SM-Takeuchi TL12R2 Track Loader Service Repair Manual (SN 412100002 and Up)

Serial No.
412100002~
Book No. CR1E005
WETL12R_E-XF
FOREWORD
This manual, which is written for engineers who service the machine, describes procedures for disassembly and as-
sembly, inspection and maintenance, and troubleshooting, as well as maintenance reference values and an outline of
the specifications. Refer to this manual during daily work to improve your services. Note that the information is subject
to change without notice due to design modifications made to the machine from time to time by the manufacturer.
Directional terms: front, rear, left, right

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

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

The symbols used in this manual have the following meanings.
Indicates the machine serial number.

Means “Refer to the section quoted.”
Indicates the mass of the equipment or machine.
Means “Tighten to the torque specified here.”
Indicates the use of thread-locking compound.
Indicates the use of grease.
Manual structure
This manual consists of the following parts.
1. Safety
2. Service data
3. Function
4. Disassembly and assembly
5. Troubleshooting
6. Other
0B0BO00
SAFETY 1
SAFETY
SAFETY ALERT SYMBOL 1
SAFETY ALERT SYMBOL
This symbol represents the safety
alert.
The message that follows the sym-
bol contains important information
regarding human safety.
Read and understand the message
to avoid personal injury or death.
Safety label
Safety labels are used to alert operators or other people
exposed to the risks of injury or damage. There are the
following three types of labels.
Read the labels carefully as they are important for your
safety.
DANGER
The word “DANGER” indicates an imminently hazard-
ous situation which, if not avoided, is likely to result
in serious injury or death.
WARNING
The word “WARNING” indicates a potentially hazard-
ous situation which, if not avoided, could result in se-
rious injury or death.
CAUTION
The word “CAUTION” indicates a potentially hazard-
ous situation which, if not avoided, may result in mi-
nor or moderate injury.
IMPORTANT: The word “IMPORTANT” is used to alert

operators and maintenance personnel about any in-
formation which requires special attention or guid-
ance; information that needs to be highlighted; and
situations which could result in damage to the ma-
chine and its components.
This manual is intended for trained and qualified person-

nel only. Warnings or cautions described in this manual
do not necessarily cover all safety measures. It is also im-
possible to cover all hazards and risks which may be as-
sociated with the maintenance of the machine in every
environment. For maintenance work, each person must
take adequate safety precautions against possible haz-
ards in the respective working environment.
1
SAFETY ALERT SYMBOL 1A0BO001
1
SAFETY
SAFETY PRECAUTIONS
SAFETY PRECAUTIONS Install an extinguisher and a first aid kit
Observe all safety rules

• Operation, inspection and maintenance of this ma-
chine must be performed only by a trained and quali-
fied person.
• All rules, regulations, precautions and safety proce-
dures must be understood and followed when per-
forming operation, inspection and maintenance of this
machine.
• Do not perform any operation, inspection or mainte-
nance of this machine when under the influence of al-
cohol, drugs, medication, fatigue or insufficient sleep.
1BAA02Z
Wear safe clothing and protective gear • Install an extinguisher to fight a fire, and learn how to
use it.
• Prepare a first aid kit and keep it at a designated
place.
• Decide on the procedures to be used in case of fire or
other hazards.
• Decide on and take note of the contact(s) in case of
emergency.
Place a “Do not operate” alert sign

Serious injury or death may result if an unauthorized per-
son starts the engine or touches the controls during in-
spection or maintenance.
1BAA01Z • Before performing maintenance, stop the engine, re-
• Do not wear loose clothing or any accessory that can move the key and store it in a safe place.
catch on the controls or the moving parts of the ma- • Prominently display a “Do not operate” alert sign on
chine. places such as the starter switch and the control lever.
• Do not wear clothing stained with oil or grease that can Place another sign outside of the machine as neces-
easily catch fire. sary.
• Wear protective gear such as helmet, safety shoes,
protective goggles, respirator, gloves and earmuffs, Use the correct tools
as appropriate, depending on the work involved. Es-
pecially make sure to wear protective eye-wear and
mask when working with a grinding/polishing/sanding
machine, hammer or compressed air, as metal frag-
ments or other objects could scatter in such an envi-
ronment.
• Wear hearing protectors when operating the machine.
Loud and prolonged noise can damage or destroy
your hearing.
1BAA03Z
Do not use damaged or weakened tools or tools de-

signed for other purposes. Use only the correct tools for
the work involved.
1
SAFETY PRECAUTIONS 1B0BF00
1
SAFETY
SAFETY PRECAUTIONS
Regularly replace the safety-critical parts When the canopy is tilted up

• Regularly replace fuel hoses to prevent a fire hazard. • If the canopy is raised or lowered while the engine is
Hoses wear out over time, even if they do not show any moving, the machine may accidentally start moving,
symptom of wear. resulting in severe injury to the maintenance person-
• Regardless of the replacement schedule, replace im- nel. Make sure that the working equipment has been
mediately if a symptom of wear is found. lowered to the ground and the engine has been turned
off before raising/lowering the canopy.
Explosionproof lighting • When the canopy is tilted up, firmly secure the canopy
with a stopper to prevent it from falling.
Keep the machine clean
1BAA04Z
To prevent an ignition or explosion, use explosion-proof

lights when inspecting fuel, oil, coolant or battery fluid.
1BAA06Z
Prohibit access by unauthorized persons • Clean the machine before performing maintenance
and try to keep it clean.
• Before washing, cover the electrical parts with vinyl to
prevent water from entering, as this could cause a
short-circuit or malfunction. Do not use water or steam
to wash the battery, sensors, connectors or the opera-
tor’s seat area.
Stop the engine before performing maintenance

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

• Select a level and firm ground on which to perform
maintenance work. Make sure that the work area is
light enough and well ventilated.
• Straighten any obstacle or dangerous object, remove
any spill of oil or grease and clean the work area.
2
1
SAFETY
SAFETY PRECAUTIONS
Keep clear of the moving fan and belt When working on the machine
1BAA07Z 1BAA09Z
• Any object that can be easily caught in moving parts • To prevent slipping/falling from machine, clear the
must be kept away. footing and observe the following:
• If a hand or tool becomes trapped in the fan or fan belt, a. Do not spill oil or grease on the machine.
you could lose your finger. Do not touch the fan or belt b. Keep the machine tidy and clean.
while they are moving. c. Be careful when walking around the machine.
• Never jump down from the machine. Climb up/down
When working under the machine the ladder (steps) holding the handrail to support your
weight in a three point secure stance (hand and feet).
• Wear protective gear according to the work involved.
Securing the working equipment

When replacing/repairing the bucket teeth or side cutter,
secure the relevant equipment to prevent any accidental
movement.
Secure the engine hood and guard when they are

open
Firmly secure the machine when the engine hood or
1BAA08Z
guard is left open. Do not keep the hood or guard open
• Before performing maintenance or repairs under the on a windy day or if the machine is parked on a slope.
machine, set all movable equipment against the
ground or in the lowermost position. Place heavy components in a stable position
• Place chocks under the crawler tracks to secure the
machine.
• If it is unavoidably necessary to work under the raised
machine or working equipment, be sure to firmly sup-
port it by using an arm stopper, wooden block, stand
or safety brace. Never go under the raised machine or
working equipment without such protection measures.
1BAA10Z
When it is necessary to temporally place a heavy compo-

nent, such as the hoe attachment, on the ground during
removal or installation, be sure to place it in a stable po-
sition.
3
1
SAFETY
SAFETY PRECAUTIONS
Caution when filling with fuel or oil Be careful with hot and pressurized components
1BAA11Z 1BAA12Z
• Keep away from heat, sparks and flame while filling Before performing inspection and maintenance, stop the
with fuel or oil. engine and allow the machine to cool down.
• Never remove the fuel cap or try to fuel when the en- • The engine, muffler, radiator, hydraulic lines, sliding
gine is running or still hot. parts and many other parts of the machine are hot im-
• Maintain control of the fuel filler nozzle when filling the mediately after the engine is stopped. Wait until it
tank. cools before making any inspection or adjustments.
• Refill with fuel or oil outdoors or in a well ventilated • The engine coolant, hydraulic oil and other oils are
place, with the engine turned off. also hot and under high pressure. Touching these liq-
• Clean up spilled fuel or oil immediately. uids will cause burns.
• Do not overfill the tank.
• Firmly tighten the fuel cap or oil cap. If the fuel cap is Handling of radiator
lost, replace it only with the original manufacturer’s ap-
proved cap. Use of a non-approved cap without prop-
er venting may result in pressurization of the tank.
• Never use fuel for cleaning.
• Use the correct grade of fuel for the operating season.
Handling of hoses
Oil leak or fuel leak can cause a fire.
• Do not twist, bend or hit the hoses.
• Never use twisted, bent or cracked pipes, tubes or
hoses; otherwise, they may burst.
• Retighten loose connections.
1BAA13Z
Do not remove the radiator cap when the coolant is hot.

Wait until it cools down, and then remove the radiator cap
by loosening it slowly to release the internal pressure.
4
1
SAFETY
SAFETY PRECAUTIONS
Be careful with oils under pressure Be careful with grease under pressure
1BAA14Z 1BAA15Z
Pressure is maintained in the hydraulic circuit long after In the track adjuster, the grease has been injected under
the engine has been shut down. high pressure. If the tension is adjusted without following
• Do not fill with, dispose of fuel/oil, or perform the in- the prescribed procedure, the grease discharge valve
spection and maintenance until the internal pressure is may fly off, resulting in injury.
completely released. • Loosen the grease discharge valve slowly.
• The hydraulic oil escaping from a small hole can be • Do not put your face, arms, legs or body in front of the
hazardous if contacted. It is under high enough pres- grease discharge valve.
sure to penetrate the skin or eyes and cause serious
injury. If leak is suspected, protect your eyes and skin Handling of the accumulator
by wearing protective glasses and thick gloves to
search for a leak. Also use a paperboard or plywood
to keep your skin from oil spurting. If oil penetrates the
skin, it must be surgically removed within a few hours
by a doctor familiar with this type of injury.
Release internal pressure before working on the

hydraulic system
Oil may spurt out if caps or filters are removed or pipes
are disconnected before releasing the pressure in the
hydraulic system.
• Gradually loosen the vent plug to release the internal
pressure of the hydraulic oil tank. 1BAA16Z
• Move all the control levers and pedals several times in Be sure to handle the high-pressure nitrogen gas en-
all directions to release the pressure from the circuit of closed in the accumulator with care according to proce-
the working equipment (for link type controls). dure. If handled incorrectly, it could explode and cause
• When removing plugs or screws, or when disconnect- serious injury. Strictly observe the following precautions:
ing hoses, stand to the side and loosen them slowly to • Do not disassemble.
gradually release the internal pressure before remov- • Do not allow flame near it or throw it into a fire.
ing. • Do not drill, weld or fuse.
• Do not subject it to physical shock such as hitting, roll-
ing or dropping.
• Before disposing of the unit, the sealed gas must be
drained. Contact your sales or service dealer for help
with this.
Disconnect the battery

Disconnect the wiring from the both terminals (+ and -)
on the battery before working on the electrical system or
doing electric welding. Otherwise, short-circuit and ex-
plosion of the battery can result.
5
1
SAFETY
SAFETY PRECAUTIONS
Use caution when handling batteries Have a service agent repair welding cracks or
other damage
Ask a service agent to make any repairs that require
welding. If the agent is unavailable, make sure the weld-
ing is done by a qualified person in a properly equipped
workplace.
Checks after maintenance

• Gradually raise the engine speed from low idle to max-
imum and check that no oil or water is leaking from the
parts serviced.
• Move the controls and check that the machine is oper-
1BAA17Z
ating properly.
• Batteries contain sulfuric acid which will damage eyes
or skin if contacted. Disposing of wastes
• If eye contact occurs, flush immediately with clean
water and get prompt medical attention.
• If accidentally swallowed, drink large quantities of
water or milk and call a physician immediately.
• If acid contacts skin or clothing, wash off immedi-
ately with a lot of water.
• Wear protective glasses and gloves when working with
batteries.
• Batteries generate flammable hydrogen gas which
may explode. Keep away from flame and sparks.
• Do not use or charge the battery when the electrolyte
level is lower than the lower limit: otherwise, it could
cause an explosion.
1BAA18Z
• Be sure to stop the engine by turning off the starter
• Always collect oil that is drained from the machine in
switch before inspecting or handling the battery.
containers. Improperly disposed waste oil can cause
• Be careful not to let metal tools (or any metal objects)
environmental harm.
such as a hammer or spanner come into contact with
• Follow appropriate laws and regulations when dispos-
the battery terminals.
ing of harmful objects such as oil, fuel, coolant, sol-
• When disconnecting the battery wiring, always discon-
vent, filters and batteries.
nect it from the earth side (-). When connecting, con-
nect the earth side last.
• Loose battery terminals may result in sparks. Be sure
to fasten terminals tightly.
• Make sure the battery caps are tightened securely.
• Do not charge a battery or jump-start the engine if the
battery is frozen; otherwise it may explode.
Warm the frozen battery to 15°C (59°F) before use.
6
1
SAFETY
CAUTIONS WHEN WORKING
CAUTIONS WHEN WORKING When removing/installing the hydraulic unit

• Make sure that the temperature of the hydraulic oil has
When disassembling or assembling dropped and is cool enough to work with.
• Clean the machine before disassembly. • To prevent the hydraulic oil from escaping under pres-
• Check the following items and record the results: sure, release the residual pressure in the piping.
a. Model, machine serial number, hour meter. • Be sure to install caps or plugs on all openings in the
b. Reason for repair, repair history. hydraulic unit to prevent dirt from getting into the unit
c. Are the filters dirty? through them.
d. The conditions of the fuel and oil.
e. Any damage or looseness to any part?
• Where necessary, draw alignment indicators to avoid
assembly errors. To avoid misconnection, place indi-
cators such as reference tags on pipes.
• Clean all disassembled parts and new parts, arrange
them neatly, and place indicators as necessary.
• Be sure to replace all seals and cotter pins with new
ones.
• Keep those parts that should not come in contact with
water or oil away from those with oil on the surface.
• When installing bearings, bushings and oil seals, a
press tool should be used. If a hammer is used, use a
cushioning material to avoid damage. • The hydraulic oil adhering to the unit is often mistaken
• Wipe all joining surfaces clean until there is no dirt or for an oil leak, so wipe off the unit thoroughly.
dust adhering to them. • Be sure that no damage is caused to the plating on the
• Wrap the thread tight with seal tape starting 1 or 2 rod in the hydraulic cylinder.
threads away from the thread end. The tape should be • Removal and installation of the hydraulic cylinder
overlapped by about 10 mm (0.39 in). should be done with the rod fully retracted.
• Be sure to bleed the air after installing the hydraulic
cylinder. ( “4. Disassembly and assembly: Cylin-
der”)
• Always bleed the air when hydraulic oil is changed or
a hydraulic device is replaced. ( “4. Disassembly
and assembly: Drive system”)
1
CAUTIONS WHEN WORKING 1C0BF001
1
SAFETY
CAUTIONS WHEN WORKING
When connecting/disconnecting the hoses or Handling of seals

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

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

• The pressure for hydraulic devices is adjusted by
Takeuchi Mfg. to optimal conditions before products
are shipped for delivery to the customer. The pressure
1CAA04Z
will not need to be adjusted again except in products
that undergo disassembly and assembly procedures.
2
CAUTIONS WHEN WORKING 1C0BF001
SERVICE DATA 2
SERVICE DATA
DIMENSIONAL DRAWING 2
DIMENSIONAL DRAWING
Machine dimensions
2A0BS01
1
DIMENSIONAL DRAWING 2A0BS00
SERVICE DATA
Unit: mm (in.)
Standard bucket
Rubber crawlers
Canopy Cab
A 4045 (159.3) 
B 3205 (126.2) 
C 1715 (67.5) 
D 2330 (91.7) / 2380 (93.7)* 
E 320(12.6) 
F 1960 (77.2) 
G 450 (17.7) 
H 1670 (65.7) 
J 1065(41.9) 
K 2030 (79.9) 
L 590 (23.2) 
M 30° 
*: Roof guard specification
2
SERVICE DATA
Operating range
2A0BS02
3
SERVICE DATA
Unit: mm (in.)
Standard bucket
Rubber crawlers
Canopy Cab
A 4245 (167.1) 
B 3200 (126) 
C 2400 (94.5) 
D 960 (37.8) 
E 2555 (100.6) 
F 1635 (64.4) 
G 1850 (72.8) 
H 30° 
4
SERVICE DATA
SPECIFICATION TABLES 2
SPECIFICATION TABLES
Performance
Bucket type Standard bucket
3 3
Bucket capacity m (ft. ) 0.595 (21.01)
Tipping load kg (lb.) 3915 (8629)
Rated loading mass kg (lb.) 1350 (2974)
Bucket kN (lbf) 36.5 (8210)
Maximum digging force
Arm kN (lbf) 35.9 (8070)
Raising time s 4.4
Lowering time s 3.2
Bucket forward tilting time s 3.1
1st km/h (mph) 8.1 (5.03)
Forward
2nd km/h (mph) 11.8 (7.33)
Travel speed
1st km/h (mph) 8.1 (5.03)
Reverse
2nd km/h (mph) 11.8 (7.33)
Maximum tractive force kN (lbf) 62.3 (14010)
Gradeability deg. 30
Minimum turning radius Outermost side of bucket m (ft.) 2.555 (8.38)
Dimensions
Without teeth mm (in.) 4045 (159.3)
Overall length
With teeth mm (in.) –
Overall width (body) mm (in.) 1960 (77.2)
Bucket width mm (in.) 2030 (79.9)
Canopy mm (in.) 2330 (91.8)
Bucket on ground
Overall height cab mm (in.) 2380 (93.7)
Max. raised height of bucket mm (in.) 4245 (167)
Crawler bearing length mm (in.) 1715 (67.6)
Track gauge mm (in.) 1510 (59.4)
Shoe width mm (in.) 450 (17.7)
Crawler bearing area m3 (ft.3) 1.55 (16.68)
Ground clearance of undercarriage mm (in.) 320 (12.5)
Bucket hinge pin height mm (in.) 3200 (126)
Dumping clearance (at 45- Without teeth mm (in.) 2400 (94.4)
degree forward tipping) With teeth mm (in.) –
Dumping reach (at 45- Without teeth mm (in.) 960 (37.8)
degree forward tipping) With teeth mm (in.) –
Bucket roll back angle On ground deg. 32
Bucket dumping angle Maximum height position deg. 42
Maximum digging depth mm (in.) 0 (0)
1
SPECIFICATION TABLES 2B0BS001
SERVICE DATA
Mass
Canopy kg (lb.) 6530 (14400)
Gross machine mass
Cab kg (lb.) 6665 (14690)
Canopy kg (lb.) 5580 (12300)
Operating mass
Cab kg (lb.) 5710 (12590)
Canopy kg (lb.) 5505 (12140)
Machine mass
Cab kg (lb.) 5635 (12420)
Canopy kg (lb.) 5420 (11950)
Shipping mass
Cab kg (lb.) 5550 (12240)
Engine
Model Kubota V3800-TIEF4B
4-cycle, vertical, water-cooled,
Type
common rail diesel
Number of cylinders Number of cylinders Quantity 4
– Internal diameter Bore mm (in.) 100 (3.94)
× stroke Stroke mm (in.) 120 (4.72)
L
Total displacement 3.8 (230)
(cu. in.)
min-1
Rated engine speed 2400 (2400)
(rpm)
Gross
kW (hp) 83 (111.3)
(SAE J1995)
Rated output Net (ISO 14396) kW (hp) 81.8 (109.7)
Net (ISO 9249/
kW (hp) 78.2 (104.9)
SAEJ 1349)
Performance Gross N·m
385.0 (284) / 1500 (min-1)
(SAE J1995) (ft.-lb.)
N·m
Maximum torque Net (ISO 14396) 379.3 (279.8) / 1500 (min-1)
(ft.-lb.)
Net (ISO 9249/ N·m
373.7 (275.6) / 1500 (min-1)
SAEJ 1349) (ft.-lb.)
Specific fuel consumption g/kW·h
234 (0.385)
(at rated output) (lb./hp-hr.)
Fuel system Speed governor Electronic control
Lubrication type Trochoid pump
Lubrication system Filter system Filter paper
Cooling system Water cooling
Air cleaner Centrifugal, filter paper
Fan Pusher type
Cooling system
Radiator Pressurization
AC/DC Three-phase, alternating current, self-rectifying
Generator Voltage V 12
Output kW 0.96
Voltage V 12
Starter generator
Output kW 3
Type 125D31L
Voltage V 12
Storage battery
Capacity A·h 72
Quantity 1
2
SERVICE DATA
Hydraulic system
Model Daikin-Sauer-Danfoss 11149204
Type Variable displacement piston
Hydraulic pump 3
cm
Displacement 0 to 51 (0 to 3.11)
(cu. in.)
Quantity 1
Model Daikin-Sauer-Danfoss 11152699
Type Variable displacement piston
Travel motor 3
cm
Motor displacement 33.4/51 (2.04/3.11)
(cu. in.)
Quantity 2
MPa
Set pressure Effective differential pressure 34.5 (5000)
(psi)
Reduction gears Epicycle 2-stage reduction gear
Brake device
Parking brake Spring-loaded, wet-type disc brake
Undercarriage
Suspension system Rigid type
Sealing system Floating seal
Roller, idler Carrier roller (one side) Quantity –
Track roller (one side) Quantity 6
Track adjustment Grease adjustment
Type One-piece rubber crawler
Grouser height mm (in.) 26 (1.02)
Crawler
Number of shoes (one side) Quantity 60 (core metal)
Pitch mm (in.) 86 (3.39)
Shoe width mm (in.) 450 (17.72)
Operating device
Position Center of machine
Cab/canopy ROPS/FOPS (Level 1, Level 2 (OPT))
Type
canopy and cabin
Operator’s seat Adjustable suspension seat
Lever Quantity 2 (Travel, attachments)
control lever and pedals
Pedal Quantity 1 (Accelerator OPT)
3
SERVICE DATA
ECM error warning light, Vehicle/Engine emergency
light, Charging warning light, Engine oil pressure warn-
ing light, Blowby heater warning light, Air cleaner warn-
ing light, SCR system warning light, DEF/AdBlue® qual-
ity warning light, Pilot line filter warning light, Hydraulic
oil temperature warning light, Cooling water tempera-
ture warning light, Fuel remaining warning light, DEF/
AdBlue® remaining warning light, Active power control
indicator light, Glow indicator light, Ride control indica-
tor light, DPF automatic regeneration/disabled indicator
light, DPF automatic regeneration underway, DPF
Instruments manual regeneration underway/regeneration accelera-
tion indicator light, Eco mode indicator light, Arm float
indicator light, Self-level indicator light, No. 1 service 1-
way indicator light, High-flow indicator light, No. 2 ser-
vice /14P connector indicator light, No. 1 service flow-
rate indicator light, Air conditioner indicator light, Work-
ing light indicator light, Travel speed indicator light,
Parking brake indicator light, Hydraulic system lock in-
dicator light, Water temperature gauge, Fuel gauge,
Hydraulic oil temperature gauge, DEF/AdBlue® gauge,
Throttle open indicator, Date/time display, Hourmeter/
Tripmeter
Front work light 12 V, 10 W × 4
Lighting device
Rear work light 12 V, 3 W × 8 + 0.5 W × 4
Horn Quantity 1
Back buzzer Quantity 1
Others
Inside rear-view mirror Quantity 2
Rear-view mirror Quantity 1
Working equipment
Link type Combination of radial arm and radial bucket
Bucket blade type Without teeth
Type –
Bucket teeth
Quantity –
Auto adjustment mechanism Hydraulic leveling device for bucket raising
Hydraulic system
Type Independent piston
Number Quantity 2
Arm cylinder
Bore mm (in.) 75 (2.95)
Stroke mm (in.) 700 (27.56)
Type Independent piston
Number Quantity 2
Bucket cylinder
Bore mm (in.) 75 (2.95)
Stroke mm (in.) 540 (21.26)
Type Triple gear pump (machine with high-flow)
Hydraulic pump 3
cm
Displacement 36.5 + 27.4 + 18.8 (2.23 + 1.67 + 1.15)
(cu. in.)
Type Hydraulic pilot-operated
Operating valve MPa
Set pressure 3.3 (479)
(psi)
4
2
SERVICE DATA
TABLE OF MASSES
TABLE OF MASSES
Upper structure kg (lb.)
Engine 426 (939)
2B1BO15
Radiator 60 (132)
2B1BO16
Control valve (machine

without second auxiliary
39 (86)
line piping and without
high-flow equipment)

with second auxiliary line
piping and with high-flow
equipment)
42 (93)
without second auxiliary
line piping and with high-
flow equipment) 2B1BO01
Gear pump (without high-

flow equipment) 10 (22)
2B1BO02
1
TABLE OF MASSES 2B1BS001
2
SERVICE DATA
TABLE OF MASSES
Gear pump (with high-

15 (33)
flow equipment)
2B1BO03
Engine housing 18 (40)
2B1BO04
HST pump 72 (159)
2B1BO05
Hydraulic tank 46 (101)
2B1BO06
2
2
SERVICE DATA
TABLE OF MASSES
Cab COMP 309 (681)
2B1BO07
Canopy COMP 227 (500)
2B1BO08
Operator seat 30 (66)
2B1BO09
Battery 23 (51)
2B1BO17
3
2
SERVICE DATA
TABLE OF MASSES
Fuel tank assembly 10 (22)
2B1BO18
Lower structure kg (lb.)
Rubber crawler 242 (534)
2B1BO10
B
Track roller A 22 (49)
Track roller B A 38 (84)
Track roller C 26 (57)

2B1BO24
Front idler assembly 73 (161)
2B1BO12
4
2
SERVICE DATA
TABLE OF MASSES
Grease cylinder 12 (26)
2B1BO13
Travel motor 81 (179)
2B1BO14
Attachments kg (lb.)
Quick-hitch bracket
93 (205)
2B1BO19
Bucket 281 (619)
2B1BO20
5
2
SERVICE DATA
TABLE OF MASSES
Arm assembly (1) 417 (919)
2
Arm cylinder (2) 41 (90)
3
Bucket cylinder (3) 3 1 30 (66)
2B1BS01
6
2
SERVICE DATA
LUBRICANT AND FUEL CHART

Select the appropriate fuel, lubricant, and grease according to temperature by referring to the table below.
• Regardless of the amount of time specified, change the oil if it becomes too dirty or degraded.
• When refilling, never mix oils of different brands. If a brand is to be changed, replace all of the fuel/oil.
Selection by air temperature
When to change/
Part Type -4 14 32 50 68 86 104°F Capacity
replenish
-20 -10 0 10 20 30 40°C
Diesel engine oil Upper limit:
API: CJ-4 class or Every 500 hrs. af- 13.2 L (13.9 US qt.)
Engine oil pan SAE 10W-30
above ter the first 50 hrs. Lower limit:
JASO: DH-2 8.8 L (9.3 US qt.)
Total amount of oil:
Diesel engine oil
85 L (22.5 US gal.)
Hydraulic tank API: CD, CE, or SAE 10W-30 Every 1000 hrs.
Tank level capacity:
CF class or above
50 L (13.2 US gal.)
**Cooling water
Engine cooling (water + coolant) Mixture of 50% coolant Every 1000 hrs. 18 L (19 US qt.)
system SAE-J814C, Mixture of 30% coolant
J1034
Travel reduction Gear oil Every 500 hrs. 1.6 L × 2

SAE 90
gear API: GL-4 after the first 250 hrs.* (1.7 US qt. × 2)
Engine oil
Track roller A and
API: CD class or SAE 30 – 0.18 L (6.09 fl. oz)
C
above
Mobil SHC Gear
Track roller B – – 0.17 L (5.75 fl. oz)
680
Mobil SHC Gear
Idler – – 0.17 L (5.75 fl. oz)
680
Working equipment Lithium grease EP-2 Daily or every 10 hrs.
– As required
Lever/pedal NLGI No. 2 When required
* If the ratio of traveling time to total operating time is high, replace the gear oil earlier than the specified time.
** For water, use tap water (soft). Do not use well or river water.
When the ambient temperature drops below 0°C (32°F), add coolant (antifreeze). Follow the coolant manufactur-
er’s instructions to determine the mixture ratio.
2C0BO01
1 Track roller A
2 Track roller B
3 Track roller C
1
LUBRICANT AND FUEL CHART 2C0BS001
2
SERVICE DATA
Diesel fuel standards

Use a diesel fuel that is compliant with any of the stan-
dards listed below. The table below shows standards
from various countries/regions.
Diesel fuel standards Country/Region
No. 2-D S-15, No. 1-D S-15, ASTM
USA
D975
EN590 EU
Part Type Capacity

• Cetane number: The minimum recommended fuel cetane
number is 45. A cetane number above 50 is desirable
when the ambient temperature is -20°C (-4°F) or below or
at an altitude of 1,500 m (4,921 feet) or above.
• The specification of the diesel fuel used and its sulfur con-
tent (ppm) must comply with all applicable exhaust gas
regulations where the engine is used.
• Do not use fuel with more than 0.001% (10 ppm) sulfur
content in Europe or Japan or 0.0015% (15 ppm) in the
United States.
• Diesel fuel described in EN590 (0.001% (10 ppm) sulfur
content) or ASTM (0.0015% (15 ppm) sulfur content) is 119.5 L
Fuel tank Diesel fuel
recommended. (31.6 US gal.)
• No.2-D is a Low volatility distillate fuel for industrial and
heavy-vehicle engine applications. (SAE J313 JUN87)
• These engines comply with the EPA Interim Tier 4 stan-
dard. Ultra-low-sulfur fuel must be used in regions subject
to US EPA regulations. Therefore, use No.2-D S15 diesel
fuel as a substitute for No.2-D. When the ambient temper-
ature is less than -10°C (14°F), use No.1-D S15 diesel fuel
as a substitute for No.1-D.
• If bio-diesel is used, replace the fuel filter, fuel hoses, and
clamp bands with new parts at half the normal replacement
period (twice as frequently).
2
2
SERVICE DATA
Handling DEF/AdBlue®
Use DEF/AdBlue® that is compliant with the standards
below.
DEF/AdBlue® Standard
ISO22241
Part Storing DEF/AdBlue® Capacity

StoringDEF/AdBlue®
• As DEF/AdBlue® prevents the evaporation of moisture, store it in a sealed
container.
• Store away from direct sunlight in a well ventilated room at an ambient tem-
perature below 25°C (77°F). Do not sore in a location with an ambient tem-
perature that reaches -5°C (23°F) or below.
• The temperature in the room affects the storage life of the DEF/AdBlue®.
• Even if DEF/AdBlue® freezes, its quality is unchanged after it thaws out.
DEF/AdBlue® Use it as normal. 18 L
tank • Use the original container from the time of purchase to store or transport the (4.8 US gal.)
DEF/AdBlue®.
If the use of a different container is unavoidable, a polyethylene (PE) or
stainless steel container can be used. Use a clean container washed out
with DEF/AdBlue® to remove water and dirt.
• Do not store DEF/AdBlue® in areas of high temperatures.
If DEF/AdBlue® gets too hot, it may generate toxic ammonia.
Keep the container sealed during storage. Open the container in a well ven-
tilated room. If you smell a pungent odor, do not approach unnecessarily.
3
SERVICE DATA
PERFORMANCE CRITERIA 2
PERFORMANCE CRITERIA
Standard values table
Item Units Standard value Allowable value
-1
min
Low 1200 +50
-50 ( 1200 +50
-50 ) -
(rpm)
1. Engine speed
min-1
High 2560 +50
-50 ( 2560 +50
-50 ) -
(rpm)
Right crawler MPa (PSI) 34.5 +6.3 +913.5
-0.5 ( 5002.6 -72.5 ) -
Travel pressure
+6.3 +913.5
Left crawler MPa (PSI) 34.5 -0.5 ( 5002.6 -72.5 ) -
+0.3 +43.5
Charge Low MPa (PSI) 2.7 -0.3 ( 391.5 -43.5 ) -
2. Hydraulic oil pressure +0.2 +29.0
High MPa (PSI) 2.9 -0.2 ( 420.5 -29.0 ) -
pressure
+1.8 +261.0
Bucket pressure MPa (PSI) 24.0 -0.5 ( 3480.1 -72.5 ) -
+1.4 +203.0
Pilot pressure MPa (PSI) 2.9 -0.2 ( 420.5 -29.0 ) -
+1.2 +174.0
High-flow pressure MPa (PSI) 24.0 -0.5 ( 3480.1 -72.5 ) -
Lowering speed when the lift arm +1.0
s 6.6 -1.0 8.3
is in float
+0.4
Raising s 4.3 -0.4 5.1
3. Cylinder speed Lift arm
+0.4
Lowering s 3.1 -0.4 3.8
+0.4
Roll back s 2.3 -0.4 2.9
Bucket
+0.4
Dump s 3.2 -0.4 3.9
+0.5
Forward s 4.5 -0.5 5.5
1st speed
+0.5
Reverse s 4.5 -0.5 5.5
4. Travel speed
+0.4
Forward s 3.1 -0.4 3.9
2nd speed
+0.4
Reverse s 3.1 -0.4 3.9
+0.6
Right Forward s 11.2 -0.6 12.9
1st crawler Reverse s 11.2 +0.6
-0.6 12.9
speed Left Forward s 11.2 +0.6
-0.6 12.9
5. Crawler shoe 5 crawler Reverse s 11.2 +0.6
-0.6 12.9
rotations Right Forward s 7.5 +0.5
-0.5 9.1
2nd crawler Reverse s 7.5 +0.5
-0.5 9.1
speed Left Forward s 7.5 +0.5
-0.5 9.1
crawler Reverse s 7.5 +0.5
-0.5 9.1
0 0
mm (in.) 125 -125 ( 4.9 -4.9 ) 500 (19.7)
Forward Veering
Left Right -
direction
6. Straight-ahead traveling
0 0
mm (in.) 125 -125 ( 4.9 -4.9 ) 500 (19.7)
Reverse Veering
Left Right -
direction
0 0
7. Amount of Lift arm mm (in.) 5 -5 ( 0.2 -0.2 ) 10 (0.4)
cylinder natural
drop Bucket mm (in.) 5 0
-5 ( 0.2 0
-0.2 ) 10 (0.4)
Right crawler mm (in.) OK NG -

8. Natural travel drop
Left crawler mm (in.) OK NG -
1
PERFORMANCE CRITERIA 2D0BS001
SERVICE DATA
9. Crawler tension mm (in.) 15 to 30 ( 0.6 to 1.2 ) -
Difference
10. Bucket front edge between right mm (in.) 0 +10
0 ( 0 +0.4
0 ) 0 (0.0)
and left
2
SERVICE DATA
Hydraulic pump assignment table
Machine without high-flow equipment
Flow rate values below are hydraulic pump specification values.

Hydraulic pump No. Hydraulic pump assignment circuit Flow rate L/min. (US gal./min.)
P1 Right crawler travel 122.4 (32.3)
P2 Left crawler travel 122.4 (32.3)
P3 Arm, bucket, 1st service, 2nd service 87.6 (23.1)
P4 Charge pressure, pilot pressure 45.1 (11.9)
The relief pressures below are the hydraulic equipment specification values (excluding charge pressures and pilot pres-
sures). Check the standard values table during performance evaluation.
Standard values table: 2. Performance Criteria, Standard values table
Hydraulic pump No. P1
Hydraulic pump assignment circuit Relief pressure MPa (psi) Pressure detection port
Forward A3
Right crawler travel 34.5 (5002.6)
Reverse A4
Forward A1
Left crawler travel 34.5 (5002.6)
Reverse A2
Arm, bucket, 1st service, 2nd service 24.0 (3480.1) A6
Charge pressure 2.4 to 3.1 (348.0 to 449.5) A5
Pilot pressure 2.7 to 4.3 (391.5 to 623.5) A7
Pressure detection port positions: 2. Performance Criteria, Methods for inspecting performance
3
SERVICE DATA
Machine with high-flow equipment
2D0BM01
Flow rate values below are hydraulic pump specification values.

Hydraulic pump No. Hydraulic pump assignment circuit Flow rate L/min. (US gal./min.)
P1 Right crawler travel 122.4 (32.3)
P2 Left crawler travel 122.4 (32.3)
P3 Arm, bucket, 1st service, 2nd service 87.6 (23.1)
P4 High flow 65.8 (17.4)
P5 Charge pressure, pilot pressure 45.1 (11.9)
The relief pressures below are the hydraulic equipment specification values (excluding charge pressures and pilot pres-
sures). Check the standard values table during performance evaluation.
Standard values table: 2. Performance Criteria, Standard values table
Forward A3
Right crawler travel 34.5 (5002.6)
Reverse A4
Forward A1
Left crawler travel 34.5 (5002.6)
Reverse A2
Arm, bucket, 1st service, 2nd service 24.0 (3480.1) A6
High flow 24.0 (3480.1) A8
Charge pressure 2.4 to 3.1 (348.0 to 449.5) A5
Pilot pressure 2.7 to 4.3 (391.5 to 623.5) A7
Pressure detection port positions: 2. Performance Criteria, Methods for inspecting performance
4
SERVICE DATA
Methods for inspecting performance
1. Engine speed
Measurement method
Low
1. Set the throttle controller to the minimum speed posi-
tion A.
2. Check the engine speed on the multi-information dis-
play (cluster).
Engine speed check method: Operator's manual
2D0BQ09
High
1. Set the throttle controller to the maximum speed po-
sition C.
2. Check the engine speed on the multi-information dis-
play (cluster).
Engine speed check method: Operator's manual
2D0BQ10
5
SERVICE DATA
2. Hydraulic oil pressure
Measurement method
Travel pressure
• Engine speed: High
• Hydraulic oil temp.: 50°C to 60°C (122°F to 140°F)
• Measuring instrument: Pressure gauge
• Install a pressure gauge on the HST pump (2) pressure
detection port. Fit the pipe (1) onto the travel motor 1
sprocket to deactivate the motor. Measure the relief
pressure during left and right crawler forward and re-
verse operation.
Pressure detection port 2D0BS01
Relief
Operation
valve Port Size
R1 (sup-
Left crawler for- plied
A1 9/16-18 UNF
ward travel with HST
pump)
R2 (sup-
Left crawler re- plied A3 R3
A2 9/16-18 UNF 2
verse travel with HST R4
pump) A4
A1 R1
R3 (sup-
Right crawler plied 9/16-18
A3
forward travel with HST UNF
pump)
R4 (sup-
Right crawler re- plied
A4 9/16-18 UNF
verse travel with HST
pump)
A2 R2
2 2D0BO16
6
SERVICE DATA
Charge pressure
• Engine speed: Low/High
• Install a pressure gauge on the pressure detection port
of the sub-valve (3) and measure the relief pressure.
Pressure detection port
Operation Relief valve
Port Size
R5 (supplied A5 (sup- A5
None with HST plied with G1/4
pump) sub-valve)
3
2D0BO17
• Adjustment method
Adjust the relief valve R5 supplied with the HST pump (4).
1. Loosen the locknut (2), and turn the setscrew (1) to
adjust the set pressure.
• Turn the setscrew clockwise to increase the set
pressure.
• Turn the setscrew counterclockwise to decrease
the set pressure.
2. In order to keep the setscrew (1) from turning after the
pressure has been adjusted, tighten the locknut (2) R5
while holding the setscrew (1) firmly in place.
4
3. Operate the relief valve once more to confirm that the 2D0BO18
pressure that has been set is stabilized.
7
SERVICE DATA
Bucket pressure
• Engine speed: High A6
Install a pressure gauge on the pressure detection port
A6 of the gear pump (machine without high-flow equip-
ment) (1) or gear pump (machine with high-flow equip-
ment) (2). Operate the bucket and measure the relief
pressure.
Pressure detection port 1

Port Size A6 2
A6 (sup-
R6 (supplied
plied with
Bucket with control G1/4
the gear
valve)
pump)
2D0BO19
Adjust the relief valve R6 supplied with the control valve
(machine without high-flow equipment) (3) or the control
valve (machine with high-flow equipment) (4).
• Turning it clockwise raises the set pressure.
• Turning it counterclockwise lowers the set pres-
sure.
2. After the pressure has been adjusted, tighten the R6 R6
locknut (6) while holding the setscrew (5) firmly in 3 4
place.
3. Operate the relief valve again to confirm that the new-
ly set pressure is stabilized.
2D0BO24
1 Locknut (6): 59 N·m to 69 N·m (44 ft-lb. to 51 ft-

lb.)
8
SERVICE DATA
Pilot pressure
A7
• Install a pressure gauge on the pressure detection port
A7 of the line filter (1) and measure the relief pressure.
Port Size
R7 (supplied A7 (sup-
None with sub- plied with G1/4
valve (2)) line filter) 1
2D0BO20
R7
2
2D0BO21
High-flow pressure (machine with high-flow equip-

ment only)
A8
• Measuring instrument: Pressure gauge 3
• Install a pressure gauge on the gear pump (3) pressure
detection port A8. Turn on the high-flow switch and
measure the relief pressure.
High-flow switch: Operator’s manual
Port Size
A8 (sup- 2D0BO22
R8 (supplied
High-flow plied with
with control G1/4
switch the gear
valve)
pump)
9
SERVICE DATA
Adjust the relief valve R8 supplied with the control valve
(4).
• Turn clockwise to increase the set pressure.
• Turn counterclockwise to decrease the set pres-
sure.
2. After the pressure has been adjusted, tighten the
locknut (5) while holding the setscrew (6) firmly in R8
place.
3. Operate the relief valve once more to confirm that the
pressure that has been set is stabilized.
4
5
6
2D0BO23
1 Locknut (5): 59 N·m to 69 N·m (44 ft-lb. to 51 ft-

lb.)
10
SERVICE DATA
3. Cylinder speed
Measurement method
Lowering speed when the lift arm is in float
• Measuring attitude: Bucket cylinder fully retracted
• Measuring instrument: Digital stopwatch
Turn ON the float mode and fully extend the lift arm cylin-
der. Return the control lever to the neutral position and al-
low the lift arm to drop under its own weight. Use a digital
stopwatch to measure the time required for the lift arm
cylinder to reach its fully retracted position. 2D0BS02
Float mode: Operator’s manual
Lift arm
• Measuring attitude: Bucket cylinder fully retracted
Up: Use a digital stopwatch to measure the time required
for the lift arm cylinder to move from the fully retracted po-
sition to the fully extended position.
Down: Use a digital stopwatch to measure the time re-
quired for the lift arm cylinder to move from the fully ex-
tended position to the fully retracted position.
2D0BS03
Bucket
• Engine speed: High 2
• Measuring attitude: Make sure that the bucket pin (1)
and the arm foot pin (2) are at the same height.
Rollback: Use a digital stopwatch to measure the time re- 1
quired for the bucket cylinder to move from the fully ex-
tended position to the fully retracted position.
Dump: Use a digital stopwatch to measure the time re-
quired for the bucket cylinder to move from the fully re-
tracted position to the fully extended position.
2D0BS04
11
SERVICE DATA
4. Travel speed
Measurement method
• Hydraulic oil temp.: 50°C to 60°C (122°F to
140°F)
• Measurement test location: Concrete level surface or
flat and firm ground
• Measuring attitude: Traveling
Drive 5 meters, then use a digital stopwatch to measure
the time required for the machine to travel another 10 me-
ters. Measure under the following 4 conditions: 2D0BO09
1. 1st speed forward
2. 1st speed reverse
3. 2nd speed forward
4. 2nd speed reverse
• Traveling attitude
The arm and bucket cylinders should be retracted as
much as possible.
2DAA11Z
5. Crawler shoe 5 rotations

Measurement method
140°F)
• Measuring attitude: Place the block (1) under the rear
of the machine to support it and raise the machine by
using the arm and bucket.
Rotate both right and left crawler belts at the same time. 2D0BO08
From the 2nd rotation, measure the time required for the
belts to finish 5 rotations. Measure under the following 8
conditions:
1. Right crawler 1st speed forward travel
2. Right crawler 1st speed reverse travel
3. Left crawler 1st speed forward travel
4. Left crawler 1st speed reverse travel
5. Right crawler 2nd speed forward travel
6. Right crawler 2nd speed reverse travel
7. Left crawler 2nd speed forward travel
8. Left crawler 2nd speed reverse travel
12
SERVICE DATA
6. Straight-ahead traveling 10m(32.8ft.)
Measurement method 5m(16.4ft.) 5m(16.4ft.)
• Engine speed: Throttle controller in cen-
tral position
140°F)
• Measuring attitude: Traveling attitude
• Measuring instrument: Measuring tape, markers
or chalk, nylon rope, tape
measure X 2D0BQ14
Measure 10 m (32.8 ft) with a measuring tape. Mark out
the start line, mid-point 5 m (16.4 ft), and end line 10 m
(32.8 ft) with markers or chalk. First drive 5 meters (16.4
ft) and then drive a further 10 meters (32.8 ft). Measure
the distance X shown in the figure. The details are shown
below.
Make marks when the machine passes the start line 0 m
(0 ft), mid-point 5 m (16.4 ft), and end line 10 m (32.8 ft).
Use nylon rope to join the marks at the start 0 m (0 ft) and
end 10 m (32.8 ft) positions. Measure the distance X be-
tween the nylon rope and the mark at the 5 m (16.4 ft) po-
sition with a tape measure. Check the veering direction.
Measure under the following 2 conditions:
1. Forward
2. Reverse
7. Hydraulic cylinder natural drop

Measurement method
• Engine speed: Engine stopped
• Measuring attitude: Make sure that the bucket pin (1)
and the arm foot pin (2) are at the same height and the
bucket is level.
• Measuring instrument: Digital stopwatch, paper tape,
tape measure
Maintain the measuring attitude for 5 minutes (measure
the time with a digital stopwatch). Measure the change in
length of the lift arm cylinder rod and bucket cylinder rod
over this time with a tape measure. Before the measure-
ment, mark the cylinder rods with paper tape and use it to
measure the change in length.
13
SERVICE DATA
8. Natural travel drop
Measurement method
• Engine speed: Low
140°F)
• Measurement test location: Sloping ground (15°±1.5°)
• Measuring attitude: Traveling attitude The ma-
chine can move forward or
in reverse.
• Measuring instrument: Digital stopwatch, markers
or chalk
Stop the machine on sloping ground. Make matchmarks
on the left and right crawlers and the ground with markers
or chalk. Lift up the safety lever and wait for 1 minute.
(Measure the time with a digital stopwatch.) OK if the
matchmarks remain unchanged. NG if the matchmarks
become displaced.
9. Crawler tension
Measurement method
140°F)
• Measuring attitude: Lower the lift arm, tilt the bucket
forward, and fully lift the front of the crawler off the
ground.
• Measuring instrument: Tape measure
Use a tape measure to measure the clearance between 2DAD04Z
the central track roller and the top of the crawler shoe.
10. Bucket front edge

Measurement method
140°F)
• Measuring attitude: Turn ON the arm float mode and al-
low the lift arm to drop under its own weight until the
bucket contacts the ground surface. Set the bottom
surface of the bucket horizontal.
Arm float mode: Operator's manual
• Measuring instrument: Tape measure
Use a tape measure to measure the heights A and B
above the ground of the right and left front edges of the
bucket front edge.
14
2
SERVICE DATA
TIGHTENING TORQUE
TIGHTENING TORQUE
Hydraulic hose
UNION NUT
Tightening torque ÜBERWURFMUTTER
ECROU D'UNION
Hose fitting size Union nut (G) Taper thread (R) 联管螺母
N·m ft.-lb N·m ft.-lb

1/8 9.8 +4.9
0 7.3 +3.5
0 11.8 ± 1.2 8.7 ± 0.8 TAPER THREAD
KEGELWINDUNG
1/4 24.5 +4.9
0 18.1 +3.5
0 29.4 ± 2.9 21.7 ± 2.1 FILETAGE CONIQUE
锥管螺纹
3/8 49.0 +4.9

0 36.2 +3.5
0 53.9 ± 5.4 39.8 ± 3.9
1/2 58.8 +4.9
0 43.4 +3.5
0 88.3 ± 8.8 65.1 ± 6.4
3/4 117.7 +4.9
0 86.8 +3.5
0 147.1 ± 14.7 108.5 ± 10.7 2E0BO01
1 137.3 +4.9
0 101.3 +3.5
0 196.1 ± 19.6 144.7 ± 14.3
Bite-type pipe fitting for steel pipe
Outer diameter of pipe Tightening torque

(mm) N·m ft.-lb
8 34.3 ± 4.9 23.5 ± 3.5
10 41.7 ± 2.5 30.7 ± 1.7
12 58.8 ± 4.9 43.4 ± 3.5
15 88.3 ± 4.9 65.1 ± 3.5
16 93.2 ± 4.9 68.7 ± 3.5
18 132.4 ± 4.9 97.6 ± 3.5 2EAA02Z
22 205.9 ± 9.8 151.8 ± 7.2

27.2 245.2 ± 9.8 181.0 ± 7.2
28 313.8 ± 19.6 231.4 ± 14.3
32 313.8 ± 19.6 231.4 ± 14.3
35 411.9 ± 19.6 303.7 ± 14.3
1
TIGHTENING TORQUE 2E0BO001
2
SERVICE DATA
TIGHTENING TORQUE
Joint for piping
Tightening torque
Nominal thread
Steel Cast steel
diameter (R)
1/8 11.8 ± 1.2 8.7 ± 0.8 10.8 ± 1.1 8.0 ± 0.7
1/4 29.4 ± 2.9 21.7 ± 2.1 24.5 ± 2.5 18.1 ± 1.7
3/8 53.9 ± 5.4 39.8 ± 3.9 49.0 ± 4.9 36.2 ± 3.5
1/2 88.3 ± 8.8 65.1 ± 6.4 73.5 ± 7.4 54.3 ± 5.3
3/4 147.1 ± 14.7 108.5 ± 10.7 127.5 ± 12.7 94.1 ± 9.3 2EAA03Z
1 196.1 ± 19.2 144.7 ± 14.3 171.6 ± 17.2 126.6 ± 12.5
Joint for piping (O-ring seal type)

O-RING
Nominal thread diameter Tightening torque O-RING
JOINT TORIQUE
(G) N·m ft.-lb O 形环
1/8 19.6 ± 2.0 14.5 ± 1.4

1/4 34.3 ± 4.9 25.3 ± 3.5
3/8 53.9 ± 4.9 39.8 ± 3.5
1/2 63.7 ± 4.9 47.0 ± 3.5
3/4 93.2 ± 4.9 68.7 ± 3.5
1 107.9 ± 9.8 79.5 ± 7.2
1–1/4 117.7 ± 9.8 86.8 ± 7.2
2E0BO02
1–1/2 137.3 ± 9.8 101.2 ± 7.2
Nominal thread diameter Tightening torque

(UNF) N·m ft.-lb
7/19–20 16.7 ± 2.0 12.3 ± 1.4
1/2–20 22.6 ± 2.0 16.6 ± 1.4
9/16–18 31.4 ± 2.9 23.1 ± 2.1
3/4–16 59.8 ± 4.9 44.1 ± 3.5
1–1/16–12 102.0 ± 5.9 75.2 ± 4.4
1–5/16–12 135.3 ± 7.8 99.8 ± 5.8
1–5/8–20 181.4 ± 9.8 133.8 ± 7.2
2
2
SERVICE DATA
TIGHTENING TORQUE
Bolts and nuts (JIS strength category 10.9)

Tightening torque
Thread Size × pitch General tightening points Special tightening points
M6 × 1.0 9.8 ± 0.8 7.2 ± 0.6 12 ± 1.0 9.0 ± 0.7
M8 × 1.25 23 ± 1.8 17 ± 1.4 26 ± 2.1 20 ± 1.6
M10 × 1.5 47 ± 3.8 35 ± 2.8 55 ± 4.4 41 ± 3.3
Coarse M12 × 1.75 83 ± 6.6 62 ± 5 97 ± 7.8 72 ± 5.8
M14 × 2.0 134 ± 10.7 99 ± 7.9 156 ± 12.5 115 ± 9.2
M16 × 2.0 208 ± 16.6 153 ± 12.2 241 ± 19.3 178 ± 14.2
M20 × 2.5 411 ± 32.9 303 ± 24.2 476 ± 38.1 351 ± 28.1
M8 × 1.0 25 ± 2.0 18 ± 1.4 28 ± 2.2 21 ± 1.7
M10 × 1.25 50 ± 4.0 37 ± 3 59 ± 4.7 43 ± 3.4
M12 × 1.5 87 ± 7.0 64 ± 5.1 102 ± 8.2 75 ± 6

Fine
M14 × 1.5 135 ± 10.8 100 ± 8 158 ± 12.6 117 ± 9.4
M16 × 1.5 221 ± 17.7 163 ± 13 256 ± 20.5 189 ± 15.1
M20 × 1.5 452 ± 36.2 333 ± 26.6 523 ± 41.8 386 ± 30.9
1. General tightening points (non-lubricated)

All securing points that have no special tightening
torque specified in this manual and that are not spe-
cial tightening points.
2. Special tightening points (grease with molybdenum
disulfide applied)
Points where a specific tightening torque is specified
in this manual.
3. Points where thread-locking compound should be
applied (ThreeBond #1324).
4. If a tightening torque value is specified in this manual
for a point not listed in the table above, follow the
specification in the manual.
5. To tighten multiple bolts and nuts evenly, tighten op-
posite bolts/nuts alternately as a pair.
3
HYDRAULIC CIRCUIT DIAGRAM
Machine without high-flow
Red: Main circuit

Pilot primary
pressure
Green: Pilot secondary
pressure
Light blue: Return piping
Drain piping
Drawing No. 1
06901-00039-00 1
2F0BS01
1
2F0BS00
Machine with high-flow equipment and machine with optional equipment
Red: Main circuit

