, replace the relevant injector. (“ Fuel injectors - Remove
(10.218) and Fuel injectors - Install (10.218)”)
10. Set the injector ID Code on the ECM.
If the reading is more than or equal to 1.0 MΩ, repair or replace the injector harness.
NOTE:
14 (55.100)
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P2149-Fuel injector group 2 supply voltage circuit

Solution:
Disconnect the harness connector from the cylinder head injector harness intermediate connector CN.E21.
Measure the voltage between the solenoid control circuit and GND.
NOTE:
A. If the reading is less than or equal to 12 V, inspect to see if there is a short circuit to the GND with the control
circuit between the ECM and injector harness intermediate connector CN.E21.
B. If a problem is found, repair the control circuit.

2. Inspect the charge voltage circuit between the ECM and the injector harness intermediate connector CN.E21.
NOTE:
• Make sure that there is no short circuit to the battery or ignition power
• Make sure that there is no short circuit to GND
B. If the charge voltage circuit between the ECM and the injector harness intermediate connector CN.E21 is
normal, replace the ECM. (Refer to “ Engine Control Unit (ECU) - Remove (55.015) and Engine Control
Unit (ECU) - Install (55.015)”)

3. Inspect the injector harness intermediate connector CN.E21 for a poor connection.
A. If a problem is found, repair the injector harness intermediate connector CN.E21.


5. Inspect to see if there is an open circuit or high resistance with the charge voltage circuit between the ECM and
the injector harness intermediate connector CN.E21.

Inspect the injector harness tightening nut for looseness.
A. If the injector harness tightening nut is loose, tighten it.
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7. Inspect to see if any foreign matter is attached to the injector terminal.
A. If any foreign matter is attached to the injector terminal, remove it.

8. Inspect the injector harness intermediate harness connector CN.E21 for a poor connection.
A. If a problem is found, repair the intermediate harness connector CN.E21.

9. Check if insulation resistance of the No.2 cylinder and No.3 cylinder injector is more than or equal to 1.0 MΩ.
A. If the reading is less than or equal to 1.0 MΩ, replace the relevant injector. (“ Fuel injectors - Remove
(10.218) and Fuel injectors - Install (10.218)”)
10. Set the injector ID Code on the ECM.
If the reading is more than or equal to 1.0 MΩ, repair or replace the injector harness.
NOTE:
14 (55.100)
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P2228-Barometric pressure circuit low

Solution:
Install (55.015)”)
NOTE:
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P2229-Barometric pressure circuit high

Solution:
Install (55.015)”)
NOTE:
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P2457-Exhaust gas recirculation (EGR) cooling system performance

Solution:
Diagnostic trouble code P040B

Diagnostic trouble code P040C
Diagnostic trouble code P040D
Inspect the EGR cooler. (Refer to “ Exhaust Gas Recirculation (EGR) valve - Inspect (10.501)”)
Inspect the engine coolant system.
• Engine coolant level
• Engine coolant leakage
A. If a problem is found, repair the applicable area.

3. Inspect the EGR system.
• Exhaust gas leakage
• Engine coolant leakage into the EGR gas passage
• Breakage or damage of the EGR cooler
• Misdetection or delayed response of EGR gas temperature sensor 1 or 2
A. If a problem is found, repair the applicable area.

4. Disconnect the harness connector CN.E10-B from EGR gas temperature sensor 1.
Inspect for poor connections at the EGR gas temperature sensor 1 harness connector CN.E10-B.
A. If a problem is found, repair the harness connector CN.E10-B.

5. Disconnect the harness connector CN.E10-A from EGR gas temperature sensor 2.
Inspect for poor connections at the EGR gas temperature sensor 2 harness connector CN.E10-A.
A. If a problem is found, repair the harness connector CN.E10-A.

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7. Inspect the circuit between the ECM and EGR gas temperature sensor 1 for high resistance.

8. Inspect the circuit between the ECM and EGR gas temperature sensor 2 for high resistance.

9. Replace the EGR cooler. (Refer to “ Exhaust Gas Recirculation (EGR) valve - Remove (10.501) and Exhaust
Gas Recirculation (EGR) valve - Install (10.501)”)
NOTE:
14 (55.100)
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P2BA7-Urea fluid quantity too low

Solution:
1. Check the remaining amount of urea fluid in the urea fluid tank.
If the urea fluid is low, add the specified urea fluid.
Observe the DCU diagnostic trouble code information with a trouble diagnosis scan tool.
NOTE:
should not be set.
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P2458-Purge time out error

Solution:

2. Inspect the exhaust system.
• Make sure that there is no absence or damage of the exhaust pipe gasket.
• Make sure that there is no exhaust gas leak from the exhaust system.
• The exhaust system should not be modified.
• Make sure that there is no incorrect detection or slow response from the exhaust gas temperature sensor.
A. If a problem is found, repair or replace the exhaust system.

Use the trouble diagnosis scan tool to confirm that a diagnostic trouble code has not been detected.
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P2BAA-SCR system error (Inducement, no purge)

Solution:
NOTE:
should not be set.
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P3093-Fuel rail pressure too low

Solution:

2. Inspect the fuel quality.
NOTE: Check whether the fuel is being used in accordance with the outside air temperature when the weather
is cold.
A. If the fuel quality is inadequate, replace it.

Wait for 2 min to reduce the fuel pressure from the common rail (fuel rail).
Use the trouble diagnosis scan tool to check if the fuel rail pressure sensor display is within 0.9 - 1.0 V.
A. If the fuel rail pressure sensor display is outside 0.9 - 1.0 V, inspect for poor connections at the FRP sensor
harness connector CN.E5.



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B. If the harness connector CN.E5 and each circuit are normal, replace the FRP sensor. (Refer to “ Common
rail - Remove (10.218) and Common rail - Install (10.218)”)

NOTE: Do not replace the fuel pressure sensor separately. If a problem is found, replace the common rail (fuel
rail) assembly.
7. Inspect the fuel system between the fuel tank and the fuel supply pump for clogging.

8. Inspect the fuel hoses between the fuel tank and the fuel supply pump for cuts or cracks.

NOTE:
• A slight vacuum is applied to the fuel hoses between the fuel tank and the fuel supply pump when the engine
is running.
• If the fuel hose is not connected securely, air can get inside.
• If the engine speed or the engine load increases when air has entered the fuel system, fluctuation in the common
rail (fuel rail) pressure occurs, and diagnostic trouble code P3093 may be set.

10. Operate the priming pump until the force required for pressing increases.
NOTE: When a leakage exists in the fuel system between the priming pump and the fuel supply pump, the
pressing weight of the priming pump does not become heavy.
Start the engine.
Inspect the high-pressure side of the fuel system and check for a fuel leakage between the fuel supply pump and
the common rail (fuel rail).
NOTE:
• The fuel may leak under the cylinder head cover from the inlet of the high pressure hose.
• If the fuel leaks under the cylinder head cover, the engine oil level will increase.
• Inspect for fuel leakage into the engine oil.
A. If fuel leak is found, repair it.

NOTE:
• Clean the pressure gauge and connection hose before connecting to the fuel piping.
• The fuel supply pump may be damaged due to the foreign material that has intruded into the connection hose.
Connect a pressure gauge between the fuel filter and the removed fuel hose.
NOTE: Check whether the fuel system is securely connected.
Bleed the air with the priming pump, and crank the engine for 5 s.
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NOTE: Repeat the process until the engine starts.
Allow the engine to idle for at least 1 min.
Check if the vacuum reading displayed is 17 kPa (2 psi) or more when inspecting the pressure gauge.
NOTE: Fuel clogging is checked with the vacuum amount in the fuel system.
If the vacuum is more than or equal to 17 kPa (2 psi), inspect the fuel system between the fuel supply pump and
the fuel tank for damage or twisting.

12. Inspect the fuel tank vent hose.
A. If a problem is found, repair the vent hose.

13. Check for foreign material in the fuel tank or for foreign material that may clog the fuel.

14. Check for foreign material in the fuel tank or for foreign material that may clog the fuel.

15. Replace the fuel filter element. (Refer to “ Fuel filters - Remove (10.206) and Fuel filters - Install (10.206)”)
If the vacuum is less than or equal to the specified value, pinch the fuel hose at a position as close as possible
to the fuel tank, so that the fuel does not flow.
Start the engine and increase the engine speed up to the maximum engine speed.
Check the pressure gauge.
NOTE:
• When the pressure gauge is likely to indicate a value exceeding the specified value during inspection, release
• Air mixture is checked with the vacuum amount while the fuel flow is being blocked.
A. If the specified vacuum cannot be maintained, inspect the fuel hoses for cuts or cracks.
B. If a problem is found, replace the fuel hose.

A. If a problem is found, replace with an appropriate clamp.

Inspect for poor connections at the FRP regulator harness connector CN.D17-1.
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B. If the FRP regulator harness connector CN.D17-1 and the ECM harness connector CN.D4 are normal and
there is no high resistance in each circuit, replace the fuel supply pump (Refer to “ High pressure pump -
Remove (10.218) and High pressure pump - Install (10.218)”) and the fuel filter element. (Refer to “ Fuel
filters - Remove (10.206) and Fuel filters - Install (10.206)”)

NOTE: When replacing the fuel supply pump, the fuel filter element must be replaced at the same time.
21. If the vacuum is normal, turn OFF the ignition switch.
Restore the fuel system.
Start the engine.
Perform the injector stop test with a trouble diagnosis scan tool.
Check for any injectors that do not change the engine speed when commanded OFF.
A. If there are any injectors that do no change the engine speed when commanded OFF, replace the applicable
injectors. (Refer to “ Fuel injectors - Remove (10.218) and Fuel injectors - Install (10.218)”)
B. If an injector has been replaced, set the Injector ID Code on the ECM.
C. If the engine speed changes for all injectors when the OFF command is given, replace the pressure limiter
valve. (Refer to “ Common rail - Remove (10.218) and Common rail - Install (10.218)”)
NOTE:
• The pressure limiter valve may be fixed open, or the operation pressure may decrease.
• Do not replace the pressure limiter with a separate unit. If a problem is found, replace the common rail (fuel
rail) assembly.
NOTE:
14 (55.100)
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U0001-CAN-Bus Malfunction
Solution:
Measure the resistance between the terminals of the termination resistor harness connector CN.D17-4.
NOTE:
• Measure from behind while the harness connector is connected.
• Verify that the parallel resistance of the 120 Ω resistor in the termination resistor and that of the 120 Ω resistor
in the ECM are both 60 Ω.
Disconnect the harness connector CN.D17-4 from the termination resistor if the resistance is outside the range of
50 - 70 Ω
A. If the resistance is outside the range of 110 - 130 Ω, replace the termination resistor.

2. Connect the harness connector CN.D17-4 to the termination resistor.
Measure the resistance between the terminals of the termination resistor harness connector.
NOTE: Measure from behind while the harness connector is connected.
Replace the DCU if the resistance is within the range of 50 - 70 Ω.
Connect the harness connector CN.D1-2 to the DCU.
Disconnect the harness connector CN.E1 from the turbo control unit.
A. If the resistance is within the range of 50 - 70 Ω, replace the turbo control unit.

3. Connect the harness connector CN.E1 to the turbo control unit.
A. If the resistance is within the range of 110 - 130 Ω, replace the ECM. (Refer to “ Engine Control Unit (ECU)
- Remove (55.015) and Engine Control Unit (ECU) - Install (55.015)”)
Set the engine No. for the ECM.
Disconnect the harness connector CN.D1-2 CN.E1 CN.D3 from the DCU, turbo control unit, and ECM.
Inspect the CAN-Low circuit and the CAN-High circuit between each control unit.
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A. If the CAN circuit is normal, turn OFF the ignition switch.

5. Connect the harness connector CN.D1-2 to the DCU.
Measure the voltage between the CAN-High terminal of the termination resistor harness connector and the GND.
Measure the voltage between the CAN-Low terminal of the termination resistor harness connector and GND.
A. If the voltage is outside the range of 1.5 - 3.5 V, replace the DCU.

Connect the harness connector CN.E1 to the turbo control unit.
A. If the voltage is outside the range of 1.5 - 3.5 V, replace the turbo control unit.

A. If the voltage is within the range of 1.5 - 3.5 V, replace the termination resistor.
B. If the voltage is outside the range of 1.5 - 3.5 V, replace the ECM. (Refer to “ Engine Control Unit (ECU) -

NOTE:
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U0073-CAN-Bus Malfunction
Solution:
1. Check and diagnose the below fault codes before you proceed with the diagnostics code U0073.
NOTE:
• Make a measurement from the back with the harness connector connected.
• Confirm that the parallel resistance of the 120 Ω resistor in the termination resistor and that of the 120 Ω resistor
in the ECM are both 60 Ω.
Disconnect the harness connector from termination resistor if the resistance value is outside the 50 - 70 Ω
A. If the resistance value is outside the 110 - 130 Ω, replace the termination resistor.

3. Connect the harness connector to the termination resistor.
Disconnect the harness connector CN.A4 from the control unit of the machine.
NOTE: Make a measurement from the back with the harness connector connected.
A. If the resistance value is within the 50 - 70 Ω, replace the control unit of the machine.

NOTE: Make a measurement from the back with the harness connector connected.
If the resistance value is within the range of 110 - 130 Ω, replace the ECM. (Refer to “ Engine Control Unit (ECU)
- Remove (55.015) and Engine Control Unit (ECU) - Install (55.015)”)
Set the injector ID Code on the ECM.
Set the engine No. for the ECM.
Disconnect the harness connector CN.A4 from the control unit of the machine or CN.D3 ECM.
Inspect the CAN-Low circuit and the CAN-High circuit between each control unit.
A. If the CAN circuit is normal, turn OFF the ignition switch.
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5. Connect the harness connector CN.D3 to the ECM.
Measure the voltage between the CAN-Low terminal of the termination resistor harness connector and the GND.
If the voltage is outside the 1.5 - 3.5 V, replace the ECM. (Refer to “ Engine Control Unit (ECU) - Remove (55.015)
and Engine Control Unit (ECU) - Install (55.015)”)
Connect the harness connector CN.A4 to the control unit of the machine.
Measure the voltage between the CAN-Low terminal of the termination resistor harness connector and the GND.
A. If the voltage is outside the 1.5 - 3.5 V, replace the control unit of the machine.
B. If the voltage is within the 1.5 - 3.5 V, replace the termination resistor.
NOTE:
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U0101-Lost communication with TCM

Solution:
1. Inspect the CAN-Low circuit and CAN-High circuit between the ECM and the control unit of the machine.
B. If the CAN circuit is normal, connect all harnesses and proceed to Step 2
Perform a test-run under the conditions for running the diagnostic trouble code.
NOTE:
Check the diagnostic trouble code.
A. If a diagnostic trouble code has been detected, replace the control unit of the machine.
B. If a diagnostic trouble code has not been detected, proceed to Step 3

3. Connect all harnesses.
Perform a test-run under the conditions for running the diagnostic trouble code.
NOTE:
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NOTE:
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U010E-Lost communications with dosing control module

Solution:
Measure the voltage between the DCU harness connector CN.D1-2 CAN High circuit and a known good GND.
A. If the reading is outside 1.5 V to 3.5 V, inspect the CAN High circuit between the DCU and the ECM for an
B. If a problem is found, repair the CAN high circuit.

2. Measure the voltage between the DCU harness connector CN.D1-2 CAN Low circuit and a known good GND.
A. If the reading is outside 1.5 V to 3.5 V, inspect the CAN Low circuit between the DCU and the ECM for an open
B. If a problem is found, repair the CAN low circuit.

NOTE:
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U0110-Lost communication with VNT system

Solution:

Diagnostic trouble code U0001
Remove the harness connector CN.E1 from the turbo control unit.
Measure the voltage between the CAN-High circuit and GND of the turbo control unit harness connector CN.E1.
A. If the reading is outside 1.5 V to 3.5 V, Inspect to see if there is an open circuit or high resistance with the
CAN-High circuit between the turbo control unit and the ECM.
B. If a problem is found, repair the CAN-high circuit.

3. Inspect to see if there is an open circuit or high resistance with the CAN-Low circuit between the turbo control unit
and the ECM.
A. If a problem is found, repair the CAN-Low circuit.

4. Inspect the turbo control unit harness connector CN.E1 for a poor connection.
B. If there are no problems, Replace the turbo control unit.

NOTE:
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U0411-Lost CAN communications with VNT control module

Solution:

Diagnostic trouble code U0001
2. Inspect the CAN circuit between the turbo control unit and the ECM.

3. Inspect the turbo control unit harness connector CN.E1 for a poor connection.

Start the engine.
Perform a test-run.
A. If a diagnostic trouble code is set, replace the turbo control unit.

Start the engine.
Perform a test-run.
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NOTE:
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U2106-Lost CAN communications with wheel loader transmission

control system
Solution:
Inspect the CAN circuit between the machine control unit and the ECM for a short circuit, an open circuit, or high
resistance.