Pilot primary
pressure
Green: Pilot secondary
pressure
Light blue: Return piping
Drain piping
Drawing No. 1
06901-00038-00 1
2F0BS02
2
2F0BS00
SERVICE DATA
ELECTRICAL CIRCUIT DIAGRAM 2
ELECTRICAL CIRCUIT DIAGRAM
Wire/cable color symbols
Wiring/cable Colors
Symbol Color Symbol Color Symbol Color
B Black W White V Violet
G Green Y Yellow Dg Dark green
L Blue P Pink Ch Chocolate
R Red O Orange
1 Cross-sectional area (mm2)

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

• Use AVSS wire for cross-sectional areas of 2 mm2 or less.
• Use AV or AVS wire for cross-sectional areas exceeding 2 mm2. (AVX wire can be used for wires of solid color.)
Temperature
Symbol Overview Characteristics
limit
AV Low-voltage cables for automobiles • Wire used in low-voltage circuits. 80°C (176°F)
• A wire with dramatically improved heat resistance over that of AV

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

2 Insulator: Vinyl
1
ELECTRICAL CIRCUIT DIAGRAM 2G0BS00
Electrical Schematic Diagram
MAIN CONTROLLER 1
MAIN CONTROLLER 2 OX CONTROLLER
Drawing No. 1
06901-00024-03 2
2G0BS01
2
2G0BS00
2G0BS02
3
2G0BS00
2G0BS03
4
2G0BS00
2G0BS04
5
2G0BS00
MAIN CONTROLLER 1
MAIN CONTROLLER 2 OX CONTROLLER
Drawing No. 1
06901-00024-03 2
2G0BS05
6
2G0BS00
E G
F H
Drawing No. 2
06901-00024-03 2
2G0BS06
7
2G0BS00
Electrical Schematic Diagram (CCV heater specification)
2G0BS07
8
2G0BS00
F
2G0BS08
9
2G0BS00
G
2G0BS09
10
2G0BS00
H
Drawing No. 2
06901-00024-03 2
2G0BS10
11
2G0BS00
SERVICE DATA
HYDRAULIC DEVICE LAYOUT DIAGRAM 2
HYDRAULIC DEVICE LAYOUT DIAGRAM
11
11
1. Left travel motor
9
2. Right travel motor
3. Left arm cylinder
4. Right arm cylinder
5. Left bucket cylinder
6. Right bucket cylinder
5 7. Quick-hitch cylinder
8. Solenoid valve (quick-hitch)
10
9. Block coupler (1st auxiliary line pip-
8 ing)
7
10. Block coupler (2nd auxiliary line pip-
ing)
2H1BS01 11. Quick coupler
1
HYDRAULIC DEVICE LAYOUT DIAGRAM 2H1BS00
SERVICE DATA
17
14
15
12
22
16
18
13 21
23
20
19
12. Control valve

13. Proportional solenoid valve (active
25 power control)
14. Solenoid valve (1Way/2way switch-
ing)
15. Sub-valve
16. Proportional solenoid valve (1st ser-
vice)
17. Line filter
18. Emergency valve
19. Accumulator
20. Solenoid valve (ride control)
21. Solenoid valve (high-flow)
24
22. Solenoid valve (2nd service)
23. Hydraulic tank
24. Shuttle valve
2H1BS02 25. Selector valve
2
SERVICE DATA
29
28
30
27
26
26. Left pilot valve

27. Right pilot valve
28. Gear pump
29. HST pump
2H1BS03 30. Oil cooler
3
FUNCTION 3
3
FUNCTION
GEAR PUMP
GEAR PUMP
Two types of gear pump (1) are available, with and with-
out high-flow installed. The first is the double-gear pump
(P3, P4) without high-flow and the second is the triple-
gear pump (P3, P4, P5) with high-flow. Each type is a
constant-volume pump that delivers a constant dis- 1 6 2
charge flow rate at a fixed rotational speed.
In the double-gear pump, pump P3 discharges pressur-
ized oil to the arm, bucket, and the auxiliary line hydraulic
piping and pump P4 discharges pressurized oil for the
charge pressure and pilot pressure. In the triple-gear
pump, pump P3 discharges pressurized oil to the arm,
bucket, and the auxiliary line hydraulic piping, pump P4 3
discharges pressurized oil for high-flow, and pump P5 3IAU01
discharges pressurized oil for the charge pressure and

pilot pressure.
The gear pump (1) is connected by the HST pump (2)
and coupling (3). The rotation of the engine rotates the
drive gear (6) of the gear pump (1).
The gear pump is located inside one of the gear cases

and is interlocked with the drive gear (6) and drive gear 6
(7). When the drive gear (6) is rotated, the space be-
tween the case and the gears is filled with the oil flowing
from the inlet to the outlet.
7 3I1AQ02Z
1
GEAR PUMP 3I1BO00
3
FUNCTION
SUB VALVE
SUB VALVE
This valve is composed of the solenoid valve A (lever
lock), the solenoid valve B (2nd speed travel) and the re-
lief valve.
This valve applies charge pressure from the pump P4
(pump P5 for a machine with high-flow) to the HST pump
and applies pilot pressure to each valve.
Port Connected to:

Control valve (arm float pilot pressure, level-
ing cancel pilot pressure, signal channel),
Port 1 proportional solenoid valve (1st auxiliary line
piping pilot pressure), solenoid valve (2nd
auxiliary line piping pilot pressure)
Port 1A Solenoid valve (parking brake release)
Travel motor (2nd-speed travel pilot pres-
Port 1B
sure)
Proportional solenoid valve (active power
Port 2
control)
Port 3 HST pump (charge pressure)
Port P Line filter
Port T Hydraulic tank
When the solenoid valve A is not energized:

The port P is connected with the circuit of the port 3
through the spool (4).
The pressure oil from the port P flows into the port 3, while
the port P is disconnected from the circuit (5) of the ports
1A and 1B.
3KAA011Z
The port P is disconnected from the circuit of the port 2

by the poppet (6).
The hydraulic oil from the port 2 pushes up the plunger
(7), flows into the port 1 circuit, and then enters the port
T together with the oil from the port 1A.
3KAA021Z
1
SUB VALVE 3K0BO00
3
FUNCTION
SUB VALVE
When the solenoid valve A is energized:

A magnetic field is generated around the coil that causes
the push rod to be pulled downward and the spool (8) to
be pushed downward. Next, the pressure oil from the
port P flows through the passages (9) and (10) and into
the chamber C.
3KAA031Z
The oil that flowed into the chamber C moves the spool
(4) downward. As a result, the port P and the port 3 are
disconnected while the port P and the passage (5) are
connected, and the oil flows from the port P to the port
1A.
3KAA041Z
The pressure oil in the port 1A passes through the bore

on the side panel of the spool (11) and the wire clearance
and then flows into the chamber D of the spool (11) and
piston (12). When the pressure in the chamber D be-
comes higher than the set pressure, the spool (11)
moves downward to allow the oil in the port 1 to flow to
the port 2. This keeps the pressure in the port 1 at the set
pressure.
The pressure oil in the port 2 pushes up the poppet (5)
and flows into the port 3.
3KAA051Z
When the solenoid valve B is not energized:

The pressure oil from the port P is blocked by the spool
(13).
The port 1B is connected with the port T.
3KAA061Z
2
SUB VALVE 3K0BO00
3
FUNCTION
SUB VALVE
When the solenoid valve B is energized:

A magnetic field is generated around the coil that causes
the push rod to be pulled downward and the spool (13)
to be pushed downward. The oil flows from the port P to
the port 1B, and the passage to the port T is blocked.
3KAA071Z
3
SUB VALVE 3K0BO00
3
FUNCTION
PILOT VALVE
PILOT VALVE
The pilot valve casing contains a vertical shaft hole that
incorporates a reducing valve. When the lever is tilted,
the push rod and spring seat are pushed down, which
changes the spring force of the secondary pressure.
The casing contains the oil inlet port P (the primary pres-
sure) and the tank port T. The secondary pressure corre-
sponding to the changes in operating angle as set with
the lever (1) can be provided through the output ports A
and B located below the vertical shaft hole. The second-
ary pressure functions as the pilot pressure to activate
the spool of the control valve (2).
When the lever (1) is in the neutral position:

1
The force of the spring (3) that determines the output
pressure (secondary pressure) of the pilot valve is not T
conveyed to the spool (4). This causes the spool (4) to be
pushed up by the return spring (5) and the output ports
A and B to be connected to the tank port T. This causes 3
the pressures in the ports A and B to be equal to the
pressure in the tank port T. 5
4
P
A B 3KAC02Z
When the lever (1) is tilted:

When the lever (1) is tilted and the push rod (6) is pushed
in, the spool (4) moves downward and the input port P
becomes connected to the output port A. Then, the oil
from the pilot pump flows into the output port A, which
generates a pressure.
3KAC031Z
When the lever (1) is kept at a certain position:

When the pressure in the output port A increases to a lev-
el equivalent to the force of the spring (3) set by the incli-
nation of the lever (1), the hydraulic pressure is balanced
with the spring force. When the pressure in the output
port A becomes higher than the set spring force, the out-
put port A is disconnected from the input port P and then
becomes connected to the tank port T. When the pres-
sure in the output port A drops below the set pressure,
the output port A becomes connected to the input port P
and is disconnected from the tank port T. The secondary
pressure is thus always kept constant.
3KAC041Z
1
PILOT VALVE 3K2AU00
3
FUNCTION
PROPORTIONAL CONTROL SOLENOID VALVE (ACTIVE POWER CONTROL)
PROPORTIONAL CONTROL SOLENOID VALVE

(ACTIVE POWER CONTROL)
This proportional control solenoid valve (2) plays a part
in the active power control system. It provides secondary
pressure control of the proportional solenoid valve (2) ac- 3
cording to the OX controller (1) output current to limit the 1 2
hydraulic oil flow rate to the pilot valve and prevent the
engine stalling.
The proportional control solenoid valve incorporates a
proportional control valve. As the force generated in the
solenoid of the proportional control valve is proportional
to the size of the current flowing in the coil, secondary
pressure is generated according to the fluctuations in the
current.
When current flows through the solenoid, a thrust force 3K4BM01
proportional to the current is generated and moves the

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

spool (6) is moved to the left, which connects the port P 9 6
(supply side) and the port A (secondary side) together
through the notch (9).
P A T
3K4AQ03Z
1
PROPORTIONAL CONTROL SOLENOID VALVE 3K4BO00
3
FUNCTION
PROPORTIONAL CONTROL SOLENOID VALVE (ACTIVE POWER CONTROL)
When the thrust force is lower than a set value, the spool
(6) is moved to the right, which connects the port A (sec- 6 10
ondary side) and the port T (tank side) together through
the notch (10).
The opening areas of the notch (9) on the supply side
and the notch (10) on the discharge side are thus con-
trolled by the movement of the spool (6), and a second-
ary (pilot) pressure can be provided that corresponds to
the thrust force generated by the solenoid.
P A T
3K4AQ04Z
2
3
FUNCTION
PROPORTIONAL CONTROL SOLENOID VALVE (1ST AUXILIARY LINE PIPING)

(1ST AUXILIARY LINE PIPING)
The proportional lever (2) and controller (3) of the pilot
valve (1) control the drive current flow to the proportional
control solenoid valve (4). This controls the pilot pressure
of the control valve (5) (1st auxiliary line piping section) 2
to change the flow rate in the 1st auxiliary line piping. 1
The proportional control solenoid valve incorporates a
proportional control valve. As the force generated in the 3
solenoid of the proportional control valve is proportional 5
to the size of the current flowing in the coil, secondary
pressure is generated according to the fluctuations in the
current.
When current flows through the solenoid, a thrust force 4
proportional to the current is generated and moves the 3K4AQ01Z
spool (6) so that the oil supplied from the port P is intro-
duced into the port A on the secondary pressure side, S 6
which increases the pressure Pa of the port A. 7 8
The pressure Pa acts on the differential area S between S=A1-B1
the cross section A1 and cross section B1 of the spool
(6), and the spool (6) is pushed to the solenoid side by B1 A1
the oil pressure, Pa × s. The spool (6) stops at the posi-
Fk
tion where the sum of the oil pressure, Pa × s, and the Fs Fks
force, Fk, exerted by the springs (7) is balanced with the Paxs
thrust force, Fs, generated by the solenoid. The weight,
Fks, of the spring (8) used for fine adjustment of the sec-
ondary pressure acts in the direction (left) of assistance P A T
of the thrust force from the solenoid.
Paxs Fk Fs Fks
3K4AQ02Z
When the thrust force is greater than a set value, the

spool (6) is moved to the left, which connects the port P 9 6
(supply side) and the port A (secondary side) together
through the notch (9).
P A T
3K4AQ03Z
1
3
FUNCTION
When the thrust force is lower than a set value, the spool
(6) is moved to the right, which connects the port A (sec- 6 10
ondary side) and the port T (tank side) together through
the notch (10).
The opening areas of the notch (9) on the supply side
and the notch (10) on the discharge side are thus con-
trolled by the movement of the spool (6), and a second-
ary (pilot) pressure can be provided that corresponds to
the thrust force generated by the solenoid.
P A T
3K4AQ04Z
2
FUNCTION
CYLINDER 3
CYLINDER
Function
A hydraulic cylinder is a type of hydraulic actuator. The energy of the oil supplied from the hydraulic pump is converted
to a high linear motion force. Operating the hydraulic directional valve switches the operating direction between exten-
sion and retraction. Its basic functions are high-force linear motion and switching the operating direction.
Functions of parts
The functions of each part of the cylinder are explained for a product with a typical construction. The product you use
may differ slightly but the functions are the same.
Cylinder head assembly

The cylinder head assembly has a bushing (4) press-fitted into the bore of the cylinder head (3) that functions as the
piston rod (2) bearing. The seal system for the cylinder head bore prevents oil leaking outside and prevents ingress of
foreign matter into the cylinder. It functions to supply and discharge high-pressure oil between the interior of the cylinder
tube and the retraction-side port.
3L0BO01
* Parts (10) to (14) do not exist in a cylinder with no cushion function.
Seal system construction-bushing (4), U-ring (5), wiper ring (6)
• Bushing (4)
This is press-fitted inside the cylinder head and makes contact with the piston rod. The transverse loads acting on the
cylinder are split between the bushing and the slide rings (18) around the outer circumference of the piston to achieve
linear motion with respect to the piston rod. They support one end of the piston rod to reduce eccentricity that can ad-
versely affect the sealing.
• U-ring (5)
The U-ring (5) seals the pressurized oil in the cylinder. It also applies a suitable thin film of oil to the piston rod surface
to prevent rusting.
• Wiper ring (6)

The wiper ring (6) is positioned at the opening where the piston rod moves in and out of the cylinder. It prevents the
ingress of dust and water into the cylinder from the outside. It also scrapes off any mud stuck onto the surface of the
piston rod as the piston rod moves.
1
CYLINDER 3L0BO00
FUNCTION
CYLINDER 3
Piston assembly
The piston assembly transmits the drive force of the cylinder. The seal ring (17) installed at the center of the piston (16)
prevents oil flowing from the chamber at the right or left of the piston into another chamber. The slide rings (18) installed
at each end of the seal ring function as bearings that bear the transverse cylinder loads.
3L0BO02
1 During installation, be aware of the orientation of the split circle

2 Align the slit toward the piston
* Parts (15) and (21) to (24) do not exist in a cylinder with no cushion function.
• Seal ring (17)

The seal ring located at the center of the piston uses the tension force of the O-ring to seal the circular gap that forms
between the piston and cylinder tube and create high- and low-pressure chambers divided by the piston.
• Slide rings (18)

These rings are located at each end of the seal ring and make contact with the inside of the cylinder tube. The transverse
loads acting on the cylinder are split between the slide rings and the bushing (4) located inside the cylinder head to
achieve linear motion with respect to the interior of the cylinder tube.
They support one end of the piston rod to reduce eccentricity that can adversely affect the sealing. Moreover, they act
to displace and trap foreign matter stuck between the cylinder tube and slide rings.
• Cushion bearing (15)

The cushion bearing engages with the cushion seal (11) or cylinder bottom when the cylinder is near maximum exten-
sion or retraction. This reduces the cylinder collision speed to alleviate shocks at maximum extension or retraction.
Pipe assembly
This is attached to the ports on top of the cylinder tube assembly (1). It supplies and discharges pressurized oil from the
main unit pump to the cylinder via a rubber hose.
2
CYLINDER 3L0BO00
FUNCTION
CYLINDER 3
Operation
A cylinder is a hydraulic device that utilizes Pascal's law. It operates due to pressurized oil supplied from outside.
P
3L0BP05
1 Large force
2 Pressure
3 Pump movement
The force generated by the cylinder is the product of the pressure P and the area A1 of the moving part to which the
pressure is applied.
F1 = A1 × P
P = F2/A2
F1 = A1 × F2/A2
Generally, the areas on which the pressure acts on the extension and retraction sides of the cylinder differ by the cross-
sectional area of the piston rod only.
3L0BP06
A1: Tube inner cross-sectional area

A2: Rod cross-sectional area
Q is the oil flow rate supplied to the cylinder

Force Extension Fe = P × A1
Retraction Fr = P × (A1 - A2)
Speed Extension Ve = Q/A1
Retraction Vr = Q/(A1 - A2)
3
CYLINDER 3L0BO00
FUNCTION
CYLINDER 3
The oil inside the cylinder is forced out when an external pushing or pulling force is applied to the cylinder. The oil that
is forced out is displaced to limit the movement of the cylinder.
3L0BP07
1 Orifice
The cylinder cushion automatically throttles the outflowing pressurized oil at the end of the stroke to reduce the cylinder
operating speed and alleviate the shock at the end of the stroke.
3L0BP08
1 Orifice
As the areas acted on by the pressure differ on the extension and retraction sides of the cylinder, cutting off the oil dis-
charged at the rod side increases the pressure on the bottom and generates a high pressure at the rod side.
4
CYLINDER 3L0BO00
FUNCTION
CYLINDER 3
3L0BP09
A1: Tube inner cross-sectional area

A3: Cushion cross-sectional area
P2 = P1 × A1/(A1 - A3)
Two forces act on the cylinder when the cushion moves: the external force (inertial force) and the pressurized oil supplied
by the pump. During the cushion stroke, the pressure between the piston and cylinder head is proportional to the ratio
between the pressure of the pressurized oil supplied by the pump and the cross-sectional area.
The cylinder may not move smoothly if air is trapped inside the cylinder.
If the cylinder rapidly operates or accelerates in this situation, high temperatures may be generated due to adiabatic
compression of the air. This may cause the packing to burn, resulting in an internal leak in the cylinder that can lead to
serious accidents, such as being unable to maintain the load.
(Air is normally dissolved in the oil and appears as bubbles when the pressure drops suddenly.)
To prevent such problems, gently move the cylinder through the full stroke several times to drive out any air contained
inside the cylinder when installing the cylinder in the machine and before starting work.
3L0BP10
1 Orifice
2 Air bubbles
5
CYLINDER 3L0BO00
DISASSEMBLY AND ASSEMBLY 4
DISASSEMBLY AND ASSEMBLY
SERVICE STANDARDS 4
SERVICE STANDARDS
Track roller A
Criteria, mm (in.)
Code
Standard dimension Allowable value
C 216 (8.5) 208 (8.2)
D 40 (1.6) —
Track roller B
Criteria, mm (in.)
Code
C 328 (12.9) 320 (12.6)
D 40 (1.6) —
C D
4A0BO04
Sprocket F
Criteria, mm (in.)
Code
E 386 (15.2) 376 (14.8)
F 46 (1.8) 36 (1.4)
4A0BO011
Idler
Criteria, mm (in.)
Code
G 450 (17.7) 444 (17.5)
H 45 (1.8) —
G
H
4A0BS02
1
SERVICE STANDARDS 4A0BS00
SERVICE STANDARDS 4
Clearance for pin and bushing
O
O
E
H E
J
J H
K
D
K
D
4A0BS01
2
SERVICE STANDARDS 4
4A0BO03
Unit: mm (in.)
Criteria
Code Item
Standard dimension A
O Arm assembly & machine frame 45 (1.8)
E Arm cylinder & machine frame 45 (1.8)
H Arm cylinder & arm assembly 45 (1.8)
J Bucket cylinder & arm assembly 45 (1.8)
K Bucket cylinder & quick-hitch bracket 45 (1.8)
D Arm assembly & quick-hitch bracket 45 (1.8)
Replacing the pin and bushing

Replace the pin or the bushing if there is looseness of 1
mm (0.04 in.) or more.
3
DRIVE SYSTEM 4
DRIVE SYSTEM
Engine
Construction diagram
6
1
13
1
2 15
131 7
2 11
3 22-4
1-4 9
20 1
2
4
8
5 15 2
27-1 12
4B0BS01
1
DRIVE SYSTEM 4B0BS00
DRIVE SYSTEM 4
83 10
10 52
83 10
4B0BS02
1 256 N·m (189 ft-lb.)

Bolt: Apply ThreeBond #1324 or an equivalent
2 110 N·m (81 ft-lb.)
Bolt: Apply ThreeBond #1324 or an equivalent
3 49 N·m (36 ft-lb.)
4 86 N·m (63 ft-lb.)
Make sure that the edge of the hydraulic pump spline re-
mains in contact with the snap ring (22-5) when tighten- 11
ing down the bolt.
5 55 N·m (41 ft-lb.)
6 1.5 N·m (1.1 ft-lb.)
7 26 N·m (19 ft-lb.)
8 When replacing the housing (23), coat the vacant seat- 4B0BS03
ing surface of the housing with black touch-up spray

paint after attaching the HST pump.
9 32 to 36 N·m (24 to 27 ft-lb.)
0 Wrap sealing tape around screw threads.
a Orient the marking (yellowish green) upward.
2
DRIVE SYSTEM 4
b Dimension A 18 mm (0.7 in.), Dimension B 32.5 mm B C
(1.28 in.), Dimension C 63.8 mm (2.51 in.)
A: Clearance between shroud (27-1) and engine cooling
fan
B: Overlapping dimensions between shroud (27-1) and A
engine cooling fan
C: Clearance between radiator and engine cooling fan
4B0BQ16
c Ensure 160 mm (6.3 in.) clearance in Post NOx Sensor
wiring from the clamp central position. 13
4B0BS04
3
DRIVE SYSTEM 4
1. Engine sub-assembly 22-5. Snap ring 51. Elbow 93. Bolt
1-1. Engine 23. Housing 52. Adapter 94. Bolt
1-2. Adapter 24. Bolt 53. Valve 95. Washer
1-3. O-ring 25. Radiator assembly 54. Plate 96. Washer
1-4. Plug 26. Bracket 55. Seat 97. Bolt
1-5. O-ring 27. Shroud assembly 56. Hose 98. Bolt
1-6. Elbow 27-1. Shroud 57. Hose 99. Bolt
1-7. Bracket 27-2. Plate 58. Hose 100.Washer
1-8. Washer 27-3. Washer 59. Hose 101.Spring washer
1-9. Bolt 27-4. Spring washer 60. DEF/ADBLUE® tank 102.Nut
1-10. Spring washer 27-5. Bolt 61. Cap 103.Nut
2. Pipe 27-6.Seal 61-1. Cap 104.Nut
3. Bolt 27-7.Seal 61-2. Filler 105.Washer
4. Cap 27-8. Tube 62. Seat 106.Spring washer
5. Pipe 28. Guard 63. Seat 107.Spring washer
6. Pipe 29. Hose 64. Seat 108.Washer
7. O-ring 30. Hose 65. Bracket 109.Band
8. Filter assembly 31. Hose 66. Plate 110.Band
8-1. Bracket 32. Hose 67. Bracket 111.Band
8-2. Filter 33. Hose 68. Plate 112.Bolt
8-3. Elbow 34. Air cleaner assembly 69. Clamp 113.SEMS bolt
8-4. Adapter 34-1. Air cleaner 70. Clamp 114.Tube
8-5. Plate 34-2. Sensor 71. Clamp 115.Tube
8-6. Bolt 34-3. Bracket 72. Spring washer 116.Washer
8-7. Washer 34-4. Washer 73. Bolt 117.Plug
8-8. Spring washer 34-5. Spring washer 74. Shim 118.Clamp
9. Hose assembly 34-6. Bolt 75. Band 119.Clamp
10. Hose assembly 34-7. Screw 76. Band 120.Collar
11. Engine hood (Front left) 35. Cable 77. Band 121.Clamp
12. Engine hood (Front right) 36. Hose 78. Drain valve 122.Band
13. Engine hood (Rear left) 37. Hose 79. Tank 123.Gasket
14. Engine hood (Rear right) 38. Protector 80. Stay 124.Bolt
15. Cap screw 39. Hose 81. Clamp 125.Hose
16. Washer 40. Protector 82. Washer 126.Band
17. Clamp 41. Hose 83. Adapter 127.Cover
18. Cushion rubber (marked D) 42. Protector 84. Band 128.Band
19. Cushion rubber (marked C) 43. Hydraulic pump 85. Band 129.Hose
20. Bolt 44. Pipe 86. Band 130.Boot
21. Spring washer 45. Nut 87. Clamp 131.Insulator
22. Coupling 46. Hose 88. Washer 132.Ring
22-1. Hub 47. Hose 89. Washer 133.Band
22-2. Flange 48. Hose 90. Bolt 134.Protector
22-3. Cap screw 49. Protector 91. Bolt 135.Protector
22-4. Cap screw 50. Elbow 92. Bolt 136.Band
4
DRIVE SYSTEM 4
Radiator
11 10-3
10 12
10-4
10-1
6 2 10-3
7 9 4
14 5 10-4
8
10-2
23
14
24 21
27
8
14
7 22
15 18 12
17
27
16
X 10-3
10-4
15 19 1
8
X 10-1
26 3
16
25
20 13
R0C020 19 4B0BS05
1. Cushion rubber 10. RAD/HOC 17. Pin

2. Cushion rubber 10-1. Plate 18. Snap pin
3. Bolt 10-2. Cap 19. Hinge
4. Spring washer 10-3. Bolt 20. Frame
5. Bolt 10-4. Washer 21. Sponge
6. Washer 11. Sponge 22. Sponge
7. Bolt 12. Sponge 23. Washer
8. Washer 13. Sponge 24. Nut
9. Stay 14. Spring washer 25. Nut
15. Pin 26. Washer
16. Snap pin 27. Sponge
5
DRIVE SYSTEM 4
Removing the engine
The numbers in parentheses ( ) after the names of parts
throughout this document do not correspond to the num-
bers in the construction diagrams or parts lists.
1. Disconnect the battery ground cable from the ma-

chine frame.
WARNING
Securely wrap or otherwise isolate the disconnected
terminal to ensure that it does not make contact with
the body or other parts.
2. Remove the lift arm.

4. Attachments
3. Remove the canopy or the cab.
4. Frame, Canopy/cab
4. Remove the covers.
4.Frame, Cover
5. Remove the floor frame.
4. Frame, Floor frame
6. Remove the hydraulic tank.
4. Hydraulic tank
7. Remove the hydraulic pump.
4. Drive system, Hydraulic pump (machine with-
out high-flow) / Hydraulic pump (machine with
high-flow)
8. Remove the control valve, sub valve, proportional so-
lenoid valve (1st service), solenoid valve (1-way / 2-
way selector), and shuttle valve.
2. Hydraulic device layout diagram
• Attach identification tags to the disconnected hos-
es and wire harnesses to use during reassembly.
6
DRIVE SYSTEM 4
9. Disconnect the fuel filters (5) and (6), as well as hos-
es (7) and (8).
4. Drive system, Fuel tank 8
To Engine
To Engine
6
5
4B0BO09
W
10. Remove the DEF/ADBLUE® tank (9), the hydraulic X
15
pump (10), the valve (11), and the hoses (12) to (16). 16 Z 13
Y
14
X
Y Z 10
W
11
12
U
U
9 V 4B0BO10
11. Remove the radiator assembly. 17

a. Remove the cap (17), remove the cap of drain
valve (18), and bleed out the engine coolant.
18
4B0BO11
7
DRIVE SYSTEM 4
b. Remove the bolts (19) and open the radiator as-
sembly (20).
c. Disconnect the hoses (21) and (22). 22 20
• Prepare a plate to catch drips of the hydraulic
oil.
19
21 4B0BO12
d. Disconnect the hose (23).

24
e. Remove the bands, and disconnect the hoses (24) W
and (25).
X
Band: 5 N·m (3.7 ft-lb.) X W
f. Remove the bands, and disconnect the hoses (26) 25

26
and (27).
Band: 5 N·m (3.7 ft-lb.)
Z
Y
Y
23
Z
27
4B0BO13
g. Remove the snap pins (29) and pins (28), and re-
move the radiator assembly (20).
Radiator: 2. Table of masses
• During assembly, the radiator is to be mounted
at a right angle to the frame and parallel to the
cooling fan. 28
29
X
28
29 4B0BO14
31
12. Remove the connectors of the hose (30) and the sen- 32
sor (31), and remove the air cleaner (32).
13. Take out the clamp (33), and remove the bracket 34
(34).
33
30
4B0BO15
8
DRIVE SYSTEM 4
14. Disconnect the hoses (36) and (37) from the com-
pressor (35). 35
6. Air conditioner
15. Remove the wire harness from the engine.
• Disconnect from each connectors.
2. Electrical circuit diagram 36
4. Wire harness
37
4B0BO16
1 Engine hood (Rear right)
16. Disconnect the sensors (40) and (41). 40

Workshop manual engine
41
4B0BO17
17. Disconnect the battery cable (42).
42
4B0BO18
1 Battery
18. Disconnect the hose (43), and disconnect the cable

(44). 46
19. Remove the cushion rubbers (45) to (48). 45
20. Suspend the engine and remove it.
Engine: 2. Table of masses
48
44
47
43
4B0BO19
1 Engine
9
DRIVE SYSTEM 4
Installing the engine
• To install the engine, follow the same procedures as for
removal but in the reverse order.
• The radiator is to be mounted at a right angle to the
frame and parallel to the cooling fan.
10
DRIVE SYSTEM 4
Hydraulic pump (without high-flow equipment)
21
A
23
4 6
20
18
3 9 4
13 15
5
19
17 1
3
11 1
8
14
22
24 23-1 7
4 6
5
16
2
7
12 2
13
R1D110 10 3 6 VIEW A
4B0BS06
1 256 N·m (189 ft-lb.)

2 47 N·m (35 ft-lb.) Thread-locking compound (ThreeBond #1324 or an equivalent)
3 40 N·m (30 ft-lb.)
4 132 N·m (97 ft-lb.)
5 When replacing the HST pump, coat the vacant seating surface with black touch-up spray paint after attaching the
gear pump.
6 Apply molybdenum disulfide grease (Zemico grease AD-1 or an equivalent) to the splines.
7 Use the O-ring (23-1) supplied with the HST pump (23).
1. Washer 10. Cap screw 19. Elbow

3. Bushing 12. Cap screw 21. Adapter
4. Bushing 13. Spring washer 22. Adapter
5. Flange 14. O-ring 23. HST pump
6. Adapter 15. O-ring 23-1. O-ring
7. Flange 16. O-ring 24. Gear pump
8. Tee 17. O-ring
9. Cap screw 18. Plug
11
DRIVE SYSTEM 4
Hydraulic pump (with high-flow equipment)
22
19 20
A
10 3 27
4
19 20
4 7
16 14
3 10 4
5
14 16
18
5
21
18
1
3
12 1
15 9
23
26 17
27-1 7
2 4 7
25 13 2
24 5
25 6
17
14
8
11 3
14
11 3 6 VIEW A
R1D120 4B0BS07
1 256 N·m (189 ft-lb.)

2 47 N·m (35 ft-lb.) Thread-locking compound (ThreeBond #1324 or an equivalent)
3 40 N·m (30 ft-lb.)
4 132 N·m (97 ft-lb.)
5 When replacing the HST pump, coat the vacant seating surface with black touch-up spray paint after attaching the
gear pump.
6 Apply molybdenum disulfide grease (Zemico grease AD-1 or an equivalent) to the splines.
7 Use the O-ring (27-1) supplied with the HST pump (27).

2. Washer 12. Cap screw 22. Adapter
3. Bushing 13. Cap screw 23. Adapter
4. Bushing 14. Spring washer 24. Hose
5. Flange 15. O-ring 25. Band
6. Flange 16. O-ring 26. Gear pump
7. Adapter 17. O-ring 27. HST pump
8. Flange 18. O-ring 27-1. O-ring
9. Tee 19. Plug
10. Cap screw 20. Elbow
12
DRIVE SYSTEM 4
Removing the hydraulic pump
1. Tilt up the canopy/cab.

4. Frame, Tilting up the canopy and cab
2. Drain the hydraulic oil from the hydraulic tank.
4. Hydraulic tank
<Machine without selector valve>

2
3. Disconnect the hoses (1) to (4). 1
4
4B0BO20
1 Hydraulic pump
<Machine with selector valve>

3. Take out the clamp (9), and disconnect the hoses (5) 5
to (8). X1
9 X2
6
X12
X11
7
4B0BO21
1 Hydraulic pump
13
DRIVE SYSTEM 4
<Machine without high-flow equipment>
11
13
12
4B0BO22
1 Hydraulic pump
<Machine with high-flow equipment>

16
4. Disconnect the hoses (14) to (18).
15
14
17 18
4B0BO23
1 Hydraulic pump

22
21
20
19
18 4B0BO24
1 Hydraulic pump
14
DRIVE SYSTEM 4
6. Remove the wire harness from the pressure switch 24
(24).
7. Remove the wire harness from the pressure switch
(25). (Only with machine without selector valve)
25
4B0BO25
1 Hydraulic pump
8. Raise and temporarily suspend the hydraulic pump

(26) with a crane.
9. Take out the cap screws (27), and remove the hy-
draulic pump (26).
Installing the hydraulic pump

To install, follow the same procedures as for removal but
in the reverse order. 27
26
4B0BO26
15
DRIVE SYSTEM 4
Bleeding air from the HST pump
WARNING
When reassembling the HST pump for repair or re-
placement, be sure to bleed the air from it before
starting the engine. Failure to do so may cause an un-
expected movement of the machine, resulting in per-
sonal injury or death.
<Machine without selector valve> X1

M4
1. Before inserting the HST pump into the machine, fill X2
the servo control chambers with hydraulic oil. M15 1
X12
a. Attach the plugs to the pilot ports (X1), (X2), (X11), M5
and (X12).
b. Fill the servo control chambers with hydraulic oil
through the pressure detection ports (M4), (M5),
(M14) and (M15), and tighten the plugs.
X11
2. Install the HST pump on the machine.
M14
4B0BO27
1 Hydraulic pump
3. Fill the hoses that are to be connected to the pilot

ports (X1) and (X11) with hydraulic oil.
• Fill the hoses with oil by holding the opening of the X11
hose at the same height as the pilot valve.
If the hose is held at a lower height than the pilot
valve, air bleeding fails. If the hose is held at a
higher height than the pilot valve, the oil poured
into the hose will flow into the tank.
4. Remove the plugs from the pilot ports (X1) and (X11),
and connect the hoses to the ports to prevent the oil
from running out.
4B0BO28
5. Remove the plugs from the pilot ports (X2) and (X12),
and connect the hoses to these ports. 1 Hydraulic pump
2 Pilot valve
6. Connect the rest of the hoses to the pump.
7. Fill the pump with oil through the plug hole (1) and the
pressure detection ports (M5) and (M15), and tighten
the plugs.
8. Start the engine, and let it run at an idling speed for
five minutes to bleed air out of the pump casing.
9. Bleed air from the main circuit and the pilot circuit by
slowly operating the pilot valve.
16
DRIVE SYSTEM 4
<Machine with selector valve> X1
M4
1. Before inserting the HST pump into the machine, fill X2
the servo control chambers with hydraulic oil. M15 1
X12
a. Attach the plugs to the pilot ports (X1), (X2), M5
(M15), and (M14).
b. Fill the servo control chambers with hydraulic oil
through the pressure detection ports (M4), (M5),
(X12) and (X11), and tighten the plugs.
X11
2. Install the HST pump on the machine.
M14
4B0BO27
1 Hydraulic pump
3. Fill the hoses that are to be connected to the pilot

ports (X1) and (M14) with hydraulic oil.
• Fill the hoses with oil by holding the opening of the M14
hose at the same height as the pilot valve.
If the hose is held at a lower height than the pilot
valve, air bleeding fails. If the hose is held at a
higher height than the pilot valve, the oil poured
into the hose will flow into the tank.
4. Remove the plugs from the pilot ports (X1) and (M14),
and connect the hoses to the ports to prevent the oil
from running out.
4B0BO29
5. Remove the plugs from the pilot ports (X2) and (M15),
and connect the hoses to these ports. 1 Hydraulic pump
2 Pilot valve
6. Connect the rest of the hoses to the pump.
7. Fill the pump with oil through the plug hole (1) and the
pressure detection ports (M5) and (X12), and tighten
the plugs.
8. Start the engine, and let it run at an idling speed for
five minutes to bleed air out of the pump casing.
9. Bleed air from the main circuit and the pilot circuit by
slowly operating the pilot valve.
17
DRIVE SYSTEM 4
Fuel tank
28
34 24
8 31
18
51
25
31
24
7 3 34 2 50 51-1
28 24 48
34 34 34
10
5
9
62 52
26 49
31
18 52
5
15
49
1
14
16
13 12
19
29 11
R1D130a 22
59 47
42
56 47 23
55 57 30
56 61 44
54 56 57 27 65 35
31 47
47 34
55 60 47 33
64 43 29
21
56 26 47 To Engine
55 53
56 31
56 34 To Engine
54 47
45
58
55 52
40
47 47
39 47
63
38
46
47 37
47
R1D130b 4B0BS08
18
DRIVE SYSTEM 4
1. Fuel tank sub assembly 25. Bolt 48. Band
2. Supply port 26. Bolt 49. Band
3. Plate 27. Bolt 50. Strainer
5. Rubber cushion 28. Nut 51. Cap
7. Band 29. Spring washer 51-1. Packing
8. Plate 30. Spring washer 52. Band
9. Rubber cushion 31. Spring washer 53. Feed pump
10. Rubber cushion 33. Washer 54. Bolt
11. Rubber cushion 34. Washer 55. Fuel pipe
12. Rubber cushion 35. Protector 56. Packing
13. Band 37. Protector 57. Packing
14. Rubber cushion 38. Protector 58. Fuel filter
15. Hose 39. Protector 59. Water separator
16. Collar 40. Protector 60. Fuel filter
18. Washer 42. Hose 61. Fuel pipe
19. Washer 43. Hose 62. Plate
21. Bolt 44. Hose 63. Tube assembly
22. Bolt 45. Hose 64. Hose
23. Bolt 46. Hose 65. Pipe
24. Bolt 47. Band
19
DRIVE SYSTEM 4
11
17
19
11
18
8 12
19
10
3
2
15
14
8
10
6
13
1
7
9
13 13
10 5 4
R0D130 16 10
8
8 4B0BS09
1. Fuel tank 8. Cap screw 15. O-ring

2. Flange 9. Screw 16. Plug
3. Flange 10. Spring washer 17. Hose
4. Flange 11. Screw 18. Band
5. Flange 12. Screw 19. Fuel sender
6. Flange 13. O-ring
7. Cushion rubber 14. O-ring
20
DRIVE SYSTEM 4
Removing the fuel tank
1. Raise the lift arm and support it using the lift arm stop-
per.
4. Frame, Lift arm stopper
4. Frame, Removing the floor frame
4. Remove the hydraulic tank.
4. Hydraulic tank, Removing the hydraulic tank
5. Remove the DEF/ADBLUE® tank.
4. Drive system, Engine
6. Remove the hydraulic pump.
4. Drive system, Removing the hydraulic pump
7. Disconnect the plug (1), and drain off the fuel.
Fuel tank capacity 2. Lubricant and fuel chart,
2
Diesel fuel standards
8. Disconnect the connectors of the fuel senders (2) and
remove the wire harness from the fuel tank.
• Remove the clamps that are used to fix the wire
harness to the fuel tank.
1
4B0BO30
1 Fuel tank
9. Remove the bands (4) and (5).

4 5
10. Remove the fuel tank.
Installing the fuel tank

in the reverse order.
4B0BO31
1 Fuel tank
21
4
TRAVEL SYSTEM
TRAVEL SYSTEM
Track roller ( 412100002 to 412100418)
3 1
5
2-11 4
2-8 2-10
2-7
2-1
2-13
2-6
1-3 2-4
1-5
1-4 1-8
4 2 1-1
6
1-6 3 1
1-4 5
2-9
1-7
1-2 2-2
1-7 2-9
1-5 2-7
1-3 2-8
1-6 2-3
6 2-5
4 2 2-12
R0A010
4C0BS01
1 Bolt: 156 N·m (115 ft-lb.)

Bolt: ThreeBond #1324, or an equivalent
2 Bolt: 241 N·m (178 ft-lb.)
3 When tightening the bolt (4), align the shaft (1-2) seat 3
with the mounting seat on the machine body frame.
4 Bolt: 55 N·m (41 ft-lb.)
Bolt: ThreeBond #1324, or an equivalent 4
1-2
4C0BS03
1. Track roller A 2. Track roller B 2-9. O-ring 3. Bolt

1-1. Roller 2-1. Roller 2-10. Plug 4. Bolt
1-2. Shaft 2-2. Shaft 2-11. Bolt 5. Washer
1-3. Cover 2-3. Cover 2-12. Bolt 6. Washer
1-4. Bushing 2-4. Cover 2-13. Spring washer
1-5. Floating seal 2-5. Plate
1-6. Retaining ring 2-6. Plate
1-7. O-ring 2-7. Bearing
1-8. Plug 2-8. Floating seal
1
TRAVEL SYSTEM 4C0BS001
4
TRAVEL SYSTEM
Track roller ( 412100419 to 412100611)

4 1 6
6
3-8 10 3-10 4
3-11 7 3-7
3-1 8
3-13
3-6
3-4 8
2-4 8
5 2 2-7 10
2-5 4 1 6
7 2-1 8 6
2-6 3-9 9
1-4 8
2-5 3-2 8
1-7 10
1-5 2-8 9 3-9 9
5 2 2-2 8 3-7
7 1-1 8 3-8 10
1-6 2-8 9
2-7 10 3-3 8 3-5
2-3 8 3-12
1-5 1-8 9
2-6
1-2 8 7
1-8 9 5 2
1-7 10
1-3 8 2-9 3
1-6
7
5 2
R0A010-1
1-9 3 4C0BO05
1 Bolt: 156 N·m (115 ft-lb.)

2 Bolt: 256 N·m (189 ft-lb.)
3 Plug: 8 to 10 N·m (6 to 7 ft-lb.)
Mount on the outside. Do not allow it to protrude outside 5
the cover (1-3) and (2-3).
4 Plug: 12 N·m (9 ft-lb.) 5
5 When tightening the bolt (5), align the seating surface of
the shaft (1-2) and (2-2) with the mounting seating sur- 1-2,2-2
face on the machine body frame.
the cover (3-3) and (3-4) with the mounting seating sur-
face on the machine body frame. 4C0BO07
7 Bolt: 55 N·m (41 ft-lb.)

8 Before installation, wash and degrease the rollers, shafts, and covers.
9 During installation, apply a quick-drying fixing wax (NOK KLÜBER CO., LTD. SEALUB L101 or an equivalent).
0 Do not twist O-rings during installation. Tilting of seal ring must be within 1 mm (0.04 inch).
Apply a little injection oil to the floating seal sliding surfaces. Injection oil: 2. Lubricant and fuel chart
1. Track roller A 1-8. O-ring 2-6. Retaining ring 3-4. Cover 3-12. Bolt
1-1. Roller 1-9. Plug 2-7. Floating seal 3-5. Plate 3-13. Spring washer
1-2. Shaft 2. Track roller C 2-8. O-ring 3-6. Plate 4. Bolt
1-3. Cover 2-1. Roller 2-9. Plug 3-7. Bearing 5. Bolt
1-4. Cover 2-2. Shaft 3. Track roller B 3-8. Floating seal 6. Washer
1-5. Bushing 2-3. Cover 3-1. Roller 3-9. O-ring 7. Washer
1-6. Retaining ring 2-4. Cover 3-2. Shaft 3-10. Plug
1-7. Floating seal 2-5. Bushing 3-3. Cover 3-11. Bolt
2
4
TRAVEL SYSTEM
Track roller ( From 412100612)

4
6
3-8 10 3-10
3-11 7 3-7
3-1 8
3-13
3-6
3-4 8
2-4 8
2-7 10
2-5 4
5
7 2-1 8 6
2-6 3-9 9
1-4 8 3-2 8
1-7 10 2-5
2-8 9
1-5 2-2 8 3-9 9
5 3-7
7 1-1 8 2-8 9
1-6 3-8 10
2-7 10 3-3 8 3-5
2-3 8 3-12
1-5 1-8 9
2-6
1-2 8 7
5
1-8 9
1-7 10 2-9
1-3 8
1-6
7
5
1-9
R0A010-2 4C0BS09
1 Bolt: 156 N·m (115 ft-lb.)

2 Bolt: 256 N·m (189 ft-lb.)
3 Plug: 8 to 10 N·m (6 to 7 ft-lb.)
Mount on the outside. Do not allow it to protrude outside 5
the cover (1-3) and (2-3).
4 Plug: 12 N·m (9 ft-lb.) 5
the shaft (1-2) and (2-2) with the mounting seating sur- 1-2,2-2
face on the machine body frame.
the cover (3-3) and (3-4) with the mounting seating sur-
face on the machine body frame. 4C0BO07
7 Bolt: 55 N·m (41 ft-lb.)

8 Before installation, wash and degrease the rollers, shafts, and covers.
0 Do not twist O-rings during installation. Tilting of seal ring must be within 1 mm (0.04 inch).
1. Track roller A 1-8. O-ring 2-6. Retaining ring 3-4. Cover 3-12. Bolt
1-1. Roller 1-9. Plug 2-7. Floating seal 3-5. Plate 3-13. Spring washer
1-2. Shaft 2. Track roller C 2-8. O-ring 3-6. Plate 4. Bolt
1-3. Cover 2-1. Roller 2-9. Plug 3-7. Bearing 5. Bolt
1-4. Cover 2-2. Shaft 3. Track roller B 3-8. Floating seal 6. Washer
1-5. Bushing 2-3. Cover 3-1. Roller 3-9. O-ring 7. Washer
1-6. Retaining ring 2-4. Cover 3-2. Shaft 3-10. Plug
1-7. Floating seal 2-5. Bushing 3-3. Cover 3-11. Bolt
3
4
TRAVEL SYSTEM
Front idler ( 412100002 to 412100574)

2-5
1-12 6
2-2
1-14 1-5 1-4 2 2-4
1-1 2
1-8 4 2-3
1-11 1-7
2-1
4
3 5 7 1-10 1
1-9 3
1-2 2
1-9 3
1-7
1-8 4
1-3 2
4 1-6
3 5 7 1-13
R0A020 4C0BS10
1 Insert the plug (1-10) on the outside.

2 Before installation, wash and degrease the idler (1-1), shaft (1-2), and covers (1-3) and (1-4).
4 Do not twist the O-ring (1-9) during installation. Tilting of seal ring must be within 1 mm (0.04 inch).
5 Bolt: 158 N·m (117 ft-lb.)
6 Bolt: 55 N·m (41 ft-lb.)
7 No clearance between covers (1-3) and (1-4), and yoke (2-1) when tightening the bolts (3).
1. Front idler 1-8. Floating seal 2. Spring assembly

1-1. Idler 1-9. O-ring 2-1. Yoke
1-2. Shaft 1-10. Plug 2-2. Rod
1-3. Cover 1-11. Spring pin 2-3. Spring
1-4. Cover 1-12. Bolt 2-4. Nut
1-5. Plate 1-13. Bolt 2-5. Split pin
1-6. Plate 1-14. Spring washer 3. Bolt
1-7. Bearing 4. Washer
4
4
TRAVEL SYSTEM
Front idler ( From 412100575)

2-5
1-12 2-2
1-14 1-5 1-4 2-4
1-1
1-8 2-3
1-11 1-7
1-10
2-1
3
1-9
1-2
1-9
1-7
1-8
1-3
1-6
3 1-13
R0A020-1
4C0BS11
1 Bolt: 158 N·m (117 ft-lb.)

2 Bolt: 55 N·m (41 ft-lb.)
3 Before installation, wash and degrease the idler (1-1), shaft (1-2), and covers (1-3) and (1-4).
4 Make sure that the O-rings are not twisted before installation. Tilting of seal ring must be within 1 mm (0.04 inch).
Apply a little injection oil to the floating seal (1-8) sliding surfaces. Injection oil: 2. Lubricant and fuel chart
5 No clearance between covers (1-3) and (1-4), and yoke (2-1) when tightening the bolts (3).
1-1. Idler 1-8. Floating seal 2-1. Yoke

1-2. Shaft 1-9. O-ring 2-2. Rod
1-3. Cover 1-10. Plug 2-3. Spring
1-4. Cover 1-11. Spring pin 2-4. Nut
1-5. Plate 1-12. Bolt 2-5. Split pin
1-6. Plate 1-13. Bolt 3. Bolt
1-7. Bearing 1-14. Spring washer
5
4
TRAVEL SYSTEM
Grease cylinder
3
5
6
4
R0A030
4C0BS04
1 Right
1. Grease cylinder
2. Piston
3. Check valve assembly
4. Oil seal
5. O-ring
6. Backup ring
6
4
TRAVEL SYSTEM
Travel motor
4
9
6
3 1
10
5 1
8
7
10
5
8
7 2
3 1
R0A040 4C0BS05
1 Bolt: 241 N·m (178 ft-lb.)

1. Sprocket 6. Adapter
2. Travel motor 7. Adapter
3. Bolt 8. O-ring
4. Elbow 9. O-ring
5. Adapter 10. O-ring
7
4
TRAVEL SYSTEM

Removing the crawler

1. Loosen the tension of the crawler (1).
• When loosening the check valve (2), do it slowly.
Stop loosening it once grease starts to come out.
If no grease comes out, slightly move the machine
forward and backward.
2. Place a block (4) under the machine to support it.
Raise the machine using the arm and bucket to lift the
crawlers off the ground.
4
1 2 4C0BO01
3. Fit the iron pipe (3) into the crawler (1) and then rotate 1
the sprocket in the reverse direction.
4. Once the pipe (3) reaches the side of the idler, stop
rotating the sprocket.
5. Slide the crawler (1) to the side, and remove it.
Crawler: 2. Service data, Table of masses
4C0BQ01
Installing the crawler 1

1. Place a block (4) under the machine to support it.
Raise the machine using the arm and bucket to lift the
crawlers off the ground.
2. Set the crawler (1) on the frame.
• Set the crawler (1) so that it is engaged with the
sprocket.
3. Fit the iron pipe (3) into the crawler (1) and then rotate
the sprocket in the reverse direction.
4. Once the pipe (3) reaches the side of the sprocket, 3
stop rotating the sprocket.
4C0BQ02
5. Slide the crawler (1) to a position where it can be
properly fitted with the idler.
6. Securely engage the crawler (1) with the sprocket
and idler. Inject grease through the check valve (2)
and adjust the crawler tension.
“2. Service data, Performance criteria”
8
4
TRAVEL SYSTEM
Removing the track roller A and C

1. Loosen the crawler tension.
2. Slightly loosen the mounting bolts (1) (about one turn)
for the track rollers A (2) and track rollers C (3).
3. Raise the machine to lift the crawlers off the ground.
Take out the mounting bolts (1) and remove the track
rollers A (2) and track rollers C (3).
Installing the track roller A and C

1. Temporarily tighten the mounting bolts (1) for the
1
3
track rollers A (2) and track rollers C (3). 2 1 4C0BS061
2. Completely lower the machine to the ground and then

further tighten the mounting bolts (1).
3. Lift up the machine, and adjust the crawler tension.
Removing the track roller B

1. Slightly loosen the mounting bolts (3) (about one turn)
for the track rollers B (4).
2. Remove the crawler. 3
“4. Travel system, Removing the crawler”
3. Take out the mounting bolts (3) and remove the track
rollers B (4). 4
Installing the track roller B

1. Temporarily tighten the mounting bolts (3) for the
track rollers B (4). 4C0BS071
2. Install the crawler.

“4. Travel system, Installing the crawler”
3. Completely lower the machine to the ground and then
further tighten the mounting bolts (3).
9
4
TRAVEL SYSTEM
Removing the front idler and grease cylinder

1. Remove the crawler.
“Removing the crawler”
2. Pull out the idler assembly (1).
Idler assembly: 2. Service data, Table of masses
3. Pull out the grease cylinder (2).
Grease cylinder: 2. Service data, Table of mass-
es
Installing the front idler and grease cylinder

To install, follow the same procedures as for removal but 4C0BO02
Removing the travel motor

1. Remove the crawler. 2
“Removing the crawler” 6 1
2. Take out the fixing bolts (1), and remove the sprocket 3
(2). 4
3. Remove the cover. Remove the hydraulic hoses (4)

and adapters (6).
4. Suspend the travel motor (3) temporarily, and remove 4
the fixing bolts (5).
5
5. Raise the travel motor (3) and then remove it.
4C0BS08
Travel motor: 2. Service data, Table of masses
Installing the travel motor

10
FRAME 4
FRAME
Machine frame
12 9
17 25 14
19 18
20
14 30 12
18 25 17
21 19
1 9
25 25
29
3
25
32
18
12 20
31 1 17 25
19
10
20
18
16
26 1 20
27 18
23 3 14 6
28 31 1 7
24 3 22 2 22 2 21
12 18
17 2 14
19 a
24 3 13 10 7
26 27 28 17
23 3 19 a 20
11 7 20
20 20 18 20 18
18 a a 4 18 14 5 18 14
R1B010 14 8 a 14 15 4E0BS01
1 Apply synthetic rubber adhesive. Make sure to put the joint upward.
2 Use shims (26), (27), and (28) to adjust the seats that receive the arm stoppers (22) of the lift arm, so that contact
is made at the left and right sides simultaneously. Adjust with a combined shim thickness of 5 mm (0.2 in.) or less.
3 Cap screw: 476 N·m (351 ft-lb.)
Cap screw: ThreeBond #1324, or an equivalent
1. Frame 12. Bolt 23. Cap screw

2. Cover (L) 13. Bolt 24. Cap screw
3. Cover (R) 14. Bolt 25. Cap
4. Cover 15. Bolt 26. Shim (t = 1.0 mm (0.04 in.))
5. Cover 16. Screw 27. Shim (t = 0.5 mm (0.02 in.))
6. Cover 17. Spring washer 28. Shim (t = 3.2 mm (0.13 in.))
7. Cover 18. Spring washer 29. Plate
8. Cover 19. Washer 30. Plate
9. Cover 20. Washer 31. Trim
10. Cover 21. Washer 32. Bolt
11. Clamp 22. Arm stopper
1
FRAME 4E0BS00
FRAME 4
Tilting up the canopy and cab
For inspection and maintenance, the canopy and cab can
C
A
be tilted up.
WARNING
• If the canopy or cab is raised or lowered while the B
engine is running, the machine may accidentally
start moving, which could lead to severe injury to
the maintenance personnel. Stop the engine before
attempting to raise or lower the canopy or cab.
• When the canopy or cab is tilted up, firmly secure
it in place with a stopper to prevent it from falling.
How to raise (tilt up) the canopy and cab

1. Select a firm and level surface, lower the working
equipment to the ground, and stop the engine.
2. Set the safety bar to the lock position.
3. Take out the lock bolts (A). 4E0BS02
4. Disconnect the R-pins and pull out the stopper pin

(B).
5. Slowly raise the canopy or cab. C B
6. Ensure that the hole in part C of the canopy/cab is

aligned with the hole where the stopper pin (B) was
pulled out. Insert the stopper pins (B) into the holes to
secure the canopy/cab in place. Then, insert the R-
pin into the hole on the stopper pin (B) to prevent it
from being disconnected.
If the engine must be started with the canopy or cab in the

raised position, follow the steps below.
7. Make sure that all levers and pedals are in the neutral
position.
8. Move the throttle controller to the low idling position.
9. Start the engine.
10. Stop the engine upon completion of the inspection
and maintenance.
4E0BS03
How to lower the canopy/cab

1. Disconnect the R-pins and pull out the stopper pin
(B).
2. Slowly lower the canopy/cab.
3. Insert the lock bolts (A).
4. Insert the stopper pin (B) into the holes in the holder
of the machine body.
2
FRAME 4E0BS00
FRAME 4
Lift arm stopper
WARNING
• If you must work beneath the raised lift arm, use the
lift arm stopper to securely support the lift arm.
Never position yourself under it without making
sure that the lift arm is securely supported.
• If a damaged or missing part is found in the lift arm
stopper, immediately repair it. Failure to do so may
cause the lift arm to fall, resulting in serious injury
or death.
4E0BS04
The inspection and maintenance work should be done

while the lift arm is lowered. If the lift arm needs to be
raised, use our approved lift arm stopper and follow the
steps below.
How to install the stopper

1. Park the machine on solid flat ground, and remove
the bucket and/or other attachments.
2. Lower the lift arm onto the ground, and stop the en-
gine.
3. Align the bar (4) in the same direction as the lock pin
(1). 4E0BS05
4. Pull out the lock pin (1) while supporting the lift arm
stopper (2) by hand.
5. Check that the spring (3) can move freely (it is disen-
gaged from the hook (5)) and then place the lift arm
stopper (2) on the cylinder.
6. Sit in the driver's seat, fasten the seat belt, start the
engine, and lower the safety bar.
7. Raise the lift arm until the lift arm stopper (2) drops
onto the cylinder rod.
8. Slowly lower the lift arm until the lift arm stopper (2)
contacts the edge of the cylinder tube and becomes
secured. 4E0BS06
9. Stop the engine.