2. Inspect for poor connections at the harness connector CN.A4.


NOTE:
06 (55.100)
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Index
FAULT CODES - DTC

0002-CAN Bus off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
0100-Lost communication with ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
029D-Lost communication with NOx sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
0607-Control module performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
060B-Internal control module A/D processing performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
062F-Control module EEPROM error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
0641-Sensor reference voltage 1 circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
0658-Actuator supply voltage circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
0659-Actuator supply voltage circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1462-Urea fluid quality sensor timeout error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1464-Main relay performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1468-DCU overtemperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1491-Urea fluid overpressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1493-DCU driver overtemperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
149C-Urea fluid pressure reduction malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
149D-Urea fluid tank overtemperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
203B-Urea Fluid Tank Level Sensor Stuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
203C-Urea fluid tank level sensor low voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
203D-Urea fluid tank level sensor high voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2048-Urea fluid injector circuit low voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2049-Urea fluid injector circuit high voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
204B-Urea fluid pressure sensor performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
204C-Urea fluid pressure sensor circuit low voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
204D-Urea fluid pressure sensor circuit high voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
205B-Urea fluid tank temperature sensor performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
205C-Urea fluid tank temperature sensor low voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
205D-Urea fluid tank temperature sensor high voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
206A-Urea fluid quality sensor circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
206B-Urea sensor over temperature condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
206C-Urea fluid quality sensor circuit low voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
206D-Urea fluid quality sensor circuit high voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
207F-Urea fluid concentration too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
208A-Urea fluid pump control circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
208B-Urea fluid pump performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
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208C-Urea fluid pump control circuit low voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
208D-Urea fluid pump control circuit high voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
208E-Urea fluid injector stuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
20A0-Urea fluid reverting valve circuit open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
20A2-Urea fluid reverting valve circuit low voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
20A3-Urea fluid reverting valve circuit high voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
20AC-Urea fluid pump temperature sensor performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
20AD-Urea fluid pump module temperature sensor performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
20B1-Urea fluid tank heater coolant control valve circuit open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
20B3-Urea fluid tank heater coolant control valve circuit low voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
20B4-Urea fluid tank heater coolant control valve circuit high voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
20E8-Urea fluid pressure underpressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
20E9-Urea fluid overpressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
20EA-Urea fluid pressure reduction malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
20FE-Urea fluid pressure build-up error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2201-Upstream NOx sensor performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
2206-NOx sensor heater control circuit low voltage sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
2207-NOx sensor heater control circuit high voltage sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
242B-Exhaust gas temperature (EGT) sensor 3 performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
242C-Exhaust gas temperature (EGT) sensor 3 circuit low voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
242D-Exhaust gas temperature (EGT) sensor 3 circuit high voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
7000-P1 Pressure sensor signal abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
7001-P2 Pressure sensor signal abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
7002-N1 Pressure sensor signal abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
7003-N2 Pressure sensor signal abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
7004-Bottom pressure sensor signal abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
7007-Pressure sensor arm cylinder rod abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
7021-Swing pressure sensor signal abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
7023-Arm-in pressure sensor signal abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
7040-Fuel level sensor signal abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
7041-Oil temperature sensor signal abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
7065-Boom-up pilot pressure sensor signal abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
7067-Bucket-close pilot pressure sensor signal abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
7068-Pressure sensor boom-down pilot abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
7069-Pressure sensor arm-out pilot abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
7070-Pressure sensor bucket-open pilot abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
7071-Pressure sensor travel right pilot abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
7072-Pressure sensor travel left pilot abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
7073-Pressure sensor travel 1 pedal abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
7074-Pressure sensor 1st option pilot (common/front pedal) abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
7075-Pressure sensor arm cylinder bottom abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
7078-Pressure sensor 1st option pilot (rear pedal) abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
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7200-Swing brake solenoid signal abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
7201-Travel high-speed solenoid signal abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
7202-Pressure boost solenoid signal abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
7203-Travel alarm buzzer signal abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
7206-Option line switchover solenoid signal abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
7207-Free swing solenoid signal abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
7213-Quick coupler buzzer abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
7214-Quick coupler solenoid abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
7247-Boom-down proportional valve signal abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
7249-Bucket-Close Pilot Proportional Valve Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
7250-Option relief pressure proportional valve signal abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
7265-Arm 1 Semi-Parallel Proportional Valve Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
7266-Arm 2 Semi-Parallel Proportional Valve Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
7267-Arm 1 Regeneration Release Proportional Valve Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
7270-Tilting 1 Proportional Valve Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
7271-Tilting 2 Proportional Valve Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
7273-Straight Travel Proportional Valve Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
7400-Abnormally high coolant temperature [105◦ C (221.0◦F) or higher] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
7401-Abnormally high coolant temperature [110◦ C (230.0◦F) or higher] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
7404-Abnormally high oil temperature [95 °C ( 203.0 °F ) or higher] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
7405-Abnormally high boost temperature [80◦ C (176.0◦F) or higher] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
7406-Abnormally high boost temperature [90◦ C (194.0◦F) or higher] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
7420-Abnormally low alternator voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
7421-Coolant level reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
7422-Abnormally low engine oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
7423-Air cleaner clogged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
7424-Return filter clogging (breaker specifications) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
7426-Fuel filter clogging 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
7427-Fuel filter clogging 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
7428-Inducement (Remaining Urea Level Low) - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
7429-Inducement (Remaining Urea Level Low) - Early . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
7430-Inducement (Remaining Urea Level Low) - Final . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
7602-ECM communication abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
7605-ECM mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
7606-EEPROM data abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
7608-Camera abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
7612-Air-conditioner communication abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
7613-Monitor communication CAN abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
7615-Sub-Controller Communication Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
7618-DCU Communication Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
P0016-Crankshaft position - Camshaft position correlation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
P0045-Turbocharger Boost Control Solenoid Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
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P0087-Fuel rail system pressure low pressure error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
P0089-Fuel pressure regulator performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
P0091-Fuel rail regulator control system low input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
P0092-Fuel rail regulator control system high input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
P0097-Intake air temperature (IAT) sensor 2 circuit low voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
P0098-Intake air temperature (IAT) sensor 2 circuit high voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
P0102-Mass air flow circuit low input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
P0103-Mass air flow circuit high input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
P0112-Intake temperature sensor signal - Shorted to low source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
P0113-Intake temperature sensor signal - Shorted to high source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
P0117-Coolant temperature sensor signal - Shorted to low source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
P0118-Coolant temperature sensor signal - Shorted to high source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
P0122-Throttle position sensor, low input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
P0123-Throttle position sensor, high input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
P0182-Fuel temperature sensor - Shorted to low source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
P0183-Fuel temperature sensor - Shorted to high source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
P0192-Fuel rail pressure sensor, low input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
P0193-Fuel rail pressure sensor, high input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
P0201-Injector circuit - Cylinder 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
P0217-Engine coolant over temperature condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
P0219-Engine overspeed condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
P0234-Turbocharger overboost condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
P0237-Turbocharger boost sensor circuit low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
P0238-Turbocharger boost sensor circuit high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
P0335-Crankshaft position sensor circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
P0336-Crankshaft position sensor circuit range/performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
P0340-Camshaft position sensor circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
P0380-Glow plug circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
P0401-EGR flow insufficient detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
P0404-EGR control circuit range/performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
P0409-Exhaust gas recirculation 1 sensor circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
P041C-EGR cooler outlet 1 temperature sensor circuit low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
P041D-EGR cooler outlet 1 temperature sensor circuit high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
P0427-Catalyst temperature sensor circuit low sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
P0428-Catalyst temperature sensor circuit high sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
P042C-Catalyst temperature sensor circuit low sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
P042D-Catalyst temperature sensor circuit high sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
P0522-Oil pressure sensor circuit low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
P0523-Oil pressure sensor circuit high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
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P0545-EGR cooler inlet 1 temperature sensor circuit low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
P0546-EGR cooler inlet 1 temperature sensor circuit high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
P0560-System voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
P0563-System voltage high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
P0601-ECU memory fault - Bad Intelligent device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
P0602-Control module programming error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
P0604-Internal control module random access memory (RAM) error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
P0606-Internal control module CPU error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
P060A-Internal control module CPU IC error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
P060C-Internal control module A/D processing performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
P0615-Starter relay circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
P0638-Throttle actuator control range/performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
P0685-ECM power relay control circuit open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
P0687-ECM power relay control circuit high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
P06A6-Sensor reference voltage 1 circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
P06AF-Torque management system - Forced engine shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
P06D5-Sensor reference voltage 5 circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
P1076-Charge air cooler (CAC) temperature sensor 1 circuit low voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
P1077-Charge air cooler (CAC) temperature sensor 1 circuit high voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
P1093-Fuel rail pressure (FRP) too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
P1097-Compressor outlet temperature sensor circuit high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
P1098-Compressor outlet temperature sensor circuit high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
P1236-Charge air cooler performance failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
P1261-Injector positive voltage control circuit group 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
P1262-Injector positive voltage control circuit group 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
P1404-Exhaust gas recirculation 1 closed position performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
P1606-SW-IC 1 internal failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
P160B-AD-IC failure error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
P160C-AD-IC2 failure error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
P1621-Control Module Long Term Memory Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
P1669-DPD Lamp control circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
P204F-SCR system error (No inducement) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
P207F-Urea fluid concentration too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
P20C9-SCR system error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
P2122-Pedal position sensor 1 circuit low input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
P2123-Pedal position sensor 1 circuit high input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
P2127-Pedal position sensor 2 circuit low input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
P2128-Pedal position sensor 2 circuit high input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
P2138-Pedal position sensor 1 – 2 voltage correlation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
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P2146-Fuel injector group 1 supply voltage circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
P2149-Fuel injector group 2 supply voltage circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
P2228-Barometric pressure circuit low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
P2229-Barometric pressure circuit high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
P2457-Exhaust gas recirculation (EGR) cooling system performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
P2458-Purge time out error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
P2BA7-Urea fluid quantity too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
P2BAA-SCR system error (Inducement, no purge) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
P3093-Fuel rail pressure too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
U0001-CAN-Bus Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
U0073-CAN-Bus Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
U0101-Lost communication with TCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
U010E-Lost communications with dosing control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
U0110-Lost communication with VNT system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
U0411-Lost CAN communications with VNT control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
U2106-Lost CAN communications with wheel loader transmission control system . . . . . . . . . . . . . . . . . . . . . . . . . 375
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SERVICE MANUAL
Booms, dippers, and buckets

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Contents
Booms, dippers, and buckets - 84
[84.910] Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.1
[84.912] Dipper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.2
[84.100] Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.3
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Boom - 910

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Contents
Boom - 910
TECHNICAL DATA
Boom
Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Boom
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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Booms, dippers, and buckets - Boom
Boom - Service limits

Attachment (Backhoe)
SMIL14CEX2913FB 1
1. Boom and swing frame mounting area

2. Boom cylinder and swing frame installation section
3. Boom and boom cylinder installation section
4. Boom and arm cylinder installation section
5. Boom and arm installation section
6. Arm and arm cylinder installation section
7. Arm and bucket cylinder installation section
8. Arm and arm link installation section
9. Bucket and bucket link installation section
10. Bucket link and bucket cylinder installation section
11. Bucket and arm installation section
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1. Boom and swing frame mounting area
SMIL14CEX2914FA 2
Part name Code Standard value Operating limit Judgment Action

860.5 mm 868.5 mm
Swing frame a Good/Bad -
(33.9 in) (34.2 in)
Boom b 857 mm (34 in) 855 mm (34 in) Good/Bad Replace
1 mm (0.04 in) or
Clearance c Shim adjustment Good/Bad Adjustment by shim
less
Pin d Ø 110 mm (4 in) Ø 109 mm (4 in) Good/Bad Replace
Ø 111.5 mm
Bushing (boom) e Ø 110 mm (4 in) Good/Bad Replace
(4.4 in)
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2. Boom cylinder and swing frame installation section
SMIL14CEX2915EA 3

Acceptable/
Swing frame a 131 mm (5 in) 137 mm (5 in) -
Unacceptable
Boom cylinder (foot Acceptable/
b 130 mm (5 in) 128 mm (5 in) Replace
section) Unacceptable
1.0 - 2.5 mm (0.0 Acceptable/
Clearance c Shim adjustment Adjustment by shims
- 0.1 in) Unacceptable
Acceptable/
Pin d Ø 90 mm (4 in) Ø 89 mm (4 in) Replace
Unacceptable
Bushing (boom Ø 91.5 mm Acceptable/
e Ø 90 mm (4 in) Replace
cylinder) (3.6 in) Unacceptable
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3. Boom and boom cylinder installation section
SMIL14CEX2916EA 4

Boom cylinder (top Acceptable/
a 123 mm (5 in) 121 mm (5 in) Replace
Acceptable/
Boom b 669 mm (26 in) 665 mm (26 in) Replace
Unacceptable
1.2 mm (0.0 in) Acceptable/
Clearance c Shim adjustment Adjustment by shims
or lower Unacceptable
Acceptable/
Unacceptable
Bushing (boom Ø 111.5 mm Acceptable/
e Ø 110 mm (4 in) Replace
cylinder) (4.4 in) Unacceptable
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4. Boom and arm cylinder installation section
SMIL14CEX2917EA 5
Standard
Part name Code Usage limit Judgement Solution
value
Acceptable/
Boom a 146 mm (6 in) 152 mm (6 in) Replace
Unacceptable
Arm cylinder (foot Acceptable/
1.2 mm (0.0 in) Shim Acceptable/
Clearance c Adjust with shims
or lower adjustment Unacceptable
Pin d Ø 99 mm (4 in) Replace
(4 in) Unacceptable
Ø 100 mm Ø 101.5 mm Acceptable/
Bushing (arm cylinder) e Replace
(4 in) (4.0 in) Unacceptable
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5. Boom and arm installation section
SMIL14CEX2918EA 6
Standard
value
Acceptable/
Boom a 392 mm (15 in) 395 mm (16 in) Replace
Unacceptable
387.7 mm 385.7 mm Acceptable/
Arm b Replace
1 mm (0 in) or Shim Acceptable/
Clearance c Adjust with shims
lower adjustment Unacceptable
Pin d Ø 114 mm (4 in) Replace
(5 in) Unacceptable
Bushing (arm) e Replace
Boom f Replace
87.5 mm Acceptable/
Boom g 89 mm (4 in) Replace
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6. Arm and arm cylinder installation section
SMIL14CEX2919EA 7
Standard
Part name Code Operating limit Judgement Action
value
Arm a 146 mm (6 in) 152 mm (6 in) Good/Bad Replacement
Arm cylinder (Top) b 145 mm (6 in) 143 mm (6 in) Good/Bad Replacement
0.5 - 3.0 mm Shim Adjustment with
Clearance c Good/Bad
(0.0 - 0.1 in) adjustment shims
Ø 100 mm
Pin d 99 mm (4 in) Good/Bad Replacement
(4 in)
Ø 100 mm 101.5 mm
Bushing (Arm cylinder) e Good/Bad Replacement
(4 in) (4.0 in)
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7. Arm and bucket cylinder installation section
SMIL14CEX2920EA 8
Standard
value
Acceptable/
Arm a 146 mm (6 in) 152 mm (6 in) Replace
Unacceptable
Bucket cylinder (foot Acceptable/
1.2 mm (0.0 in) Shim Acceptable/ Adjust with
Clearance c
or lower adjustment Unacceptable shims
Acceptable/
Unacceptable
Bushing (bucket cylinder) e Ø 95 mm (4 in) Replace
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8. Arm and arm link installation section
SMIL14CEX2921EA 9
Standard
value
Acceptable/
Arm link a 50 mm (2 in) 48 mm (2 in) Replace
Unacceptable
Acceptable/
Arm b 375 mm (15 in) 373 mm (15 in) Replace
Unacceptable
Clearance c
Acceptable/
Unacceptable
Bushing (arm) e Ø 85 mm (3 in) Replace
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9. Bucket and bucket link installation section
SMIL14CEX2922EA 10
Standard
value
Acceptable/
Bucket a 401 mm (16 in) 406 mm (16 in) Replace
Unacceptable
Acceptable/
Bucket link b 400 mm (16 in) 398 mm (16 in) Replace
Unacceptable
1.0 - 3.5 mm Shim Acceptable/ Adjust with
Clearance c
(0.0 - 0.1 in) adjustment Unacceptable shims
Acceptable/
Unacceptable
Bushing (bucket link) e Ø 90 mm (4 in) Replace
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10. Bucket link and bucket cylinder installation section
SMIL14CEX2923EA 11
Standard
value
Acceptable/
Arm link a 50 mm (2 in) 48 mm (2 in) Replace
Unacceptable
Acceptable/
Bucket link b 375 mm (15 in) 373 mm (15 in) Replace
Unacceptable
Clearance c
Acceptable/
Bucket link d 121 mm (5 in) 123 mm (5 in) Replace
Unacceptable
Bucket cylinder (top Acceptable/
e 120 mm (5 in) 118 mm (5 in) Replace
1.0 - 2.0 mm Shim Acceptable/ Adjust with
Clearance f
(0.0 - 0.1 in) adjustment Unacceptable shims
Pin g Replace
(4 in) (4 in) Unacceptable
Bushing (bucket link) h Replace
Bushing (bucket cylinder) i Replace
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11. Bucket and arm installation section
SMIL14CEX2924EA 12
Standard
value
Acceptable/
Bucket a 401 mm (16 in) 406 mm (16 in) Replace
Unacceptable
Acceptable/
Arm b 400 mm (16 in) 398 mm (16 in) Replace
Unacceptable
Clearance c
Acceptable/
Bushing (bucket) d 16 mm (1 in) 7 mm (0 in) Replace
Unacceptable
Acceptable/
Pin e Ø 90 mm (4 in) Ø 89 mm (4 in) Replace
Unacceptable
Bushing (arm) f Ø 90 mm (4 in) Replace
Bushing (bucket) g Ø 90 mm (4 in) Replace
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Boom - Prepare
WARNING
Lock the tracks.
W0944D
WARNING
W0287A
WARNING
Avoid injury!
W1036A
WARNING
Crushing hazard!
latches.
W0256A
WARNING
Heavy objects!
W0398A
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Items to prepare:
• Wrench [ 10 mm, 19 mm, 22 mm, 30 mm, 36 mm,
41 mm]
• Slide hammer [ 24 mm]
• Nylon sling (that fulfills slinging capacity)
• Marking pen
• Cap
• Plug
• Rag
• Striking rod
• Cleaning fluid
• Striking wood plank
• Square block, etc.
• Wire, etc.
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Boom - Remove
• Remove the bucket. (For details, see Bucket - Re-
move (84.100))
• Remove the bucket link. (For details, see Link and
rod - Remove (84.100))
• Remove the bucket cylinder. (For details, see
Bucket cylinder - Remove (35.738))
• Remove the arm cylinder. (For details, see Dipper
cylinder - Remove (35.737))
• Remove the arm. (For details, see Dipper - Remove
(84.912))
• Here, procedure is explained with the case to leave
the boom cylinder mounted on the frame.
Refer to the Boom cylinder - Remove (35.736) for
the procedure to remove the boom cylinder as well.
1. Position the end of the boom (1) on the ground.
SMIL14CEX1389AB 1
2. Remove the grease hoses (1) in left and right with a