10. Insert the lock pin (1) through the front hole in the lift
arm stopper (2), under the cylinder rod, and through
the rear hole.
11. Turn the bar (4) perpendicular to the lock pin (1) to
prevent the lock pin (1) from pulling out.
4E0BS07
3
FRAME 4E0BS00
FRAME 4
How to remove the stopper
1. Align the bar (4) in the same direction as the lock pin.
2. Pull the lock pin (1) out of the lift arm stopper (2).
3. Lift the loop at the end of the spring (3) and engage
the spring with the hook (5) on the lift arm stopper (2).
4. Sit in the driver's seat, fasten the seat belt, start the
engine, and lower the safety bar.
5. Raise the lift arm. The lift arm stopper (2) disengages
from the cylinder rod.
6. Lower the lift arm onto the ground and stop the en- 4E0BS08
gine.
7. Lift the lift arm stopper (2) to the storage position. In-
sert the lock pin (1) to secure it to the bracket.
8. Turn the bar (4) perpendicular to the lock pin (1) to
prevent the lock pin (1) from pulling out.
4E0BS09
4
FRAME 4E0BS00
FRAME 4
Floor frame
30
24 14 9 25
7 25 3 24
13 25 24
14 20
24 25
14 25 14
9 2-4
25 10 24
X 2-1
24 10
33
32 13
34 31 25
24
11 Y
6 26
14
25 5
26 15
24 14
21 4 2-3 2-2
22 18 25
23 14
24
X 25 Y 28
24 33
32
13 31
25
24 35
1-2 37 8
1-1
29 14 36
25
24
R0E050 4E0BS10
1-1. Plate 9. Cover 25. Spring washer

1-2. Cover 10. Foot rest 26. Screw
2-1. Cover 11. Grommet 28. Seal
2-2. Sponge 13. Bolt 29. Sponge
2-3. Sponge 14. Bolt 30. Nut
2-4. Sponge 15. Sponge 31. Screw
3. Plate 18. Seal 32. Spring washer
4. Cover 20. Seal 33. Washer
5. Cover 21. Washer 34. Floor mat
6. Support 22. Spring washer 35. Sponge
7. Plate 23. Bolt 36. Seal
8. Plate 24. Washer 37. Sponge
5
FRAME 4E0BS00
FRAME 4
Removing the floor frame
“Tilting up the canopy and cab”
2-1
2. Remove the floor mat (27).
3. Take out the bolts and remove the plate (7).
38
6. Take out the bolts and remove the cover (2-1).
• Remove the plate (38).
4E0BS11
7. Take out the bolts and remove the plate (1-1).

• Remove the wire harness from the clamp (39).
• Remove the valve bracket and (40). (Machine with 39
40
selector valve)
8. Take out the bolts and remove the support (6).
Installing the floor frame

1-1 4E0BS12
6
FRAME 4E0BS00
FRAME 4
Cover assembly (Canopy)
29
22
40 1
41 1
3
4E0BS13
1 Select the spacers (40) and (41) to adjust the opening and closing of the engine hood assembly (28).
2 Leave a clearance of 2 mm (0.08 in.) between the gas spring (29) and washer (22). Install the gas spring (29) in the
same direction as the rod in the engine hood assembly (28).
3 Apply grease to the sliding surfaces between the pin (9) and collar (6) and between the collar (6) and washer
(24).
1. Center cover assembly 16. Bolt 31. Plate (R)

2. Side cover (L) 17. Nut 32. Trim
3. Side cover (R) 18. Nut 33. Trim
4. Rear door assembly 19. Spring washer 34. Trim
5. Plate 20. Spring washer 35. Trim
6. Collar 21. Spring washer 36. Trim
7. Spring 22. Washer 37. Trim
8. Plate 23. Washer 38. Striker
9. Pin 24. Washer 39. Washer
10. Bolt 25. Snap pin 40. Spacer (t = 4.5 mm (0.18 in.))
11. Bolt 26. Stopper 41. Spacer (t = 1.6 mm (0.06 in.))
12. Bolt 27. Washer 42. Split pin
13. Bolt 28. Engine hood assembly 43. Washer
14. Bolt 29. Gas spring
15. Pin 30. Plate (L)
7
FRAME 4E0BS00
FRAME 4
Removing the covers
WARNING
1. Disconnect the ground cable on the battery from the

engine body.
3. Open the engine hood assembly (28), and suspend it
with a hoisting cable.
4. Take out the bolts and remove the gas spring (29).
5. Take out the bolts and remove the engine hood (28).
• If the machine has an air conditioner, remove the
condenser assembly before removing the engine 45
hood (28).
6. Air conditioner
44 44
6. Open the rear door assembly (4). Disconnect the con-
nectors of the rear lights (44) harness and reversing
alarm (45) harness from the wire harness.
• For the back camera specification, also discon-
nect the reversing camera harness from the rear
door assembly (4).
4 4E0BS18
7. Suspend the rear door assembly (4) with a hoisting

cable. Remove the snap pin (25), split pin (46), and
pin (47), and then remove the rear door assembly (4).
8. Take out the bolts and remove the side cover (R) (3).
46
47
46
4
47
4E0BS19
9. Remove the bolts and switch (48), and remove the

side cover (L) (2).
10. Take out the bolts and remove the center cover as-
sembly (1).
Installing the covers

48
in the reverse order. 2
4E0BS20
8
FRAME 4E0BS00
FRAME 4
Cover assembly (Cab)
29
22
38 1
39 1
3
4E0BS14
1 Select spacers (40) and (41) and use them to adjust the opening and closing of the engine hood assembly (28).
2 Leave a clearance of 2 mm (0.08 in.) between the gas spring (29) and washer (22). Install the gas spring in the same
direction as the rod in the engine hood.
3 Apply grease to the sliding surfaces between the pin (9) and collar (6) and between the collar (6) and washer
(24).
1. Center cover assembly 12. Bolt 23. Washer 34. Trim

2. Side cover (L) 13. Bolt 24. Washer 35. Trim
3. Side cover (R) 14. Bolt 25. Snap pin 36. Striker
4. Rear door assembly 15. Pin 26. Stopper 37. Washer
5. Plate 16. Bolt 27. Washer 38. Spacer
6. Collar 17. Nut 28. Engine hood assembly (t = 4.5 mm (0.18 in.))
7. Spring 18. Nut 29. Gas spring 39. Spacer
8. Plate 19. Spring washer 30. Plate (L) (t = 1.6 mm (0.06 in.))
9. Pin 20. Spring washer 31. Plate (R) 40. Washer
10. Bolt 21. Spring washer 32. Trim 41. Split pin
11. Bolt 22. Washer 33. Trim
9
FRAME 4E0BS00
FRAME 4
Removing the covers
4. Frame, Removing the covers
Installing the covers

10
FRAME 4E0BS00
FRAME 4
Center cover assembly
4
5
6
8 1
R1E030 4E0BS15
1. Center cover
2. Rubber cushion
3. Cover
4. Bolt
5. Spring washer
6. Washer
8. Insulator
11
FRAME 4E0BS00
FRAME 4
Rear door assembly
7
27
26
17
21
27 15
26
13
3
12 21
2 27
9
8 32 26
6
4
24 20
29 2 11 1 19
31
23 33
10 1 5 26 35
16 27
28
34 18
1
20
19
14 26
27
28
R1E040 30
25 22 3 18 4E0BS16
1 Insert from the front of the machine toward the rear.

2 To ensure smooth opening and closing, apply grease to the contact surface of the plate (29).
3 Temporarily fasten the rear door lamp assembly (L) (22) and plate (L) (25) with the nut (28), spring washer (27), and
washer (26). Then, fully tighten the nut to install them on the rear door (1). Check that the grommet (30) is not ab-
normally squashed. Use the same procedure to install the rear door lamp assembly (R) (23).
1. Rear door 13. Bushing 25. Plate (L)

2. Rod assembly 14. Seal 26. Washer
3. Plate 15. Trim 27. Spring washer
4. Pin 16. Trim 28. Nut
5. Spring 17. Buzzer 29. Plate
6. Bolt 18. Hinge 30. Grommet
7. Nut 19. Pin 31. Grommet
8. Spring washer 20. Split pin 32. Trim
9. Washer 21. Bolt 33. Protector
10. Snap pin 22. Rear door lamp assembly (L) 34. Sponge
11. Snap pin 23. Rear door lamp assembly (R) 35. Sponge
12. Cap 24. Plate (R)
12
FRAME 4E0BS00
FRAME 4
Engine hood assembly
14
13
12
1
5
10 3 1
11 17
6
7
4
9
8
R1E050
4E0BS17
1 To ensure smooth opening and closing, apply grease to the contact surface of the plate (3).
1. Plate 9. Nut
2. Engine hood 10. Washer
3. Plate 11. Snap pin
4. Pin 12. Washer
5. Lock assembly 13. Spring washer
6. Collar 14. Screw
7. Spring 17. Cap
8. Bolt
13
FRAME 4E0BS00
FRAME 4
Canopy mounting assembly
4E0BS21
1 Use the rear edge as the reference when sticking on the

noise absorber (27).
27 4E0BS22
1. Canopy assembly 10. Collar 16. Nut

3. Gas spring 11. Pin assembly 18. Spring washer
4. Pipe 11-1. Pin 19. Washer
5. Rubber cushion 11-2. Chain 20. Washer
6. Rubber cushion 11-3. Snap pin 21. Cushion rubber
7. Bolt 13. Bolt 25. Collar
8. Plate 14. Bolt 26. Collar
9. Washer 15. Nut 27. Noise absorber
14
FRAME 4E0BS00
FRAME 4
Canopy exterior assembly
43 4 5
100 9
46 99 10 1
43
43 102 132
5
46 35 101
45 43
29 3
2
46 113
118 99
100
101 45
102 43
38
43 42 18 45
46
39 118
125 46
39
131 126 43
123 9
130 46
124
127 128
83
41 43
129 123 9
R1E070a 4E0BS23
49 18
50
48
67 17
b
6 76 16
18
77 68 120 120
32
b 85 82
a
112 96
63 7
112
a
18
121
R0E250b 4E0BS24
15
FRAME 4E0BS00
FRAME 4
a b c
36
84 85
37
14 b
c
c
a
15
a
117
96 43
111
37
117-2
117-1
R0E250c 4E0BS25
1 Bolt: 25 N·m (18 ft-lb.)

2 Apply sealant. 3 3
3 Apply sealant (clear) around the outside of the gray area
in the illustration at the right.
4 Apply sealant (clear) across an approximately 100 mm 96 2
4
(3.9 in.) range, centered on the handle (5).
5 Install the H-rubber (3) on the inside.
6 Connect the black lead to the lower terminal.
7 The wire harness (63) is installed at the position where
the clamp is attached on the white tape around the wire
harness (63).
4E0BS26
8 The insulation (127) and (129) is installed at the position

of the 20 mm (0.8 in.)-diameter hole.
9 Stick on the seal (123) straight so that it contacts the trim 10
(83).
0 Position of seal (83) joint 8 8
127 129
4E0BS28
16
FRAME 4E0BS00
FRAME 4
a Position of H-rubber (3) joint: 120 mm (4.7 in.)
b Handle (5) installation position: 100 mm (3.9 in.) from
edge of glass
5
3
12
11
4E0BS27
1. Canopy 42. Guard 102.Screw

2. Rear glass 43. Bolt 111.Nut
3. H-rubber 45. Plate 112.Clamp
4. Ring 46. Screw 113.Cover
5. Handle 48. Lamp assembly 117.Case assembly
9. Plate (polycarbonate) 49. Nut 117-1. Lock
10. Dam 50. Washer 117-2. Trim
14. Cover 63. Wire harness 118.Plate
15. Rivet 67. Cover 120.Trim
16. Cover 68. Screw 121.Cover
17. Cover 76. Horn 123.Seal
18. Screw 77. Bolt 124.Insulation
29. Visor 82. Cap 125.Insulation
32. Grommet 83. Trim 126.Insulation
35. Seal 84. Cap 127.Insulation
36. Rearview mirror 85. Cap 128.Insulation
37. Washer 96. Cap 129.Insulation
38. Trim 99. Washer 130.Insulation
39. Trim 100.Rivet 131.Seal
41. Guard 101.Rubber cushion 132.Cap
17
FRAME 4E0BS00
FRAME 4
Canopy interior assembly
5
12 6
5 9
6 4
16
15
14
13
3
1
5
7
6 6
5
10
8
11-1-1
11-1 2
11
11-2
R0E090 11-3 4E0BS29
1. Cover 11. Starter switch assembly

2. Cover 11-1. Starter switch
3. Cover 11-1-1. Key
4. Display 11-2. Cover
5. Screw 11-3. Harness
6. Washer 12. Plate
7. Socket assembly 13. Bolt
8. Resistor assembly 14. Spring washer
9. Knob 15. Washer
10. Bracket 16. Screw
18
FRAME 4E0BS00
FRAME 4
Cab mounting assembly
4E0BS30
1 Use the rear edge as the reference when sticking on the

noise absorber (31).
2 First, install the gas spring (27) shown in the illustration
at the right on the machine body frame and then install
the remaining 2 gas springs.
27 2
31 1 4E0BS31
1. Cab assembly 11. Pin assembly 19. Washer

3. Gas spring 11-1. Pin 20. Washer
4. Pipe 11-2. Chain 21. Cushion rubber
5. Rubber cushion 11-3. Snap pin 25. Collar
6. Rubber cushion 13. Bolt 26. Collar
7. Bolt 14. Bolt 27. Gas spring
8. Plate 15. Nut 28. Sponge
9. Washer 16. Nut 29. Sponge
10. Collar 18. Spring washer 31. Noise absorber
19
FRAME 4E0BS00
FRAME 4
Cab exterior assembly
43 1
102
100
99 101
43 1 43
128
43
35
29
99
42 100
113
47 43 1
47 101
43 1 18 101 102
102
47
119
120 43 1
126 117 9 47
122 118 43 1
121
83 124 41
123 117 9
R1E100a 4E0BS32
125 15
51
4 5
12
9
125 15 10
5
13
3
38 21 2 51
7
20 11
21 8 X
Y
125 15
X
52
21
40 39
21 20 Y 125 15
52 40 1
39
95
8
R0E220b 6 4E0BS33
20
FRAME 4E0BS00
FRAME 4
a
24
61-1
61 18
67 17
b
49 18 16
50
48
68
a d
c 82 13
e 19
76 6 32
c 85 d
b
77 96
112 63 7
d 112
64
22 b
23
24
e
65
66
127
R0E220c 4E0BS34
a b c d e f g
36 108
78 79 16 28 84 85
27 98
37
26 25
28 103
80
h
14 f
54 g
57
d
55 116 d
56 e h
m
j a
104 56
b 15
59 14 c
58 d a
j b 53
60 d
e 24
k c 105
71
c
72
70 k
m c
72 24
73
R0E220d 4E0BS35
21
FRAME 4E0BS00
FRAME 4
1 Bolt: 25 N·m (18 ft-lb.)
2 Apply sealant. 3 3
3 Apply sealant (clear) around the outside of the gray area
in the illustration at the right.
4 Apply sealant (clear) across an approximately 100 mm 96 2
4
(3.9 in.) range, centered on the handle (5).
5 Install the H-rubber (3) on the inside.
6 Connect the black lead to the lower terminal.
7 The wire harness (63) is installed at the position where
the clamp is attached on the white tape around the wire
harness (63).
4E0BS26
8 The insulation (121) and (123) is installed at the position

of the 20 mm (0.8 in.)-diameter hole.
9 Stick on the seal (117) straight so that it contacts the trim 10
(83).
0 Position of seal (83) joint 8 8
121 123
4E0BS36
a Position of H-rubber (3) joint: 120 mm (4.7 in.)

b Handle (5) installation position: 100 mm (3.9 in.) from
edge of glass
c Antenna (82): 5 N·m (4 ft-lb.)
5
d One shim (59) is used as standard. Add shims as re- 3
quired. 12
11
e Install the side sash assembly (L) (11) and side sash as-
sembly (R) (12).
f When storing the front door assembly (95) in the ceiling,
install the bracket (R) (78) and bracket (L) (79), while ad-
justing to eliminate looseness and play.
4E0BS27
g Windshield washer fluid spray range

220mm
(8.7in.)
Φ100mm
(Φ3.9in.)
17
4E0BS37
22
FRAME 4E0BS00
FRAME 4
1. Cab 39. Trim 79. Bracket (L)
2. Rear glass 40. Seal 80. Bolt
3. H-rubber 41. Guard 82. Antenna
4. Ring 42. Guard 83. Trim
5. Handle 43. Bolt 84. Cap
6. Glass 47. Cushion rubber 85. Cap
7. Glass 48. Lamp assembly 95. Front door assembly
8. Dam 49. Nut 96. Cap
9. Plate (polycarbonate) 50. Washer 98. Nut
10. Dam 51. Dam 99. Washer
11. Side window assembly (L) 52. Washer 100.Rivet
12. Side window assembly (R) 53. Hose 101.Rubber cushion
13. Trim 54. Striker 102.Screw
14. Cover 55. Bolt 103.Washer
15. Rivet 56. Grommet 104.Seat
16. Cover 57. Cap 105.Pocket
17. Cover 58. Striker 108.Seat
18. Screw 59. Shim 112.Clamp
19. Wire harness 60. Bolt 113.Cover
20. Gas spring 61. Room lamp 116.Screw
21. Nut 61-1. Valve 117.Seal
22. Speaker 63. Wire harness 118.Insulation
23. Grill 64. Wire harness 119.Insulation
24. Screw 65. Clip 120.Insulation
25. Stopper 66. Screw 121.Insulation
26. Stopper 67. Cover 122.Insulation
27. Nut 68. Screw 123.Insulation
28. Stopper 70. Windshield washer nozzle 124.Insulation
29. Visor 71. Joint 125.Spacer
32. Grommet 72. Joint 126.Seal
35. Seal 73. Hose 127.Band
36. Rearview mirror 76. Horn 128.Cap
37. Washer 77. Bolt
38. Trim 78. Bracket (R)
23
FRAME 4E0BS00
FRAME 4
Front door assembly
65 51
66
67
41 52
47 42 52
X 68 30 11 39
89 41 44 45 80 38
64 14 73 34
24 40 28 29 37
97 26 15 31
46 6 63
94 33
93
100 16 41 62 14
99 36
95 98 35
96 89 45 32
92 14 24 44 22
73 Y X 23
27 87 11 10 24
90 13 9
99
98 49
99 48 6
98 6
25 100 16
7
8 1 Y 48
91 9
1
50
8 1
7
25
6
See "R0E230b"
R0E230a 4E0BS38
2 3
3
5
16
19 24 79
14 79 2 82
16
17
15
18 24 82 13
4 13
polycarbonate type
69 74
See "R0E230a"
47 53
67 86 52
12 5 17
16 72 87
71
16 7 58 12
60
85 57 11 52
71 58 12
70 57 11
55 10 75 14
61 88
59 11
12 5
60
8516 20
polycarbonate type 61 11 6
56 8 14
polycarbonate type
R0E230b 4E0BS39
24
FRAME 4E0BS00
FRAME 4
1 Nut (8): 67 to 83 N·m (49 to 61 ft-lb.)
2 Nut (79): 7 to 8 N·m (5 to 6 ft-lb.)
3 Nut: 8 to 10 N·m (6 to 7 ft-lb.)
4 Nut: 15 N·m (11 ft-lb.)
3
5 Install the trim (12) with the edge on the inside.
6 Apply sealant to both ends of the trim (11). 14
7 Apply sealant. 4
8 Push in the push button the end of the stroke to return it
to its original position. 3
9 The sheet (20) installation position is shown in the illus-
tration at the right.
0 Bolt (55): 6 N·m (4 ft-lb.) 13
Apply grease to the bracket that contacts the head 4E0BS41
of the bolt (55) and the bolt (55) itself. Use TCG-400L
lithium universal grease manufactured by TRUSCO, or
an equivalent.
a : Apply a thread-locking compound.
b Bolt (58): 5 to 5.5 N·m (4 ft-lb.)
c Adjust to prevent overstroke.
d Grease the sliding surfaces. Use TCG-400L lithium
universal grease manufactured by TRUSCO, or an
equivalent.
e Grease the door lock parts. Use TCG-400L lithium
universal grease manufactured by TRUSCO, or an
equivalent. 20mm 20 9
f Parts for adjustment. Install as required. (0.8in.)
4E0BS40
1. Front door 25. Collar 49. Screw 73. Washer

2. Glass 26. Lock 50. Screw 74. Screw
3. Windshield wiper motor 27. Bracket 51. Cover 75. Inner handle assembly
4. Windshield wiper arm 28. Bolt 52. Clip 79. Nut
5. Windshield wiper blade 29. Bracket 53. Cover 80. Snap
6. Roller 30. Screw 55. Bolt 82. Washer
7. Bolt 31. Nut 56. Outer handle 85. Nut
8. Nut 32. Lock 57. Washer 86. Screw
9. Dam 33. Bolt 58. Bolt 87. Nut
10. Dam 34. Yoke 59. Nut 88. Screw
11. Seal 35. Bolt 60. Rubber cushion 89. Bolt
12. Trim 36. Washer 61. Bezel 90. Plate
13. Collar 37. Nut 62. Link 91. Plate
14. Collar 38. Pin 63. Screw 92. Plate
15. Handle 39. Snap pin 64. Link 93. Plate
16. Grommet 40. Rod 65. Snap pin 94. Cylinder
17. Plate 41. Snap 66. Washer 95. Spring
18. Screw 42. Rod 67. Screw 96. Washer
19. Handle 44. Clip 68. Spring 97. Plate
20. Seat 45. Screw 69. Clip 98. Screw
22. Latch 46. Cover 70. Retainer 99. Washer
23. Bolt 47. Wire cable 71. Packing 100.Washer
24. Washer 48. Clip 72. Washer
25
FRAME 4E0BS00
FRAME 4
Side window assembly
8-1 7
6
9-1
8 7
4 5
2-1 1-1 9 6
a
3-1
2
5
a 4
a
3
1
3
3-1
R0E240 4E0BS43
1. Frame (L)
1-1. Frame (R)
2. Door (window) seal (L)
2-1. Door (window) seal (R)
3. Lock assembly (L)
3-1. Lock assembly (R)
4. Lock
5. Seal
6. Seal
7. Stopper
8. Glass (L)
8-1. Glass (R)
9. Glass (L)
9-1. Glass (R)
26
FRAME 4E0BS00
FRAME 4
Cab interior assembly
25 30
29
28
26 8
12 7
8 11 11
27
7
3
7 12
8
17 11 9 27
12 11
8
8 27
6 9
11
24 27 12
23
22 8
21 27
19 11
1
7
10
20 16 4 27
13 18
5 11
8 8
11 2
15-1-1
27 31
15-1
15 14 10
15-2
8 23 27
15-3
11 22 13
R1E110 21 4E0BS42
1. Cover 13. Louver 21. Bolt

2. Cover 14. Side cover (L) 22. Spring washer
3. Cover 15. Starter switch assembly 23. Washer
4. Cover 15-1. Starter switch 24. Screw
5. Cover 15-1-1. Key 25. Cover
6. Display 15-2. Cover 26. Cover
7. Sponge 15-3. Harness 27. Clamp
8. Screw 16. Bracket 28. Washer
9. Hose 17. Knob 29. Spring washer
10. Hose 18. Resistor assembly 30. Bolt
11. Washer 19. Socket assembly 31. Plate
12. Louver 20. Plate
27
FRAME 4E0BS00
FRAME 4
Removing the canopy assemble/cab assemble
WARNING
• Securely wrap or otherwise isolate the disconnect-
ed terminal to ensure that it does not make contact
with the body.
• Attach the hoisting cable to the hook but do not lift
the canopy/cab assembly

1. Raise the lift arm, and attach the arm stopper.

3. Temporarily suspend the canopy assembly or cab as-
sembly.
• Pass the hoisting cable through the canopy as-
sembly or cab assembly and temporarily suspend
it.
WARNING
4. Disconnect the ground cable on the battery from the

engine body.
5. Disconnect the wire harness from the canopy assem-
bly or cab assembly.
• If working with air conditioner specifications, dis-
connect the air conditioner hoses and electrical
wiring.
6. Remove the nuts and remove the gas springs (1).
7. Lower the canopy assembly or cab assembly, and
lower the lift arm to the ground. 1
8. Remove the two mounting bolts located at the rear of

the machine (B).
4E0BS44
9. Temporarily suspend the canopy assembly or cab as-

sembly and remove it.
• Pass the hoisting cable through the center of the
canopy assembly or cab assembly so that the can-
opy assembly or cab assembly is kept horizontal.
Canopy assembly/cab assembly: 2. Table of
masses
Installing the canopy/cab

28
FRAME 4E0BS00
OPERATING DEVICE 4
OPERATING DEVICE
Remote control piping assembly
Construction diagram (machine without selector valve)
a b c
40 43
2 32 30 27 43
3
31
a 45
45
44 29 Pa3 48 45
25 17
b 5 X 36
35 20 55
Pb3 Pa2 53
Pb2 15
X
6 MP2
Pa1 7
36
a 52 ST2
c b Pb1 S1 16
50 58
R1 RT R2 S2
49
R4 RP R3 39 16
45 45 APCP
56 13 SOLA1
a 14 SOLP
4 SOLB
22
SOLT
1
32
29
30
24 54
28
38
(R1B020a)
T7 8
4F0BS01
<Table of Connections>
Right pilot valve (50) R1  Pb3 Control valve (52)
Right pilot valve (50) R2  Pa2 Control valve (52)
Right pilot valve (50) RP  S1 Sub valve (53)
Right pilot valve (50) RT  T7 Hydraulic tank (56)
Proportional solenoid valve (active power control) (58) APCP  S2 Sub valve (53)
Proportional solenoid valve (1st service) (54) SOLA1  Pa1 Control valve (52)
Proportional solenoid valve (1st service) (54) SOLB  Pb1 Control valve (52)
Proportional solenoid valve (1st service) (54) SOLP  MP2 Manifold (55)
Proportional solenoid valve (1st service) (54) SOLT  ST2 Sub valve (53)
1
OPERATING DEVICE 4F0BS00
OPERATING DEVICE 4
d e
25
4 32 30 27 Y 4 29
26
29
31
d 32 31
30
LP L4 L1 51 28
L3 23
L2 LT 45
d 42
47 45
45 g
21 45 e
1 33
56 10
29 47 12 X1
34 Y 41
24 g
X2
APCA2 X12 34
57
33 45
g
58 18 f 45
9 X11 f
38 11
g 44 43
46
T8 19 g
g
44
37 44 43
R1B020b 4F0BS02
Left pilot valve (51) L1  X12 HST pump (57)
Left pilot valve (51) LP  APCA2 Proportional solenoid valve (active power control) (58)
Left pilot valve (51) LT  T8 Hydraulic tank (56)
1. Washer 16. Hose assembly 31. Washer 46. Band

2. Clamp 17. Hose assembly 32. Washer 47. Pressure switch
3. Clamp 18. Hose assembly 33. Elbow 48. Pressure switch
4. Clamp 19. Hose assembly 34. Elbow 49. Pressure switch
5. Hose assembly 20. Hose assembly 35. Bushing 50. Right pilot valve
6. Hose assembly 21. Grommet 36. Tee 51. Left pilot valve
7. Hose assembly 22. Grommet 37. Elbow 52. Control valve
8. Hose assembly 23. Guide 38. Elbow 53. Sub-valve
9. Hose assembly 24. Bolt 39. Protector 54. Proportional solenoid valve
10. Hose assembly 25. Bolt 40. Protector (1st service)
11. Hose assembly 26. Bolt 41. Protector 55. Manifold
12. Hose assembly 27. Bolt 42. Protector 56. Hydraulic oil pump
13. Hose assembly 28. Bolt 43. Ring 57. HST pump
14. Hose assembly 29. Spring washer 44. Band 58. Proportional solenoid valve
15. Hose assembly 30. Spring washer 45. Band (active power control)
2
OPERATING DEVICE 4
Construction diagram (machine with selector valve)
a b
58
2 48 46 42 4
61
47 55
a Pa2
63 25
62 45 33
40 9
b 6 X
X Pa3
64
71
Pb3 Pa1
a 11
R1 RT R2 66 53 Pb2 Pb1 MP2
R4 RP R3
26 68
63 b SOLA1 64
SOLB
a 56 SOLP
5 72 69 10
63
37 70 SOLT
1 ST2 64
48
45
46 7 12
39 S1
43 F’
14 APCA1
75 E’
3 6
S6 73 APCP
13
33
54
S5 74
(R1B030a)
T7 8 4F0BS03
Right pilot valve (66) R2  S5 Selector valve (73)
Right pilot valve (66) R4  S6 Selector valve (73)
Proportional solenoid valve (active power
Right pilot valve (66) RP  APCA1
control) (75)
Right pilot valve (66) RT  T7 Hydraulic tank (72)
Proportional solenoid valve (active power con-
APCP  S1 Sub valve (69)
trol) (75)
Shuttle valve (74) E'  Pa2 Control valve (68)
Shuttle valve (74) F'  Pb2 Control valve (68)
Proportional solenoid valve (1st service) (70) SOLA1  Pa1 Control valve (68)
Proportional solenoid valve (1st service) (70) SOLB  Pb1 Control valve (68)
Proportional solenoid valve (1st service) (70) SOLP  MP2 Manifold (71)
Proportional solenoid valve (1st service) (70) SOLT  ST2 Sub valve (69)
3
OPERATING DEVICE 4
c d 40
41
45
5 48 46 42 5 45
47
47
48
46 Y
43 38
c
LP L4 L1 67 60
L3
L2 LT 63 63
72 c 63 d
75
63
APCA2 Y 59
34 36
1
45 63
43
39 46
35
54 63 48 57
17
16 S2
T8 64 e
S3 5 63
e
S1
S4 62
73
15 61
18
R1B030b 4F0BS04
Left pilot valve (67) L1  S1 Selector valve (73)
Left pilot valve (67) LP  APCA2 Proportional solenoid valve (active power control) (75)
Left pilot valve (67) LT  T8 Hydraulic tank (72)
4
OPERATING DEVICE 4
49
30-3 30-6 30-7 44
46 f f 65
30-4 30-4 X1
48
30-3 3 52
30-3 63 X2
43 f
30-7 46
20 32
SB 48 76
30-2 30-7 62 61
30-1 21 SD X12
30-5 30-3 50 62
SC 22
44 SE 27
46 73 X11
30-8 48
50 f
28
SA
SF 24 f 31-7
F 74 31-4
19 23 31-7 31-7
A’ 31-11 31-5
29 Dr E
31-6 31-9
T11 C’ C
31-8 31-10
72 51 A 31-7 31-4
31-7
f 31-1
31-3 43
31-2 46 31-6
48
31-9
R1B030c
31-6
4F0BS05
Selector valve (73) SA  A Shuttle valve (74)
Selector valve (73) SB  X2 HST pump (76)
Selector valve (73) SC  C Shuttle valve (74)
Selector valve (73) SD  X1 HST pump (76)
Selector valve (73) SE  E Shuttle valve (74)
Selector valve (73) SF  F Shuttle valve (74)
Shuttle valve (74) A’  X12 HST pump (76)
Shuttle valve (74) C’  X11 HST pump (76)
Shuttle valve (74) Dr  T11 Hydraulic tank (72)
5
OPERATING DEVICE 4
1. Washer 25. Hose assembly 32. Plate 56. Protector
2. Clamp 26. Hose assembly 33. Hose assembly 57. Protector
5. Clamp 29. Hose assembly 36. Grommet 60. Protector
6. Hose assembly 30-1. Bolt 37. Grommet 61. Ring
7. Hose assembly 30-2. Spring washer 38. Guide 62. Band
8. Hose assembly 30-3. Elbow 39. Bolt 63. Band
9. Hose assembly 30-4. Elbow 40. Bolt 64. Band
10. Hose assembly 30-5. Elbow 41. Bolt 65. Pressure switch
11. Hose assembly 30-6. Selector valve 42. Bolt 66. Right pilot valve
12. Hose assembly 30-7. Adapter 43. Bolt 67. Left pilot valve
13. Hose assembly 30-8. Bracket 44. Bolt 68. Control valve
14. Hose assembly 31-1. Bracket 45. Spring washer 69. Sub-valve
15. Hose assembly 31-2. Bolt 46. Spring washer 70. Proportional solenoid valve
16. Hose assembly 31-3. Spring washer 47. Washer (1st service)
17. Hose assembly 31-4. Bushing 48. Washer 71. Manifold
18. Hose assembly 31-5. Elbow 49. Elbow 72. Hydraulic oil pump
19. Hose assembly 31-6. Elbow 50. Elbow 73. Selector valve
20. Hose assembly 31-7. Elbow 51. Tee 74. Shuttle valve
21. Hose assembly 31-8. Adapter 52. Elbow 75. Proportional solenoid valve
22. Hose assembly 31-9. Pressure switch 53. Elbow (active power control)
23. Hose assembly 31-10. Pressure switch 54. Elbow 76. HST pump
24. Hose assembly 31-11. Shuttle valve 55. Elbow
6
ATTACHMENTS 4
ATTACHMENTS
Mechanical quick-hitch assembly
16
14
10
16
15
18 14
12
7 3
6 13 16 19
11 14
2 10
8 17
5 13 16
W 4 15
9 14
12
18
W 7
1 6
17
11
X 9
8
5
4
X
21
20
R1F020
4G0BS01
1 Bolt: Apply ThreeBond #1324 or an equivalent.

2 Block the hydraulic hose port in a machine with hydraulic quick-hitch with the plug (19).
3 Drive in the spring pin (17) so that the tip is aligned with the front face of the bracket (1).
1. Bracket 12. Nut

2. Lever (L) 13. Split pin
3. Lever (R) 14. Washer
4. Pin 15. Spring washer
5. Yoke 16. Bolt
6. Washer 17. Split pin
7. Pin 18. Conical washer
8. Pipe 19. Plug
9. Grease fitting 20. Bolt
10. Spring 21. Nut
11. Spring
1
ATTACHMENTS 4G0BS00
ATTACHMENTS 4
Hydraulic quick-hitch assembly
21 50
16 52 16
14 49 15 16
10 14 15
3 18 22 19 48 A
35
4 31 43 T
12 39
47 Y Z
7 H
16 44
15 38
6 13 20 R 16
15 55
11 14 45
8 38
17 18 46
5 13 16
41 14
W 10
9 2 55
12 27
4 33 P
W 7 T
1 6 40
17 Y A
11 Z
X 9 B 42
8
5 38
41
X
54
53
R1F030a
4G0BS02
25
51 28
29 33
30 32
37
24
X
34
23
30
26 36
R1F030b
4G0BS20
2
ATTACHMENTS 4G0BS00
ATTACHMENTS 4
1. Bracket 29. Nut

2. Plate (L) 30. Spring washer
3. Plate (R) 31. Collar
4. Conical washer 32. Spring washer
5. Yoke 33. Washer
6. Washer 34. Bushing
7. Pin 35. Conical washer
8. Pipe 36. Switch
9. Grease fitting 37. Bolt
10. Spring 38. Elbow
11. Spring 39. Elbow
12. Nut 40. Adapter
13. Split pin 41. Pin
14. Washer 42. Solenoid valve
15. Spring washer 43. Elbow
16. Bolt 44. Quick-hitch cylinder
17. Split pin 45. Hose assembly
18. Washer 46. Hose assembly
19. Washer 47. Hose assembly
20. Clamp 48. Hose assembly
21. Guard 49. Protector
22. Rod cover 50. Protector
23. Plate 51. Screw
24. Plate 52. Band
25. Cover 53. Bolt
26. Cap screw 54. Nut
27. Bolt 55. Band
28. Cap screw
Switch (36) adjustment method

With the plate (23) perpendicular to the switch stroke, ad-
just the protrusion of the head of the screw (51) that
presses the switch (36) to set the switch stroke to 4 to 5 4~5mm
(0.16~0.20in.)
mm (0.16 to 0.20 in.). 51
36
23
4G0BS18
3
ATTACHMENTS 4G0BS00
ATTACHMENTS 4
Removing the quick-hitch
WARNING
• Be sure to release any residual pressure in the pip-
ing before disconnecting the hydraulic hose.
• Do not attempt to insert any fingers into the hole
when adjusting the pin hole position.
Important:
• When tightening the lock bolt with a double nut, al-
low a clearance of 0.5 mm to 1.0 mm (0.02 to 0.04
in.) between the nut and the lock collar.
• During installation, adjust the pin-connecting area
with shims until no clearance remains. Reduce the
clearance until a 0.2 mm (0.01 in.)-thick shim can-
not be inserted by hand.
• Be sure to bleed the air from the cylinder before
starting operation for the first time after reassem-
bling hydraulic devices such as the hydraulic cylin-
der or hydraulic piping.
4G0BO05

1 0.5 to 1.0 mm (0.02 to 0.04 in.)
1. Lower the bucket-mounting surface of the bucket (3)

onto the ground.
<Machine with mechanical quick-hitch>
2. Pull out the pins (1) and (2), and remove the bracket
(3).
<Machine with hydraulic quick-hitch>

2. Pull out the pins (1) and (2), remove the hose assem-
blies (7) and (8), and remove the bracket (3).
2 2
Bracket (3): 2. Table of masses
7 8
1 3 1
4G0BO07
4
ATTACHMENTS 4G0BS00
ATTACHMENTS 4
3. Disconnect the hose assembly (4) from the left bucket
cylinder (5).
4. Temporarily suspend the left bucket cylinder (5), pull 6
out the pin (6), and then remove the left bucket cylin- 5
der (5).
5. Follow the same procedure to remove the right buck- 4
et cylinder.
Bucket cylinder: 2. Table of masses
Installing the quick-hitch 4G0BO06

5
ATTACHMENTS 4G0BS00
ATTACHMENTS 4
Lift arm
17
a 1-5
a
Y 1-4 1-5
a
1 17
1-4 a
20 22 23
20 24 25
Z
W
37
14 36
18 7
29
20 Y
15
X
19 14
Z
37
36
18 7
29
1-5 W
15 19
1-5 29
1-3 7
36
X 37
1-3
29 37
7
36
R1F010a
4G0BS03
44
32 36
Z 31 45 42
46 47
37
36 34 Z 48 35
35 41 36
13 40 44 30 50
37 39 49
38 49
36
35 a 43
8 33
X
41 40 28 7
a
Y 21 26 27 X
16
19 2 18 18
3
5 19 a
9
18 7 4
V 11 19 Y
6
18
19
W V
5 12
16 16 10
16 12
18 19
19
R1F010b W
4G0BS04
6
ATTACHMENTS 4G0BS00
ATTACHMENTS 4
1 Pin
2 Tighten the Quietite (6) nut as far as possible by hand and then turn a further 3.5 turns with a tool.
1. Arm 16. Grease fitting 34. Cover

1-3. Bushing 17. Grease fitting 35. Washer
1-4. Bushing 18. Bolt 36. Spring washer
1-5. Dust seal 19. Nut 37. Bolt
2. Step 20. Shim 38. Bracket
3. Cover 21. Shim 39. Washer
4. Pin 22. Shim 40. Spring washer
5. Pin 23. Shim 41. Bolt
6. Nut (Quitite) 24. Washer 42. Spring
7. Washer 25. Washer 43. Rubber
8. Bolt 26. Washer 44. Bolt
9. Bolt 27. Washer 45. Washer
10. Left bucket cylinder 28. Washer 46. Rubber
11. Right bucket cylinder 29. Pin 47. Rubber
12. Pin 30. Lock 48. Rubber
13. Handrail 31. Bracket 49. Rubber
14. Arm cylinder 32. Pin assembly 50. Trim
15. Pin 33. Cover
7
ATTACHMENTS 4G0BS00
ATTACHMENTS 4
Removing the lift arm
1. Disconnect the hydraulic hoses (1) from the pipes

2 1
(bucket) (2).
2. Disconnect the electrical wiring.
4. Wire harness
4G0BS19
3. Disconnect the hydraulic hoses (3) from the pipes

(auxiliary line) (4).
4. Disconnect the hydraulic hoses (5) from the arm cyl-
inder (6).
5. Temporarily suspend the lift arm (7), and pull out the
pin (8) on the rod side of the arm cylinders (6).
• Place a wooden block (9) under the cylinders in
advance.
6. Pull out the arm foot pin (10). Suspend the lift arm (7)
and remove it.
Lift arm: 2. Table of masses
7. Pull out the pins (11) on the head side of the arm cyl-
inder. Suspend the arm cylinders (6) and remove it.
Arm cylinder: 2. Table of masses
Installing the lift arm

8
ATTACHMENTS 4G0BS00
ATTACHMENTS 4
Adjusting the arm stopper
DANGER
When working under the raised lift arm, use the lift
arm stopper to securely support the lift arm. Never
position yourself under the lift arm without making
sure that it is securely supported.
WARNING
• Park the machine on solid flat ground for work.
• Be sure to sit in the driver's seat when operating
the machine, including when starting and stopping
the engine.
• Set the engine speed to low when operating the
control lever.
Adjust the left and right arm stoppers (1) on the machine
frame so that the lift arm contacts them at the same time
when it is lowered.
4G0BO24
1. Raise the lift arm and support it with the lift arm stop-
per (2).
9
ATTACHMENTS 4G0BS00
ATTACHMENTS 4
2. Take out the cap screws and remove the arm stop-
pers (1).
1 4G0BQ19
3. Place an approximately 55 mm (2.2 in.)-high block (3)

at the position where the end of the lift arm descends.
• Use a metal or concrete block.
55mm
[2.2in.] 4G0BS23
4. Remove the lift arm stopper (2).

5. Start the engine, and lower the lift arm.
Position the lift arm at a height approximately 300 mm
(11.8 in.) above the ground.
3
300mm
[11.8in.]
4G0BS22
10
ATTACHMENTS 4G0BS00
ATTACHMENTS 4
6. Set the float mode and allow the lift arm to drop spon-
taneously. When the end of the lift arm contacts the
block (3), stop the engine.
4G0BO18
7. Measure and record clearance A on each side (right

and left).
4G0BO25
8. Install the arm stoppers (1) and shims (4) on the left
and right sides of the machine frame, and fasten them B
with the cap screws.
• Select shims so that the combined thickness of
section B of the arm stoppers (1) (27 mm (1.1 in.))
1
and the shims (4) is the same as clearance A mea-
sured above.
• The lift arm contacts the left and right arm stoppers
(1) at the same time. 1
1 1 4
• Adjust with a combined shim thickness of 5 mm
(0.2 in.) or less.
1 1 4 4G0BQ18
1 Cap screw: ThreeBond 1324

Cap screw: 476 N·m (351 ft-lb.)
11
ATTACHMENTS 4G0BS00
ATTACHMENTS 4
Attachment pipe assembly (machine without high-flow equipment, machine with mechanical quick-hitch,
machine with 1st service 1/2 quick coupler, machine without 2nd service, machine without ride control)
46
50
53
23 L1
51 35
54 L2
48 14
A
W L3
51 T
54 40
15
51
54 36
48 14 12 B
44 W
48
51 5154 X 13 48
54 15
42 51
37 54
48 Y
51 43 44
3 X
58
1 57 Y
3
Z
16
Z 17
R1F120a
4G0BS05
12
ATTACHMENTS 4G0BS00
ATTACHMENTS 4
46 32
50 X
53
45 X
53
50 4650
34 53
IN2
IN1 L1
5 L2
L3
8
33 H1
B1 21 L4
B2 R1 19
A1 22 18
L5
B2
46
A2 50 10
24 53
60
A2 T2
R1F120c
4G0BS06
1 Bolt: 68 N·m (50 ft-lb.)

2 Bolt: 118 N·m (87 ft-lb.)
1. Washer 22. Hose assembly 43. Rubber

2. Adapter 23. Hose assembly 44. Rubber
3. Connector 24. Hose assembly 45. Bolt
4. Clamp 25. Hose assembly 46. Bolt
5. Hose assembly 26. Hose assembly 47. Bolt
8. Guide 29. Hose assembly 50. Spring washer
9. Hose assembly 30. Hose assembly 51. Spring washer
10. Left bracket 31. Pipe 52. Spring washer
11. Pipe 32. Guide 53. Washer
12. Pipe 33. Hose assembly 54. Washer
14. Clamp 35. Hose assembly 56. O-ring
15. Clamp 36. Hose assembly 57. Plug
16. Valve assembly 37. Pipe 58. Connector
17. Protector 38. Pipe 59. Tee
18. Hose assembly 39. Pipe 60. Elbow
19. Hose assembly 40. Left bracket 61. Adapter
20. Hose assembly 41. Right bracket 62. Clamp
21. Hose assembly 42. Clamp
13
ATTACHMENTS 4G0BS00
ATTACHMENTS 4
Attachment pipe assembly (machine without high-flow equipment, machine with mechanical quick-hitch,
machine with 1st service 1/2 quick coupler, machine without 2nd service, machine with ride control)
45
48
51
23 L1
49 35
52 L2
46 14
A
W L3
49 T
52 40
15
49
52 36
46 14 12 B
43 W
46
49 4952 X 13 46
52 15
41 49
37 52
46 Y
49 42 43
3 X
56
1 55 Y
3
Z
16
Z 17
R1F050a
4G0BS07
14
ATTACHMENTS 4G0BS00
ATTACHMENTS 4
4G0BS08
1 Bolt: 68 N·m (50 ft-lb.)

2 Bolt: 118 N·m (87 ft-lb.)
1. Washer 21. Hose assembly 41. Clamp

3. Connector 23. Hose assembly 43. Rubber
10. Left bracket 30. Hose assembly 50. Spring washer
11. Pipe 31. Pipe 51. Washer
14. Clamp 34. Hose assembly 54. O-ring
16. Valve assembly 36. Hose assembly 56. Connector
19. Hose assembly 39. Pipe 59. Adapter
20. Hose assembly 40. Left bracket 60. Clamp
15
ATTACHMENTS 4G0BS00
ATTACHMENTS 4
Attachment pipe assembly (machine with hydraulic quick-hitch, machine with 1st ser-
vice 1/2 quick coupler, machine without 2nd service, machine without ride control)
45
49
L1 52
22
50 34
53 L2
47 14
A
50 W L3
53 T
15 39
50
53 35
47 14 12 B
43 W
47
50 5053 X 13 47
53 15
41 50
36 53
47 Y
50 42 43
3 X
57
1 56 Y
3
Z
63
Z 16
R1F070a
4G0BS09
16
ATTACHMENTS 4G0BS00
ATTACHMENTS 4
45 31
49 X
52
44 X
52
49 45 49
33 52
IN2
IN1 L1
5 L2
L3
8
32 H1
B1 20 18 L4
B2 R1
A1
21 17
L5
B2
45
A2 49 10
23 52
59
A2 T2
R1F070c
4G0BS10
1 Bolt: 68 N·m (50 ft-lb.)

2 Bolt: 118 N·m (87 ft-lb.)

2. Adapter 23. Hose assembly 44. Bolt
9. Hose assembly 30. Pipe 51. Spring washer
10. Left bracket 31. Guide 52. Washer
13. Pipe 34. Hose assembly 55. O-ring
15. Clamp 36. Pipe 57. Connector
18. Hose assembly 39. Left bracket 60. Adapter
19. Hose assembly 40. Right bracket 61. Clamp
20. Hose assembly 41. Clamp 63. Valve assembly
21. Hose assembly 42. Rubber
17
ATTACHMENTS 4G0BS00
ATTACHMENTS 4
Attachment pipe assembly (machine with hydraulic quick-hitch, machine with 1st
service 1/2 quick coupler, machine without 2nd service, machine with ride control)
44
47
L1 50
22
48 34
51 L2
45 14
A
W L3
48 T
51 39
15
48
51 35
45 14 12 B
42 W
45
48 4851 X 13 45
51 15
40 48
36 51
45 Y
48 41 42
3 X
55
1 54 Y
3
Z
61
Z 16
R1F080a
4G0BS11
18
ATTACHMENTS 4G0BS00
ATTACHMENTS 4
4G0BS12
1 Bolt: 68 N·m (50 ft-lb.)

2 Bolt: 118 N·m (87 ft-lb.)

10. Left bracket 30. Pipe 50. Washer
13. Pipe 33. Hose assembly 53. O-ring
15. Clamp 35. Hose assembly 55. Connector
18. Hose assembly 38. Pipe 58. Adapter
19. Hose assembly 39. Left bracket 59. Clamp
20. Hose assembly 40. Clamp 61. Valve assembly
19
ATTACHMENTS 4G0BS00
ATTACHMENTS 4
vice 1/2 and 3/4 quick coupler, machine with 2nd service, machine with ride control)
4G0BS13
20
ATTACHMENTS 4G0BS00
ATTACHMENTS 4
4G0BS14
1 Bolt: 68 N·m (50 ft-lb.)

2 Bolt: 118 N·m (87 ft-lb.)
1. Washer 26. Valve assembly 51. Pipe

2. Adapter 27. Protector 52. Pipe
3. Connector 28. Hose assembly 53. Pipe
4. Clamp 29. Hose assembly 54. Clamp
5. Hose assembly 30. Hose assembly 55. Rubber
13. Hose assembly 38. Hose assembly 63. Washer
15. Guide 40. Hose assembly 65. O-ring
16. Clamp 41. Hose assembly 66. Connector
17. Hose assembly 42. Hose assembly 67. Tee
18. Hose assembly 43. Hose assembly 68. Elbow
19. Hose assembly 44. Hose assembly 69. Adapter
20. Left bracket 45. Left bracket 70. Adapter
21. Pipe 46. Pipe 71. Clamp
22. Hose assembly 47. Guide 73. Right bracket
23. Pipe 48. Pipe 74. Bolt
24. Clamp 49. Pipe 75. Spring washer
25. Clamp 50. Pipe 76. Washer
21
ATTACHMENTS 4G0BS00
ATTACHMENTS 4
vice 1/2 and 3/4 quick coupler, machine with 2nd service, machine with ride control)
4G0BS15
22
ATTACHMENTS 4G0BS00
ATTACHMENTS 4
4G0BS16
1 Bolt: 68 N·m (50 ft-lb.)