wrench [ 19 mm].
• Attach caps and plugs so as to prevent invasion of
water, dust and dirt.
SMIL14CEX1390AB 2
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3. Remove the double nut (1) with a wrench [ 36 mm] and

then pull out the bolt (2) to remove the fixation ring (3).
Remove them in the cab side in the same manner.
SMIL14CEX1391AB 3
4. Push out the pin (1) with a hammer (2) and a striking
rod (3).
Support the boom cylinders (left) (right) with a lifting
equipment and a nylon sling (4) from dropping down
at this moment.
SMIL14CEX1392AB 4
5. Start the engine and then drive the boom-down opera-

tion in idling speed to retract the rods of the boom cylin-
ders (1) and (2).
SMIL14CEX1393AB 5
6. Tie the cylinder rods in left and right with wires (1) so
that they do not slip out.
SMIL14CEX1394AB 6
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7. Secure root of the boom cylinder with a striking wood

plank (1).
SMIL14CEX1395AB 7
8. Lower the boom cylinders (left) (right) so as to support

them by the striking wood plank (1).
• Remove the boom cylinder in the cab side in the
same manner.
SMIL14CEX1396AB 8
9. Attach the pin (1) that has been pulled out in the Step
4.
Tighten the bolt (3) by the 2 double nuts (2) with a
wrench [ 36 mm] to attach the fixation ring (4).
Attach them in the cab side in the same manner.
SMIL14CEX1397AB 9
10. Remove the hoses (1), (2) and (3) with a wrench [
41 mm].
Remove the 4 hexagon bolts (5) and the 2 split flanges
(6) with a hexagon wrench [ 12 mm] to remove the hose
(4).
• Apply marking at each location of the hoses and lines
• Attach caps and plugs at the hoses and lines so as
to prevent invasion of water, dust and dirt.
• Wash each location of the hoses and lines by blow-
ing parts cleaner so as to prevent adhering dirt at
connections and not to damage them. SMIL14CEX1398AB 10
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11. Wind nylon slings (1) around the pins in left and right
that have been attached in the step 9 to secure with
lifting equipment.
SMIL14CEX1399AB 11
12. Remove the bolt (1) and washer (2) with a wrench [
30 mm].
SMIL14CEX1400AB 12
13. Remove the pin (2) with a slide hammer (1) [ 36 mm].
SMIL14CEX1801AB 13
14. Move the machine backward to remove the boom (1).
SMIL14CEX1802AB 14
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Boom - Install
• Here, procedure is explained with the case not to
mount the boom cylinder.
• Each bolt has to be tightened in the specified torque.
• Refer to Torque – Bolt and nut () for those without
specified torque.
1. Clean pins and pin holes in respective parts.
SMIL14CEX1803AA 1
2. Mount the pin (1).

Tighten the bolt (3) by the 2 double nuts (2) with a
SMIL14CEX1804AB 2
3. Wind nylon slings (1) around the pins in left and right
that have been attached in the procedure 2 to secure
with lifting equipment.
SMIL14CEX1805AB 3
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4. Tie the cylinder rods in left and right with wires (1) so
that they do not slip out.
SMIL14CEX1806AB 4
5. Align the boom to the pin hole of the swing frame

and then tighten the pin (2) with a slide hammer (1) [
36 mm].
• Pay attention not to damage the dust seal when in-
serting the pin.
• If insertion of a shim is possible according to the
tolerance, adjust the shim.
SMIL14CEX1807AB 5
6. Tighten the bolt (1) and washer (2) with a wrench [

30 mm].
• Apply grease.
SMIL14CEX1808AB 6
7. Attach the hoses (1), (2) and (3) with a wrench [

41 mm].
Set the O-ring to the line side to attach the hose (4) with
the 2 split flanges (6) and the 4 hexagon bolts (5).
• The O-ring cannot be used again. Use new one.
SMIL14CEX1851AB 7
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8. Start the engine and then drive the boom-up operation

in idling speed to extend the rods of the boom cylinders
(1) and (2).
SMIL14CEX1852AB 8
9. Push in the pin (1) with a hammer (2). Support the

boom cylinders (left) (right) with a lifting equipment and
a nylon sling (3) from dropping down at this moment.
SMIL14CEX1853AB 9
10. Tighten the bolt (2) and the double nut (1) with a
SMIL14CEX1854AB 10
11. Attach the grease hoses (1) in left and right with a
wrench [ 19 mm].
SMIL14CEX1855AB 11
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12. Position the end of the boom (1) on the ground.

• Install the boom cylinder. (For details, see Boom
• Install the arm. (For details, see Dipper - Install
(84.912).)
• Install the arm cylinder. (For details, see Dipper
• Install the bucket cylinder. (For details, see Bucket
• Install the bucket link. (For details, see Link and
rod - Install (84.100))
SMIL14CEX1856AB 12
• Install the bucket. (For details, see Bucket - Install
(84.100))
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Index
Boom - 910
Boom - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Boom - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Boom - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Boom - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Dipper arm - 912

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Contents
Dipper arm - 912
TECHNICAL DATA
Dipper arm
Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Dipper
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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Booms, dippers, and buckets - Dipper arm
Dipper arm - Dimension

Standard arm
SMPH15CEX0434EA 1
1. Bucket cylinder
2. Arm link
3. Bucket link
4. Bucket pin (connection between bucket and arm)
5. Bucket pin (connection between bucket and bucket link)
Part a b c d e f g
3235 mm 955 mm 530 mm 271 mm 268 mm 283 mm 798 mm
Dimension
(127.362 in) (37.598 in) (20.866 in) (10.669 in) (10.551 in) (11.142 in) (31.417 in)
Part h i j1 j2 k1 k2
Ø 210 mm Ø 170 mm Ø 90 mm Ø 85 mm 379 mm 375 mm
Dimension
(8.268 in) (6.693 in) (3.543 in) (3.346 in) (14.921 in) (14.764 in)
1. Bucket cylinder
Part Maximum retracted length Stroke Cylinder top width
Dimension 1870 mm (73.622 in) 1210 mm (47.638 in) 120 mm (4.724 in)
2. Arm link
SMPH15CEX0435EA 2
Part l
Dimension 710 mm (27.953 in)
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3. Bucket link
SMPH15CEX0436EA 3
Part m n o p q1 q2
675 mm 400 mm 121 mm 375 mm Ø 90 mm Ø 105 mm
Dimension
(26.575 in) (15.748 in) (4.764 in) (14.764 in) (3.543 in) (4.134 in)
4. Bucket pin (connection between bucket and arm)
SMPH15CEX0437EA 4
Part r s t1 t2 u v
90 mm 90 mm 638 mm 32 mm Ø 25 mm Ø 17 mm
Dimension
(3.543 in) (3.543 in) (25.118 in) (1.260 in) (0.984 in) (0.669 in)
5. Bucket pin (connection between bucket and bucket link)
SMPH15CEX0438EA 5
Part w x y1 y2 z aa
90 mm 90 mm 591 mm 35 mm Ø 25 mm Ø 17 mm
Dimension
(3.543 in) (3.543 in) (23.268 in) (1.378 in) (0.984 in) (0.669 in)
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Dipper - Prepare
WARNING
Lock the tracks.
W0944D
WARNING
W0287A
WARNING
Avoid injury!
W1036A
WARNING
Crushing hazard!
latches.
W0256A
WARNING
Heavy objects!
W0398A
Items to prepare:
• Wrench [ 30 mm]
• Hammer
• Striking rod
• Grease
• Rag
• Cleaning fluid
• Crosstie
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Dipper - Remove
• Remove the bucket. (For details, see Bucket - Re-
move (84.100))
• Remove the bucket link. (For details, see Link and
rod - Remove (84.100))
• Remove the bucket cylinder. (For details, see
Bucket cylinder - Remove (35.738))
• Remove the arm cylinder. (For details, see Dipper
cylinder - Remove (35.737))
1. Bring the arm (1) end in contact with the ground and
use a lifting equipment and nylon sling (2) to fasten it.
At this time, insert the arm cylinder pin (3) and fasten
with the nylon sling.
SMIL14CEX1381AB 1

spacer (2).
SMIL14CEX1382AB 2
(2) out and remove the arm (1).
• If the pin is hard to remove, there is a load on the pin.
the installed dust seals.
• Be very careful. When the pin is removed, the arm
may fall slightly.
• Be very careful. The arm may fall over to the side.
SMIL14CEX1383AB 3
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4. Lift the arm, and then place it on the crossties.
SMIL14CEX1384AA 4
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Dipper - Install
• When installing the bolts, tighten them to the speci-
fied torque.
• When the torque is not specified, check the Torque
– Bolt and nut ().
SMIL14CEX1385AA 1
2. Bring the arm (1) end in contact with the ground and
use a lifting equipment and nylon sling (2) to fasten it.
At this time, insert the arm cylinder pin (3) and fasten
with the nylon sling.
SMIL14CEX1386AB 2
3. Align the arm (1) with the boom, use a hammer (3) to
push in the pin (2), and then install the arm (1).
SMIL14CEX1387AB 3
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spacer (2).
• Install the arm cylinder. (For details, see Dipper
• Install the bucket cylinder. (For details, see Bucket
• Install the bucket link. (For details, see Link and rod
- Install (84.100))
(84.100))
SMIL14CEX1388AB 4
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Index
Dipper arm - 912