2 Bolt: 118 N·m (87 ft-lb.)
1. Washer 26. Valve assembly 51. Pipe

2. Adapter 27. Protector 52. Pipe
3. Connector 28. Hose assembly 53. Pipe
4. Clamp 29. Hose assembly 54. Clamp
15. Guide 40. Hose assembly 65. Washer
16. Clamp 41. Hose assembly 66. Washer
17. Hose assembly 42. Hose assembly 67. O-ring
18. Hose assembly 43. Hose assembly 68. Connector
19. Hose assembly 44. Hose assembly 69. Tee
20. Left bracket 45. Left bracket 70. Elbow
21. Pipe 46. Pipe 71. Adapter
22. Hose assembly 47. Guide 72. Adapter
23. Pipe 48. Pipe 73. Clamp
24. Clamp 49. Pipe 74. Right bracket
25. Clamp 50. Pipe
23
ATTACHMENTS 4G0BS00
ATTACHMENTS 4
Block coupler (machine with 1st service 1/2 quick coupler)
X
10-5
10-1
10-4-1
10-4-2
10-2
10-3 10-5
6
1 10-4-4
10-4-3
10
2 1
5 9 3
4
1
8
X 7
R0F090
4G0BS21
1 Adapter: 31 N·m (23 ft-lb.)

2 Nut: 34 N·m (25 ft-lb.)
1. Washer 10. Block coupler

2. Adapter 10-1. Adapter
3. Bracket 10-2. Adapter
4. Spacer 10-3. Adapter
5. Bracket 10-4-1. O-rings
6. Bolt 10-4-2. Relief valve
7. Nut 10-4-3. Cap screws
8. Spring washer 10-4-4. Decal
9. O-ring 10-5. Adapter
24
ATTACHMENTS 4G0BS00
ATTACHMENTS 4
Block coupler (machine with 1st service 1/2 and 3/4 quick coupler, ma-
chine with 2nd service)
11 Y 16-1
7
11
16-4-1
1
12 16-4-2
16-2
2 2 16-3
12 16-4-3
14
3 16-4-4
8
10 9
1
4
5
6 17
15 13 18
X
21
X
13-1
13-4-1 17
13-2 18
13-4-2
1
9
13-3 8 19
13-4-3
16 20
Y
13-4-4
R0F100
4G0BS17

2 Nut: 34 N·m (25 ft-lb.)
3 Nut, tee, adapter: 102 N·m (75 ft-lb.)
1. Washer 13-1. Adapter 16-3. Adapter

2. Nut 13-2. Adapter 16-4. Spare kit
3. Adapter 13-3. Adapter 16-4-1. O-ring
4. Bracket 13-4. Spare kit 16-4-2. Relief valve
5. Bracket 13-4-1. O-ring 16-4-3. Cap screw
6. Spacer 13-4-2. Relief valve 16-4-4. Decal
7. Bolt 13-4-3. Cap screw 17. Adapter
8. Nut 13-4-4. Decal 18. O-ring
9. Spring washer 14. Quick coupler 19. Washer
10. O-ring 15. Quick coupler 20. Bolt
11. Adapter 16. Coupler block 21. Adapter
12. Tee 16-1. Adapter
13. Coupler block 16-2. Plug
25
ATTACHMENTS 4G0BS00
HYDRAULIC TANK 4
HYDRAULIC TANK
14
17
19
13 7
30 23 17
12 30-1 19 20
16 X
5 1 2
18
24 9
23 Y 21
26
a
28
26
39
4 36 a
10 16 18 37
8
27 29
32
18
38 b Y
25
X
35
11
b 16 a
31-3 31
18
31-2
31-1
33 34
22 6
(R0D110)
4H0BS01
1 Bolt: 55 N·m (41 ft-lb.) Bolt: Apply ThreeBond #1324 or an equivalent

2 Bolt: 8 N·m (6 ft-lb.)
3 Stick the sponge (35) so that the gauge (31) is at the center position.
4 Install the gauge (31) such that the scale lines face the left side of the machine.
First, front and rear, left and right of the machine
6 Be careful to stick it on in the correct direction. Adhesive must not be applied to some faces.
1. Hydraulic tank 17. Spring washer 30-1. Element
2. Cover 18. Washer 31. Gauge
4. Pipe 19. Washer 31-1. Bolt
5. Cover 20. O-ring 31-2. Packing
6. Hose assembly 21. O-ring 31-3. Float
7. Cover 22. Plug 32. Temperature sensor
8. Washer 23. Plug 33. Clamp
9. Spring 24. Hose 34. Tube
10. Bolt 25. Band 35. Sponge
11. Bolt 26. Band 36. Sponge
12. Bolt 27. Filter 37. Bolt
13. Bolt 28. Valve 38. Bolt
14. Bolt 29. Filter 39. Bracket
16. Spring washer 30. Air breather
1
HYDRAULIC TANK 4H0BS00
HYDRAULIC TANK 4
Removing the hydraulic tank
2. Drain the hydraulic oil from the hydraulic tank.
4. Frame, Removing the floor frame
4. Remove the line filter, emergency valve, and propor-
tional solenoid valve (active power control).
2. Hydraulic device layout diagram
2
HYDRAULIC TANK 4
54 63
24
44 47
43
50
49
51
46 48
52
53
55
45
4H0BS02
5. Remove the hose clamps (43) and (44).

6. Remove the hoses (6), (24), (45) to (53), and (63)
from the hydraulic tank side.
7. Remove the hose (54) from the hydraulic tank side.
(machine with ride control)
8. Remove the hose (55) from the hydraulic tank side.
(machine with selector valve)
3
HYDRAULIC TANK 4
9. Remove the connector (56).
10. Remove the clamps (57) to (62) and remove the wire
harness (63) from the tank.
57
58
63 59 62
61
60
56
4H0BO04
11. Remove the bolt (37).

12. Suspend the tank and remove it.
2. Table of masses
37
Installing the hydraulic tank

4H0BS03
4
HYDRAULIC TANK 4
Filling with hydraulic oil
The oil level changes with the oil temperature. Inspect the
oil while maintaining the machine at the attitude shown in
the figure.
Machine attitude for inspecting the hydraulic oil level

1. Start the engine, and run it at low speed.
2. Fully retract the lift arm cylinder and the bucket cylin-
der.
3. Stop the engine.
4. Inspect the oil level using the sight gauge (2).
When the oil temperature is about 20°C (68°F), the
level should be halfway between the upper limit (H)
and the lower limit (L). If it is below the lower limit (L),
replenish.
When the oil temperature is about 50 to 80°C (122 to 4H0BO06
176°F), the level should be near the upper limit (H).
5
HYDRAULIC TANK 4
Bleeding the air
After replacing the hydraulic oil, bleed the air from the hy-
draulic circuits and hydraulic devices. Failure to do so
may damage the hydraulic devices.
Hydraulic pump
“4. Disassembly and assembly, Frame, Tilting up
the canopy and cab”
2. Loosen the air-vent plug (1) in the hydraulic pump.
3. Tighten the plug (1) once the hydraulic oil overflows
from the air bleed plug (1) hole.
Cylinder
1. Start the engine, and let it run at a low-idling speed for
10 minutes.
4H0BQ06
2. Set the engine to low idle, then extend and retract

each cylinder 4 or 5 times, without letting any of them
reach the stroke end.
3. Run the engine at high speed and then extend and re-
tract each cylinder 4 or 5 times without letting any
reach the stroke end.
4. Return the engine speed to low idle, then extend and
retract each cylinder to the stroke end 4 or 5 times.
6
bly
em
g ass
urin
GEAR PUMP
td 3-shaped gasket
par
ew
an
Construction
e
Us
ark
"m
GEAR PUMP
"1R
Exploded diagram
ark Backup ring

tc hm
Ma
rk
ma
tch
Ma Figure 4. Installing backup ring
of Discharge m ark 56
er tch
lay ar side Ma
t hin e ge
a th e 55
ply to s
sid rs e
Ap ase face llow gea qu
Ye ard g tor
gr e e s u r tow
rk sid ly nin
ma mb hte
F" sse Tig
bly "1 Intake side r i n ga
Oil seal
sem t du
as par
ring new
Flathead ar t du ea
wp Us
screwdriver, ne rk
etc. ea ma ark
Us R" "m
"1N "2R
rk rk
ma
tch ma
Ma tch
1
ark Ma
Figure 1. m
tch
Ma
Removing the e
sid rs
oil seal llow gea
Ye ard Drive gear
to w of
er direction
h i n lay ear
g e of rotation
a t the sid rs
ply to s llow gea
Ap ase face Ye ard
k g re sur
tow Large notch
r d e
" ma si Small notch (non-engaged side)
F (engaged side)
m bly "2
sse Mark
ga Discharge
rin
t du side Intake side
par Pliers
new Oil seal snap tool
a
U se
a rk Driven gear
rk (View from rear of pump)
tc hm ma direction of rotation
Ma " Oil seal guide C-ring
rk "2 NR
ma Figure 5. Gear engagement marks
tch
Ma
e Dust lip
sid rs Oil seal
llow gea
Ye ard
tow Fill with
grease
Main lip
Figure 2. Installing the oil seal Figure 3. Installing C-ring Figure 6. Oil seal
GEAR PUMP
4I1BO01
4
4I1BO00
4
GEAR PUMP
Internal construction diagram
4I1BO02
1. Front cover 50. Backup ring

2. Body (No. 1) 51. 3-shaped gasket
3. Gear drive (No. 1) 52. Gasket
4. Driven gear (No. 1) 55. Hardened washer
5. Side plate (No. 1) 56. Hexagon socket head bolt
6. Adapter plate 59. Key
7. Body (No. 2) 65. Oil seal
8. Drive gear (No. 2) 70. C-ring
9. Driven gear (No. 2)
10. Side plate (No. 2)
11. Rear cover
2
GEAR PUMP 4I1BO00
4
GEAR PUMP
Disassembly and assembly

General precautions
• All pumps are run-in before shipping to ensure perfor-
mance. Therefore, the performance cannot be guaran-
teed after a pump is disassembled and reassembled.
If a pump should fail, replace the assembly if possible.
If disassembly and reassembly cannot be avoided, fol-
low the instructions in this manual.
• This manual describes the L-type gear pump (counter-
clockwise rotation when viewed from the end of the
shaft). For the R-type (clockwise rotation when viewed
from the end of the shaft), the disassembly and assem-
bly procedures are the same except that the suction
side and discharge side are reversed.
• Perform disassembly and assembly work in a clean
place. Provide clean containers to hold parts during
disassembly.
• Clean around the ports before disassembly. Remove
paint around connectors with a wire brush.
• Clean the disassembled parts with wash oil.
• Put alignment marks on all parts to ensure that they are
reassembled in the same positions.
• After each disassembly, replace all seals and apply a
thin layer of grease to each.
• Check each part for abnormal wear or seizing. Re-
move any burrs with sandpaper.
• Remove adhesive from screw holes that use adhesive
through the tap. Do not reuse mounting bolts or
screws.
• Do not use cloth gloves during assembly. Fibers from
the gloves could fall off and clog valves, etc., which
could cause parts to become faulty.
• During assembly, be sure to apply clean hydraulic oil
to all moving parts and in sliding parts that come into
contact with the hydraulic motor and valve parts be-
fore installing or attaching the part.
• Plug all ports after assembly is complete to prevent
dust and dirt from entering.
3
GEAR PUMP 4I1BO00
4
GEAR PUMP
Disassembly
1. Turn the rear cover facing upwards and hold the front
cover installation position in a vise.
2. Before disassembly, put alignment marks on the
joints between the front cover, bodies, adapter plate,
and drive side of the rear cover.
3. Remove the 4 mounting bolts and remove the rear
cover, No. 2 body, adapter plate, and No. 1 body in
sequence, following the precautions in the exploded
diagram.
4. Each of the side plate is assembled facing in oppo-
site directions. When disassembling, make sure to
apply marks to the positions shown in the instructions
in the exploded diagram.
5. The driven gears of each pump are symmetrical. To
prevent incorrect assembly, apply marks to the posi-
tions on the shaft indicated in the diagram.
(Incorrect assembly will cause damage to the pump
and defective operation.)
Example of marks
(1NR) = Rear side of driven gear, No. 1 pump
6. After removing the C-ring, engage the tip of a screw-
driver on the inner surface of the oil seal and remove
the oil seal, as shown in Figure 1.
At this time, take care not to damage the oil seal hole.
4
GEAR PUMP 4I1BO00
4
GEAR PUMP
Assembly
For assembly, refer to the construction diagram, and re-
peat the disassembly procedures but in the reverse or-
der.
1. Replace the oil seal, gaskets, and backup ring with
new parts.
2. During assembly, carefully wash all parts and dry
them with an air gun before assembling the parts.
3. Hold the body in a vise with the front cover mounting
surface upwards. Reverse the disassembly proce-
dure, while following the notes in the exploded dia-
gram.
4. When inserting a backup ring, take care that it does
not twist inside the 3-shaped gasket. (See Figure 4.)
5. Assemble the side plates with the yellow surface fac-
ing toward the gears.
6. The drive gear and driven gear have asymmetric
tooth profiles. Assemble the gears so that the tooth
surfaces with the small notch engage with each oth-
er. (See Figure 5.)
7. Tighten the 4 hexagon socket head bolts to 98 to 108
N·m (72 to 80 ft-lb.) torque.
8. Next, invert the assembled pump so that the oil seal
faces upwards.
9. Add grease between the main lip and dust lip of the
oil seal. (See Figure 6.)
10. Use the oil seal guide and oil seal snap to drive in the
oil seal, as shown in Figure 2.
11. Install the C-ring, as shown in Figure 3.
5
GEAR PUMP 4I1BO00
rk
ma
tch
ark Ma
m
tch
Ma
ly
e mb
g ass
rin
du
art
e wp
e an
Us
rk
" ma
Construction
"1R
m ark
tch rk
Ma ma
tch
m ark Ma
Exploded diagram
m ark tch
tch Ma
Ma
of bly
er Discharge ss em
lay ar
ga
GEAR PUMP (HIGH FLOW)

hin ge side
ly a t the urin
p t o s e rt d
Ap a s e face sid rs pa
n ew
g r e e sur llow gea ea
rk sid Ye ard Us
" ma tow
1F rk
bly " Intake side " ma
em "2R
g ass
Oil seal urin ark
rt d m
pa tch
Flathead w Ma rk
ne m ark ma
screwdriver, ea tch tch
etc. Us Ma Ma ue
m ark orq
R" of ly gt
er mb
ark "1N lay ar a sse te nin
hm ing igh
Matc a thin he ge
t r T
ply to s du
e art
Ap a s e face sid rs wp
Figure 1. e g r e e sur llow gea a ne
sid rs id Ye ard se
Removing the llow gea rk s o w U
Ye ard a t
w "m ark
oil seal to "2F "m
art "3R
w p ly
n e emb
e a ss m ark
Us ing a tch
r rk
du Ma
ma
tch
Ma
of
er
ark lay ar
R "m
"2N a thin he ge
t
ply to s
e e
1
Ap ase face
sid rs gre e sur sid rs
llow gea sid llow gea
Ye a r d r k Ye ard
tow ma to w
"3 F"
art
w p ly
n e emb
e a ss
Us ing a
r
du
rk
ma
R"
"3N
e
sid rs
llow gea
Ye ard
to w
Drive gear
direction of
rotation
Large notch
Pliers Small notch (non-engaged side)
Oil seal snap tool
(engaged side)
Mark
Discharge
side Intake side
Oil seal guide

C-ring Direction of
(View from rear of pump) rotation
Driven gear
Oil seal 3-shaped gasket Figure 5. Gear engagement marks
Dust lip
Fill with
grease
Backup ring
Main lip
Figure 2. Installing the oil seal Figure 3. Installing C-ring Figure 4. Installing backup ring Figure 6. Oil seal
4
4I1BO03
4I1BO01
4
Internal construction diagram
4I1BO04
1. Front cover 50. Backup ring

2. No. 1 Body 51. 3-shaped gasket
3. No. 1 Drive gear 55. Hexagon socket head bolt
4. No. 1 Driven gear 56. Hardened washer
5. No. 1 Side plate 57. Bushing
6. No. 1 Adapter plate 65. Oil seal
7. No. 2 Body 70. C-ring
8. No. 2 Drive gear
9. No. 2 Driven gear
10. No. 2 Side plate
11. No. 2 Adapter plate
12. No. 3 Body
13. No. 3 Drive gear
14. No. 3 Driven gear
15. No. 3 Side plate
16. Rear cover
2
GEAR PUMP (HIGH FLOW) 4I1BO01
4

General precautions
• All pumps are run-in before shipping to ensure perfor-
mance. Therefore, the performance cannot be guaran-
teed after a pump is disassembled and reassembled.
If a pump should fail, replace the assembly if possible.
If disassembly and reassembly cannot be avoided, fol-
low the instructions in this manual.
• This manual describes the L-type gear pump (counter-
clockwise rotation when viewed from the end of the
shaft). For the R-type (clockwise rotation when viewed
from the end of the shaft), the disassembly and assem-
bly procedures are the same except that the suction
side and discharge side are reversed.
disassembly.
thin layer of grease to each.
• Remove adhesive from screw holes that use adhesive
through the tap. Do not reuse mounting bolts or
screws.
to all moving parts and in sliding parts that come into
• Plug all ports after assembly is complete to prevent
dust and dirt from entering.
3
4
Disassembly
1. Turn the rear cover facing upwards and hold the front
cover installation position in a vise.
2. Before disassembly, put matchmarks on the joints
between the front cover; No. 1, No. 2, and No. 3 bod-
ies; No. 1 and No. 2 adapter plates; and drive side of
the rear cover.
3. Remove the 4 mounting bolts and remove the rear
cover, No. 3 body, No. 2 adapter plate, No. 2 body,
No. 1 adapter plate, and No. 1 body in sequence, fol-
lowing the precautions in the exploded diagram.
4. Each of the side plate is assembled facing in oppo-
site directions. When disassembling, make sure to
apply marks to the positions shown in the instructions
in the exploded diagram.
5. To prevent incorrect assembly of the drive gears and
driven gears, apply pump identification marks and
gear engagement marks. (Incorrect assembly will
cause damage to the pump and defective opera-
tion.)
Pump identification mark (driven gear only) (See ex-
ploded diagram.)
Gear engagement marks (See Figure 5.)
Pump identification mark

6. After removing the C-ring, engage the tip of a screw-
driver on the inner surface of the oil seal and remove
the oil seal, as shown in Figure 1.
At this time, take care not to damage the oil seal hole.
4
4
Assembly
For assembly, refer to the construction diagram, and re-
peat the disassembly procedures but in the reverse or-
der.
1. Replace the oil seal, gaskets, and backup ring with
new parts.
2. During assembly, carefully wash all parts and dry
them with an air gun before assembling the parts.
3. Hold the No. 1 body in a vise with the front cover
mounting surface upwards. Reverse the disassem-
bly procedure, while following the notes in the ex-
ploded diagram.
4. When inserting a backup ring, take care that it does
not twist inside the 3-shaped gasket. (See Figure 4.)
5. Assemble the side plates with the yellow surface fac-
ing toward the gears.
6. The drive gear and driven gear have asymmetric
tooth profiles. Assemble the gears so that the tooth
surfaces with the small notch engage with each oth-
er. (See Sheet 1, Figure 5.)
7. Tighten the 4 hexagon socket head bolts to 98 to 108
N·m (72 to 80 ft-lb.) torque.
8. Next, invert the assembled pump so that the oil seal
faces upwards.
9. Add grease between the main lip and dust lip of the
oil seal. (See Figure 6.)
10. Use the oil seal guide and oil seal snap to drive in the
oil seal tool, as shown in Figure 2.
11. Install the C-ring, as shown in Figure 3.
5
4
SUB VALVE
SUB VALVE
Construction
1. O-ring 11. Plunger 21. Plug

2. O-ring 12. Spring 22. Plug
3. O-ring 13. Piston 23. Plug
4. O-ring 14. Plug 24. Plug
5. O-ring 15. Shim 25. Solenoid B
6. O-ring 16. Shim 26. Spring
7. O-ring 17. Spring 27. Shim
8. O-ring 18. Washer 28. Plug
9. Poppet 19. Solenoid A 29. Plug
10. Spring 20. Plug 30. Cap screw
1
SUB VALVE 4K0AT00
4
SUB VALVE

General precautions
The numbers in parentheses, (), listed after the names of
parts throughout this document do not correspond to the
same parts as the numbers listed in the construction di-
agram or parts lists.
place. Provide clean containers to store parts in during
disassembly.
• After each disassembly procedure, replace all seals
and apply a thin layer of grease to each.
• Remove adhesive from screw holes that use the adhe-
sive through the tap. Do not reuse mounting bolts or
screws.
to all moving parts in and sliding parts that come into
• Plug all ports once assembly has been completed in
order to prevent dust and dirt from entering.
Disassembly
1. Remove the solenoid valve B.
a. Take out the cap screws, and remove the sole-
noid (1).
Cap screw: 3.92 N·m (2.9 ft.-lb)
• Take care not to allow the push rod to fall from
the solenoid.
b. Remove the O-ring from the solenoid (1).
2
SUB VALVE 4K0AT00
4
SUB VALVE
c. Remove the spool (2), the sleeve (3), the washer

(4), and the spring (5). 2
4
5
4KAA03Z
2. Remove the solenoid valve A.

a. Take out the nut (6) and then remove the solenoid
(7).
Solenoid: 37.3 N·m (27.5 ft.-lb)
• Take care not to allow the push rod to fall from
the solenoid.
Solenoid: 29.4 N·m (21.7 ft.-lb)
b. Remove the O-ring from the solenoid (7).
c. Remove the spool (8) and the sleeve (9).
4KAA05Z
3. Take out the plug (10), and remove the O-ring from
the plug (10).
Plug: 98 N·m (72.3 ft.-lb)
4. Remove the spring (11) and the washer (12).
the plug (13).
Plug: 76 N·m (56.1 ft.-lb)
6. Remove the spool (14).
3
SUB VALVE 4K0AT00
4
SUB VALVE
the plug (15).
Plug: 76 N·m (56.1 ft.-lb)
8. Remove the spring (16).
the plug (17).
Plug: 49 N·m (36.1 ft.-lb)
10. Remove the spool (18).
11. Remove the piston (19) from the spool (18).
the plug (20).
Plug: 49 N·m (36.1 ft.-lb)
13. Remove the spring (21) and the poppet (22).
the plug (23).
Plug: 21 N·m (15.5 ft.-lb)
15. Remove the spring (24) and the plunger (25).
4
SUB VALVE 4K0AT00
4
SUB VALVE
Inspection and adjustment

Checking the parts
Part Criteria Action
Coil assembly • The solenoid is burned, short-circuited, or has a wire • Replace
break
• There is a short-circuit or break in the wiring • Replace
Body • There are scratches, rust, or corrosion on the parts that • Replace
come into sliding contact with the spool
• There are scratches, rust, or corrosion on the seal part • Replace
that comes into contact with the O-ring
• There is other damage that may hinder or impair normal • Replace
function
Spool, plunger • There are scratches on the outer circumference that • Replace
could easily become caught on a fingernail
• The movement is not smooth • Repair or replace
Spring • There is rust, corrosion, deformation, breakage, or other • Replace
notable damage
O-ring — • Replace
5
SUB VALVE 4K0AT00
4
PILOT VALVE
PILOT VALVE
Construction
1. Casing 11. Washer 2

2. Plate 12. Spring
3. Spool 13. Spring
4. Plug 14. Spring
5. Push rod 15. Spring
6. Push rod 16. Joint
7. Seal 17. Cam
8. O-ring 18. Adjusting nut
9. Spring seat 19. Lock nut
10. Spring seat
1
PILOT VALVE 4K2AT00
4
PILOT VALVE
Special tools
Unit in diagrams: mm
Installation jig A
Quantity: 1
Material A: S45C
Material B: SCM415N (Carburized and hardened)
Installation jig B
Quantity: 2
Material B: SCM415N (Carburized and hardened)
2
PILOT VALVE 4K2AT00
4
PILOT VALVE

General precautions
The numbers in parentheses, (), listed after the names of
parts throughout this document do not correspond to the
same parts as the numbers listed in the construction di-
agram or parts lists.
place. Provide clean containers to store parts in during
disassembly.
• After each disassembly procedure, replace all seals
and apply a thin layer of grease to each.
• Remove adhesive from screw holes that use the adhe-
sive through the tap. Do not reuse mounting bolts or
screws.
the gloves could shed or fall off and clog valves, etc.,
which could cause parts to become faulty.
to all moving parts in and sliding parts that come into
• Plug all ports once assembly has been completed in
order to prevent dust and dirt from entering.
3
PILOT VALVE 4K2AT00
4
PILOT VALVE
Disassembly
1. Take out the adjusting nut (1), and remove the cam
(2) from the joint.
• Secure the valve to the vice using a copper or
lead plate.
2. Take out the joint (3), and then remove the plate (4).
• Use the installation jigs A and B.
3. Take out the plug (5), and remove the push rod (6)
from the plug (5).
• If it is hard to remove by hand, use a flat-bladed
screwdriver to remove it.
• Watch out for the plug popping out due to spring
pressure.
4
PILOT VALVE 4K2AT00
4
PILOT VALVE
4. Remove the O-ring (7) and the seal (8) from the plug.
5. Remove the reducing valve (12) and the spring (13).

• To avoid misconnection when reassembling, in-
sert marks indicating the matching positions for
the reducing valve (12) and the casing hole.
6. Disassemble the reducing valve (12).

a. Push in the spring seat (14) to compress the
spring (15) and to move the spool (17) from the
small hole side to the large hole side on the spring
seat (14).
• The spring seat (14) is not to be pushed down
by more than 6 mm (0.24 in.).
7. Remove the spring seat (14), the spring (15), and the
washer 2 (16) from the spool (17).
5
PILOT VALVE 4K2AT00
4
PILOT VALVE
Assembly
1. Assemble the reducing valve (12).
a. Place the washer 2 (16), the spring (15), and the
spring seat (14) on the spool (17).
b. Push in the spring seat (14) to compress the

spring (15) and to move the spool (17) from the
large hole side to the small hole side of the spring
seat (14).
• The spring seat (14) is not to be pushed down
by more than 6 mm (0.24 in.).
2. Install the spring (13) and the reducing valve (12).

• Install them in the locations where they were be-
fore disassembly.
3. Fit the O-ring (7) and the seal (8) to the plug (5).
6
PILOT VALVE 4K2AT00
4
PILOT VALVE
4. Install the push rod (9) on the plug (5).

• Apply hydraulic oil to the push rod (9).
5. Install the plug (5), the plate (4), and the joint.
• Use the installation jigs A and B to install the joint.
Joint: 41.7 ± 2.9 N·m (30.8 ± 2.1 ft.-lb)
6. Install the cam (2) and the adjusting nut (1).

• Tighten the adjusting nut (1) to the point where it
uniformly contacts all four push rods.
• When tightening the adjusting nut (1), do not
move the cam (2).
Adjusting nut: 68.6 ± 4.9 N·m (50.6 ± 3.6 ft.-lb)
Grease the rotating part of the joint and its con-

tact surfaces with the disc and the push rod.
7
PILOT VALVE 4K2AT00
4
PILOT VALVE

Checking the parts
Seal — • Replace
Spool • The wear on the sliding portions is 10 µm (0.0004 in.) • Replace
or greater compared to that on the non-sliding por-
tions
• There are scratches on the sliding portions • Replace
• The spool does not move smoothly • Replace
Push rod • The front end is worn by 1 mm (0.04 in.) or more • Replace
• There are scratches on the sliding portions • Replace
Plug • The seal is imperfect due to damage • Repair or replace
Controls • The tightening is loose at the pin, shaft, or joint of the • Tighten to the specified torque
controls, with looseness of 2 mm (0.08 in.) or greater
• The tightening is loose at the pin, shaft or joint of the • Replace
controls due to wear, etc., with looseness of 2 mm
(0.08 in.) or greater
Casing, port plate • There are scratches, rust, or corrosion on the parts • Replace
that come into sliding contact with the spool
• There are scratches, rust, or corrosion of the seal part • Repair or replace
that comes in contact with the O-ring
8
PILOT VALVE 4K2AT00
4

Construction
5 6 7
8 9 10 11 12
3・
2・
4K4BM01
1 7.0 ± 1.0 N·m (5.2 ± 0.7 ft-lb.)

2 7.4 ± 0.5 N·m (5.5 ± 0.4 ft-lb.)
1. Solenoid proportional pressure reducing valve 7. Spring

2. Bolt 8. Sleeve
3. Seal nut 9. O-ring
4. Casing 10. O-ring
5. Spool 11. O-ring
6. Retaining ring 12. O-ring
1
PROPORTIONAL CONTROL SOLENOID VALVE 4K4BM00
4
Disassembly and Assembly

The numbers in parentheses () listed after the names of
parts in this document match the numbers used in the
construction diagrams and parts lists.
General Precautions
disassembly.
• Put alignment marks on all parts to reassemble them in
the same positions.
thin layer of grease to them.
• Do not move adjusting screws, unless absolutely nec-
essary.
• All components are precision parts. Take care not to
drop or hit the parts when handling them.
• Never pry open or hit parts. This may cause burrs or
other damage that results in loss of function.
• Leaving the parts in a disassembled state may result
in rusting.
Disassembly
1. Remove the bolts (2), and remove the solenoid pro-
portional pressure reducing valve (1).
• Do not attempt to remove the sleeve (7) unless
absolutely necessary. It is swaged to the solenoid
by the retaining ring (6).
Assembly
For assembly, reverse the disassembly procedure.
2
4

Checking the parts

Coil assembly • The solenoid is burned-out, short-circuited, or a wire is broken. • Replace
• Wiring short-circuit or a wire is broken • Replace
Body • Scratches, rust, or corrosion at the parts in sliding contact with the • Replace
spool.
• Scratches, rust, or corrosion of the part of the seal in contact with the • Replace
O-ring.
• Other damage considered to impair the normal functions • Replace
Spool • Scratches on the outer circumference that easily catch a fingernail • Replace
• Movement is not smooth • Repair or replace
Spring • Rust, corrosion, deformation, breakage, or other notable damage • Replace
3
4

Construction
601 601
171
101
901
4K4BO01
1 : 7.0 ± 1.0 N·m (5.2 ± 0.7 ft-lb.) 901.Name plate label

601.Solenoid proportional pressure reducing valve
171.Hexagon bolt
101.Casing
Solenoid proportional pressure reducing valve
312 361 362 363 (861) 901 801 (802) 1 4K4BO02
1 : 7.4 ± 0.5 N·m (5.5 ± 0.4 ft-lb.) 311.Spool 361.O-ring 802.Seal nut
312.Sleeve 362.O-ring 861.O-ring
326.Retaining ring 363.O-ring 901.Name plate
324.Spring 801.Solenoid
1
PROPORTIONAL CONTROL SOLENOID VALVE (1ST 4K4BO00
AUXILIARY LINE PIPING)
4

General precautions
• All components are precision parts. Take care not to
drop or hit the parts when handling them.
• Never pry open or hit parts. This may cause burrs or
other damage that results in loss of function.
• Leaving the parts in a disassembled state may result
in rusting.
• Before reassembly, check that all parts are free of dirt.
Also check that they are free of burrs. Remove any
burrs found with an oilstone.
• In principle, replace O-rings with new ones.
• Be careful not to damage the O-ring when installing it.
(Apply a small amount of grease before installation.)
• When reassembly is complete, insert plugs in all ports
to keep out dirt.
Disassembly
1. Remove the solenoid valve block and place it on a
workbench.
2. Remove the hexagon bolts (171) and remove the so-
lenoid proportional pressure reducing valve (601)
from the casing (101).
3. Do not attempt to remove the sleeve (312) unless ab-
solutely necessary. It is swaged to the solenoid (801)
by the retaining ring (326).
Assembly
To assemble, complete the steps for disassembly in re-
verse order.
1. Preparing the solenoid proportional pressure reduc-
ing valve (601)
If the retaining ring (326) is cut to disassemble the
sleeve (312) and solenoid (801), use a new solenoid
proportional pressure reducing valve.
Otherwise, continue to use the proportional control
solenoid valve.
2. Installing the solenoid proportional pressure reduc-
ing valve (601)
Insert the solenoid proportional pressure reducing
valve (601) into the casing (101) and secure it with
the hexagon bolts (171).
2
4
Service standards
Servicing standard Standard

Leakage volume Replace if the amount of leakage increases and affects related systems
Solenoid Replace if deformation has occurred due to external forces
• O-rings and other seals should be replaced after re-

moval. However, they can be reused if they are
checked and found free of damage.
3
4
CYLINDER
CYLINDER
Lift arm cylinder
15
17 16 13
22 20 23 18 8 7 8 19 3 6 3 4 5 2
26
28
27
29
DETAIL "B" 21 1 14
DETAIL "A"
15
25 A
30 31 32 30
B
10
12
9
B 24 11
R0H040-1
A
4L0BS01
1 Set screw: 16.2 N·m (11.9 ft-lb.) Tighten the set screw 1. Rod packing 17. Set screw
and caulk the circumference in two positions with a punch. 2. Dust seal 18. Steel ball
2 Piston: 1053 N·m (777 ft-lb.) 3. O-ring 19. Cushion bearing
3 Rod cover: 422 N·m (311 ft-lb.) 4. Backup ring 20. Cushion bearing
Rod cover: Apply Three Bond #1901, or an equiva- 5. O-ring 21. Cushion ring
lent. 6. Backup ring 22. Stopper
4 Align the slit toward the piston. 7. Piston packing 23. Snap ring
5 Plug: 160 ± 7.8 N·m (118 ± 5.8 ft-lb.) 8. Wear ring 24. Pipe assembly
6 Bolt: 17.2 N·m ± 0.9 N·m (12.7 ft-lb. ± 0.7ft-lb.) 9. Tube assembly 25. Pipe assembly
10. Bushing 26. Plug
11. Piston rod assembly 27. O-ring
12. Bushing 28. Bolt
13. Rod cover 29. Pipe holder
14. Bushing 30. Dust seal
15. Holder assembly 31. Grease fitting
16. Piston 32. Grease fitting
1
CYLINDER 4L0BS00
4
CYLINDER
Bucket cylinder (left)

14 1 23 3
15 7 6 7 13 2 8 10 3 4 1 5 12 2
22
A
17 5
21 9 18 11 21
20 16
19 4
6
R0H050
VIEW A
4L0BS02
1 Set screw: 16.7 N·m (12.3 ft-lb.) Tighten the set screw 1. Rod packing 13. Piston
and caulk the circumference in two positions with a punch. 2. Dust seal 14. Set screw
2 Piston: 909 N·m (670 ft-lb.) 3. O-ring 15. Steel ball
3 Rod cover: 422 N·m (311 ft-lb.) 4. Backup ring 16. Pipe assembly
4 Bolt: 17.2 ± 0.9 N·m (12.7 ± 0.7 ft-lb.) 5. O-ring 17. Plug
5 Plug: 160 ± 7.8 N·m (118 ± 5.8 ft-lb.) 6. Piston packing 18. O-ring
6 Caulk the cylinder head in two positions with a punch to 7. Wear ring 19. Bolt
stop it rotating. At least one punch in the shaded range in 8. Tube assembly 20. Holder
the illustration. 9. Bushing 21. Dust seal
10. Piston rod assembly 22. Grease fitting
11. Bushing 23. Rod cover
12. Bushing
2
CYLINDER 4L0BS00
4
CYLINDER
Bucket cylinder (right)

14 1 23 3
15 7 6 7 13 2 8 10 3 4 1 5 12 2
19 4 20 16
17 5
21 22 9 18 11 21
6 VIEW A
R0H060 4L0BS03
1 Set screw: 16.7 N·m (12.3 ft-lb.) Tighten the set screw 1. Rod packing 13. Piston
and caulk the circumference in two positions with a punch. 2. Dust seal 14. Set screw
2 Piston: 909 N·m (670 ft-lb.) 3. O-ring 15. Steel ball
3 Rod cover: 422 N·m (311 ft-lb.) 4. Backup ring 16. Pipe assembly
4 Bolt:17.2 ± 0.9 N·m (12.7 ± 0.7 ft-lb.) 5. O-ring 17. Plug
5 Plug: 160 ± 7.8 N·m (118 ± 5.8 ft-lb.) 6. Piston packing 18. O-ring
6 Caulk the cylinder head in two positions with a punch to 7. Wear ring 19. Bolt
stop it rotating. At least one punch in the shaded range in 8. Tube assembly 20. Holder
the illustration. 9. Bushing 21. Dust seal
10. Piston rod assembly 22. Grease fitting
11. Bushing 23. Rod cover
12. Bushing
3
CYLINDER 4L0BS00
4
CYLINDER

Preparations: Complete the preparations below be-
fore disassembly.
1. Preparing the workbench
Use a solid and stable workbench that is large
enough to place the parts without the parts moving or
falling off during work.
2. Preparing tools and materials
Prepare the tools and materials required.
General precautions
• Before disassembly, thoroughly wash away any dust
and dirt adhering to the outside wall of the cylinder.
• The parts are made to extremely high precision. Han-
dle the parts carefully, taking care not to knock them to-
gether or drop them.
• During work, do not hit or lever any part that is stuck.
This may cause burrs or damage that results in oil leaks
and reduces performance of the product. Perform all
work carefully and with patience.
• Leaving a cylinder fully or partly disassembled may re-
sult in rust on the parts due to humidity and dirt. If the
work has to be interrupted before it is complete, take
measures to prevent rust and dust.
Service standards
Follow the procedure below to replace sliding parts or
seal parts.
1 Rod cover bushing If the entire length over 1/4 circumference is worn to copper color.
2 Seals and wear ring Replace with new parts when the cylinder is disassembled.
3 Clevis bushing If severe scoring occurs
4 Oil leak from piston rod sliding surfaces If bending of 5 mm/1 m or more occurs
4
CYLINDER 4L0BS00
4
CYLINDER
Inspection after assembly
No-load operation After five or more full-stroke operations at no load, check that operation is smooth and no ab-
test normalities have occurred in the parts.
Dimensional inspec- Check the maximum retraction length and stroke indicated in the drawing.
tion
Pressure test After applying the test pressures indicated on the drawing at the stroke ends for at least 3 min-
utes, check that no looseness, permanent deformation, or external leaks occur.
External leak test Check the oil leakage amount from the rod.
(See “Oil leakage evaluation criteria for the rod” below.)
Internal leak test Oil leakage amount units: mL/10 minutes (fl oz./10 minutes)
Inner diameter Oil leakage Inner diameter Oil leakage Inner diameter Oil leakage
mm (in.) amount mm (in.) amount mm (in.) amount
32 (1.3) 0.4 (0.01) 100 (3.9) 4.0 (0.14) 160 (6.3) 10.0 (0.34)
40 (1.6) 0.6 (0.02) 125 (4.9) 5.6 (0.19) 180 (7.1) 12.6 (0.43)
50 (2.0) 1.0 (0.03) 140 (5.5) 6.0 (0.20) 200 (7.9) 15.6 (0.53)
63 (2.5) 1.6 (0.05) 220 (8.7) 20.0 (0.68)
80 (3.1) 2.3 (0.08) 250 (9.8) 22.0 (0.74)
Oil leakage evaluation criteria for the rod

After 20 reciprocating movements at an oil temperature of
20°C to 40°C (68°F to 104°F), evaluate the condition of
the oil rings formed on the piston rod surface. Evaluate an
abnormality if the oil ring is broken, such as A in the dia-
gram.
5. Cylinder
1 Oil rings
2 Fail
4L0BP01 3 Pass
5
CYLINDER 4L0BS00
4
CYLINDER
Tools required
Special jigs
The following special jigs are required to assemble the
cylinder.
1. Rod cover bushing press-fitting jig
-0.1
φD -0.2
φd1 -0.1
0
φd2
30°
2
L1 L2
15 L3
L
4L0BQ04 1 Within R 0.2
Units: mm (in.)
Dimensions
Applicable cylinder D (rod Material
d1 d2 L1 L2 L3 L
diameter)
Lift arm cylinder 45 (1.8) 50 (2.0) 82 (3.2) 39 (1.5) 25 (1.0) 64 (2.5) 79 (3.1) S45C or
Bucket cylinder (left) (right) 45 (1.8) 50 (2.0) 82 (3.2) 39 (1.5) 25 (1.0) 64 (2.5) 79 (3.1) equivalent
6
CYLINDER 4L0BS00
4
CYLINDER
2. Clevis bushing press-fitting jig
-0.08
φD -0.09
-0.5
φd1 -1.0
φd2
3*30
(20) L2
L1+0.1
0
4L0BQ05
Units: mm (in.)
Dimensions
Applicable cylinder D (pin Material
d1 d2 L L1 L2
diameter)
Lift arm cylinder 45 (1.8) 55 (2.2) 64 (2.5) 70 (2.8) 5 (0.2) 45 (1.8) S45C or
Bucket cylinder (left) (right) 45 (1.8) 55 (2.2) 64 (2.5) 70 (2.8) 5 (0.2) 45 (1.8) equivalent
7
CYLINDER 4L0BS00
4
CYLINDER
3. Seal ring fitting jig
3
φD
φD1
φD2
4L0BQ07 1 Slit
Units: mm (in.)
Dimensions
Applicable cylinder (Tube inner Material
D D1 D2 D3
diameter)
Lift arm cylinder 75 (3.0) 80 (3.2) 76 (3.0) 72 (2.8) 68 (2.7)
MC nylon
Bucket cylinder (left) (right) 75 (3.0) 80 (3.2) 76 (3.0) 72 (2.8) 68 (2.7)
8
CYLINDER 4L0BS00
4
CYLINDER
4. Seal ring corrective jig
4L0BO08
Units: mm (in.)
Dimensions
Applicable cylinder Material
d (Tube inner diameter) D
Lift arm cylinder 75.030 to 75.076 (2.9539 to 2.9557) 90 (3.5) STKM13C or SS400,
Bucket cylinder (left) (right) 75.030 to 75.076 (2.9539 to 2.9557) 90 (3.5) or equivalent
9
CYLINDER 4L0BS00
4
CYLINDER
5. Rod cover dust seal press-fitting jig
4L0BO09
Units: mm (in.)
Dimensions
Applicable cylinder (Rod diame- Material
D d1 d2 d3
ter)
Lift arm cylinder 45 (1.8) 43.5 (1.71) 53.5 (2.11) 64 (2.5) 30 (1.2) S45C or an
Bucket cylinder (left) (right) 45 (1.8) 43.5 (1.71) 53.5 (2.11) 64 (2.5) 30 (1.2) equivalent
10
CYLINDER 4L0BS00
4
CYLINDER
Disassembly
1. Drain the oil.
2. Secure the cylinder.
Secure the cylinder vertically or horizontally.
Holding the cylinder vertical makes disassembly and
assembly easier.
When securing the cylinder, use the bottom pin hole
to prevent rotation and secure it in the axial direction.
(When securing the cylinder, remove any piping or
other object that interferes with it.)
3. Loosen the cylinder head.
Lift up the 1 rod cover detent (rod cover end) (2 posi-
tions at the rod cover end and tube end if lock wash-
ers are used) and loosen the rod cover one or two
turns with a hook wrench. (It is easier to work with the
piston rod extended to a position about 5 cm (2.0 in.)
shorter than the fully extended position.)
4L0BO10
1 Hammer
2 Chisel
3 Pipe
4L0BO11
4 Hook wrench
11
CYLINDER 4L0BS00
4
CYLINDER
4. Pull out the piston rod.

a. Ensure that the cap is removed from the pipe.
b. Place an oil pan under the retraction-side port (cyl-
inder head side).
c. Pull out the piston rod as far as possible and re-
move the remaining screws from the rod cover.
d. Withdraw the piston rod and rod cover together
and place them on wooden blocks.
CAUTION
Take special care of the points below if disassembly
work is performed with the cylinder vertical.
If all the rod cover screws are removed before the pis-
ton rod is pulled out, the rod cover comes out of the
cylinder tube and a gap forms with the piston.
If work is performed in this situation, the cylinder
head may suddenly slip off at a certain height and in-
4L0BO12
jure a worker. Make sure that the rod cover is in con-
tact with the piston when working. Falling parts are dangerous. Working with the cylinder
vertical
CAUTION
Take special care of the points below if disassembly
work is performed with the cylinder horizontal.
When pulling out the piston rod, the piston rod may
fall and the piston rod and its parts get damaged im-
mediately after it is withdrawn.
Put the rod on wooden blocks to keep it horizontal
and work carefully.
4L0BP10
1 Wooden block
Falling parts are dangerous. Working with the cylinder
vertical
12
CYLINDER 4L0BS00
4
CYLINDER
5. Secure the piston rod.

Use the width between the two faces and pin hole of
the rod head to prevent rotation.
4L0BO13
6. Disassemble the piston.

a. Take out the set screw.
After insertion, the set screw is punch caulked at
two positions.
Use a hand drill or other similar tools to grind down
the punched positions before loosening the set
screw.
b. Remove the steel ball inserted under the set
screw. 4L0BP12
c. Remove the piston nut.

1 Drill
The piston nut is tightened to the torque specified
2 Steel ball
in the construction diagram. To loosen the piston
nut, about 1.5 times this torque is required. Pre-
pare a powered wrench using a hydraulic jack and
hydraulic cylinder.
4L0BP13
1 Hydraulic jack
2 Hydraulic cylinder
7. Removing the rod cover assembly.
4L0BO14 1 Rod cover assembly
a. Remove the rod cover assembly.
13
CYLINDER 4L0BS00
4
CYLINDER
8. Remove the piston seals.

a. The wear ring can be easily removed by hand.
b. Apply a flathead screwdriver against the seal ring,
as shown in the diagram to the right. Hit it with a
hammer to cut and remove the ring.
c. Use a spatula to pull out the O-ring.
d. The removed seal parts cannot be reused.
4L0BO15
1 Flathead screwdriver
2 Wear ring
3 Seal ring
4 O-ring
5 Hardwood
6 Vise
9. Removing the seal from the rod cover assembly.

a. Use a spatula to pull out the O-ring.
b. Use a screwdriver or similar tool to remove the rod
packing and backup ring.
c. The dust seal is press-fitted. Pierce the rubber
with a screwdriver or similar tool and strike it to re-
move the ring.
d. The removed seal parts cannot be reused.
10. Removing the bushing.
a. Use the jig to press out the bushing.
4L0BQ08
1 Dust seal
2 O-ring and backup ring
3 Bushing
4 Rod packing
5 Apply a press
6 Jig
7 Rod cover
9 Jig
14
CYLINDER 4L0BS00
4
CYLINDER
11. Disassemble the clevis.

a. Remove the dust seals from the tube and piston
rod.
Use a screwdriver or other similar tool to remove
it, in the same way as from the cylinder head.
b. Use a metal rod to remove the bushing.
12. Washing and storage
a. After washing the removed parts in white kero-
sene, apply hydraulic oil to them and cover them
for storage.
b. Leaving the parts as they were disassembled may
4L0BO17
cause rusting or dust adhesion so that they will not
function correctly after reassembly.
1 Press
2 Metal rod
3 Jig
15
CYLINDER 4L0BS00
4
CYLINDER
Assembly
CAUTION
Paint peeling off the parts during assembly may enter
the cylinder. Take due care as this may result in oil
leaks.
1. Assembling the clevis

a. Use the clevis bushing press-fitting jig to press-fit
the bushing into the piston rod and tube. (Apply a
coating of hydraulic oil first.)
b. Use a metal rod to insert the dust seal.
4L0BQ09
1 Press
2 Clevis bushing press-fitting jig
3 Bushing
4 Piston rod
5 Metal rod
6 Dust seal
16
CYLINDER 4L0BS00
4
CYLINDER
2. Assembling the rod cover assembly

a. Use the rod cover press-fitting jig to press-fit the
bushing.
(Apply hydraulic oil to the inside surface of the rod
cover first. Ensure no difference in level with the
bushing after it is press fitted.)
b. Install the rod packing.
(Insert it in the correct direction. Take care not to
damage the rod packing during installation.)
4L0BQ10
1 Apply a press
2 Rod cover bushing press-fitting jig
3 Bushing
4 Rod cover
5 Press with a spatula or other similar tool
c. Install the dust seal. (Assemble using the rod cov-

er dust seal press-fitting jig.)
17
CYLINDER 4L0BS00
4
CYLINDER
d. Install the backup ring and O-ring.

(Install the backup ring and O-ring in sequence.)
4L0BO19
1 Dust seal
2 O-ring and backup ring
3 Bushing
4 Rod packing
5 Rod cover dust seal press-fitting jig
6 Rod cover
3. Assembling the piston assembly

a. Assemble the seal ring assembly.
a-1. Insert the O-ring in the mounting groove.
(Check that the O-ring is not twisted.)
a-2. Use the seal ring press-fitting jig to push the
seal ring on the piston.
4L0BO20
1 Seal ring press-fitting jig

2 Seal ring
3 O-ring
4 Piston
18
CYLINDER 4L0BS00
4
CYLINDER
a-3. As the seal ring is stretched when it is in-

stalled, correct the shape of the seal ring us-
ing the corrective jig.
(Assembly is not possible unless the seal ring
shape is corrected.)
b. Install the wear ring
b-1. Open the cut in the wear ring with both hands
and install it in the axial direction.
(Open the cut in the wear ring the minimum
amount possible. It cannot be correctly installed if
it is opened too far.)
4L0BO21
1 Seal ring corrective jig
4. Assembling the piston rod assembly

a. Secure the piston rod.
b. Install the rod cover on the piston rod. Take care
that the lip of the dust seal and rod packing does
not catch on the shoulder.
1 Piston rod
4L0BO22 2 Rod cover insertion jig
3 Cylinder head
19
CYLINDER 4L0BS00
4
CYLINDER
c. Next, tighten the piston.

d. Tighten the piston to the torque shown in the con-
struction diagram.
Take due care, as inadequate tightening torque
can lead to internal leaks, the nut coming loose, or
damage to the threads.
Conversely, excessive tightening torque may lead
to swelling of the cushion bearing on the extension
side or wearing of the piston contact surface. 4L0BP26
Wash and degrease the parts with thinner, for ex-
ample, and wipe it well before tightening the pis- 1 Caulking
ton. 2 Punch
e. After tightening the piston, insert the steel ball and 3 Set screw
tighten the set screw to the torque specified in the 4 Steel ball
table below. Caulk the circumference in two posi-
tions with a punch.
Width across flats

Set screw (hexagon socket) mm
Cylinder Piston mm (in.)
(in.)
Lift arm cylinder 65 (2.6) 5.0 (0.20)
Bucket cylinder (left) (right) 50 (2.0) 4.0 (0.16)
20
CYLINDER 4L0BS00
4
CYLINDER
5. Inserting the piston rod

a. Secure the tube vertically or horizontally.
b. Insert the piston rod in the tube. If the tube is ver-
tical, the piston rod will slide into the tube under its
own weight.
If the tube is horizontal, push the slide ring in by
hand.
• When the piston enters the tube, make sure that
the wear ring does not fall off.
1 Wear ring
2 Piston rod
3 Piston
4 Piston insertion jig
4L0BO23
5 Tube
6. Tightening the rod cover

a. Tighten to the torque shown in the construction di-
agram with a hook wrench.
4L0BO24
1 Hook wrench
2 Pipe
7. Folding the detent

a. Fold the cylinder tube groove to prevent the rod
cover coming loose.
21
CYLINDER 4L0BS00
4
CYLINDER
8. Installing piping on the cylinder tube assembly (for

separate piping)
a. Temporarily screw in the screws for the extension
side port and retraction side port and the bolt for
the pipe support.
b. Tighten the port screws to the torque shown in the
construction diagram.
c. Tighten the bolt for the pipe support to the speci-
fied torque.
CAUTION
When installing the cylinder piping and the rubber
hoses and nipples in the machine, hold the cylinder
pipe ports with a wrench or similar tool. Tightening
without holding them may result in bending of the
piping and pipe support holders, oil leaks, or interfer-
ence with the machine.
4L0BO25
9. Start-up operation 1 Pipe support

a. After installing the cylinder in the machine, move 2 I-joint port
the switching valve full stroke eight times or more. 3 I-joint type
This fills the cylinder with oil. Moving the valve too 4 O-ring
suddenly initially results in aeration of the hydrau- 5 I-joint details
lic oil.
b. Supply oil to the two end pins.
22
CYLINDER 4L0BS00
SERVICE DATA
WIRE HARNESS 2
WIRE HARNESS
Electrical wiring assembly: 06942-00271-01
ENG_AL1
BACK ALARM+
ENG_AL2
D7
ALARM GND
D11 R_LIGHT(L)
CLUTCH
ALT B
ALT WASHER F
H_ENG_AL1
HENG-AL2
GND2 BLOWER
WASHER R 45
D4
SBF SBF1
SBF2
D21 WATER VALVE
FEED
HL5 HL4 R13
MAIN RY AC PSW+ R12

H2 ST RY2 ST RY
M2
M4 G RY+-
M1 D9 G RY-IN 14PIN1
M_CAB ECU BODY
G RY-OUT
D6 AC PSW-
H_ENG_ST1
ECO SW RIDE SW
HECU4 R_LIGHT(R)
R WIP
F WASHER SW ARARM2 UREA_FUEL_P CN C
F WIP
LIGHT SW 14P3
DPF SW
HYD ROCK M5
KYE SW
OPT+ 44 COMP RELAY1 H1 H_SCR1
OPT- M_RADIO+ AIR SUS+
ACCEL
PS 44 M_RADIO-
FAN RELAY1 RR 13 AIR SUS- HECU3
H_GPS 12 HENG3
RR TM1
QH
Shuttle2 HSEAT SW TM4
PB D2 TM3
2nd 14P RL
G-H
SL SW R_GRIP ESG
HF SW
DETENT SW
13
1WAY SW L_GRIP1 Shuttle1 GND1 BAT OUT
TAKE2
2 GND3 SG
CT2-B
CAN1 TAKE1 ER 9
ND
FOOT ACCEL H6 SE RSG
CT2-A EL
FU ACUBODY
R7
R11 15
FUSE BOX RL
R4
RELAY BOX 12
CT3 Shuttle1
CT2 Shuttle2
CT1 R2 HACU1
D3 HACU2
D14
D12
LLRC
D10 R8
LL1
16 R1
D13LL2 D5
IMB1
4T0BS01
1
WIRE HARNESS 4T0BS00
SERVICE DATA
WIRE HARNESS 2
POST Nox
25
D18 COND FAN
21
AIR CLEANER
D19 22 RIDE SOL2(TL12R-2)

AIR
FLO WASHER R
W
23 HEATER2
RIDE SOL1(TL12R-2) SCR1
FLOAT HEATER1
ARM DOWN
24 ENG_ST GLOW
Pre Nox RIDE SOL2(TL12V-2)
Self level D14 RIDE SOL1(TL12V-2)
STMS
P4
20 ARM UP
1WAY SOL HIGH FLOW ENG_SCR1
CLS-GND
ENG3 ECU1
AUX2 A ECU2
CLS 19
R5
AUX2 B L5 DPF
L4
INJ
ARARM ENG-STOP ENG5
AUX1B SOL
AUX1A SOL ECU4
18 ECU_3
COMP RY
LINE F 31 HEATER RY
D24
TRAVEL+
TRAVEL-
LL
D25
AS SOL
P.B SOL 27
TANK HE
R6 SUCTION HE
R9 DELIVERY HE
HYD TEMP
SUPPLY SG2
R6 GND4
LF6
ACU
RETURN HE
FUEL SENDER TULC
ACU1
28
ACU2 4T0BS02
2
SERVICE DATA
WIRE HARNESS 2
33
31
30
34
A
35 4T0BS03
3
SERVICE DATA
WIRE HARNESS 2
39
38
37
36
4T0BS04
4
SERVICE DATA
WIRE HARNESS 2
42
29
43
4T0BS05
5
SERVICE DATA
WIRE HARNESS 2
9 Secure together with the battery negative cable
b Machine with lever pattern change device
c Machine without lever pattern change device
e Secure the fuel sender connector
f Stick on rubber sheet to protect the harness* <Guidelines> Left/right directions: Stick on from edge of main unit; Up/down directions: Stick on from the main unit tap block position
h AUX1: Mark tube exists at side A
i AUX2: Yellow tape exists at side A
j For the pattern change specification, secure with a butterfly clamp.
k Secure the blockage sensor connector
l Ride control for TL12R-2 If not used, do not remove tape. Completely remove tape for L9ER.
m Rear washer tank for TL12V-2 When not used, bundle with a butterfly clamp.
n Ride control for TL12V-2 If not used, do not remove tape. Do not remove the black tape for L9EV.* If it is removed inadvertently, bundle the surplus cable using harness tape or cable ties.
o If not used, do not remove tape.
q Fueling switch Securely connect the connector. If poorly connected, the switch may malfunction if subjected to water.
r Stick on the ACU side. This is a waterproofing measure at the ACU air intake. Orient in the correct direction. If reversed, water may enter the air intake.
s Also secure for the pattern change specification
t Secure the fuel sender connector
u Do not apply excessive torque, which causes the sound tone to change. 0.3 N·m (0.2 ft-lb.)
w Stick sponge to cover (25).
x 6 to 8 N·m (4 to 6 ft-lb.)
y 0.8 to 1 N·m (0.6 to 0.7 ft-lb.)
z Secure the connector from the DEF tank.
A Secure with the remote control unit mounting bolt.
B 10 to 11 N·m (7 to 8 ft-lb.)
C 3 to 4 N·m (2 to 3 ft-lb.)
G Secure so that the diode/resistance wiring is not trapped
H Not used
Rear washer tank for TL12R-2 When not used, bundle with a butterfly clamp.
1. Washer 20. Sponge 39. Bolt 59. Washer 79. Trim

2. Washer 21. Cover assembly 40. Bolt 60. Screw 80. Trim
3. Collar 22. Wire harness: 06942-00199-02 41. Bolt 61. Grommet 81. Trim
4. Washer 22-1. Diode 42. Bolt 62. Ring 82. Trim
5. Collar 23. Wire harness: 06942-00201-02 43. Bolt 63. Band 83. Sponge
6. Buzzer 24. Wire harness: 06942-00202-00 44. Bolt 64. Band 84. Seal
7. Plate 24-1. Diode 45. Bolt 65. Mount 85. Switch
8. Wire harness: 06842-00174-00 25. Cover 46. Bolt 66. Spacer 86. Clamp
9. Bracket 26. Bracket 47. Bolt 67. Edge clip 87. Clamp
10. Wire harness: 06942-00067-03 27. Unit assembly 06942-00291-00 48. Nut 68. Edge clip 88. Clamp
11. Wire harness: 06942-00069-04 28. Wire harness: 06942-00218-01 49. Nut 69. Band 89. Clip
12. Wire harness: 06942-00071-04 29. Plate 50. Nut 70. Band 90. Relay
13. Bracket 30. Plate 51. Spring washer 71. Clamp 91. Clamp
14. Bracket 32. Rubber cushion 52. Spring washer 72. Clamp 92. Clamp
15. Bracket 33. Bracket 53. Spring washer 73. Clamp 93. Battery relay
16. Bracket 34. Tube 54. Spring washer 74. Clamp 94. Clamp
17. Wire harness: 06942-00173-03 35. Bolt 55. Washer 75. Clamp 95. Air heater relay
17-1. Diode 36. Bolt 56. Washer 76. Clamp 96. ECU
18. Wire harness: 06942-00179-00 37. Bolt 57. Washer 77. Clamp 97. ACU
19. Plate 38. Bolt 58. Washer 78. Clamp
6
SERVICE DATA
WIRE HARNESS 2
Wire harness: 06842-00174-00
Line Connections Remarks

Pin no. Color diameter
Pin no. Color Line Line type Connections Remarks Line

diameter Pin no. Color diameter Connections Remarks
TWIST
TWIST
Socket SHIELD
Terminal
TERMINAL RESISTANCE CONNECTOR
SHIELD
Pin no. Color Line Line type Connections Remarks

diameter
Terminal

diameter
Terminal

Pin no. Color diameter
MODEL CONNECTOR TYPE MODEL CONNECTOR TYPE

diameter
SHIELD SHIELD Pin no. Color Line Line type Connections Remarks
diameter
SHIELD
SHIELD
TWIST
TWIST
Drawing No. 1
06842-00174-00 1
4T0BS11
7
SERVICE DATA
WIRE HARNESS 2
Wire harness: 06942-00067-03
Pin no. Color Line Line type Connections

diameter Remarks
Line
Line type Remarks1 Remarks2
MODEL CONNECTOR TYPE Pin no. MODEL CONNECTOR TYPE Pin no. Color diameter
Pin no. Color Line Connections

diameter Remarks
Pin no. Color Line

diameter Line type Connections Remarks
Housing OR EQUIVALENT )
Terminal (SILVER)
Terminal (SILVER)
Housing
diameter Line type

Pin no. Color Line Connections Remarks
diameter Line type
Housing OR EQUIVALENT )
Terminal (SILVER)
Terminal (SILVER)
Drawing No. 1
06942-00067-03 1
4T0BS14
8
SERVICE DATA
WIRE HARNESS 2
Wire harness: 06942-00069-04
Line
MODEL CONNECTOR TYPE Pin no. MODEL CONNECTOR TYPE Pin no. Color Line type diameter Remarks 1 Remarks 2
SHIELD
SHIELD
SHIELD
Pin no. Color Line

SHIELD
SHIELD
SHIELD
Pin no. Color Line

diameter Line type Remarks Housing
Housing
Pin
Pin no. Color Line

diameter Line type Remarks
Yazaki
Housing
Terminal
Waterproof plug
Rear holder
Pin no. Color Line

SHIELD
SHIELD
SHIELD
Drawing No. 1
06942-00069-04 1
4T0BS10
9
SERVICE DATA
WIRE HARNESS 2
Wire harness: 06942-00071-04
Color Line type Line

diameter Remarks 1 Remarks 2 Remarks 3
MODEL CONNECTOR TYPE Pin no. MODEL CONNECTOR TYPE Pin no.
SENSOR
SENSOR
SENSOR
Pin no. Color Line

diameter Connections Remarks
Connector
Socket
Wedge
Pin no. Color Line
Sumitomo
Housing
Terminal
Wire seal
Pin no. Color Line

Pin no. Color Line

Pin no. Color Line

Pin no. Color Line

Pin no. Color Line
Yazaki
Housing
Terminal
Pin no. Color Line
Connections Pin no. Color Line
diameter Remarks
Yazaki
Yazaki
Housing Housing
W Diode unit Terminal
Rear holder
Pin no. Color Line

Yazaki
Housing
Terminal
With the cap DIODE

Waterproof plug
TAPING Rear holder
Yazaki
Housing
Housing Terminal
Terminal Rear holder
Pin no. Color Line
diameter Connections Remarks Pin no. Color Line
Pin no. Color Line

Pin no. Color Line

Connections Remarks Pin no. Color Line
Connections Remarks Drawing No.
diameter diameter diameter diameter
1
06942-00071-04 1
4T0BS15
10
SERVICE DATA
WIRE HARNESS 2
Wire harness: 06942-00173-03
Pin no. Color Line type Connections Remarks Pin no. Color Line type Connections Remarks
SHIELD SHIELD
SHIELD
Connector Connector
Pin no. Color Line type Connections Remarks
Pin no. Color Line type Connections Remarks Connector
Connector
Connector
Sumitomo Yazaki
Sumitomo Housing
Housing Pin no. Color Line type Connections Remarks
Sumitomo
Yazaki
Yazaki
Housing
Pin no. Color Line type Connections Remarks Sumitomo
Yazaki Housing
Housing
Yazaki
Housing
Connector
Yazaki
Housing
SHIELD
Housing
SHIELD Diode
SHIELD Housing
SHIELD Diode Housing
Pin no. Color Line type Connections Remarks Diode
TWIST Pin no. Color Line type Connections Remarks Pin no. Color Line type Connections Remarks
TWIST Pin no. Color Line type Connections Remarks
TWIST TWIST
TWIST TWIST
Yazaki
Housing
Sumitomo Waterproof
Terminal
Housing Housing Terminal
Waterproof plug
Waterproof plug
Pin no. Color Line type Connections Remarks Rear holder
Delphi
Connector
Housing Drawing No. 1

TWIST 06942-00173-03 2
TWIST
4T0BS12
11
SERVICE DATA
WIRE HARNESS 2
Line
Color Line type diameter Remarks 1 Remarks 2
diameter

diameter

diameter
TWIST
TWIST

diameter
TWIST
TWIST

diameter

diameter
SHIELD
diameter
SHIELD
SHIELD
SHIELD

diameter

diameter
Drawing No. 2
06942-00173-03 2
4T0BS13
12
SERVICE DATA
WIRE HARNESS 2
Wire harness: 06942-00179-00
Pin no. Connections Remarks Pin no. Connections Remarks Pin no. Connections Remarks
Pin no. Connections Remarks Pin no. Connections Remarks
Housing
Housing Housing Housing Housing Housing
Housing
MARKING TAPE WHITE
Housing
Pin no. Connections Remarks

Yazaki
Housing
Terminal
Terminal
Yazaki
Housing
Pin no. Connections Remarks Holder
Terminal

SHIELD Pin no. Connections Remarks
SHIELD SHIELD
SHIELD
SHIELD
SHIELD
Yazaki SHIELD
Housing SHIELD
Rear holder SHIELD
Terminal
Terminal
Blank cap Connector
Blank cap
Blank cap
Blank cap Vacant plug
SHIELD
SHIELD
SHIELD
MARKING TAPE WHITE SHIELD
Housing
Terminal
Terminal
Cover
Drawing No. 1
06942-00179-00 2
2H0BO32
13
SERVICE DATA
WIRE HARNESS 2
Line type Line Remarks 1 Remarks 2

MODEL CONNECTOR TYPE Pin no. MODEL CONNECTOR TYPE Pin no. Color diameter
SHIELD SENSOR
SHIELD Line
SENSOR Pin no. Color Line type Connections Remarks
SHIELD diameter

diameter

diameter

diameter

diameter

diameter
SHIELD
SHIELD
SHIELD
SHIELD
SHIELD
Drawing No. 2
06942-00179-00 2
2H0BO33
14
SERVICE DATA
WIRE HARNESS 2
Wire harness: 06942-00199-02
Pin no. Color diameter Line type Connections Remarks
SHIELD
SHIELD
Pin no. Color diameter Line type Connections Remarks Pin no. Color diameter Line type Connections Remarks
SHIELD
Connector Connector Pin no. Color diameter Line type Connections Remarks
Wedge Wedge
Connector
Wedge Housing
Terminal
Diode
yazaki
Housing
Housing
Housing yazaki
Terminal Housing
Diode
Housing
Connector
Wedge
yazaki
Housing
Terminal
yazaki
Rubber plug Housing
Terminal Housing
Vacant plug Pin no. Color diameter Line type Connections Remarks
Rubber plug
Holder
Holder
Drawing No. 1
06942-00199-02 2
4T0BS06
15
SERVICE DATA
WIRE HARNESS 2
Pin no. Line type Connections Remarks

Line Pin no.
Color diameter Color diameter Line type Connections Remarks
Color Line type diameter Remarks 1

SHIELD
SHIELD
SHIELD
SHIELD Drawing No. 2
SHIELD 06942-00199-02 2
SHIELD
4T0BS07
16
SERVICE DATA
WIRE HARNESS 2
Wire harness: 06942-00201-02
Line
Line
Line
Housing
Line
Housing Housing Housing Housing

Line Line Line Line
Pin no. Color diameter Line type Connections Remarks Pin no. Color diameter Line type Connections Remarks Pin no. Color diameter Line type Connections Remarks Pin no. Color diameter Line type Connections Remarks
Housing
Line
Housing Housing
Line
Pin no. Color diameter Line type Connections Remarks Line
Drawing No. 1
06942-00201-02 2
2H0BQ13
17
SERVICE DATA
WIRE HARNESS 2
Line
Housing
Terminal
Terminal
COVER
Line
Line Line
Line
Line
Line
Drawing No. 2
06942-00201-02 2
2H0BQ14
18
SERVICE DATA
WIRE HARNESS 2
Wire harness: 06942-00202-00
Pin no. Color Line

diameter Line type Connections Remarks Pin no. Color Line
Color Line Line type Connections

Pin no. diameter Remarks
Housing
Housing
Diode
Diode
Yazaki
Housing
Pin no. Color Line

With the cap

OR EQUIVALENT
Pin no. Color Line

Yazaki
Housing
Yazaki
Housing
Pin no. Color Line

Packard
Connector
Pin no. Color Line

Pin no. Color Line

DIODE
TAPING
Line
DETAIL OF PORTION DIODE
Drawing No. 1
06942-00202-00 1
2H0BO28
19
SERVICE DATA
WIRE HARNESS 2
Unit assembly 06942-00291-00
4T0BS16
20
SERVICE DATA
WIRE HARNESS 2
1. Bracket 10. Controller 14-5. Diode
2. Bracket 11. Grommet 14-6. Slow blow fuse (60 A)
3. Resistor 12. Nut 14-7. Slow blow fuse (120 A)
4. Clip 13. Spring washer 15. Clamp
5. Bolt 14. Wire harness: 06942-00186-04 16. Nut
6. Washer 14-1. Fusible link 17. Spring washer
7. Bracket 14-2. Fusible link 18. Washer
8. Controller 14-3. Fuse 19. Band
9. Controller 14-4. Diode
21
SERVICE DATA
WIRE HARNESS 2
Wire harness: 06942-00186-04
Color Line Connections Remarks
Pin no. diameter Line type
Color Line Connections Remarks Line

Pin no. diameter Line type Pin no. Color diameter Line type Connections Remarks
Contact SENSOR
SENSOR
Color Line Connections Remarks Line Remarks

Pin no. diameter Line type Pin no. Color diameter Line type Connections

SENSOR
SENSOR
Diode

Color Line Connections

Pin no. diameter Line type Remarks

Pin no. Color diameter Line type
Diode Unit Resistor

Diode Unit Pin no. Color diameter Line type
Diode Unit
Diode Unit

Resistor
Diode Unit
diameter Line type
Color Line Connections Remarks Color Line Connections Remarks

Pin no. diameter Line type Pin no. diameter Line type
Resistor
diameter Line type

Diode Unit
Line
Pin no. Color Line

Drawing No. 1
06942-00186-04 9
SENSOR
SENSOR 4T0BS17
22
SERVICE DATA
WIRE HARNESS 2
REAR LIGHT
MARKING TAPE

FUSE RELAY BOX

AS SEEN FROM MACHINE FRONT
Pin no. Color Line

FUSE RELAY BOX

AS SEEN FROM MACHINE FRONT


Fuse box
Housing
REAR LIGHT
Bracket
Puller
Terminal
Terminal
Terminal
COVER
Relay box
Housing
Bracket
Terminal
Terminal
Drawing No. 2
06942-00186-04 9
4T0BS18
23
SERVICE DATA
WIRE HARNESS 2
Pin no. Color Line
Yazaki
Housing
Pin no. Color Line

Yazaki
Housing
Carling
Terminal
Line
Line type Connections Line
Line type Connections Terminal
Pin no. Color diameter Remarks Pin no. Color Line
diameter Line type Connections Remarks Pin no. Color diameter Remarks Cable seal
Cable seal
Waterproof plug
Housing
Housing
Socket
Pin no. Color Line
Housing
RESISTOR ASSEMBLY Sumitomo
Housing Yazaki
Pin no. Color Line
diameter Line type Connections Remarks Housing
Pin no. Color Line
Yazaki Pin no. Color Line

Housing Body Earth 1
Line
Line type
Sumitomo
Pin no. Color diameter Connections Remarks Housing
Sumitomo
Housing
Pin no. Color Line
diameter Line type Connections Remarks diameter Line type
Pin no. Color Line Connections Remarks Line
Line type
Pin no. Color diameter Connections Remarks
Sumitomo GROUND
Housing
Pin no. Color Line
Pin no. Color Line
diameter Line type Connections Remarks Line
Line type Connections
Sensor Pin no. Color diameter Remarks
Yazaki
Housing
Housing Pin no. Color Line
RESISTOR ASSY
Housing
Yazaki
Blank cap Housing
Lock Plate
Pin no. Color Line
Yazaki
Housing Housing
Blank cap
Pin no. Color Line
Lock Plate
Housing Housing Housing

Shield
Pin no. Color Line
Sensor
Drawing No. 3
06942-00186-04 9
4T0BS19
24
SERVICE DATA
WIRE HARNESS 2
Pin no. Color Line
Pin no. Color Line

Pin no. Color Line
Housing
Cover
Yazaki
Housing
Pin no. Color Line
Pin no. Color Line
Pin no. Color Line
Yazaki
Housing
Pin no. Color Line

diameter Line type Connections Remarks Yazaki
Housing Yazaki
Housing
Housing Housing
Waterproof plug Waterproof plug
Pin no. Color Line

Pin no. Color Line

Sumitomo
Housing
Pin no. Color Line

Yazaki
Housing
Pin no. Color Line

Pin no. Color Line

Pin no. Color Line

Pin no. Color Line
Housing Housing
Diode Diode
Housing
Housing
Diode
Cover
Pin no. Color Line
Pin no. Color Line
Pin no. Color Line

Housing
Connector
Wedge SENSOR
Pin no. Color Line

Pin no. Color Line
Connector Ground
Housing Wedge
Pin no. Color Line
diameter Line type Connections Remarks Housing
Pin no. Color Line
Drawing No. 4
06942-00186-04 9
4T0BS20
25
SERVICE DATA
WIRE HARNESS 2
Line
Pacific Engineering Corporation
Pin no. Color diameter Line type Connections Remarks Fuse Holder
SLOW BLOW BT Line
Yellow
Pin no. Color Line

Line
White
Line
Pin no. Color Line

Line Red
Pin no. Color diameter Line type Connections Remarks Yazaki Yazaki
Housing Housing
Connector Connector
Yazaki Socket
Housing
Black
Yazaki
Housing Pin no. Color Line
Line
Line
Pin no. Color diameter Line type Connections Remarks Yazaki
Housing
Line
Body Earth
Line
Pin no. Color Line
Pin no. Color Line Line type Connections Remarks Pin no. Color Line
diameter
Yazaki Yazaki
Housing Housing
Yazaki
Housing
Yazaki Yazaki
Housing Housing
Line
Pin no. Color diameter Connections Remarks
Pin no. Color Line

Line
Yazaki
Housing
Yazaki
Housing
Line
Yazaki
Housing
Yazaki
Housing
Pin no. Color Line
Pin no. Color Line
diameter Line type Connections Remarks Battery Relay Pin no. Color Line
Housing
Diode With the cap With the cap
OR EQUIVALENT OR EQUIVALENT
Pin no. Color Line
Battery Relay Pin no. Color Line

Body Earth 1
Yazaki
Housing
Pin no. Color Line

Relay
Drawing No. 5
Pin no. Color Line
diameter Line type Connections Remarks 06942-00186-04 9
4T0BS21
26
SERVICE DATA
WIRE HARNESS 2
Pin no. Color Line

Line type Connections Remarks Pin no. Color Line
Line type Connections Remarks Line
Line type Connections Pin no. Color Line
Line type Connections Remarks
diameter Pin no. Color Line
diameter Line type Connections Remarks diameter
Pin no. Color diameter Remarks diameter
RELAY
BODY EARTH 1
Pin no. Color Line

Pin no. Color Line
diameter Line type Connections Remarks REAR LIGHT Pin no. Color Line
REAR LIGHT
Pin no. Color Line

Pin no. Color Line
Pin no. Color Line
BODY EARTH 1
Pin no. Color Line

Pin no. Color Line
Pin no. Color Line
Pin no. Color Line

diameter Line type Connections Remarks BODY EARTH 1
Pin no. Color Line

Pin no. Color Line
BATTERY RELAY -
BATTERY RELAY - BODY EARTH
BATTERY RELAY - Pin no. Color Line
Pin no. Color Line
EARTH
Pin no. Color Line
diameter Line type Connections Remarks EARTH
Pin no. Color Line
Pin no. Color Line
Pin no. Color Line
Pin no. Color Line

SENSOR
Pin no. Color Line
Line
Line type Connections BATTERY RELAY -
Pin no. Color diameter Remarks SHIELD
Pin no. Color Line
Line type Connections Pin no. Color Line
diameter Remarks
SHIELD
SHIELD
Pin no. Color Line
Pin no. Color Line
diameter
Pin no. Color Line
SENSOR Pin no. Color Line
Line type Connections
diameter Remarks
SENSOR

Pin no. Color Line

SENSOR
SENSOR
Pin no. Color Line
Pin no. Color Line
Pin no. Color Line
diameter Line type Connections Remarks SENSOR Pin no. Color Line
SENSOR
Pin no. Color Line
Pin no. Color Line
SHIELD
Pin no. Color Line
Pin no. Color Line
Pin no. Color Line

Pin no. Color Line
Pin no. Color Line
Pin no. Color Line
Pin no. Color Line
Pin no. Color Line

Pin no. Color Line
Pin no. Color Line
Pin no. Color Line

Pin no. Color Line
Pin no. Color Line

Line type Connections Remarks
Pin no. Color Line
Pin no. Color Line

Pin no. Color Line
Pin no. Color Line
Pin no. Color Line
DIODE
TAPING
Pin no. Color Line
Pin no. Color Line
Pin no. Color Line
Pin no. Color Line

diameter Line type Connections Remarks Drawing No. 6
06942-00186-04 9
4T0BS22
27
SERVICE DATA
WIRE HARNESS 2
Line Color Line type Line Remarks 1 Remarks 2

MODEL CONNECTOR TYPE Pin no. MODEL CONNECTOR TYPE Pin no. Color Line type diameter Remarks 1 Remarks 2 MODEL CONNECTOR TYPE Pin no. MODEL CONNECTOR TYPE Pin no. diameter
TWIST
TWIST
TWIST
TWIST
SENSOR
SENSOR
SHIELD
BATTERY RELAY
BODY EARTH
BODY EARTH
SENSOR SHIELD
SENSOR SHIELD
SHIELD
REAR LIGHT
BATTERY RELAY -
SENSOR
RELAY -
BODY EARTH
BODY EARTH
EARTH
EARTH
TWIST
TWIST
TWIST
TWIST
SENSOR
SENSOR
TWIST
TWIST
Drawing No. 7
06942-00186-04 9
4T0BS23
28
SERVICE DATA
WIRE HARNESS 2
Line type Line Line type Line Remarks 1 Remarks 2

MODEL CONNECTOR TYPE Pin no. MODEL CONNECTOR TYPE Pin no. Color diameter Remarks 1 Remarks 2 MODEL CONNECTOR TYPE Pin no. MODEL CONNECTOR TYPE Pin no. Color diameter
TWIST
TWIST
SHIELD SHIELD
SHIELD SHIELD SHIELD
SHIELD
SHIELD
SHIELD
SHIELD
SENSOR SHIELD SHIELD SHIELD
SHIELD SHIELD
TWIST
SHIELD TWIST
TWIST
TWIST
TWIST
SENSOR TWIST
TWIST
TWIST
TWIST
TWIST TWIST
TWIST
TWIST
TWIST
TWIST REAR LIGHT

TWIST
TWIST
TWIST
TWIST
TWIST
SHIELD
SHIELD
SHIELD
SHIELD
TWIST
TWIST
TWIST TWIST
TWIST
TWIST
TWIST
TWIST
TWIST
TWIST
SHIELD
SHIELD
SHIELD
TWIST
TWIST
BATTERY RELAY
TWIST
TWIST

SHIELD
SHIELD 06942-00186-04 9
SHIELD 4T0BS24
29
SERVICE DATA
WIRE HARNESS 2
Pin no. Color Line

SHIELD
Connector Pin no. Color Line

Wedge
Pin no. Color Line

Pin no. Color Line
diameter Connections Remarks Housing
Sumitomo
Housing Diode
Sumitomo Pin no. Color Line
Housing
Drawing No. 9
06942-00186-04 9
4T0BS25
30
SERVICE DATA
WIRE HARNESS 2
Wire harness: 06942-00218-01
TWIST
TWIST
TWIST Pin no. Connections Remarks

TWIST
TWIST TWIST
TWIST TWIST
TWIST
TWIST

Terminal
Cover
Blank cap
Insulator Color Grey
TWIST
TWIST
Terminal
Terminal Terminal
Cover
Blank cap Cover
Insulator Color Blue
Terminal
Terminal
Terminal
Terminal
Drawing No. 1
06942-00218-01 2
4T0BS08
31
SERVICE DATA
WIRE HARNESS 2
MODEL CONNECTOR TYPE MODEL CONNECTOR TYPE MODEL CONNECTOR TYPE MODEL CONNECTOR TYPE
SHIELD SHIELD
SHIELD SHIELD
SHIELD SHIELD
SHIELD
SHIELD
SHIELD
Pin no. Color Line Connections Remarks Pin no. Color Line Connections Remarks
diameter diameter
SHIELD
SHIELD Line Line
SHIELD Pin no. Color diameter Connections Remarks Pin no. Color diameter Connections Remarks

diameter

diameter

diameter

diameter

diameter

diameter
TWIST
TWIST
TWIST
TWIST
SHIELD
SHIELD
Line Pin no. Color Line Connections Remarks Line

Pin no. Color diameter Connections Remarks diameter Pin no. Color diameter Connections Remarks Pin no. Color Line

Pin no. Color Line Connections Pin no. Color Line Connections Remarks
SHIELD diameter Remarks diameter
SHIELD
SHIELD
SHIELD
TWIST TWIST
TWIST TWIST
SHIELD
SHIELD
Pin no. Color Line Pin no. Color Line Connections Remarks
SHIELD diameter Connections Remarks diameter
SHIELD
SHIELD
SHIELD Line Line
SHIELD Pin no. Color diameter Connections Remarks Pin no. Color diameter Connections Remarks
SHIELD
SHIELD SHIELD
SHIELD Line Line
SHIELD Pin no. Color diameter Connections Remarks Pin no. Color diameter Connections Remarks SHIELD
06942-00218-01 2
SHIELD SHIELD
4T0BS09
32
SERVICE DATA
WIRE HARNESS 2
GPS Unit Assembly
Cabin specification 06942-00159-00
Canopy specification 06942-00176-00
2-3
2-2
CAB
1-4 1-5
1-3
1-2
1-1
GPS_H
2
GPS1
2-5 3
2-1 GPS2
CANOPY
R0C040 1-6 4T0BS26
33
SERVICE DATA
WIRE HARNESS 2
1 To be secured with the double-sided tape supplied
2 Connect the thin cable to “GPS” on the controller (1-1). 1 N·m (0.7 ft-lb.)
3 Connect the thick cable to “COM1” on the controller (1-1). 1 N·m (0.7 ft-lb.)
1-1. Controller 1-5. Cap screw 2-3. Antenna

1-2. Nut 1-6. Wire harness: 06942-00172-00 2-5. Band
1-3. Washer 2-1. Mount
1-4. Spring washer 2-2. Band
34
SERVICE DATA
WIRE HARNESS 2
Wire harness: 06942-00172-00
Plug
Front cap
Contact
Dummy stopper
Pin no. Color Line
Sumitomo
Housing
Terminal
Waterproof plug
Pin no. Color Line

TWIST
TWIST Plug
Front cap
Contact
Dummy stopper
Pin no. Color Line

TWIST
TWIST
Line Remarks 2
TWIST
TWIST
Drawing No. 1
06942-00172-00 1
2H0BO39
35
SERVICE DATA
WIRE HARNESS 2
Battery assembly: 06944-00006-02
14
16-1
11 1
15 16-1 11 11 6
10 7 15
8 3 1 10
20 2 10
19
6 11
22 10 8
7
6 17-1
5 21 17
4 22 4
16 3
13
18
4 5
9 9
5
6
12
R1C060 4T0BS27
36
SERVICE DATA
WIRE HARNESS 2
1 Nut: 11 N·m (7 ft-lb.)
2 The starter side is marked “ST”
3 Take care not to apply too much tension to the battery cable (16)
4 Secure together with the wire harness (06942-00186-04)
5 Secure together with the round terminal of the wire harness (06942-00186-04)
6 Upper nut: 10 N·m (7 ft-lb.)
Lower nut: 4 N·m (3 ft-lb.)
When tightening the upper nut, hold the lower nut with a wrench or a similar tool.
7 Secure the battery cable (17) so that it cannot move
8 Secure together with wire harness (06942-00067-03)
1. Clamp 9. Bolt 16-1. Cap

2. Collar 10. Washer 17. Battery cable
3. Bolt 11. Nut 17-1. Cap
4. Bolt 12. Washer 18. Battery cable
5. Spring washer 13. Battery 19. Washer
6. Washer 14. Cover 20. Spring washer
7. Clamp 15. Spring washer 21. Clamp
8. Clamp 16. Battery cable 22. Band
37
SERVICE DATA
WIRE HARNESS 2
Radio assembly: 06947-00004-03
7 6
3 1
4 2
1
4
8
R0C130 4T0BS28
38
SERVICE DATA
WIRE HARNESS 2
1 Install to the interior cover with the bolts supplied with the radio
2 Bundle the AUX cables
3 Connect to the radio power supply wire harness (06842-00127-01)
4 Speaker R+: Connect to the wire harness installed in the canopy/cabin
5 Speaker R-: Connect to the wire harness installed in the canopy/cabin
6 Speaker L+: Connect to the wire harness installed in the canopy/cabin
7 Speaker L-: Connect to the wire harness installed in the canopy/cabin
8 Connect the antenna cable installed in the canopy/cabin
1. Wire harness: 06847-00004-00

3. Radio
4. Band
39
SERVICE DATA
WIRE HARNESS 2
Wire harness: 06847-00004-00
Line
Pin no. Color Line

Pin no. Color Line

Pin no. Color Line
Pin no. Color Line

Pin no. Color Line

Pin no. Color Line

MODEL CONNECTOR TYPE Pin no. MODEL CONNECTOR TYPE Pin no. Color Line type Line
diameter
Remarks 1 Remarks 2
Drawing No. 1
06847-00004-00 1
2H0BQ37
40
SERVICE DATA
WIRE HARNESS 2
Attachment wiring assembly (machine with mechanical quick-hitch): 06942-00273-00
a b c
7 6
12 12
15 15
17 17
16
c
a b
3 1
c
a
b
14PIN
9
11
14
18
13
19 10
8
1
20 4
5
CN100
14PIN2 CN77
13
10
CN78
8
R1C040 2
4T0BS31
41
SERVICE DATA
WIRE HARNESS 2
1 Install the corrugated tube with the split facing downward
1. Bracket 8. Nut 15. Washer

2. Bracket 9. Nut 16. Band
3. Wire harness: 06942-00277-01 10. Spring washer 17. Clamp
4. Bracket 11. Spring washer 18. Relay box
5. Insulator 12. Spring washer 19. Clamp
6. Bolt 13. Washer 20. Clamp
7. Bolt 14. Washer
42
SERVICE DATA
WIRE HARNESS 2
Wire harness: 06942-00277-01
Pin no. Color Line Line type Connections Remarks Line type
diameter
Pin no. Color Line
Housing Housing
Terminal Terminal
Terminal Terminal
Terminal Terminal
Wire seal Wire seal
Wire seal Wire seal
Wire seal Wire seal
Unused
Pin no. Color Line
Auxiliary2
Auxiliary2
Protection cap Line type

Pin no. Color Line
Pin no. Color Line

Housing
Terminal
Rubber plug
Holder
Housing
Terminal
Housing
Pin Waterproof plug
Waterproof plug
Holder
Pin no. Color Line
Pin no. Color Line

Auxiliary
Auxiliary
Auxiliary
Auxiliary Line Remarks 1 Remarks 2
Auxiliary MODEL CONNECTOR TYPE Pin no. MODEL CONNECTOR TYPE Pin no. Color Line type diameter
Auxiliary
Unused
diameter
Pin no. Color Line
Auxiliary Auxiliary
Auxiliary Auxiliary
Auxiliary
Auxiliary
Auxiliary2 Auxiliary
Drawing No. 1
06942-00277-01 1
4T0BS32
43
SERVICE DATA
WIRE HARNESS 2
Attachment wiring assembly (machine with hydraulic quick-hitch): 06942-00281-00
a b c d
8 7 18
13 13
16 16 17
20 20 18
18
e f
e
b 19 3
4 1
a e
D17 b
D16 x
a
b
14PIN
f 10
12
d 15
21
14
22 11
d 9
2
1 c
23 5
OH OPEN
OH CLOSE
x 6
4-1 CN100 14
CN77
14PIN2
11
CN78 9
R1C050 2
4T0BS29
44
SERVICE DATA
WIRE HARNESS 2
1 Install the corrugated tube with the split facing downward
2 The solenoid valve (quick-hitch) OPEN connector is marked with yellow tape

3. Bracket 11. Spring washer 20. Clamp
4. Wire harness: 06942-00285-01 12. Spring washer 21. Relay box
4-1. Diode 13. Spring washer 22. Clamp
5. Bracket 14. Washer 23. Clamp
6. Insulator 15. Washer
7. Bolt 16. Washer
8. Bolt 17. Ring
45
SERVICE DATA
WIRE HARNESS 2
Wire harness: 06942-00285-01
Pin no. Color Line Line type Connections Remarks Pin no. Color Line Line type Connections Remarks Line type Connections
diameter diameter Pin no. Color Line
diameter Remarks
Sumitomo Pin no. Color Line
Housing
Sumitomo Terminal
Housing Wire seal
Terminal
Wire seal Line type Connections
Housing Housing Pin no. Color Line
diameter Remarks
Terminal Terminal
Terminal Terminal
Terminal Terminal
Wire seal Wire seal
Wire seal Wire seal
Wire seal Wire seal Pin no. Color Line Line type Connections Remarks
diameter
Pin no. Color Line

Pin no. Color Line

Pin no. Color Line

Pin no. Color Line

Pin no. Color Line
Pin no. Color Line

Housing Auxiliary2
Housing Auxiliary2
Terminal Terminal
Diode Diode Pin no. Color Line Line type Connections Remarks
diameter
Protection cap Pin no. Color Line

Housing
Terminal
Rubber plug
Holder
Housing
Housing Terminal
Pin Waterproof plug
Waterproof plug
Holder
Pin no. Color Line

Pin no. Color Line
Auxiliary
Line
Auxiliary
Auxiliary Auxiliary
Auxiliary Auxiliary
Auxiliary Auxiliary
Auxiliary Auxiliary
Unused
Pin no. Color Line
Auxiliary
Auxiliary
Connector
Socket
Wedge
Pin no. Color Line
Drawing No. 1
06942-00285-01 1
4T0BS30
46
SERVICE DATA
WIRE HARNESS 2
Cabin wiring diagram
a d
c
e 19
c
b
R0E220c 4T0BS33 19. Wire harness: 06986-00229-00
47
SERVICE DATA
WIRE HARNESS 2
Wire harness: 06986-00229-00
To speaker L.H
Terminal: YAZAKI 7116-2090

To radio
Connector: YAZAKI 7123-2228
CA104:Bullet terminal M
CB104:Bullet terminal F
CA104:Bullet terminal M
To speaker R.H CB104:Bullet terminal F
Terminal: YAZAKI 7116-2090 To radio
Connector: YAZAKI 7123-2228
No. Connections Color Line Type diameter
Speaker R.H - Radio
Speaker L.H - Radio
Speaker R.H + Radio
Speaker L.H + Radio
Drawing No. 1
06986-00229-00 1
4T0BS34
48
TROUBLESHOOTING 5
TROUBLESHOOTING
ABOUT THE TROUBLESHOOTING SECTION 5
ABOUT THE TROUBLESHOOTING SECTION
This “Troubleshooting” section describes the fault diagnosis and corrective actions mainly for hydraulic systems. The
cause of the problem can be investigated by following the steps in the chart shown at the beginning of each item.
Notes on troubleshooting and servicing

1. Do not disassemble the faulty part without first investigating a, b, and c below.
a. Ask the user the following questions.
• The situation when the fault occurred.
• Any abnormalities or changes before the fault occurred.
• Any faulty parts other than the part in question.
• Any identical failure in the past
b. Drive the machine yourself and confirm the faulty condition.
• Determine if it is really faulty by referring to the performance criteria. Note that such determination may differ
depending on the person.
Important
By operating the user’s machine, you could make a bad situation worse. Therefore, before driving the machine,
always ask the user’s permission to do so.
c. Determine the cause of trouble based on the information obtained from the user and by driving the machine your-
self. Also remember that once the machine has been disassembled, it is almost impossible to reproduce the con-
ditions of the trouble, and so there will be no second chance to find out the true cause. Therefore be sure to find
the true cause of the trouble before attempting disassembly.
2. When multiple causes are suspected, start with the simplest one.
3. Think why the trouble occurred and try to correct the root cause of the problem.
1
ABOUT THE TROUBLESHOOTING SECTION 5A0BQ00
TROUBLESHOOTING
OVERALL MACHINE 5
OVERALL MACHINE
No operation is possible.
Check the hydraulic oil Faulty

1 Add oil.
level.
Normal
Check the hydraulic Faulty • Repair or replace.
2
pump. • Replace the coupling.
Normal
Faulty
3 Check the fuse. Replace.
Normal
Check the lever lock Faulty
4 Replace.
switch.
Normal
Check the lever lock sole- Faulty
5 Repair or replace.
noid.
Normal
Faulty
6 Check the SUB valve. Repair or replace.
Normal
Check the proportional Faulty
7 solenoid valve (active Repair or replace.
power control).
Normal
8 The pilot valve is faulty. Repair or replace.
1. Check the hydraulic oil level.

Check the hydraulic oil tank level.
• Normal if the hydraulic oil level is sufficient.
• Faulty if the hydraulic oil level is insufficient. Add
oil to the specified level.
4. Hydraulic oil tank
When adding, use the same brand of oil currently be-
ing used.
2. Fuel and lubricant table
1
OVERALL MACHINE 5B0BS00
TROUBLESHOOTING
OVERALL MACHINE 5
2. Check the hydraulic pump.
Check the discharge pressures from the hydraulic
pumps P1, P2, P3, P4, and P5.
• The pumps are operating normally if the pressures
are within specifications.
• Faulty if the pressures are not within specifica-
tions. Repair or replace the hydraulic pumps. All
pumps will not operate if the pump coupling is
faulty.
2. Performance Criteria
• Pump P5 exists only in machines with high-flow
equipment
2D0BM01
3. Check the fuse.

Check the fuse (F6A) in the power supply circuit that
operates the lever lock solenoid valve.
• Normal if the fuse is not blown.
• Faulty if the fuse is blown. Replace the fuse.
5B0BO01
4. Check the lever lock switch.

Remove the harness of the lever lock switch (1). 3
Move the safety bar (2) to the driving position and turn
on the lever lock switch (1). 1
Next, check for continuity in the lever lock switch (1)
using a circuit tester (3).
• If there is continuity, the switch is normal.
• If there is no continuity, the switch is faulty. Re-
place the lever lock switch.
2
5B0BO02
5. Check the lever lock solenoid valve.

Check the lever lock solenoid on the SUB valve.
a. Turn on the starter switch.
b. Lightly press down the protruding part on the sole-
noid end.
c. Move the safety bar to turn on the lever lock
switch.
• The solenoid valve is operating normally if you
feel vibration under your fingers when the spool
is moved and the circuit is switched.
• The solenoid valve is faulty if no vibration is felt.
Repair or replace the solenoid valve.
5BAA04Z
4. Sub-valve
2
TROUBLESHOOTING
OVERALL MACHINE 5
6. Check the SUB valve. 5
Machine without selector valve
7 6
Check whether hydraulic oil is supplied from the sub- 4 APCP
valve to the proportional solenoid valve (active power
control) and right pilot valve.
a. Disconnect the hose between the sub-valve (4) 6
and proportional solenoid valve (active power con- RP
trol) (5) from the proportional solenoid valve (ac- S2
tive power control) (5). S1
b. Connect a pressure gauge (6) to the hose and
measure the supply pressure (charge pressure) to
the proportional solenoid valve (active power con-
5B0BS01
trol) (5).
c. Disconnect the hose between the sub-valve (4)
and the right pilot valve (7) from the sub-valve (4).
d. Connect a pressure gauge (6) to the hose and
measure the supply pressure (pilot pressure) to
the right pilot valve (7).
• Normal if the pressure supplied (pilot pressure)
to the right pilot valve (7) and the pressure sup-
plied (charge pressure) to the proportional sole-
noid valve (active power control) (5) are within
specifications.
• Faulty if the pressures (charge pressure and pi-
lot pressure) are not within specifications. Re-
pair or replace the sub-valve.
4. Sub-valve
Machine with selector valve
Check whether hydraulic oil is supplied from the sub- 4
valve to the proportional solenoid valve (active power 5
control).
a. Disconnect the hose between the sub-valve (4)
and proportional solenoid valve (active power con-
APCP
trol) (5) from the proportional solenoid valve (ac-
tive power control) (5).
b. Connect a pressure gauge (6) to the hose and 6 S1
the proportional solenoid valve (active power con-
trol) (5).
• Normal if the pressure (charge pressure) is 5B0BS02
within specifications.
• Faulty if the pressure (charge pressure) is not
within specifications. Repair or replace the sub-
valve.
4. Sub-valve
3
TROUBLESHOOTING
OVERALL MACHINE 5
7. Check the proportional solenoid valve (ac-
tive power control)
Machine without selector valve
Check whether hydraulic oil is supplied from the pro-
portional solenoid valve (active power control) to the
8
left pilot valve.
a. Disconnect the hose between the proportional so- 6
LP
lenoid valve (active power control) (5) and the left 5
pilot valve (8) from the left pilot valve (8).
APCA2
b. Connect a pressure gauge (6) to the hose and
the left pilot valve (8). 5B0BS03
• Normal if the pressure (charge pressure) is

within specifications. If faulty, repair or replace
the proportional solenoid valve (active power
control).
4. Proportional Solenoid Valve (active power
control)
Machine with selector valve
Check whether hydraulic oil is supplied from the pro-
portional solenoid valve (active power control) (5) to 6
the right pilot valve (7) and left pilot valve (8).
a. Remove the hoses between the right pilot valve 7 8
APCA1
(7) and left pilot valve (8) and the proportional so-
lenoid valve (active power control) (5) from the
RP 6
right pilot valve (7) and left pilot valve (8). LP
b. Connect pressure gauges (6) to the hoses and 5
measure the supply pressure (charge pressure) to APCA2
the right pilot valve (7) and left pilot valve (8).
• Normal if the pressure (charge pressure) is
within specifications. 5B0BS04

within specifications. If faulty, repair or replace
the proportional solenoid valve (active power
control).
4. Proportional Solenoid Valve (active power
control)
8. The pilot valve is faulty.

4. Pilot valve
4
TROUBLESHOOTING
OVERALL MACHINE 5
All systems working, but insufficient power.

1 Add oil.
level.
Normal
Check for abnormal noise Noise
2 generated by the hydrau- Suction line faulty Replace the O-ring, and hose.
lic pump.
No noise
Take action appropriate to re-
Foaming in the tank solving the cause of the foam-
ing.
Faulty
3 Check the line filter. Clean or replace.
Normal
Faulty
4 Check the SUB valve. Repair or replace.
Normal
Check the proportional Faulty
5 solenoid valve (active Repair or replace.
power control).
Normal
The hydraulic pump is
faulty.

5. Overall Machine, No operation is possible
2. Check for abnormal noise generated by the

hydraulic pump.
The abnormal noise is likely to be caused by cavita-
tion in the pump, due to a faulty suction line. Check
the following.
a. Check the lines for hydraulic oil suction.
• Apply grease or oil to the suspected faulty sec-
tions, and check for signs of change. (Check if
air is being sucked)
b. Check for clogging in the suction filter.
3. Check the line filter.

Remove the case, and take out the filter element to
check for any clogging.
• The filter is normal if no clogging is found.
• The filter is faulty if clogging is found. Clean or
replace the line filter.
5
TROUBLESHOOTING
OVERALL MACHINE 5
4. Check the SUB valve.
5. Check the proportional solenoid valve (ac-

tive power control).
6. The hydraulic pump is faulty.

If the inside of the pump is excessively worn or dam-
aged, it is likely that there are pieces of metal present
in the hydraulic oil. If this is the case, complete the
items outlined below to resolve the issue.
• Replace the elements of the line filter and the re-
turn filter.
• Replace the hydraulic oil, or perform flushing.
• When replacing the hydraulic oil, clean the tank
and suction strainer.
4. Hydraulic oil tank
If the pump seal is damaged, replace it.
4. HST pump
6
TROUBLESHOOTING
OVERALL MACHINE 5
Lift arm and bucket fail to move or are too slow.
Check the hydraulic Faulty

pump.
Normal
Check the main relief Faulty
valve.
Normal
3 The pilot valve is faulty. Repair or replace.

Check the hydraulic pump P3 that supplies hydraulic
pressure for the lift arm and bucket.
5. No operation is possible
2. Check the main relief valve.

Measure the relief pressure of the main relief valve on
the control valve.
• The valve is operating normally if the measured
value is within specifications.
• Faulty if the relief pressure is not within specifica-
tions. Repair or replace the main relief valve.
2. Performance criteria
4. Control Valve
3. The pilot valve is faulty.

4. Pilot valve
7
TROUBLESHOOTING
TRAVELING 5
TRAVELING
Traveling fails.
Check the charge pres- Faulty

sure.
Normal
Faulty
2 Check the pilot valve. Repair or replace.
Normal
Check the HST pump dis- Normal
3 The travel motor is faulty. Repair or replace.
charge pressure.
Pressure too low
Test the high-pressure re- Problem solved
4 lief valve using a replace- Repair or replace.
ment valve.
No change
5 HST pump is faulty. Repair or replace.
1. Check the charge pressure.

Measure the charge pressure of the HST pump.
• Normal if the pressure (charge pressure) is within
specifications.
within specifications. Repair or replace the HST
pump.
4. HST pump
2. Check the pilot valve. 1

Y
a. Disconnect the hydraulic hoses between the left
pilot valve (1) and HST pump (2) (ports X1, X2,
X11, X12) from the HST pump side.
b. Attach a pressure gauge (3) to the disconnected
3
hose.
X1
c. Operate the lever (travel) and measure the pres- X2
Y
sure (charge pressure). 2

• Normal if the pressure (charge pressure) is X12
X11
within specifications. Repair or replace the left
5C0BO01
pilot valve.
1
TRAVELING 5C0BS00
TROUBLESHOOTING
TRAVELING 5
3. Check the HST pump discharge pressure.
Check the HST pump discharge pressure (travel
pressure).
• The pump is normal if the pressure (travel pres-
sure) is within specifications. As the travel motor
may be defective, repair or replace the travel mo-
tor.
• The pump is faulty if the pressure (travel pressure)
is not within specifications. Proceed to the next
step.
4. HST Pump
4. Test the high-pressure relief valve using a

replacement valve.
Perform a testing of high-pressure relief valves (3) for
the HST pump (2) with replacement valves.
• If normal, repair or replace the high-pressure relief
valve from before the valve was switched.
• If no change occurs, proceed to the next step.
5. The HST pump is faulty. 3

4. HST pump
2
3 5C0BS01
2
TRAVELING 5C0BS00
TROUBLESHOOTING
TRAVELING 5
Right or left travel speed decelerates and the machine veers to one side.
Is the veering value of the Within spec

Problem caused by the
1 straight-ahead traveling normal
combination of devices
test within specs?
Out-of-spec
Check the crawler belt
Faulty
tension. Check to see if Adjust to the specified crawler
2 there is any foreign mat- tension and remove any for-
ter caught in the crawler eign matter.
belt.
Normal
Faulty
3 Check the pilot valve. Repair or replace.
Normal
Check the HST pump dis- Normal
4 The travel motor is faulty. Repair or replace.
charge pressure.
Pressure too low
Test the high-pressure re- Veering is changed to the opposite side
ment valve.
No change
6 HST pump is faulty. Repair or replace.
1. Is the veering value of the straight-ahead

traveling test within specs?
• If the veering value falls within the specifications,
the machine itself is operating normally. The prob-
lem is instead caused by the combination of devic-
es used.
• If not within specification, proceed to the next step.
2. Check the crawler belt tension. Check to see

if there is any foreign matter caught in the
crawler belt.
• Normal if the crawler tension is within specifica-
tions and no foreign matter is trapped in the crawl-
er.
• Faulty if the crawler tension is not within specifica-
tions or foreign matter is trapped in the crawler.
3. Check the pilot valve.

5. Traveling, Traveling fails
4. Check the HST pump discharge pressure.

3
TRAVELING 5C0BS00
TROUBLESHOOTING
TRAVELING 5
5. Test the high-pressure relief valve using a
replacement valve.
6. The HST pump is faulty.

4. HST pump
4
TRAVELING 5C0BS00
TROUBLESHOOTING
TRAVELING 5
Operating temperature of the travel system is too high.

1 Add oil.
level.
Normal
Faulty • Clean the oil cooler and ra-

diator.
2 Check the oil cooler.
• Repair or replace the oil
cooler.
Normal
Test the high-pressure re- Faulty
ment valve.
Normal
Check the parking brake Faulty
release pressure.
Normal
Is the travel motor gener- Yes
ating heat?
No
Is the HST pump generat- Yes
ing heat?

2. Check the oil cooler.

Check for clogging in the suction filter and related
problems.
• Normal if no excessive dirt/dust is accumulated in
the cooling fins of the oil cooler or radiator.
• Faulty if excessive dirt/dust is accumulated in the
cooling fins of the oil cooler or radiator. Clean the
oil cooler and radiator. Repair or replace the oil
cooler.
5
TRAVELING 5C0BS00
TROUBLESHOOTING
TRAVELING 5
3. Test the high-pressure relief valve with a re-
placement valve.
5.Traveling, Traveling fails
4. Check the parking brake release pressure 5 S1A1
3
(pilot pressure).
a. Disconnect the hose connecting the SUB valve (4) TRMPB
and the travel motor (5) from the SUB valve (4). S1A2
b. Attach a pressure gauge (3) to the SUB valve (4), 5

and measure the parking brake release pressure
(pilot pressure). 4
• Normal if the pressure (pilot pressure) is within
specifications.
• Faulty if the pressure (pilot pressure) is not with-
in specifications. Repair or replace the sub- TLMPB
valve. 5C0BO03
4. Sub-valve
5. Is the travel motor generating heat?

5. Travel motor
6. Is the HST pump generating heat?

5. HST Pump
6
TRAVELING 5C0BS00
TROUBLESHOOTING
TRAVELING 5
2nd-speed travel is not possible.
Check the hydraulic Faulty

1 pump P4 (P5 for machine Repair or replace.
with high-flow equipment)
Normal
Check the pilot relief Faulty
2 Adjust, repair, or replace
valve
Normal
Check the 2nd speed Faulty
3 Replace.
switch.
Normal
Check the 2nd-speed so- Faulty
lenoid valve.
Normal
The 2nd speed control
valve is faulty.

Check the hydraulic pump P4 (P5 in machine with
high-flow equipment) that supplies hydraulic pressure
for the 2nd speed switching.
Also, check the line filter for possible clogging, and
clean it as necessary.
2. Check the pilot relief valve.

Measure the relief pressure of the pilot relief valve.
• The valve is operating normally if the measured
pressure is within specifications.
• Faulty if the relief pressure is not within specifica-
tions. Repair or replace the pilot relief valve.
3. Check the 2nd speed switch.