Dipper - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Dipper - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Dipper - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Dipper arm - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Bucket - 100

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Contents
Bucket - 100
SERVICE
Bucket
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Link and rod
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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Booms, dippers, and buckets - Bucket
Bucket - Prepare
WARNING
Lock the tracks.
W0944D
WARNING
W0287A
WARNING
Avoid injury!
W1036A
Items to prepare:
• Hammer
• Striking rod
• Grease
• Rag
• Cleaning fluid
• Wrenches [ 36 mm] x 2
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Bucket - Remove
NOTE: Place the back of the bucket parallel to the ground.
1. Remove the bolts (1) and the nuts (2).
SMIL14CEX1369AB 1
2. Use a hammer (4) and striking rod (5) to push out the
bucket side pin (3) and arm side pin (2), and then re-
move the bucket (1).
SMIL14CEX1370AB 2
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Bucket - Install
SMIL14CEX1371AA 1
2. Place the back of the bucket parallel to the ground.

Use a hammer (4) to push in the bucket side pin (3) and
arm side pin (2), and then install the bucket (1).
Do not force it in. Adjust the bucket installation posi-
tion.
SMIL14CEX1372AB 2
3. Install the bolts (1) and nuts (2) to the bucket and arm
side pins.
• When installing the pin bolts, leave about 1 - 2 mm
(0.039 - 0.079 in) of gap between both nuts and the
retaining ring.
• Grease up.
SMIL14CEX1373AB 3
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Link and rod - Prepare

WARNING
Lock the tracks.
W0944D
WARNING
W0287A
WARNING
Avoid injury!
W1036A
Items to prepare:
• Wrenches [ 36 mm] x 2
• Hammer
• Striking rod
• Grease
• Rag
• Cleaning fluid
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Link and rod - Remove

Remove the bucket. (For details, see Bucket - Re-
move (84.100))
1. Place the bucket link (1) parallel to the ground.
SMIL14CEX1374AB 1
2. Use 2 wrenches [ 36 mm] to remove the double nuts

(1), and then pull out the bolts (2) and (3).
SMIL14CEX1375AB 2
(2) out and remove the bucket link (1).
SMIL14CEX1376AB 3
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(3) out and remove the arm links (1) and (2).
SMIL14CEX1377AB 4
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Link and rod - Install

SMIL14CEX1378AA 1
2. Use a hammer (4) to push in the pin (1) and install the
arm links (2) and (3).
SMIL14CEX1379AB 2
3. Place the bucket link (1) parallel to the ground.

Use a hammer (3) to push in the pin (2) and install the
bucket link (1).
SMIL14CEX1380AB 3
4. Use 2 wrenches [ 36 mm] to install the double nuts (1),

and then install the bolts (2) and (3).
• When installing the pin bolts, leave about 1 - 2 mm
(0.039 - 0.079 in) of gap between both nuts and the
retaining ring.
• Grease up.
(84.100)).
SMIL14CEX1375AB 4
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Index
Bucket - 100
Bucket - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Bucket - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Bucket - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Link and rod - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Link and rod - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Link and rod - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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EN
SERVICE MANUAL
Platform, cab, bodywork, and decals

47843027 21/05/2015
90
Contents
Platform, cab, bodywork, and decals - 90
[90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1
[90.156] Cab glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2
[90.118] Protections and footboards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3
[90.120] Mechanically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.4
[90.100] Engine hood and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.5
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Cab - 150

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Contents
Cab - 150
SERVICE
Cab and platform

Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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Platform, cab, bodywork, and decals - Cab
Cab and platform - Prepare

WARNING
Avoid injury!
W1128A
WARNING
Crushing hazard!
latches.
W0256A
WARNING
Heavy objects!
W0398A
Items to prepare:
• Wrenches [ 10 mm, 12 mm, 13 mm, 19 mm,
24 mm, 41 mm ]
• Box wrenches [ 10 mm, 13 mm, 19 mm ]
• Long-nose pliers
• Screwdriver
• Eyebolts ( M24 x 4 )
• Chains (wire ropes) (with the required breaking load)
• Lubricant
• Rag
• Cleaning fluid
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Cab and platform - Remove

• Remove the operator's seat. (Refer to the Operator
seat - Remove (90.120) for detail.)
1. Remove the 10 bolts (1) with a box wrench [ 13 mm] to
remove the trim rear assembly (2) and the rear lower
trim (3).
Bolt (1) tightening torque: 5.9 - 7.8 N·m (4.352 -
5.753 lb ft)
SMIL14CEX1861AB 1
SMIL14CEX1862AB 2
2. Remove the 3 bolts (1) with a box wrench [ 10 mm] to

remove the air conditioner ducts (2) and (3) in left and
right.
2.876 lb ft)
SMIL14CEX1863AB 3
3. Remove the 2 bolts (1) with a Phillips screwdriver or

a box wrench [ 10 mm] to remove the side front lower
trim (2).
5.753 lb ft)
SMIL14CEX1864AB 4
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4. Pull out the clip pin (1) with a screwdriver or radio pliers
to remove the air conditioner duct (2) pulling it to front
side.
SMIL14CEX1865AB 5

move the bracket (1) and the air conditioner duct (3).
SMIL14CEX1866AB 6
6. Remove the radio antenna (1).
SMIL14CEX1867AB 7
7. Remove the bolt (2) for the ground wire (1) that con-
nects the cab and the floor with a wrench [ 13 mm].
SMIL14CEX1868AB 8
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8. Remove the 4 bolts (1) with a Phillips screwdriver or a

box wrench [ 10 mm] to remove the side rear B trim (2).
SMIL14CEX1869AB 9
9. Remove the connector (1), and remove the clamp (2),

and then remove the bolt (3) with a wrench [ 13 mm].
SMIL14CEX1870AB 10
10. Disconnect the hose (1) for washer fluid.
SMIL14CEX1871AB 11

remove the stay (2).
Disconnect all the harnesses (3) that are led to the cab.
• Remove all the clamps that secure the frame main
wire harness.
SMIL14CEX1872AB 12
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12. Disconnect the connector (1) of the GPS antenna and

the connector (2) for the controller.
Remove the 4 bolts (3) and the 2 nuts (4) with a wrench
[ 13 mm] to remove the bracket rear (5).
SMIL14CEX1873AB 13
13. Pull out the clip pin (1) with a screwdriver or radio
pliers to remove the suction ducts (2) and (3).
SMIL14CEX1874AB 14
14. Remove the 4 bolts ( M16) (1) at top of the cab.
SMIL14CEX1875AB 15
15. Attach the 4 eyebolts ( M16) (1) at locations from

which the caps have been removed.
• Tighten up the eyebolt all the way and then loosen
it for a half turn.
SMIL14CEX1876AB 16
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16. Secure the cab with a chain (1) and lifting equipment.
SMIL14CEX1877AB 17
17. Remove the 8 bolts (1) and the 4 nuts (2) with a
wrench [ 19 mm].
SMIL14CEX1878AB 18
SMIL14CEX1879AB 19
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18. Remove the anchor bolt (1) with a wrench [ 41 mm].
SMIL14CEX1880AB 20
19. Remove the cab (2) by lifting it with a chain (1) and
lifting equipment.
SMIL14CEX1881BB 21
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the cab on a wood plank (1).
• Make sure to secure the cab with a chain or lifting
equipment so as to prevent it from falling.
SMIL14CEX1882BB 22
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Cab and platform - Install

dure.
If the torque is not specified, see Cab glazing - Torque
(90.156).
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Index
Cab - 150
Cab and platform - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Cab and platform - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cab and platform - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Cab glazing - 156

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Contents
Cab glazing - 156
TECHNICAL DATA
Cab glazing
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Cab windshield glass

Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Windshield latch
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Adjust – Front side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Adjust – Rear side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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Platform, cab, bodywork, and decals - Cab glazing
Cab glazing - Torque

When installing cab inner and outer parts, for bolts and screws for which the torque is not specified, tighten according
to the following.
M3 X 0.5 M4 X 0.7 M5 X 0.8 M6X1.0 M8X1.25 M10X1.5

0.59 - 0.79 N·m 1.27 - 1.86 N·m 2.45 - 3.53 N·m 4.52 - 6.14 N·m 9.84 - 14.74 N·m 19.58 - 28.40 N·m
(0.4352 - (0.9367 - (1.8070 - (3.3338 - (7.2576 - (14.4415 -
0.5827 lb ft) 1.3719 lb ft) 2.6036 lb ft) 4.5286 lb ft) 10.8717 lb ft) 20.9468 lb ft)
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Cab windshield glass - Prepare

NOTICE: Reinforced glass is used for the front window. Be extremely careful not to damage it when touching it during
removal or installation.
Items to prepare:
• Wrench [ 10 mm ]
• Rag
• Cleaning fluid
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Cab windshield glass - Remove

1. Use a Phillips screwdriver to remove the 8 clips (2), and
then remove the cover (1).
SMIL14CEX1934AB 1
2. Use a Phillips screwdriver to remove the screw (1), and

then install the removed screw (1) into the screw hole
(2).
• The assist spring is locked.
SMIL14CEX1935AB 2
3. Use a wrench [ 10 mm] to remove the 3 bolts (1) each,

and then remove the brackets (2) and (3).
Tightening torque for bolt (1) installation: 8.80 -
12.70 N·m (77.89 - 112.40 lb in).
SMIL14CEX1936AB 3
4. Remove the covers (1) and (2) for the bracket.
SMIL14CEX1937AB 4
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then remove the left lower bracket (2) on the wind-
shield.
12.70 N·m (77.89 - 112.40 lb in).
SMIL14CEX1938AB 5

then remove the right lower bracket (2) on the wind-
shield.
12.70 N·m (77.89 - 112.40 lb in).
SMIL14CEX1939AB 6
7. Remove the cab windshield (1).
SMIL14CEX1940BB 7
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Cab windshield glass - Install

dure.
If the torque is not specified, see the Cab glazing -
Torque (90.156) section.
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Windshield latch - Prepare

Items to prepare:
• Rag
• Cleaning fluid
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Windshield latch - Adjust – Front side

1. Release the lock with the lever (1), and then unlock the
cab front glass.
SMIL14CEX1941AB 1
2. Use a wrench [ 10 mm] to loosen the 2 bolts (1).
SMIL14CEX1942AB 2
3. Set the cab front glass (1) in place.
SMIL14CEX1943AB 3
4. Use a wrench [ 10 mm] to retighten the 2 bolts (1).
SMIL14CEX1944AB 4
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Windshield latch - Adjust – Rear side

1. Use a Phillips screwdriver to remove the 8 clips (2), and
then remove the cover (1).
SMIL14CEX1945AB 1
2. Use a wrench [ 14 mm] to loosen the 2 bolts (1).
SMIL14CEX1946AB 2
3. Set the cab front glass (1) in place.
SMIL14CEX1947AB 3
4. Use a wrench [ 14 mm] to retighten the 2 bolts (1).
SMIL14CEX1948AB 4
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Index
Cab glazing - 156

Cab glazing - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cab windshield glass - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cab windshield glass - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cab windshield glass - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Windshield latch - Adjust – Front side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Windshield latch - Adjust – Rear side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Windshield latch - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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Protections and footboards - 118

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Contents
SERVICE
Handrails
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Platform, cab, bodywork, and decals - Protections and footboards
Handrails - Prepare
WARNING
Avoid injury!
W1128A
NOTICE: Make sure that the removal and installation work is performed by two or more persons.
Items to prepare:
• Wrench [ 19 mm ]
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Handrails - Remove
move the right-front housing guardrail (2).
SMIL14CEX1883AB 1

move the right-center housing guardrail (2).
SMIL14CEX1884AB 2

move the cover (2).
move the right-rear housing guardrail (4).
SMIL14CEX1885BB 3
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move the cover (2).
move the left housing guardrail (4).
SMIL14CEX1886BB 4
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Handrails - Install
To install, reverse the removal procedure. Each bolt
has to be tightened in the specified torque.
specified torque.
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Index

Handrails - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Handrails - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Handrails - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Mechanically-adjusted operator seat - 120

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Contents
SERVICE
Operator seat
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
47843027 21/05/2015
90.4 [90.120] / 2
Platform, cab, bodywork, and decals - Mechanically-adjusted operator seat
Operator seat - Prepare

Items to prepare:
• Wrench [ 13 mm]
47843027 21/05/2015
90.4 [90.120] / 3
Operator seat - Remove

1. Pull the slide lever (1) to slide the seat (2) to the rear.
Use a wrench [ 13 mm] to remove the 2 bolts (3) from
the front of the seat.
Bolt (3) tightening torque: 19.6 N·m (14.456 lb ft)
SMIL14CEX1857AB 1
2. Pull the slide lever (1) to slide the seat forward, and then
pull the reclining lever (2) to fold the seatback forward.
SMIL14CEX1858AB 2
3. Use a wrench [ 13 mm] to remove the 2 bolts (1) from

the rear of the seat.
Bolt (1) tightening torque: 19.6 N·m (14.456 lb ft)
SMIL14CEX1859AB 3
4. Remove the operator's seat (1).
SMIL14CEX1860AB 4
47843027 21/05/2015
90.4 [90.120] / 4
Operator seat - Install

dure.
47843027 21/05/2015
90.4 [90.120] / 5
Index

Operator seat - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Operator seat - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Operator seat - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
47843027 21/05/2015
90.4 [90.120] / 6
Engine hood and panels - 100

47843027 21/05/2015
90.5 [90.100] / 1
Contents
SERVICE
Hood
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
47843027 21/05/2015
90.5 [90.100] / 2
Platform, cab, bodywork, and decals - Engine hood and panels
Hood - Prepare
WARNING
Rotating parts!
Shut off the engine before opening the engine hood.
W1059A
WARNING
Crushing hazard!
latches.
W0256A
WARNING
Heavy objects!
W0398A
WARNING
Heavy parts!
Once the hood is completely opened, make sure the locking system engages correctly.
W0279A
NOTICE: Do not perform this operation in strong wind.

NOTICE: Pay attention not to pinch fingers or hands when the hood drops.
NOTICE: Lifting equipment should be operated gently and calmly.
Items to prepare:
• Wrench [ 19 mm]
• Nylon sling (with the required breaking load)
47843027 21/05/2015
90.5 [90.100] / 3
Hood - Remove
1. Open the engine hood by hand until the lock is en-
gaged.
Lift up the engine hood slowly until a force on the open
lock stay (1) is relieved by winding a nylon sling around
the hook of the engine hood.
Remove the pin (2) and the washer (3) at fixation por-
tion between the open lock stay (1) and the engine
hood to pull out the open lock stay (1) from the guide
hole (4).
SMIL14CEX1002BB 1
2. Remove the 5 bolts (1) of the engine hood with a

wrench [ 19 mm] to remove the engine hood.
SMIL14CEX1003BB 2
47843027 21/05/2015
90.5 [90.100] / 4
Hood - Install
dure.
47843027 21/05/2015
90.5 [90.100] / 5
Index

Hood - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hood - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hood - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
47843027 21/05/2015
90.5 [90.100] / 6
47843027 21/05/2015
90.5 [90.100] / 7
47843027 21/05/2015
EN
SPECIAL TOOL INDEX
Genuine Reference PAGE

380300009 [Angle Gauge] Cylinder heads - Special tools 10.4 / 3
380001721 [Nozzle Sleeve Cylinder head - Special tools 10.4 / 4
Installer]
380300014 [Valve Guide Cylinder head - Special tools 10.4 / 5
Remover / Installer]
380002626 [Compression Cylinder head - Special tools 10.4 / 5
Gauge Adapter]
380300015 [Compression Cylinder head - Special tools 10.4 / 5
Gauge Adaptor]
380300013 [Valve Guide Oil Valve guide - Special tools 10.4 / 7
Seal Installer]
380300022 [Piston Ring Piston - Special tools 10.5 / 3
Compressor]
380300005 [Piston Ring Piston - Special tools 10.5 / 3
Setting Tool]
380002574 [Slinger Puller] Crankshaft - Special tools 10.6 / 3
380002611 [Oil Seal Installer Crankshaft - Special tools 10.6 / 3
Kit]
380002613 [Crankshaft Gear Crankshaft - Special tools 10.6 / 4
Puller]
380002630 [Main Filter Fuel filters - Special tools 10.8 / 3
Wrench]
380002602 [Sliding Hammer] Fuel injectors - Special tools 10.9 / 3
380002601 [Fuel Injector Fuel injectors - Special tools 10.9 / 3
Remover]
380002630 [Main Filter Engine oil filter - Special tools 10.18 / 3
Wrench]
380200121 [Wrench Boom hydraulic system - Special tools 35.13 / 4
Assembly]
47843027 21/05/2015
47843027 21/05/2015
EN
FUSE BOX;2 FUSE BOX;1
8R 109 2 8R 109
5RW 103 1 5RW 103 DISEL ENGINE
F41 F47 F59 F56 F57 F58