Press the 2nd-speed travel switch on the left pilot 1
valve (1) to turn it ON. Next, check for continuity using
a circuit tester (6).
• If there is continuity, the switch is normal. 6
• If there is no continuity, the switch is faulty. Repair
or replace the 2nd-speed travel switch. GRAY
2. Electrical circuit diagram GRAU
GRIS
4. Wire Harness
YELLOW
GELB
JAUNE
5C0BO04
7
TRAVELING 5C0BS00
TROUBLESHOOTING
TRAVELING 5
4. Check the 2nd-speed solenoid valve.
Check the 2nd speed solenoid valve on the SUB
valve.
a. Turn on the starter switch.
b. Lightly press down the protruding part on the sole-
noid end.
c. Turn on the 2nd speed switch.
• The solenoid valve is operating normally if you
feel vibration under your fingers when the spool
is moved and the circuit is switched.
• The solenoid valve is faulty if no vibration is felt.
Repair or replace the 2nd speed solenoid valve.
5CAA05Z
4. Sub-valve
5. The 2nd speed control valve is faulty.

Check if there is sticking or foreign matter caught in
the spool of the 2nd speed control valve for the travel
motor.
4. Travel motor
8
TRAVELING 5C0BS00
5
TROUBLESHOOTING
LIFT ARM
LIFT ARM
Arm cylinder does not move
Check the operation of Faulty

Check the relief valve and hy-
1 actuators other than the
draulic pump.
arm cylinders.
Normal
Faulty Repair or replace the pilot
2 Check the pilot valve.
valve.
Normal
Test the overload relief Normal
Repair or replace the over-
3 valve using a replace-
load relief valve.
ment valve.
No change
Check the arm float pilot Faulty Repair or replace the arm
4
check valve float pilot check valve
Normal
Check the spool opera- Faulty
Repair or replace the spool in
5 tion in the control valve
the control valve arm section.
arm section.
Normal
Repair or replace the arm cyl-
6 The arm cylinder is faulty.
inder.
1
LIFT ARM 5G1BS001
5
TROUBLESHOOTING
LIFT ARM
1. Check the operation of actuators other than

the arm cylinders.
Check the operation of the lift arm only as listed in the
Device to check
table on the right. Lever to operate
• Normal if the actuators other than the arm cylinder Relief valve Pump
can operate. Bucket R6 P3
• Faulty if the actuators other than the arm cylinder
cannot operate. If defective, check the relief valve
R6 in the control valve (1) and the hydraulic pump
P3.
R6 1 5G1BO10

a. Disconnect the control valve end of the hose be- 1
tween the right pilot valve (1) and control valve (2)
(Pa2, Pb2) that is to be checked. Pa2
b. Attach a pressure gauge to the disconnected
hose.
c. Operate the lever (lift arm) and measure the pres-
R4 R2
sure (charge pressure (pilot pressure for a ma- Pb2
chine without a selector valve)).

• Normal if the pressure (charge pressure (pilot
pressure for a machine without a selector
2
valve)) is within specifications.
5G1BO02
• Faulty if the pressure (charge pressure (pilot
valve)) is not within specifications. If defective,
repair or replace the pilot valve.
4. Pilot valve
3. Test the overload relief valve using a re-

placement valve.
Switch the normal bucket section overload relief
valve in the control valve (1) with the arm section
overload relief valve suspected of being defective.
• If the arm cylinder operates normally, the overload
relief valve of the arm section is faulty. Repair or
replace the arm section overload relief valve.
1
5G1BO11
2
LIFT ARM 5G1BS001
5
TROUBLESHOOTING
LIFT ARM
4. Check the arm float pilot check valve

The arm movement becomes faulty if the pressurized
oil to the arm cylinder (2) leaks into the tank circuit
due to foreign matter caught between the arm float pi- 2 1
lot check valve (1) seat surfaces in the control valve
or sticking of the poppet.
Disassemble and check that no foreign matter is
caught between the arm float pilot check valve (1)
seat surfaces and the poppet is not sticking.
• Normal if no foreign matter is caught between the
arm float pilot check valve seat surfaces and the
poppet is not sticking.
• Faulty if foreign matter is caught between the arm
float pilot check valve seat surfaces and the pop- 5G1BQ03
pet is sticking. If defective, repair or replace the

arm float pilot check valve.
4. Control valve
5. Check the spool operation in the control

valve arm section.
a. Disconnect the control valve end of the hose be-
tween the arm cylinder and control valve (2) (A2, 2
B2) that is to be checked.
b. Attach a pressure gauge to the ports of the control
valve (A2, B2) to be checked.
c. Operate the lever (lift arm) and measure the pres-
sure (bucket pressure). B2
• The spool operation in the control valve arm
section is normal if the pressure (bucket pres-
sure) is within specifications. A2
• The pump is faulty if the pressure (bucket pres-
sure) is not within specifications. If defective, re-
pair or replace the spool. 5G1BS01
4. Control valve
6. The arm cylinder is faulty.

• If defective, repair or replace the arm cylinder.
5. Cylinder
4. Cylinder
3
LIFT ARM 5G1BS001
5
TROUBLESHOOTING
LIFT ARM
Arm cylinder moves too slowly or lacks force
Is the speed of the arm Within spec.

1 Normal
cylinder within spec.?
Out-of-spec.
valve.
Normal
load relief valve.
ment valve.
No change
4
check valve. float pilot check valve
Normal
Check the spool opera- Faulty
Repair or replace the spool in
5 tion in the control valve
the control valve arm section.
arm section.
Normal
Check for leaks inside the Faulty Repair or replace the arm cyl-
6
arm cylinder. inder.
1. Is the speed of the arm cylinder within

spec.?
• Normal if within specification.

5. Lift arm, Arm cylinder does not move, Check
the pilot valve

placement valve.
5. Lift arm, Arm cylinder does not move, Test the
overload relief valve using a replacement valve
4. Check the arm float pilot check valve.

the arm float pilot check valve
4
LIFT ARM 5G1BS001
5
TROUBLESHOOTING
LIFT ARM

valve arm section.
the spool operation in the control valve arm sec-
tion
6. Check for leaks inside the arm cylinder.

a. With the bucket tilted slightly forward from the hor-
izontal (approx. 10°), lower the bucket tip to the
ground.
b. Check the right and left arm cylinders individually.
On the side not being checked, disconnect the cyl-
inder hose from the arm cylinder and insert a plug
in the disconnected hose.
c. On the arm cylinder (1) being checked, disconnect
the hose (2) at the rod end only and drain the oil
from the hose. Insert a plug (3) in the disconnected
hose.
d. Tilt the bucket backwards and raise it from the
ground. 5GAC06Z
• If the lift arm drops with oil coming out at the rod
end of the arm cylinder, it indicates an internal
leak in the arm cylinder. If defective, repair or re-
place the arm cylinder.
4. Cylinder
2
3
5G1BS02
5GAC07Z
5
LIFT ARM 5G1BS001
5
TROUBLESHOOTING
LIFT ARM
When the control lever is pulled slowly, the lift arm drops once.
Faulty Repair or replace the load

Check the load check
1 check valve in the arm sec-
valve in the control valve.
tion.
No change
2
1. Check the load check valve in the control

valve.
When the spool first starts to pull, the oil pressure is
low and the flow rate is low. If the load check valve (1) 1
is faulty, the oil will temporarily flow backward due to
the load applied to the arm cylinder. As a result, the
lift arm temporarily drops. Perform the check at the
next step.
WARNING
• Before starting the work below, lower the lift arm
and bring the bucket in contact with the ground.
5GAC08Z
• As the lift arm and bucket operations are reversed
in the work below, take due care when operating
the machine.
• When all work is complete, return the machine to
the condition it was in before the work was started.
A3
B3
a. Disconnect the pipe connected to port A2 (arm
section) of the control valve (2), and connect it to
A2
port A3 (boom section) or port B3. After the pipe is
removed, insert a plug in the port to prevent oil
leaks.
b. Operate the arm cylinder.
• The load check valve (1) of the arm section is 2
faulty if the arm cylinder operates normally. 5G1BQ02

If the oil is flowing from the head side (A) to the rod
side (B) due to the faulty arm cylinder piston or the B
tube, the lift arm temporarily drops because of the low
A
oil pressure and small flow rate at the beginning of the
spool drawing. Also, the cylinder will have insufficient
drive force. However, the amount of spontaneous
drop is large in this case.
Check method: 5. Lift arm, Arm cylinder is slow or
lacks force, Check for leaks inside the arm cylinder
5GAC09Z
6
LIFT ARM 5G1BS001
5
TROUBLESHOOTING
LIFT ARM
Spontaneous drop of the lift arm is too large.
Is the spontaneous drop Within spec.

1 of the arm cylinder within Normal
spec?
Out-of-spec.
2
Normal
load relief valve.
ment valve.
No change
4
check valve. float pilot check valve.
Normal
There is oil leaking inside Repair or replace the control
5
the control valve. valve.
1. Is the spontaneous drop of the arm cylinder

within spec.?

5. Lift arm, Arm cylinder is slow or lacks force,
Check for leaks inside the arm cylinder

placement valve.
5. Lift arm, Arm cylinder does not move, Test the
overload relief valve using a replacement valve
4. Check the arm float pilot check valve.

the arm float pilot check valve
5. There is oil leaking inside the control valve.

Repair or replace the control valve.
5. Control valve
4. Control valve
7
LIFT ARM 5G1BS001
5
TROUBLESHOOTING
BUCKET
BUCKET
Bucket cylinder does not move.

1 actuators other than the
draulic pump.
bucket cylinders.
Normal
valve.
Normal
Test the overload relief Faulty
3 valve with a replacement
load relief valve.
valve.
No change
Check the operation of Faulty Repair or replace the spool in
4 the spool in the control the control valve bucket sec-
valve bucket section. tion.
Normal
The bucket cylinder is Repair or replace the bucket
5
faulty. cylinder.
1
BUCKET 5G2BS001
5
TROUBLESHOOTING
BUCKET

the bucket cylinders.
Check the lift arm as listed in the table on the right to Device to check
check operation of the bucket only. Lever to operate
Relief valve Pump
• Normal if actuators other than the bucket cylinder
Lift arm R6 P3
can operate.
• Faulty if the bucket cylinder cannot operate. If de-
fective, check the relief valve (R6) of the control
valve (1) and the hydraulic pump P3.
R6 1 5G1BO10

a. Disconnect the control valve end of the hose be- 1
tween the right pilot valve (1) and control valve (2) Pa3
(Pa3, Pb3) that is to be checked.
hose. Pb3
c. Operate the lever (bucket) and measure the pres-
sure (charge pressure (pilot pressure for a ma- R1 R3
chine without a selector valve)).
• Normal if the pressure (charge pressure (pilot
pressure for a machine without a selector 2
valve)) is within specifications.
5G2BO01
• Faulty if the pressure (charge pressure (pilot
valve)) is not within specifications. If defective,
repair or replace the pilot valve.
4. Pilot valve

placement valve.
Switch the normal arm section overload relief valve in
the control valve (1) with the bucket section overload
relief valve suspected of being defective.
• If the bucket cylinder operates normally, the over-
load relief valve of the bucket section is faulty. Re-
pair or replace the bucket section overload relief
valve.
1
5G1BO11
2
BUCKET 5G2BS001
5
TROUBLESHOOTING
BUCKET
4. Check the operation of the spool in the con-

trol valve bucket section.
tween the left bucket cylinder (1) and control valve
(2) (A3, B3) that is to be checked.
b. Attach a pressure gauge to the port of the control
valve (2).
c. Operate the lever (bucket), and measure the pres-
sure (bucket pressure).
• The spool operation in the control valve bucket
sure) is within specifications. 2
• The pump is faulty if the pressure (bucket pres-
sure) is not within specifications. If defective, re-
pair or replace the spool.
4. Control valve
A3
5. Faulty bucket cylinder
Repair or replace the bucket cylinder. B3
5. Cylinder
4. Cylinder
5G2BO02
3
BUCKET 5G2BS001
5
TROUBLESHOOTING
BUCKET
Bucket cylinder is slow or lacks force.
Is the speed of the bucket Within spec.

1 Normal
cylinder within spec?
Out-of-spec.
valve.
Normal
load relief valve.
ment valve.
No change
Check the operation of Faulty Repair or replace the spool in
4 the spool in the control the control valve bucket sec-
valve bucket section. tion.
Normal
Check for internal leaks in Faulty Repair or replace the bucket
5
the bucket cylinder. cylinder.
1. Is the speed of the bucket cylinder within

spec?

5. Bucket, Bucket cylinder does not move,
Check the pilot valve

placement valve.
5. Bucket, Bucket cylinder does not move, Test
the overload relief valve using a replacement
valve
4. Check the operation of the spool in the con-

trol valve bucket section.
5. Lift arm, Bucket cylinder does not move,
Check the spool operation in the control valve
bucket section
4
BUCKET 5G2BS001
5
TROUBLESHOOTING
BUCKET
5. Check for internal leaks in the bucket cylin-

der.
a. Lower the bucket to the ground in a horizontal po-
sition.
b. Check the right and left cylinder individually.
The hose connected to the bucket cylinder not to
be checked should be disconnected and fitted with
a plug.
c. On the bucket cylinder (1) being checked, discon-
nect the hose (2) at the rod end only and drain the
oil from the hose. Insert a plug (3) in the discon-
nected hose.
d. Raise the lift arm to lift the bucket from the ground.
• If the bucket drops with oil coming out at the rod
end of the bucket cylinder, it indicates an inter- 5GAD03Z
nal leak in the arm cylinder. If defective, repair

or replace the arm cylinder.
4. Cylinder
3 1
5G2BO04
5GAD04Z
5
BUCKET 5G2BS001
5
TROUBLESHOOTING
BUCKET
Spontaneous drop of the bucket is too large
Is the spontaneous drop Within spec.

1 of the bucket cylinder Normal
within spec?
Out-of-spec.
Check for internal leaks in Faulty Repair or replace the bucket
2
the bucket cylinder. cylinder.
Normal
There is oil leaking inside Repair or replace the control
3
the control valve. valve.
1. Is the spontaneous drop of the bucket cylin-

der within spec?
2. Check for internal leaks in the bucket cylin-

der.
5. Bucket, Bucket cylinder is slow or lacks force,
Check for leaks inside the bucket cylinder
3. Oil is leaking inside the control valve.

Repair or replace the control valve.
5. Control valve
4. Control valve
6
BUCKET 5G2BS001
5
TROUBLESHOOTING
SERVICE
SERVICE
The prescribed pressure is not supplied to the 1st service

1 actuators other than
draulic pump.
those for the 1st service.
Normal
Check the vehicle error Faulty Repair or replace the electri-
2
codes. cal system.
Normal
Check the proportional Faulty Repair or replace the propor-

3 solenoid valve (1st ser- tional solenoid valve (1st ser-
vice) vice).
Normal
Check the spool opera- Faulty Repair or replace the spool in

4 tion in the control valve the control valve 1st service
1st service section. section.

those for the 1st service.
Use the table on the right to check whether only the Device to check
1st service is faulty. Lever to operate
Relief valve Pump
• Normal if the bucket cylinder can operate.
Bucket R6 P3
• Faulty if the bucket cylinder cannot operate. If de-
fective, check the relief valve (R6) in the control
valve (1) and the hydraulic pump P3.
4. Control Valve
R6 1 5G1BO10
1
SERVICE 5G6BS001
5
TROUBLESHOOTING
SERVICE
2. Check the vehicle error codes.

Check on the cluster or maintenance tool that no ve-
hicle error code has occurred related to the 1st ser-
vice.
Vehicle error codes related to the 1st service

Error code Limitations on operation under an error/
Type of error/malfunction
No. a malfunction
2503 Sensor voltage error occurred (Voltage high) MC1 Operation is not possible when the 1st
service sliding switch is in the neutral
2504 Sensor voltage error occurred (Voltage low) MC1
position.
Error occurred at the neutral position of the 1st service slide
6509
switch
6519 1st service (L) switch error occurred
6529 1st service (R) switch error occurred
6503 1st service slide switch voltage error occurred (Voltage high)
6504 1st service slide switch voltage error occurred (Voltage low)
1st service (L) PWM output current error occurred (Current Output to 1st service A and 1st service
8015 B solenoids stopped.
low)
1st service (L) PWM output current error occurred (Current
8016
high)
1st service (R) PWM output current error occurred (Current
8025
low)
1st service (R) PWM output current error occurred (Current
8026
high)
6. Vehicle error codes

• Normal if no error code has occurred related to 1st
service.
• Faulty if an error code has occurred related to 1st
service. If defective, repair or replace the electrical
system.
2. Electrical circuit diagram
4. Wire Harness
2
SERVICE 5G6BS001
5
TROUBLESHOOTING
SERVICE
3. Check the proportional solenoid valve (1st

service).
tween the proportional solenoid valve (1st service)
(1) and control valve (2) (Pa1, Pb1) that is to be 2
checked. Pa1
hose.
c. Operate the proportional control lever of the left pi-
Pb1
lot valve and measure the pressure (pilot pres- SOLA1
sure). SOLB
1
• Normal if the pressure (pilot pressure) is within
specifications.
• Faulty if the pressure (pilot pressure) is not with-
in specifications. If defective, repair or replace 5G6BO01
the proportional solenoid valve.

2. Service data, Performance criteria
5. Proportional solenoid valve (1st service)
4. Proportional solenoid valve (1st service)

valve 1st service section.
a. Disconnect the control valve end of the control
valve (1) (1st service section (A1, B1)) hose that is 1
to be checked.
b. Attach a pressure gauge to the port of the control
valve (1).
c. Operate the proportional control lever of the left pi- B1
lot valve and measure the pressure (bucket pres-
sure). A1
• The spool operation in the control valve bucket
sure) is within specifications.
• Faulty if the pressure (bucket pressure) is not
within specifications. If defective, repair or re- 5G6BO02
place the spool.

4. Control valve
3
SERVICE 5G6BS001
5
TROUBLESHOOTING
GEAR PUMP
GEAR PUMP
Symptoms Major causes Remedies
Oil leak from the oil seal • Reverse rotation • Eliminate cause of reverse rotation or ab-
• Abnormally high pressure at intake normally high pressure at intake
• Seal lip damaged due to dirt, etc. • Replace the oil seal
• Scratches or wear at shaft seal • Correct the centering
• Shaft centering defective • Replace the pump
Oil leak from joints be- • Loose bolts or damage to cover or • Eliminate vibrations or abnormally high
tween cover and body body pressures that caused loose bolts or dam-
• Poor sealing performance or damage age
to the sealing due to heat hardening of • Replace the gaskets
external leak prevention gasket • Replace the pump
Oil leaking from port • Loose or damaged port connector • Eliminate vibrations or abnormally high
• Damaged connector seal material pressures that caused loose connector or
• Damaged port damage
• Replace the connector seal material
• Replace the pump
Low discharge pressure • Inadequate tank oil volume • Use appropriate tank oil volume and hy-
or pressure does not rise • Increased internal leaking due to ab- draulic oil type, or replace cooling unit
normally high temperature or inappro- • Replace the contaminated hydraulic oil
priate viscosity of hydraulic oil • Eliminate cause of abnormal negative pres-
• Reduced pump performance due to sure by re-examining the length and thick-
contamination of hydraulic oil ness of the intake pipe and replacing filter
• Cavitation due to abnormal negative etc.
pressure • Open the intake valve
• Damaged internal parts • Replace the pump
• Reverse rotation • Eliminate cause of reverse rotation or ab-
normally high pressure at intake
Abnormal temperature • Abnormal heat generation due to fre- • Use appropriate pressure settings
rise in pump or hydraulic quent operation of the pressure control • Replace the cooling unit
oil valve • Replace the pump
• Cooling unit inadequate oil capacity or
damage
• Damaged internal parts
Noise and vibrations • Defective installation • Correct the centering and tighten mount-
• Cavitation ings
• Ingress of air • Eliminate cause of abnormal negative pres-
• Vibration of piping or mounting flanges sure by re-examining the length and thick-
• Chattering of relief valve ness of the intake pipe and replacing filter
• Damaged shaft seal etc.
• Eliminate the cause of low oil volume and air
ingress in intake pipe
• Eliminate the cause of resonance by rein-
forcing piping or mounting flanges
• Replace the relief valve
1
GEAR PUMP 5I1BO00
5
TROUBLESHOOTING
SUB VALVE
SUB VALVE
A
B
A B C
5K0BO01
1
SUB VALVE 5K0BO00
5
TROUBLESHOOTING
SUB VALVE

External oil leaks • Damage to O-ring seal surface in ports • Repair the ports or replace the assembly
• Damaged O-rings • Replace the damaged O-rings
No conductivity between • Shorting or discontinuity in coil or leads • Replace
port P and port 1 when the of solenoid A (14)
voltage is applied to sole- • Foreign matter caught in spool (23) • Disassemble and clean. Repair or replace
noid A (14) the assembly.
• Foreign matter caught in spool (25) • Disassemble and clean. Repair or replace
the assembly.
• Port 3 downstream pressure is 0.49 • Check port 3 downstream pressure
MPa or less.
Conductivity remains be- • Foreign matter caught in spool (23) • Disassemble and clean. Repair or replace
tween port P and port 1 the assembly.
when the voltage is cut to • Foreign matter caught in spool (25) • Disassemble and clean. Repair or replace
solenoid A (14) the assembly.
• Problem, such as broken spring (11) or • Disassemble, check, and replace defective
(22) part
• Foreign matter caught in poppet (1), or • Disassemble and clean. Repair or replace
damage or corrosion to the seat of the the assembly.
body (24)
When the voltage is cut to • Foreign matter caught in sliding parts of • Disassemble and clean. Repair or replace
solenoid A (14), port 2 the plunger (3) the assembly.
pressure drops slowly • Foreign matter caught in poppet (1), or • Disassemble and clean. Repair or replace
damage or corrosion to the seat of the the assembly.
body (24)
Port 1 (1A) pressure does • Foreign matter caught in the piston (6) • Disassemble and clean. Repair or replace
not reach the set pressure or spool (13) the assembly.
(unstable pressure) • Spring (31) deformed or broken • Disassemble, check, and replace defective
part
• Foreign matter caught in sliding parts of • Disassemble and clean. Repair or replace
the poppet (1) or plunger (3) the assembly.
• Foreign matter caught in seats of the • Disassemble and clean. Repair or replace
plunger (3) and body (24), or damage the assembly.
or corrosion to the seats.
• Foreign matter blocks the gap between • Disassemble and clean
the hole in the spool (13) and the wire
(15)
• Wire (15) fell off • Replace
• Port 3 downstream pressure signifi- • Check port 3 downstream pressure
cantly differs from 1.96 MPa or unstable
pressure
No conductivity between • Shorting or discontinuity in coil or leads • Replace
port P and port 1B when of solenoid B (30)
the voltage is applied to • Foreign matter caught in spool (17) • Disassemble and clean. Repair or replace
solenoid B (30) (solenoid the assembly.
A (14) remains ON)
Conductivity remains be- • Foreign matter caught in spool (17) • Disassemble and clean. Repair or replace
tween port P and port 1B the assembly.
when the voltage is cut to • Problem, such as broken spring (5) • Disassemble, check, and replace defective
solenoid B (30) (solenoid part
A (14) remains ON)
2
SUB VALVE 5K0BO00
5
TROUBLESHOOTING
PILOT VALVE
PILOT VALVE
The secondary pressure • Primary pressure is insufficient. • Maintain the primary pressure.
does not increase • The secondary pressure spring (241) is • Replace with a new one.
broken or worn out.
• The clearance between the spool (201) • Replace with a new remote-controlled
and the casing (101) is too large. valve.
• Too much play in the handle. • Replace the handle.
The secondary pressure • Sliding parts catch. • Repair the position that catches.
is unstable • The tank line pressure fluctuates. • Return directly to hydraulic tank
• Air is present in the piping. • Bleed air by operating the valve several
times.
The secondary pressure • Pressure in the tank line is high. • Return directly to hydraulic tank.
is too high • Sliding parts catch. • Repair the position that catches.
241
201
101
5K2BO01
1
PILOT VALVE 5K2BO00
5
TROUBLESHOOTING
PROPORTIONAL SOLENOID VALVE (ACTIVE POWER CONTROL, 1ST AUXILIARY LINE PIPING)
PROPORTIONAL SOLENOID VALVE (ACTIVE POWER CONTROL, 1ST

Proportional solenoid • Defective wiring. • Check and repair the wiring.
valve pressure does not • Solenoid (1) is damaged. • Replace.
increase
• Spool (2) is sticking. • Disassemble, check and clean.
Movement is not smooth • Spool (2) is getting stuck. • Disassemble, check and clean.
Delayed response • Supply pressure too low. • Set within the specified operating pressure
range.
Oil leaks from the solenoid • O-ring (3) is damaged. • Replace the O-ring (3).
(1) • Seal nut (4) is damaged. • Replace the seal nut (4).
3 1
5K3BO01
1
PROPORTIONAL SOLENOID VALVE (ACTIVE POWER 5K3BO00
CONTROL, 1ST AUXILIARY LINE PIPING)
TROUBLESHOOTING
CYLINDER 5
CYLINDER
“4. Disassembly and assembly, Cylinders”
Troubleshooting problems with hydraulic cylinders
It is not easy to find where the problem is. The table below shows the common problems with probable cause and rem-
edy. When making repairs, refer to the probable cause and remedy in the table.
Machine issues are seldom caused by a problem in a single part but are often also related to other parts. Other remedies
than the one shown in the table may also be required. In such cases, contact Takeuchi to further investigate the cause
of the problem and take appropriate remedies.
Items Problem seen

1 Oil leak from piston rod sliding surfaces
2 Oil leak from cylinder head joint
3 Oil leak from welded joint between the pipe and cylinder tube
4 Operation malfunction
Related
Items Problem seen Symptoms Remedies
parts
1. Remove scratches with an oilstone to make the slid-
ing surfaces smooth (1.5 s max.). If the oil leak con-
tinues, damage on the rod may have scratched the
Scratches, rust, or
U-ring or other seal. Disassemble and inspect.
corrosion on sliding
2. In the event of extensive scratching or rust that can-
surfaces.
Piston rod not be repaired with an oilstone, replace the piston
rod and associated seals, such as U-ring and wiper
rings, and the piston rod bearing material.
1. Replate or replace the piston rod.
Plating peeling off. 2. At this time, inspect the seals and piston rod bearing
material and replace them if any damage is found.
Foreign matter 1. Remove the foreign matter.
trapped in the inside 2. Replace the packing if any damage is found.
Oil leak from or outside diameter
1 piston rod slid- Scratches observed Replace
ing surfaces on the inside or out-
side diameter.
1. Suspect burning due to adiabatic compression of re-
Rod pack- sidual air in the cylinder.
Lip or groove is par-
ing 2. Bleed out the air in low-pressure, low-speed opera-
tially carbonized.
(Buffer ring, tion when operating the cylinder the first time after
U-ring) replacing the packing.
The packing has lost 1. Replace.
its rubber elasticity 2. Suspect packing has passed its service life or dete-
and is crumbling and rioration or overheating of the hydraulic oil.
fragmented. a. Replace the hydraulic oil.
b. Check the temperature of the hydraulic oil.
The entire lip is miss-
(The oil temperature should not exceed 80°.)
ing.
c. Check for localized overheating.
1
CYLINDER 5L0BP00
TROUBLESHOOTING
CYLINDER 5
Related
parts
1. Replace.
Rod pack- 2. Abnormally high pressure may be applied to the
ing Heel of the packing is packing.
(buffer ring, protruding too much. a. Check the pressure during cylinder operation.
U-ring) b. Suspect an abnormality in the buffer ring. Inspect
the buffer ring.
1. As a rule, replace the rod packing at the same time.
2. Suspect that abnormally high pressure is the cause.
Backup ring Large deformation.
Perform the same checks described above when
the heel of the packing is protruding too much.
Foreign matter is 3. Remove the foreign matter.
Oil leak from trapped in the lip
1 piston rod slid- Wiper ring
The lip is damaged. 4. Replace.
ing surfaces
Other damages.
Piston rod clearance 5. Replace.
exceeds the inside di-
ameter wear limit due
Bushing to excessive wear.
6. Replace.
Serious scratching on
7. Check for scratches or rust on the piston rod sliding
the sliding surface
surfaces.
Scratches or rust at 8. Remove the scratches or rust with an oilstone.
Cylinder
the seal mounting po- 9. If they cannot be repaired, replace the cylinder
head
sition. head.
2
CYLINDER 5L0BP00
TROUBLESHOOTING
CYLINDER 5
Related
parts
1. Remove the foreign matter.
2. Replace the O-ring if any damage is found.
3. Inspect the tube inside surface: Remove any
Foreign matter
scratches or rust with an oilstone to make the sur-
trapped in the inside
face smooth.
O-ring or outside diameter.
4. Inspect the O-ring groove in the cylinder head: as
The O-ring is dam-
above
aged.
5. Inspect the backup ring: replace if any deformation
or protrusion is found.
After the inspections above, replace the O-ring.
Deformation or pro-
Backup ring Replace together with the O-ring.
trusion.
Oil leak from 1. Disassemble the cylinder head and inspect the O-
2 cylinder head ring and backup ring.
joint Replace if any damage is found.
Cylinder 2. Check for damage to the threads of the tube and cyl-
Loose
head inder head. Replace if any damage is found.
3. When the inspection is complete, tighten to the pre-
scribed torque.
4. Secure it with the anti-rotation lock.
Loose, stretched, Replace all bolts and tighten them to the prescribed
Bolt
damaged torque.
1. Replace with a new one.
2. Oil leaks from joints may be caused by abnormally
Cylinder
Abnormal swelling. high pressures (including cushion pressure). If the
tube
tube is swelled or deformed, replace it with a new
one. Also inspect the circuit pressure.
Replace with a new one.
Oil leak from Important:
pipe and cylin- Pipe, cylin- Crack in the welded If the cracking advances, it may lead to failure.
der tube welded der tube joint. A failure is extremely dangerous. If a crack is found,
joint immediately stop work and replace the part.
3 Welding over the crack will not be effective.
The pipe fixing bolts Follow the work procedure to tighten to the prescribed
Pipe
Oil leak from are loose. torque.
cylinder pipe The pipe is bent. Replace with a new one.
joints Assembly Scratches on the con- 1. Smooth the surface with an oilstone.
tact surface. 2. Replace if the oil leak does not stop.
3
CYLINDER 5L0BP00
TROUBLESHOOTING
CYLINDER 5
Related
parts
Excessive bending 1. Replace with a new one.
Piston rod
exceeds the pre- 2. Perform an inspection, as the seal and sliding sur-
Cylinder
scribed bending face material may also be damaged. Replace if any
tube
strain. abnormality is found.
Operation mal-
Cylinder Replace with a new one. Inspect the seal and sliding
function Indentation
tube surface material, as above.
Operation is not Piston rod Abnormal wear or 1. Replace with a new one. Inspect the seal and sliding
smooth Cylinder damage to the sliding surface material, as above.
tube surfaces or foreign 2. Remove the foreign matter. Inspect the seal and
Sliding sur- matter trapped in the sliding surface material, as above.
face materi- cylinder head sliding
al surfaces.
Scratches, wear or 1. Replace with a new one.
Internal oil leak Piston seal
other damage. Also inspect the inside surface of the cylinder tube.
1. Remove scratches by honing or with an oilstone to
Piston rod ex-
Cylinder Scratches or rust on make the surfaces smooth. If large scratches can-
tends under its
tube the inside surface. not be repaired, replace the cylinder tube.
own weight
2. Replace the piston seal with a new one.
or descends ab-
1. Tighten to the specified torque.
normally during
2. The piston rod threads may be stretched. Measure
operation.
Piston nut Loose the diameters at the rod and piston engagement po-
Or the pre-
sition. If a taper is found, replace the piston rod as-
scribed speed is
sembly.
not achieved.
Valves Leak from the valve Check and adjust the amount of leakage from the valve.
4 Bleed the air.
a. Cylinder with no air bleeder
Perform low-pressure, low-speed operation sev-
eral times to bleed out the air.
b. Cylinder with air bleeder
Operation is not Air remains trapped Secure the machine so that the cylinder cannot
Air
smooth in the cylinder. move and bleed the air from the air bleeder.
[Reference]
The cylinder may move in and out slightly when it
stops suddenly. This phenomenon is due to the
compressibility of the hydraulic oil. This phenome-
non occurs more readily in a long-stroke cylinder.
Large shocks
when switching Large clearance be-
Pin Measure the pin and pin bushing dimensions. Replace
between exten- tween the mounting
Pin bushing any part outside the specified dimensions.
sion and retrac- and pin bushing
tion
Supply oil Inadequate oil. Supply oil.
Cylinder makes
Pin
a noise during
During pin
sliding opera- Galling occurs. Replace with a new one and supply oil.
bushing op-
tion
eration
IMPORTANT
The hydraulic oil expands and contracts due to changes in temperature and pressure.
This makes the cylinder extend or retract and can be misinterpreted as an internal oil leak. Check for
internal oil leaks under conditions of constant temperature and pressure.
4
CYLINDER 5L0BP00
Other 6
MAINTENANCE SOFTWARE MANUAL
6
1
6S1BO00
CONTENTS 6
CONTENTS
1. Outline
2. Connection methods
2-1. Items needed
2-2. Installation of the PLUS+1 GUIDE Service Tool
2-3. Installation of the Maintenance Tool driver
2-4. Connection to the machine and startup of the Maintenance Software
3. Description of functions
3-1. Home
3-2. Machine status
Inputs1
Inputs2
Outputs
CAN
Feedback
Error Code
Vehicle status
3-3. Engine status
Engine status
DPF status
SCR status
3-4. AUX1 Settings
AUX1
Grip settings
Stroke setting
1way current setting
HF current setting
3-5. Active power control
Active power control (without selector valve)
Active power control (with selector valve)
Active power control
3-6. Other
Option
Hourmeter
Misc
Display
Immobilizer
2
CONTENTS 6S1BO00
1. OUTLINE 6
1. OUTLINE
This software program is designed for use in mainte-
nance procedures. You can perform the various types of
maintenance listed below using this software and a main-
tenance cable.
• Machine status
This function can be used to check the input/output con-
ditions for the controller, the actual current output by the
auxiliary line piping, the status of CAN communications,
the malfunction error codes displayed, and the status of
other machine parts and sections.
• Engine status
Check the status of the engine and DOC SCR system.
• AUX1 Settings
Check the status and change the settings for AUX1.
• Active power control

Make settings and check the status for active power con-
trol.
• Other
Make settings and checks for other functions.
3
1. OUTLINE 6S1BO00
2. CONNECTION METHODS 6
2. CONNECTION METHODS
• To use the Maintenance Software program, complete
Steps 2-2 to 2-4 in sequential order.
• Screens shown and installation instructions may vary
depending on the operating system used due to differ-
ences in the language settings and OS used among
other factors. Refer to the instruction manual for the
computer you are using for additional information
should you have questions or need computer-specific
assistance.
• Note that the PLUS+1 GUIDE Service Tool installation
method may change without prior notice. Contact
Takeuchi Manufacturing should any questions arise re-
garding installation.
2-1. Items needed

1. Computer
2. Service Tool (Product no.: 06901-00025)
• Installation CD for the Maintenance Software
(Product no. 06901-00026)
• Maintenance Tool (Product no. 17301-41811)
6S1BM01
1 CAN activity
2 Power
• Cable assembly (Product no.: 17301-41820)
4
2. CONNECTION METHODS 6S1BO00
2-2. Installation of the PLUS+1 GUIDE Service Tool
a. Start up the setup.exe file (Installation CD-ROM).
• You must have administrator privileges to start
up the Setup Tool. Contact your system admin-
istrator for assistance if you are unable to exe-
cute the file.
b. Once you have executed the setup.exe file, the

screen shown below will appear. Click the [Next] on the screen to proceed.
5
c. Click [Next] to proceed.
d. Click [Next] to proceed.
6
e. Select “I accept the agreement” and then click [Next] to confirm and proceed.
f. Specify the folder for installation (continue as is unless wanting to use a folder other than the one selected) and
then click [Next] to proceed.
7
g. Click [Next] to proceed.
• Uncheck the box if you do not wish to create a desktop icon.
h. Click [Install] to start the installation.
8
i. The screen shown below will appear if the installation is successful.
Installation of the Maintenance Tool driver will start once the installation of the above file is completed. Proceed
to Step 2-3 to continue.
9
2-3. Installation of the Maintenance Tool driver
1. Install the Maintenance Tool driver.
a. The window shown below will appear once Step 2-2 has finished. Click the [Next] in the window to proceed.
b. Select “I accept the agreement” and then click [Next] to confirm and proceed.
10
c. Specify the folder for installation of the driver (continue as is unless wanting to use a folder other than the one
selected) and then click [Next] to proceed.
d. Click [Install] to start the installation.
11
e. The screen shown below will appear if the installation is successful.
Click [Finish] to complete the installation and close the window.
12
2-4. Connection to the machine and startup of the Maintenance Software
1. Connect the Maintenance Tool (product no. 17301-
41811) to the USB port on your computer.
a. The message shown at right will appear as soon
as you connect the Maintenance Tool to the USB
port on your computer and the device is recog-
nized.
Click on the message to start the Found New Hard-
ware Wizard.
6S1AT22
b. Select 2 “Yes, now and every time I connect a device” and then click 4 [Next] to proceed.
1 “Yes, this time only.”

2 “Yes, now and every time I
connect a device.”
3 “No, not this time.”
4 Next
13
c. Select 1 “Install the software automatically.” Click 3 [Next] to start the Search wizard.
1 “Install the software auto-

matically.”
2 “Install from a list or specific
location.”
3 Next
d. A message such as the one shown below will appear to inform you that the installation has been completed.
Click 1 [Finish] to end the Wizard and close the window.
1 Finish
14
2. Start up the PLUS+1 GUIDE Service Tool installed in Step 2-2.
a. Select [Program] from the Start menu and then click on [Sauer-Danfoss]. Click on PLUS+1 GUIDE 5.1, and select
PLUS+1 GUIDE Service Tool.
• You can also start the program by clicking on the desktop icon if you chose to create one.
b. When the window shown below appears, confirm that [CG150-2] has been selected and then click [OK] to pro-
ceed.
-2
6S1AT271
15
c. When the window shown below appears, confirm that [Sauer-Danfoss CG150-2 #0 (Channel 0)] has been se-
lected and then click [Set] to proceed.
3. Select [Communication]-[Gateway]-[CG150-2]-[Sauer-Danfoss CG150 #0 (Channel 0)].

• The Maintenance Tool may not be properly connected if the above is not available as a selection. Make sure that
the Maintenance Tool is firmly connected and then try again.
-2 -2
16
4. Start up the Maintenance Software.
a. Select [File]-[Open].
b. Open the Maintenance Software file (File name: TL12v2_Servicetool_v101F.PID).

• The file should be located in the save location selected for the Maintenance Software (product no. 06901-
00026) that was selected in Step 2-1 above.
6S1BO59
17
5. Connect to the actual machine.
a. Open the cover (B) under the seat.
6S1BO01
b. There is a connector (D) that is marked with a

“TAKE1” mark tube. Connect the cable assembly
(E) to this connector (D).
6S1BO03
c. Connect the cable assembly (E) to the Mainte-

nance Tool (A).
1 To actual machine
2 To computer
18
3. DESCRIPTION OF FUNCTIONS 6
3. DESCRIPTION OF FUNCTIONS
3-1. Home
Click these buttons to switch to other screens.
7
3
6S1BO01
1 Check the program version of the main controller (main controller 1) and sub-controller (main controller 2).
2 Check the machine status.
Inputs 1: Check the inputs to the main controller (main controller 1).
Inputs 2: Check the inputs to the sub-controller (main controller 2).
Outputs: Check outputs processed by the controllers.
CAN: Check the CAN reception status from each device.
Feedback: Check the actual values output by the controller.
Error Code: Check the machine and engine error codes.
Status: Check the machine status.
3 Check the status of the engine.
Status: Check the engine status.
DPF: Check the status related to DPF.
SCR: Check the status related to SCR.
19
3. DESCRIPTION OF FUNCTIONS 6S1BO00
4 Check and set the AUX1 settings.
AUX1: Check the AUX1 functions.
Grip Setting: Check and set the slide switch operation distance corresponding to the slide switch input voltage.
Stroke Setting: Check and set the output corresponding to the slide switch operation distance.
Current 1Way: Checks and sets the output current value to the solenoid corresponding to the AUX1 slide switch opera-
tion distance when the 1-Way switch is ON and the HIGH FLOW switch is OFF (if installed).
Current 2Way: Checks and sets the output current value to the solenoid corresponding to the AUX1 slide switch opera-
tion distance when the 1-Way switch is OFF and the HIGH FLOW switch is OFF (if installed).
High Flow: Checks and sets the output current value to the solenoid corresponding to the AUX1 slide switch operation
distance when the HIGH FLOW switch is ON (if installed).
5 Check and adjust the status of active power control
TL10v2(wo sel. Valve): Click for a Model TL10V-2 machine with no selector valve installed to check and adjust the active
power control status.
TL10v2(w sel. Valve): Click for a Model TL10V-2 machine with a selector valve installed to check and adjust the active
power control status.
TL12v2: Click for a TL12V-2 model to check and adjust the active power control status.
6 Check and change the settings for other functions.
Option: Check and set the optional functions.
Hourmeter: Adjust the hourmeter.
Misc: Check and set the functions related to the intermittent wipers. Change the password required for the Service Tool.
Display: Change the password to operate the cluster.
7 Check the model type.
20
3-2. Machine status
Pin wiring diagrams for the controllers
The pin wiring diagrams for each controller and cluster
are shown below. The pin numbers correspond to the pin
numbers shown for the controller symbols and cluster
symbols in 2. Electrical circuit diagrams.
1 Pin wiring diagram for the main controller (main control-

ler 1)
2 Electrical circuit diagram symbols for the main controller
(main controller 1)
2. Electrical circuit diagrams
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40
41 42 43 44 45 46 47 48 49 50
1 6S1BO04
MAIN CONTROLLER 1
21
3 Pin wiring diagram for the sub-controller (main controller
2)
4 Electrical circuit diagram symbols for the sub-controller
(main controller 2)
2. Electrical circuit diagrams
1 2 3 4 5 6 1 2 3 4 5 6
12 11 10 9 8 7 12 11 10 9 8 7
C2P＊＊ C1P＊＊
MAIN CONTROLLER 2
4 6S1BO32
22
5 Pin wiring diagrams for the OX module (OX controller)
6 Electrical circuit diagram symbols for the OX module
(OX controller)
1 2 3 4 5 6 1 2 3 4 5 6
12 11 10 9 8 7 12 11 10 9 8 7
C2P＊＊ C1P＊＊
5
OX CONTROLLER
6 6S1BO33
23
7 Pin wiring diagram for the cluster
8 Electrical circuit diagram symbols for the cluster
12 1
11 2
10 3
9 4
8 5
7 6
8
6S1BO57
24
Inputs1
6S1BO05
• Main controller
Check the digital and converted analog signals input to the main controller (main controller 1).
C1P15: Line filter clogging
On: Line filter clogged sensor is ON
Off: Line filter clogged sensor is OFF
C1P16: Air cleaner filter clogging
On: Air cleaner clogged sensor is ON
Off: Air cleaner clogged sensor is OFF
C1P17: Battery charge
On: Alternator relay (CR7) is ON
Off: Alternator relay (CR7) is OFF
C1P18: Grip E button
On: E switch on right operating grip is ON
Off: E switch on right operating grip is OFF
C1P19: Grip F button
On: F switch on right operating grip is ON
Off: F switch on right operating grip is OFF
C1P20: AUX2 select switch (machine with 14-pin connector installed)
On: 2nd service/14-pin connector selector switch is at the 2nd service symbol position
Off: 2nd service/14-pin connector selector switch is OFF
C1P21: 14Pin select switch (machine with 14-pin connector installed)
On: 2nd service/14-pin connector selector switch is at the 14-pin connector symbol position
Off: 2nd service/14-pin connector selector switch is OFF
25
C1P22: High-flow switch (machine with high-flow installed)
On: High-flow switch is ON
Off: High-flow switch is OFF
C1P23: DPF manual reg. inhibit switch
On: DPF manual regeneration/inhibit selector switch is at the inhibit symbol position
Off: DPF manual regeneration/inhibit selector switch is OFF
C1P24: DPF manual reg. switch
On: DPF manual regeneration/inhibit selector switch is at the regeneration symbol position
Off: DPF manual regeneration/inhibit selector switch is OFF
C1P25: Parking brake switch (machine with parking brake)
On: Parking brake switch is ON
Off: Parking brake switch is OFF
C1P26: Detent mode switch
On: Detent mode switch is ON
Off: Detent mode switch is OFF
C1P27: Fuel sender
Top: Input voltage from fuel gauge
Middle: Resistance value of fuel gauge
Bottom: Level of fuel remaining
C1P28: Self level switch
On: Self-level switch is ON
Off: Self-level switch is OFF
C1P29: Fuel sender (gasup) (Model TL12V-2 only)
Input voltage from fuel gauge 2
C1P31: Back alarm press.sw
On: Pilot pressure (travel reverse) switch is ON
Off: Pilot pressure (travel reverse) switch is OFF
C1P32: Gas up switch
On: Fuel-DEF/AdBlue® injection switch is at the DEF/AdBlue® symbol position
Off: Fuel-DEF/AdBlue® injection switch is OFF
C1P33: Urea up switch
On: Fuel-DEF/AdBlue® injection switch is at the fuel symbol position
Off: Fuel-DEF/AdBlue® injection switch is OFF
C1P34: Work lights switch
On: Light switch is ON
Off: Light switch is OFF
C1P35: AUX1 A-side full button
On: A switch on left operating grip is ON
Off: A switch on left operating grip is OFF
C1P36: AUX1 B-side full button
On: B switch on left operating grip is ON
Off: B switch on left operating grip is OFF
C1P37: AUX1 slider switch
Top: Input voltage from slide switch (proportional control) on left operating grip
Bottom: Slide position of slide switch (proportional control) on left operating grip
26
C1P38: Travel speed button
On: Travel speed button on left operating grip is ON
Off: Travel speed button on left operating grip is OFF
C1P39: 1way switch
On: Flow selector switch is ON
Off: Flow selector switch is OFF
C1P41: Ride control switch (machine with ride control)
On: Ride control switch is ON
Off: Ride control switch is OFF
C1P43: ECO mode switch
On: Eco mode switch is ON
Off: Eco mode switch is OFF
C1P44: Starter switch ACC
On: Key switch is ON or START
Off: Key switch is OFF
C1P46: CCV heater in
Input voltage from the CCV IN heater
C1P47: CCV heater out
Input voltage from the CCV OUT heater
C1P49: Hydraulic temp
Top: Input voltage from hydraulic oil temperature sensor
Middle: Resistance value of hydraulic oil temperature sensor
Bottom: Hydraulic oil temperature
27
Inputs2
6S1BO06
• Sub-controller
Check the digital and converted analog signals input to the sub-controller (main controller 2).
C1P06: Hyd. Quick-hitch close
On: Hydraulic quick-hitch lock/unlock switch is at the lock symbol position
Off: Hydraulic quick-hitch lock/unlock switch is OFF
C1P07: Hyd. Quick-hitch open
On: Hydraulic quick-hitch lock/unlock switch is at the unlock symbol position
Off: Hydraulic quick-hitch lock/unlock switch is OFF
C1P10: Hyd.system unlock sw
On: Hydraulic system unlock switch is ON
Off: Hydraulic system unlock switch is OFF
C1P11: Arm down press switch
On: Pilot pressure (lift arm down) switch is ON
Off: Pilot pressure (lift arm down) switch is OFF
C1P12: Arm up press. Switch
On: Pilot pressure (lift arm up) switch is ON
Off: Pilot pressure (lift arm up) switch is OFF
C2P01: Seat switch (machine with seat switch)
On: Seat switch is ON
Off: Seat switch is OFF
28
C2P02: Safety bar switch
On: Safety bar is in the lock position
Off: Safety bar is in the unlock position
C2P03: Arm float button (Grip)
On: A switch on right operating grip is ON
Off: A switch on right operating grip is OFF
C2P04: Hyd.quick-hitch enable sw
On: A hose is connected to the quick coupler of the 1st auxiliary line piping.
Off: No hose is connected to the quick coupler of the 1st auxiliary line piping.
C2P05: Accel(dial)
Top: Input voltage from throttle controller
Bottom: Degree of opening of the throttle controller (0% to 100%)
C2P05: Accel (foot)
Top: Input voltage from accelerator pedal
Bottom: Degree of opening of the accelerator pedal (0% to 100%)
• Cluster
Check the digital signals input to the cluster.
C1P07: Wiper interval
On: Front wiper switch in INT position (intermittent)
Off: Front wiper switch is OFF
C1P08: Wiper continuous
On: Front wiper switch is ON (continuous)
Off: Front wiper switch is OFF
C1P09: A/C compressor
On: Compressor relay is ON
Off: Compressor relay is OFF
29
Outputs
6S1BO34
• Main controller (Main controller 1)

Check the digital signals output to the main controller (main controller 1).
C1P30: Urea up lamp
On: Output
Off: Not output
C1P40: Back up relay
On: Output
Off: Not output
C1P50: Gas up lamp
On: Output
Off: Not output
• OX module (OX controller)

Check the digital and analog signals output to the OX module (OX controller).
C1P06: AUX 1way solenoid
On: Output
Off: Not output
C1P07: Load dump relay
On: Output
Off: Not output
C1P08: Wiper relay
On: Output
Off: Not output
30
C1P09: AUX2 A-side solenoid
On: Output
Off: Not output
C1P10: AUX2 B-side solenoid
On: Output
Off: Not output
C1P11: Travel solenoid
On: Output
Off: Not output
C1P12: AUX1 prop.sol.A
Output current value (target value)
C2P01: AUX1 prop.sol.B
C2P02: Ride control solenoid 1
On: Output
Off: Not output
C2P03: Ride control solenoid 2
On: Output
Off: Not output
C2P04: 14 Pin E
On: Output
Off: Not output
C2P05: High-flow solenoid
On: Output
Off: Not output
C2P06: 14 Pin F
On: Output
Off: Not output
C2P07: Lights relay
On: Output
Off: Not output
C2P08: Actv pwr control sol.
C2P09: Self level cancel sol.
On: Output
Off: Not output
• Sub-controller (Main controller 2)

Check the digital signals output to the sub-controller (main controller 2).
C2P09: Safety lever lock sol.
On: Output
Off: Not output
C2P10: Quick hitch open sol.
On: Output
Off: Not output
C2P11: Quick hitch close sol.
On: Output
Off: Not output
C2P12: Arm float sol.
On: Output
Off: Not output
31
CAN
6S1BO35
• CAN Communication
Check the main controller (main controller 1) CAN reception status from each device.
Engine ECU
On: Receiving
Off: Not receiving
OX module (OX controller)
On: Receiving
Off: Not receiving
Sub-controller (Main controller 2)
On: Receiving
Off: Not receiving
Cluster
On: Receiving
Off: Not receiving
Engine ACU (ACU) (Model TL12V-2 only)
On: Receiving
Off: Not receiving
Urea tank (DEF/ADBLUE® tank) (Model TL12V-2 only)
On: Receiving
Off: Not receiving
Pre NOx sensor (Model TL12V-2 only)
On: Receiving
Off: Not receiving
Post NOx sensor (Model TL12V-2 only)
On: Receiving
Off: Not receiving
32
Feedback
6S1BO36
• PWM Outputs (OX)

Check the current values (actual values) output from the OX module (OX controller).
C1P12: AUX1 hydraulic A
Output current value (actual value)
C2P01: AUX1 hydraulic B
C2P08: Actv pwr control
• Supply power
Check the power supply and sensor voltages for each controller.
Main ECU supply power
Main controller (main controller 1) power supply voltage value
OX supply power
OX module (OX controller) power supply voltage value
Sub ECU supply power
Sub-controller (main controller 2) power supply voltage value
Main ECU sensor power
Main controller (main controller 1) sensor power supply voltage value
Sub ECU sensor power
Sub-controller (main controller 2) sensor power supply voltage value
33
Error code
6S1BO37
• Vehicle side error codes

Active: Currently issued vehicle error codes
Logged: Previously issued vehicle error codes
• Engine side error codes

Active: Currently issued engine error codes
Logged: Previously issued engine error codes
1 Clears the vehicle error code log.

2 Reads the previously issued engine error codes.
3 Clears the engine error code log.
34
Vehicle status
6S1BO38
• Vehicle status
Check the status of the vehicle.
ACC On: Displays the accessory power supply On/Off status
Engine On: Displays the engine start On/Off status
Hour meter: Displays the hourmeter On/Off status
Trip meter 1: Displays the trip meter 1 value
Trip meter (engine oil): Engine oil trip meter
Trip meter (hydraulic oil): Hydraulic oil trip meter
Trip meter (coolant): Coolant trip meter
Fuel meter: Displays the amount of fuel remaining
Arm float mode: Float mode On/Off status
Work mode: Work mode* On/Off status
* Work mode: Status where the hydraulic system lock lamp is off on the cluster screen and the machine is ready to
operate.
35
3-3. Engine status
Engine status
6S1BO39
• Status
Check the status of the engine.
Engine on: Displays the engine start On/Off status
Engine speed: Displays the actual engine speed
Actual engine torque: Displays the actual engine torque
Engine fuel rate: Displays the rate of engine fuel consumption
Coolant temperature: Displays the coolant temperature
Engine mode: 1.Droop control, 2. Isochronous control
Glow lamp: Displays the glow lamp ON/OFF status
Glow relay: Displays the glow relay On/Off status
Diag lamp: ON when an engine error code is detected
Engine Oil Press: Displays the engine oil pressure
Turbo protect mode: Displays the turbo protect mode* On/Off status
* Turbo protect mode: Mode that reduces the engine output to protect the turbocharger when the ambient temperature
is low.
Request engine torque limit: Shows the limit value on the engine torque sent to the engine control unit (ECU) from the
main controller (main controller 1). (Example: “85%” indicates that the engine torque is limited to 85%.)
Request engine speed (iso): Shows the engine speed command value sent to the engine control unit (ECU) from the
main controller (main controller 1).
Accel pedal: Degree of opening of the accelerator pedal (0% to 100%)
36
DPF status
6S1BO40
• DPF system
Check the statuses related to dust particulate filter (DPF).
Engine on: Displays the engine start On/Off status
DPF derating level: See the diagram below.
Regeneration Control Approximate operating time

Worst case (High idle, No load): 1 hour 1 hour 1 hour
25 % load: 1.5 hour 1.5 hour 1.5 hour
Accumulated PM quantity
1800 sec
Estimated PM value
DTC 3006: DTC 3007: DTC 3008:

Start Auto-Active Time to request
Excessive PM3 Excessive PM4 Excessive PM5
regeneration parked re-gen
- De-rating level 2 - De-rating level 2
- Engine restart - Parked re-gen
- De-rating level 1 possible impossible
- Parked re-gen - Parked re-gen - Engine restart
execution possible possible only by possible
service tool
Inhibit ON
Default Automatic active re-gen inhibit
Inhibit OFF Automatic active Automatic active re-gen
User execution
re-gen execution disactivated
Parked re-gen
Valid while Parked active re-
conditions satisfied gen disactivated
Parked re-gen Not
Valid
by service tool valid
DPF derating level Level: 0 Level: 1 Level: 2 Level: 3 Level: 4 Level: 5
6S1BO58E
37
DPF regeneration status:
0: Out of active regeneration mode
1: Automatic active regeneration mode
2: Parked regeneration mode
DPF soot mass: Displays the mass of particulate matter
DPF soot load percent: Displays the amount of accumulated particulate matter
Neutral: ON only when the work mode* is OFF
* Work mode: Status where the hydraulic system lock lamp is off on the cluster screen and the machine is ready to
operate.
DPF system lockout: ON when the DPF system is non-functional due to an error.
• Active regeneration inhibit due to…

One of the following turns ON if DPF regeneration is not possible.
Inhibit switch: DPF manual regeneration/inhibit selector switch is at the inhibit symbol position
Low idle: ON when the engine is not in low idle
Neutral: ON in work mode
Parking brake: ON when the parking brake switch is OFF (Model TL12V-2 only)
Exhaust gas temperature low: ON when the temperature of the gas exhaust is low
Time out: On when DPF regeneration is not complete
38
SCR status
6S1BO41
• SCR system
Check the statuses related to selective catalytic reduction (SCR).
Pre NOx concentration: Displays the pre NOx concentration
Post NOx concentration: Displays the post NOx concentration
Urea temperature: Displays the urea temperature
Urea tank level: Displays the level remaining in the urea tank
Urea tank fault: Displays the urea tank error 3: Sensor discontinuity 4: Sensor short
Urea tank frozen: ON when the urea tank is frozen
SCR induce severity:
0: No inducement active
1: Warning level 1-Initial warning
3: Reduction level 1-Low level inducement active
4: Warning level 2-Waiting for activation condition
5: Reduction level 2-Severe inducement active
6: Restored operation
SCR induce reason:
0: No inducement
1: DEF Level
2: DEF Quality
4: Tampering
39
3-4. AUX1 Setting
AUX1
6S1BO42
• AUX1 status
Check the status and change the settings for AUX1.
Flow mode: Displays the flow setting mode selected in the cluster
I: Mode 1
II: Mode 2
III: Mode 3
AUX1 setpoint: Displays the operation distance of the AUX1 slide switch
Highflow mode
On: High-flow switch is ON
Off: High-flow switch is OFF
Detent mode
On: Detent mode switch is ON
Off: Detent mode switch is OFF
• Flow status
Flow I
Max flow (L): Displays the Mode 1 left side maximum current setting
Max flow (R): Displays the Mode 1 right side maximum current setting
Flow II
Flow III
40
• Settings
Exp filter: Displays the filter correction time for the output current value
1 Resets all AUX1 settings to the default values.

2 Applies the changed settings.
3 Reads the current settings.
4 Check this checkbox to enable operation of the 1st auxiliary line piping.
5 Applies the settings changed in “Exp Filter”
41
Grip setting
DANGER
Exercise extreme caution after making adjustments, as the machine could operate in an unexpected manner
and could cause severe injury or even death. Be extremely careful when operating the auxiliary line piping.
Check and set the slide switch operation distance corresponding to the slide switch input voltage.
1100 3900
6S1BO43
• Grip voltage
Center: Displays and sets the voltage at the neutral position
Neutral Dead Band: Displays and sets the neutral dead band
Example: 2500 - 200 = 2300, 2500 + 200 = 2700
The deadband ranges from 2300 to 2700 mV.
Range: Displays and sets the operation range.

Example: 2300 - 1200 = 1100, 2700 + 1200 = 3900
The operating ranges are from 1100 to 2300 mV and 2700 to 3900 mV.
The changes above are reflected in the output curve.
1 Returns to the AUX1 screen.

42
Stroke setting
Check and set the output curve corresponding to the slide switch operation distance.
DANGER
6S1BO44

43
Check and set the output curve to the solenoid corresponding to the slide switch operation distance when the flow se-
lector switch is ON (1Way).
DANGER
6S1BO45

44
Check and set the output curve to the solenoid corresponding to the slide switch operation distance when the flow se-
lector switch is OFF (2Way).
DANGER
6S1BO46

45
HF current setting
Check and set the output curve to the solenoid corresponding to the slide switch operation distance when the high-flow
switch is ON.
DANGER
6S1BO47

46
3-5. Active power control
Make settings and check the status for active power control in a Model TL10V-2 machine with no selector valve installed.
In this screen, you can also change the settings of sensitivity when the engine speed drops while active power control
is functioning.
6S1BO48

3 Switches the display to the Scope screen.
4 Resets the settings to the default values.
• Proportional-integral-derivative (PID) parameter settings

Parameter P: This is used to change the P (proportional) control variable for PID control.
Parameter I: This is used to change the I (integral) control variable for PID control.
Parameter D: This is used to change the D (derivative) control variable for PID control.
Parameter T1: This is used to change the time (in ms) for PID control.
Parameter torque: This is used to change the threshold value of the engine torque at which PID control starts.
Torque hys: This is used to change the threshold value of the engine torque at which PID control ends.
Parameter Min: This is used to change the minimum current value (in increments of 0.1 mA) used to control the current
value for PID control.
47
• Current settings
Current Max: This is used to change the maximum current value (A) that can be output by the controller.
Current High: This is used to change the standard current value at engine maximum speed.
Current Low: This is used to change the standard current value at engine low speed.
Engine speed delta HI: This is used to change the target engine speed for engine maximum speed.
(Example: The value in the frame □ can be changed. 2400 - 400 = 2000 rpm)
Engine speed delta LO: This is used to change the target engine speed for engine low speed.
Engine speed delta GP: This is used to change the target engine speed for lift arm operations.
(Example: The value in the frame □ can be changed. 2400 - 400 - 0 = 2000 rpm; 1200 - 200 - 0 = 1000 rpm)
• Status
Actual engine speed: This is used to check the actual engine speed.
Rated engine speed: This is used to check the rated engine speed which varies according to the degree to which the
accelerator is opened.
Actual engine torque: This is used to check the actual engine torque.
AS sol. current: This is used to check the target current value (A) for the active power control solenoid.
P: This is used to check the P control variable.
I: This is used to check the I control variable.
D: This is used to check the D control variable.
PID On:
On: PID control is ON
Off: PID control is OFF
Disable status:
1. Engine is OFF
2: Turbo protect function is ON
3: SCR abnormal
4: DPF abnormal
5: Active power control function is disabled
48
Scope screen
6S1BO49
1 Changes the time scale per unit mass.

2 Check this checkbox to display the points on the waveform.
3 Check this checkbox to update the waveform. Uncheck this checkbox to stop the waveform.
4 Copies the waveform to the clipboard.
5 Selects the color of the waveform.
CP_LP_PID_Fdbk: Feedback value for PID control

A_P: P control variable
A_I: I control variable
CP_LP_OutVal_dmA: Target current value (A) for the active power control solenoid
CP_ENgActualRPM: Actual engine speed
49
Active power control (with selector valve)
Make settings and check the status for active power control in a Model TL10V-2 machine with a selector valve installed
is functioning.
6S1BO50


50
• Status
PID On:
On: PID control is ON
Off: PID control is OFF
Disable status:
1. Engine is OFF
2: Turbo protect function is ON
3: SCR abnormal
4: DPF abnormal
5: Active power control function is disabled
Scope screen
51
Active power control
Make settings and check the status for active power control in a Model TL12V-2 machine.
is functioning.
6S1BO51


52
• Status
Scope screen
53
3-6. Other
Option
Check and set the optional functions.
6S1BO52
14Pin: Check this checkbox if the machine has a 14-pin connector.

AUX1: Check this checkbox if the machine has a 1st auxiliary line.
AUX2: Check this checkbox if the machine has a 2nd auxiliary line.
FootAccel: Check this checkbox if the machine has a foot accelerator.
ParkingBrake: Check this checkbox if the machine has a parking brake.
Active power control: Check this checkbox to turn ON the active power control function.
Active power control with selector valve: Check this checkbox to turn ON the active power control function in a Model
TL10V-2 machine with a selector valve installed

54
Hourmeter
Adjust the hourmeter and trip meters.
6S1BO53
1 Display and set the hourmeter value.

2 Click to set the hourmeter. (This setting can only be increased. Once increased, it cannot be turned back.)
3 Display and set the trip meter values.
4 Click to set the trip meters.
Update: Click the “Update” button to synchronize the main controller (main controller 1) and the engine ECU hourmeter).
55
Misc
Check and set the intermittent wiper and main controller (main controller 1) settings.
6S1BO54
1 Change the intermittent wiper time (in seconds).

2 Change the main controller (main controller 1) password.
56
Display
Check and set the cluster password.
6S1BO55
1 Changes the cluster password. The cluster does not request a password if this is set to 0.
57
Immobilizer
Check and set the settings related to the immobilizer.
6S1BO56

3 Turns the immobilizer function ON and OFF.
4 Click to turn ON the immobilizer function.
GPS Low Idle

On: The engine speed is limited to low speed.
Off: The engine speed is not limited to low speed.
GPS Engine
On: The engine will not start.
Off: The engine is running.
Leverlock
On: The lever lock will not release.
Off: The lever lock is released.
58
OTHER
AIR CONDITIONER 6
AIR CONDITIONER
Compressor assembly
21 27
23
28 13 27
23 21
24 28
22
26 19
9 19
22
28 24 24 32
13 22 8
19
34 1
32
31
32 1
29
22
24 5 20 5
36 37 2 23 4
19 30
2
18
10
15
6 21
25 3
3
(R1E190) 6S2BS01
IMPORTANT
• Perform all installation and refrigerant gas filling operations carefully and accurately to prevent foreign mat-
ter entering the pipes.
• The compressor is filled with a dry gas. Before connecting pipes, carefully remove the blank plugs to bleed
the gas from the interior. The compressor oil may spurt out if a blank plug is removed too rapidly.
1
AIR CONDITIONER 6S2BS00
OTHER
AIR CONDITIONER 6
2 Use shims (36) and (37) to fill the gap between the compressor (1) and bracket.
3 Leave a clearance of 1 mm (0.04 in.) between the nut (30) and bracket (6).
4 Adjust the fan belt until it deflects approximately 8 mm (0.3 in.) at the midpoint between the pulley and the compres-
sor when a force of 98 N (22 lbf) is applied. If a belt tension gauge is used, set to 529 N (119 lbf) tension.
5 Nut (inside): 17 N·m (13 ft-lb.)
Nut (outside): 83 N·m (61 ft-lb.)
When tightening the outside nut, hold and apply torque to the inside nut with a wrench.
1. Compressor 13. Clamp 26. Clamp

2. Pulley 15. Bolt 27. Bolt
3. Shaft 18. Bolt 28. Clamp
4. Collar 19. Nut 29. Bolt
5. Collar 20. Nut 30. Nut
6. Bracket 21. Spring washer 31. Ring
7. V-belt 22. Spring washer 32. Band
8. Spring washer 23. Washer 34. Protector
9. Hose 24. Washer 36. Shim
10. Hose 25. Gas 37. Shim
2
OTHER
AIR CONDITIONER 6
Condenser assembly
30 31
28
40 2 X b 37
41
a
34 14
38 16
20
29
38 19
41 17
40 Y
39 8
10 26
11 9
13
12 35 26
1 29
5 27 X 36
32
6 b 33
7 18
25 22 32
24 27
33 29
a b 23 35
4 25
21 15 24 Y
3
43 23
b
13 41
39 40 41 39 40 41 40
42 28
R1E200
6S2BS02
Amount of refrigerant: 800 g (1.76 lb)
IMPORTANT
• Perform all installation and refrigerant gas filling operations carefully and accurately to prevent foreign mat-
ter entering the pipes.
• When connecting the air conditioner hoses, ensure that the rubber hose sections are not twisted. Apply com-
pressor oil to the O-ring of the air conditioner hose attachments. (Compressor oil standard: SP-20 or an
equivalent)
• Take care not to over-bend the air conditioner hoses. Minimum bending radius 65 mm (2.6 in.).
• Incorrect piping connections to the dryer (3) may damage the compressor.
1. Hose 12. Washer 23. Nut 34. Grommet

2. Hose 13. Band 24. Spring washer 35. Bolt
3. Dryer 14. Trim 25. Washer 36. Condenser
4. Switch 15. Ring 26. Bracket 37. Motor
5. Clamp 16. Bracket 27. Washer 38. Clamp
6. Clamp 17. Bracket 28. Nut 39. Bolt
7. Band 18. Plate 29. Spring washer 40. Spring washer
8. Rubber cushion 19. Washer 30. Screw 41. Washer
9. Seal 20. Bolt 31. Screw 42. Bracket
10. Bolt 21. Tube 32. Grommet 43. Bracket
11. Spring washer 22. Plate 33. Bolt
3
OTHER
AIR CONDITIONER 6
Installing the condenser
1. Install the brackets (26) and plates (18) and (22) on
the condenser (36) and temporarily tighten the nuts
(23).
2. Install the bushings (33) and grommets (32) in the
plates (18) and (22). Install the seals (8) and (9) on
the bracket (16) and attach the plates with the bolts
(35).
3. Fully tighten the nuts (23) that were temporarily tight-
ened at step 1. Fully tighten the nuts on plate (22)
last.
4
OTHER
AIR CONDITIONER 6
Air conditioner unit
41 a
15 25 21 29-1
13 5
2 14 5 12 5
11 5
Y
X 14 5 Z 19
19 8
41 38 10 19 38 8
36
38
17
27
1 26 17
24
Y 19 4 30
X 9
19 26 42 9 37
18 25
15 23 24
32 22 38
18 25 20
18 18
21 4 20
31 23
3 25
40 1
3 6
28 33
3534 Z
5
7
29
a
(R1E210)
2
6S2BS03
1 Engine
2 Wire harness 4. Wire harness
3 Inside canopy/cab
4 Bolt: 2 N·m (1 ft-lb.)
Direction of wrapping sealing tape: 1. Cautions when working
6 Fan relay
7 Compressor relay
8 Secure to the heater hose.
9 Install near the air conditioner unit (1) mounting bolt.
1. Air conditioner unit 17. Clamp 29-1. Diode (3 A, yellow)

2. Filter 18. Clamp 30. Bolt
3. Hose 19. Band 31. Bracket
4. Valve 20. Bolt 32. Bracket
5. Valve assembly 21. Bolt 33. Nut
8. Hose 22. Nut 34. Spring washer
9. Hose 23. Spring washer 35. Washer
10. Hose 24. Spring washer 36. Protector
11. Valve 25. Washer 37. Protector
12. Adapter 26. Washer 38. Band
13. Elbow 27. Screw 40. Relay
14. Joint 28. Screw 41. Sponge
15. Nut 29. Wire harness 42. Protector
5
OTHER
AIR CONDITIONER 6
AC component
0-1 0-2
14 13 12
11 11
5 2
1 10 10
6 4
3
7
6S2BS04
0-1. Air conditioner unit 0-2. Panel assembly

1. Heater core 10. Knob
2. Evaporator core 11. Nut
3. Filter 12. Potentiometer
4. Thermostat 13. Air conditioner switch
5. Motor 14. Rotary switch
6. O-ring
7. Valve
6
AIR CONDITIONER SYSTEM
Overview of System Operation
• Truck and Heavy Equipment Systems
• Air Conditioner-System Operation
• Heater System Operation
• Environmental Effects on System Operation
• Chapter Review
Truck and Heavy Equipment Systems

A variety of HVAC systems are in use today, some old and some new. There are:
• Vehicle manufacturer installed systems
• Owner specified systems
• Add-on systems
• Retrofit systems
The system components come in different colors, shapes, and sizes. They may be
mounted in or on the cab in varied locations. Owners or fleet maintenance people can
modify systems by adding controls, auxiliary units or ducts. Major components are
sometimes replaced due to damage or failure. All systems were, at least originally,
designed and installed to meet the needs of an operator. Figure 2-1 includes illus-
trations of various AC and Heater systems. They illustrate system advantages and
disadvantages explained in the paragraphs that follow.
The HVAC system includes both heater and air conditioner components, usually
a common control, and air ducts. The system cools the cab by removing heat energy.
It removes moisture from damp air in the cab and adds fresh outside air to the cab. In
this way, the operator can work comfortably in all kinds of weather.
A sleeper unit, built in or added on, increases the air volumes in the cab. The air
conditioner or heater must circulate and cool or heat a larger amount of air. This is ac-
complished by routing ducts and controls to the sleeper compartment as part of system
design. Components may be increased in size to handle the larger cab air volume. A
bigger heater core, air conditioning evaporator coil, condenser, blower or fan may be
included. Often, on long haul trucks, auxiliary air conditioning and heater components
and controls are added. The objective remains the same, to move heat energy and
maintain occupant comfort.
1 6S2BE011
System Operation
Air Conditioner—System Operation

We have described the movement of heat energy and basic HVAC system function in
Chapter 1. Now we will go into some detail on how an air conditioner operates. The
system is sealed to keep out air and moisture. To operate properly, the inside of the
system contains a measured amount of refrigerant and special refrigerant oil that keeps
the system lubricated. Figure 2-2 is an illustration of system components without the
cab outline, in-cab controls, component housing, and air ducts or vents. Please study
it for a moment. Note the information printed next to each component. Remember that
the components may be positioned and attached to the truck in various locations.
2 6S2BE011
The following AC components are discussed in detail in this section:

1. Compressor/Clutch Assembly
2. Condenser
3. Receiver-Drier
4. Expansion Valve
5. Evaporator Coil
Figure 2-2
Air Conditioner components
are connected together to
illustrate system operation.
The components shown are
not to scale. The refrigerant
and refrigerant oil are clear
in color and not visible in
this drawing. The small ar-
rows inside the components
and connecting hoses show
the direction of refrigerant
flow (refrigerant circuit).
1. Compressor/Clutch Assembly
The compressor/clutch assembly is the heart of the system. When the clutch is engaged,
the compressor pumps refrigerant and oil around the system. It raises the temperature
and pressure of the refrigerant gas, and forces it to the condenser where it changes
state and becomes a liquid. The compressor also sucks the vaporized refrigerant out
of the evaporator and back inside itself in the form of gas. One way valves inside the
compressor separate the compressed gas (high pressure) side of the system from the
suction (low pressure) side. Figure 2-3 shows a cutaway view of a compressor with the
high and low pressure sides noted.
3 6S2BE011
System Operation
Figure 2-3
The compressor inlet is
low pressure and the outlet
is high pressure. The reed
valves are one way. They
open to allow refrigerant gas
to enter the compressor on
the down stroke and exit on
the upstroke. Note the open
valves in the illustrations.
The clutch is mounted on the shaft of the compressor and is engaged by electromag-
netic action. Part of the clutch assembly is an electromagnetic wire coil. The coil is
energized through a thermostat that senses the temperature in the evaporator coil. If
the evaporator is too warm the electrical contacts close and allows power to flow to the
clutch. The compressor shaft is engaged and moves the refrigerant around inside the
system. Figure 2-4 is a cutaway view of the clutch mounted on the compressor.
Figure 2-4
The clutch shown here has
its electromagnetic coil
mounted on the compressor
body. When the coil is ener-
gized, magnetic force pulls
the clutch drive plate into
the pulley. This action locks
the pulley to the compressor
drive shaft and drives the
compressor.
2. Condenser
The refrigerant gas leaves the compressor and moves through a high pressure hose to
the condenser. Inside the condenser the gas “changes state” and becomes a liquid. It
is still hot and under pressure. Remember in Chapter 1 when we talked about water at
212 degrees Fahrenheit? Heat energy was involved in the “change of state,” but the
temperature did not change. The same kind of action happens inside the AC system.
The refrigerant gas gives up a lot of heat energy to the outside air as it “changes state”
in the condenser. Figure 2-5 illustrates a condenser. Air moving through the condenser
absorbs heat from the refrigerant. The amount of air flow through the condenser is the
major factor in how well the condenser functions.
4 6S2BE011
Figure 2-5
As the refrigerant gas moves
through the tubing coil from
top to bottom, it condenses
(changes state) into a liquid.
For ease of installation,
condenser fittings are often
routed close together.
3. Receiver-Drier
The liquid refrigerant continues to move inside the system, out of the condenser
through a tube or hose to the receiver-drier. The receiver-drier serves as a small stor-
age tank and filter for the refrigerant. It is also a good location to mount pressure
switches and often contains a sight glass (small window) used to view activity inside
the system. The receiver-drier, Figure 2-6, also separates gas (bubbles) from the liquid
with a pick-up tube as shown in this illustration. Some receiver-driers have a spring to
preload the desiccant pack.
Figure 2-6
This cutaway view of a re-
ceiver-drier shows the filter
elements, inlet, outlet and
refrigerant path. The sight
glass is a small window into
the system used in diagnosis
and when adding refrigerant
(charging the system).
5 6S2BE011
System Operation
4. Expansion Valve (Refrigerant Metering Device)

When refrigerant moves from the receiver-drier, it travels through another high pres-
sure hose to a metering device at the inlet of the evaporator coil. The metering device
can be an expansion valve, an expansion tube or a combination (multiple function)
valve. Between the compressor and this point inside the system, the pressure is high
and can range from 150 to 250 pounds per square inch. The expansion valve (TXV) is
closely connected to the evaporator. A diaphragm opens the valve by exerting pressure
on the spring. Pressure comes from gas inside the diaphragm housing on top of the
valve and in the sealed sensing bulb. The sensing tube is located in the outlet of the
evaporator and picks up heat from warm refrigerant leaving the evaporator. The gas in
the valve diaphragm housing and sensing tube expands when it gets warmer and forces
the expansion valve open at the metering orifice.
Figure 2-7
This block type expansion
valve cutaway view will
give you a better idea how
these valves work. Spring
pressure holds the valve
closed.
5. Evaporator Coil
The expansion valve or other type of metering device bleeds high pressure refrigerant
into the evaporator coil, where the pressure is low. The refrigerant expands rapidly in
this low pressure environment. When it expands it “changes state”. The sudden drop
in pressure brings the refrigerant temperature down quickly inside the evaporator coil.
Figure 2-8 shows an evaporator coil and thermostat. Refrigerant is sprayed into the
evaporator by the high side pressure when the expansion valve opens. The refrigerant
absorbs heat from the air when the blower forces the air through the fins. When the
thermostat probe senses the upper limit of the thermostat heat setting, a circuit closes.
The compressor clutch engages and the compressor operates and moves more refriger-
ant to the high side of the system.
6 6S2BE011
Figure 2-8
The evaporator coil as
shown is of fin and tube
construction. The thermostat
probe is positioned in
between the evaporator fins
and senses the temperature.
Note: Moisture in the air (humidity) condenses on the fins of the evapo-
rator as water droplets which drain out of the evaporator through
a drain hose. This action dehumidifies the air in the cab as part of
system operation, and contributes to operator comfort.
Cab air forced across the evaporator coil gives up heat energy to the cold refrig-
erant inside the coil. The cooled air circulates in the cab for occupant comfort.
Refrigerant continues to expand and absorb heat energy in the evaporator coil.
Refrigerant changes from liquid to gas before it leaves the evaporator on the way
back to the compressor. The refrigerant gas moves to the compressor through a
low pressure (suction) hose. When the compressor is operating, it sucks the re-
frigerant gas back inside, compressing and raising its temperature and pressure.
Some of AC system operation is controlled by the operator, and some is automatic.
The operator can turn the system on and off, regulate the air velocity with the blower
control, and in some designs adjust the thermostat control. The system and component
operating range settings automatically cycle the clutch on and off. The operation of
the expansion valve or other refrigerant metering device at the inlet to the evaporator
is automatic.
Individual system features may differ, but the basic system function remains the
same. Variations in components and controls are described in Chapters 4 and 5. The
engine provides the power for both air conditioner and heater operation. It drives the
AC compressor and the cooling system water pump. Engine RPM affects the efficiency
of both the heater and air conditioner. The slower the engine RPM, the less capacity a
heater or AC system will have.
WARNING When an AC system is operating, the high pressure side com-

ponents, fittings and high pressure lines or hoses can be hot
enough to burn your skin if you touch them. This includes the
compressor, clutch, hoses, condenser, receiver-drier, and any
control devices or metal tubing. The low pressure side will be
cool to the touch. In operation the AC system is under load
and high side pressures normally range between 150 and 250
pounds per square inch for R-12 and higher for some other
refrigerants.
7 6S2BE011
System Operation
Heater System Operation

Heater and air conditioner systems both have the same basic function of moving heat.
They take advantage of nature’s laws where heat energy always moves from a warmer
to a cooler area. In a heater system there is no “change of state” involved in system
operation. The system is sealed and operates under pressure, but the pressure is low
when compared to an air conditioner.
A heater system uses the engine coolant to carry excess heat energy to the cab air.
The heart of the system is the water pump. The water pump forces hot coolant through
a hose from the engine block and through the heater core. The coolant is returned to the
engine cooling system either at the suction side of the water pump or to the radiator.
The heater fan or blower forces cab air through the heater core where heat energy
moves from the engine coolant to the air in the cab. Figure 2-9 illustrates the main
heater system components. In-cab controls, component housing and air vents are not
shown.
The following heater components are discussed in detail in this section:
1. Heater Core
2. Water Valves
3. Defrosters and Ducts
4. Blowers and Fans
Figure 2-9
This view of a heater system
shows the main components
and how they are connected.
Additional heater controls, ducts, air vents, blend-air doors, temperature regulating
devices and auxiliary heaters may be installed as part of a heater system. These may be
air, vacuum, electrical or mechanically operated.
8 6S2BE011
Environmental Effects
1. Heater Core
Heater cores are like small radiators. The fin and tube construction is designed to
route coolant flow for the best possible heat energy transfer from coolant to cab
air. Hoses from and to the engine are connected to the core with clamps. The core
outlet may be larger or the same size as the inlet.
2. Water Valves
Water valves may be cable, vacuum or air controlled. The valve can be either
open, closed or set part way open. Some valves have a bypass design to return
coolant to the engine. Most are manually controlled although electronic systems
are now being installed.
3. Defrosters and Ducts

Defrosting is accomplished by directing heated dry air through ducts to the
windshield. The heater system serves the dual purpose of defrosting and heating.
Controls are used to route the air flow to the windshield and occupant areas by
opening and closing duct doors. Controls may be manual, air or vacuum.
Many vehicles use a “defrost interlock” system which utilizes the air condi-
tioner to dry the defrost air and clear the cab windows more quickly.
4. Blowers and Fans

Blowers or fans are used in the system to move cab air through the heater core
and evaporator. Air can be pushed or pulled through the core depending on sys-
tem design. Blower or fan speed is usually selected by the operator.
Environmental Effects on System Operation

The environment outside the cab involves more than the weather. It may be hot and
humid or cold and dry. That is only part of the condition the HVAC system must handle
to maintain an ideal comfort range. A truck can be at idle, in traffic or moving along
for hours on the Interstate at 65 M.P.H. The load condition on a trip can include going
out full, coming home empty, or driving across the Rockies or Kansas plains during
the day or night. The truck color and shape, the windows and angle of the sun are all
variables that can increase or decrease the “load” on the system. The following are a
few examples of environmental effect:
• A black cab-over (COE) with a dark color interior will be more dif-
ficult to cool than the same vehicle with white paint and a light colored
interior. The black cab picks up and holds the radiant heat from the sun
more easily than the white one.
• In Florida or Houston the humidity in mid summer can be very high
with the temperature in the high 90’s or low 100’s. The AC unit must
remove a lot of moisture from the air in the cab as the air moves through
the evaporator fins. The more moisture on the fins, the less effective the
transfer of heat is to the refrigerant inside the evaporator coil.
9 6S2BE011
System Operation
• On a cold day the temperature can drop below zero. The engine may
run cooler so the engine coolant is cooler when it circulates through
the heater. The heat in the cab moves out of the cab faster (remember
heat always moves to a cooler area until both are the same tempera-
ture—nature’s law). To maintain cab comfort you have to increase the
flow of coolant through the heater, increase coolant temperature, and/or
move more air through the heater core.
• On a hot day, an off-road vehicle experiences cooling at a slower rate
than an on-road vehicle. This is a result of high sun-load, large window
area and often less insulation.
It is important for you to keep environmental effects in mind when you are servicing
or diagnosing heater or air conditioner systems. If you work in Denver the altitude will
affect system function and pressure. In Houston the heat and humidity may lower heat
transfer to the air at the condenser and increase system operating pressures.
Chapter Review
• HVAC systems range from simple cab heaters to multi-function com-
bination systems. The multi-function system can heat and cool the cab
and sleeper unit, and have separate auxiliary components and controls
for driver and passenger comfort.
• Both heater (engine) coolant and air conditioner refrigerant circulate
inside sealed, pressurized systems. The normal air conditioner operat-
ing pressure ranges from 150 to 250 pounds per square inch, sometimes
higher with a different refrigerant.
• Air conditioners have a high and a low pressure side within the system.
The compressor is the starting point of the high side. Pressure drops at
the expansion valve opening to the evaporator.
• The basic components of an AC system are the compressorclutch as-
sembly, high pressure lines, condenser, receiver-drier, expansion valve,
evaporator, thermostat, blower assembly, and suction lines. There may
be other controls installed for more complex systems.
• The basic components of a heater system are the inlet and outlet hoses,
a water valve and valve control, heater core and fan or blower assembly.
There may be other controls for more complex systems.
• An air conditioner system uses the “change of state” of refrigerant inside
the system to move heat from the cab air to the outside air. Refrigerant
changes from a gas to a liquid in the condenser, and back to a gas in the
evaporator.
• A heater system uses the heat from the engine, carried to the heater core
by the action of the water pump, to warm the air in the cab. There is no
change of state within the heater system.
• Environmental conditions affect how both heaters and air conditioners
work. Weather, driving conditions, color of the vehicle are factors. All
contribute to heat gain or loss inside a cab and how much heat energy
must be moved to maintain occupant comfort.
10 6S2BE011
Inspection and Maintenance-
without gauges
• Discussion of Inspection & Maintenance Survey Results
• Visual Inspection - System Off
• Electrical System Inspection
• Performance Inspection - Engine Running
• Heater System Inspection
• Preventive Maintenance Worksheet
• Chapter Review
Discussion of Inspection & Maintenance Survey Results

There are three reasons for regular inspection and maintenance procedures:
1. They save money in the long run by reducing down time and often
prevent more costly repairs.
2. They help to insure driver comfort and safety.
3. They add to your store of knowledge about these systems and main-
tain your level of efficiency.
About half of all heavy duty vehicles have air conditioners. Surveys of AC system
owners find that over 30% of the systems are serviced every six months or less, and
another 62% are serviced at least once a year.
The survey also covered how often the different components required maintenance.
Figure 7.1 below shows survey finding percentages. Failure of any of the AC compo-
nents listed in the survey could cause a system to malfunction or stop cooling.
Figure 7-1 INSPECTION & MAINTENANCE SURVEY

This chart shows mainte-
nance frequency, lists key
parts and how often they
require maintenance.
Note: The above survey results may not apply to your situation. Actual
operating conditions for the vehicles you service will determine
or influence maintenance frequency and requirements.
The following inspection procedures should take about 15 to 20 minutes, longer if
corrective steps, part replacement or adding refrigerant is necessary. There is a “Pre-
ventive Maintenance Worksheet” you may use at the end of this chapter, Figure 7-9
11 6S2BE011
Inspection & Maintenance
Visual Inspection - System Off

Your observations and the corrective measures you take may be different depending
on circumstances. The following inspection procedures are explained in more detail
below:
1. Observe the System
2. Inspect Parts
3. Check Hoses and Fittings
4. Check for Refrigerant Leaks
Use the following procedures as a general rule in performing a visual inspection with
the AC system off:
1. Observe the System

Your first inspection step is to answer the following question if you can:
• Has the vehicle just come in off the road and has the HVAC system
been in use?
• Did the operator or work order explain or describe any problems
about the system?
• Did someone else work on the system yesterday, 700 miles down the
road? Your first inspection step is to answer these questions if you
can.
CAUTION Even when someone has told you what is wrong with an HVAC
system, you should perform a visual inspection. Always make
a visual inspection before you hook up the manifold gauge set.
Never add refrigerant to a system until you have made a com-
plete visual and performance inspection.
2. Inspect Parts
Look at the system for what might come loose, leak, wear out or become dirty
and not function the way it should. The main points for visual inspection of the
system are emphasized in Figure 7-2.
12 6S2BE011
Visual Inspection
Figure 7-2
This system illustration
notes the main points for
visual inspection.
A. Condenser – Is it free of leaves, bugs, bird feathers or mud? The condenser must
be relatively clean to work well as a heat exchanger. How you clean the condenser
depends on where it is mounted. The condenser fin comb, air hose and nozzle, or
soap and water may be used. Where possible, check condenser mounting bolts or
screws and tighten them if necessary.
Condenser failure often results from loose hoses. Hose movement will cause
fatigue failure of condenser tubing adjacent to the fittings. Make sure the hoses are
securely clamped.
While inspecting the condenser check the receiver-drier sight glass and connec-
tions. Look to see if the sight glass has a moisture indicator that is showing moisture
in the system.
B. Components Under the Hood – Tip the cab or raise the hood. Look at the
compressor mounting bracket, compressor clutch assembly, drive belt and pulley
alignment. The mounting bracket, compressor, clutch and drive pulley should be
fastened securely, and a clutch groove (there may be two groves) should be in line
with the drive pulley. Tighten all bolts shown in Figure 7-3, as you inspect.
Figure 7-3
Engine and compressor
vibration can work mount-
ing bolts loose. Tighten
all mounting bolts as you
inspect the system. Slots in
the mounting bracket are
used to move the compressor
clutch assembly in order to
adjust belt tension or align-
ment.
13 6S2BE011
C. Drive Belt – The drive belt should be tight and in good condition. Use a belt ten-
sion gauge to check tension (120 pounds maximum). With experience, you can feel
belt tension by twisting the belt. Try feeling belt tension after using the gauge, when
you know the tension is correct. Replace belts if they are frayed or look worn.
If the clutch pulley/belt alignment is obviously off, you need to loosen the com-
pressor or mounting bracket, or both—and use the alignment bar to line up the clutch
pulley with the drive pulley. Tighten compressor mounting bolts first, then the bolts
holding the bracket. The mounting bracket should have slots or other means of
adjustment to allow you to adjust the tension of the drive belt. When you use a pry
bar to apply tension, be sure you do not pry against the compressor. Pry against the
mounting bracket.
3. Check Hoses and Fittings

Check all hoses and fittings. Look for places where hoses flex when the cab is tilted.
Any places the hoses or fittings are fastened, clamped, connected, bent or secured are
potential wear points. This also applies to places where hoses are not clamped or sup-
ported but should be (often near the condenser). All of these spots are potential leak or
damage points. Tighten, re-fasten, add, or replace as indicated by your inspection.
4. Check for Refrigerant Leaks

System refrigerant leaks can be anywhere but there are obvious places. You can spot
some by looking for signs of refrigerant oil forced out with refrigerant leakage. One
location leaks frequently occur is the compressor shaft seal. The shaft and seal are
hidden behind the clutch assembly, but centrifugal force will throw the oil off the
shaft and against the engine, bracket or whatever is close. Check these points when
you examine the compressor clutch and mounting bracket. A solution of soap and
water applied around potential leak points works well for detecting leaks. A leak in the
evaporator may be indicated if you feel around the condensate drain hole and find oil
present.
Note: You can add inexpensive dry nitrogen gas to the system instead of
R-12 if system pressures are low. Dispense the gas at no more than
200-250 PSI as this is sufficient pressure to cause or indicate a leak
point in the AC system. AC service procedures for complete system
recovering of refrigerant, evacuating, and recharging are covered and
illustrated in Chapter 9.
Note: A leaking heater core could also result in coolant at the condensate
drain.
14 6S2BE011
Electrical System Inspection
You can feel for oil at the bottom of all connections (see Figure 7-4) if the system
is not too hot. Of course, a few minutes with an electronic leak detector is the
best way to check for leaks. Keep in mind that pressure is different in a system at
rest, so small leaks may be hard to find. Pressure in a system at rest, will equalize
at from 60 to 95 PSI, depending on outside air temperature. This means there is
more pressure in the low side of the system at rest than during normal system
operation. Just the opposite is true of the high side; at rest, high side pressure is
lower. You may want to use the detector to check for leaks in the high side when
the air conditioner is operating, if you suspect a leak and can’t find it when the
system is at rest.
Figure 7-4
This illustration shows a po-
tential refrigerant leak point
at the condenser fitting.

The two stages of an electrical inspection are explained in more detail below:
1. Inspect Electrical Connections
2. Check Electrical Current Flow and Device Functions
Use the following procedures to perform an electrical system inspection:
1. Inspect Electrical Connections

First, while you are making your visual inspection under the hood (cab) and/or at
the roof top condenser, take a moment and check all electrical connections visu-
ally and by feel. Look for any corrosion on leads or connectors and clean them.
Make sure all leads and wires are properly supported and securely connected.
2. Check Electrical Current Flow and Device Functions

Perform the following steps to check current flow and electrical device func-
tions:
A. Turn the Ignition On – To check current flow the ignition must be on.
15 6S2BE011
B. Turn the AC System On – This will power the thermostat and clutch.
If it does not come on, use the AC mode switch to check the leads to the
switch. You should be able to hear a “click” from the thermostat and hear
the clutch drive plate “snap” against the clutch pulley. You can not check
thermostat cycling on and off until you do the performance inspection. Fig-
ure 7-5 illustrates a typical AC electrical system and the places you should
inspect.
Figure 7-5
The electrical system inspec-
tion points are noted with
check marks (✔) on this
wiring diagram (electrical
schematic).
C. Check Fuses – If there is a failure and you have made sure all con-
nections are clean and tight, you need to check fuses—in-cab as well as
in-line.
D. Check Clutch Engagement – Since you can’t see and may not hear the
clutch engage, get out and look at the clutch. If it’s engaged, you will see
that the drive plate is against the pulley and not slightly spaced from it. If
you are not sure the clutch is engaged, look for the lead wire connector near
the clutch. Break and close that connection. The clutch will disengage and
engage again.
E. Test Blower Speed Operation – Some systems have a common switch

that turns on the air conditioner and powers the blower motor. Test blower
speed operation by adjusting this or the separate blower control switch.
Feeling the air flow from the ducts or note blower sound (speed) changes.
F. Inspect Roof Mounted Condensers – Don’t forget to inspect roof

mounted condensers and AC systems for dirt and debris. Be sure the con-
denser fan(s) are working properly and all parts and electrical connections
are securely fastened. The roof mounted condenser fans may come on when
the system is turned on. Like the thermostat and most clutches, the normal
on-off cycling action can not be observed until the engine is running with
the AC system on.
16 6S2BE011
Performance Inspection – Engine Running

The purpose of visual and electrical inspection is to detect obvious problems and assure
AC system function for an accurate performance inspection. If you do the performance
inspection first, you could be mislead. Problem areas discovered during the perfor-
mance inspection can give you false clues or symptoms, and result in repair errors and
come-backs. The following performance inspection procedures are explained in more
detail below:
1. Inspect System Component Cycling and
Cab Temperature Levels
2. Check Clutch Cycling Under Load
3. Check Sight Glass
The performance inspection does not cover pressure and temperature sensitive safety
devices (cutout switches, fan control, Trinary etc.). Testing these devices requires the
use of the manifold gauge set for observation of internal system pressures during tests.
These are explained in Chapter 8.
Use the following procedures as a general rule in a performance inspection:
1. Inspect System Component Cycling and Cab

Temperature Levels
A. Turn On the Engine and Air Conditioner – Inspect for system compo-
nent cycling and cab temperature levels.
Note: System performance testing will be much faster if all doors

and windows in the cab are closed.
The cab air must cool down to thermostat control setting lev-
els before system components will cycle on and off, indicating
correct function. This is called ‘stabilizing the system’ and takes
about five minutes of operation. In very hot weather the system
may not cycle.
B. Check Thermometer Readings – In the cab you can use your thermom-
eter to measure air temperature at the vents. When the evaporator is easy to
reach with a thermometer probe without removing some of the dash or duct
work, use the probe to measure evaporator temperature. When the AC unit
is on and working correctly, you can see the thermometer dial needle move
down to about 32 degrees, then rise six to ten degrees and move back down
again. The movement up and down indicates that the cycling clutch and
thermostat, or orifice tube and accumulator pressure switch (to the clutch)
are functioning correctly. In systems with a non-cycling clutch, this move-
ment indicates correct function of the refrigerant metering device.
The needle movement is called “temperature swing.” When you can ad-
just the thermostat setting, the range of swing should change. For example,
from full cooling (cold) to moderate (between cold and warm), the swing
may change from 32-38 to 32-42 degrees.
17 6S2BE011
These readings at the vents will be higher and temperature swing slower
and not as obvious. Also blower speed will cause the temperature, levels to
read higher (high air speed) or lower (low air speed) at the same thermostat
setting. When you measure air temperature, an electronic thermometer/py-
rometer is a great tool to have. You can easily measure cab air temperature
at several locations quickly.
Swing temperatures vary depending on where you measure temperature,
and on outside temperature, humidity and altitude. The chart in Figure 7-6,
shows some examples of typical temperature variables. Don’t forget that
cab and sleeper area temperatures can vary within the same vehicle. Also,
electronic controls used in newer HVAC systems often keep the tempera-
ture spread within a narrower range.
air temp. 70° 80° 90° 100°

Figure 7-6
degrees f. The chart of AC system and
air quality humid dry humid dry humid dry humid dry
cab temperature range shows
you typical variables.
center outlet 43° 40° 44° 40° 47° 40° 52° 41°
air temp. to to to to to to to to
degrees f. 47° 44° 48° 44° 51° 44° 56° 45°
left & right air outlet temperature will vary
left right left right left right left right
outlet air temp. 40° 41° 41° 43° 46° 47° 48° 50°
range degrees f. to to to to to to to to
41° 44° 45° 47° 52° 54° 55° 56°
2. Check Clutch Cycling Under Load

The following operating inspections, visual and by feel, are done outside the cab
while you wait for the system to stabilize.
A. Lift hood – With the hood up (or cab tilted) observe the clutch cycling
under load.
Note: If the condenser is hood mounted you may not have adequate air
flow through it.
B. Touch suction and discharge lines – Soon after system start up you can
safely feel the suction and discharge lines and note their change in tempera-
ture. The discharge line will get hot (after a while it may be to hot to touch)
and the suction line will get cooler.
3. Check Sight Glass

The sight glass is the only point where you can actually see inside the air condi-
tioner during operation. Check the sight glass through the window on the top of
the receiver-drier (or the separate in-line sight glass). If the system is functioning
properly and cooling the cab adequately, the sight glass should be clear (you will
not see anything in it). If it is not clear when the system is first turned on, wait a
few minutes for the system to stabilize, then look again. Figure 7-7 illustrates and
explains what you may observe in the sight glass. Roof mounted condenser fans
may run continuously or cycle on and off. If you can’t tell by sound you may have
to climb a ladder and observe the fan blades.
18 6S2BE011
Performance Inspection
Figure 7-7
These drawings illustrate
conditions you may observe
in the sight glass window.
Note: A roof mounted condenser or AC unit assembly often includes

a roof mounted receiver-drier (and sight glass) close to the con-
denser.
Heater System Inspection

A heater system inspection is really a combination engine cooling system and heater
inspection. All heater/cooling system rubber parts deteriorate due to the air (ozone),
heat, coolant and oils. They should be replaced at regular intervals to prevent break-
down on the road. Metal parts and gaskets are subject to malfunction or breakdown
due to fatigue and corrosion.
Coolant has a limited life and should be replaced regularly. If it is dirty, the cool-
ing system should be drained and flushed or back flushed (using special equipment)
before refilling with clean water and anti-freeze. Coolant must be hot when using the
hydrometer to check protection (freeze-up) level. The following inspection procedures
are explained in more detail below:
1. Check Heater Control Valve Function
2. Inspect Other Functions
1. Check Heater Control Valve Function

Many air conditioner/heater systems depend on the heater control valve for tem-
perature control and positive closure. You can easily check heater control valve
function as follows.
A. Cool engine – Start with the engine cool, set the temperature to cold and
leave the fan off. As the engine warms up, feel the heater return hose. If the
hose feels warm or hot, the heater control valve is leaking internally. This
type of leak can seriously reduce air conditioning performance.
19 6S2BE011
B. Warm up engine – Next, let the engine warm up to normal operating

temperature and set both fan and temperature on high. Feel both heater sup-
ply and return hoses. If there is a noticeable difference in their temperature,
it indicates a low flow of coolant through the heater core (a partially closed
or blocked heater control valve). This could result in poor heating perfor-
mance during cold weather conditions.
Figure 7-8
Heater/cooling system
potential problem areas and
checks are indicated in this
drawing.
2. Inspect Other Functions

There are some things you can’t see or feel when you inspect the thermostat,
heater core, radiator pressure cap, electrical switch and control valve functions.
Some of these can be checked with the pressure and thermostat testers as de-
scribed in Chapter 6. A hand pump pressure tester can also be used to check for
coolant leaks. This is done by using the pump to raise the pressure inside the
system above normal operating pressure to force small suspected leaks to show
up.
Heater/cooling electrical and valve component inspection is the same as air
conditioner inspection. The controls are operated to see if they function correctly
to maintain or vary cab temperature and air flow.
Preventive Maintenance Worksheet

Please feel free to modify or copy the worksheet in Figure 7-9. Actual vehicle use, mile-
age, operating conditions and maintenance budget may influence service frequency.
20 6S2BE011
Chapter Review
Chapter Review
The purpose of these brief inspection procedures is for vehicle system maintenance
and to determine if further, more detailed service is required. The uses of a manifold
gauge set, system troubleshooting, recovery, flushing, evacuating and charging are
explained in the next chapter.
High usage and operating condition variations are tough on air conditioning and
heater components. You should establish and follow regular inspection and mainte-
nance procedures to improve overall system function and component service life.
The typical inspection should not take more than 15 to 20 minutes unless com-
ponent replacement and/or complete system evacuation and recharging is warranted.
The survey results shown in Figure 7-1, indicate belts, compressor clutch assembly,
condenser and the refrigerant lines are the most frequent problem areas. However,
your own experience with service and maintenance may vary from survey results.
Inspection should first be visual and by feel. Some of your electrical system inspec-
tion will be done as you inspect other components (checking leads, connections and
for loose wires). When you check the electrical circuit, begin with the engine off but
ignition on. A system performance inspection with the engine running and system on
really combines electrical and AC or heater system function.
21 6S2BE011
22 6S2BE011
Troubleshooting
& Service Procedures
• Troubleshooting Overview
• Understanding System Function
• A Troubleshooting Example
• Manifold Gauge Set Installation
• Troubleshooting by Manifold Gauge Set Readings
• Review of Frequent Problem Areas
• Conclusion
Can you fix an air conditioner or heater system without finding and correcting the
cause of the problem? You bet you can! It happens every day and it’s not good for
business. Here is an example. A truck pulls in off the road and the operator asks to have
his rig serviced in a hurry. He tells you the air conditioner isn’t cooling like it should
and dashes into the restaurant for lunch.
You tip the hood, and check the sight glass on top of the receiver-drier. You see
bubbles, not a lot but a fairly constant stream of them. It is obvious the system is low
on refrigerant so you hook up the manifold gauge set, purge the gauge set hoses of
air, and add refrigerant until the sight glass clears. Then you check evaporator tem-
perature and it’s OK. The air conditioner is repaired right? Wrong! What you did is
add refrigerant and the problem went away. You did not find and fix the cause of the
problem.
Component failure in an air conditioning system may be the result of a problem
elsewhere in the system. For example, a belt or clutch failure might be caused by a
dirty condenser restricting air flow and increasing head pressures. High head pressures
commonly create problems with other system components. Take time to look beyond
the obvious for a potential hidden problem.
Troubleshooting Overview
Troubleshooting includes collecting enough information to locate the cause of the
problem, then correcting the problem and its cause by replacement, adjustment, and/or
repairing. You begin by gathering information from the most to the least important
sources.
Starting with the most important:
1. Your personal knowledge and experience with AC systems.
2. The vehicle operator's knowledge and experience—question him or her.
3. The work order.
4. Good test equipment and the HVAC system
The routine you follow when troubleshooting should proceed from the most to least
productive way of locating the problem and fixing the cause.
23 6S2BE011
Troubleshooting & Service Procedures
Experienced troubleshooters talk to the operator if they can, then personally verify the
symptoms of the problem whenever possible. They attempt quick fixes on the basis
of their knowledge of common system problems and causes when appropriate. They
know where components are located, and make repairs when they have a good idea
of what the problem is. They fix the cause or causes as well as the problem. They are
confident of their knowledge and ability.
Note: The best troubleshooters all know who to call when they get
stuck. They know someone who knows more than they do and
are not too proud to ask for help or suggestions when needed. The
key—understanding system function
The Key–Understanding System Function

Your complete understanding of AC and heater systems and how they work, plus
what can go wrong, is the key to troubleshooting and repair. We have talked about
components and system function before. Now let’s take a little different approach in
describing what happens when the air conditioner is turned on. In Figure 8-1 we have
used numbers on the illustration to track normal air conditioner function.
Figure 8-1
An illustration of the typical
HVAC system. The numbers
follow the action when the
AC part of the system is
working properly (moving
heat out of the cab and into
the outside air).
24 6S2BE011
Understanding System Function
When you turn on the air conditioner at the control panel (1), the thermostat (2), is
supposed to sense a warm temperature at the evaporator. A circuit in the thermostat
should close, allowing current to flow through the thermostat to the compressor clutch
field coil (3). When this happens, the clutch field coil becomes an electromagnet and
pulls the clutch drive plate (4) tight against the clutch pulley (5).
Note: The same AC switch (1) may also turn on the fan or blower motor
(2a) to circulate air in the cab. The air feels warm at first but will
cool quickly.
A belt connects the clutch pulley to a drive pulley (6) on the engine. The engine pro-
vides the power to turn the clutch pulley and drive the compressor (7) when the clutch
is engaged. When operating, the compressor compresses and pushes refrigerant gas
to the condenser (8), through the receiver-drier (9), and to the expansion valve (10)
orifice. When it does, it puts a lot of pressure on the gas. The compressor raises the
temperature and pressure of the refrigerant inside the high side of the system.
At the same time, the compressor is also sucking in low pressure refrigerant gas
from the expansion valve orifice, evaporator and through the low side of the system.
The movement of the refrigerant inside the system transfers heat energy from the cab
to the outside air for occupant comfort.
The automatic functions of the thermostat (or the pressure valve on some accumu-
lators), and the expansion valve, help maintain pressures and temperatures inside the
system at safe and efficient operating levels. Pressure and temperature are constantly
changing due to compressor and expansion valve action, the amount of heat energy
being moved and the environment or weather conditions.
The engine cooling system fan and clutch (11), and the evaporator blower motor
(2a), move a sufficient amount of air through the condenser and evaporator. On the
road, vehicle speed provides most of the (ram) air required for the condenser to work
right. In a parked or slow moving vehicle the engine fan (or roof or remote mounted
condenser and fans) moves sufficient air through the condenser fins.
Note: Clean refrigerant and refrigeration oil should be inside the system
in the amount specified by the manufacturer. Moisture, sludge
(moisture combined with refrigerant oil or desiccant), or desic-
cant particles will prevent the correct performance of the system
and may cause component damage.
A Troubleshooting Example
Remember the story at the beginning of this chapter? The vehicle operator pulled in
off the road and asked you to repair the rig. He was in such a hurry he didn’t tell you
anything except that the air conditioner wasn’t cooling. Here is the best way to handle
that kind of situation.
25 6S2BE011
Use your knowledge and experience. Ask yourself what could have caused a lack of
cooling in that rig! Did the compressor drive belt break? Did a pressure switch or
relief valve cutout the compressor because of high or low system pressure? Does the
switch or valve in this type of system reset itself? Could there be a superheat switch
and thermal limiter with a melted fuse. Did someone else service the system recently
and put in too much refrigerant?
Could there be contaminants in the system blocking the expansion valve (expan-
sion tube)? If there is a leak, why and how did refrigerant get out of the system? You
know if refrigerant can get out, air and moisture may get inside as well, especially if
the leak is on the suction side of the system. Could there be a restriction to refrigerant
flow in one of the high pressure lines because of a kink? From your knowledge and
experience, you already know about these possibilities and others when you talk to the
operator (before he has the chance to leave).
The right kind of questions can speed up troubleshooting and your service work
by pinpointing the problem(s) that needs fixing. Your conversation with the operator
might be as follows:
• How long ago did the AC system stop cooling?

Answer: About an hour ago.
• What steps did you take when you noticed the lack of cooling?
Answer: I put it on maximum cool.
• Then what did you do?

Answer: When it wouldn’t cool, I opened the window and turned
the air conditioner off.
• Is this problem new or has it happened before, and when?

Answer: In the last few days I’ve had problems with cooling off
and on—this is the first time it’s happened when I was close to a
place that did AC service.
• Do you get any cooling at all?

Answer: Yes but it seems to quit after a while.
• Do you still get air flow at the vents from the blower?
Answer: Yes.
• When was your air conditioner checked thoroughly?