G2
3RW 103b
3RW 103a
FUSIBLE LINK UREA REFUEL FUEL FUSIBLE LINK 1 ALTERNATOR
YAZAKI
FUSIBLE LINK 2
(CN.A50)
3R 109g
3R 109d
3R 109b
3R 109e
3R 109c
3R 109a
3R 109f
58L
BACK UP SCR SPARE PUMP PUMP PUMP SAFTY RL
2
SAFTY RL
1
(RED TAPE) (NO TAPE) (BLUE TAPE) 20fB 797 E 24V 50A
(RED TAPE) (BLUE TAPE) (BLUE TAPE)
YAZAKI M5
50A 20A 20A 10A 15A 10A 60A 60A (CN.D15)
10 10
(F74)
(F73)
(F72)
(F71)
(F70)
(F69)
(F09)
(F26)
(F21)
(F18)
(F14)
(F68)
(F17)
(F67)
(F66)
(F06)
(F65)
(F64)
(F05)
(F63)
(F07)
(F04)
(F62)
(F61)
(F03)
(F02)
(F01)
11 12 13 14 15 16 17 18 19 20 11 12 13 14 15 16 17 18 19 20 IC
YAZAKI YAZAKI YAZAKI
20A
15A
10A
10A
10A
10A
10A
15A
15A
10A
10A
15A
10A
15A
10A
15A
15A
10A
10A
10A
10A
10A
10A
10A
10A
REGULATOR
5A
5A
1 2 3 4 5 6SUMITOMO 1 2 3 4 5 6SUMITOMO 1 YAZAKI
1 2(CN.D68) YAZAKI YAZAKI 1 1
7 8 9 1 2 3YAZAKI 1 2 3YAZAKI 1 2 3YAZAKI 1 2 3YAZAKI 58L 1 2(CN.D69) 1 2(CN.D70) 58L 58L
2
1
1
2
1
2
7 8 9
3
4
1
2
3
4
1
2
3
4
1
2
(CN.A35) (CN.A36) 2 (CN.D67) 2 (CN.D71) 2 (CN.D72)
4 5 (CN.A34)
6 4 5 (CN.A33)
6 4 5 (CN.A37)
6 4 5 (CN.A38)
6 3 4 3 4 3 4
8R 109
5RW 103
5RW 102
2R 105
2R 104
1.25R 265
3R 106
0.85YR 260
0.85R 106c
2W 255
1.25R 106b
0.75YG 250
0.85R 106a
5R 002
5R 003
5R 002a
5R 003a
BLOWER MOTOR
PROP-SOLENOID
CIGAR LIGHTER
1.25G 501c 1 0.75R R
(CONTROLLER)
(CONTROLLER)
(QUICK&CTWT)
COMPRESSOR
(PROP-LEVER)
BOOM,HOUSE
CONTROLLER
CONTROLLER
CONTROLLER
SUS&HEATER
(RELAY_SPK)
AIRCON UNIT
LEVER LOCK
CONVERTOR
KEY SWITCH
ACCESSARY
1.25Br 515 2 0.75L L
20
20
10
12
13
14
15
16
17
18
19
10
12
13
14
15
16
17
18
19
(BACK UP)
11
11
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
(CONT_C)
MONITOR
MONITOR
SOLNOID
BACK UP
WASHER
(IMMOBI)
BEACON
AIRCON
AIRCON
SPARE3
SPARE2
SPARE1
OPTION
ENGINE
WIPER
DC/DC
(CN.D14)
HORN
0.85GW 943 0.85GW 943
LAMP
LAMP
1
SEAT
YAZAKI
YAZAKI
CAB
FVM
GPS
P CH0
P CH1
P CH2
P CH3
P CH4
P CH6
RL 135
RL 135a
RL 135b
RL 135c
RL 135d
0.85G 501a
G 501b
G 501c
0.85G 501d
0.85G 501e
PG CL0
PG CL1
PG CL2
PG CL3
PG CL4
PG CL6
1.25BG 600
BG 605
1.25BG 610
0.85BG 620
BG 630
BG 631
BG 634
1.25BG 636
0.85BG 660
1.25BG 600a
1.25BG 601a
1.25BG 601b
BG 601c
BG 601d
1.25BG 601e
1.25BG 601
1.25B 701a
1.25B 701b
1.25B 701c
1.25B 701d
B 701e
1.25B 701
0.85B 703
0.85B 704
B 705
B 706
B 707
1.25B 708
1.25B 708
0.85B 709
0.85B 720
1.25B 740
1.25B 741
1.25B 700
60A
1 2
SWP
LR 880 2 0.85LR 880 YAZAKI (CN.D79) 3R 106
YR 881 3 0.85YR 881 (CN.D77) JST
0.5μF
LgR 235
W 230
LR 225
GR 220
0.85OR 215
1.25LW 210
1.25GrR 205
GW 200
YR 195
0.85BrR 190
LW 185
LR 180
0.85WR 175
VR 170
LgW 165
1.25LR 160
1.25GR 155
0.85VW 150
W 145
0.85WB 140
RL 135
0.85RY 130
1.25RW 125
0.85RB 120
RW 115
0.85R 110
(CN.D81) 20fR 030
0.85WR 240
1.25Y 870 4 1.25Y 870

K7 B
W 145b
LW 185a
RL 135e
LgR 235a
R 885 5 0.85R 885 20fR 031 100A YAZAKI M6

0.85WV 829 0.85WG 829 JST JST (CN.D13)
6 (C YA
1.25B 700 7 2B 700 N. ZA
D7 K RELAY BATTERY T )
(CN.D80) (CN.D82)
BATTERY SWITCH 6) I JS D78
5RW 103a
1.25BG 600 8 2BG 600 N. STARTER MOTOR
(C
60B 799 60R 100 60R 101 60R 001 B
M
M8 M8YAZAKI M10
1 2 3 4
5 6 7 8
YAZAKI
(CN.A51)
CONTROLLER X4 (CN.D74) 5Y 004 S
M1
58M
M10 M10 M10 M10
M4YAZAKI
(CN.D11)
YAZAKI M4
YAZAKI
(CN.D12)
S94 - + - + (CN.D73)
58Y
A1
1
24V 4.0kw
60B 799a
M4
808a
POWER 24V_BACKUP 10 RL 135a 5L 021 5BW
1.25WR 812
1
1.25G 501
21 RL 135b GLOW PLUG

Service Manual Cx350d

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Service Manual Cx350d

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SERVICE MANUAL

1/3 SERVICE MANUAL

Part number 47843027

CX350D Crawler excavators LC version (TIER4 FINAL) - EU Market

[10.102] Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2

[10.106] Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3

[10.101] Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4

[10.105] Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5

[10.103] Crankshaft and flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6

[10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7

[10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8

[10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9

[10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10

[10.250] Turbocharger and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11

[10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12

[10.500] Selective Catalytic Reduction (SCR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . 10.13

[10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16

[10.310] Aftercooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17

[10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18

[35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2

[35.106] Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3

[35.102] Pump control valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4

[35.304] Combination pump units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5

[35.357] Pilot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7

[35.355] Hydraulic hand control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.8

[35.356] Hydraulic foot control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.9

[35.352] Hydraulic swing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.10

[35.353] Hydraulic travel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.11

[35.354] Hydraulic central joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.12

[35.736] Boom hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.13

[35.737] Dipper hydraulic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.14

[35.738] Excavator and backhoe bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.15

[35.360] Hammer and rotating bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.16

Frames and ballasting ................................................................. 39

Tracks and track suspension ........................................................ 48

[48.100] Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.2

[48.134] Track tension units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.3

[48.138] Track rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.4

Cab climate control ..................................................................... 50

[50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.2

Electrical systems ....................................................................... 55

[55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2

[55.525] Cab engine controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3

[55.015] Engine control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4

[55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5

[55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6

[55.202] Cold start aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8

[55.011] Fuel tank system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9

[55.010] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.10

[55.014] Engine intake and exhaust system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.11

[55.988] Selective Catalytic Reduction (SCR) electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . 55.12

[55.989] Exhaust Gas Recirculation (EGR) electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.13

[55.012] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.14

[55.013] Engine oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.15

[55.640] Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.16

[55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.17

[55.036] Hydraulic system control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.18

[55.051] Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls. . . . . . . . . . . . . . . . . 55.19

[55.050] Heating, Ventilation, and Air-Conditioning (HVAC) control system. . . . . . . . . . . . . . . 55.20

[55.524] Cab controls (Lift arm, Boom, Dipper, Bucket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.21

[55.416] Swing control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.22

[55.417] Travel control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.23

[55.530] Camera. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.24

[55.518] Wiper and washer system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.25