Answer: Before I bought the rig last May (a year ago).
• Has the heater been used recently and did it work OK?
Answer: Yes.
26 6S2BE011
A Troubleshooting Example
• Have you had other service problems in the last few months?
Answer: No.
• (If the answer was yes, you should ask—When? Where?

What was fixed or replaced?).
• Finally, ask the operator if he or she has a wiring diagram for the
system.
Now let’s look at the information you have gathered from the operator and what you
know from experience. He believes the problem is that the AC system quits cooling
after it has been on for a while! You know that the AC system has not been maintained
since the rig was purchased a year ago. Because of that, there could be several causes
for the problem (lack of cooling) and there may be other potential problems about to
develop.
It is possible that some refrigerant has leaked. Moisture and other contamination
may be inside the system. You have been told there are no heater problems, but that
doesn’t mean there are none that might affect AC system operation. The AC system
has quit cooling several times in the last few days. The problem may have become
more severe than when it quit cooling the first time.
If enough refrigerant or oil has leaked out, a low pressure cutout switch may have
cut the circuit to the clutch, protecting the compressor. Because the system has not
been maintained in a year, there may be other components that should be serviced. You
could fix the probable causes, and the system might work and then break down again
as the rig drives out of your place. From your knowledge and what the operator has just
told you, you know this may not be a quick fix problem.
It’s up to you to describe the service situation to the operator. Tell him you need to
do a complete system maintenance inspection to find and correct the problem or other
potential problems. He can give you the go ahead for full service and repair now, wait
till you have inspected the system to determine cause and cost, or delay repair until he
has some down time available.
Normally when the operator can tell you what the problem is, you would first oper-
ate the system to verify the problem. In this situation your troubleshooting (your own
knowledge added to what the operator told you), indicates the next step. You need to
do a complete maintenance inspection instead! Proceed as described in Chapter 7.
Correct any obvious problems and check carefully for leaks. Leak testing should be
visual, by feel and with a leak detector. Next, do your performance test with the engine
running and the AC system on.
Note: Don’t forget to check the heater system too! If the water valve
is not closed, then hot engine coolant flowing through the heater
core would warm the air at the same time the evaporator was
trying to cool it. The result would be the appearance of an AC
problem.
27 6S2BE011
If your AC and heater visual, electrical and leak inspections don’t turn up any problems,
save time by hooking up the manifold gauge set before you make the performance test.
If you find a leak and can correct it easily by tightening a connection, do so. But if too
much refrigerant leaked out, you may have to add some refrigerant to the system for an
effective performance test. We will get into detail on troubleshooting with gauges after
we explain manifold gauge set installation and adding refrigerant.
Manifold Gauge Set Installation
CAUTION Never hook up the gauge set when the engine and air con-
ditioner are running. Be sure all the valves on the manifold
are closed all the way (turn them clockwise). Check the hose
connections on the manifold for tightness.
Locate the low and high side system service fittings and remove their protective caps.
Position or hang the manifold gauge set in a convenient location. Figure 8-2 illustrates
a good example of manifold gauge set hookup in one service situation.
Figure 8-2
A typical manifold gauge
set hookup is shown in this
illustration. The center hose
on the gauge set is con-
nected to the vacuum pump.
The manifold gauge set is a necessary tool in troubleshooting AC system problems.

The following steps are performed during and after installing the manifold gauge set:
1. Purging Air from the Gauge Set Hoses
2. Adding Refrigerant to the System
3. Stabilizing the AC System.
28 6S2BE011
1. Purging Air From Gauge Set Hoses

Environmental regulations require that all service hoses have a shutoff valve
within 12 inches of the service end. These valves are required to ensure only a
minimal amount of refrigerant is lost to the atmosphere. R-12 gauge set hoses
have a valve near the end of all three hoses. R-134a gauge sets have a combina-
tion quick disconnect and shutoff valve on the high and low sides. The utility
(center) hose also requires a valve.
The initial purging is best accomplished when connected to recovery or re-
cycle equipment. Figure 8-3 illustrates the gauge set connections for purging and
refrigeration recovery.
Figure 8-3
The purging setup for
manifold gauge set and
compressor service valves
are shown here.
Note: The manifold gauges read system pressure when the hand valves
are closed if the hose end valves, and the stem type service valves
(if included) are open.
2. Adding Refrigerant to the System

Now that the gauges are connected, you may need to add some refrigerant to the
AC system before you can do an effective performance inspection. However, if
leaks are obvious they should be repaired prior to adding refrigerant.
Note: Loss of some refrigerant is not unusual over an extended period

of time. Adding refrigerant is a typical procedure when the AC
system is maintained on a regular basis.
When adding refrigerant to the system, connect the center hose from the mani-
fold gauge set to the refrigerant dispensing valve on the container. Figure 8-4
illustrates this connection.
29 6S2BE011
Figure 8-4
In this illustration we have
noted how refrigerant is
added to the air conditioner.
Before adding refrigerant to the system you should study the sight glass while the
engine is running and the air conditioner is on. Even if you found a leak during the
system inspection and corrected it, you have no way of knowing how much refriger-
ant has leaked. You will not be able to tell how much refrigerant is in there, but you
can see if bubbles are present.
Then check the gauges for unusually high or low readings, or a lack of pressure.
Following this procedure, and using your knowledge and experience, decide if it
is safe and makes sense to add refrigerant in order to make your full performance
inspection.
You are now ready to add refrigerant to the system. For your safety and to
prevent system damage use the following procedure.
1. Turn on the engine and set the idle at 1200 to 1500 RPM and then turn
on the air conditioner.
CAUTION Do not open the high pressure hand valve on the manifold
gauge set. The compressor could pump refrigerant into the
container and cause it to BURST. Be sure to keep the refriger-
ant container upright to prevent liquid refrigerant from enter-
ing the compressor.
2. Open the refrigerant dispensing valve on the container and then the
low pressure hand valve on the manifold. This allows refrigerant to
enter the system as a gas on the low pressure or suction side of the
compressor. The compressor will pull refrigerant into the system.
30 6S2BE011
3. Add refrigerant until the gauges read in the normal range and the sight
glass appears clear. The sight glass may not be clear for a moment just
before or after the clutch cycles on and off but should generally be
clear. Gauge readings will fluctuate as the compressor cycles on and
off.
Note: Pressures within the air conditioning system vary with ambient
temperature. A normal pressure range is defined as follows:
Low side 15–30 PSIG
High side 150–280 PSIG
If R-134a is used in place of R-12 the high side readings will
be about 20 PSI higher. For this reason many OEMs are recom-
mending an increase in condenser capacity when retrofitting to
the new refrigerant, R-134a.
CAUTION If the gauges show any abnormally high or low pressures as

you are adding refrigerant, stop and investigate for probable
cause. Never add more than one pound of refrigerant. If the
system is low enough on refrigerant to require more than that
amount you should stop and check again for leaks. Then re-
cover all of the refrigerant, repair, evacuate and recharge the
air conditioner. (See Chapter 9). You may want to add dry
nitrogen gas to the AC system instead of R-12 if pressures are
below normal and a leak is suspected. Nitrogen gas is sold in
cylinders under high pressure, 1800 to 2000 PSI. Be sure the
cylinder has a pressure regulating valve to control the pressure
when dispensing nitrogen gas. Dispose the gas at no more than
200-250 psi, as this is sufficient pressure to cause or indicate a
leak point. See note under Troubleshooting by Manifold Gauge
Set Readings in this chapter.
4. When the gauges show normal, close the hand valve on the manifold,
the hose end shutoff valve, and the valve on the refrigerant container.
You can now proceed with the performance inspection.
3. Stabilizing The AC System

For reliable gauge readings as an aid in troubleshooting, the AC system must be
stabilized.
CAUTION Be sure your tools and test equipment are clear of all moving
parts of the engine and air conditioner.
31 6S2BE011
Start the engine and set to a fast idle of 1200 to 1500 RPM. Turn on the air con-
ditioner. After a quick in-cab performance test of control function, blower speeds
and air flow, set the AC system controls to maximum cooling and blower speed
on high. All windows must be closed. If cab temperature is hot (rig has been sit-
ting in the sun with the windows closed), open the windows for a minute or so to
let the hot air out. Run the engine and air conditioner about five minutes for the
system to stabilize. In hot humid weather or where the AC condenser can’t re-
ceive adequate air flow from the engine fan you may have to use a floor mounted
fan to force sufficient air flow through condenser fins. This helps to stabilize the
system by simulating ram air flow found under normal operating conditions.
When a vehicle has a tilt cab or hood and the condenser is part of the grill, you
must use the floor fan to get air to the condenser. You could tilt the cab or hood
back to normal position, carefully routing the manifold gauge set and hoses away
from moving parts. Then place the gauges so you can read system pressure.
Troubleshooting by Manifold Gauge Set Readings

The series of figures that follow (Figures 8-6 through 8-15) show gauges with typical
readings indicating AC system problems. Each figure is followed by troubleshooting
tips, probable causes for the gauge readings shown, and appropriate service and repair
procedures.
Low Refrigerant Charge in the System

Figure 8-5
Gauge reading, low refriger-
ant charge in the system.
Tip: You see bubbles in the sight glass. The air from vents in the
cab is only slightly cool.
Cause: Insufficient refrigerant (charge) in the system.
32 6S2BE011
Manifold Gauge Set Readings
Repair Procedure:
Check for leaks with your leak detector. If you find a leak
at a connection, tighten it then add refrigerant as necessary.
If a component or line is leaking (defective), recover all
refrigerant from the system. Replace the defective part and
then check the compressor oil level and replace missing
oil. Evacuate and recharge with refrigerant, then check AC
operation and performance.
Figure 8-6 Extremely Low Refrigerant Charge in the System

Gauge reading, extremely
low refrigerant charge in
system.
Tip: The sight glass is clear or shows oil streaks. The air from
vents in the cab seems warm. If there is a low pressure or
Trinary™ switch in the system it may have shut off the
compressor (clutch).
Cause: Extremely low or no refrigerant in the system. There is a

leak in the system.
Repair Procedure:
Add refrigerant to the system, at least half of the normal
full charge amount. Then perform your leak test. As an al-
ternative to a refrigerant, add dry nitrogen gas to the system
and then test for leaks.
Note: It may be necessary to use a jumper wire to bypass some

types of low pressure cutout switches to operate the com-
pressor (clutch) when you add refrigerant to the system.
33 6S2BE011
After finding a leak, recover all refrigerant from the system

and repair the leak. Check the compressor and replace any
refrigeration oil lost due to leakage. Evacuate and recharge
the system with refrigerant, then check AC operation and
performance.
Air and/or Moisture in the System

Figure 8-7
Gauge reading, air and/or
moisture in the system.
Tip: The sight glass may be clear or show some bubbles. The
air from vents in the cab is only slightly cool. In a cycling
clutch type system with a thermostatic switch, the switch
may not cycle the clutch on and off, so the low pressure
gauge will not fluctuate.
Cause: Air and/or moisture in the system.
RepairProcedure:
Test for leaks, especially around the compressor shaft seal
area. When the leak is found, recover refrigerant from the
system and repair the leak. Replace the receiver-drier or
accumulator because the desiccant may be saturated with
moisture (there is no way to tell). Check the compressor
and replace any refrigeration oil lost due to leakage. Evacu-
ate and recharge the system with refrigerant, then check AC
operation and performance.
34 6S2BE011
Figure 8-8 Excessive Air and/or Moisture in the System

Gauge reading, excessive
air and/or moisture in the
system.
Tip: There may be occasional bubbles in the sight glass. Air

from vents in the cab is only slightly cool.
Cause: System contains excessive air and/or moisture.
Repair Procedure:
Test for leaks, recover refrigerant from the system and re-
pair the leak. Depending on the type of system, replace the
receiver-drier or accumulator. The desiccant is saturated
with moisture. Check and replace any compressor oil lost
due to leakage. Evacuate and recharge the system, then
check AC operation and performance.
Figure 8-9 Expansion Valve (TXV) Stuck Closed or Plugged

Gauge reading, expansion
valve (TXV) stuck closed.
Tip: Air from vents in the cab is only slightly cool. The expan-
sion valve body is frosted or sweating.
35 6S2BE011
Cause: An expansion valve malfunction could mean the valve is

stuck in the closed position, the filter screen is clogged
(block type expansion valves do not have filter screens),
moisture in the system has frozen at the expansion valve
orifice, or the sensing bulb is not operating. In vehicles
where the TXV and sensing bulb are accessible, perform
the following test. If not accessible, then proceed to Repair
Procedure.
Test: 1. Warm diaphragm and valve body in your hand or care-

fully with a heat gun. Activate system and watch to see
if the low pressure gauge rises.
2. Next, carefully spray a little nitrogen, or any substance

below 32 degrees Fahrenheit, on the capillary coil
(bulb) or valve diaphragm. The low side gauge needle
should drop and read at a lower (suction) pressure on the
gauge. This indicates the valve was part way open and
that your action closed it. Repeat the test, but first warm
the valve diaphragm or capillary with your hand. If the
low side gauge drops again, the valve is not stuck.
3. Clean the surfaces of the evaporator outlet and the cap-

illary coil or bulb. Make sure the coil or bulb is securely
clamped to the evaporator outlet tube and the insulation
is in place. Next proceed with recovering refrigerant
from the system.
Repair Procedure:
Inspect the expansion valve screen (except block type
valves). To do this you must recover all refrigerant from the
system. Disconnect the inlet hose fitting from the expan-
sion valve. Remove, clean and replace the screen, then re-
connect the hose. Any signs of contamination will require
flushing the system. Next, replace the receiverdrier. Then
evacuate and recharge the system with refrigerant, and
check AC operation and performance.
36 6S2BE011
Note: If the expansion valve tests did not cause the low pressure
gauge needle to rise and drop, and if the other procedures
described did not correct the problem, the expansion
valve is defective. You must recover all refrigerant from
the system again, and replace the expansion valve and
receiver-drier. Evacuate and recharge the system with
refrigerant, then check AC operation and performance.
Expansion Valve (TXV) Stuck Open

Figure 8-10
Gauge reading, expansion
valve (TXV) stuck open.
Tip: Air from vents in the cab is warm or only slightly cool.
Cause: The expansion valve is stuck open and/or the capillary tube
(bulb) is not making proper contact with the evaporator
outlet tube. Liquid refrigerant may be flooding the evapora-
tor making it impossible for the refrigerant to vaporize and
absorb heat normally. In vehicles where the TXV and sens-
ing bulb are accessible, check the capillary tube for proper
mounting and contact with the evaporator outlet tube. Then
perform the following test. If the TXV is not accessible,
then proceed to Repair Procedure.
Test: 1. Operate the AC system on it’s coldest setting for a few

minutes. Carefully spray a little nitrogen or other cold
substance, on to the capillary tube coil (bulb) or head of
the valve.
2. The low pressure (suction) side gauge needle should

now drop on the gauge. This indicates the valve has
closed and is not stuck open. Repeat the test, but first
warm the valve diaphragm with your hand.
37 6S2BE011
3. If the low side gauge shows a drop again, the valve is

not stuck. Clean the surfaces of the evaporator outlet
and the capillary coil or bulb. Make sure the coil or bulb
is securely fastened to the evaporator outlet and covered
with insulation material. Operate the system and check
performance.
Repair Procedure:
If the test did not result in proper operation of the expansion
valve, the valve is defective and must be replaced. Recover
all refrigerant from the system and replace the expansion
valve and the receiver-drier. Evacuate and recharge the
system with refrigerant, then check AC operation and per-
formance.
System High Pressure Side Restriction

Figure 8-11
Gauge reading, system high
pressure side restriction.
Tip: Air from vents in the cab is only slightly cool. Look for
sweat or frost on high side hoses and tubing, and frost ap-
pearing right after the point of restriction. The hose or line
may be cool to the touch near the restriction.
Cause: There could be a kink in a line, or other restriction in the

high side of the system.
38 6S2BE011
Repair Procedure:
After you locate the defective component containing the
restriction, recover all of the refrigerant. Replace the de-
fective component and the receiver-drier. Evacuate and
recharge the system with refrigerant, then check AC opera-
tion and performance.
Compressor Malfunction
Figure 8-12
Gauge reading, compressor
malfunction.
Tip: The compressor may be noisy when it operates.
Cause: Defective reed valves or other compressor components. If

the compressor is not noisy, there may be a worn or loose
compressor clutch drive belt.
Repair Procedure:
If you find the belt worn or loose, replace or tighten it and
recheck system performance and gauge readings. To in-
spect and service the compressor, you must isolate (front
seat the stem type compressor service valves) and recover
refrigerant, or fully recover R-12 from systems containing
Schrader valves. Remove the compressor cylinder head
and check the appearance of the reed valve plate assembly.
If defective, replace the valve plate and install with new
gaskets, or replace the compressor assembly.
39 6S2BE011
If you find particles of desiccant in the compressor, remove

and replace it and the receiver-drier. Before doing so, back
flush other system components (except the expansion
valve) using a flushing kit. If there are stem type valves
and you isolate the compressor, the rest of the system must
be purged of refrigerant before you can disconnect and
flush system components (Chapter 9 describes the flush-
ing procedure). After flushing, reassemble the components.
Always check the oil level in the compressor, even if you
install a new or rebuilt unit. Tighten all connections and
evacuate the system. Recharge the air conditioner with re-
frigerant and check system operation and performance.
Note: Rotary compressors have a limited oil reservoir. Extra oil

must be added for all truck installations
Condenser Malfunction or System Overcharge
Figure 8-13
Gauge reading, condenser
malfunction or system
overcharge.
Tip: The air from vents in the cab may be warm. In R-12 systems
there can be bubbles in the sight glass. The high pressure
hoses and lines will be very hot. Don’t forget to check the
engine cooling system components—fan and drive belt, fan
clutch operation, and the radiator shutter.
40 6S2BE011
Cause: The condenser is not functioning correctly or there may

be an overcharge of refrigerant inside the system. Another
possibility is lack of (ram) air flow through the condenser
fins during testing. Engine cooling system component
malfunction can cause high pressure by blocking air flow
(radiator shutter) or not providing air flow (fan clutch) in
sufficient quantity.
Repair Procedure:
Inspect the condenser for dirt, bugs or other debris and clean
if necessary. Be sure the condenser is securely mounted and
there is adequate clearance (about 1-1/2 inches) between
it and the radiator. Check the radiator pressure cap and
cooling system, including the fan, fan clutch, drive belts
and radiator shutter assembly. Replace any defective parts
and then recheck AC system operation, gauge readings and
performance.
If the problem continues, the system may be over- charged

(have too much refrigerant inside). Recover the system
slowly until low and high pressure gauges read below nor-
mal, and bubbles appear in the sight glass. Then add refrig-
erant (charge the system) until pressures are normal and
the bubbles disappear. Add another quarter to half pound of
refrigerant and recheck AC system operation, gauge read-
ings and performance.
If the high gauge readings do not change, you should recover

all of the refrigerant and flush (it may be partially plugged)
or replace the condenser. Also replace the receiver-drier or
accumulator. Then connect the components and evacuate
the system. Recharge the air conditioner with refrigerant
and check system operation and performance.
41 6S2BE011
Thermostatic Switch Malfunction Figure 8-14

Gauge reading, thermostatic
switch malfunction.
Tip: The low side gauge needle may fluctuate in a very narrow
range compared to a normal range. The compressor clutch
may be cycling on and off more frequently than it should.
The low side gauge needle may fluctuate in an above nor-

mal range as the clutch cycles. This may be an indication
that the thermostat is set too high (someone may have at-
tempted to adjust the factory setting). A new thermostat may
have been installed incorrectly (capillary tube not inserted
between the evaporator fins in the proper position).
Cause: The thermostatic switch is not functioning properly or at

all.
Repair Procedure:
Replace the thermostatic switch. When you remove the
old thermostat, replace it with one of the same type. (They
operate in a factory preset temperature range.) Take care in
removing and handling the thermostat and thin capillary
tube attached to it. Don’t kink or break the tube.
Position the new thermostat capillary tube at or close to

the same location and seating depth between the evaporator
coil fins as the old one. Connect the electrical leads.
42 6S2BE011
Review of Frequent Problem Areas
Note: See the Thermostat section in Chapter 10. Fan clutch, ra-
diator shutter, condenser, compressor, and the newer air
and water valve control systems are covered in Chapter
10.
Review of Frequent Problem Areas

In HVAC systems a limited number of things can go wrong. Moving parts of the com-
pressor, clutch, and expansion valve or refrigerant metering device can malfunction or
break down from metal fatigue, contamination, abnormal pressure or lack of lubrica-
tion. Electrical connections may corrode, become disconnected or break. Fuses blow
from shorts or overload. Belts slip or break.
Vibration from the engine or road surface can work bolts and air or vacuum lines
loose, or rub and break or wear parts out. Motors may burn out. The inside of the
system can become contaminated from moisture, air or desiccant material breakdown.
Refrigerant may leak out of the system quickly or very slowly. Moisture in the system
can combine with refrigerant to form acid and attack (corrode) metal parts from the
inside. Moisture and refrigeration oil can combine to form sludge that may block re-
frigerant flow.
The following problems are discussed in more detail in this section:
1. Belts and Compressor Clutch
2. Condenser
3. Refrigerant Lines, Hoses, and Fittings
4. Refrigerant Metering Valves
5. Other Problems
1. Belts and Compressor Clutch

Let’s review problem areas listed at the beginning of Chapter 7. The most fre-
quent repairs are replacing belts and servicing or replacing the compressor or
clutch. Heavy duty vehicle operation puts a lot of stress on these parts. There are
several main reasons.
There is often continuous operation for long periods of time. There may be
frequent sudden RPM variations when shifting gears up or down. For this reason
the AC clutches used in heavy duty systems usually have double row ball bear-
ings. Vibration and road shock contribute to loose or broken mounting brackets,
electrical connections and fittings. Belts, bearings and compressor reed valves
wear out.
Various compressor clutch cutout switches are used because the AC designers
know about compressor operating conditions. System leaks, high operating pres-
sures, malfunctioning engine cooling system components—all cause compressor
problems and failures. When refrigerant and refrigeration oil leaks out of a sys-
tem or there is contamination blocking oil flow, the compressor will be starved
for oil and seize.
43 6S2BE011
2. Condenser
Condensers get dirty and the dirt reduces heat movement by insulating the con-
denser. The fittings come loose or break from stress if the condenser or connecting
hoses are not secured properly to keep the effects of vibration at a minimum.
Heat transfer efficiency and pressure in the condenser are affected by the
amount of outside air flowing through condenser fins. A lack of air flow can mean
the refrigerant doesn’t give up enough heat energy to the outside air (it doesn’t
change state). The refrigerant arrives at the evaporator as a gas and can’t pick up
any heat energy from cab air. In the cab, air from the vents is only slightly cool
or warm.
One possible cause of condenser malfunction could be the engine cooling sys-
tem. This is why fan clutches and radiator shutters are often controlled or over-
ridden by AC switch function. In fact, we can add fan clutch, radiator shutters and
also fan motors to condenser problems. If they don’t function to allow sufficient
air through the condenser, pressure inside the system may become dangerously
high. A lack of air through the condenser fins can raise high side pressure and
blow out the weakest point in a system, or damage the compressor.
3. Refrigerant Lines, Hoses and Fittings

Problems with these parts may be caused by normal deterioration, vibration dam-
age, lack of maintenance or human error (improper installation or replacement).
All rubber parts are attacked by ozone (oxygen) in the air. Rubber parts break
down slowly and become more vulnerable to the effects of vibration with the
passage of time.
Heavy duty vehicle vibration causes stress on all lines, fittings and connections.
Regular maintenance includes checking and tightening any suspect line, or hose
retainers, or grommet position where the grommet is protecting a line or hose
from abrasion. Any insulating material wrapped around hoses must be in place
and securely fastened.
4. Refrigerant Metering Valves

When you consider valve problems there are obvious differences in valve con-
struction and what can go wrong. If a valve is clogged with sludge or other
obstruction, the result is a valve problem but the cause is contamination in the
system. Valves get stuck open or closed, although most often closed when the
gas charge is lost from the diaphragm housing in a traditional TXV. The capillary
tube can vibrate loose from the evaporator outlet tube. The capillary can break
and the small quantity of temperature sensitive gas can escape. The diagnosis of
a valve as defective calls for replacement.
5. Other Problems—Leaks, Moisture, and Adding

Refrigerant
Before any refrigerant was put inside the AC system, someone used a vacuum
pump to evacuate any air and moisture. Vacuum is really a force pulling against
all hoses, fittings and components from the inside. When the system is charged
with refrigerant, the pressure goes from minus (a vacuum) to plus pressure inside
the hoses and all components. The refrigerant and refrigeration oil are trying to
escape from the system at all times.
44 6S2BE011
Conclusion
Technicians frequently add refrigerant to a system, replacing refrigerant seep-

age through system connections or fittings. If the system has been maintained
regularly (every three to six months), adding a small amount of refrigerant may
result in normal system function. However, the best procedure is to check all
connections and look for, find and repair any leaks before adding refrigerant.
When your leak detector indicates the presence of a leak, you can’t tell how
long the system has been leaking. Finding one leak doesn’t mean there are not
others. Until you have some AC system work experience, it will be hard to guess
how much refrigerant may have leaked. If you have to top a system off with a half
pound of refrigerant or more, adding refrigerant is not the answer.
Find the leak. Recover all of the refrigerant and repair the system. The mois-
ture absorbing capacity of any desiccant material is limited and cannot be mea-
sured. For that reason, replace the receiver-drier or accumulator. Then evacuate
the system for an hour and recharge with refrigerant.
When a compressor shaft seal has leaked oil and the refrigerant charge is a little
low, the shaft seal may have leaked because the air conditioner was not used. The
seal can get a little out of round from the weight of the crankshaft and leak above
the shaft. Running the compressor may cause the seal to swell and close up the
leak. The shaft rotation exerts force all around the seal and puts life back into it.
To prevent this from happening, manufacturers recommend regular AC system
operation a minimum of every couple of weeks even in cool weather.
Keep in mind that the compressor can cause a vacuum inside the system if there
is a restriction in the system. That means it can suck air and moisture inside under
some conditions. It will pull these contaminants in through the same space where
refrigerant and refrigerant oil has leaked out.
Conclusion
What could the air conditioning problem and it’s cause have been at the beginning of
this chapter? The operator was in a hurry, but you were able to start your troubleshoot-
ing with the answers he gave you. Problems your inspection may have turned up are
a very low refrigerant charge, a contaminated system or defective compressor. Those
are not quick fix jobs.
On the other hand, you might have found enough debris on the condenser fin sur-
face to boost high side pressures to an abnormal level during the hottest part of the day.
So the Trinary™ or high pressure switch would cut out from high pressure—but reset
itself. You cleaned the condenser, added a half pound of refrigerant and AC system
pressures and function returned to normal. Service and repair took a half hour. But
there was no way to tell without using your knowledge and experience. By now you
are pretty familiar with AC system problems, the reasons for some of them, trouble-
shooting and repair. In Chapter 9 we will describe complete system purging, evacua-
tion, flushing and recharging.
45 6S2BE011
Electrical Wiring Diagram
6S2BE011
6
OTHER
VEHICLE ERROR CODES
VEHICLE ERROR CODES

MAIN CONTROLLER 1 PROGRAM VERSION
Model Version
TL10V-2, TL12R-2 2.05
TL12V-2 1.13
Emergency
Limitations on operation under Buzzer Error code re- Recovery from Time to warning
Code Type of error/malfunctions Detection port*1 Criteria for errors/malfunctions On delay*2 (s)
an error/a malfunction sound corded*3 error*4 recovery (s) lamp ON/
OFF
0.3 s ON, 0.3 s ON,
9 ACC key not detected MC1_C1P44 Voltage at 9 V or below 60 No limits.   5
0.3 s OFF 0.3 s OFF
MC1 stops transmission from
MC1_C1-P11 MC1 received data from MC2 and MC2 0.3 s ON, 0.3 s ON,
157 MC2 part number error occurred 5 CAN2. Data received by MC1   1
MC1_C1_P12 part number does not match 0.3 s OFF 0.3 s OFF
from CAN2 is reset.
CAN communications error occurred (EE- MC1_C1-P3 0.3 s ON, 0.3 s ON,
502 MC1 receives no data from ECU 2 No limits.   1
CU) MC1_C1_P4 0.3 s OFF 0.3 s OFF
CAN communications error occurred (DEF MC1_C1-P3 0.3 s ON,
512 MC1 receives no data from DEF tank 5 UREA lamp flashes. OFF   1
tank) MC1_C1_P4 0.3 s OFF
CAN communications error occurred (Clus- MC1_C1-P3 MC1 receives no data from the cluster 0.3 s ON, 0.3 s ON,
602 5 No limits.   1
ter gauge) MC1_C1_P4 gauge 0.3 s OFF 0.3 s OFF
CAN communications error occurred MC1_C1-P6 0.3 s ON, 0.3 s ON,
612 MC1 receives no data from OX 0.5 No limits.   1
(OX024) MC1_C1_P7 0.3 s OFF 0.3 s OFF
MC1_C1-P11 MC1 stops transmission from 0.3 s ON, 0.3 s ON,
672 CAN communications error occurred (MC2) MC1 receives no data from MC2 0.5   1
MC1_C1_P12 CAN2. 0.3 s OFF 0.3 s OFF
CAN communications error occurred MC2_C1-P3 0.3 s ON, 0.3 s ON,
802 MC2 receives no data from MC1 0.5 No limits.   1
(AUXIO4) MC2_C1_P4 0.3 s OFF 0.3 s OFF
MC1 power supply voltage error occurred Voltage 16 V or above after engine 0.5 s ON, 0.3 s ON,
1703 MC1_C1P2 1.5 No limits.   5
(Voltage high) speed reaches 750 min-1 0.5 s OFF 0.3 s OFF
MC1 power supply voltage error occurred Voltage 10 V or below after engine 0.5 s ON, 0.3 s ON,
1704 MC1_C1P2 1.5 No limits.   5
(Voltage low) speed reaches 750 min-1 0.5 s OFF 0.3 s OFF
OX power supply voltage error occurred Voltage 16 V or above after engine 0.5 s ON, 0.3 s ON,
1713 OX_C1P2 1.5 No limits.   5
OX power supply voltage error occurred Voltage 10 V or below after engine 0.5 s ON, 0.3 s ON,
1714 OX_C1P2 1.5 No limits.   5
MC2 power supply voltage error occurred Voltage 16 V or above after engine 0.5 s ON, 0.3 s ON,
1763 MC2_C1P2 1.5 No limits.   5
MC2 power supply voltage error occurred Voltage 10 V or below after engine 0.5 s ON, 0.3 s ON,
1764 MC2_C1P2 1.5 No limits.   5
MC1 power supply voltage 10 V or Operation is not possible when
Sensor voltage error occurred (Voltage 0.5 s ON, 0.3 s ON,
2503 MC1_C1P8 above and detection port voltage 5.2 V 0.5 the AUX1 sliding switch is in   2
high) MC1 0.5 s OFF 0.3 s OFF
or above the neutral position.
MC1 power supply voltage 10 V or Operation is not possible when
Sensor voltage error occurred (Voltage low) 0.5 s ON, 0.3 s ON,
2504 MC1_C1P8 above and detection port voltage 4.8 V 0.5 the AUX1 sliding switch is in   2
MC1 0.5 s OFF 0.3 s OFF
or below the neutral position.
Accelerator sensor and foot ac-
MC2 power supply voltage 10 V or
Sensor voltage error occurred (Voltage celerator pedal in low-speed 0.5 s ON, 0.3 s ON,
2543 MC2_C1P8 above and detection port voltage 5.2 V 0.5   2
high) MC2 position and operation is not 0.5 s OFF 0.3 s OFF
or above
possible.
Accelerator sensor and foot ac-
MC2 power supply voltage 10 V or
Sensor voltage error occurred (Voltage low) celerator pedal in low-speed 0.5 s ON, 0.3 s ON,
2544 MC2_C1P8 above and detection port voltage 4.8 V 0.5   2
MC2 position and operation is not 0.5 s OFF 0.3 s OFF
or below
possible.
1
VEHICLE ERROR CODES 6T1BQ001
6
OTHER
VEHICLE ERROR CODES
0.5 s ON, 0 s after voltage reaches 3 V or 0.3 s ON,

3300 Alternator charge faulty MC1_C1P17 Voltage at 2 V or below 1.5 No limits  
0.5 s OFF above 0.3 s OFF
MC1_C1-P3 Engine oil switch is ON after engine 0.5 s ON, 0.3 s ON,
3401 Engine oil pressure error occurred 1.5 No limits   0
MC1_C1_P4 speed reaches 750 min-1 0.5 s OFF 0.3 s OFF
Coolant temperature reached 110°C
MC1_C1-P3 0.5 s ON, 5 s after coolant temperature drops 0.3 s ON,
3500 Overheating occurred (230°F) or above after engine speed 5 No limits  
MC1_C1_P4 0.5 s OFF below 100°C (212°F) 0.3 s OFF
reaches 750 min-1
Air cleaner switch is ON after engine 0.5 s ON, 0.3 s ON,
3600 Air cleaner clogged MC1_C1P16 1.5 No limits   0
speed reaches 750 min-1 0.5 s OFF 0.3 s OFF
Line filter indictor switch is ON after en- 0.5 s ON, 0.3 s ON,
3810 Line filter clogged MC1_C1P15 1.5 No limits   0
gine speed reaches 750 min-1 0.5 s OFF 0.3 s OFF
Hydraulic oil temperature error (Tempera- Hydraulic oil temperature is 103°C 10 s after hydraulic oil temperature
3820 MC1_C1P49 30 No limits OFF   OFF
ture high) (217°F) or above drops below 98°C (208°F)
Volume of accumulated PM exceeds Engine speed limited to 1800
MC1_C1-P3 0.5 s ON, 0.3 s ON,
3360 DPF full (Lv2) the “Regeneration level = 3” value and 3.2 min-1 and active power control   0
MC1_C1_P4 0.5 s OFF 0.3 s OFF
regeneration is not being performed disabled
Volume of accumulated PM exceeds Engine speed limited to 1800
MC1_C1-P3 0.2 s ON, 0.3 s ON,
3370 DPF full (Lv1) the “Regeneration level = 2” value and 3.2 min-1 and active power control   0
MC1_C1_P4 0.8 s OFF 0.3 s OFF
regeneration is not being performed disabled
Hydraulic oil temperature sensor voltage er- Code No. 3820 (hydraulic oil 0.2 s ON, 0.3 s ON,
3823 MC1_C1P49 Voltage at 4.9 V or above 5   5
ror occurred (Voltage high) temperature error) is cancelled. 0.8 s OFF 0.3 s OFF
Hydraulic oil temperature sensor voltage er- Code No. 3820 (hydraulic oil 0.2 s ON, 0.3 s ON,
3824 MC1_C1P49 Voltage at 0.1 V or below 5   5
ror occurred (Voltage low) temperature error) is cancelled. 0.8 s OFF 0.3 s OFF
CCV heater 1 (IN) voltage error occurred 0.5 s ON, 0.3 s ON,
3843 MC1_C1P46 Voltage at 4.8 V or above 60 No limits   5
(Voltage high) 0.5 s OFF 0.3 s OFF
CCV heater 1 (IN) voltage error occurred 0.5 s ON, 0.3 s ON,
3844 MC1_C1P46 Voltage at 0.15 V or below 5 No limits   5
(Voltage low) 0.5 s OFF 0.3 s OFF
CCV heater 2 (OUT) voltage error occurred 0.5 s ON, 0.3 s ON,
CCV heater 2 (OUT) voltage error occurred 0.5 s ON, 0.3 s ON,
Accelerator sensor error occurred (Voltage 0.2 s ON, 0.3 s ON,
high) Accelerator dial operation is 0.8 s OFF 0.3 s OFF
Accelerator sensor error occurred (Voltage not possible. 0.2 s ON, 0.3 s ON,
low) 0.8 s OFF 0.3 s OFF
Foot accelerator sensor error occurred 0.2 s ON, 0.3 s ON,
(Voltage high) Foot accelerator pedal opera- 0.8 s OFF 0.3 s OFF
Foot accelerator sensor error occurred tion is not possible. 0.2 s ON, 0.3 s ON,
Fuel sender 1 voltage error occurred (Volt- 0.2 s ON, 0.3 s ON,
age high) 0.8 s OFF 0.3 s OFF
age low) 0.8 s OFF 0.3 s OFF
age high) 0.8 s OFF 0.3 s OFF
age low) 0.8 s OFF 0.3 s OFF
2
6
OTHER
VEHICLE ERROR CODES
Lower the safety bar. Voltage is outside

Error occurred at the neutral position of the
6509 MC1_C1P37 2.3 V to 2.7 V when the HYD LOCK 0 OFF   OFF
AUX1 slide switch
switch turned on.
Lower the safety bar. AUX1 (L) switch Clear the malfunction evaluation
6519 AUX1 (L) switch error occurred MC1_C1P35 is on when the HYD LOCK switch 0 OFF   condition and turn off the HYD LOCK OFF
turned on. switch.
Output to AUX1A and AUX1B
Lower the safety bar. AUX1 (R) switch
solenoids stopped.
6529 AUX1 (R) switch error occurred MC1_C1P36 is on when the HYD LOCK switch 0 OFF   OFF
turned on.
AUX1 slide switch voltage error occurred 0.2 s ON, 0.3 s ON,
6503 MC1_C1P37 Voltage at 4.8 V or above 0.5   2
AUX1 slide switch voltage error occurred 0.2 s ON, 0.3 s ON,
6504 MC1_C1P37 Voltage at 0.2 V or below 0.5   2
Lower the safety bar. Quick-hitch
Output to the quick-switch
6709 Quick-hitch switch (OPEN) error occurred MC2_C1P7 switch is open when the HYD LOCK 0 OFF   OFF
open solenoid stopped. Clear the malfunction evaluation
switch turned on.
condition and turn off the HYD LOCK
Lower the safety bar. Quick-hitch
Output to the quick-switch switch.
6719 Quick-hitch switch (CLOSE) error occurred MC2_C1P6 switch is closed when the HYD LOCK 0 OFF   OFF
close solenoid stopped.
switch turned on.
AUX1 (L) PWM output current error oc- 0.2 s ON, 0.3 s ON,
8015 OX_C1P12 Up to 200 mA below target current 1  × –
curred (Current low) 0.8 s OFF 0.3 s OFF
AUX1 (L) PWM output current error oc- 0.2 s ON, 0.3 s ON,
8016 OX_C1P12 Up to 200 mA above target current 1  × –
curred (Current high) Output to AUX1A and AUX1B 0.8 s OFF 0.3 s OFF
AUX1 (R) PWM output current error oc- solenoids stopped. 0.2 s ON, 0.3 s ON,
8025 OX_C2P1 Up to 200 mA below target current 1  × –
curred (Current low) 0.8 s OFF 0.3 s OFF
AUX1 (R) PWM output current error oc- 0.2 s ON, 0.3 s ON,
8026 OX_C2P1 Up to 200 mA above target current 1  × –
curred (Current high) 0.8 s OFF 0.3 s OFF
Active power control current error occurred 0.2 s ON, 0.3 s ON,
8095 OX_C2P8 Up to 200 mA below target current 1 No limits   1
(Current low) 0.8 s OFF 0.3 s OFF
Active power control current error occurred 0.2 s ON, 0.3 s ON,
8096 OX_C2P8 Up to 200 mA above target current 1 No limits   1
(Current high) 0.8 s OFF 0.3 s OFF
MC1_C1-P3
9990 Model changed Engine model changed 0 No limits OFF  × – OFF
MC1_C1_P4
*1: MC1: MAIN CONTROLLER 1
MC2: MAIN CONTROLLER 2
OX: OX CONTROLLER
2. Electrical Circuit Diagram
*2: Retention time to evaluate a malfunction when an error is evaluated
*3: Error codes recorded in controller?
: Recorded
×: Not recorded
*4: Error code displayed when malfunction evaluation condition is cleared?
: No error code displayed
×: Error code displayed until starter switch turns OFF
3
6
OTHER
ENGINE ERROR CODES
ENGINE ERROR CODES

Error code No.
Error details DTC
SPN FMI
3 Accelerator position sensor 2: High P2128
29
4 Accelerator position sensor 2: Low P2127
2 Accelerator position sensor correlation error P2135
91 3 Accelerator position sensor 1: High P2123
4 Accelerator position sensor 1: Low P2122
100 1 Oil pressure error P0524
3 Boost pressure sensor: High P0238
102
4 Boost pressure sensor: Low P0237
3 Barometric pressure sensor error (High side) P2229
108
4 Barometric pressure sensor error (Low side) P2228
0 Engine overheat P0217
110 3 Coolant temperature sensor: High P0118
4 Coolant temperature sensor: Low P0117
1 Intake air volume: Low P0101
3 MAF sensor: High P0103
132
4 MAF sensor: Low P0102
15 Boost pressure low P3011
0 High rail pressure P0088
1 Rail pressure too low P0191
157 2 C/Rail Press. Sensor Signal keeping a middle range P0194
3 Rail pressure sensor: High P0193
4 Rail pressure sensor: Low P0192
3 Battery voltage: High P0563
168
4 Battery voltage: Low P0562
3 Intake air temp. built-in MAF sensor: High P0073
171
4 Intake air temp. built-in MAF sensor: Low P0072
0 Intake air temp: high(Inter cooler model only) P0111
172 3 Intake air temp. error: High P0113
4 Intake air temp. error: Low P0112
183 2 Invalid Engine Fuel Rate Data P1A20
0 Engine overrun P0219
190
2 Invalid Engine Speed Data P0726
628 2 ACU FLASH ROM error P0605
2 NE sensor (Crank position sensor) pulse number error P0336
636 7 NE-G phase shift P0016
8 No input of NE sensor (Crank position sensor) pulse P0335
3 Open circuit of harness or coil in 1st cylinder injector P0201
651 6 Coil short in 1st cylinder injector P1A07
8 TWV1 driving circuit error P1A18
1
ENGINE ERROR CODES 6T1BO01
6
OTHER
ENGINE ERROR CODES
Error code No.

Error details DTC
SPN FMI
3 Open circuit of harness or coil in 2nd cylinder injector P0204
652 6 Coil short in 2nd cylinder injector P1A0A
8 TWV4 driving circuit error P1A1B
3 Open circuit of harness or coil in 3rd cylinder injector P0202
653 6 Coil short in 3rd cylinder injector P1A08
8 TWV2 driving circuit error P1A19
3 Open circuit of harness or coil in 4th cylinder injector P0203
654 6 Coil short in 4th cylinder injector P1A09
8 TWV3 driving circuit error P1A1A
675 3 Heater Lamp error P0381
677 3 Starter relay driving error P081B
2 G-sensor (Camshaft position sensor) pulse number error P0341
723
8 No input of G sensor (Camshaft position sensor) pulse P0340
1077 2 ECU CPU (Main IC) error P0606
1239 1 Fuel leak (in high pressured fuel system) P0093
1485 2 Main relay is locked in closed position P0687
1 DEF Tank Level: Leakage P204F
11 DEF Tank Level sensor error P203E
1761
17 DEF Tank Level: Low P203B
18 DEF Tank Level: Empty P203F
2 DEF Tank Temperature sensor error P205B
3031 3 DEF Tank Temperature sensor error: Out-of-Range High P205D
4 DEF Tank Temperature sensor error: Out-of-Range Low P205C
1 Pre NOx sensor error: Tampering P1A21
3216
12 Pre NOx sensor error P2200
3223 12 Pre NOx sensor heater error P220E
1 Post NOx sensor error: Tampering P1A22
3226
12 Post NOx sensor error P229E
3233 12 Post NOx sensor Heater error P220F
0 Exhaust gas temperature sensor 1: High P3003
3242 3 Exhaust gas temperature sensor 1: High P0544
4 Exhaust gas temperature sensor 1: Low P0543
3246 3 Exhaust gas temperature sensor 2: High P242D
4 Exhaust gas temperature sensor 2: Low P242C
3 Differential pressure sensor 1: High P2455
3251
4 Differential pressure sensor 1: Low P2454
3252 0 Emission deterioration P3001
2
6
OTHER
ENGINE ERROR CODES
Error code No.

Error details DTC
SPN FMI
2 DEF Injector QR Data Fault: Invalid QR Data P1A24
3361 5 DEF Injector short to ground or open circuit or short to +B P2047
7 DEF Injector QR Data Fault: No QR Data P1A23
3 Coolant Valve for Tank Heater short to +B P202C
3363 4 Coolant Valve for Tank Heater short to ground P202B
5 Coolant Valve for Tank Heater open circuit P202A
3 Sensor supply voltage: High P0643
3509
4 Sensor supply voltage: Low P0642
3 Sensor supply voltage 2: High P0653
3510
4 Sensor supply voltage 2: Low P0652
2 Diesel in DEF Tank P207F
11 DEF Tank Quality sensor error P206A
3516 12 DEF Tank Quality: Incorrect sensor reading P206B
16 DEF Tank Quality: High P206D
18 DEF Tank Quality: Low P206C
3697 3 Parked regeneration request Lamp error P1A0F
0 Excessive PM5 P3008
3701 15 Excessive PM3 P3006
16 Excessive PM4 P3007
3702 13 Regeneration inhibit request reception(Not DTC) P1A14
4115 3 Engine warning Lamp error P1A12
3 DEF Pressure sensor error:Out-of-Range High P204D
4 DEF Pressure sensor error: Out-of-Range Low P204C
4334 15 DEF Pressure sensor error: Offset High P204B
16 DEF Dosing Pressure error: High P20E9
18 DEF Dosing Pressure error: Low P20E8
4350 15 DEF Consumption High P20F5
3 Heater Relay short to +B P21C4
4353
4 Heater Relay short to ground or open circuit P21C3
2 Suction Tube Heater coil short circuit P20BA
3 Suction Tube Heater short to +B P20BC
4354
4 Suction Tube Heater short to ground P20BB
5 Suction Tube Heater open circuit P20B9
2 DEF Pump Heater coil short circuit P20BE
3 DEF Pump Heater short to +B P20C0
4355
4 DEF Pump Heater short to ground P20BF
5 DEF Pump Heater open circuit P20BD
2 Delivery Tube Heater coil short circuit P20C2
3 Delivery Tube Heater short to +B P20C4
4356
4 Delivery Tube Heater short to ground P20C3
5 Delivery Tube Heater open circuit P20C1
3
6
OTHER
ENGINE ERROR CODES
Error code No.

Error details DTC
SPN FMI
2 Return Tube Heater coil short circuit P20C6
3 Return Tube Heater short to +B P20C8
4357
4 Return Tube Heater short to ground P20C7
5 Return Tube Heater open circuit P20C5
2 SCR Temperature sensor error: Rationality P2046
3 SCR Temperature sensor error: Out-of-Range High P2045
4360
4 SCR Temperature sensor error: Out-of-Range Low P2044
15 SCR Temperature sensor error: Stuck High P2043
4364 1 Low Conversion Efficiency P20EE
2 Invalid DOC Inlet Temperature (T0) Data P2080
4765
4 Exhaust gas temperature sensor 0: Low P0546
1 DEF Pump failed to prime (circulate) P208B
3 DEF Pump short to +B P208D
5435
4 DEF Pump short to ground or open circuit P208C
12 DEF Pump Motor uncontrollable P208B
2 Injector drive circuit open in No.1 & 4 cylinder simultaneously P2146
No. 1 & 4 cylinder injector short to +B at power supply side, or all cylinder injector
3 P2148
523523 short to +B
No. 1 & 4 cylinder injector short to ground at power supply side, or all cylinder in-
4 P2147
jector short to ground
2 Injector drive circuit open in No.2 & 3 cylinder simultaneously P2149
No. 2 & 3cylinder injector short to +B at power supply side, or all cylinder injector
3 P2151
523524 short to +B
No. 2 & 3cylinder injector short to ground at power supply side, or all cylinder in-
4 P2150
jector short to ground
523525 1 Injector charge voltage: Low P0611
523527 2 ECU CPU (Monitoring IC) error P0606
523535 0 Injector charge voltage: High P0200
2 QR data error
523538 P0602
7 No QR data
523539 2 Pump seizing 1 P1274
523540 2 Pump seizing 2 P1275
523543 2 Accelerator position sensor error (CAN) P2131
3 +B short of air heater relay driving circuit
523544 P0380
4 Ground short of air heater relay driving circuit
523547 2 CAN2 Bus off U0075
523548 2 CAN-KBT Frame error U0081
523572 4 EGR position sensor failure P0409
3 EGR actuator open circuit P0403
523574
4 EGR actuator coil short P0404
4
6
OTHER
ENGINE ERROR CODES
Error code No.

Error details DTC
SPN FMI
523575 7 EGR actuator valve stuck P2413
523576 2 EGR (DC motor) overheat P2414
523577 2 EGR (DC motor) temp. sensor failure P2415
523578 2 No communication with EGR U0076
523580 2 Intake throttle feedback error P2108
3 Intake throttle lift sensor: High P2622
523582
4 Intake throttle lift sensor: Low P2621
523589 17 Low coolant temp. in parked regeneration P3012
523590 16 Parked regeneration time out P3013
523591 2 CAN CCVS (Parking SW and Vehicle speed) frame error U0082
523592 2 CAN CM1 (Regen SW) frame error U0083
523594 2 CAN ETC2 (Neutral SW) frame error U0085
523595 2 CAN ETC5 (Neutral SW) frame error U0086
523596 2 CAN TSC1 frame error U0087
523598 2 CAN EBC1 frame error U0089
523599 0 All exhaust temp. sensor failure P3018
523600 0 Initial pump-calibration incomplete P3019
523601 0 High exhaust gas temp. after emergency high temp. DTC P3023
523602 0 High frequency of regeneration P3024
523603 15 Over heat pre-caution P3025
523604 2 CAN1 Bus off U0077
523606 2 Pressure relief valve error P2293
PCV or PRV drive line short to +B at power supply side (COM3), or all driver line
3 P0092
short to +B simultaneously
523607
PCV or PRV drive line short to ground at power supply side (COM3), or all driver
4 P0091
line short to ground simultaneously
523608 2 High pressure delivery system too high P1A06
523609 6 Coil short in PCV P1A0B
523610 6 Coil short in PRV P1A0C
523611 2 High pressure pump too high P1A0D
523612 5 Open circuit of harness or coil in PCV line P0090
523613 5 Open circuit of harness or coil in PRV line P2294
523614 2 Internal IC (VDIC2) clock error 1
523614 2 Internal IC (VDIC2) clock error 2
P062B
523614 2 Internal IC (VDIC2) communication error 1
523614 2 Internal IC (VDIC2) communication error 2
523616 2 No communication with Tank sensor U010E
523617 2 No communication with Pre-NOx sensor U029D
523618 2 No communication with Post-NOx sensor U029E
523619 2 No communication with Engine ECU U0100
523620 2 ECU-ACU CAN communication error U02A3
5
6
OTHER
ENGINE ERROR CODES
Error code No.

Error details DTC
SPN FMI
523621 3 Stop Lamp error P1A10
523622 3 Low oil pressure Lamp error P1A11
523623 3 Active regeneration Lamp error P260E
523624 3 Over heat Lamp error P0655
523625 2 TSC1 priority reception error P1A13
523626 2 SUB CPU software version unmatch P1A16
523627 8 PCV driving circuit error P0089
523628 8 PRV driving circuit error P2293
523631 2 Invalid Intake MAF data per Cylinder P1A1E
523632 2 EGR system error P0404
523700 13 EEPROM check sum error P1990
6

SM-Takeuchi TL12R2 Track Loader Service Repair Manual (SN 412100002 and Up)

Uploaded by

Copyright:

Available Formats

You might also like

SM-Takeuchi TL12R2 Track Loader Service Repair Manual (SN 412100002 and Up)

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

SM-Takeuchi TL12R2 Track Loader Service Repair Manual (SN 412100002 and Up)

Uploaded by

Copyright:

Available Formats

Serial No.

Directional terms: front, rear, left, right

Machine serial number

Symbols used in this manual

Indicates the machine serial number.

IMPORTANT: The word “IMPORTANT” is used to alert

This manual is intended for trained and qualified person-

SAFETY PRECAUTIONS Install an extinguisher and a first aid kit

Observe all safety rules

Place a “Do not operate” alert sign

Do not use damaged or weakened tools or tools de-

Regularly replace the safety-critical parts When the canopy is tilted up

Keep the machine clean

To prevent an ignition or explosion, use explosion-proof

Stop the engine before performing maintenance

Prepare the work area

Securing the working equipment

Secure the engine hood and guard when they are

When it is necessary to temporally place a heavy compo-

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

Release internal pressure before working on the

Disconnect the battery

Checks after maintenance

CAUTIONS WHEN WORKING When removing/installing the hydraulic unit

When connecting/disconnecting the hoses or Handling of seals

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

Pressure adjustment for hydraulic devices

*: Roof guard specification

Engine 426 (939)

Control valve (machine

Control valve (machine

Gear pump (without high-

Gear pump (with high-

Engine housing 18 (40)

HST pump 72 (159)

Hydraulic tank 46 (101)

Cab COMP 309 (681)

Canopy COMP 227 (500)

Operator seat 30 (66)

Fuel tank assembly 10 (22)

Lower structure kg (lb.)

Rubber crawler 242 (534)

Track roller B A 38 (84)

Track roller C 26 (57)

Front idler assembly 73 (161)

Grease cylinder 12 (26)

Travel motor 81 (179)

Bucket 281 (619)

Arm assembly (1) 417 (919)

LUBRICANT AND FUEL CHART

Travel reduction Gear oil Every 500 hrs. 1.6 L × 2

Diesel fuel standards

Part Type Capacity

Part Storing DEF/AdBlue® Capacity

Right crawler mm (in.) OK NG -

Flow rate values below are hydraulic pump specification values.

Flow rate values below are hydraulic pump specification values.

pressure that has been set is stabilized.

Pressure detection port 1